Case Study

Spirax sarco steam experts delivered a total solution by integrating the monitoring equipment with the know-how needed to turn data into useful information that helps in tracking energy.

El-Qaed is one of the pioneers in animal and poultry feeds manufacturing in Egypt, that’s why they knew that steam is considered as a strategic component in their industries so when the customer launched his new SAP system, he wanted to execute a cost allocation system for each production unit in the factory by using accurate steam metering system.

The Customer chose Spirax Sarco for this project based on the previous successful experience in enhancing products quality through correct steam conditioning and increasing steam quality.

So we started by installing one steam flowmeter on a 20 Ton/h pelleting mill and that’s when we discovered that the cost of generating steam is approximately four times the normal range due to a great drop in boiler efficiency.

When the customer saw the amount of financial loss he had to bear for the last years due to the problems in boiler efficiency, that’s when he decided to implement the steam monitoring system for the whole factory production units and also the two steam boilers.

The resulting system is seven Target variable area flowmeters (TVA’s) installed on each pelleting mills, full fat extruder and steam boilers.

Also the faulted steam boiler was changed by a new one with all Spirax sarco steam ancillaries and boiler controls.

Not just energy monitor and cost allocation

The installed flowmeters all feed information back over to a central SCADA system that is also monitored by the quality team to ensure that sufficient amount of steam is delivered to the pellet mill conditioner and also monitored by maintenance team for faster and easier steam ancillaries and traps fault finding.