At the Meppen site in Germany, SONAE ARAUCO focuses on sustainable production and energy-efficient processes in the processing of wood-based materials. Together with NESS Wärmetechnik, a pioneering solution was implemented: The previous gas-based dryer heating was supplemented by a supply from the existing biomass steam network – for greater efficiency, security of supply and CO2 savings.
The aim of the project was to significantly reduce natural gas consumption and CO2 emissions by integrating steam from the existing biomass power plant into the dryer heating system. The focus was on an economical solution that can be implemented with minimal technical effort and can be expanded in the long term. The result is a flexible, sustainable heating concept with high security of supply and a short amortization period.
„Every saving is a gain for the environment and the future of our company. By working well together, we can achieve a great deal and ensure sustainable success.“
At the start of the project, the existing energy system was comprehensively
analyzed. The aim was to evaluate the current system in terms of its performance limits, weak points and optimization options. Long-term site developments and future energy requirements were also incorporated into the planning.
The heat requirement of the dryer was examined in detail, taking into account the varying product ranges and operating conditions. Particular attention was paid to the requirements of the dryer air – especially temperature limits, air volume flows and technical interfaces. On this basis, a realistic, future-proof concept was developed.
In order to significantly reduce natural gas consumption, the supply air to the dryer was to be heated in future using steam from the internal network. The challenge: the new solution had to fit seamlessly into the existing infrastructure from a technical point of view – without complex conversions or adjustments to the dryer blower or exhaust gas cleaning system.
This is exactly where the chosen solution comes in: A supplementary steam feed that utilizes existing potential and can be flexibly expanded. The dryer supply air is now heated with high-pressure steam via heat exchangers – an economical, scalable step towards CO2-neutral production.
A two-stage heat exchanger system was implemented. In the first stage, the dryer supply air is heated to up to 120 °C using the available excess steam output – exactly within the permissible limits of the existing dryer.
The system has been designed so that it can be expanded at any time: Additional heat exchangers can be added with little effort if more steam is available in the future. This means that the system is already equipped for the long-term development of the site.
The installation was carried out in a conversion lasting several weeks during a planned maintenance shutdown. The heat exchanger unit was installed directly at the inlet duct of the dryer supply air – without interfering with the existing main systems.
In the very first year of operation, the customer was able to save a considerable amount of natural gas as a result of the measure – thus significantly reducing operating costs and avoiding CO2 emissions at the same time. The combination of minimal construction work and maximum savings potential makes the project a successful model for sustainable process heat supply.
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