Manufacturing a Greener Future: Steam Recovery at PVS Chemicals
Imagine a Chicago manufacturing facility not just making essential chemicals but also generating its own power and sending excess back to the grid. That’s the remarkable story unfolding at PVS Chemicals (PVS), thanks to a transformative partnership with Energy Systems Group (ESG). This is about more than technical upgrades; it's a vision realized, a commitment to a sustainable future, and a testament to American ingenuity.
Transforming Steam Waste to Renewable Power
Since the Chicago, IL plant was constructed in 1896, it relied on external electricity. When PVS purchased it, they began to cast a vision of one day being able to harness the waste steam, a byproduct of the sulfuric acid the manufacturing plant creates. However, they needed a partner to custom-design and build the system without causing any production downtime in the process. It was a tall order, and they knew they could count on Energy Systems Group to deliver.
ESG’s engineers worked around PVS’s needs and challenges to draft a design and a construction plan. Today, the byproduct steam powers a turbine that generates electricity, drastically cutting costs and reducing environmental impact.
“No one likes waste, and for many years we researched how to harness our wasted energy. I could not be more pleased that the completion of this project is the solution to harnessing our waste energy and reducing our carbon footprint.”
— David Nicholson, President and Chief Executive Officer, PVS Chemicals, INC.
Technical Implementation
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- Waste-to-Steam Power Generation: ESG designed and installed a system to capture previously vented steam from PVS's sulfuric acid production process. This captured steam drives a high-speed turbine operating at 4,800 RPM.
- Electrical Power Generation: The turbine is mechanically coupled to an electrical generator, producing 2.6 MW of electrical power. This on-site generation significantly reduces PVS's reliance on external electricity providers.
- Condensate Recovery: After passing through the turbine, the steam is condensed back into water and recirculated within the plant, minimizing water consumption and optimizing resource utilization.
- System Integration: ESG engineered a solution that seamlessly integrates with PVS's existing infrastructure, requiring minimal operational downtime. The design addressed the logistical constraints of an urban manufacturing environment, including limited space and existing utility networks.
Engineering Challenges and Solutions
Urban Site Constraints
Building in the heart of Chicago presents its own set of complexities. Tight spaces, existing utilities, and the constant hum of urban life demand smart, tailored solutions. ESG delivered just that: a compact, efficient, and reliable system that seamlessly integrates into PVS’s ongoing operations. Their solutions respect the unique urban environment and ensure that while energy generation is a key advantage, the primary focus remains on delivering essential chemicals.
Production Continuity
Recognizing PVS's 24/7 operation and limited maintenance windows, ESG implemented a phased installation approach. They performed initial infrastructure modifications during a scheduled shutdown and then completed final system integration and commissioning during a subsequent maintenance period. This strategy ensured uninterrupted production.
Unexpected Project Variances
Implementing such a significant change required meticulous planning. With only brief planned shutdown windows, every minute counted. ESG’s detailed roadmap ensured minimal disruption, even as they faced the inevitable challenges of any major project.
The team proactively managed project challenges, including unexpected subsurface conditions, permitting delays, and supply chain disruptions. They effectively mitigated these issues through transparent communication and collaborative problem-solving with PVS.
Project Outcomes
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- Cost Reduction: The on-site power generation system significantly reduces PVS's energy costs, resulting in substantial financial savings.
- Energy Independence: PVS’s Chicago plant now generates a significant portion of its own electricity, enhancing energy security and reducing dependence on external providers.
- Sustainability Enhancement: The project reduces PVS's carbon footprint by capturing and utilizing waste steam, contributing to improved environmental performance.
- Competitive Advantage: The implementation of sustainable practices enhances PVS's market position, aligning with increasing customer demand for environmentally responsible products.
More Than Compliance: A Vision for the Future
While reducing impact to the environment is important, this project goes beyond “the right thing to do”. It’s a win for the people who live and work at or near the PVS Chicago plant, now and in the future.
Energy costs are one of the biggest line items in manufacturers' budgets. The 2.6 MW waste-to-steam power plant now operating at PVS reduces and stabilizes that line item by millions. It puts PVS's cost of electricity generation and a significant portion of the plant’s water supply in the hands of PVS rather than outside providers.
In addition, customers in the United States and worldwide are seeking to work with responsible suppliers, as they work to reduce their own negative impact on the planet. By implementing this steam capture system, PVS operates a cleaner manufacturing process, keeps manufacturing jobs in the U.S., and increases its market share, a win-win for all involved.
