paper machine energy considerations - nip impressions®--on the...
TRANSCRIPT
Paper Machine Energy Considerations
Dick ReeseDick Reese and Associates IncDick Reese and Associates, Inc.
Peachtree Corners, GA770-448-8002
Paper Machine Energy Overview Energy efficiency on paper machines varies widely. This presentation will:
Discuss paper machine energy benchmarks Discuss paper machine energy scorecards used to
benchmark energy performance and identifybenchmark energy performance and identify opportunities for improvement
Provide examples of some recommendations that phave been successfully implemented
Primary goal is to help paper companies be more energy efficient and stay in businessmore energy-efficient and stay in business
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. Reduce paper losses between reel and winderb. Press section optimization
Steam and condensate system operationc. Steam and condensate system operationd. Water heatinge. Air handling systemsf. Pulper operationg. Refining h. Steam box operationpi. Trim optimization
Energy Pop Quiz-34 Whi h d i h l ?4. Which grade requires the least energy use per ton?
Fine Paper Linerboard Corrugating Medium Bleached Board
Paperboard Paperboard LWC Newsprint Tissue/Towel Kraft Paper Fluff Pulpp Market Pulp
Energy Pop Quiz-4Energy Pop Quiz 45. What country has the most fossil fuel
reserves?reserves?Answer-United States“The U S has more oil in the ground than all of theThe U. S. has more oil in the ground than all of the
Middle East put together.”-Forbes Brothers-101 billion barrels of oil offshore-88 billion barrels onshore
New drilling techniques such as hydraulic fracturing have greatly increased access to oil and natural gas.g
The American Petroleum Institute estimates that within 15 years, U. S. and Canadian energy resources could supply 100% of U. S. liquid fuel needs.
U. S. has 28% of the world’s coal reserves.
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
Reasons Natural Gas Prices will Pop in 2013
Winter chill increases natural gas demand Industrial and petrochemical usage on risep g Natural gas fleets expand across USA Electricity consumption from gas set to spike Electricity consumption from gas set to spike U. S. LNG trade set to go global
Dr. Kent Moors-Oil Investor and Energy Reports
Thermal Kinetic Energizer (TKE)
T h l f i l ffi i l i Technology for using natural gas more efficiently in boilers, lime kilns, and other applications
E = ½ mv2 EK= ½ mv2
If you want to double steam generation with a conventional burner, you have to double gasconventional burner, you have to double gas consumption since velocity (150 m/sec) does not change.With TKE l it i i d t 220 / With TKE, velocity is increased to 220 m/sec
At constant mass of gas, EK is 2.15 times higher with TKE than a conventional gas burnerTKE than a conventional gas burner
(220 m/sec)2 / (150 m/sec)2 =2.15
The Revolution in Heat Transfer TechnologyUnderstanding the TKE-EnergizerUnderstanding the TKE-Energizer
Price is the Problem with Renewable Energy
Th i f h d b h t b hi h t j tif lt ti The price of hydrocarbons has to be high to justify alternative sourcing.
Solar and wind have high implementation cost and are less cost-ff ti th t l j t ith teffective than natural gas projects even with government
subsidies. At least 10 “green” companies that DOE has “loaned” money to
t d l h fil d f b k tor guaranteed loans have filed for bankruptcy. Nuclear is the cheapest way to generate electricity but has high
development and startup cost and is not popular politically. Coal reserves are plentiful but emission standards being
introduced are changing the economics of using coal. Biofuel projects have lower energy production ratio. For
example, ethanol provides only 84% of the power provided by gasoline.
Green Energy’s Baptists and Bootleggers WSJ-1-16-13
“Baptists and bootleggers” is term used to describe coalitions of do-gooders and mercenaries that gather around green energy issuesaround green energy issues.
“The green political machine exists to extract high prices from electricity users for the machine’s own p ybenefit”.
The green lobby has had to attack shale because it t t th hi h t f i d d laccentuates the high cost of wind and solar.
Warren Buffet is investing in a solar power plant that is guaranteed to yield large cash flows for 20-25is guaranteed to yield large cash flows for 20 25 years due to California legislative mandate.
Federal Subsidies for Electric Power by SourceFederal Subsidies for Electric Power by Source-Fiscal 2010 WSJ 8/18/2012
Energy Source Subsidy Dollars-Millions
Dollars per Megawatt Hour
Oil and Gas $654 $0.64$ $
Hydropower $215 $0.82
Coal $1 189 $0 64Coal $1,189 $0.64
Nuclear $2,499 $3.14
Solar $968 $775 64Solar $968 $775.64
Wind $4,986 $56.29
Energy Power DensityEnergy Power Density WSJ-1-19-2012
Energy Source Watts Generated/Square Meter of Land
Corn Ethanol 0.05
Wind Turbine 1.0
Small Natural Gas Well 28
Nuclear Reactor 2000
If you wanted to replace 10% of U. S. oil consumption with
fuel derived from switch grassfuel derived from switch grass, it would require 37 million
acres-roughly the size of Illinois
New Power Plant CostsFuel $ Cost per Megawatt Hour*
Natural Gas 66
Wind 96Wind 96
Coal 98
Nuclear 114
Solar Photovoltaic 153
Solar Thermal 242
*Includes capital, fuel, operations, and maintenance
U. S. Energy InformationU. S. Energy Information Administration-2012
Hidden Flaw of Energy Efficiency Lowering the price of something means more will be
consumed Mexico’s cash for coolers program subsidized
swapout of inefficient refrigerators and air conditioners for more efficient ones.
Projected energy savings were 30%. Actual savings were only 7% because buyers chose
larger capacities and options like ice makers in the door and lowered temperature settings.
Some efficiency laws can be good but unintended Some efficiency laws can be good but unintended consequences need to be considered.
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 and updated regularly)
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.
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
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%
Energy Evaluation ResultsBased on energy evaluations on over 125 pulp andBased on energy evaluations on over 125 pulp and
paper machines in North America: Annual energy savings opportunities range from gy g pp g
$100,000 to $10 million on single machines. Typically 25% of savings opportunities identified can
be implemented with no capital costbe implemented with no capital cost. A recent evaluation in a top performing
containerboard mill with three paper machines found p pover $800,000 in annual energy savings with no capital required.S l ti h b f d d b DOE Some energy evaluations have been funded by DOE and others are paid for by paper companies.
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
Paper Machine Energy Scorecards
Give me your business card or send me an email and I will send the latestan email and I will send the latest scorecards to you.
Dick ReeseDick [email protected]
ll b h k hI will be happy to work with you on any questions or assistance you may need.
Top Areas for Energy Reduction
Reduce paper losses between reel and
Pulpers and Agitators
winder Water Systems
Refining Steam Boxes
Steam and Condensate Systems
Vacuum Systems Size Press and
Pressing Pumps
S e ess a dCoaters
Slowed Back Heat Recovery Production Rates
Reduce Paper Losses Between Reel and Winder
Grade Yield-%
Causes Potential Yield-%
Net TPD
Potential Profit/yr @$200/t
Recycled Medium 89.5 Winder Issues 97 525 $2.9 Million
Recycled Liner 91.8 Reel, Turn-ups 97 1120 $4.4 Million
Kraft Paper 89.9 Tests 95 195 $0.8 Million
Liner (some White Top)
87.2 Grade Changes
95 929 $6.0 Million
Specialty 85.7 Grade Ch
90 100 $0.3 MilliChanges Million
Water Energy Saving Opportunities Use warm water from pulp mill Increase use of clarified whitewater Reuse vacuum pump seal water or install blowers Minimize mill water make-up to stock and whitewater
systems Maximize entering stock temperatures Maximize entering stock temperatures Use single nozzle traversing showers and smaller
diameter nozzles Keep cool water out of warm and hot water systems Recover heat from paper mill effluent or hood
e ha stexhaust Modern saveall in good operating condition
Dryer Ventilation Systems Operate air systems in automatic temperature control Operate air systems in automatic temperature control
with recommended set points Pocket ventilation-180oF or lower-High enough to prevent
hood sweatinghood sweating Dryer section blow boxes- 160oF Building ventilation units- 75oF Roof supply units- 120oF
Industry best practice includes high-performance dryer hoods and heat recovery from hood exhaust todryer hoods and heat recovery from hood exhaust to preheat PV, glycol systems for machine room ventilation, and water heating
Recover heat from condensate flash to heat air
Press Optimization Run advanced technology fabrics Run advanced technology fabrics Move towards nip dewatering Optimize nip conditions Optimum roll, shoe, and sleeve designs Effective doctoring of suction rolls and shoe press sleeves Minimize sheet rewet Optimize fabric conditioning-monitor water flows, vacuum
application, showering, shower water temperature, etc. Consider use of chemicals to improve water removal Consider use of chemicals to improve water removal Increase sheet filler content Conduct press optimization per TIP 0404-52
Refining Opportunities Run low intensity plate designs, especially on
hardwood Check refiner mechanical condition regularly Refine each pulp type separately
Shut down tickler refiners when possible Shut down tickler refiners when possible Operate in design hydraulic flow ranges Upgrade disk refiners with splined rotors Upgrade disk refiners with splined rotors Consider modern energy-efficient designs when
replacing refiners Minimize stock flow through deflakers
Vacuum System Opportunities Based on a Metso evaluation, over 50% of paper machines have Based on a Metso evaluation, over 50% of paper machines have
poor vacuum system operating efficiency. Conduct regular performance tests-rebuild/replace inefficient
pumps. Do not rebuild obsolete inefficient designs.pumps. Do not rebuild obsolete inefficient designs. Manage seal water temperature to maintain 40oF below
whitewater temperature. Consider cool seal water injection. Check vacuum pipe sizing Check vacuum pipe sizing. Monitor pump motor loads. Graduate flatbox vacuums.
h ff/l fl b d hl b Shut off/lower unnecessary flatboxes and uhle boxes. Vacuum system power consumption can typically be reduced by
10 to 15% by optimizing existing equipment. Consider blowers if electricity cost is high or water use is a
problem
Size Press and Coater Opportunities
Increase entering sheet moisture content >3% on fine paper and bleached board 10 to 15% on recycled liner
Increase starch and coating solids and reduce pick-up
Maximize cylinder drying Measure gas/electricity flows to IR dryers and
floatation dryers. Optimize burners. Replace puddle size presses with metering
size presses
Pump Optimization Average pumping efficiency is below 40% Over 10% of pumps Average pumping efficiency is below 40%. Over 10% of pumps
run below 10% efficiency. Major factors affecting pump efficiency are throttled valves and pump over-
sizing.g Seal leakage causes highest downtime and cost. Check for multiple parallel pumps when number of operating pumps is
seldom changed.Check batch or cyclical start/stop system with frequent pump cycling Check batch or cyclical start/stop system with frequent pump cycling.
Look for significant cavitation noise.
Consider variable-speed drives.E i f 20% ibl ith t Energy savings of 20% or more are possible with system optimization.
More than 50% of pump lifecycle costs result from energy and maintenance e pense Less than 15% a e initial p chase costsmaintenance expense. Less than 15% are initial purchase costs.
Candidates for Variable Frequency Drives
C h it Couch pit pump Dry end pulpers y p p Broke HD
C i t dil ti Consistency dilution pump Other pumps where flows change a p p g
lot or cavitation problems are experiencedexperienced
Motor Efficiency Evaluate motors on life cycle cost rather than initial price Evaluate motors on life-cycle cost rather than initial price.
Energy usage accounts for more than 95% of its lifetime cost. Proper size is important.
Specify NEMA Premium efficient motors for continuous duty Specify NEMA Premium efficient motors for continuous duty applications
Consider upgrading to permanent-magnet (PM) rotor motors for even greater efficiencyeven greater efficiency
System-efficiency upgrades (such as adjustable-speed drives) are possible to maximize potential gainsC id d hi h ffi i V b lt Consider grooved high-efficiency V-belts
Use fan-system analysis tools from DOE Specify three-phase motors if possible
Low Production Rate Energy Saving Opportunities
Lower whitewater temperature Lower whitewater temperature Maintain press loads to maximize sheet dryness Reduce steam flow/shut off steam boxes Reduce steam flow/shut off steam boxes Ensure there is no venting from dryer steam systems Utilize low pressure steam sources where possiblep p Reduce PV supply air temperatures or shut off if
profiles and hood conditions allowSh t d i t fi Shut down unnecessary equipment-refiners, pumps, agitators, vacuum pumps, exhaust fans, and in some cases cleaners
Additional Energy Saving Opportunities
Replace steam turbines Replace obsolete vacuum pumps Replace obsolete vacuum pumps Move trim squirts on narrow deckle
gradesgrades Make good use of flash steam Improve steam line insulation
Compressed Air System Quick Hits Check the filters-Pressure drop across a filter rises rapidly as it Check the filters-Pressure drop across a filter rises rapidly as it
reaches the end of its service life. Manage leaks-The average facility has 30 to 35% leakage if it has not
taken recent action to identify and repair leaks.y p Fix the filter/regulator/lubricators (FRLs)-Be sure:
Filter bowls are not cracked or leaking Manual drains are closed Gauges are readable and in good working order Regulators are set to correct end use specification
Undo unauthorized modifications-Cooling personnel or equipment or g p q pcleaning floors can be expensive and reduce pressure and flow.
Check drains at air/lubrication separators, air receiver, air dryer, coalescing filters, and distribution low points.
Make sure controls are working properly.
Paper Machine Energy Quick HitsPM Action
C Conduct trial shutting off dryer 51 (700 lb steam/hr)
B C Conduct trials with lower PV supply air temperaturesB,C Conduct trials with lower PV supply air temperatures
D Identify additional equipment to shutdown
B,C Conduct trials with higher moisture content into first coater
C Determine cause of condensate return contamination
C Repair third section steam and condensate differential pressure (swinging)
A Conduct evaluation to reduce reel to winder losses
C Repair third section thermocompressor insulation
350
Electrical Consumption: kWh/ton ‐ PM4 versus 5
300
200
250
150
PM4
PM5
100
0
50
Drives Vac. Pumps MCC Gen. S/C
Paper Machine Energy Quick Hits (cont)
PM Action
A Check press exit consistency regularly
C Recalibrate 40 lb steam to dryers and hot well flow metersC Recalibrate 40 lb steam to dryers and hot well flow meters
A,B,C Recalibrate common whitewater chest drain line flow meter
B Cond ct t ials sh tting off one co ch pit agitato henB Conduct trials shutting off one couch pit agitator when sheet is on reel
B Repair 410 lb steam leak at No. 1 air cap
C R i t l k t il t t kC Repair steam leak to oil storage tank
C Repair steam leak on breast roll shower heat exchanger
A,B,C Enermin system adherence at reel pulpers
Longer Term Energy Projects PM Action
A,B,C Develop water balances-determine requirements to reduce water useeduce ate use
A Determine requirements to improve screening and reduce fiber losses
B,C Kaizen/KT implementation to reduce high fiber lossesB,C Kaizen/KT implementation to reduce high fiber losses
C Check steam box-conduct trials
B Determine requirements to recover condensate on supercalenderssupercalenders
B Investigate inside air source for wet end motor cooling fan
A Improve steam and condensate maintenanceA Improve steam and condensate maintenance
Investigate upgrading Kraft pulper rotor and extractionplate
Longer Term Energy Projects (cont)
PM Action
A Consider changing couch transfer geometry to reduce stretch marksst etc a s
C,D Determine causes of high water use when shutdown
C Troubleshoot high motor load on Somarakis vacuum pump
A B C Change ac m condense feed ate f om lake ate toA,B,C Change vacuum condenser feed water from lake water to warm water
A,B,C Develop check list for correcting contaminated condensate
A B C Pit h t dj t t li t t b dA,B,C Pitch management-adjust centerline targets based on amount of pitch seasonally
A,B,C Inspect/repair steam traps regularly
B,C Improve cooling water measurement and management on vacuum condensers
Longer Term Energy Projects (cont)
PM Action
B,C Reuse coater air cap exhaust to heat PV supply air
B C Evaluate/optimize after coater dryingB,C Evaluate/optimize after coater drying
A,B,C Investigate additive dilution to reduce water use
A,B,C Determine requirements to increase pump seal water t ttemperature
A,B,C Investigate pressurizing condensate return systems
B Investigate splitting first section dryers into separatesteam groups
A,B,C Use whitewater to fill empty machine chests
A,B,C Identify candidates for variable frequency drives and develop projects
New Paper Machine Energy-Steam Considerations Install forgiving press section with excellent dewatering Install forgiving press section with excellent dewatering Install a modern press section steam box Install modern steam and condensate system with stationary
syphons and a dryer management systemsyphons and a dryer management system Minimize condensing steam outside the dryers Maximize condensate return flow and pressure to power house
ll h h h d l d h d Install a high humidity closed hood Operate with PV temperature as low as possible Design for good moisture profiles so reel moisture can be
maximized Install tight water system to minimize water heating If a size press is required, install metering type and run starchIf a size press is required, install metering type and run starch
solids as high as possible Recover heat from dryers
New Paper Machine Energy-Electricity Considerations
Install modern energy efficient refiners and controls Install modern energy-efficient refiners and controls Install energy-efficient vacuum pumps (blowers if
electricity cost is high)y g ) Properly size pumps Install variable-frequency drives Install energy-efficient agitators in chests and pulpers Install vertical agitators in chests
If d fl k i d t k fi t t If deflakers are required, screen stock first to minimize deflaker size and energy use
New Paper Machine Energy-Other Considerations
I ll d i i f l i i d Install good monitoring of steam, electricity, and water and display for operators. Include alarms when energy consumption is high.gy p g
Minimize thick stock system size with good agitation Install compact wet end system Install additive injection system Install adequate water system surge capacity
If t d i i i d i t ll If coater drying is required, install new energy efficient equipment with heat recovery
If trim will vary, design for excess trim removal at If trim will vary, design for excess trim removal at wet end