Introduction
A multinational company that manufactures inks, resins, and varnishes faced challenges with its multiple thermic fluid systems. These systems had a common expansion tank and separate deaerators, holding a total of approximately 150,000 liters of thermic fluid. The distance between the deaerator and the expansion tank was about 25 meters.
Background
The plant operates continuously, 24/7, throughout the year. The flash point of the thermic fluid began to drop rapidly, posing a fire hazard as the auto-ignition point was also decreasing. To maintain safety, the company was replacing 20,000 to 40,000 liters of oil annually, leading to high operational costs. Both the heater and oil manufacturers recommended a complete oil replacement, which included significant costs for cleaning, system shutdowns, and production losses.
Challenges
- Rapid reduction in the flash point of thermic fluid.
- High annual replacement costs for thermic fluid.
- Potential safety hazards due to lowered flash and auto-ignition points.
- Expensive shutdown and cleaning processes.
The company turned to Eximious, specialists in thermic fluid management, for a simple and innovative solution.
Solution
Eximious took the following steps:
- Investigation and Trials: Eximious conducted a thorough audit to identify the cause of the flash point reduction.
- Development of System – RELIEF: Based on the findings, Eximious designed and built a machine called System – RELIEF. This simple, online, side-stream machine was installed to remove gases and enhance the flash point of the thermic fluid.
Results
- Improved Flash Point: Over a period of three months, the flash point increased from 135°C to 177°C.
- Cost Savings: The company saved approximately 150,000 liters of thermic fluid, significantly reducing replacement costs.
- Sustainability: This solution contributed to the company’s sustainability efforts by minimizing waste.
Conclusion
Eximious with System – RELIEF successfully improved the flash point of the thermic fluid, enhancing safety and operational efficiency while providing significant cost savings. For simple and innovative solutions in thermic fluid management, call Eximious.