Impact of LPG on Steam Generation

Benefits of Switching to LPG from HSD

A case study of a trusted mineral water brand who successfully transitioned from HSD to LPG for their steam generation needs, to save operational cost, improve efficiency and reliable supply.

Abstract

This case study explores how a prominent Indian mineral water brand, renowned for its dedication to delivering safe and pure water for half a century, embraced change by transitioning from High-Speed Diesel (HSD) to SUPERGAS LPG for steam generation. Battling with high operational costs and frequent maintenance due to HSD, the switch to LPG represented a strategic move. The study highlights the resulting operational efficiencies and maintenance cost reduction, reinforcing the brand's legacy of trust and quality while fortifying its commitment to sustainability and operational excellence.

Role of LPG in Steam Generation

In a water bottling company, steam plays several crucial roles, making it an indispensable element in the overall operation. Before being filled, bottles must be thoroughly sterilized. Steam, due to its high heat and thorough penetration, kills bacteria, viruses, and other microorganisms, ensuring effective sterilization.

LPG combustion is cleaner than other fuels, leading to better quality steam and thus better sterilization effectiveness and reduced risk of contamination. As LPG produces fewer residues, the boiler and other associated components require lesser maintenance, saving costs, and reducing downtime.

Benefits of Partnering with SUPERGAS

Navigating challenges with a customer swamped by production issues due to the use of HSD, SUPERGAS took a committed, holistic approach to provide relevant solutions. By aiding in the procurement of burners and leveraging a close relationship with Thermax for critical boiler modification, we went above and beyond to deliver robust LPG support.

We meticulously oversaw LPG site selection in strict compliance with IS 6044 PESO guidelines prioritizing safety and the responsible handling of LPG cylinders. Our steadfast, professional dedication to safety and procedural compliance instilled confidence in the customer, showcasing a stark contrast to the disorganized service they experienced elsewhere.

Operational Impact Study

While Using HSD	After Switching to LPG
HSD has a lower energy content than traditional fuels, such as natural gas and coal, so more fuel may be required to generate the same steam.	LPG has High calorific value which means translates to more heat with less fuel. Increased heat transfer efficiency, resulting in operational productivity.
High fuel consumption as HSD requirement was 20.8KL/month	Fuel consumption was reduced to 15 MT/month.
HSD fuel is more prone to contamination and requires frequent fuel filter changes. The higher sulphur content in HSD can cause corrosion to the boiler components if not appropriately managed.	LPG is a clean burning fuel, which leaves no residual elements behind. Sulphur free environment in and outside the plant.
Boiler downtime, which is necessary to reduce the build-up of dissolved solids in the boiler, is more frequent with HSD	No downtime and maintenance requirements.