Scope: TIP Category: Automatically Periodically Reviewed (Five-Year Review)

TIP 0404-63
ISSUED 2003
REVISED - 2006
2006 TAPPI
The information and data contained in this document were
prepared by a technical committee of the Association. The
committee and the Association assume no liability or responsibility
in connection with the use of such information or data, including
but not limited to any liability under patent, copyright, or trade
secret laws. The user is responsible for determining that this
document is the most recent edition published.
Paper machine energy conservation

Scope
The paper mill area is a major energy consumer in most pulp and paper mills. The rising cost of energy makes it
important to implement energy management and conservation measures. Paper machine energy consumption
represents 50-70% of purchased energy for an otherwise efficient integrated mill. If the paper machine is
uncompetitive on energy, the mill will be as well. Efforts to reduce energy consumption can reduce operating costs
and increase profitability. Reducing paper machine energy consumption requires attention to details in design,
operation, maintenance, and control of nearly all aspects of the papermaking process. This TIP discusses guidelines
for monitoring, benchmarking, and optimizing energy-intensive unit operations to reduce paper machine energy
consumption.
Safety precautions
Follow normal safety precautions when working around paper machinery, including use of personal protective
equipment. Do not allow loose clothing or equipment to contact rotating machinery or ropes. Beware of overhead
cranes and thermal and slip hazards around the dryer section. Avoid direct contact with hot surfaces. Use hearing
protection in noisy areas. Eye protection should be worn in all production areas. Safety shoes and safety helmets
should also be worn where required.
Energy reduction strategy
Efforts to improve paper machine energy efficiency center around five basic principles:
Minimize the amount of water to evaporate in the dryers (and pressure of steam used to evaporate it).
Minimize the amount of steam condensed outside the dryers.
Maximize condensate return flow and pressure to the powerhouse.
Minimize electrical consumption for key users.
Monitor and manage energy consumption and cost.
Mill-wide energy savings require a multi-faceted approach, including purchasing smarter, using less, integrating
processes from different parts of the mill, and generating more and cheaper electricity. Human factors such as
training, publicity, visibility, accountability, benchmarking, and targets can aid in achieving energy conservation
goals.
System monitoring
Scottish mathematician and physicist Lord William Thomson Kelvin (1824-1907) said, If you cant measure it, you
cant improve it. A key first step in energy conservation activities is monitoring energy consumption and making
sure flowmeters and cost information are accurate. Some mills have developed mill-wide system balances that can
be used to check accuracy of individual flowmeters. Assigning a person to be responsible for energy conservation in
the mill and/or paper machine area can help increase visibility and accountability of conservation efforts. Steps for
an effective monitoring program include:
Meter energy flows to each machine.
TIP Category: Automatically Periodically Reviewed (Five-year review)
TAPPI
TIP 0404-63
Paper machine energy conservation / 2
Establish key energy parameters.

Highlight variables that affect energy consumption.
Include energy parameters in operator rounds and centerlining efforts.
Provide information to operators, engineers, and managers to encourage continuous improvement.
Discuss energy cost and conservation efforts in production meetings.
Conduct periodic check-ups of key systems.
Benchmark machine operation with best in class and best achievable for the equipment installed.
Utilities to be monitored include:
Pressure (kPa or psig), temperature (C or F), and flow (kg/hr or lb/hr) for each steam header supplying the
machine.
Electrical consumption for each machine (MW).
Natural gas (m3/hr or scfm)
Water flows and temperatures mill water, warm or hot water from other areas of the mill, and sewer (l/min or
gpm, C or F).
Compressed air pressure (kPa or psig) and flow (m3/hr or scfm).
Condensate return flow (l/min or gpm, kg/hr or lb/hr) and temperature (C or F).
Based on these measurements and paper machine production rates, specific energy indices can be calculated and
tracked:
Steam consumption (kg/tonne or lb steam/ton paper)

Electrical consumption (kWh/ton)
Natural gas consumption (m3/tonne or kscf/ton)
Total energy consumption (kWh/tonne or MMBtu/ton)
Water consumption (m3/tonne or gal/ton)
Compressed air consumption (m3/tonne or kscf/ton)
Condensate return (%)
Total energy cost ($/ton)
Determination of energy unit costs typically requires assistance from mill accounting and powerhouse personnel.
Understanding the relative cost of different energy sources can help papermakers minimize total energy costs. Note
that the cost of various energy sources will change based on relative cost of corresponding raw materials. Cost
components that should be included in evaluation of total costs include:
Net cost of steam to each paper mill supply header ($/kg or $/klb). One method is to determine fuel cost for
high-pressure steam minus the value of electricity generated by turbines. Marginal cost of steam (cost of the last
steam generated) should be used to measure the value of steam savings. Marginal cost is usually higher than
average cost since powerhouses use more expensive fuel to top off demand. Note that this method of calculation
may be an over-simplification if pressure and flow in a low-pressure steam header are maintained by highpressure make-up steam supplied from a pressure-reducing valve in the powerhouse.
Natural gas cost (typically expressed in $/kcal, $/therm or $/MMBtu)
Electrical cost ($/MWh). Calculating $/kW/yr or $/hp/yr can assist in calculating electrical energy savings.
Water and sewer costs ($/M liter or $/MMgal). Both supply and sewer water treatment costs should be included
to determine true value of water conservation projects.
The value of condensate returned to the powerhouse. This should include associated energy, water treatment
costs, wastewater treatment costs, and raw water pumping costs to get it to the water treatment plant. Cost
should be adjusted downward for condensate polishing costs.
The combination of production rates, energy consumption, and cost information can be used to determine energy
cost per ton of product. It is also important to understand energy contracts. Generally managing energy savings
downward is the correct move; however, with some peak energy contracts unless you are able to save off of peak
there are no apparent savings and conversely if you can save off of peak there is an immediate benefit.
3 / Paper machine energy conservation
TIP 0404-63
Performance indices
Performance indices can be used to benchmark energy consumption and identify opportunities for improvement.
TAPPI TIP 0404-47 Paper machine performance guidelines (1) provides a broad range of indices for different
grades of paper. Target values for key indices applicable to energy consumption are shown in Table 1 for various
grades.
Table 1. Energy performance indices
Index
Units
Grade
Bleached
Fine Board
Liner
Uptime
First quality
Overall machine
efficiency
Total steam
consumption
%
%
93
93
93
90
94
97
94
97
95
99
95
97
87
84
91
91
94
92
lb/ton
kg/tonne
kWh/ton
kWh/tonne
MMBtu/ton
kWh/tonne
gal/ton
m3/ton
%
%
%
%
lb steam /
lb water evap
F
C
%
4,000
2,000
350
385
6.0
1,935
2,000
7.6
22
42/45
3.0
5.0
4,000
2,000
350
385
7.0
2,260
2,000
7.6
25
42
3.0
5.0
2,800
1,400
300
330
5.0
1,615
1,500
5.7
27
42/50
NA
7.5
2,750
1,400
300
330
5.0
1,615
1,500
5.7
27
42/50
NA
9.0
2,000
1,000
150
165
4.0
1,290
1,000
3.8
28
50
NA
7.5
2,500
1,250
150
165
4.5
1,450
1,000
3.8
28
45
NA
7.5
1.2
180
80
75-80
1.2
180
80
75-80
1.2
180
80
75-80
1.2
180
80
75-80
1.2
NA
NA
75-80
1.2
NA
NA
75-80
Electrical consumption
Total energy cons.
Water consumption
Couch solids
Press solids
Size press moisture
Reel moisture
Drying steam
PV supply temperature
Condensate return
Corrugating Market
Medium
Pulp
Fluff
Pulp
Key factors
Each machine typically has several key factors that influence energy consumption on the machine. Green/yellow/red
indicators can be used for key process conditions that affect energy consumption to show whether values are in
desired ranges. DCS and/or data historian trending can be used to track trends of key parameters.
Sheet consistency out of the press section is often the primary variable affecting paper machine energy consumption.
Regular grab samples (TAPPI TIP 0404-01 Determination of water removal by wet presses discusses the proper
procedure) or the use of portable or fixed sheet moisture gauges specifically designed for use in the press section are
recommended to track solids. Press solids can also be calculated based on press section and/or dryer section water
balances. Typical additional key factors include:
Venting from dryer section thermocompressor or cascade sections
Condenser water valve output/condensate flow
Differential pressure (especially for lead dryers)
Wire pit steam valve position
Basis weight versus standard
Press section weir flows
TIP 0404-63
Moisture to the size press

Size press starch solids
Pocket ventilation temperature
Temperatures through hood exhaust heat recovery systems
Warm water flow from pulp mill
Winter/summer operating strategy for machine room ventilation
Any additional steam venting
Energy surveys
Energy audits can provide useful first steps to identify and prioritize opportunities to reduce paper machine energy
consumption.
Data can be collected from direct observation; data historians; discussions with mill operating; maintenance, and
engineering personnel; and previous reports conducted on subsystems of the paper machine. A computer simulation
of the papermaking process can help validate data and determine potential benefits from process changes.
Keys to successful implementation of recommendation from an energy audit include:
Obtaining buy-in from all parties involved
Focusing on optimal measures, but not forgetting incremental gains
Understanding the costs, risks, and benefits of potential projects
Considering life cycle costs in project evaluation
Thoroughly planning implementation
Training
Documenting results
Optimizing the system after the project
Additional surveys
A detailed review of various paper machine systems can ensure that systems and equipment are operating
efficiently. Some of these recommended surveys and suggested frequency are shown below.
Steam trap surveys (annual)
Compressed air system surveys (annual)
Refining optimization (on-going) and mechanical surveys (annual)
Saveall audit to check capacity and filtrate quality (annual)
Showering surveys (every 2 years)
Press section optimization (on-going)
Press section nip surveys (every 2-3 years)
Vacuum pump boroscopes or orifice plate testing (annual)
Vacuum system surveys/optimization (every 3 years)
Thermography to check for leaks and hot spots (annual)
Steambox surveys (annual)
Dryer steam and condensate system surveys (annual)
Hood air system surveys (annual)
Machine room ventilation studies (every 5 years)
Pulp dryer maintenance/capacity reviews (annual)
Tissue machine hood balances/inspections (annual)
System optimization
Key process areas to consider when in a program to reduce paper machine energy consumption are discussed below.
TIP 0404-63
Reducing the amount of water to evaporate

Drying steam represents the majority of energy consumption on a paper machine. A step in minimizing energy
consumption is reducing the amount of water to evaporate in the dryers. Opportunities to do this include:
Increase press dryness (high-load, shoe presses)

Optimize press fabrics and roll cover designs (venting and hardness, nip dewatering vs. Uhle box dewatering)
Reduce basis weight (while meeting the product specifications)
Trim the sheet at the wet end rather than at the dry end
Improve moisture profiles
Reduce amount of over-drying before the size press
Increase starch solids used in size press (metering size press)
Increase moisture content of the sheet at the reel (when sheet properties and profiles allow).
Machine efficiency
Increasing overall machine efficiency has a direct effect on specific energy consumption since it takes as much or
more energy to produce a ton of broke as it does to make a ton of first-quality paper. Some steps that can be taken to
increase machine efficiency include:
Reduce sheet break and grade change times.

Shorten open press-to-dryer draws, provide direct sheet support.
Minimize trim losses with good edge control and coordination with business logistics.
Full machine threading - including features that minimize break recovery and thread times.
Optimize performance of trim squirts.
Utilize camera systems to identify and characterize breaks.
Optimize quality control system (QCS) performance to ensure good machine-direction (MD) and cross-machine
direction (CD) profiles.
Control sheet in open draws in the dryer section.
Utilize capability of distributive control systems (DCS) and data historians to impact efficiency and
troubleshooting.
Optimize process chemistry for runnability and maximizing ash content - closed loop control of retention,
charge, etc.
Manage broke to maintain stability.
Optimize whitewater saveall to maximize overall retention, to stabilize wet end during break conditions, and to
increase clear filtrate quality and quantity for replacement of mill water in showers.
Agitation
Chest agitation is a significant contributor to paper machine electrical consumption. Opportunities to reduce energy
consumption with design and operation of agitation include:
Do not overestimate consistency when designing systems

Design chests for the optimum dimensional ratios (cube is best)
Do not underestimate temperature
Allow for a larger manhole to install a larger impeller at low speed
Keep flow impediments [ladders, etc] out of chest design
Only operate the number of pulper agitators necessary
Consider variable-speed or two-speed agitator motors
Utilize zone agitation where complete mixing is not required.
Consider top-entry instead of side-entry agitators
Do not put pump suction behind the impeller
TIP 0404-63
Slow down an agitator and reduce horsepower if operating consistency has dropped substantially from design.
Make sure there is not excessive motion when you look in a chest.
Work with a supplier that understands the mixing process intimately
Pump and motor systems

U.S. Department of Energy (DOE) information indicates that average motor energy cost/mill/year is $1.7 MM for
pulp mills, $4.6 MM for paper mills, and $3.0 MM for board mills. Average available motor savings opportunities
per year are estimated to be $483,000 for pulp mills, $679,000 for paper mills, and $492,000 for board mills. The
U.S. DOE Office of Industrial Technologies web site (3) includes information on pump and motor systems,
compressed air systems, steam, and other opportunities to conserve energy.
Approximately 30% of paper mill electrical energy consumption is by pumps, 20% by fans, 5% by compressors, and
45% by other equipment. Potential electrical energy savings opportunities are available through pumps and fans
(53%), motor efficiency upgrades (23%), air compressors (6%), rewind improvements (6%), motor downsizing
(6%), and other systems (6%). Pump-based systems represent the largest single group of energy-consuming
equipment and offer greatest potential savings.
DOE indicates that 80% of electrical consumption is by 10% of the motor population (motors greater than 50 hp).
200-500 hp motors typically have the largest percentage of savings opportunities.
The primary reasons pumps waste energy are over-design, change in process conditions, or degradation. Overdesign can be the result of overestimating design conditions, contingencies, safety factors, catch-up capability,
room to grow, or design for a wide range of process conditions.
Energy is wasted when a pump system is changed; resulting in a lower flow rate or lower head pressure
requirements, but the pump, motor, and/or piping are not downsized to meet the change. Energy is also wasted when
a larger pump than required is used for the purpose of commonality of spares. This also highlights the need to build
to what will be required instead of building to some future incremental capacity.
Pumps that operate in caustic or solids applications tend to experience impeller and wear ring degradation, causing a
loss in pump efficiency. Routine inspection of pumps in these applications is recommended. Parts should be
maintained and/or replaced as necessary.
DOE promotes identifying motors with the greatest saving potential for further investigation. The greatest savings
potential is typically centrifugal loads with a high duty cycle. These motors are referred to as the vital few. The
following steps can identify them:
1.
2.
3.
Categorize motors by size times operating time. Establish a threshold for more detailed consideration. (Should
be a one-day effort in most plants a plant-wide motor inventory is not necessary).
Segregate by load type (focus on centrifugal loads)
Look for symptoms in pumping systems that indicate potential opportunity:
Systems controlled by throttling valves
Recirculation line normally open
Systems with multiple parallel pumps with the same number of pumps always operating
Constant pump operation in a batch environment or frequent cycle batch operation in a continuous process.
Cavitation noise (at pump or elsewhere in the system)
High system maintenance
Systems that have undergone a change in function.
4. Establish policies to replace seldom-used, small-load, and large, non-centrifugal systems with high-efficiency
motors. PSAT is downloadable at http://www.oit.doe.gov/bestpractices (3).
The Pumping System Assessment Tool (PSAT) can be used to quantify energy consumption and cost savings
potential from a pump. The assessment requires flow rate, pressure, and motor current or power data.
TIP 0404-63
Note that cost to buy a pumping system is usually much less than its operating cost. Life cycle cost should be used
for evaluating pumps.
Opportunities to reduce energy consumption by pumps and motor systems include:
Replace throttling valves with speed controls where appropriate

Reduce speed for fixed-load pumps
Install parallel system for highly variable loads
Equalize flows using surge vessels
Replace motors and/or pumps with more efficient models
Avoid recirculation control
Avoid incompatible duties on common pumps
Do not operate in startup configurations permanently
Design systems with proper line sizes
Avoid tanks where feasible
Optimize process configuration, consistency and pressure setpoints
Determine what can be shut off or bypassed during slow backs.
Refining
Refiners must be in good mechanical condition to minimize energy consumption and optimize fiber development.
Effective life of refiners between rebuilds is typically 10-15 years. Mechanical condition can be estimated by
checking no-load horsepower by backing off refiners while stock is running through them. Higher than normal noload power indicates mechanical problems such as bad bearings, sticking quill, improperly greased slide coupling,
etc. Lower than normal no-load horsepower indicates worn refiner plates. Poor mechanical condition can increase
no-load horsepower by over 10%. Refiners should be inspected annually to check mechanical condition.
Some questions to ask when evaluating a refining system include:
Is the Net Specific Energy applied within normal guidelines for the grade/pulp?
Is the refiner operating properly alignment and no sticking (e.g., splined shaft conversions can prevent
sticking and alignment problems)?
Is plate design matched properly to the fiber and refiner to achieve effective compression index and number of
fiber treatments (optimize strength lift per unit of freeness loss)?
Is the impact of refining on water retention value (WRV) and dewatering understood, i.e., run just enough
refining?
Is the hardware run within proper flow limits?
Opportunities to optimize refining energy include:
Select refiner type, size, speed, and plates to minimize pumping and no-load energy losses.
Operate refiners within design hydraulic flow range. Stocks flow above and below design capacity will reduce
refining efficiency.
Refine at 3.5-5.0% stock consistency for best fiber development, depending on fiber type.
Select refiner plate patterns to provide desired fiber property development with the lowest net energy applied.
Operate with recommended refiner rpm. No-load horsepower increases exponentially with higher refiner rpm.
Operate with lowest plate diameter consistent with stock flow and refining intensity requirements. No-load
horsepower increases exponentially with refiner plate diameter.
Bypass and shut down unnecessary and underused refiners.
Check freeness drop per hpd/t regularly to monitor refining efficiency and determine whether refiners are
working correctly. Typical Canadian Standard Freeness (CSF) drops per net hpd/t are 25-60 for Southern
bleached softwood kraft and 50-60 CSF/net hpd/t for bleached hardwood.
TIP 0404-63
Approach systems
Opportunities to reduce energy consumption in the stock approach system include:
Determine whether cleaners are needed. Size system properly for machine wet end.
Utilize cleaners designed for low pressure drops (less than 207 kPa or 30 psi pressure drop).
Conduct flow balances and verify operating conditions (consistency, pressure drop, efficiency, and debris
removal) of cleaners.
Reduce flows to fiber recovery stages based on balancing the system properly.
Shut down cleaners where product quality permits.
Determine whether deaeration is needed.
Monitor pressure screen differential pressure and reject flows.
Minimize stuff box flow and recirculation.
Install variable-speed drives for machine chest pump (to eliminate stuff box), fan pumps, and other variableflow requirements.
Design for low friction losses in piping.
Consider installing compact stock approach systems offered by several suppliers. Some systems have reported
energy savings as much as 25% from elimination of tanks and pumps.
Recycled fiber systems

Opportunities to minimize energy consumption in recycled fiber systems include:
Ensure that pumps are not oversized.
Install frequency control on motors to reduce energy waste.
Reduce pulp and water volume.
Increase consistency as much as possible to reduce hydraulic volume for pumping and agitating.
Simplify process configuration.
Run equipment at optimum operation point.
Make process stable and homogeneous.
Increase process temperature to gain additional production, being careful not to exceed the stickies activation
temperature.
Close water loops.
Refine and disperse pulp as little as necessary.
Use latest development of machinery equipment to increase overall efficiency.
Water heating
Substantial savings in water consumption can be accomplished with limitations in retention, quality, and energy
dissipation. The reduction in water-usage will also lead to an equivalent saving in energy consumption.
Basic rules for water conservation include reduce, reuse, and recycle. Reduce simply means reducing water fresh
water usage. A systematic approach is recommended with clear identification of every stream. Paper mill water
usage varies between 0 and 60 ton of water per ton of paper produced. Approximately 4-6 tons per ton represent a
practical minimum. Zero consumption is possible, but only with serious quality drawbacks and only achievable with
products such as recycled fiber grades. Simple water reduction possibilities are often overlooked, so it is sometimes
possible to achieve reduction of water and wet end energy consumption by up to 50%. Wet end water consumption
can represent 20-45% of overall paper machine energy consumption.
Reuse can require a systematic study of possibilities of substitution. New process equipment, such as filters, will be
required to allow whitewater streams to be reused.
Recycling can result in significant water and energy reduction, but extra equipment such as filters and/or evaporators
may be required. Heat dissipation and chemical concentration can become issues as water systems are closed.
TIP 0404-63
Opportunities to minimize steam required for water heating include:

Maximize stock temperature from the pulp mill.
Utilize waste heat from the pulp mill or hood exhaust heat recovery instead of steam to heat whitewater and
warm water.
Return only warm/hot water streams to the warm/hot water systems.
Minimize mill water infiltration into whitewater and warm water systems.
Minimize flow and maximize temperature of water from condenser systems.
Maximize strained/polished whitewater reuse in paper machine showers.
Ensure proper saveall design, maintenance, and operation.
Utilize strainers and polishing filters after saveall clear legs to allow reuse in showers.
Utilize circulation cooling towers for vacuum pump seal water.
Keep whitewater temperature set point at 140oF (60oC). Higher temperatures do not significantly increase
drainage rate.
Savealls
Effective saveall design and operation are essential for minimizing material losses and reducing water consumption
on the machine. Increasing capacity, improving maintenance, and/or installing post-saveall strainers and filters can
improve filtrate water quality to allow saveall filtrate to be reused in place of fresh water. Key saveall parameters to
evaluate include:
Installation and equipment, including size (number of installed discs and available blanked-off discs), droplegs
(diameter and layout), and sector type (cover type and condition).
Operation, including proper sweetener type and quantity, well-tuned vat level control, dilution of recovered
stock with rich white water bypass, and cloudy filtrate recycle.
Maintenance including sector cover condition, sector-to-rotor seals, and knock-off and oscillating cleaning
showers.
Showering
Showering is a major source of fresh water consumption on many machines. Any shower water used on the former
that is below whitewater temperature requires steam to return the silo to desired temperature. Cool showers in the
press section can lead to deposits and reduced press solids. From an energy and water conservation perspective,
showers should utilize filtered/polished whitewater wherever feasible. One approach to optimize shower
performance is to assign a whitewater reuse risk factor for each shower based on:
Water filtered with current technology
Likelihood nozzles will plug
Potential felt plugging from fines
Negative effect on paper making process
Typical low-risk showers include:
Breast roll showers
Knock-off showers
Medium-risk showers typically include:
Lubrication showers
Wetting showers
High-risk showers include:
High-pressure wire cleaning
High-pressure felt cleaning
Steps for optimizing shower performance include:
Determine optimum shower flows, shower and nozzle design, and water quality requirements.
Calculate potential energy and fiber savings from utilizing whitewater instead of fresh/warm water.
TIP 0404-63
Improve saveall and filtering to achieve water quality requirements.
Chemistry
Chemistry can impact paper machine energy consumption by affecting sheet properties and improving drainage.
Make-down and introduction of chemicals into the system can also affect energy consumption. Opportunities to
reduce energy consumption through chemical systems include:
Utilize polyamine products to increase strength. This can provide savings through reduced refining, reduced
basis weight, increased couch and press solids, and /or reduced starch usage.
Utilize enzymes for fiber modification to reduce refining needs.
Utilize silica and microparticles to improve drainage.
Utilize whitewater instead of mill water for chemical injection.
Maximize ash content in the sheet.
Headboxes
Basis weight profiles ultimately impact pressing, runnability, and dryer operation. Pressure drop through headboxes
have increased with headbox design evolution. Turbulence level and nozzle convergence impact MD/CD ratio
capability. Consistency profiled designs require lower flow from the cleaner system.
Some areas where headboxes affect paper machine energy consumption include:
Minimize MD and CD basis weight variability to improve runnability and maximize dewatering and drying
efficiency
Improve moisture profile to allow maximum possible moisture content at the reel
Optimize turbulence level and nozzle convergence. The impact on MD/CD ratio capability can help optimize
required strength characteristics to allow for reduced basis weight or reduced refining levels
Impact MD/CD ratio capability
Optimize headbox contribution to formation and sheet uniformity to aid forming, pressing, and drying rates,
improve runnability, and to improve strength allowing the use of higher freeness furnishes.
Operate headbox within designed flow range. Over-designed flow capability generally has very poor results
Maintain cleanliness for efficiency.
Formers
Formers consume energy directly through drive load and vacuum systems. Formation and drainage affect
performance of downstream processes.
Areas where the former affects energy consumption include:
Utilize former type and headbox that provide optimum formation results at higher consistency
Match hardware to drainage needs
Avoid sealing the sheet early in the forming process.
Graduate vacuum down the table to reduce drag load and provide proper sheet consolidation.
Utilize multi-compartment high-vacuum boxes.
Evaluate drainage element materials for impact on drag load
Avoid couch re-wet (suction box orientation, double doctors, air doctors)
Optimize headbox and forming temperatures for impact on drainage and solids
Monitor former solids frequently, maintain high level of solids
Paper machine clothing
Properly designed clothing can have an impact on energy consumption that far exceeds the cost of the fabrics.
Forming fabrics affect energy efficiency in much the same way as formers:
Consistency off the couch, with ~10% of solids improvement transferring to the dryers
Improved formation resulting in better pressing uniformity
Flatbox vacuum requirements
TIP 0404-63
Reduced drive loads
Press fabrics are an important part of press section optimization. Opportunities include:
Pressure uniformity through micropressing
Increasing consistency into dryers
Minimizing sheet rewet
Nip dewatering
Opportunities to reduce Uhle box vacuum
Dryer fabrics can affect capacity and energy efficiency through:
Fabric tension
Surface contact heat transfer
Pocket ventilation mass transfer
Resistance to contamination
Vacuum systems
The vacuum system is often the second largest process in the paper mill for electrical energy consumption (after
paper machine drives), and is frequently one of the least understood parts of the papermaking process. Vacuum
systems can have from 1,000 to 10,000 installed horsepower.
Some of the most common vacuum system problems that can increase energy consumption and/or reduce system
efficiency include:
Hot seal water.

High backpressure on vacuum pumps.
High seal water pressure.
Use of synchronous versus induction motors can affect power factor for the entire paper mill.
High seal water flow from recirculated system without cooling or a poorly operated cooling tower.
High pressure.
Worn or missing orifices and nozzles.
Scale build-up in pumps and piping.
Worn pump rotor, casing, or lobes.
Older, less efficient vacuum pumps.
High piping losses and incorrect system design.
Additional guidelines to minimize vacuum system energy consumption include:
Use fans or exhausters instead of vacuum pumps for low-vacuum applications such as vacuum foils.
Control vacuum level by bleeding air into the system instead of by throttling liquid ring pumps.
Graduate flatbox vacuum to maximize dryness and minimize drag load.
Eliminate unnecessary vacuum boxes (remove or drop out of contact with the fabrics). In addition to requiring
additional vacuum pumps, sucking excessive air through the sheet can cool the sheet and cause press solids to
drop more than the small amount of water that comes out with the air, especially on lightweight, open webs.
Extra flatboxes also add drag load to the table. Proper flatbox setup can remove more water while reducing
table drive load by as much as 10%.
Ensure proper Uhle box slot size to provide required flow capacity and dwell time.
Ensure proper vacuum pump application (high-vacuum vs. low-vacuum pump design).
Prevent carryover of process fluids from suction point.
Provide water/air separation ahead of the pump to prevent two-phase flow at the pump.
Use proper separator removal pump design.
Take unnecessary vacuum pumps out of service.
Check vacuum pump internal clearances and/or capacity annually. Rebuild pumps operating at less than 80% of
design capacity.
TIP 0404-63
Conduct routine maintenance of vacuum pumps and auxiliary equipment, including belt and gear drives and
motors.
Replace and calibrate gauges and process instrumentation (vacuum gauges, seal water pressure gauges, level
transmitters in vacuum pump sumps, amp meters for motors)
Remove old, inefficient vacuum pumps from service. Do not rebuild obsolete pumps with inefficient designs.
System audits can be used to help reduce wasted energy. Replacing or calibrating gauges can ensure proper
indication of vacuum levels. Key operating data should be monitored, reviewed and recorded. Sheet and fabric
moisture should be checked regularly to ensure effective use of vacuum. As with many areas, one of the most
effective ways to manage vacuum system energy is through EMBWA (Energy Management By Wandering
Around). Additional information on vacuum system optimization is included in TAPPI TIP 0404-55 Performance
evaluation techniques for paper machine vacuum systems (4).
Press section
On a typical paper machine with 0.5% headbox consistency, 20% couch solids, 40% press solids, and 5% reel
moisture, 195 kg water is removed per kg fiber in the forming section, 2.5 kg water per kg fiber in the press section,
and 1.45 kg water per kg fiber in the dryer section. However, the cost of water removal is significantly lower in the
forming and pressing sections than in the dryer section. Removal of the water content after the press section
represents more than 50% of the energy consumption in the paper machine system. Each one percentage-point
improvement in solids out of the press section results in 3-5% less water that needs to be evaporated in the dryer
section. Maximizing press performance is thus one of the most important aspects of paper machine energy
conservation.
Primary conservation opportunities in the press section are increased water removal, steam savings, increased
production, more efficient water removal, and fiber savings on bulk sensitive and strength grades. Factors
influencing press water removal are furnish, time, temperature, and pressure.
Press performance can be improved by increasing nip load and by increasing the time during which the press load is
applied. Press impulse (press nip load / nip residence time) has been shown to be a good performance indicator for
press water removal. Development of shoe presses has significantly increased time available in the nip.
Press performance can also be improved by increasing temperature of the web during pressing. Experience indicates
that solids content of the pressed web can be increased by one percentage point for each 10C (18F) increase in
web temperature. Methods to increase temperature in the press section include increased stock temperature, steam
shower applications on the sheet or on the fabric, heated press rolls, or hot water flooded nip showers. Energy
efficiency of heating the sheet in the press section should be compared with that in the dryer section (typically 1.3 kg
steam per kg water evaporated).
Operating felt showers with cool water (such as fresh water) further cools the fabric. High-pressure and low-pressure
shower water should be at least equal to the temperature of stock at the headbox. Shower water temperature of 54C
(130F) or above is beneficial in maintaining fabric temperatures. Shower water heating is an excellent application
for heat recovery.
Uniformity of pressure applied to the sheet in the press is important, especially with modern shoe press technology,
because of increased nip dwell times and lower peak nip pressures. Modern press fabric designs provide improved
pressure uniformity and higher sheet solids content. Multi-axial laminated fabrics provide superior pressure
uniformity, excellent bridging on vented/drilled rolls, and more steady-state pressing compared to conventional
fabrics. Flat batt fibers can offer contact area equal to round fine denier batt without sacrificing wear volume.
TAPPI TIP 0404-52 Press Section Optimization (5) provides guidelines for evaluating and improving press
section performance. The TAPPI Paper Machine Wet Press Manual (6) provides more complete coverage of press
section optimization.
Opportunities to optimize pressing include:
TIP 0404-63
Shoe pressing increases dryness potential, and for bulk-sensitive grades, adds degree of freedom (bulk vs.
dryness).
Single versus double felting impact on press solids. Double felting improves dewatering on heavyweight grades.
Steam boxes increase sheet temperature and increase exiting dryness; can also be used for profile improvement.
Felt heating will help clean the fabric as well as help maintain or increase sheet temperature.
Optimizing roll cover hardness and use of blind drilled or other cover designs where required can improve press
dewatering.
Balance between nip and Uhle box dewatering over fabric life.
Nip dewatering efficiency, press geometry, fabric selection, and operations can result in improved profiles,
solids, and in vacuum for uhle boxes.
Felt and belt design optimization - press fabric design greatly impacts press efficiency, solids level.
Minimize rewet (fabric runs / sheet runs; sleeve doctors, double doctors, air doctors, use of catch pans on high
dewatering nips that generate water spray).
Minimize draw to maximize CD strength on grades requiring high CD strength properties.
Check nip profiles and optimize crowns, dubs, and fabric cleaning to improve moisture profiles.
Monitoring of pressing performanceon-line monitoring of press water flows, frequent CD and MD
monitoring of fabric permeability, moisture, and temperature.
Check press solids frequently.
Steam showers
Steam shower efficiency depends on the product being made, where the steambox is installed and how it is operated.
TAPPI TIP 0404-58 discusses steam shower applications in the forming section. Steam showers are most energy
efficient with low steam ratios on relatively cool systems with vacuum assist beneath the steambox. Best steam
utilization efficiency occurs when steam showers are located ahead of the last press nip since there is less water to
heat. For most applications, efficient steam flow ratios are 0.10 lb steam/lb paper for fourdrinier applications and
0.075 lb/lb for press section applications. Mills should determine the value of steamboxes for specific applications
and operate accordingly. Opportunities to optimize steam shower performance include:
Utilize low pressure waste or vented steam.
Turn off/reduce steam flow when grades that are not drying limited are being produced.
Apply only as much steam as can be condensed in or on the sheet.
Lower steam supply to reduce excess fog in the machine room.
Use profiling capability to apply steam only where needed.
Reduce vacuum to reduce sheet cooling and air infiltration under the steam shower.
Increase vacuum to improve steam penetration into sheet.
Control steam temperature to improve condensation rates.
Provide proper mist elimination when utilizing flash steam. In many cases, some high-pressure make-up steam
is required to introduce a small amount of superheat.
Cut off non-profiling preheat section of profiling steam shower.
Extend and contain steam in wedges and tunnels.
Maintain pressure and temperature gauges.
Eliminate pulp splatter from trim squirts.
Utilize Teflon and/or polished surfaces to minimize build-up and allow operation at design clearances.
Dryer section
The dryer section represents the largest thermal energy consumer on the paper machine. Information on monitoring
dryer section performance is included in TAPPI TIP 0404-33 Dryer section performance monitoring (7).
The 10 Commandments of energy efficient drying are:
1. Dont dry any more than you must
2. Dont vent steam anywhere
3. Match the air flow to drying
4. Use steam from lowest header pressure possible
TIP 0404-63
5.
6.
7.
8.
9.
10.
Keep the machine running

Improve the moisture profile
Increase the heat transfer rate
Measure what you must control
Keep the steam system calibrated
Dont use motive when you can use make-up
Five rules for dryer energy efficiency are:

1. Keep the system tight
2. Efficiently utilize flash steam from high temperature condensate
3. Maximize use of low pressure steam
4. Minimize heat used for hood supply air heating
5. Manage the system
Energy efficient drying requires a combination of steam system design, equipment, operation, maintenance, and
control.
Dryer arrangement
Dryer section arrangement primarily affects energy consumption by increasing machine efficiency. Examples
include:
Single tier arrangements increase dryer wrap and reduce unsupported length. Threading efficiency also
improves.
Increased sheet restraint improves contact with dryers and reduces CD shrinkage.
Draw reduction increases CD strength vacuum assisted blow boxes, placement and quantity of draw points
Windage control impacts runnability
Optimize felt tension for best drying heat transfer.
Felt design to optimize uniformity of sheet contact with dryer surface and heat transfer. Cleanliness impacts
performance.
Blow box systems to improve high speed runnability and efficiency.
Thermocompressor systems
Thermocompressor systems utilize high-pressure motive steam to recompress blowthrough steam and reuse it in the
same dryer section. Good separators, proper piping design, and adequate motive steam pressure are critical for
efficient operation. Opportunities to minimize energy consumption using thermocompressor systems include:
Ensure no steam venting during normal operation.
Utilize blow-through control and/or automatic pressure letdown to minimize venting during sheet breaks.
Optimize differential pressures for condensate evacuation and blow-through flows.
Utilize properly sized thermocompressors.
Optimize motive steam pressure to minimize amount of motive steam flow required and net thermal energy
cost.
Utilize non-condensable bleed steam in low-pressure dryers or other low-pressure steam user such as air preheat coils.
Cascade systems
Cascade systems reuse flash and blowthrough steam in a different dryer section that operates at lower steam
pressure. Opportunities to reduce energy consumption with cascade systems include:
Arrange dryers to minimize steam venting
Minimize number of dryers draining to a condenser and amount of blowthrough steam from these dryers.
Ensure proper section splits to prevent venting during normal operation.
Provide make-up steam from the lowest available steam pressure header that will support section pressure
requirements.
TIP 0404-63
Steam system design

There is no one and only correct solution for steam and condensate system design. The proper application depends
on the mill steam supply and condensate return systems. Proper sizing of piping and equipment are critical. Detailed
piping design should be done and reviewed by a qualified party to ensure proper system operation. Considerations
for energy-efficient steam system designs include:
Ensure no steam venting during normal operation.
Utilize low-pressure instead of high-pressure steam where appropriate.
Separator efficiency is important, especially with blow through control.
Measure condenser water temperature at outlet.
Recover flash steam from separator tanks.
Return condensate to the boiler house at 230F.
Do not shut down dryers to control drying capacity. Improve flexibility of the steam and condensate system
instead.
Steam system hardware
Proper syphon design is a key component in making the steam system energy efficient. Stationary syphons tend to
reduce blow through steam (as low as 10% of condensing load with stationary vs. 15-30% with rotary) and
differential pressure (15-35 kPa or 2-5 psi with stationary vs. 40-95 kPa or 6-14 psi with rotary). In dryers draining
directly to a condenser or heat exchanger, reduced blowthrough steam directly results in energy savings. In sections
that cascade to lower pressure groups or in sections with thermocompressors, evaluation of energy savings is more
complicated.
In a thermocompressor section, energy savings will be achieved with stationary syphons if the section is venting
with rotary syphons and lower differential pressures and blowthrough flows prevent the venting. In a section that is
not venting, savings opportunities depend on relative cost of motive and make-up steam. Reduced blowthrough and
differential pressure will result in less motive steam and more make-up steam but the total amount of steam will
remain the same. If both motive and make-up steam are supplied from the same header, there will be no energy
savings resulting from converting to stationary syphons. However, if the powerhouse is able to generate significantly
more electricity from the lower-pressure make-up steam extraction than from the higher-pressure motive steam,
energy savings can be significant. Turbines typically make the most electricity when most of the high-pressure
steam goes through all of the stages.
Likewise, in a cascade system, there is no net energy savings from simply converting to stationary syphons if the
lower-pressure section condenses all of the blowthrough steam sent to it (with the exception of wet end sections).
Dryer bars are recommended for all dryers operating above rimming speed to provide optimum profile, heat transfer,
and drying rate. Rimming speed depends on dryer diameter and condensate layer thickness, but is typically around
300 meters/minute (1000 fpm). A dryer section will evaporate more water with dryer bars installed. However, it
takes additional steam to evaporate this water, so the kg steam used per kg of water evaporated remains nearly the
same. This same principle also applies to felting unfelted dryers or increasing dryer fabric tension. Drying rates will
improve, but energy efficiency (as measured by kg of steam used per kg of water evaporated) will see little change.
Additional information on dryer bars is included in TAPPI TIP 0404-35 Application of dryer bars (8). Minor
reductions in energy consumption are possible with dryer bars related to operation at lower steam pressures with
improved heat transfer.
Guidelines for steam system hardware include:
Utilize stationary syphons where advantages can be realized from lower differential pressures and blow-through
flows.
Install modern steam joints.
Install dryer bars (increase drying rates in most cases).
Size thermocompressors for the current steam system operation.
TIP 0404-63
Optimize thermocompressor design and operation.

Check sizing of rotary syphons.
Use appropriate steam trap designs for heaters.
Utilize pilot-operated safety relief valves for applications that operate close to maximum allowable working
pressure.
Improve mechanical reliability of equipment to prevent leaks.
Steam system operation

A properly designed steam and condensate with good equipment will still waste energy if not operated properly.
Considerations for energy-efficient steam system operation include:
Operate dryer differential pressures at the proper setpoint for condensate evacuation and blow-through flows.
Ramp warm-up dryers to maximize runnability
Maximize drying in sections that use low-pressure whenever possible
Minimize dryer can surface contamination
Minimize steam venting to condensers
Utilize proper dryer warm-up procedures to minimize steam joint leaks.
Close separator tank drains
Check separator tank level controls
Check vacuum tank level control
Avoid over drying minimize number of cans in the falling rate zone
Conduct regular roof rounds to check for venting and leaking safety relief valves.
Regularly check vacuum systems for air leaks.
Steam system maintenance
Dryer section maintenance items that can affect energy consumption include:
Ensure tight shut-off of steam vent, bypass, and blow-down valves
Calibrate pressure and differential-pressure transmitters
Disconnect steam to bottom unorun dryers, felt dryers, and Feeney dryers that do not contact the sheet
Check that steam traps are functioning properly
Check steam valves and thermocompressor actuators
Fix leaks. A small pinhole, a leaking gasket, a trap thats stuck open, or a leaky steam joint can easily waste
150-250 lb/hr steam. The cost of maintenance is typically small compared to potential energy savings.
Steam system control
Opportunities to utilize steam system control to minimize energy consumption include:
Control vacuum condenser to match differential pressure requirement.
Automate dryer warm-up and shutdown sequencing.
Automate dryer sheet break recovery response.
Automate grade change response.
Automate dryer steam system pressure and differential control.
Install thermocompressor cut-off control to prevent venting.
Install smart control valves to support preventive maintenance.
Trend major process variables.
Provide troubleshooting help.
Flash steam utilization
High temperature condensate will generate flash steam as it is collected in a lower pressure tank. This flash steam is
often wasted or poorly used. Often it is vented either at the machine or at the boiler house. Low pressure flash steam
can be reused as make-up steam to wet end dryers, steam showers, water heating, or flash coils in the pocket
ventilation system. If flash steam is used for steam showers, condensate carryover must be avoided through good
separation, steam traps, and proper piping design. In some cases, small amounts of higher-pressure steam are
TIP 0404-63
required to provide a small amount of superheat to the line. Note that care should be taken in reusing flash steam. It
is possible to distill pH-controlling amines from flash steam and end up with corrosive carbonic acid that will
quickly eat through steam coils.
In some cases it may be easier and more cost effective to pump hot condensate through air heating coils rather than
utilizing a low-pressure flash tank. It is important to keep the condensate pressurized to prevent flashing and
hammering before the coil, so level control valves must be positioned downstream of the coils.
Pocket ventilation and hood supply systems
Supply air temperatures of 82-93C (180F to 200F) are generally optimal for pocket ventilation system
performance. Dryer air systems operated at elevated temperatures increase energy consumption, but offer little or no
improvement in drying capacity. There is typically no need for pocket ventilation temperature to be higher than
sheet temperature.
As an example, a machine with 3400 m3/min (120,000 cfm) of pocket ventilation air supplied to the dryers will
utilize 8,220 kg/hr (18,100 lb/hr) of steam at 116C (240F), and only 6,040 kg/hr (13,300 lb/hr) steam at 93 C
(200F). Operation at the lower temperature results in $230,000/yr energy savings at steam costs of $13.20/1000 kg
steam ($6.00/1000 lb steam). Additional information on hood air systems is included in TAPPI TIP 0404-24
Recommended operation of dryer section hood air systems (9).
Opportunities to reduce energy consumption with dryer section hoods and air systems include:
Operate pocket ventilation system at 180 -200F.

Optimize hood exhaust humidity. Adjust air exhaust to match drying load and hood capability.
Recover heat from hood exhaust streams.
Use inside air rather than outside air for pocket ventilation.
Insulate dryer hoods and ductwork.
Replace damaged hood panels and panel seals.
Monitor condition and cleanliness of air system filters and coils.
Change ventilation system filters when necessary.
Check heater tubes for leaks
Check air heater uniformity from top to bottom
Pocket humidity control impacts drying rate and profiles.
Monitor supply ventilation air temperature rise
Monitor ventilation air exhaust temperature drop
Replace existing hoods with high-performance hood designs.
Size press
The size press offers opportunities to reduce energy consumption by reducing the amount of water evaporated,
increasing machine efficiency, and optimizing sheet strength. Opportunities include:
Evaluate product need to dictate application technique surface application or heavy penetration.
Film-type designs can minimize water load applied.
Maximizing solids content of material applied.
Maximize ingoing moisture content.
Threading and spreading (efficiency).
Early after dryer surfaces to improve runnability and minimize picking (air turns, alternative drying methods).
Optimize strength with size press application - to minimize fiber, optimize filler content.
Reel
Improvements to reel operation contribute to increased machine efficiency. Sheet defects near the spool and edges
negatively increase slab losses and impact process efficiency. Spool deflection can contribute to defects.
Opportunities include:
TIP 0404-63
Rubber covered reel spools to minimize turn-up losses

Nip relieving and/or controlled primary/secondary arm transfers can reduce defects
Control winding parameters (torque, nip, tension)
Maximize turn-up efficiency (# sets)
Utilize turn-up systems and reel brakes to minimize slab losses
Monitor and display slab losses, report results - control to maintain world class levels
Miscellaneous steam systems

The energy lost in steam lines from the powerhouse to the paper machine room and in condensate lines back to the
powerhouse can be reduced by eliminating steam leaks, avoiding unnecessary pressure drops, ensuring proper
operation of steam traps, and maximizing the amount of condensate that is returned.
Opportunities to reduce energy consumption in the overall steam and condensate system include:
Repair steam leaks.

Insulate steam system piping and separators.
Utilize the lowest feasible steam pressure for miscellaneous steam users such as steam showers, water heating,
and air heating.
Conduct regular steam trap surveys and repair leaking or plugged traps.
Check for excessive pressure drops through flowmeters, lines, etc.
Ensure that proper pressure and temperature compensation factors are used in steam flowmeter calculations.
Utilize pilot-operated safety relief valves for applications that operate close to maximum allowable working
pressure.
Conduct regular roof rounds to check for venting and leaking safety relief valves.
Utilize degrees of superheat control for desuperheaters, where temperature setpoints are established based on
a given superheat level above saturated steam pressure.
Determine standard operating procedures for steam trap and drain line valving during warm-up and normal
operating conditions.
Clean heat exchanger and monitor U-factors.
Maximize condensate return to the powerhouse.
Compressed air systems

Compressed air is one of the most inefficient sources of energy in the mill. It takes 5-6 kW (7-8 hp) of electricity to
generate sufficient compressed air to drive a 0.75 kW (1-hp) air motor. A typical 56 kW (75 hp) compressor with 5day/week, 2-shift operation will typically have $20,000 equipment cost, $20,000 maintenance cost, and $130,000
electrical cost over a 10-year life. Replacement of the air-driven motor with an efficient electric motor has the
potential for significant savings over the life of the unit. Opportunities to minimize compressed air cost include:
Instrument air dew point should be 10C (18F) below the lowest temperature the system would see.
Utilize ultrasonic leak detectors to identify system leaks.
Conduct annual air system audits.
Utilize dedicated compressor instead of mill air for headbox air pads
Reclaim water from compressors where appropriate.
Air system audits can typically identify energy savings of approximately 30% of compressor energy consumption.
For a large mill, this can result in $250,000 - $1,000,000/yr in energy savings.
Compressed air surveys typically involve:
Developing a block diagram of the system.

Measuring baseline conditions.
Implementing an appropriate control strategy.
Re-measuring after controls are adjusted.
TIP 0404-63
Walking through the system to find preventive maintenance and additional opportunities.
Identifying and fixing leaks and correcting inappropriate use.
Implementing awareness and continuing improvement plans and reporting results to management.
Air-padded headboxes require relatively high volumes of compressed air (4.25 to 7 m3/min or 150 to 250 scfm) at
low pressures (less than 100 kPa or 15 psig). These should utilize dedicated headbox compressors instead of
bleeding off of mill air headers.
Reclaiming water from air compressors can also provide energy and water savings. Additional information and
references on compressed air systems are included in reference 3.
Machine room ventilation
Effective maintenance, proper temperature setpoints, and winter/summer operating strategies can be used to improve
energy efficiency of machine room ventilation systems. Machine room ventilation is discussed more completely in
TAPPI TIP 0404-50 Machine room ventilation guidelines (10). Opportunities to reduce energy consumption
associated with machine room ventilation include:
Establish winter and summer operating conditions for machine room supply and exhaust fans.
Operate air make-up units at 21C (70F) setpoints and roof supply systems at 49C (120F).
Utilize water or glycol systems (with heat recovery) to heat make-up air.
Utilize inside air instead of outside air for motor cooling, roof supply, and pocket ventilation.
Shut off steam coil or glycol systems to air make-up units when fans are shut off. Ensure that there is proper
freeze protection.
Heat recovery
An energy balance around the paper machine room shows that all thermal energy provided to the machine room
exits with the sheet (very small amount), exhaust air streams, and water streams.
Opportunities for dryer hood heat recovery are typically limited to supply air preheating. Air-to-air economizers
have limited potential to recapture energy from exhaust streams. The amount of energy recoverable in the drying
section is limited due to the ratio of latent heat in the exhaust and the sensible heating of the dryer air. Overall
energy content in the exhaust air is about 6-10 times greater than the potential heating of incoming air.
Air-to-liquid economizers used for heating fresh water, whitewater, or circulating water or glycol systems provide
greater opportunity to improve the amount of recovered heat. More elaborate heat recovery systems could
substantially improve the degree of energy saving, but these systems typically have increased complexity. High
humidity closed hoods require much less hood exhaust and offer much greater heat recovery potential.
Areas with opportunity for heat recovery include:
Dryer section hood exhaust
Yankee hood exhaust
Pulp machine air dryer hood exhaust.
TMP steam
Vacuum blower exhaust
Waste heat from pulp mill and evaporators.
Sewer streams
Tissue machines
Tissue and towel machines offer additional opportunities to optimize energy consumption. Most machines with
conventional Yankee dryers utilize steam showers, suction pressure rolls, steam-heated Yankee dryers, and gas-fired
hoods to remove water from the sheet. Energy conservation requires maximizing use of low-cost energy sources
TIP 0404-63
(typically low-pressure steam used in steam showers) and minimizing consumption of high-cost sources (typically
natural gas used for hood burners).
Increasing recirculation air and reducing make-up air and exhaust from the Yankee hood system will reduce energy
consumption at the cost of drying rate.
Good performance for tissue machine drying steam and gas usage is 5.2 GJ/tonne (6.0 MMBtu/ton). Low energy
users utilize 3.4-4.3 GJ/tonne (4-5 MMBtu/ton), below average users are 4.3-5.2 GJ/tonne (5-6 MMBtu/ton), highenergy users are 5.2-6.0 GJ/tonne (6-7 MMBtu/ton), and very high-energy users are 6.0-6.9 GJ/tonne (7-8
MMBtu/ton). Through-air dried (TAD) machines typically use significantly more energy per kg of product than
conventional Yankee machines. This is because more water is dried and none is mechanically pressed from the
sheet. Additional information on TAD is included in TAPPI TIP 0404-25 Through drying (11).
Opportunities to optimize energy consumption on tissue machine hood and air systems include:
Operate in cascade mode instead of parallel mode.
Optimize air system burner efficiency and stabilize static pressure to nozzles.
Set up air supply and exhaust dampers (or fan speeds) to optimize energy efficiency. Utilize hood humidity
sensors (0.40 0.45 lb/lb typically optimal).
Adjust air system fuel/air ratio.
Optimize hood impingement temperature vs. impingement velocity.
Optimize air cap gap (3/4) to increase heat transfer from the nozzles.
Balance hood to minimize infiltration and exfiltration.
Maximize heat recovery from hood exhaust.
Preheat air make-up and combustion air streams to minimize natural gas usage.
Ensure no leaks from hood, bypass dampers, or duct flange connections.
Conduct regular system surveys.
Additional opportunities to minimize energy consumption on tissue and towel machines include:
Monitor and benchmark energy flows.
Optimize pressing to maximize sheet solids. Take regular sheet moisture samples after suction pressure rolls.
Optimize use of press section steam showers.
Maximize Yankee operating steam pressure (within limits of dryer code), sheet quality, Yankee coating, and
thermocompressor venting issues) to minimize use of natural gas in heating hood air.
Maximize proportion of drying done by after-dryers on wet-crepe machines.
Utilize infrared cameras to check ductwork insulation for hot spots.
Optimize thermocompressor system operation to eliminate venting.
Increase reel moisture when quality considerations allow.
Conversions
GJ/t X 0.8606 = MMBtu/ton
KWh/t X 0.9072 = kWh/ton
Keywords
Energy, Paper Machines
Literature cited
1.
2.
3.
4.
5.
6.
TAPPI TIP 0404-47 Paper Machine Performance Guidelines

Energy Cost Reduction in the Pulp and Paper Industry, First Edition, PAPRICAN, November 1999
U.S. Department of Energy Office of Industrial Technologies web site: http://www.oit.doe.gov/bestpractices
TAPPI TIP 0404-55 Performance Evaluation Techniques for Paper Machine Vacuum Systems
TAPPI TIP 0404-52 Press Section Optimization
Paper Machine Wet Press Manual, Fourth Edition, TAPPI PRESS, 1999.
7.
8.
9.
10.
11.
TIP 0404-63
TAPPI TIP 0404-33 Dryer Section Performance Monitoring

TAPPI TIP 0404-35 Application of Dryer Bars
TAPPI TIP 0404-24 Recommended Operation of Dryer Section Hood Air Systems
TAPPI TIP 0404-50 Machine Room Ventilation Guidelines
TAPPI TIP 0404-25 Through Drying
Note that this TIP was originally developed from a panel discussion on Paper Machine Energy Conservation at the
2001 TAPPI Engineering Conference. The 2006 revision utilized material and discussions from the Energy
Conservation Track at the 2006 TAPPI Papermakers Conference.
Additional information
Effective date of issue: August 29, 2006.
Working Group:
Jeff Reese Chairman, International Paper
Marc Foulger GL&V
Helmuth Gabl Andritz
Ken Hill , Kadant Johnson Systems
Jon Kerr Andritz
Pekka Kormano Deublin Steam Systems
Jack Milliken GL&V
John Neun Albany International
Dick Reese Dick Reese and Associates
Doug Sweet Doug Sweet and Associates
Rick Wasson Irving Tissue
Greg Wedel Kadant Johnson
Philip Wells Wells Enterprises Inc.
Paper Machine Energy Update

Dick Reese
Dick Reese and Associates, Inc.
5121 Edgerton Dr
Norcross, GA 30092
(770) 448-8002
rareese@bellsouth.net
2006 TAPPI Papermakers

Energy Track Summary

Energy costs are not likely to go down soon.

The rising cost of energy makes the case for
implementation of energy management and
conservation measures.
Paper machine energy consumption is 50-70% of
purchased energy for an efficient integrated mill.
If the paper machines are uncompetitive on energy,
the mill will be as well.
Reducing paper machine energy consumption
requires attention to details in design, operation,
maintenance, monitoring, and control of nearly all
aspects of the papermaking process.
Whats New?

Energy prices are down-Will they stay down?

Some mills have reduced energy expenses by
focusing on reducing consumption.
DOE is now supporting paper machine energy
surveys.
TIP 0404-63, paper machine energy
conservation updated.
Low-Cost Producer
Labor
32%
Energy
37%
Chemicals
Fiber
24%
Energy Cost

Energy cost is typically one of the highest

components of manufacturing cost and as
much as 40% of total cost.
Some fuel costs have more than doubled in
the past 3 years.
Mills that do not focus on reducing energy
cost and consumption will not be competitive.
Energy management will become a life or
death issue in many mills.
Typical U.S. Energy Costs

Units
Average
Range
65-psig Steam
$/klb
$5.00
$2 to 10
165-psig Steam
$/klb
$6.00
$2.50 to 11
400-psig Steam
$/klb
$7.00
$4 to 12
$40.00
$35 to 110
$260
$225 to 700
Electricity (MW) $/MWh

Electricity (hp)
$/hp/yr
Energy Opportunities
Energy consumption on the average

paper machine is ~20% higher than
good performance targets.
Based on 2005 TAPPI PM Energy Survey
TIP 0404-63 Whats New?

Updated to include information

presented at 2006 TAPPI Papermakers.
Very comprehensive energy bible.
Twice as long as 2003 version, now 21
pages.
Includes energy performance indices for
fine paper, liner, medium, market and
fluff pulp, and bleached board.
TAPPI TIP 0404-63

Paper Machine Energy Conservation
Five Basic Principles
1.
Minimize amount of water evaporated in the
dryers.
2.
Minimize amount of steam condensed
outside the dryers.
3.
Maximize condensate return flow and
pressure.
4.
Minimize electrical consumption for key
users.
5.
Monitor and manage energy consumption
and cost.
Energy Observations
There are opportunities to improve condenser

operation on many machines.
There are opportunities to improve press
section dewatering at low cost on many
machines.
Whitewater system design and operation is
often not energy efficient.
There are opportunities to recover heat from
hood exhausts and effluent in several mills.
Energy Observations
Wet End Dryer Control
One machine did not have a differential

pressure valve after wet end separator. Flash
steam was vented to atmosphere.
One machine was sending flash steam from
nearly half of the dryers to condensers.
Three machines in one mill were trying to
control condenser operation by monitoring
condensate temperature.
Energy Observation
Specialty Fine Paper Mill
50% of dryers flash steam to

condensers.
Comments
Opportunity to reduce dryer steam

consumption by 10% by rebuilding steam
and condensate system.
Potential annual savings $400,000.
Energy Observations
Dryer Condensers
Control vacuum and/or cooling water

exit temperature (not condensate
temperature).
Check system for vacuum leaks on
every shutdown.
Energy Observations
Wet End Dryer Control
Control differential pressure for dryers

draining to condensers to minimize
blowthrough steam flow.
Use stationary syphons and steam
joints to minimize differential pressure.
Shut off and disconnect steam to
bottom unorun dryers.
Use flash steam for steam showers, etc.
Flash Steam Utilization

Make-up Steam
From Low Pressure
Header
TT
PT
To Wet End Steam

Shower
FT
Moisture
Eliminator
High Temperature Condensate

From Individual Separator Stations
1
Atmos.
PT
Alternatively
Steam Can Be
Flashed Into A
Low Pressure Header
LT
Flash Steam To
Wet End Steam
Shower
Flash Steam Uses

Flash Steam Use
Ranking
Send pressurized condensate to boiler
Best
In low pressure dryers
Good
Pocket ventilation preheat air
Good
Former or wet end steam shower
Fair?
Machine shower water heating
Fair?
Machine silo
Poor
Discharge to atmosphere
(machine or boiler)
Unacceptable
Energy Observation
Corrugating Medium Paper Mill
Run steam in bottom unorun dryers to improve

runnability? Running 9 lb dp with stationary syphons
and flash steam going to a condenser.
Comments
Most machines shut off steam to bottom unorun dryers since

the sheet does not contact these dryers.
Many medium and liner machines run high steam pressures
in early dryers and do not need a condenser.
Reducing dp to 4 lb would reduce blowthrough steam flow
by a factor of 2+.
Syphon Blowthrough Versus Differential Pressure

15
14
Rotary Syphon
Operating Point
13
Differential Pressure (psi)
12
11
10
9
8
7
6
5
4
3
Stationary Syphon
Operating Point
2
1
0
0
100
200
300
400
500
600
700
Blowthrough Flow (pph)

Rotary Syphon
Stationary Syphon
800
900
1000
Energy Observation
Specialty Wallboard Mill
Discharges 200,000 gallons per day of

150oF effluent. Average fresh water
temperature is 55oF.
Comments
Opportunity to recover 75 MM Btu per day

by installing a spiral heat recovery unit to
preheat fresh water.
Potential annual energy savings are
$260,000.
Energy Observation
Recycled Paperboard Mill
Discharges 400,000 gallons per day of

80oF effluent. Average fresh water
temperature is 55oF.
Comments
Opportunity to recover 67 MM Btu per day

by installing a spiral heat recovery unit to
preheat fresh water.
Potential annual energy savings are
$240,000.
Spiral Heat Exchanger-Single

Channel with Counter-current Flow
Spiral Heat Exchanger
Liquids Flow Counter-currently

in Individual Spiral Channels
Energy Observation
Specialty Wallboard Mill
Has gas-fired kiln dryer with no heat

recovery. Exhaust temperatures are 320
to 350oF.
Comment
Opportunity to recover heat to preheat

burner combustion air, kiln edge seal air,
and building supply air.
Energy Observation
Recycled Paperboard
Have six-high stacked dryers

(midwestern U S State).
Comment
Opportunity to recover heat to preheat

vapor absorption system make-up air,
incoming mill water, and machine room
supply air.
Typical Multi-Stage
Heat Recovery System
3 Stages For Maximum

Heat Recovery
Stage 1- Air to Air (24/7)
Stage 2- Air to Glycol (seasonal)
Stage 3- Air to Process Water (24/7)
Typical 3 Stage Heat Recovery System

Air/Liquid
2nd Stage
Air/Air
1st
Stage
Air/Liquid
3rd Stage
Exhaust
Energy Observation
Trim loss at winder is 10% of reel deckle on

major grade that is 55% of grade mix.
Comments
Opportunity to reduce dryer steam consumption

by 10% on this grade. Potential annual steam
savings $400,000.
Will require wet trim capability and small pulping
unit (cylinder wet end with no broke pit).
Narrow Deckle Considerations

Machines that produce grades with

narrow deckles can reduce dryer steam
consumption by moving trim squirts.
Potential problems include press fabric
filling, broke handling, threading issues,
changes in blow through steam, roll
wear issues, and winder operating
issues.
Lateral Corrugator Technology

Description
Conventional corrugating does not utilize the strength

advantage of machine direction fiber alignment.
Compression strength enhancement by orienting the
linerboard transversely can as much as 30%.
Project Goal: Develop a commercially viable lateral

corrugating process including designing and building
a pilot lateral corrugator, testing and evaluating the
pilot machine, and developing a strategy for
commercialization.
Lateral Corrugator Benefits

Lateral corrugating is a cut-to-width operation

resulting in considerable benefits at the box plant
(bp) and paper mill (pm):
Waste reduction (bp)
Trim optimization (bp & pm)
Ability to utilize paper machine trim rolls (pm)
May permit basis weight reduction (pm)
Reduced inventory (bp)
Shipping optimization (pm to bp)
Lateral Corrugator Project Partners

Financial Support:
Temple-Inland Paperboard and Packaging
Smurfit-Stone Container Corp.
U. S. Department of Energy
IPST at Georgia Tech
Equipment and Expertise:
Corrugated Gear
MarquipWardUnited

Hardy Instrumentation
Albany International
Container Graphics Corp.
Kadant Johnson Corp.
WIKA Instrument Corp.
Pamarco

Corn Products
CUE
Armstrong
Chicago Electric
Bill Nikkel
Lateral Corrugator Contact

Information
Michael Schaepe
Institute of Paper Sci & Tech @GT
500 10th St, NW
Atlanta, GA 30332-0620
404-894-6640
michael.schaepe@ipst.gatech.edu
Web site www.ipst.gatech.edu/research/projects/
corrugating.html
Energy Observation
Press Dewatering Improvement
Many mills are using advanced

technology press fabrics, optimizing nip
geometry, and other techniques to
increase web dryness entering the
dryers.
TIP 0404-52, press section optimization,
provides guidelines.
Relative Cost of Water Removal

124
2.25
1.25
Gravity
Mechanical
Fabric Tension
Compression
Vacuum
$0.014/ton
Former
Evaporation
Specific Cost of Water Removal
Water Removal kg/kg fibers
$0.019/ton
$22.00/ton
Presses
Dryers
* Source Pressing Principles Dr. Ivan Pikulik Paprican 2002
Containerboard Press Solids vs

Steam Consumption
55
Press Solids %
50
45
40
35
2000
3000
4000
Steam Consumption lb/t
5000
6000
Corrugated Medium
Improved Speed and Reduced Steam Usage
2.55
2120
2.50
2100
2080
2.40
Machine ran 3.5% faster
while using 10% less steam
Potential Annual Value = $1.9 MM
2.35
2060
2040
2.30
2020
2.25
2000
2.20
2.15
1980
2.10
Engineered Density Technology 1960
Supplier A
Supplier B
Steam Usage (klb/ton)
AstenJohnson Stylus
Machine Speed (fpm)
Machine Speed (fpm)
2.45
Energy Observation
Using fresh water at 40 to 70oF for

press fabric conditioning. Press dryness
43.8% with 1,200 pli last press.
Comments
Recommended shower water temperature

is 130oF.
Lower temperature cools sheet, reduces
press dewatering, and provides less
efficient fabric conditioning.
Whitewater Filter
How Does It Work ?

INNER DISC
FLOW
SUPPORT SCREEN
FILTER MEDIA
Filtrate
3
1
Shower Water Filter

Vessel is full of process water and operates at low pressure
(0,1 - 0,3 bar)
Disks are completely submerged and slowly rotate
Rotation speed increases as vessel pressure increases
Clean filtrate passes through the media to central hollow shaft
Disks are continuously cleaned in three stages :
A.
Filter cake is doctored off and pumped away (if necessary)
B.
Clean filtrate is pulled back through media removing debris
C.
Oscillating high pressure, submerged shower cleans the

media
BRUSH SHOWERS
Brush Shower
Energy Observation
Have to run two dry end pulper

agitators full time to slush winder trim.
Comment
Pulper modifications will permit operation

with one agitator and provide $75,000
annual savings.
Energy Efficient Repulper

Rotor Blade
Energy is a
Controllable
Operating Expense !
Batch Repulper Power Response

Three Day Comparison
Summary of Energy Savings

Batch Repulper
Conventional Rotor
Low Energy
Rotor
Peak Consumption (kW)
368
265
Avg. Consumption (kW)
336
259
Motor hours/day
20.8
20.8
6,989
5,387
2,446,150
1,885,450
kWh/day
kWh/350 day year
kWh/year saved
560,700
Cost Savings (USD)

Energy Cost (USD)
28,035
0.05/kWh
0.05/kWh
Energy Observation
Kraft Specialty Machine
Whitewater system is too small so mill

water is used in pulper when running
purchased pulp.
Comment:
Larger whitewater system would permit

using whitewater for pulp dilution.
Energy Observation
Sheet follows second/last press fabric ~

10 feet after press nip
Comment:
Estimated sheet rewet is 2 to 3 percentage

points that equates to 4,000 to 6,000 lb/hr
increase in dryer steam consumption.
Mill is looking at different press fabric
designs and ways to get sheet off fabric
without compromising runnability.
Press Rewet
Single Felt
Rewet
Single Felt
Rewet Minimized
Double Felt
Rewet Minimized
Energy Observation
Rebuilt refiners and changed to spiral

logarithmic refiner plates.
Comment:

Rebuilds increased plate life and capacity.

Plate changes reduced energy consumption
by 10% at comparable strength and
freeness.
Logarithmic Spiral Design
Spiral Refiner Plate Benefits

Better Strength
Average Experience: 5-10%
Improvement
Comparable Energy Consumption
Energy Savings
Average Experience: 10%
Reduction
Comparable Strength and CSF
Energy Saving Reduced Diameter Plate Designs
No load: Wasted energy required just to spin a refiner rotor in a pulp slurry
No Load Equation (HP): = (3.083 X 10-13)(Dia4.249)(RPM3)
42 Refiner @ 514 Rpm = 330 Hp no-load
38 Reduced diameter plate @ same 514 Rpm = 215 Hp no-load
Energy Observation
Specialty Kraft Paper Mill
Has many vacuum pumps

manufactured before 1960 that are
energy inefficient (high hp and seal
water flow).
Comment
Pumps should be replaced (not rebuilt)

when capacity falls below 80% of design.
Nash Vacuum Pump Comparison

Model
H4408
CL4002
904M2
Vintage
1930-1960
1960-1984
1984-
CFM@in Hg
4,000@20
4,000@20
4,000@20
257
400
327
Seal Water
100 gpm
60 gpm
65 gpm
Horsepower
205
180
160
0.051
0.045
0.040
RPM
Hp/cfm
Energy Observation
Stacked Dryer Cylinders
Pro

Less machine direction space required.

Better for heat recovery.
Con

Higher radiant heat loss (7 vs 3%?).

Difficult to apply fabrics.
More difficult to thread and remove broke.
Mechanical stability of frames.
STACKED
DRYER
SECTION
THREE-TIER
DRYER
SECTION
Energy Optimization
Low Energy Mode
When drying or speed limited:

Lower whitewater temperature.

Turn off/reduce steam flow to steam
showers.
Lower temperature or turn off PV and VA
systems if does not cause sweating or
moisture profile to get worse.
Reduce steam pressures in wet end dryers
that flash to condenser.
Relative Steam Application Efficiency

Pounds Steam Per Extra
Pound Water Removed
Heating White Water
5 to 10
Fourdrinier Steambox
3 to 5
Press Steambox
1 to 2?
Dryers
1.3
IR Temperature Gun
Identify leaks in steam system:

Relative dryer temperatures

Sheet temperatures
Fresh water, whitewater, shower, and
effluent water temperatures
Vent valves
Condensate system
Steam traps
Flat black paint required to get emissivity right.
Leaking valves in fresh water make-up
Appendix
Information in TIP 0404-63
TAPPI TIP 0404-63

Paper Machine Energy Conservation
Five Basic Principles
1.
Minimize amount of water evaporated in the
dryers.
2.
Minimize amount of steam condensed
outside the dryers.
3.
Maximize condensate return flow and
pressure.
4.
Minimize electrical consumption for key
users.
5.
Monitor and manage energy consumption
and cost.
Energy Monitoring

Meter energy flows to each machine.

Establish key energy parameters.
Highlight variables that affect energy consumption.
Include energy parameters in operator rounds and
centerlining.
Provide information to operators, engineers, and
managers to encourage continuous improvement.
Discuss energy cost and conservation in production
meetings.
Conduct periodic checks of key systems.
Benchmark machine operation.
Utility Monitoring

Pressure, temperature, and flow for each

steam header.
Electricity consumption for each machine.
Natural gas consumption.
Water flows and temperatures-mill water,
water from other areas of the mill, and
sewer.
Compressed air pressure and flow.
Condensate return flow and temperature.
Calculate Specific Energy

Indices

Steam consumption-lb steam/ton paper

Electricity consumption-kWh/t
Natural gas consumption-Kscfm/t
Total energy consumption- MM Btu/ton
Water consumption-gal/ton
Compressed air consumption-kscf/ton
Condensate return-%
Total energy cost-$/ton
Paper Machine Energy Targets

Fine Paper and Bleached Board
Index
Units
Grade
Fine
Bleached Board
Uptime
93
93
First Quality
93
90
Overall Machine
Efficiency
87
84
Total Steam
Consumption
Lb/ton
4,000
4,400
Electricity
Consumption
kWh/ton
350
350
MMBtu/ton
6.0
7.0
Gal/ton
2,000
2,000
Couch Solids
22
25
Press Solids
42/45
42
Size Press Moisture
3.0
3.0
Reel Moisture
5.0
5.0
Drying Steam
Lb steam/lb water
evap
1.2
1.2
180
180
75-80
75-80
Total Energy Cons.

Water Consumption
PV Supply
Temperature
Condensate Return

Linerboard and Medium
Index
Units
Grade
Liner
Corrugating Medium
Uptime
94
94
First Quality
97
97
Overall Machine
Efficiency
91
91
Total Steam
Consumption
Lb/ton
2,800
2,750
Electricity
Consumption
kWh/ton
300
300
MMBtu/ton
5.0
5.0
Gal/ton
1,500
1,500
Couch Solids
27
27
Press Solids
42/50
42/50
Reel Moisture
7.5
9.0
Drying Steam
Lb steam/lb water
evap
1.2
1.2
PV Supply
Temperature
oF
180
180
75-80
75-80
Total Energy Cons.

Water Consumption
Condensate Return

Pulp Machines
Index
Units
Grade
Market Pulp
Fluff Pulp
Uptime
95
95
First Quality
99
97
Overall Machine
Efficiency
94
92
Total Steam
Consumption
Lb/ton
2,000
2,500
Electricity
Consumption
kWh/ton
150
150
MMBtu/ton
4.0
4.5
Gal/ton
1,000
1,000
Couch Solids
28
28
Press Solids
50
45
Reel Moisture
10
7.5
Drying Steam
Lb steam/lb water
evap
1.2
1.2
75-80
75-80
Total Energy Cons.

Water Consumption
Condensate Return
Key Energy Factors

Venting from dryer thermocompressor or

cascade sections.
Condenser water valve output/condensate
flow.
Differential pressures.
Wire pit steam valve position.
Basis weight versus standard.
Press section weir flows.
Moisture to size press.
Key Energy Factors (cont)

Size press starch solids.

Pocket ventilation temperature.
Temperatures in hood exhaust heat
recovery system.
Warm water flow from pulp mill.
Mill water leakage into whitewater
system.
Winter/summer operating strategy for
machine room ventilation.
Any additional steam venting.
Energy Survey Guidelines

Keys to identifying opportunities and

successfully implementing recommendations.
Suggested frequency of additional detailed
surveys-steam and condensate, steam traps,
refining, pressing, vacuum systems, steam
showers, hood air and heat recovery systems,
compressed air, etc.
Additional Surveys

Steam trap surveys (annual)

Compressed air system
surveys (annual)
Refining optimization (ongoing) and mechanical
surveys (annual)
Showering surveys (every 2
years)
Press section optimization
(on-going)
Press section nip surveys
(every 2-3 years)
Vacuum pump boroscopes or
orifice plate testing (annual)
Vacuum system
surveys/optimization (every
3 years)

Thermography to check for

leaks and hot spots (annual)
Steambox surveys (annual)
Dryer steam and condensate
system surveys (annual)
Hood air system surveys
(annual)
Machine room ventilation
studies (every 5 years)
Pulp dryer
maintenance/capacity
reviews (annual)
Tissue machine hood
balances/inspections
(annual)
Energy Optimization
Reduce Evaporation of Water

Increase press exit dryness.

Optimize press fabrics and roll cover designs.
Reduce basis weight.
Trim sheet at wet end on narrow deckle
grades.
Improve moisture profiles.
Reduce over-drying before size press.
Increase starch solids with metering size
presses.
Increase reel moisture content.
Energy Optimization
Paper Machine Efficiency
Paper machine uptime is important since up to 50%

of full-load energy is consumed during sheet breaks
and other outages.
Reduce warm-up time, sheet breaks, tail
threading, time getting on grade, and
maintenance outages.
Avoid making paper twice. Yield is important since it
takes as much or more energy to produce a ton of
broke as it does to make a ton of first quality paper.
Guidelines for uptime, yield, and overall machine
efficiency by grade are included in TAPPI TIP 040447, Paper machine performance guidelines.
Energy Optimization
Agitation

Only operate pulper agitators when necessary.

Higher consistency increases energy demand
exponentially above 2%.
Consider variable-speed or two-speed motors on
agitators.
Consider energy when installing new or replacing
existing agitators.
Factors to consider include chest shape and
dimensions, flow impediments, agitator size and
design, top vs. side entry, etc.
Pump and Motor Systems

Replace throttling valves with

speed controls
Reduce speed for fixed load
Install parallel system for
highly variable loads
Equalize flows using surge
vessels
Replace motor with a more
efficient model
Replace pump with a more
efficient model
Look for symptoms in pumping

systems that indicate potential
opportunity:

Systems controlled by throttle

valves
Recirculation line normally
open
Systems with multiple parallel
pumps with the same number
of pumps always operating
Constant pump operation in a
batch environment or frequent
cycle batch operation in a
continuous process.
Cavitation noise (at pump or
elsewhere in the system)
High system maintenance
Systems that have undergone a
change in function.
Energy Optimization
Refining
Refiner design, mechanical condition, plate

design, plate diameter, operating rpm, and
other factors can have a significant affect on
refining energy consumption.
Optimized refiner plate designs can permit
achieving paper test requirements at higher
stock freeness.
40-50 point CSF change results in ~one point
change in sheet dryness leaving the last
press.
Energy Optimization
Refining
Refiner mechanical condition should be checked

regularly. Factors to check include adjusting
mechanism backlash, rotating head run-out, vertical
play, and hub run-out.
No-load horsepower monitoring with comparison to
design no-load is a good way to check mechanical
condition. No-load horsepower can increase over
10% due to poor mechanical condition.
Effective life between refiner rebuilds is 10 to 15
years depending on application. Spline/rotor rebuilds
can reduce energy consumption.
Refining energy varies widely depending on the types
of pulp used, paper grade, paper test requirements,
and other variables.
Energy Optimization
Approach System

Is all equipment necessary-cleaners,

screens, deaeration, stuff box, etc.?
Minimize flows to fiber recovery stages.
Consider variable speed drives.
Consider compact approach systems to
save up to 25% of required energy.
Recycled Fiber Systems
Ensure that pumps are not

oversized.
Install FC on motors to
reduce energy waste.
Reduce pulp and water
volume.
Increase consistency as
much as possible and reduce
hydraulic volume for
pumping and agitating.
Simplify process
configuration.

Run equipment at optimum

operating point.
Make process stable and
homogeneous.
Increase process
temperature to gain
production.
Close water loops.
Refine, disperse pulp as little
as necessary.
Use latest technology of
equipment to increase
overall efficiency.
Energy Optimization
Water Heating

Reduce, reuse, and recycle.

Maximize stock temperature from pulp mill.
Use waste heat from pulp mill and hood or effluent
heat recovery to heat water instead of steam.
Minimize mill water infiltration.
Minimize flow and maximize temperature from
condensers.
Maximize clarified whitewater use in showers.
Circulate vacuum pump seal water.
Reduce whitewater temperature. Do not exceed
140oF.
Energy Optimization
Savealls
Evaluate key saveall

parameters
Installation & Equipment

Operation

Size
Droplegs
Sector type
Process conditions
Controls
Maintenance

Sector cover condition

Seals
Showers
Increase capacity,
improve maintenance,
and/or install postsaveall strainers and
filters as necessary to
achieve desired water
quality.
Energy Optimization
Showering

Low risk of plugging-breast roll and

knock-off.
Medium risk-lube and wetting showers.
High risk-high pressure wire and felt
cleaning.
Determine optimum shower flows,
shower and nozzle designs, and water
quality requirements.
Energy Optimization
Chemistry

Use additives to increase strength.

Use enzymes to reduce refining.
Use silica or microparticles to improve
drainage.
Use whitewater for chemical injection.
Maximize ash content in the sheet.
Energy Optimization
Headboxes
Profiles ultimately impact

pressing, runnability, and
dryer operation.
Consistency profiled designs
require lower flow from
cleaner system.
Minimize MD and CD
variability.
DP has gone up in time with
headbox design evolution.
Turbulence level and nozzle
convergence impact MD/CD
ratio capability.
Design that optimizes

headbox contribution to
formation and strength allows use of higher freeness
furnish; aids forming,
pressing, drying rates.
Headbox design flow versus
actual flow - crucial for best
results. Over-designed flow
capability generally very
poor results.
Maintain cleanliness for
efficiency.
Energy Optimization
Formers

Optimize formation at high consistency.

Avoid sealing the sheet.
Graduate vacuum to reduce drag load.
Avoid couch rewet.
Monitor and maintain high couch exit
solids.
Paper Machine Clothing Impact on

Energy Consumption
Forming Fabrics

Press Fabrics

Consistency into Press Section

Drive Loads
Steam Usage
Consistency into Dryers
Sheet Rewet
Dryer Fabrics

Fabric Tension
Surface Contact Heat Transfer
Pocket Ventilation Mass Transfer
Forming Case History

Southwestern USA
Base position
Fourdrinier with 2 Bel-Bonds

Linerboard
100% recycled
2100 fpm (640 mpm)
Savings in Energy Cost - Motor Loads

Results

Couch power reduction = (935 - 629) = approx 300 amps (~ 30% )

WTR torque reduction also = 30%
Assume WTR: Couch power ratio is 50:50
Total amp reduction is 600 amps equivalent
Converting torque to amps:

HP savings is 600 x 440 V / 748 = 352 HP
Mill reported savings of $2000 - $2500/day
Let savings be $2000/day x 355 days*

(The figure of $2000 is quadruple the value normally used,
but understandable, given fabric length and current energy change!)
*Annualized using 355 operating days
Annualized* $710,000
Corrugated Medium
Improved Speed and Reduced Steam Usage
2.55
2120
2.50
2100
2080
2.40
Machine ran 3.5% faster
while using 10% less steam
Potential Annual Value = $1.9 MM
2.35
2060
2040
2.30
2020
2.25
2000
2.20
2.15
1980
2.10
Engineered Density Technology 1960
Supplier A
Supplier B
AstenJohnson Stylus
Machine Speed (fpm)
Machine Speed (fpm)
2.45
Dryer Fabric Case Study

Aerodynamically active design in

conventional third section
Woodfree fine paper
2750 fpm
Results

Reduced absolute humidity in

3rd section by 16%
Increased speed by 50 fpm
Reduced steam consumption
by 6%
Combined savings of
$630,000 annually
lb Water/ lb Dry Air

0.50
0.45
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
Before Installation
After Installation
Vacuum System Opportunities

Run with cool seal water.

Ensure no backpressure on
vacuum pumps.
Operate with proper seal water
pressure and flow.
Use of synchronous versus
induction motors can affect the
power factor.
Ensure no scale build-up in
pumps and piping.
Ensure no worn pump rotor,
casing, or lobes.
Replace older, less efficient
vacuum pumps.

Use fans or exhausters instead

of vacuum pumps for lowvacuum applications such as
vacuum foils.
Control vacuum level by
bleeding air into the system
instead of by throttling liquid
ring pumps.
Graduate flatbox vacuum to
maximize dryness and minimize
drag load.
Eliminate unnecessary vacuum
boxes.
Ensure proper Uhle box slot size
to provide required flow
capacity and dwell time.
Ensure proper vacuum pump
application (high-vacuum vs.
low-vacuum pump design).
Paper Machine Energy Opportunities

Vacuum Systems
Vacuum systems typically have the second largest electrical

energy consumption (after drives). Installed horsepower range
is 1,000 to 10,000.
Vacuum application should be checked and system audits
conducted regularly following guidelines in TIP 0502-01,
vacuum selection factors.
Vacuum pump internal clearances and/or orifice plate testing
should be done annually. Pumps operating at less than 80% of
design capacity should be rebuilt.
Obsolete pumps should be removed from service and not rebuilt
(Nash Number series-no letter, H, K, & L; Roots Connerville;
Bingham; etc.).
Common vacuum system problems include high seal water
temperature, worn or missing orifices and nozzles, scale buildup, and worn rotors, casings, or lobes.
Vacuum System Opportunities

Prevent carryover of process

fluids from suction point.
Provide water/air separation
ahead of the pump to prevent
two-phase flow at the pump.
Use proper separator removal
pump design.
Take unnecessary vacuum
pumps out of service.
Check vacuum pump internal
clearances and/or capacity
annually. Rebuild pumps
operating at less than 80% of
design capacity.
Remove old, inefficient vacuum
pumps from service. Do not
rebuild obsolete pumps with
inefficient designs.

Vacuum system audits or

surveys
Routine maintenance of vacuum
pumps and auxiliary equipment,
including belt and gear drives
and motors
Replacement and calibration of
gauges and process
instrumentation (vacuum
gauges, seal water pressure
gauges, level transmitters in
vacuum pump sumps, amp
meters for motors)
Understanding the vacuum
system by recording and
frequently reviewing vacuum
system operating data
EMBWA (Energy Management
By Wandering Around)

Pressing
Cost of water removal after the press section is

expensive so maximizing press performance is critical
to paper machine energy conservation.
Factors to consider to improve press section
dewatering include:
Optimizing press fabric application (typical gain
1.0 to 1.5%).
Optimizing press loads and nip conditions
Increasing temperature of the web
Installing a shoe press
Using grooved belts on shoe presses
TAPPI TIP 0404-52, press section optimization, has
good guidelines for improving press section
performance.

Steam Boxes
Wet end steamboxes are used on fourdriniers and in

press sections to heat the sheet, lower water
viscosity, and improve pressing.
Steam consumption should be 0.15 0.25 lb
steam/lb paper fourdrinier and 0.10-0.15 press.
Profiling steamboxes provide a good method to
control CD moisture profiles.
Uhle box steamboxes are used to heat the fabric,
improve fabric conditioning, and sometimes improve
pressing.
Hot water weirs are used on some pulp dryers to
heat the sheet ahead of pressing.
Steam Shower Optimization

Utilize low pressure waste

or vented steam.
Reduce steam supply and
fog.
Use profiling capability.
Reduce vacuum to reduce
sheet cooling.
Cut off non-profiling preheat.
Apply steam at suction press
where less water.
Extend and contain steam in
wedges & tunnels.
Steam shower efficiency

depends on where installed
as well as how operated and
documented.
Most valuable at low flow
ratios on cold systems with
vacuum assist.
The most efficient steam
flow ratios are 0.10 for
fourdrinier applications and
0.075 for press section
applications.
Mills should determine value
of steam showers and
operate accordingly.
Ten Commandments of Drying

Dont dry any more than you must

Dont vent steam anywhere
Match the air flow to drying
Use low-pressure steam
Keep the machine running
Improve the moisture profile
Increase the heat transfer rate
Measure what you must control
Keep the steam system calibrated
Dont use motive when you can use make-up
Five Rules For Dryer Energy

Efficiency
1) Keep the system tight.
2) Efficiently utilize flash steam from high
temperature condensate.
3) Maximize use of low pressure steam.
4) Minimize heat used for hood supply air
heating.
5) Manage the system.
Energy Considerations
Dryer Arrangement
Single tier
arrangements increase
dryer wrap and reduce
unsupported length.
Threading efficiency
improves also.
Increased sheet
restraint improves
contact with dryer and
reduces CD shrinkage.
Draw reduction
increases CD strength
vacuum assisted blow
boxes, placement and
quantity of draw points
Windage control
impacts runnability
Optimize felt tension for
best drying heat
transfer
Felt design to optimize
uniformity of sheet
contact with dryer
surface and heat
transfer. Cleanliness
impacts performance.
Blow box systems to
improve high speed
runnability and
efficiency
Energy Optimization
Thermocompressor Systems

Ensure there is no steam venting during

normal operation.
Use blow-through control and/or auto
pressure letdown to minimize venting during
breaks.
Optimize differential pressures for condensate
evacuation and blow-through flows.
Use properly sized thermocompressors.
Optimize motive steam pressure.
Energy Optimization
Cascade Systems

Arrange dryers to minimize steam venting.

Minimize number of dryers and blow-through
steam flow from dryers draining to a
condenser.
Use blow-through control and/or auto
pressure letdown to minimize venting during
breaks.
Use make-up steam from lowest available
steam pressure header that will support
pressure requirements.
Steam System Design

There is no one & only

correct solution
Review the whole steam
supply system
Simple system will often
work best
Cascade system where
practical
Thermocompressor
systems should be
equipped with blow
through control
Separator efficiency
important, especially
with blow through
control
Proper sizing of piping
and equipment critical
Detailed piping design
should be done and
reviewed by a qualified
party to ensure proper
system operation
Steam System Hardware

Utilize stationary
syphons where
advantages can be
realized from lower
differential pressures
and blow-through flows.
Install modern steam
joints
Install dryer bars
(increase drying rates in
most cases)
Size thermocompressors for

the current steam system
operation
Optimize thermocompressor
design and operation
Check sizing of rotary
syphons
Use appropriate steam trap
designs for heaters
Utilize pilot-operated safety
relief valves for applications
that operate close to
maximum allowable working
pressure.
Steam System Operation

Operate dryer differential

pressures at the proper setpoint
for condensate evacuation and
blow-through flows.
Ramp warm-up dryers to
maximize runnability
Maximize drying in sections that
use low-pressure whenever
possible
Minimize dryer can surface
contamination
Minimize steam venting to
condensers
Utilize proper dryer warm-up
procedures to minimize steam
joint leaks.

Close separator tank drains

Check separator tank level
controls
Check vacuum tank level control
Shut off dryer steam bleeds
Avoid over drying minimize
number of cans in the falling
rate zone
Can the pre-size moisture level
be increased? Main section CD
profiling.
Conduct regular roof rounds to
check for venting and leaking
safety relief valves.
Regularly check vacuum
systems for air leaks.
Steam System Maintenance

Ensure tight shut-off of

steam vent, bypass,
and blow-down valves
Calibrate differential
pressure cells
Disconnect steam to
bottom unorun dryers,
felt dryers, and Feeney
dryers that do not
contact the sheet
Check that steam traps
are functioning properly
Check steam valves and
thermocompressor
actuators
Steam System Control

Control vacuum
condenser to match
differential pressure
requirement
Optimized energy
consumption
Automate dryer warmup and shutdown
sequencing
Automate dryer sheet
break recovery
response
Automate grade change
response
Automate dryer steam

system pressure and
differential control
Install
thermocompressor cutoff control to prevent
venting
Install smart control
valves to support
preventive maintenance
Trend of major process
variables
Troubleshooting help
Flash Steam Utilization

Make-up Steam
From Low Pressure
Header
TT
PT
To Wet End Steam

Shower
FT
Moisture
Eliminator
High Temperature Condensate

From Individual Separator Stations
1
Atmos.
PT
Alternatively
Steam Can Be
Flashed Into A
Low Pressure Header
LT
Flash Steam To
Wet End Steam
Shower
Energy Optimization
Dryer Hood and Air Systems

Operate pocket ventilation and vapor

absorption systems at 180-200oF.
Optimize hood exhaust humidity.
Recover heat from hood exhaust streams.
Use inside air for PV and VA supply.
Monitor condition air system filters and coils.
Replace damaged hood panels and seals.
Replace existing hoods with high performance
designs.
Energy Optimization
Size Press
Evaluate product need

to dictate application
technique surface
application or heavy
penetration
Film type designs can
minimize water load
applied
Maximizing solids
content of material
applied
Maximize ingoing
moisture content
Threading and
spreading (efficiency)
Early after dryer surface
to improve runnability
and minimize picking
(air turns, alternative
drying methods)
Optimize strength with
size press application to minimize fiber,
optimize filler content
Energy Optimization
Reel
Sheet defects near

spool and edges
negatively impact
process efficiency
Spool deflection can
contribute to defects
Rubber covered reel
spools to minimize turnup losses
Slab losses are high if
defects near the spool
exist
Nip relieving and/or

controlled primary/secondary
arm transfers can reduce
defects
Control winding parameters
(torque, nip, tension)
Maximize turn-up efficiency
(number sets)
Turn-up systems and reel
brakes to minimize slab
losses
Monitor and display slab
losses, report results control to maintain world
class levels
Energy Optimization
Miscellaneous Steam Systems

Recover pulp mill or boiler

house low-pressure steam
Use waste steam from TMP pulp
mills for drying the paper.
Repair steam leaks.
Insulate steam system piping
and separators.
Utilize the lowest feasible steam
pressure for miscellaneous
steam users such as steam
showers, water heating, and air
heating.
Ensure that proper pressure and
temperature compensation
factors are used in steam
flowmeter calculations.
Conduct regular steam trap

surveys and repair leaking or
plugged traps.
Check for excessive pressure
drops through flowmeters, lines,
etc.
Utilize degrees of superheat
control for desuperheaters,
where temperature setpoints
are established based on a
given superheat level above
saturated steam pressure.
Determine standard operating
procedures for steam trap and
drain line valving during warmup and normal operating
conditions.
Maximize condensate return to
the powerhouse.
Compressed Air Systems

Instrument air dew point should be 18oF

below the lowest temperature the system will
see.
Use ultrasonic leak detectors to identify
system leaks.
Conduct annual air system audits.
Use dedicated compressor for headbox air
pads.
Reclaim water from compressors.
Machine Room Ventilation
Establish winter and

summer operating
conditions for machine
room supply and
exhaust fans.
Operate air make-up
units at 21C (70F)
setpoints and roof
supply systems at 49C
(120F).
Utilize water or glycol
systems (with heat
recovery) to heat makeup air.
Utilize inside air instead

of outside air for motor
cooling, roof supply,
and pocket ventilation.
Shut off steam coil or
glycol systems to air
make-up units when
fans are shut off.
Ensure that there is
proper freeze
protection.
Heat Recovery
Heat recovery opportunities include:
Dryer hood exhaust.
Yankee hood exhaust.
Pulp machine air dryer hood exhaust.
TMP steam.
Vacuum blower exhaust.
Waste heat from pulp mill and evaporators.
Effluent streams.
Tissue Machines

Optimize air burner efficiency and stabilize static pressure to

nozzles.
Set air supply and exhaust dampers to optimize energy
efficiency. Use hood humidity sensors (0.40-0.45 lb/lb).
Adjust air system fuel/air ratio.
Optimize hood impingement temperature vs. impingement
velocity.
Optimize air gap (0.75) to increase heat transfer.
Balance hood to minimize infiltration and exfiltration.
Maximize heat recovery from hood exhaust.
Preheat air make-up and combustion air streams.
Optimize thermocompressor system operation.

Scope: TIP Category: Automatically Periodically Reviewed (Five-Year Review)

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TIP 0404-63

Paper machine energy conservation

Paper machine energy conservation / 2

Establish key energy parameters.

Utilities to be monitored include:

Steam consumption (kg/tonne or lb steam/ton paper)

3 / Paper machine energy conservation

Paper machine energy conservation / 4

Moisture to the size press

5 / Paper machine energy conservation

Reducing the amount of water to evaporate

Increase press dryness (high-load, shoe presses)

Reduce sheet break and grade change times.

Do not overestimate consistency when designing systems

Paper machine energy conservation / 6

Pump and motor systems

7 / Paper machine energy conservation

Replace throttling valves with speed controls where appropriate

Paper machine energy conservation / 8

Recycled fiber systems

9 / Paper machine energy conservation

Opportunities to minimize steam required for water heating include:

Paper machine energy conservation / 10

Improve saveall and filtering to achieve water quality requirements.

11 / Paper machine energy conservation

Reduced drive loads

Hot seal water.

Additional guidelines to minimize vacuum system energy consumption include:

Paper machine energy conservation / 12

13 / Paper machine energy conservation

Paper machine energy conservation / 14

Keep the machine running

Five rules for dryer energy efficiency are:

15 / Paper machine energy conservation

Steam system design

Paper machine energy conservation / 16

Optimize thermocompressor design and operation.

Steam system operation

17 / Paper machine energy conservation

Operate pocket ventilation system at 180 -200F.

Paper machine energy conservation / 18

Rubber covered reel spools to minimize turn-up losses

Miscellaneous steam systems

Repair steam leaks.

Compressed air systems

Developing a block diagram of the system.

19 / Paper machine energy conservation

Paper machine energy conservation / 20

TAPPI TIP 0404-47 Paper Machine Performance Guidelines

21 / Paper machine energy conservation

TAPPI TIP 0404-33 Dryer Section Performance Monitoring

Paper Machine Energy Update

2006 TAPPI Papermakers

Energy costs are not likely to go down soon.

Energy prices are down-Will they stay down?

Energy cost is typically one of the highest

Typical U.S. Energy Costs

Electricity (MW) $/MWh

Energy consumption on the average

Based on 2005 TAPPI PM Energy Survey

TIP 0404-63 Whats New?

Updated to include information

TAPPI TIP 0404-63