Paper Technology International 2024 - Journal - Page 73
PAPERTECHNOLOGYINTERNATIONAL
energy challenges to solutions:
FFromTURBAIR
Vacuum Systems
at the forefront
Matthew Hildebrand, Market Manager TURBAIR® Systems, MAN Energy Solutions
INTRODUCTION:
Ef昀椀cient and resource-saving technology solutions play an increasingly vital role for the paper industry due to rising energy prices
and growing environmental awareness. Thus, paper manufacturers are facing challenges that require them to rethink their processes. With
the dewatering process being one of the most energy-intensive stages in the papermaking process, this is the focal point where paper
manufacturers can achieve energy savings by installing or upgrading to a vacuum system.
In 2021, global tissue consumption reached
approximately 41 million tons. Forecasts indicate a
consistent annual increase in global tissue demand over
the next decade, with expectations to reach 55 million tons
by the year 2032. This growth can be attributed not only
to population expansion but also to heightened demands
associated with an increased awareness of hygiene.
Simultaneously, the growing emphasis on sustainability
and environmental impact underscores the importance of
not only adopting eco-friendly materials but also optimizing
paper production processes.
The pulp and paper sector accounted for slightly
less than 2% of total industrial emissions in 2022. While
there was an average annual decline in emissions intensity
of nearly 3% between 2010 and 2022, paper production
processes must be optimized in order to achieve a further
reduction in energy requirements. The urgency is ampli昀椀ed
by soaring energy prices, driven by factors such as the
long-standing con昀氀ict between Russia and Ukraine and
continuous supply chain challenges, pushing paper
manufacturers to explore more ef昀椀cient technological
solutions.
The demand for ef昀椀ciency in paper production becomes
evident when considering the processes involved. Paper production
requires process water, which is not always easily accessible
and contributes to increased energy consumption and costs. A
particularly energy-intensive stage during the paper manufacturing
process is the dewatering of the paper roll, where vacuum systems
account for up to 20-25% of the total electrical energy consumption.
Beyond dewatering the paper sheet, the vacuum systems also
transport the paper between the sections of the paper machine
and clean the press felts, which remove moisture from the paper
sheet. TURBAIR® vacuum systems, engineered and manufactured
by MAN Energy Solutions in Zurich (Switzerland), are designed
to accomplish these tasks, keeping the focus on energy ef昀椀ciency
and sustainability. These systems are applied in numerous new
installations of board, tissue, and paper machines, progressively
replacing outdated water ring pumps
“Our TURBAIR® vacuum systems provide an eco-friendly
alternative to water ring pumps, enabling board and tissue
manufacturers to achieve substantial savings in water and energy
consumption. As a result, our technology not only reduces CO2
emissions in paper production but also signi昀椀cantly cuts down on
production costs”, states Manfred Dobler, Head of Paper Industry at
MAN Energy Solutions.
Harnessing vacuum systems to reduce energy consumption
The vacuum level and volume required in paper production
are contingent on the speci昀椀c paper type in manufacturing. MAN
Energy Solutions offers two versions of vacuum systems tailored
to these needs: the compact single-stage radial blower achieves
a vacuum level of up to 65 kPa, and the multi-stage radial blower,
equipped with up to four vacuum levels, can attain a maximum of
80 kPa. Both variants are available with options for 昀椀xed or variable
speed.
Utilizing these vacuum systems in paper mills brings forth a
range of operational advantages for users that signi昀椀cantly enhance
ef昀椀ciency and sustainability. The vacuum blowers distinguish
themselves from water ring pumps, which often experience wear
and performance decline over time. In conversion projects, where
old water ring pumps are replaced with TURBAIR® blowers, typical
energy savings range between 40% and 60%. Furthermore, the
systems achieve an absorbed energy consumption that is up to 30%
lower compared to conventional water ring pumps as there are no
friction losses caused by the water ring.
Ef昀椀cient dewatering of paper on the machine depends
on factors such as grammage, speed, and paper composition,
necessitating varying air and vacuum levels. The TURBAIR®
blowers are designed with a broad working range, ensuring ef昀椀cient
operation even under partial load conditions.
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