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Research Project Information




Research Project Summary Information



Ball Wallkill RTO Heat Recovery(ST9912-1)

Ball Metal Plastic Packaging Division, A

Background

The Ball Wallkill, New York plant (Wallkill) opened in 1972, and was acquired by Ball in 1998. Three high-speed lines produce several different sizes of aluminum beverage cans. In general, the plant operates continuously about 51 weeks per year, although there are various down times for can size changes and maintenance. In 2008, the plant produced 1.4 billion cans. About 175 people are employed at the 317,000 square foot plant, with a total payroll of $10MM US. A regenerative thermal oxidizer (RTO) was installed in 2004 for continuous air pollution control. Currently two can manufacturing processes (washer and soluble oil) are heated by a closed-loop boiler system. The heat demand for these processes is continuous.

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Project Description

An onsite heat recovery system designed to recover 1.9 MM BTU/hr of waste heat from the existing RTO, consisting of an insulated, clad heat recovery coil, expansion tank, platform and all necessary supporting infra-structure. Actual first year operation results for the heat recovery system averaged 1.25 MM BTU/hr due to issues with build up on the heat exchanger and the resulting down-time for cleaning and maintenance. The project recovers heat from the RTO stack to heat the washer and soluble oil can manufacturing processes. The Wallkill facility was an excellent pilot location due to the proximity of the boiler loop to the RTO. The piping and installation costs were minimal due to the equipment configurations.

Benefits

The first year net energy cost savings from the heat recovery system were $137,537.00. The main environmental benefit other than recovered energy is to reduce greenhouse gas emissions (GHG). The implementation of the heat recovery system has resulted in a net reduction of 676 metric tons of CO2 emissions. There have also been additional reductions in EPA Criteria air pollutants. This project has demonstrated cost and performance benefits to help justify the implementation of heat-recovery projects at other Ball plants in the US. The largest Ball aluminum beverage can manufacturing plant is located in Saratoga Springs, NY. Due to the success of the Wallkill project, NYSERDA is again partnering with Ball on another RTO waste heat recovery project at the Saratoga facility. Details of the lessons learned from the project will be presented at the 2009 ACEEE Summer Study in Niagara Falls, NY.

Project Results

The first year net energy cost savings from the heat recovery system were $137,537.00. The main environmental benefit other than recovered energy is to reduce greenhouse gas emissions (GHG). The implementation of the heat recovery system has resulted in a net reduction of 676 metric tons of CO2 emissions. There have also been additional reductions in EPA Criteria air pollutants. This project has demonstrated cost and performance benefits to help justify the implementation of heat-recovery projects at other Ball plants in the US. Details of the lessons learned from the project were presented at the 2009 ACEEE Summer Study in Niagara Falls, NY.

Contractor

Ball Metal Plastic Packaging Division, A
9300 W. 108th Circle
Broomfield, CO 80021

Principle Investigator

Doug Barndt

Universities Involved

Technologies

Project Type:

On-site Process Improvement


Technologies Types:

Waste Heat

NYSERDA Contact Information

Scott Larsen
LSL@nyserda.ny.gov

Program

R&D - Mfg Tech & On-Site Pwr

Contract Details

Start Date: 1/11/2010
Project Status: Active
Contract Number: ST9912-1




Last Updated: 1/10/2014