Surfactants Reduce Energy Demand

Transcription

1 2006 Forum on Energy: Immediate Solutions, Emerging Technologies May Appleton, WI Surfactants Reduce Energy Demand Improve Yield, Eliminate Scale, Reduce Lime Kiln Fuel Presented by: Michael Blackstone President ChemStone

2 Surface Active Agents in the Pulp Mill Digester Additive Defoamer Scale control Pitch Control Lime Mud Dewatering Aids

3 Digester Additives Chip Penetrant, Catalysts, Detergents Sodium sulfide Anthraquinone Polysulfide Phosphonates Dispersants / wetting agents Pitch control (deresinators)

4 Nice Grant Novel Chemistry Improves Pulp Yield While Reducing Energy & Chemical Requirements Can be used in conjunction with AQ, Phosphonates, Polysulfide Currently used to treat > 8MM tons/year Kraft pulp production in North America Users in Russia, New Zealand, South Africa

5 Mill Trial Data Southern pine market pulp Hydraulic Kamyr Feeding diffusion washer bleach plant Limited by White Liquor, ClO2, Recovery

6 OFFICIAL PRODUCTION RATE/RPM DAILY AVG TPD / RPM DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

7 21.5% 21.0% 20.5% 20.0% 19.5% 19.0% 18.5% 18.0% 17.5% ACTUAL AA /WOOD CALCULATED FROM RPM %NA2O DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

8 BLOW LINE VISCOSITY CED VISCOSITY DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

9 CLO2 GALS/TON (CORRECTED to 10% STRENGTH) GALS/TON DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

10 EO CAUSTIC FLOW GALLONS PER TON DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY TRIAL-AUG

11 KAMYR TOTAL STEAM LBS / TON DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

12 Pulp Dryer Total Steam LBS / TON DEC JAN PRETRIAL- FEB TRIAL 2/15-3/31 OFF MAY 9-28 TRIAL - JUNE TRIAL - JULY

13 Increased Yield=Energy Savings Trucking cost Electric power to chippers Reclaim operation Fuel to Lime Kiln Steam to digester Steam to Evaporator Recovery Island Steam Requirement Electricity to Recovery Island Aeration

14 Increased Yield=Energy Savings Making 4% more pulp from these same resources: Reduces Lime kiln fuel Reduces digester steam/ton pulp Reduces evaporator steam/ton pulp (twice) Don t dissolve it, so don t make liquor with it Make more pulp

15 Pulp or Fuel? Make Pulp valued at $xxx/ton Black Liquor 6000 btu/lb before credits for Digestion Evaporation Heating in storage Air Heating Liquor Heating Steam to generate Electricity Aeration, pumping, and more Net is actually btu/lb BLS or 0.8 mmbtu/ton

16 DOE Grant 2004 Investigates Use of Phosphonates to Improve Yield Phosphonates generally used for scale control, metals control, peroxide stabilization Yield increase of 4-6% shown with 5 lbs/ton of HEDP, DTMPA Not commercially viable, because of degradation of the phosphonates with temperature Called for development of new high temperature/high alkali stable phosphonates

17 Scale Control Case History Surface active phosphonate developed for evaporator scale control Stable to >400f for days Improved capacity from 550 gpm to 635 gpm Increased steam economy from 5.02lbs/lb evaporated to 5.9 Saved 110,000 lbs steam/day Approximately 62,000 mmbtu/year

18 Physical Inspection Verifies Bolt is Normally Scaled Over + Tubes are clean

19 Cost of Boilouts NUMBER PER YEAR HOURS WATER FLOW SODA LOSS COST OF SODA BOD LOSS STEAM COST ECONOMY STEAM FLOW WHILE BOILING 1/6days $ $ /10days $ $

20 Cost of Boilout LBS WATER USED Savings LBS STEAM TO EVAPORATE WATER LBS STEAM TO BOIL TOTAL STEAM PER BOILOUT ,277,901 lbs/yr STEAM COST PER BOILOUT $1,617 $1,459 SODA COST PER BOILOUT $4,000 $4,000 COST PER BOILOUT $5,617 $5,459 COST PER YEAR $683,367 $398,477

21 Scale control in Kamyr White Liquor Line (XY) 650 R 2 = R 2 = % Valve Position

22 TOP SEPARATOR MOTOR LOAD IV TOP SEP MOTOR LOAD DIG TOP SEPARATOR LOAD DSC400M Trial Start 9/ 22 6:30 AM

23 Inline Drainer Comparison

24 Scale Control + Yield Increase Bleach Plant (Inv Corr) Tons per Chip Meter RPM 9/22 start 08/27 08/28 08/29 08/30 08/31 09/01 09/02 09/03 09/04 09/05 09/06 09/07 09/08 09/09 09/10 09/11 09/12 09/13 09/14 09/15 09/16 09/17 09/18 09/19 09/20 09/21 09/22 09/23 09/24 09/25 09/26 09/27 09/28 09/29 09/30 65 tons per rpm 68 tons per rpm 4.6% increase in production 10/01 10/02 10/03 10/04 10/05 10/06 10/07 10/08 10/09 10/10 10/11 08/23 08/24 08/25 08/26

25 Lab Study Confirmation Data on Hardw ood Surf 1 + high temp phosphonate Surf Alder HTP Surf Base hwd M y apologies for drawing lines through 2 point s. The slope is t ypical of our lab evaluations.

26 Lime Mud Dewatering Assuming a 400 TPD Lime Kiln Increase solids from 71%>76% Water into the Kiln drops 676 tpd>523 tpd Eliminating 153 tpd of water. Ballpark 3.2 mmbtu/ton of water Saves 490 mmbtu/day Some kilns have increases 71%>80%

27 Lime Mud Dewatering BENEFITS Reduced energy in the lime kiln. Less water entering the kiln and a higher drying rate. Typical savings are 0.5 to 1.0 MBtu/short ton. Precoat filter production rate increase due to improved packing of the cake and better water removal. Typical increases are up to 15%. Better washout of sodium. TRS emissions reduced due to improved washing. Less backwashing and acid washing of the filter are required.

28 Lime Kiln Gas Usage Vs. Lime Production Natural Gas Usage (KCFt/day) Post Trials 1 and 2 y = x R 2 = Trials 1 and 2 y = x R 2 = Lime Thruput (tpd)

29 Quick Energy Savings With No capital outlay Digester Surfactant Digester Steam 8% Dryer Steam 10% Evaporator Steam 5% +4% Lime Kiln 7% +4% Evaporator Scale Control 14% +Boilout Lime Mud Dewatering 17%

30 PRESENTED BY Michael Blackstone President ChemStone Thank You