Simpsons Malt - 1 million litre chemical-free water treatment (CFWT) of a MTHW system
This IWTM-UK project had complex water quality requirements with different requirements from the high technology heating manufacturers all quoting slightly different targets from three different EU standards. It was clear from the outset that none of these targets were achievable by using chemicals so IWTM-UK were approached by Vital Energi after their client Amp Clean Energy suggested our technology due to our products being able to operate on having approval for being used on medium temperature hot water (MTHW) systems.
This project has innovative electrode boilers, powered by curtailed wind energy, and is set to revolutionise energy use at Simpsons Malt Limited and within the Scotch Whisky industry. Alongside the three 6MW biomass boilers, the project will deliver impressive environmental benefits:
25,000 tonnes of CO2 emissions saved annually. An 80% reduction in carbon emissions at their malting facility. More sustainable malt production, helping Simpsons and their customers achieve ambitious net- zero target. In excess of 2 million litres of water saved by the CFWT process during the filling and commissioning of the system. Prevented the use of around 30,000 litres of harmful chemicals and up to 1200 x 25 litre plastic drums of chemicals being delivered.
The electrode boilers required for their feed water compliance with BS EN12953-10 which is a standard for steam boilers that IWTM Norway have worked with in the Marine steam industry. This controlled pH, ultra-low conductivity water was needed to provide the electrode boiler fill point where the electrode boiler manufacturer raises the conductivity slightly to allow the electrode boilers to function.
Our filling solution uses a combination of reverse osmosis and our pH controlled resin to meet the filling water requirements and the IWTM T1000 industrial units consume the dissolved oxygen and keep the pH in balance. Future top up water will be provided by the clients own reverse osmosis system and our ProFill Array which has 4 x 50 litre units with our DFU controller that provides real time information of the fill water quality and the amount of make-up water.
The project provided by Amp Clean Energy has picked up its second award of the year, claiming the Best In Class award at the 2025 British Renewable Energy Awards, to go with the Best Initiative Award at the Utility Week Flex Awards 2025.
The MTHW boilers and heat network needed the requirements of AGFW 510 which is similar to VDI2035 in many ways but has more stringent requirements on conductivity and dissolved oxygen for the higher operating temperature. AGFW recognises the benefits of electrochemistry and its process of controlling pH and the removal of dissolved oxygen to negligible levels.
The DNV (Det Norske Veritas) Marine approval of the IWTM Industrial reaction tanks encompasses not only use on LTHW but also on MTHW and Steam and IWTM are the only electrochemistry reaction tank manufacturer who can meet these standards. This DNV type approval specifically verifies that our products are designed and manufactured to meet the required standards and regulations, often for use in harsh environments or critical applications and it provides a recognized mark of quality and reliability for our Industrial products and assurance for our customers.
This DNV approval means that each reaction tank undergoes an extensive quality control procedure starting from the procurement and traceability of the raw materials, through the entire manufacturing process including x-ray testing of the welds, the factory acceptance test (FAT) were signed off by the Principal Engineer at Vital Energi.
With our vast Nordic and Maritime experience we are proudly leading the way in delivering CFWT solutions for large volume and MTHW networks in the UK, after the initial design meeting and assurance that IWTM-UK could meet the required water quality standards the project was designed to use 4 x IWTM-UK Ltd T1000 Industrial reaction tanks were selected to keep it corrosion free & provide the very precise water quality requirements required for the heating technology that is installed.
It’s great recognition for a project which is combining creativity, innovation and technical excellence to harness curtailed North Sea wind electricity to power a 12MW electric boiler used for the malting process and is 100% chemical free.
To give you an idea of how impressive the project is alongside the saving of 25,000 tonnes of carbon per year, not only decarbonising Simpsons Malt, but it is also making a big contribution to reducing the scope 3 emissions of their customers in the distillery industry.
Simpsons Malt, a certified B Corporation, has long been committed to sustainability. To meet an ambitious target of reaching Net Zero by 2030, they sought a transformative energy solution that would support their energy-intensive malting process while reducing reliance on fossil fuels and to have such an environmentally friendly project and then to have filled it up with chemicals would have contradicted all they were setting out to achieve.
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