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Grease-proof paper is an energy-demanding paper product to manufacture, especially during refining and dewatering. Increases in energy efficiency in either stage could result in major savings. This article investigates the potential gains with addition of a stepwise progression vacuum suction box to the forming section during production. For both a lighter, 50 g/m2, and a heavier paper grade, 100 g/m2, with a pulp-drainability of 86 °SR, a stepwise progression vacuum suction box in four steps would result in increased dryness, simultaneously with decreased energy expenditure. The observed effects were higher for the lower basis weight paper (50 g/m2). Both basis weights experienced clogging of the forming fabric due to the high degree of refining. This adversely affected the dewatering rate, decreasing the amount of air pulled through the paper even when increasing the vacuum pressure. When a stepwise progression suction box in four steps was compared to a single vacuum suction box, there was a 14% increase in dryness for lighter paper, over an equal energy consumption, measured as amount of air pulled through the paper. For the 100 g/m2 paper, the increase in dryness was 3% compared to the 50 g/m2 paper run over a single vacuum suction box. The results show great promise for energy savings when utilizing stepwise progression suction box dewatering for grease-proof paper production.

State-of-the-art manufacturing of tissue paper by Through Air Drying provides excellent product performance, although at a high production cost and energy use. In this work, a laboratory scale vacuum suction box was used to mimic the initial dewatering and the Through Air Drying molding, together with a pilot-scale trial. The purpose was to investigate both how the laboratory scale corresponds to pilot scale testing and investigate how fabric design, basis weight, beating, and fibers affect dewatering and sheet caliper. This study reevaluates dewatering mechanisms during molding, challenging the previous hypothesis of pure air displacement dewatering. Results show a parallel mechanism of compression dewatering and air displacement. The influence of rush transfer is examined, impacting the sheets’ visual appearance, thickness, and solids content. Correlations between molding box solids content and headbox freeness emphasize significance of fibers and beating levels. Pilot results confirm the link between former solids and molding box solids. Pilot trials validate the laboratory results, facilitating comprehensive simulation of full-scale manufacturing. This research reveals dewatering mechanisms, highlights operational parameters, and enables effective Through Air Drying process design and refinement.

The pulp and paper industry (PPI) has several opportunities to contribute to meeting prevailing climate targets. It can cut its own CO2 emissions, which currently account for 2% of global industrial fossil CO2 emissions, and it has an opportunity to produce renewable energy, fuels, and materials for other sectors. The purpose of this study is to improve understanding of the decarbonization prospects of the PPI. The study provides insights on the magnitude of needed annual renewal rates for several possible net-zero target years of industrial fossil CO2 emissions in the PPI and discusses decarbonization opportunities, namely, energy and material efficiency improvement, fuel switching, electrification, renewable energy production, carbon capture, and new products. The effects of climate policies on the decarbonization opportunities are critically evaluated to provide an overview of the current and future business environment of the European PPI. The focus is on Europe, but other regions are analyzed briefly to widen the view. The analysis shows that there are no major technical barriers to the fossil-free operation of the PPI, but the sector renovates slowly, and many new opportunities are not implemented on a large scale due to immature technology, poor economic feasibility, or unclear political environment. [ABSTRACT FROM AUTHOR]

This study delves into the dynamic evolution of solids content in a pilot-scale through air drying tissue machine, aiming to enhance comprehension and refine optimization strategies for tissue manufacturing. It focuses on development of solids content throughout the process. Analyzing the interaction between process parameters and solids content provides deeper insights into water removal dynamics. The research employs solid contents monitoring techniques in pilot scale, offering a detailed view of solids content evolution from the wet web's inception to the final tissue product. It significantly highlights the impact of key parameters, particularly pulp refining, on solids content across all positions of the pilot machine. Additionally, the study emphasizes the influence of vacuum system configurations, identifying the relationship between energy expended in the vacuum system and evaporation energy. Furthermore, the results indicate that compression and air displacement dewatering in vacuum boxes are less speed-sensitive compared to heat-driven evaporation in the TAD- and Yankee cylinders. Solid contents at all positions in the tissue machine correlates between various dewatering elements. Optimizing site-specific dewatering and evaporation strategies can potentially save drying energy in the Yankee drying phase which hold promise for enhanced energy and resource utilization, aligning with demands for sustainable manufacturing practices. [ABSTRACT FROM AUTHOR]

This study aims to highlight the energy improvement potentials of Pakistan's paper sector that is one of the most energy intensive industries by benchmarking its specific energy consumption (SEC) to produce a similar grade of paper. To address issues such as the lack of indicators for energy efficiency benchmarking in Pakistan's paper industry. Furthermore, energy saving potential was estimated by comparison with paper industries in the United Kingdom and Canada, where energy benchmarks have already been established and data on energy benchmarking is readily available. This study energy consumption data accounts for 75% of the total energy utilized in Pakistan's paper industry and is compared with the energy consumption of the UK and Canada paper sectors where the most up-to-date energy-saving techniques are used. The calculation shows that when compared to the paper industries in the UK and Canada, Pakistan's paper industry utilizes an additional 1.3 MWh of energy for every tonne of paper produced. With a total yearly paper production of 314,549 metric tonnes, this equates to an additional 408,913 MWh of overall annual energy use. It is concluded that if the proposed energy benchmark in this study is applied within the country's mill comparison, savings of 16.4% of overall energy consumption in the Pakistan paper sector can be achieved. It is also shown that the implementation of the best available techniques used in the UK and Canada in Pakistan's paper sector could result in a potential energy saving of 43% of the total energy consumed by this sector.

Producing tissue paper is an energy-demanding process; a significant amount of energy is expended when removing water by vacuum, mechanical pressing, and thermal drying. Because the water is most energy-demanding to remove in drying, making the preceding step of vacuum dewatering more efficient would benefit the whole process. This article focuses on developing a laboratory-scale method for verifying the nature of diminishing returns of water removal and investigating efficiency strategies of the vacuum dewatering. The theoretical concept of successive vacuum suction boxes with progressing vacuum levels was tested at the laboratory scale in order to show quantifiable results of the previously solely theoretical concept. The results confirmed that vacuum dewatering can be improved by adding progressively higher vacuum levels and that such a practice can benefit both outgoing dryness levels and expended vacuum pump energy. To truly examine the power of progression of vacuum levels, rewetting can be included in the calculations, by using an approximate value collected from pilot or full-scale measurements. For any new fiber mix, pulp type, vacuum level setup, basis weight, etc. the vacuum levels, rewetting, and dwell times need to be tuned to that specific case.

A growing research interest currently exists in the use of paper as a building material. This work aims to present the results of a measurement campaign developed on innovative waste paper-based building components. The research was carried out in Southern Italy and used some local by-product aggregates. Three different mixture designs were developed in the laboratory by adding three kinds of biomass to a pulp paper blend: fava bean residues (FB), sawdust powder (SP) and coffee grains (CG) extracted from exhausted chaffs. A physical characterization was carried out measuring the bulk density and bulk porosity. Scanning Electron Microscopy (SEM) analysis of the single aggregates was followed by a microstructure analysis of the final components. Bulk density evaluation showed a range between 200 and 348 kg·m−3. Furthermore, thermal performances were measured; the thermal conductivity of the experimented samples ranged from 0.071 to 0.093 W·m−1·K−1, thus it is possible to classify the tested materials as thermal insulators. Moreover, the acoustic properties were evaluated and tested. The normal incidence sound absorption coefficient was measured by the impedance tube on cylindrical specimens. In general, a different behavior was observed between the upper and lower base of each specimen due to the manufacturing process and the shrinkage caused by the different interactions occurring between the aggregates and the pulp paper waste; for example, the presence of sawdust reduced shrinkage in the final specimens, with consequent smaller physical variations among the two faces. The correlation existing between the manufacturing process and the microstructural properties was also investigated by the estimation of the non-acoustical parameters using the inverse method and taking into account the JCA (Johnson, Champoux and Allard) model as a reference.

State-of-the-art manufacturing of tissue paper by Through Air Drying provides excellent product performance, although at a high production cost and energy use. In this work, a laboratory scale vacuum suction box was used to mimic the initial dewatering and the Through Air Drying molding, together with a pilot-scale trial. The purpose was to investigate both how the laboratory scale corresponds to pilot scale testing and investigate how fabric design, basis weight, beating, and fibers affect dewatering and sheet caliper. This study reevaluates dewatering mechanisms during molding, challenging the previous hypothesis of pure air displacement dewatering. Results show a parallel mechanism of compression dewatering and air displacement. The influence of rush transfer is examined, impacting the sheets' visual appearance, thickness, and solids content. Correlations between molding box solids content and headbox freeness emphasize significance of fibers and beating levels. Pilot results confirm the link between former solids and molding box solids. Pilot trials validate the laboratory results, facilitating comprehensive simulation of full-scale manufacturing. This research reveals dewatering mechanisms, highlights operational parameters, and enables effective Through Air Drying process design and refinement. [ABSTRACT FROM AUTHOR]

A growing research interest currently exists in the use of paper as a building material. This work aims to present the results of a measurement campaign developed on innovative waste paper-based building components. The research was carried out in Southern Italy and used some local by-product aggregates. Three different mixture designs were developed in the laboratory by adding three kinds of biomass to a pulp paper blend: fava bean residues (FB), sawdust powder (SP) and coffee grains (CG) extracted from exhausted chaffs. A physical characterization was carried out measuring the bulk density and bulk porosity. Scanning Electron Microscopy (SEM) analysis of the single aggregates was followed by a microstructure analysis of the final components. Bulk density evaluation showed a range between 200 and 348 kg·m−3. Furthermore, thermal performances were measured; the thermal conductivity of the experimented samples ranged from 0.071 to 0.093 W·m−1·K−1, thus it is possible to classify the tested materials as thermal insulators. Moreover, the acoustic properties were evaluated and tested. The normal incidence sound absorption coefficient was measured by the impedance tube on cylindrical specimens. In general, a different behavior was observed between the upper and lower base of each specimen due to the manufacturing process and the shrinkage caused by the different interactions occurring between the aggregates and the pulp paper waste; for example, the presence of sawdust reduced shrinkage in the final specimens, with consequent smaller physical variations among the two faces. The correlation existing between the manufacturing process and the microstructural properties was also investigated by the estimation of the non-acoustical parameters using the inverse method and taking into account the JCA (Johnson, Champoux and Allard) model as a reference. [ABSTRACT FROM AUTHOR]

Producing tissue paper is an energy-demanding process; a significant amount of energy is expended when removing water by vacuum, mechanical pressing, and thermal drying. Because the water is most energy-demanding to remove in drying, making the preceding step of vacuum dewatering more efficient would benefit the whole process. This article focuses on developing a laboratory-scale method for verifying the nature of diminishing returns of water removal and investigating efficiency strategies of the vacuum dewatering. The theoretical concept of successive vacuum suction boxes with progressing vacuum levels was tested at the laboratory scale in order to show quantifiable results of the previously solely theoretical concept. The results confirmed that vacuum dewatering can be improved by adding progressively higher vacuum levels and that such a practice can benefit both outgoing dryness levels and expended vacuum pump energy. To truly examine the power of progression of vacuum levels, rewetting can be included in the calculations, by using an approximate value collected from pilot or fullscale measurements. For any new fiber mix, pulp type, vacuum level setup, basis weight, etc. the vacuum levels, rewetting, and dwell times need to be tuned to that specific case. [ABSTRACT FROM AUTHOR]

Protests during the 2021 Climate Conference in Glasgow exemplified our dilemma. The establishment perpetuates old thinking, while young people demand a new approach to mitigate the impact of climate change. The authors agree with the young people, and as a solution we propose to replace the current fragmentary approach with a new holistic one. The passive house approach that was conceptualized by the University of Illinois and built in Canada in 1977 showed us that energy consumption can be reduced about half of that used in the traditional design. Seventeen years later, a European passive house was built in Darmstadt. In 2008, a demonstration house in Syracuse, NY, showed that integrated passive measures produced energy use by about half of the NY state code for 2004. At the same time, some advanced houses in the USA showed total energy use of about 70 kWh/(m2∙y). In 2008, at the first Building Enclosure Science and Technology Conference, two equally important objectives for 2030 were proposed by the Lawrence Berkeley National Laboratory: (1) a 90% reduction of energy use in new buildings and (2) 50% for the retrofitting of existing buildings, i.e., to the level achieved in the 1980s. The first objective has recently been achieved in small buildings while the large residential buildings remain on the level obtained in the 2000s. Yet, the retrofitting of existing buildings (the second objective) has been a dismal failure. This paper acknowledges progress in hydronic heating and cooling involving electric heat pumps and hybrid solar panels, building automatics used for operation of HVAC, and modification of air distribution systems that comes from experience with the SARS-CoV-2 pandemic. Furthermore, it highlights that to accelerate energy efficiency and carbon emission reductions, there must be broad public-private educational programs with demonstrations of a new generation of retrofitting. Economically and ecologically retrofitted buildings will create a new approach to real estate investment.

Paper drying is the most energy-intensive step in papermaking and around 90% of the total amount of manufactured paper is produced in multi-cylinder dryers. A framework based on a physical model of multi-cylinder drying was developed to assess the effect of various energy-saving measures at a production site. The framework was applied to the drying section of a paper machine producing corrugated paper. The calculated steam and power savings reach up to 1.55 GJth/tpaper and 0.1 GJel/tpaper respectively, depending on the chosen combination of efficiency measures. The cumulative effect of the measures is not equal to the sum of their individual effects, which highlights the importance of accounting for interactions when considering the implementation of several measures. [ABSTRACT FROM AUTHOR]

As a mainstream power storage and supply device, batteries are continuously upgraded. The microfluidic fuel cell has great development potential, and the paper-based microfluidic fuel cell is the latest achievement of its lightweight, which can be applied in the field of medical and biological detection. In this work, the cell models with various folding forms and unconventional absorption pads are creatively constructed, then the influence mechanism on cell performance is revealed by numerical simulation. Both transient and steady-state simulation methods are employed to monitor the whole process of paper-based microfluidic fuel cell. Conclusions show that the cell performance decreases with the increase of folding angle, the peak power density is as low as 1.71 mW/cm2, and the corresponding fuel utilization is only 2.73%. The changes in the absorbent pad shapes have little improvement on cell performance, thus the most direct way is increasing the absorbent pad volume. Moreover, materials with better water absorption capacity can increase the maximum current density to 28.70 mA/cm2, and the appropriate increase of operating temperature can also increase the peak power density to 2.36 mW/cm2, but the effect on the cell is significantly weakened if the temperature exceeds a certain limit. [ABSTRACT FROM AUTHOR]