FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement

PVT-1 Boiler 5

Boiler 9 Reduce start-up times on all boilers. Utilize natural

gas as a start-up fuel to reduce levels or organic

toxics. $50,000 NA 0

PVT-2 General Revise SO2 limit in existing air permit to reduce the need for multiple start-ups caused by SO2 limitations. $10,000 to $15,000 NA 0

PVT-5 General Improve shut down procedures for unneeded boilers $0 $1,500 <1%

PUB-3 General Reduce start-up times to reduce levels of toxics emitted during start-up procedures. NA NA 0

PVT-1 General Fuel dry bark to improve combustion of bark fuel

source. $100,000 fuel dryer capable of treating bark at a rate of 6 tons per hour . Up to $300,000

per year savings in coal use by increasing Btu value of wood fuel. 1 to 2%

PVT-1 General Cover bark fuel storage area to reduce moisture and improve combustion of bark. $50,000 to $100,000 Up to $300,000

per year savings in coal use by increasing Btu value of wood fuel. 0.50%

PVT-2 Boiler 9 Reinject ash to reduce the amount of ash (and cost) for disposal. Operators stated that reworking the ash removal system on this unit would greatly reduce

maintenance requirements. $75,000 $13,300 to $26,600 1 to 2%

PVT-2 Boiler 9 Install sootblowers to improved heat transfer and reduce back-end temperatures. $100,000 NA Additional assessment needed by vendor. Fuel Management 

### Table 3-2: Recommendation Summary

Start-up/Shut-down Procedures

Page 1 of 6FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement 

### Table 3-2: Recommendation Summary

PVT-2 General Re-use bottom boiler ash to take advantage of Btu value. Bottom boiler ash has been analyzed and contains up to 8000 BTU/lb (better than dry wood). $75,000 Fuel cost saving: $8,200 to $27,900. Disposal Cost saving: $48,000 1 to 2%

PVT-2 GeneralModify limestone conveying system to improve delivery of correctly sized limestone and minimize quantity of

limestone used. $100,000 Further assessment by vendor needed. Further

assessment by vendor needed.

PVT-3 General Tarp rail cars to reduce excess moisture to coal and bark fuel sources to improve combustion process.10 tarps at $500 per tarp: $5,000 $5,800 0.2% overall improvement for three boiler system

PUB-2 General Replacing fuel feeders with newer, more modern design to improve opacity and decrease toxic

emissions. $123,000 per boiler $128,000 0.25%

PUB-3 General Co-fire (or over-fire) up to 20% natural gas to reduce criteria and toxic pollutant emissions. $35,000 to $45,000 to install one gas burnerDependent on

the price of natural gas. 0

PVT-2 GeneralAutomated boiler conductivity blowdown and feedwater monitoring instrument systems. $50,000 to $100,000 $29,000 to

$58,000 1-2%

PVT-2 General Upgrade water clarifier to minimize the amount of blowdown required and reduce boiler fouling. $100,000 to $200,000 $29,000 1%

PVT-3 Boiler 1

Boiler 2 Boiler 10Upgrade water cleaning system to reduce tube fouling. <$100,000 $14,400 0.5% overall improvement for three boiler system

PVT-5 Plant 1 Return condensate to boiler units for reuse. $48,000 $10,480 4%

PVT-1 GeneralPreheating inlet combustion air to reduce the amount of heat needed for combustion process. Further assessment by vendor needed. Further

assessment by vendor needed. 0.5 to 2% Water Treatment

Combustion air pre-heating

Page 2 of 6FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement 

### Table 3-2: Recommendation Summary

PUB-1 GeneralPreheat inlet combustion air using heat exhaust and/or air preheaters to reduce the amount of heat needed for

the combustion process. $12,000 to $75,000 

### $146,700 2%

PUB-4 General Increase temperature in the condensate (feed water) using boiler exhaust heat and/or to preheat the inlet air

with the spent condensate. Further assessment by vendor needed. Further

assessment by vendor needed. 0.5 to 1%

PVT-2 Boiler 6

Boiler 8 Retrofitting two boilers with underthrow feeders and

variable frequency drive (VFD) grate drives. $150,000 $45,400 (2 boilers) 1% per boiler

PVT-2 Boiler 7 Convert boiler control to computer based distributed control system to improve overall combustion process. $50,000 $114,700 2%

PVT-2 GeneralImproved monitoring/metering of the specific paper mill steam and electrical usage to refine power plant

operation. $30,000 Further assessment by vendor needed. Further

assessment by vendor needed.

PVT-3 Boiler 10 Updgrade O2 controls to maintain outlet temperatures. $50,000 to $100,000 $33,300 to

$83,200 1% to 2.5%

PVT-4 Boiler 3

Boiler 4 Boiler 9 Improve burner tip workmanship to improve combustion of fuel oil. $5,000 to $10,000 per year $36,200 to

$72,500 1% to 2% overall

improvement for three boiler system

PVT-5 General Setting combustion on all boilers $5,780 $3,145 1%

PUB-2 General Conduct a “NOxvs. % overfire air” study to assess potential NOxreductions. $20,000 for study Further

assessment by vendor needed. Further

assessment by vendor needed.

PUB-3 General Conduct a “NOxvs. % overfire air” study to assess potential NOxreductions. $20,000 for study Further

assessment by vendor needed. Further

assessment by vendor needed.

PUB-1 General Install CO/VOC catalyst unit to reduce toxics. $150,000 NA 0

PUB-3 Boiler 1

Boiler 2 Boiler 3 Replace old baghouses for three boiler units. This

would reduce the metals portion of the toxic pollutants

by, conservatively, 98%. $250,000 per boiler NA 0 Controls

Flue gas treatment

Page 3 of 6FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement 

### Table 3-2: Recommendation Summary

PVT-2 Boiler 6 Install new forced draft fan and improve overfire air flow measurement. <$100,000 $49,000 2%

PVT-2 Boiler 6

Boiler 7 Boiler 8 Chemically clean three boilers to remove scale and improve heat exchange. $30,000 $170,600 for three boiler system 5%

PVT-2 General Conduct regular maintenance of 300 to 400 steam traps. $50,000 to $60,000 per year$1,200,000 10% to 20% (1)

PVT-5 General Conduct steam pressure profiling on 2 boilers $11,900 Further assessment by vendor needed. Further

assessment by vendor needed. PVT-5 General Insulate steam and condensate lines. $42,300 $21,100 8%

PVT-5 Plant 1 Conduct flash steam loss study to reduce utilizable steam lost to the atmosphere $2,900 Further assessment by vendor needed. Further

assessment by vendor needed.

PVT-5 Plant 2 Reduce utilizable flash steam currently vented to the atmosphere $13,000 $29,400 11%

PVT-5 Plant 1 Reduce operational steam pressure $3,000 $5,200 2%

PVT-3 Boiler 10 Relatively high outlet temperature (489oF to the precipitator) indicate that some excess heat still available. No immediate potential process uses were

apparent. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PUB-1 Boiler 1

Boiler 2 Boiler 3 Relatively high outlet temperatures for three boilers

(530oF) indicate some excess heat is available. No immediate process uses for the excess heat were identified; however, a study should be completed to

assess potential. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed. Steam systems

Heat Recovery Associated equipment

Page 4 of 6FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement 

### Table 3-2: Recommendation Summary

PUB-2 Boiler 1

Boiler 2 Boiler 3 Relatively high outlet temperatures for three boilers

(450oF) indicate some excess heat is available. No immediate process uses for the excess heat were identified; however, a study should be completed to assess potential since ductwork combines the exit

gases into one plant stack. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PUB-3 Boiler 1

Boiler 2 Boiler 3The boilers are all designed to produce 425 psi steam.

In reality they generate steam at only 175 psi. No immediate uses were identified. Consideration should be given to purchasing a larger steam turbine that can accept the higher pressure steam and, in turn, generate (20% to 30%) more megawatts using the

same amount of fuel. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PVT-1 GeneralInstall activated carbon filters to collect vapors from the paper rolling/process rooms. Organic vapors are generated from the steam injection process. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PVT-2 General Redesign the turbines for efficiency improvements. Turbines with less extracting ability and more condensing ability would result in more efficient units,

but not without significant cost. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PVT-2 GeneralConsider installing a new boiler and removing two old boilers from service. This would prolong the life of the existing baghouse and eliminate the need for costly installation of additional additional modules while upgrade to new, higher efficiency boiler units. Further assessment by vendor needed. Further

assessment by vendor needed. Further

assessment by vendor needed.

PVT-5 GeneralConnect boilers in Plants 1 and 2. Two boilers would be sufficient to meet the steam needs of the facility. Connecting the systems would remove redundency

and excess energy use. $64,700 $23,600 9% Facility specific Recommendations

Page 5 of 6FacilityBoiler Unit Recommendation Estimated Capital Cost Estimated

Yearly Cost Savings Estimated

Efficiency Improvement 

### Table 3-2: Recommendation Summary

(1) SIP Energy Efficiency Renewables Catalog 9Draft), Jaunary 5, 1999, Table C-1.

Page 6 of 6