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How to use the glass tube level gauge to save you $165000 per year

Time: August 16, 2019 18:24:07 source: Author:
Menasha packaging is the largest independent, retail focused packaging and sales solution provider in the United States, with a network of design centers, manufacturing plants, packaging and fulfillment service centers. Menasha packaging works with good retailers and consumer goods (CPG) companies around the world to provide greater measurable value for the entire integrated commodity supply chain.
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Menasha packaging was assisted by the sparsak team when their energy services group (ESG) conducted a complete energy assessment, including a steam trap survey. ESG found a way for Menasha packaging to save money by reducing energy use. In order to ensure the normal and effective operation of Menasha's steam system, ESG recommends the use of glass tube level gauge blowdown heat recovery package, replacement of steam trap and pipeline modification to meet better practice.
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With the help of the sparsak team, Menasha packaging can save us $85000 per year in steam and condensate losses, US $68000 in blowdown heat recovery and $12000 in the prevention of compressed air leakage.
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Steam heating roller problem
Part of the paperboard manufacturing process involves melting the adhesive that holds the surfaces together. Accurate temperature control is essential. If the temperature is too high, the paper will burn and the adhesive will burn. Poor adhesion due to uneven and unmelted adhesives, insufficient and inconsistent heat. Sufficient heat and steam must be provided to ensure consistent quality of the product.
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During the steam trap investigation, ESG found that the size of the existing steam trap in the plant was too small to fully remove condensate, resulting in waste and waste of production materials.
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To address this issue, the sparsak Energy Systems Division (ESG), working closely with Paul Turner of Michigan steam and skip lake of Macomb group, provides replacement steam traps, most of which are floats and thermostats with steam lock release (SLR). features. The ESG team also used visual inspection valves for visual inspection.
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To ensure a high degree of heat transfer, the condensate must be removed immediately. Otherwise, the heat transfer efficiency of the roller will be reduced. In rotating cylinders such as these heat transfer rolls, a vapor bag can be formed in the condensate removal draw tube, which prevents the condensate from reaching the trap. This is referred to as "steam lock". The SLR option discharges the steam bag from the system to effectively release the steam lock and enable proper steam trap operation to effectively remove condensate.
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By removing the condensate from the steam heated roller, the heat is now uniform, which allows the binder application process to operate as designed. Since the rollers - and therefore the adhesive - are uniformly heated, multiple layers of cardboard now adhere correctly.
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Heat recovery saves energy
Speisak's ESG team also provided a heat recovery package for the glass tube level gauge blowdown. The glass tube level gauge needs a control when the steam is generated Glass tube level gauge Method for the amount of total dissolved solids (TDS) formed in water. When the water conductivity exceeds the preset limit, the TDS system usually opens the valve to drain the glass tube level gauge water. The relatively low TDS feed water replaces the drained glass tube level gauge water.
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It is important to maintain the TDS level recommended by the manufacturer of the gauge in operation. This is achieved by reading the TDS conductivity level of the glass tube level gauge water and purging the glass tube level gauge when the water level exceeds the specification. Blowing down the glass tube level gauge will basically exhaust the valuable heat discharged. However, the waste heat recovery packaging provided by sparsak can prevent this energy from being wasted. In some cases, the blowdown heat recovery system can recover up to 80% of the heat from the blowdown cycle.
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The blowdown heat recovery module allows pressurized condensate from the blowdown cycle to flash in the flash vessel and the steam is sent directly back to the glass tube level gauge feed tank. In addition to the energy saved by heat recovery, the flash steam from the blowdown water is condensed into relatively pure water and returned to the system, which reduces the amount of make-up water and the chemical treatment required. The float type drain valve discharges the residual blowdown condensate. This residual water is still hot and is directed to the heat exchanger to heat the cold make-up water.
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The evidence of thrift is
The ESG team of spicak determined that the long start-up time and cold point of the rollers were due to improper condensate removal. The new steam trap solves these problems. Traps also help to remove air from the system, greatly reducing start-up time. Additional savings are achieved by installing a blowdown heat recovery device in the glass tube level gauge room. The return on the unit is less than a year.
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According to an old saying, "if something sounds too good to be true, it may be." Sparsak's ESG team recorded the estimated savings. In addition to providing quotes, drawings, and estimated savings, the team provided all the formulas and thoroughly explained these theories in multiple people at Menasha packaging.
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Menasha is concerned about the replacement of steam traps. As the existing trap size is insufficient and there is no SLR (steam lock release) function, it is useless to continue using the existing inventory. The SLR function is necessary to keep the drum at the correct and consistent temperature. Some pipe changes have to be made, but they simplify the pipe geometry and actually save space.
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The team's extra effort applies to Menasha packaging. Menasha's energy saving and increased production have convinced the company that the sparsak team can conduct a comprehensive factory audit to find more energy saving and process improvements. In addition to being able to take advantage of the gas supplier's energy rebate, Menasha realized that the cost savings were so high that they had replaced every trap on the corrugator.
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The company saves $85000 a year to prevent steam and condensate losses, $68000 to recover blowdown heat, and $12000 to prevent compressed air leakage. Energy saving is not only of great significance, but also will benefit the facilities and the environment through the installation of these equipment.