Paper Machine Energy Considerations

Dick ReeseDick Reese and Associates IncDick Reese and Associates, Inc.

Peachtree Corners, GA770-448-8002

rareese@bellsouth.net

How to Conserve EnergyHow to Conserve Energy

Energy Pop Quiz-11 O “ i l” hi i i1. On a “typical” paper machine, energy consumption is

___% higher than on top performing machines.

2. Energy consumption can usually be reduced by ___% without capital expenditures.

3. What operating changes provide good opportunities for reducing energy use without capitalfor reducing energy use without capital expenditures?

Energy Pop Quiz-23 Wh i h id d i i3. What operating changes provide good opportunities

for reducing energy use without capital expenditures?p

a. Press section optimizationb. Steam and condensate system operation

Water heatingc. Water heatingd. Air handling systemse. Pulper operationf. Refining g. Steam box operationh. Trim optimizationp

Energy Pop Quiz-34 Whi h d i h l4. Which paper grade requires the least energy use per

ton? Fine Paperp Linerboard Corrugating Medium

Bleached Board Bleached Board Paperboard LWC Newsprint Tissue/Towel Kraft Paperp Fluff Pulp Market Pulp

Energy Pop Quiz-45. What country in the world has the

most fossil fuel reserves?

Energy Pop Quiz-45. What country has the most fossil fuel

reserves?Answer-United States“The U. S. has more oil in the ground than all of the

Middle East put together.”-Forbes BrothersMiddle East put together. Forbes Brothers“According to Energy Department figures, almost 80%

of potentially oil-rich offshore sites are off-limits to drilling; 60% of onshore sites are inaccessible as g;well” Investors Business Daily 10/11/2010

New drilling techniques such as fracturing have greatly increased access to oil and natural gas.g

Energy pricing and supply areEnergy pricing and supply are a complicated political puzzle.

World Energy Demand isWorld Energy Demand is Increasing Energy demand is increasing rapidly in

emerging market countries and exceedsemerging market countries and exceeds 22 million barrels of oil per year.

China India Russia and the Middle China, India, Russia, and the Middle East combined consumed more crude oil than the U S for the first time inoil than the U. S. for the first time in 2008.

International Energy AgencyInternational Energy Agency

“Subsidy Dollars” to Produce One MWh of Electricity EIA

Energy Source Subsidy Dollars

Refined Coal $29.81

Solar $24.34

Wind $23.37

Nuclear $1.59

Coal $0.44$

Natural Gas $0.25

U. S. Steam Cost-$ per M lb

U. S. Electricity Cost-$ per MWh

Reducing Energy Operating Costs

Papermaking is a complex process and each machine is unique. Improving energy efficiency requires careful evaluation of total paper machine operation.

Significant energy savings can be realized on most paper machines by monitoring and benchmarking energy consumption andbenchmarking energy consumption and implementing cost effective changes.

How Can Opportunities to Reduce E C ti PEnergy Consumption on Paper Machines be Identified? The U. S. Department of Energy (DOE)

funded development of a paper machine energy scorecard system.

The scorecard system Uses Excel spreadsheets to ask comprehensive

questions on paper machine components related to energy consumptionto energy consumption.

Compares each paper machine to energy performance on other machines producing similar grades.

Paper Machine Energy Scorecard System

Scorecards are based on TAPPI technical information papers.technical information papers. 0404-63-Paper Machine Energy

Conservation (developed from energy ( p gyconservation tracks at TAPPI Papermaker conferences)

0404-47-Paper Machine Performance Guidelines

Other TAPPI TIPs

TAPPI TIP 0404-63 (2011)TAPPI TIP 0404 63 (2011) Paper Machine Energy Conservation

Five Basic Principles1. Minimize amount of water evaporated in the

dryers.2. Minimize amount of steam condensed

outside the dryersoutside the dryers.3. Maximize condensate return flow and

pressure to the power house.pressure to the power house.4. Minimize electrical consumption for key

users.5. Monitor and manage energy consumption

and cost.

Paper Machine EnergyPaper Machine Energy Scorecard System Improves awareness of paper

machine energy consumptionmachine energy consumption Helps identify opportunities to

reduce energy consumption and cost

Provides comparison to energy best practicespractices

Paper Machine Energy Scorecard Worksheets Paper machine basic data Grade specific information Paper machine energy monitoring Dryer section Press section Auxiliary systems including refining, vacuum

li ti t t t k it tapplication, water systems, stock agitators and pumps, steam showers, CD profile control, and machine room ventilationco t o , a d ac e oo e t at o

Summary

Grade Specific Energy Scorecard Worksheets Linerboard Corrugating medium

Fi Fine paper Bleached board Kraft paper Kraft paper Recycled Paperboard Newsprinte sp t LWC Market pulp Fluff pulp

© 2008 - Dick Reese & Associates Inc.

GRADE ENERGY SCORECARD

Why Important Comparison of energy performance to other paper machines producing the same grade is a good way to benchmark energy consumption.

What is the major grade produced?

ACTIONS

Paperboard

ACTIONS YOUR

SCORE COMMENTS

G4 What is total steam consumption on the paper machine 10 4,295lb/gross ton)?

4,201-5,000

g )

G5 What is electrical consumption (kWh/gross ton)? 0 346>400

G5 What is electrical consumption (kWh/gross ton)? 0 346

Gas=0.37 MMBtu/t

7 0G6 What is total energy consumption (MMBtu/gross ton)? 0 7.8>7.0

G7 What is total water consumption (gal/gross ton)? 10 1,7421,501-2,000

PAPER MACHINE ENERGY SCORECARD 28/Sep/10

COMPANY NAME ABC PaperMILL LOCATION Great Place CA USAMILL LOCATION Great Place, CA, USAPAPER MACHINE NUMBER 1

© 2008 - Dick Reese & Associates Inc.SUMMARY RESULTS

POSSIBLE YOUR PERCENTPAPER MACHINE ENERGY QUESTIONS SCORE SCORE

ENERGY MONITORING 200 200 100%

DRYER SECTION-CYLINDER DRYERS 340 205 60%

PRESS SECTION 285 62 22%

AUXILARY SYSTEMS AUXILARY SYSTEMS A. REFINING 165 123 75% B. VACUUM APPLICATION 145 60 41% C. WATER SYSTEMS 160 133 83% D. STOCK PREPARATION AND PUMPS 100 40 40% E. STEAM SHOWERS 40 30 75% F. CD PROFILE CONTROL 30 15 50% G. MACHINE ROOM VENTILATION 90 55 61%

GRADE SCORECARD 305 90 30%GRADE SCORECARD 305 90 30%Grade Selected Paperboard

TOTAL SCORE 1,860 1,013 54%

Scorecard SummaryScorecard SummaryScorecard

(N b f Q ti )Possible S

Your S

Percent of P t ti l(Number of Questions) Score Score Potential

Grade (14) 170 85 50

Energy Monitoring (19) 155 75 48gy g ( )

Dryer Section (24) 190 135 71

Press Section (18) 180 150 83

f ( )Refining (13) 90 64 71

Vacuum Systems (11) 95 80 84

Water Systems (12) 130 67 52Water Systems (12) 130 67 52

Agitators and Pumps (7) 10 6 60

Steam Showers (7) 40 25 63

CD Profile Control (3) 30 23 77

Machine Room Ventilation (8) 50 25 50

Paper Machine Energy Evaluation ObservationsEvaluation Observations

Indices Units Low Observed

High Observed

Good Performance

Fiber Loss % Production 0.04 2.0 <0.1/<0.5

Cleaner Diameter in 3 12 <9

Vacuum Pumps model Nash # Blowers Modern DesignsVacuum Pumps model Nash # Blowers Modern Designs

Press Shower Temp oF 43 150 Sheet Temp. or Higher

Trim Loss % 1.0 10.0 <2

Wet End Dryer Control

None Low DP-Stationary

Low DP-Stationary

Syphons Syphons

Reel Moisture % 3.6 10.5 Varies By Grade

Moisture to Size Pr % 0 7? 5 0 3 0Moisture to Size Pr % 0.7? 5.0 3.0

Starch Solids % 4.5 19 8/13

Condensate Return % ? 90+ 75-80

Paper Machine Energy Evaluation ObservationsIndices Units Low

ObservedHigh

ObservedGood

Performance

Steam Use lb/gross t 2,121 17,300 2,000-5,000g

Electricity Use kWh/gross t 133 1,132 150-500

Total Energy Use MMBtu/gross t 4.6 12.4 4.0-7.0

Water Use gal/gross t 129 25 520 500 2 000Water Use gal/gross t 129 25,520 500-2,000

Whitewater Temp. oF 95 165 <120-130

Couch Solids % 15 30 21-30

Press Solids % 26 54 42-51

PV Temperature oF 150 270 <180

Drying Steam lb steam/lb 1.2 1.5 <1.3y g /H2O evap

Liner and Medium Energy Performance TargetsTAPPI TIP 0404-63-2011 CorrugatingTAPPI TIP 0404 63 2011 Corrugating

Index Units Liner MediumUptime % 94 94

First quality % 97 97Overall machine efficiency % 91 91Overall machine efficiency % 91 91 Total steam consumption lb/ton 2,800 2,750

kg/tonne 1,400 1,400Electrical consumption kWh/ton 300 300

kWh/tonne 330 330Total energy cons. MMBtu/ton 5.0 5.0

GJ/tonne 5.8 5.8Water consumption gal/ton 1,500 1,500p g

m3/ton 5.7 5.7Couch solids % 27 27Press solids % 42/50 42/50

Size press moisture % NA NASize press moisture % NA NAReel moisture % 7.5 10.5Drying steam lb steam/lb water evap 1.2 1.2

PV supply temperature °F <180 <180°C <80 <80°C <80 <80

Condensate return % 75-80 75-80

Relevant Quotation

“Do what you can with what youDo what you can with what you have, where you are.”

Teddy Roosevelt, 26th President of US

What Are the Ultimate LowWhat Are the Ultimate Low Hanging “Fruits”?

 Energy Reduction Opportunities Implementation Total PaybackC t R S i P i dCost Range Savings Period

$ ($/year) Range (years)1 Shut off steam to bottom unrun dryers 1,000 190,000 0.01

2 000 0 012,000 0.012 Reduce VA supply air temperature 1,000 37,000 0.03

2,000 0.053 Increase press showerwater temperatures 10 000 148 000 0 073 Increase press shower water temperatures 10,000 148,000 0.07

20,000 0.144 Increase second main press loads 10,000 148,000 0.07

20 000 0 1420,000 0.145 Change to 480 volt‐Install VFD on boiler feedwater pump 100,000 96,000 1.04

130,000 1.356 Install new trim air compressor with VFD and control system 200 000 96 000 2 086 Install new trim air compressor with VFD and control system 200,000 96,000 2.08

240,000 2.50

Total 619 000Total 619,000

Top Areas for Energy Reduction

Water Systems Steam and

Pulpers and Agitators

Condensate Systems Pressing

Refining Steam Boxesg

Pumps Heat Recovery

Vacuum Systems Size Press and eat eco e y

Slowed Back Production Rates

S e ess a dCoaters