M&C Energy Group were appointed energy consultants to Visteon Europe in 2002 and provide the company with both utility purchasing and energy engineering expertise. The Basildon Radiator Plant manufactures all the cooling radiators, air conditioning condensers and turbo diesel intercoolers for Ford Europe.

During the course of identifying and implementing a number of energy saving recommendations at the Basildon Plant, M&C Energy Group identified that significant savings could be achieved by de-centralising the heating system within the factory. The existing heating system consisted of approximately 65 high-level forced draft steam heating units, supplied with steam from a central boiler house fired on a combination of natural gas and heavy fuel oil.

Whilst there were two small process steam heating requirements, the primary steam load consisted of space heating. The nature of the large steam distribution system, resulted in significant energy loss, coupled with the expense of operating large steam boiler plant.

In order to stimulate interest in the project, M&C Energy Group put together a proposal consisting of budgetary costing for a completely de-centralised, natural gas-fired heating system. The level of savings identified and the cost of the system, resulted in the plant requesting a complete proposal with firm costs and detailed savings calculations.

The project was given the green light in early 2004 and work commenced in June 2004. During the course of the project, many obstacles, both technical and operational had to be overcome. An alternative water heating system was developed for the primary consumer of process steam. This involved designing and implementing a bespoke gas fired submerged tube heating system.

The primary space heating plant consisted of approximately 65 high level indirect gas fired unit heaters, mounted in such a way as to re-circulated much of the heat that would become trapped at high level with the old system. M&C Energy Group project managed the entire installation to the full satisfaction of Visteon.

The new system, not only provides much improved heating output, at hugely reduced energy input, but has reduced maintenance requirements and reduced the emissions of CO2 associated with the heating system by over 2,000 Tonnes each year.

The total contract savings since 2002 are approximately £350,000.