Steaming ahead...

• Dairy producer tackles its inefficient steam and sterilising system on multiple fronts
• Measures result in energy savings of 1 372 000 kWh and € 62 500 in cost savings a year

An Austrian dairy food-maker requires vast quantities of steam for heating, sterilisation and preparing its long-lasting milk products. The ageing system used for steam production and operating pressure needed to be upgraded and better optimised to meet demand in a cost-effective and environmentally friendly way.

To improve the existing steam boiler system, the feed water tank was replaced, the degassing process optimised and converted to a continuous feed-water control system. Additionally, a three-stage economiser was installed from which the energy is used for feed-water or for preheating it. The flue was insulated with a stainless steel inner tube, which lowered the gas temperature at partial load from 195 °C to 70 °C, thus reducing emissions.

Further monitoring and repair of insulation in the boiler, steam piping system and condensate return lines was carried out, and the measuring and control system of the steam generator was refurbished.

Key benefits

Together, all these measures resulted in energy savings of some 1 372 000 kWh per year, which corresponds to a 7 % efficiency gain and € 62 500 cost savings. This is significant enough to recuperate the company's € 175 000 investment within 2 to 3 years.