Sofame Energy Recovery Masthead
Energy Recovery NewsMay 2012
In This Issue
AstraZeneca's Newark, Delaware, Plant Earns Energy Star Certification with Sofame Percotherm
Sofame's Energy Efficient Industrial Water Heaters Reduce CO2 Emissions and Fuel Bills - Power Generation Applications
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Welcome to our latest issue of Energy Recovery News - focused on ways you and facilities managers around the globe are recapturing energy to reduce utility bills and greenhouse gases. Please let us know what you think of this issue and how we can help better serve you.

 

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AstraZeneca's Newark, Delaware, Plant Earns Energy Star Certification with Sofame

 

Reproduced from EPA Profile in Energy Efficiency 

 

The EPA has announced that AstraZeneca's Newark, Delaware, facility has earned the Energy Star certification after installing a Sofame waste heat recovery system.

 

AstraZeneca's Newark facility uses natural gas boilers for space heating, domestic hot water, and process heating applications. To improve fuel efficiency and reduce greenhouse gas emissions, the Newark facility was interested in recovering the heat from their boiler's flue gas.

 Skid Mounted Heat transfer System

After evaluating several options, the Newark facility selected a two-stage system, consisting of a direct contact and an indirect contact heat exchanger developed by Sofame. This system allows the Newark site to recover more heat from the flue gas than traditional heat exchangers or economizers. By utilizing the recovered heat to preheat water for various processes, including boiler make-up, the Newark facility has reduced boiler fuel consumption, energy costs, and greenhouse gas emissions.

 

Savings:

  • 15% reduction in natural gas use.
  • Lower fuel costs.
  • Reduced annual CO2 emissions by 1800 metric tons.
  • Reduced NOx emissions.

Additional Benefits:

  • The CO2 reduction at the site supports the corporate goal of a 20% reduction in greenhouse gas emissions.
  • The estimated payback of this project is between 4 to 5 years and meets AstraZeneca's requirements for strategic climate and energy projects.
  • Increased efficiency to help ensure ENERGY STAR certification in the future.
  • Continuously improving energy efficiency keeps the facility competitive. 

Sofame's Energy Efficient Industrial Water Heaters Reduce CO2 Emissions and Fuel Bills 

 

Sofame has invested over twenty-five years developing its leading technology and proving it in the field. The technology is called "direct contact", and its advantage is that it captures all the heat contained in a boiler's combustion gases. This thermal energy would normally be exhausted into the atmosphere from a regular boiler.

 

Sofame uses the direct contact technology to engineer and manufacture environmentally efficient industrial water heaters and cost-effective waste heat recovery systems for traditional boilers. Sofame's systems guarantee an instantaneous fuel-to-water efficiency between 91% and 96.7%, whereas a regular boiler's efficiency varies from as low as 50% to 82%.

 

Sofame is based in Montreal and has sold several systems in France, but it quietly entered the U.S. industrial energy efficiency market space in 2007. By signing up manufacturers' representatives on the east coast, Sofame extended its net sales without incurring major costs. It took two years to generate the first results, but today two multinational food processors, based in Battle Creek, MI, and Hershey, PA, are using Sofame Percotherm® systems to reduce fuel costs and CO2 emissions by over 10%. Two hospitals in New Jersey and Maine have purchased Sofame's equipment. Two universities, one in Colorado and one in Princeton, NJ, have also used Sofame engineering and equipment to cut fuel costs and CO2 emission by about 10%.  Sofame's newest customer is Butterball, the largest supplier of turkey products in the United States.
 

These environmental investments help mitigate climate change, but they also offer a handsome dividend in the form of fuel cost reduction, so financial payback periods are typically less than three years. In the case of large gas consumers (over $1,000,000 per year at current prices), payback can be closer to one year. Sofame's newest customer is Butterball, the largest supplier of turkey products in the United States.

 

Power Generation Applications

 

LNG Terminal using a GE Turbine, Montoire de Bretagne, France

An exciting new opportunity for Sofame is the way that direct contact technology has been applied to electric power generation. The U.S. electricity market is the world's largest, comprising one-fifth of both global demand and power plant capacity.

 

With natural gas prices at historic lows compared to all other fuels, many utilities are converting to gas-fired turbines which are about 40% efficient. In a well-run power plant generating electricity, steam and cooling for air conditioning, co-generation brings efficiency up to 70%. Sofame can take that number up to 99% if there is a need and a use for hot water at 135ºF. The potential additional fuel savings of 29% represent a corresponding reduction in CO2 emissions.

 

Today, institutions, universities, hospitals and industrial plants are also opting to generate their own electricity due to the availability of clean-firing gas turbines. This trend led Siemens and Alstom to build gas turbine plants in the United States to meet the demand. Since the demand for electricity is ever on the rise, Sofame's direct contact heat recovery technology can cost-effectively help reduce the impact on the atmosphere.

So Energy Efficient. Sofame.