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The state of the art pulp mill – a biorefinery ?

The state of the art pulp mill – a biorefinery ?. Mats Nordgren Lars Sjödin & Krister Sjöblom Valmet. IPPTA March 6-7, 2014 Delhi, India. Contents. Pulp Mill sizes and Region Drivers Modern Mills = Energy suppliers Mid Market mills Non-wood potential. IPPTA March 6-7, 2014

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The state of the art pulp mill – a biorefinery ?

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  1. The state of the art pulp mill – a biorefinery ? Mats Nordgren Lars Sjödin & Krister Sjöblom Valmet • IPPTA • March 6-7, 2014 • Delhi, India

  2. Contents Pulp Mill sizes and Region Drivers Modern Mills = Energy suppliers Mid Market mills Non-wood potential IPPTA March 6-7, 2014 Delhi, India

  3. Global Pulp Mills Trends IPPTA March 6-7, 2014 Delhi, India

  4. World demand for P&B will continue to grow ... • World demand for P&B is expected to grow by CAGR 1.6%/a • Demand for tissue paper and packaging boards is expected to continue to grow. • Demand for graphic papers is expected to decline • Growth willbe driven by emerging markets ̶ main growth potential in China • Decline in demand is expected in mature markets Total Pulp (Integrated + Market) Total Pulp (Integrated + Market) IPPTA March 6-7, 2014 Delhi, India Source: World Fiber Outlook up to 2025, 2012 Edition, Pöyry ... but not all product areas ...

  5. Market wood pulp is expected to grow ... • Eucalyptus and Acacia pulps are the most rapidly growing market sub grades, but share of Acacia is still marginal. • China is responsible for more than 70% of world’s incremental demand Market Pulp Only Market Pulp Only IPPTA March 6-7, 2014 Delhi, India Source: World Fiber Outlook up to 2025, 2012 Edition, Pöyry … with BHKP to account for most of the market pulp demand

  6. Current trends and facts Mill in South America Mill in China, Asia or Russia IPPTA March 6-7, 2014 Delhi, India Hardwood Pulp Mills continously increasing their size. Softwood Pulp Mills continous to be built for 750-800 000 adt/y The average mill size increase has been 100.000 adt/y per year during the last ten years. Current standard size for a state of the art BHKP mill is 1,5 -1,8 Madt/y. 90 % of the new hardwood capacity has been built in South America during the last 10 years. Major Pulp Mills built since 2000 Under construction or in proposal phase

  7. TwinRoll™ development Capacity Capacity up to 9000 Adt/d TwinRoll™Evolution TRPE Generation 5 Capacity TRPB Generation 4 DPB Generation 3 Feed consistency LC MC IPPTA March 6-7, 2014 Delhi, India

  8. Boiler capacity increase 12 000 t DS/24h 2014 7000 t DS/24h 2010 6000 t DS/24h 2004 2600 t DS/24h 1990 3800 t DS/24h 1999 2000 t DS/24h 1986 120 t DS/24h 1933 IPPTA March 6-7, 2014 Delhi, India

  9. What drives the industry? IPPTA March 6-7, 2014 Delhi, India

  10. Trends in the six key fibre supply regions… … NA, NOC, Russia, Latin America, China and Southeast Asia • Shut down of pulp and paper mills • Softwood pulp production • Softwood Pulp global supply? • Rising investment activity? • Difficulties to find a good greenfield concept. • Shutdown of pulp & paper mills • • Role of USA as a global RP supplier? • Rapidly growing paper market • Closures of old non-wood pulp mills on environmental grounds • Dependency on recovered paper and virgin wood pulp imports • Hardwood (Acacia, Eucalyptus) pulp supply • Development of plantation resources • Hardwood pulp (Euca) global supply • Fast-growing hardwood plantations • Increasing land costs? • Indian trends • Integrated solutions mainly. • Mid size mills with focus on domestic market • Wood supply an important issue IPPTA March 6-7, 2014 Delhi, India

  11. State of the art pulp mill IPPTA March 6-7, 2014 Delhi, India

  12. Key factors IPPTA March 6-7, 2014 Delhi, India • Raw material High yield & high bleachability • Energy Low consumption and high energy production Environmental impact Low air emissions Low water consumption • CAPEX Scale of Economy

  13. Raw material utilization = high cooking yield Reject IPPTA March 6-7, 2014 Delhi, India • CompactCookingTM G2 and SuperBatch Cooking • Higher kappa • High yield • Black liquor impregnation and low cooking temparature Kappa no INTERNAL

  14. Today’s pulp mills have large energy excess – is the biorefinery already implemented? Today’s pulp mills have large energy Almost 50 % of power production as sale to grid Almost zero steam production from biomass Major steam flow for power production IPPTA March 6-7, 2014 Delhi, India

  15. Energy flows in a Kraft pulp mill Wood rejects Electrical energy for internal use Electrical energy export Black liquor Power boiler Biofuels Turbine Recovery boiler Steam to the pulping process Steam Lignin IPPTA March 6-7, 2014 Delhi, India

  16. LignoBoost in the Kraft pulp mill Flow of chemicals and possible revenues H2SO4 CO2 Precipitation Dewatering Conditioning Dewatering & washing Cooking chemicals and organic substances Black liquor OUT Exporting Lignin: • For the production of chemicals, carbon fiber etc. or as fuel Evaporation • Lignin as fuel in the lime kiln: • Replaces fossil fuels • Saves up to 50 l (13 gallons) of fuel oil per ton pulp Lime kiln Pulp mill IPPTA March 6-7, 2014 Delhi, India 16

  17. Lignin – a versatile product Fuel Fuel oil replacement for lime kilns High heating value Hydrophobic and very easy to dry Successful trial at a Swedish mill has been carried out Sold as biofuel to an external customer Has been burnt in a CHP-plant in Sweden IPPTA March 6-7, 2014 Delhi, India

  18. Lignin – a versatile product IPPTA March 6-7, 2014 Delhi, India

  19. Mid market mills IPPTA March 6-7, 2014 Delhi, India

  20. Mid Size mills – what is that? • Mega Mills • 1 500 000 ADt/year • Green Field • Market pulp – HW / EUC • Mid – size mills • 100 000 – 800 000 Adt/year • Brown or green field • Many grades: • Market pulp SW and HW • Dissolving • High kappa pulp (liner, sack etc) Both can utilize same technology and technically be equal ! INTERNAL

  21. Oji Paper, China1600 Adt/d Market pulp, Ze-D-P • Recirculation of Ze-filtrate • Total effluent flow: 26 m3/Adt • Secondary treatment & membran filtration of effluent • Reuse of all effluent IPPTA March 6-7, 2014 Delhi, India

  22. Sappi Ngodwana, South Africa700 Adt/d Dissolving pulp, AZ-EOP-P • Viscosity control in digester, oxygen delign and ozone stage • Flexible fiberline - ca produce market pulp as well • Designed for 9.4 m3/adt in bleach plant IPPTA March 6-7, 2014 Delhi, India

  23. Non-wood IPPTA March 6-7, 2014 Delhi, India

  24. Non-wood material – how to utilize the resource? IPPTA March 6-7, 2014 Delhi, India Today fiber for paper production- future but is declining. • Environmental problems (lime mud) • Scaling evaporation plants Interest for Biofuels accelerating. Future focus will be how to maximize the utilization of the whole biomass.

  25. Enzymatic hydrolysis Fermentation Main routes Distillation Bioethanol Pre- hydrolysis Biomass Platform chemicals Conc. acid hydrolysis Refining Separation Lignin Steam explosion Bio coal Pelletization Co-firing in PC boilers IPPTA March 6-7, 2014 Delhi, India

  26. Biorefinery front-end equipment • Screens • TwinRoll ™ presses • Liquor filters • Steam separators • Disintegration • Drying • Plug screw feeders • LP and HP feeders • Prehydrolysis • Conc. acid hydrolysis • Delignification Chemical reaction Separation Biomass pretreatment Feeding Steam Solid material Liquor IPPTA March 6-7, 2014 Delhi, India

  27. Bioethanol unit operations Biomass handling Pre-hydrolysis Separation Enzymatic hydrolysis Fermentation Biomass Automation Evaporation Lignin separation Distillation Power plant Pelletizing Molasses Lignin pellets Ethanol Valmet Partner IPPTA March 6-7, 2014 Delhi, India

  28. Technology for full-scale 2nd generation bioethanol is available • Valmet front-end technologies for • Biorefinery plants • Feed capacities, odt/d: • 250 • 600 • 1200 Inbicon Biomass Refinery at Kalundborg, Denmark IPPTA March 6-7, 2014 Delhi, India

  29. Summary IPPTA March 6-7, 2014 Delhi, India

  30. The state of the art pulp mill – a biorefinery ? Summary State of the art pulp mills – huge energy surplus Electrical power LignoBoost Other biorefinery alternatives will come Mega mill Market pulp and based on plantations Mid market Many pulp qualities As efficient as the Mega Mills Low water Non-wood Paper grade production declining. The door is open for biorefinery options. IPPTA March 6-7, 2014 Delhi, India

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