Paper Machine Energy Considerations

Transcription

1 Paper Machine Energy Considerations Dick Reese Dick Reese and Associates, Inc. Peachtree Corners, GA

2 How to Conserve Energy

3 Energy Pop Quiz-1 1. 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 capital expenditures?

4 Energy Pop Quiz-2 3. What operating changes provide good opportunities i for reducing energy use without capital expenditures? a. Press section optimization b. Steam and condensate system operation c. Water heating d. Air handling systems e. Pulper operation f. Refining g. Steam box operation h. Trim optimization

5 Energy Pop Quiz-3 4. Which h paper grade requires the least energy use per ton? Fine Paper Linerboard Corrugating Medium Bleached Board Paperboard LWC Newsprint Tissue/Towel Kraft Paper Fluff Pulp Market Pulp

6 Energy Pop Quiz-4 5. What country in the world has the most fossil fuel reserves?

7 Energy Pop Quiz-4 5. 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 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 well Investors Business Daily 10/11/2010 New drilling techniques such as fracturing have greatly increased access to oil and natural gas.

8 Energy pricing and supply are a complicated political puzzle.

9 World Energy Demand is Increasing Energy demand is increasing rapidly in emerging market countries and exceeds 22 million barrels of oil per year. China, India, Russia, and the Middle East combined consumed more crude oil than the U. S. for the first time in International Energy Agency

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12 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

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16 U. S. Steam Cost-$ per M lb

17 U. S. Electricity Cost- $ per MWh

18 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 and implementing cost effective changes.

19 How Can Opportunities to Reduce Energy 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 consumption. Compares each paper machine to energy performance on other machines producing similar grades.

20 Paper Machine Energy Scorecard System Scorecards are based on TAPPI technical information papers Paper Machine Energy Conservation (developed from energy conservation tracks at TAPPI Papermaker conferences) Paper Machine Performance Guidelines Other TAPPI TIPs

21 TAPPI TIP (2011) Paper Machine Energy Conservation Five Basic Principles 1. Minimize amount of water evaporated in the dryers. 2. Minimize amount of steam condensed outside the dryers. 3. Maximize condensate return flow and pressure to the power house. 4. Minimize electrical consumption for key users. 5. Monitor and manage energy consumption and cost.

22 Paper Machine Energy Scorecard System Improves awareness of paper machine energy consumption Helps identify opportunities to reduce energy consumption and cost Provides comparison to energy best practices

23 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 application, water systems, stock agitators t and pumps, steam showers, CD profile control, o and machine room ventilation Summary

24 Grade Specific Energy Scorecard Worksheets Linerboard Corrugating medium Fine paper Bleached board Kraft paper Recycled Paperboard Newsprint LWC Market pulp Fluff pulp

25 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? Paperboard ACTIONS YOUR SCORE COMMENTS 4,201-5,000 G4 What is total steam consumption on the paper machine 10 4,295 lb/gross ton)? >400 G5 What is electrical consumption (kwh/gross ton)? Gas=0.37 MMBtu/t > G6 What is total energy consumption (MMBtu/gross ton)? ,501-2,000 G7 What is total water consumption (gal/gross ton)? 10 1,742

26 PAPER MACHINE ENERGY SCORECARD 28/Sep/10 COMPANY NAME ABC Paper MILL LOCATION Great Place, CA, USA PAPER MACHINE NUMBER 1 SUMMARY RESULTS Dick Reese & Associates Inc. POSSIBLE YOUR PERCENT PAPER MACHINE ENERGY QUESTIONS SCORE SCORE ENERGY MONITORING % DRYER SECTION-CYLINDER DRYERS % PRESS SECTION % AUXILARY SYSTEMS A. REFINING % B. VACUUM APPLICATION % C. WATER SYSTEMS % D. STOCK PREPARATION AND PUMPS % E. STEAM SHOWERS % F. CD PROFILE CONTROL % G. MACHINE ROOM VENTILATION % GRADE SCORECARD % Grade Selected Paperboard TOTAL SCORE 1,860 1,013 54%

27 Scorecard Summary Scorecard (Number of Questions) Possible Your Percent of Score Score Potential ti Grade (14) Energy Monitoring (19) Dryer Section (24) Press Section (18) Refining (13) Vacuum Systems (11) Water Systems (12) Agitators and Pumps (7) Steam Showers (7) CD Profile Control (3) Machine Room Ventilation (8)

28 Paper Machine Energy Evaluation Observations Indices Units Low Observed High Observed Good Performance Fiber Loss % Production <0.1/<0.5 Cleaner Diameter in 3 12 <9 Vacuum Pumps model Nash # Blowers Modern Designs Press Shower Temp o F Sheet Temp. or Higher Trim Loss % <2 Wet End Dryer Control None Low DP- Stationary Syphons Low DP- Stationary Syphons Reel Moisture % Varies By Grade Moisture to Size Pr % 0.7? Starch Solids % /13 Condensate Return %?

29 Paper Machine Energy Evaluation Observations Indices Units Low Observed High Observed Good Performance Steam Use lb/gross t 2,121 17,300 2,000-5,000 Electricity Use kwh/gross t 133 1, Total Energy Use MMBtu/gross t Water Use gal/gross t , , Whitewater Temp. o F < Couch Solids % Press Solids % PV Temperature o F <180 Drying Steam lb steam/lb <1.3 H 2 O evap

30 Liner and Medium Energy Performance Targets TAPPI TIP Corrugating Index Units Liner Medium Uptime % First quality % Overall machine efficiency % Total steam consumption lb/ton 2,800 2,750 kg/tonne 1,400 1,400 Electrical consumption kwh/ton kwh/tonne Total energy cons. MMBtu/ton GJ/tonne Water consumption gal/ton 1,500 1,500 m3/ton Couch solids % Press solids % 42/50 42/50 Size press moisture % NA NA Reel moisture % Drying steam lb steam/lb water evap PV supply temperature F <180 <180 C <80 <80 Condensate return %

31 Relevant Quotation Do what you can with what you have, where you are. Teddy Roosevelt, 26 th President of US

32 What Are the Ultimate Low Hanging Fruits?

33 Energy Reduction Opportunities Implementation Total Payback Cost Range Savings Period $ ($/year) Range (years) 1 Shut off steam to bottom unrun dryers 1, , , Reduce VA supply air temperature 1,000 37, , Increase press shower water temperatures 10, , , Increase second main press loads 10, , , Change to 480 volt Install VFD on boiler feedwater pump 100,000 96, , Install new trim air compressor with VFD and control system 200, , , Total 619,000

34 Top Areas for Energy Reduction Water Systems Steam and Condensate Systems Pressing Pumps Heat Recovery e Slowed Back Production Rates Pulpers and Agitators Refining Steam Boxes Vacuum Systems Size Press and Coaters