Project Snapshot

boiler image Project Name: Nalco Company, Burlington, Ontario
Project Description: Process and Plant Heating system upgrade at the Burlington plant.
Focus: Reducing the energy consumption, removing a major batch process heating load of 3.2 million BTUH and a raw material storage room heating load of 0.5 Million BTUH from the existing high pressure steam boiler and converting it to hot water heating and upgrading the old (south zone) plant heating system and shower boilers with new boilers.
pump image Nalco Canada Company, a Fortune 500 company and a leading manufacturer of water treatment chemicals, embarked on phase 1 of an energy retrofit project. The process heating of 3.2 million BTUH was supplied by the main 15 Million BTUH High pressure steam boiler. A 4.7 Million BTUH boiler was dedicated for the plant heating system. Another 1 Million BTUH boiler was dedicated for the 12 shower stalls in the change room.
Following discussion with Nalco and an energy audit it was determined by Wesatyn engineers that a new heating plant had to be designed, keeping in mind the changes envisioned. Our scope of work:

  • Replace the 4.7 Million BTUH plant heating boiler
  • De-commission the 1 Million BTUH boiler supplying hot water to the change room showers (12 Stalls)
  • Convert process heating and the heating source for a raw material storage room from an inefficient steam boiler to a hot water system
  • Install a new boiler plant consisting of two boilers and a provision for adding a third
  • Design a PST piping system to handle the variable demand load from the process, the heated chamber, the showers and the plant heating
  • pipesInstall VFD for the main circulating pumps
  • Install control valves on all how water demand loops
  • Design and install an automation system to manage all of the demand loads and accurately control hot water temperature and flow into the various demand loops.
  • Energy Management
boiler

The automation systems were designed to control:

  • Two stage heating and boiler operation
  • Supply of hot water at required temperatures and flow rates to multiple demand loads
    • boiler
  • Circulating and zone pumps
  • VFD’s
  • Control Valves
  • Operating schedules
  • Energy usage
  • Logging critical trend data

The automation has a web interface for remote control and operation. The new system and automation delivers savings of more than $ 135,000/year, with an ROI of just over two years.