Pulp and Paper Industry: Energy Conservation

Pulp and Paper Industry

Energy Conservation

Pratima Bajpai

Table of Contents

Cover

Title page

Copyright

Preface

List of Abbreviations

Chapter 1: General Background

Abstract

Chapter 2: Global Pulp and Paper Production and Consumption

Abstract

Chapter 3: Pulp and Paper Production Processes and Energy Overview

Abstract

3.1. Process Description

3.2. Greenhouse Gas Emission Sources

3.3. Energy Overview

Chapter 4: Energy Conservation Measures for Raw Material Preparation

Abstract

4.1. Cradle Debarker

4.2. Ring-Style Debarkers

4.3. Chip Conditioning

4.4. Chip-Conveying Systems

4.5. Use of Secondary Heat Instead of Steam in Debarking

4.6. Automatic Chip Handling and Thickness Screening

4.7. Bar-Type Chip Screens

4.8. Fine-Slotted Wedge Wire Baskets

Chapter 5: Energy Conservation Measures for Chemical Pulping

Abstract

5.1. Batch Digester Modification

5.2. Continuous Digester

5.3. Digester Blow/Flash Heat Recovery

5.4. Using Flash Heat in a Continuous Digester to Preheat Chips

5.5. Optimization of the Dilution Factor Control

5.6. Use of Evaporator Condensates on Decker Showers

5.7. Use of Two Pressure Level Steaming of Batch Digesters to Maximize Back-Pressure Power Generation

5.8. Use of Digester Additives to Increase Yield

5.9. Use of Extended Delignification and Oxygen Delignification

Chapter 6: Energy Conservation Measures for Bleaching

Abstract

6.1. Improved Brown Stock Washing

6.2. Washing Presses

6.3. Ozone Bleaching

6.4. Heat Recovery

6.5. Optimization of the Filtrate Recycling Concept for Optimum Chemical and Energy Use

Chapter 7: Energy Conservation Measures for Chemical Recovery

Abstract

7.1. Black Liquor Solids Concentration

7.2. Lime Kiln Oxygen Enrichment

7.3. Lime Kiln Modification

7.4. Lime Kiln Electrostatic Precipitators

7.5. Improved Composite Tubes for Recovery Boilers

7.6. Quaternary Air Injection

7.7. Recovery Boiler Deposition Monitoring

7.8. Convert Evaporation to Seven-Effect Operation (Install Additional Evaporator Effect)

7.9. Performing Evaporator Boilout With Weak Black Liquor

7.10. Converting Recovery Boiler to Nondirect Contact and Implementing High Solids Firing

7.11. Condensate Stripping

7.12. Installation of a Methanol Rectification and Liquefaction System

7.13. Tampella Recovery System

Chapter 8: Energy Conservation Measures for Mechanical Pulping

Abstract

8.1. Energy Efficient TMP Processes

8.2. Pressurized Groundwood Pulping

8.3. Heat Recovery in Thermomechanical Pulping

8.4. Improvements in Chemithermomechanical Pulping

8.5. Refiner Improvements

8.6. Efficient Repulping Rotors

8.7. Continuous Repulping

8.8. Countercurrent Coupling of Paper Machine and Mechanical Pulping White Water Systems

Chapter 9: Energy Conservation Measures for Recovered Fiber Processing

Abstract

9.1. Drum Pulpers

9.2. Heat Recovery from Deinking Effluent

9.3. Supply of Waste Heat from Other Process Areas to Deinking Plant

9.4. Implementation of Closed Heat and Chemical Loop

9.5. Increased Use of Recycled Pulp

9.6. Fractionation of Recycled Fiber

Chapter 10: Energy Conservation Measures for Stock Preparation and Papermaking

Abstract

10.1. Shoe (Extended Nip) Press

10.2. Advanced Dryer Controls

10.3. Optimization of Water Removal in Forming and Pressing

10.4. High Consistency Forming

10.5. Condebelt™ Drying Process

10.6. Hot and Superhot Pressing

10.7. Gap Formers

10.8. Direct Drying Cylinder Firing

10.9. Paper Machine Vacuum System Optimization

10.10. Energy Savings Through Heat Recovery Systems

10.11. Implementation of Efficient Control Systems for the Machine Steam and Condensate Systems to Eliminate Excessive Blowthrough and Steam Venting During Machine Breaks

10.12. Optimization of Pocket Ventilation Temperature

10.13. Control of Dew Point

10.14. Closing Hoods and Optimizing Ventilation

10.15. Infrared Drying and Moisture Profiling

10.16. Dry Sheet Forming

Chapter 11: Emerging Technologies

Abstract

11.1. Gas-Fired Paper Dryer

11.2. Air Impingement Drying

11.3. Steam Impingement Drying

11.4. Impulse Drying

11.5. Infrared Drying

11.6. Multiport Dryer

11.7. Boost Dryer

11.8. Advanced Fibrous Fillers

11.9. Microwave Drying

11.10. Aq-vane Technology

11.11. Displacement Pressing

11.12. Laser Ultrasonic Stiffness Sensor

11.13. New Flotation Deinking Processes

11.14. Surfactant Spray Deinking

11.15. Pulsed Power Technology for Decontamination of Recycled Paper

11.16. Directed Green Liquor Utilization Pulping

11.17. Membrane Concentration of Black Liquor

11.18. Dual-Pressure Reheat Recovery Boiler

11.19. Borate Autocausticizing

11.20. Steam Cycle Washing

11.21. Black Liquor Gasification

11.22. LignoBoost™

11.23. Extraction of Hemicellulose Before Chemical Pulping

11.24. Utilization of Residuals in Concrete Production

11.25. Chemical Pretreatment With Oxalic Acid for Mechanical Pulping

11.26. Biopretreatment for Mechanical Pulping

11.27. Enzymatic Prebleaching

11.28. Enzymatic Refining

11.29. Enzymes for Drainage Improvement

11.30. Enzymatic Deinking

11.31. Enzymatic Debarking

11.32. Enzymatic Removal of Shives

11.33. Enzymes for Reduction of Vessels in Tropical Hardwoods

Chapter 12: Future Perspectives

Abstract

Index

Copyright

Elsevier

Radarweg 29, PO Box 211, 1000 AE Amsterdam, Netherlands

The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK

50 Hampshire Street, 5th Floor, Cambridge, MA 02139, USA

Copyright © 2016 Elsevier Inc. All rights reserved.

No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions.

This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).

Notices

Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library

Library of Congress Cataloging-in-Publication Data

A catalog record for this book is available from the Library of Congress

ISBN: 978-0-12-803411-8

For information on all Elsevier publications visit our website at http://store.elsevier.com/

Typeset by Thomson Digital

Preface

The pulp and paper industry plays an important role in a country’s economic growth. It is, in general, highly energy intensive. It consumes energy in the form of power as well as fuel. Globally, pulp and paper manufacturing is the fourth largest industry in terms of energy use, using 6.87 EJ of final energy in 2007, which is 5% of total world industrial energy consumption and 2% of global direct carbon dioxide emissions from the industrial sector in that year. However, unlike the iron and steel industry, the pulp and paper sector is one of the least carbon-intensive industries as a result of the large share of biomass. The energy cost as a percentage of manufacturing cost has increased from 15% in 1979–1980 to more than 25% by 2009. This is mainly because of the increase in energy prices. The pulp and paper industry emitted 183 Mt of direct carbon dioxide, accounting for only 2% of direct carbon dioxide emissions from the global manufacturing sector. World paper production is expected to grow from about 403 Mt in 2013 to approximately 700 Mt (low estimate) and 900 Mt (high estimate) by 2050. The bulk of this growth will take place in China, India, and other developing countries. This significant increase in paper production will cause a corresponding significant increase in the industry’s absolute energy use and carbon dioxide emissions.

Energy conservation measures in the pulp and paper industry are the need of the hour. There is a need to develop short- and long-term strategies for energy conservation. Modernization of old mills, use of energy-efficient equipment/processes, and improvement of quality and productivity are the immediate steps in this direction. Energy conservation includes several benefits: lower production cost, improved ability to withstand future fluctuations in energy costs, improvement in productivity, more competitive edge, and environmental benefits. Any process that significantly decreases the energy requirement in the pulp and paper process will have a significant effect on the overall energy input. Recently, there has been increased awareness of biotechnological processes, especially enzymatic processes, in the industry to reduce energy consumption and improve product quality. This book consolidates available information on energy-efficient and low-carbon technologies for the pulp and paper industry. Emerging energy-efficient technologies and future perspectives are also dealt with.

List of Abbreviations

AF&PA American Forest and Paper Association

AHQ Anthrahydroquinone

AOX Adsorbable organic halogens

AQ Anthraquinone

ATMP Advanced thermomechanical pulp

BAT Best available technology

BCP Beck cluster press

BLG Black liquor gasification

BLGCC Black liquor gasification integrated with combined-cycle technology

BLS Black liquor solids

BOD Biological oxygen demand

BPR Boiling point rise

CC Combined cycle

CCS Carbon capture and storage

CFD Computational fluid dynamics

CHP Combined heat and power

COD Chemical oxygen demand

CSF Canadian standard freeness

CTMP Chemithermomechanical pulping

CTS Chip thickness screening

DCE Direct contact evaporators

DD Double disc

D-GLU Directed green liquor utilization

DIP Deinked pulp

DME Dimethyl ether

DMS Dryer management system

DOL Department of Labor

ECF Elemental chlorine free

ESPS Electrostatic precipitators

FAO Food and Agriculture Organization

FRCA Fine recycled concrete aggregate

GFPD Gas-fired paper dryer

GHG Greenhouse gas

GL Green liquor

HC High consistency

HTCTMP High-temperature chemithermomechanical pulping

IEA International Energy Agency

IPCC Intergovernmental Panel on Climate Change

LC Low-consistency

LEF Low Energy Flotation

LNG Liquefied natural gas

LPG Liquefied petroleum gas

MC Medium consistency

MEA Model-based energy assessment

MEE Multiple effect evaporators

MF Microfiltration

NCG Noncondensable gases

NDCE Nondirect contact evaporator

NF Nanofiltration

NSSC Neutral sulfite semichemical process

OECD Organization for economic cooperation and development

PGW Pressure groundwood

PHAST Process heating assessment and survey tool

RMP Refiner mechanical pulping

RO Reverse osmosis

SCW Steam cycle washer

SD Single disc refining

SEC Specific energy consumption

SETIS Strategic energy technologies information system

SOGS Stripper off-gases

TBTu Trillion Btu

TCF Totally chlorine free

TEF Totally effluent free

TMP Thermomechanical pulping

TOWL Total oxidized white liquor

TRS Total reduced sulfur

UF Ultrafiltration

Chapter 1

General Background

Abstract

The pulp and paper industry in general is highly energy intensive, consuming energy in the form of power as well as fuels. Due to shortages in energy availability and increase in energy cost, energy conservation has become a necessity in the paper industry. There is a need to develop short- and long-term strategies for energy conservation. There is a strong business case for investing in energy efficiency in the pulp and paper sector. Investing in energy efficiency can yield several benefits. Completely new process designs and processing techniques could bring long-term energy efficiency improvements in paper production. The general background on energy efficiency improvement and cost-saving opportunities are presented in this chapter.

Keywords

pulp and paper industry

energy

energy intensive

energy efficiency

energy conservation

energy cost

The pulp and paper industry plays an important role in the economic growth of the country. It is, in general, highly energy intensive (Kong et al., 2012, 2013; Martin et al., 2000; Bajpai and Bajpai, 1998; Bajpai, 2011; Kramer et al., 2009; European Commission, 2001, 2013; Peng et al., 2015; Blomberg et al., 2012; Xu et al., 2014). It consumes energy in the form of power as well as fuels and is the fifth largest industrial energy user in the United States, consuming about 11% of the total industrial energy per year. In India, it is the sixth largest consumer of energy in the industrial sector. Papermaking energy intensities in the United States are found to be greater than those in many other countries (Farla et al., 1997). The pulp and paper industry spent approximately $7.5 billion on purchased fuels and electricity in 2006 in the United States, making energy use a significant cost driver for the industry. Energy efficiency improvement is an important way to reduce these costs and to increase predictable earnings in the face of ongoing energy price volatility. Several pulp and paper companies have already accepted the challenge to improve their energy efficiency and have started reaping the rewards of energy efficiency investments. Energy efficiency is doing more work with the same amount of energy or doing the same amount of work using less energy. There appears to be a strong business case for investing in energy efficiency in the pulp and paper sector. Energy efficiency reductions can make a significant difference to the bottom line as energy constitutes as much as 15% of total operating costs. Investing in energy efficiency can also yield benefits from (Metz et al., 2007; Worrell et al., 2009):

• Reduced water and associated chemical use

• Improving energy and water security for the plant

• Building goodwill in the regional communities in which companies operate

de Beer (1998) has reported that completely new processing techniques and process designs could bring long-term energy efficiency improvements of 75–90% in paper production.

The global paper industry is the fourth largest consumer of primary energy in the industrial sector. Annual primary energy consumption has been estimated at 8 exajoules (EJ), of which 2.3 EJ are from black liquor and wood waste (nonconventional energy) (de Beer, 2000). The average specific energy consumption (SEC) of papermaking only, excluding pulping, is about 3.1 EJ. SEC in pulp and paper production is highly affected by several factors listed as follows (Vakkilainen and Kivistö, 2010; Farla et al., 1997; IEA, 2007; Worrell et al., 2007):

• Product mix (i.e., structure)

• Processes used

• Plant size

• Plant location

• Technology used

• Technical age of the mill

• Feedstock quality

• Fuel prices

• Utilization rate of plant capacity

• Integration level

• Climate conditions

• Level of management attention to energy efficiency

In the United States, the pulp and paper industry has reduced energy use by about 42% during the period 1975–2005 (as per Intermediate Energy Infobook, 2007) (Bajpai, 2011). The SEC in the Indian pulp and paper industry is 33.7–47.7 GJ/t. The average SEC (GJ/t) was 60 in 1987, reduced to 51 in 2002, and to 40 in 2009, whereas it is 23 GJ/t by best available technology (BAT). Energy cost as a percentage of manufacturing cost has increased from 15% in 1979–1980 to about 24.5% in 1992–1993 and to more than 25% by 2009. This is mostly due to increase in energy prices.

The average greenhouse gas (GHG) emission is 2.5 ton carbon dioxide per ton of paper production, which is quite high compared to BAT. By reducing the SEC, the consumption of fuel will also reduce, resulting in the reduction of carbon dioxide emission as well. Several options are available for reducing the energy consumption (Table 1.1) (Bajpai, 2011).

Table 1.1

Options for reducing the energy consumption

Starting point for reducing energy consumption and energy costs

Saving by optimizing the existing plants

Saving due to procurement of energy (fuels, electricity)

Saving by optimizing papermaking

Generation and use of heat and power

Operation of combined heat and power systems to provide steam and electricity

Increased cogeneration and additional use of waste out of production and refuse-derived fuels

Heat integration/use of pinch technique

Optimization, control, and new technologies

Change over to energy efficient technologies – very often, capital intensive

Better control of various operations

Maximizing the utilization of existing plants/equipment

Based on Bajpai (2011).

According to the Strategic Energy Technologies Information System (SETIS) over half (55%) of the energy used by the industry comes from biomass and most of the remaining 38% from natural gas. Usually mechanical pulp making is more electricity intensive and less heat intensive than chemical pulping. As heat is produced in the pulp and papermaking process, this can be used to generate electricity in combined heat and power installations. In Europe, the industry produces about 46% of the electricity it consumes.

In Europe, the industry has invested in combined heat and power generation to improve energy efficiency. Europe now produces almost half the electrical energy it consumes. Direct carbon dioxide emissions have decreased and pulp and paper production has increased due to efficiency improvements over the last two decades. Potential breakthrough technologies now need to be examined to demonstrate market viability and increase efficiency even further.

The pulp and paper industry accounted for approximately 5% of total industrial final energy consumption and 2% of direct carbon dioxide emissions from the industrial sector globally in 2007 (IEA, 2011; Kong et al., 2012). World paper and paperboard demand and production are increasing. Annual production is expected to grow from approximately 403 million tons (Mt) in 2013 to between 700 Mt (low estimate) and 900 Mt (high estimate) by 2050. The largest share of this growth will take place in China, India, and other developing countries (IEA, 2009). This significant increase in paper production will cause a corresponding significant increase in the pulp and paper industry’s absolute energy consumption and GHG emissions.

The major energy-related GHG emission sources are natural gas, fuel oil, biomass-based materials, purchased electricity, and coal. When biomass-derived GHG emissions are not counted, the remaining four energy sources accounted for an estimated 80% or more of the industry’s energy-related GHG emissions in 2002 in US pulp and paper mills. Therefore, to reduce GHG emissions, the primary option is to improve energy efficiency. The pulp and paper manufacturing industry consumed over 2200 trillion Btu (TBtu) in 2002. This accounted for about 14% of all fuel consumed by the US manufacturing sector (Kramer et al., 2009). Black liquor and hog fuel (i.e., wood and bark), which are the two biomass by-products of the pulp and paper manufacturing process, meet over half of the industry’s annual energy requirements.

Many pulp and paper facilities generate over half of their energy needs from biomass fuels recovered from the pulp and paper production process. The American Forest and Paper Association (AF&PA) estimates that biomass comprises 64% of total fuel use by AF&PA members’ pulp and paper facilities (AF&PA, 2008). The use of these by-products as fuels significantly reduces the industry’s dependence on purchased fossil fuels and electricity, with the added benefits of reduced raw material and reduced generation of waste. Coal and natural gas comprise most of the remaining fuel used by the industry (Kramer et al., 2009). Incidental amounts of pulping vent gases and pulping by-products such as tall oil and turpentine are also used. Steam is the largest end use of energy in the pulp and paper industry, with more than 1026 TBtu used in 2002. The next largest end use of energy is electricity, with approximately 339 TBtu of electricity (purchased and self-generated) consumed in 2002. Therefore, energy efficiency initiatives that are aimed at reducing steam system losses and improving the efficiency of process steam-using equipment are likely to reduce energy use at pulp and paper mills. Energy efficiency improvements lead to reduced fuel consumption or reduced electricity demand.

The pulp and paper industry consumed 6.87 EJ of final energy in 2007 as the fourth largest industrial energy consumer worldwide. This accounted for 5% of total global industrial energy consumption and 2% of global direct carbon dioxide emissions from the industrial sector in that year (Trudeau et al., 2011). China’s pulp and paper industry alone used 0.75 EJ of final energy, which represented 11% of total final energy used in the global pulp and paper industry in that year (NBSC, 2010). Extensive studies have explored opportunities to reduce energy consumption and carbon dioxide emissions in the pulp and paper industry. Klugman et al. (2007) conducted an energy audit of a Scandinavian pulp mill and concluded that 22% of electricity and 1% of process heat could be saved per year, for overall energy savings of 113 gigawatt hours per year. Gong et al. (2011) using Simprosys software conducted an energy audit on a paperboard drying line in Slovakia and found three ways to improve dryer energy performance: decreasing heat loss, effectively recovering waste heat, and reducing drying time. Hong et al. (2011) examined the energy flow of the pulp and paper industry in Taiwan and identified 3.2 petajoules of total energy conservation potential per year, equal to 6.5% of Taiwanese pulp and paper industry energy consumption in 2009. Afshar et al. (2012) conducted energy audit operation in two UK paper machines. These researchers found that improving drainage and avoiding overdrying of the sheet provided two important opportunities for thermal energy reduction in the papermaking process. Reese (2012) carried out energy evaluations on more than 300 paper machines in North America and reported that 25% of energy consumption in these paper machines could be reduced without significant capital investment.

The major target for the industry is to make its technology more energy efficient. There are many new and breakthrough technologies. But most are presently at a standstill. The bioroute is aiming to develop integrated bio-refinery complexes producing pulp, paper, chemicals, bioenergy, biofuels, and also bio-carbon capture and storage. This route includes further development of the black liquor gasification. Black liquor is an energy rich by-product produced during the production of kraft. It is presently burned in a recovery boiler to generate electricity and steam for the pulp mills. Utilization of black liquor for the production of transportation fuels appears to be a better option economically. After some initial attempts to introduce innovative drying technologies, R&D in this area is not progressing further. As the pulp and paper industry also produces energy, an important synergy in efforts to reduce carbon dioxide emissions could be exploited by sharing innovation initiatives with the power sector or with any other energy-intensive manufacturing industry that could launch initiatives in the field of carbon capture and storage (e.g., the cement industry or the iron and steel industry). Since the mid-1990s, the sector has invested annually 6–8% of its annual revenue to improve its capacity. However, many companies focus their R&D investments mainly on new products; investment in R&D regarding technology and processes is made by a number of specialized machine and equipment suppliers. The economic crisis in 2009 hit the pulp and paper industry hard, even though a lot of restructuring work had already been carried out, which may have reduced the impact of the crisis somewhat. The industry has partially recovered, but is not back to its precrisis level yet. For some grades of paper, for example, newsprint, a decline in production is forecast, which will not reach precrisis levels, but overall the sector is expected to keep growing at a steady pace, with new grades of paper developing. Where the sector will be in 2020, 2030, and 2050 will also largely depend on the export market and the competitiveness of the sector worldwide.

Energy conservation measures in the pulp and paper industry are the need of the hour. The main objective of energy conservation is to optimize energy use, that is to say, reduce the net specific energy per unit of product. There is a need to develop short- and long-term strategies for energy conservation. The following are the immediate steps in this direction:

• Modernization of old mills

• Use of energy efficient equipment/processes

• Productivity

• Improvement of quality

The benefits of energy conservation include:

• Lower production cost

• More competitive edge

• Improved ability to withstand future fluctuations in energy costs

• Improvement in productivity

• Environmental benefits

Consequently, any process that significantly decreases the energy requirement in the pulp and paper process will have a significant impact on the overall energy input. Recently, there has been increased awareness of biotechnological processes, especially enzymatic processes in the pulp and paper industry to reduce energy consumption and improve product quality. In addition, the biotechnological processes are highly specific in action, require milder conditions, and generate lesser pollution as compared to chemical processes (Bajpai, 2012).

Several studies have documented the potential to reduce energy use and GHG emissions by implementing commercially available energy-efficiency technologies and measures in the pulp and paper industry worldwide (Worrell et al., 2001; Kinstrey and White, 2006; IEA 2007, 2011; UNIDO, 2010; Zafeiris, 2010; Kong et al., 2012, 2013; Martin et al., 2000; Bajpai and Bajpai, 1998; Bajpai, 2011; Kramer et al., 2009; Xu et al., 2014). However, given the projected continual increase in absolute paper production, future reductions in absolute energy use and carbon dioxide emissions will require additional innovations. Innovations will likely include development of different processes and materials for pulp and paper production or technologies that can economically capture and store the industry’s carbon dioxide emissions. The development of these emerging technologies and their deployment in the market will be a key element in the pulp and paper industry’s mid- and long-term climate change mitigation strategies.

Many studies from around the world have identified energy-efficiency technologies for the pulp and paper industry that have already been commercialized and are sector specific or cross-cutting (Jaccard/Willis, 1996; Alsema, 2001; FOE, 2005; NEDO, 2008; Kramer et al.,  2009; EPA, 2010; Zafeiris, 2010; CEPI, 2011; ITP, 2006, 2011; Martin et al., 2000; Bajpai, 2011; European Commission, 2001; 2013; Peng et al., 2015; Xu et al., 2014). However, information is scarce and scattered regarding emerging or advanced energy efficiency and low-carbon technologies for the pulp and paper industry that have not yet been commercialized. This book provides thorough and in-depth coverage of energy conservation strategies and low-carbon technologies for the pulp and paper industry. It also presents emerging energy-efficient technologies and biotechnological processes, especially enzymatic processes to reduce energy consumption, and future perspectives.

References

American Forestry and Paper Association (AF&PA), 2008. Memorandum from Rhea Hale, AF&PA, to Reid Harvey, U.S. EPA Climate Change Division. May 22, 2008.

Afshar P, Brown M, Austin P, Wang H, Breikin T, Maciejowski J. Sequential modelling of thermal energy: new potential for energy optimisation in papermaking. Appl. Energy. 2012;89(1):97–105.

Alsema EA. ICARUS-4: Sector Study for the Paper and Board Industry and the Graphical Industry. The Netherlands: Department of Science, Technology and Society, Utrecht University; 2001.

Bajpai PK. Emerging applications of enzymes for energy saving in pulp & paper industry. IPPTA J. 2011;23(1):181–185.

Bajpai P. Biotechnology for Pulp and Paper Processing. New York: Springer; 2012.

Bajpai P, Bajpai PK. Biotechnology in Pulp and Paper Industry: A Route to Energy Conservation. UK: Pira International; 1998.

Blomberg J, Henriksson E, Lundamark R. Energy efficiency and policy in Swedish pulp and paper mills: a data envelopment analysis approach. Energy Policy. 2012;42:569–579.

Confederation of European Paper Industries (CEPI), 2011. Unfold the future – the forest fiber industry: 2050 roadmap to a low-carbon bio-economy. Brussels, Belgium.

de Beer, J., 1998. Potential for Industrial Energy Efficiency Improvement in the Longer Term, PhD Thesis, Utrecht University, Utrecht.

de Beer J. Potential for industrial energy-efficiency improvement in the long term. Springer Press, USA; 2000: vol. 5, pp. 13–42.

EPA Available and Emerging Technologies for Reducing Greenhouse Gas Emissions From the Pulp and Paper Manufacturing Industry. Research Triangle Park, NC: U.S. Environmental Protection Agency (EPA); 2010.

European Commission (EC), 2001. Reference Document on Best Available Techniques in the Pulp and Paper Industry. Integrated Pollution Prevention and Control (IPPC). Available from: http://eippcb.jrc.ec.europa.eu/reference/BREF/ppm_bref_1201.pdf.

European Commission, 2013. Best Available Techniques (BAT) Reference Document for the Production of Pulp, Paper and Board. Industrial Emissions Directive 2010/75/EU.

Farla J, Blok K, Schipper L. Energy efficiency developments in the pulp and paper industry. Energy Policy. 1997;25(7–9):745–758.

Focus on Energy (FOE) Pulp and Paper Energy Best Practice Guidebook. Madison, WI: Focus on Energy; 2005.

Gong ZX, Stanovský J, Mujumdar AS. Energy audit of a fiberboard drying production line using Simprosys software. Drying Technol. 2011;29(4):408–418.

Hong GB, Ma CM, Chen HW, Chuang KJ, Chang CT, Su TL. Energy flow analysis in pulp and paper industry. Energy. 2011;36(5):3063–3068.

International Energy Agency (IEA), 2007. Tracking Industrial Energy Efficiency and CO2 Emissions. Paris, France.

International Energy Agency (IEA), 2009. Energy Technology Transitions for Industry – Strategies for the Next Industrial Revolution. Paris, France.

International Energy Agency (IEA) and United Nations Industrial Development Organization (UNIDO), 2011. Technology Roadmaps: Carbon Capture and Storage in Industrial Applications.

Industrial Technologies Program (ITP) Forest Products Technologies: Public Private Partnerships Produce R&D Results. Washington, DC: U.S. Department of Energy; 2006.

Industrial Technologies Program (ITP) IMPACTS: Industrial Technologies Program: Summary of Program Results for CY2009. Washington, DC: U.S. Department of Energy; 2011.

Jaccard/Willis, 1996. Pulp and paper. In: Industrial Energy End-Use Analysis & Conservation Potential in Six Major Industries in Canada. Prepared for Natural Resources Canada. MK Jaccard and Associates & Willis Energy Services Ltd., Ottawa, Canada (Chapter 3).

Kinstrey, R.B., White D., 2006. Pulp and Paper Industry Energy Bandwidth Study: Greenville (SC): Jacobs Engineering & Atlanta (GA): Institute of Paper Science and Technology (IPST) at Georgia Institute of Technology; 2006 Aug. Project Number: 16CX8700. Sponsored by the American Institute of Chemical Engineers (AIChE) and U.S. Department of Energy (DOE).

Klugman S, Karlsson M, Moshfegh B. A Scandinavian chemical wood pulp mill. Part 1. Energy audit aiming at efficiency measures. Appl. Energy. 2007;84(3):326–339.

Kong L, Hasanbeigi A, Price L. Emerging Energy-Efficiency and Greenhouse Gas Mitigation Technologies for the Pulp and Paper Industry. Berkeley, CA: Lawrence Berkeley National Laboratory; 2012: Report no. LBNL-5956E.

Kong L, Price L, Hasanbeigi A, Liu H, Li J. Potential for reducing paper mill energy use and carbon dioxide emissions through plant-wide energy audits: a case study in China. Appl. Energy. 2013;102:1334–1342.

Kramer KJ, Masanet E, Xu T, Worrell E. Energy efficiency improvement and cost saving opportunities for the pulp and paper industry. Berkeley, CA: Lawrence Berkeley National Laboratory; 2009: Report no. LBNL-2268E.

Martin N, Anglani N, Einstein D, Khrushch M, Worrell E, Price LK. Opportunities to Improve Energy Efficiency and Reduce Greenhouse Gas Emissions in the U.S. Pulp and Paper Industry. Berkeley, CA: Lawrence Berkeley National Laboratory; 2000: Report no. LBNL-46141.

Metz B, Davidson OR, Bosch PR, Dave R, Meyer LA. Climate change 2007: mitigation. Contribution of Working Group III to the Fourth Assessment Report of the Intergovernmental Panel on Climate Change. Cambridge, UK and New York, NY, US: Cambridge University Press; 2007.

National Bureau of Statistics of China (NBSC) China Energy Statistical Yearbook 2009. Beijing: China Statistic Press; 2010.

New Energy and Industrial Technology Development Organization (NEDO), 2008. Japanese Technologies for Energy Savings/GHG Emissions Reduction (2008 Revised Edition). Kanagawa, Japan.

Peng L, Zeng X, Wang Y, Hong GB. Analysis of energy efficiency and carbon dioxide reduction in the Chinese pulp and paper industry. Energy Policy. 2015;80:65–75.

Reese D. Improve Paper Machine Energy Performance. Dick Reese and Associates Inc. Norcross, USA; 2012.

Trudeau N, Tam C, Graczyk D, Taylor P. Energy Transition for Industry: India and the Global Context. Paris, France: International Energy Agency (IEA), Energy Technology Policy Division; 2011.

United Nations Industrial Development Organisation (UNIDO), 2010. Global Industrial Energy Efficiency Benchmarking – An Energy Policy Tool.

Vakkilainen E., Kivistö A., 2010. Energy Consumption Trends and Energy Consumption in Modern Mills in Forest Industry Production; Technical Report LUT/Energy-RR-10; LUT Energy: Lappeenranta, Finland.

Worrell E., Martin N., Anglani N., Einstein D., Khrushch M., Price L., 2001. Opportunities to improve energy efficiency and reduce greenhouse gas emissions in the U.S. Pulp and Paper Industry. Paper presented at the Proceedings of Paper Machine Technology, Lanaken, Belgium Energy Efficiency in the Pulp and Paper Industry. Available from: https://setis.ec.europa.eu/../energy../energy..in..industry/info.

Worrell E, Price L, Neelis M, Galitsky C, Nan Z. World Best Practice Energy Intensity Values for Selected Industrial Sectors. Berkeley, CA: Ernest Orlando Lawrence Berkeley National Laboratory; 2007.

Worrell E, Bernstein L, Roy J, Price L, Harnisch J. Industrial energy efficiency and climate change mitigation. Energy Efficiency. 2009;2(2):109–123.

Xu TF, Sathaye J, Kramer K. Bottom-Up Representation of Industrial Energy Efficiency Technologies in Integrated Assessment Models for the U.S. Pulp and Paper Sector. California, USA: Lawrence Berkeley National Laboratory; 2014.

Zafeiris T., 2010. Global CO2 Abatement Potential in the Pulp and Paper Industry up to 2030. Masters Thesis, Utrecht University, The Netherlands.

Chapter 2

Global Pulp and Paper Production and Consumption

Abstract

The pulp and paper industry is one of the largest industries in the world with very high capital investments. Over 400 million metric tons of paper and cardboard are produced worldwide every year, with China being responsible for around one-quarter of the total production. Global pulp and paper production and consumption are presented in this chapter.

Keywords

pulp and paper industry

pulp and paper production

pulp and paper consumption

per capita paper consumption

paperboard

The pulp and paper industry produces and sells cellulose-based products, derived from wood. The major product groups of this industry are packaging paper, graphic paper, and hygienic paper (Smook, 2003). Although China is the world’s leading paper and paperboard producer, the international pulp and paper market is dominated by companies from North America, northern Europe, and Japan. Over 400 million metric tons of paper and cardboard are produced worldwide every year. China is responsible for around one-quarter of the total production (www.statista.com; www.forestindustries.se; www.greenamerica.org/pdf/paperfacts.pdf). The world’s largest paper and paperboard producers are the United States, Japan, Germany, Canada, China, Finland, Republic of Korea, Indonesia, Sweden, and Brazil, whereas the largest pulp producers are the United States, China, Canada, Brazil, Sweden, Finland, Japan, Russian Federation, Indonesia, and Chile. These countries together were responsible for approximately 81% and 73% of the world’s pulp and paper and paperboard production in 2010, respectively (FAO, 2011; Fracaro et al., 2012; www.fao.org/forestry/statistics; www.paperindustryworld.com; Global Paper & Pulp Mills Market Research Report, 2015).

The industry is dominated by Kimberly-Clark and International Paper from the United States, Oji Paper and Nippon Paper Group from Japan, and UPM-Kymmene and Stora Enso from Finland (www.statista.com). The top 20 companies produce around 40% of the total global paper and paperboard production. Among the top data of the pulp and paper subcategory are rankings of these major companies. Consumption figures on global and regional levels reveal that paper utilization almost totally equates to the global industry’s production. As paper is a renewable resource, recycling is a major issue for this industry. Enormous amounts of paper are collected worldwide annually, making it a significant part of the industry. According to Kevin Conley, Senior Economist of World Graphic Paper at RISI, China has maintained the top spot for both demand and production of total paper and board over the past five years, with the United States remaining in second place (RISI, 2014). China accounted for 25% of world demand and 26% of world production of total paper and board in 2013. The United States remained the top producing country in the world with 49.4 Mt in 2013 in terms of pulp production. Canada stood second, producing 17.3 Mt, with China a close third at 17.1 Mt. Global paper and board production advanced 0.8% to reach a new record level of 403 Mt in 2013 inspite of the continuous decline in North America and Europe (RISI, 2014). Positive growth in tissue and packaging grades continued to counterbalance the retreat in global graphic paper production.

Table 2.1 presents global paper and board production and Table 2.2 shows production and consumption of pulp in different parts of the world in 2011 and 2012 (Facts on Paper, 2014).

Table 2.1

Global paper and board production

Based on Facts on Paper (2014); https://www.vdp-online.de/en/publikationen/angebot.html?eID=dam.

Table 2.2

Production and consumption of pulp

Based on Facts on Paper (2014): https://www.vdp-online.de/en/publikationen/angebot.html?eID=dam.

The global paper and pulp mills industry has contracted slightly over the last few years. This is basically due to the transition to digital media and paperless communication across most of the developed countries. However, manufacturing booms in many emerging markets have partially offset the decline by driving increased demand for paper used in packaging materials. As a whole, the industry is expected to shift its focus toward packaging materials and sanitary products – the two most promising segments for growth. Industry revenue is expected to resume slow expansion over the next 5 years, although growth in developing markets will outpace the increase in revenue in the United States and Europe (www.ibisworld.com).

According to