Dual-fuel steam boilers contribute to major efficiency upgrade for manufacturer

As a diversified producer of a wide range of sophisticated chemical products, FUJIFILM Hunt Chemicals, in Dayton Tenn., has expertise in applying advanced, cost-effective technologies to its complex manufacturing processes. After initiating an energy-efficiency survey in 2009, the company determined that its steam-generation capabilities needed upgrading. 

To meet its goal of energy economy and reduced downtime for its cyclical manufacturing processes, the company chose two EX-200 SGO dual-fuel units from Miura, a leader in ultra-low NOx modular on-demand steam solutions.

“Overall, we run cyclical reaction batch processes,” states Manuel Calero, maintenance manager at FUJIFILM Hunt Chemicals. “We heat up our reactors and then cool them down. We had two old locomotive-style boilers, which were not well suited to the turndown when we cooled the reactors. Those boilers just sat there and made steam that was not being used, which was very inefficient.”

Calero researched the latest industrial steam boilers and obtained quotes from two makers of traditional-style fire-tube models, and one from Miura. Assisted by Tennessee Tech University, FUJIFILM Hunt Chemicals examined the efficiency specs of each brand and model of boiler and chose Miura.

“The Miura boilers definitely provide better cost efficiencies,” Calero explains, adding that current figures indicate a savings of approximately 33 per cent in natural gas costs. “We expect that to continue to improve as we get everything in place. And whereas we once had two boilers with a full combined output of 450 horsepower, we now have one on-demand 200 horsepower Miura boiler basically running the facility on low fire, with the second on-demand Miura sitting there on standby.” 

The dual-boiler system has reduced potential downtime situations due to equipment failures. In the past, it was difficult not to impact production for maintenance. Now the facility is able to operate with one boiler while performing repairs on the second unit. In addition, the facility is experiencing a reduction in production downtime when repairs are performed on steam piping. 

“Once the repair is completed, steam service is back within five minutes. It took the old boilers about 20 minutes, or 80 per cent longer,” says Calero.

Miura’s unique “once-through” fin-tube design not only requires less fuel and produces fewer emissions, it also generates full steam from a cold start in five minutes or less. This modular on-demand steam capability makes Miura boilers particularly well suited to a multiple installation in which boilers can be selectively turned on or off as needed to best manage changing load conditions, as opposed to idling in standby while they consume energy and generate emissions.

“These boilers also heat our buildings,” says Calero. “Our facility runs 24/7, and we anticipate that with redundant Miura EX-200 SGO boilers in place, we’ll never have to shut down because of steam issues. That’s going to give us a great deal of savings.” 

Click here to read this article in its entirety, and to learn more about the benefits of Miura boiler design. 

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