Latest Case Studies & White Papers

A 2021 Prewin Network Unplanned Shutdown Survey has revealed that equipment failures in Waste to Energy (WtE) and Biomass plants were responsible for a total of 22.9 days of unplanned shutdowns in 2021, and 43% of equipment failure classifications were boilers.

A leading food waste-to-energy operation has increased its biogas yields by an average of more than 43% - due to a new digester mixing system.

 After evaluating the performance of the facility’s first digester, built a decade ago, engineering component specialists Hayley Group were consulted about the availability of an alternative, superior mixing system for its customer’s second digester; mixers that unlike those in first tank, would eliminate typical biogas process problems such as foam, blocking and crusting – and in doing so, help boost the levels of methane.

 Hayley Group’s Engineer, Rob Bentley, said: “We constantly look to help customers improve efficiencies. This project is of particular note, because with the new, superior mixing system, the increase per cubic metre in gas from the second digester is over 40%. This is extremely encouraging to say the least, especially when you consider that the second digester also has 10% less capacity than the older first tank”.

Introduction
In 2020, a large power generation company in Southeast Asia commissioned the production of a new 600MW Pulverized Coal (PC) Boiler at its plant. The company had a requirement to be able to burn the full range of its coal, which had proved challenging due to the high calcium content of the fuel. As a result, a new boiler had been built and commissioned by a reputable manufacturer.
Since the boiler has been in operation, the plant has suffered with a build-up of slagging on the tubes. The plant’s requirement to burn the full range of coal means that some ranges had to be burned at an increased temperature, which had been causing excessive slagging at the bottom of the boiler. To fix the problem, the build-up was being regularly blasted, which was time consuming and inefficient.

The Issue of Boiler Slagging

Pulverized Coal boilers experience slagging as the molten ash adheres to the surrounding substrates. This is also commonly referred to as slag. The amount of slag is primarily dependent on temperature and the types of coal being used and whether it is anthracite, bituminous coal, subbituminous coal, or lignite. Boilers will often slag in the upper sections of the furnace where the temperatures are higher near the superheat pendants, but slagging may also occur on the waterwalls. The build-up has a negative effect on boiler operation. The slag acts as an insulation to the tube substrate and this loss of heat transfer is detrimental to performance. When the slag builds up on the tubes, the heat transfer decreases lowering the temperature of the steam going to the superheated portion of the system, therefore decreasing the overall efficiency of the system. Finding a solution to excessive slagging can have tremendous benefits for a boiler operator’s bottom line.
The Solutions

Since Belzona’s inception in 1952, the company has been committed to pioneering innovative protective coatings and repair composites that meet the maintenance demands found across numerous application areas in a variety of different industries.

Built on this extensive experience and knowledge, the company is delighted to expand its product offering with a new high-performance structural epoxy adhesive: Belzona 7311.

This cold bonding adhesive is specially optimised for structural bonding applications subject to cyclic and repeated load where high mechanical strength, cleavage, shear and fatigue resistance are required. Thanks to its combination of high-performance properties and ease of use, Belzona 7311 is a valuable asset for any engineer looking for bonding solutions.

Throughout Ohio there is a large a number of meat/food processing plants and municipal sites whose wastewater system is plagued by fats, oils, greases (FOG) and debris. 

Many of these may already have some sort of pump/mixer - perhaps sold on the basis of it being supposedly ‘non-clog’ - but staring down at a tank crusted over so badly that you might not be able to see any wastewater, tells you immediately that this isn’t the case. Chances are that the odor from the tank/collection system is so bad that even a new visitor to site - blindfolded – could locate it in seconds.

A classic example of this came to light just recently, when a leading meat processor, bogged down by reoccurring costs, foul odors and poor performance of its wastewater treatment system, looked for a cost-effective, long-term solution.

The problem at this particular site was so bad that you could (not that anyone in their right mind would) walk on or jump up and down on the layer of the tank’s crust because it was so thick!

Hoist and Winch Ltd has come a long way in a short space of time. From humble beginnings in 2007, the company today offers a full spectrum of lifting equipment services to the UK and global marketplace. Indeed, the Hoist and Winch portfolio now comprises product sales, installation, service, inspection, repair and hire, with a special emphasis on project work. With increasing demand, the reputation and corporate profile of this ISO9001-accredited business is rising fast.

The company excels in managing the supply and installation of standard and explosion-proof air-powered/electric hoists, while another strong business area is hoist hire, an offer that includes higher capacity air/electric hoists. As one of many market differentiators with its competitors, the company also offers installation services for rental hoists.

Although Hoist and Winch serves a number of sectors, the company is particularly at home supplying demanding industries such as heavy construction, cement production, petrochemical, offshore, marine, mining and tunnelling, many of which require explosion-proof equipment.

The Water Jetting Association is introducing a new code of practice for pressure washing to counter ignorance about the risks associated with the cleaning technique and to improve safety for operatives and others in the workplace.

The code lays out, in plain terms, the steps needed to optimise the safe use of pressure washing equipment. It also explains why these steps are important and what needs to be done if something does go wrong.

The Water Jetting Association (WJA), the UK’s trade body for the water jetting industry, says awareness of water jetting risks has not, until now, stayed in step with the development and increasing availability of pressure washing technology.

WJA Training and Safety Committee Chairman Darren Hamilton said: “Over recent years, companies and individuals have been able to buy evermore powerful pressure washing systems.

“However, many people don’t realise the risks they face if they don’t handle this equipment properly or if it malfunctions. Our new Pressure Washing Code of Practice addresses these issues, giving users of this very useful technology the guidance needed to work safely at all times.”

The WJA points to incidents like an experienced operative who suffered severe injuries, including 4^th degree burns, when a 3,000 pounds per square inch pressure washing jet pierced his boot, filling it with 110⁰C water.

This incident is just one of many pressure washing injuries. In another, a dockyard operative slipped due to the unexpected power of a pressure washing jet, allowing the nozzle to swipe across his supervisor, lacerating his upper thigh.

The WJA has already developed two codes – the Blue Code for high pressure and ultra-high pressure water jetting, and the Red Code for water jetting used for drain and sewer cleaning.

The new pressure washing code will support safe and productive water jetting at lower pressures, introducing a new operational standard and health and safety support for companies and agencies that carry out pressure washing and who rely on its advantages.

The code of practice gives the WJA’s definition of pressure washing, or power washing as it is also called. This is any jetting activity with a water pressure of up to 3,000 psi, or 207 bar (20.7 MPa).

Pressure washing is used to clean equipment and machinery in factories and engineering environments. It is also used to clean brickwork, remove graffiti, and clean mud and oil from the carriageway during highway repairs and construction.

In all these tasks, without a clear operational framework that a code of practice provides, there is opportunity for field teams to improvise and develop both unsafe and suboptimal practices.

The new code of practice includes sections on training and competency, site and equipment set-up, and the different types of pressure washing pumps and equipment, including hot water systems.

There is detailed advice on risk assessment, including a pre-start checklist, and emergency first aid specifically for the risk of fluid injection injuries that can be sustained during water jetting.

The WJA is the UK’s main provider of water jetting training. This includes a City & Guilds accredited pressure washing course which lasts at least five hours and is delivered by WJA-approved training providers and instructors.

Pressure washing contractors who are WJA members have welcomed the new code of practice, which is due to be published in early 2022.

Kris Jasinski, owner of TPC Brickwork Cleaning, in Southampton, said: “Having a code of practice to work to will benefit our industry greatly. People will be able check that standards are being set. The advice the WJA gives is central to how we go about our work and to our business success. I have no doubt about that.”

Find out more about pressure washing training and WJA membership:

www.waterjetting.org.uk

Leading British condiments maker, Tracklements, has boosted its production capacity and enhanced its environmental credentials by switching its energy supply from oil to liquid gas from Flogas. The move to modern, efficient liquid gas-fired Fulton VSRT steam boilers is expected to cut the company’s costs by a significant 21%, whilst also reducing carbon emissions by almost 25% and nitrous oxide (NOx) levels by 75%.

The Wiltshire-based company has been making condiments for more than 50 years and has an extensive range of over 60 artisan products, from mustards, ketchups and sauces to pickles, chutneys, jams and jellies. All ‘handmade in small batches’ using natural ingredients, these are made in unique jacketed steam cooking pans that mimic traditional homemade methods, and for the last 40 years they have been powered by two Kerosene oil-fired steam boilers.

“We needed to increase our steam capacity to support the continued growth of the business,” said Ben Read, Operations Director at Tracklements. “But we’re also fully committed to improving our environmental footprint, so we wanted to move away from the higher carbon footprint which oil represents. By replacing our ageing oil-fired steam boilers with the latest liquid gas-fired VSRT models we’ve not only increased our steam capacity by 100%, but we’ve also cut costs and significantly reduced our carbon emissions in the process. This was a major factor in our decision, as Tracklements continues to work tirelessly towards our goal of planet-friendly products.”

Having worked with Fulton for over 40 years, Tracklements looked to them to specify a cutting-edge system that would help minimise its environmental impact. Fulton also recommended Flogas as a liquid gas supplier – one that could provide a reliable supply and trusted on-going service. Flogas and Fulton partnered to deliver Tracklements a full turnkey, end-to-end energy solution that also included all necessary ancillary equipment as well as service and training contracts.

Commenting on the project, Jeff Byrne, aftercare and business development manager at Fulton said: “By modernising their steam raising equipment and changing their fuel type to liquid gas, Tracklements can expect an impressive 21% financial saving and a near 25% reduction in carbon emissions. These cost savings are based on current gas oil prices before the planned withdrawal of tax relief on red diesel in April 2022, so looking forward they’re actually far more favourable. Cost and carbon savings can also significantly increase by up to 30% when combined with the potential steam system efficiency savings by running the latest fully-modulating, high-turndown liquid gas boilers. What’s more, our liquid gas-fired VSRTs will help minimise other pollutants, with NOx levels projected to reduce by 75% compared to the previous oil-fired steam boilers.”

Tracklements has a strong environmental policy and holds ISO 14001 certification for its green credentials. “We’re constantly looking at ways we can enhance efficiencies and minimise the environmental impact of our artisan manufacturing process,” continued Ben Read. “We’re really glad to have now made a great step in that direction. Liquid gas is also more reliable for our business. Our tanks are fitted with auto-ordering technology, so as soon as they hit 40%, it triggers a re-order. It’s great peace of mind and leaves us able to focus on making great green condiments.”

Jude Hurley, Business Energy Manager at Flogas added, “This is a great example of how a simple switch from oil to liquid gas can have a major impact, logistically, financially and environmentally. Not only will the company benefit from a more efficient, reliable fuel with fewer emissions, but it is also setting itself up perfectly for a seamless transition to renewable green gas in the future. Bio-propane is chemically identical to liquid gas, so when the time comes for Tracklements to become carbon neutral, it can be simply dropped in without any changes to equipment or infrastructure. It’s an energy solution that’s truly fit for the future.”

Flogas Britain Ltd

As ‘Experts in Energy’, Flogas has more than 35 years’ experience in providing tailored energy solutions to commercial, industrial and domestic customers across the UK. From Liquefied Petroleum Gas and Liquefied Natural Gas to propane enrichment of biomethane – the company delivers high-performance, reliable, cost-effective energy solutions to suit customers' exact needs.  www.flogas.co.uk/business

Tracklements

Based in the heart of Wiltshire, Tracklements has been making award-winning artisan condiments for over 50 years. Along with chutneys, relishes, pickles and sauces, The Tracklements range includes ketchups, jellies, salsas, mustards, fruit cheeses and Charcuteriments. It uses only the very best quality, natural ingredients, and works with British famers and spice growers from all around the globe to ensure the Tracklements products taste as good as the best homemade versions. For more information visit www.tracklements.co.uk

Fulton Limited

With manufacturing facilities in the United States, Great Britain and China, Fulton is a global manufacturer of steam, hydronic and thermal fluid heat transfer systems. Backed by over 60 years of research, innovation and experience, Fulton is building on a tradition of success and is focused on improving life through heat transfer solutions. For additional information about Fulton please visit www.fulton.co.uk.

Author: Mark Guest - Product Manager for Power Distribution Systems

When NU-Design Limited, a marine electrical services business based in Peterhead, Aberdeenshire, Scotland needed help in the designing of a very specific control centre specification, the company’s engineers contacted Rittal UK to design a marine switchboard for a distribution and motor control centre (MCC) to be installed in a new Scottish trawler, the Endeavour V. 

The Challenge:

The Endeavor V is a Bureau Veritas +1A1 fishing vessel, she was designed by Macduff Shipyards Ltd. While the hull of the boat was built at Finomar shipyard, Szczecin, Poland.  The MCC panels feed-out to all the electric motors onboard the vessel, the main switchboard feeds-out to both the 415V distribution boards and the 415/230V transformers, which in turn feeds into the applications on board the commercial vessel. 

Bostik adhesives, including solutions from its Born2Bond™ Engineering Adhesives range, comprise an integral part of a vital Repair Kit or ‘Kit à partir’ that was offered by Arkema, Lalou Multi and Bostik to all 79 teams in the Transat Jacques Vabre (TJV) multi-day yacht race.

The adhesives have been chosen for their fast-curing, high-strength, and optimum moisture, humidity and chemical resistance qualities, crucial for the rigours of a global sea challenge.

The Repair Kit, is used in the event of any equipment failure, delivering a more sustainable maintenance approach than replacing entire parts. The kit provides the required range of fast, instant, and primer-free structural adhesives, sealants and lubricants, with anti-corrosive and hydrophobic qualities suitable for underwater and minute-size applications.

Arkema, a major specialty materials company and Bostik’s parent company, is the headline sponsor of the Arkema 4 Ocean Fifty trimaran, one of the yachts competing in the TJV race. It also has an exhibition stand in the event village, focusing on ‘Energy, Sport and Preservation of Resources’.