OPTIMISING ENERGY USAGE
18 December 2012
BABCOCK WANSON DESIGNS ENERGY CENTRE FOR KODAK
Babcock Wanson UK has completed the design and construction of a new ‘energy centre’ for Kodak Limited’s Harrow site in North West London, based around its ESM8000 Steam Generator.
The Kodak Harrow site operates a combined heat and power (CHP) plant that delivers steam to the factory producing colour negative paper for world-wide use, and to maintain building conditions, using a 50 ton Water Tube Boiler.
Built during the heyday of film processing, the plant is sized for a historically larger factory operating seven days a week. With changing patterns of usage, the current site now operates weekdays only. Running the existing CHP plant through the weekend when demand for steam is low is both inefficient and costly.
Kodak launched a project in 2011 to look at ways of reducing its energy consumption at the weekends and other periods of low energy demand. As a result of this study Kodak decided to install a steam generator able to supply 8000 kg/h of steam to maintain the steam service for non production needs, allowing the CHP plant to be switched off at the weekend and restarted on Sunday night in readiness for manufacturing operation on Monday morning.
As space in the existing boiler house was at a premium, Babcock Wanson designed a separate ‘Energy Centre’ for Kodak, based around its ESM8000 Steam Generator.
A coil type Steam Generator, the ESM 8000 provides high operating efficiency coupled with low emissions. It utilises modern controls to maintain a close ratio between the burner firing rate and water input with inverter drive of both the combustion air and feed water pumps. This ensures close control of both steam output and steam quality and lowest practicable consumption of both fuel and electrical power.
In addition to its operating efficiency, the ESM was chosen because of its quick Autostart facility which enables the Generator to be brought on line in a very short timeframe if steam demand fluctuates. This can be controlled remotely from the Kodak main process control centre for maximum convenience.
Construction of the new energy centre housing the ESM required careful planning due to space and access restrictions. Babcock Wanson designed a dedicated vented steel frame boiler house with a separate self supporting flue for the ESM. The latter proved particularly challenging due to the height requirements of the flue – 14m above the factory roof - requiring 8m deep foundations and a cruciform pile.
According to Abid Khalil, Project Manager, Paper Manufacturing Operations, the key to the success of this project has been the close working relationships created between Kodak, Babcock Wanson and the sub contractors. The result is a system that puts Kodak in position to control and monitor its steam requirements on a more precise basis and enable significant energy cost savings. “The new plant set up has driven an estimated 18% reduction in total energy cost for the site. Reduced energy consumption is also driving a reduction in greenhouse gas emissions of NOx, CO and CO2.”
It is anticipated that the new Energy Centre with the ESM Steam Generator will offer a full payback to the company within six months.
Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs, from steam boilers, thermal fluid heaters, rapid steam generators and hot water boilers to VOC and odour treatment by thermal oxidation, water treatment or process air heating solutions. The company aims to help optimise customer’s energy production with high quality products and efficient service.
For more information, please contact Babcock Wanson on 0208 9537111 or email@example.com or go to www.babcock-wanson.co.uk