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Kinergetics Discovers Significant Cost Reduction Opportunity, AFTER Completion of Pinch Study

Pinch Analysis is a respected and viable method of identifying process energy cost reduction opportunities in the pulp and paper industry. However, like any simplified methodology, it does have its limits. During a Facility Opportunity Assessment five months after another firm completed the Pinch Study, Kinergetics founder Tom Tucker identified an opportunity to reduce steam consumption on a liquor evaporator in the recovery area of a pulp mill. The annual savings was estimated to be in the range of $750,000 to $1,000,000 per year with an expected simple return of one year.

In another area, the mill Power House, the Pinch Study correctly identified boiler blow down as a viable source of 150-psig “flash steam” to help reduce fuel costs. However, flashing of steam at 150-psig also provides high temperature condensate that was NOT considered in the Pinch Study. Discussions with mill staff indicate that there is potential for reuse of this condensate for makeup water preheating, providing an annual savings of approximately $200,000 per year with a simple return of less than one year.