Energy recovery reduces annual steam consumption by 26,000 tons

Dairy cooperative Milcobel converts milk from local farmers into dairy products that are sold worldwide. For years, the company has been committed to sustainable initiatives that are economically interesting at the same time.

For a major project on waste heat recovery at its site in Langemark, West Flanders, the company partnered with DD Engineering. The result? By optimally recovering and reusing waste heat, savings of 26,000 tons of energy, 7% less gas consumption and 3,600 tons less CO2 emissions per year were realized.

Milcobel has already had a cogeneration (CHP) installation at its Langemark site since 2009. With this, the dairy cooperative generates sustainable electricity on site. But the ambition was to do even better and reduce annual energy consumption by 5%. A challenge that DD engineering only too happy to take on with his multidisciplinary team. The CHP had to be even more energy efficient, by also centrally recovering the residual heat from the flue gases. So a heat recovery network that would significantly reduce the use of steam. From the layout determination to the drafting of the specifications, the follow-up of the construction and even the delivery, DD Engineering cast himself as the ideal partner and advisor throughout the entire process.

Piping network fitted perfectly

The solution consisted of two circuits of circulating water accompanied by a network of heat exchangers. In the primary circuit, heat is extracted directly from the flue gases. This heat is then transferred to the water of the secondary circuit. This is then passed through a buffer tank directly to certain pasteurization and CIP processes to release its heat. The challenge was initially in fitting the pipe network, which was more than 2 km, into already crowded areas to get to the consumers. The distance between the primary circuit and the buffer tank was 300 m. The team from DD Engineering went to work using 3D scans to determine the correct positions and engineer the layout. A concept that took into account space, desired flexibility and maintenance considerations.

From specifications to completion

To put together the puzzle of the right components, the DD Engineering of clearly specified specifications. As Milcobel's partner and advisor, DD Engineering was responsible for the negotiation process, determining the most suitable supplier and the contractual side. The actual construction could then be confidently placed in the hands of the chosen suppliers. DD Engineering was also fully responsible for project management, ensuring planning, budget, safety and proper follow-up. This was done in four phases. First, two large pipe bridges were installed. Next came the economizer in the chimney of the CHP. Phase three included the supporting piping. Finally, the 25 m high buffer tank was realized along with 2 km of piping and all process components. DD Engineering took care of the complete coordination, including welding checks. After all, proper follow-up of the construction phase leads to smoother delivery.

Also full safety hatch

Once construction was complete, DD Engineering shifted its focus to aftercare. The engineers tested and verified that the plant and its components were working properly. In addition, knowledge transfer to Milcobel and its operators and engineers was provided. They could count on support and explanations where necessary. Finally, DD engineering took care of the entire safety part of this project, by taking care of the HAZOP study, the technical construction file, the commissioning report and the CE conformity declaration. This helped Milcobel from A to Z on delivery and the plant was up and running in the shortest possible time.

Also curious what the plant engineers of DD Engineering can do for your production floor? Then get in touch with us. We will be happy to help you.