Natural gas energy reduction update   fujifilm hunt chemicals
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Natural gas energy reduction update   fujifilm hunt chemicals Natural gas energy reduction update fujifilm hunt chemicals Presentation Transcript

  • Energy Reduction Increased efficiency of steam generating system at FHDY
  • Options explored 2008 1. BURNER – MANAGEMENT and FLAME SAFE GUARD SYSTEM (RM 7895) 2008 – Install pressure controllers to manage steam – Install VFD drives for burner blower – Efficiency gains 10 to 12 % 2. Reduced steam pressure form 225 to 160 psi – Could still be implemented – Estimated savings $ 20K annual – Production
  • Options explored 3. Replace two exiting boilers (450 HP) with one 350 HP unit – ROI: 4 years 4. Decided to conduct an accurate assessment and establish windows of opportunity – In service efficiency study 2010
  • Base line  Energy Assessment completed on line 1 – Results  Average HP 32.3  Peak HP 98.8  Gas cot saving 45.9 %  Electricity and water savings 10 % – CO2 savings: 422 ton/year
  •  Explored central boiler room Drum pad 1 LAB Bldg 2Bldg 4 S c a l e BLDG 5 Warehouse Office Office Bldg 1 Line # 1 Line 1 tanker pad PSA Line 1 Tank Farm Bldg4 Tanker Pad Hazardous waste drum pad BLDG 6 Line 3 Line 2 BLDG 6 Tank Farm BLDG 8 Tank Farm BLDG 7 Cooling Tower I s o T a n k e r s t o r a g e N MCC 2MCC 3 Hot oil unit Manufacturers Rd Parking Parking Emergency Shutdown 7" 7" New boiler room Phase I
  • Efficiency study Bldg 6 Measurement Value In-Service Efficiency 71.6% Expected Gas Saving Rate 12.7% Average HP 76.55 Load in % of Boiler Capacity 25.6% Max HP 201 Min HP 65 CO2 Saving in tons per year 201.1
  • Measurement Bldg 1 Bldg 6 Average In-Service Efficiency 43.8% 71.6% 57.7% Expected Gas Saving Rate 46.7% 12.7% 29.7% Average HP 31.3 76.55 53.9% Load in % of Boiler Capacity 20.9% 25.6% 23.2% Max HP 96.35 201 66% Min HP 10 65 37.5
  • Solution  Install Two 200 HP EXG  Locate in existing boiler room  Install piping to connect buildings
  • Drum pad 1 LAB Bldg 2Bldg 4 S c a l e BLDG 5 Warehouse Office Office Bldg 1 Line # 1 Line 1 tanker pad PSA Line 1 Tank Farm Bldg4 Tanker Pad Hazardous waste drum pad BLDG 6 Line 3 Line 2 BLDG 6 Tank Farm BLDG 8 Tank Farm BLDG 7 Cooling Tower I s o T a n k e r s t o r a g e N MCC 2MCC 3 Hot oil unit Manufacturers Rd Parking Parking 7" 7" New Steam piping
  • Performance Boiler nat gass usage (therms) - 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 Jan Feb M ar Apr M ay Jun Jul Aug Sep O ct N ov D ec 2011 2012 2013 New boilers installed 4/5/2012
  • Opportunities  Approximately $450,000.00 Savings / 2 Years  95% Reduction in Maintenance Costs / 2 Years  Perfect Continuance of Recent Green Efforts  Approximately 1,400 tons C02 Savings / 2 Years  Plant Now Operates Under EPA 10MMbtu Mandate  100% Backup for Entire Current Plant Load  Plant Easily Scaled for Future Expansion  Consolidated Steam Plant – Maintenance / Costs  Corporate Leader With a Corporate Showcase