MANTRA Innovative Systems 2013

Tomorrow's Energy Solutions.
PROTEIN MANUFACTURING FACILITY INTEGRATES GAS-TO-WATER CONDENSER
An abundance of energy is required to heat the large volume of water utilized daily in the cleaning processes for a facility that has the capacity to process 200,000 tons of meat products annually.




SELECTION CRITERIA
CHALLENGES
The main goal for this manufacturing plant was to reduce the energy utilized by gas fired steam boilers responsible for heating the daily process and cleaning water throughout the facility. Due to the nature of the industry, a system manufactured to food-grade applications negating cross-contamination was essential. The exchange unit was also required to be designed with easy accessibility for cleaning and maintenance.
TECHNICAL DATA
Exhaust temp in: 221 F
Exhaust temp post recuperator: 212 F
Water temp in: 68 F
Water temp out: 149 F
Exhaust mass flow: 1,836 lb/h
Water mass flow: 22,044 lb/h
Energy recovered: 1.787 MMBTU
Payback period: 21 months
SOLUTION
RESULTS
In order to reduce their energy demand, MANTRA proposed a custom-designed through-flow gas-to-water heat exchanger manufactured with 2.5mm thick-walled 304 stainless steel heat pipes. The unit was designed to deliver 22,000 pounds of emission-free hot water per hour to meet the total daily process and cleaning water requirement for the facility.
The exchanger operates at a highly efficient rate, recovering 1.787MMBtu of energy per hour. The company approved the installation on the basis of a 24 month return on investment. The actual return was 21 months.