Energy saving potential in steam systems: A techno-economic analysis of a recycling pulp and paper mill industry in Morocco

Abstract

The industrial sector represents nearly 40 % of global energy consumption, with steam systems accounting for 30 % of energy use in manufacturing. As the need for cleaner processes intensifies within African and global energy transitions, adopting energy efficiency practices becomes imperative. Governments are focusing on reducing energy losses in fossil fuel-dominated manufacturing industries, which are major producers of greenhouse gas emissions. Despite their significant energy consumption, industrial heat processes are often overlooked in efforts to reduce costs and emissions. To address this, the study examines thermal energy processes and identifies energy-saving opportunities within steam systems through a techno-economic analysis of a recycling pulp and paper mill in Morocco. This is the first study focusing specifically on steam systems within a particular industry in the country. The research uses a system approach covering steam generation, distribution, end-use, and recovery. The current system is benchmarked through a rating questionnaire, and proposed energy-saving actions include leak repair, pipe insulation, blowdown management, and improved boiler combustion efficiency. An economic study evaluates the cost-effectiveness of these opportunities. Findings reveal a 6 % reduction in thermal energy consumption, annual savings of $417 899 and nearly 482 TJ, a 6 % decrease in GHG emissions (2158.5 tons of CO₂ per year), and water savings of approximately 5300 m³ per year (13 %). The total investment of $8750 has negligible payback periods. Despite diverse industrial activities, this work is useful for other industries since the fundamental components of the steam system are widely shared. Moreover, it supports the African Union's Agenda 2063 and United Nations Sustainable Development Goals by providing practical insights and recommendations for enhancing industrial energy efficiency.