HPP £1m boiler upgrade project at will benefit the environment

A £1m upgrade of the biomass heating systems at board, doors and fittings manufactures Hill’s Panel Products (HPP) will make them even greener and more efficient.

 

The Oldham-based business was one of the first to join the government’s Renewable Heat Incentive (RHI) programme - set up to minimise the effects of climate change - when it was launched almost 10 years ago. The scheme works by rewarding firms with financial support when they employ renewable energy technologies.

 

Work to install two new, more powerful and efficient boilers, and associated extractors, has already started and the state-of-the-art system is expected to be fully operational by the autumn.

 

The new installations will combine to work in the same way as HPP’s existing biomass systems, which reduce the firm’s carbon footprint by collecting wood waste otherwise destined for landfill via an extraction system. It is then stored in huge silos to fuel boilers heating production warehouses, in addition to supplying heat needed for the manufacturing process.

 

HPP’s Marketing and Business Development Director, Dan Mounsey, says: “Our infrastructure was ageing so we wanted to update it for greener, more efficient options. These new boilers will reduce our carbon footprint to the point that we don’t use any fossil fuels to heat those warehouses at all.

 

“The big difference between old and new is the new feature ceramic filters that extract exhaust gases before they leave the boiler. It means the emissions are much lower, which is better for the environment, while creating more heat output.”

 

Overcoming logistical and production challenges

 

The new systems are replacing existing boilers and extractors serving the door production and panel production warehouses, with work underway in the door production area.

 

Both installations involve huge logistical and production challenges, especially in the panel production area, where restricted access means a wall will have to be demolished to facilitate the removal of the old boiler when work begins on that aspect of the project in September. It will then be rebuilt when the new boiler is in place.

 

Various sized cranes are needed to lift out the old equipment and lower the new boilers into place, and production schedules have had to be cleverly adapted to keep disruption to a minimum.

 

A HPP team made up of members with maintenance, health and safety, site and production responsibilities – the four areas that need the most planning and coordination – are working with the contractors to ensure a smooth transition.

 

The project manager is Colin Taylor, HPP’s Chief Engineer, says: “We’re working with the installers to ensure the project runs as smoothly as possible. There’s a lot of re-wiring involved, removing old control panels, preparing for the new one and laying wiring where it needs to go to ensure that connections are available where we need them.

 

“We’re also having to extend the boiler building at the door production warehouse to accommodate the larger boiler. Although the new boilers are more efficient, and create fewer emissions, they are bigger with greater heat output than the old ones.”

 

One of the biggest challenges of the first phase of the project was the removal of a redundant silo, which took two cranes to manoeuvre it onto a low-loader HGV before it was transported for scrap.

 

Renewing long-standing partnerships

 

The project means HPP is renewing its partnership with the two firms that installed the existing system - Talbott’s Biomass Energy Systems, which is supplying the boilers, and Air Plants Dust Extraction, which is providing the extraction systems.

 

The new 999KW biomass system will feature modern PLC (programmable logic controller) touchscreen controls, including full remote monitoring and maintenance via a LAN connection.

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