Paper Machine Water System Audits

Scott Romenesko Product Line Manager

Filtration Systems

Kadant Solutions Division

 Drivers for Water Reduction
Corporate directives
Environmental awareness / activism
Paper consumers
Regulation
Sustainability / survivability
Cost to heat and treat fresh water and effluent
Audit Equipment
Portable Sample Point
Documenting the Water System
 Fourdrinier Shower Map
Deckle Boards Trim Squirts

Flooded Nip
Edge Showers
Inside HP Shower

Manual Guide Auto Guide Stretch

Outside HP Shower

Hot Treated Water Cold Treated Water

City Water Filtered Clear WW Water

Chemical Shower
Discover Opportunities for Improvement
 Benchmarking - TAPPI TIP 0404-63 Energy
Performance Indices
Gallons of Fresh Water Consumed per Gross Ton Produced

Water Fine Bleached Liner Corrugated Market Fluff Recycle News- LWC Kraft
Usage Paper Board Medium Pulp Pulp Board print

gals/ton 2,000 2,000 1,500 1,500 1,000 1,000 <1,000 2,000 2,000 1,500

m3/ton 7.6 7.6 5.7 5.7 3.8 3.8 <3.8 7.6 7.6 5.7

How does your machine compare to others making

similar grades?
 Benchmarking Graphics or Fine Paper
Grades
Graphics - Gal Wtr/ Ton
Graphics - Gal Wtr/ Ton

18000

16000

14000

12000

10000

8000

6000
Target

4000

2000

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
Existing Equipment Evaluation
 Historical Data Collection
Main Break Detector Values Clear WW Chest Level Clear WW Chest Makeup Valve Machine Heated Mill Service Water
80 8000

70 7000

60 6000

50 5000

40 4000

30 3000

20 2000

10 1000

0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
 0
20
40
60
80
100
120
140
160
180
200
1
19
37
55
73
91
109
127
145
163
181
199
217
235
253
271
WW Chest Calcium mg/L

289
307
325
343
361
379
397
415
433
451
WW Chest Temp F

469
487
505
523
541
559
577
595
613
631
649
WW Chest Turbidity NTU

667
685
703
721
739
757
775
793
811
829
847
Sheet Break Detector

865
883
901
919
937
955
Portable Sensor Data Collection

973
991
1009
1027
WW Chest TDS ppm

1045
1063
1081
1099
1117
1135
0
200
400
600
800
TDS Scale

1000
1200
1400
 Economics
An example of the cost to heat and treat 100 GPM of cold fresh
water to targeted system process temperature = $96,500
Incoming fresh water temperature 72F
Targeted process temperature - 120F
Cost per MMBTU - $4.75
Cost to treat 1000 gallons of fresh water - $0.04
Water Savings
Energy Calculation Average Annual
Water Flow (gpm) Process Temp Mill Water Temp Energy Cost ($/MMBTU) $/hour of flow $/Day of flow $/350 Days of flow
100 120 72 $4.75 $11.29 $270.86 $94,802.40

Water Savings
Influx Calculation
Water Flow (gpm) Water Cost ($/1000 gal) $/hour of flow $/Day of flow $/350 Days of flow
100 $0.04 $0.21 $5.11 $1,787.18

Note: Data shown is hypothetical and not Total Economic Cost

to Heat & Treat Water $96,589.58
from an actual mill.
 Justification

Prioritize opportunities for improvement

Utilize a step-by-step approach to water management
projects
Implement best practices when modifying water
systems
Measure the effect of process changes to determine if
expected project objectives were met
Project Development
 Summary
A commitment to water management is required for success
Utilize a systematic approach
Initiate a complete audit of the water system and the process to
develop the facts
Define the savings and benefits of potential projects
Prioritize identified opportunities and develop a roadmap
The roadmap will include projects based on robust designs and
managed control strategies
After system modifications are implemented, measure the
changes against expected project objectives
Disseminate the results throughout the organization
Questions ?