Energy-saving opportunities were constrained by the need to keep multiple boilers in operation in order to maintain spare capacity.
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.
Changes to the site operating policy saved $3 million dollars per year.