Thermal carrier choice and management across multi-use sites
When choosing a thermal carrier for multi-use process optimisation, AES’s Commercial Director, Dennis Williams, emphasises the importance of asking questions to help understand the use requirements. He then goes on to highlight the place for steam and its alternatives.
start is by fully understanding the company’s primary product, and the potential roles of different thermal carriers in the production process. Steam and multiple-use challenges Steam remains the most user-friendly thermal carrier. Inert, non-toxic and safe, it minimises dangers such as product contamination or fire in the event of a leak, which can happen with thermal oil, which is highly flammable and op - erates at high temperatures. Therefore, from a process safety management perspective, steam is a good choice. Furthermore, steam can be generated across a range of pressures, and heating can be tightly controlled. In the event of the thermal carrier of choice being steam, and in an ideal world, a single steam user has a consistent load demand and operates continuously. In reality, it is more common to have to manage a dynamic steam plant operation, featuring multiple users, which requires strong technical skills, good communication and close attention to optimise results, emphasises Williams. Understanding the process comes first
when setting out to achieve efficient, optimal steam generation and thermal energy supply across a multi-use site, he notes: “This is criti- cal to determine the energy flows required in terms of timing, tonnages, pressures, variabil- ity profiles and condensate return generated. These factors form an overall operational ‘map’ of the variation in demand and load on the steam plant.” AES then determines the best operational strategy, including when to start which assets, specific boilers’ load profiles at particular times, and the management of risk in the event of equipment challenges or breakdowns. Site- specific operating procedures (SSOPs) are optimised based on the plant's configuration and user requirements. AES’s Remote Monitoring System (RMS) gathers steam generation plant data and records critical operational monitoring pa- rameters. This data is essential to monitor boiler efficiency and steam quality,” Williams explains. The focus is not only on minimising steam use to achieve energy requirements, but also
W hen it comes to making the correct choice of thermal carrier for production opti- misation, boiler operations and maintenance service provider AES’s Com- mercial Director Dennis Williams believes many questions must be asked: “These include how the energy is being used, if its supply should be outsourced, and if it is the right fit for every manufacturing process,” he says. “Other pertinent questions would be how much of the facility is aligned with steam and how much with another thermal car- rier? What are the implications of switching those? If changes are made, could the cost of production be reduced and quality improved?” he continues, advising that the best place to
A steam header with multiple process steam offtakes
30 ¦ MechChem Africa • November-December 2025
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