Philippine Test Case 1201-C: What Better Option(s) Would You Suggest?

A MetroManila-based Paper Mill recycling & converting "Scrap Paper" into various customer-specified grades of paper (Newsprint, Writing Paper, Book Paper, Kraft Paper, etc) has a 24x7 CHP System in place - to operate PM-1, PM-2, PM-3, PM-4. Its HEAT requirement is supplied by Boiler-1A producing 6MT/hr of STEAM (@ 5-Bar PRESSURE / @ 350F-degree TEMPERATURE) and fueled by 12-13MT of Coal every 24hrs. Its supply of Coal (5-6K BTU) costs about P3,500/MT. The Factory has an existing "standby" bunker-fired Boiler-1B operated whenever Boiler-1A is on periodic Maintenance. Its POWER Consumption (during the last 6 months, costing about P5 million/month @ present FX rate of P42:U$1 and @ P6.87/KWh and supplied by the Electric Utility Distributor in the area - MERALCO) was about 700MWh/month - to run all the Electric Motors: (1st) for existing PM-1, PM-2, PM-3, PM-4; (2nd) for drawing-up Water 8hrs/day from its own underground Water-Well; (3rd) for the Factory's in-house Maintenance Machine Shop; AND to provide Lighting for the entire 3-hectare Factory Site. MERALCO-supplied Grid Electricity is 33.5KV fed into the Factory's Sub-Station (2 step-down Transformers) supplying 440-480V @ 60Hz Frequency @ 96% Power Factor. This Paper Mill uses up 120,000 gal/24-hrs of "Process Water" - turning out about 20% as WasteWater treated and discharged to the Public Drains. Chemical Analysis of "Discharged" WasteWater, last taken in Yr2009, was as follows: BOD(47mg/l); COD(83mg/l); DSS(8mg/l); Oil&Grease(2.8mg/l). Fresh-Water Spray-System is being installed - designed to reduce "Discharge" WasteWater down to 10%. Solid Waste volume is considered insignificant @ about 1MT/month - of various kinds of "Scrap Plastics", etc.

This Paper Mill is undergoing Plant Expansion with a Target Completion Date - Year-end 2011 for PM-5 & Mid-Yr2012 for PM-6. When all Lines (PM-1 to PM-6) would be operational, this Paper Mill would require an upgraded CHP System probably at about 3x its present requirement. Towards this end, Boiler-2 (Output STEAM of 6MT/hr) is now being installed - in anticipation of PM-5 Requirement. Boiler-3 (Output STEAM of 4MT/hr) is also being installed - in anticipation of PM-6 Operations. The 16MT/hr combined STEAM Output (Boiler-1 + Boiler-2 + Boiler-3) has already elicited an Offer-to-Supply a STEAM Turbine from a Manila-based Supplier. Land Space (inside the 3-hec Factory Site), available for the envisioned CHP Facility, is 4000 sq mtr.

Given the present CHP set-up and despite on-going phased-in Plant Expansion, further studies are being considered: (1st) Replace Coal-fired Boilers1, 2, 3 with 1-unit Coal-fired 30MT/hr-Steam Boiler to run 2 x 2.5MW Steam-Turbines OR 1-Unit Coal-fired 20MT/hr-Steam Boiler to run 1 x 3.5MW Steam-Turbine + 1-unit ORC; (2nd) Install 1-unit ORC tapping WasteHeat (160-deg F) from FlueGas coming out of Smoke-Stacks from existing Boilers-1,2,3; (3rd) Investigate the 20% WasteWater Volume as feedstock for Power Generation &/or as recycled Process Water.

We value your Inputs &/or Insights. Thanks.