Metsä Board case
– Energy and material audit model implmentation
In 2016 Metsä Board implemented energy and material efficiency audits at all its sites in Finland.
The audits produced clear efficiency optimisation measures for each target and an overall picture of the efficiency of its Finnish operations.
The starting point at Metsä Board was very good:
- ISO 50001 energy efficiency system in use
- Energy audits conducted for each site
- Energy and mass balance models implemented at several sites
- Dedicated person responsible for energy efficiency at each mill
- Several energy efficiency projects implemented over the years
However, several process changes had been implemented since the previous audits: new power plants were introduced at some mills while production changes were introduced at others. For these reasons, the energy and material efficiency situation required updating, but Metsä Board wanted to implement a less intensive audit model than the Motiva model. The goal was to benefit from existing materials and surveys to the maximum and to conduct them with mill staff with a focus on the most potential entities.
Optimisation of mill service systems and production process
The audits identified over 30 energy efficiency measures with an overall efficiency potential for electricity of 7,500 MWh and for heating of 61,000 MWh. In terms of cost savings this amounts to 1.5 M€ a year. Several maintenance observations and procedures that affect material efficiency came to the fore. The efficiency optimisation measure breakdown is illustrated below.
Implementation and deeper process focus
The next step is focusing on implementation of the optimisation measures and conducting surveys to gather more detailed information. Most savings measures and small improvements can be implemented quickly with little effort.
A more detailed supplementary survey will be conducted for the entity comprising the dryer series, steam and condensation system, warm water tank and heat recovery. Another interesting target for further investigation is the utilisation of low-temperature heat sources to heat the process water of the board production line.
”The latest energy and material efficiency audits have helped us to develop a new way of gaining energy efficiency and a less intensive way of analysing data. In the first year we reviewed all seven Metsä Board mills in Finland and identified over 30 optimisation targets. In 2017 seven projects have been started up based on the observations, of which the effect on cost efficiency is over a million euros a year,” says Metsä Board Energy and Material Efficiency Manager, Matti Korhonen.