⎪ PowerGen,PetroChem and Sustainable energy management ⎪
on maximising the percentage and quality of condensate return to save water and recover heat. Additionally, pivotal Process Safety Management (PSM) within a multi-user environment requires consistent practices across multiple boilers: “We must ensure safe operation for multiple boiler plants, multiple combustion devices, more hot surfaces, more maintenance and variations thereof if using different boiler designs, fuels or combustion systems,” Williams points out. Alternatives to steam Pressurised hot water: Williams says that lower temperature requirements of 120 to 150°C do not require steam. Instead, by using a pressurised water heater, the water tem- perature will rise to the desired level without boiling and flashing to steam. This process is widely used in companies such as breweries. Another example is when cleaning a plant or equipment. Gas and hot air: The textile and paper industries use gas and hot air extensively. “In the paper industry, there is a hood over the main paper cylinder, which is heated using gas. The flame is not fired onto the paper. Instead, it is used to heat the air directly in front of the burner flame. A flue gas-air mixture radiates
In summary, when considering thermal carrier changes or upgrades – including across multi-use sites -Williams warns against price-based procurement and recommends a longer-term, value-based approach: “It is about deriving maximum value from the production process and achieving optimal operational performance, margin and end- product,” he concludes. AES is a leading steam and boiler op- erations and maintenance (O&M) service pro- vider that operates in the power generation, chemical, plastics and rubber, timber, pulp and paper, textiles, food and beverage, and mining sectors of South Africa. The company helps industrial plants optimise their energy pro- duction processes and achieve best-practice energy use, including reduced downtime, efficient and cost-effective fuel combustion, extended plant life, energy resource diversifi - cation, and a smaller carbon footprint. www.aes-africa.com
onto the paper surface to dry out the last bit of moisture,” Williams explains. Alternatively, manufacturing or processing companies can use a combination of thermal carriers. For example, in the food production sector, an AES client that manufactures coffee and coffee creamer utilises gas and steam- heated air to dry the product. Thermal oil: Thermal oil is widely used in the textile sector, where it is circulated through stenters and other textile machinery to provide the required temperatures for fab- ric heat treatments. “Thermal oil, therefore, has specific applications, where higher tem - peratures can be achieved than when using a typical industrial process steam application,” Williams points out. Making the right choice “Decision-makers could unlock far more lasting and meaningful savings by carefully analysing key issues such as sustainability and efficiency,” he continues, adding that many companies are now integrating different thermal processes, including across multi-use sites, into one fully optimised system. However, the capital outlay will differ across thermal carriers, with decisions influ - enced by the selection of the fuel and associ- ated technology.
A thermal oil heater plant that uses liquid fuel burners to heat and circulate high-temperature oil through equipment such as textile machinery.
A steam plant for the food processing industry with multiple offtakes.
November-December 2025 • MechChem Africa ¦ 31
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