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For paper manufacturers, the mandate is clear: reduce energy, cut emissions, and increase throughput – often which the same assets. The drying section is the largest consumer of steam, so even small thermal-efficiency gains translate into meaningful improvements in t/24h, Gj/t, and CO2. Kurita'nın Dropwise Yoğuşma Teknolojisi transform how condensation occurs inside cylinders and other steam-heated equipment, enabling up to ~30% higher heat-transfer efficiency and delivering higher machine speed or lower steam usage.
Industrial context: why efficiency now
European companies must hit 2030/2050 environmental targets and recover margins amid volatile energy prices. Compared to capita-intensive projects, energy efficiency on existing systems offers a reliable and cost-effective path to measurable savings and capacity gains in the drying section. In this context, the main advantage of Kurita’s Dropwise Condensation Technology over other energy-efficient solutions is its low CAPEX requirements, which enables flexible and versatile application while delivering a short payback period – typically under one year.
The science: from filmwise to dropwise
In natural (‘filmwise’) condensation, a water film forms on metal surfaces, adding thermal resistance; even a thin film can cut heat transfer. Kurita Dropwise Condensation Technology creates a hydrophobic layer so water forms droplets and is swept away, removing the thermal barrier and maintaining a high overall heat-trander coefficient (U). In terms of overall heat transfer coefficient, both field and laboratory experience across different metals and system configurations show up to ~30% improvement compared to untreated surfaces.
Flagship application: paper machine cylinders
With Dropwise Condensation Technology the steam-side U remains high and stable, enabling two operating strategies: (a) increase machine speed – typical outcomes of +10-15%; or (b) hold output while reducing steam by 3-15%, cutting energy cost and CO2.
Additional high-impact applications
- Evaporators (black liquor, chemical, F&B): +3-11% productivity and +4-6ºC process-temperature gains with 2-5% steam savings.
- Distillation columns: ∼28-35% U increases and 2-5% steam savings.
- Rankine/power-cycle condensers: +0.5-5% cycle efficiency and up to ∼10% more power, plus relief from hot-weather cooling bottlenecks.
Implementation: technology + service
Kurita supplies formulations compatible with most boiler-treatment programs, dosing equipment installed in the steam line near the condensation zone, expert application engineering – including periodic visits – and value demonstration via U-value trends, energy balances, and line KPIs (speed, GJ/t, t/24h, CO2).
Dosage and response
Continuous dosing (not one-shot). Typical dosing levels are 20-30 ppm, efficiently adapted case by case to boost performance, with residual condensate reference levels of 0.2-0.4 ppm. Time to full dropwise effect is usually 4-8 weeks, depending on system size and dynamics. Dropwise Condensation Technology does not compromise steam or condensate quality; Kurita’s range includes options suitable for direct food-contact steam where required.
Benefits for Paper & Packaging
+10-15% machine speed; -3 to 15% steam at constant output; unlocked hidden capacity in drying/evaporation; low investment with fast, measurable payback.
Rollout roadmap
(1) Thermal baseline (U, steam, temperature maps, normalization process parameters); (2) Steam-line dosing design and compatibility checks; (3) 4-8 week stabilization; (4) verified value report (speed, steam, CO2); (5) Scale-up to other condensation zones.
Request Your Dropwise Condensation Technology Technical Evaluation
Request a Dropwise Condensation Technology technical evaluation for your paper machine or evaporation line to review U-curves, energy balances, and case-backed gains.
Kağıt Kurutucu Bölümünde Verimliliğin Artırılması
Discover how Dropwise Condensation Technology can boost drying performance and cut steam consumption.
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