Project Overview: The Problem

A key consideration in choosing Kemco was efficiency in thermal energy for direct-to-process. The Kemco DCWH has an efficiency rate because it minimizes loss of energy from the stack. As such, the Perdue team saw the DCWH as advantageous over boilers, which only manage a 65% total system efficiency due to their blow down and their larger steam loop for thermal losses with little to no condensate return.

DCWHs were the obvious choice for Perdue’s applications and specifications. Kemco installed two 3 MMBTU direct contact water heaters at the facility. Notably, unlike competitors, Kemco’s DCWHs provide hot water within 15 minutes of startup compared to the several hours needed by competing equipment. Kemco has accomplished its unique design through a patented direct contact process between flame and water that captures all the flame’s heat energy, allowing for the fastest and most efficient water heating process. This eliminates the need for facilities to plan production around hot water availability or heat during peak production times.

The non-pressure vessel design of the direct contact water heater eliminates the need for a licensed operator, which is standard for boilers. The DCWH also removes the need for boiler feed chemicals and reduces maintenance costs. In many cases, the Kemco DCWH can completely replace steam, providing a fully steam-free heating system. In the case of this facility, there are no boilers present. Kemco’s DCWHs are the main source for generating hot water.