Pergamon 0360-5442(95)00039-9 Energy Vol 20, No 10, pp 1005-1019, 1995 Copyright© 1995ElsevierScienceLtd Pnnted m Great Britain All nghts reserved 0360-5442/95 $q 50 + 0 00 ENERGY END-USE MODELS FOR PULP, PAPER, AND PAPERBOARD MILLS-] LUIS GIRALDO and BARRY HYMAN$ :~Department of Mechamcal Engmeenng, FU-10, Unmverslty of Washington, Seattle, WA 98195, U.S A (Recewed 24 January 1995) Abstract--Thts paper deals with energy end-use models for pulp, paper, and paperboard mtlls The models are consistent wtth data published in the U.S Department of Energy's 1991 Manufac- tunng Energy Consumption Survey (MECS) A graphical framework for depicting these energy flows is presented. Development of these models is a key step in creating energy process-step models for pulp, paper, and paperboard produchon. The applicability of the modeling approach and framework to other industries is &scussed. INTRODUCTION Two approaches have traditionally been used to model energy pattems in manufacturing processes. The first is concentrated on generic end-uses such as machine drive, lighting, HVAC, and process heating; the second is focused on sequential process steps such as washing, coolong, mixing, etc. Each only gives a partial picture of energy-usage patterns, and both suffer from the inability to calibrate the models with systematically collected data. A general approach for combining end-uses and process steps into calibrated energy consumption models of manufacturing processes was recently completed.~ This paper is the first part of an effort to apply that technique to pulp, paper, and paperboard mills. MECS The Manufacturing Energy Consumption Survey (MECS) conducted by the U.S. Department of Energy is the most comprehensive source of manufacturing-energy consumption data.: Published every 3 years since 1985,§ MECS details manufacturing-energy use by industry, fuel type, end-use, and geographic region. The 1991 MECS,¶ the most recent edition, provides energy data for all 20 manufac- turing major groups designated as Standard Industrial Classifications (SIC) 20-39. The SIC system also disaggregates each 2-digit SIC major group into 3-digit SIC industry groups and 4-digit SIC indus- tries, and energy data for 40 4-digit SICs are included in the 1991 MECS. MECS definitions, variables, and data are the logical foundation for building manufacturing-energy consumption models because of wide manufacturing sector coverage, use of statistically rigorous samphng and data analysis techniques, availability of regular updates, and consistent data treatment across all industries. The Paper and Allied Products (SIC 26) major group is composed of the five 3-digit industry groups and the 17 4-digit industries listed in Table 1. This paper deals with SIC 2611-pulp mills, 2621-paper mills, and 2631-paperboard mills; these three industries used 94.5% of the energy consumed by the SIC 26 major group in 1991. We wall describe-our analysis for SIC 2631 in detail, and present the results for SIC 2611 and SIC 2621 in summary form. tThls research was supported by Battelle-Paofic NorthwestLaboratoryunder Task Order 210457 and Bonneville Power Adnums- traUon under Purchase Order DE-AP79-93BP06172. Preparation of the manuscnpt was supported under Grant DE-FG06- 89ER-75522 or DE-FG06-92RL-12451 with the U.S. Department of Energy. By acceptance of this article, the pubhsher acknowledges the U.S Government's right to retain a non-excluswe, royalty-free hcense in and to any copyright covenng this paper ~:To whom all correspondence should be addressed §Starting in 1994, MECS wall be conducted every 2 years ¶When th~s paper was wntten, the data tables for the 1991 MECS were avadable but the document aself had not yet been pubhshed. Hereafter we will refer to th~s data source as the 1991 MECS. E~v zo/lo-o 1005