Boosting Production with a New Unical Steam Boiler
The Challenge: Insufficient Steam Capacity Hampering Production
The existing steam supply for the crucial production lines was generated by a Thermal Oil steam generator. A review highlighted a significant limitation in the steam generation capacity, operating at a pressure of 4 Bar and transported through an extensive pipe network. This insufficient steam supply was impacting production efficiency and creating a bottleneck.
Furthermore, the facility is embarking on an expansion project, including a new Deep Fryer that will utilise Thermal Oil for heating. This new addition would further strain the existing Thermal Oil system if no adjustments were made.
The Existing System
Steam Generation: Thermal Oil steam generator supplying steam at 4 Bar to production lines.
- Hot Water: Two 4000-litre tanks heated via heat recovery exchangers, with a 3MW hot water boiler for on-demand heating.
- Thermal Oil: System upgraded in 2020 with a pump capable of a flow rate of approximately 80 litres/sec, connected to a VSD for flow rate adjustments.
The Proposed Solution: A Dedicated Unical Steam Boiler
To overcome the steam capacity limitations and accommodate the new Deep Fryer, Tubman Heating proposed a strategic upgrade focusing on a dedicated steam generation system:
- Decommissioning the Thermal Oil Steam Generator: This crucial step will free up the existing Thermal Oil capacity, allowing it to be effectively allocated to the new Deep Fryer.
- New Thermal Oil Piping: Installation of new piping to directly supply the new Deep Fryer.
- New Hot Water Washdown Line: Installation of a dedicated hot water line to the new Deep Fryer facility.
- Installation of a New Unical 1500 BAHR 12 Steam Boiler: This high-efficiency boiler will be dedicated to supplying the production area with up to 1500 kg/steam/hr at 12 Bar. The boiler will be strategically located just outside the old plant room and connected to the existing steam network, operating at a controlled 10 Bar.
- New Feedwater and Blowdown Tanks: The replacement of the existing feedwater tank with a new, corrosion-resistant duplex stainless 2205 tank, along with the installation of a new blowdown tank for efficient system management.
- System Commissioning: Comprehensive commissioning of the new system, including checks on flow rates and steam delivery to all production areas.
Minimising Downtime and Installation Considerations:
To minimise disruption to the facility’s production, a containerised boiler option was chosen. This approach involved prefabrication of key components at Tubman Heating’s workshop in Auckland, streamlining the on-site installation process. While a traditional in-plant room installation was considered, the containerised solution significantly reduced downtime to just the steam pipe changeover and pressure reduction valve installations which was completed over the Christmas break. This ensured a quicker return to full production capacity.
Unical 1500 BAHR 12: A Reliable and Efficient Choice
The selection of the Unical 1500 BAHR 12 gas steam boiler offers several key benefits:
- Increased Steam Capacity: The boiler’s capacity of up to 1500 kg/steam/hr at 12 Bar directly addresses the previous steam supply limitations, ensuring sufficient steam for the production lines and future production needs.
- Improved Efficiency: Modern steam boilers like the Unical BAHR series are designed for optimal efficiency, potentially reducing energy consumption and operational costs.
- Unattended Operation: The inclusion of an unattended control panel streamlines operation and reduces the need for constant manual monitoring.
- Integration with Existing Infrastructure: Positioning the new boiler in the existing steam generator location allows for easier connection to the existing steam network, minimizing disruption.
The installation of the Unical 1500 BAHR 12 steam boiler, coupled with the decommissioning of the existing Thermal Oil steam generator, delivers a more efficient, reliable, and scalable heating system. Tubman Heating’s expertise in boiler installations and system integration ensured a smooth and effective project delivery.
Keen to upgrade your heating system? Get in touch with Tubman Heating today to explore your options.
