Energy efficiency in the textile sector
The pulp and paper industry is known for its high energy intensity, especially in steam generation, drying, and fluid handling processes. A distinctive feature of this sector is its ability to integrate biomass cogeneration, enabling many plants to supply up to 95% of their thermal and electrical energy needs using their own residues such as bark, sludge, and black liquor. This strategy not only reduces fuel costs but also allows energy efficiencies above 75%, far exceeding conventional plants that produce steam and power separately.
Biomass boilers are a critical component, and their efficiency largely depends on combustion control, excess air optimization, and the incorporation of heat recovery systems in exhaust gases. Economizers and air preheaters can increase thermal efficiency by 4% to 6%, reducing fuel consumption per ton of product.
The steam system is another major energy consumer in the industry. Proper management of operating pressures, condensate recovery—which in well-optimized plants can exceed 85%—and minimizing unnecessary blowdowns significantly reduce thermal losses and makeup water consumption. Additionally, insulating lines and equipment helps decrease energy losses during distribution.
On the electrical side, the compressed air system accounts for between 8% and 12% of a pulp and paper plant’s consumption. Leaks, which can reach up to 30% of the air generated, along with oversized configurations and compressors running constantly at full load, cause significant overconsumption. Leak detection, reducing operating pressures, using variable frequency drives on compressors, and intelligent demand management greatly improve the efficiency of these systems.
In the electrical domain, the compressed air system accounts for between 8% and 12% of a pulp and paper plant’s consumption. Leaks, which can reach up to 30% of the generated air, combined with oversized configurations and compressors operating constantly at full load, lead to significant overconsumption. Leak detection, reducing operating pressures, the use of variable frequency drives on compressors, and intelligent demand management significantly improve the efficiency of these systems.
The vacuum system, mainly used in the forming and pressing sections, is another major consumer of electrical energy. Improvement opportunities include pump modernization, adjusting vacuum levels to actual needs, and reducing leaks in pipes and connections, resulting in savings between 10% and 20%.
Pumping and ventilation systems, used in washing processes, pulp transport, and humid area ventilation, offer significant energy-saving potential through the incorporation of variable speed drives, selection of higher-efficiency equipment, and flow adjustment according to the actual demands of each process.
In the paper drying process, which accounts for up to 70% of a plant’s steam consumption, the main opportunities lie in improving control of temperature and steam profiles, recovering heat from exhaust air, and implementing hybrid drying systems that combine steam with recycled hot air.
Finally, the digitalization of energy consumption through real-time monitoring platforms enables the detection of deviations, optimization of operational parameters, and predictive maintenance, generating sustained improvements in the plant’s energy performance and reducing operational costs.
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