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Application Note: Irish Distillers (Midleton) Hot water circuit October 2015

Irish Distillers (Midleton) Midleton is one of the most modern distilleries in the world and has its
production areas linked via fibre-optic networks. The Midleton factory, with a production capacity of
64 million litres per annum, is the largest in Ireland. The distillery boasts three 75,000 litre pot stills,
and three column stills, which are used in combinations of three to produce different types of
whiskey.

The distillery continually strives to provide and implement best practices throughout the operation.

Distilling makes use of significant volumes of water, both in the production of product as well in the
many ancillary activities required to support the distilling process.

Phoenix Ring Manufaktur, at the invitation of our partners, Plate Tek Engineering, was invited to
discuss the use of the Sialex®, Scale and Corrosion control system, on a section of the Distillery’s hot
water system. This section consisted of hot water storage tanks and circulation pumps.

Geschäftsführer: Bank: Sparkasse Odenwaldkreis


Michael T. Laverty Konto-Nr.: 140247537 IBAN: DE61508519520140247537
Sven Gagel BLZ: 508 519 52 SWIFT/BIC: HELADEF1ERB
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The application: A circulation loop including a hot water storage tank holding approximately 165m³
of water, a circulation pump, interfacing with a PHE (Plate heat exchanger). The water is held within
the holding tank at 65⁰C. Water is circulated past the pumps at approximately 23m³ per hour.

Due to the temperature / circulation profile “Scale” builds up on the circulation system. In particular
the “Scale” buildup impacts the performance of the circulation pumps. There is a requirement on
maintenance personnel to remove and replace circulation pumps to ensure access to hot water.
These pumps are then cleaned and re-installed when “Scale” buildup re-occurs.
Water Analysis, with particular emphasis on “Water hardness” highlights the underlying issue
contributing to “Scale” build up within the water circuit.

Total “Hardness” in the process water gradually increases with use. Although 160 – 180ppm is not
extremely high by itself, this combined with temperature results in “Scaling” on the re-circulating
system. This results in the need to remove re-circulating pumps from service each 6 weeks for
cleaning.

Sialex®Ring:
Is installed without need to stop production
Does not require cutting of pipes
Does not require stopping of water flow
Does not require addition of any chemicals to water
Does not generate any “waste” by-products requiring subsequent treatment
Does not require external power to operate device
Removes “existing” “Scale” from pipes and devices exposed to “hard” water
Stops “New” “Scale” from forming
A “Green” technology

Geschäftsführer: Bank: Sparkasse Odenwaldkreis


Michael T.Laverty Konto-Nr.: 140247537 IBAN: DE61508519520140247537
Sven Gagel BLZ: 508 519 52 SWIFT/BIC: HELADEF1ERB
Seite 3

IDL personnel confirmed the need to replace the circulation pump will occur every 6 weeks. A simple
“Pass / fail” criterium was agreed with the staff. The ability to extend the period between replacing
pumps by a factor of 2 (that is from every 6 weeks to at least every 12 weeks) would be deemed a
success for the Sialex® device.
th
On July 9 2015, during the annual plant “shut down”, a Sialex® optimum 6” device was fitted in front
of the re-circulation pump attached to one of the “re-circulation” systems (see above diagram).

Sialex®Optimum 6” Ring installed in


front of circulation pump 9th July
2015

W/C 13th July, production re-commenced at the facility.

For the next 90 days, the situation was monitored. At the end of the 90 day period, IDL confirmed that
the pump, in front of which the Sialex® Ring was fitted, performed continuously without need of
maintenance / removal / cleaning.

The device met the client’s expectations.

Geschäftsführer: Bank: Sparkasse Odenwaldkreis


Michael T.Laverty Konto-Nr.: 140247537 IBAN: DE61508519520140247537
Sven Gagel BLZ: 508 519 52 SWIFT/BIC: HELADEF1ERB
Seite 4

Update: June 1st 2016. Follow up contact with Irish Distillers; it is confirmed that since installation date
of July 2015, the pump in question has not required removal for cleaning. Before installation of
Sialex®Ring this pump required removal and “cleaning” every 6 weeks.

In summary; during the past 12 month period savings to Irish Distillers include:

8x Maintenance interventions to include:


Removal of 6” pump from circulating loop
Installation of replacement pump into circulating loop
Re-commissioning of hot water circuit
Cleaning and repair of the “removed pump”

Secondary benefits of Sialex® include:

No need to carry additional “Swap out” pump


Reduction in “Carbon footprint”
Reduction in energy consumption
No chemicals required in operation of Sialex®
No by-products produced (requiring disposal)

Sialex®Ring: Ein Produkt der Phoenix Ring Manufaktur, Deutschland

Geschäftsführer: Bank: Sparkasse Odenwaldkreis


Michael T.Laverty Konto-Nr.: 140247537 IBAN: DE61508519520140247537
Sven Gagel BLZ: 508 519 52 SWIFT/BIC: HELADEF1ERB