Case Study: Energy Reduction in Mechanical Pulping
Overview
The Advanced Fibre Processing Lab is collaborating with fourteen pulp and paper industry partners and NSERC CRD to develop a 5-year, $4 million program to reduce total pulp and paper energy consumption by at least 20%.
High energy costs and strong competition have forced many pulp mills to shut down over the past several years. The main problem is that the mechanical pulping process consumes so much electricity; indeed, the BC pulp and paper industry consumes 11% of the province’s electricity.
Funding
This project is funded by NSERC, BC Hydro, Catalyst papers, Howe Sound Pulp and Paper, Canfor, West Fraser, Paprican, Andritz, Advanced Fibre Technology, WestCan, CEATI / OPA and Honeywell.
Solution
The consortium has developed a range of realistic projects that embody major problems. The program supports a shared vision that future mechanical pulp mills will have:
- Lower energy consumption
- Low consistency (LC) refining
- Reduced high consistency mainline refining
The research projects include:
- Novel mechanical pulping
- Ultra-low intensity LC refining
- Chemical and biological pre-treatments
- Reducing LC refining no-load power
- Improving latency removal
- Increasing pumping efficiency
- System integration and control
Finding innovative solutions to industrial needs is of paramount importance. The university has therefore consulted world experts and members of each company, and included them in the project’s steering committee.
Results
To date, the research has allowed for a reduction in screen rotor energy consumption by 52% compared to current state-of-the-art machinery. The research is still in progress and the consortium expects to achieve even better results by the project’s completion.
The Lab: Advanced Fibre Processing Laboratory
The Advanced Fibre Processing Laboratory offers expertise on the application of fluid mechanics and physics to the pulp and paper industry. The lab has a history of successful cooperation with major pulp and paper companies. Its innovations have been commercialized and are sold and used in mills worldwide.
The laboratory aims to support partners’ competitiveness through:
- Improving mechanical and process efficiency
- Supporting diversification towards a bio-product based industry
The lab’s work is recognized worldwide. Graduate students trained through industry funding often go on to work with the funding partner after graduation. The quality of their training is recognized throughout the industry.