Why Is Your Dryer Section Consuming Too Much Steam?
Excessive dryer section steam consumption is one of the most common and costly problems in paper mills. The dryer section accounts for 60-70% of total energy consumption — even a 5% reduction can save hundreds of thousands of dollars annually.
Root Cause Analysis
1. Improper Dryer Fabric CFM
- CFM too low: Poor ventilation, requiring higher temperatures
- CFM too high: Reduced conductive heat transfer contact area, requiring more steam
- Optimal CFM matched to the paper grade is critical
2. Fabric Contact Area Issues
- Flat yarn fabrics provide 60-75% contact area — suitable for most grades
- Spiral fabrics provide 25-40% — suitable for tissue, less efficient for packaging
- Worn fabrics lose contact uniformity over time
3. Pocket Ventilation Problems
- Blocked or misaligned ventilation ducts
- Insufficient blow box pressure
- Poor pocket ventilation geometry design
4. Inefficient Vacuum Systems
- Vacuum pipe leaks
- Undersized vacuum pumps
- Poor suction roll maintenance
Energy-Saving Checklist
| Area | What to Check | Potential Savings |
|---|---|---|
| Dryer Fabric CFM | Match to paper grade | 3-8% |
| Fabric Contact Area | Maximize with flat yarn | 2-5% |
| Pocket Ventilation | Clean ducts, proper pressure | 3-10% |
| Vacuum Optimization | Fix leaks, right-sizing | 2-5% |
| Steam Trap Maintenance | Replace failed traps | 5-15% |
PAPTEX Energy-Saving Fabrics
PAPTEX HR-PET dryer fabrics operate continuously at 160°C, enabling higher drying temperatures without degradation. Optimized CFM design ensures the best balance of ventilation and heat transfer.
Need an energy audit? Contact PAPTEX engineers for a free dryer section assessment.