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The challenge

Energy-saving opportunities were constrained by the need to keep multiple boilers in operation in order to maintain spare capacity.

The solution

A site utility model, process model and pinch analysis were used to analyze current operations and determine energy-saving opportunities. A risk analysis and an online steam modeling tool provided real-time recommendations on when to shut down and restart boilers. In addition, a specific equipment-reliability program was developed to support sustained, reliable operation of the boilers.

The results

Changes to the site operating policy saved $3 million dollars per year.

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