<ul><li>Efficient Enterprises: Powering American Industry  </li></ul><ul><li>Heavy Industries: Advancing American Manufact...
Snapshot of the U.S. Forest Products Industry - Paper (2008 data) Transforming the forest products industry through innova...
Snapshot of the U.S. Forest Products Industry - Wood (2008 data) Transforming the forest products industry through innovat...
The Impacts of Forest Products Industry  on the U.S. Economy <ul><li>Manufacturing  Jobs in 2008 = 905,000 </li></ul><ul><...
Forest Products Industry: Energy Efficiency Initiatives and Successes  Transforming the forest products industry through i...
Forest Products Industry: Energy Efficiency Initiatives and Successes  <ul><ul><li>Industry-Wide  </li></ul></ul><ul><ul><...
Forest Products Industry: Energy Efficiency Initiatives and Successes  <ul><ul><li>Pulp and Paper Mills </li></ul></ul><ul...
Energy Efficiency Initiatives and Successes  <ul><ul><li>Wood Products Facilities </li></ul></ul><ul><ul><li>Biomass mater...
Energy Efficiency Initiatives and Successes  Reinventing the forest products industry through innovation
Forest Products Industry: Energy Efficiency Initiatives and Successes  <ul><ul><li>Cogeneration </li></ul></ul><ul><ul><li...
Appropriate Federal Role for the  Industrial Technologies Program  <ul><ul><li>The research portfolio of the forest produc...
Agenda 2020 Public/Private Partnerships in R&D <ul><ul><li>DOE ITP: Forest Products Industry Roadmap - 2009 </li></ul></ul...
DOE ITP  Forest Products Projects <ul><ul><li>Current Projects - 2009 </li></ul></ul><ul><ul><li>Highly Energy Efficient D...
New Recovery Boiler Concept  Reinventing the forest products industry through innovation
New Recovery Boiler Concept  <ul><ul><li>Steam Cycle Efficiency </li></ul></ul>Reinventing the forest products industry th...
New Recovery Boiler Concept  Reinventing the forest products industry through innovation
New Recovery Boiler Concept  <ul><ul><li>Efficiency improvement from 16% to 25%  </li></ul></ul><ul><ul><li>Power generati...
Competitiveness Issues in the  Forest Products Industry <ul><ul><li>Challenged by competitors in a global market </li></ul...
2009 Forest Products Roadmap  Technology Objectives <ul><ul><li>Energy Use and CO 2  Emissions </li></ul></ul>Transforming...
2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products ...
2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products ...
2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products ...
Thank you! Please contact me for more information: John Cowie, Technology Director  Tel: 1-202-463-2749 (USA) Email:  [ema...
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Heavy Industries: Advancing American Manufacturing - Forest Products Industry, John Cowie, American Forest and Paper Association

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Nov 17, 2009: Alliance to Save Energy Congressional briefing, "Heavy Industries: Advancing American Manufacturing," - A discussion by industry experts centering on the current and future prospects for energy efficiency in their four respective industries. All agreed on the great potential for energy efficiency projects but acknowledged the formidable barriers that inhibit investment.

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Heavy Industries: Advancing American Manufacturing - Forest Products Industry, John Cowie, American Forest and Paper Association

  1. 1. <ul><li>Efficient Enterprises: Powering American Industry </li></ul><ul><li>Heavy Industries: Advancing American Manufacturing </li></ul><ul><ul><li>Forest Products Industry </li></ul></ul><ul><li>Presentation to </li></ul><ul><li>The Alliance to Save Energy </li></ul><ul><li>Briefing Series #4 </li></ul><ul><li>John G. Cowie Ph.D. </li></ul><ul><li>American Forest & Paper Association </li></ul><ul><li>Agenda 2020 Technology Alliance </li></ul><ul><li>November 17, 2009 </li></ul>
  2. 2. Snapshot of the U.S. Forest Products Industry - Paper (2008 data) Transforming the forest products industry through innovation Paper and Allied Products Number of pulp, paper and paperboard mills 532 Employment 445,000 Value of shipments $140 billion Paper/paperboard capacity 96.3 million tons Paper/paperboard production 88.8 million tons Paper/paperboard exports 42.9 million tons Paper/paperboard imports 24.0 million tons Pulp capacity 66.0 million tons Pulp consumption by U.S. mills 56.6 million tons Energy consumption (2006 data) 2,346 trillion Btu Recovered paper consumption 51.8 million tons Recovered paper recovery rate 57.4%
  3. 3. Snapshot of the U.S. Forest Products Industry - Wood (2008 data) Transforming the forest products industry through innovation Wood Products Employment 460,000 Value of shipments $70 billion Production of softwood 27,351 million board feet Production of hardwood 9,501 million board feet Value of exports (2002 data) $5.3 billion Value of imports $15.2 billion Energy consumption (2006 data) 450 trillion Btu
  4. 4. The Impacts of Forest Products Industry on the U.S. Economy <ul><li>Manufacturing Jobs in 2008 = 905,000 </li></ul><ul><li>Among the top 10 manufacturing employers in 48 states </li></ul><ul><li>Economic Activity: Accounts for ~ 6 percent of mfg. GDP </li></ul><ul><ul><li>On par with the automotive and plastics industries </li></ul></ul><ul><li>Generates more than $200 billion a year in sales </li></ul><ul><ul><li>Employees earn ~ $54 billion in annual payroll </li></ul></ul><ul><li>Dependent on forest products industry: </li></ul><ul><ul><li>Consumer goods marketing and distribution </li></ul></ul><ul><ul><li>Shipping and warehousing </li></ul></ul><ul><ul><li>Printing and print advertising </li></ul></ul><ul><ul><li>Housing and construction </li></ul></ul><ul><ul><li>Furniture manufacture and others </li></ul></ul>Transforming the forest products industry through innovation
  5. 5. Forest Products Industry: Energy Efficiency Initiatives and Successes Transforming the forest products industry through innovation
  6. 6. Forest Products Industry: Energy Efficiency Initiatives and Successes <ul><ul><li>Industry-Wide </li></ul></ul><ul><ul><li>Renewable Fuel Use </li></ul></ul><ul><ul><li>Compared with all other sectors, pulp and paper mills and wood products production facilities far exceed all other industries in their utilization of renewable biomass energy </li></ul></ul><ul><ul><li>U.S. DOE data show that pulp and paper and wood products facilities produced 82% of the biomass-based energy generated by all industrial sectors in 2005 </li></ul></ul>Reinventing the forest products industry through innovation
  7. 7. Forest Products Industry: Energy Efficiency Initiatives and Successes <ul><ul><li>Pulp and Paper Mills </li></ul></ul><ul><ul><li>In 2006, biomass energy sources satisfied 64% of the total energy demand in pulp and paper mills </li></ul></ul><ul><ul><li>Largest components of energy sources: </li></ul></ul><ul><ul><ul><li>Spent pulping liquors </li></ul></ul></ul><ul><ul><ul><li>Logging or wood processing byproducts </li></ul></ul></ul><ul><ul><li>Total energy needs is supplied by </li></ul></ul><ul><ul><ul><li>Spent pulping liquors 46% </li></ul></ul></ul><ul><ul><ul><li>18% is generated from wood residuals </li></ul></ul></ul>Reinventing the forest products industry through innovation
  8. 8. Energy Efficiency Initiatives and Successes <ul><ul><li>Wood Products Facilities </li></ul></ul><ul><ul><li>Biomass materials are the predominant source of energy at wood products manufacturing facilities </li></ul></ul><ul><ul><li>In 2006, wood residuals provided 74% of the energy needed to power these facilities </li></ul></ul>Reinventing the forest products industry through innovation
  9. 9. Energy Efficiency Initiatives and Successes Reinventing the forest products industry through innovation
  10. 10. Forest Products Industry: Energy Efficiency Initiatives and Successes <ul><ul><li>Cogeneration </li></ul></ul><ul><ul><li>Cogeneration is the practice of using exhaust steam from electrical generators for heat in manufacturing processes or for space heating </li></ul></ul><ul><ul><li>Industry leader in the production and use of cogenerated electricity, second only to the chemical industry in cogenerated electricity </li></ul></ul><ul><ul><li>In 2005, 98% of electricity produced at paper mills was cogenerated </li></ul></ul><ul><ul><li>Cogeneration by wood products facilities was 96% of total electricity produced </li></ul></ul>Reinventing the forest products industry through innovation
  11. 11. Appropriate Federal Role for the Industrial Technologies Program <ul><ul><li>The research portfolio of the forest products industry is consistent with the mission and goals of the ITP </li></ul></ul><ul><ul><li>ITP to update the industry roadmap and identify grand challenges </li></ul></ul><ul><ul><li>Include both energy reduction and economic constraints of the industry when selecting R&D projects </li></ul></ul><ul><ul><li>Assist Agenda 2020 in generating ideas and concepts for development into R&D projects </li></ul></ul><ul><ul><li>Need a strong Public/Private Partnerships with Agenda 2020 to advance R&D projects </li></ul></ul>Reinventing the forest products industry through innovation
  12. 12. Agenda 2020 Public/Private Partnerships in R&D <ul><ul><li>DOE ITP: Forest Products Industry Roadmap - 2009 </li></ul></ul><ul><ul><li>DOE EERE: Value Prior to Pulping (VPP) – Integrated Biorefinery Project </li></ul></ul><ul><ul><li>USDA Forest Service: Biorefinery and Nanotechnology Technology </li></ul></ul><ul><ul><li>2007 NNI Forest Products Industry (CBAN) Consultative Board for Advancing Nanotechnology </li></ul></ul>Reinventing the forest products industry through innovation
  13. 13. DOE ITP Forest Products Projects <ul><ul><li>Current Projects - 2009 </li></ul></ul><ul><ul><li>Highly Energy Efficient Directed Green Liquor Utilization </li></ul></ul><ul><ul><li>Development of Screenable Wax Coatings and Water-Based Pressure Sensitive </li></ul></ul><ul><ul><li>Direct Causticization for Black Liquor Gasification in a Circulating Fluidized Bed </li></ul></ul><ul><ul><li>Development of Renewable Microbial Polyesters for Cost Effective and Energy-Efficient Wood-Plastic Composites </li></ul></ul><ul><ul><li>Some Past Projects - 2008 </li></ul></ul><ul><ul><li>Biological Air Emissions Control for an Energy Efficient Forest Products </li></ul></ul><ul><ul><li>Integration of the Mini-Sulfide Sulfite Anthraquinone (MSS-AQ) Pulping Process and Black Liquor Gasification in a Pulp </li></ul></ul><ul><ul><li>Fibrous Fillers to Manufacture Ultra High Ash / Performance Papers </li></ul></ul><ul><ul><li>Engineering of Syringyl Lignin in Softwood Species Through Xylem-Specific Expression of Hardwood Syringyl Monolignol Pathway Genes </li></ul></ul><ul><ul><li>Development of Renewable Microbial Polyesters for Cost Effective and Energy-Efficient Wood-Plastic Composites </li></ul></ul>Reinventing the forest products industry through innovation
  14. 14. New Recovery Boiler Concept Reinventing the forest products industry through innovation
  15. 15. New Recovery Boiler Concept <ul><ul><li>Steam Cycle Efficiency </li></ul></ul>Reinventing the forest products industry through innovation
  16. 16. New Recovery Boiler Concept Reinventing the forest products industry through innovation
  17. 17. New Recovery Boiler Concept <ul><ul><li>Efficiency improvement from 16% to 25% </li></ul></ul><ul><ul><li>Power generation more than doubles </li></ul></ul><ul><ul><li>When all the boilers are replaced: ~ 15 Gigawatts of additional power output </li></ul></ul><ul><ul><li>Potential to make Forest Products Industry energy independent or even a net energy producer </li></ul></ul><ul><ul><li>Presently unfunded project </li></ul></ul><ul><ul><ul><li>Cost too high for ITP budget </li></ul></ul></ul><ul><ul><ul><li>Not within scope of EERE goals </li></ul></ul></ul>Transforming the forest products industry through innovation
  18. 18. Competitiveness Issues in the Forest Products Industry <ul><ul><li>Challenged by competitors in a global market </li></ul></ul><ul><ul><li>Emerging economies enjoy economic advantages in wood, labor, energy, and environmental costs </li></ul></ul><ul><ul><li>Capacity in pulp and paper is growing overseas </li></ul></ul><ul><ul><li>Slower growth is anticipated in the U.S. </li></ul></ul><ul><ul><ul><li>Major structural changes in companies </li></ul></ul></ul><ul><ul><ul><li>Mill closures and workforce reductions </li></ul></ul></ul><ul><ul><ul><li>U.S. has lost 250,000 jobs , or 19% of its workforce, since 2006 </li></ul></ul></ul><ul><ul><li>Other pressures include: </li></ul></ul><ul><ul><ul><li>The growing use of electronic media </li></ul></ul></ul><ul><ul><ul><li>An aging process infrastructure in U.S. mills </li></ul></ul></ul><ul><ul><ul><li>Limited capital available for new investments </li></ul></ul></ul><ul><ul><ul><li>Few technology breakthroughs in the last decade </li></ul></ul></ul>Transforming the forest products industry through innovation
  19. 19. 2009 Forest Products Roadmap Technology Objectives <ul><ul><li>Energy Use and CO 2 Emissions </li></ul></ul>Transforming the forest products industry through innovation Summary of Top Priority R&D Needs Generate Energy More Efficiently Develop and deploy black liquor gasification Develop new materials to enable high temperature operation (especially in recovery boilers) Significantly improve fluidized-bed boilers to achieve high steam values and power values Improve energy efficiency of recovery boilers Develop advanced gasification combined-cycle technologies for black liquor and solid forest-based biomass Use Energy More Efficiently in Existing Technology Better recover and utilize waste heat Develop a next generation refiner to achieve more efficient mechanical pulping. Dry wood more efficiently Alternative way to change sulfate to sulfide Use steam more efficiently Reduce energy use in chemical pulping—including pumping pulp and chemicals Breakthrough Technology to Reduce Energy Demand 2. Deliver a drier sheet to dryer section 55% - 65% 3. Reduce energy for black liquor concentration by 50% - including reducing pulp washing water usage Increase pulping consistency to 30 percent from current levels of 15%–16%) Reduce energy intensity of fiber preparation Reduce product weight required to enable the product’s intended function Improve lime kiln efficiency Reduce process water needs to that which enters with wood Eliminate CO2 Generation from Fossil Fuels 1. Renewable source for non-steam thermal demand – use biomass to replace fossil energy Develop waste water treatment as an energy source—recover VOCs Incinerate internally generated solid waste stream Better utilize lignin as an energy source Eliminate fossil fuel use in lime kiln Recover CO 2 and Use On-Site Co-generate fuels (i.e., algae with CO 2 feed, target trees optimized for co-generation) Recover CO 2 from lime kiln stack
  20. 20. 2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products industry through innovation
  21. 21. 2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products industry through innovation
  22. 22. 2009 Forest Products Roadmap - Technology Objectives for Energy Use and Carbon Emissions Transforming the forest products industry through innovation
  23. 23. Thank you! Please contact me for more information: John Cowie, Technology Director Tel: 1-202-463-2749 (USA) Email: [email_address] American Forest & Paper Association 1111 19 th Street NW, Suite 800 Washington, DC 20036 USA Transforming the forest products industry through innovation

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