In 2010, Decas Cranberry Products Inc., the second-largest processor of sweet dried cranberries in the world, was nearing capacity on the 1998 Cleaver-Brooks CBLE 500-hp boiler at its facility in Carver, Mass. With National Grid, the local gas utility, awarding rebate incentives to companies that increased their energy efficiency, Facility Manager Mike Janick contacted Robert Cifello, aftermarket manager for Frank I. Rounds Co., to explore the facility’s boiler-room options.
Cifello conducted an energy audit, utilizing the BOOST (Boiler Operation Optimization Savings Test) software program from Cleaver-Brooks. BOOST generates a variety of financial metrics showing upgrades, retrofits, and replacements that maximize a company’s energy-saving and environmental goals.
Using information specific to the facility, Cifello presented retrofit options that would increase Decas Cranberry’s energy efficiency and reduce its carbon footprint. He recommended the company install an advanced Hawk integrated control system.
By adding the Hawk control system to its existing boiler, Decas Cranberry could realize energy savings of 6.1 percent annually and reduce carbon dioxide (CO2) by 462 metric tons and nitrogen oxide (NOx) by 6 percent. Based on the anticipated savings, Decas Cranberry would recoup its equipment cost within eight months.
Cifello also presented financial data to support adding a stack economizer to the boiler. The economizer would increase energy savings by 1.6 percent and further reduce CO2 by 120 metric tons and NOx by 2 percent.
The new control system and economizer were installed in December 2010, during the facility’s holiday break.
"The control used to go from low to high fire to meet plant demands," Janick said. "Now, it stays within operating variance in loads. Also, we are able to maintain water levels in the flash tanks much more effectively. Prior to the installations, we were experiencing a lot more surging, and now the unit responds more efficiently."
With the Hawk control system and the stack economizer, Decas Cranberry will emit 4,620 fewer metric tons of CO2 into the environment and save more than $1 million in energy costs over the next 10 years.
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