Energy analysis of impulse technology: research-scale experimental papermaking trials and simulations of industrial applications

The impact of impulse technology on a system-wide level has been investigated in this study for non-integrated fine paper and linerboard mills. Impulse unit data were obtained from STFIʹs EuroFEX research paper machine and correlations were developed in order to predict performance (dewatering, electricity consumption) under commercial operating conditions. Mill analyses were conducted for different configurations (i.e. one or two impulse units with and without web preheating) operating with roll temperatures of 200–320 °C. Results show that the ingoing dryness to the dryer section can be increased within a wide span, from 7 to 27 percentage points depending upon the grade and operating parameters. Even though electricity consumption rises dramatically from the inductively heated rolls, overall fuel savings of up to 20% can be achieved with either one or two impulse units operating at 200 °C (external power plant efficiency assumed to be 45%). Impulse technology appears to be neutral in terms of production costs since increases in energy costs are expected to be counterbalanced by savings in feedstock materials and enhanced product quality. Estimates show that this technology can lead to substantial reductions in dryer section sizes for new installations or alternatively enhance productivity in existing paper machines.