The pulp and paper industry annually produces over 300 million tons of paper products used across society in print media, packaging, tissue, and hygiene. Transforming wood into useful products involves energy- and resource-intensive processing to separate cellulose fibers from wood components, including hemicellulose, lignin, and extractives. The industrial sector is the largest user of energy in many parts of the world. The pulp and paper industry accounted for 6% of total global industrial energy consumption, being the fourth largest energy consumer worldwide. Pulp and paper production, an energy-intensive process, is among the main light industries contributing to energy saving and pollution emission reduction. Pulp and paper mills are highly complex and integrate many different process areas including wood preparation, pulping, chemical recovery, bleaching, and papermaking to convert wood to the final product. Processing options and the type of wood processed are often determined by the final product. With the rise in environmental awareness due to the lobbying by environmental organizations and with increased government regulation there is now a trend towards sustainability in the pulp and paper industry. Sustainable pulp and paper manufacturing requires a holistic view of the manufacturing process. During the last decade, there have been revolutionary technical developments in pulping, bleaching and chemical recovery technology. These developments have made it possible to further reduce loads in effluents and airborne emissions. Thus, there has been strong progress towards minimum-impact mills in the pulp and paper industry. The minimum-impact mill is a holistic manufacturing concept that encompasses environmental management systems, compliance with environmental laws and regulations and manufacturing technologies. This study aims to highlight the pulping processes for Pulp Mill A, energy use and loss analysis, and energy-saving opportunities identified during the case study. The main objective of the case study was to help identify areas where energy is being lost and recommend possible energy-saving suggestions that can be incorporated into real-world operations.
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