The new system was brought online seamlessly within a 24 hour shut, and has reduced the mill’s yearly power and water usage.
Australian Paper's Maryvale Mill had a centralised compressed air system that was energy inefficient and lacking in capacity. The resulting high costs, compounded by problems during the winter months with water contaminations and instrument failures, led Australian Paper to engage Beca AMEC to design and construct a new compressed air system.
Beca AMEC provided a full engineering package, including structural, mechanical, piping, electrical, controls and DCS software works, and full project, construction and commissioning management.
Simplicity was essential for the new system, with importance being placed on the ease of future expansions. A common air header arrangement was therefore selected for unifying the existing and new compressors. The three oldest and most inefficient compressors were replaced by three of the latest design. To replace the old and water-thirsty refrigeration dryers, blower purge desiccant dryers were chosen for their low energy and water consumption.
A further complexity was the age of the current piping installation and structural elements, meaning that the mill’s drawings were outdated or non-existent. With the use of 3D piping design software, Beca AMEC was able to obtain detailed drawings and bill of materials for the best possible tender prices.
The new compressed system was brought online seamlessly, in parallel with the existing system, making full use of the mill’s annual 24 hour shut.
Following deployment, the system was estimated to reduce the mill’s yearly power use by 11,784 MWh or 14,494t of carbon dioxide, with water use cut by 0.3 ML/d.