The decarbonisation of the drying process in tissue making can be attained through two pathways: the adoption of carbon-free alternative fuels and the complete electrification of the process powered by green electricity.
Stefano Pecchia, Energy Technology Director at Toscotec says: “In response to the need of paper mills to drastically reduce or bring down to zero the carbon emissions of tissue machines, Toscotec has invested in the development of key technological innovations aimed to deliver high performances through the use of clean energy. As we push forward along the path of an energy transition for paper manufacturing, we also want to make sure that tissue producers are equipped to achieve the maximum possible energy efficiency based on their current means of production. In short, the strategic targets of carbon reduction and carbon-free technology underscore all our efforts in this space.”
Alternative fuels
In order to meet the thermal requirements of the tissue machine while eliminating the carbon emissions linked to its energyintensive drying process, Toscotec has developed cutting-edge technology to switch from fossil to alternative fuels, including hydrogen and syngas.
Toscotec is the only supplier in the world capable of offering a hood system burner that allows the flexibility and optionability of using both fossil fuels such as natural gas and renewable fuels such as syngas from biomass and hydrogen.
This optionability allows Toscotec to install its TT Hydrogen burner and TT Syngas Burner as standard technology in all its hood systems in order to equip paper mills for the energy transition today. TT Hydrogen Burner is a patented innovation of a 100% hydrogen fueled burner designed and tested specifically for Yankee hoods, i.e. under the same conditions of air speed, temperature, humidity of a tissue machine. It is devised to optimize the combustion of both natural gas and hydrogen, as well as a blend of the two, where the percentage of hydrogen is well accepted across the entire range.
With minor component replacements performed on site on a short machine shutdown, Toscotec can easily adapt its innovative burners to the use of hydrogen and syngas based on the specific availability of alternative fuels at the mill. Apart from the abovementioned in-line burners, Toscotec is also developing an innovative corner burner designed and tested both for fossil-based and alternative fuels such as hydrogen and syngas, which is presently undergoing a prototype construction phase.
Electrification
The second pathway to decarbonisation consists of the electrification of the entire tissue making process, including highperformance air heating and steam generation for traditional Yankees or the use of induction with Toscotec’s breakthrough TT Induction SYD steel Yankee dryer. Toscotec’s TT Induction SYD is heated up by electromagnetic induction instead of steam to dry the paper web, thereby entirely redefining Yankee dryer technology. Powered by green electricity, it cuts its direct greenhouse gas emissions to zero.
The development of this technology is undergoing the construction of a medium-scale prototype where the operating conditions of an industrialscale Yankee can be accurately simulated to test its design. Its market launch is planned for 2025, following the completion of the industrial development process.
Meanwhile, the installation of a fully electrical air system is already a reality in the tissue industry precisely on Toscotec’s machines. MPH1865’s new Toscotecsupplied tissue line operates with e-powered TT Hood with multiple stages of heat recovery. More recently, Toscotec has announced that its tissue line installed by Portuguese tissue manufacturer Fortissue will be upgraded to become the first high-speed machine in the world that can be powered entirely – both for its electric and thermal requirements – by green electricity from solar and wind farms.
This new machine will feature e-powered TT Hood, as well as 100% electrical steam generation via the combined use of recovered heat from the hood exhaust through a TT Steam Booster and an electric steam boiler.
Finally, Toscotec is also developing high-efficiency heat pumps for steam generation in tissue making application, where the recovery of flue gases from the hood exhaust with the possibility of increasing the air temperature offers the benefit of generating steam for use in the Yankee dryer with significantly lower electricity requirements than those of electrical boilers.
TOSCOTEC
Founded in 1948, Toscotec specializes in the design and manufacture of turn-key projects, complete machines, rebuilds and stand-alone systems for the tissue and paper and board industries. Headquartered in Lucca (Italy), with subsidiaries and service centers in China and North America, Toscotec offers cutting-edge technology and customized solutions to paper producers around the world. The technology is designed to achieve high production efficiency, low energy consumption and products of the highest quality. Decarbonisation, energy efficiency and paper quality are the basis for all its research and development, design and manufacturing.
