Sustainability

Redefining Energy Efficiency in Paper Production

EMRE BILGIN

a single stage rt
A single-stage RT 71-1 vacuum blower awaiting installation.

The paper industry is currently undergoing a shift due to rising energy costs and the urgent need to reduce its carbon footprint. While companies are streamlining production systems to increase their competitiveness, they are also prioritizing energy savings, sustainability development, and diversification into new business areas, such as the development of innovative products.

In 2023, the production of board and packaging paper surpassed 265 million tons, with forecasts predicting an average annual growth rate of around 4.6 percent. As sustainability and environmental responsibility gain importance, the industry is not only adopting eco-friendly materials, but also focusing on optimizing energy use in the papermaking process. One of the most energy-intensive stages in paper manufacturing is dewatering the paper roll, where vacuum systems account for 20-25 percent of the total electrical energy consumption.

VACUUM SYSTEMS FOR GREATER ENERGY EFFICIENCY

Unlike conventional water ring vacuum pumps, which tend to wear out and lose efficiency over time, vacuum blowers can offer more consistent performance. TURBAIR® vacuum systems, developed by MAN Energy Solutions in Switzerland, are vacuum blowers designed for energy efficiency and sustainability. In conversion projects, energy savings typically range between 40 and 60 percent. Additionally, these vacuum systems consume up to 30 percent less energy than conventional water ring vacuum pumps, thanks to a unique design that eliminates friction losses caused by the water ring.

TURBAIR vacuum blowers are engineered to operate efficiently across a wide range of conditions—including partial load scenarios, which can lead to additional energy savings of up to 30 percent. With frequencycontrolled drives, these blowers offer flexible control of air volume and vacuum levels, allowing operators to adjust them to the specific needs of the paper machine. This not only helps to prevent unnecessary energy loss due to over-expansion but can also result in additional energy reduction of up to 20 percent, depending on the process requirements.

Moreover, TURBAIR technology eliminates the need for sealing water, resulting in further cost savings and reducing the system’s environmental impact. By removing the need for sealing water, the blowers contribute to a more sustainable and eco-friendly operation.

“TURBAIR vacuum systems stand out for their efficiency and reliability. A major advantage of this system is the ability to harness the hot exhaust air from the blowers with a heat exchanger, leading to even more energy savings,” says Manfred Dobler, head of paper industry at MAN Energy Solutions. “The exhaust air temperature of these blowers typically ranges between 120° and 165°C. As a rule, approximately 70 to 80 percent of the blower’s drive energy can be recovered through waste heat.”

Considering the potential savings mentioned, paper manufacturers can significantly reduce energy consumption of the vacuum system by up to 80 percent.

VERSATILE SOLUTIONS

To meet the different needs of papermaking, single- stage RT or multistage RC blower types are available in different sizes. These include:

Single-stage RT blower—The RT vacuum blower has a capacity range of 200 to 1,450 m3/min [7,000 to 52,000 CFM], with a pressure of up to 62 kPa [18.3″ HgV]. Thanks to its automatic capacity control system, the flow rate can be dynamically adjusted to the demands of paper machines. This versatility makes the RT series especially suitable for felt conditioning in tissue production.

Multi-stage RC blower—The RC vacuum blower provides a wide capability range, from 180 to 2,800 m3/min [6,300 to 98.900 CFM] with a vacuum of up to 75 kPa [22.2″ HgV], and is equipped with up to four suction nozzles and four vacuum levels. This enables effective operation across all vacuum levels in the wire and press sections.

The RC blower is designed for high-demand scenarios and is well-suited for systems used in graphic paper, cardboard, or pulp production. Its multi-stage radial design ensures consistently high vacuum levels.

Emre Bilgin handles sales—paper industries for MAN Energy Solutions. Headquartered in Germany, MAN Energy Solutions employs about 14,000 people at more than 120 sites globally. To learn more about vacuum blowers and other solutions for process industries, visit man-es.com/company.

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