Meat + Poultry - December 2005 - 51
Boiling POINT
Relieving the stress of
high boiler fuel costs
By Gerard Miron
meatpoultry@sosland.com
A
s 2005 comes to a close, there
appears to be no end in sight to
the rising fuel costs that continue to tighten the margins on already
strapped meat and poultry processors.
Natural gas and crude oil prices have
more than doubled from a year ago and
fuel oil prices are expected to increase
by as much as 50 percent during the
winter months. With no relief in sight,
these conditions have led processors to
evaluate their options and hunker down
for the long haul.
For some processors, fuel can account for up to 20 percent of their total
manufacturing costs. The major consumer of fuel in a meat and poultry
processing plant is the boiler, and more
than 75 percent of boilers in operation
today are at least 30 years old, according to data from the American Boiler
Manufacturers Association. Most of
these older units were not designed for
energy efficiency, and the vast majority run on natural gas. Considering the
current high cost of natural gas and that
a typical poultry processing plant uses
28 billion to 42 billion British thermal
units of fuel annually, even a small
improvement in boiler efficiency can
quickly add up to significant savings.
Fine tuning boilers
According to the Univ. of Georgia
cooperative extension service, finetuning boilers by paying attention to
things such as proper air-to-fuel ratios,
reducing scale or deposit buildup and
52
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MEAT&POULTRY
I
December 2005
I
capturing wasted heat can lead to thousands of dollars in savings annually.
In addition, there are many options
in boiler equipment and controls that
can help save energy. Typical gas-fired
boilers, for example, send 30 percent
of the energy they consume up the exhaust stack, but a portion of this wasted
heat can be captured through the use of
stack economizers that help return the
heat to the boiler system.
Randy Rawson, president of the
ABMA, says that while no one can
completely avoid the impact of rising
fuel costs, processors can minimize the
impact by ensuring their systems are
operated properly by well-trained employees in accordance with manufacturers' instructions.
"The costs of operation and maintenance may appear high, but they are
easily dwarfed by the cost of poorly
operated and maintained equipment,"
Rawson says.
While it always makes economic
sense to tune up current boiler systems
and evaluate the purchase of energy
saving enhancements, some processors
are making the leap to replace older,
traditional boiler units with new, highefficiency systems.
Oakwood, Ga.-based Wayne Farms
LLC, the nation's sixth-largest poultry
processor, processes 1.5 billion pounds
of chicken annually and reported sales
of $1.16 billion in 2004. Officials with
Wayne Farms recently wanted to improve the efficiency and production
www.MEATPOULTRY.com
The high-efficiency burner in a direct-contact
gas-fired water heater fires downward, and
cold water is introduced through nozzles at
the top of the unit. Water is heated quickly,
and few emissions are lost up the exhaust
stack. (Illustration courtesy of Armstrong
International)
of their plant operations. Ricky Culpepper, maintenance supervisor of the
plant in Laurel, Miss., turned his attention to the plant's boiler system.
"Our old boiler was installed back in
1958," Culpepper says. "Not only was
http://www.MEATPOULTRY.com
Meat + Poultry - December 2005
Table of Contents for the Digital Edition of Meat + Poultry - December 2005
Contents
Meat + Poultry - December 2005 - 1
Meat + Poultry - December 2005 - 2
Meat + Poultry - December 2005 - 3
Meat + Poultry - December 2005 - Contents
Meat + Poultry - December 2005 - 5
Meat + Poultry - December 2005 - 6
Meat + Poultry - December 2005 - 7
Meat + Poultry - December 2005 - 8
Meat + Poultry - December 2005 - 9
Meat + Poultry - December 2005 - 10
Meat + Poultry - December 2005 - 11
Meat + Poultry - December 2005 - 12
Meat + Poultry - December 2005 - 13
Meat + Poultry - December 2005 - 14
Meat + Poultry - December 2005 - 15
Meat + Poultry - December 2005 - 16
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Meat + Poultry - December 2005 - 18
Meat + Poultry - December 2005 - 19
Meat + Poultry - December 2005 - 20
Meat + Poultry - December 2005 - 21
Meat + Poultry - December 2005 - 22
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Meat + Poultry - December 2005 - 24
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Meat + Poultry - December 2005 - 29
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Meat + Poultry - December 2005 - 37
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