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The two sources of steam use (dry and live) were calculated using orifice and pipe diameters, steam pressure, and enthalpy differences. Table 1 provides a summary of the inputs and results of the steam use. The baseline energy consumption measured to be 1.28 kWh and 0.247 therms per board foot. Table 1. Total steam energy inputs Parameter Heat (dry steam) Live steam injection Percent of time open 37% 8% Totalhoursperyear(1 3,215 672 kiln) Totalannualhours(all 12,861 2,689 kilns) Energy rate (Btu/hr) 310,000 290,000 Steinway has identified a Vacutherm AirVac 4 system to install. Table 2 shows the equipment components for the new kiln and duty cycles provided by the manufacturer. Table 2. Vacuum-kiln operating characteristics Equipment Air circulation fans Vacuum pump Condenser fan Quantity Duty cycle 4 0.63 1 0.20 2 0.50 Voltage HP 480 5 480 7.5 480 0.5 Amperes kW 6.5 12.2 10 1.5 0.75 0.6 The air circulation fans on the new kilns are expected to operate at full speed half the time and at 25% speed for the other half. The vacuum pump is projected to operate only half the time at 40% speed. The duty cycle fractions are based on post-installation data at another installation of the kiln. Wood types and moisture contents are not expected to differ materially from the operations at Steinway. According to the manufacturer, drying cycles can vary depending on the lumber species, but the typical average is 4 days (96 hours), significantly shorter than the 4 to 5 weeks of the existing kilns. For the types of wood that Steinway dries, and the moisture reduction required, this is a reasonable expectation. The operation of an additional 5 hp condensate return pump was added to account for site-specific conditions to return the condensate to the boiler feed water system. Steinway has identified an outbuilding on the property in which to install the new kiln. Because the new kiln is small, it does not require a standalone structure. By housing the kiln indoors, additional benefits can be realized, since the kiln can now be loaded and unloaded in all weather conditions as the finished wood will be protected from the elements. The existing kilns only had exterior access points, limiting unloading to dry days. Several options were identified for use as a heat source for the new kiln. A local hot water gas-fired boiler was considered, but it would have required permitting and a gas line. Due to the configuration of the Steinway campus, the boilers are located on the opposite side, and the 6PDF Image | Quick-dry Partial Vacuum System
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