Cellulase-assisted refining in a paperboard mill: Avoided emissions from energy savings. A case study of a Finnish paperboard mill

The 2023 being on its way to be the warmest year in the 174-year global surface temperature history it is becoming more and more evident how crucial it is to break the linkage between economic growth and greenhouse gas emissions.

The pulp and paper industry is highly energy intensive industry sector. It is the fourth largest industrial energy user and currently produces approximately 1.3% of global greenhouse gas emissions. While the demand for paper and paperboard products keeps rising, it is essential for the industry to find energy efficient solutions for reducing the environmental impact of the pulp and paper products. 80% of the progress in energy efficiency in Finnish paper mills is due to improved technology and more optimal operational modes. Optimizing existing processes has bigger effect on energy efficiency than closing old and starting new paper mills.

Pulp refining is one of the most energy intense steps in the paperboard production, representing 15%–18% of the total energy consumption of a paper mill. The effect of a commercial cellulase enzyme product was evaluated for energy savings and avoided emissions in the refining process of a paperboard mill. Data from a paperboard line using Bleached Softwood Kraft Pulp (BSKP) from a separate pulp mill was provided by a Finnish paperboard mill containing production runs both with and without commercial cellulase product ECOPULP® R. Data was collected from the mill automation system to evaluate and compare a refining capacity restricted run and a run that was not refining capacity restricted.

Analysis of the data showed a reduction of refining energy by approximately 16%–17% when the cellulase enzyme was used. This corresponds to 2 kg of CO₂ emissions avoided per tonne of pulp refined when calculated using the Finnish average electricity emissions intensity in 2022. Use of the cellulase enzyme enabled the refining results that could not have been reached with the bare mechanical refining capacity of the mill.

Cellulases can be efficient processing aids in pulp refining. The reduction of required mechanical refining and electrical power to run the refiners to achieve the required freeness can significantly affect the carbon footprint of the paperboard products, whereas the negative impact of emissions from enzyme production is negligible. Reduction of CO₂ emissions is especially significant in the areas where the electricity mix used for the production is based heavily on fossil fuels.