Situation:

Tanker unloading pumps were being run continuously

Need:

A way to lower energy usage and cost

Solution:

Replacing inefficient pumps that need to be run 24/7 with pumps that can be powered down when not required

Annual Energy Savings:

358 MWh

Overview of the Phenol Unloading Application

SI Group is a global leader in the manufacturing of performance additives among many things.  Their UK manufacturing facility, based in the Midlands, produces Phenol-based products and constantly looks to improve working practices, save energy, and minimise hazards.  Moreover, they allocate their resources to create and manage sophisticated, accurate and productive facilities that emphasize a no-waste, high-efficiency philosophy.

A review highlighted the process of unloading Phenolic from road tankers (26,000 litres) and moving it to bulk storage tanks for further processing. Phenol, also known as Carbolic Acid, Phenylic acid and Benzophenol, is an organic substance used in the production of many chemical compounds. This material is subject to the highest tier of COMAH (Control of Major Accidents Hazards) regulations and has a number of associated handling precautions due to its tendency to solidify at low temperatures, as well as its hazardous and flammable nature.

The Issue

When the tanker unloading applications were first installed, a selection of canned seal-less pumps had been fitted.  These pumps were powered by 11kw ATEX Hazardous area electric motors. Since the product solidifies at lower temperatures, it was necessary to keep the pumps running all the time to guarantee the product is to ensure the product is agitated, heat conductivity is spread throughout the entire feedstock and the pump is kept warm and ‘moving’ to make sure small lubrication ports are clear.

For a period of 180 days, the pump runs for 24 hours, resulting in 99,360kWh of electricity consumed in one year. As there are 4 pumps, the total amount of energy used annually is 397MWh.

In that period, the number of hours totalled 4,320 hours adding up to a total of 49,680kWh of electricity being generated at 11.5kw.

Improving the Process

In this instance, the right unloading pump for this application was a magnetically driven centrifugal pump manufactured in stainless steel.  Offering a zero-vapour loss, seal-less design means that the fluids and vapours have been contained and present no hazard to the immediate or wider environment or to the individuals working in that environment. Choosing a UTS-B mag drive pump also meant that the amount of power needed to drive the pump could be significantly reduced, dropping from an 11 kw motor to 5.5 kw motor saves on the amount of energy being used by the solution whilst not compromising on loading and unloading times or compromising the operational effectiveness and lifespan of the pumps.

The solution included the use of heating jackets, which had been evaluated for their capacity to work with high pressure. This made it possible to harness the steam that was already accessible at the location and use it to keep the necessary temperatures.

Reviewing and modifying the original operating procedures on site also meant that the UTS-B pumps could be safely switched off when not in use and still maintain efficiency thereby reducing energy consumption further still, reducing mechanical wear and tear but also reducing the inherent risks that are associated with ‘live’ process lines when circulating fluids. This not only helped to conserve energy but also spared the components from unnecessary wear and tear. Additionally, it decreased the risks associated with operating process lines with liquids in them.

As a result, the new pumps now operate fewer than five hours a day, resulting in a yearly energy saving of 9,866 kW/h per pump. The collective energy savings of installing four pumps is estimated to be 39MWh/year, with an annual financial benefit of over £31’000.

The annual savings on energy expenditures amount to £31,600 at the current 2022/23 costs

CO2 Emissions were reduced by 90%, amounting to a total of 186 tonnes

Improve Processes, Save Energy. Reduce Costs

Needs and requirements can change as your business develops so to find out if your fluid handling solutions are still the right choice for your applications, call 01933 674777 or arrange a meeting with your area sales engineer.