CP Kelco Oy case
Implementation of heat exchanger efficiency monitoring at CP Kelco Oy
In the autumn of 2017, performance monitoring was carried out for strippers and preheaters at CP Kelco Oy in Äänekoski, Finland. Performance monitoring was implemented using Savcor’s Wedge software, which enabled real-time performance monitoring. This made it possible to note the performance reduction in the preheaters between washes and its relation to the increased energy consumption of stripping.
The operation of the preheaters was monitored with regards the transferred thermal power. The aim of pre-heating the stripper input stream was to reduce the stripping energy needs. However, no methods were available for evaluating the status of the preheaters or monitoring the stripper’s energy consumption.
As there were no methods available for real-time evaluation of the preheaters’ condition, they were washed during production shutdowns and were run continuously until the next downtime.
Implementation of efficiency monitoring
It was found that the fouling of preheaters occurred readily in their specific heat flux, so their performance monitoring was focused on this area. The decrease in the performance of the preheaters was found to correlate with the increase in the specific energy consumption of the strippers. This helped to identify the costs of the reduced preheater performance.
An annual savings potential of about 1800 MWh in a single preheater was identified, which can be achieved by correctly timing the washing of the preheater. In addition, on the basis of the review, Elomatic was able to recommend better running conditions for the preheaters.