MOCM-12 Volume 4 ROMANIAN TECHNICAL SCIENCES ACADEMY - 2008

ESTIMATING ENERGY PERFORMANCE INDICATORS OF PULP AND PAPER MILLS

HAZI ANETA*, HAZI GHEORGHE*, GRIGORE ROXANA *
*

University of Bacau

Abstract:. This paper presents the calculation and use of energy indicators in paper mills. Numerical results that are presented in this paper show estimating energy performance of a pulp and paper mill and of the installations components, determining the energy needs for a period, the effect of modernization of installations, compared to other companies. Keywords: energy indicators, pulp and paper mill

1.

INTRODUCTION

In our country, in 2007, from data supplied by National Institute of Statistics, [5], can be see that a considerable share of final energy consumption is in industry., Table 1. Table 1. Energy consumption in Romania, in 2007 Name U.M. Total final energy consumption Energy thousand 25028 tep Electricity thousand 41207 MWh Heat thousand 17520 Gcal

Final energy consumption in industry (without energy industry) 9989 22837 2075

Percent final energy consumption in industry 39,9 55,42 17,55

Therefore, improving energy efficiency in industry is an extremely important for sustainable development Energy efficiency can help companies to reduce energy and production costs, improve environmental performance and reduce greenhouse gas emissions, reduce exposure to rising energy prices and energy shortages, improve productivity and product quality Energy performances indicators can play an important role in supporting energy efficiency policy development and evaluation. These indicators are needed for several purposes: - to describe and monitor energy efficiency trends. - to compare end use energy efficiency across companies (economies). - to evaluate the impact of energy efficiency programs. - to forecast future levels of energy consumption. The pulp and paper industry is a large industrial user of energy, consuming 222 thousand tep in 2007. Approximately two-thirds of final energy consumption is fuel that is used to produce heat, while the remaining third is electricity, either from the grid or produced on site. The pulp and paper industry also produces energy as a by-product and currently generates energy from biomass residues

MOCM-12 Volume 4 ROMANIAN TECHNICAL SCIENCES ACADEMY - 2008

2.

TECHNOLOGICAL PROCESSES OF THE PULP AND PAPER MILLS

The pulp and paper industry converts fibrous raw materials into pulp and paper. Broadly paper production can be divided into 3 steps, figure 1, [2]: 1. raw material preparation 2. pulping 3. papermaking The most significant energy consuming processes are pulping and the drying section of papermaking Raw materials preparation. The main raw materials preparation operations typically include debarking, chipping, and conveying. Logs are placed in a rotating drum, where rubbing against each other and the edge of the drum removes the bark which is then used for fuel. After debarking the logs are chipped in a chipper. Energy is used in conveyors to transport chips to the digesters. Pulping . The next stage in the papermaking process is pulping. The primary purpose of pulping is to free the fibers from the lignin that binds the fibers together in wood, and then to suspend the fibers in water. There are three main pulping processes: mechanical and chemical Papermaking. The papermaking process is composed of stock preparation, sheet formation and finishing. The end of the process involves the drying section where steam filled rollers dry the paper through evaporation. Energy use in the paper and pulp industry is divided among these processes: motor drives, pulping electric, refining electric, lighting, steam and high enthalpy heat, low enthalpy heat, pulping, drying and separation, refining steam. 3. ESTIMATING ENERGY PERFORMANCE INDICATORS Assessment of energy efficiency in a paper factory is made using qualitative indicators in terms of value and physical. Primary energy intensity, IE, is energy indicator in term of value that expresses the value of primary energy consumption, CE, per production value of goods, VPM, [4]. CE (1) IE VPM Using this indicator has the advantage that the denominator expressed in value allows the calculation of this indicator in a pulp and paper mill where a large variety of products is made. The disadvantage is that the denominator is affected by exchange rate, purchasing power etc. and require correction This indicator would be used to compare different periods of energy and economic development of the same paper mill and for comparison with other paper mill. Energy indicators, [3], expressed in physical units, specific to a pulp and paper mills are following: - energy indicators determined on the basis of the energy balances drawn up for various periods at the paper mill Energies are measured on the balance perimeter of the productive sectors and of the utilities sectors. - specific electricity consumption, kWh/U.M., and heat, Gcal/U.M. for - final product: paper - intermediate products of technological chain: mechanical pulp, chemical pulp - power plant efficiency, if the factory has its own central - indices determined from energy balances on installations: - energy efficiency of installations that consume electricity - thermal and exergy efficiency of installations that consume heat - specific consumption of steam, air, water For example, the energy indices that are determined from the heat balance of a paper machine are: - specific consumption of steam for the water evaporated : D [kg steam/kg water evaporated] (2) csab ab W where: Dab steam flow, in kg/s , W Gi Ge (3) is moisture that is removed from the paper, in kg, Gi, Ge hourly amount of paper in, respectively out from the dryer section of the paper machine, [kg/h] - specific consumption of steam for the paper dried:

MOCM-12 Volume 4 ROMANIAN TECHNICAL SCIENCES ACADEMY - 2008

csabh
- specific consumption of heat for the paper dried :

Dab Ge

[kg steam/kg paper]

(4)

csc
where:

Qab Qrec Ge

[kJ/kg paper]

(5)

[kW] (6) Qab Dab iab Qab heat flow of steam, in kW ; iab steam enthalpy, in kJ/kg, Qrec - heat flow of condensate recovered, in kW, that is calculated as (6) - net thermal efficiency: Q [%] (7) n util .100 Qab - gross thermal efficiency: Q Qrec [%] (8) b util .100 Qab where Qutil is useful heat flow, in kW. - efficiency of use of heat: Qutil [%] (9) u .100 Qab Qrec Exergy indicators are determined with similar relationship with the energy indicators. 4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL Energy indicators expressed in physical units are suitable for: establish standardized specific consumption with planned production, serve to determine the energy needs - estimating technical and energetical level of the technological processes - comparison with other paper mills A numerical example for estimating the energy efficiency of a pulp and paper mills, is presented below. The principle scheme presented in figure 1, shows the installations: - debarking, chiping - mechanical pulping - chemical pulping - papermaking that contain two paper machine: newsprint and sanitary paper. Energy intensity is calculated for a period of 8 years, figure 2. If the denominator of relation 1, is expressed in national currency, RON, there is a substantial decrease in this indicator. But, exchange rate RON / $ -

Figure 1. Pulp and paper mill

MOCM-12 Volume 4 ROMANIAN TECHNICAL SCIENCES ACADEMY - 2008

has changed to the detriment of the national currency. So an expression value in $ is almost conclusive data in terms of energy and value. However, in a transitional period, one sees that this indicator is not conclusive.

12000 10000 8000 6000 4000 2000

3,000

2,500
tcc*100/mil.l ei tcc/mil.$

2,000

tcc/t MWh/t

1,500
0 1 2 3 4 5 6 7 8

1,000

Figure 2. Energy intensity

Figure 3. Specific energy consumption per total

0,800

2,500

0,700

2,000

0,600 tcc/t MWh/t 0,500

1,500 tcc/t MWh/t

1,000

0,400

0,500

0,300 1 2 3 4 5 6 7 8

Figure 4. Specific energy consumption for pulping

Figure 5. Specific energy consumption for paper machine

If this indicator is related to physical production, fig.3, then it is more convincing for the evolution of the energy 90 efficiency of the paper mill. Energy indicators determined on the basis of the energy 85 balances drawn up for various periods, for the 80 technological processes with intermediate products or utilities are frequently used in the energy departments of 75 company. These indices are used for fixing the price of 70 paper. They also form the basis of energy analysis in the 65 energy department of each company and production sector for establishing measures to increase energy efficiency. 60 1 2 3 4 5 6 7 8 Power plant efficiency are determined at the same period as specific energy consumption because they are used for Figure 6. Power plant efficiency evaluated conventional fuel consumption. Energy indicators determined from heat and exergy balance for a paper machine are presented in Tables 2 and 3. These indices show the technical condition of the installations in terms of energy consumption and underlying standardized specific consumption.
95

MOCM-12 Volume 4 ROMANIAN TECHNICAL SCIENCES ACADEMY - 2008

Table 2. Energy indicators of the newsprint Name specific consumption of steam for the water evaporated specific consumption of steam for the paper dried specific consumption of heat for the paper dried specific consumption of heat for the paper dried net thermal efficiency gross thermal efficiency efficiency of use of heat Table 3. Exergy indicators of the newsprint Name specific consumption of exergy for the paper dried specific consumption of exergy for the paper dried net exergy efficiency gross exergy efficiency efficiency of use of exergy

Unit measure kg steam/kg water evaporated kg steam/kg paper kJ/kg paper Gcal/kg paper % % %

Value 1.753 2.308 5574 1.334 73.9 93.0 91.3

Unit measure kJ/kg paper Gcal/kg paper % % %

Value 1963 0.470 52.9 57.5 55.5

For determining the energy needs on different periods, standardized specific consumption and production plan are using, table 4. Table 4. Energy needs for a year Production plan Instalation Machine 1 Machine 2 Grinding Digesters Power plant Total Product Newsprint Sanitary paper Mechanical pulping Chemical pilping electricity heat Unit measure t t t t MWh Gcal Value 65000 2400 43100 23300 23100 256351 standardized specific energy needs consumption Electricity Heat Electricity Heat kWh/U.M. Gcal/U.M. MWh. Gcal. 940 1,69 61100 109850 974 1985 294 2,2 19 2,76 1,45 0,12 3,29 2338 85554 6850 51 4871 160763 7896 0 64308 33495 30762 246311

The energy needs is split on sources, table 5, because: - electricity supply is made both own power plant and National Energy System - steam can be produced using various fuels Table 5. Energy needs split on sources Name Unit measure Value Electricity Total MWh 160763 From NES MWh 137463 From CHP MWh 23300

Name Heat Total From natural gas From oil From biomass

Unit measure Gcal tcc tcc tcc tcc

Value 246311 44541 37860 4899 1782

For estimating technical and energetically level of technological processes and to ascertain the need for modernization of installations are used energy indicators. They emphasize low energy efficiency of installations

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during operation and its improvement after an upgrade. In table 6 are given specific consumption of heat and electricity for newsprint machine (inclusive grinding) Table 6. Specific consumption of heat and electricity for newsprint machine (inclusive grinding) after 20 years of Specific consumption Unit measure project after upgrade operations heat tcc/t 0,344 0,476 0,319 electricity MWh/t 1,797 2,148 2,097 compared to the project heat % 0 38,4 -7,3 electricity % 0 19,5 16,7 Energy indicators expressed in physical units used for comparison with other paper mills is presented in fig.5.

5 4 3 2 1 0 mill1 mill2 mill3 mill4 mill5 mill6 tcc/t Mw h/t

Figure 7. Comparison with other paper mills

4. CONCLUSIONS Energy efficiency indicators are of great importance for the energy policy objectives. These indicators are used to: - identify the factors driving and restraining the demand for energy, - explain why there are differences in energy intensities amongst companies, - quantify how the introduction of best available technology can help reduce energy use. Numerical results presented for a pulp and paper mill highlighted the usefulness of these indicators for: - energy and production departments, - production sectors, - management company.

REFERENCES 1. 2. 3. 4. Gh.Hazi, A.Hazi, Bilanturi energetice. Teorie si aplicatii, Editura Tehnica Info Chisinau, 2009 EUROPEAN COMMISSION, Integrated Pollution Prevention and Control (IPPC ), Reference Document on Best Available Techniques in the Pulp and Paper Industry , December 2001 A.T. Mrquez Arreaza, Energy Consumption Scenario in the Industry Sector, Master of Science Thesis, Royal Institute of Technology Stockholm, Sweden, 2003 Vasile Rugin, Maria Rugin, Anca Badea, Promotion of energy efficiency under the energy market conditions, THE 7th INTERNATIONAL WORLD ENERGY SYSTEM CONFERENCE, June 30-July 2, 2008, Iasi https://statistici.insse.ro/

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