Efficient Enterprises: Powering American Industry Heavy Industries: Advancing American Manufacturing
Forest Products Industry
Presentation to The Alliance to Save Energy
Briefing Series #4
John G. Cowie Ph.D.
American Forest & Paper Association
Agenda 2020 Technology Alliance
November 17, 2009
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Snapshot of the U.S. Forest Products Industry - Paper (2008 data)
Transforming the forest products industry through innovation
Paper and Allied ProductsNumber of pulp, paper and paperboard mills 532
Employment 445,000
Value of shipments $140 billion
Paper/paperboard capacity 96.3 million tons
Paper/paperboard production 88.8 million tons
Paper/paperboard exports 42.9 million tons
Paper/paperboard imports 24.0 million tons
Pulp capacity 66.0 million tons
Pulp consumption by U.S. mills 56.6 million tons
Energy consumption (2006 data) 2,346 trillion Btu
Recovered paper consumption 51.8 million tons
Recovered paper recovery rate 57.4%
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Snapshot of the U.S. Forest Products Industry - Wood (2008 data)
Transforming the forest products industry through innovation
Wood ProductsEmployment 460,000
Value of shipments $70 billion
Production of softwood 27,351 million board feet
Production of hardwood 9,501 million board feet
Value of exports (2002 data) $5.3 billion
Value of imports $15.2 billion
Energy consumption (2006 data) 450 trillion Btu
The Impacts of Forest Products Industry on the U.S. Economy
Manufacturing Jobs in 2008 = 905,000 Among the top 10 manufacturing employers in 48 states Economic Activity: Accounts for ~ 6 percent of mfg. GDP
On par with the automotive and plastics industries Generates more than $200 billion a year in sales
Employees earn ~ $54 billion in annual payroll Dependent on forest products industry:
Consumer goods marketing and distribution Shipping and warehousing Printing and print advertising Housing and construction Furniture manufacture and others
4Transforming the forest products industry through innovation
Forest Products Industry:Energy Efficiency Initiatives and Successes
5Transforming the forest products industry through innovation
Forest Products Industry:Energy Efficiency Initiatives and Successes
Industry-Wide
Renewable Fuel Use Compared with all other sectors,
pulp and paper mills and wood products production facilities far exceed all other industries in their utilization of renewable biomass energy
U.S. DOE data show that pulp and paper and wood products facilities produced 82% of the biomass-based energy generated by all industrial sectors in 2005
Reinventing the forest products industry through innovation 6
Forest Products Industry:Energy Efficiency Initiatives and Successes
Pulp and Paper Mills In 2006, biomass energy sources
satisfied 64% of the total energy demand in pulp and paper mills
Largest components of energy sources: Spent pulping liquors Logging or wood processing byproducts
Total energy needs is supplied by Spent pulping liquors 46% 18% is generated from wood residuals
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Energy Efficiency Initiatives and Successes
Wood Products Facilities Biomass materials are the
predominant source of energy at wood products manufacturing facilities
In 2006, wood residuals provided 74% of the energy needed to power these facilities
Reinventing the forest products industry through innovation 8
Energy Efficiency Initiatives and Successes
Reinventing the forest products industry through innovation 9
Forest Products Industry:Energy Efficiency Initiatives and Successes
Cogeneration Cogeneration is the practice of using exhaust steam
from electrical generators for heat in manufacturing processes or for space heating
Industry leader in the production and use of cogenerated electricity, second only to the chemical industry in cogenerated electricity
In 2005, 98% of electricity produced at paper mills was cogenerated
Cogeneration by wood products facilities was 96% of total electricity produced
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Appropriate Federal Role for the Industrial Technologies Program
The research portfolio of the forest products industry is consistent with the mission and goals of the ITP
ITP to update the industry roadmap and identify grand challenges
Include both energy reduction and economic constraints of the industry when selecting R&D projects
Assist Agenda 2020 in generating ideas and concepts for development into R&D projects
Need a strong Public/Private Partnerships with Agenda 2020 to advance R&D projects
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Agenda 2020Public/Private Partnerships in R&D
DOE ITP: Forest Products Industry Roadmap - 2009
DOE EERE: Value Prior to Pulping (VPP) – Integrated Biorefinery Project
USDA Forest Service: Biorefinery and Nanotechnology Technology
2007 NNI Forest Products Industry (CBAN) Consultative Board for Advancing Nanotechnology
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DOE ITP Forest Products Projects
Current Projects - 2009 Highly Energy Efficient Directed Green Liquor Utilization Development of Screenable Wax Coatings and Water-Based Pressure
Sensitive Direct Causticization for Black Liquor Gasification in a Circulating Fluidized
Bed Development of Renewable Microbial Polyesters for Cost Effective and
Energy-Efficient Wood-Plastic Composites
Some Past Projects - 2008 Biological Air Emissions Control for an Energy Efficient Forest Products Integration of the Mini-Sulfide Sulfite Anthraquinone (MSS-AQ) Pulping
Process and Black Liquor Gasification in a Pulp Fibrous Fillers to Manufacture Ultra High Ash / Performance Papers Engineering of Syringyl Lignin in Softwood Species Through Xylem-Specific
Expression of Hardwood Syringyl Monolignol Pathway Genes Development of Renewable Microbial Polyesters for Cost Effective and
Energy-Efficient Wood-Plastic Composites
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New Recovery Boiler Concept
Reinventing the forest products industry through innovation 14
New Recovery Boiler Concept
Steam Cycle Efficiency
Reinventing the forest products industry through innovation 15
New Recovery Boiler Concept
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New Recovery Boiler Concept
Transforming the forest products industry through innovation
Efficiency improvement from 16% to 25% Power generation more than doubles When all the boilers are replaced: ~ 15 Gigawatts of
additional power output Potential to make Forest Products Industry energy
independent or even a net energy producer Presently unfunded project
Cost too high for ITP budget Not within scope of EERE goals
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Competitiveness Issues in the Forest Products Industry
Transforming the forest products industry through innovation
Challenged by competitors in a global market Emerging economies enjoy economic advantages in wood,
labor, energy, and environmental costs Capacity in pulp and paper is growing overseas Slower growth is anticipated in the U.S.
Major structural changes in companies Mill closures and workforce reductions U.S. has lost 250,000 jobs, or 19% of its workforce, since 2006
Other pressures include: The growing use of electronic media An aging process infrastructure in U.S. mills Limited capital available for new investments Few technology breakthroughs in the last decade
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2009 Forest Products Roadmap Technology Objectives
Transforming the forest products industry through innovation
Summary of Top Priority R&D NeedsGenerate Energy More Efficiently
Develop and deploy black liquor gasification
Develop new materials to enable high temperature operation (especially in recovery boilers)
Significantly improve fluidized-bed boilers to achieve high steam values and power values
Improve energy efficiency of recovery boilers
Develop advanced gasification combined-cycle technologies for black liquor and solid forest-based biomass
Use Energy More Efficiently in Existing Technology
Better recover and utilize waste heat
Develop a next generation refiner to achieve more efficient mechanical pulping.
Dry wood more efficiently
Alternative way to change sulfate to sulfide
Use steam more efficiently
Reduce energy use in chemical pulping—including pumping pulp and chemicals
Breakthrough Technology to Reduce Energy Demand
2. Deliver a drier sheet to dryer section 55% - 65%
3. Reduce energy for black liquor concentration by 50% - including reducing pulp washing water usage
Increase pulping consistency to 30 percent from current levels of 15%–16%)
Reduce energy intensity of fiber preparation
Reduce product weight required to enable the product’s intended function
Improve lime kiln efficiency
Reduce process water needs to that which enters with wood
Eliminate CO2 Generation from Fossil Fuels
1. Renewable source for non-steam thermal demand – use biomass to replace fossil energy
Develop waste water treatment as an energy source—recover VOCs
Incinerate internally generated solid waste stream
Better utilize lignin as an energy source
Eliminate fossil fuel use in lime kiln
Recover CO2 and Use On-Site
Co-generate fuels (i.e., algae with CO2 feed, target trees optimized for co-generation)
Recover CO2 from lime kiln stack
Energy Use and CO2 Emissions
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2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions
Transforming the forest products industry through innovation
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2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions
Transforming the forest products industry through innovation
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2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions
Transforming the forest products industry through innovation
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Thank you!
Please contact me for more information:
John Cowie, Technology Director
Tel: 1-202-463-2749 (USA)
Email: [email protected]
American Forest & Paper Association
1111 19th Street NW, Suite 800
Washington, DC 20036 USA
Transforming the forest products industry through innovation