Pulp Mills in Transition -from net consumers of energy to producers of energy and services
Peter Axegård
Chalmers Energy Conference, January 26 – 27, 2011
Axegård, Chalmers Energy Conference, Jan 26-27, 20112
Innventia (former STFI) is a R&D company
Pulp, paper, packaging, new materials and biorefining
270 employees
Located close to KTH
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Axegård, Chalmers Energy Conference, Jan 26-27, 20113
One of the world’s leading R&D companies in P&P
with customers world-wide in the pulp, paper and packaging industry
Some customersABB Alabama River PulpAlbanyAprilBASFBillerud
Br Hartmann Eka Chemicals Ericsson Fibria Celulose Holmen Kemira Klabin Korsnäs Mercer Pulp Metso Mondi M-real
Nalco Norske Skog SCA Smurfit Kappa Speciality Minerals Stora Enso Södra Tetra Pak UPM Voith Weyerhaeuser
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The bleached kraft pulp mill
Recovery bolier
Chemical recoveryEvaporation
Digester
Pulp Bleach plantChippingDebarkingWood
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Sidan 6
Fuel oil - Swedish P&P industry1973 - 2007
0
500
1000
1500
2000
250019
73
1976
1979
1982
1985
1988
1991
1994
1997
2000
2003
2006
1000 m3
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
Model Mill
1975
Model Mill 1993
KAM Ref. Mill
1998
KAM Ref. Mill
2000
Swedish Average
2000 Kappa number
-after cooking -to bleach plant
32 32
20 10
22 9
27 10
- -
Oxygen delignificaiton No Yes 2 stages 2 stages Yes
Heat consumption, process GJ/ADt 10.0 9.4 10.4 10.8 15.2
Sold surplus power kWh/ADt 610 886 663 543 -140
Cooling towers No No Yes Yes -
Consumption of process water m3/ADt 30 23 15 16 58
Effluent load, COD kg/ADt 45 18 11 7 26
Direct minus avoided CO2 kg/ADt +60 -290 -240 -260 -
Solid residues1) kg DS/ADt 502) 382) 47 44 51
1) Wood yard (mainly sand and gravel), bio-sludge, construction and demolition wastes excluded. 2) ESP dust not included
Comparison with Earlier Published Model Mills
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7Axegård, Chalmers Energy Conference, Jan 26-27, 2011
Bleached kraft – increased energy effiency
Before 1965 1300 kg per ton
80-ies 650
90-ties 100-250
2010 -250
Future < < 0
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Alternatives for exporting the energy excess
Electricity Solid fuels Liquid fuels
Chemicals
District heating
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The pulp mill biorefinery – Studied products
Lignin
Cellulose
Bark
Forestry residues
Hemi-cellulose
Extractives
Lignin
• Functional polymers• Bioactive compounds
• DME • Ethanol• FT-diesel • Biooil• Heat• Electricity• Pellets• Lignin
• Fiber additives• Barriers• Hydrogels
• Phenols• Carbon fiber• Binders• Dispersants• Activated carbon
Chemicals/MaterialsEnergy
Cellulose • Fibers• Derivatives• Nanocellulose
Axegård, Chalmers Energy Conference, Jan 26-27, 20112011-02-15
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Modern kraft pulp mills - high energy efficiency
Model Mill Case Sold Fuel
GJ/ADt
Produced Power
kWh/ADt
Sold power
kWh/ADt
Fossil CO2
kg/ADt
Modern mill – bark boiler 0,6 1520 730 -260 Modern Mill – no bark boiler 3.1 1255 545 -260 Typical mill -0.6 645 -140 +320
Power Balance for the Reference Mill
KAM2 kWh/ADt
KAM1 kWh/ADt
Production Back-pressure power 790 788 Condensing power 465 616 Total 1255 1404 Consumption 712 742 For sale 544 663 Total 1255 1405
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Biomass solid fuels Fuel P&P industry applicability Potential raw material
source
Wood pellets High Saw dust
Torrefied wood High Wood
Lignin High Black liquor
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
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Sidan 14
Biomass liquid fuelsFuel P&P industry applicability Potential raw
material source
Annual plant ethanol Medium if co-located Corn, bagasse, etc.
Wood based ethanol High, integrated/co-located Forestry residues
Pyrolysis oil High
Synthetic ethanol Medium Black liquor, forestry residues,lignin MeOH/DME/FT-diesel High
Biodiesel High Tall oil, methanol
Biogas Medium Biological sludge
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
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Cellulose Products
NanoCellulose Gel
Kraft Pulp Fibres
Transparent Films
Fibre PLA Composite
Axegård, Chalmers Energy Conference, Jan 26-27, 20112011-02-15
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Carbohydrates
Extractives
Lignin
Black liquor
50 % of the wood becomes organic material in the cooking liquor
Wood to kraft pulp mill
Pulp
Cellulose
55- 60 % of energy goes into the black liquor
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
The LignoBoost process
Lignin OUT
Recovery Boiler
Digester
Evaporation
BleachingWood Chips Pulp/Paper
Lignin INReplacement of fossil fuel in lime kilns50 L fuel oil ptp can be saved
Wood
Lime Kiln
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LignoBoost – developed by Chalmers and Innventia
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LignoBoost lignin – a new material
C 64 - 66 Na 0.05 - 0.4 Ash 0.3 - 1 S 1 - 3 N 0.1
Typical composition, %
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Välj 'Visa sidhuvud....' för att ändraSidan 22
Potential for replacement of fuel oil
Lignint/y
Replaced fuel oil m3 /yr
25 % lignin removal in all Swedish kraft pulp mills
1 200 000 780 000
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
Potential kraft/soda lignin applicationsLignin fuel in lime kilns Lignin pellets
Lignin to carbon fibres
Spun lignin fibres
Lignin in fuel oil
• Binders• Benzene/Phenols• Activated carbon
Dispersants
Kaolin/Water
Other applications
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New Pulp Mill Revenues
650 000 ton pulp/y
Removal of 10% lignin = 33 000 t/y
… 16 000 t carbon fibres
…replaces 40% steel in i 160.000 cars
Axegård, Chalmers Energy Conference, Jan 26-27, 20112011-02-15
Forestry residues
0.4
Chips 0.8
Wood pellets
3
Lignin5
Ethanol6
Energy density key-issue for biofuels kWh/m3
Our focus
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Alkaline fractionation
Hydrolysis, Fermentation &
Distillation
Lignin Separation
Energy Recovery
Chemicals Recovery
Forestry Residues Ethanollactic acid
Sulphur-FreeLignin
Electric Power
Alkaline route from wood to ethanol/lactic acid
CO2
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2G Ethanol- Alkaline ProcessWill it work in practice? Yes!
Tested in mill and pilot scale trials
70 t soda pulp produced 40 m3 pulp suspension used 700 litres of ethanol produced
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Near Future Kraft Pulp Mill Biorefinery
Energy and Recovery
Pre-treat-ment
Forestry residues
PulpingWood chips
LignoBoost
Axegård, Chalmers Energy Conference, Jan 26-27, 2011
Sepa-ration
Today Future
Pulp CottonreplacementNanocellulose
No FuelCarbon fibresPhenols
No Fibre additivebarrierscomposites
No Lactic acidXylitolEthanol
PowerHeat
Motor fuelsPellets
Polymeric carbohydrates
Monomeric carbohydrates
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