In the industrial sector, optimizing energy consumption while maintaining system reliability is crucial. One leading oleochemical manufacturer in India recently undertook a significant upgrade to their boiler feed system, resulting in impressive energy savings and improved operational efficiency.
The Challenge: Inefficient Boiler Feed System
The manufacturer was using a 45kW centrifugal pump for their boiler feed application, which operated continuously. The feed water was regulated through a feed valve controlled by level sensors inside the boiler, with excess water being bypassed to a de-aerator. This setup led to low system efficiency and high energy consumption, exacerbated by the need for periodic maintenance of the feed valve and the requirement for higher pump capacity to compensate for pressure drops.
The Solution: Grundfos iSOLUTIONS
To address these challenges, the manufacturer implemented Grundfos iSOLUTIONS, integrating intelligent built-in controls that significantly simplified field instrumentation. The new system adapts seamlessly to process requirements, eliminating the need for external controls.
By deploying the CRNE solution, the boiler feed valve and bypass line were entirely removed, leading to improved process efficiency. The Grundfos CRN pump with fixed speed, coupled with the CRNE-SF model, now operates at a total energy consumption of just 16.5kW. The level transmitter signal (4-20mA) is directly fed to the CRNE pump, which is set to operate in constant level mode. This direct control based on boiler steam consumption ensures that there is no bypass of feed water, effectively minimizing energy waste.
The Outcome: Significant Improvements in Efficiency and Reliability
The implementation of Grundfos iSOLUTIONS resulted in a remarkable 63% reduction in energy consumption for the boiler feed application. The complexity of the system was minimized, allowing the boiler feed pumps to be sized accurately to match steam production, which in turn enhanced overall system efficiency.
Additionally, the quality of steam improved due to the constant water level maintained in the boiler drum. This consistency not only optimized steam production but also reduced boiler maintenance needs, further contributing to operational savings.
Conclusion: A Model for Energy Efficiency
The successful integration of Grundfos CRNE and iSOLUTIONS in this boiler feed application demonstrates the potential for significant energy savings and enhanced reliability in industrial processes. By simplifying operations and improving efficiency, manufacturers can not only reduce costs but also contribute to sustainable practices within their facilities.
For industries seeking to optimize their energy usage and enhance system performance, embracing innovative solutions like Grundfos iSOLUTIONS can lead to transformative results. The future of industrial efficiency is here, and it’s powered by intelligent technology.
Being a leading Grundfos dealer, Alantech offers a wide range of high-quality and innovative solutions. The expert team at Alantech is well-versed and has in-depth knowledge about Grundfos products and supplies the most efficient and highly reliable pump technology prioritising customer satisfaction. As the best Grundfos pump distributor, Alantech will always be committed to delivering the best solution according to customer requirements.
