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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY 3.0 Forest Products The pulp and paper industry accounts for over 12% of total manufacturing energy use in the U.S., contributing 9% to total manufacturing carbon dioxide emissions. In the last 25 years, primary energy intensity in the pulp and paper industry has declined by an average of 1% per year. The estimated primary energy consumption is 2,970 TBtu. Of this, 1,348 TBtu of biomass is used in boiler plant facilities to produce steam for various paper manufacturing processing. A large number of technologies and measures exist that can reduce energy intensity (i.e., electricity or fuel consumption per unit of output) of the various process stages of pulp and paper production. Advanced technology energy-efficient measures projected for future pulp and paper application include alcohol-based solvent pulping, black liquor gasification, pre-treatment of incoming pulp into drying section, and several new drying technologies including infrared, impulse, airless, press, air impingement, and steam impingement drying. Process Description of Conventional Paper Making In conventional paper making, the fiber is mixed with about 100 times their weight of water, then the water is removed. The processes in a conventional, non-integrated paper mill can be categorized into three sequential clusters: stock preparation, paper machine, and finishing operations. In the stock preparation, pulp and waste paper are screened and de-inked and then mixed with water. Fibers are refined and additives brought in. The mixture is called the stock. The percentage of dry solids (ds), also called the consistency of the sheet, is about 1%. The operations in the paper machine are conducted in three steps: forming, pressing, and drying. The forming process disperses the stock over a wire screen to form a sheet, and subsequently removing most of the water by gravity and suction. The consistency of the sheet at the end of the forming section is about 20% ds. Next, the consistency is increased to 40-45% ds; water is removed by passing the sheet, supported by a felt, through three or four pairs of press cylinders. Finally, when no more water can be removed mechanically, the sheet is passed over 40-50 steam-heated cylinders (drying section), the final consistency being about 90-95% ds. Finishing operations are calendaring to smooth the paper surface, winding on wheels, cutting, etc. Main Production Parameters in Paper Making For each new technology, the impact on the production rate, the runnability, and the paper quality should be considered. The production rate of modern paper machines ranges from lower than 1000 m/min for board to 1600 m/min for newsprint. The production rate is determined largely by the drying rate in the drying section, expressed in kg water removed per m2 contact surface between paper and heated surface per unit of time. Increasing the drying rate makes it possible to increase the production rate without having to extend the drying section. The drying rate in a traditional drying section with 55 drying cylinders operating at a speed of 1500 m/min is about 15-30 kg water/m2h. 122PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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