PAPTACMontréal February 2006

Steam and Condensate Closed System (SCCS)

100 % condensate return Reality or Utopia ?

lalondesysthermique inc The Steam and Condensate Closed System Group (SCCS) Expertise in how to use steam without losses Expertise in how to use steam without losses A unique system technology developed & improved since A unique system technology developed & improved since Currently installed in over 52 mills Currently installed in over 52 mills Caddet : Caddet : Paptac Energy Award : Paptac Energy Award :

Energy Saving Achievements Eliminate steam & condensate losses Stop flash steam, steam trap & pump gland losses Eliminate steam & condensate losses Stop flash steam, steam trap & pump gland losses Better control & efficiency of thermal equipment Eliminate excessive pressure, temperature & flow drops Modify steam side control Control on the condensate side Better control & efficiency of thermal equipment Eliminate excessive pressure, temperature & flow drops Modify steam side control Control on the condensate side Reduce fossil fuel & green house gases Reduce fossil fuel & green house gases More than 10 % steam savings 1000 lbs of steam = 10.8 U.S. gallon of bunker oil = 0.13 tonne of CO 2 gas 1 tonne of steam = 90.2 liter of bunker oil = 0.28 tonne of CO 2 gas 1 tonne of steam = 82.3 meter 3 gas = 0.16 tonne of CO 2 gas

Basic Principles of the Steam and Condensate Closed System (SCCS) Use of saturated steam at 0 deg superheat Usually steam enters heat exchanger with 10 ºC or more of superheat Use of saturated steam at 0 deg superheat Usually steam enters heat exchanger with 10 ºC or more of superheat Mechanically remove non-condensible gases on the steam side Mechanically remove non-condensible gases on the steam side Typically ignored or conventionally done on condensate side and amines have to be added Typically ignored or conventionally done on condensate side and amines have to be added Return condensate to the deaerator &/or a flash tank at the highest possible pressure & temperature using mechanical force of steam pressure to return condensate Return condensate to the deaerator &/or a flash tank at the highest possible pressure & temperature using mechanical force of steam pressure to return condensate Usually, condensate was vented to an atmospheric tank and pumped Usually, condensate was vented to an atmospheric tank and pumped No condensate tank, no pump No condensate tank, no pump No flash steam to atmosphere, no use of electrical power, lower maintenance

SCCS METHOD BENEFITS Convert heat exchangers, evaporator, black liquor heaters etc, to full pressure steam Convert heat exchangers, evaporator, black liquor heaters etc, to full pressure steam Control process heat exchanger on the condensate side Control process heat exchanger on the condensate side Control heat exchangers to less than ± 1 ° F Control heat exchangers to less than ± 1 ° F Condensate returned under full pressure to steam plant Condensate returned under full pressure to steam plant Better control & efficiency of thermal equipment Better control & efficiency of thermal equipment Control all steam system vents to atmosphere (without steam loss) with mechanical O 2 & CO 2 eliminators Control all steam system vents to atmosphere (without steam loss) with mechanical O 2 & CO 2 eliminators Guaranteed boiler water make-up reduction Guaranteed boiler water make-up reduction Up to 10 % total steam savings Up to 10 % total steam savings

Last lalondesysthermique Steam and Condensate Closed System results

Average Steam production per hour Before : lbs/hour After : lbs/hour

Power Generation Before : MW After : MW

Natural gaz consumption Before : m 3 /day After : m 3 /day

Water regeneration Before : 6 /day After : 3 /day

As an exemple, deaerator steam demand Before : lbs/hour After : lbs/hour

Pulp Production Same

MUCH MORE …

February 2005 Energy conservation awards are presented to individuals working in the industry who submit the best examples of energy conservation opportunities applied in Canada. Les Papetières du Québec sponsors this competition. 1st Prize : Jack Smith (Tembec – Smooth Rock Falls) for his Steam and Condensate Optimization.

February 2005 Working with the mill in this effort, from the beginning, has been Systhermik Canada inc. (lalondesysthermique inc.). Their expertise revolves around closed system approaches towards handling steam and condensate. The first prize was attributed for : Innovation, creativity, originality Innovation, creativity, originality Applicability in the pulp and paper industry Applicability in the pulp and paper industry Size of savings and cost-effectiveness Size of savings and cost-effectiveness Installation and implementation Installation and implementation Environmental impact Environmental impact

Basic Questionnaire for Energy Conservation Calculations 1.Operation in days ______ / yr 2.Steam production (approx) Summer______ lbs/hr or ______ tons/hr Winter______ lbs/hr or ______ tons/hr Average______ lbs/hr or ______ tons/hr 3. Total steam production______ lbs/yr or ______ ton/yr 4.Boiler feed water flow Summer______ US gpm or ______ l/min Winter______ US gpm or ______ l/min Average______ US gpm or ______ l/min 5.Process direct steam injection in % of steam production :____ % 6.Continuous blowdown in % of steam production :____ % 7.Boiler water make-up in % of steam production :____ % 8.Steam pressures in plant Pressure 1 _____ psig, or ______ KPa Pressure 2 _____ psig, or ______ KPa Pressure 2 _____ psig, or ______ KPa Pressure 3 _____ psig, or ______ KPa Pressure 3 _____ psig, or ______ KPa Pressure 4 _____ psig, or ______ KPa 9. Deaerator pressure :______ psig,______ KPa 10.Make-up water temperature in :______ °F, or______ °C 11.Steam production cost in $ / 1000 lbs ______ or/tons ______