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High Impact Projects Arising from the EnMS Process

Energy efficient design & retrofit


of boiler & steam generation system
This project involved developing and installing innovative variable
steam generators and heat recovery system with the flexibility to
meet the site variable steam requirements.
Heinz followed the SEAI EED Methodology to design the new
steam generating system to meet the variable steam demand
requirements and provide future flexibility in the system.
Project objectives
Implement the SEAI EED methodology to develop a steam
generation scheme that matches the specific, variable site steam
user profile.
l Improve boiler efficiency from 70% to over 90%
l Reduce the size of the replacement boiler (1 x 12.5 tonne to
2 x 7 tonne)
l Reduce gas consumption costs
l Reduce boiler maintenance costs and down time
l Improve business continuity and reduce business risk
l Develop a steam generation configuration that is future proof
and readily adapted to meet future steam/process requirements
l Integrate EnMS procedures into engineering and design
project. EnMS certified to ISO 50001.
l

Project background
HJ Heinz Dundalk manufactures approximately 19,000 tonnes per
year of frozen ready meals. Steam production, accounts for over 90%
of all gas use.
Prior to this project, the sites steam was generated by a 12.5 tonne
natural gas fired boiler. Despite modifications, the steam boiler
was unable to meet the required lower variable steam profile in an
energy efficient manner. As a result of constant on/off operation
of the boiler and inflexibility of the system, the boiler was only
operating at around 70% efficiency.
This project involved developing and installing innovative steam
generators and heat recovery system with the flexibility to meet the
site variable steam requirements.

Gas kwh / production Tonne

Energy efficiency design

900
850

Boiler replacement projects in industry are generally significant but


infrequent events occurring every 10-15 years. Traditionally boiler
replacement projects are based on upgrading like for like boilers
based on an analysis of demand, peak steam requirements and
assume steady loads.

800
750
700

600
Aug

Gas ActualFY12

Contact:
Mohamed Hamouda
EHS Department
Heinz European Frozen Foods and
Chilled Foods, Dundalk.
Office: 042-9385264
mohamed.hamouda@ie.hjheinz.com

FY12Gas target

7
FY11Gas target

Pat McGee
Utilities Supervisor
Office: 042-9385264
pat.mcgee@ie.hjheinz.com

Oct

Nov

Dec

Old boiler

Results.

1,550,000
1,500,000
1,450,000
1,400,000
1,350,000
1,300,000
1,250,000
1,200,000
1,150,000
1,100,000
1,050,000
1,000,000
950,000
900,000
2

Sep
FY12

Gas kwh shift efficiency

Actual use with new steam


generators

650

10

Based on an analysis of the past 12 months data, the project has


delivered the following results;
l 20% reduction in overall site steam v product KPI ie. from 823
kWh/tonne (FY 10) to 686 kWh/tonne (FY 12)
l 7.8% reduction in FY 12 shift steam use between target and actual
l Reduced down time/lost production by 100%
l Reduce annual maintenance costs by 88%

Key Learning
Commenting on the success of the project, Stuart Lawson,
Plant Manager, Heinz says, It is essential that all projects with a
significant energy impact address Energy Efficiency Design at all stages
of the process. The SEAI Energy Efficiency Design Methodology is an
excellent resource to guide companies through the relevant
stages of the EED process.

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