Objective:
A renowned kraft paper manufacturing giant in Thailand used our energy audit services to address key issues faced in their plant.
Issues:
During our audit, we found that the plant had many problems. Firstly, the process temperature overshoots to 166oC against the required 150oC. The fluctuations in temperature not only affected plant operations but also resulted in excess steam consumption. Another issue was two different pressure steam supplies of 13 bar g & 6 bar g at the 3rd and 2nd zone respectively being connected to single flash steam leading to high back pressure on 6 bar g steam traps.
Solution:
After studying the issues deeply, we recommended some solutions. By the application of the air- preheater, a reduction in overall steam consumption was achieved by avoiding back pressure on steam traps. Flash vessels with accessories were used to segregate different pressure condensates.
Benefits:
a. Effective utilization of flash steam in the preheating zone lessened steam consumption.
b. Back pressure control system for LP zone.
c. 11% of the steam savings was achieved, this is 18 TPD approximately.
d. 740 kg/hr of flash steam recovered.
e. Monetary savings of 67,000 USD per annum.
f. The plant’s CO₂ emissions were reduced by 1,961 tons/annum.
