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Skid-mounted boiler frees up process space

07 October 2017

An outdoor skid-mounted horizontal boiler solution has helped one company to maximise its available process space. The boiler solution can also be left unattended while operational.

Baking pans are often refurbished by industrial bakeries but, over a period of use, they become caked in carbon and flour residue and the release qualities of the non-stick coating starts to diminish. 

The American Pan UK offers a solution, restoring pans using a process that starts by soaking the them for up to 24 hours in heated low volatility organic solvent. From here, the soaked pans go through a series a hot and cold rinses and conditioning tanks, before a new non-stick is applied and the pans returned to their owners.

A heating mechanism fault in the company’s plant process line resulted in a fire spreading throughout the facility due to a solvent used for the cleaning process overheating and igniting. 

Re-thinking operations
Although devastating for the company, it did provide the company with an opportunity to re-think operations and re-design its process lines.

Rather than wait and lose business the decision was made to reappoint an existing warehousing facility to a new process line. Because it was a new line with new equipment, it was possible to design an optimum layout with facilities and processes to future-proof the company and enhance its process.

While a decision on a new boiler system was considered, on advice from Fulton, a temporary, diesel-powered boiler was hired to provide steam for the new process line. Because it had reconfigured and relocated the entire line, American Pan UK also had to consider how it was going to heat the process and, additionally, consider provisions for downtime, maintenance, etc. However, with the new process line using most of the available space within the new facility, the decision was made to site the plant room for the new steam boiler system outside.

Fulton’s skid-mounted heat transfer solution features a horizontal, gas-fired RBC1500 boiler with NU-WAY gas burner and fully-modulating burner controls to provide a steam output of 2,393kg/hr and maximum working pressure of 10.34 barg. The skid also features ancillaries including automatic boiler controls, blowdown vessel, condensate return and feed tank and water treatment including water softener, chemical dosage sets and sample cooler.

The skid-mounted system was delivered to site and craned into position. Once the solution was sited and installed, the plant room was built around it. Following commissioning the temporary hire boiler was removed with its connecting pipework left in-situ should a requirement for additional steam be required in the future.

“Fulton’s heat transfer solution was chosen for a number reasons, with one main factor being the monitoring of the system, which does not require 24/7 supervision so at weekends, for example, it can be left unattended but operational for periods of time. 

Steam from the boiler system is now being used to heat water to 50°C for the pre-wash facility, for heating the solvent to 106°C for the deep clean cycle and for heating water for one of the two final cleaning cycles.

Thanks to the efficiency of the system, with the process heating the solvent to 106°C, the company has been able to reduce the acidity content of its cleaning solution to make best use of the increase in cleaning performance from the solvent. 

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