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FACILITIES / PAINT 7TH
TERM IMPROVEMENT
PLAN
Natural Gas
Consumption
Natural Gas Consumption Analysis
Actual Billing ( including Taxes and Surcharges from Provider)
Period CCF'sBTU Factor Therms Nymex Adder $ / Therm Gas Cost Plus Service
April '02 13,052 1.013 13,222 $0.3472 $0.180 $0.527 $6,970 $8,713
May '02 10,198 1.008 10,280 $0.3319 $0.180 $0.512 $5,262 $6,578
June '02 10,862 1.007 10,938 $0.3420 $0.180 $0.522 $5,710 $7,137
July '02 12,703 1.005 12,767 $0.3278 $0.180 $0.508 $6,483 $8,104
Aug '02 12,723 1.005 12,787 $0.2976 $0.155 $0.453 $5,787 $7,234
Sept '02 16,209 1.006 16,306 $0.3278 $0.155 $0.483 $7,873 $9,841
Oct '02 16,043 1.005 16,123 $0.3686 $0.155 $0.524 $8,442 $10,553
Nov '02 22,742 1.007 22,901 $0.4126 $0.155 $0.568 $12,999 $16,248
Dec '02 20,194 1.011 20,416 $0.4140 $0.155 $0.569 $11,617 $14,521
Jan 03 26,718 1.016 27,145 $0.4998 $0.155 $0.655 $17,775 $22,219
Feb 03 24,686 1.019 25,155 $0.5660 $0.155 $0.721 $18,137 $22,671
Mar 03 16,936 1.018 17,241 $0.9113 $0.155 $1.066 $18,384 $22,980
April 03 17,044 1.018 17,351 $0.5146 $0.155 $0.670 $11,618 $14,523
May 03 13,303 1.008 13,409 $0.5123 $0.155 $0.667 $8,948 $11,185
June 03 10,560 1.006 10,623 $0.5945 $0.155 $0.750 $7,962 $9,953
July 03 12,516 1.001 12,529 $0.5291 $0.155 $0.684 $8,571 $10,713
Aug 03 13,703 1.003 13,744 $0.4693 $0.120 $0.589 $8,099 $10,124
Sept 03 16,228 1.006 16,325 $0.4927 $0.120 $0.613 $10,003 $12,503
Oct'03 16,306 1.005 16,388 $0.4430 $0.120 $0.563 $9,226 $11,533
Nov '03 17,653 1.008 17,794 $0.4459 $0.120 $0.566 $10,070 $12,587
Dec'03 19,202 1.009 19,375 $0.4860 $0.120 $0.606 $11,741 $14,676
Jan '04 19,329 1.018 19,677 $0.6150 $0.120 $0.735 $14,463 $18,078
Feb '04 17,963 1.018 18,286 $0.5775 $0.120 $0.698 $12,755 $15,943
Mar '04 15,821 1.019 16,122 $0.5150 $0.120 $0.635 $10,237 $12,899
Apr 04 14,827 1.011 14,990 $0.5365 $0.120 $0.657 $9,841 $12,400
May 04 13,373 1.009 13,493 $0.5935 $0.120 $0.714 $9,627 $12,130
June 04 11,450 1.007 11,530 $0.6680 $0.120 $0.788 $9,086 $11,448
July 04 11,370 1.007 11,450 $0.6680 $0.120 $0.788 $9,022 $11,639
Aug 04 14,646 1.005 14,719 $0.6140 $0.120 $0.734 $10,804 $13,613
Sept 04 14,700 1.005 14,774 $0.5082 $0.145 $0.653 $9,650 $11,580
Oct 04 16,968 1.009 17,121 $0.5723 $0.145 $0.717 $12,281 $14,184
Nov 04 18,182 1.008 18,327 $0.7626 $0.145 $0.908 $16,634 $18,830
Dec 04 18,805 1.01 18,993 $0.7976 $0.145 $0.943 $17,903 $20,266
Jan 05 20,779 1.018 21,153 $0.6123 $0.145 $0.757 $16,019 $18,502
Feb 05 19,158 1.018 19,503 $0.6840 $0.145 $0.829 $16,168 $18,351
Mar 05 18,845 1.016 19,147 $0.6840 $0.145 $0.829 $15,872 $18,015
Apr 05 15,334 1.016 15,579 $0.7323 $0.145 $0.877 $13,668 $15,650
May 05 16,524 1.013 16,739 $0.6748 $0.145 $0.820 $13,723 $15,713
June 05 16,367 1.008 16,498 $0.6123 $0.145 $0.757 $12,494 $14,407
July 05 15,261 1.007 15,368 $0.6976 $0.145 $0.843 $12,949 $14,889
Aug 05 16,193 1.007 16,306 $0.7647 $0.145 $0.910 $14,834 $16,862
Sept 05 16,628 1.008 16,761 $1.0847 $0.124 $1.209 $20,259 $22,465
Oct 05 20,134 1.008 20,295 $1.3900 $0.124 $1.514 $30,741 $33,576
Nov 05 22,060 1.007 22,214 $1.3800 $0.124 $1.504 $33,481 $36,479
Dec 05 20,271 1.016 20,595 $1.1180 $0.124 $1.242 $25,579 $28,103
Jan 06 20,774 1.025 21,293 $1.1430 $0.124 $1.267 $26,980 $29,588
Feb 06 20,413 1.019 20,801 $0.8400 $0.124 $0.964 $20,052 $22,244
Mar 06
To Date Average 17657 0.802$ 13,929$ 16,499$
5th Term Average 16267 0.776$ 12,742$ 15,080$
6th Term to date Average 18405 1.082$ 20,433$ 22,725$
Historical Consumption
0
5,000
10,000
15,000
20,000
25,000
30,000
April'02
May'02
June'02
July'02
Aug'02
Sept'02
Oct'02
Nov'02
Dec'02
Jan03
Feb03
Mar03
April03
May03
June03
July03
Aug03
Sept03
Oct'03
Nov'03
Dec'03
Jan'04
Feb'04
Mar'04
Apr04
May04
June04
July04
Aug04
Sept04
Oct04
Nov04
Dec04
Jan05
Feb05
Mar05
Apr05
May05
June05
July05
Aug05
Sept05
Oct05
Nov05
Dec05
Jan06
Feb06
Month
Therm(1000BTU)
$0.000
$0.200
$0.400
$0.600
$0.800
$1.000
$1.200
$1.400
$1.600
$/Therm
Usage
$ / Therm
Linear ($ / Therm)
Linear (Usage)
5th Term Consumption
0
5,000
10,000
15,000
20,000
25,000
Apr04
May04
June04
July04
Aug04
Sept04
Oct04
Nov04
Dec04
Jan05
Feb05
Mar05
Month
Therm(1000BTU)
$0.000
$0.100
$0.200
$0.300
$0.400
$0.500
$0.600
$0.700
$0.800
$0.900
$1.000
$/Therm
Usage
$ / Therm
Linear ($ / Therm)
Linear (Usage)
6th Term Consumption
0
5,000
10,000
15,000
20,000
25,000
Apr05
May05
June05
July05
Aug05
Sept05
Oct05
Nov05
Dec05
Jan06
Feb06
Month
Therm(1000BTU)
$0.000
$0.200
$0.400
$0.600
$0.800
$1.000
$1.200
$1.400
$1.600
$/Therm
Usage
$ / Therm
Linear ($ / Therm)
Linear (Usage)
Calculations of Natural Gas Consumption byComponent
Incinerator on line with Current Paint Schedule
Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year
Demand Therm/HrDaily per Day Therm
Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$
Maintain(25%) 17 106.25
LowFire(10%) 2 5
Incinerator Full (100%) 35 3 105 588 0.77$ 452.76$ 108,662.40$
Maintain(80%) 17 476
LowFire(10%) 2 7
Boiler Full (100%) 40 4 160 330 0.77$ 254.10$ 60,984.00$
Maintain(25%) 15 150
LowFire(10%) 5 20
Total 1104.3 850.27$ 204,065.40$
Trial
•Run the oven without the oxidizer while using the
blower to expel the smoke out the stack
•Record the Natural Gas consumption and
compare to average daily consumption
•Note any changes in operation
Trial Results
• The oxidizer was turned off for three days
• During that time , our Natural Gas consumption dropped
from 70,000 cu. ft / day to 40,000 cu. ft which equals 47%
which is about $8000 / month
Oxygen Meter Test
On August 23 at 10:30 am, the "sniffer " or multi gas monitor was used to check for abnormalities
at the oven stack on the roof. The oxidizer was by passed at the time of this test.
Four sets of readings were taken for a period of 5 minutes at each location.
Results were as follows
Location CO H2S O2 LEL
Carbon Hydrogen Oxygen Combustible
Monoxide Sulfide Gases
Measurement PPM PPM % %
Limits 35 - 70 10 - 20 19.5 - 23.5% 10%-20%
Base of Stack
with monitor directly in smoke 4-6 0 20.8 0
10' from stack
with monitor directly in smoke 1 0 20.9 0
30' from stack
with monitor directly in smoke 0 0 20.9 0
70' from stack ( edge of roof )
0 0 21 0
Concept Now After Judgement
Investigate an air scrubber
to remove / control the smoke Might be effective
and possibly the smell for Bluish smoke
but would not
provide air
velocity
The most
effective method
of smoke and odor
control
More expensive
Investigate the concept of injection
of clean air into the smoke stack
at a 3~5 to 1 ratio and push it up into More commonly
the air to dissipate the visual concern used in industry
Will mix fresh air
and smoke at a
predetermined ratio
and drive it up into
the air
Will reduce smell
Oven
Air Scrubber and
fan
Roof mounted Fan
Manually Controlled
Dampers (2)
Manually Controlled
Dampers (2)
Oven
Oven
Oven
Concept Options
Incinerator off line with Current Paint Schedule
Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year
Demand Therm/Hr Daily per Day Therm
Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$
Maintain(25%) 17 106.25
Low Fire(10%) 2 5
Incinerator Full (100%) 35 0 0 0 0.77$ -$ -$
Maintain(80%) 0 0
Low Fire(10%) 0 0
Boiler Full (100%) 40 6 240 456 0.77$ 351.12$ 84,268.80$
Maintain(40%) 12 192
Low Fire(10%) 6 24
Total 642.25 494.53$ 118,687.80$
YEARLY SAVINGS OF
$80/000
F&P Georgia Improvement Plan Made
Glen Tuplin
Purpose Investment and Payback
Equipment
To reduce the Natural Gas utility expense Blower $12,500 Based on Natural gas prices an
Ductwork, Dampers and Insulation $5,000 Payback would be less than 4 M
Electrical $1,000 Investment
Installation $6,000 Savings / 12
$24,500
Consulting Fees An air scrubber would add $40
Baseline of Emissions $3,500 would extend the payback sche
$28,000
Current Situation Schedule
Events
Our biggest consumers of Natural Gas are in the Paint system. The oven, the oxidizer, and April May
the hot water boiler. Equipment Evaluation
With our new generation paint from PPG, it has been determined that the oxidizer is not necessary Plan Approval
in our case to super heat the solvents and fumes from the paint oven.
Order Equipment
The oxidizer also heats up a hot water generator which we use for paint system tank heating .
Install Ductwork and Dampers
Install Equipment and Auto Control Programming
Trial and Monitor Results
Report
Improvement / Countermeasure Merit
By-pass the oxidizer exhaust piping with duct work and controls as per concept #2 shown in Reduce Natural Gas monthly Bill by up to 47% or $8000 / month
attachment.The oven exhaust would go directly outside with the assistance of a roof mounted blower.
This blower would also introduce outside air at a 3 : 1 ratio and accelerate it into the air to remove the bluish
color and the undesirable appearance seen during a previous trial.
By accelerating it up into the air, the odor noticed during the last trial would also be dissipated.
Installing an Air Scrubber would eliminate the exhaust particulate and the odors but an investigation
would be needed to ensure expectations are met without compromise
The by-pass would still allow oxidizer operation should the EPA restrictions become Demerit
tighter in the Rome area.
Hot Water boiler will have increased load, need to ensure PMs are adequate and back up plan is available
Increase emissions into environment (Blower Option only)although below allowable limits of permit
Must purge the oxidizer periodically to ensure no build up of fumes getting past the dampers
Monday morning paint system start up might need to be modified to allow the boiler to do the extra heating nec
cold weather months
An air scrubber would add to water consumption, and waste discharge
Comments: Evaluation / Further Instruction
Our air permit is based on the calculated emissions given the paint VOC data. Our
permit was based on no credit for oxidizer benefit which means we would be still within our permitted
restrictions but a baseline or scientific test could be performed to ensure compliance
WithrecentpriceincreasesonNaturalGas,arecalculationbasedonanaveragecost /therm,ourpaybackwouldbe:
IncineratoronlinewithCurrentPaintSchedule IncineratorofflinewithCurrentPaintSchedule
Component Max Avg.Hrs Therms Daily $/Therm $/Day $/Year Component Max Avg.Hrs Therms Daily $/Therm $/Day $/Year
DemandTherm/HrDaily perDay Therm Demand Therm/Hr Daily perDay Therm
Oven Full(100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$ Oven Full(100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$
Maintain(25%) 17 106.25 Maintain(25%) 17 106.25
LowFire(10%) 2 5 LowFire(10%) 2 5
Incinerator Full(100%) 35 3 105 588 1.15$ 676.20$ 162,288.00$ Incinerator Full(100%) 35 0 0 0 1.15$ -$ -$
Maintain(80%) 17 476 Maintain(80%) 0 0
LowFire(10%) 2 7 LowFire(10%) 0 0
Boiler Full(100%) 40 4 160 330 1.15$ 379.50$ 91,080.00$ Boiler Full(100%) 40 6 240 456 1.15$ 524.40$ 125,856.00$
Maintain(25%) 15 150 Maintain(40%) 12 192
LowFire(10%) 5 20 LowFire(10%) 6 24
Total 1104.3 1,269.89$ 304,773.00$ Total 642.25 738.59$ 177,261.00$
Estimation: Basedonremovingtheoxidizerfromtheoperation,andrunningatwoshiftschedule,savingof $125,000/yearwouldberealized.
Project Status
• Matching equipment to requirement
• Ensure expectation / result is achieved
• Investigating Vertical Scrubber application
• Capital cost
• Expense to operate – added water cost
• Procurement and Installation information

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Oxidizer PPT

  • 1. FACILITIES / PAINT 7TH TERM IMPROVEMENT PLAN Natural Gas Consumption
  • 2. Natural Gas Consumption Analysis Actual Billing ( including Taxes and Surcharges from Provider) Period CCF'sBTU Factor Therms Nymex Adder $ / Therm Gas Cost Plus Service April '02 13,052 1.013 13,222 $0.3472 $0.180 $0.527 $6,970 $8,713 May '02 10,198 1.008 10,280 $0.3319 $0.180 $0.512 $5,262 $6,578 June '02 10,862 1.007 10,938 $0.3420 $0.180 $0.522 $5,710 $7,137 July '02 12,703 1.005 12,767 $0.3278 $0.180 $0.508 $6,483 $8,104 Aug '02 12,723 1.005 12,787 $0.2976 $0.155 $0.453 $5,787 $7,234 Sept '02 16,209 1.006 16,306 $0.3278 $0.155 $0.483 $7,873 $9,841 Oct '02 16,043 1.005 16,123 $0.3686 $0.155 $0.524 $8,442 $10,553 Nov '02 22,742 1.007 22,901 $0.4126 $0.155 $0.568 $12,999 $16,248 Dec '02 20,194 1.011 20,416 $0.4140 $0.155 $0.569 $11,617 $14,521 Jan 03 26,718 1.016 27,145 $0.4998 $0.155 $0.655 $17,775 $22,219 Feb 03 24,686 1.019 25,155 $0.5660 $0.155 $0.721 $18,137 $22,671 Mar 03 16,936 1.018 17,241 $0.9113 $0.155 $1.066 $18,384 $22,980 April 03 17,044 1.018 17,351 $0.5146 $0.155 $0.670 $11,618 $14,523 May 03 13,303 1.008 13,409 $0.5123 $0.155 $0.667 $8,948 $11,185 June 03 10,560 1.006 10,623 $0.5945 $0.155 $0.750 $7,962 $9,953 July 03 12,516 1.001 12,529 $0.5291 $0.155 $0.684 $8,571 $10,713 Aug 03 13,703 1.003 13,744 $0.4693 $0.120 $0.589 $8,099 $10,124 Sept 03 16,228 1.006 16,325 $0.4927 $0.120 $0.613 $10,003 $12,503 Oct'03 16,306 1.005 16,388 $0.4430 $0.120 $0.563 $9,226 $11,533 Nov '03 17,653 1.008 17,794 $0.4459 $0.120 $0.566 $10,070 $12,587 Dec'03 19,202 1.009 19,375 $0.4860 $0.120 $0.606 $11,741 $14,676 Jan '04 19,329 1.018 19,677 $0.6150 $0.120 $0.735 $14,463 $18,078 Feb '04 17,963 1.018 18,286 $0.5775 $0.120 $0.698 $12,755 $15,943 Mar '04 15,821 1.019 16,122 $0.5150 $0.120 $0.635 $10,237 $12,899 Apr 04 14,827 1.011 14,990 $0.5365 $0.120 $0.657 $9,841 $12,400 May 04 13,373 1.009 13,493 $0.5935 $0.120 $0.714 $9,627 $12,130 June 04 11,450 1.007 11,530 $0.6680 $0.120 $0.788 $9,086 $11,448 July 04 11,370 1.007 11,450 $0.6680 $0.120 $0.788 $9,022 $11,639 Aug 04 14,646 1.005 14,719 $0.6140 $0.120 $0.734 $10,804 $13,613 Sept 04 14,700 1.005 14,774 $0.5082 $0.145 $0.653 $9,650 $11,580 Oct 04 16,968 1.009 17,121 $0.5723 $0.145 $0.717 $12,281 $14,184 Nov 04 18,182 1.008 18,327 $0.7626 $0.145 $0.908 $16,634 $18,830 Dec 04 18,805 1.01 18,993 $0.7976 $0.145 $0.943 $17,903 $20,266 Jan 05 20,779 1.018 21,153 $0.6123 $0.145 $0.757 $16,019 $18,502 Feb 05 19,158 1.018 19,503 $0.6840 $0.145 $0.829 $16,168 $18,351 Mar 05 18,845 1.016 19,147 $0.6840 $0.145 $0.829 $15,872 $18,015 Apr 05 15,334 1.016 15,579 $0.7323 $0.145 $0.877 $13,668 $15,650 May 05 16,524 1.013 16,739 $0.6748 $0.145 $0.820 $13,723 $15,713 June 05 16,367 1.008 16,498 $0.6123 $0.145 $0.757 $12,494 $14,407 July 05 15,261 1.007 15,368 $0.6976 $0.145 $0.843 $12,949 $14,889 Aug 05 16,193 1.007 16,306 $0.7647 $0.145 $0.910 $14,834 $16,862 Sept 05 16,628 1.008 16,761 $1.0847 $0.124 $1.209 $20,259 $22,465 Oct 05 20,134 1.008 20,295 $1.3900 $0.124 $1.514 $30,741 $33,576 Nov 05 22,060 1.007 22,214 $1.3800 $0.124 $1.504 $33,481 $36,479 Dec 05 20,271 1.016 20,595 $1.1180 $0.124 $1.242 $25,579 $28,103 Jan 06 20,774 1.025 21,293 $1.1430 $0.124 $1.267 $26,980 $29,588 Feb 06 20,413 1.019 20,801 $0.8400 $0.124 $0.964 $20,052 $22,244 Mar 06 To Date Average 17657 0.802$ 13,929$ 16,499$ 5th Term Average 16267 0.776$ 12,742$ 15,080$ 6th Term to date Average 18405 1.082$ 20,433$ 22,725$ Historical Consumption 0 5,000 10,000 15,000 20,000 25,000 30,000 April'02 May'02 June'02 July'02 Aug'02 Sept'02 Oct'02 Nov'02 Dec'02 Jan03 Feb03 Mar03 April03 May03 June03 July03 Aug03 Sept03 Oct'03 Nov'03 Dec'03 Jan'04 Feb'04 Mar'04 Apr04 May04 June04 July04 Aug04 Sept04 Oct04 Nov04 Dec04 Jan05 Feb05 Mar05 Apr05 May05 June05 July05 Aug05 Sept05 Oct05 Nov05 Dec05 Jan06 Feb06 Month Therm(1000BTU) $0.000 $0.200 $0.400 $0.600 $0.800 $1.000 $1.200 $1.400 $1.600 $/Therm Usage $ / Therm Linear ($ / Therm) Linear (Usage) 5th Term Consumption 0 5,000 10,000 15,000 20,000 25,000 Apr04 May04 June04 July04 Aug04 Sept04 Oct04 Nov04 Dec04 Jan05 Feb05 Mar05 Month Therm(1000BTU) $0.000 $0.100 $0.200 $0.300 $0.400 $0.500 $0.600 $0.700 $0.800 $0.900 $1.000 $/Therm Usage $ / Therm Linear ($ / Therm) Linear (Usage) 6th Term Consumption 0 5,000 10,000 15,000 20,000 25,000 Apr05 May05 June05 July05 Aug05 Sept05 Oct05 Nov05 Dec05 Jan06 Feb06 Month Therm(1000BTU) $0.000 $0.200 $0.400 $0.600 $0.800 $1.000 $1.200 $1.400 $1.600 $/Therm Usage $ / Therm Linear ($ / Therm) Linear (Usage)
  • 3. Calculations of Natural Gas Consumption byComponent Incinerator on line with Current Paint Schedule Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year Demand Therm/HrDaily per Day Therm Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$ Maintain(25%) 17 106.25 LowFire(10%) 2 5 Incinerator Full (100%) 35 3 105 588 0.77$ 452.76$ 108,662.40$ Maintain(80%) 17 476 LowFire(10%) 2 7 Boiler Full (100%) 40 4 160 330 0.77$ 254.10$ 60,984.00$ Maintain(25%) 15 150 LowFire(10%) 5 20 Total 1104.3 850.27$ 204,065.40$
  • 4. Trial •Run the oven without the oxidizer while using the blower to expel the smoke out the stack •Record the Natural Gas consumption and compare to average daily consumption •Note any changes in operation
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  • 6. Trial Results • The oxidizer was turned off for three days • During that time , our Natural Gas consumption dropped from 70,000 cu. ft / day to 40,000 cu. ft which equals 47% which is about $8000 / month
  • 7. Oxygen Meter Test On August 23 at 10:30 am, the "sniffer " or multi gas monitor was used to check for abnormalities at the oven stack on the roof. The oxidizer was by passed at the time of this test. Four sets of readings were taken for a period of 5 minutes at each location. Results were as follows Location CO H2S O2 LEL Carbon Hydrogen Oxygen Combustible Monoxide Sulfide Gases Measurement PPM PPM % % Limits 35 - 70 10 - 20 19.5 - 23.5% 10%-20% Base of Stack with monitor directly in smoke 4-6 0 20.8 0 10' from stack with monitor directly in smoke 1 0 20.9 0 30' from stack with monitor directly in smoke 0 0 20.9 0 70' from stack ( edge of roof ) 0 0 21 0
  • 8. Concept Now After Judgement Investigate an air scrubber to remove / control the smoke Might be effective and possibly the smell for Bluish smoke but would not provide air velocity The most effective method of smoke and odor control More expensive Investigate the concept of injection of clean air into the smoke stack at a 3~5 to 1 ratio and push it up into More commonly the air to dissipate the visual concern used in industry Will mix fresh air and smoke at a predetermined ratio and drive it up into the air Will reduce smell Oven Air Scrubber and fan Roof mounted Fan Manually Controlled Dampers (2) Manually Controlled Dampers (2) Oven Oven Oven Concept Options
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  • 10. Incinerator off line with Current Paint Schedule Component Max Avg. Hrs Therms Daily $/Therm $ / Day $ / Year Demand Therm/Hr Daily per Day Therm Oven Full (100%) 25 3 75 186.25 0.77$ 143.41$ 34,419.00$ Maintain(25%) 17 106.25 Low Fire(10%) 2 5 Incinerator Full (100%) 35 0 0 0 0.77$ -$ -$ Maintain(80%) 0 0 Low Fire(10%) 0 0 Boiler Full (100%) 40 6 240 456 0.77$ 351.12$ 84,268.80$ Maintain(40%) 12 192 Low Fire(10%) 6 24 Total 642.25 494.53$ 118,687.80$
  • 12. F&P Georgia Improvement Plan Made Glen Tuplin Purpose Investment and Payback Equipment To reduce the Natural Gas utility expense Blower $12,500 Based on Natural gas prices an Ductwork, Dampers and Insulation $5,000 Payback would be less than 4 M Electrical $1,000 Investment Installation $6,000 Savings / 12 $24,500 Consulting Fees An air scrubber would add $40 Baseline of Emissions $3,500 would extend the payback sche $28,000 Current Situation Schedule Events Our biggest consumers of Natural Gas are in the Paint system. The oven, the oxidizer, and April May the hot water boiler. Equipment Evaluation With our new generation paint from PPG, it has been determined that the oxidizer is not necessary Plan Approval in our case to super heat the solvents and fumes from the paint oven. Order Equipment The oxidizer also heats up a hot water generator which we use for paint system tank heating . Install Ductwork and Dampers Install Equipment and Auto Control Programming Trial and Monitor Results Report Improvement / Countermeasure Merit By-pass the oxidizer exhaust piping with duct work and controls as per concept #2 shown in Reduce Natural Gas monthly Bill by up to 47% or $8000 / month attachment.The oven exhaust would go directly outside with the assistance of a roof mounted blower. This blower would also introduce outside air at a 3 : 1 ratio and accelerate it into the air to remove the bluish color and the undesirable appearance seen during a previous trial. By accelerating it up into the air, the odor noticed during the last trial would also be dissipated. Installing an Air Scrubber would eliminate the exhaust particulate and the odors but an investigation would be needed to ensure expectations are met without compromise The by-pass would still allow oxidizer operation should the EPA restrictions become Demerit tighter in the Rome area. Hot Water boiler will have increased load, need to ensure PMs are adequate and back up plan is available Increase emissions into environment (Blower Option only)although below allowable limits of permit Must purge the oxidizer periodically to ensure no build up of fumes getting past the dampers Monday morning paint system start up might need to be modified to allow the boiler to do the extra heating nec cold weather months An air scrubber would add to water consumption, and waste discharge Comments: Evaluation / Further Instruction Our air permit is based on the calculated emissions given the paint VOC data. Our permit was based on no credit for oxidizer benefit which means we would be still within our permitted restrictions but a baseline or scientific test could be performed to ensure compliance
  • 13. WithrecentpriceincreasesonNaturalGas,arecalculationbasedonanaveragecost /therm,ourpaybackwouldbe: IncineratoronlinewithCurrentPaintSchedule IncineratorofflinewithCurrentPaintSchedule Component Max Avg.Hrs Therms Daily $/Therm $/Day $/Year Component Max Avg.Hrs Therms Daily $/Therm $/Day $/Year DemandTherm/HrDaily perDay Therm Demand Therm/Hr Daily perDay Therm Oven Full(100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$ Oven Full(100%) 25 3 75 186.25 1.15$ 214.19$ 51,405.00$ Maintain(25%) 17 106.25 Maintain(25%) 17 106.25 LowFire(10%) 2 5 LowFire(10%) 2 5 Incinerator Full(100%) 35 3 105 588 1.15$ 676.20$ 162,288.00$ Incinerator Full(100%) 35 0 0 0 1.15$ -$ -$ Maintain(80%) 17 476 Maintain(80%) 0 0 LowFire(10%) 2 7 LowFire(10%) 0 0 Boiler Full(100%) 40 4 160 330 1.15$ 379.50$ 91,080.00$ Boiler Full(100%) 40 6 240 456 1.15$ 524.40$ 125,856.00$ Maintain(25%) 15 150 Maintain(40%) 12 192 LowFire(10%) 5 20 LowFire(10%) 6 24 Total 1104.3 1,269.89$ 304,773.00$ Total 642.25 738.59$ 177,261.00$ Estimation: Basedonremovingtheoxidizerfromtheoperation,andrunningatwoshiftschedule,savingof $125,000/yearwouldberealized.
  • 14. Project Status • Matching equipment to requirement • Ensure expectation / result is achieved • Investigating Vertical Scrubber application • Capital cost • Expense to operate – added water cost • Procurement and Installation information