Latest pulp mill technologies. November, 2017 Mats Nordgren

Transcription

1 Latest pulp mill technologies November, 2017 Mats Nordgren

2 Contents Technology trends in general New technologies: LignoBoost Sulphuric Acid

3 Key item for the biggest Hardwood new mills Maranhao Guaiba LOW CAPEX No / low Smell Energy Efficiency 3

4 Overall concepts in the biggest expansions / new mills Low Effluent Flow Energy Efficiency High Pulping Yield No Fossil Fuel Use Östrand Äänekoski Värö = Low operating cost / utilization of raw material 5 27 November, 2017

5 Energy efficient mill is the first step towards a biorefinary mill 140 t/h 91 bar(g ) 490 C 921 t/h Power export : 120 % of consumption Onsite generation of chemicals 182 MW 84 MW 56 t/h 272 t/h 98 MW 193 t/h 574 t/h 0 t/h Wood handling 121 t/h Power export 69 t/h 43 t/h 17 t/h 173 t/h 188 t/h 7 t/h 35 t/h 49 t/h 0 t/h 20 t/h 15 t/h Digester Fiberline Pulp Dryer Evaporation Recovery boiler Recaust& LK Other Lignoboost Pyrolysis Gasification Biochemicals Solid fuel Storable Liquid fuel / replace oil Storable Replace oil New revenue Alt markets 6 27 November, 2017

6 What s in focus today? Or in addition rather Market pulp as base Dissolving as potential New revenue streams as honey Process integration = Somewhat changed direction Sveza SunPaper 7 27 November, 2017

7 Low water consumption Suzano Maranhão Raw water intake: 21 m 3 /adt Effluent volume: 16 m 3 /adt Blach plant: 8 m 3 /adt 9 Valmet

8 Modern mill water saving measures New line very low water consumption (20 m 3 /ADT) and effluent discharge (18 m 3 /Adt) Biggest fresh water consumers / effluent flows in normal pulp mills Bleach plant Cooling water = energy surplus November, 2017

9 100 % closed mill Oji Paper, Nantong, China Raw water treatment Condensat Evaporation Fiberline Cooling water to nearby industries Membranefiltration External treatment Spill November 2017

10 Measures to improvement cash cost / lower OPEX Numbers indicate % of mill cash cost Wood consumption % Increased kappa number in cooking Chemical consumption % Internal production of Sulfuric acid Fuel consumption 10 % Non fossil fuel in kiln Energy generation / consumption % High power features 12

11 Lignin extraction with LignoBoost Black liquor Lignin lean black liquor Lignin LignoBoost Valmet s technology for producing clean lignin from black liquor and make it available as a new product Cooking chemicals back to recovery boiler with reduced thermal load Lignin is an excellent raw material for biobased products but can also be used to replace fossil fuels in the lime kiln or a power boiler Valmet Technology Days

12 The benefits of lignin extraction Increased pulp production Fuel cost savings New sources of income Extraction of lignin off-loads the recovery boiler Lignin can replace fossil fuel in boilers and lime kilns High value products from lignin Valmet Technology Days

13 Sulphuric acid production from CNCG Consequences of closed mill new ways to control Na/S and reducing OPEX Burner Sulphur compounds oxidixed to SO 2 Boiler Heat transferred to water to produce MP-steam Catalytic converter SO 2 converted to SO 3 Acid condensation SO 3 reacts with water and sulphuric acid is produced Flue gas scrubber SO 2 tail gas is washed 15

14 M 1973 s level L K J I S, kg/adt 10 8 N R O P Q F G H B Sulphur losses / makeup s reduced to 1/3 compared to 70:ies C D E C B G D E F Today s level T M N K R S Q J L O P I H 2 S 1 T A A Na, kg/adt

15 16 Effects of Internal Sulfuric Acid Production M 1973 s level L K J I N S, kg/adt 10 8 R O P Q F G H B Benefits: Less makeup / costs Less salts to recipient C D E C B G D E F Today s level T M N K R S Q J L O P I H 2 1 S T Internal Sulfuric Acid Production A A Na, kg/adt

16 Valmet the market leader in DWP cooking DWP cooking plants from 2008 Mill Year Valmet supply Production Raw material DP grade Sun Paper Laos 2018 Cooking plant 800 Adt/d Eucalyptus Viscose Confidential customer 2017 Confidential customer 2015 Cooking plant Rebuild conversion Cooking plant Rebuild conversion Sappi Ngodwana, South-Africa 2013 Cooking plant 750 ADt/d Eucalyptus Viscose DoubleA, Thailand 2013 Cooking plant Rebuild conversion 500 ADt/d Eucalyptus Viscose Phoenix Pulp & Paper, Thailand 2013 Cooking plant Rebuild conversion 300 ADt/d Eucalyptus Viscose StoraEnso Enocell, Finland 2012 Cooking plant Rebuild conversion 900 ADt/d Birch Viscose Sodra, Mörrum Sweden 2011 Cooking plant Rebuild conversion 500 ADt/d Birch Viscose Anhui Huatai, China 2012 Cooking plant 350 ADt/d P. massonian Viscose Hunan Juntai, China 2011 Cooking plant 960 ADt/d P. massonian / Eucalyptus Viscose Qingshan, China 2011 Cooking plant 350 ADt/d Pinus massonian Viscose Bahia Pulp, Brazil 2008 Cooking plant 1050 ADt/d Eucalyptus Acetate/ Viscose 18 October 10, 2017 Valmet Boreal presentation

17 Valmet: World leading supplier of dissolving lines Sappi Ngodwana, South Africa adt/a New cooking plant and fiber line + rebuilds in other parts of the mill, started up in 2013 Very quick and smooth start-up Produced high-quality product immediately: new fiber line produced in-spec product within 72 hours of first chip feed Produced 97% grade-a product for first year of operation Process is robust and allows good control over product quality Valmet Technology Days

18 Future new revenues example Demo plant in Sappi Ngodwana, SouthAfrica New revenue opportunities include possibilities to extract biobased materials from the cooking plant such as hemicellulose sugars and lignin for beneficiation to higher value biochemicals. The products under development will expand Sappi s renewable biomaterials offering which include nanocellulose, biocomposites and lignosulphonate Louis Kruyshaar leader of the new Sappi Biotech division November, 2017

19 How to attract younger persons? And keep them? November, 2017 Valmet Author / Title

20 How to beat Tesla? How to beat Google? November, 2017 Valmet Author / Title

21 Skillfull personnel is a must how to ensure? Can we attract the desired next generation? Where is a work place located? Can we do more with less & lower labor cost, by centralizing. 23

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