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Situation
A malt roasting plant in Latin
America was facing serious
operational issues with radiator
tubes. Used to roast turkey grain,
these radiator tubes were corroding at an excessive rate due to
aggressive condensate water and
oxygen corrosion. Costs for these
systems were excessive. In one
year, the plant spent over
$200,000 US dollars for radiator
tube replacements. They also
spent $35,000 US dollars in
excessive maintenance costs.
Due to the corrosive nature of
the condensate, chemical costs
were also high.
Program
Knowing the plants concerns, the
Nalco representative looked for
alternatives for this facility. The
representative utilized the 7- Step
Problem Resolution method to
solve this facilitys concerns.
Working with plant staff, they
worked through the process.
Return on Investment
This facility noticed considerable
results within days of implementing the Nalco ACT program. Some
of the results the supervisors of
this facility saw were:
Savings of $200,000 US dollars
by minimizing radiator tube
replacements
Decreased maintenance costs
Reduction in makeup water
due to the increased condensate
return
Fuel savings from latent heat
being returned with the
condensate