Fray Bentos mill status. Eugenio García Sami Saarela
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1 Fray Bentos mill status Eugenio García Sami Saarela
2 Milestones of the pulp mill project Eucalyptus plantations established in Uruguay at the beginning of 1990 s by UPM-Kymmene and Shell (Compañia Forestal Oriental) Botnia purchases 60 % of Forestal Oriental (early 2003), today a fully owned subsidiary of Botnia Botnia S.A. founded (October 2003) Preliminary Environmental Authorization (February 2005), the project starts Fibre line installation starts in November 2006 Readiness for start-up in September 2007 Final Environmental Permit in October 2007 Start-up November 9th, 2007 Reaching the nominal capacity of the mill (as 30 days average) 145 from the start-up 2 EGa
3 Key data of the mill Capacity ADT/year of fully bleached eucalyptus pulp Target brightness % ISO, ECF-bleaching Raw material mixture comprises of E. Grandis, E. Dunnii and E. Maidenii Basically the entire raw material supply comes from the plantations of Forestal Oriental within max. distance of 200 km from the mill, wood usage > 3 million s-m3 The entire fiberline and chemical recovery process delivered by Andritz 3 EGa
4 Process and equipment Woodhandling Fiberline Recovery Effluent treatment 4 EGa
5 Woodhandling Debarking in the forest Two parallel chipping lines at the mill (capacity 2 x 330 s- m³/h) Final debarking (diameter 4 m, length 15 m debarking drums) Chippers of horizontal feeding (HHQ-ChipperTM) Two chip piles (diameter 106 meters, capacity s-m3) Gyratory screening of chips 5 EGa
6 Fiberline 6 EGa
7 Basic features of the fiberline Cooking: Process Lo-Solids Downflow Diamondback chip silo, Turbofeed chip feeding system (three chip pumps in series) Brown stock washing: Three DD-washers in parallel (DD4580.3) Oxygen delignification: Two stages min residence time Bleaching: Sequence (A/D)-Eop-D-P Drying of pulp: Two parallel drying machines, capacity 2 * 1800 ADT/d Twin Wire Formers 7 EGa
8 Chemical Recovery Evaporation plant: 7 effects, capacity 1100 tons water/h Recovery boiler: Combustion capacity 4450 tons/d Steam values: pressure 94 bar (g) and temperature 490 oc Vapor generation capacity 182 kg/s Electric power generated with two 70 MW turbines White liquor preparation: X-Filters for green liquor filtration, disc filters for the the white liquor filtration Lime kiln with the capacity of 830 tons CaO/d 8 EGa
9 Effluent treatment Activated sludge biological treatment, for ca m3/d effluent flow: Coarse screening to remove bigger particles Primary clarifier to remove solids (mainly fibers) from the high solods stream Safety and equalization basins (three m3 basins in parallel) Cooling tower for temperature control Aeration basins (rwo in parallel) Secondary clarifiers (two in parallel, dia. 65 m) Excess sludge disposal system 9 EGa
10 Effluent treatment plant 10 EGa
11 Botnia FRB Key Figures EGa Cumulative production up to 21/04/09 : tons Record day production up to 31 Oct: 3890 t/d (25/01/09) TONS in moving 12 month just reach 75,6 81,1 92,8 95,3 94,7 83,7 AVAILABILITY % 96,3 92,7 97,8 89,9 65,9 99,9 97,5 93,4 92,3 JANUARY FEBRUARY MARCH APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH ,7 JANUARY FEBRUARY MARCH 98,1 98,1 98,8 APRIL MAY JUNE JULY AUGUST SEPTEMBER PRIME GRADE % 99,9 99,7 99,8 99, ,9 97,9 99,5 99,4 OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH 97,3 87
12 12 EGa
13 TONS/DAY Botnia FRB Production: Nov 07- actual DAILY PRODUCTION (month average) MONTH 13 EGa
14 PROD (TONS) Botnia FRB Production: Nov 07- actual MONTHLY PRODUCTION MONTH EGa
15 15 EGa Botnia FRB quality trends
16 16 EGa ISO Brightness (%) DM2 BRIGTHNESS /01/ /02/ /02/ /03/ /03/ /03/ /04/ /04/ /05/ /05/ /06/ /06/ /07/ /07/ /08/ /08/ /09/ /09/ /09/ /10/ /10/ /11/ /11/ /12/ /12/ /01/ /01/ /02/ /02/ /03/ /03/ /03/ /04/2009 DM1 BRIGTHNESS /01/ /02/ /03/ /04/ /05/ /06/ /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /03/2009
17 21/01/ /02/ /03/ /04/ /05/ /06/ /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /03/ /04/ /01/ /02/ /03/ /04/ /05/ /06/ /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /03/ /04/2009 Dirts on pulp (mm2/kg) DIRT DM DIRT DM EGa
18 21/01/ /02/ /03/ /04/ /05/ /06/ /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /03/ /04/ /01/ /02/ /03/ /04/ /05/ /06/ /07/ /08/ /09/ /10/ /11/ /12/ /01/ /02/ /03/ /04/2009 Viscosity (ml/g) VISCOSITY DM1 VISCOSITY DM EGa
19 Successes and bottlenecks EGa
20 Successes Good production figures Good learning curve of operators and engineers. Effective organization Emissions under permit limits and most parameters have already achieved long term average targets (expected to be reached about 3 years after start up) Good and even pulp quality Safety 20 EGa
21 Performance tests Wood Handling: chips production accepted Fiberline: done, but line needs more tunning on digester and brownstock washing to achieve guarantee figures. Drying machines: done and accepted Evaporation: done Boiler: done 21 EGa
22 Bottlenecks White liquor plant: Had been bottleneck until September Green liquor filtration (due to bad quality welding of recirculation pipes), and to much solids in the circulation White liquor filtration (learning what parameters affect WL filtrability, adjusting slits and correcting start up procedure) Lime kiln bricks Now very good production level Evaporation: Bottleneck during May and June Hydroblasting and acid washing of effect 2 performed in June and periodical boil outs have improve situation 22 EGa
23 Bottlenecks Drying machines: Bottleneck for short periods, due to side deckers on wet end worn out, felts changes and cutter jams. Availability problems Fiberline: Bottleneck for short periods, due to lower than expected availability. Main problems: chip pums, steam nozzles leakages, combi screens operability, unstable consistencies, corrosion D2 control valve, fiber reinforced pipes breaks. It is present bottleneck together with RB Recovery Boiler: It is present bottleneck if fiberline is in steady operation 23 EGa
24 24 EGa Process and availability optimization challenges
25 Wood and wood handling Minimizing cost of handling Amount of bark. Have effects on: quality of product, availability of the area and in the future whole mill, and gasifier. Dryness of wood: Have effect on cooking. To check logistic chain. More efficient use of water. 25 EGa
26 Fiberline Digester parameters fine tunning to get stable discharge (kappa and consistency) at blow line and stable higher pulp viscosity To check yield: TDS/ADT very high (there are other reasons also: high dead load at liquor circulation, high ashes recirculation) Digester bottom & brownstock washing improving continues Improving availability issues: chips pumps problems Desing/operation of screening Consistency control Tank agitation and pipes desing Rotors and baskets Sand separation Better control of consistency along the line Better understanding of the effect of key parameters on papermaking characteristics. 26 EGa
27 Drying machines Moisture and basis weight control after drying machines optimization ongoing Sectional drives (situation it is better) Fabrics (to develop the suppiers) to improve durability and runnability Dryer threading still some problems, have improved Pick up rolls water splashing ( dealing with the issue, some modifications next shutdown) Screening improvement (sand separation and secondary accepts to primary accepts) 27 EGa
28 Evaporation and boilers EVAPORATION not important continuous problems. Future situation depending on better reduction efficiency at boiler and optimizacion of caustizicing efficiency RECOVERY BOILER Learning to run Recovery Boiler with higher reduction efficiency and lower carbon to green liquor Chloride and potasium removal: corrosion and plugging at continuous high load. Some construction issues. 28 EGa
29 WLP and Lime Kiln WLP Design/construction issues at X filters To optimize caustizicing efficiency LIME KILN Brick lining design To maximize hydrogen burning Help for success of gasifier project 29 EGa
30 Electricity and ETP ELECTRICITY to achieve optimum distribution between selling for chlorate production and the national grid Load shedding: Changes in the program to shed only what it is necessary Changes in the priorities between areas ETP Treatment of domestic effluents 30 EGa
31 Summary of challenges Improving availability of whole mill to improve quality stability, increasing production, lowering cost and lowering even further emmisions; overcoming bottlenecks. Continue with test runs on wood handling, fiberline & recovery Understanding effect of key process parameters on papermaking properties of pulp Improving bales quality 31 EGa
32 32 EGa Environmental figures March 2009 Effluent
33 Effluent discharge - COD COD (DQO) - Kg/ADT Permit limit (annual): 15 Kg/ADT Long Term Average (IFC, annual): 8 Kg/ADT Target 2009 (annual): 5 Kg/ADT /08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 COD (DQO) - ton/d Permit limit (monthly): 56 ton/d Avg /08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg EGa Avg 2009
34 Effluent discharge BOD 5 0,8 0,7 0,6 0,5 0,4 0,3 0,2 0,1 BOD 5 (DBO 5 ) - Kg/ADT Permit limit (annual): 0,7 Kg/ADT Long Term Average (IFC, annual): 0,3 Kg/ADT 0,0 3,0 2,5 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 BOD 5 (DBO 5 ) - ton/d Permit limit (monthly): 2,6 ton/d Avg ,0 1,5 1,0 0,5 0,0 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg EGa Avg 2009
35 Effluent discharge - AOX 0,16 0,14 AOX - Kg/ADT Permit limit (annual): 0,15 Kg/ADT 0,12 0,10 0,08 0,06 Long Term Average (IFC, annual): 0,08 Kg/ADT 0,04 0,02 0,00 0,60 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 AOX - ton/d Permit limit (monthly): 0,56 ton/d Avg ,50 0,40 0,30 0,20 0,10 0,00 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg EGa Avg 2009
36 Effluent discharge P Total 0,024 P Total - Kg/ADT 0,020 Permit limit (annual): 0,020 Kg/ADT 0,016 0,012 Long Term Average (IFC, annual): 0,012 Kg/ADT 0,008 0,004 0,000 0,08 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 P Total - ton/d Permit limit (monthly): 0,074 ton/d Avg ,07 0,06 0,05 0,04 0,03 0,02 0,01 0,00 36 EGa /08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 Avg 2009
37 Effluent discharge N Total 0,24 N Total - Kg/ADT 0,20 Permit limit (annual): 0,20 Kg/ADT 0,16 Long Term Average (IFC, annual): 0,15 Kg/ADT 0,12 0,08 0,04 0,00 0,80 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 N Total - ton/d Permit limit (monthly): 0,74 ton/d Avg ,70 0,60 0,50 0,40 0,30 0,20 0,10 0,00 37 EGa /08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 Avg 2009
38 Effluent discharge - TSS 1,2 TSS (SST) - Kg/ADT 1,0 Permit limit (annual): 1,0 Kg/ADT 0,8 Long Term Average (IFC, annual): 0,7 Kg/ADT 0,6 0,4 0,2 0,0 4,0 3,6 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 TSS (SST) - ton/d Permit limit (monthly): 3,7 ton/d Avg ,2 2,8 2,4 2,0 1,6 1,2 0,8 0,4 0,0 07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg EGa Avg 2009
39 Effluent discharge - Flow 50 Effluent flow (Caudal de efluente) - m 3 /ADT BAT (annual): m 3 /ADT Target 2009 / LTA (annual): 25 m 3 /ADT /08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg 2008 Avg EGa
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