Case Studies
Steam and Condensate System Optimization and Upgrade for a Juice Production Plant
30% Reduction in Steam Consumption!
Chalenge:
The facility faced high energy intensity and significant losses of treated water (condensate). An inefficient recovery thermal scheme led to excessive fuel consumption in the boiler house and increased operational costs.
Our Solution:
Conducted a comprehensive energy audit of the existing thermal distribution network.
Designed and implemented a closed-loop condensate recovery system.
Executed all installation works without interrupting the plant's production cycle.
Provided technical training for personnel on advanced steam trap management and automation.
Impact & Sustainability:
Resource Efficiency: Achieved a 30% reduction in annual steam consumption.
Circular Economy: Recovered up to 2 t/h of high-temperature condensate, significantly reducing raw water intake and chemical treatment costs.
Decarbonization: Drastic reduction in the facility's carbon footprint by optimizing combustion processes and minimizing thermal energy waste.
Large-Scale Steam Network Reconstruction at an Oil Refinery
Annual Energy Savings:
34,000 Gcal
Challenge:
The refinery experienced massive heat losses through main steam lines and malfunctioning condensate discharge units. High maintenance costs of legacy equipment were impacting the facility's overall thermal efficiency.
Our Solution:
Full-scale diagnostic assessment of the refinery's steam networks (inspecting over 100 critical nodes).
Engineering design compliant with stringent EU industrial safety and environmental standards.
Supply and integration of high-performance steam traps and specialized valves with extended service life.
Turnkey installation and commissioning of automated monitoring stations.
Impact & Sustainability:
Operational Excellence: Direct thermal energy savings of over 34,436 Gcal/year.
Risk Mitigation: Eliminated water hammer risks and improved the structural integrity of the steam distribution system.
ROI & ESG: Rapid payback period driven by operational cost reduction and alignment with corporate social responsibility (CSR) goals regarding energy conservation.
1.8 MW Sunflower Husk Biomass CHP Plant
Comprehensive Engineering & Design
Challenge:
A large-scale oil extraction plant required a sustainable energy strategy to handle massive volumes of sunflower husk waste. The objective was to design a high-efficiency Combined Heat and Power (CHP) solution to ensure thermal and electrical autonomy for the production facility.
Engineering Scope:
Technological Design: Development of a unique energy cycle featuring two high-pressure steam boilers (16 t/h each) and a specialized 1.8 MW steam turbine.
Customization: Engineering a fuel-feeding system specifically optimized for the combustion characteristics of sunflower husks.
Sustainability Integration: Designing a closed-loop system for 100% waste utilization, eliminating landfill dependency and reducing the facility's carbon footprint.
Operational Reliability: Developing a redundant technical scheme to allow maintenance without interrupting the plant's core manufacturing process.
Strategic Value:
Circular Economy: Transitioned the business model from waste disposal to internal energy generation.
Decarbonization: Replaced fossil fuel reliance with carbon-neutral biomass, aligning with European Green Deal objectives.
Efficiency: Provided a blueprint for significant long-term reduction in utility costs.
High-Capacity Biomass Thermal Energy Center
Large-Scale Process Steam Generation from Wood Waste
Challenge:
A massive woodworking facility required a reliable and cost-effective supply of high-pressure process steam for its industrial cycles. The challenge was to eliminate dependence on expensive fossil fuels and solve the logistical burden of disposing of large volumes of high-moisture wood waste (bark and wood chips).
Our Solution:
EPC (Engineering, Procurement, and Construction) of a centralized Thermal Energy Center.
Installation of high-performance biomass boilers specifically engineered for the combustion of low-grade wood residues with high moisture content.
Integration of an automated fuel feeding and ash removal system to ensure continuous 24/7 heat delivery to production lines.
Advanced water treatment and thermal deaeration systems to maintain the longevity of the steam distribution network.
Impact & Sustainability:
Thermal Power: Secured a stable supply of process steam in volumes sufficient for the facility's intensive industrial requirements.
Circular Economy: Implemented a "Zero Waste" strategy by converting production by-products into a primary thermal energy source.
Sustainability: Significantly lowered the carbon intensity of the final product by replacing natural gas/oil with carbon-neutral biomass.
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