| Source Newsletter 2007 issue 2 |
|
 |
Increasing the efficiency of heating water
In April 2007, the Kraft New Ulm plant began using Complete Thermal Exchange (CTE) technology and now conserves energy while heating water, reducing costs at the same time.
CTE water heating technology boasts energy efficiencies near 100 percent and long service lives, two factors that are missing from traditional steam boilers like those the plant formerly used for its hot water needs. This technology utilizes a gas-fired burner and an enclosed chamber for combustion. This chamber allows for the vapor produced during heating to be condensed, thereby eliminating lost heat.
Installing new technology
The direct heat system that Kraft installed is 99.7 percent efficient. It is capable of heating potable water within 20 seconds of starting and does not require fuel for warm-up or idle time, further reducing the amount of fuel used. Additionally, while heating the water, it produces very low levels of nitrous oxide and carbon monoxide.
In contrast, the old water heating system used steam from two boilers. This method was estimated at 65 to 75 percent efficient and did not maintain a constant water temperature for the facility. Additionally, the steam/water mixing system created excessive noise from the hammering produced as steam was injected into the cold water supply.
The new direct heat system is NSF certified for food grade water and does not require a lot of space in the plant. Norm Melville, engineering manager at Kraft, reports that the system was easy to install with the plant’s current space configuration.
Positive Results
Since starting the system in April, Kraft has seen a downward trend in natural gas usage for 2007. Overall usage is tracked against previous years using a chart which is reviewed monthly. “We believe we are seeing a natural gas savings from this new system and are pleased with the change,” Melville said.
Kraft has not only realized cost and energy savings, but now also achieves a flow of hot water consistently measuring 140 degrees.
|
|
Reducing raw material wastes
MnTAP staff makes changes
Improving cleaning processes
Increasing the efficiency of heating water
Benchmarking Minnesota's ethanol industry
Summer interns help reduce waste across state
Chemicals of interest list finalized for chemical facility anti-terrorism standards.
Materials Exchange
E-Waste
Calendar
|
