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Challenges in Black Liquor
Recovery in Modern Kraft
Pulp Mills
Honghi TranUniversity of Toronto
Toronto, ON, CANADA
Roberto VillarroelEldorado Brazil
Sao Paulo, BRAZIL
The 5th International Conference on Eucalyptus Pulp
Porto Seguro, Brazil, May 12, 2011
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Presentation Outline
Black Liquor
Operating Issues
Modern Kraft Mills
Challenges
Future Trends
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Kraft Pulping Process
+
Wood
Fibre
White
Liquor
(NaOH + Na2S)
Lignin
Fibre
Pulp
155oC
900 kPa
Water
Weak Black Liquor
(8 to 10 t/t pulp)
Lignin
Residual fibre
Chemicals
Water
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Black Liquor (as-fired) Composition (750 liquor samples; Various Wood Species)
Typical Range
Solids content, % 72 65 – 85
HHV, Btu/lb 5900 5300 – 6600
C, wt% d.s. 33.9 30 – 40
H 3.4 3.2 – 4.0
O 35.8 34 – 38
Na 19.6 17 – 22
S 4.6 3.6 – 5.6
K 2.0 1 – 3
Cl 0.5 0.1 – 4
Co
mp
osit
ion
13.8 MJ/kg
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Black liquor is an important,
challenging “bioresource” that
need to be processed
Kraft pulp mills have been doing
just that to recover energy and
chemicals
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(Courtesy Metso Power)
Recovery
Boiler
DigesterWood
Chips
Power
Boiler
Slaker
Waste Water
Treatment
Green Liquor
Na2CO3, Na2S
Black Liquor Recovery
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Presentation Outline
Black Liquor
Operating Issues
Modern Kraft Mills
Challenges
Future Trends
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Common Operating Problems Evaporators
Scaling
Corrosion
High steam consumption
Low solids in product liquor
Recovery Boilers Fouling and plugging
Corrosion and cracking
Low steam production
Poor sootblowing efficiency
Poor water circulation
Smelt-water explosions
Gaseous/particulate emissions
Tube damage by falling deposits
Unstable combustion/blackouts
“Jelly roll” smelt/smelt run-off
Low reduction efficiency
High dregs in smelt
Lime kiln and Recausticizing High kiln fuel consumption
Burners
Ring/ball formation
Refractory and chains
Gaseous/particulate emissions
Poor green liquor filterabilty
Poor lime quality/availability
Overliming
Poor causticizing efficiency
Poor mud settling/low solids
Clarifier corrosion
Process control
Liquor Cycle NPE accumulation (Cl and K)
High deadload
Na and S imbalance
High sulphidity operation
Corrosion
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RB Fouling
RB Superheater
Corrosion
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Lime Kiln Ring
Formation
Ball
Formation
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Presentation Outline
Black Liquor
Operating Issues
Modern Kraft Mills
Challenges
Future Trends
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Mill Features
Located mostly in South America, Asia and
Scandinavia
New equipment/facilities and advanced
technologies
Large capacity
Energy self-sufficient
Generate more energy but consume less
Tight mill closure
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Advances in Evap. Technology
Falling film, plate-type
Less susceptible to
fouling
Superconcentrators
>80% ds
Mill waste streams
processing Evaporators installed at a Brazilian
mill in 2009
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Andritz’s Evaporation SystemDigester area:
Digester Evaporator
Vapor Re-boiler
Firing liquor at high DS
and optimum temperature
to RB
Side Streams
Bio sludge
ClO2 plant waste
Foul condensates
Effluent/wash waters
Bleaching effluents
CTMP filtrates
High quality
secondary
condensates
Hot steam
condensate to RB
Methanol Fuel
Ash treatment /
NaCl Purge
Warm/District
heating water
EVAPORATION
7+ effects
CNCG & DNCG
to Incineration
(Courtesy Andritz Inc.)
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Advances in RB Technology (1)
Large firing capacity
High steam temperature and pressure
>500oC and 120 bars
High solids firing
78 to 85% d.s.
Burning CNCG and DNCG
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Kari Mäkelä – Metso Power
7000 t ds/d, 2010
3000 t ds/d, 1990
2000 t ds/d, 1986
1500 t ds/d, 1976
120 t ds/d, 1933
Relative Size and Capacity of
Recovery Boilers
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Advances in RB Technology (2)
Vertical (multi-level) air
systems
Low carryover
Low NOx
Sootblowers
Fully-expanded nozzles
Blowing optimization
Using low pressure steam
(Courtesy Andritz Inc.)
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Advances in Caust. Technology
Pressurized filters
X filters (green liquor)
CD filters (white liquor)
On-line FT-NIR liquor analyzers and control
systems
FP Innovations, Metso Automation, etc.
On-line lime mud solids analyzers
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Advances in Kiln Technology
High lime production capacity
High mud solids content (>80%)
Equipped with
Lime mud driers (LMD)
Efficient product coolers
Thermal imaging systems
Low heat rate (< 6 GJ/t CaO)
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Kiln Capacity vs. Startup Year
Francey, S. (2010)
0
200
400
600
800
1000
1200
1950 1960 1970 1980 1990 2000 2010 2020
Cap
acit
y (
t C
aO
/d)
Startup Year
Eldorado
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Lime Kiln at the Eldorado Mill
1200 t/d lime
5.5 m in diameter x 160 m in length (5 piers)
Startup: Oct. 2012
Courtesy Eldorado and Andritz
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Problems in Modern Pulp Mills
Evaporators Scaling
Corrosion
High steam consumption
Low solids in product liquor
Recovery Boilers Fouling and plugging
Corrosion and cracking
Low steam production
Poor sootblowing efficiency
Poor water circulation
Smelt-water explosions
Gaseous/particulate emissions
Tube damage by falling deposits
Unstable combustion/blackouts
“Jelly roll” smelt/smelt run-off
Low reduction efficiency
High dregs in smelt
Lime kiln and Recausticizing High kiln fuel consumption
Burners
Ring/ball formation
Refractory and chains
Gaseous/particulate emissions
Poor green liquor filterabilty
Poor lime quality/availability
Overliming
Poor causticizing efficiency
Poor mud settling/low solids
Clarifier corrosion
Process control
Liquor Cycle NPE accumulation (Cl and K)
High deadload
Na and S imbalance
High sulphidity operation
Corrosion
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Advanced technologies have
helped alleviate many problems in
modern kraft mills, but they have
also created new challenges....
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Presentation Outline
Kraft pulping process and black liquor
Operating Issues
Modern Kraft Mills
Challenges
Future trends
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Tighter Mill Closure
Due to
High energy and waste disposal costs
Stringent environmental regulations
Mill responses
Lowering effluent discharge
Reclaiming mill waste (ClO2 generator waste,
biosludge, bleaching plant effluents, etc.)
Consequences
Accumulation of NPEs and impact
Excess sulphur
Larger facilities are more susceptible
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Non-Process Elements (NPE)
Elements that do not participate in the
pulping process
Elements other than Na and S in the liquor cycle
Elements other than Ca in the lime cycle
Common referred NPE:
Cl, K
Mg, Si, Al, P, Mn, Fe, Cr, Ni, Zn, Pb, Cu, V, Ti, Ba
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Main Sources of NPE
Source Elements
Wood K, Cl, Si, Al, Mg, Mn, P, Fe, etc.
Makeup caustic Cl
Makeup lime Si, Al, Mg, P, Fe
Makeup water P, Cl
Additives Si, Mg
Refractory bricks Si, Al
Corrosion products Fe, Ni, Cr, Mn
Biosludge Si, Mg, P, Al, Cl
Petcoke V, Ni
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0
500
1000
1500
2000
2500
3000
Ca K Mg Fe Mn P Si Zn Na Al Ba
mg
/kg
ds
Pine
Spruce
Aspen
< 10 ppm: S, B, Cu, Cd, Ti,
Cr, V, Li, Co, Ni, As, Pb, Mo
NPE Content in Various Wood
Species at a Canadian Mill
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NPE in Eucalyptus
Salmenoja, K. et al.
0
500
1000
1500
2000
2500
3000
Ca Mg K Cl Na P Mn Fe Si
mg
/kg
ds
Mill A
Mill B
Mill C
Mill D
Mill E
Mill F
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0
20
40
60
80
100
Mg Mn Fe Zn Pb Al Ba Cu Ni Cr Cd Be Si V P K
Rem
oval E
ffic
ien
cy
NPE Removal by GL Clarifiers
Average of 7 Canadian Mills
Cl/KSi
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Chloride (Cl) and Potassium (K)
Accumulate in the liquor cycle due to the
high solubility of their compounds
Have adverse effects on fouling and
corrosion in recovery boilers
Worse for boilers with high furnace and
superheated steam temperatures
Ash treatment systems for removing Cl & K
have become more common
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Ash Treatment Systems
Several ash treatment systems are now
available
Most rely on effective separation of solids
from ash-water slurries
Ash with a high carbonate content is much more
difficult to separate
High solids firing and ash treatment lead to:
High carbonate content in ash
Excessive S retention (high sulphidity)
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0.1 wt% CO3
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12.4 wt% CO3
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Effect of CO3 Content on DS
Slurry Conc. = 0.8 kg/L at T= 85°C
60
70
80
90
100
0 4 8 12 16
Degre
e o
f S
epara
tion
(%)
CO3 in Slurry (wt%)
2 6 10 14
Ash A + Na2CO3 sol.
Ash B + Ash C
Ashes C,D,E, F
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Effect of CO3 on Composition of
Solids in Ash-Water Slurry
0
20
40
60
80
100
0 5 10 15 20
CO3 Content in Ash (wt %)
Co
mp
osit
ion
(W
t %
)
BurkeiteNa2SO4
Glaserite
D. Saturnino (2007)
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Effect of Silica on Mud Solids
30
40
50
60
70
80
90
100
0 4 8 12 16
SiO2 Content in Lime (wt%)
Mu
d S
olid
s (
wt%
)
Mill A #1 Kiln
Mill A #2 Kiln
Arpalahti et al (1999)
Mill B #3 Kiln
Mill C #2Kiln
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Large Pulp Mills
Often large equipment
Recovery boiler: > 5000 t/d BLDS
Lime kiln: > 800 t/d lime
Challenges
Sensitive to process disturbance
Sensitive to emissions (TRS)
Stable operation is vital
Opportunities
Waste stream recovery more economically
feasible
Great waste energy recovery
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Presentation Outline
Kraft pulping process and black liquor
Operating Issues
Modern Kraft Mills
Challenges
Future trends
Alternative fuel use in lime kilns
High efficiency recovery boilers
Biorefinery
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Alternative Fuel Use
Lime kilns are the major fossil fuel users
Alternative fuel use is driven by
High costs of fuel oil and natural gas
“Green” image of biofuel
Current StatusFrancey, S., Tran, H.N., Jones, A.K., “Current Status of
Alternative Fuel Use in Lime Kilns”, TAPPI
Journal, October, p.33-39 (2009)
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Types of Alternative Fuels
Petroleum Coke
Wood Biofuels
Directly fired wood residues (bark, sawdust)
Biogas (biomass gasification)
Bio-oil (biomass pyrolysis)
Precipitated lignin (from black liquor)
Olein Biofuel
Animal fat
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Installation at Stora Enso
Norrsundet Mill (1985)
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Today’s Gasifiers
Offered by various suppliers
Better biomass drying systems
Types
Fluidized bed gasifiers
Fixed bed updraft gasifiers
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Direct-Fired Lime Kiln System
Gasifiers
Lime Kiln
Syngas
Pressurization
fan
Dual fuel burner
(syngas/natural gas)
Courtesy Nexterra
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Bio-Oil
A mixture of pyrolysis
tar, water and pulverized char
HHV: 16-19 MJ/kg (water
content of 20%)
Atomizes and burns well with
similar flame to natural gas
May be used as fossil fuel
substitute
Challenges:
Corrosive (acidic)
Lack of standard
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Precipitated Lignin(LignoBoost Process)
(Courtesy Metso Power)
High pH Low pH
Lignin-lean
Liquor
Liquo
r
~40%H2SO4
Wash
Water
pH 2.5
Washed
Lignin
Wash liquid
~2 m3/t
lignin
Liquor from
Digester
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Precipitated Lignin
LignoBoost Process
Developed and marketed by
Inventia and Metso Power
Properties
High heating value
Hydrophobic and easy to dry
Successful mill trials in
Sweden (Courtesy of Metso Power)
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(Courtesy Andritz Inc.)
High Efficiency Recovery Boiler515oC; 110bar560-600oC
200oC
145oC
85%
160oC
210oC
125oC
+15oCGasifier
WoodGasification
Lime Kiln
Gas Cleaning
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(Courtesy Andritz Inc.)
High Efficiency Recovery Boiler515oC; 110bar560-600oC
200oC
145oC
85%
160oC
210oC
125oC
+15oCGasifier
WoodGasification
Lime Kiln
Gas Cleaning
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AbitibiBowater
AFRI/ALPAC
Andritz
Babcock & Wilcox
Boise
Carter Holt Harvey
Cenibra
Clyde-Bergemann
Daishowa-Marubeni
DTE Petcoke
Fibria
FPInnovations
International Paper
Irving Pulp & Paper
Jammbco
Kiln Flame Systems
MeadWestvaco
Metso Power
StoraEnso
Tembec
Zellstolf Celgar
NSERC
Acknowledgements