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Georgia Pacific Corporation Project Overview Quick Facts About

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Georgia Pacific Corporation Project Overview Quick Facts About Powered By Docstoc
					                                 Helping Northwest secondary wood products
                                 manufacturers improve the efficiency of their
                                 wood waste removal systems




                                                        objectives – 98 percent reduced emissions, 44
                                                        percent energy savings compared to the secondary
                                                        baghouse alternative and 16 percent noise reduction.

                                                        This installation is an excellent example of an
                                                        energy-efficient dust collection system and is
                                                        being recognized by Just Enough Air, a project
                                                        sponsored by the Northwest Energy Efficiency
                                                        Alliance to promote energy-efficient pneumatic
                                                        conveying systems in the region.

    Georgia-Pacific Corporation, Philomath, Oregon
                                     planer mill site   About Georgia-Pacific Corporation
                                                        Georgia-Pacific Corporation is a leading
Georgia-Pacific Corporation                             manufacturer of paper and building products.
Project Overview                                        Founded in 1927, Georgia-Pacific employs more
                                                        than 85,000 people at nearly 600 plants, mills
A dust collection system retrofit project at a
                                                        and distribution centers throughout the United
Georgia-Pacific Corporation planer mill facility in
                                                        States, Canada and 11 other countries.
Oregon significantly reduced emissions and noise
while saving the company more than $20,000              In Philomath, Oregon, the company operates a
annually in energy bills.                               sawmill and a planer mill that produce Douglas
                                                        fir and kiln-dried hemlock dimension lumber.
Georgia-Pacific gained these benefits by replacing
an inefficient dust-collection system with a new,
low pressure-drop baghouse and an energy-
efficient airfoil fan. The fan is equipped with inlet     Quick Facts
guide vanes and automatic controls that                   Owner:                  Georgia-Pacific Corporation
maintain airflow at the target level regardless of
                                                          Project Description:    Dust collection system
baghouse bag condition.                                                           improvements
Energy savings are a bonus for the company and            Location:               Philomath, Oregon
not expected to pay for the capital investment.           Annual Savings:         $20,141 (44%)
Georgia-Pacific mainly wanted to reduce wood-             Incremental
waste emissions and had the option to add a               Project Cost:           $119,500
secondary baghouse to the cyclone discharge.              Simple Payback:         5.9 years
This would have cost less initially (about                Case Study Sponsor:     Northwest Energy
$120,000 less) but would have used 30 percent                                     Efficiency Alliance
more energy than the existing system and would            Alliance Contractor:    Just Enough Air Efficient
not have reduced noise. Because the company                                       Pneumatic Conveying
maintains high standards for protecting the               Equipment supplier:     Baxter Air Engineering
environment and being a good neighbor in the              Installation contractor: Qualair Pneumatics
community, it sought a solution that also                 Local Utility:          Pacific Power
achieved energy savings and kept operations as
quiet as possible. This solution achieved all the
This dust collection system retrofit                 “Our primary reason for undertaking this
took place at the planer mill, where a               project was to reduce our emissions, and if
planer, trim saws and chipper all share
                                                     possible to lower our energy costs. We also
a pneumatic dust collection system.
The planer operates about 4,000 hours                want to be a good neighbor in the
each year and surfaces about 180                     community by making our operation as
million board feet.                                  quiet as possible. With this retrofit, we were
                                                     able to achieve all these objectives.”
The Old System                                       Jeff Hensley, Georgia-Pacific Corporation
The replaced dust collection system
had two material-handling fans. One,                 The New System
driven by a 200-horsepower motor,
removed material generated at the trim               The new system features a Donaldson-
saw and planer system; the other fan,                Torit 484RFW-10 baghouse to separate
driven by a 50-hp motor, pulled from                 the material and a 125-hp New York
the chipper. Residue materials and air               Blower 44-inch Class IV Acoustafoil
were carried out of the mill via ducts               airfoil fan.                                                      Newly installed low pressure-drop
and pulled through a cyclone, which                                                                                     baghouse and efficient airfoil fan
                                                     The baghouse has a significantly lower
used centrifugal force to spin the waste
                                                     pressure drop through it than the
and separate it from the air. The                                                                                increase. This results in lower airflow
                                                     cyclones, and thus is much more
conveying air moved upward through                                                                               volumes. Traditionally, system
                                                     energy-efficient. It also cleans the air
the center of the cyclone and out the                                                                            designers compensate for this by
                                                     much better and allows use of the
top of the cyclone, while the wood                                                                               ensuring adequate airflow for dirty bags.
                                                     considerably more efficient airfoil fan.
wastes dropped through air locks at                                                                              However, that creates excess flow and
the bottom of the cyclone into a                     The inlet guide vanes controlling airflow                   wasted power when the bags are clean.
mechanical conveyor delivering to a                  are a key element of this new system.
                                                                                                                 In this retrofit project, the controls
truck bin.
                                                     Air volume generated by the fans – and                      compensate for the changing
This old system had three main                       thus the system’s ability to collect and                    resistance in the bags by automatically
problems: 1) It lacked sufficient volume             transport dust – varies with the                            opening and closing the guide vanes to
to adequately serve all the machine                  condition of the bags in the baghouse.                      continuously maintain design flow
centers. 2) The cyclones didn’t fully                Clean bags have very little pressure                        through the ducts. When the bags are
remove the fine materials from the                   drop through them, offering minimal                         clean the guide vanes are partially
airstream, which led to excessive                    resistance. As the bags get dirtier the                     closed, reducing flow and power; as the
discharges. 3) It was very loud.                     pressure drop and the resistance both                       bags become dirty the guide vanes



                                                                                                                                                                          s
                                                                                                                                                                        es
                                                                                                                                                                    roc
                                                                                                                                                                 eP
                                                                                                                       Photohelic                             th
                                                                                                                                                         m
                                                                                                                         Sensor                     ro
                   Air Out                                                                       Donaldson-Torit                                  ef
                                                     Air to the Fan                               RF Bag House                            s idu
                                                                                                                                       Re
                                                                                                                                  nd
                                                                                                                              ra
                                                                                                                            Ai
         New York
           Blower                           Photohelic Magnehelic
         Airfoil Fan                                                                                                                                         n
                                                                                                                                                         Bi
                                                                                                                                                    ck
                                                  Control                                                                                        Tru
                                                  System                                                                                    to
                                                                                                                                  ri   al
                           Inlet Guide                                                                                         te
                           Vanes with                                 Cleaning Blower                                        Ma
         125 hp motor   Electric Actuator                                                             Air Lock
                                                                        7.5 hp motor                 Material Out
                                                                                         Air Lock
                                                                                        5 hp motor
                                                                                                                            50 hp Transfer Blower

New System layout
open to maintain constant airflow.
Matching airflow with the condition of
the bags means the system is
                                            Energy Efficiency Measure: Replace an existing dust-collection system with an efficient
                                            system instead of replacing it with less efficient and lower initial cost system. Georgia-Pacific
delivering the right amount of air all
                                            replaced the existing system consisting primarily of two material-handling fans (a 200-horsepower
the time, resulting in energy savings
                                            and a 50-hp) and two cyclones with a more efficient system consisting primarily of one 125-hp
compared to traditional systems. This       airfoil fan, a low-pressure drop baghouse and controls to maintain flow at the target volume
also maintains safe transport velocity      regardless of the condition of the bags in the baghouse (bag condition varies between bag
preventing material from dropping out       changes from clean to dirty). An alternative idea of a secondary baghouse for the cyclone
and building up in the duct.                discharge would have cost less initially, but would have used much more energy and would not
                                            have reduced noise.
The control system includes
•   a photohelic sensor (a pressure         The Savings
    gauge with two electrical relays)       Original annual energy costs                                              $35,848
•   inlet guide vanes                       Annual energy costs with secondary baghouse                               $45,291
                                            Post-upgrade annual energy costs                                          $25,150
•   an actuator motor.
                                            Annual energy cost savings                                             $20,141 (44%)
The photohelic sensor monitors the
                                            Original annual energy consumption                                      718,400 kWh
pressure on the dirty side of the
                                            Annual energy consumption with secondary baghouse                       907,645 kWh
baghouse. When the pressure exceeds
                                            Post-upgrade annual energy consumption                                  504,000 kWh
the high-pressure setpoint, the high
                                            Annual energy savings                                                   403,645 kWh
pressure contact on the photohelic
closes, which starts the actuator motor     Original system demand                                                     179.6 kW
running in the direction that closes the    System demand with secondary baghouse                                      227.0 kW
guide vanes. When the pressure drops        Post-upgrade system demand                                                 126.0 kW
below the low-pressure setpoint the         Demand savings                                                             101 kW
other contact closes, which operates the
actuator motor in the opposite direction,   Savings Comparisons
opening the guide vanes. When the                                          Secondary Baghouse             Actual Installed System
pressure comes into the desired                                                Compared to             Compared to Secondary Baghouse
pressure range, the contacts open and                                         Original System          Equipment   Controls       Total
the actuator motor is turned off.           Annual Energy Savings (kWh):         (189,245)             367,645     36,000       403,645
                                            Demand Savings (kW):                   -47.3                 91.9         9           101
After the retrofit was complete, a JEA
                                            Annual Energy and
engineer visited the site. The bags were    Demand Cost Savings:                 $(9,443)              $18,345      $1,796     $20,141
relatively clean and the magnehelic         Project Cost:                        $100,000              $108,501    $11,000     $119,501
gauge on the control system showed 1        Simple Payback (years):                n/a                   5.9         6.1         5.9
inch of pressure drop across the
baghouse. The photohelic was set to         Pacific Power Rate Schedule 27, Large General Service (secondary service voltage)
hold the static pressure in the duct in          $4.13/kilowatt/month - demand charge
front of the baghouse at minus 10                $0.03751/kilowatt-hour - energy charge
inches. The guide vanes were partially
closed and the fan was generating           Key Data                                     Pre-Upgrade        Post-Upgrade          Savings
34,000 cubic feet per minute of airflow.
                                            Emissions (grains per cubic foot):               0.2                0.005          0.195 (98%)
Suction pressure at the planer was
                                            Noise level (dBA):                                95                 80             15 (16%)
measured at minus 6.6 inches of static
pressure; system velocity was
measured at slightly under 3,500 feet
                                            Non-Energy Benefits
per minute.                                 In addition to cost savings, the new installation resolved the previous problems with air flow
                                            adequacy, improved particle capture by 98%, and reduced noise levels by 16%.
Baxter Air Engineering supplied the
new equipment while Qualair
Pneumatics performed the mechanical
installation and Georgia-Pacific completed the          For More Information
electrical work.
                                                        For more information, an evaluation of existing
The new equipment was installed alongside the           pneumatic conveying systems or assistance with
old to allow continued production; the actual           the design of efficient new systems, contact:
switch occurred during a planned maintenance
shutdown of the mill.
                                                        QEI Energy Management, Inc.
                                                        John Shinn
An Alternative Solution                                 Phone (503) 626-4731    john.shinn@qeiem.com
Georgia-Pacific had an alternative approach of
                                                        Carroll, Hatch & Associates, Inc.
adding a secondary baghouse to the cyclone
discharge. This would have initially cost about         John Vranizan
$120,000 less than the actual retrofit. However,        Phone (503) 977-7973    jvcha@attbi.com
increased system resistance and new cleaning
requirements would have increased the annual
electricity consumption about 30 percent and            About Just Enough Air
added some $10,000 to annual power bills,               Just Enough Air is a project sponsored by the
compared with the retrofit. Also, this alternative      Northwest Energy Efficiency Alliance to help
would not have lessened noise from the plant.           Northwest wood-products manufacturers
                                                        improve the efficiency of their wood-waste
Project Cost                                            removal systems.

Secondary Baghouse Alternative:             $100,000
Actual Installed System:                    $219,501
Incremental Cost:                           $119,501

The $219,501 total includes removing the old            About the Alliance
equipment, site preparation for the new
equipment, as well as labor and materials for the       The Northwest Energy Efficiency Alliance is a
new equipment installation. The installed cost          non-profit group of electric utilities, state
associated with the guide vanes and control             governments, public-interest groups and industry
system was $11,000 of the total and had a simple        representatives committed to bringing affordable,
payback of 6 years.                                     energy-efficient products and services to the
                                                        marketplace. Information on the Alliance is
                                                        available on the Alliance web site at
                                                        www.nwalliance.org




“The system does a good job. It definitely reduces
emissions and is a lot quieter, which is good for the
community. Overall, it is a great improvement over
the old system.”
Jeff Hensley, Georgia-Pacific Corporation