fray bentos mill status eugenio garcía sami saarela
TRANSCRIPT
Fray Bentos mill status
Eugenio García Sami Saarela
2 EGa 03.11.2008
Milestones of the pulp mill project
Eucalyptus plantations established in Uruguay at the beginning of
1990’s by UPM-Kymmene and Shell (Compañia Forestal Oriental)
Botnia purchases 60 % of Forestal Oriental (early 2003), today a fully
owned subsidiary of Botnia
Botnia S.A. founded (October 2003)
Preliminary Environmental Authorization (February 2005), the project
starts
Fibre line installation starts in November 2006
Readiness for start-up in September 2007
Final Environmental Permit in October 2007
Start-up November 9th, 2007
Reaching the nominal capacity of the mill (as 30 days average) 145
from the start-up
3 EGa 03.11.2008
Key data of the mill
Capacity 1000 000 ADT/year of fully bleached eucalyptus pulp
Target brightness 89 – 92 % ISO, ECF-bleaching
Raw material mixture comprises of E. Grandis, E. Dunnii and E. Maidenii
Basically the entire raw material supply comes from the plantations of Forestal Oriental within max. distance of 200 km from the mill, wood usage > 3 million s-m3
The entire fiberline and chemical recovery process delivered by Andritz
4 EGa 03.11.2008
Process and equipment
Woodhandling
Fiberline
Recovery
Effluent treatment
5 EGa 03.11.2008
Woodhandling
Debarking in the forest
Two parallel chipping lines at the mill (capacity 2 x 330 s-
m³/h)
Final debarking (diameter 4 m, length 15 m debarking
drums)
Chippers of horizontal feeding (HHQ-ChipperTM)
Two chip piles (diameter 106 meters, capacity 93 000
s-m3)
Gyratory screening of chips
6 EGa 03.11.2008
Fiberline
7 EGa 03.11.2008
Basic features of the fiberline
Cooking:
Process Lo-Solids® Downflow
Diamondback® chip silo, Turbofeed® chip feeding system (three
chip pumps in series)
Brown stock washing:
Three DD-washers in parallel (DD4580.3)
Oxygen delignification:
Two stages 10 + 60 min residence time
Bleaching:
Sequence (A/D)-Eop-D-P
Drying of pulp:
Two parallel drying machines, capacity 2 * 1800 ADT/d
Twin Wire Formers
8 EGa 03.11.2008
Chemical Recovery
Evaporation plant:
7 effects, capacity 1100 tons water/h
Recovery boiler:
Combustion capacity 4450 tons/d
Steam values: pressure 94 bar (g) and temperature 490 oC
Vapor generation capacity 182 kg/s
Electric power generated with two 70 MW turbines
White liquor preparation:
X-Filters for green liquor filtration, disc filters for the the white liquor filtration
Lime kiln with the capacity of 830 tons CaO/d
9 EGa 03.11.2008
Effluent treatment
Activated sludge biological treatment, for ca. 73 000 m3/d effluent
flow:
Coarse screening to remove bigger particles
Primary clarifier to remove solids (mainly fibers) from the high
solods stream
Safety and equalization basins (three 25 000 m3 basins in
parallel)
Cooling tower for temperature control
Aeration basins (rwo in parallel)
Secondary clarifiers (two in parallel, dia. 65 m)
Excess sludge disposal system
10 EGa 03.11.2008
Effluent treatment plant
11 EGa 03.11.2008
Botnia FRB Key Figures
Cumulative production up to
21/04/09 : 1358578 tons
Record day production up to 31
Oct: 3890 t/d (25/01/09)
1000000 TONS in moving 12
month just reach
PRIME GRADE %
99,798,1 98,1
98,899,9 99,7 99,8 99,2
10098,9
97,9
99,5 99,4
97,3
87
80
85
90
95
100
105
JANUARY
FEBRUARY
MARCH
APRIL
MAY
JUNE
JULY
AUGUST
SEPTEMBER
OCTOBER
NOVEMBER
DECEMBER
JANUARY
FEBRUARY
MARCH
AVAILABILITY %
75,681,1
92,8 95,3 94,7
83,7
96,392,7
97,8
89,9
65,9
99,9 97,593,4 92,3
0
20
40
60
80
100
120
JANUAR
Y
FEB
RUAR
Y
MARCH
APR
IL
MAY
JUNE
JULY
AUGUST
SEP
TEM
BER
OCTO
BER
NO
VEM
BER
DECEM
BER
JANUAR
Y
FEB
RUAR
Y
MARCH
12 EGa 03.11.2008
13 EGa 03.11.2008
Botnia FRB Production: Nov’07- actual
DAILY PRODUCTION (month average)
2 2 0 32 0 72
2 2 2 2
2 54 12 6 11 2 59 3
2 2 0 1
2 9 4 5
2 6 8 7
2 8 9 22 8 0 7
2 59 1
3 154 3 1543 0 2 3 2 9 6 9
1000
1500
2000
2500
3000
3500
12.200
7
02.200
8
04.200
8
06.200
8
08.200
8
10.200
8
12.200
8
02.200
9
MONTH
TO
NS
/DA
Y
14 EGa 03.11.2008
Botnia FRB Production: Nov’07- actual
MONTHLY PRODUCTION
3 0 .8 9 2
78 .3 3 2
6 6 .0 3 5
9 1.3 0 9
8 3 .2 9 2
57.0 0 4
9 7.76 2
75.58 7
9 2 .0 3 4
9 7.771
8 6 .76 68 7.0 2 3
8 0 .3 9 878 .78 3
6 4 .2 3 1
6 8 .2 8 9
6 4 .4 3 8
0
20.000
40.000
60.000
80.000
100.000
120.000
11.2007
01.2008
03.2008
05.2008
07.2008
09.2008
11.2008
01.2009
03.2009
MONTH
PR
OD
(T
ON
S)
15 EGa 03.11.2008
Botnia FRB quality trends
16 EGa 03.11.2008
ISO Brightness (%)
DM2 BRIGTHNESS
86
87
88
89
90
91
92
93
21
/01
/20
08
04
/02
/20
08
18
/02
/20
08
03
/03
/20
08
17
/03
/20
08
31
/03
/20
08
14
/04
/20
08
28
/04
/20
08
12
/05
/20
08
26
/05
/20
08
09
/06
/20
08
23
/06
/20
08
07
/07
/20
08
21
/07
/20
08
04
/08
/20
08
18
/08
/20
08
01
/09
/20
08
15
/09
/20
08
29
/09
/20
08
13
/10
/20
08
27
/10
/20
08
10
/11
/20
08
24
/11
/20
08
08
/12
/20
08
22
/12
/20
08
05
/01
/20
09
19
/01
/20
09
02
/02
/20
09
16
/02
/20
09
02
/03
/20
09
16
/03
/20
09
30
/03
/20
09
13
/04
/20
09
DM1 BRIGTHNESS
85
86
87
88
89
90
91
92
93
21/0
1/20
08
21/0
2/20
08
21/0
3/20
08
21/0
4/20
08
21/0
5/20
08
21/0
6/20
08
21/0
7/20
08
21/0
8/20
08
21/0
9/20
08
21/1
0/20
08
21/1
1/20
08
21/1
2/20
08
21/0
1/20
09
21/0
2/20
09
21/0
3/20
09
17 EGa 03.11.2008
Dirts on pulp (mm2/kg)
DIRT DM1
01234567
21/0
1/20
08
21/0
2/20
08
21/0
3/20
08
21/0
4/20
08
21/0
5/20
08
21/0
6/20
08
21/0
7/20
08
21/0
8/20
08
21/0
9/20
08
21/1
0/20
08
21/1
1/20
08
21/1
2/20
08
21/0
1/20
09
21/0
2/20
09
21/0
3/20
09
21/0
4/20
09
DIRT DM2
0
2
4
6
8
10
12
21/0
1/20
08
21/0
2/20
08
21/0
3/20
08
21/0
4/20
08
21/0
5/20
08
21/0
6/20
08
21/0
7/20
08
21/0
8/20
08
21/0
9/20
08
21/1
0/20
08
21/1
1/20
08
21/1
2/20
08
21/0
1/20
09
21/0
2/20
09
21/0
3/20
09
21/0
4/20
09
18 EGa 03.11.2008
Viscosity (mL/g)
VISCOSITY DM1
0
200
400
600
800
100021
/01/
2008
21/0
2/20
08
21/0
3/20
08
21/0
4/20
08
21/0
5/20
08
21/0
6/20
08
21/0
7/20
08
21/0
8/20
08
21/0
9/20
08
21/1
0/20
08
21/1
1/20
08
21/1
2/20
08
21/0
1/20
09
21/0
2/20
09
21/0
3/20
09
21/0
4/20
09
VISCOSITY DM2
0
200
400
600
800
1000
21/0
1/20
08
21/0
2/20
08
21/0
3/20
08
21/0
4/20
08
21/0
5/20
08
21/0
6/20
08
21/0
7/20
08
21/0
8/20
08
21/0
9/20
08
21/1
0/20
08
21/1
1/20
08
21/1
2/20
08
21/0
1/20
09
21/0
2/20
09
21/0
3/20
09
21/0
4/20
09
19
19 EGa 03.11.2008
Successes and bottlenecks
20 EGa 03.11.2008
Successes
Good production figures
Good learning curve of operators and engineers. Effective
organization
Emissions under permit limits and most parameters have already
achieved long term average targets (expected to be reached about 3
years after start up)
Good and even pulp quality
Safety
21 EGa 03.11.2008
Performance tests
Wood Handling: chips production accepted
Fiberline: done, but line needs more tunning on digester and
brownstock washing to achieve guarantee figures.
Drying machines: done and accepted
Evaporation: done
Boiler: done
22 EGa 03.11.2008
Bottlenecks
White liquor plant:
• Had been bottleneck until September
• Green liquor filtration (due to bad quality welding of recirculation
pipes), and to much solids in the circulation
• White liquor filtration (learning what parameters affect WL filtrability,
adjusting slits and correcting start up procedure)
• Lime kiln bricks
• Now very good production level
Evaporation:
• Bottleneck during May and June
• Hydroblasting and acid washing of effect 2 performed in June and
periodical boil outs have improve situation
23 EGa 03.11.2008
Bottlenecks
Drying machines: • Bottleneck for short periods, due to side deckers on wet end
worn out, felts changes and cutter jams. Availability problems
Fiberline: • Bottleneck for short periods, due to lower than expected
availability.
• Main problems: chip pums, steam nozzles leakages, combi screens operability, unstable consistencies, corrosion D2 control valve, fiber reinforced pipes breaks.
• It is present bottleneck together with RB
Recovery Boiler: • It is present bottleneck if fiberline is in steady operation
24 EGa 03.11.2008
Process and availability optimization
challenges
25 EGa 03.11.2008
Wood and wood handling
Minimizing cost of handling
Amount of bark. Have effects on: quality of product, availability of the
area and in the future whole mill, and gasifier.
Dryness of wood: Have effect on cooking. To check logistic chain.
More efficient use of water.
26 EGa 03.11.2008
Fiberline
Digester parameters fine tunning to get stable discharge (kappa and
consistency) at blow line and stable higher pulp viscosity
To check yield: TDS/ADT very high (there are other reasons also:
high dead load at liquor circulation, high ashes recirculation)
Digester bottom & brownstock washing improving continues
Improving availability issues: chips pumps problems
Desing/operation of screening
• Consistency control
• Tank agitation and pipes desing
• Rotors and baskets
Sand separation
Better control of consistency along the line
Better understanding of the effect of key parameters on papermaking
characteristics.
27 EGa 03.11.2008
Drying machines
Moisture and basis weight control after drying machines optimization ongoing
Sectional drives (situation it is better)
Fabrics (to develop the suppiers) to improve durability and runnability
Dryer threading still some problems, have improved
Pick up rolls water splashing ( dealing with the issue, some modifications next shutdown)
Screening improvement (sand separation and secondary accepts to primary accepts)
28 EGa 03.11.2008
Evaporation and boilers
EVAPORATION
not important continuous problems.
Future situation depending on better reduction efficiency at boiler
and optimizacion of caustizicing efficiency
RECOVERY BOILER
Learning to run Recovery Boiler with higher reduction efficiency and
lower carbon to green liquor
Chloride and potasium removal: corrosion and plugging at
continuous high load.
Some construction issues.
29 EGa 03.11.2008
WLP and Lime Kiln
WLP
Design/construction issues at X filters
To optimize caustizicing efficiency
LIME KILN
Brick lining design
To maximize hydrogen burning
Help for success of gasifier project
30 EGa 03.11.2008
Electricity and ETP
ELECTRICITY
to achieve optimum distribution between selling for chlorate
production and the national grid
Load shedding:
• Changes in the program to shed only what it is necessary
• Changes in the priorities between areas
ETP
Treatment of domestic effluents
31 EGa 03.11.2008
Summary of challenges
Improving availability of whole mill to improve quality stability,
increasing production, lowering cost and lowering even further
emmisions; overcoming bottlenecks.
Continue with test runs on wood handling, fiberline & recovery
Understanding effect of key process parameters on
papermaking properties of pulp
Improving bales quality
32 EGa 03.11.2008
Environmental figures – March 2009 – Effluent
33 EGa 03.11.2008
Effluent discharge - COD
COD (DQO) - Kg/ADT
0
2
4
6
8
10
12
14
16
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 8 Kg/ADT
Permit limit (annual): 15 Kg/ADT
Target 2009 (annual): 5 Kg/ADT
COD (DQO) - ton/d
0
10
20
30
40
50
60
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 56 ton/d
34 EGa 03.11.2008
Effluent discharge – BOD5
BOD5 (DBO5) - Kg/ADT
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 0,3 Kg/ADT
Permit limit (annual): 0,7 Kg/ADT
BOD5 (DBO5) - ton/d
0,0
0,5
1,0
1,5
2,0
2,5
3,0
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 2,6 ton/d
35 EGa 03.11.2008
Effluent discharge - AOX
AOX - Kg/ADT
0,00
0,02
0,04
0,06
0,08
0,10
0,12
0,14
0,16
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 0,08 Kg/ADT
Permit limit (annual): 0,15 Kg/ADT
AOX - ton/d
0,00
0,10
0,20
0,30
0,40
0,50
0,60
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 0,56 ton/d
36 EGa 03.11.2008
Effluent discharge – P Total
P Total - Kg/ADT
0,000
0,004
0,008
0,012
0,016
0,020
0,024
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 0,012 Kg/ADT
Permit limit (annual): 0,020 Kg/ADT
P Total - ton/d
0,00
0,01
0,02
0,03
0,04
0,05
0,06
0,07
0,08
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 0,074 ton/d
37 EGa 03.11.2008
Effluent discharge – N Total
N Total - Kg/ADT
0,00
0,04
0,08
0,12
0,16
0,20
0,24
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 0,15 Kg/ADT
Permit limit (annual): 0,20 Kg/ADT
N Total - ton/d
0,00
0,10
0,20
0,30
0,40
0,50
0,60
0,70
0,80
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 0,74 ton/d
38 EGa 03.11.2008
Effluent discharge - TSS
TSS (SST) - Kg/ADT
0,0
0,2
0,4
0,6
0,8
1,0
1,2
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Long Term Average (IFC, annual): 0,7 Kg/ADT
Permit limit (annual): 1,0 Kg/ADT
TSS (SST) - ton/d
0,0
0,4
0,8
1,2
1,6
2,0
2,4
2,8
3,2
3,6
4,0
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
Permit limit (monthly): 3,7 ton/d
39 EGa 03.11.2008
Effluent discharge - Flow
Effluent flow (Caudal de efluente) - m3/ADT
0
10
20
30
40
50
07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg
2008
Avg
2009
BAT (annual): 30 - 50 m3/ADT
Target 2009 / LTA (annual): 25 m3/ADT