Case Study: Loparex
Steam Boiler Replacement: How We Helped a Manufacturer Identify Gas Reductions of up to 32% Using Dynamic Simulations
Executive Summary
For many industrial manufacturers, the central steam boiler is the heart of the factory—but it is often an inefficient, aging heart. We recently delivered an energy feasibility study for a release liner factory looking to replace its central steam generation system.
Instead of a simple one-for-one replacement, we evaluated multiple technologies to find the most efficient path forward. By utilizing dynamic simulation software rather than static calculations, we engineered a decentralized strategy. The result? A projected 32% reduction in gas consumption and a 39% drop in CO2 emissions.
The Challenge: The "Always-On" Inefficiency
The facility relied on a single, central steam boiler for every thermal need, from process humidification to building heating. This centralized approach meant the gas boiler had to run even for minor loads, leading to:
High Distribution Losses: Energy was wasted transporting steam across the facility for small consumers.
Lack of Flexibility: The system couldn't adapt efficiently to the varying schedules of different heating needs.
Rising Costs: With natural gas prices and carbon taxes increasing, the "old way" was becoming a financial liability.
The goal was clear: replace the central steam boiler. But the question remained: What is the best technology to replace it with?
The Solution: A Multi-Technology Approach
We didn't just look for a newer boiler; we identified the right heat source for each specific application. Our feasibility study proposed a decentralized, hybrid approach:
Decentralized Process Humidification: For production lines requiring steam, we replaced the long pipe runs from the central boiler with dedicated steam generators that can ramp up within a few minutes. This eliminated distribution losses and allowed independent control for each line without requiring the main boiler to be on standby.
Hybrid Electrification for Buildings: For the office and technical buildings, we designed a Hybrid Heat Pump system (combining a 75 kWe heat pump with a backup boiler). The heat pump handles the baseload heating and provides summer cooling, while the boiler only activates during peak winter demands.
Recovering Waste Heat from Existing Cooling Systems: Loparex uses cooling units in their process. These units produce waste heat that was previously vented to the outside air. Our solution captures this waste heat as a source for building heating, thereby reducing total utility costs.
The Dynamic Difference: Why "Average" Isn't Good Enough
Standard engineering studies often use Excel to calculate equipment size based on "average" winter days. This static approach is risky; it often leads to oversizing equipment (wasting CapEx) or undersizing it (risking production downtime).
We used Dynamic Simulation Software to model the factory’s thermal and electrical loads with precision:
Real-World Modeling: We simulated the plant’s energy profile hour-by-hour for a full year.
Optimizing the Hybrid Mix: Our software calculated exactly how many hours a heat pump could run efficiently versus when a gas backup would be more cost-effective. For example, we identified that a 17 kWe heat pump could cover over 90% of the demand for the dispatch building.
De-risking the Investment: We provided visual load profiles showing exactly how the new mix of technologies would perform under extreme weather conditions (down to -5°C).
The Results
By moving away from central steam generation, we identified the following reductions in energy use and emissions:
32% Reduction in total natural gas consumption.
39% Reduction in CO2 emissions (approx. 250,000 kg reduction).
38% Reduction in NOX emissions.
Future-Proofing: The transition to hybrid systems prepares the facility for further electrification as the grid becomes greener. We would like to thank Loparex and its team for their collaboration and trust. Onward to a decarbonized future!
Take the Guesswork Out of Your Energy Transition
Replacing major utility infrastructure is a high-stakes decision. Don't rely on static spreadsheets to model your plant's dynamic reality.
