Valmet innovations in use at the Äänekoski bioproduct mill

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1 Valmet innovations in use at the Äänekoski bioproduct mill

2 Valmet s delivery Recovery boiler Biomass dryer and gasification plant Lime kiln Sulfuric acid plant Pulp drying line Mill-wide automation system

3 Maximum energy efficiency with high power recovery boiler

4 High Power RECOX Metsä Fibre Äänekoski Boiler capacity 7,200 t DS/d Steam parameters 515 C/110 bar(a) Feed water preheater and interheater Vent gas heat recovery High power features enable the mill to produce 260 MW of electricity and sell 1.4 times more electricity than it needs for its own operation. Black liquor dry solids 83% Combustion air heated up to 215 C Flue gas coolers Without the high power features the electricity production capacity would be 206 MW 4 October, 2018 Valmet Customer Days 2018

5 Improved safety with smelt spout cleaning robot 5 October, 2018 Valmet Customer Days 2018

6 Benefits and experience of using smelt spout cleaning robot Automated cleaning cycles reduce operator work and makes it safer Reduced smelt splatter hazard No heat hazards No operator rodding injuries No green liquor splash hazard The robot ensures stable smelt flow by removing smelt deposits of all 11 spouts Robot operation and optimization require learning and cooperation Valmet has delivered 10 robots so far, both for new and existing boilers 6 October, 2018 Valmet Customer Days 2018

7 Good performance based on 1 st year operational experiences Successful project implementation All milestones reached as agreed Recovery boiler was started up just as planned Availability 98-99% boiler availability Production Finetuning of the boiler together with Metsä to reach the optimal reduction rate levels Performance levels achieved in steam production Emissions Valmet ESP works well in recovery boiler circumstances with modern control opportunities Boiler emission levels below the set levels warranty tests passed 7 October, 2018 Valmet Customer Days 2018

8 Fossil fuel free lime kiln with biomass gasification

9 Drivers for choosing biomass gasification for the lime kiln Cheap fuel readily available Saving about 100,000 /day Bark available at the site reduction in need for bark storage and logistics CO 2 neutral solution Biomass dryer utilizes mill waste heat improved energy efficiency no need for cooling towers Proven technology Technology and automation as one delivery from Valmet Disadvantages outweighed by benefits Kiln burner larger due to high gas flow Requires back-up fuel oil or natural gas Slightly increased dumping of lime mud 9 October, 2018 Valmet Customer Days 2018

10 Valmet s solution Automation Biomass dryer Biomass gasifier Lime kiln Evaporation capacity: 23,700 kg/h Application: Lime kiln gasifier Materials: Birch, pine and spruce bark Product gas: Application: Fuels: 87 MWth Lime kiln Birch, pine and spruce bark Capacity: Fuels: 1,200 t/h CaO Gasifier product gas, tall oil pitch Moisture in 62% out 8 % 10 October, 2018 Valmet Customer Days 2018

11 Operational experience at Äänekoski Performance tests approved for biomass dryer and gasifier Fine tuning for lime kiln test ongoing In continuous operation Lime kiln running with 100% biogas - oil as back-up fuel Lime kiln has been operating at 5-10% above design capacity Challenges in optimized operation Each unit can operate as a single island, but more challenging to operate the whole chain from start to finish Different bark types perform very differently in dryer, e.g. pine vs birch 11 October, 2018 Valmet Customer Days 2018

12 Savings and improved environmental performance with sulfuric acid plant

13 Metsä and Valmet jointly developed sulfuric acid plant solution Turns sulfurous emissions into valuable products Sulphur in odorous gases is converted to sulfuric acid Production 13 kg H 2 SO 4 /ADt Concentration 60 % Conversion rate 94 % Internally produced acid closes the mill s Na- S chemical balance Improved environmental performance with minimized sodium sulfate ash dumping Showcases Valmet s capability to develop new technologies to fulfill customer s needs 13 October, 2018 Valmet Customer Days 2018

14 Sulfuric acid plant production process Sulfur compounds oxidized to SO 2 Heat transferred to water to produce MP-steam SO 2 converted to SO SO 3 reacts with water and sulfuric acid is produced SO 2 tail gas is washed October, 2018 Valmet Customer Days 2018

15 Experiences gained from operating the sulfuric acid plant Overall experience Smooth start-up and high availability High conversion efficiency Good quality acid well suited for mill use No need to buy sulfuric acid from outside Sodium sulfate ash dumping is minimized Sulfuric acid is used in: Tall oil separation and bleaching plant Possibly for lignin separation in the future With the internal acid plant the savings in chemical costs are 5 EUR/ADt * * 3 kg S/Adt in CNCG converted to acid. NaOH 0,5 EUR/kg H 2 SO 4 0,1 EUR/kg 15 October, 2018 Valmet Customer Days 2018

16 Condition Monitoring using Industrial Internet Remote Analysis Predictive action at the right time

17 It s all about availability the process and the resources Metsä Group Äänekoski bioproduct mill The challenges at a state-of-the-art mill Process availability: A modern mill wants to run everything to full capacity. Revealing potential failures during warranty period: Technical, automation and process problems must not be allowed to develop unnoticed. Availability and cost of expertise: The mill s own personnel can only do a part of the job. Hiring more specialist workforce for the relatively short period of time would not be economically viable. 17 October, 2018 Valmet Customer Days 2018

18 Covering vital process areas Turbine Pulp dryer Lime kiln Recovery boiler Evaporation plant Fans Typical problems that have been stopped in time from developing Lubrication problems Balancing problems Bearing faults Coupling alignment problems Pump impeller contamination Mechanical loosening Cavitation and flow problems Over loading Subprocess malfunction Belt drive problems 18 October, 2018 Valmet Customer Days 2018

19 Fighting back against machine efficiency and quality problems Valmet DNA Machine Monitoring with Reporting and Analysis Services Some key figures of the Äänekoski mill 15 departments with over 600 pieces of equipment. Over analyzed measurements. Weekly analysis with reporting early warnings Approx. 300 reported findings during 08/ / October, 2018 Valmet Customer Days 2018

20 Findings and savings examples Case example Bearing outer race damage

21 Damage was found in the relative change report 21 October, 2018 Valmet Customer Days 2018

22 Timely action and remedy Defect is developing quickly and the bearing damaged by current is changed Waterfall diagram shows the change after bearing change Bearing changed 23 October, 2018 Valmet Customer Days 2018

23 Sharing is essential and timing crucial Local and remote resources collaborating VALMET PERFORMANCE CENTER COLLABORATION BETWEEN EXPERTS ÄÄNEKOSKI MILL S OWN EXPERTS Analysis support Condition Analysis Expert Daily checking for alarms and deviations Daily/weekly reporting Personnel training Valmet DNA Machine Monitoring maintenance METSÄ GROUP S BIOPRODUCT MILL Using all resources efficiently Mr. Vesa Onnela, Certified Condition Monitoring Specialist Shared setting of goals and operation development Automation and other mill systems (MES, ERP etc.) 24 October, 2018 Valmet Customer Days 2018

24 Knowledge is power. Knowing and acting in time is superpower. Results at the Äänekoski mill Emerging faults detected already during warranty period Considerable equipment damage has been prevented Good availability of the equipment and production line Employee safety secured because exposure to equipment in dangerous locations has been avoided Reduced Total Cost of Ownership through predictive maintenance 25 October, 2018 Valmet Customer Days 2018

25 Valmet s machine monitoring and remote analysis service has proved invaluable during the startup phase of the mill, Juha Anttonen, Mill Reliability Engineer

26 New pulp drying features

27 Latest Latest developments developments on on the the Äänekoski Äänekoski drying drying line line Nominal capacity: 2,700 ADT/day, birch and softwood Nominal capacity: 2,700 ADT/day, birch and softwood Advanced bale Advanced bale weight control weight control Motorized trim Motorized trim showers showers Slack control Slack control Automatic tail Automatic tail threading threading between presses between presses Valmet Author / Title

28 Latest developments on the Äänekoski drying line Nominal capacity: 2,700 ADT/day, birch and softwood Low energy trim handling >80% energy savings in normal operation

29 Patented Advanced Bale Weight Control Real case of 3,500 ADT/d HW machine, 9.5 m trim width 14% 13% 12% 11% 10% 9% 8% 7% 6% 5% 4% 3% 2% 1% 0% Percentage of adjusted bales at scale Acceptable bale weight range kg during this measurement Bale Weight Control - ON 4

30 Automatic tail threading system Safe operation and less variance between different shifts Tail threading robots can be installed on most machines 5

31 27 6 Valmet September, Author 2018 / Title

32 Roller lists at dryer inlet A simple innovation that reduces dust generation A roller list for the dryer inlet to reduce dust formation at the inlet

33 Movable platforms improved for broke removal Dry end movable platform with improved broke removal features

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35 Summary 1) Minimum bale and unit size variation 2) Low energy trim band handling 3) Eliminated risk of sheet breaks 4) Safe and reliable operation 5) Reduced dust formation at dryer inlet 6) Improved broke removal features for safe and effective dryer cleaning 10

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