Boilers & Burners

The Combustion Engineering Association (CEA) is pleased to announce Michael Kaye as its new General Manager. With a strong background in mechanical and design engineering, coupled with years of industry leadership, Michael brings both expertise and a fresh perspective to this long-standing trade association and educational charity.

Graduating from Nottingham Trent University with a degree in mechanical engineering, Michael began his career as a design engineer at APV Baker PMC where he honed his technical skills before moving into leadership roles across various industries. His career spans sectors including textile testing instrumentation and bulk materials handling, where he earned a reputation for fostering innovation, building effective teams, and driving business growth. At Flexco, where he also served as General Manager, Michael led initiatives that not only grew the business but also set new benchmarks for industry standards.

In addition to his professional achievements, Michael has also been deeply involved in association work where, as a long-time member and former president of the Materials Handling Engineers Association (MHEA), he gained valuable experience in bringing members together, organising impactful events, and promoting technical excellence, skills that align perfectly with the CEA’s mission.

Commenting on behalf of the CEA, President Mick Casey shared his thoughts on Michael’s appointment: “We are thrilled to welcome Michael as our new General Manager. His leadership comes at a pivotal time for the CEA as we navigate changes across the combustion-related sectors, and his vision for enhancing member engagement and promoting sustainable practices will undoubtedly strengthen our role in the industry.”.

Michael himself expressed enthusiasm for his new role: “The energy sector is undergoing significant transformation as we tackle challenges including the adoption of alternative fuels, decarbonisation and achieving net-zero goals. I see the CEA playing a key role in driving these conversations and supporting our members with practical solutions. Together, we’ll focus on alternative fuels, energy efficiency, and sustainable practices.”.

One of Michael’s immediate priorities is overseeing the CEA’s transition into a Charitable Incorporated Organisation (CIO). He also aims to expand training programs such as the Boiler Operation Accreditation Scheme (BOAS) while building stronger connections with academic institutions to nurture future talent in combustion engineering.

Under his leadership, the CEA also plans to reinvigorate its events calendar with site visits, networking opportunities, and conferences designed to deliver real value to members. The first of these initiatives – a site visit to James Cropper’s paper mill scheduled for February 2025 – will combine technical insights with opportunities for collaboration.

For further information on CEA initiatives or membership opportunities, visit www.cea.org.uk, email This email address is being protected from spambots. You need JavaScript enabled to view it., or call 01740 625538.

We aim to establish a directory of businesses supporting the steam industry, providing end users with a centralised resource for services, products and expertise. Our easy to navigate website features categorised sections which enables services to be located with ease. Additionally we utilise social media to share members services, products and case studies with a wide audience.

Our mission is to support business and end users of steam and boiler systems across manufacturing, process and industrial environments. By fostering a network that facilitates business to business interactions, we aim to address the growing scarcity of engineering disciplines in todays industrial sectors.

Our platform is broken down into key elements supporting the generation and distribution of steam. The main categories being:

• Burner Manufactures
• Boiler Manufacturers
• Consultancy Services
• Training Providers
• Components and Ancillaries
• Control and Automation
• Temporary Solutions
• Water Treatment
• Chimneys and Flues
• Emissions

So how can Steam Network benefit me?

If you’re a Businesses supplying products, service into the steam industry:

By becoming a member of Steam Network UK offers businesses a unique opportunity to be listed under categories specific to their services and products. We will actively promote your business to our extensive network and end users. As the only directory dedicated to supporting the steam industry, Steam Network UK ensures that your services are showcased to key stakeholders in need of your expertise.

If you are an end user of Steam and boiler systems:

In need of a boiler service engineer, Combustion Engineer, new Water treatment? Then look no further, Steam Network UK has all the contacts you need at your finger tips.

Our website allows for individuals to search the directory for relevant services that they may require. Whether you work in Engineering, Procurement, Management or Health and Safety, you’re sure to find a member that can support your needs.

Whether you are on the look out for a new Boiler, Water treatment services or stack emissions testing, then Steam Network can put you in contact direct with a reputable business to support you and your asset base. Partnering with one of our members provides peace of mind that your assets are in the capable hands of the UK’s leading specialist in their field of expertise.

Visit www.steamnetwork.co.uk today, to find the support you need.

Please contact This email address is being protected from spambots. You need JavaScript enabled to view it. should you have any further questions.

It is estimated that unplanned downtime costs oil and gas companies an average of $42 million per year, and up to $88 million per year in worst-case scenarios. In response to this substantial financial impact, advancements in automation and material science are revolutionising refinery inspection and maintenance, offering promising solutions to enhance efficiency, reliability, and cost-effectiveness.

Such technologies are being adopted by the industry and the trend is set to grow phenomenally in the next five years. In fact, according to a recent GlobalData article, sales of industrial robots are predicted to be worth $352 billion by 2030, growing at a compound annual growth rate (CAGR) of 38%. This article explores three key reasons why automation and material science are defining the future of refinery operations.

1. Enhanced Safety through Robotic Solutions

Safety is crucial in refinery operations, and automation is key in enhancing safety and efficiency. Most importantly, it reduces the risk of human intervention during hazardous inspection and maintenance processes. Robotic crawlers and rovers now perform critical tasks in environments too hazardous for human entry. These next-generation robots provide essential services such as inspection, cleaning, and alloy upgrades, all while ensuring the safety of personnel.

Integrated Global Services (IGS) is an example of a company that are at the forefront of this technological revolution, developing robotics for inspection and maintenance that identify and solve asset integrity issues early on, increasing safety standards and minimising unplanned downtime. As Eric Hellström, a Mechanical Engineer from Borealis, Sweden, attests: "IGS Tube Tech's expertise and commitment to quality ensures projects run smoothly, and on-site personnel are always a pleasure to work with. We have full confidence in their ability to deliver excellent results."

2. Advanced Materials for Extreme Conditions

The harsh environments within refineries demand materials that can withstand extreme conditions. Developments in material science are solving this challenge, with researchers and engineers creating solutions, such as:

• Unique superalloys, such as High Velocity Thermal Spray (HVTS), designed to combat specific corrosion and erosion challenges
• NASA-approved high-emissivity Cetek ceramic coatings for use in high-temperature rocket nozzles, control surfaces, industrial furnaces, and transfer lines.
• Proprietary claddings that address thermal efficiency and erosion-corrosion issues

These advancements are being used in the field, with proven results. A NASA Tech Brief, comments:

"The high emissivity coating was instrumental in advancing the radiation-cooled metallic nozzle extension for the J-2X Upper Stage Engine. It exceeded our thermal performance expectations and brought significant design efficiency and weight reduction to the table."

3. Cost Reduction and Sustainability

Automation reduces labour costs and minimises human error, leading to more accurate and consistent inspections. At the same time, material science innovations lead to the creation of more durable materials and coatings that can withstand harsh refinery environments, reducing the frequency of maintenance and replacement.

Case Study Example:

A refinery had been suffering from reduced performance due to fouling on the convection bank tubes within a steam methane reformer, a problem that had persisted since the unit came online in 1993. The refinery faced increased fuel consumption, higher flue gas temperatures, and reduced heat transfer efficiency. Integrated Global Services (IGS) applied a Cetek high-emissivity ceramic coating to address these issues, followed by Tube Tech’s robotic convection section cleaning service. This combination restored the heat transfer efficiency and resulted in a 20% increase in steam production and a 3% improvement in the furnace’s thermal efficiency. Additionally, the project delivered a rapid return on investment, with the cost of hydrogen production decreasing by $24.6 per ton, and the payback period being less than 60 days. This case exemplifies how material science and automation advancements can lead to significant cost reductions and sustainability improvements in refinery operations.

Conclusion

According to industry reports, implementing predictive maintenance strategies can reduce maintenance costs by 10% to 40% and increase equipment uptime by 5% to 20%. This highlights the significant financial advantages that refineries can achieve through the integration of automation and material science, ultimately leading to improved operational efficiency and cost-effectiveness in refinery operations.

To find out how automated solutions and material science advancements could benefit your plant, www.integratedglobal.com

A new international survey¹, published at the end of 2023, by the Institution of Engineering and Technology (IET) confirms what the engineering sector has been saying for years: that a considerable skills gap exists which impacts productivity.  What’s particularly interesting to note from this latest survey is that, in the face of climate change, that gap feels more like a chasm.

According to the survey, two thirds of UK employers are concerned about climate change and most have made a technological or organisational change to lower their environmental impact in the last three years, primarily focussed on emissions reductions.  However, around three-quarters think their organisation does not have the full skillset to be resilient against climate change, and 29% feel their organisation is not agile enough to adapt.  Furthermore, they cite increased costs in their supply chain because of climate change which, ironically, is seen as a widespread barrier to becoming net zero.

The findings of this survey is supported by the government’s November 2023 research briefing, ‘The UK's Plans and Progress to Reach Net Zero by 2050’.  It states that the industrial sector was responsible for 14% of UK emissions in 2022, with the Climate Change Committee 2023 Progress Report considering there to be higher risks to decarbonisation than in 2022, with insufficient plans for the majority of the Carbon Delivery Budget Plan targets for the fifth and sixth carbon budgets due to a continuing lack of progress.

UK Engineering employers surveyed by the IET largely put the blame for the skills gap on the education system.  63% think the UK education system does not prepare young people to work in their industry.  However, the engineering sector also has a role to play here by providing appropriate training and quality apprenticeship schemes. 

To make these changes will take political willpower, time and investment.  But time is one thing we are running short of when it comes to climate change and the UK’s 2050 Net Zero goal.  We need to act now to decarbonise industry. 

With process heating being a major consumption of energy and source of emissions within industry, it’s an area that manufacturers and engineering firms across the UK – and the world – are focussing their decarbonisation efforts and resources on.  Inefficient boilers and burners are being replaced with modern energy efficient heat raising equipment and systems that incorporate heat recovery, and we are seeing a big move towards electric powered systems, away from fossil fuel.

But as we make these changes, the skills to operate and manage much of this equipment is in short supply as we have clearly seen.  So, if the skills aren’t readily available, what options does industry have?  The answer has to be to reduce or remove the skills required, which is where manufacturers such as Babcock Wanson have a role to play.  We can’t solve the skills gap but we can engineer some of the skill out of day to day operation.  Here we suggest four ways to help bridge the skills gap:

1 Thermal fluid heaters

Increasingly popular, thermal fluid heaters work at high temperatures in a simple closed loop.  When compared to a steam system this means no change of state of the fluid so no condensate and therefore no flash steam losses, no blow down losses or make up water required, no effluent discharge and completely corrosion free without the need for expensive chemical treatment.  Not only are they more energy and cost-effective but in the context of the skills gap they are much easier to operate daily.  Furthermore, they operate outside the Pressure Systems Safety Regulations as the fluid is not maintained in the liquid phase by pressure, so are safer. 

Across Europe and now in the UK there is a move towards electric thermal fluid heaters, such as own newly launched EPC EL which, being modular, can be configured in series and parallel to meet different applications and site requirements. 

2. Unattended boiler operation

Where thermal fluid heaters are not an option, steam generators remain, but these require a far higher level of skill to operate.  Some of this can be mitigated by introducing unattended boiler operating systems.  Traditionally these were used by organisations whose operational hours extend beyond the standard.  However, recent years have seen a considerable acceleration in both the popularity of these systems (our customers now ask for it as standard) and the length of time they are able to safely operate unattended, from three to seven days.  Systems, such as our own BW7DAYS, make for easier operation requiring less skill.  Once set up for unattended operation, all the user needs to do is monitor for any operational alarms and undertake a very simple 15 minute test every three or seven days, which is completed without interfering with boiler operation and is acknowledged to the boiler control system, thereby ensuring the tests are completed to the operating schedule.  Improved safety and conformance with current and future UK & EU legislation is also a key benefit and one that even 24/7 operational sites that are fully staffed are increasingly attracted to. 

3. Water treatment services

All steam raising equipment requires the feed water to be treated to prevent corrosion.  Both the quality of the steam and the longevity of the boiler producing it are completely dependent upon the condition of that water feed.  Poorly prepared water can cause rapid and costly damage to the heating surface and can lead to the end of a boiler’s working life in a short period of time.  Water treatment is a skilled task, so consider outsourcing this.  At Babcock Wanson we have a partnership with water treatment specialists Deep Water Blue to conduct this service and, in between scheduled consultancy visits, our vSteam web portal allows customers to simply enter daily readings on-line and receive real-time feedback support.

4. Outsource maintenance

Regular service and maintenance are essential for steam plant to ensure smooth operation and safety, but even thermal fluid heating systems benefit from regular servicing.  Being able to operate such a system does not mean you have the skills to maintain it. Outsourcing this to a specialist, or the manufacturer itself, ensures the work is conducted to a professional level by experienced, trained service engineers. 

Babcock Wanson offers a complete range of products and services for boiler houses and other process heating needs. 

020 89537111

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www.babcock-wanson.com

In this article, Fulton managing director Carl Knight delves into the importance of BG13 and the insights it provides into how to ensure the safe operation of electric powered steam boilers.

Guidance for the Safe Operation of Electrically Powered Steam Boilers (Ref: BG13) is a guidance document intended to assist the managers, designers, operators, maintenance personnel and Competent Persons (CP) of new and existing steam boiler systems. Developed and written by the Combustion Engineering Association (CEA) and in consultation with other stakeholders – like Fulton – within the steam boiler industry. It serves as a vital resource to those named and addresses key issues including design, installation, safe operation, maintenance requirements, and compliance with legal standards.

The document covers various dangers and challenges including loss of feed water, over-pressure, overheating, electrical safety, and water treatment. Electric boilers – classified as small, medium, or large – encompass two main types: electric boilers and electrode boilers. Electric boilers utilise fully immersed heating elements, while electrode boilers employ conducting probes or electrodes to directly heat the water.

BG13 applies to industrial and commercial electrically powered steam boiler plants with a working pressure up to 32 bar gauge. It excludes steam boilers exceeding 37 MW nett rated thermal input or above 32 bar gauge working pressure, as well as coffee boilers, jet type electrode boilers, and hot water boilers. Nevertheless, the principles outlined in BG13 can still be applied where suitable and applicable, even to excluded boiler types.

DESIGN & INSTALLATION

Proper design and installation are fundamental to the safe operation of electric steam boilers. BG13 outlines design considerations such as sizing the boiler to meet the specific requirements of the application, ensuring adequate ventilation, and implementing appropriate safety features such as pressure relief valves and automatic shutdown systems.

To guarantee compliance with BG13 standards, installation should be undertaken by qualified professionals and follow manufacturer guidelines and relevant regulations.

BOILER OPERATION

This section outlines operational requirements and routine checks for electric boiler systems. Employers must conduct site-specific risk assessments to determine appropriate controls, supervision levels, and maintenance. Before use, boilers must be examined by a competent person and subsequently tested according to a Written Scheme of Examination (WSE).

Boiler instructions should cover safe operation, daily checks, start-up procedures, safe work practices, and notification of significant operational changes. System re-starts following lock-out require a suitably experienced operator to avoid potential risks.

Routine testing of controls, limiters, and water quality is crucial for safe and efficient operation. Testing frequency should be based on risk assessment, manufacturer's instructions, and operational requirements. Records of tests and maintenance activities must be maintained for audit purposes.

Water level controls need specific testing, with results logged and corrective actions taken as necessary. Feed water and boiler water checks, including chemical dosing and quality assessments, should be conducted regularly.

Special consideration must be given to water treatment for standby and unused boilers to prevent scale build-up and ensure system integrity.

PERSONNEL & RESPONSIBILITIES

The user/owner must appoint competent individuals responsible for daily boiler operation, with competence entailing relevant education, training, and experience.

Operators must be capable of recognising the limits of their expertise and seeking assistance when necessary and their duties are determined by site-specific risk assessments. Employers have general duties to provide safe workplaces and adequate staff training under the Health & Safety at Work Act 1974, MHSWR, and PUWER. These responsibilities cannot be delegated to employees or third parties.

Qualified electricians or electrical engineers must manage electrical issues associated with boilers, ensuring electrical safety, compliance with regulations, and implementing safety measures. Individuals monitoring boiler alarms must be adequately trained to respond appropriately to alarm conditions, ensuring safety before seeking assistance. Access during emergencies should be restricted to trained personnel.

Maintenance personnel require sufficient knowledge and training to carry out their duties safely, performing tasks only for which they are trained and competent. User/owners hiring subcontractors for specialised tasks must ensure their competency, oversee their work, and ensure compliance with legal requirements and safety standards.

Manning and supervision levels are determined by detailed risk assessments, considering factors like automation, location, water quality, and operational scenarios. Electric boilers require a competent operator present during start-up and lockout. Advanced automation may still necessitate full-time supervision for steam security or other reasons.

MAINTENANCE, REPAIR & MODIFICATION

Boiler systems must be properly maintained to prevent danger, adhering to PSSR Regulation 12 and PUWER Regulation 5. Responsibility for maintenance should be clearly defined, with the user/owner ensuring all personnel are competent, boiler operators handing over safely, and maintenance checked before the boiler is back in operation.

Steam leaks should be promptly repaired, and maintenance activities should be documented, including maintenance frequency, and logs kept up to date.

Before any modifications or repairs, a risk assessment must be conducted and the CP should assess the effects on pressure equipment, reviewing the WSE as required.

Significant repairs must address causal factors and comply with PSSR Regulation 13, documenting alterations and ensuring equivalent standards.

OPERATOR TRAINING

Employers must ensure all personnel possess adequate knowledge of boiler systems and receive training under PUWER Reg 9. Training should be ongoing, structured, and updated to reflect technological advancements and legislative changes, and should cover boiler operation, controls, emergency procedures, legal aspects, and site-specific elements.

Competence levels and training requirements must be reviewed, especially with system modifications, and employers must maintain training and assessment records securely for audit purposes.

Personnel, including managers and operators, must undergo regular work audits and periodic reassessment of training. Training validation must include written and/or oral assessments with recorded results.

Essential elements of boiler house training should include understanding Steam Boiler Water Treatment (SBWT) principles to maintain water quality. Recommended courses include CertIBO for operators, DipBOM for managers, and SBWT training as part of the CEA suite.

PERIODIC INSPECTION

A boiler must be examined according to a WSE that details parts, examination types, and intervals, and may be written and certified by an independent or in-house CP.

The examination includes two phases: "out of service" and "in service.", with the latter involving verifying protective devices such as pressure gauge, controller, safety relief valve, and water level controls.

Post-examination, the CP should issue a report with recommendations, while other devices such as control system power failure and critical alarms should also be checked and tested.

ENERGY & THE ENVIRONMENT

Efficient boiler energy management is crucial for cost reduction, safety, and plant longevity, so seeking expert advice before altering operating parameters ensures safety, environmental compliance, and efficiency.

Options such as metering for efficiency monitoring, water treatment, energy improvement devices (e.g., variable speed drives), and plant scheduling for optimisation should all be considered. It is worth noting that simply reducing steam pressure may not always enhance efficiency, so measurement is therefore recommended to demonstrate efficiency.

Electric boilers are not subject to emissions regulations, but environmental considerations such as noise and waste streams require attention. Water discharged must meet utility restrictions, and resources on legislation and guidance are available from government and industry websites.

Large organisations may need to comply with the Energy Saving Opportunities Scheme (ESOS).

CONCLUSION

The CEA’s BG13 stands as a comprehensive guide for the management of electric steam boilers, addressing design, installation, operation, and maintenance best practices. It serves as a vital resource for professionals involved in boiler systems, covering essential aspects such as safety and compliance with legal standards.

By adhering to BG13 guidelines, organisations can ensure the safe and efficient operation of boiler systems, mitigating risks and maximising longevity. Furthermore, considerations for energy management and environmental impact underscore the document's relevance in promoting sustainable practices within industrial settings.

Overall, BG13 provides a comprehensive framework for ensuring the optimal performance and safety of electric steam boilers, contributing to the overall efficiency and sustainability of industrial operations.

www.fulton.co.uk

Within the oil and gas industry, pipeline integrity and corrosion control are top concerns. Transporting untreated wet gas poses significant risks, as the presence of corrosive contaminants like hydrogen sulfide (H₂S) and carbon dioxide (CO₂) can severely damage critical pipeline assets. This damage results in leaks, loss of containment, and costly unplanned shutdowns.

Integrated Global Services (IGS) understands the urgency of effective corrosion control to maintain pipeline integrity and operational efficiency. As a result, IGS has developed a cutting-edge Metalspray® Pipe ID Rover system, representing a major leap forward in internal corrosion protection strategies for oil and gas pipelines.

The Challenges of Internal Corrosion

Corrosion in wet gas pipelines develops from various mechanisms, including CO₂ corrosion (sweet corrosion) and H₂S corrosion. CO₂ dissolves in water, forming carbonic acid that attacks the pipe wall, while H₂S dissociates to form sulfuric acid, leading to pitting. Additionally, the oxygen content, corrosive by-products, and contaminants introduced during production operations further contribute to internal corrosion.

Existing prevention methods, such as chemical inhibitors and coatings, have limitations in addressing the complexities of internal corrosion in hazardous environments like wet gas pipelines.

The Metalspray® Pipe ID Rover: A Breakthrough Solution

IGS's Metalspray® Pipe ID Rover system represents a breakthrough solution for pipeline corrosion protection. By offering a field-applied alloy upgrade for pipelines, slug catchers, and flare lines, this cutting-edge technology addresses the challenges of wet CO₂ corrosion and internal corrosion with unparalleled precision.

The self-propelled rover navigates through pipelines, applying a durable alloy coating to interior surfaces without the need for direct human intervention. This approach ensures comprehensive surface preparation, alloy application, and quality control in environments previously considered challenging or impossible to treat effectively.

Key Benefits of the Metalspray® Pipe ID Rover

• Targeted Protection: 360-degree access to critical areas ensures comprehensive coverage, protecting bottom sections, low spots, and weld seams.
• Pipe ID Corrosion Mitigation: Alloy upgrades restore and reinforce affected areas, significantly extending the asset's life.
• Laser Integrity Scans and Visual Documentation: Real-time scans provide essential documentation, ensuring quality and accountability.
• Safe Operation in Hazardous Environments: Designed for operation in hazardous wet gas environments, eliminating the need for confined space entry.
• Cost-Effectiveness: Maximizes capital efficiency, avoiding expensive replacements and providing a financially viable corrosion prevention solution.

A Comprehensive Corrosion Control Strategy

By stopping further damage and mitigating pipeline corrosion, the Metalspray® Pipe ID Rover becomes more than a technology; it becomes a comprehensive strategy to tackle CO₂ and H₂S corrosion. The solution supports operators in strengthening offshore infrastructure, ensuring uninterrupted production, and protecting their investment in pipeline systems.

Whether addressing finger slug catcher corrosion, enhancing flare line durability, or controlling corrosion in wet gas systems, IGS's Metalspray® Pipe ID Rover system is at the forefront of internal corrosion control technology.

With a track record of success and a team of experts dedicated to excellence, IGS is pushing the boundaries of innovation to safeguard operations against the threats of corrosion.

www.integratedglobal.com

Getec and Babcock Wanson Group are pleased to announce that they have agreed to the sale of the VKK Group, a prominent German company renowned for its expertise in industrial boiler technology.

 VKK Group, comprising VKK Standardkessel Köthen GmbH, VKK Standardkessel Service Köthen GmbH, VKK Standardkessel Verwaltung Köthen GmbH, Dampferzeuger-Rohrleitungsbau GmbH and PCE GmbH was originally acquired by Getec Group in 2018. Under Getec’s ownership, the boiler manufacturer, with physical presence in Kothen, Duisbourg and Lichtentanne, has undergone significant reorganisation, restructuring, and strategic positioning over the past five years, positioning VKK Group as a leading and innovative player in the German industrial boiler market.

Coming from the still famous story of Standardkessel boilers, the group of companies nowadays known as VKK Group, is a specialist in the design and manufacture of industrial boilers for the energy, food, chemical and other diverse industries. VKK Group also offers a wide range of services including engineering, installation of turnkey projects, monitoring and maintenance of equipment. The company has developed an expertise in high power boilers that gives it a strong competitive advantage in the industrial boiler market in Germany.

“With the takeover by Babcock Wanson Group, VKK Group will benefit from a strong and highly respected European specialist to pursue its growth trajectory” states Volker Schulz, chairman of the advisory board. “VKK Group can look ahead with optimism and confidence to its next step of development.”

 Babcock Wanson Group is pleased to make this strategic move and lay the foundation for its expansion into Germany, being one of the largest markets for industrial boilers, leveraging the production site in Kothen and the service site in Duisbourg.

“We are thrilled to welcome VKK Group to our journey of growth,” remarks Cyril Fournier-Montgieux, Chairman of Babcock Wanson Group. “VKK’s stellar reputation and expertise in industrial boilers make it the perfect gateway for our entry into Germany, enabling us to continue supporting our industrial clients in their energy transition and decarbonisation efforts.”

The Babcock Wanson Group intends to leverage the expertise of the VKK Group’s management and existing teams to bring to local customers the most energy and cost efficient solutions for their boiler room needs. This acquisition thereof represents a mutually beneficial arrangement, facilitating the integration of VKK’s expertise in high power boilers across all of Babcock Wanson’s European subsidiaries while harnessing its production capabilities. In parallel, VKK will benefit from Babcock Wanson Group’s advanced portfolio of technologies, including Parat’s high-voltage electric boilers, thereby contributing to the decarbonisation efforts within the industrial sector.

Supported by its main shareholder, Kartesia, Babcock Wanson Group remains committed to expansion and aims to cement its position as the European leader in decarbonisation solutions for industrial processes.

For information on Babcock Wanson, go to www.babcock-wanson.com

Overview

In a collaborative effort with a prominent global copper smelting operation, IGS (Integrated Global Services) successfully executed a groundbreaking project aimed at enhancing the reliability and longevity of a waste heat boiler.

The project not only showcased the technical capabilities of IGS but also delivered substantial commercial benefits to the plant.

Commercial Benefit Analysis

Avoided Downtime and Replacement Costs

Traditionally, the copper smelter plant faced significant challenges with the waste heat boiler, experiencing only 11 to 13 months of service life for critical panels. This led to extensive downtime, high replacement costs, and logistical challenges, particularly exacerbated by supply chain disruptions due to the COVID-19 situation.

IGS intervened with a high velocity thermal spray (HVTS) cladding solution, aiming to extend the intervals between turnarounds. The successful application resulted in a remarkable avoidance of downtime and replacement costs, contributing significantly to the project’s return on investment.

Identification of Issues and Initial Contact

The copper smelter plant in Chile, facing corrosion and erosion issues in their waste heat boiler, had historically resorted to panel replacements, single tube replacement and weld build-up strategies.

The turning point occurred when a representative came across another waste heat boiler reliability project delivered by IGS and approached the company seeking alternative solutions. This led to a comprehensive technical presentation to the plant’s maintenance and commercial teams.

Contract Award and Application

Following successful presentations and discussions, IGS secured a contract for a 70-square-meter application of their proprietary HVTS high-nobility alloy. The application took place in a laydown yard in October 2022, targeting critical areas of the waste heat boiler was applied.

Post-Application Inspection

The waste heat boiler ran continuously until the end of September 2023. In August, anticipating an outage, IGS mobilized an inspection crew, including local representatives from Chile. Despite a tight five-hour window, the team conducted a thorough inspection using magnetic lift-off (MLO) gauge testing. The results were overwhelmingly positive, with the cladding exhibiting no degradation after 11.5 months of service. Kevin Phillips, who has overseen both the project and inspection, described the cladding as in-applied condition.

“In all my years as a technical solutions partner, I have never had a client hug me. They were so pleased with the outcome!”, said Kevin.

Future Collaborations and Market Expansion

The success of the waste heat boiler project paved the way for potential collaborations on other critical components within the copper smelter. Converter hoods, copper cooling plates, and other identified assets are now under consideration for IGS solutions. The client’s satisfaction has positioned IGS as a trusted partner.

Conclusion

The IGS project on the waste heat boiler at the copper smelter stands as a testament to the company’s innovative solutions, delivering both commercial benefits and engineering excellence. This case study exemplifies how IGS’s proactive approach and proven solutions can transform operational challenges into opportunities for extended asset life and enhanced productivity.

Integrated Global Services, IGS - Your Efficiency & Reliability Partner

Established in 1974, Truck Trye Specialists has a reputation for providing premium bead-to-bead (hot cure) and procure (cold cure) remould tyres with over 100 tread patterns to suit all relevant commercial vehicle operations. Its products are manufactured using the highest-grade rubber compounds available and have a proven track record of improving mileage, traction and fuel efficiency, equalling and even outperforming tyres from established brands.

With a five-yearly NDT inspection due on its ageing horizontal steam boiler within 18 months, and given past experiences, there was a very real prospect of it requiring major coded pressure vessel repairs again. Truck Tyre therefore needed to find a replacement solution that could cope with current and future demands, while ensuring its Net Zero commitments – already established thanks to existing recycling procedures, upgrades to facility insulation and the installation of roof-mounted PV panels – weren’t compromised.

So having discussed the requirements and researched the options with its existing steam solutions specialist, the tyre manufacturer was presented with just one realistic option, VSRT vertical steam boilers from Fulton!

Steam is used throughout Truck Tyre’s facility – including steam and waste steam via heat exchangers for domestic hot water and space heating for the facility’s offices and factory – but plays a crucial role in the vulcanisation process when moulded rubber that is extruded onto the tyre structure is placed in high-pressure curing presses or autoclaves, with steam introduced at a controlled temperature and pressure, and serving several critical functions during the process.

Firstly, steam is an excellent heat transfer medium. It transfers heat efficiently to the rubber components, causing the necessary chemical reactions for vulcanisation to occur. The heat and pressure help the sulphur atoms in the rubber chains form crosslinks, which strengthen the material. Secondly, many vulcanisation accelerators work more effectively at elevated temperatures, with heat from the steam therefore accelerating the chemical reactions between the rubber and curing agents, reducing the curing time and improving the overall process efficiency. Finally, steam ensures uniform heating throughout the company’s curing chambers and autoclaves, preventing hotspots or temperature variations that could lead to uneven vulcanisation.

In a typical five-day work week, the boiler is operational for 12 hours per day, giving Truck Tyre the ability to produce over 30,000 tyres annually using its 28 commercial presses and autoclaves. Its maximum requirement for steam peaks at approximately 1,800kg/h and the original horizontal boiler would achieve this. However, during breakdowns, regular servicing, five-yearly NDT inspections and maintenance periods, the boiler and processes using steam were all shut down. It was therefore recommended that the new system should allow for duty assist within the specification.

Two VSRT-60 steam boilers were subsequently specified, each with a rated output of 960kg/h, easily coping with demand and affording the company the ability to reduce, not completely stop, throughput during planned shutdowns.

Commenting for Truck Tyre Specialists, director Daniel Collins says: “In the 12 months prior to the installation of the two VSRT steam boilers, we were using up to 213,000kWh of gas per month during high throughput periods. However, in the six months since Fulton’s VSRTs were commissioned, we’re now using around 155,000kWh.”.

As Carl Knight, Fulton’s managing director explains, a VSRT installation has once again resulted in significant savings for the end user. “With turndown increasing from 2.5:1 to 20:1 for the installation, Truck Tyre has reported a reduction in gas consumption of nearly 30% and over 140 tonnes per year of CO₂ emissions reduced, savings that can be credited towards its Net Zero goals. Additionally, based on historical data, there has been a reduction in NOx emissions in excess of 75%.

“These alone are truly impressive, but let’s not forget savings achieved from the reduction in water usage, chemical dosing, annual inspection, five-yearly NDTs and of course process downtime haven’t been factored in, making overall financial savings compared to the original horizontal boiler installation even more impressive!”.

Applications using steam, like those at Truck Tyre, have revolutionised over the years, yet the same cannot be said for steam boilers themselves. That was until, in 2018, Fulton launched the VSRT vertical steam boiler.

Claimed to be the most radical change to vertical steam boiler design since it first pioneered the vertical tubeless boiler in 1949, Fulton’s VSRT has rocked the steam boiler market since its launch to become class-leading and a symbol of efficiency, with many users benefitting from excellent savings in gas and water consumption and reductions in CO₂ and NO_X emissions.

At launch, the seven-model VSRT range was available with outputs from 160 to 960 kg/h, but with demand increasing for an energy efficient boiler with larger outputs, Fulton has now expanded the range and introduced two new, re-designed VSRTs with outputs of 1,565 and 1,956 kg/h.

Thanks to its unique design, the VSRT’s patented spiral-rib heat exchanger virtually eliminates thermal stress, so Fulton has therefore created a longer-lasting boiler that not only improves boiler efficiency but one that the company believes will beat the competition in every category of durability. This is why all VSRTs come with the assurance of a 10-year ‘unparalleled’ warranty on the pressure vessel, double that of the industry standard.

Additionally, with features including a vertical tubeless design with no refractory whatsoever, and thanks to its industrial control platform and easy access to the pressure vessel, the VSRT is also extremely easy to maintain. As the design is tubeless, there is no requirement for five-yearly, NDTs, which contributes to reduced lifecycle costs when compared to standard horizontal boilers.

In summary, as Carl Knight explains, Fulton’s VSRT can deliver steam (at up to two tonnes per hour from single boiler) while helping with both the financial and environmental challenges that are at the forefront of mind for many decision makers.

www.fulton.co.uk