Reducing gas consumption through steam harmonisation

Paper mill small-footprint installations transforming the sludge into carbon-neutral fuel and reusable high brightness fillers

Ideal Cart S.p.A. designed and implemented a very efficient system to reduce emissions. Earlier, a gas turbine had provided electricity and steam to two machines. Changes to the production set-up eliminated one of the machines; which meant the turbine was only partially used, generating a thermic excess, and consequently hot fumes were leaking into the atmosphere.

In order to optimise that process, Ideal Cart decided to harness the excess fumes, significantly reducing gas consumption. A piping system now connects the turbine with the hood air system; the hot gases are also managed by a system of automatic closures, in order to harmonise steam production, hood activity and the constant pressure of the turbine. In addition, a further steam generator was installed on the hood drain to improve performance.

With this modification the two hood burners remain switched off for most of production, with huge economic benefits for the company.

This configuration reduces CO2 emissions by more than 10%, so that the entire system contributes to the site’s environmental sustainability in accordance with Ideal Cart’s corporate philosophy. The overall cost of the project was approximately €1.7 million. The results were in line with expectations, and in addition to the CO2 reduction, methane gas release was also reduced by more than 10%.