FOMOP - Climate-neutral paper production Model Factory Paper Research Cluster (FOMOP)

Funding reference  | 03STG011F

Project duration  | 08/2023 – 07/2027

Initial situation:

The paper industry is the fifth most energy-intensive sector in Germany. In the context of the ongoing transformation of the paper industry, there is a clear objective to achieve a substantial reduction in process energy requirements, whilst concurrently implementing sustainable energy supply systems. It is challenging to achieve savings in the heat cycles of established production technologies. Furthermore, it is difficult to integrate other energy supply systems into existing production facilities. Consequently, novel, potentially disruptive concepts are required. These range from customised raw materials to extended and innovative processes and procedures and their energy and resource efficiency, through to embedding these concepts in an overall system of a sustainable circular economy. The objective of this research project is therefore to deviate from the well-trodden paths of small-step efficiency increases, which are often based on lengthy trial-and-error processes, and to systematically develop completely new processes for the production of fibre-based materials. Production processes are typically characterised as the conversion or formation of materials, with the provision of energy typically not being a salient factor in this context.

The project:

The focus of our work at the NOWUM-Energy Institute in the FOMOP project is to determine the specific energy requirement per tonne of paper and the associated CO2 emissions for the technologies to be developed. On the one hand, the technologies are optimally integrated into the paper production process chain by modelling and simulation. This process chain is considered as a whole, i.e. from the fibre through stock preparation to dewatering and drying. The reintegration of waste heat into the process is a key feature of the system. On the other hand, the resulting demand for electricity and heat must be met in a CO2-neutral manner by energy supply systems. Consequently, the investigation focuses on CO2-neutral energy supply, despite the challenge posed by market volatility. The integration of the energy analysis and evaluation of the various technologies in this sub-project ensures standardisation and consistency, facilitating the comparison of the individual technologies developed in the joint project using benchmarks.

A key element of the investigation pertains to the establishment of an electrified dryer section, with the objective of facilitating a CO2-neutral energy supply through the utilisation of electricity derived from renewable sources. In this regard, a range of concepts for heat recovery at varying temperature levels are under development. These concepts involve the integration of high-temperature heat pumps, vapour recompression and low-pressure steam generation within the dryer section.

In addition, a system for evaluating the energy efficiency of paper production is being developed, which includes time-dependent effects of energy supply when determining CO2 emissions. The subsequent utilisation of modelling and simulation will facilitate the development of solutions for the optimal integration of the innovative technologies into the four distinct paper manufacturing processes: tissue, newsprint, packaging and coated graphic papers. This will be achieved by determining the energy requirements and the quality level of the energy required. The optimum energy supply system, in terms of cost and CO2 emissions, is then developed for each solution. The utilisation of volatile energy sources has given rise to a range of solutions for the implementation of discontinuous operation of paper machines. Furthermore, the economic viability of energy and pulp storage systems in the context of minimising or avoiding the use of CO2-emission energy sources has been examined. Finally, the establishment of benchmarks for the comparison of innovative technologies will be determined from the results of tests conducted on technology carriers.

Objectives:

The objective of this project is to use knowledge-based approaches to develop the basis for climate-neutral paper production, in which the specific energy requirements of paper production are reduced by 80% by 2045, thereby realising sustainable and future-proof paper production. In order to achieve this objective, it is intended to employ entirely novel technology carriers for the development, investigation and techno-economical evaluation of previously uncharted technological production concepts. These concepts will be based on established scientific and physical phenomena, with the objective of realising the aforementioned overall energy savings in a synergistic manner.

Modellfabrik Papier gGmbH (MFP)

Technical University of Darmstadt, Institute for Paper Manufacturing and Mechanical Process Engineering (PMV)

Technical University of Darmstadt, Institute for Macromolecular Chemistry and Paper Chemistry (MAP)

Dresden University of Technology, Chair of Wood Technology and Fibre Materials Technology (TUD)

Heidenau Paper Technology Foundation (PTS)

RWTH Aachen University, Institute of Textile Technology (ITA)

Jülich Research Centre, Institute of Plant Sciences (FZJ)