ESTIMATING ENERGY PERFORMANCE INDICATORS OF PULP AND PAPER MILLS

Aneta Hazi, Gheorghe Hazi, Roxana Grigore

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

1. INTRODUCTION
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

1. INTRODUCTION
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 byproduct and currently generates energy from biomass residues

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: 1. raw material preparation 2. pulping

3. papermaking
The most significant energy consuming processes are pulping and the drying section of papermaking

2. TECHNOLOGICAL PROCESSES OF THE PULP AND PAPER MILLS

Pulp and paper mill

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 :

IE = CE / VPM

3. ESTIMATING ENERGY PERFORMANCE INDICATORS

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.

3. ESTIMATING ENERGY PERFORMANCE INDICATORS

Energy indicators expressed in physical units, specific to a pulp and paper mills are following: a) 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

3. ESTIMATING ENERGY PERFORMANCE INDICATORS

b) 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

3. ESTIMATING ENERGY PERFORMANCE INDICATORS

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] csab ab W - specific consumption of steam for the paper dried: D [kg steam/kg paper] csabh ab Ge - specific consumption of heat for the paper dried : Q Qrec [kJ/kg paper] csc ab Ge

3. ESTIMATING ENERGY PERFORMANCE INDICATORS

- net thermal efficiency: Q [%] n util .100 Qab - gross thermal efficincy: Qutil Qrec b .100 [%] Qab - efficiency of use of heat: Qutil u .100 [%] Qab Qrec Exergy indicators are determined with similar relationship with the energy indicators.

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

12000 10000 8000 tcc*100/mil.l ei tcc/mil.$ 4000 2000 0 1 2 3 4 5 6 7 8

Energy intensity

6000

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

2,500

2,000

Specific energy
consumption for paper machine
1,000 1,500 tcc/t MWh/t

0,500 1 2 3 4 5 6 7 8

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

0,800

0,700

Specific energy consumption for pulping

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

0,400

0,300 1 2 3 4 5 6 7 8

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

95 90

Power plant efficiency

85 80 75 70 65 60 1 2 3 4 5 6 7 8

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

Energy indicators of the newsprint Name specific consumption of steam for water evaporated specific consumption of steam for paper dried specific consumption of heat for paper dried specific consumption of heat for paper dried net thermal efficiency gross thermal efficiency efficiency of use of heat 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

the the the the

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

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 kJ/kg paper Gcal/kg paper % % % Value 1963 0.470 52.9 57.5 55.5

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

Energy needs for a year Production plan Instalation Machine 1 Product 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

Newsprint Sanitary Machine 2 paper Mechanical Grinding pulping Chemical Digesters pilping Power plant electricity heat Total

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

Energy needs split on sources Name Electricity Total From NES From CHP Unit measure MWh MWh MWh Value 160763 137463 23300 From natural gas From oil From biomass Heat Total Name Unit measure Gcal tcc tcc tcc tcc Value 246311 44541 37860 4899 1782

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

Specific consumption of heat and electricity for newsprint machine Specific consumption Unit measure project heat electricity compared project heat electricity tcc/t MWh/t to the % % 0 0 38,4 19,5 -7,3 16,7 0,344 1,797 after 20 years after upgrade of operations 0,476 0,319 2,148 2,097

4. NUMERICAL RESULTS FOR A PULP AND PAPER MILL

Comparison with other paper mills

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

5. 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.