10. Case Studies

1. Cargill – Trafford Park To recover waste heat from a multiple hearth oven used for the reactivation of carbon and provide free steam for the factory. This was achieved by the installation of a waste heat boiler between the oven and the water scrubber. This not only provided free steam but also reduced water consumption in the scrubber due to the reduced temperature of the flue gases. 2. Ford Motor Co. Bridgend To recover heat from the boiler flue gas and preheat the boiler feed water to reduce boiler gas consumption. This was achieved by installing an economiser (which had to be designed on wheels in order to get it into position) in the boiler flue which raised the temperature of the boiler feed water and reduced gas consumption by 5%. 3. Aluminium Smelting Plant – Bridgnorth To the design, supply, manufacture, delivery and setting to work of a flue gas cooling system for the furnaces to reduce the temperature of the gases to a level suitable for the bag filters and together with a heat recovery system use that heat to supply hot water to the adjacent metal treatment plant. 4. Hospital/University CHP Plant – Leeds To increase steam production from a waste heat boiler. This was achieved by installing an economiser in the boiler flue which raised the temperature of the boiler feed water and increased steam production by 5%. 5. Power Station – Antigua To provide high pressure hot water and reduce the high parasitic load on the generator. This was achieved by installing a heat recovery unit on the exhaust of a 2MW heavy fuel oil fired Mirrlees V16 engine which provided the main power supply to Antigua. The unit generated high pressure hot water at 140 degrees. 6. Guilford Performance Fabrics – Somercotes To reduce the oily smoke fumes from textile stenters. An Electrostatic Precipitator is an extremely energy efficient abatement solution for oily smoke fumes. A heat recovery system was also incorporated to recover heat from the fumes and use it to supply hot water for use in the dye house thus reducing the boiler house steam load and giving a useful return on investment.

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