experiences on mill scale with enzymes final seminar of subproject 3 of ecotarget tuesday 1 april,...

Experiences on mill scale with enzymes

Final Seminar of Subproject 3 of ECOTARGET

Tuesday 1 April, 2008at STFI-Packforsk

Ir. Loud van Kessel

Senior Process Engineer

Smurfit Kappa Roermond Papier

2

Content

Introduction Smurfit Kappa Roermond Papier

Fluctuations: long term

Fluctuations: short term

The effect of enzyme treatment on the paper production performance

Conclusions

Introduction Smurfit Kappa Roermond Papier

4

Production facilities: Europe

Czech Republic

Switzerland

Slovakia

Russia

Finland

Lithuania

Operations

Mills/Depots (42)

Solid Board (14)

Paper Sacks (13)

Corrugated Plants (230)

Graphic Board (2)

Specialities (15)

Generating employment for approx. 34,000

6

Mill key information

Products Testliners, fluting and chip (Schrenz)

Customers Packaging industry

Production 525,000 ton/year papertestliner : 100 - 220 grs/m²fluting : 105 - 180 grs/m²chip : 90 - 140 grs/m²15 kt/year Rofire

Paper machines 3

Employees 260

7

Logistics 2006

Recovered paper is main raw material

consumption + 570,000 ton/year (22 % of NL)

+ 11,000 tons/week

delivery + 85 lorries/day

stocks: + 3 weeks of production

max. stock capacity 30,000 ton

Produced paper

+ 525,000 ton / year

shipment: + 75 lorries / day

max. stock 18,000 ton

8

Utilities 2006

Energy usage 160,000 MWh

Own power plant 4 turbines 14 MWproducing 114,000 MWh35,000 household equivalent

Gas 89 million m3/year45,500 household equivalent

Civil water usage 169,000 m3/year

3,550 person equivalent

Water treatment 4,750 m3/day130,000 civil equivalent

9

Kappa Roermond Papier

Development of the use of fibre material (world wide)

0

40

80

120

160

200

1980 1990 2000 2010year

Recycled fibre

Chemical fibre

Woodcontaining fibre

10

Evolution of the recovered paper utilisation and the recycling rate in Europe (CEPI 2002)

0

5

10

15

20

25

30

35

40

45

1991 1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002

R.P

. U

tilis

atio

n (

Mill

ion

to

nn

es)

38%

40%

42%

44%

46%

48%

50%

52%

54%

56%

Recycling rate

Utilisation

Recycling rate

11

Price fibres (€ )average 2003

0

50

100

150

200

250

300

Virgin Fibre

Recycled Fibre

12

Effects of recycling

Fibre damage

Change in physical properties

Change in surface properties

Accumulation of additives

13

Fibre damage

Fibre shortening Minor influence

Creation and accumulation of fines Great influence on process and product

14

Identification of fine particles inrecycled fibre pulp

Fibre chunks

15

Identification of fine particles inrecycled fibre pulp

Fibre fibrils

16

Identification of fine particles in recycled fibre pulp

Ash

17

6

8

10

12

14

16

18

20

22

1970 1975 1980 1985 1990 1995 2000 2005 2010

Asc

h c

on

ten

t (%

)Ash content Mixed (PM2)

18

Ash content Mixed (PM2)

6

8

10

12

14

16

18

20

22

1970 1975 1980 1985 1990 1995 2000 2005 2010

As

ch

co

nte

nt

(%)

19

6

8

10

12

14

16

18

20

22

1970 1975 1980 1985 1990 1995 2000 2005 2010

Asc

h c

on

ten

t (%

) ?


20

6

8

10

12

14

16

18

20

22

1970 1975 1980 1985 1990 1995 2000 2005 2010

As

ch

co

nte

nt

(%)

?


Germany

21

Fines in head box

Fines in headbox

0,49

0,50

0,51

0,52

0,53

0,54

0,55

0,56

0,57

0,58

16-10-0620:24

16-10-0621:36

16-10-0622:48

17-10-060:00

17-10-061:12

17-10-062:24

17-10-063:36

17-10-064:48

17-10-066:00

17-10-067:12

17-10-068:24

Fin

es (

%)

22

Examples: Paper properties

Berst and SCTd of Fluting 105 grs

220

240

260

280

300

320

340

5-jan 5-jan 5-jan 5-jan 6-jan 6-jan 6-jan 6-jan 6-jan 7-jan 7-jan

Be

rstp

res

su

re (

kP

a)

1,4

1,45

1,5

1,55

1,6

1,65

1,7

1,75

1,8

1,85

1,9

SC

Td

(k

N/m

)

Berst

SCTd

23



220

240

260

280

300

320

340


Be

rstp

res

su

re (

kP

a)

1,4

1,45

1,5

1,55

1,6

1,65

1,7

1,75

1,8

1,85

1,9

SC

Td

(k

N/m

)

Berst

SCTd Specifications

24



220

240

260

280

300

320

340


Be

rstp

res

su

re (

kP

a)

1,4

1,45

1,5

1,55

1,6

1,65

1,7

1,75

1,8

1,85

1,9

SC

Td

(k

N/m

)

Berst

SCTdExcess of raw material/additives

25

Energy consumption

-250

-200

-150

-100

-50

0

50

100

150

weeknr.

10 20 30 40 50 8 18 28 38 48 5 15 25

kg s

team

/ to

n

20042003 2005

26

Energy consumption

-250

-200

-150

-100

-50

0

50

100

150

weeknr.

10 20 30 40 50 8 18 28 38 48 5 15 25

kg s

team

/ to

n

20042003 2005

250 kg steam per ton

> 5 Euro per ton

27

Enzymes

Improved drainability and porosity without strength loss and without significant loss of mass

Increased relative bonded area, flexibility and fibrillation without affecting fibre length

28

Influence of enzyme activity on the dewatering speed

0%

5%

10%

15%

20%

25%

0 5 10 15 20 25 30 35 40 45

Time (min)

Incr

ease

of

the

dew

ater

ing

sp

eed

(%

)Influence of enzymes (cellulase) ondewatering speed

29

Prevention - Compression refining

Beating degree development

0

5

10

15

20

25

30

35

40

45

0 1000 2000 3000 4000 5000 6000 7000

PFI revolutions

Bea

ting

degr

ee [

oS

R]

2612

Speed difference in PFI-mill [m/s]

30

Washing

Effect of washing on refining curvesResults pilot scale trials

0

5

10

15

20

25

30

35

40

20 25 30 35 40 45 50 55

Beating degree [0SR]

Te

ns

ile

In

de

x [

Nm

/g]

Maximum washed (21% loss, 7.4% Ash)

Minimum washed (7% loss 14% Ash)

Mixed Waste Reference (17% Ash)

Sustainable paper production in the future

Zero emission strategy

32

Raw Material Recycled Paper

94% Paper fibre

5% Organic material

1% Inert, inorganic material(metal, glass, sand etc.)

33

Upgrading Recycled Paper

Fluting + Testliners

Secondary fuel - Rofire®

34

Process Scheme

35

The Rofire® Rational

Better use of valuable raw materials

Advanced separation process

Useful, new product with good market conditions

36

Rofire® and Environment (1)

Roermond

30,000 tonnes less waste disposal p.a.

16,000 Rofire® p.a.

12,000,000 m³ natural gas p.a.

Biomass content 50%

37

Rofire® and the Economics

Rofire® average price 15 €/ton

Equivalent coal 50 €

Equivalent natural gas 90 €

CO2 reduction

38

Rofire® and Environment

Europe

1,300,000 tonnes less waste disposal p.a.

700,000 tonnes Rofire® p.a.

525,000,000 m³ natural gas p.a.

39

Return of investment:

Savings on reject costs:

€ 4.000.000,- a year*

A pay-back of 2 years on the described installation

* Based on landfill costs of €160,-/tonne (Netherlands 2003)

40

Forbonium

The biology of the water treatment plant at Roermond Papier has a lack of the element phosphorous: phosphoric acid is used as a nutrient.

A food producer in Holland needs to de-phosphorize baby food products. There is an emission (waste) of a phosphorous concentrate.

Both companies invested in a storage and dosing unit in Roermond to reduce both on variable costs.

A paper mill has different costumers, depending on the point of view:

42

Core competence from different views:

Employee

ShareholderCustomer

Environment

Neighbourhood

experiences on mill scale with enzymes final seminar of subproject 3 of ecotarget tuesday 1 april,...

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