Analysis of alternative secondary heat uses to improve energy efficiency-case: a Finnish mechanical pulp and paper mill.

Abstract This study considers different alternative uses of secondary heat in a mechanical pulp and paper mill. The considered alternatives are (1) three different heat exchanger network retrofits, (2) drying of bark, (3) drying of primary and activated sludge and (4) drying of both bark and sludge. The data has been gathered from an operating mill and a simulation model has been built to examine the mill-wide effects of the proposed changes. Targets for steam and cooling water use, used in the heat exchanger network retrofits, have been evaluated using pinch analysis. The amount of available secondary heat found in the pinch analysis can be used in drying of bark or sludge. Sludge is typically burned together with mill fuel in the bark boiler of a power plant to deliver heat and electricity to the mill. These wood-based biofuels typically consist of 50% w.b. water, which will evaporate and consume some of the fuel's energy content during combustion. Fuel drying is a way to increase the heating value of fuels and to increase the energy efficiency of heat and power production. The utilisation of low-temperature secondary heat in the drying may reduce the need for fuels and primary energy in the mill. The different ways of using the secondary heat have different effects on primary fuel consumption and electricity production. Therefore the different results are compared using the reduction of CO 2 emissions as a common criterion. The results show that all the considered alternatives have great energy-saving potential up to 8 MW steam use in winter and 6 MW in summer time.