Retrofits and reliability upgrades
OKI 2000 and HST 20 boost performance and efficiency
In Belgium, Ecofrost is a specialist in frozen potato products. Many processes require water that must be treated before it is reused or returned to the environment. The plant uses two aeration tanks, six meters deep, equipped with surface aerators and mixers that have to work around-the-clock. The process had problems with aerosols from the aerators and sludge that accumulated at the bottom of the tank. Sulzer was able to offer Ecofrost a proven solution to cut costs and improve performance.
kgO2/kWh efficiency
1.94
Efficiency improvement
52
%
Year ROI
4
The challenge
Potato processing produces a lot of contaminated wastewater that must be treated effectively. The surface aerators in the tank generated a lot of aerosols. Due to the tank depth of 6 meters, mixers were added but still the aeration process was not optimized. Sulzer suggested installing the OKI 2000 submersible aerator and an HST 20 turbocompressor. The solution would also require a new blower house to be constructed.
The solution
To prove the concept, Sulzer loaned Ecofrost an OKI 2000 and a containerized turbocompressor, which were installed within a week. The improvement was obvious compared to the surface aerators. Sulzer supplied four OKI 2000 aerators and two HST 20 turbocompressors for installation. The design allows for the remaining aeration tank to be upgraded in the future. Based on the results, Phase 2 is already planned.
Customer benefit
The new aerators have eliminated the problem of aerosols, reduced energy consumption and improved aeration efficiency. Remote monitoring of the HSTs ensures optimum performance and a maintenance contract minimizes any interventions. The return on investment (ROI) has been calculated at just four years, which will support the plans to upgrade the two remaining aeration tanks.
The loan of the submersible aerator and compressor was instrumental in understanding the benefits of the new system. Sulzer has enabled our aeration process to be much more efficient with an excellent ROI.
Jeannot Hoflack
Production & Operations / Ecofrost SA