Document 6wYM8RmmdxeMVjGzMaqK9Q6v9

Date CestainleecO June 1, 1979 Subject CROSS BLOWING OF STEAM BETWEEN AUTOCLAVES AT THE A/C PLANTS To D. Wigfield F=r=s^^Kterg^ng Location and mail code 2126 ^ Location and mail code 2126 PLAINTIFF'S EXHIBIT Reference: G. Stelian -- D. Wigfield 3-6-79 D. Wigfield -- G. Stelian 3-16-79 F. Niedergang -- F. Hawkins 5-21-79 Please find enclosed a report from Fred Hawkins dated May 30, 1979 concerning this subject. Given the continued increase in energy costs for the last few months, it is necessary that you have an evaluation done of the cost of the modifications to be made to the autoclaves in each plant. You can contact Fred Hawkins directly, for the definition of the necessary equipment. You can split up your price studies, beginning with the Ambler plant and the Hillsboro plant. T. Dougherty cc: L. Ambler 6. Stelian FN/pha 01-25-00*5 CTD001291 Date CeriamTeed May 30, 1979 Subiect CROSS-BLOWING OF STEAM BETWEEN AUTOCLAVES AT THE A/C PLANTS To Mr. F. Niedergang |4-Fran ?-<. Mr.*?^ 3. Hawk'ins Location and mail code # 2126 Location and mail code #2126 In answer to your request of May 21st, I have reviewed cross-blowing and evaluated it against present fuel costs. Company-wide $45,600 in fuel could be saved yearly at current fuel costs. The cost would be some re duction in autoclave capacity and the cross-blowing connections. I have gone on past this to calculating the savings if we went all-out to save the heat in' the condensate, and recover some of the heat in the pipe and autoclave as well as the heat in the steam. Savings yearly would be $239,000 with the same expenses as above plus additional expense for pumps, sprays, and some autoclave modifications. Attachment 01-25-0005 CTD001292 STEAM SAVINGS BY CROSS-BLOWING AUTOCLAVES Summary Cross-Blowing Autoclaves is usually considered to be the discharge of the steam in an autoclave at the end of the cycle into an autoclave just starting up. This report gives the savings in fuel costs which can be made by doing this and then goes further to describe how even greater savings may be made. The savings can be summarized as follows based on 100 foot long auto claves: Savings Per Year Conventional Improved Cross-Blowing Cross-Blowing Ambler Riverside Santa Clara Hillsboro $14,700 8,200 .6,100 16,600 $77,000 43,000 32,000 87,000 $45,600 $239,000 No amortization of cost of autoclave modifications. Background Information Cross-blowing of autoclaves has been investigated in the past and with low cost fuel it did not seem worth the scheduling problems and the loss of autoclaving time resulting from extending the heat-up and pressure release phase of autoclaving. Now that fuel prices have increased, it is time to look at cross-blowing again and the ways to make cross-blowing more efficient. Conventional Cross-Blowing An autoclave contains hot pipe, a hot autoclave shell, hot autoclave cars and trays, steam under 150 lbs/sq.in. pressure, and a small amount of hot con densate. The only heat that is saved by cross-blowing is the heat in the com pressed steam. In an autoclave 100 feet long this amounts to 981 lbs. of steam per autoclave cycle (Calculations page 6). CTD001293 Plant Savings $/Autoclave Cycle Savings Per Year Ambler Riverside Santa Clara Hillsboro $5.99 3.33 3.33 3.38 Est. $14,700 8,200 6,100 16,600 $45,600 In Ambler and Hillsboro this is getting to be worth the trouble but hardly worth it in the other plants. Improved Cross-Blowing - To make cross-blowing worth the trouble, the savings should be increased and I propose doing this by utilizing some of the heat in the pipe, trays and autoclave shell and the heat in the condensate. This would be done by the following means: 1. Raise the condensate outlets so all of the condensate is retained in the autoclave. 2. Install a pump and sprays so that the condensate can be sprayed over the pipe and on the autoclave walls. 3. Interconnect the autoclaves so the steam from the auto clave finishing its cycle will go to an autoclave just starting up. The results would be as follows - when the autoclaves are cross-connected the pump is turned on. Spraying the walls of the autoclave, the pipe, and the trays extracting heat as steam. It is assumed that the temperature can be re duced 100F by spraying. Reducing the pressure turns more of the condensate to steam and the steam under pressure in the autoclave goes to the fresh autoclave Calculations are given on page 7 and can be summarized that in one autoclaving 5,141 pounds of steam can be saved. On a yearly basis savings would be: Ambler Riverside Santa Clara Hillsboro $77,000 43.000 32.000 . 87,000 $239,000 CTD001294 3 Discussion The savings are based on cooling the autoclave and contents 100F, re ducing the condensate temperature from 366F to 220F, and reducing steam pressure to 10 psi by cross-blowing. For cooling the autoclave and contents a 75% efficiency is used to correct for possible poor spray coverage. The modifications necessary for the autoclaves are not extensive. The condensate drains should be raised so that 203 cubic feet of condensate can be retained in the autoclave. This raises the water level to a depth of 10 inches (Calculation page 9 ). This may require some changes in autoclave car wheel bearings. The condensate spray system should have well insulated lines and should spray the pipe and the autoclave walls. A 100 gpm pump on each autoclave should be adequate. This would spray 800 lbs. per minute and since cool down will take 30 to 60 minutes this rate of flow should be adequate. The pump can also be used to clear the condensate from the autoclave. The pumping system gives an opportunity to spray the pipe during auto claving which should .yield better and more uniform pipe strength. Recommedations This idea should be verified in the Ambler plant and put into use if it proves warranted. F. E. Hawkins Hay 30, 1979 CTD001295 4 Autoclave Energy Calculations 150 psig steam pressure A. Btu to heat autoclaves, trays and cars. Weight of autoclave and cars Specific heat Btu/F ^ T lb. AT Btu/autoclave charge Pounds of Steam - at 860 Btu/lb. 115,000 lbs. .1 306 3,500,000 4,070 lbs. B. Btu to heat pipe and sand Weight of pipe and sand Specific heat assume 15% moisture AT Btu/autoclave charge Pounds of Steam - at 860 Btu/lb. 48,900 lbs. .32 306 4,800,000 5,580 lbs. C Heat loss to atmosphere Square feet of surface Conductivity Hours at Temperature AT Btu/autoclave charge Pounds of Steam - at 860 Btu/lb. 2,277 .175 10 306 1,200,000 1,490lb.s D. Total Condensate Heat available in cooling from 366F to 220F Total heat available as steam Volume of Condensate at 366F (.01819 cu.ft./lb.) 11,140 lbs. 146 Btu/lb. 1,600,000 Btu 203 cu.ft. E. Steam in Autoclave Improved Cross-Blowing Volume of Steam Cu.Ft. 3174-203 Cubic ft. per lb. steam at 150F Pounds of Steam Cubic feet per lb. of steam at 10 psi Pounds of steam at 10 psi Pounds of steam recoverable 2,971 cu.ft 2.8 1,100 lbs. 163 182 918 lbs. CTD001296 F. Steam, in Autoclave Regular Cross-Blowing -uii Volume of ou: .Cubic ft. .rcu:. Pounds of Cubic ft. Pounds of Pounds of Steam per lb. steam 150psi steam 150 psi per lb. steam 10 psi steam at 10 psi steam recoverable I I ........ 5 3,174 cu.ft. 2.7 .1,176 lbs. 16.3 195 981 CTD001297 Cost of Fuel per 1,000 lbs. Steam 6 Assume boilers are 75% efficient in making steam at 150 psi 1,000 lb. steam absorbs 1,168 Btu from fuel 1,000 lb. steam at 75% boiler efficiency requires 1,557 Btu in Fuel Gallons of #6 oil/1,000 lb. steam 1,557,000 t 145,360 = 10.7 gal oil/1,000 lb. steam Oil cost/1,000 lbs. steam 10.7 x $.56/gal. = $5.99 Assuming the same efficiency for the boilers in the other plants: Riverside (1,557,000 * 10,400,000) Btu/103 cu.ft. x $2,223 = $3.33/1,000 lbs. Hillsboro 1,557,000 i 10,040,000 x $2,253 = $3.37/1,000 lbs. Santa Clara est. $3.33/1,000 lbs. Savings by Regular Cross-Blowing 981 lb. of steam x $/l,000 lb. 1000 Ambler Riverside Hillsboro Santa Clara Per Cycle $5.88 3.27 3.31 3.27 CTD001298 Savings possible per year 2,500 autoclavings Ambler and Riverside 1,875 at Santa Clara, 5,000 at Hillsboro. Per year at X cycles/day 250 days/year Ambler Riverside Hillsboro Santa Clara 10 x 250 x $5,.88 = $14,700 10 x 250 x 3,.27 = 8,200 20 x 250 x 3..31 = 16,400 7.5 V: 250 x 3..27 = 6,100 $45,400 Savings by Improved Cross-Blowing * Assume spraying water in autoclave cools pipe, trays and autoclave shell to 266F for a ^ T of 100F. Heat is recovered as steam. A. Heat from shell and steel 115,000 lb. x 100 ^ T x .1 sp.ht. = 1,150,000 Btu B. Heat from pipe 48,100 x 100 x .32 = 1,560,000 Btu C. Heat Saved by Condensate Spray ASB Max. Assume 75% Efficiency Pounds of Steam at 860 Btu/lb. 2,710,000 Btu 2,032,500 2,363 lbs. D. Heat from Cooling Condensate to 220F 11,140 lb. x 146 A T x 1 SpHt = Pounds of Steam at 860 Btu/lb. 1,600,000 Btu 1,860 lbs. Steam saved from steam in autoclave 918 lbs. TOTAL STEAM SAVED C 6 D S E 5,141 lbs. CTD001299 Savings possible per year 2,500 autoclavings Ambler and Riverside 1,875 at Santa Clara, 5,000 at Hillsboro. Ambler $5.99 Riverside 3.33 Santa Clara 3.33 Hillsboro 3.37 x 5.141 x 2500 = $77,000 /year x 5.141 x 2500 = 43,000 x 5.141 x 1875 = 32,000 x 5.141 x 5000 = 87,000 POSSIBLE SAVINGS $239,000 CTD001300 Calculations of Depth of Condensate in the Autoclave Autoclave Diameter Autoclave length Volume of Condensate 7 feet 100 feet 203 cu.ft Assume depth of 10", how many cubic feet of condensate: 9 Area AOC = (32) (27.2) Area ACB = 1243 sq.in. = 870 373 sq.in 373 = 2.59 sq. ft. 144 Cubic Feet (2.59) (100) = 259 cu.ft. Needed 203 cu.ft. Therefore, providing for a 10 inch depth of condensate in the autoclave should be sufficient. CTD001301