Energy efficient alternatives to decarbonize the pulp and paper industry – the case of linerboard production

Abstract

Listen

Translate article

Abstract Variability in fossil fuel prices and a commitment to reducing greenhouse gas (GHG) emissions have driven the US pulp and paper (P&P) industry to adopt technologies that decrease reliance on fossil fuels. In this regard, enhancing energy efficiency is crucial to the decarbonization of the sector. This study evaluates several energy‐efficient alternatives for one of the main P&P products, linerboard, focusing on black liquor concentration, steam generation, and paper‐drying processes. The key technologies assessed include: (a) high‐efficiency recovery boilers and electric boilers as substitutes for natural gas, (b) graphene oxide (GO) nanofiltration membranes and mechanical vapor recompression (MVR) for black liquor concentration, and (c) advanced paper machine techniques like shoe presses, nylon mesh felts, and condebelt drying. Using process simulations in Windows‐based Generic Energy and Material System (WINGEMS), Life Cycle Assessment in OpenLCA, and financial modeling, the study found that GO membranes for black liquor and condebelt drying were the most effective, reducing emissions by 15%. High‐efficiency recovery boilers added another 10% reduction. Cost analysis showed that technologies like nylon felts, shoe presses, and MVR not only cut operational costs but achieved carbon reductions of up to 8%, with costs of avoided carbon (CAC) ranging from −$67 and −$19 per metric tonne of CO2‐eq. avoided. In contrast, GO membranes and recovery boilers had higher CAC values, from $237 to $392 per metric tonne. The findings suggest that the benefits of MVR, GO membranes, electric boilers, and condebelt drying increase with greater renewable energy use in the US grid, highlighting the decarbonization potential of electrifying the pulp and paper sector.