PULP AND PAPER INDUSTRY

A Life Cycle Assessment

Presented to Aileen D. Nieva,
Professor, School of Chemical Engineering,
Chemistry, Biological Engineering and
Material Science Engineering

In Partial Fulfillment of the Requirements

for CHE 185-1 Industrial Waste Management
And Control

By
Hayag, Christine Aira
Jacobe, Lanz
Landingin, Junard
Macalino, Angelo
Salen, Vladimir
March 2016

Introduction
The concept of sustainable development involves LCA of products, efficient resource utilization, energy
conservation, limitation of wastes from households and industries. The pulp and paper industry is also
seeking to embrace the benefits that come with sustainable development by striking a balance between
economic, social and environmental aspects of development. The main purpose of carrying out the study
was the identification and assessment of the environmental impacts that are a result of the production of
paper.

The industry is also improving its environmental performance through improved waste treatment systems.
This study determines the different hotspot on the process and recommend different control and
management on each hotspots. One management and control method was designed to make it sustainable
enough to be used in the manufacturing process. Life Cycle Assessment (LCA) is thus an appropriate
method to get a global overview of the pulp and paper industry and therefore be able to identify
opportunities for raw material and energy optimization as well as improving the efficiency of waste
treatments systems.

Goal and Scope of the Study

As part of company continuous environmental performance improvement efforts, technical teams
have to assess the potential environmental impacts of paper and to identify the top management and
control methods for different hotspots that should reduce the products impacts on the environment.
The organization now wishes to quantify the perceived potential improvement and establish
whether there are still other opportunities that could be exploited to optimize the environmental
performance of the product.
The range of actions, alternatives and impacts that are to be examined is defined to allow
stakeholders to make their concerns known and ensures the issues and potential impacts are addressed.

Objectives of the Company

Our company target to be the most sustainable manufacturer of paper within our vicinity and
nearby areas, providing a high quality and eco-friendly paper for daily writing and printing use or
purposes.

To be the most trusted paper producing company that supports the improvement and development
of the communities within our vicinity and nearby areas through the use of sustainable high
quality made paper.

To be the best business partner of big companies to promote sustainability, improvement and
development of environment.

System Boundary
The system boundary includes the (1) raw material acquisition, (2) manufacturing, (3) emission to
air, water and land and (4) treatment and disposal of waste. Raw material acquisition involves the growth,
management and harvesting of the tree. Manufacturing involves the process concerned in paper
production. Emissions to air, water and land from raw materials acquisition and manufacturing of paper
are also involved. Lastly, proper treatment and disposal of emission and waste are needed before releasing
it to the environment. The system boundary is shown in the figure below.

Raw Materials
Acquisition:

Energy

Harvesting of

Emission:
Air Emission: CO2,
PM, NOX, SOX,
VOC
Waste Water

Manufacturing:
Water

Solid Waste

Debarking,
Chipping,
Screening,
Digesting,
Bleaching,
Washing,
Refining,
Filtering,
Forming,
Clarifying,
Pressing, Drying,
Coating,
Calendar,

Materials:
NaOH, Na2S, Cl2,
NaClO2, CaCO3,
Starch, Aklyl
Ketone Dimer
(AKD),
Packaging
Material
Container

Treatment and
Disposal

Transportation

WITHIN THE BOUNDARY:

INPUT
Raw
Materials
and Energy
Acquisition
Wood, energy,
water,

Raw Materials: wood, water

and chemicals
Energy: coal, diesel and
Manufacturi
electricity
ng and

Processing:
Pulping,
papermaking
and packaging

Distribution
and

Use,
reuse,

Recover,
Recycle

OUTPUT
Treatment and
Disposal

Usable Products:
Newsprint paper
By-products: paper and
wood

Environmental
Impacts:

Airborne Emissions:
CO2, SO2, NOx
Water Effluent: BOD,
COD, metals
Solid Waste: bark,
sludge, paper, etc.

INVENTORY ANALYSIS:
Life Cycle Inventory Analysis (LCIA) is a thorough procedure accounting for the environmental loads
during the products life cycle (Babu and Ramkrishna, 2003). Inventory Analysis is a systematic,
objective, stepwise procedure for quantifying energy and raw materials requirement, atmospheric
emissions, water borne emissions, solid wastes, and other releases for the entire life cycle of a product,
package process, material or activity (Manjare and Babu, 2005). It is a process of data collection and
calculations intended to quantify the inputs and outputs of a product system. These inputs and outputs
may include resources used, as well as release to air, water, or land (SAIC, 2006). This data was made
available by the pulp and paper industry in San Ildefonso, Bulacan. Some of the data was collected
through databases.
The system starts with wood harvesting that involves felling, cutting and truck loading. Data was
collected for the transportation of the wood to the pulp mills. Transportation of raw materials such as coal
was also considered in the study. Energy use data was also collected. The pulp and paper industry
purchases electricity from the national grid and data was collected for the production of electricity from
coal, which is the main fossil fuel, used for the production of electricity. The pre-combustion effects of
the fuels used in the other paper life cycle stages were explored. The main fuel used is coal.
INPUTS: (in kg/hr)

Stream

Water

O2

N2

13,536.98

50,924.82

Wood Chip

50,924.82

35,156.10
-

54,431.04

54,431.04

54,431.04

54,431.04

INDIVIDUAL PARAMETERS AND ITS EFFECTS

Energy Consumption
The pulping processes and the paper making process at the mills are the most important consumer of nonrenewable energy in the form of coal. This is followed by the production of electricity that is used in the
production of the paper. The production of chemical pulp also consumes a significant amount of energy
even. Transportation also accounts for a significant amount energy consumed in the life cycle.
Water Emissions
The pulping processes at the pulp mill are the most important contributor as far as the chemical oxygen
demand is concerned. The generation of electricity and the extraction of coal are also significant
contributors to the emissions to water systems.
Air Emissions
The major source of carbon dioxide is onsite energy use at the pulp mills where pulping and papermaking
is carried out. Transportation generates most of the NOx during the transportation of wood from the forest
to the pulp mill and also transportation of coal to the pulp and paper mills. Wood harvesting is also an
important contributor to air emissions and the pulp mill also contributes significantly to air emissions.
Sulphur dioxide is mainly produced during production processes at the pulp mills. The production of the
electricity that is used at the mills is also an important contributor to air emissions.
Global Warming
As seen in the figure above, the pulping and paper making process has about 72-73% contribution to the
global warming potentials for 100 years. The extraction of coal accounts for close to 10% contribution to
this impact category. Transportation and generation of electricity from coal have almost equal
contributions of about 5% each to global warming.

Figure3. Global Warming Potentials in 100 years

Figure 4.Damage assessment

Acidification

As seen on the graph above, the pulp and the paper is the greatest contributor to acidification with a
contribution of about 42%. This is due to the sulphur dioxide that is emitted into the atmosphere during
the combustion of coal for steam production. Transportation is the second in contribution at about 35%,
due to the release of NOx from transportation of wood and coal to the pulp mills.
Eutrophication
Pulp and paper is also the largest contributor to eutrophication as observed in figure 4. This has a
contribution of 42 % followed by transportation, which accounts for about 35% contribution. The reason
for such a scenario is mainly due to the release of nitrates into the water from the mechanical pulping that
takes place at the pulp mills.
Climate Change
The pulp mills contribute more than 70% to climate change which is mainly the result of emissions.
Extraction of coal is the second largest contributor with close to 10% contribution. Transportation and the
production of electricity have very little contribution to this parameter.

Ozone Depletion
Transportation takes account in ozone depletion since it produces much of carbon monoxide.
Transportation accounts for approximately 50% contribution to this impact category. Chemical pulp
contributes about 23% to this impact category.
Eco-toxicity
Pulp and paper industry contributes much to the toxicity of ecosystem because of the chemicals that are
used during the production of pulp and these include defoamers, biocides and dyes. This stage accounts
for slightly above 65% contribution to this impact category. Chemical pulp also contributes significantly
to this impact category followed by transportation, which has a relatively low contribution to this impact
category about 7%.

Characterizations and Environmental Impacts

Air Emissions
Air Emission Table 1. Characterization of air emissions
Outputs
Source
General Impact
Carbon Dioxide (CO2) From combustion of
Climate Effect
fuel
Air Resources
Sulfur Oxides (SOx)
From combustion of
Human Health
fuel
Climate Effect
Ecotoxicity

Specific Impact
Global warming
Acid Rain,
Respiratory Damage,
Corrosion

Air Resources
Nitrogen Oxides
(NOx)

From combustion of
fuel

Particulate Matter
(PM)

Fine particles from the

paper manufacturing
process

Carbon Monoxide
(CO)

Incomplete
combustion of fuel

Human Health
Climate Effect
Ecotoxicity
Air Resources
Human Health
Climate Effect
Ecotoxicity
Air Resources
Climate Effect
Human Health
Air Resources

Waste Water Waste Water Table 2. Characterization of waste water

Outputs
Source
General Impact
Waste Water:
From Maintenance
Water resources
Turbidity
Human health
Ecotoxicity
Waste Water: Heavy
Metals

From Maintenance

Water resources
Human health
Ecotoxicity

Waste Water: Total

Dissolved Solids

From Maintenance

Water resources
Human health
Ecotoxicity

Waste Water: Total

Suspended Solid

From Maintenance

Water resources
Human health
Ecotoxicity

Waste Water: DO

From Maintanance

Water Resources
Ecotoxicity

Solid Waste Solid Waste Table 3. Characterization of solid wastes

Outputs
Source
General Impact

Photochemical Smog,
Eutrophication,
Acid Rain
Respiratory Disease,
Retard Plant Growth,
Climate Cooling
Effect
Ground level ozone
formation,
Asphyxiation

Specific Impact
Water quality effects:
TSS
Public Chronic
Aquatic - Chronic
Water quality effects:
BOD
Public Acute
Aquatic Acute
Nutrient
enrichment/Water
quality effects: TDS
Public Chronic
Aquatic - Chronic
Nutrient
enrichment/Water
Quality effects: BOD
Public- Chronic
Aquatic- Chronic
Nutrient
enrichment/Water
Quality effects: BOD
Public- Chronic
Aquatic- Chronic

Specific Impact

Sludge

Used Sacks
Rejected plastic
Packaging

Sludge from waste

water pretreatment.
contains fillers, ink
particles, fibers
From wood chips
Packaging with
defects to be sent
back to the supplier

Landfill space use

Solid waste

Landfill space use

Landfill space use

Solid waste
Solid waste

Process Flow Diagram

Environmental Impacts on Main Processes

Process: Debarker
Wastewater

Air Emission

Process: Chipper
Wastewater

Air Emission

Process: Screening
Wastewater

Air Emission

Process: Digester
Wastewater

Air Emission

Process: Bleaching
Wastewater

Air Emission

Process: Bleaching
Wastewater

Air Emission

Process: Chloro-alkali Reactor

Wastewater

Air Emission

Process: Reactor
Wastewater

Air Emission

Process: Washing
Wastewater

Air Emission

Process: Refiner
Wastewater

Air Emission

Process: Forming
Wastewater

Air Emission

Process: Presser
Wastewater

Air Emission

Process: Dryer
Wastewater

Air Emission

Process: Coating
Wastewater

Air Emission

Process: Calendering
Wastewater

Air Emission

Process: Reeling
Wastewater

Air Emission

Process: Winder
Wastewater

Air Emission

Process: Quality Control

Wastewater

Air Emission

Process: Packaging
Wastewater

Air Emission

Process: Multi effect Evaporator

Wastewater

Air Emission

Process: Recovery Furnace

Wastewater

Air Emission

Process: Smelt Dissolving Tank

Wastewater

Process: Green Liquor Clarifier

Air Emission

Wastewater

Air Emission

Process: Dreg Washing

Wastewater

Process: Slaker/Causticizer
Wastewater

Solid Waste

Air Emission

Process: White Liquor Clarifier

Wastewater

Air Emission

Process: Lime Mud Washing

Wastewater

Air Emission

Process: Filter
Wastewater

Air Emission

Process: Lime Kiln

Wastewater

Air Emission

Hotspots
Bleaching

includes multiple steps which consumes a lot of material and produces a lot of waste and power
utilizes chlorine dioxide

Control and Management Method

1. Dry Debarking
Process water is used only for log washing and de-icing and is recirculated effectively
with minimum generation of wastewater and water pollutant
Creates bark with a lower water content, which will result in a better energy balance for
the mill
Less water is needed in the debarking and the dissolved amount of organic substance is
reduced.
2. Extended modified cooking to a low kappa
Balance between kappa reduction in cooking and in oxygen delignification since the
selectivity is much higher in the latter system
Decrease the lignin content (lower kappa numbers) in the pulp entering the bleach plant
so as to reduce the use of the expensive bleaching chemicals
Reduction in lignin content will reduce the amount of pollutants discharged while
increasing the amount of organic substances going to the recovery boiler
3. Closed Screening
Contributes to the reduction of organic compounds in the effluents
Recovery and incineration in the recovery boiler
Bring the clean counter-currently through the fibreline, which gradually increases the dry
solid content of the liquor

Chemical Pulping

Required to convert wood chips into paper

Chemicals used in the pulping process, namely: sodium hydroxide and hydrogen sulphide,
produces harmful chemical compound.

Control and Management Method

1. Combined Heat and Power in Chemical Recovery
Using an extraction back pressure and/or extraction condensing turbine, the heat content
of the black liquor can be converted both to electricity and heat
Significantly increase the amount of useful energy extracted from black liquor, thereby
helping reduce the need for electricity or fuel purchase.
2. Collection of Spillages
Carry out on-site measures to minimize the discharged of process chemicals
Pulping liquor can escape the seals on brown stock washers, pumps and valves
Liquor spill can cause process interruption, tank overflows, mechanical breakdowns and
other errors
3. Lime Kiln Modifications
Calcination of the CaCO3 in lime mud to generate CaO
Modifications are possible to decrease energy consumption in the kiln
Evaporation energy can be reduced by installing high efficiency filters to decrease the
water content of the kiln intake
Higher efficiency refractory insulation bricks can be fitted to increase heat transfer in the
kiln
Heat energy can be recovered from the lime and from the kiln-off gas to preheat input
lime and combustion air
Furthermore, such improvements may also improve the rate of the recovery of lime from
green liquor, thus reducing a mills requirement for additional purchased lime

Chemical Recovery

In Kraft Process, chemicals used in the pulping process are recovered

Energy and material extensive utilizing and produces a considerable amount of waste, greatly
dregs and grits which is of importance in terms of solid waste.

Control and Management Method

1. Partial Closure of the Bleach Plant
Substantial further reductions in discharges to water of organic substances, nutrients and
metals
Recycling of filtrates to the chemical recovery
Reduce the volumetric flow through the bleach plant
Leading the liquids counter-currently from the last bleach stage through the sequence via
the oxygen stage washing apparatus to the brown stock washer.
2. Total Chlorine Fee (TCF) Bleaching Technique
Bleaching process carried out without any chlorine containing chemicals

 Hydrogen peroxide together with ozone or peracetic acid are the most commonly used
chemical
Possible to attain full market brightness with peroxide as the sole bleaching chemical
with low kappa content
Dose-response curve for brightness versus peroxide consumption is quite shallow at top
brightness
3. Ozone Bleaching
Provide more delignification power
Ozone activates the fibres towards peroxide and this result in higher brightness nad lower
peroxide consumption
Ozone is generated by means of silent electrical discharges in a stream of oxygen gas
Since the ozone concentration will be only 14-16% in oxygen, fairly large volumes of
oxygen are required
Ozone bleaching (O3) has very investment costs due to the high costs of ozone generators
and auxiliary equipment for ozone generators

Dimensions of Sustainable Development for Treatment on Hotspots

Treatment on Chemical Pulping

Control for
Chemical Pulping

Dimensions of Sustainable Development

Economic
Advantage

Dry Debarking

Extended
modified cooking
to a low kappa

Closed Screening

1. Same equipment
investment
compared to wet
debarking
2. Improves energy
efficiency
1. Bleaching
chemicals needed
decreases
2. No loss in strength
properties

1. Energy
consumption
increases due to
increased need for
evaporation

Disadvantage

1. Consumption of
active alkali (NaOH
and Na2S) may
slightly increase
2. Amount of
dissolved substances
going to the recovery
system increases
3. Heat generation in
the recovery boiler
increases

Ecological
Advantage
1. Decrease
wastewater amount
2. Decreases TSS,
BOD and COD load
as well as organic
compounds
1. Lower lignin
content meaning
fewer discharges of
organic substances
and nutrients
2. Lower pollutant
load in the
wastewater from
bleaching
3. Reduction of
emissions to water
1. Significant
reduction of organic
compounds in the
effluents
2. Screening plant
has no discharges to
water
3. Reduction of

Disadvantage

Social
Advantage

1. Requires fresh
wood
2. High energy
consumption

1. Mitigation of heal
risks

1. Increase wood
consumption

1. Mitigation of heal
risks
2. Safer working
conditions

1. Safer working
conditions

Disadvantage

emission to water

Treatment on Chemical Recovery

Control for
Chemical
Recovery

Dimensions of Sustainable Development

Economic
Advantage

Disadvantage

Combined Heat
and Power in
Chemical
Recovery

1. High energy yield

2. Extract energy
from black liquor

Collection of
Spilages

1. Energy savings
due to collected
spills

Lime kiln
modifications

1. Lime kiln energy

savings up to 5%
2. Reduce lime
usage

1. Savings
dependable on the
price and of
electricity and fuels
in the country
1.The investment
cost for spill-liquor
handling systems
producing 1500
ADt/d pulp mill is
estimated to be EUR
0.8 1.5 million
1. Investment cost of
about $2.5/t pulp has
been assumed

Ecological
Advantage

Disadvantage

Social
Advantage

1. Reduce CO2
release rate by half

1. Electricity
generation

1. Reduction of
wastewater from
chemical recovery
process
2. Reduce wasted
pulping liquor

1. Better publicity

1. Reduction of
wastewater from
lime kiln

1. Safer working
conditions

Disadvantage

Treatment on Bleaching

Control for
Bleaching

Dimensions of Sustainable Development

Economic
Advantage

Partial Closure of
the Bleach Plant

1. Additional
capacity

TCF Bleaching
Tecnique

1. No significant
differences in
chemical and energy
consumption in ECF
and TCF alternative

Ozone Bleaching

1. Result in the same

papermaking
properties

Ecological

Disadvantage

Advantage

1. Total rebuild of
the water
distribution system
including extra
storage for internal
waters
2. Control strategy
for the water
management
3. Additional energy
consumption

1. Reduction of
wastewater
2. Reduction of
BOD and COD loads
3. Less sludge
generation

1. High investment
and operating cost

Disadvantage

Social
Advantage

Disadvantage
1. Less job
Opportunities

1. No AOX and
chloro organic
compounds
formation

1. Mitigation of
health risks

1. Reduction of
emission to water
(AOX)

1. Mitigation of
health risks

Treatment Design
Combined Heat and Power in Chemical Recovery

Principle of CHP:

The energy losses from power generation and from heat production can be reduced by combined
generation of both, heat and power (CHP, also called cogeneration). Cogeneration plants raise the
conversion efficiency of fuel use from around one-third in conventional power stations to around 80% (or
more). Thus, for many paper mills it is possible to increase the overall energy efficiency of the process by
making use of the cogeneration thus reducing fuel consumption and air emissions. The energy
requirement and the heat-power ratio in the paper and board industry is very appropriate for the use of
CHP [Prger, 1996]. The characteristics of the processes as high and balanced electricity and heat needs,
and regularity of operation over the year are also favourable.

Many paper mills have installed different kinds of cogeneration processes. For instance, for boiler houses
fired with gas one or several gas turbines prior to the existing supplementary fired steam generator can be
installed to reach a higher output of electricity from the plant. If a steam turbine is already in operation a
gas turbine can be installed before the steam generator to generate a higher yield of power.

There are different schemes for combined cycle power plants on the market. Which system is applied
depends mainly on the existing power plants already in operation and on local conditions.

To verify the literature efficiency (80% > ) of CHP, the overall efficiency of the cycle is computed using
the formula:

|W T +W P +QS|
QB

2885.89+ 130.6755( 2935.01 )

x 100 =

56308.34578

( 54431.04
3600 )|
x 100

84
Based from the computed efficiency of the cycle (84%), the literature efficiency of CHP processes is valid
and higher compared to conventional power stations where energy loss/waste is high.

Emissions per unit of generated heat or power drop significantly as a result of the increased thermal
efficiency of CHP. Overall thermal efficiencies can reach 93% thus reducing the carbon dioxide release
rate by about 50% compared to conventional power generation combustion systems with an electrical
efficiency of about 38%. In contrast, emissions to air on the site will increase.

The following reduction rates are achieved by the application of combined co-generation relative to using
coal-fired utilities for electricity generation (Biberach, 2001):

Fuel consumption: 29 % reduction,

NOx: 38 % reduction,
CO: 97 % reduction,
SO2: 100 % reduction,
CO2, fossil: 46 % reduction.

In bigger co-generation plants NOx and CO content of the exhaust gas is controlled continuously. Other
mills may have periodic measurements of NOx and CO.

In conjunction with the greenhouse effect, cogeneration power plants based on gas turbines in combined
cycle application are regarded as being an important option for the reduction of CO2 because of their
comparatively high thermal efficiency also for relatively small capacity units (from some MW upwards).
The high electricity/heat ratio and the high efficiency of the conversion of fuels to power and heat reduces
significantly the specific CO2 emission per kWh produced compared to conventional power plants. The
overall emissions for power generation decrease due to higher thermal efficiency.

Process Flow Diagram

Summary of Material Balances: (Flows in kg/hr)

Strea
m

Water

O2
13,536
.98

54,431
.04

N2
50,924
.82
50,924
.82
-

Wood
Chip
35
,156.10

Nox

So
x

PM

Total

64,4
61.79

35,1
56.10

CO2

18,613
.34
-

10.1
4
-

4.05
-

10.1
4
-

69,5
62.49
54,4
31.04

54,431
.04

54,4
31.04

54,431
.04

54,4
31.04

54,431
.04

54,4
31.04

Hypothetical Material Balances:

A typical Kraft Pulp and Paper plant would require about 120,000 lb/hr of low pressure steam for heating
purposes in chemical recovery. (Source: CHP Feasibility Analysis, EPA)

Basis: 120,000 lb/hr of steam

S 6=120,000

lb
kg
0.453592
=54,431.04 kg steam
hr
lb

Assuming no loss in water during whole process:

S 6=S 5=S 4=S 3=54,431.04 kg steam

Wood Chip Properties (Source: Engineeringtoolbox.com)

Heating Value
Moisture Content
Energy per Weight Unit

Heating Value of Woodchip= 9,000

Woodchip Input in Boiler:

9,000 kj/kg
50%
62%

kJ
( 0.62 )=5,766 kJ /kg
kg

From Energy Balance:

Qb=56,308.34578 kW
56,308.34578
S 1=
5,766

kJ
s

kJ
kg

(3600 hrs )=35,156.09518 kg

For theoretical air requirement:

Air Required = 318 kg/GJ (Source: Boiler Plant Systems)

S 2= 318

kg
GJ
202.71
=64,461.79 kg /s
GJ
hr

)(

Air Composition:
Component
N2
O2
Total

Mass Flow (kg/hr)

50,924.82
13,536.98
64,461.79

Flue Gas:
Assumptions:
All O2 in air is converted to CO2
N2 feed is equal to N2 in flue gas
Other emissions are based on typical emission levels based on boiler duty.
(Data from: biomassenergycentre.org.uk)

CO 2=13,536.98 kg

( 4432 )=18,613.34 kg/hr

N 2=50,924.82 kg/hr

Component
NOx
PM
SOx

Qb= 56,308.35

mg/MJ
50
50
20

kJ
s
MJ
3600
1
=202,710.0448 MJ /hr
s
hr
1000 kj

)(

)(

MJ
hr

NOx= 202,710.0448

)( 50MJmg )( 101 kgmg )=10.13550224 kg /hr

6

MJ
hr

)( 50MJmg )( 101 kgmg )=10.13550224 kg/hr

MJ
hr

)( 20MJmg )( 101 kgmg )=4.054200896 kg/ hr

PM = 202,710.0448

SOx= 202,710.0448

Equipment: Combined Heat and Power (CHP) Generation from Chemical Recovery

Hypothetical Material Balance

Basis: Steam requirement of 120000 lb/hr
Converting basis to kg/hr:

Steam requirement =S 6=

At TB101:

lb 0.453592 kg
kg
=54431.04
( 120000
)(
)
hr
lb
hr

S 5=S 6
S 5=54431.04

kg
hr

At BO101:
No mixing of water (S4) & biomass/wood (S1), therefore:

S 4=S 5

S 4=54431.04

kg
hr

At PM101:

S 3=S 4
S 3=54431.04

kg
hr

Hypothetical Energy Balance

At TB101:
For superheated steam @ 250C & 1200 kPa:

H 6=2935.01

kJ
kg

s 6=6.8293

kJ
kgK

v 6 =0.19235

m3
kg

kJ
kgK

v 5=0.04739

m
kg

For superheated steam @ 400C & 6000 kPa:

H 5=3177.17

kJ
kg

For the power recovered from the turbine:

Since m5 = m6,

W T =m5 ( H 6H 5 )

s 5=6.5407

W T = 54431.04

kg
hr

hr
kJ
( 2935.013177.17 ) =3661.395 kW
)( 3600
s)
kg

Since the turbine has an efficiency of 78%, computing for the capacity:

W T =( 0.78 ) (3661.395 kW ) 2800 kW

At PM101:
For saturated liquid water @ 10 kPa:

H 3=191.79

kJ
kg

s 3=0.6492

kJ
kgK

v 3=0.00101

For the power requirement of the pump:

Assumptions:
Incompressible fluid (v3 = v4)
Pressure of water at BT101 is constant (P4 = P3)
Since m3 = m4,

W p=m3 ( H 4H 3 )=m3 v 3 (P4 P3)

W p= 54431.04

kg
hr

)(

hr
m3
0.00101
( 600010 ) kPa=91.47288 kW
3600 s
kg

)(

Rearranging the equation to solve for H4:

kJ 3600 s
91.47288 )(
(
W
s
hr )
kJ
kJ
H =H +
=191.79 +
=197.8399
p

m3

kg

54431.04

kg
hr

Since the pump has an efficiency of 70%, computing for the capacity:

W p=

91.47288 kW
131 kW
0.70

At BO101:

kg

m
kg

For the heat added to the pumped water:

Since m4 = m5,

Qh=m4 ( H 5 H 4 )

Qh= 54431.04

kg
hr
kJ
( 3177.17197.8399 ) =45046.67662 kW
hr 3600 s
kg

)(

For the heat requirement of the boiler:

Assume a boiler efficiency of 80%:

Q b=

Qh 45046.67662 kW
=
57000 kW

0.8

Equipment Data Sheet

PM101
Volumetric Flow Rate (m3/s)
0.01512
Type of Pump
Centrifugal
Efficiency
70%
Capacity (kW)
131

BO101
Efficiency
Capacity (kW)

80%
57000

TB101
Type of Turbine
Efficiency
Capacity (kW)

Steam
78%
2800

Possible Innovations/Improvements on CHP design:

Based on the generated material balances, combustion of wood chips produces particulate matter (PM),
NOx, SOx, Carbon dioxide (CO2) and Carbon monoxide (CO).
These pollutants are mainly found in the flue gases in the boiler, thus the design improvement shall focus
on methods to reduce the pollutants from the flue gas generated.

Emission Abatement Technologies

(Based from: Biomass heating: a guide to medium scale wood chip and wood pellet systems)
Technology
Cyclone grit
arrestor

Advantages
-Will take out most
particulates down to
about 20
micron.

Disadvantages
-Will not take out a
significant proportion
of PM10 and smaller.
-Will not take out any
gas including NOx.

Bag filter

-Will take out most

particulates down to
about 1 micron
(0.001mm) diameter.
-Will take out almost all
PM10 and PM2.5
particulates.

-Regular filter cleaning

required.
-Will not take out any
gas including NOx.
-Unlikely to be
commercially viable if
flue gas temperatures
exceed 200oC.

Electrostatic filter

-Will take out almost all

particulates down to
ultrafine
particles, i.e. smaller than
PM2.5.
-Will take out almost all
particulates down to
ultrafine
particles, i.e. smaller than
PM2.5.
-Will dissolve gases
including CO2 and (less
effectively)
NO2.
-Enables a high degree of
heat recovery from the
boiler flue gases.
-Able to remove most
particulates from high
temperature flue gas.
-Long life expectancy

-Must be used in series

with a cyclone.
-Will not take out any
gas including NOx.

Wet scrubber

Ceramic filter

-Must be used in series

with a cyclone.
-Weak acid produced
as gases dissolve;
requires
neutralisation and the
removal of salts from
the
scrubber water.
-Significantly reduces
flue gas buoyancy
-Will not remove any
gas including NOx.
-Must be used in series
with a cyclone.
-High cost.

Reference:
1. C .T Mbohwa1, L. Mashoko. Application of Life Cycle Assessment in the Zimbabwean Pulp and
Paper industry from http://www.lcm2007.org/paper/Mbohwa.pdf
2. Gavrilescu D. (2004). Management of Pulp and Paper Mill Waste. Switzerlan: Springer
International Publishing
3. The EIA in the Pulp and Paper Industry, Forestry Department. from
http://www.fao.org/docrep/005/v9933e/V9933E03.htm#ch3.2.1