Title: Opportunities to Improve Energy Efficiency on paper machine Dr. Vivek Kumar Department of Paper Tech
1 Opportunities to Improve Energy Efficiency
on paper machineDr. Vivek KumarDepartment of
Paper TechnologyIIT Roorkee, Saharanpur Campus
2Introduction
- The paper mill area is a major energy consumer in
most integrated pulp and paper mills. - Energy consumption and cost per ton vary widely
on paper machines. - Mills have different energy costs based on mill
configuration, vintage of papermaking equipment,
geographic location, and other parameters. - Each mill needs to develop an understanding of
energy cost factors before preparing an effective
energy reduction program.
3- Techniques for improving energy efficiency on
paper machine i.e., Forming Section, Pressing
section, Drying section. - Optimize performance of equipment.
- Use steam, water, air, and vacuum pressures
appropriate to processes. - Minimize energy losses.
- Minimize water evaporated in the dryers.
- Heat Recovery.
4Forming section
5Vacuum system
- The vacuum system is among largest process in the
paper mill with respect to space requirements,
piping, and energy usage. Vacuum systems can have
installed and required energy of 500 to 8,000 hp. - Several steps are required to guarantee the
vacuum system is operating as efficiently as
possible. - Vacuum system audits or surveys.
- Routine maintenance of vacuum pumps and auxiliary
equipment, including belt and gear drives and
motors - Replacement and calibration of gauges and process
instrumentation
6How do we control or minimize wasted energy?
- Vacuum system audits
- Once identified, some vacuum system problems
may cause higher energy usage, costs, and
inefficiencies for the entire system. - Hot seal water.
- High seal water flow due to unregulated or high
seal water pressure. - Back pressure on the vacuum pumps due to system
design or operational problems. - Synchronous vs. induction motors, which may
affect the power factor.
7Vacuum system........
- Elevated seal water will reduce vacuum pump
efficiency and will lower vacuum system capacity. - However, there are methods to reduce seal water
consumption without sacrificing vacuum pump
performance. This can involve a water recovery
plan and/or cooling the water with a cooling
tower. It is important to note that special,
dirty-water cooling towers have been successful
in this application.
8Vacuum system........
- We must have to maintain a vacuum system in such
a way that it should not have more than 1 psig of
back pressure measured at the pump discharge. - Also we have to maintain the system clean and the
scale build up as minimum as possible. - In systems where a discharge sump is used, high
water levels within the sump can cause back
pressure as well as contribute to poor air/water
separation within the sump.
9Vacuum system........
- MOTOR SIZE/VACUUM PUMP HORSEPOWER
- Another issue involving motors is the selection
of the motor size with respect to the vacuum pump
horsepower. Many mills elect to install oversized
motors on equipment to reduce spare parts and
storeroom inventory. Many vacuum pumps are
installed and driven with a motor from an old
refiner that may have 50 more horsepower than
the vacuum pump requires. - A frequent practice is to replace a correctly
sized drive motor with a larger size to eliminate
overloading and trip-out problems. This is an
example of correcting the symptom rather than
solving the problem.
10Vacuum system........
- MOTOR SIZE/VACUUM PUMP HORSEPOWER
- Older, inefficient vacuum pumps versus new,
modern designs - Scale build-up
- Process carryover and high seal water flows
- Piping losses or poor system design.
11Vacuum system........
- Newer larger pumps can reduce the quantity of
pumps on a paper machine by one half. - Scale, or calcium carbonate buildup, will
increase vacuum pump horsepower requirements by
as much as 20 to 30 and often locks up the
rotor within the vacuum pump. - Water treatment and descaling programs are useful
in the prevention of scaling. Recirculated seal
water systems with cooling towers, have
experienced better control of the water quality
for the vacuum pumps.
12 13Vacuum system........
- In one audit it is mentioned as, the total vacuum
system power consumption was 3,040 hp. Allowing
for performance tolerances and drive losses, the
system should require only 2,775 hp. This
excessive power consumption of 265 hp was due to
several factors affecting. The problems included
overloading due to high seal water flows and
internal scaling. - Vacuum pump operated at 11.3 in. Hg,
- Highest vacuum level of the was 7.0 Hg. The
extra horsepower to operate the vacuum pump at
11.3 in. Hg required an additional 34 hp
14- Another vacuum pump was requiring 36 hp more than
necessary due to the incorrect model being
installed. This was a high vacuum model, designed
for more efficient operation at above 15 in. Hg.
However, the pump was on the low vacuum press
zone and operated at only 7 in. Hg. A low vacuum
model needed to be installed to reduce
horsepower. - By making some changes in felt conditioning,
there was an opportunity to save an additional
108 hp.
15Replacement of Existing Vacuum Pumps
- Current Situation
- In Paper machine No. 1 two vacuum pumps
(capacity 1800 m3/hr rated vacuum 400 mm Hg
each) are provided and having common header (i.e.
for Flat Boxes uhle Boxes) and consuming 107
kWh - Suggestion Benefits
- As the suction vacuum requirement is only 200
mm Hg. It is recommended to install a new vacuum
pump of higher capacity (rated suction vacuum 300
mmHg, capacity 3500 m3/hr) in place of existing 2
vacuum pumps, which will consume about 65 kWh.
Saving potential is 107 65 42 kWh or Rs. 8.05
lacs/annum against investment of Rs. 3.00 lacs.
16- Situation Current
- In Paper machine No. 2 two vacuum pumps
(capacity 1800 m3/hr rated vacuum 400 mmHg
each) are provided and having common header (i.e.
for Flat Boxes uhle Boxes) and consuming 77
kWh. - Suggestion Benefits
- As the vacuum requirement is only 200 mmHg.
It is recommended to install a new vacuum pump of
higher capacity (rated vacuum 300 mmHg, rated
capacity 3200 m3/hr) in place of existing 2
vacuum pumps, which will consume about 56 kWh.
Saving potential is 77 56 21 kWh or Rs. 4.02
lacs/annum against investment of Rs. 3.00 lacs.
17- Current Situation
- In paper machine No.4 one vacuum pump (KVM
900 capacity 3600 m3/hr, Rated vacuum 500 mmHg)
has been installed for uhle Box, which is
consuming 104 kWh. - Suggestion Benefits
- As the requirement of suction vacuum in
uhle Box is around 200 mmHg. It is suggested to
convent it as per the specification i.e. Capacity
4125 m3/hr, Rated vacuum 300 mmHg. At these
specification the power consumption will be about
70 kWh. Therefore saving potential is 104 70
34 kWh resulting in saving of Rs. 6.5 lacs/annum
against investment of Rs. 5.00 lacs.
18- Current Situation
- In paper machine No.5 one vacuum pump (7LV
Capacity 1410 m3/hr, Rated vacuum 660) has been
installed for flat boxes, which is consuming 48.7
kWh power. - Suggestion Benefits
- As the requirement of suction vacuum is only
200 mmHg in flat boxes, it is suggested to
replace existing vacuum pump with KVM 300
(Capacity 1500 m3/hr, Rated vacuum 300 mmHg),
which will consume only 24.5 kWh power. Therefore
saving potential is about 48.7-24.5 24 kWh
resulting in saving of Rs. 4.6 lacs/annum against
investment of Rs. 2.00 lacs.
19- Current Situation
- In the paper machine No.7 four vacuum pumps
(all KVM 600) are running continuously and
having common header for Couch, suction press,
flat boxes uhle box. Requirement of suction
vacuum in Couch and suction press is high i.e.
upto 400 mmHg and in Flat Box and uhle Box, it is
less i.e. 200 mmHg. All the four pumps are
consuming about 273 kWh power. - Suggestion Potential
- As the requirement of suction vacuum is
less in case of Flat Boxes and uhle box it is
recommended to fabricate separate lines for two
vacuum pumps and reduce the rpm 500 from present
550 rpm. A saving potential of 14 kWh is
estimated against reduction of rpm resulting in
saving of Rs. 2.7 lacs with an investment of Rs.
50,000.
20- Improvement Effect(A) Rs. 32.96 lacs/annum
- Investment (B) Rs. 13.50 lacs
- Simple Pay Back (B/A) 5 months
21Energy Efficient Formers
- Twin wire forming is new principle had the
advantages of avoiding the free surface between
mix and air, of increasing the dewatering
capacity by allowing dewatering capacity through
two wires. - The forming sections is very short and the
formation takes place in a fraction of the time
it takes for a Fourdrinier machine.
22- Produces a paper of equal and uniform quality at
a higher rate of speed. Coupling the former with
a press section rebuild or an improvement in the
drying capacity increases production capacity by
as much as 30. - Energy savings come from reduced electricity
consumption . The technology also may improve
quality and electricity savings of 41 kWh/t of
paper.
23High consistancy forming
- In high consistency forming, the furnish (process
pulp) which enters at the forming stage has more
than double the consistency (3) than normal
furnish. This measure increases forming speed,
and reduces dewatering and vacuum power
requirements. - Electricity savings are estimated at 8 that is
about 41 kWh/t of paper.
24Pressing section
25PRESSING ARRANGEMENTS
- Drying the sheet of paper using steam heated
dryers is a lot more expensive than using
efficient presses. The primary function of the
press section therefore is to remove as much
water from the sheet as possible, consolidate the
sheet and improve the surface smoothness.
26Extended nip press (Shoe press)
- The additional pressing area allows for greater
water extraction, (about 5-7 more water removal)
to a level of 35-50 dryness. - This technology reduces the load on the dryer, it
allows plants to increase capacity up to 25 in
cases where the plant was dryer limited. - Extended nip pressing also increases wet tensile
strength.
27Hot pressing
- Pre-heating the water in the paper sheet before
pressing can reduce the evaporation load. - Use of steam showers has been estimated to reduce
the steam requirement by 1 kg of steam per kg
paper. We estimate steam energy savings of 0.61
GJ/t paper through hot pressing.
28 29- Installation of Steam Boxes in the Press Sections
- Current Situation
- There are no steam boxes installed in the
press section - Suggestion
- With the Installation of steam boxes the
following optimizations are possible - Increase of production capacity or reduction of
steam consumption in the dryer section - Improve moisture profile
30-
-
- In general the design data of steam boxes are
- Steam consumption approx. 80 - 120 kg steam /
tonne paper (the value depends on the dryness
of the paper) - Potential of warming up the paper web from 10 to
15 K - 10 K increase of paper web temperature
corresponds with an increase of dryness after the
press section of about 1 - 1 increase of dryness after press section leads
to 5 higher production or 5 less steam demand
in the drying section - With the installation of steam boxes in the press
sections of PM 4 and PM 5 the following steam
reduction is possible-
31- PM 4 (3.26 t paper / hour)
- Steam consumption 3.4 t/t 11 t/h
- Steam saving in drying section 6 0.66
t/h - Steam demand steam box 0.3 t/h.
- PM 5 (2,6 t paper / hour)
- Steam consumption 3.9 t/t 10 t/h
- Steam saving in drying section 6 0.6
t/h - Steam demand steam box 0.23 t/h.
- Furthermore after installation of a steam box
less evaporation (0.1 to 0.2 m³/h) occurs in the
drying section which can reduce condensation in
the pre-drier section of PM 5.
32potential
- Improvement Effect (A) Rs. 21.0 lacs/annum
in PM 4 - (Steam reduction 2880 t/a)
- Rs.
21.6 lacs/annum in PM 5 -
(Steam reduction 2960 t/a) - Investment (B) 100.00 lacs / steam
Box - Simple Pay Back (B/A) 5 years
33 34DRYING ARRANGEMENTS
- To optimize energy use in the drying process, it
is essential to clearly identify the areas and
actions that offer measurable opportunities for
improvement. Reducing the evaporation load to the
dryer section is a smart starting point. Pressing
improvements are the best way to reduce dryer
section steam use.
35- Improving machine efficiency is another obvious
path. - Identifying losses from the dryer drainage system
is essential. - The cost of high-pressure steam should be
factored into dryer energy cost. - Minimizing the dryer air heating requirement.
36Improper siphon size
- Replacing rotary siphons with stationary siphons
in dryers that discharge directly to the
condenser offers potential for improvement.
Stationary siphons are designed for a blowthrough
steam flow of 10 versus 20 to 25 often
required with rotary siphons. - Proper siphon design is a key to keeping the
system "tight".
37Maximize the Use of Low-Pressure Steam
- This allows the most electricity to be generated
at the boiler house, using the high-pressure
steam to power an electricity-generating turbine.
- Using dry low pressure steam is advantageous when
considering energy efficiency due to high
condensing heat rate.
38Minimize Dryer Air Heating Requirement
- Adjust the pocket ventilation air temperatures to
match the drying requirements and hood design. - The hood must be well sealed and have good
insulation properties to operate with low pocket
ventilation air temperatures. - Air to air heat recovery systems on existing
machines recover only about 15 of the energy
contained in the hood exhaust air. This
percentage could be increased to 60-70.
39- Paper machines with enclosed hoods require about
one-half the amount of air per machine reduces
thermal energy demands since a smaller volume of
air is heated. Electricity requirements in the
exhaust fan are also reduced. Steam savings of
0.76 GJ/t paper and electricity savings of 6.3
kWh/t paper by installing a closed hood and an
optimized ventilation system is estimated.
40 41- Stopping of steam condensate leakages from the
pocket ventilation system - The Pocket ventilation system for dryer group
(II) (III) consists of steam heaters for heating
the inlet air. There are two rows of steam
battery which operates on the steam pressure of
3.5 Kg/ cm2 .
42- The condensate of steam is collected through
bottom line in separate tank. It was found, that
there was lot of steam and condensate leakages
and all area below Pocket ventilation system
nearby is flooded with condensate. - RECOMMENDATION
- It is recommended that steam condensate
leakages should be stopped immediately.
ECONOMICS Cost of 1 m3 condensate Rs. 60
(including heat value) Improvement Effect
Saving by stopping condensate
draining (5m3 daily) Approx 60 5 Rs.
300 wastage Annual Saving 300330 Rs.
99,000/- Investment Negligible Pay
back Immediate
43Closing of side panels doors of dryer hoods of
both machines
- Background
- It was observed that the lifting doors of both
machines are always partially lifted and all
basement area is open. - The closed hood is therefore working as semi
closed hood and lot of air infiltration is takes
place from machine house. - This reduces the drying efficiency of dryers and
hence more steam is consumed for drying the same
quantity of paper. It also reduces the
efficiency of pocket ventilation system and also
increases steam consumption in PV system.
44- Beside this the condition of side panels of hood
was not proper resulting in heavy Infiltrations
from sides . - The insulation of side panels were also in bad
shape. All these reduce the efficiency of hood,
resulting in more power consumption at exhaust
fans. - Recommendation
- It is recommended that machine should run with
lifting door in down position. - The doors should be lifted only at the time of
paper break and should be brought down after
rethreading of paper. - Also all infiltration should be stopped and
insulation of side panels and roof should be
repaired / replaced.
45- BENEFITS
- By proper insulation, repairing and stopping
infiltration of air in hood efficiency in drying
will be improved. - By assuming 1 improvement in hood efficiency,
mill can save 0.24 t/hr steam resulting in saving
of Rs. 15.20 lacs/annum as shown below. - 1 improvement in drying 0.24 t/hr after
reducing in steam consumption. -
0.24t/hr -
5.76T/day or 1900 T/annum -
1900 400 - ECONOMICS
- Savings Rs. 15,20,320/-
- Investment Rs. 5,00,000
- Pay back 3 months
46Insulation of Hot Surfaces in Paper Machine
- BACKGROUND
-
- During the audit at mill, it was observed
- that various pipelines and Paper machine
- dryers having higher temperature are not
- insulated resulting in high heat losses
- through these uninsulated insulated
- surfaces in the form of radiations.
47- It is suggested to put proper insulation on all
bare surfaces to reduce the heat loss through
radiation and save the energy wastage. - Detail of Uninsulated lines
-
48- Benefits
- By putting the insulation on the uninsulated
surfaces enormous calories of heat energy can be
saved, which is equivalent to a saving of 2127
ton of steam per annum resulting in saving of
Rs.8.51 lacs per annum with a payback period of
2-8 months for putting the insulation. - Economics
- Improvement effect (B) Rs.
8.51Lacs/annum - Investment Amount (A) Rs. 4.28 Lacs
- Simple pay Back (B/A) 2-8 months
49Replacing of the missing air filter panels and
cleaning of air filters .
- RECOMMENDED
- It is recommended that air filter panel of PV
system should be repaired and maintained in
proper condition regularly. All missing filter
panels should be placed in position and should
be cleaned from dust.
50-
- BENEFITS
- By adopting this proposal, clean air will be
purged in pocket ducts of dryer, reducing chance
of dirty air to bleached paper. - This would improve the paper surface quality.
Also the energy consumed by PV fan would reduces
marginally.
51Use of flash steam of main condensate tank in
pocket ventilation system
- The condensate of last group dryers are
collected in the main condensate tank from where
it is pumped to boiler house. - It was observed that the flash steam from main
condensate tank is vented to atmosphere. - Without recovering its heat value. About 80 kg/hr
flash steam is vented.
52- RECOMMENDATION
- It is recommended that this flash steam should be
used in the steam battery of PV system. Since the
flash steam is not sufficient for PV system, the
live steam will also be used but the use of flash
steam would reduce the use of live steam in PV
system. - BENEFITS
-
- Assuming 2 tonne flash steam per day utilized in
the PV system, mill can save Rs. 3.96 lacs/annum
by using it in PV system.
53- Installation of Heat Recovery System in Paper
Machine 5 - Current Situation
- The pre-dryer section of PM 5 is equipped with a
closed hood - The current situation is as follows
- Daily production of PM 4 60 t/d
- Evaporation rate 4 m³/h (pre-drier
section) - Exhaust pre-dryer section 1 17530 kg/h
68.3C / 51.2 - Exhaust pre-dryer section 2 14250 kg/h
71.4C / 43.5 - Exhaust air mass flow 31780
kg/h - Supply air mass flow 21000
kg/h(66 ) - Leak air mass flow
10780 kg/h
54Current Situation
17.530 kg/h 68,3C/51,2
14.250 kg/h 71,4C/43,5
29C / 33,3
Supply air for the hood coming from the hall
18.200 kg/h
Filter by-passed
Leak air from the hall into the hood
external air polluted
Exhaust air from the hood in the hall
Exhaust air from the vacuum system into the hall
50C/ 99/ 85,3 g/kg
55- There is no heat recovery system installed in the
exhaust air system. The supply air (120C) is
heated by live steam. - The supply / exhaust air proportion (66 ) is
within the range of recommended values. - The filter in the external supply air system is
by-passed. - Furthermore wet exhaust air from the vacuum
system is led into the basement. There is
condensation in the hood when the hood is closed.
56Suggestion
25C /49
70C 32,000 kg/h
54C
44C 21,000 kg/h
57Suggestion
- To make hood closing possible and thus increasing
the quality of paper it is suggested to increase
the supply and exhaust air mass flows step by
step (target values supply air mass flow 28,000
kg/h / exhaust air mass flow 42,000 kg/h the
target values might not be reached because of
design of the existing air system). - This leads to an increase of electricity
consumption but also to a reduction of steam
consumption. It is estimated that these changes
in energy consumption are not affecting the
operational costs. - Furthermore it is recommended to lead the exhaust
air from the vacuum system out of the hall and to
lead the external supply air through the filters.
58 59Impulse Drying
- Impulse drying works by lowering the moisture
content of the paper web entering the drying
section by up to 38 percent. In a conventional
papermaking operation, the web has a moisture
content of 50 to 60 percent as it enters the
drying phase. - It is estimated that the operation of 65 impulse
drying units in the year 2020 could save 13
trillion Btus of energy annually for the
industry.
60Infrared drying
- Along with improved energy efficiency, it
increases the drying power output. Infrared
dryers are powered by electricity, and require
about 4.08 GJ of electricity/t paper versus 8.16
GJ of steam/t paper for conventional steam dryers
(Jaccard, Willis.). We therefore estimate primary
energy savings of 3.3 GJ/t paper. - Investment costs for infrared dryer installation
are Rs.5203/t paper including OM costs
requirements.
61Condebelt drying
- This drying technique has the potential to
completely replace the drying section of a
conventional paper machine, with a drying rate
5-15 times higher than conventional steam drying. - For large machines savings of 10-20 steam are
possible (1.6 GJ/t of paper) and a slight
reduction in electricity consumption (20 kWh/t of
paper). Capital costs are considered to be high,
although the size of the drying area can be
reduced. - This provides opportunities to enhance energy
economy. Energy for the Condebelt has three
components primary steam used per kg of
evaporated water, recovery of the latent heat
from the steam evaporated from the web, and
electrical energy. -
62- Typical steam consumption is about1.31.5 kg per
kg of evaporated water. - In the Condebelt process, about 85 of the heat
can be recovered. Thus the temperature of the
pulp entering the headbox can be increased by
10C using the excess heat from the Condebelt. - The total electrical energy consumption in a
Condebelt dryer is comparable to that found in
conventional cylinder drying.
63Air impingement drying
- This technology can be combined with existing
technologies. Heat input requirements have been
modelled at 3 MJ/kg evaporated water, or a 10-40
savings in steam requirements. Electricity
requirements are expected to increase by 0-5. - This involves optimization of the geometry of the
nozzle pattern, nozzle type ,nozzle
velocitydiameter, nozzle to sheer distance.
64Steam impingement drying
- Steam requirements are estimated at 4.5 GJ/t
paper with additional savings available if the
latent heat from the purge steam is captured. De
Beer, estimates a savings of 10-15, with a
slightly lower reduction in electricity
requirements (5-10).
65 66Avoid Idle running of motor of hood blower in
paper machine
- Background
- During the visit it was observed that motor of
hood blower of paper machine was running idle
without fan. - The shaft or connection between motor fan has
been broken and motor runs continuously without
fan for 24 hours.
67- RECOMMENDATION
- It is recommended that proper maintenance
should be taken care and all such system should
be checked at least once a shift. - BENEFITS
- Assuming the motor running goes unnoticed for
a day, Loss in electrical energy 30kW X24
720kWh. - Assuming 30 load 216 kWh/ day
- Annual saving 216 1.61 330
- 1.14
Lacs/annum
68- ECONOMICS
-
- Investment Negligible
- Savings Rs. 1.14 Lacs/annum
- Pay back period with in one month
69Motor considerations
- Vacuum pumps are driven by induction and
synchronous motors using v-belt drives and gear
reducers, as required. - The use of synchronous motors is based on
reliability, space considerations, and
elimination of the need for power transmission
equipment (v-belt drives and gear reducers). - Also it is observed that some mills elect to use
higher speed synchronous motors (1,200 or 1,800
rpm) and gear reducers that may offer cost
savings over the larger, slow speed synchronous
motors.
70- Current Situation
- In Paper Machine No.3 one vacuum pump
(KVM-600) has been installed for S. Couch and
drawing 90 kWh. - Suggestion Benefits
- As per the manufacturer performance table,
motor should draw only 53 kWh against present 90
kWh. Therefore it is suggested to contact the
supplier for the root cause analysis of higher
Energy Consumption. Saving potential is 90 69
37 kWh resulting in saving of Rs.7.10 lacs /annum
by maintenance of existing pump.
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