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About William G. Acker

[ HPAC Advisory Board (PDF) ]
[ Full Synopsis ]
[ Energy Resume (PDF) ]

Education

University of Wisconsin – Madison
B.S. Civil and Environmental Engineering  (1970 – 1974)

Professional Affiliations

AEE, ASHRAE and TAPPI

Work History

1996 - Present   Acker & Associates                                President
1993 - 1996       Foth & Van Dyke                                  Technical Development Consultant
1982 - 1993       James River Corporate Engineering        Senior Project Engineer
1976 - 1982       American Can Corporate Engineering      Utility Engineer
1974 - 1975       Self-Employed                                      HVAC Consultant
1966 - 1974       S.J. Bausch & Associates, Inc.                Draftsman

Articles

Boiler Analysis ( PDF )

Water Vapor Migration &
Condensation Control in Buildings
( PDF )

Dehumidification ( PDF )

Compressed Air ( PDF )

Cost of Electricity & Air Emissions from Systems ( PDF )

Waterborne Freight Fuel Consumption Efficiency ( PDF )



Synopsis

William G. Acker has more than thirty five years experience in design, engineering and construction in the pulp and paper industry.  As a Senior Project Engineer he has successfully managed from conception to completion a unique variety of Engineering Projects.  His responsibilities include:  request for funding, engineering, supervision of designers and draftsmen, equipment specification, bid preparation, estimating, budgeting, scheduling, cost control and construction management. 
In addition to his experience as a Senior Project Engineer, he has also participated in several paper machine process audits, energy audits, ventilation surveys, steam piping pressure drop studies and paper machine hood surveys, in an effort to assist mills with their capital budgeting plans.  His duties also include the review of audits submitted by outside consulting firms. [ learn more ]

Strong Experience

1. HVAC
2. Cogeneration
3. Steam and Condensate Return
4. Environmental
5. Water Treatment 
6. Papermachine Dryers
7. Papermachine Hoods
8. Corrosion Control
9. Sludge Handling and
    Incineration
10. Indoor Air Quality
11. Secondary Fiber
12. Emission Control
      NOx, SO₂, CO, VOC’s
      Lead, Chlorine, Chlorine
      Dioxide, etc.
13. Energy Surveys
14. Package Boilers
15. Black Liquor Boilers
16. Coaters and Coater Dryers
17. Heat Recovery
18. Compressed Air
19. Air Purification
20. Insulation
21. Dust Collection
22. Ventilation Surveys
23. Operating Costs
24. Manpower Requirements
25. Instrumentation and
      Controls
26. Reroofing
27. Condensation Control
28. Project Management
29. Estimating
30. Industrial Hygieneology

Experience

1. Waste Water Treatment 
2. Pulp Mills
3. Bleach Plants
4. Converting
5. Woodyard and Sawmills
6. Timberland Management
7. Papermachine Wet End
    and Press Section
8. Fire Protection

Engineering Expertise

A.  High Level of Expertise

1. Industrial HVAC
2. Condensation Prevention and Control 
3. Indoor Air Quality
4. Dust Collection - Commercial
5. Dust Collection - Industrial and Boiler
6. Ventilation Surveys
7. Chilled Water Systems
8. Reroofing Industrial Buildings
9. Cooling Towers
10. Compressed Air Systems
11. Industrial Hygieneology
12. Steam and Condensate Return
13. Cogeneration System
14. Package Boilers
15. Recovery Boilers 
16. Boiler Energy Surveys
17. Heat Recovery Systems
18. Boiler Emission Analysis and Control
19. VOC Emissions Control
20. Papermachine Installed Cost Estimating
21. Sludge Incineration
22. Entire Plant Energy Surveys
23. Insulation Design
24. Compressed Air Systems
25. Flow Metering
26. Control Valve Sizing
27. Boiler Water Treatment
28. Papermachine Dryers
29. Papermachine Hoods
30. Papermachine Steam and Condensate Return
31. Landfill Gas Cogeneration
32. Corrosion Analysis and Control
33. Woodyard Design
34. Pulp and Paper Manpower Analysis
35. Project Management
36. Papermachine Coaters and Coater Dryers
37. Lime Kiln Design
38. Papermachine Dry End Speed-Up Study
39. Project Estimating
40. Greenfield Pulp and Papermill Design and Estimating
41. Greenfield Secondary Fiber Plant Design and Estimating
42. Pump & Fan Systems Design & Testing
43. Freezer Storage Facilities
44. Solve Ice Problems At Freezer Storage Doors

B.  Average Level of Expertise

1. Pulp Mill Operations
2. Bleach Plant Operations
3. Papermill Wastewater Treatment
4. Lubrication Systems
5. Digesters and Evaporators
6. Chlorine and Chlorine Dioxide Scrubbers
7. Secondary Fiber Plant

C.  Low Level of Expertise

1. Instrumentation
2. Electrical Wiring
3. Papermill Converting Systems
4. Hydraulic Systems
5. High Temperature Piping Expansion Design
6. Material Conveying
7. Papermachine Wet End Speed-Up Study
8. Forest Land Management
9. Papermachine Wet-End Design

Professional Achievements

  • Conducted a tissue machine dryer survey for the James River No. 6 machine in Naheola, Alabama.  My survey identified low dryer nozzle velocity due to supply fan problems.  The correction increased production by 7,050 tons per year resulting in $7,755,000 of additional sales.
  • In 1995 completed the design and purchase of equipment for the first combination thru air dryer and high velocity impingement dryer for the Proctor and Gamble Green Bay Mill.  The Yankee Hood exhaust fan discharge is fed to the thru air dryer system.  The fan is the largest single width single inlet fan made.  It is designed to deliver 210,070 ACFM at 526ºF and 644 BHP.
  • Completed a tissue machine dry end production increase survey for the James River No. 1 machine in Old Town Maine.  The purpose of the study was to look at the ROI for three possible projects:  a new dryer hood, a new dryer cylinder and a combination new hood and dryer cylinder.
  • Lead engineer for the design and installation of the largest gas-fired make-up air system built in Wisconsin.  The system provides 170,000 SCFM of make-up air to Curwood in Oshkosh Wisconsin.
  • Developed a procedure to monitor nozzle velocity on high temperature high velocity impingement dryers for tissue machines.  Began to file for a patent on the system during employment at Foth and Van Dyke.  However, it was never completed.
  • In 1989 received a Bronze Key Engineering Excellence Award from James River for a psychrometric and thermodynamic air and water vapor analysis computer program.  This program was the first program in the USA.  Enerdry had since developed a similar program.
  • In 1992 developed a water vapor migration computer program which was one of only three programs in the USA.  The program is used to calculate water vapor transmission through building walls and roof systems and determines if condensation occurs in the construction.
  • Consultant for James River Green Bay Mill on the use of gas turbine generator flue gas for the tissue machine dryer systems.  The project would install a 50.5 MW combined cycle gas fired cogeneration facility and would feed the flue gas to the papermachine hoods.  Estimated project cost was $40,942,000.
  • In 1993 developed the first computer program that sizes the hood exhaust and supply systems for cylinder dryer papermachines.  The program can size open hoods, partially enclosed hoods, totally enclosed hoods and totally enclosed high humidity hoods.  The program also calculates the annual operating cost for electricity and steam.  To date, this is the only such program in the USA. 
  • Lead design engineer for a 10,200 KW steam turbine generator installation at the James River Green Bay Mill.  The project saves $890,500/year.
  • Project Manager and Design Engineer for the installation of a boiler feedwater heat recovery system at the James River Ashland Wisconsin Mill.  The project saves $38,000/year.
  • Project Manager and Design Engineer for a second boiler feedwater heat recovery system at James River Ashland Wisconsin Mill. 
  • In 1981 designed a heat exchange system to recover heat from the paper mill effluent water and pass it to the mill fresh water intake for the James River Ashland Wisconsin Mill.  The project saves $123,000/year and received a top energy award from James River.
  • Consultant to the James River Project Manager for the Old Town Maine chlorine and chlorine dioxide scrubber system.  Installed cost of the project was $3,237,300. 
  • Project Manager and Design Engineer for the installation of two false ceiling exhaust systems for the James River No. 3 boardmachine and No. 2 boardmachine in Naheola Alabama.  Installed cost was $303,000.
  • In 1988 designed a system to feed pentane VOC emissions to an existing boiler for incineration at the James River Polystyrene Cup Facility in Metuchen, New Jersey.
  • Conducted a ventilation survey and roofing survey on a building housing five papermachines at the James River Naheola Alabama Plant.  The survey revealed a need for 1,377,000 SCFM of additional make-up air.  The estimated installed cost was $8,000,000 for ventilation and $4,000,000 for reproofing.
  • Design Engineer for the installation of the new No. 7 tissue machine installed at the James River Naheola Alabama Plant.  Installed cost was $73,706,000.
  • Expert Witness for Giddings and Lewis in Michigan over air emissions discharge from an emissions capture device over the melting furnances.
  • Expert Witness for a client who had a building with condensation problems resulting in $35,000 of building damage.
  • Consultant to the Project Manager for the James River Naheola Alabama Recovery Boiler and Pulp Mill Modification Project.  Project installed cost was $30,762,000.
  • Lead Design Engineer for a No. 6 fuel unloading facility at the James River Ashland Wisconsin Plant.
  • Consultant to the Project Manager on a new pulp machine and pulp dryer for the James River Marathon Canada Pulp Mill Expansion Study.  Estimated installed cost was $298,931,000.
  • Project Estimator for the study of a James River Greenfield tissue mill.  Estimated installed cost was $1,200,000,000.
  • Consultant to the Project Manager for the installation of coater dryers on the James River No. 3 boardmachine in Naheola, Alabama.  Installed cost was $2,218,000.
  • Complete testing and design for a digestor blow heat recovery system at the James River Green Bay Mill.
  • In 1984 conducted a ventilation and energy survey for the James River Berlin New Hampshire Mill.  The study identified a potential for $1,280,267/year of energy savings.  The plant installed the recommendations in 1986. 
  • Consultant for James River Marathon Canada on the failure of two boiler economizers installed on two natural gas fired boilers.  Failure occurred eleven months after installation.
  • Consultant on sludge incineration projects, VOC control, NOx reduction, baghouses and electrostatic precipitators.
  • Completed a pressure drop analysis of the entire 150 PSIG header system for the James River Naheola Alabama Plant.  The purpose of the study was to find ways to increase the steam supply pressure to the tissue machine Yankee Cylinder dryers.
  • Selection to the Advisory Board of Heating Piping and Air Conditioning Engineering Magazine in 1999.
  • Selected by the U.S. EPA in 2000 to the Enhanced Ventilation for Schools Project Development Team.
  • In 2003 Mr. Acker was selected by the U.S. Department of Energy (DOE) to peer review their Distributed Energy Program for Thermally Activated Technologies.  This program provides grants to companies for developing clean, efficient and affordable on site generation, thermal energy and combined heat and power (CHP).
  • In 2006 ASHRAE selected a team of 10 experienced professionals which included Mr. Acker, to assist Professor Gronzik in the rewriting of the Air Conditioning Systems Design Manual.  Due to many energy analysis errors, discovered by Mr. Acker, Mr. Acker had to work closely with Professor Gronzik. 
  • In 2003 Mr. Acker took on the Department of Transportation and the Maritime Administration (MARAD) over incorrect and false transportation energy data, comparing the energy efficiency of freight movement by truck, rail and barge.  The data on the MARAD website as well as many U.S. port websites, had the wrong engineering units in its example, was very old data, and it said that waterborne freight consumed less energy to move freight then rail or truck.  Mr. Acker used Department of Transportation data to prove that Class I rail transport was more efficient then waterborne freight.  After much time and effort MARAD agreed with Mr. Acker and removed the incorrect data from their website.  Mr. Acker’s data exposing the MARAD website errors was published in August 2003 by Transportation and Distribution magazine.
  • From 1985 to Present Mr. Acker and his colleague Mr. Nels Strand have developed over 60 proprietary engineering computer programs.  The programs are primarily energy programs, combustion programs, emissions programs, psychrometric and thermodynamics of air and water vapor, pressure drop, fan performance, steam turbine performance and much much more.  The primary advantage of these programs is the significant reduction in engineering time and the in-depth analysis capabilities.
  • Over Mr. Acker’s thirty-three  year career, he has taught classes on psychrometric and thermodynamics of air and water vapor, boiler combustion and air emissions, water treatment, water vapor transmission and condensation analysis, heat recovery, air flow and flue gas flow testing, mass flow analysis and Btu analysis and fan performance testing and efficiency.
  • Worked with Mr. George R. Smith president of HCR Incorporated on designs to prevent ice build-up in freezer storage doorways from the loading dock building to the freezer building. I also worked on George’s new international patent.
divider divider (920) 465-3548
PO Box 8695
Green Bay, WI 54308