Sequential modelling of thermal energy: New potential for energy optimisation in papermaking

Papermaking is known as an energy-intensive, but not always efficient industry. This is at least partly due to the fact that the majority of papermaking technologies and procedures were established at a time when energy was both cheap and plentiful. A considerable fraction of the energy required for papermaking is consumed in removing water by the use of steam in the paper machine's drying section. It is also known that even a small reduction in steam use can result in a significant reduction in production costs and environmental effects. To date, a great deal of research has been undertaken, aimed at improving the performance of the drying section by making more efficient use of dryer steam. This paper investigates a new approach to reducing thermal energy use in paper making by seeking to enhance the amount of water removed in sections of the machine prior to the drying section. The proposed method is focused on sequential modelling of the effect of vacuums used in the forming section on the thermal energy consumption in the drying section. The primary models explain how different vacuum pressures can affect the flow of water from the sheet in the forming section whilst the secondary models describe the effect of increased drainage on the steam requirements in the dryer. Operational data from a UK paper mill are used to illustrate the proposed method. The models developed can have subsequent application to optimising the use of thermal energy in paper making.