Superheated steam drying for sustainable and recyclable web-like materials

Project Information

SteamDry

Grant agreement ID: 101137906

DOI

10.3030/101137906

EC signature date 24 November 2023

Start date 1 January 2024

End date 30 June 2027

Funded under

• Digital, Industry and Space

Total cost

No data

EU contribution

€ 9 843 168,48

Coordinated by

TEKNOLOGIAN TUTKIMUSKESKUS VTT OY
Finland

Periodic Reporting for period 1 - SteamDry (Superheated steam drying for sustainable and recyclable web-like materials)

Reporting period: 2024-01-01 to 2025-06-30

Summary of the context and overall objectives of the project

The SteamDry project aims to develop and pilot innovative superheated steam drying (SSD) technologies for web-like materials such as paper, board, tissue, and nonwovens. The primary goal is to significantly reduce the CO2 footprint of the paper and pulp industry by enhancing energy efficiency and sustainability.

Context and Motivation

The paper and pulp industry is one of the most energy-intensive sectors, with significant CO2 emissions resulting from conventional drying processes. Traditional drying methods, such as contact cylinder and convective hot air drying, have limited energy efficiency and inevitably produce CO2 emissions. The need for more sustainable and energy-efficient drying technologies is critical to address the environmental challenges posed by this industry. The SteamDry project tackles these challenges by developing SSD technology, which utilises the superior heat transfer properties of superheated steam. This closed-loop system electrifies the drying process and maintains temperatures above the vaporisation point, resulting in lower net energy consumption and the use of surplus steam for other purposes within the facility.

SteamDry Project Objectives

The SteamDry project aims to revolutionise drying in the pulp and paper industry by developing superheated steam drying (SSD) technology. Its objectives include reducing energy use by over 60%, eliminating CO2 emissions, piloting SSD for web-like materials, and deploying AI-supported control systems for safe, efficient, and scalable industrial adoption

Pathway to Impact

SteamDry follows a structured path from research to commercialisation, involving seven research institutions, five industry stakeholders, and two technology providers. The project’s comprehensive approach starts with R&D, proceeds through pilot trials, and prepares for commercial scale-up. Collaboration is key, with partners ensuring successful SSD development and implementation. Pilot and lab results benchmark SSD technology against existing best practices, with advanced controls optimising performance and safety.

Expected Impacts

SSD technology’s use of superheated steam dramatically cuts energy use, repurposes surplus steam, and sustains closed-loop efficiency. This supports the EU Green Deal and climate goals by potentially saving 127 TWh/year in Europe and up to 870 TWh globally, translating to billions in cost savings and substantial CO2 emission reductions. Faster drying enhances product quality while compact design and system integration improve efficiency. Digital control and innovations in steam-air separation and purification further drive sustainable, energy-efficient manufacturing.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

Technical Activities

The SteamDry project focuses on developing and piloting SSD technology for industrial use. Superheated steam enables faster drying and notable energy savings, with closed-loop systems maximising internal steam utilisation. Modelling plays a key role, as well as mapping drying dynamics, temperature profiles, and moisture content, as well as optimising steam generation and condensation for efficiency and safety.

A drying concept was selected and will be adapted for the VTT Sampo pilot line in Jyväskylä, Finland, to align with the pilot line’s convective drying capabilities. The team evaluated requirements, developed process layouts and initial cost estimates, and designed key systems for sealing and steam purification to facilitate integration.

Scientific Achievements

SSD technology has the potential to cut drying energy by over 60% versus BAT reference levels. Safety is supported by robust sealing, purification, and risk management procedures. New concepts block fibre and air contamination, ensuring high product quality. Simulations and lab tests validate SSD’s adaptability for different dryers.

In its first 1.5 years, the project has made strong progress toward pilot-scale deployment, with SSD technology poised to reduce both energy use and CO2 emissions in industrial applications.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

SSD technology significantly enhances energy efficiency in the paper and pulp industry, reducing drying energy use by over 60%—and up to 85% depending on temperature—compared to BAT, marking a major breakthrough. Key safety features have been developed, including advanced sealing, purification, and risk management processes. Measures to prevent fiber and air contamination in the closed-loop system have also been refined.

Lab-scale measurements are ongoing, and pilot-scale testing is underway, validating SSD technology for various dryer types. The AI-supported control platform ensures both safe and efficient operation.

SSD’s efficient heat transfer with superheated steam reduces energy use, enables steam recycling, and increases drying rates compared to cylinder drying, improving product quality and reducing degradation. Its compact design and advanced system integration further boost efficiency and sustainability in manufacturing. The project provides valuable insights into steam-gas separation, cleaning biobased particles, and safe, AI-driven industrial processes.

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