Installing High Efficiency Thermal Fluid Heaters
The site has been operating for many years, handling chemicals, petroleum, pharmaceutical and agricultural products, but more recently has added a bitumen facility to its portfolio. Originally operating at 134,000 M³, Stolthaven Dagenham has now expanded its capacity to 160,000 M³ and is home to 120 tanks ranging from 66 to 11,000 M³.
Babcock Wanson worked closely with Stolthaven Dagenham’s consultants to provide the final design of the boiler house and then install and fit it out with its EPC ES and TPC B Thermal Fluid Heaters. A large proportion of the thermal design was also carried out by Babcock Wanson with the supply of all the system valves and ancillary equipment to provide a complete system with single point of responsibility. The system also incorporates a secondary circuit to provide lower temperature thermal fluid for the bitumen pump casing heating. The project was a fast moving one with tight deadlines, all of which Babcock Wanson met.
The Solution
The Babcock Wanson EPC1000ES and TPC1000B Thermal Fluid Heaters are being used at the site to heat the bitumen to a constant 165°C to maintain its fluid state. If the bitumen falls below this temperature it becomes difficult – and eventually impossible - to pump it where it needs to go. An accurate and reliable heat source is therefore essential. The heaters are fitted with dual fuel burners to guarantee fuel supplies with gasoil as backup if natural gas is not available. These are ideal for interruptible site gas supplies as they reduce operational costs whilst ensuring operational availability of the heating equipment.
The Babcock Wanson EPC ES and TPC B are fully automatic coil type, multi-pass Thermal Fluid Heaters and were chosen for this application as they offer a high efficiency solution to a very energy intensive process. They provide optimal distribution of the heat, high fluid velocity in the exchange tubes and continuous flow monitoring to ensure long fluid life and the highest level of safety. The EPC Heaters also precisely match fuel input to plant energy requirements and include their own in-built exhaust gas to combustion air economiser for highest practicable operating efficiency. With lower energy input demand also comes lower total exhaust emissions, so there are also environmental benefits.
What the Client Thought
Denis Kelly, Engineering & Construction Manager at Stolthaven Dagenham, comments on the decision to use Babcock Wanson for this latest project: “we looked at the market and what was available to suit our needs. We were familiar with Babcock Wanson and I have seen their equipment previously when working at other similar sites. It’s a good, well known brand with competitively priced products and with a UK base which was important for ongoing support.
“The Thermal Fluid Heaters themselves were ideal for this project as they are based on mature technology and are well proven in the field. They are robust and also require very little maintenance.”
Stolthaven Dagenham is one of many bulk liquid storage and logistics companies that Babcock Wanson has worked with over recent years. The company has gained an excellent reputation in the industry for its reliable, cost-effective heaters and excellent service.
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