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Case Savings – Selected from over 40 Installations

 

Installation

Boiler Types

Total BHP
Installed

BHR
Installed

1st Year
Savings

Masterfeeds
Komoka

Cleaver
Brooks

110

BHR-150

$8,750

Masterfeeds
Cavan

Cleaver
Brooks

150

BHR-15

$11,000

Strathroy Foods
Ingersoll

Cleaver
Brooks

300

BHR-150

$15,000

Shur-Gain
St. Marys

Miura
Cleaver Brooks

1,000

2 x BHR-150

>$10,000

Genpak
Mississauga

Miura
Thermogenics

1,100

BHR-250HM

>$10,000

Canadian Linen
Toronto

Miura

500

BHR-150

>$9,000

Cadbury Adams
Gladstone

Vapor

1,500

BHR-250HM

>$10,000

Korex
Don Valley Toronto

Thermogenics

1,500

BHR-48HM

>$20,000

Kellogg Canada
London

B&W

3,600

BHR-48HM

>$21,000

 

BHP = Boiler Horse Power
Savings calculated based on make-up water temperature differences and steam saved in boiler feedwater tank or deaerator.

 

 

Case History Data

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KOREX DON VALLEY ULC
Blowdown Heat Recovery Energy Saving Calculation Worksheet - click here (excel document)

 

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Unilever (Good Humor) Simcoe
Saves >$20,000 in First Year With Patented Blowdown Heat Recovery Process

Boilers:
2 x Miura 200 BHP

Boiler Feedwater: 
Atmospheric Tank
Heated with steam to 160°f (71°C)

Make-up:
Softened city supply

Condensate:
Process condensate sewered
Estimated 30% returns

 

The patented Blowdown Heat Recovery (BHR) process recovers the flash steam produced during blowdown functions to the atmospheric Boiler Feedwater Tank.  This reduces the amount of steam needed to be generated for preheating the make-up water in the Boiler Feedwater Tank.

The remaining energy in the blowdown is sufficient to heat the make-up water from 55°f (12.7°C) to 87°F (30.5°C).  A 32°F temperature increase.

Process condensate, normally discharged to sewer is now passed into the storage section of the BHR vessel to allow the make-up water to pick-up the extra thermal energy.  The make-up temperature now ranges between 95 – 100°F (35 – 37.8°C).  Typically 40 – 45°F above normal city supply water temperatures.

With the recovery of flash steam and heated make-up, the energy required to heat the boiler feedwater to steam temperature is reduced by 494,460 BTU per hour.  This is equivalent to 13.7 cubic meters of natural gas.

On an average day, approximately 330 cubic meters of gas are saved through this process.  At their current gas prices, the savings are projected to be greater than $30,000 per year.

PROJECT COST PROFILE:
          Savings Potential:                  >$30,000
          BHR-150 Capital Cost:                 $6,000
          Installation:                             $10,000
          First Year Projected Savings:     $14,000
          Gas Supplier Rebate:                  $6,000
          Total First Year Savings:     $20,000

 

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References: 

Available upon request – specific to your plant / boiler style