Paper companies
Paper companies save money on Fuel
October 2008
Magnetic fuel treatment technology is helping some of the biggest names in the paper industry to cut fuel costs and reduce carbon emissions.
The squeeze of an uncertain economy means that companies are looking for ways to cut costs wherever possible and with rising energy prices fuel consumption is a key area of focus. Investing in energy efficient technologies is one sure-fire way to rake in the savings. Yet the substantial capital investment needed for new equipment – such as new boiler system can be off putting. This is the conundrum facing many companies in the paper industry. However, it is not as impossible to solve as it might seem, the key is investing wisely in innovation.
DS Smith Speciality Packaging is one business which recognised that the increasing fuel costs at its Launceston site in Cornwall were a problem that needed to be addressed. Quality Manager, Steve Porter comments: “With the cost of energy escalating massively and the increasing need to reduce our carbon footprint, it seemed sensible to stage a review of our boiler plant.”
The company runs two Danks gas-fired, steam raising boilers at the plant, where it manufactures cardboard transit cases, as well as speciality, decorative and heavy duty packaging. The boilers are required for both general heating and process heat. While the boilers are still functional, they do not provide the levels of energy efficiency achievable through newer equipment and purchasing new boilers would have meant a substantial, long-term financial investment. The alternative was to retrofit the heating system with a stand-alone device that reduces fuel consumption without requiring a complete system overhaul. Magnetic fuel treatment technology, which is now widely adopted within the paper industry, seemed like the logical solution.
“Magnetic fuel treatment technology pre-treats fuel (gas and oil) supplied to the burners. The magnetic field aggregates nanoparticles in the fuel, which has two beneficial effects: preventing fouling of the burner exchange surface and enhancing combustion, creating a hotter flame,” comments Paul Finnegan, Commercial Director of Maxsys Ltd, whose patented Maxsys Fuel Systems have been installed at a number of paper making plants.
After reviewing the boiler plant, Mr. Porter decided to fit the Fuel Systems to the two boilers at DS Smith. The fuel savings were found to be substantial. “The results have been fantastic,” says Mr. Porter. “Not only have we reduced our carbon emissions by cutting gas consumption by 5.8%, we have also made substantial financial savings in the 12 months since installation.”
With companies struggling to comply with government legislation on reducing industry’s carbon footprint, magnetic fuel treatment technology provides a timely solution for commercial and industrial operations. It can also send a positive environmental message to companies stakeholders. After reducing its emissions, the Launceston DS Smith plant carried off the top prize in the paper and packaging category of the National Green Apple Awards 2007, which recognize environmental achievement.
Another company to benefit from installing Maxsys Fuel Systems is Mondi Packaging. As a leading International paper and packaging group in an industry where energy-intensive steam generation is part of its process, Mondi recognises that its profitable business performance can only continue if it makes efficient use of energy. Mondi’s Holcombe site has one central boiler house which raises around 20 to 25 tonnes of steam per hour – and it was this heavy steam demand that encouraged Mondi to adopt the Fuel Systems.
Chris Lord, Business Improvement Manager at Mondi, Holcombe Ltd, comments: “Heightened by rising manufacturing costs in the paper industry, Mondi has a clear focus on improving operational plant efficiency. Maxsys were confident of achieving at least a 5% gas saving, but managed to exceed this. The project very quickly paid for itself.”
In fact, data collected showed that the gas consumption was lower by 6% for an identical amount of steam generated, following the installation of the Fuel Systems. This equated to a substantial saving of over 733,000 kW of gas during the post data period of just over a month. These savings, in turn, provided a reduction in CO2 emissions of over 139 tonnes during the post data period (equivalent to 1,412 tonnes every year).
Innovative, fuel-saving technologies need not be complicated to install and maintain. Union Papertech, which produces speciality papers for the beverage industry at its Simpson Clough Mill, has achieved a 6.8% reduction in its gas consumption using the Fuel Systems. Steve Sherlock, Chief Engineer at Union Papertech, comments: “Initially, I was concerned that high levels of maintenance might offset the benefits offered by this technology. However, there are no maintenance issues whatsoever. I can’t be anything else but pleased with the benefits.” With no moving parts and no electrical supply requirement, the design and high standard of engineering in the Maxsys Fuel Systems guarantees optimum long term reliability.
During the economic downturn, proven technologies such as magnetic fuel treatment can assist paper companies to cut costs and remain competitive. Energy-saving technologies like the Maxsys Fuel Systems make good business sense in terms of a fast payback, ease of use and retrofitting to existing plant that may not be due for complete upgrade for some time. It is also key to helping the paper industry to make a successful transition to the low carbon economy that is now increasingly vital to its long-term success.
