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Report on an Energy Survey at PZ Cussons Indonesia

December 2005

Prepared for:

Tel: E-mail

Mr. Duncan Wright PZ Cussons Engineering Executive PZ Cussons (International) Ltd Bird Hall Lane Stockport Cheshire SK3 0XN 0161 491 8000 Duncan.wright@pzcussons.com

Contact:

Des Murphy NIFES Consulting Group Charringtons House North The Causeway Bishops Stortford Hertfordshire CM23 2ER 01279 658412 d.murphy@nifes.co.uk

Tel: E-mail

Ref: Date Issue

UKE782/DM/DB DECEMBER 2005 DRAFT Rel 1.0

CONTENTS
Page 1.0 2.0 3.0 4.0 5.0 6.0 INTRODUCTION REPORT HEAT RECOVERY POSSIBILITIES ENERGY MANAGEMENT TRAINING ACTION PLAN 1 3 9 11 14 15

APPENDICES

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1.0

INTRODUCTION This report documents the findings of an energy survey carried out at the PZ Cussons, Jakarta plant during Dec 2005. The primary purpose of the study was to identify opportunities for energy savings and to comment on possible improvements with regard to management of energy at the site. The survey considered energy utilisation under three headings: Housekeeping: This examines how well the plant is maintained. It considers issues such as leaks, insulation, etc. It is understood that a campaign to identify and repair leaks was initiated some months ago. The survey showed that this was successful. This heading examines the scope for Operator influence on how energy is used. With much automated plant, Operators have limited control over how energy is used. The Cussons plant has low/medium automation and this affords significant control to the Operators. As a result, there is potential for a high degree of efficiency slippage in how energy is used. At present there is no system in place to manage energy effectively. The only yardstick is total energy consumption against total production on a weekly basis. This cannot take cognisance of changes in product mix or the other parameters which would justifiably change energy consumption. Plant: This heading seeks out opportunities for making improvements to the plant to reduce its energy consumption. These improvements generally require investment. The survey, where possible, provides an estimate of the capital cost and the expected savings.

Operation:

When evaluating savings, the report uses current energy prices at the factory: Residual Oil: 11.4 pence / litre (1.9 p/kWh) Electricity: 3.1 p/kWh Annual energy consumptions were advised as follows: Oil:3.9 million litres 928,000 Electricity: 7,300 MWh 226,000 Total energy cost 1,154,000 or rp 20,772 million An exchange rate of 1.00 = rp18,000 is used in this report. The management advised that energy constitutes 5% of total manufacturing cost. The electricity price is very low and Mr Voutiritsas advised that high

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increases are expected. The figures in the report can easily be adjusted to account for any such increase. Prior to our visit it is understood that considerable efforts were made by Mr Kostas Voutiritsas and engineering staff in general to compile records and usage data. This was very worthwhile and has enhanced the quality of the survey. We would like to acknowledge the assistance given to Mr Murphy by all staff, and particularly by Kostas Voutiritsas and Suranto, during the survey in Jakarta.

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2.0 2.1

REPORT Steam System There are three steam boilers installed. One of these, a new unit rated at 16 t/h, is used on its own to supply the full factory demand. It was suggested that this new boiler may be over sized. However, based on an annual fuel consumption of 3.9 million litres (as advised by local staff), the average load factor on the boiler is 60% (Appendix 1). Given the peaky nature of many of the steam loads, it is likely that the peak steam load is in the region of 12 tonnes/hour. If this is the case then the loss due to oversizing is not very large circa 5,000 pa (APPENDIX 1). The boilers can burn either residual oil or diesel oil. It is noted that 18% of total oil consumption for the past year was diesel oil. Local staff explained that this was due to the fact that for a period, diesel oil was cheaper than residual oil (State subsidy distortion). Also, supplies of residual oil are not always available. At present diesel oil is 50% more expensive than residual oil (2.9 p/kWh versus 1.9 p/kWh). The Action Plan advises that oil stocks be closely monitored to avoid situations were residual oil stocks become low and availability is a problem. Local staff advised that this is current practice. The results of boiler efficiency tests were available. These were carried out when the boiler was installed (June 05) and no readings have been taken since (no instrument available). The efficiency of boilers does decay with time and regular checking (monthly) should be carried out. The retrofitting of a combustion oxygen trim system to the boiler would automatically maintain the boiler efficiency at optimum. This was investigated during the survey. Such a system optimises the boilers efficiency automatically by compensating for fluctuations in fuel consistency (very pertinent in the case of residual oil), atmospheric conditions and boiler fouling. It is estimated that such a system would provide a saving of 2% in oil consumption which equates to 19,000 pa at present fuel costs. This would provide a payback of less than one year. A further saving could be realised by fitting a variable speed drive to the boiler combustion fan. At present the output from the combustion air fan is throttled to match the boilers firing rate. APPENDIX 2 calculates the saving as 2,700 pa with a one year simple payback. Another application of motor speed control concerns the boiler feed pump. The pump (18.5 kW) runs constantly with the output throttled by a modulating valve. Installing a variable speed drive unit has the potential to save 1,300 pa with a simple payback of one year based on local prices for VSDs. This project would require some more technical analysis given that the pump operates against an almost constant head (the boiler pressure). Because of the risk of contamination of condensate in the various processes, only a small proportion of condensate is returned to the boilerhouse. This necessitates a high use of fresh make-up water which in turn dictates a high boiler blowdown rate (exacerbated by the high silica content of the raw water). The survey examined the possibility of recovering the heat in the blowdown water to preheat the feedwater. Section examines the case for blowdown recovery.

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The steam distribution system was surveyed for leaks. The situation here can be reported as very good but this may be the consequence of a recent maintenance campaign in this regard. It was advised that prior to the campaign there were very many leaks. There is some scope for upgrading of insulation on steam piping and process plant. APPENDIX 5 calculates the cost/benefit for steam pipe insulation and indicates a payback of just one month based on local fuel and insulation costs (rigid pipe insulation with stainless steel cladding). 2.2 Compressed Air System Compressed air is used throughout the factory. It is generated centrally by three screw compressors located. A 24 hour consumption test was carried out which indicated that the compressed air system is responsible for circa 7% of total electricity consumption (APPENDIX 5).A leak survey was carried out. The situation can be described as good but there is scope for improvement in this respect. APPENDIX 6 quantifies the potential savings from leaks. The sources of the leaks were notified to local staff. On the basis of electricity costs pertaining at the site, a 3 mm dia. hole would lose the equivalent of 900 pa. It would be possible to recover the waste heat from the compressors. This heat would be available at a temperature of 80 oC hot water. The value of the recoverable heat would be 8,000 pa. The use for this heat is considered in the Section , Heat Recovery Possibilities. 2.3 Chilled Water System Chilled water is used in most of the process areas mainly for vacuum pump water cooling. This is generated in two chiller packs with reciprocating compressors. The total electrical rating of the compressors is 200 swathe chilled water is circulated in two main circuits to the various processes. The circulating pumps have a combined electrical rating of 50 kW. Based on a chiller load factor of 50% (guesstimate) the system would account for some 13% of total factory electricity consumption representing a cost of circa 30,000 pa. With some minor exceptions, the insulation level of the piping is satisfactory. A reliable method of assessing chiller system efficiency is provided by the evaporating and condensing temperatures of the refrigerant. During the survey these temperatures were noted for each of the units (APPENDIX 7). Ideally these reading should be compared to the compressors commissioning readings but such records were not available. However, the following comments can be made. The condensing temperatures on Chiller #1 were satisfactory at 47 oC which was 12 oC above ambient temperature. However, on Chiller #2 the condensing temperature on one circuit was 40 oC (very low) and on the other it was 58oC which is very high. This has significant energy consumption implications and should be investigated. Each 1 oC of excess condensing temperature requires 3% more compressor electricity. Another area of potential saving is to reduce or totally cease the use of chilled water to sub-cool the tower water supply to the vacuum pumps. The performance of ring seal vacuum pumps is dependant on the supply water temperature but it is possible that acceptable performance will be obtained by using the cooling tower water without further cooling with chilled water. If the

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operation of the cooling towers is optimised (see section below on Cooling Towers) then this possibility is further enhanced. This was discussed with the local staff who will carry out tests in this regard. It may be the case that the chilled water supply is needed only during the rainy season when web bulb temperatures are very high and the cooling effect of the cooling towers is marginal. A 30% reduction in chilled water would reduce costs by 9,000 pa. 2.4 Cooling Tower Water System There are five cooling tower water systems supplying cooled water to the various processes. Most of this water is further cooled using chilled water prior to being used in the process. The cooling towers should be capable of cooling the water very close to the wet bulb temperature of the ambient air. Tests were carried out to check the effectiveness of the cooling towers. The results are summarised in the table below. Note that the ambient temperature at the time of test was 35 oC (dry bulb). Return o C 41 48 36 34 38 Tower Sump o C 34 34 28 27 34

Cooling Tower Service Evaporator Talc Steriliser Bleaching Drier Distillation

All of the cooling towers should have been producing water at 27 oC (if one of them was capable of this then they all should). The reason why this is not the case is due to fouling of the cooling tower packing which results in shortcircuiting of the water as it falls through the tower. The fouling is a problem for some of the towers due to product carry-over. Given that practically all of this water is subsequently cooled with chilled water, any loss of cooling in the towers must be made good by chilled water cooling - at significant cost using the mechanical refrigeration equipment. It is noted that the circulating pumps for these cooling water circuits have a rating of 225 kW. The tower fans constitute another 64 kW. Both the fans and the pumps run continuously once the plant is operation. On this basis the cooling tower system is responsible for some 22% of total electrical consumption at the factory. The cost at present rates is 50,000 pa. (See APPENDIX 13). This is a key cost and it is recommended that: Renewed efforts are made to ensure that the towers are optimally maintained. A review is undertaken of the need for cooling water throughout the plant including the quantities per item of plant.

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Following the above, a study should be carried out to ascertain if the use of variable speed drives on the circulating pumps would be cost effective.

2.5

Split Air Conditioning Systems There are approximately 70 split air conditioning systems spread around the site. The total rated load of these units is 120 kW. Based on the hours of usage per day and applying a reduction factor for actual consumption versus rated consumption, the annual electricity consumption is estimated at 190 MWh. At current site electricity costs this amounts to 6,000 pa. This represents 2.6% of total site consumption (APPENDIX 12). Spot checks were made on a sample of units to check the quality of maintenance. For these the internal filters were clean. However the outside condenser heat exchangers were partially blocked. This has the effect of increasing the required condensing temperature (and pressure) thereby increasing the power consumption. Equipment was not available to check the condensing pressures. Each 1 oC increase in condensing temperature results in 3% additional electricity consumption. It is estimated that there is scope here for reducing consumption by 15% by improving maintenance in this area. Most of the units should operate from 08.00 17.00 but it was not possible during the survey to verify if this regime is being adhered to. The operation of a Monitoring and Targeting system as advised elsewhere in this report will help to flag significant excessive usage.

2.6

Processes The individual processes were examined in some detail for energy reduction possibilities. The findings are summarised as follows. Process Bleaching: During the cooling down stage of the process the batch is cooled from 140 oC to 90 oC using chilled water. Energy Saving Possibility This is high grade heat and the possibility of recovery and use elsewhere is explored in Section . If it is decided that heat recovery is impractical then consideration should be given to using cooling tower water instead of chilled water. It is appreciated that this would extend the process cycle time but local staff have advised the this is not a critical issue.

Also, the cooling of this vessel with chilled water places a very high shock load on the chiller system and affects other processes. Bleaching: The vacuum pumps are It was not clear during the survey if required for only a portion of the cycle normal practice is to switch off these time. vacuum pumps when they are not required. This should be followed up and an appropriate operating procedure put in place.
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The proposed Monitoring & Targeting (M&T) system will pick up on this issue.

Bleaching: Barometric condensers are used on the vacuum lines even though there is no moisture being drawn from the oil vessel. Kostas Voutiritsas advised that on another similar plant in Africa these were removed with no adverse affect.

A small saving might result due to less cooling tower water pumping but this would be very small. Not further considered.

Lye Treatment: Heat is removed from The possibility of recovering this heat is the product in a downstream heat examined in Section - 3.0 HEAT exchanger using cooling tower water. RECOVERY POSSIBILITIES. The temperature is reduced from 80oC to 50oC. Soap Dryer: Here the neat soap is No energy reduction opportunities dried in a flash dryer. The dryer identified on this process. operates under strong vacuum thereby dictating a low exit steam condensing temperature. PCC Liquids: Batch sterilization. The batch (mostly DI water) is first raised from 30 oC to 95 oC and held for 15 minutes to ensure sterilization. It is then cooled down to 60 oC using chilled water in the jacket. If sterilisation of the DI water could be effected using an alternative method (e.g., UV) then a saving would be made by not having to heat and then cool the water (double saving). APPENDIX 11 Calculates the savings as 9,000 pa based on current fuel and electricity prices. PCC Liquids: Vessel Sterilization is carried out after each batch. It consists of filling the vessel with heated DI water via a spray ball. The water in the vessel is then maintained at 95oC and circulated for 30 min to ensure sterilization of the vessel. It may be possible to sterilize using a non-thermal method (e.g., chemicals in the spray water). This would reduce energy consumption and perhaps even speed up the process (the sterilization process currently takes about an hour). APPENDIX 11 Calculates the savings as 1,800 pa based on current fuel and electricity prices.

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Soap Finishing - Glycol Chillers: There are four glycol chillers on the lines used for mould cooling. These are each rated at 6.4 kW electrical.

The glycol flow temperature varied across the four units from 10 oC to 18 oC. If 10 oC is adequate for the process then all units should be set at this temperature. The air cooled condensers on these units are quite badly fouled which invariably results in higher than needed condensing temperatures/pressures and excessive electricity consumption. APPENDIX 9 calculates the annual operating cost at 3,600 pa. It is likely that a saving of at least 10% (360 pa) could be made by cleaning of the condenser heat exchanger. Besides the energy implications, it is likely that the fouled condensers will result in premature failure of the compressors.

Evaporator: There is one 3-stage evaporator and one single-stage unit.

The process design information was not available to allow an analysis of this process. It is recommended in the Action Plan that the present operational regime be reviewed against the design parameters for the evaporators. It is possible that operational changes have been made over the years to facilitate production but at the expense of energy consumption.

Distillation: There is one distillation Comment as per Evaporators process.

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3.0

HEAT RECOVERY POSSIBILITIES The chart below shows the heat available for recovery and possible uses for the recovered heat. The y axis shows the temperature level ( oC) of the heat and the x axis the quantity of heat (kWh per day)
Heat Availability versus Requirement
3 200 2 180 6 9 10

160

140 5 120 7 8

*C

100

11

80

60

40

20

0 0 1000 2000 3000 4000 5000 6000 7000 8000

kWh per day

From oC Heat required by [ (2) Boiler Feedwater preheating (8) Sap Pan Water Preheating (9) Bleaching Oil Preheating (10) Boiler Combustion Air Preheating: Heat available from [ (5) Compressor Heat Recovery (7) Lye Heat Exchanger (3) Boiler Blowdown Recovery (6) Bleaching Vessel Cooling (11) Chiller Heat Recovery ]: 80 80 190 140 47 ]: 40 30 30 35

To oC 150 80 140 135

kWh / day 1,900 3,200 4,400 6,900

60 50 30 90 40

1,340 2,200 1,980 2,010 5,400

From this the following possibilities for heat recovery are explored. 3.1 Boiler Blowdown Recovery to Feedwater Heating This is standard technology. The blowdown at present is controlled using a timed solenoid valve. This would be replaced by a special labyrinth valve to control the flow of blowdown at a constant flow rate. A standard heat exchanger would recover the heat to the feedwater.

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APPENDIX 4 shows the saving to be 11,000 pa. It was beyond the scope of the survey to obtain capital costs but the installation is unlikely to cost more than 11,000 giving a one year payback. 3.2 Heat Recovery from Chillers and Air Compressors to SAP Water Supply In the Sap process there is a requirement for 55 tonnes of water at 80 oC per day. At present this is heated in the pans using steam. It is understood that, from a process viewpoint, there is no reason why the water could not be supplied heated to the pans. Assuming this to be the case then this water could be preheated by first passing it through heat exchangers in the chillers (to recover heat from the condensing refrigerant at ~ 47 oC and then to pass it through a heat exchanger (oil cooler) in the compressors. Because the flows are not constant, it is expected that the design would have to incorporate a hot water buffer tank. Based on current fuel costs, the saving would be circa 17,000 pa. (See APPENDIX 14) The capital cost cannot be estimated until preliminary design is carried out but a payback of ~3 years is expected. 3.3 Bleaching Process During the cooling down stage of the process the batch is cooled from 140 oC to 90 oC using chilled water. If this heat could be used to preheat the next batch then a double saving would be made; the steam saving in heating the next batch, and, the chiller saving. APPENDIX 15 estimates the saving as 18,000 based on current fuel and electricity prices. The technical feasibility of this should require further investigation which is beyond the scope of this survey.

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4.0

ENERGY MANAGEMENT Our review of the plant has indicated that operator diligence could have a significant effect on energy consumption. Many energy using operations are under the control of the operator. Examples are the heating of vessels, switching of pumps, etc. It would not, from an energy saving viewpoint, be cost effective to automate all of these processes. A different approach is called for. We propose a two pronged approach: Operation of a Monitoring & Targeting system (M+T). Essentially, this allows, each week, the actual consumption of energy in each process to be compared to a target.

Checklist system for tracking problems such as leaks, damaged insulation, fouled refrigeration condensers, etc.

Both of these systems are relatively low cost yet provide an effective method of energy management. 4.1 Monitoring & Targeting System As an example of this technique, the total production at the facility was plotted against the fuel oil used (last 20 weeks only were available). Using regression analysis, the best fit line was drawn, as shown below. It can be seen that for a production of ~ 700 tonnes/wk the fuel consumption varied between 56,000 litres and 95,000 litres. Even neglecting these extreme points (weeks) there is still a wide spread (deviation) for similar production outputs. The question arises as to why the fuel consumption should vary so much for the same product consumption. It is possible that these variations can be explained by differing product mixes, but unlikely. An M&T system uses this technique to obtain a Target Line for each process. Weekly consumption is then compared to the target. Significant deviations then have to be investigated.

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Production versus Fuel Oil Regresssion

900

800

Total Production (tonnes)

700

600

500

400

300

200

100

0 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000

Fuel Oil (litres)

It is appreciated that at present there are only main meters, i.e., oil consumption and total electricity. In the short term this is sufficient to commence the M&T system. Correction factors can be used to adjust for changes in production mix compared to the mix used to form the target line. The above analysis chart is for oil versus production. A separate analysis should be set up for electricity versus production and another for production versus air compressor run time. Ideally meters should be fitted to each main process and the regression carried out for that process and also for the facility overall. However, it may transpire that acceptable results will be obtained using the existing meters. Ten weeks of analysis should determine this. Specialist software packages are available for this but there can be expensive to purchase, to set up and to modify. We would recommend using a simpler but equally effective approach using such data sources as are available on site and using spreadsheets and targeting analysis that is easy to follow and could be modified by site staff. 4.2 Checklists The M&T system can be described as a Indirect approach to energy management by ensuring that overall performance is maintained on target. It will not identify any problem but merely flag that a problem exists. This is important given that many causes of excessive energy consumption are not always obvious. The Checklist system can be described as a more Direct approach and will supplement the M&T system. It involves, for each energy using process, making a list of the indicators of excessive energy consumption. These will be checked regularly (e.g., weekly) and will highlight problems with equipment.
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Taking the steam boiler as an example, the checklist would comprise the following.

Checklist item: Flue gas temperature Oxygen concentration in flue gas Boiler chamber water total dissolved solids (TDS)

Information provided: Fouling of the boiler heat transfer surfaces. Excessive combustion air being provided to the burner. Excessive blowdown being used.

Once these few parameters are within limits it can be concluded with a high degree of confidence that the boiler is operating efficiently. Similar check lists can be set up for all utilities (compressed air, chillers, air conditioning units, etc) and for the processes. The test equipment needed to operate the checklist system would be minimal. 4.3 Energy Management Strategy To ensure an effective drive at reducing energy use there needs to be an energy management system in place that is structured, planned and well integrated into overall management objectives. Energy management at the moment is slightly informal and dependent as the drive of a few individuals. It lacks structure, policy, strategy planning and useful reporting. The reporting can be taken care of in the M&T systems discussed above. There are a series of actions identified here that form the basis of an action plan. There is a need to identify a suitable structure, assign responsibilities and to set objective with a company policy and site strategy.

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5.0

TRAINING A full compendium of energy efficiency Good Practice Guides was handed over to local staff during the survey. In setting up and operating the M&T and the Checklist systems recommended above it would be very useful for the local staff to have access to a hand holding advice from energy specialists. The need for on-the-job training should be reviewed.

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6.0

ACTION PLAN The site spends over 1m on energy per year and they are anticipating further price rises. There is an informal approach to energy management and commitment from senior management. The site has recently made good progress in reducing energy use by undertaking leak surveys, etc. However, the positive benefits from such energy actions are difficult to maintain over the long-term, without a systematic approach to energy management. In this report, based on a very brief survey, possible savings of over 100,000 or 10% of the energy bill have been identified. A list of these are given below and rough details are given in supporting appendices. We would recommend that the site:1. 2. 3. Initiate an energy management system and integrate energy reporting into normal management responsibilities. Install an M&T system to allow proper tracking of projects. Adopt a check-list approach to help operators maintain efficiency of significant energy using operations. This could be combined with handholding assistance. Possible on-the-job training should be reviewed. Correct some obvious faults identified. Look in detail at the list of projects and select those that are implementable and show worthwhile savings. Further develop M&T. Provide steam and electricity meters to show performance of key areas. Track progress of energy saving projects.

4. 5. 6. 7.

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List of Possible Actions Process Set up M&T system. Action At this stage no capital cost is required. Some degree of consultancy could be required to set up the system but site visits would not be necessary. Later, it may transpire that metering of some of the processes proves necessary to provide adequate control. No capital cost required. Some small degree of consultancy may be required. Investigate the possibility of recovering cooling heat as outlined in Section 3. the

Set up Checklist System

Bleaching Process heat recovery Heat Recovery from Chillers and Air Compressors to SAP Water Supply Boiler Blowdown Recovery to Feedwater Heating Distillation process

Carry out detailed analysis of this energy saving option as described in Section 3.

Carry out detailed analysis of this energy saving option as described in Section 3. The current operating parameters of this process should be reviewed against the original design to check for drift in practices which could adversely affect energy consumption. Determine Checklist items for the process.

Evaporators Soap Finishing - Glycol Chillers

As per Distillation process. Further investigate the operation of these units: evaporating temperature, condensing temperature. Compare to commissioning data. Take action as appropriate (which will definitely include cleaning of the condenser coils). Investigate the possibility of carrying out the sterilisation using a non-thermal process. Investigate the possibility of carrying out the sterilisation using a non-thermal process. The current operating parameters of this process should be reviewed against the original design to check for drift in practices which could adversely affect energy consumption. Determine Checklist items for the process.

PCC Liquids: Vessel Sterilization PCC Liquids: Batch sterilization. Soap Dryer

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Bleaching: Control of vacuum pumps

Check that the optimal regime is in place for control of these pumps. Can they be switched off when not required during the cycle? Examine the technical feasibility of using cooling tower water instead of chilled water. Also examine the possibility of heat recovery as outlined in Section 2. Set up a regime for regularly (every three months) checking the operation of these 70 units. Prepare checklist. Renewed efforts should be made to ensure that the towers are optimally maintained. It is appreciated that the carryover from the process can make this difficult. A review is undertaken of the need for cooling water throughout the plant including the quantities per item of plant. Following the above, a study should be carried out to ascertain if the use of variable speed drives on the circulating pumps would be cost effective. Clean the condenser coils on unit 2. This may solve the current low efficiency problem. If not further investigate the problem. Review the need for using chilled water on vacuum pumps. Optimal operation of the cooling towers is vital in this respect.

Bleaching: Batch cooling

Split Air Conditioning Systems

Cooling Tower Water System

Chilled Water System

Compressed Air System Steam System

Continue with the leak checklist system. Give strong consideration to installation of an oxygen trim system and combustion fan variable speed drive. If this system is not being installed, than an oxygen test instrument should be purchased (circa 1,000). Further investigate/confirm the technical viability of installing variable speed drive (or soft start) control on the feedwater pump.

Maximise use of residual oil

Put in place a formal system for logging residual oil stocks to ensure that stocks are sufficient to allow for short term unavailability.
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Energy monitoring equipment

The company should invest in equipment to assist with energy use tracking and problem solving. Cost circa 5,000. Equipment required: portable data logger with probes/sensors, boiler efficiency tester, ultrasonic leak detector. Details can be provided on request.

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APPENDIX 1

STEAM BOILER CALCULATIONS

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APPENDIX 2

BOILER COMBUSTION FAN SPEED CONTROL

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APPENDIX 3

BOILER FEED PUMP VSD CONTROL

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APPENDIX 4

BOILER BLOW DOWN HEAT RECOVERY

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APPENDIX 5

STEAM PIPING COST/BENEFIT

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APPENDIX 6

COMPRESSED AIR

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APPENDIX 7

CHILLERS

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APPENDIX 8

LYE HEAT EXCHANGER HEAT RECOVERY

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APPENDIX 9

SOAP FINISHING LINE GLYCOL CHILLERS

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APPENDIX 10

COMBUSTION AIR PREHEATING

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APPENDIX 11

PCC WATER HEATING

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APPENDIX 12

SPLIT AIR CONDITIONING SYSTEMS

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APPENDIX 13

COOLING TOWER COSTS

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APPENDIX 14

HEAT RECOVERY TO SAP PAN WATER PREHEATING

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APPENDIX 15

BLEACHING PROCESS HEAT RECOVERY

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