A new high efficiency turn-key steam plant was designed and constructed for Alliance One (A1) manufacturing in Wilson, NC. The 650,000-square-foot manufacturing facility utilizes up to 50,000 pounds per hour of high pressure steam for heating and process. Until construction of the new boiler plant, steam was generated by two 40+ year old 75,000 PPH coal-fired boilers. In an effort to reduce plant operating costs and ensure production reliability moving forward, A1 selected AC Technical Services and RMF Engineering Inc. to provide a successful turn-key steam production solution.
Size650,000 SF
LocationWilson, North Carolina
ServicesDistrict Energy
The team began the planning process by evaluating existing systems, obtaining feedback from facility engineers, gaining a thorough understanding of the production processes and related operational patterns. Options including boiler retrofit, new plant construction, and cogeneration were considered. Financial and energy models were then created to compare first cost, energy costs, and maintenance costs of the new options to the business as usual case. The net present value analysis indicated that use of three gas/oil 900 BHP fire-tube boilers with feedwater economizers in a new plant would provide excellent operational flexibility, n+1 reliability, and a substantial reduction in both energy, operation, and maintenance costs. Additionally, installation in a new butler building type plant would eliminate any manufacturing process downtime.
The plant was designed with ease of operations and maintenance in mind and boasts four large roll-up doors and permanent service platforms for each critical valve and meter location.