General Session

Energy Saving Ideas

for Your Box Plant

Moderator:
Jeff Pallini
Fosber America, Inc.
 Program Overview:
Immediate Ideas: Jim Simko of Simtek Systems, Inc.

Mid-Term Ideas: John Donahue of Donahue & Associates

&
Bud Stickle of Stickle Specialties Company

Future Energy Professor Art J. Ragauskas,

Opportunities: School of Chemistry & Biochemistry
Institute of Paper Science & Technology at
Georgia Institute of Technology

Q & A Session: Moderated by Pete Snyder of

Harper/Love Adhesive Corporation
Energy Saving Ideas
for Your Box Plant

Presented By:
Jim Simko
Simtek Systems Inc.
 Benefits of Saving Energy
• Lower cost more money to your bottom
line
• Beneficial to our environment, smaller
carbon footprint
• Prolong the life of fossil fuels
• Make alternative energy sources more
realistic
 Office Lighting
• Change incandescent light bulbs to
compact fluorescent lamps
• A 14 watt compact fluorescent will replace
a 60 watt incandescent
• Replace or upgrade existing T-12
fluorescent fixtures with T-8 fixtures with
electronic ballasts
 Office Lighting
• Automatically control light fixtures
• Install occupancy sensors especially in
restrooms and conference rooms that are
not always occupied
• Install ambient light sensors with dimming
ballasts
• Add additional switching for large office
areas
 Plant Lighting
• Replace 400 watt metal halide fixtures with T-
5HO fluorescent fixtures.
• T-5HO fixtures will cut your energy
consumption for your plant lighting by more
than half
• Install occupancy sensors in areas of your
facility where traffic is light especially in off
shifts
• Replace existing incandescent exit signs with
LED exit signs
 Plant Lighting
• Check with your local utility for rebates or
incentives for installing the F-Bay fixtures
• Review EPACT 2005 tax incentives to see
if your lighting project qualifies for the tax
rebate
 Estimated Savings
• Example
• If you currently have 300 metal halide 400
watt fixtures installed in your facility and
you replace them with 300, 4 lamp, T-5HO
fixtures, you would save the following:
• Assuming your lights are on 136 hours per
week or 7072 hours per year
• Also assume $.06 per Kwh
 Savings Estimate
• 300 fixtures X 460 watts per fixture =
138,000 watts or 138 KW
• 300 new fixtures X 216 Watts per fixture =
64,800 watts or 64.8 KW
• Savings = 73.2 KW
• 73.2 KW X 7072 hr = 517,670 KWh
• 517,670 KWh X $.06 = $31,060.00 per
year
• @ $0.10 per KWh = $51,767.00 per year
 Compressed Air System
• Repair air leaks
• Have a company that performs ultrasound
testing for leaks perform an audit at your
facility
Approximate Costs of Air Leaks
• 1/64” = $66.00 per year
• 1/16” = $1,051.00 per year
• 1/8” = $4,202.00 per year
• 1/4” = $16,744.00 per year
• These costs are for each air leak of the
given size
 Operations
• Automatically control scrap blowers
• They should turn off when not in use
• They should be controlled so as not to
allow starting of more than one fan at a
time
• This will reduce your demand charge from
your power company
 Operations
• Feed vacuum blowers and vacuum
transfer blowers should be automatically
controlled so they will turn off when not in
use
• Install AC drives or inverters on vacuum
blowers
 Operations
• Train front line supervisors to recognize
energy wasted at work station.
• Water hoses left running down the sewer,
dedicated lighting for machines left on when
not in use, limit the use of air motors where
possible, turn off air lines with leaks until
maintenance can repair them, turn down
discharge temperatures in air make up units
• In the office, turn down the thermostat in the
winter and up in the summer
 Conclusion
• Higher energy costs are here to stay
• Fossil fuels have a limited availability, we
will run out
• Saving energy now makes the possibility
and use of alternative energy sources in
the future more realistic
• Saving energy means more money to your
bottom line
• Thank you
Energy Saving Ideas
for Your Box Plant

Presented By:
John Donahue
Donahue & Associates
 Heat Balance Study of a
Corrugated Box Plant
ENERGY IN = ENERGY OUT

BOILER STACK LOSS SCRAP SYSTEM & VENTILATION

STEAM SHOWERS & LEAKS

BOILER FUEL IN

PRODUCT
CITY MAKE-UP WATER IN

BOILER BLOWDOWN FLASH LOSS FROM CONDENSATE

A LOOK AT THE TOTAL PLANT SYSTEM
HEAT BALANCE
A. Defines the areas of loss – REDUCE THEM.
B. Design from the total plant heat balance system –
as a system – A TOTAL SYSTEM.
C. Invent other systems for your needs.
1. Surge requirements.
2. Superheated steam from a paper mill.
3. Waste steam from a paper mill.
4. Steam from a power plant.
5. New steam shower design.
 BOILER ENERGY HEAT BALANCE
ENERGY IN = ENERGY OUT

BOILER STACK LOSS SCRAP SYSTEM & VENTILATION

2.9 MMBTU/HR 6.35 MMBTU/HR

STEAM & LEAKS SHOWER

FUEL IN STEAM TO
4 PASS 2.21 MMBTU/HR
14.5 MMBTU/HR CORRUGATOR 110”
BOILER
At 210# CORRUGATOR
12.98 MMBTU/HR. PRODUCT
(391F)
WATER IN
CORRUGATOR 1.24 MMBTU/HR
.138 MMBTU/HR BOILER

CONDENSATE RETURN
1.38 MMBTU/HR
BOILER
BLOWDOWN FLASH LOSS
.138 MMBTU/HR FROM CONDENSATE
1.8 MMBTU/HR

THE CONVENTIONAL CORRUGATOR HEAT SYSTEM

 COST PER HOUR FOR THE
CONVENTIONAL STEAM SYSTEM
BASED ON NATURAL GAS COST OF $15.20/MCF
(1 MCF = 1,000,000 BTU)

BOILER STACK LOSS SCRAP SYSTEM & VENTILATION

$44.08/HR $96.52/HR

STEAM SHOWER & LEAKS

FUEL IN STEAM TO
4 PASS $33.59/HR
$220.40/HR CORRUGATOR 110”
BOILER
At 210# CORRUGATOR
$197.30/HR. PRODUCT
(391F)
WATER IN
CORRUGATOR $18.85/HR
$2.10/HR BOILER

CONDENSATE RETURN
$20.98/HR
BOILER
BLOWDOWN
$2.10/HR FLASH LOSSES
FROM CONDENSATE
$27.36/HR
BOILER ENERGY HEAT BALANCE
ENERGY IN = ENERGY OUT

BOILER STACK LOSS SCRAP SYSTEM & VENTILATION

1.8 MMBTU/HR 5.79 MMBTU/HR

STEAM SHOWER & LEAKS

FUEL IN STEAM TO
4 PASS .18 MMBTU/HR
9.00 MMBTU/HR CORRUGATOR 110”
BOILER
At 210# CORRUGATOR
7.447 MMBTU/HR. PRODUCT
(391F)
WATER IN
CORRUGATOR 1.12 MMBTU/HR
.079 MMBTU/HR BOILER

CONDENSATE RETURN

BOILER .247 MMBTU/HR

BLOWDOWN FLASH LOSS
.079
FROM CONDENSATE
MMBTU/HR
.11 MMBTU/HR

A RE-DESIGNED CORRUGATOR HEAT SYSTEM

 COST PER HOUR FOR THE
RE-DESIGNED STEAM SYSTEM
BASED ON NATURAL GAS COST OF $15.20/MCF
(1 MCF = 1,000,000 BTU)

BOILER STACK LOSS SCRAP SYSTEM & VENTILATION

$27.36/HR $88.00/HR

STEAM SHOWER & LEAKS

FUEL IN STEAM TO
4 PASS $2.74/HR
$136.80/HR CORRUGATOR 110”
BOILER
At 210# CORRUGATOR
$113.19/HR. PRODUCT
(391F)
WATER IN
CORRUGATOR $17.03/HR
$1.20/HR BOILER

CONDENSATE RETURN
$3.76/HR
BOILER
BLOWDOWN
$1.20/HR FLASH LOSSES
FROM CONDENSATE
$1.67/HR
 SUMMARY
THE COST SAVINGS REALIZED WITH THE
INSTALLATION OF THE RE-DESIGNED STEAM SYSTEM

ENERGY INTO CONVENTIONAL STEAM SYSTEM REDESIGNED COST SAVINGS

THE PLANT DOLLARS/HOUR STEAM SYSTEM DOLLARS/HOUR
1-BOILER FUEL $ 220.40 $ 136.80 $ 83.06
2-WATER ENERGY $ 2.10 $ 1.20 $ .90
____________________________________________________________________
TOTAL $ 222.50 $ 138.00 $ 84.50
ENERGY LOSSES
FROM THE PLANT
1-BOILER STACK LOSS $ 44.08 $ 27.36 $ 16.72
2-THE SCRAP SYSTEM
& VENTILATION LOSSES $ 96.52 $ 88.00 $ 8.52
3-STEAM SHOWER AND
STEAM LEAK LOSS $ 33.59 $ 2.74 $ 30.85
4-ENERGY LOST
WITH PRODUCT $ 18.85 $ 17.03 $ 1.82
5-CONDENSATE FLASH
LOSS $ 27.36 $ 1.67 $ 25.69
6-LOSS WITH BOILER
BLOWDOWN $ 2.10 $ 1.20 $ .90
____________________________________________________________________

TOTAL $ 222.50 $ 138.00 $ 84.50

YOU MAY REALIZE A LESS THAN ONE YEAR PAYBACK BASED ON FUEL SAVINGS ALONE
 COSTS OF STEAM LEAKS
Cost of various sized steam leaks at 100psi
(Assuming steam costs of $15 per 1000 lbs.)
Orifice size Steam wasted
(inches) ____ (lbs per month) Total cost/month Total cost/year

1/2 835,000 $12,525 $150,300 _ .

7/16 637,000 $9,555 $114,660 .

3/8 470,000 $7,050 $84,600 _ .

5/16 325,000 $4,875 $58,500 _ .

1/4 210,000 $3,150 $37,800 .

3/16 117,000 $1,755 $21,060 .

1/8 52,500 $787.50 $9,450 .

NOTE: The steam-loss values assume clean, dry steam flowing through a sharp-edged orifice to atmospheric
pressure with no condensate present. Condensate would normally reduce these losses because of the flashing
effect that occurs when a pressure drop is experienced.
Energy Saving Ideas
for Your Box Plant
Thanks to
John Kohler Presented By:
Harper/Love
Tom Evans Bud Stickle
CSI Stickle Steam Specialties Co., Inc.
 Cost of Steam
For this discussion it cost $20.00 to produce
1,000 lbs of steam
• We are saying 1.2 million BTU’s/1,000 lbs
• Cost include fuel, water, electricity & water
chemistry
 Eliminating Steam Leaks
• The equivalent of 3/16” leak equals 180
lbs/hr
• $3.60/hr
 Traps and By-Pass Valves
• One trap blowing thru w/5/32” orifice
equals 160 lb/hr
• $3.20/hr
• One ¾” failed by pass valve equals 1,100
lb/hr
• $22.00/hr
 Un-insulated Pipe Radiation Loss
• Example: 2” pipe 200 ft long @360 (F)
• Radiation loss 61bls/hr
• $1.23/hr
 Boilers and Burners
• A boiler is just a heat exchanger and it is
the burner that counts.
• A high efficiency burner reduces excess
air and will give you a higher turn down
ratio
• A major integrated has installed high
efficient Weishaupt burners and reduce
gas usage 13.5%
High Pressure Condensate Return
• Return High Temp. effluent directly to the
boiler with HP Return System
• Condensate @ 360 (F) verses 250 (F)
deaerator
• Savings achieved 18-20%
• $40.00/hr
 Efficient Utilization of Energy
• Speed Up
• 675 fpm 10,951 lbs/hr 36-23-36 .27 lbs/ft
• 908 fpm 12,100 lbs/hr 36-23-36 .22 lbs/ft

lbs of steam per linear Ft of board

 Cooler Corrugator
• Running Hot Plates “Backwards”
• Achieve better heat transfer and higher
energy efficiency
• Potential of .305 therms/msf
Future Energy
Opportunities
Presented By:
Dr. Art J. Ragauskas,
School of Chemistry & Biochemistry
Institute of Paper Science & Technology at
Georgia Institute of Technology
Questions
&
Answers
Thank You
For
Attending!