heavy industries: advancing american manufacturing - forest products industry, john cowie, american...

Efficient Enterprises: Powering American Industry Heavy Industries: Advancing American Manufacturing

Forest Products Industry

Presentation to The Alliance to Save Energy

Briefing Series #4

John G. Cowie Ph.D.

American Forest & Paper Association

Agenda 2020 Technology Alliance

November 17, 2009

2

Snapshot of the U.S. Forest Products Industry - Paper (2008 data)

Transforming the forest products industry through innovation

Paper and Allied ProductsNumber of pulp, paper and paperboard mills 532

Employment 445,000

Value of shipments $140 billion

Paper/paperboard capacity 96.3 million tons

Paper/paperboard production 88.8 million tons

Paper/paperboard exports 42.9 million tons

Paper/paperboard imports 24.0 million tons

Pulp capacity 66.0 million tons

Pulp consumption by U.S. mills 56.6 million tons

Energy consumption (2006 data) 2,346 trillion Btu

Recovered paper consumption 51.8 million tons

Recovered paper recovery rate 57.4%

3

Snapshot of the U.S. Forest Products Industry - Wood (2008 data)


Wood ProductsEmployment 460,000

Value of shipments $70 billion

Production of softwood 27,351 million board feet

Production of hardwood 9,501 million board feet

Value of exports (2002 data) $5.3 billion

Value of imports $15.2 billion

Energy consumption (2006 data) 450 trillion Btu

The Impacts of Forest Products Industry on the U.S. Economy

Manufacturing Jobs in 2008 = 905,000 Among the top 10 manufacturing employers in 48 states Economic Activity: Accounts for ~ 6 percent of mfg. GDP

On par with the automotive and plastics industries Generates more than $200 billion a year in sales

Employees earn ~ $54 billion in annual payroll Dependent on forest products industry:

Consumer goods marketing and distribution Shipping and warehousing Printing and print advertising Housing and construction Furniture manufacture and others

4Transforming the forest products industry through innovation

Forest Products Industry:Energy Efficiency Initiatives and Successes

5Transforming the forest products industry through innovation


Industry-Wide

Renewable Fuel Use Compared with all other sectors,

pulp and paper mills and wood products production facilities far exceed all other industries in their utilization of renewable biomass energy

U.S. DOE data show that pulp and paper and wood products facilities produced 82% of the biomass-based energy generated by all industrial sectors in 2005

Reinventing the forest products industry through innovation 6


Pulp and Paper Mills In 2006, biomass energy sources

satisfied 64% of the total energy demand in pulp and paper mills

Largest components of energy sources: Spent pulping liquors Logging or wood processing byproducts

Total energy needs is supplied by Spent pulping liquors 46% 18% is generated from wood residuals


Energy Efficiency Initiatives and Successes

Wood Products Facilities Biomass materials are the

predominant source of energy at wood products manufacturing facilities

In 2006, wood residuals provided 74% of the energy needed to power these facilities


Energy Efficiency Initiatives and Successes



Cogeneration Cogeneration is the practice of using exhaust steam

from electrical generators for heat in manufacturing processes or for space heating

Industry leader in the production and use of cogenerated electricity, second only to the chemical industry in cogenerated electricity

In 2005, 98% of electricity produced at paper mills was cogenerated

Cogeneration by wood products facilities was 96% of total electricity produced


Appropriate Federal Role for the Industrial Technologies Program

The research portfolio of the forest products industry is consistent with the mission and goals of the ITP

ITP to update the industry roadmap and identify grand challenges

Include both energy reduction and economic constraints of the industry when selecting R&D projects

Assist Agenda 2020 in generating ideas and concepts for development into R&D projects

Need a strong Public/Private Partnerships with Agenda 2020 to advance R&D projects


Agenda 2020Public/Private Partnerships in R&D

DOE ITP: Forest Products Industry Roadmap - 2009

DOE EERE: Value Prior to Pulping (VPP) – Integrated Biorefinery Project

USDA Forest Service: Biorefinery and Nanotechnology Technology

2007 NNI Forest Products Industry (CBAN) Consultative Board for Advancing Nanotechnology


DOE ITP Forest Products Projects

Current Projects - 2009 Highly Energy Efficient Directed Green Liquor Utilization Development of Screenable Wax Coatings and Water-Based Pressure

Sensitive Direct Causticization for Black Liquor Gasification in a Circulating Fluidized

Bed Development of Renewable Microbial Polyesters for Cost Effective and

Energy-Efficient Wood-Plastic Composites

Some Past Projects - 2008 Biological Air Emissions Control for an Energy Efficient Forest Products Integration of the Mini-Sulfide Sulfite Anthraquinone (MSS-AQ) Pulping

Process and Black Liquor Gasification in a Pulp Fibrous Fillers to Manufacture Ultra High Ash / Performance Papers Engineering of Syringyl Lignin in Softwood Species Through Xylem-Specific

Expression of Hardwood Syringyl Monolignol Pathway Genes Development of Renewable Microbial Polyesters for Cost Effective and

Energy-Efficient Wood-Plastic Composites


New Recovery Boiler Concept



Steam Cycle Efficiency


17



Efficiency improvement from 16% to 25% Power generation more than doubles When all the boilers are replaced: ~ 15 Gigawatts of

additional power output Potential to make Forest Products Industry energy

independent or even a net energy producer Presently unfunded project

Cost too high for ITP budget Not within scope of EERE goals

18

Competitiveness Issues in the Forest Products Industry


Challenged by competitors in a global market Emerging economies enjoy economic advantages in wood,

labor, energy, and environmental costs Capacity in pulp and paper is growing overseas Slower growth is anticipated in the U.S.

Major structural changes in companies Mill closures and workforce reductions U.S. has lost 250,000 jobs, or 19% of its workforce, since 2006

Other pressures include: The growing use of electronic media An aging process infrastructure in U.S. mills Limited capital available for new investments Few technology breakthroughs in the last decade

19

2009 Forest Products Roadmap Technology Objectives


Summary of Top Priority R&D NeedsGenerate Energy More Efficiently

Develop and deploy black liquor gasification

Develop new materials to enable high temperature operation (especially in recovery boilers)

Significantly improve fluidized-bed boilers to achieve high steam values and power values

Improve energy efficiency of recovery boilers

Develop advanced gasification combined-cycle technologies for black liquor and solid forest-based biomass

Use Energy More Efficiently in Existing Technology

Better recover and utilize waste heat

Develop a next generation refiner to achieve more efficient mechanical pulping.

Dry wood more efficiently

Alternative way to change sulfate to sulfide

Use steam more efficiently

Reduce energy use in chemical pulping—including pumping pulp and chemicals

Breakthrough Technology to Reduce Energy Demand

2. Deliver a drier sheet to dryer section 55% - 65%

3. Reduce energy for black liquor concentration by 50% - including reducing pulp washing water usage

Increase pulping consistency to 30 percent from current levels of 15%–16%)

Reduce energy intensity of fiber preparation

Reduce product weight required to enable the product’s intended function

Improve lime kiln efficiency

Reduce process water needs to that which enters with wood

Eliminate CO2 Generation from Fossil Fuels

1. Renewable source for non-steam thermal demand – use biomass to replace fossil energy

Develop waste water treatment as an energy source—recover VOCs

Incinerate internally generated solid waste stream

Better utilize lignin as an energy source

Eliminate fossil fuel use in lime kiln

Recover CO2 and Use On-Site

Co-generate fuels (i.e., algae with CO2 feed, target trees optimized for co-generation)

Recover CO2 from lime kiln stack

Energy Use and CO2 Emissions

20

2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions


21



22



23

Thank you!

Please contact me for more information:

John Cowie, Technology Director

Tel: 1-202-463-2749 (USA)

Email: [email protected]

American Forest & Paper Association

1111 19th Street NW, Suite 800

Washington, DC 20036 USA


heavy industries: advancing american manufacturing - forest products industry, john cowie, american...

Technology

chemical industry

innovation paper

energy efficiency initiatives

allied products number

tons energy consumption

energy reduction

biomass energy sources

space heating industry