Modernization of the CHP plant at Schumacher Packaging – annual savings of 20 million PLN
We carried out a comprehensive modernization of the CHP plant at the Saica Group facility (formerly Schumacher Packaging) in Myszków. The 43.4 million PLN investment enabled a 20% increase in boiler efficiency, annual savings of 20 million PLN, and a reduction of CO2 emissions by 24,000 tons.
The challenge
The facility producing corrugated cardboard faced low efficiency of existing industrial boilers and high operating costs for thermal and electrical energy. Outdated automation systems limited precise control over combustion and heat recovery processes, and CO2 emissions were significantly higher than what is achievable with modern technologies. It was necessary to develop a solution that would simultaneously increase energy efficiency, reduce operational costs, and limit pollutant emissions, while maintaining continuous production in the plant.
Our approach
DB Energy experts conducted a comprehensive energy audit of the CHP plant, including analysis of boiler operation, heat recovery systems, and automation. The main sources of energy losses were identified, including excessive fuel consumption and lack of optimization during partial load operation. The modernization concept considered boiler control and regulation scenarios, selection of modern heat exchangers, and the possibility of implementing an integrated automation system that allows precise adjustment of energy production to the current plant demand. Additionally, the potential for CO2 reduction and the impact of modernization on operating costs and reliability of heat supply for production processes were assessed.
Solution
DB Energy engineers highlighted the very low initial boiler efficiency, numerous operational problems with the infrastructure, and the lack of automatic regulation of operating parameters. Implementing improvements in these areas resulted in enhanced energy efficiency of the CHP plant at Schumacher Packaging.
As part of the thorough modernization of the first boiler, the following actions were carried out:
- repaired the drum,
- replaced the supporting structure,
- replaced the pressure part,
- replaced the complete grate,
- replaced the boiler lining and insulation,
- implemented auxiliary installations: dedusting, desulfurization, and denitrification of flue gases,
- installed a new electrical system,
- automated processes enabling unattended boiler operation.
The use of proper automation with intelligent control algorithms allows predicting boiler load and makes the system resilient to sudden changes in steam demand by reducing blowdowns. The overarching boiler automation also controls steam production so that cooperating boilers achieve maximum combustion efficiency and ensure optimal use of the system for energy production within the existing 7.5 MWel back-pressure turbine.
Boiler modernization results – tangible gains for Schumacher Packaging
The project works estimated the energy effect and its impact on operating costs as well as the environmental effect related to the reduction of primary fuel consumption. The data below refer to the entire investment.
- Total cost of CHP plant modernization: 43.4 million PLN
- Increase in boiler efficiency by 20% (from 65% to 85%): improved combustion process
- Total annual savings achieved through modernization of both boilers: 20 million PLN
- Final energy savings of over 6.2 thousand toe = possibility to obtain energy efficiency certificates worth approx. 11.5 million PLN
- Simple payback period for the projects is about 1.5 years
Conclusions
The modernization of the CHP plant at Schumacher Packaging is an excellent example of an effective investment in improving energy efficiency. Thanks to a comprehensive approach, including audit, design, implementation, and automation, significant financial and environmental savings were achieved. This investment demonstrates that modernization of energy infrastructure is a key step towards sustainable industrial development.
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