FOREST Framework for Resources, Energy, Sustainability Treatment in Paper Production

Funding reference number | 03EN2095G

Project duration | 1 April 2023–31 March 2026

Background:

The paper industry currently ranks fifth among the most energy-intensive sectors in Germany. As part of the transformation of the paper sector, the aim is to significantly reduce process energy requirements and utilise sustainable energy supply systems. Due to the strong interdependence between the production process and the energy supply, these areas cannot be considered in isolation from one another, particularly when waste heat and volatile, renewable energy sources are to be utilised. The complex process of decarbonising the paper industry could be very well supported by software, but no tools have yet been developed for this purpose.

The project:

The aim of the project is to develop a framework – that is, a tool – in which the paper production process and the required energy supply systems are modelled as a digital twin, enabling energy and material flows to be tracked down to the level of sub-processes and sub-products. These models form the methodological basis for using simulation to identify options for reducing CO₂ emissions, whilst ensuring the economic viability and quality of paper production.

The project is therefore developing the foundations and tools necessary for sustainable, low-carbon and cost-effective paper production. In this way, the project results contribute to gaining a deeper understanding of the paper production process, further optimising it and supporting the paper industry on its path towards achieving climate targets. The project thus lays the foundation for the continued existence of paper companies in Germany.

The framework offers several avenues of support for the targeted acceleration of the paper industry’s transition to climate neutrality. A key aspect of this is the preparation of product-specific carbon footprint assessments to optimise processes, enclosures and energy supply, and to minimise waste and emissions.

Our contribution to the project:

The focus of the work carried out by the NOWUM-Energy Institute is on modelling energy supply systems and their interfaces with production. To this end, white-box, grey-box and black-box models of various energy conversion plants are being developed, for example of large-scale heat pumps as a key technology for the future. This enables future energy supply systems to be simulated in order to test how the energy requirements of production processes could be met as efficiently and sustainably as possible. Another focus is on waste heat integration and the cascading of energy flows to make optimum use of them. To this end, models are being integrated into the framework to optimise heat exchanger networks.