Illustration of Top D

Energy Efficiency BA

May 26, 2010

NESCAUM/EDF
Goals and Cautio

• Goal

– Provide a simplified version of a c

example to demonstrate concept oEnergy Efficiency BACT

• Cautions

– NOT a regulatory proposal– Illustration does not imply judgme

BACT for pulp and paper industry
Top Down Energy Efficien

• Identify benchmarks 

– EPA EnergyStar, DOE Industrial Techn

Program, Lawrence Berkeley Laborator

• Step 0: Frame use of benchmark

– Level A: Consider full facility– Level B: Consider source and those port

production that create a load for that sou

– Level C: Consider only source and energ

system

– All levels should include consideration o

management systems
Top Down Energy Efficien

• Step 1: Identify all energy efficiency option

– Conduct audit of facility for comparison to benc

– Consider CHP and water efficiency improvemen

included in benchmark

• Step 2: Eliminate technically infeasible opti

– Benchmarks are generally based on available tec

• Step 3: Rank efficiency options

– Include consideration of pollutant emissions red

usage, etc. 

– Efficiency gains are likely to be additive, and ran

address grouping of compatible technologies

• Step 4: Eliminate control options

– Look to impact on other pollutants, cost-effectiv
Some Observation

• Appropriate level of analysis may var

– Pulp plant: Steam generated is used thro

Level C may be appropriate.

– Chemical Industry: Multiple, widely var

lines per plant could make Level B apprpoint.

– EGU’s: Where most efficiency gains are 

source itself, Level C might be appropria

• But consider demand-side management if av

• When addressing multiple pollutants

gains from GHG BACT may influenrates for other pollutants.
Some Observations 

• Cost-efficiency

– Lack of prior PSD determinations 

alternative comparisons

• Consider payback periods for efficien

– Do payback periods below (2, 5, 10) yea

presumption of cost-effectiveness?

– Improvements without an available pay

still be considered.

• Avoid strict comparisons with early G

permits to avoid path-dependent lock

– Allow time for a broad array of example
Illustration: Pulp and Pape

• Based on 2006 DOE Energy Ban

study

• Baseline is based on average ind

usage in 2002

• Efficiency gains are based on new 

plant designs from 2006 for a blehardwood Kraft pulp and printinwriting paper plant
Wood 

Handling

Lime Kiln / 

Slacker

Pulping Washing & 

Screening

Bleaching

Evaporators 

/ Recovery 

Boiler

Total Pulp 

Demand

Stock Prep & 

PM Wet En

Pressing

PM Dryer

Dry End / 

Calenderin

Pulp a

P

From figure 4.6 of Jacobs & IPST, Pulp and Paper Industry Energy Bandwidth Study (2006), http://www1.eere.e

Based on production figures from Sappi Cloquet Mill (455,000 mt pulp/yr.; 330,000 mt paper/yr), http:/

HVAC/Lighting

Pulping

Paper Machine

Facility

Raw Material Prep

Annual 5.7 trilli410 Gw910 billi

Lime Kiln / 

Slacker
Wood 

Handling Pulping Washing & 

Screening

Bleaching

Evaporators 

/ Recovery 

Boiler

Lime Kiln / 

Slacker

Total Pulp 

Demand

Stock Prep & 

PM Wet En

Pressing

PM Dryer

Dry End / 

Calenderin

Level A 

Re

From figures 4.6 and 6.7 of Jacobs & IPST, Pulp and Paper Industry Energy Bandwidth Study (2006), http://www1.e

Based on production figures from Sappi Cloquet Mill (455,000 mt pulp/yr.; 330,000 mt paper/yr), http:/

HVAC/Lighting

Pulping

Paper Machine

Facility

Raw Material Prep

Steam Btu/yr Electric(25%)Direct Btu/yr 

Level A includes wood handling, pulp, and paper processes.Note: HVAC/lighting data unavailable.
Wood 

Handling Pulping Washing & 

Screening

Bleaching

Evaporators 

/ Recovery 

Boiler

Lime Kiln / 

Slacker

Total Pulp 

Demand

Stock Prep & 

PM Wet En

Pressing

PM Dryer

Dry End / 

Calenderin

Level B 

All P

From figures 4.6 and 6.7 of Jacobs & IPST, Pulp and Paper Industry Energy Bandwidth Study (2006), http://www1.e

Based on production figures from Sappi Cloquet Mill (455,000 mt pulp/yr.; 330,000 mt paper/yr), http:/

HVAC/Lighting

Pulping

Paper Machine

Facility

Raw Material Prep

Steam Dtrillion BElectrici(11%)Direct FBtu/yr (

Level B includes wood handling, and pulp processes.
Wood 

Handling Pulping Washing & 

Screening

Bleaching

Evaporators 

/ Recovery 

Boiler

Lime Kiln / 

Slacker

Total Pulp 

Demand

Stock Prep & 

PM Wet En

Pressing

PM Dryer

Dry End / 

Calenderin

Level C

Pulping 

From figures 4.6 and 6.7 of Jacobs & IPST, Pulp and Paper Industry Energy Bandwidth Study (2006), http://www1.e

Based on production figures from Sappi Cloquet Mill (455,000 mt pulp/yr.; 330,000 mt paper/yr), http:/

HVAC/Lighting

Pulping

Paper Machine

Facility

Raw Material Prep

Steam Dbillion BElectriciby 2.5 GDirect F

Level C+ includes pulp digestion/cooking only. Gains from digester controls and modifications and pulping aids are included, and thus overstate gains from boiler and steam improvements.