Case 1 - District Heating Plant
This district heating company supplies heating and hot water to a community of approx. 8,200 households and businesses. The plant has two biomass boilers, each with a nominal capacity of 15 MWh and it is equipped with a heat recovery system based on flue gas condensation. Via a plate heat exchanger, the recovered energy is re-directed into the heating supply system.
Despite cyclones and filters, particles and bacteria are found in the condensate. In fact, data showed fouling reduced the heat recovery significantly. After 24 weeks, performance was down by 15%. Further, the data showed that the total energy loss due to fouling was 3,077 MWh per year.
A FoulingCure system was installed, and after 20 weeks of operation, no fouling was detected in the plate heat exchanger for heat recovery. Performance was close to 100%.
Potential annual heat recovery: 3,077 MWh
Potential annual savings, primary energy: approx. 66,000 EUR = 80,000 USD.
Additionally, the plate heat exchanger no longer needs full service once a year, but rather every five years.
Potential annual savings, maintenance: approx. 16,000 EUR = 20,000 USD.
Potential annual operational savings: 82,000 EUR = 100,000 USD.
Case 2 - Power and District Heating plant
The district heating company supplies heating and hot water to a community of approx. 36,000 households and businesses. The plant has two biomass boilers, each with a nominal capacity of 95 MWh. Flue gas condensate is used as fluid in the plate heat exchangers – to optimize heat production and primary energy consumption.
Despite electrostatic precipitators in the flue gas system, particles accumulate in the condensate and settle in heat exchangers. Data showed that fouling reduced the heat recovery after only six weeks of operation. After 16 weeks, performance was down by 10%, and after 20 weeks by 15%. Calculations revealed that the total energy loss due to fouling was 12,000 MWh per year.
Potential annual heat recovery: 12,000 MWh
The foulingCure application was installed, and the performance of the plate heat exchanger was monitored on a weekly basis. After 16 weeks, data showed that fouling had occurred, resulting in a heat transfer reduction of 5%. Further inspections and analyses were carried out. There was still fouling in the form of bacteria growth settling on the plates. After 24 weeks, performance was down by 9%.
CIP with disinfectants was carried out in combination with a FoulingCure flushing for 30 minutes. Within 24 hours the plate heat exchanger was back at 100% performance.
Potential annual operational savings: 404,000 EUR = 476,000 USD
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