Paper Machine Water System Audits

Paper Machine Water System Audits
Scott Romenesko – Product Line Manager
Filtration Systems
Kadant Solutions Division
Drivers for Water Reduction
•
•
•
•
•
•
Corporate directives
Environmental awareness / activism
Paper consumers
Regulation
Sustainability / survivability
Cost to heat and treat fresh water and effluent
Audit Equipment
Portable Sample Point
Documenting the Water System
Fourdrinier Shower Map
Trim Squirts
Deckle Boards
Flooded Nip
Edge Showers
Inside HP Shower
Manual Guide Auto Guide
Stretch
Outside HP Shower
Hot Treated Water
Cold Treated Water
City Water
Filtered Clear WW Water
Chemical Shower
Discover Opportunities for Improvement
Benchmarking - TAPPI TIP 0404-63 Energy
Performance Indices
Gallons of Fresh Water Consumed per Gross Ton Produced
Water
Usage
Fine Bleached
Paper
Board
Liner
gals/ton
2,000
2,000
1,500
1,500
m3/ton
7.6
7.6
5.7
5.7
•
Corrugated Market
Medium
Pulp
Fluff
Pulp
Recycle
Board
Newsprint
LWC
1,000
1,000
<1,000
2,000
2,000 1,500
3.8
3.8
<3.8
7.6
7.6
How does your machine compare to others making
similar grades?
Kraft
5.7
Benchmarking Graphics or “Fine Paper”
Grades
Graphics - Gal Wtr/ Ton
Graphics - Gal Wtr/ Ton
18000
16000
14000
12000
10000
8000
Target
6000
4000
2000
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Existing Equipment Evaluation
Historical Data Collection
Main Break Detector Values
Clear WW Chest Level
Clear WW Chest Makeup Valve
Machine Heated Mill Service Water
80
8000
70
7000
60
6000
50
5000
40
4000
30
3000
20
2000
10
1000
0
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
1
19
37
55
73
91
109
127
145
163
181
199
217
235
253
271
289
307
325
343
361
379
397
415
433
451
469
487
505
523
541
559
577
595
613
631
649
667
685
703
721
739
757
775
793
811
829
847
865
883
901
919
937
955
973
991
1009
1027
1045
1063
1081
1099
1117
1135
Portable Sensor Data Collection
WW Chest Calcium mg/L
WW Chest Temp F
WW Chest Turbidity NTU
Sheet Break Detector
WW Chest TDS ppm
TDS Scale
200
1400
180
1200
160
140
1000
120
800
100
80
600
60
400
40
20
200
0
0
Economics
• An example of the cost to “heat and treat” 100 GPM of cold fresh
water to targeted system process temperature = $96,500
– Incoming fresh water temperature – 72°F
– Targeted process temperature - 120°F
– Cost per MMBTU - $4.75
– Cost to treat 1000 gallons of fresh water - $0.04
Water Savings
Energy Calculation
Water Flow (gpm)
100
Water Savings
Influx Calculation
Water Flow (gpm)
100
Process Temp
120
Average Annual
Mill Water Temp
72
Energy Cost ($/MMBTU)
$4.75
$/hour of flow
$11.29
$/Day of flow $/350 Days of flow
$270.86
$94,802.40
Water Cost ($/1000 gal)
$0.04
$/hour of flow
$0.21
$/Day of flow $/350 Days of flow
$5.11
$1,787.18
Note: Data shown is hypothetical and not
from an actual mill.
Total Economic Cost
to Heat & Treat Water
$96,589.58
Justification
• Prioritize opportunities for improvement
• Utilize a “step-by-step approach to water management
projects
• Implement “best practices” when modifying water
systems
• Measure the effect of process changes to determine if
expected project objectives were met
Project Development
Summary
• A commitment to water management is required for success
• Utilize a systematic approach
• Initiate a complete audit of the water system and the process to
develop the facts
• Define the savings and benefits of potential projects
• Prioritize identified opportunities and develop a “roadmap”
• The “roadmap” will include projects based on robust designs and
managed control strategies
• After system modifications are implemented, measure the
changes against expected project objectives
• Disseminate the results throughout the organization
Questions ?