Eco-Oil, a leading UK industrial waste oil recycler, has installed a TPC1000B thermal fluid heating system from industrial process heating specialist Babcock Wanson in its Ipswich oil recycling plant.
Heating System for an Industrial Waste Oil Recycler
A fully automatic coil type, multi-pass thermal fluid heater complete with integrated burner, control system and safety devices, the TPC1000B has been installed in Eco-Oil’s process area and is being used to generate heat for the production of Processed Fuel Oil. Eco-Oil is one of the largest suppliers of this type of fuel product in the UK.
The Solution and Client Reaction
The TPC Heater has been supplied with a dual fuel burner facility, running on gas oil but with the option to switch to the recycled Processed Fuel Oil Eco-Oil produces at the plant.
This is the first time Eco-Oil has opted for a thermal fluid heating system having relied on steam boilers previously. Allan Goulden, Engineering Director at Eco-Oil, explains his company’s decision to switch: “Reducing energy costs was at the heart of our decision and we knew we could make considerable savings by moving from steam to thermal fluid as the heat source for our process. We investigated the options thoroughly and decided Babcock Wanson offered the best solution. To date we have been proven right: the system has reduced our energy costs and is easy to use with very good control.”
The TPC1000B can achieve 20-50% energy savings when compared to the transfer of the same amount of heat using traditional steam boilers. The system precisely matches fuel input to plant energy requirements for high efficiency. With lower energy input demand also comes lower total exhaust emissions so it’s a “win-win” solution for both operating costs and the environment.
— Loucas Antoniou, Engineering Manager at Bakkavor Meals London
“The Thermal Oxidiser is the most efficient way of removing any smells and it’s also very straightforward to use. We have been a customer of Babcock Wanson for many years and have always enjoyed a good service.”
— Carbon Trust Annual Report 2009/10
“A major carbon footprint reduction will be achieved when the scheme currently in progress to change the main boiler fuel from heating oil to gas is completed in summer 2010. This £900k project will reduce our carbon emissions via energy usage by around 15% by removing the need to use heavy fuel oil, as the new boiler plant will use natural gas as its main fuel source.”
— Webster & Horsfall
“What we hadn’t expected initially though is the level of control the new system provides us with; it’s amazing. It alerts us to any potential issues, is easy to maintain (no annual statutory inspection is required) and is quick to respond. All that and it doesn’t take up much room.”
— Peter Connolly, Production Engineer at Vacu-Lug
“The ESM 2000 installation, together with an ongoing programme of process plant lagging and steam trap maintenance, has enabled us to significantly reduce our gas usage and cushion the company against rising gas prices.”
— Dave Scrivens, Facilities Manager at Plastic Omnium
“Babcock Wanson’s expertise and ability to provide a whole package made them the leading contender for this project. On further investigation, their proposal was also commercially viable, which sealed the deal.”
— Denis Kelly, Engineering & Construction Manager at Stolthaven Dagenham
“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.”
— Ian McQuarrie, Engineering Manager at Puredrive
“During my three years here, the Steam Generators and Thermal Fluid Heaters have worked flawlessly. Babcock Wanson carries a good name in the business for both quality and equipment longevity. Their knowledge, company wide, is exceptional and the whole package from installation through to service is managed professionally.”
— Jason Hall, J&A Young Engineering Manager
“We had estimated our steam requirements, but Babcock Wanson had the experience to understand that we had underestimated this. In fact, the erratic nature of the steam loads would have been impossible to meet under our existing spec. Babcock Wanson was able to identify this as well as provide a very energy efficient solution with a number of enhanced features”.
— Lee Bullen, Corrugated Services Manager at Board24
“It’s running very well, both easy to use and efficient. The service from Babcock Wanson has also been very good.”
— Peter Shrimpton, Engineering Projects Manager at Bridgnorth Aluminium Ltd
"We were unfamiliar with Babcock Wanson, but we’ve had no problems with it whatsoever; you simply switch it on and it works – simple as that! The service we have received from Babcock Wanson has also been great.”