Energy efficiency in the pulp & paper sector
The pulp and paper industry is among the most energy-intensive industrial sectors, primarily due to its high demand for steam and electricity in digestion, washing, drying, and conversion processes. Globally, this sector accounts for approximately 6% of the total energy used by the manufacturing industry, and in some pulp mills, energy consumption can represent up to 20% of total production costs.
Energy efficiency opportunities in this industry mainly focus on optimizing thermal and electrical systems, with an emphasis on cogeneration of energy and steam using biomass. Modern plants can supply up to 95% of their energy consumption through biomass boilers, using bark, fiber sludge, and black liquor as fuels. Cogeneration in these facilities enables energy efficiencies exceeding 75%, significantly higher than the 50%–55% efficiency of plants that generate energy and steam separately.
The efficiency of biomass boilers largely depends on fuel quality, the operation of feeding systems, optimization of excess air, and heat recovery from combustion gases. The incorporation of economizers and air preheaters enables the recovery of part of the residual thermal energy, achieving efficiency increases of 4% to 6% in boiler operation.
The steam system is another critical area. Managing optimal pressures, condensate recovery, and minimizing blowdowns are essential practices to reduce fuel consumption. Plants with well-optimized systems can recover more than 85% of the condensate generated, thereby reducing the demand for fresh steam and makeup water consumption.
In auxiliary systems such as compressed air, consumption is estimated to represent between 8% and 12% of a pulp and paper plant’s electrical use.
The main opportunities lie in systematically detecting and repairing leaks—which can account for up to 30% of losses—reducing operating pressures, and incorporating compressors with variable frequency drives (VFDs) that adjust energy consumption to actual demand.
The vacuum system, used in forming and pressing sections, also consumes a significant proportion of electrical energy. Modernizing vacuum pumps, reducing losses from leaks in piping, and optimizing vacuum levels according to the actual requirements of each machine can yield savings on the order of 10% to 20%.
Regarding pumping and ventilation systems—used in washing processes, pulp transport, and humid area ventilation—the implementation of variable speed drives, proper selection of high-efficiency pumps and fans, and correct flow alignment to process needs can reduce energy consumption by 15% to 25%.
Paper drying is one of the processes with the highest thermal demand in the industry, accounting for up to 70% of the plant’s steam consumption. Energy efficiency opportunities in this stage include improved control of steam and temperature profiles, the use of high-efficiency drying hoods, heat recovery from exhaust air, and the implementation of hybrid drying systems that combine steam with recycled hot air.
Finally, energy digitalization through the incorporation of real-time monitoring systems and energy management platforms enables the detection of deviations, overconsumption, and continuous improvement opportunities at each process stage, generating sustained benefits of between 5% and 15% of total energy consumption.
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