Chemical Pulp Mills Research Articles

Lignin extraction in chemical pulp mills: The role of flexible operation

Lignin extracted from black liquor in chemical pulp mills can potentially replace fossil carbon feedstocks in fuels and materials, thereby increasing the economic and environmental added values of woody biomass. However, since lignin extraction reduces the electricity generation of the mill, the added value depends on the characteristics of the electricity market in which the mill operates. In this study, a model mill is exposed to two different electricity price profiles: the low and steady prices of south-central Sweden in Year 2019; and the high and volatile prices of the same region in Year 2022. For the model mill, investments in lignin extraction designed to increase pulp production are economically viable and have low levels of sensitivity to electricity price levels and price volatility. The viability of lignin extraction without increased pulp production depends on the relationship between the electricity and lignin prices. With stable electricity prices, or steady mill operation, a rule-of-thumb holds that for lignin extraction to be viable, the lignin price (€/t) must be 1.8-times the average electricity price (€/MWh) plus 40 €/t for the supply of chemicals. With volatile electricity prices and flexible operation of the recovery boiler, the mill can shift the loss in electricity sales to low-price hours, thereby saving 15–70 % of the operational costs of lignin extraction, as compared to steady operation. This effect can be further enhanced by increasing the capacity of the lignin extraction process or extending the size of the black liquor storage tank. The proposed flexibility measures allow the market-integrated pulp mill to export lignin to replace fossil carbon supplies in other sectors, while supporting the electricity system during hours with high demand and low supply.

Industrial Data-Driven Processing Framework Combining Process Knowledge for Improved Decision-Making—Part 2: Framework Application Considering Activity-Based Costing Concepts

Operating time series data collected and stored in historian must be managed to extract their full potential. Part 1 of this paper proposed a structured way (a sophisticated approach) to process industrial data; this first part explains in detail the data processing framework used as the basis for the costing analysis present in the second part of this series. The framework considers the analysis scope definition, data management steps, and operating regimes detection and identification. The added value of this proposed framework is demonstrated in Part 2 via the use of cost accounting for operational problem-solving (debottlenecking), i.e., its practicality is validated via its application alongside a cost analysis on the brownstock washing department of a kraft pulp mill. The traditional debottlenecking approach assumes a single operating condition considering that operating regimes allow for a much more sophisticated debottlenecking study of the washing department. With the use of operations-driven cost modeling (contingent on activity-based costing concepts) and processed time series data corresponding to steady-state operation, incremental profit can be assigned to each operating regime in order to identify the most cost-efficient one. The overall objective of this two-part series is to convert processed industrial steady-state data and cost information into knowledge that can be used to optimize the washing department of a chemical pulp mill. More specifically, different operating regimes are assessed, and the most suitable operating strategy is defined. The application of activity-based costing on a large amount of historically processed industrial data led to the improvement in the operation. The identified optimal way to operate (pulp throughput, pulp conductivity, defoamer and bleaching chemical quantity, etc.) led to a profit of CAD 49 M per year. Lastly, a contribution analysis of the regimes based on PCA highlighted how the process was operated when the preferred performances happened.

Microwave wood chip treatment use in chemical pulp manufacturing (technical-economic assessment)

The low permeability of many wood species causes problems in the chemical pulp industry. These include very long cooking times, high chemical consumption, large material losses, high energy consumption, and environmental pollution. New microwave (MW) wood modification technology can provide an increase in wood permeability for liquids and gases that solves many of these problems. MW wood pre-treatment can increase pulp mill throughput, reduce chemical and power consumption, increase pulp quality and yield, and improve environmental performance. Economic modelling of this new technology use in different chemical pulp mill conditions allowed to assess the effect of capital costs, electricity costs, labour costs and other cost components to specific total costs of MW chip processing. MW chip treatment costs for pulp mills with output 50,000 to 500,000 ait dry ton (ADT) per year at electricity cost range US$0.04 to US$0.24/kWh vary in the range from US$17.7 to US$60.8 per air dry ton of pulp. Electricity costs form the most significant part – 51- 69% of the total specific costs of MW chip processing at electricity costs US$0.08 to US$0.12/kWh. New technology applications in different Russian conditions can provide benefits up to 7 – 22 Mil US$ per year for pulp mills with output of more than 200,000 ADT/year. The ecological effect and high economic advantages of this MW technology provide a good opportunity for commercialisation.

Integration of carbon capture in a pulp mill—effect of strategic development towards better biomass resource utilization

The pulp and paper industry has an important role in the industrial transition towards net zero or negative emissions, given its renewable biomass-based feedstock and energy supply. In particular, pulp and paper mills have large existing sources of biogenic CO2, with a high potential to contribute to carbon dioxide removal through carbon capture and storage (CCS). To effectively navigate anticipated changes in feedstock and energy markets, there is a need for a better understanding of how different technology pathways for the pulp and paper industry interact with one another, for instance, how enhanced valorization of biomass side streams may affect the potential for carbon capture. This paper aims to investigate the effect of combining carbon capture with lignin extraction in a chemical pulp mill. Pinch analysis is used to study how the targets for heat recovery, fuel usage and electricity generation, are affected by different mill and capture configurations. Based on these results, the effect on carbon flows is evaluated. The results show that when carbon capture technology is implemented and fuel use is minimized at the case-study mill, there is still enough heat available from the recovery boilers to supply the process needs without requiring usage of a utility boiler. However, when carbon capture is combined with lignin extraction, the heat production of the recovery boilers is no longer sufficient to cover the process demands, and additional heat from a utility boiler is required. However, this case implies that some of the carbon leaves the mill embedded in the extracted lignin product, which can be expected to have a higher value than captured carbon dioxide. When back-pressure electricity production was maximized for the different mill configurations, a very high fuel-to-electricity efficiency could be achieved, but since the CO2 emissions from the utility boiler were not assumed to be captured, this would lead to more carbon being emitted compared to the capture scenarios with minimized fuel use.

The chemical pulp mill as a flexible prosumer of electricity

Chemical pulp mills act as industrial-scale prosumers of energy, in that they demand heat and electricity for the production processes while supplying heat and electricity from the combustion of by-products. As such, they have potential relevance as providers of flexibility to the electricity system, supporting the integration of variable renewable electricity generation.In this study, a novel dispatch optimisation model is presented and applied to a generic mill, covering the production processes, boilers, and turbines, together with the associated storage of intermediate products. We analyse the trade in electricity between the mill and the central grid, the economic value of pulp mill flexibility, and the internal dynamics of the mill, when flexibility measures in different parts of the mill are combined.The results show that the suggested flexibility measures increase the amount of sold electricity during high-value hours and reduce the amount of sold electricity during low-value hours. In the present electricity market, the value of the electricity traded with the central grid is, thereby, increased by 1–8% compared to steady-state operation, without impacting the pulp production volume. The results reveal both synergies and conflicts between the different flexibility measures, underlining the importance of mill-wide optimisation.

Screening of chemical pulp, revisiting technology options, and the state‐of‐the‐art equipment—A critical review

AbstractScreening of pulp can be expressed as a process where solid contaminants are removed from a pulp slurry without an excessive loss of fibres of acceptable quality. The impurities originate from the feedstock, or they are generated during the transport, handling, storage, or pulping process. The most typical impurities include bark, fibre bundles or shives, knots, plastic, rubber, and sand. Moreover, there are also other objectives for screening, such as the improvement of the pulp quality, savings in bleaching chemical consumption, and protection of process equipment. In industrial applications, pulp screening is typically carried out with more than one screen for a more beneficial screening result. The pulp screening equipment can be divided into different types by the separation technique employed, such as atmospheric or pressurized screens, centrifugal screens, vibrating screens, etc. In addition, there are other types of related equipment that are common in the pulp screening process, such as knotters, refiners, and hydrocyclones. The main objective of this review is to discuss the advantages and disadvantages of modern screening equipment as well as introduce contemporary screening strategies for chemical pulp mills.

Energy Optimization in a Paper Mill Enabled by a Three-Site Energy Cooperation

Although there are opportunities to reduce electrical energy demand in unit processes of mechanical pulp-based paper and paperboard production, this may not be financially beneficial. This is generally because energy optimization opportunities connected to reduced refiner electricity demand in mechanical pulping systems also results in less steam available for the drying of the paper. As modern high consistency refiner systems produce approximately one ton of steam for each MWh of electricity when producing one ton of pulp, a reduction in electric energy demand leads to increased fuel demand in steam boilers to compensate for the steam shortage. In this study, we investigated what the financial and environmental situation would look like if we were to expand the system border from a paper mill to a larger system consisting of a mechanical pulp-based paper or paperboard mill, a district heating system with an incineration boiler and a chemical pulp mill. Mechanical pulp production has a wood to product yield of >90%, a high electric energy demand to separate woodchips to pulp and is a net producer of heat and steam while chemical pulp-based production has a wood to product yield of 50%, a low electric energy demand and is a net heat and electricity producer due to the combustion of dissolved wood polymers. The aim of this research is to create useful and robust models of how to use excess heat from certain industry sites to cover the steam shortage in other industry sites by means of utilizing and optimizing the district heating systems connecting these sites. For this purpose, we used a simulation tool which dynamically allows us to evaluate different scenarios. Our results shows that there is great potential to reduce both carbon dioxide emissions and production costs for industry sites and society by means of these tools.

Considerations in managing wastewater odor at pulp and paper operations

Many pulp and paper mills are, at least periodically, faced with the release of odors that can migrate offsite and be considered a nuisance by nearby residents. At chemical pulp mills, perceptible odors associated with reduced sulfur compounds (RSCs) are common, many of which are highly perceptible owing to their low odor thresholds. As releases of RSCs and other odorous substances from production processes are progressively controlled, the proportional contribution from wastewater treatment systems to areal odors can increase. This review paper summarizes important fundamentals of odor generation, source identification, and control. Common odorous substances are identified, and mechanisms for their generation are summarized. Approaches for measuring odorous substances are detailed to enable more effective management, and various odor control strategies are discussed.

Critical parameters for tall oil separation I: The importance of the ratio of fatty acids to rosin acids

Tall oil is a valuable byproduct in chemical pulping of wood, and its fractions have a large spectrum of applications as chemical precursors, detergents, and fuel. High recovery of tall oil is important for the economic and environmental profile of chemical pulp mills. The purpose of this study was to investigate critical parameters of tall oil separation from black liquor. To investigate this in a controlled way, we developed a model test system using a “synthetic” black liquor (active cooking chemicals OH- and HS- ions), a complete process for soap skimming, and determination of recovered tall oil based on solvent extraction and colorimetric analysis, with good reproducibility. We used the developed system to study the effect of the ratio of fatty acids to rosin acids on tall oil separation. When high amounts of rosin acids were present, tall oil recovery was low, while high content of fatty acids above 60% significantly promoted tall oil separation. Therefore, manipulating the content of fatty acids in black liquor before the soap skimming step can significantly affect the tall oil solubility, and hence its separation. The findings open up chemical ways to improve the tall oil yield.

Optimized Catalytic Bleaching Sequences for Eucalyptus Kraft Pulp

Contemporary multi-stage bleaching processes partially remove residual lignin and hexenuronic acid from cellulosic pulps. The reactions in the steps could be faster and consume smaller amounts of chemicals. Catalytic bleaching (Hcat), utilizing hypochlorite (H), triethylenediamine (DABCO) and its derivative N-carboxymethyl triethylenediamine (CM-DABCO), is a new discovery that has the potential to improve the chemical and energetic efficiency of bleaching processes in chemical pulp mills, e.g. through reducing the reaction time of the bleaching processes. The objective of this study was to clarify if new kraft pulp bleaching sequences with initial stage of chlorine dioxide (ClO2; D) and an intermediate stage of Hcat could provide fully bleached pulps. The bleaching sequences of the studied eucalyptus pulps include D0E(OP)Hcat(Q)P and HcatZ/DP, which attained a final brightness of 88 and 89% ISO, respectively. HcatZ/DP showed to be the best sequence for the catalytic bleaching of eucalyptus kraft pulps. This study may open new doors to future bleaching of cellulose pulps with fewer towers and decreased use of chemicals.

An assessment of side-stream generation from Finnish forest industry

This study examined side-stream generation from Finnish forest industry comprising data from 19 sawmills, 1 plywood mill, 1 particleboard mill, 10 paper and board mills, 1 semi-mechanical mill, and 15 chemical pulp mills. A structured questionnaire survey was carried out for this study. The results revealed that the generation of side stream in sawmills, plywood mills, paper and board mills, mechanical pulp mills, and chemical pulp mills accounted for 42.2%, 56.1%, 23.8%, 30.7%, and 56% of round wood log input, respectively, and 91.2%, 135.5%, 42.2%, 44.7%, and 238.5% of the finished product, respectively. Woodchips, sawdust, and bark were recognized as the significant side streams in sawmills and plywood mills, whereas fiber sludge was found the main side stream in paper, board and mechanical pulp mills. In chemical pulp mills, black liquor was found the greatest side stream, which comprises 43% of the wood input and 183.3% of the finished product. The study estimated that in 2016, Finnish forest industry generated a total 27.7 million tons of side streams, consisting of 49.2% black liquor, 28.5% solid wood-based waste, 14.1% sludge, 4.4% ashes, and 3.8% others. A current use of these side streams and their future utilization potential is also discussed.

Removal of hazardous trace elements from green liquor dregs by mechanical separation methods

Abstract Green liquor dregs represent the most important inorganic residue of chemical pulp mills. The dregs are usually settled in thickeners, washed and deliquored with lime mud precoat filters, and transported to the landfill. The utilization of dregs is challenging, due to the high concentration of hazardous trace elements (HTE) in their solid phase. There are basically two potential strategies for the reduction of the HTE content of dregs: mechanical classification according to differences in the size and density of particles, and removal of HTE by various chemical treatments. The objective of this study was to evaluate the applicability of straightforward mechanical separation methods for the purification of dregs from HTE. The evaluated separation methods included particle size–based classification by sieving, and classification on the basis of differences in the settling properties of particles in gravitational and centrifugal separation. It can be concluded that all the evaluated separation methods could be used to reduce the HTE content of dregs, although the separation efficiency was not very high in most cases. Centrifugation had clearly the best performance of the investigated techniques. The fractions consisting of large particles contained consistently lower concentrations of HTE, compared to fractions containing a lot of fines.

Gasification Integrated with Small Chemical Pulp Mills for Fuel and Energy Production

Pulp mills without black liquor recovery cycle could play a major role in employing black liquor gasification (BLG) to produce transport fuels. In conventional chemical pulp mills, black liquor is burnt in recovery boilers to generate steam and electricity to meet energy demands. The inorganic chemicals are reused for the digestion process. However, the energy content and inorganic chemicals are not recovered in small scale pulp mills especially in the developing countries which do not employ recovery cycle. This study investigates the potential of synthetic natural gas (SNG) production by integrating BLG island with a reference pulp mill without chemical recovery cycle. The improvements in overall energy efficiency are evaluated using performance indicators such as biofuel production potential, integrated system’s efficiency, and energy ratios. The oxygen-blown circulating fluidized bed (CFB) gasification with direct causticization is integrated with reference pulp mill. The results showed considerable SNG production without external biomass import. However to compensate total electricity deficit, the electricity will be imported from the grid. There is a substantial CO2 abatement potential of combining CO2 capture using seloxol absorption, and CO2 mitigation from SNG by replacing gasoline.

Operational Flexibility in Pulp Mill Steam Production at Off-design Heat Loads

This paper focuses on the steam production in a chemical pulp mill that is retrofitted to reduce its process heating demand. A multi-period optimization model for design decisions is proposed that takes into account the operational limits of the steam production units as well as the heat load variations over the year. Large variations in combination with the retrofit that causes off-design loads in the steam production system will influence the flexibility of the steam system. Minimum boiler load limits will then be a greater constraint on operation since the average load of boilers is moved closer to the minimum for longer periods of time. A conventional approach that considers fixed annual averages of process parameters therefore risks leading to sub-optimal solutions because of neglecting the variations in heat demand and the operational limits. The multi-period approach suggested in this paper considers this operational flexibility associated with different design choices. A case study based on a Kraft pulp mill with a recovery boiler and a bark boiler shows the benefit of properly modelling the varying heat demand. Numerical results are presented that compares the results of the multi-period model with that of a conventional annual average approach. Differences in design decisions, energy balances and economic performance are demonstrated and discussed.

Energy Analysis for Conversion of a Kraft Pulp Mill into a Dissolving Pulp Mill

Currently, kraft pulp mills in Europe and North America are facing several challenges and have been forced to think along new products and new business areas. One opportunity is the conversion of chemical pulp mills into dissolving pulp mills by extracting hemicellulose prior to digesting via pre-hydrolysis. From the extracted wood chips, the more valuable dissolving pulp can be produced whereas the hydrolysate can be upgraded to high-value products. In this paper, pinch analysis is used to evaluate the consequences in the energy balance and utility system of a kraft mill converted into dissolving pulp production as well as to identify the potential for heat integration within the host mill itself, between the host mill and the pre-hydrolysis unit and with a hemicellulose upgrading process. The results show that proper heat integration within the host mill itself, and between the host mill and the pre-hydrolysis unit gives significant amounts of surplus steam which could be exported to a hemicelluloses upgrading process, used for power generation or to facilitate lignin extraction.

New alternative energy pathway for chemical pulp mills: From traditional fibers to methane production

Chemical pulp mills have a need to diversify their end-product portfolio due to the current changing bio-economy. In this study, the methane potential of brown, oxygen delignified and bleached pulp were evaluated in order to assess the potential of converting traditional fibers; as well as microcrystalline cellulose and filtrates; to energy. Results showed that high yields (380mL CH4/gVS) were achieved with bleached fibers which correlates with the lower presence of lignin. Filtrates from the hydrolysis process on the other hand, had the lowest yields (253mL CH4/gVS) due to the high amount of acid and lignin compounds that cause inhibition. Overall, substrates had a biodegradability above 50% which demonstrates that they can be subjected to efficient anaerobic digestion. An energy and cost estimation showed that the energy produced can be translated into a significant profit and that methane production can be a promising new alternative option for chemical pulp mills.

Comparative global warming potential assessment of eight microcrystalline cellulose manufacturing systems

In this study, we conducted a comparative global warming potential assessment of eight microcrystalline cellulose manufacturing systems using life cycle assessment software and global warming potential (GWP) as a measure of environmental burden. The studied systems included both non-integrated (stand-alone system) and integrated (located within the chemical pulp mill) manufacturing systems. The results indicate that the Non-integrated AaltoCell™ system has lower GWP than the Non-integrated market MCC systems as well as slightly lower GWP than the AaltoCell™ plant integrated to chemical pulp mill systems. However, the lowest GWP was produced by the AaltoCell™ plant integrated to chemical pulp mill due to use of unbleached pulp as a raw material. Our results indicate that the relative shares of chemical pulp, heat, ammonia and electricity processes contribute to a very large share of the GWP results. Chemical pulp has the biggest influence on GWP results, but it is also the main raw material. Comparison of manufacturing without chemical pulp production indicates that heat energy and ammonia have the biggest impacts.

Transportation fuel production from gasified biomass integrated with a pulp and paper mill – Part A: Heat integration and system performance

Production of transportation fuels from biorefineries via biomass gasification has been suggested as a way of introducing renewable alternatives in the transportation system with an aim to reduce greenhouse gas emissions to the atmosphere. By co-locating gasification-based processes within heat demanding industries, excess heat from the gasification process can replace fossil or renewable fuels. The objective of this study was to compare the heat integration potential of four different gasification-based biorefinery concepts with a chemical pulp and paper mill. The results showed that the choice of end-product which was either methanol, Fischer-Tropsch crude, synthetic natural gas or electricity, can have significant impact on the heat integration potential with a pulp and paper mill and that the heat saving measures implemented in the mill in connection to integration of a gasification process can increase the biomass resource efficiency by up to 3%-points. Heat saving measures can reduce the necessary biomass input to the biorefinery by 50% if the sizing constraint is to replace the bark boiler with excess heat from the biorefinery. A large integrated gasification process with excess steam utilisation in a condensing turbine was beneficial only if grid electricity is produced at below 30% electrical efficiency.

Integration of next-generation biofuel production in the Swedish forest industry – A geographically explicit approach

The geographic locations of biofuel production facilities should be strategically chosen in order to minimise the total cost of using biofuels. Proximity to biomass resources, possibilities for integration, and distance to biofuel users are aspects that need to be considered. In this paper, the geographically explicit optimisation model BeWhere Sweden was used to investigate the future production of next-generation biofuels from forest biomass in Sweden. A focus was placed on the integration of biofuel production with the existing forest industry, as well as on how different parameters affect biofuel production costs, the choice of technologies and biofuels, and the localisation of new biofuel plants. Six examples of different biofuel routes were considered. A methodology was developed considering detailed, site-specific conditions for potential host industries. The results show that the cost of biomass and the biofuel plant capital cost generally dominate the biofuel cost, but the cost for biomass transportation and biofuel distribution can also have a significant impact. DME produced via black liquor gasification (naturally integrated with chemical pulp mills) and SNG produced via solid biomass gasification (mainly integrated with sawmills), dominate the solutions. The distribution of these technology cases varies depending on a number of parameters, including criteria for sizing biofuel plants, the electricity price, the biofuel distribution cost and the cost of biomass, and is sensitive to changes in these parameters. Generally, plants with low specific investment costs (i.e., high biofuel production) and/or plants with low specific biomass transportation costs occur most frequently in the solutions. Because these properties often vary significantly among biofuel production facilities at different host industry sites of the same type, the results show the advantage of including site-specific data in this type of model. (C) 2015 Elsevier Ltd. All rights reserved.

Optimization of a brownstock washing line

The objective of this study was to improve the efficiency of a certain Scandinavian chemical pulp mill’s brownstock washing line. The information was collected by using online devices (a refractometer and a conductivity meter), and the whole line was controlled by an upper level control system. The results indicate that it is possible to reduce the amount of brownstock washing loss by controlling the dilution factor (DF) of the entire brownstock washing line, via the use of torque control of washers and real time wash loss measurements. Simultaneously, the amount of used wash water is decreased, thus significantly improving the economic efficiency of the fiber line, especially in the evaporation and bleaching plant. Real time dissolved dry solids (DDS) measurements proved useful for controlling and monitoring the wash loss and water consumption.