Clean-Air Technology

Analysis of energy and material flows in the metal coating of paper

An analysis of the energy and material flows showed that solvent and carbon emissions can be reduced significantly in the paper coating process.

Schoeller & Hoesch GmbH & Co. KG manufactures metallised base papers and films for the labelling and packaging industry.

The paper is metallised with a lacquer machine as follows:

Objectives of the project

To achieve transparency regarding operating energy and material flows, particularly in the lacquer machine used to coat paper
To draw up a solvents balance for the year 2004 and a reduction plan describing ways of complying with the 31st Federal Immission Control Act (BlmSchV)
To prepare a specifications sheet for the treatment of waste air containing solvents
To research and evaluate technical options for the treatment of waste air containing solvents
To draw up an economic comparison (estimation) of different ways of treating waste air containing solvents (energy and material requirements, cost of investment and operation)

The evaluations focused particularly on solvent emissions in view of the 31st BlmSchV.

Findings

Measures reducing solvent emissions are necessary for compliance with the 31st BlmSchV
Compliance with the 31st BlmSchV would offer the following savings potential: using the energy contained in the solvents would reduce solvent emissions by at least 90% and up to 40% carbon emissions from the waste air purification process
A first evaluation of possible methods of purifying the waste air shows that there are considerable differences in the annual cost: an estimation of operating costs and the amortisation period of a regenerative incinerator showed significant economic benefits as against thermal post-combustion, including a difference in operating costs of >EUR 400,000 p.a.; the potential to reduce carbon emissions amounts to 30%-40%
It was recommended that a holistic approach be taken in the selection of a suitable technology, i.e. an evaluation of the energy and material flows together with a comprehensive analysis of economic viability

Source: Landesanstalt für Umwelt Baden-Württemberg