Projective Delivers £425,000 Annual Savings and Reduced Water Consumption

Heineken engaged Projective to carry out a major overhaul of the CO2 recovery plant at a large brewery. We applied our Process Energy approach to realise efficient CO2 recovery with a reduction to water consumption of 80,000 m3 per annum.

The existing CO2 recovery plant was no longer performing to specification. Both recovery volume and plant availability fell below that expected. The challenge was to maximise recovery and upgrade the existing plant.

We conducted a Process Energy review and determined the amount of CO2 available for recovery. We then evaluated the effectiveness of the existing plant and identified several areas for improvement. To reduce water consumption and loading of the existing carbon filters, we redesigned the entire low-pressure end of the plant to include more efficient gas cleaning vessels. We sized new variable-speed compressors to enable the plant to meet the fluctuating loads of the recovered CO2 with the lowest possible specific power consumption. The outdated control hardware and software was replaced and a new control philosophy written to provide greater visibility of plant performance.

The new plant was successfully engineered, managed and commissioned by Projective as principal contractor. We delivered the complete project with no disruption to day-to-day site activities. Operational data proved water consumption was reduced by 80,000 m3 and CO2 import reduced by 5,500 tonnes per annum. Further energy savings were obtained by re-commissioning the liquefaction system which had previously relied on manual control.