The Paper industry consumes more than 15% of the total US Manufacturing energy and is the largest industrial energy load in Northwest, with drying consuming the most energy. This study and proposal by students at St. Martin's University in Lacey Washington, with a grant from Puget Sound Energy, offers a unique retrofit using infrared Salamander emitters to existing paper pulp dryers.

1. Paper Drying Mechanical Engineering Department This project was funded by Puget Sound Energy (PSE), Inc of Bellevue, WA through a grant awarded to the Independent Colleges of Washington. Steven Campbell Eric McKnight Michael Roberts Erin Woodward Advisor: Dr. AmanieAbdelmessih April 8, 2010

2. Introduction Paper industry consumes more than 15% of the total US Manufacturing energy Largest industrial energy load in Northwest Drying section consumes the majority of the energy http://www.epc-resources.com/images/pulp_image.jpg

3. Problem Statement The purpose of this project is to design a new innovative way to dry paper. The design is to be more efficient than the systems that are already in place.

4. Overview of Paper Industry http://www.astenjohnson.com/images/images_paper-machine.jpg

5. Overview of Paper Drying Conventional Paper Drying http://www.energysolutionscenter.org/gasirpaper/Images/ABBDrumDryer2.jpg

7. Over 17,000 tons/day capacity

9. Literature Review Comprehensive literature search April 2009-September-December 2009 Online library interloan TAPPI, ASME, IEEE, ACS publication databases Saint Martin’s library, UW library Focused on last 10 years of developments 26 papers/articles

10. Topics of Research Conventional Enhancements Superheated Steam Electromagnetic Modeling Infrared

11. Conventional Enhancements Spoiler Bars Increases turbulence in condensate layer Increased rate of heat transfer Levels moisture profile Increases drying efficiency Practical Aspects of Pressing and Drying Seminar, TAPPI, 1986

12. Conventional Enhancements Multiport cylindrical dryer 90% less condensate Small channels, higher velocities http://www.anl.gov/Media_Center/News/2006/photo/060818_multiport_dryer-hirez.jpg

13. Superheated Steam Impinging jets Temperatures > 400 ºC Higher drying rates Higher recovery of energy Less trauma to microstructure of finer grades of paper

14. Electromagnetic Microwaves – 2.45 GHz Serpentine slotted waveguide Hot-air assist High efficiency Uniform drying Zero warm-up time Quiet, cool working environment

15. Modeling System design vs. discreet sections Computational Statistical Measurement methods Alternative optimization

16. Infrared Radiation & Convection Specific wavelength http://www.energysolutionscenter.org/GasIRPaper/Images/ABBDrumDryer.jpg

17. Infrared Gas-fired drums Resistance emitters Increased output Profiling capabilities Penetrates coatings Highly modular http://www.tchigh-tec.com/english/admin/UploadFiles/cp/200761233401751.JPG

18. Literature Review With IR, 20% moisture loss within 1 sec Less moisture = More reflectivity Kuang, H., Thibault, J., Chen, R., and Grandjean, B., 1995, "Pilot Scale Investigation of Infrared Drying of Paper." Tappi J. 78(7), pp. 129-137

19. Literature REview IR above a black tray of water Intensity is much higher in the center Petterson, M., and Stenström, S., 2000, "Experimental Evaluation of Electric Infrared Dryers." TAPPI JOURNAL PEER REVIEWED PAPER

20. Literature review Created a theoretical model and ran trials Seyed-Yagoob, J., S. J. Sikirica, and K. M. Counts, 2001, "HEATING/DRYING OF PAPER SHEET WITH GAS-FIRED INFRARED EMITTERS—PILOT MACHINE TRIALS." DRYING TECHNOLOGY, 19(3&4), pp. 639–651

21. Literature review IR Placement 35th Drum Seyed-Yagoobi, J., and H. Noboa, 2003, "Drying of Uncoated Paper with Gas-Fired Infrared Emitters—Optimum Emitters’ Location Within a Paper Machine Drying Section." DRYING TECHNOLOGY, 21(10), pp. 1897–1908

22. Literature review Compared electric and gas fired emitters Developed software for simulations Ran machine trials Poulin, A., Dostlie, M., and Bédard, N., 2005, “Investigation of Efficiency and Potential Benefits of Infrared Systems for Uncoated Paper Drying.” Annual Meeting of the Pulp and Paper Technical Association of Canada, C, pp. C77-C81

23. Design 1:Infrared Paper Drying This design completely new and innovative design. The drying will be done using Salamander Infrared Emitters Working in a wavelength range of 3.0 – 3.25 micrometers Design required drying the paper from 50% water by mass to 6% water by mass

24. Design Calculations Material Balance Representation for Paper Drying Process

25. Design Calculations The power required to dry the paper from 50% water by mass to 6% by mass is 21 MW Based on view factor and radiation properties radiation absorbed by the paper is 33.17 kW/ m2 47,520 Salamander Emitters 1,326 Rows of Emitters, which span the width of the paper which is assumed as 8.13 m

26. Design Considerations

27. Infrared Emitter Blocks The rows have been separated into blocks One block as 6 rows of emitters Emitters are staggered

28. Infrared Ventilation System Humid Air IR IR Dry Air Humid Air IR Dry Air IR Humid Air IR H= 4 m Dry Air IR Humid Air IR IR Dry Air Humid Air IR Dry Air IR W= 0.8 m Alternating Infrared Block & Cool Down Block Mounted to the side of ventilation ducts Remove Humid air and supply dry air to system Manifolds

29. Infrared Paper Drying Section

30. Maintenance Emitter life is 10,000 hours running at max power Estimated life is 417 days, if run for 24 hours/day Removal of Infrared Blocks Wheels and Angle Iron

31. Retro-Fit Design Retro-fit design 72 infrared emitter rows 12 row of infrared blocks Implemented in entire 3rd drying section

32. Retrofit Design Section Infrared Emitter Block

33. Infrared Paper drying More compact Easily maintainable dryer Lower Capital Cost Increase Speed in a Retrofit Design

34. Budget

35. Budget

36. Budget

38. Budget

39. Remaining Budget

40. Publication Generated a 9 page publication-ready paper Submitted to ASME in February International Heat Transfer Conference Presentation August 8-13th in D.C.

41. Lessons Learned How to navigate publication databases How to read How to write (and get published) Project management skills A bit of “real world” engineering Work environments for engineers

42. Acknowledgements Puget Sound Energy Michael Beakley Sonoco Mill in Sumner, WA Kraft Simpson Mill in Tacoma, WA Weyerhaeuser Mill in Longview, WA Norpac Mill in Longview, WA

43. Questions?