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Why You Should Still Buy a Heat Recovery System Even When Fuel Prices Are Low

by Madden Manufacturing • October 21, 2015


Want in on a secret? Madden had its highest sales years during the recession. Why? We’re not entirely sure, but one definite part of it was the rise in fuel prices. Everyone with a boiler system wanted to save money and be more efficient in their operations. Madden heat recovery systems usually pay for themselves in a matter of months and so these units became quite popular.

We’re writing this blog as a reminder of the obvious, that a heat recovery system still works on boilers burning cheaper fuel, and buying a heat recovery system will still result in savings; it just may be a couple more months before it pays itself off.

Example

Here is a simple example of savings with two different Therm costs:


Example 1 (Therm cost $0.60) 
Number of boilers: 3
Total steam capacity: 90,000 PPH
Operating Pressure: 200 psig
Average Steam generation: 50,000 PPH
a. Avg continuous blowdown: 4,000 PPH
b. Flash steam pressure: 5 psig
c. Flash steam produced: 720 PPH
d. Heat in flash steam: 1,155 BTU/LB
e. Heat recovery, steam: 831,600 BTY/HR
f. Hot water after flash: 3,280 PPH
g. Heat recover, hot water:
459,200 BTU/HR. Combined total recovery
(e+g): 1,290,800 BTU/HR
Fuel Savings
i. Fuel Saved: 16.14 Therms/HR
j. Cost per Therm: $0.60
k. Savings per day: $232.34
l. Savings per year: $84,806.00

 
Example 2 (Therm cost $0.50)
Number of boilers: 3
Total steam capacity: 90,000 PPH
Operating Pressure: 200 psig
Average Steam generation: 50,000 PPH
a. Avg continuous blowdown: 4,000 PPH
b. Flash steam pressure: 5 psig
c. Flash steam produced: 720 PPH
d. Heat in flash steam: 1,155 BTU/LB
e. Heat recovery, steam: 831,600 BTY/HR
f. Hot water after flash: 3,280 PPH
g. Heat recover, hot water:
459,200 BTU/HR. Combined total recovery
(e+g): 1,290,800 BTU/HR
Fuel Savings
i. Fuel Saved: 16.14 Therms/HR
j. Cost per Therm: $0.50
k. Savings per day: $193.68
l. Savings per year: $70,693.20

As you can see, big savings for your company are still available. Even in the second example, the heat recovery system will be paid off in a matter of months with the savings it provides. So if your company would ever consider the investment in heat recovery system, why not look into it now? Let it pay for itself and be already operating before the next time fuel prices go up. Your company will be able to better handle the increase in cost and at the same time you’ll be showing a green initiative. These units help show you as an environmentally friendly company willing to invest in the efficient use of energy. 

Features

Madden blowdown heat recovery systems are designed to be simple and rugged. No sediment accumulation, no scaling. Twenty standard models with capacity ranging from 2,000 PPH up to our largest standard model with 50,000 PPH of blowdown capacity.
Three different styles and twenty standard models are available to match a Madden blowdown Heat Recovery System to your boiler system for the best performance and the most economical return on investment. Look at these Madden results:

  • Recover 90% of the heat energy in continuous top blowdown that would be lost down the drain
  • Reduce temperature of blowdown discharge to drain to meet statute limits
  • Fast investment payback from fuel, cooling water and makeup water savings, Madden systems usually pay for themselves in less than 12 months
  • Durable, time proven designs, built to take the punishment of continuous, 24 hour a day service for years
Madden HC heat recovery system Madden HV heat recovery system


                          

         

Conclusion

If your boiler system does not have a heat recovery unit in place, give us a call (574) 295-4292 or shoot us an email (info@maddenmfg.com). We’re always happy to discuss concerns and issues to help find a solution. And don’t forget to check for one of our reps, odds are there is one in your back yard and they can certainly help you as well.

Faster Lead Times than Neptune & Milton Roy

Madden Manufacturing is currently quoting lead times of:
  • Chemical Metering Pumps @ 1-2 weeks
  • Fully Assembled Chemical Feed Systems @ 3-6 weeks
  • Sample Coolers & Small Heat Exchangers @ < 1 week
  • Emergency/Rush pumps in 1-2 days!


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