Pulp Mills in Transition€¦ · Boiler Digester Evaporation. Wood Chips. Bleaching. Pulp/Paper....

Pulp Mills in Transition -from net consumers of energy to producers of energy and services

Peter Axegård

Chalmers Energy Conference, January 26 – 27, 2011

Axegård, Chalmers Energy Conference, Jan 26-27, 20112

Innventia (former STFI) is a R&D company

Pulp, paper, packaging, new materials and biorefining

270 employees

Located close to KTH

2011-02-15


One of the world’s leading R&D companies in P&P

with customers world-wide in the pulp, paper and packaging industry

Some customersABB Alabama River PulpAlbanyAprilBASFBillerud

Br Hartmann Eka Chemicals Ericsson Fibria Celulose Holmen Kemira Klabin Korsnäs Mercer Pulp Metso Mondi M-real

Nalco Norske Skog SCA Smurfit Kappa Speciality Minerals Stora Enso Södra Tetra Pak UPM Voith Weyerhaeuser

2011-02-15

4Axegård, Chalmers Energy Conference, Jan 26-27, 2011

2011-02-15

The bleached kraft pulp mill

Recovery bolier

Chemical recoveryEvaporation

Digester

Pulp Bleach plantChippingDebarkingWood

2011-02-15


2011-02-15

Sidan 6

Fuel oil - Swedish P&P industry1973 - 2007

0

500

1000

1500

2000

250019

73

1976

1979

1982

1985

1988

1991

1994

1997

2000

2003

2006

1000 m3


Model Mill

1975

Model Mill 1993

KAM Ref. Mill

1998

KAM Ref. Mill

2000

Swedish Average

2000 Kappa number

-after cooking -to bleach plant

32 32

20 10

22 9

27 10

- -

Oxygen delignificaiton No Yes 2 stages 2 stages Yes

Heat consumption, process GJ/ADt 10.0 9.4 10.4 10.8 15.2

Sold surplus power kWh/ADt 610 886 663 543 -140

Cooling towers No No Yes Yes -

Consumption of process water m3/ADt 30 23 15 16 58

Effluent load, COD kg/ADt 45 18 11 7 26

Direct minus avoided CO2 kg/ADt +60 -290 -240 -260 -

Solid residues1) kg DS/ADt 502) 382) 47 44 51

1) Wood yard (mainly sand and gravel), bio-sludge, construction and demolition wastes excluded. 2) ESP dust not included

Comparison with Earlier Published Model Mills

2011-02-15


Bleached kraft – increased energy effiency

Before 1965 1300 kg per ton

80-ies 650

90-ties 100-250

2010 -250

Future < < 0

2011-02-15


Alternatives for exporting the energy excess

Electricity Solid fuels Liquid fuels

Chemicals

District heating

2011-02-15


The pulp mill biorefinery – Studied products

Lignin

Cellulose

Bark

Forestry residues

Hemi-cellulose

Extractives

Lignin

• Functional polymers• Bioactive compounds

• DME • Ethanol• FT-diesel • Biooil• Heat• Electricity• Pellets• Lignin

• Fiber additives• Barriers• Hydrogels

• Phenols• Carbon fiber• Binders• Dispersants• Activated carbon

Chemicals/MaterialsEnergy

Cellulose • Fibers• Derivatives• Nanocellulose

Axegård, Chalmers Energy Conference, Jan 26-27, 20112011-02-15

10

Modern kraft pulp mills - high energy efficiency

Model Mill Case Sold Fuel

GJ/ADt

Produced Power

kWh/ADt

Sold power

kWh/ADt

Fossil CO2

kg/ADt

Modern mill – bark boiler 0,6 1520 730 -260 Modern Mill – no bark boiler 3.1 1255 545 -260 Typical mill -0.6 645 -140 +320

Power Balance for the Reference Mill

KAM2 kWh/ADt

KAM1 kWh/ADt

Production Back-pressure power 790 788 Condensing power 465 616 Total 1255 1404 Consumption 712 742 For sale 544 663 Total 1255 1405

2011-02-15


2011-02-15

Sidan 13

Biomass solid fuels Fuel P&P industry applicability Potential raw material

source

Wood pellets High Saw dust

Torrefied wood High Wood

Lignin High Black liquor


2011-02-15

Sidan 14

Biomass liquid fuelsFuel P&P industry applicability Potential raw

material source

Annual plant ethanol Medium if co-located Corn, bagasse, etc.

Wood based ethanol High, integrated/co-located Forestry residues

Pyrolysis oil High

Synthetic ethanol Medium Black liquor, forestry residues,lignin MeOH/DME/FT-diesel High

Biodiesel High Tall oil, methanol

Biogas Medium Biological sludge


Cellulose

16

Cellulose Products

NanoCellulose Gel

Kraft Pulp Fibres

Transparent Films

Fibre PLA Composite


Lignin from black liquor

2011-02-15

Sidan 18

Carbohydrates

Extractives

Lignin

Black liquor

50 % of the wood becomes organic material in the cooking liquor

Wood to kraft pulp mill

Pulp

Cellulose

55- 60 % of energy goes into the black liquor


The LignoBoost process

Lignin OUT

Recovery Boiler

Digester

Evaporation

BleachingWood Chips Pulp/Paper

Lignin INReplacement of fossil fuel in lime kilns50 L fuel oil ptp can be saved

Wood

Lime Kiln


19

LignoBoost – developed by Chalmers and Innventia


20

LignoBoost lignin – a new material

C 64 - 66 Na 0.05 - 0.4 Ash 0.3 - 1 S 1 - 3 N 0.1

Typical composition, %


21

2011-02-15

Sidan 22

15/02/2011

Välj 'Visa sidhuvud....' för att ändraSidan 22

Potential for replacement of fuel oil

Lignint/y

Replaced fuel oil m3 /yr

25 % lignin removal in all Swedish kraft pulp mills

1 200 000 780 000


Potential kraft/soda lignin applicationsLignin fuel in lime kilns Lignin pellets

Lignin to carbon fibres

Spun lignin fibres

Lignin in fuel oil

• Binders• Benzene/Phenols• Activated carbon

Dispersants

Kaolin/Water

Other applications


23

24

New Pulp Mill Revenues

650 000 ton pulp/y

Removal of 10% lignin = 33 000 t/y

… 16 000 t carbon fibres

…replaces 40% steel in i 160.000 cars


Forestry residues

0.4

Chips 0.8

Wood pellets

3

Lignin5

Ethanol6

Energy density key-issue for biofuels kWh/m3

Our focus


25

Alkaline fractionation

Hydrolysis, Fermentation &

Distillation

Lignin Separation

Energy Recovery

Chemicals Recovery

Forestry Residues Ethanollactic acid

Sulphur-FreeLignin

Electric Power

Alkaline route from wood to ethanol/lactic acid

CO2


26

2G Ethanol- Alkaline ProcessWill it work in practice? Yes!

Tested in mill and pilot scale trials

70 t soda pulp produced 40 m3 pulp suspension used 700 litres of ethanol produced


27

28

Near Future Kraft Pulp Mill Biorefinery

Energy and Recovery

Pre-treat-ment

Forestry residues

PulpingWood chips

LignoBoost


Sepa-ration

Today Future

Pulp CottonreplacementNanocellulose

No FuelCarbon fibresPhenols

No Fibre additivebarrierscomposites

No Lactic acidXylitolEthanol

PowerHeat

Motor fuelsPellets

Polymeric carbohydrates

Monomeric carbohydrates

2011-02-15

Biofuels

Integrated

Energy

System

Fibre processing

Primary treat-ment

Pulpwood

Forestry/agri residues

Pulp &Cellulose

Chemicals

The Future Pulp Mill Biorefinery

Conver-sion

Conver-sion

Black liquor Heat & Power


29

Pulp Mills in Transition€¦ · Boiler Digester Evaporation. Wood Chips. Bleaching. Pulp/Paper....

Documents

Transcript of Pulp Mills in Transition€¦ · Boiler Digester Evaporation. Wood Chips. Bleaching. Pulp/Paper....