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Energy Efficiency OpportunitiesIn the U.S. Pulp and Paper Industry

Klaas Jan Kramer, Eric Masanet, and Ernst WorrellLawrence Berkeley National Laboratory

ABSTRACT

The U.S. pulp and paper industry consumes over $7 billionworth of purchased fuels and electricity per year. Energy efficiencyimprovementisanimportantwaytoreducethesecostsandtoincreasepredictableearnings,especiallyintimesofhighenergypricevolatility.There are a variety of opportunities available at individual plants in the industrytoreduceenergyconsumptioninacost-effectivemanner.ThisarticleprovidesabriefoverviewoftheU.S.EPAENERGYSTAR® for Industry energy efficiency guidebook (a.k.a. the “Energy Guide”)forpulpandpapermanufacturers.TheEnergyGuidediscussesawiderange of energy efficiency practices and energy efficient technologiesthatcanbeimplementedatthecomponent,process,facility,andorga-nizationallevels.Alsoprovidedisadiscussionofthetrends,structure,and energy consumption characteristics of the U.S. pulp and paperindustry, along with a description of the major process technologiesusedwithintheindustry.Manyenergyefficiencymeasuredescriptionsincludeexpectedsavingsinenergyandenergy-relatedcosts,basedoncase studydata from real-world applications inpulp andpapermillsand related industries worldwide. The information in this EnergyGuide is intended to help energy and plant managers in the U.S. pulp andpaperindustryreduceenergyconsumptioninacost-effectiveman-nerwhilemaintaining the quality of productsmanufactured. Furtherresearch on the economics of allmeasures—aswell as on their appli-cabilitytodifferentproductionpractices—isneededtoassesstheircosteffectiveness at individualplants.

22 Energy Engineering Vol. 107, No. 1 2010

THE ENERGY STAR® FOR INDUSTRYPROGRAM

ENERGY STAR is a voluntary government program that offers businesses and consumers a broad range of resources on the best inenergyefficiencytohelpsavemoneyandprotect theenvironment.TheENERGYSTARforIndustryProgramworksdirectlywithU.S.manufac-turers tohelp themimprovecompetitiveness through improvedenergymanagement, increased energy efficiency, and reduced environmentalimpact. To date, the ENERGY STAR for Industry program has established 10differentindustrialfocusesinpartnershipwithspecificenergy-inten-siveindustries intheUnitedStates.Currentandpast industrial focusesincludemotorvehiclemanufacturing,cornrefining,cementmanufactur-ing,breweries,petroleumrefining,glassmanufacturing,pharmaceuticalmanufacturing,foodprocessing,petrochemicalmanufacturing,andpulpandpapermanufacturing.Manyofthecompaniesparticipatingintheseindustrialfocuseshavereportedsignificantcostandenergysavingsandhavegoneon to receive recognitionas leaders inenergyefficiencyandenvironmentalperformance. As part of each industrial focus, participating companies haveaccess to energy professionals who offer assistance to plant energymanagersandshareproven,non-proprietaryapproaches for improvingcorporateenergymanagement.Anannualindustrialfocusforumisalsoheld,where companies canopenlydiscussnon-confidential issues con-fronting their energy management programs. Last, for many industries an energy use benchmarking tool—the Energy Performance Indicator(EPI)—isalsodeveloped.Formore informationon theprogram,pleasevisitwww.energystar.gov/industry. ENERGYSTARalsoofferseach industrial focusadetailedEnergyGuide,which discusses awide variety of energy efficiency opportuni-ties applicable to plantswithin the focus industry. The EnergyGuidesareresearchedandauthoredbyLawrenceBerkeleyNationalLaboratory(LBNL) in partnership with ENERGY STAR and participating focuscompanies.TheEnergyGuidesareusedbyenergymanagerstoidentifyareas for energy efficiency improvements, to evaluate potential energyimprovementoptions, todevelopactionplans and checklists forplant-level energymanagement, and to educate company employees on theimportanceof andactions for improvedenergyefficiency. The EnergyGuide for theU.S. pulp and paper industry contains

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detailed information on over 125 energy efficient technologies and en-ergymanagementpracticesapplicabletothetypicalpulpandpapermillin the followingcategories:

• Energy management programs and systems• Steam systems• Motor systems• Pumps• Fan systems• Compressed air systems• Rawmaterialpreparation• Chemicalpulping,bleaching, andchemical recovery• Mechanicalpulping• Papermaking• Emergingenergyefficient technologies

Given the importance of water as a resource in pulp and papermaking, theEnergyGuidealso containsa chapteronprovenmeasuresfor plant-level water efficiency. This article provides a brief summaryand an advance preview of information contained in the forthcomingEnergyGuide [1].

THEU.S.PULPANDPAPER INDUSTRY

The U.S. pulp and paper industry—defined in the Energy Guideasfacilitiesengagedinthemanufactureofpulp,paper, and paperboard (i.e., NAICS 3221)—is an important industry from both an economicand an energy-use perspective. In 2006, the industry generated nearly$79billioninproductshipmentsanddirectlyemployedaround139,000people in nearly 600mills. The industry spent roughly $7.5 billion onpurchased fuels and electricity in 2006; around $4.7 billion of thiswasfor purchased fuels, and around $2.8 billion of thiswas for purchasedelectricity[2,3].BecausethecostsofelectricityandnaturalgasarerisingrapidlyintheUnitedStates,energyefficiencyimprovementsarebecom-ing an increasingly important focus area in the industry formanagingcosts andmaintaining competitiveness. Pulpmills are located in regions of theUnited Stateswhere treesareharvestedfromabundantforestsortreefarms.Morethan70percent


ofU.S.wood pulp capacity is located in the SouthAtlantic and SouthCentral regions, close to the source ofwoodfibers [4].Other keypulpmill locations include the Northwest, Northeast, and North Centralregions [5]. Pulpmills that process recycled fiber are generally locatednear largepopulation centers,whicharekey sourcesofwastepaper. Paper and paperboardmills are more widely distributed, but ingeneral they are locatednear pulping operations and/or close to largepopulation centerswhere final consumers are located.Over 50 percentof paper andpaperboardmills are located in theNortheast andNorthCentral regions [4]. Wisconsin,Alabama, Pennsylvania, Georgia, and South Carolinaarethetopfiveproducersofpulpandpaperproducts,basedonindustryvalueofshipmentsin2006.Wisconsinranksfirstbyasignificantmargin,accounting for10percentof industryvalueof shipments,11percentofindustryemployment, and10percentof industryestablishments [2, 3]. Pulp and paper are commodities, and therefore their prices arevulnerabletoglobalcompetition.Inordertomaintainmarketshareinanincreasinglycompetitiveglobalmarket,U.S.pulpandpapercompanieshave undergone a significant number of acquisitions and mergers inrecentyears.Forexample,between1997and2002at least12 importantmergers occurred,with a combined value of around $55 billion [5]. Inallpulpandpaper industry sub-sectors, the four largest companiesac-count forat leasthalfof industryvalueof shipments [6]. Virgin wood is used to manufacture a variety of pulps in theUnitedStates,mostimportantlychemicalwoodpulp,mechanicalwoodpulp, semi-chemicalwood pulp, and dissolvingwood pulp. TotalU.S.productionofwoodpulpincreasedfrom40milliontons(Mt)in1976to56Mt in 2006; however, currentU.S.wood pulp production is around15percent lower than its 1994peakof 66Mt [7]. In 1976, chemical pulping accounted for 78 percent ofU.S.woodpulpproduction,whilemechanicalandotherpulpingaccounted for10percentand12percent, respectively.While totalwoodpulpproductionhas increased significantly since 1976, the composition of U.S. woodpulpproductionhaschangedlittle.Chemicalwoodpulpproductionhasbecomemoredominantandcomprisednearly85percentofU.S.woodpulpproductionin2006,whilemechanicalpulpingnowrepresentsonlyaround8percentofproduction. Inaddition to thevarious typesofwoodpulp, recoveredpaper isused as a rawmaterial in producing paper products. Recovered paper

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use in theUnited States pulp and paper industry grew from 14Mt in1976 to nearly 47Mt in 2006,which represents a growth ofmore than200percent [7]. Figure 1 depicts the trends in the production of paper and paper-boardproducts in theUnitedStatesbetween1976and2006 [7].Printingandwriting paper,wrapping and packaging paper, and paperboard ac-counted for around80percentof totalU.S.productionbymass in 2006.The remaining production wasmade up of newsprint, household andsanitarypaper,andpaperandpaperboardnotelsewherespecified(NES),whichisacatch-allcategorythatincludesKraftpaper,constructionpaper,blottingpaper,filterpaper,andothermiscellaneouspaper types. TotalU.S.productionofallpaperproductsincreasedfrom52Mtin1976to84Mtin2006.However,U.S.productionhasfluctuatedbetween84Mtand88Mtsince1999.Themostsignificantgrowthinproductionsince 1976 occurred in the printing and writing paper and householdand sanitary paper categories,which both grew by around 80 percent.Newsprint production peaked at nearly 7 Mt in 2000, but has sincedecreasedby30percent (to4.7Mt in2006).

ENERGYUSE INTHEU.S.PULPANDPAPER INDUSTRY

Energy represents a significant cost to the U.S. pulp and paperindustry. In 2006, the industry spent roughly $7.5 billiononpurchasedfuels and electricity [2].Around $4.7 billion of thiswas for purchasedfuelsandaround$2.8billionwasforpurchasedelectricity.Energycostsareasizeablefractionofoperatingcosts,equaltoroughly20percentofthe industry’s total costofmaterials. The industry is also among the largest energy-consuming indus-tries in the United States.As of 2006, the industry (NAICS 3221) ac-countedforover8percentofthepurchasedfuelsandover9percentofthe electricity consumption of the entireU.S.manufacturing sector [2].Moreover,purchasedfuelsrepresentlessthanhalfofthefuelsconsumedby U.S. pulp and paper mills, since much on-site energy is generatedusingwastewoodandbark(i.e.,hogfuel)andspentcookingchemicals(i.e., black liquor) [5, 9]. Electricity is used throughout the typical pulp and papermill topowermotorsandmachinedrives,conveyors,andpumps,aswellasforbuildingoperationssuchaslightingandventilationsystems.Thelargest


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use of fuels is in boilers to generate steam for use in pulping, evapora-tion, papermaking, and other operations. Black liquor is the dominantfuel for boilers in the pulp and paper industry, followed by hog fuel,natural gas, and (to a lesser extent) coal [10]. Natural gas and oil aretypicallyused in limekilns [9]. The major processes employed in the manufacture of pulp andpaper products include rawmaterials preparation, pulping (chemical,semi-chemical,mechanical,andwastepaper),bleaching,chemicalrecov-ery,pulpdrying, andpapermaking.Figure2providesaflowdiagramof theseprocessesand theiruseof fuels, steam,andelectricity [11].

Figure 2. Schematic of major pulp and paper manufacturing processesSource: [11]


Figure3plotsthecostsofpurchasedelectricityandfuelsintheU.S.pulpandpaper industryovertheperiod1997to2006[2,12,13].Whilethe total cost of purchased electricity remained fairly steady over thisperiod,thetotalcostofpurchasedfuelsincreasedbyaround50percent(innominaldollars).Naturalgasaccountsforroughlytwo-thirdsofthefuelpurchasedby the industry,with coal and fueloil comprisingmostoftheremainingfuelpurchases[9].Thesteepriseinpurchasedfuelcostmay therefore be explained in part by the similarly steep rise in U.S. industrial natural gas prices that occurred over the sameperiod ($3.59per1000 ft3 in1997versus$7.86per1000ft3 in2006) [14]. Theindustryisthesinglelargestself-generatorofelectricityintheU.S. manufacturing sector. Thus, the electricity purchases illustratedin Figure 3 represent only a portion of the industry’s electricity use.In 2002, the industry generated over 50 billion kWh of electricity onsite,which accounted for around40percentof total industrial on-siteelectricitygeneration in theUnitedStates [15]. Table 1 summarizes estimates of the total energy use of the U.S. pulpandpaper industryasof2002,whichis thelatestyearforwhichdetailed industry fuel use data are available from the U.S. Department of Energy [15]. In 2002, the industry consumed over 2,200 trillionBritish thermalunits (tBtu) of energy,which accounted for around 14percentofallthefuelconsumedbytheU.S.manufacturingsector.Thedata in Table 1 are ranked in order of fuel type-use importance fromleft to right. It can be seen that the use of two by-products of the pulp andpaper production process—black liquor and hog fuel (i.e., wood andbark)—meet over 50 percent of the industry’s annual energy require-ments.Thisself-generationsignificantlyreduces the industry’sdepen-dence on fossil fuel inputs and purchased electricity, with the addedbenefitsof reduced rawmaterial costs (i.e., avoidedpulping chemicalpurchases) and reducedwaste generation.Natural gas and coal com-prise themajority of the remaining fuelusedby the industry. Black liquor, hog fuel, coal, and residual oils areused exclusivelyas boiler fuels to generate power and to produce steam for use in thevarious pulping and papermaking processes [16]. Black liquor is com-busted in a recovery boiler,which is designed for the dual purpose ofgenerating steam and recovering inorganic smelt for regeneration intowhite liquor. Because of the lowheat contents of black liquor andhogfuel, the efficiencies of boilers that combust these fuels are around 65

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ENERGY MANAGEMENTHANDBOOK, Seventh Edition Steve Doty and Wayne C. TurnerNewly revised and edited, this seventh edition includes extensive revisions to seven of its twenty-eight chapters, including those covering waste heat recovery, HVAC systems, energy management and control systems, energy systems maintenance, alternative energy, indoor air quality, and codes, standards and legislation. This comprehensive handbook has become recognized as the definitive stand-alone energy manager’s desk reference, used by thousands of energy management professionals throughout the industry. You’ll find coverage of every component of effective energy management, including energy auditing, economic analysis, boilers, steam systems, cogeneration, waste heat recovery, building envelope, HVAC systems, motors and drives / electric energy management, energy management control systems, lighting, energy systems maintenance, insulation systems, alternative energy, sustainability and high performance green buildings, ground-source heat pumps, indoor air quality, utility rates, thermal energy storage, codes and standards, energy legislation, natural gas purchasing, electric deregulation, financing and performance contracting, commissioning, and measurement and verification. Detailed illustrations, tables, graphs and many other helpful working aids are provided throughout.

ISBN: 0-88173-609-0

8 21 x 11, 847 pages, Illus.,

Hardcover $245

1 – Introduction 2 – Effective Energy Management 3 – Energy Auditing 4 – Economic Analysis 5 – Boilers and Fired Systems 6 – Steam and Condensate Systems 7 – Cogeneration 8 – Waste-Heat Recovery 9 – Building Envelope 10 – HVAC Systems 11 – Motors, Drives & Electric Energy Management 12 – Energy Management Control Systems 13 – Lighting 14 – Energy Systems Maintenance 15 – Industrial Insulation 16 – Use of Alternative Energy

17 – Indoor Air Quality 18 – Electric & Gas Utility Rates for Commercial &

Industrial Consumers 19 – Thermal Energy Storage 20 – Codes, Standards and Legislation 21 – Natural Gas Purchasing 22 – Control Systems 23 – Sustainability & High Performance Green

Buildings 24 – Electric Deregulation 25 – Financing and Performance Contracting 26 – Commissioning 27 – Measurement & Verification of Energy Savings 28 – Ground-Source Heat Pumps Applied to

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THE SMART GRID: Enabling Energy Efficiency and Demand Response Clark GellingsThe power system has often been cited as the greatest and most complex machine ever built, yet it is predominantly a mechanical system. How-ever, technologies and intelligent systems are now available which can significantly enhance the overall functionality of power distribution, and make it ready to meet the needs the 21st century. This book explains in detail how sensors, communications technologies, computational ability, control, and feedback mechanisms can be effectively combined to create this new, continually adjusting “smart grid” system. You’ll gain an un-derstanding of both IntelliGridSM architecture and EnergyPortSM, as well as how the integration of intelligent systems can be effectively utilized to-ward achieving the goals of reliability, cost containment, energy efficiency in power production and delivery, and end-use energy efficiency.

6 x 9, 301 pp., Illus.Hardcover, $125

1 – What is the Smart Grid? 2 – Electric Energy Efficiency in Power Production & Delivery 3 – Electric End-Use Energy Efficiency 4 – Using a Smart Grid to Evolve the Perfect Power System 5 – DC Distribution & the Smart Grid 6 – The IntelliGridSM Architecture for the Smart Grid 7 – The Smart Grid – Enabling Demand Response: The Dynamic Energy Systems Concept 8 – The EnergyPortSM as Part of the Smart Grid 9 – Policies & Programs to Encourage End-Use Energy Efficiency 10 – Market Implementation 11 – Efficient Electric End-Use Technology Alternatives 12 – Demand-Side Planning 13 – Demand-Side EvaluationAppendix, Index

ISBN: 0-88173-623-6

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percent[9].Naturalgasisalsousedasaboilerfuel,butitisalsousedinsignificantquantitiesfordirect-processheatinginlimekilnsandlimiteddryingapplications (e.g., coatingand tissuedrying) [16]. In the manufacture of pulp, evaporation, cooking (including di-gestionthroughwashingforchemicalpulps),andchemicalpreparationare the most energy-intensive processes. Steam is used in significantquantitiesfornearlyeveryprocessbutmostnotablyintheevaporation,cooking,andbleachingprocessesforprocessheat.Thesoleuseofdirectfuel is in the chemicalspreparationprocess (in the limekiln) [16]. Drying is by far the most energy-intensive step associated withpaper machine operations, accounting for roughly two-thirds of totalpapermaking energy use. U.S. papermaking requires in total around 6-9 million Btu per ton in integrated mills, depending on the paper grade [16].

ENERGYEFFICIENCY IMPROVEMENTOPPORTUNITIES

ManyopportunitiesexistwithintheU.S.pulpandpaper industrytoreduceenergyconsumptionwhilemaintainingorenhancingproduc-tivity. Ideally, energy efficiency opportunities should be pursued in acoordinated fashion at multiple levels within a facility.At the compo-nent and equipment level, energy efficiency can be improved throughregular preventative maintenance, proper loading and operation, andreplacementofoldercomponentsandequipmentwithhigherefficiencymodels (e.g., high efficiencymotors)whenever feasible.At the processlevel, process control and optimization can be pursued to ensure thatproductionoperationsarerunningatmaximumefficiency.Atthefacilitylevel, the efficiency of space lighting and ventilation can be improvedand total facility energy inputsminimized throughprocess integration,wherefeasible.Last,attheleveloftheorganization,energymanagementsystems can be implemented to ensure that a strong corporate frame-workexistsforenergymonitoring,targetsetting,employeeinvolvement,andcontinuous improvement. The Energy Guide for pulp and paper manufacturers discussessome of themost significant energy efficiencymeasures at the compo-nent, process, facility, and organization levels. The focus of theEnergyGuide is on energy efficiencymeasures that are proven, cost effective,and available for implementation today. Whenever possible, measure


descriptions include case studies of pulp and paper mills that havesuccessfully implemented the measure, both in the United States andabroad. Many case studies include specific energy and cost savingsdata,aswellastypicalinvestmentpaybackperiods.Formeasureswheredata are not available for pulp and paper mills, the Energy Guide also presents case study data from other similar industries. Last, for mostmeasures, references to the technical literatureandonline resourcesareprovided,which canbe consulted for further information. TheEnergyGuidealsopresentsabriefoverviewofselectedemerg-ing energy efficient technologies that have recently been developed orcommercialized and hold promise for reducing energy use in the U.S.pulp and paper industry in the near future. Atindividualpulpandpapermills,theactualpaybackperiodandsavingsassociatedwithagivenmeasurewill vary,dependingon facil-ityactivities, configuration, size, location, andoperatingcharacteristics.Thus, the values presented in the Energy Guide are offered as guidelines. Further researchon the economicsof allmeasures—aswell onas theirapplicabilitytodifferentproductionpractices—isneededtoassesstheircost effectivenessat individualplants. TheEnergyGuide classifies energy efficiencymeasures into threeprimary categories:

• Cross-cutting measures, which are measures applicable to cross-cuttingsystems (e.g.,motorsandpumps) thatarecommonacrossindustries.

• Process-specific measures, which are measures applicable to pro-cesses specific to thepulpandpaper industry (e.g.,pulping).

• Emergingtechnologies,whichareenergyefficienttechnologiesthathold significantpromise for commercializationand/or substantialmarket penetration in the next several years.

Table2providesasummaryofsomeofthekeycross-cuttingmea-sures that arepresented in theEnergyGuide [1]. The following sections highlight a few of the key efficiencymea-suresdiscussedin theEnergyGuide,withcasestudies fromreal-worldapplicationsof eachmeasure.

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Table 2. Summary of cross-cutting energy efficiency measures


EXAMPLESOFCROSS-CUTTINGEFFICIENCYMEASURES

Steam Systems Steam systems are by far the most significant end use of energyintheU.S.pulpandpaperindustry.Over80percentoftheenergycon-sumedbytheindustryisintheformofboilerfuel[16].Energyefficiencyimprovementstosteamsystemsthereforerepresentthemostsignificantopportunities forenergysavings inpulpandpapermills.According toa recent studyby theU.S.DOE, the industry could reduce its fuel useby12.5percent(andsave278tBtu)byimplementingbestpracticesteamsystem improvementopportunities [17]. Several examples of steam system measures presented in the En-ergyGuideareprovidedbelow.

Boiler Process Control Flue gas monitors maintain optimum flame temperature and monitor carbon monoxide (CO), oxygen, and smoke. The oxygencontent of the exhaust gas is a combination of excess air (which isdeliberatelyintroducedtoimprovesafetyorreduceemissions)andairinfiltration. By combining an oxygen monitor with an intake airflowmonitor, it ispossibletodetectevensmall leaks.Asmall1percentairinfiltrationwill result in 20 percent higher oxygen readings.AhigherCO or smoke content in the exhaust gas is a sign that there is insuf-ficient air to complete fuel burning. Using a combination of CO andoxygen readings, it is possible to optimize the fuel/air mixture for highflametemperature(thusthebestenergyefficiency)andlowerairpollutant emissions. Typically,thismeasureisfinanciallyattractiveonlyforlargeboil-ers, because smaller boilers oftenwill notmake up the initial capitalcost as easily. Several case studies indicate that the average paybackperiod for thismeasure is around1.7 years [18]. At theAppletonPapermill inWestCarrolton,Ohio, threeboilers(two fired by coal, one by natural gas) produce 250,000 pounds perhourofsteamforseveralheatinganddryingprocesses.Anenergyauditof themill found that themill’s boiler control system did not providecontinuous monitoring or control of combustion air. The audit teamrecommendedthatthemillinstallacontrolsystemtomeasure,monitor,and control oxygen and carbonmonoxide levels on its coal-fired boil-ers,giventhattheseboilersoperatednearfullcapacityandwouldreap

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the greatest benefits of improved control. Thismeasurewas estimatedtosavenearly$475,000inannualenergycosts;ataninvestmentcostof$200,000, thepaybackperiodwas less than sixmonths [19].

Reduction of Excess Air Boilersmustbefiredwithexcessairtoensurecompletecombustionandtoreducethepresenceofcarbonmonoxideintheunburnedfuelinexhaust gases.When toomuch excess air is used to burn fuel, energyiswasted,becauseexcessiveheat is transferredtotheairratherthantothe steam.Air slightly in excess of the ideal stoichiometric fuel-to-airratio is required for safety and to reduce emissions of nitrogen oxides(NOx),butapproximately15percentexcessair(around3percentexcessoxygen) is generally adequate [20, 21]. Most industrial boilers alreadyoperateat15percentexcessairorlower,andthusthismeasuremaynotbewidelyapplicable[22].However,ifaboilerisusingtoomuchexcessair, numerous industrial case studies indicate that the payback periodfor thismeasure is less thanoneyear [18]. Examples of improvements to reduce excess air include changingautomatic oxygen control setpoints, periodic tuning of single setpointcontrolmechanisms, installing automatic flue gasmonitoring and con-trol,fixingbrokenbaffles,andrepairingairleaksintotheboiler.TheU.S.DOEestimatesthatU.S.pulpandpaperplantscouldreduceboilerfueluseby around2.3percent throughapplicationof thismeasure. (Itwasassumedthatthismeasurewouldbefeasibleataroundone-thirdoftheplants).[17]Theestimatedaveragepaybackperiodforthismeasurewasfivemonths. As part of the U.S DOE’s Save Energy Now Program, an auditwasconductedattheBoiseCascademillinJackson,Alabama.Thiskraftpulpmillproducesaround1,000tonsofpaperperdayanduses(amongotherboilers)acombinationfuelboilerthattypicallyburnsgreenwoodand bark. Combustion tuning of this boiler reduced flue gas oxygenconcentrationsfromthe8-12percentrangetothe6-7percentrange.Theamount of savings in green wood was reported to be around $70,000peryear [23]. SimilarbenefitswerepredictedattheWestLinnPaperCompany’scoated papermill inWest Linn,Oregon.AU.S.DOE audit found thatby adjusting boiler oxygen trim controls to lower the oxygen levels to2.5-3percent,boilerefficiencyimprovementswouldsave15,500MMBtuperyear, at a cost savingsof around$118,000 [24].


Blowdown Steam Recovery Boilerblowdownisimportantformaintainingpropersteamsystemwaterproperties.However, blowdowncan result in significant thermallossesifthesteamisnotrecoveredforbeneficialuse.Blowdownsteamistypicallylowgrade,but itcanbeusedforspaceheatingandfeedwaterpreheating. In addition to energy savings, blowdown steam recoverymayreducethepotentialforcorrosiondamageinsteamsystempiping.Examplesofblowdownsteamrecovery in thepulpandpaper industrysuggest a payback period of around 12 to 18months for thismeasure[25]. TheU.S. DOE estimates that the installation of continuous blow-downheatrecoverysystemsisfeasibleataround20percentofU.S.pulpandpapermillsandwouldreduceboilerfuelusebyaround1.2percent[17]. Forexample, aboilerblowdownheat recoveryprojectatAugustaNewsprintCompany’sAugusta,Georgia,mill led to significant energyand cost savings.An existing boiler blowdown system was modifiedby installing a plate-and-tube heat exchanger and associated piping torecover energy from themill’s continuous blowdown stream from theboilerblowdownflash tank.Theproject resulted inannualenergysav-ings of 14,000MMBtu, with annual fuel cost savings of over $30,000.Theperiodofpayback for thisprojectwasabout sixmonths [26]. Similarly impressive savingswere identified by Boise Cascade attwo different mills.At the company’s mill in International Falls, Min-nesota,aplant-wideassessmentestimatedthatthepursuitofblowdownheat recovery (asopposed to thecurrentpracticeofventingblowdownto atmosphere) could save the mill around $370,000 per year [27].Atthe company’s mill in Jackson,Alabama, it was estimated that a sig-nificant amount of additional thermal energy could be recovered fromthe liquid blowdown rejected from the flash vessel. If a second stageofblow-downenergyrecoverywere installedon the remainingboilers,additionalblowdownrecoverenergysavingsof$100,000peryearwereprojected [23].

Steam Distribution Controls Steam demand can be interrupted due to changing operatingproceduresat steamusingprocesses (e.g.,papermachineor turbines)orduetooperational failures (e.g.,asheetbreakage).Thiscan leadtothedumpingofexcesssteamoradditionalfueluseforback-upboilers.

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Moderncontrolsystemshavebeendeployedtobettermanageasteamsystem, reducing the need for back-up steam capacity or the need todump steam. Forexample,AylesfordNewsprint,Ltd., in theUnitedKingdom,implementedasecond-generationcontrolsystemfor itssteamsystem,which consisted of three paper machines, two natural gas-fired gasturbine-based combined heat and power (CHP) units, one steam tur-bine,andasteamaccumulator.Thesystemisamodel-basedpredictivecontrol system tomanage steam loads better. The system resulted ina95percentreductionofsteamventinganda70percentreduction infuel use for back-up steam generation,with a payback period of lessthan 6months [28].

Motor Systems Motor-driven systemsareby far themost significant consumerofelectricalenergyinatypicalU.S.pulpandpapermill.Asof2002,motor-drivensystemsaccountedforaround90percentofalltheelectricityusedbytheindustry[15].Furthermore,pumps,fans,andmaterials-processingequipment account for the majority (over 70 percent) of motor-drivensystems electricity use in the typical U.S. mill [29]. Other importantuses of electricity in pulp and papermanufacturing includematerials-handling systems (e.g., conveyors) andcompressedair systems. Efficiency improvements to motor-driven systems can thereforelead to significant energy savings inmost pulp and papermills. TheU.S.DOEestimates (asof 2002) that efficiency improvements tobasiccomponents of motor-driven systems in the industry could lead toelectricity savingsof 14percent [29].

Adjustable-speed Drives (ASDs) Adjustable-speeddrivesbettermatchspeedtoloadrequirementsfor motor operations and therefore ensure that motor energy use is optimized to a given application.Adjustable-speed drive systems areofferedbymanysuppliersandareavailableworldwide.Worrelletal.[30]provideanoverviewofsavingsachievedwithASDsinawidear-rayofapplications;typicalenergysavingsareshowntovarybetween7and60percent. Industrialcasestudies fromthe IACdatabasesuggestthat the payback period associatedwith the installation ofASDs in anumberofdifferentapplicationsrangesbetweenroughlyoneandthreeyears [18].


TheAugustaNewsprintmill (partofa jointpartnershipbetweenAbitibi Consolidated and theWoodbridge Company, Ltd.) manufac-tures over 400,000metric tons of standard newsprint each year fromsouthern pine and recycled newspaper andmagazines.As part of anenergyefficiencyreviewofthemill’sboilersystem,thecompanyfoundan idealapplicationofanASDtosaveenergyand improvereliability.The boiler’s re-circulation scrubber was equipped with a 1,100 rpmpump; however, this pump was being driven by a fixed-speed 1,800rpmmotor such that the operators could only adjust the flow of thepumpbyusinganinefficientsheave.ThecompanyinstalledamagneticdriveASDinthisapplicationtobettermatchmotorsizewithflowre-quirements,with the addedbenefit of providingoperatorswithmoreefficientcontroloverpumpflow.Thenewmotor reportedlydeliveredannual cost and energy savingsof about $4,000 (114MWh) [31].

EXAMPLESOFPROCESS-SPECIFICEFFICIENCYMEASURES

Table 3 provides a summary of someof theprocess-specificmea-sures that arepresented in theEnergyGuide [1].

Raw Material Preparation The processes associated with rawmaterial preparation are esti-matedtoconsumeroughly10percentoftheelectricityuseand3percentof thesteamuse inU.S.pulpmanufacturingoperations [16].Oneoptionforreducingtheenergyuseassociatedwithdebarkingisdescribedbelow.

Cradle Debarker The cradle debarker is designed to remove bark from de-limbedlogsinamannerthatreducesdebarkingenergyusebyupto33percent[32].A cradle debarker is said towork in the followingmanner: Logsare loaded into a long trough that contains a series of horizontal andverticalconveyorchains,whichareorientedataslightangletothepathof the logs. The chains lift and drop the logs as theymove along thetrough;thisactionloosensandremovesbarkviacompressiveandshearforcesthataregeneratedbetweenthelogsinthetrough[32].Additionalreportedbenefitsincludelessdamagetologs,leadingtoagreaterwoodrecoveryrate,decreasedtransportationcoststhrougheliminationofoff-site debarking, and greater process control. TheU.S.DOE reports that

41

the cradle debarker can save amill $30 per ton ofwood in debarkingcosts [33].

Chemical (Kraft) Pulping TheEnergyGuideshowsthatthevastmajority(85percent)ofU.S.wood pulp is produced by chemical pulping processes. Furthermore,chemical (i.e., Kraft) pulping and its associated chemical recovery ac-count for thevastmajorityofsteam,electricity,anddirect fuelusedbytheindustryinthemanufactureofpulp.Efficiencyimprovementstothechemicalpulpingprocesscanthereforeleadtosignificantenergysavingsacross the industry.Twosuchmeasuresaredescribedbelow.

Table 3. Summary of process-specific energy efficiency measures


Digester Heat Recovery Inthekraftchemicalpulpingprocess,steamisproducedwhenhotpulpandcooking liquor is reduced toatmosphericpressureat theendof thecookingcycle. Inbatchdigesters,steamis typicallystoredashotwater in an accumulator tank. In continuous digesters, extracted blackliquor flows to a tank where it is flashed [34]. Recovered heat fromthese processes can be used in other facility applications, such as chippre-steaming,facilitywaterheating,orblackliquorevaporation[34,25]. Forblackliquorevaporation,flashsteamfrombatchdigesterblow(created by flashing from the hot water accumulator) or black liquorflash from a continuous digester can be used for thermal energy ina multi-stage evaporator. This thermal energy will offset the need forsteamgeneratedbyaboiler forblack liquorevaporation [34]. In chip steaming, the black liquor that is flashed in stages fromcontinuousdigesterscanbeusedintwoways.Flashvaporfromthefirststageisnormallyusedtoheatthechipsinthesteamingvessel,whiletheflashvaporofthesecondstagecanbeusedinsteadoflivesteaminthechipbin[34].Reportedly,theuseofflashsteaminthechipbinhasbeenproven out at severalNorthAmericanmills; however,U.S. regulationsstate that the vent from the chip bin has to be collected and treated ifflash steam isused for chippreheating [34]. A plant-wide energy audit of Georgia-Pacific’s mill in Crossett,Arkansas, recommended improvingblowheat recovery from themill’stwo parallel batch digester lines. At the time of the audit, a coolingtowerwasusedtoremoveexcessheatfromtheblowsteamaccumulator,andasteamheaterwasusedtogeneratehotwaterforthebleachplant[35].Theaudit teamrecommended installingnewheat exchangersandreroutingwaterlinessuchthatthecoolingtowerandsteamheatercouldbe shut down. It was estimated that this project would save 940,000MMBtu of fuel, 705,000MMBtu of natural gas, and $2,350,000 in costseachyear,withapaybackperiodof aroundoneyear [35]. At the Weyerhaeuser pulp and paper mill in Longview, Wash-ington, the proposed addition of a digester heat recovery systemwasexpected to result in annual natural gas savings of 130,000 MMBtu,leading to$280,000peryear in cost savings [36].

Black Liquor Solids Concentration Black liquorconcentratorsaredesignedto increase thesolidscon-tent of black liquorprior to combustion in a recovery boiler. Increased

43

solids content means less water must be evaporated in the recoveryboiler, which can increase the efficiency of steam generation substan-tially.Thereare twoprimary types inuse today—submerged tubecon-centratorsand fallingfilmconcentrators. In a submerged tube concentrator, black liquor is circulated insubmerged tubes, where it is heated but not evaporated; the liquor isthenflashed to the concentratorvapor space, causing evaporation [34].An analysis by NCASI suggests that for a 1,000 ton-per-day pulp plant, increasingthesolidcontentinblackliquorfrom66to80percentwouldleadtofuelsavingsof30MMBtu/hour,orroughly$550,000[34].Capitalcosts of the high solids concentrator will include concentrator bodies,piping for liquor and steam supplies, and pumps. A tube-type falling film evaporator effect operates almost exactlythe same way as a more traditional rising film effect, except that theblack liquor flow is reversed. The falling film effect is more resistantto fouling,because the liquor isflowing faster and thebubblesflow inthe opposite direction of the liquor. This resistance to fouling allowsthe evaporator toproduceblack liquorwith considerablyhigher solidscontent (up to 70percent solids rather than the traditional 50percent),thuseliminatingtheneedforafinalconcentrator[37].Martinetal. [11]estimatea steamsavingsof 0.8GJper tonofpulp [38]. A U.S. pulp and paper mill with 900-ton paper production perdayinstalledaliquorconcentratortoincreaseitssolidscontentfrom73to 80 percent. This increase results in annual energy savings of about110,000MMBtu,withcostsavingsofabout$900,000/year,leadingtoanestimatedperiodofpaybackof 4years [1].

Papermaking Thepapermakingprocessaccountsforabouthalfofthetotalsteam,electricity, and direct fuel used by the U.S. pulp and paper industry[16]. In particular, the drying stage of the papermachine accounts forthe vastmajority of thermal energy use in papermaking.Most energysaving opportunities for papermaking are therefore related to improving the efficiency of the drying process and recovering its waste heat forbeneficialuse.Fourexamplemeasuresareprovidedbelow.

Advanced Dryer Controls Control systems are a well-knownway to optimize process vari-ablesandtherebyreduceenergyconsumption,increaseproductivity,and


improve the quality of industrial processes. One example of a controlsystem for dryers is Dryer Management SystemTMcontrolsoftware,whichreportedlyoffersadvancedcontrolofdryersystemsetpointsandprocessparameters to reduce steam use and improve productivity [25, 39, 40].Several casestudiesof this technologyareavailable in the literature. Focus on Energy [39] describes a pilot of theDryerManagementSystem software at a StoraEnsomill in Steven’sPoint,Wisconsin.Themill’spapermachinewasmetered todetermine energy savings,whichwere deemedquite significant: 4,500 pounds of steamper hour,whichled to an estimated $360,000 in annual energy cost savings [39].Addi-tionally, the company reportedly experienced significant improvementwithproductqualityandthroughput.Thepaybackperiodwasestimatedat under 3 years, based on energy savings alone (i.e., no considerationofproductivitybenefits) [39]. Reese[40]describesresultsfromanotherStoraEnsoinstallationofDryerManagement System software, this time on a Voith lightweightcoatedmachine with two on-machine coalers. Reportedly, annual sav-ings of $263,000 were observed due to reduced energy consumption,lowermaintenance cost, and higher production. The reported paybackperiodwas sevenmonths [40].

Waste Heat Recovery In thepaperdryingprocess, severalopportunitiesexist to recoverthermalenergyfromsteamandwasteheat.Onemillreplacedthedryerswith stationary siphons in its papermachine andwas able to achieveenergysavingsof0.89GJ/tdue to improveddryingefficiency,withanoperationcost savingsof$25,000 ($0.045/t) [11].A secondsystemusedmechanicalvaporrecompression inapilot facility toreusesuperheatedsteam in thedryingprocess [41].Steamsavings for thisapproachwereupto5GJ/t(50percent),withadditionalelectricityconsumptionof160kWh/t [41].A third systemnoted in the literaturewas the use of heatpump systems to recoverwaste heat in thedrying section [42].Martinet al. [11] estimates that team energy savings of around 0.4MMBtu/tonofpaperareachievable throughpapermachineheat recovery,withinstallationcostsofaround$18per tonofpaper.However, the installa-tionofheatrecoverysystemswill leadtomoremaintenance,sinceheatexchangers requireperiodic cleaning. Heat can also be recovered from the ventilation air of the dryingsectionandusedforheatingofthefacilities[43].Forexample,amill-wide

45

energy assessment atAppleton Paper’s mill inWest Carrollton, Ohio,found that the recovery of papermachine vent heat could be used forheatingtheplant inwintermonths. Itwasrecommendedthatcross-flowheat exchangers be installed to generate hot air for plant heating fromrecoveredheatinthepapermachineventexhaustgas.Theestimatedan-nual cost savingswere about $1,000,000.With investment costs of about$1,500,000, thepaybackperiodwasestimatedatonly1.5years [44]. AnotherreportedopportunityistorecoveryheatfromUhleboxef-fluents.AttheBlueHeronPaperCompanymillinOregonCity,Oregon,theUhle box removes a combination of showerwater andwater fromthe sheet at a temperature between 115°F and 120°F.A heat recoveryproject identified for thisUhlebox estimated annual energy savingsof32,000MMBtu, with estimated costs savings around $100,000. Capitalcosts were estimated at around $110,000, leading to a payback periodof aroundoneyear [45].

Shoe (Extended Nip) Press After paper is formed, it is pressed to remove asmuchwater aspossible.Normally,pressingoccursbetween two felt linerspressedbe-tweentworotatingcylinders.Extendednippressesusea largeconcaveshoe instead of one of the rotating cylinders. The additional pressingarea allows for greaterwater extraction (about 5-7 percentmorewaterremoval), toa levelof35-50percentdryness [11].Greaterwaterextrac-tion leads to decreased energy requirements in the dryer, which leadstoreductionsinsteamdemand.Furthermore,reduceddryerloadsallowplants to increase capacity up to 25 percent in caseswhere productionis dryer limited [11]. Extended nip pressing also increases wet tensilestrength [46]. Published estimates for the steam savings achievable through theinstallation of extendednippresses range from2percent to around 15percent, depending on product and plant configuration [11, 25]. Forexample, the application of the X-NIP T shoe press in tissue plants isestimated to reducedryingenergyuseby15percent [47].Capital costshavebeenestimatedat$38pertonofpaper,andadditionalmaintenancecostshavebeenestimatedat $2.24per tonofpaper [48].

Reduced Air Requirements Airtoairheatrecoverysystemsonexistingmachinesrecoveronlyabout 15 percent of the energy contained in the hood exhaust air [11].


Thispercentagecouldbeincreasedto60-70percentformostinstallationswithpropermaintenanceandextensionsofthesystems.Papermachineswith enclosed hoods require about one-half the amount of air per tonofwater evaporated compared to papermachineswith canopy hoods.Enclosing thepapermachine reduces thermal energydemands, sinceasmallervolumeof air isheated.Electricity requirements in the exhaustfanarealso reduced [38]. Published estimates suggest steam savings of 0.76 GJ per ton ofpaperandelectricitysavingsof6.3kWhpertonofpaperbyinstallingaclosedhoodandanoptimizedventilationsystem.Investmentcostsandoperations andmaintenances costs have been reported at $9.5/t paperand$0.07/tpaper, respectively [11].

SUMMARY

The U.S. pulp and paper industry spent roughly $7.5 billion onpurchasedfuelsandelectricityin2006,makingenergyasignificantcostdriver for the industry.Energy efficiency improvement is an importantway to reduce these costs and to increase predictable earnings in thefaceofongoingenergypricevolatility.ManycompaniesintheU.S.pulpandpaperindustryhavealreadyacceptedthechallengetoimprovetheirenergyefficiencyinthefaceofhighenergycostsandhavebeguntoreapthe rewardsof energyefficiency investments. The Energy Guide summarizes a number of energy efficient tech-nologies and practices that are proven, cost-effective, and available forimplementation.Energyefficiencyimprovementopportunitieshavebeendiscussed that are applicable at the component, process, facility, andorganizational levels. Preliminary estimates of savings in energy andenergy-relatedcostshavebeenprovidedformanyenergyefficiencymea-sures, based on case study data from real-world industrial applications.Additionally,typicalinvestmentpaybackperiodsandreferencestofurtherinformationinthetechnicalliteraturehavebeenprovided,whenavailable. ItishopedthattheEnergyGuidecanbeusedbyenergymanagersintheU.S.pulpandpaperindustrytoidentifyareasforenergyefficiencyimprovements, to evaluate potential energy improvement options, to developactionplansandchecklistsforplant-levelenergymanagement,and to educate company employees on the importance of and actionsfor improvedenergyefficiency.

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Newand improved technologies forpulpandpapermillsarebe-ingdevelopedandevaluatedcontinuously,manyofwhichcanprovidenot only energy savings but also water savings, increased reliability,reducedemissionstowaterandair,higherpaperquality,andimprovedproductivity.

Acknowledgments Thisworkwas supported by the Climate Protection PartnershipsDivision of the U.S. Environmental ProtectionAgency as part of itsENERGY STAR program through the U.S. Department of Energy, under ContractNo.DE-AC02-05CH11231.

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[24] UnitedStatesDepartmentofEnergy (DOE) (2008). SaveEnergyNow, IndustrialTechnologyProgramCaseStudy.Longest-ServingActivePaperMillintheWesternUnitedStatesUncov-ersNewWays toSaveEnergy.OfficeofEnergyEfficiencyandRenewableEnergy, IndustrialTechnologiesProgram,Washington,D.C.

[25] FocusonEnergy(2006).PulpandPaperEnergyBestPracticeGuidebook.Madison,Wisconsin.ISBN: 1-59510-120-9.

[26] UnitedStatesDepartmentofEnergy(DOE)(2002).ForestProducts.BestPracticesAssessmentCaseStudy.BoilerBlowdownHeatRecoveryProjectReducesSteamSystemEnergyLossesatAugustaNewsprint.OfficeofEnergyEfficiencyandRenewableEnergy, IndustrialTechnolo-giesProgram,Washington,D.C.DOE/GO-102002-1536.

[27] United States Department of Energy (DOE) (2006). Boise Cascade International Falls PublicReport (ESA 019). OfficeofEnergyEfficiencyandRenewableEnergy,IndustrialTechnologiesProgram,Washington,D.C.

[28] Austin,P.,M.McEwan,J.Mack,J.GodsalandJ.Tyler(2008).OptimisationofFuelUsageandSteaminthePower&SteamPlantataPaperMillusingAdvancedProcessControl.Proceed-ings COST StrategicWorkshop “Improving Energy Efficiency in Papermaking”AmsterdamAirport, The Netherlands. June 9-11th, 2008.

[29] United States Department of Energy (DOE) (2002). United States Industrial Electric MotorSystemsMarketOpportunitiesAssessment.OfficeofEnergyEfficiencyandRenewableEnergy,Officeof IndustrialTechnologies,Washington,D.C.

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[32] UnitedStatesDepartmentofEnergy(DOE)(2002).ForestProducts.SuccessStories.Removalof Bark fromWhole Logs.Office ofWeatherization and Intergovernmental ProgramEnergyEfficiencyandRenewableEnergyU.S.DepartmentofEnergyWashington,D.C.Order#I-FP-653.

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[33] UnitedStatesDepartmentofEnergy (DOE) (2007).RemovalofBark fromWholeLogs.NewTechnology Saves Trees, Increases Product Value, and Lowers Production Costs. Office ofEnergyEfficiencyandRenewableEnergy,IndustrialTechnologiesProgram,Washington,D.C.

[34] NationalCouncilforAirandStreamImprovement(NCASI)(2001).TechnologiesforReducingCarbonDioxide Emissions:A ResourceManual for Pulp, Paper andWood ProductsManu-facturers. SpecialReportNo. 01-05.ResearchTrianglePark,NorthCarolina.

[35] UnitedStatesDepartmentofEnergy (DOE) (2003).ForestProducts.BestPracticesPlant-WideAssessment Case Study. Georgia-Pacific: CrossetMill Identifies Heat Recovery Projects andOperations Improvements thatMay Save $9.6MillionAnnually.Office of Energy EfficiencyandRenewableEnergy,IndustrialTechnologiesProgram,Washington,D.C.DOE/GO-102003-1722.

[6] UnitedStatesDepartmentofEnergy (DOE) (2004).ForestProducts.BestPracticesPlant-WideAssessmentCaseStudy.WeyerhaeuserCompany:LongviewMillConductsEnergyandWaterAssessmentthatFindsPotentialfor$3.1MillioninAnnualSavings.OfficeofEnergyEfficiencyandRenewableEnergy,IndustrialTechnologiesProgram,Washington,D.C.DOE/GO-102004-1809.

[37] Nilsson,L,E.Larson,K.GilbreathandA.Gupta.(1995).EnergyEfficiencyandthePulpandPaper Industry.AmericanCouncil for anEnergyEfficientEconomy.WashingtonD.C.

[38] Elaahi,A.andH.E.Lowitt(1988).TheU.S.PulpandPaperIndustry:AnEnergyPerspective.U.S. Department of Energy, Washington, D.C.

[39] Focus on Energy (2006). Pulp & Paper Industry Case Studies. DryerManagement System.WisconsinFocusonEnergy.BP-3186-0106.Madison,Wisconsin

[40] Reese,D.(2005).Low-CostDryerUpgradeOpportunitiesOfferEfficiencyGains,EnergySav-ing.Pulp&Paper,March.

[41] VanDeventer,H.C. (1997) Feasibility of EnergyEfficient SteamDrying of Paper andTextileIncludingProcess Integration.AppliedThermalEngineering17 (8-10),pp1035-1041.

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[43] DeBeer,J.G.,M.T.vanWees,E.WorrellandK.Blok(1994).Icarus-3:ThePotentialofEnergyEfficiencyImprovementsintheNetherlandsupto2000and2015.UtrechtUniversity,Depart-mentofScience,TechnologyandSociety.Utrecht,TheNetherlands.

[44] UnitedStatesDepartmentofEnergy(DOE)(2002).ForestProducts.BestPracticesAssessmentCase Study. Appleton Paper Plants-Wide EnergyAssessment Saves Energy and ReducesWaste.Office of Energy Efficiency andRenewable Energy, Industrial Technologies Program,Washington, D.C. DOE/GO-102002-1512.

[45] UnitedStatesDepartmentofEnergy (DOE) (2004).ForestProducts.BestPracticesPlant-WideAssessmentCaseStudy.BlueHeronPaperCompany.:OregonMillsUsesMode-BasedEnergyAssessmenttoIdentifyEnergyandCostSavingOpportunities.OfficeofEnergyEfficiencyandRenewableEnergy,IndustrialTechnologiesProgram,Washington,D.C.DOE/GO-102004-1758.

[46] Lange,D. andM.Radtke (1996).ExtendedNipPressingofPaperGrades:ATechnical Sum-mary.BeloitCorporation,Beloit,Wisconsin.

[47] Baubock,J.andA.Anzel(2007).Reduceyourdryingcosts.SteelYankeeandshoepressmakeamore attractive alternative to conventional technology, as energy costs rise. TissueWorldMagazine,December2007/January2008.

[48] DeBeer,J.G.,M.T.vanWees,E.WorrellandK.Blok(1994).Icarus-3:ThePotentialofEnergyEfficiencyImprovementsintheNetherlandsupto2000and2015.UtrechtUniversity,Depart-mentofScience,TechnologyandSociety.Utrecht,TheNetherlands.

————————————————————————————————ABOUT THE AUTHORS Klaas Jan Kramer, Ph.D., is a guest researcher at LawrenceBerkeleyNational Laboratory. Previously he hasworked at the Centerfor Energy and Environmental Studies of the University of Groningen


(The Netherlands) and theAgricultural Economic Research Instituteof theWageningen University (The Netherlands). His work includesresearch and evaluation projects in industrial energy efficiency im-provement and energy and greenhouse gas emission assessment and reductions, as well as life cycle assessments. Contact: EnergyAnalysisDepartment,LawrenceBerkeleyNationalLaboratory,MailStop90-4000,Berkeley, CA 94720 USA. Telephone: (510) 486-4228. Fax: (510) 486-6996. E-mail: [email protected].

Eric Masanet, Ph.D., is a principal scientific/engineering as-sociate intheInternationalEnergyStudiesGroupatLawrenceBerkeleyNational Laboratory. His research areas include life-cycle assessmentof products and industrial systems, industrial energy demand andefficiency analysis, and the development of models for evaluatingproduct- and process-related energy efficiency and greenhouse gasmitigation strategies in various geographic regions. Eric holds a jointresearch appointment at the University of California, Berkeley, wherehecurrentlyservesasprogrammanager for theUCBerkeleyEngineer-ing and Business for Sustainability (EBS) Certificate Program. Contact:EnergyAnalysis Department, Lawrence Berkeley National Laboratory,1CyclotronRoad,Building90R4000,Berkeley,California,94720.Phone:(510)486-6794. Email: [email protected].

Ernst Worrell, Ph.D., is Professor of Energy, Materials & theEnvironment at Utrecht University (TheNetherlands) andmanager ofenergyefficiencyatEcofys(TheNetherlands),aswellasastaffscientistat Lawrence BerkeleyNational Laboratory.Hiswork includes researchand evaluation projects in industrial energy efficiency improvement,greenhousegasemissionmitigationinindustry,energyefficiencybench-marking,energypolicy,energymodeling,emissiontrading,energyandmaterials,andwasteprocessing.Contact:Ecofys,POBox8408,NL-3503RK,Utrecht,TheNetherlands.Phone:+1-31-30-6623374.Email: [email protected].

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