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Packaging Corporation of America

Tomahawk, Wisconsin, May 2002-January 2007

Floating cover
Project: Floating cover on four anaerobic basins
Size: Phase One: 140 ft x 107 ft, Phase Two: (3) 140 ft x 107 ft, Phase 3: (4) 248 ft x 107 ft
Material: 8130 XR-5
Installer: Environmental Fabrics, Inc.

A survey of the four existing anaerobic basins at the Packaging Corporation of America indicated sufficient biogas was being produced to be economically recoverable. Phase One: A cover was fabricated and installed on 107 ft. of one 140 ft. basin. After the partial cover was put in operation, the amount of methane recovered was more than anticipated.

Phase Two: Covers were fabricated and installed on 107 ft. of the three remaining 140 ft. basins. After these covers were placed in operation the biogas was collected and a pipeline constructed to the plant. Further calculations indicated that covering additional sections of the basins was economical.

Phase Three: Covers were fabricated and installed on an additional 107 ft on all four 248 ft. basins.

The material used for all the anaerobic basin covers was 8130 XR-5 from Seaman Corporation. The plant is now using the recovered methane as an alternative fuel source for the boilers in the production facility.

Environmental Fabrics, Inc. of Gaston, SC was chosen for the geomembrane work on this project which began in the spring of 2002, and was continued over several years as scheduled. After it was placed in operation, the cover system has functioned as designed with little required maintenance.