E-Newsletter - A Publication of Interstate Resources


Thursday, August 18, 2016

Evergreen Community Power Energy-Saving Efforts Highlighted in Renewable Energy Magazine

Interstate Resources News homepage: http://news.interstateresources.com

Renewable Energy from Waste Magazine discusses Evergreen Community Power’s efforts to help sister company in Reading, Pennsylvania reduce energy use and carbon footprint in the July/August 2016 issue.

Sourced from: http://magazine.rewmag.com/article/july-2016/energy-saving-paper-making.aspx 

Energy-Saving Paper Making

By Hilary Crisan 

The Evergreen Community Power plant is helping a Reading, Pennsylvania paper mill lower its carbon footprint.


Making paper takes up an expansive amount of steam and power. While most paper mills use separate heat and power—an on-site boiler for steam and power from the grid or from a power plant—Interstate Resources Inc., Arlington, Virginia, decided to take an alternative route toward combined heat and power (CHP) for its paper mill located in Reading, Pennsylvania. It built Evergreen Community Power LLC (ECP) to provide fuel and heat for its 100 percent recycled corrugated medium paper mill, United Corrstack (UCI).


Chady Zablit has been general manager of the power facility since it became operational in 2010. He began his career with Interstate Resources and in 1995 and managed the design and construction of ECP in 2006.

“Interstate’s mission spins around sustainability,” he says. “Its core beliefs are that industries can and should care for the environment. Simply put, Evergreen Community Power is one attempt for U.S. manufacturing companies to be less reliant on foreign oil, reduce our carbon footprint and have a diversified national energy source.”


CREATING THE ALTERNATIVE

UCI has the ability to produce 200,000 tons of corrugated medium each year. Each ton of paper requires about 6 million British thermal units (mmBtu) of energy.

ECP combusts two primary types of fuel in its boilers: alternative fuel (AF) and clean fuel (CF). AF is the result of a negative picking process where contaminants in the feedstock that increase ash, chlorine and sulfur are removed. The feedstock is shredded and screened before being delivered to ECP. AF is composed of 85 percent wood with the remainder being paper, some plastic and inerts, such as sand and gravel.


CF is the result of a positive picking process where clean and untreated wood is picked, shredded and finely screened out before being delivered to ECP. The plant also receives tire-derived fuel, shredded rail road ties, utility poles, paper mill rejects and sludge in limited quantities.


Since it opened, ECP has combusted more than 1.4 million tons of these fuels. Zablit says when the plant began operations, it had one local feedstock supplier that had all the permits to process the materials but no experience to produce it to the quality required. Over the years ECP geographically broadened its fuel supply mix with feedstock coming to the plant from several different states within a 200-mile radius, including Maryland, Pennsylvania, New Jersey, New York and Connecticut.


“ECP constantly conducts search activities to identify potential feedstock suppliers through information available from the states and permits issued to processors and transfer stations,” Zablit says. Another way the plant discovers feedstock suppliers is through word of mouth among haulers, suppliers and contractors, he adds.


Once a new source is identified and deemed qualified, ECP builds a contractual relationship with the partner.


Since the feedstock is already brought to ECP as a processed material ready to be used as boiler fuel, the company coordinates with a supplier if it doesn’t have the proper equipment to process the feedstock, such as permit changes, adding a shredder or sorting line or introducing a new type of permitted feedstock, explains Zablit.


AT A GLANCE: EVERGREEN COMMUNITY POWER PLANT

Location: Reading, Pennsylvania
Project cost: $175 million
Year opened: 2010
System type: circulated fluidized bed boiler
Fuel created: combined heat and power (CHP)
Purpose: Steam and power for United Corrstack’s papermaking process
Feedstock used: Wood waste, C&D debris, paper and some types of plastics
Carbon equivalent saved per year: 100,000 metric tons
Waste diverted from landfill: More than 1.4 million tons

As the plant progressed, feedstock quality from suppliers started to improve as well. Contaminants such as ash, chlorine and sulfur dropped sharply within ECP’s requirements, which was a result of “a combined effort of ECP’s team and our suppliers, who we value as stakeholders in our business,” says Zablit.


The feedstock’s quality also depends on the weather and several different markets. In the winter, obtaining feedstock is difficult because of the snow and freezing temperatures, and the spring causes a wood shortage due to mulch production.


The health of the housing market has its impact on the generation of feedstock materials from construction and demolition (C&D) debris, and industrial power plants using the same type of feedstock can cause unwanted competition.


HOW IT WORKS

The plant uses a circulated fluidized bed boiler to heat up the waste used as feedstock. This particular type of boiler, Zablit says, exceeds 99 percent combustion efficiency and is primarily used to fire solid feedstocks such as wood and coal. The temperature of the furnace is between 1,500 and 1,600 degrees Fahrenheit. 

The ECP boiler is rated at 300,000 pounds per hour of steam flow generation with 1,500 pounds per square inch gage pressure and a temperature of 840 degrees Fahrenheit.

The steam created from the boiler is fed to a 33-megawatt rated turbine equipped with three extractions at different pressure levels. These different pressure levels were implemented to support the steam demand of the plant and the paper mill, according to Zablit.


A water-cooled condenser is located at the exhaust of the turbine to cool down the balance of the steam exiting the turbine which becomes water and is fed back into the boiler to complete the steam-water cycle. The cold water is supplied from a cooling tower, which minimizes water needed from outside sources, Zablit says.


The turbine then drives an electric generator that provides electricity to the plant, the mill and to a grid belonging to PJM Interconnection LLC, a Valley Forge, Pennsylvania-based regional transmission organization (RTO) that, according to its website, coordinates movement of wholesale electricity in the District of Columbia and 13 states, including Pennsylvania.


About 70 percent of what is produced at ECP is used for the plant and the mill, Zablit says. The rest is sold to the PJM grid for use in the surrounding area.


Zablit says ECP is currently evaluating the feasibility of adding a grinding operation to the plant, which would allow the company to source clean but oversized wood materials for feedstock.


THE DOWNS IN REVENUE

While ECP is saving about 100,000 metric tons of carbon dioxide equivalent per year, competition is tough.

“Without Interstate Resource’s commitment to the mission and the raison d’ĂȘtre of ECP, I am afraid the plant would have been curtailed a long time ago,” Zablit says. “ECP is in a competitive market where others enjoy a much lower cost to operate and compete.” 

ECP has been working to get the ash generated from the combustion process to become integrated into beneficial use with certain applications, but a lack of interest and regulatory barriers add to the challenges.

“It’s very challenging to operate ECP profitably with the lack of incentives to support this renewable form of generating energy,” Zablit says. “Sales to the PJM grid comes with significant losses, and natural gas, which is the other alternative to generate energy for the paper mill, is also cheap.”

ECP has been running on less than 75 percent of its capacity due to the lack of cost-effective feedstock and a decrease in grid pricing.

“I believe that the public notion of ECP should be positive after converting so many million tons of what would have ended in landfills into a useful form of energy while meeting one of the most stringent air emission permits that regulators produced,” Zablit says. “Such a notion is needed to help establish some incentives and help ECP stay in business.”

The author is assistant editor of Renewable Energy from Waste and can be reached at hcrisan@gie.net.


Evergreen Community Power and United Corrstack are member companies of Interstate Resources, Inc. and INDEVCO.


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Friday, February 12, 2016

Photoblog: Interstate Container Offers Poultry Processors Strong Warehousing & Mechanical Packaging Services at IPPE 2016

Interstate Resources News homepage: http://news.interstateresources.com

Interstate Container meets with poultry processors to promote sustainable packaging during the International Production & Processing Expo (IPPE) from January 26 – 28 at the Georgia World Congress Center in Atlanta, Georgia. 

During the exhibition, Interstate Container emphasized its expanded warehousing and services in the Southeast which support poultry industry growth and industry shift to wax-free boxes. The coated corrugated packaging manufacturer offers Mechanical Packaging Services dedicated to ensuring poultry processors' box rooms produce the best quality boxes to ship and store poultry.











About Interstate Container

Interstate Container combines local presence with global experience as a division of Interstate Resources, Inc., employing over 1500 people in the US, and a member of the multinational INDEVCO Group. The company’s reach spans the Eastern and Southern US with 12 manufacturing plants and 7 warehouses located in the New England, Mid-Atlantic, and Southeast regions.

Contact Info

Mindy Myrick, Marketing Manager
Interstate Container

Tel: 410-251-9570
Email: Mindy.Myrick@interstatecontainer.com  Website: www.interstatecontainer.comwww.greencoat.net
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Wednesday, January 20, 2016

Interstate Container to Highlight Mechanical Packaging Services for Poultry Processors at IPPE 2016

Interstate Resources News homepage: http://news.interstateresources.com


Interstate Container’s Mechanical Packaging Services provides technical support to poultry processors for box making and box room needs. The corrugated packaging manufacturer will exhibit at IPPE 2016 Booth #B7647 at the Georgia World Congress Center in Atlanta, GA from January 26 - 28.

Columbia, South Carolina. January 20, 2016 – Interstate Container’s Mechanical Packaging experts are singularly focused on one goal: to ensure that poultry processors’ box rooms produce the best quality boxes to ship and store poultry. The corrugated packaging manufacturer works hand-in-hand with poultry processors to transition, one phase at a time, from wax boxes to 100% recyclable and repulpable wax-free Greencoat boxes.

Interstate Container will exhibit its range of wax and no-wax coated poultry boxes and trays at Booth #B7647 at the 2016 International Production & Processing Expo (IPPE) from January 26 – 28 in Atlanta, Georgia. In addition, members of the Mechanical Packaging team will be present at the show to discuss services for poultry processors.

Matt Clark, Mechanical Packaging Manager, explains, Our customers depend on quick responses to their needs, whether they’re having problems with their box forming machines, tray formers, case erectors, bliss machines, or their pneumatic and electric glue systems.”

Interstate Container’s Mechanical Packaging experts travel from the Southeast and Mid-Atlantic to wherever their customers need. Technicians not only solve problems related to machinery but also evaluate the efficacy of box room design, provide training on packaging and palletizing, and recommend waste reduction measures.

Machine Inspection & Preventive Maintenance Planning


Mechanical Packaging works closely with the maintenance teams at poultry processing plants to identify and correct machine related issues. They issue machine inspection reports, assist with machine repair and set forth preventive maintenance planning. Interstate Container is able to expedite spare parts and provide troubleshooting support.

Machine Refurbishment


The Mechanical Packaging team evaluates and provides quotes for machine rebuild to be completed on-site or at Interstate Container's Mechanical Packaging Machine Shop in West Columbia, SC. Then the team provides installation assistance.

According to Clark,

“Our technical experience, combined with our equipment, allows us to offer high-quality refurbished machines as a much more affordable option than buying new machinery. From our machine shop, which is fully equipped with tooling and parts, we can refurbish a customer’s current box machines or procure used equipment and rebuild to a customer’s specifications.”


Box Room Efficiency Evaluation


In order to increase efficiencies and reduce waste, Mechanical Packaging experts systematically evaluate box room operations, and provide data and recommendations.  
They inspect poultry-packed boxes in the cooler and on the production floor to ensure no signs of crushing, popping, and box damage. Further, they examine such process handling issues as box handling, palletizing and stacking.  


Training


Production and maintenance teams at the poultry processor receive training from the Mechanical Packaging team. Says Clark, “We work with our customers to make sure they are familiar with what to expect from the box and the box forming equipment.”

Training topics for production teams include how to properly operate the box former and how to identify and troubleshoot packaging problems. Topics for maintenance staff include troubleshooting machine performance issues and proper diagnosis of problems.

Clark continues, “We offer recommendations on setting up preventive maintenance schedules to reduce downtime and optimize machine performance.”

Waste Reduction Measures


Interstate Container’s Mechanical Packaging team works closely with poultry processors’ plant, production, and maintenance personnel to effectively identify waste and troubleshoot its origin.

A key area for reducing waste begins with training about the box forming equipment. When equipment is properly operated and maintained, it provides more consistent product quality over time.

Poultry processors can meet members of Interstate Container’s Mechanical Packaging Services team at IPPE 2016’s Booth #B7647.


About Interstate Container

Interstate Container combines local presence with global experience as a division of Interstate Resources, Inc., employing over 1500 people in the US, and a member of the multinational INDEVCO Group. The company’s reach spans the Eastern and Southern US with 12 manufacturing plants and 7 warehouses located in the New England, Mid-Atlantic, and Southeast regions.

Contact Info

Mindy Myrick, Marketing Manager
Interstate Container

Tel: 410-251-9570



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