Energy efficient alternatives to reduce the carbon emissions in the production of linerboard, 2023 PEERS Conference

The variation in the prices of fossil fuels and the commitment to reduce GHG emissions have driven the US pulp and paper industry to adapt technologies to break the dependency on fossil sources. In this sense, improving energy efficiency is a vital strategy to decarbonize the sector. The present study evaluates the implementation of energy-efficiency alternates in key areas in the production of linerboard, including the concertation of black liquor, steam generation in recovery and auxiliary boilers, and the press and drying section in the paper machine. The technologies include: a) installing a high-efficiency recovery boiler and replacing natural gas boilers with electric boilers, b) graphene oxide (GO) nanofiltration membranes and mechanical vapor recompression (MVR) systems for black liquor concentration, c) Paper machine technologies including shoe press, a modified felt (nylon mesh) in the press section, and condebelt for drying. The technologies are evaluated based on detailed process simulations in WINGEMS, Life Cycle Assessment within the OpenLCA software, and financial models to determine the cost of avoided carbon. This parameter is the base to construct the carbon abatement cost curve, a methodology to categorize the alternative by its cost-effectiveness.

The analysis showed that the use of GO-nanofiltration membranes to pre-concentrate the black liquor and the installation of a condebelt in the drying section were the best alternatives with a 15% reduction in emissions scope 1,2, and 3. In addition, installing a high-efficiency recovery boiler provides an additional 10% carbon reduction. On the other hand, the financial analysis showed that the nylon felt in the press section, the installation of a shoe press, and the mechanical vapor recompression system for black liquor evaporation are alternatives with an important reduction in the operating cost, allowing a return on the investment. These technologies offer a maximum 8% reduction in carbon emissions, with a cost of avoided carbon (CAC) ranging between -$67 to -$19 per metric tonne CO2-eq avoided, representing a saving to the mill. In contrast, the GO-nanofiltration membrane system and the recovery boiler study shows that the benefits of MVR, GO-nanofiltration membrane, electric boilers, and condebelt are enhanced in a scenario where the higher participation of renewable energies reduces carbon emissions in the US electric system. Therefore, the electrification of the pulp and paper industry under this scenario represents an opportunity to decarbonize the sector.

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