A major industrial facility specializing in the food sector approached us to improve the efficiency of their heat exchanger system. The existing burners were outdated and inefficient, leading to higher operational costs and inconsistent performance. The primary issues faced by the client included inefficient heat transfer, increased operational costs and frequent maintenance requirements. The outdated burners were unable to provide consistent and efficient heat transfer to the heat exchangers, resulting in higher energy consumption. Inefficiencies in the burner system led to excessive fuel usage, driving up operational costs. Additionally, the aging burner technology required frequent maintenance, causing unnecessary downtime and further increasing costs.
To address these challenges, we proposed a comprehensive burner upgrade using our state-of-the-art PC2 packaged burner to enhance their heat exchanger efficiency. This solution involved the installation of burners capable of delivering precise and consistent heat, optimizing fuel usage and improving heat output. We integrated Siemens LMV37 control systems into the new burners, allowing for precise regulation of the fuel and air mixture, ensuring optimal combustion, maximizing heat transfer efficiency and minimizing fuel consumption. The upgraded burners also included features that simplified maintenance processes, reducing downtime and risk of operational disruptions. These features included easy-access components and advanced diagnostic capabilities.
The implementation process was carried out in two main phases: assessment and planning, followed by installation and commissioning. Our Sales Team conducted a thorough assessment of the existing system to understand the specific needs and challenges. Based on this assessment, a detailed bespoke upgrade plan was developed by our in-house design team. The old burners were carefully removed and the new PC burners were installed. The integration of smart burner controls (Siemens LMV37) was carried out seamlessly to ensure minimal disruption to ongoing operations. Comprehensive pre-firing, testing and commissioning were conducted to validate the performance of the new system.
The burner upgrade project successfully addressed the client's challenges by significantly enhancing the efficiency of their heat exchanger system.
This case study demonstrates the tangible benefits of investing in modern combustion solutions to achieve operational excellence and cost efficiency in industrial applications without the need to replace the complete heat exchanger.
