2A1 Seven Decades of Development in Continuous Kraft Cooking
R. Thomas Boughner, Tetrahedron Performance Resources, Cobble Hill, BC
Two major chemical engineering processes for the conversion of natural materials to commercially useful products were both launched about a century ago. Kraft pulping and petroleum refining each had their genesis early in the 20th century but the latter was the first of the two to become an entirely continuous process. Kraft pulping lagged behind due to difficulties of feeding heterogenous streams to and from a pressurized reactor. For the first four decades, all kraft cooking was done in batch reactors.
Then, just after the end of World War II, the company we came to know as Kamyr was able to extrapolate the technology for feeding to and discharging from continuous reactors that they had already applied to bleaching. The first continuous cooking installation had a capacity of 50 tons per day. Over the next 60 years, capacities have increased by almost two orders of magnitude and as a result of ownership separation and subsequent acquisition, no company bearing the name Kamyr is any longer involved in producing digesters. Systems supplied worldwide by both Metso and Andritz continue to push the envelope on capacity, energy consumption and process simplicity and selectivity.
2A2 Measuring Uniformity in kraft digesters using flow-following MICRO sensors
E. Albadvi †, T. C. M. Graham†, E. Liu", C. P. J. Bennington†, R. J. Kerekes†, M. Martinez†, and S. Mirabbasi"
†Department of Chemical and Biological Engineering
"Department of Electrical and Computer Engineering
University of British Columbia, Vancouver,
Measurements of kraft pulp variability within digesters have been the subject of intense interest for many years. The cause of variability is attributed to a number of different factors and this paper will provide an overview of the many studies investigating the extent of delignification diversity within batch and continuous kraft digesters. However, data taken from within the digester directly, during the cook, is scarce in the analysis of variability thus far. This has motivated the development of a flow-following device, the “SmartChip”, to measure and record various parameters including the temperature while following the same path as a wood chip through the digester. The SmartChip has been tested in a 5L M/K laboratory batch digester and a kappa variation of about 2-3 units was observed based on the kappa tests taken along the length of the digester. Subsequently, multiple SmartChips are being deployed in a single cook to measure the variability of temperature by position throughout the cook within a larger batch digester. To establish a correlation between pulp non-uniformity and temperature gradients, kappa tests are being performed on the wood chips in the vicinity of the SmartChip sensors. The increased size of modern digesters is believed to reduce the flow uniformity within them, increasing the risk of pulp variability (Vlaev and Bennington, 2004) and highlighting the need to collect data from within the digesters themselves.
2A3 Mitigating the Impact of Beetle-killed Whole Log Chips on Kraft Pulping and Pulp Quality
Ranbir Heer, Tim Sutton, Sandra Morrison & Paul Watson, Canfor Pulp LP
A combination of the Mountain Pine Beetle infestation and a dramatic slowdown in the US housing market has resulted in increased volumes of whole log chips delivered to pulpmills. Detailed laboratory trials whereby the percentage of whole log chips was increased in a sawmill residual chip furnish confirmed that production and pulp quality changes in terms of pulp yield and fibre properties only occurred when 80% or more whole log chips were used. Whole log chips are generally prepared from smaller diameter trees and were expected to have higher juvenile wood content which should result in lower yield and higher pulp tensile strength. We observed that the average age of these trees was in excess of 100 years hence the percent of juvenile wood in these chips was less than 40% which explains our laboratory findings. Kraft mill experience confirmed the laboratory results as pulp quality was maintained even when the mills ran whole log chip volumes in excess of 35%.
2A4 Detailed Investigation of Lime Kiln Mud Ring Formation
Kevin Taylor, Taylor Industrial Research, Inc.
At a 600 tonne/day lime kiln, rapid ring formation occurred immediately after the chain section over a two day period, causing a mill shutdown. The ring material was relatively soft and extended for a distance of approximately 70 feet from the chain section. This kiln did not have a history of ring formation. The ring material was examined in detail by X-ray diffraction analysis (XRD), elemental analysis and scanning electron microscope/energy dispersive x-ray spectroscopy (SEM/EDX). To the best of the author’s knowledge, this type of study has not been previously reported for a kiln ring at this location.
Results showed that the kiln ring material was formed by growth of calcite crystals that acted to bridge particles and increase compressive strength. The likely reaction mechanism is reactive precipitation of calcite. Kiln precipitator dust recycle was a contributing factor. This mechanism is compared with mid-kiln ring formation that occurs by recarbonation and sintering of calcite crystals. Based on the results, operating conditions of the kiln were modified and ring formation has not recurred.
2A5 Is there a Relationship between Viscosity and Tensile Strength?
Alice Obermajer, Canfor Pulp Research and Development
The viscosity-strength relationship for softwood Kraft pulp was studied over a viscosity range of 10 to 24 mPas both in the lab and for in-mill produced low viscosity events. Low viscosity laboratory pulps produced by increasing the temperature in the oxygen delignification stage, exhibited linear correlation between the extent of delignification in the oxygen stage and the viscosity of the final pulp of only 0.2mPas per km of breaking length. For mill-produced low viscosity pulps, much of the strength data fall within the variability of the mill data. Viscosity loss generally occurred in response to digester events. The differences in viscosity loss between the source pulps suggest different mechanisms. Overall, the results suggest that although a relationship exists, regardless of whether viscosity is affected during cooking or duing oxygen delignification, significant tensile strength loss does not occur until viscosity values fall below 14mPas.
2A6 Mechanical and Kraft Pulping of Brown-Rot Decayed Lodgepole Pine
Paul Bicho and Rod Stirling, FPInnovations – Paprican, Vancouver, BC, Canada
The objective of this research was to examine the effects of brown-rot decay on the pulping of lodgepole pine. Pine chips inoculated with Gloeophyllum trabeum, a brown rot fungus. Refiner mechanical pulps produced from advanced brown-rot decayed wood reached a target freeness with about 50% less energy than was required for sound wood. However, the RMP pulps from decayed woods were 20 ISO points darker and had more long fibres than the pulps produced from sound wood. The RMP pulps produced from decayed wood also had poorer strength properties due to weakening of the individual fibres. Kraft pulps prepared from advanced decayed wood chips had lower yields, more screen rejects, and greater alkali consumption, than those produced from sound wood chips. The long fibre fractions of the kraft pulps made from decayed wood were lower, and fines contents higher, than pulps made from sound wood. This contributed to increase air resistance and scattering coefficient, and to decrease tear, tensile and burst indices in pulps produced from the decayed wood. The solids content and ratio of organics to inorganics in the black liquor also increased with decay; this could impact recovery systems. Because of the inferior wood quality of highly decadent wood, kraft mills would require more than double the volume of wood chips to produce 1 tonne of unbleached pulp if they switched from sound to advanced brown-rot decayed lodgepole pine chips. The increased EA consumption of decayed wood would also require mills to increase EA, increase H-factor, or increase both when pulping decayed wood.
Session 2B – NEW TECHNOLOGY AND OPPORTUNITIES
2B1 Scientific Research and Experimental Development Tax Credits (SR&ED) in the Pulp and Paper Industry: How to strategically apply for available credit for the mill challenges you face and the developments you initiate.
Edward (Ted) C. Bell, Ernst & Young LLP, Vancouver
The Federal SR&ED program is a tax incentive program to encourage economic development and job creation in Canada. In fact, the SR&ED program is the largest source of federal funding for industrial research and development (R&D) performed in Canada and is one of the most generous R&D programs in the world today. However, Canada still lags behind other countries in terms of R&D spending. The basic federal credit is 20% of eligible expenditures, with most provinces providing an additional credit at varying percentage rates. British Columbia and Alberta have 10% credits, Manitoba has a 15% credit, and Saskatchewan has a 10% credit.
This paper provides a brief overview of the scientific requirements, in mill terms, related to securing the tax credits and the types of costs that are eligible to be claimed under the program. Recent changes to the program are highlighted. Real examples of mill level claims from the pulp and paper industry are reviewed that bring context to your projects. Tips for a well structured claim are reviewed. Finally, an examination of controversial situations that can arise during review with the Canada Revenue Agency (CRA) and how to deal with these situations is provided.
2B2 Near Infrared Process Analyzers for Rapid Determination of Pulp Mill Process Variables
Brian Curtiss, Don Campbell, ASD Inc., Boulder, Colorado; and Thanh Trung, FPInnovations-Paprican, Vancouver
Real-time knowledge of pulp mill process variables allows for optimization of the mill’s pulping, bleaching and recovery processes. Near Infrared (NIR) process analyzers are being used increasingly to provide information necessary to optimize aspects of a wide range of mill processes. The ability of NIR analyzers to accurately measure chemical and physical properties of solid materials enables rapid at-line and on-line analysis of such materials as wood chips, hog fuel, lime mud, burnt lime, brown stock, bleached pulp and finished pulp sheets. Calibrations for NIR analyzers are developed using statistical methods that relate measured NIR reflectance to the material properties of interest. The development of NIR calibrations involves five steps: 1) a set of samples with known physical and/or chemical properties is assembled; 2) the NIR reflectance spectra of these samples are collected; 3) the NIR spectra and the properties of interest are correlated using one of several multivariate regression techniques; 4) the reliability of each calibration is validated using independent data; and, 5) the validated calibrations are used to predict properties of interest for unknown samples. At-line and over-the-conveyor on-line NIR analyzer systems have been developed for several applications. Examples presented include: at-line analysis of pulp kappa and brightness; on-line analysis of lime mud moisture, color and NPEs; and, on-line analysis of wood chip moisture.
2B3 Low Consistency Refining of Oxalic Acid Pretreated Wood Shavings
Taegeun Kang1*, George Soong1, Harry Chang2, Rodger Beatson2, James A. Olson1 and D. Mark Martinez1
1 Pulp and Paper Centre, The University of British Columbia, 2385 East Mall, Vancouver.
2 Department of Chemical Science, British Columbia Institute of Technology, 3700 Willingdon Avenue, Burnaby
* Now with Winstone Pulp International Ltd., Ohakune, NEW ZEALAND.
The objective of this study was to evaluate the potential use of wood shavings as a raw material for the low consistency (LC) refining at the primary refining stage to significantly reduce electrical energy consumption. It was possible to produce wood shavings with longer fibre length than wood chips. Oxalic acid, followed by alkaline peroxide, were applied to both wood shavings and wood chips before LC refining. LC refined wood shavings were found to be a low energy raw material. The refining energy was reduced by about 33% using wood shavings compared to wood chips at a given freeness, and oxalic acid pretreatment of wood shavings further reduced the refining energy by approximately 57%. Tensile strength and brightness of LC refined wood shavings was found to be higher than high consistency refined wood chips. Oxalic acid pretreatment further improved the tensile strength of LC refined wood shavings, but not the brightness. This study demonstrates the potential to develop a novel mechanical pulping process that produces high tensile, high brightness pulp with half the electrical energy consumption.
2B4 Low Consistency refining of mechanical pulp: The effect of gap, speed and power
A. Luukkonen1, J.A. Olson1, D.M. Martinez2
1) Department of Mechanical Engineering
2) Department of Chemical and Biological Engineering
Pulp and Paper Centre, The University of British Columbia, Vancouver
Our research is focussed on reducing the total energy consumption in the mechanical pulping process by offsetting the energy consumed during high consistency refining (HCR) with an increase in the energy applied in low consistency refining (LCR). To do so, a further understanding of the mechanism of property development during LCR is required to avoid the deleterious effect of fibre cutting at excessive high specific energy.
In this paper, we report a three-step scheme by which we correlate operational variables to final pulp properties. To do so we developed an experimental database in which we refine a 4% consistency SPF mix from Northern British Columbia in 22-inch Twin-Flow LCR located at the Andritz pilot plant facility in Springfield Ohio. The papermaking suspension was refined in seven stages, with the specific energy per pass held constant. In particular we studied the effect of rotational velocity, plate design, net power, and number of passes on pulp properties for pulps with different initial Canadian standard freeness. In addition we measured the gap between the plates for each trial condition.
In the first step of the correlation procedure, a closure relationship is developed in which we can relate the net power to operational variables such as gap, flow rate, and rotational speed. The closure relationship was based upon a traditional dimensional analysis and the key-finding here is that the net power is inversely proportional to gap. In the second stage of the process, we relate operational variables to two key pulp properties, i.e. the fibre length distribution and the Canadian standard freeness. In the third stage, we follow the method given by Forgacs and show that paper properties such as tensile strength, burst and tear, scale with fibre length distribution and freeness.
Using this procedure, we can relate operational variables directly to paper properties. To highlight this we demonstrate a non-monotonic relationship between gap and tensile strength and show how to maximize tensile strength.
2B5 Ozonation of TMP – Part II – Interstage treatment of primary pulp in a dedicated reactor.
Jean-Noël Cloutier, - Hydro-Québec, Shawinigan, Québec, Canada
Robert Lanouette, Centre intégré en pâtes et papiers de l’UQTR, Trois-Rivières, Québec, Canada
Michel Epiney, Air Liquide Canada, Boucherville, Québec, Canada
Québec pulp and paper industry consumes about 20 TWh/y with close to 50% for the thermomechanical pulp (TMP) sector. A few percent reduction in refining energy translates in substantial unloading of the Hydro-Québec distribution network contributing significantly to achieve the objective of the energy savings program. The ozonation of TMP also represents an attractive opportunity for pulp property improvement allowing the use of less-desired species.
Primary TMP was treated in a dedicated reactor with 2% ozone charge. The energy savings were more moderate than the results obtained with direct injection in the secondary refiner. The effect of ozone on mechanical/ optical properties and fibre properties were investigated for Birch, Jack Pine and Black Spruce pulp.
An important economical aspect of ozone treatment is the possibility of kraft chemical pulp partial substitution with ozonated TMP pulp. Results showed that a significant fraction of kraft pulp could be substituted if tear is not a main concern for the mill.
TMP ozonation technology addresses two urgent needs of the industry: energy savings and less expensive fibre source. Its implementation could contribute to improve the positioning of TMP manufacturers in the world market.
2B5 Sommaire – Ozonisation de la PTM - Partie II – Traitement interstage de la pâte primaire dans un réacteur dédié.
L’industrie des pâtes et papiers du Québec consomme environ 20 TWh/an pour la transformation de la matière ligneuse du bois en une pâte de fibres, et pour la fabrication du papier. Le secteur de fabrication des pâtes thermomécaniques (PTM) utilise à lui seul près de 50% de cette consommation affectée aux étapes de raffinage, soit environ 12 TWh/an. Une réduction de l’énergie de raffinage de quelques pourcents se traduit par une baisse de charge substantielle sur le réseau d’Hydro-Québec permettant de contribuer significativement à l’atteinte des objectifs du programme d’économie d’énergie. L’ozonisation de la PTM représente une opportunité intéressante tant au point de vue de l’économie d’énergie qu’au point de vue de l’amélioration de la qualité de la pâte et la revalorisation des espèces de bois sous-utilisées.
Nous avons soumis de la pâte primaire à un traitement à l’ozone dans un réacteur dédié en appliquant une charge de 2%. Les économies d’énergie ont été plus modestes comparé aux essais par injection directe dans le raffineur secondaire. L’effet de l’ozonisation sur les propriétés mécaniques et optiques ainsi que les caractéristiques de la fibre a été étudié pour les espèces suivantes : bouleau, pin gris et épinette noire.
Un aspect économique important du traitement à l’ozone est la possibilité de substituer la pâte kraft avec de la TMP ozonisée. Les résultats indiquent qu’une fraction importante de pâte kraft peut être remplacée si la déchirure n’est pas critique. L’ozonisation de la pâte mécanique peut répondre aux deux besoins les plus pressants de l’industrie : la réduction de la consommation énergétique (électricité) et la substitution de fibres de bois résineux. Son implantation pourrait contribuer à améliorer la position des producteurs de pâtes et papiers du Québec.
2B6 Utilizing BC Feedstocks in Lignol's Biorefining Platform for Renewable Fuels and Chemicals
Gurminder Minhas, Lignol Innovations
Worldwide concerns around the effects of climate change, the desire to reduce greenhouse gas emissions and reduce dependence on fossil based energy have increased the interest in products derived from renewable resources. Government targets for renewable fuels, fundamental concerns around limited fossil fuel resources and the effects of GHG emissions are driving unprecedented demand for renewable fuel (ethanol) in North America. To meet this demand, new technologies are required which can convert readily available biomass to cellulosic ethanol and biochemcials, which will displace traditional gasoline and petrochemicals.
Lignol, a BC based technology company is commercialization its patented biorefining technology to produce ethanol and biochemcials from cellulosic biomass. The technology is currently being demonstrated at Lignol’s Biorefining Technology Development Centre and is widely regarded as one of the most promising cellulosic ethanol solutions under development. Lignol’s facility in Burnaby employs 50 highly skilled people, primarily consisting of scientist, engineers and technologists, most of whom are graduates from local Universities and Institutions. Lignol’s industrial pilot plant is a complete “end to end” biorefinery capable of processing 1 tonne per day of biomass and is operated in multi day campaign on feedstock from within the province.
Session 3A – CONTINUOUS IMPROVEMENT
3A1 Multivariable Control and Production Optimization of Paper Machines
Stephen Chu, Johan Backstrom, Honeywell, North Vancouver
With dryer limited paper machines, operations always find it a challenge to achieve the maximum production rate without disturbing paper quality and runabilty. Further, this optimization is performed in an ad-hoc manner thus producing results inconsistently from shift to shift.
This paper examines production optimization using model predictive control technology with an optimization layer that automatically drives the process towards maximum production while honoring hard process and quality constraints. The studied paper machines include a tissue machine and a linerboard machine using the same model predictive control techniques.
3A2 Multivariable CD Control of Fine Paper Machine Using Multiple MPC Controllers
Amor Lahouaoula, Honeywell, North Vancouver
Paper quality has greatly benefited from the application of multivariable cross direction (CD) controls. There are, however, some complex control scenarios that require advanced implementations of CD multivariable control. Fine paper, where it is typical to have multiple scanners to measure critical parameters such as size press moisture and reel caliper variability, is an excellent example of a challenging and complex control opportunity. The challenges can be handled by using three multivariable MPC controllers. The first MPC controller can be configured to minimize the reel dry weight and reel moisture variability by coordinating the slice lip actuators and rewet shower actuators. The second MPC controller can be configured to minimize the size press moisture variability by coordinated control of the steam shower actuators. The third MPC controller can be configured to minimize the reel caliper variability by coordinated control of induction heating systems with feed-forward from the steam shower and rewet shower actuators. This configuration has the advantage of giving the induction heating system forewarning of set-point changes from both the steam and rewet shower actuators that may adversely affect the caliper profile. This paper provides details of this multivariable CD control approach and the results achieved in terms of reel dry weight, size press moisture and caliper spread reductions, when compared to the traditional CD control.
3A3 Continuous inline fiber quality measurement and prediction of sheet quality potential
Fadi Nohra, Lorentzen-Wettre, Canada
Increasing demands to produce uniform high quality products at minimal cost require better monitoring of the process. Many advanced control strategies are based on in-direct measurements. A more direct strategy, where the fiber morphology and the resulting sheet properties are linked directly to the process, has several advantages. This paper discusses a new device, an in-line fiber quality transmitter, which measures fiber morphological characteristics on a continuous basis at frequencies, which are 10-50 times higher than existing sampling devices. The high sampling rate allows us to control both short and long term variation. Physical models based on data from the quality transmitter are utilized to determine pulp drainage and important physical property characteristics. The laborious and time-consuming intermediate stages of hand sheet preparation are bypassed. The advanced software residing in the transmitter creates a “virtual hand sheet” and then proceeds to calculate important sheet quality parameters very
rapidly. Engineering principles like FEM calculations are used. The calculated parameters include pulp freeness, drainage time, density, strength, as well as user defined properties. The paper is concluded with results from mill installations.
3A4 HS-480; a New Fine-fibred High-cedar Containing Pulp Prepared in a Continuous Digester
Paul Watson, Ranbir Heer & Gerry Pageau, Canfor Pulp LP & Howe Sound Pulp
Market kraft pulp prepared from chip furnishes which predominate in fine-fibred western red cedar (WRC), are highly prized globally in high value end-use applications. Consequently WRC-containing pulps generally command a market premium. The production of WRC-containing pulps exceeding 50% is generally confined to batch pulping systems owing to low wood density, low pulp yield, corrosivity of the black liquors and, most importantly, significant issues with chip movement in continuous digesters. To overcome the production issues we developed a new pulp grade comprising WRC mixed with a unique coastal species which exhibits a similar fibre properties distribution to WRC, yet the chip blend is much higher in basic density which alleviates digester operation issues. Laboratory cooking and bleaching led to a mill trial which confirmed the WRC-like quality of this new HS-480 grade.
3A5 Effectively Bombing Filaments in Activated Sludge
Vince Martell – Slave Lake Pulp, Rick Marshall – Marshall Environmental Training & Consulting Group
Many activated sludge treatment plants experience periodic filamentous bacterial growths causing sludge settling issues and sometimes foaming problems. These situations can lead to effluent compliance problems. Short-term filament control practices typically involve using hypochlorite (more common) or hydrogen peroxide. Success in using these chemicals involves adding them to the RAS line at the proper dosage over 3 to 7 days. This practice works well in systems with shorter hydraulic detention times
(hours) as the biomass gets exposed to the chemical 2-3 times per day. In treatment systems with long multi-day detention times, this strategy does not work as the filaments have time to recover from being exposed to the chemical less than once per day. One strategy used at a 100% Aspen High Yield BCTMP mill was to add large amounts of hypochlorite in a short period of time into the distribution chamber ahead of the aeration basins. By temporarily isolating the organic loading to the treatment plant the mill was able to expose the filaments to a high dosage for 90-180 minutes. The filaments experienced severe damage making it difficult for them to recover and flourish. The mill was able to refine this strategy by using three different addition rates or points to achieve sufficient filament damage and allow them to produce a more normal settling sludge and still maintain effluent compliance.
3A6 Minimizing Final Brightness Variability while Reducing Chemical Consumption in Kraft Bleaching
Alison Rowat, Metso Automation, Norcross, GA; Jessica Paul, NewPage Corporation, Rumford, ME
NewPage Corporation in Rumford, Maine mill installed and calibrated an on-line Kajaani Kappa Q Analyzer to measure Kappa and Brightness after the first Extraction Stage, and Brightness after the D1 stage of their bleach plants with sequence D0 Eop D1. This paper describes how these measurements, along with a predictive and adaptive control strategy reduced brightness variability by over 50% while at the same time reducing consumption of Chlorine Dioxide by 14%.
Session 4A – SUSTAINABILITY, ENERGY AND ENVIRONMENT
4A1 Carbon Risks and Opportunities – The evolving markets and regulations relating to carbon offsets, carbon reporting, and other incentives in Western Canada and how they might affect your mill.
Edward (Ted) C. Bell, Ernst & Young LLP, Vancouver, BC
British Columbia first introduced the Carbon Tax Regulation in 2008. Since that time, there have been many developments in Canada relating to the carbon markets ranging from the Federal government’s Credit for Early Action Program, to the development (or lack thereof) of cap and trade systems such as the Western Climate Initiative, to the creation of a regulated emitters market in Alberta through the Specified Gas Emitters Regulation and the associated Alberta Offset Program, to the new GHG Reporting Regulation in BC and an Emissions Offsets Regulation related to carbon neutral government legislation. This tangled web of regulations presents both opportunities and risks for facilities in the pulp and paper industry. Different facilities will have different risks and opportunities depending on location and level of emissions.
This paper will provide of summary of the main regulations affecting pulp and paper mills (and other types of facilities) in Western Canada with a specific focus on the emission aspects of the mills and how they are affected by the regulations. Real mill examples are provided for both offset projects and regulatory reporting situations, including how to proceed in developing an offset projects, and what needs to be done to ensure your facility is ready for reporting and the associated third party assurance activities for GHG inventories.
4A2 4 way Partnering for Energy Management Success
Stephen Kranz, Domtar, Kamloops
Domtar Kamloops project initiatives starting in 2009 have involved partnerships between four organizations to find the right mix of expertise and capital. Projects focusing on energy management and environmental protection have captured the attention of the partners: FP Innovations, Natural Resources Canada, BC Hydro Power Smart and Domtar Pulp. This presentation describes some of the projects from inception, the process of partnering and the role of each partner.
4A3 Waste Heat Recovery from Existing Simple Cycle Gas Turbine Plants – A Case Study
Randy Bohl, Chinook Engineering
Waste heat recovery from the exhaust of existing simple cycle gas turbine plants is effective for powering new sources of electric generation without new sources of greenhouse gas emissions. This paper discusses two such projects in British Columbia, Canada. Discussed are the project conception, technology selection, regulatory considerations, and initial operation of these plants. Two 4.5 MW Enpower Green Energy Generation Limited Partnership plants are operating adjacent to Spectra Energy Corporation’s natural gas transmission compression facilities at 150 Mile House, BC and Savona, BC. These plants are powered by the gas turbine exhaust heat of previously installed 18.5 MW ISO rated pipeline compressor drives taking an original simple cycle LHV net efficiency from 36.5% to 45.2% at the design point of the Energy Recovery Generation System
4A4 Managing your Energy Business in Real-time
Terrance Chmelyk, NORPAC Controls Ltd.; Barry Hirtz, Canfor Pulp – PGI
Leading pulp and paper companies have recognized that energy is much more than a cost centre. In fact, energy management and cogeneration is a business that can have a tremendous impact on the mill’s overall profitability. Many mills have the ability to cogenerate power and export their electrical energy to the marketplace and, as a result, are entering into longer term, potentially complex buy/sell agreements with the local utilities. This presents a significant challenge in making critical decisions in a timely manner and requires a great deal of real-time economic information in conjunction with the process operating parameters. As a result, the actual achievable profit is not always optimized on a continuous basis. Significant manual intervention occurs as operations personnel are multi-tasking, and trying to make critical process decisions that include:
Adjustment of steam supply to meet process demands
Selection of various possible fuels based on cost and availability
Loading of available boilers based on cost and constraints
Amount of electricity to purchase versus generate
Loading of turbines based on cost, steam availability, and constraints
Response to disruptions and equipment breakdowns.
This paper presents a real-time Energy Management optimization system that is used to reduce the total cost of energy in a integrated pulp and paper mill by automating critical decision making and process adjustment. The Energy Management System (EMS) employs facility-specific business models and to continually manage the energy contract and determine the optimum operating parameters to maximize profitability. Case study results will be presented from a mill in northern B.C.
4A5 A Thermochemical Biorefinery Integration Strategy for Pulp and Paper Mills and the Status and Results of an Operating TCB Pilot Plant
Eric Connor, Dave Newport & Dan Burciaga, Thermochem Recovery International Inc.
TRI (ThermoChem Recovery International) has been commercializing the thermochemical biorefinery platform in the Pulp and paper industry for over four years. The first part of this presentation will be to review the integration of the thermochemical biorefinery platform strategy in a pulp and paper mill and provide an update of two pulp and paper biorefineries currently in engineering design that will use forest residuals and non-merchantable wood as feedstock.
TRI has constructed a biomass gasification process demonstration unit (PDU) at Durham NC. The PDU is designed to process 4 dry tons per day of biomass to syngas. It includes biomass storage and feed, gasification using a proprietary indirectly heated gasification technology, and gas clean-up. The PDU is designed to be integrated to any number of downstream catalytic processes to produce fuels and chemicals. It is currently integrated to Emerging Fuels Technologies (EFT) Fischer-Tropsch(FT) process. A number of trials have been run on various biomass feedstocks producing FT hydrocarbon fuels and chemicals. The second part of this presentation will provide a review the status of the PDU, test results to date and future test plans.
4A6 High Efficiency Fan Retrofits Provide Efficiency, Performance and Reliability Improvements to Power, Recovery and Kiln ID Fans.
David Roberts, Airstream Inc
Green Transformation Project funding has motivated the P&P industry to look for innovative and reliable ways to improve productivity and efficiency in their process systems.
Re engineering of existing fans has been shown to provide significant, cost effective benefits in efficiency, performance and reliability while keeping project ROI’s low and modification time very short.
Results of over 250 upgrade projects have shown that energy reductions of 15% to 50%, for the same performance, can be achieved. Optimizing the aerodynamic and mechanical efficiency of the process fans resulted in additional benefits: reductions of abrasive wear by 50% to 75% and increased reliability due to less build up of dust. Available and saved power has been utilized to increase air flow by up to 30% with existing installed equipment. Most projects allowed reuse of fan housings, bearings, coupling, motor and spare shaft assembly.
This paper will present a number of fan upgrade projects in Pulp and Paper mills.
Ralph Lunn, Zellstoff Celgar
PROGRAM CHAIR
Paul Watson, Canfor Pulp Sales