Marlux - Energy retrofit steam rooms & conversion of fuel oil to gas

Customer request

Significant CO2 - emission reductions and cost effective energy savings in production. Thus, a roadmap was drawn up of  energy projects with CEE. Two elements of this roadmap include: 

1. Targeted research into energy savings around steam use in the steam rooms.
   
2. Conversion from fuel oil to gas and boiler room optimization.

Result

• Optimization of the steam consumption in the steam rooms.
  • implementation of new delivery system in steam rooms to standardise the heat output (new steam piping,
    new chimney valves and associated instrumentation)
  • Automation of steam cycles: a required standard temperature profile was followed in the steam rooms
  • Isolation of the steam rooms

After control measurements, the steam consumption at Marlux was significantly reduced (over 25%) with a quality advantage in the manufacturing process.

• Switching fuel oil to gas
  • New natural gas pipeline (underground and 
    above ground)
    
  • Implementation of new burners and
    economizer on the existing steam boilers
  • Centralization of overall control of the boiler room with expansion capacity

Approach

From energy monitoring to turnkey implementation

• Optimization of the steam consumption in the
  steam rooms
  • Energy monitoring of steam distribution & reduction through relative humidity, temperature & flow measurement
  • Detailed simulation and extrapolation techniques
  • Basic & financial engineering of different options, taking into account
    • Optimization of energy flows
    • Uniform temperature profile in the steam room
• Detailed engineering and implementation of improved demand-driven steam cycles, with guaranteed savings target concerning steam consumption
  • Replace open cooling systems by closed cooling systems  
  • Economizer on the boiler and overall control of the boiler house 
    
  • CHP installation linked to steam and hot water process, integrated in the production process