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Understanding the energy and emission implications of new technologies in a kraft mill: Insights from a CADSIM Plus simulation model, TAPPI Journal June 2024

ABSTRACT: Kraft mills play a vital role in energy transition because they have significant potential to reduce their own energy utilization and produce energy/products to decarbonize other sectors. Through biomass combustion and potential biogenic carbon emissions capture, these mills can contribute to offsetting emissions from other sectors. This research investigates the departmental and cross-departmental implications of technology upgrades on energy, steam, emissions, water, and chemicals using a CADSIM Plus simulation model. The model provides a comprehensive analysis of mass and energy balances, offering valuable insights into the benefits and limitations of each technology. The model facilitates scenario analysis and comparisons of process configurations, enabling data-driven decision-making for sustainable and competitive operations. Six high-impact technologies, including additional evaporator effects, weak black liquor membrane concentration, belt displacement washer for brownstock washing, oxygen delignification, and improvements to the pulp machine shoe press and vacuum pumps, are evaluated. Individual technologies resulted in energy savings of 1.2% to 5.4%, biomass consumption reductions of 8.6% to 31.6%, and total emissions reductions of 1.6% to 5.9%. Strategic decision-making must consider existing mill limitations, future technology implementation, and potential production increases. Future research will explore product diversification, biorefineries, and pathways to achieve carbon-negative operations, aiming to reduce emissions and secure a competitive future for kraft mills.

Journal articles
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Saica Champblain Beats Mist—But How?, Paper360º March/April 2020

Saica Champblain Beats Mist—But How?, Paper360º March/April 2020

Journal articles
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TAPPI Journal Summaries, Paper360º March/April 2020

TAPPI Journal Summaries, Paper360º March/April 2020

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TAPPI News, Paper360º March/April 2020

TAPPI News, Paper360º March/April 2020

Journal articles
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Open Access
Fundamental understanding of removal of liquid thin film trapped between fibers in the paper drying process: A microscopic approach, TAPPI Journal May 2020

ABSTRACT: In the fabrication of paper, a slurry with cellulose fibers and other matter is drained, pressed, and dried. The latter step requires considerable energy consumption. In the structure of wet paper, there are two different types of water: free water and bound water. Free water can be removed most effectively. However, removing bound water consumes a large portion of energy during the process. The focus of this paper is on the intermediate stage of the drying process, from free water toward bound water where the remaining free water is present on the surfaces of the fibers in the form of a liquid film. For simplicity, the drying process considered in this study corresponds to pure convective drying through the paper sheet. The physics of removing a thin liquid film trapped between fibers in the paper drying process is explored. The film is assumed to be incompressible, viscous, and subject to evaporation, thermocapillarity, and surface tension. By using a volume of fluid (VOF) model, the effect of the previously mentioned parameters on drying behavior of the thin film is investigated.

Journal articles
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Open Access
Alternative “green” lime kiln fuels: Part II—Woody biomass, bio-oils, gasification, and hydrogen, TAPPI Journal May 2020

ABSTRACT: This paper is the second of a two-part series on “green” lime kiln fuels. The first part of this work reviews the use of pulp mill and recovery byproducts as either full or partial replacement of oil or natural gas in the kiln. The second part reviews the use of various forms of woody biomass, bio-oils, gasification and hydrogen as potential carbon neutral or carbon-free lime kiln fuels. Several of these options require specialized burners to supply the fuel to the kiln and high-quality metallurgy to withstand the acidic conditions of the fuel.

Journal articles
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SetPoint: Creating a New Normal, Paper360º May/June 2020

SetPoint: Creating a New Normal, Paper360º May/June 2020

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Safety Leaders Should ´Go to the Gemba’, Paper360º May/June 2020

Safety Leaders Should ´Go to the Gemba’, Paper360º May/June 2020

Journal articles
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The Coronavirus and the European Pulp and Paper Industry, Paper360º May/June 2020

The Coronavirus and the European Pulp and Paper Industry, Paper360º May/June 2020

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COVID-19: The Industry Responds, Paper360º May/June 2020

COVID-19: The Industry Responds, Paper360º May/June 2020

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