Value through efficient fibre supply and new pulp mill concepts, Pauliina Tukiainen

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FIBIC Seminar 20.11.2013

FIBIC Seminar 20.11.2013

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  • 1. Value through efficient fibre supply and new pulp mill concepts Pauliina Tukiainen, Program Manager WP Managers: Teemu Teeri, Jari Hynynen, Jarmo Hämäläinen, Herbert Sixta, Tapani Vuorinen, Janne Vehmaa 25.11.2013
  • 2. Strategic research themes & program coverage Intelligent and resource efficient production technologies EffTech: Intelligent and resource-efficient production technologies EffFibre: Value through intensive and efficient fibre supply EffNet: Efficient Networking towards Novel Products and Processes Radically improved resource efficiency FuBio JR2: Future Biorefinery FuBio JR1: Future Biorefinery Future Biorefinery –Joint research 2 FuBio Cellulose: Future Biorefinery – Products from Dissolved Cellulose Customer solutions for the future RAMI: Radical market innovations Finnish Bioeconomy Cluster FIBIC Oy Knowledge platform for new value chains New growth opportunities 25.11.2013 2
  • 3. Value through Intensive and Efficient Fibre Supply (EffFibre) • Value through Intensive and Efficient Fibre Supply program focuses on the competitiveness and quality aspects of forest based raw materials and on development of radically new energy – and resource efficient production technologies for chemical pulp. • The objectives of the EffFibre programme are to – Improve availability raw material, to improve cost-efficiency of wood supply value chain, and to increase the utility value of domestic raw material. – Develop novel fiber production technologies. The main challenges are how to utilize the existing pulp mills more profitably and how to respond to the process modification needs which arise from the new value chains of cellulose, hemicelluloses and lignin based products. Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013 3
  • 4. Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013 4
  • 5. Competitiveness through tailored raw materials Tree breeding • Traditional tree breeding – Scots pine and silver birch: up to 25 % increase in volume in experimental stands – A breeding strategy for decay resistance – State-of-art understanding of lignin polymerization • Gene-based research on transgenic trees in greenhouses – up to 50% higher volume growth compared to control trees – Field trial – pilot experiment established this summer at the UH campus experimental field – TECHNOLOGY CAN BE APPLIED TO DOMESTIC AS WELL AS TROPICAL FORESTRY EffFibre 5
  • 6. The potential of intensive management of Finnish forest resources • Intensive management allows increment of annual removals by over 40 % (85 mill m3) • Target production level of energy wood can be met • 11 mill m3 by recovering only small-size stemwood, logging residues and stumps • more if pulpwood is used for energy Mean annual removals 2010 - 2110 6
  • 7. Profitability of forest management • Intensive forest management improves profitability of forest management by nearly 50%. • There is a large variation between forest centres due to – differences in climate – production potential of forest sites – current structure of forests. • Intensive management provides annually over 11 500 jobs (vs. BAU 7600) in – silvicultural practices – harvesting – long-distance transportation Present values of net incomes by forestry centers 7
  • 8. Potential export value of forest industry products • The potential of intensive management scenario in annual export value of forest industry products is worth of over 10.6 billion euros • BAU scenario produces export value of ca. 8.5 billion euros Annual export value potential of forest industry products 2010 - 2040 8
  • 9. Improved productivity and cost effectiveness of mechanized timber harvesting • Intelligent operator tutoring systems and data visualization tools improve efficiency of wood harvesting • Visualization of more accurate terrain data helps the harvester operator to plan the strip road network. • New geographical information - like Terrain Wetness Index - support planning and execution of harvesting • CAN-bus –based mobility mapping system for harvester to predict soil bearing capacity for the execution of wood forwarding. • Automatic Tree Map System for harvester • Potential savings, 40-70M€/year EffFibre 25.11.201 3
  • 10. Improved productivity and cost effectiveness of mechanized forest regeneration • Automatic planting spot detection system and practices for cost-effective seedling logistics for continuously operating planting machine. • Cleaning with uprooting method was identified to be the most cost competitive mechanized concept for the moment. But anyhow, all other mechanized methods reduce manpower requirements compared to manual methods. • Potential savings, 15 – 20 M€/year EffFibre 25.11.201 3
  • 11. Concept of High-Yield Chemical Pulping Preferred Raw material: Softwood (Pine, Spruce) FT-OD EffFibre Herbert Sixta = Flow-through O-delignification 11
  • 12. High alkalinity cooking (HA) Tot Yield, % odw Two-stage kraft oxygen-alkali pulping process 70 HA-PS 60 Refere nc + 11.7 % e 50 14 12 10 8 GGM stabilization and Xylan solubilization. 7-11,7 % yield increase Lignin, % od pulp Transfer to commercial scale Challenge for equipment suppliers constant EA, high L:S Novel CSTR-O-stage Selective K-removal from 60 to 15 feasible, while preserving yield advantage from cooking Separation into hemi-rich and lignin-rich fractions in high yields. Re-precipitation in O-stage to be optimized Utilization of dissolved polysaccharides EffFibre Herbert Sixta
  • 13. Virtual Chemical Pulping model • Novel tool for understanding the behavior of wood chips and their constituents in a wide variety of chemical conditions. • The first phenomenological model for chemical pulping at molecular level • Molecular level reactions for chemical compounds & structures (lignin and polysaccharides) • Mass transfer, kinetic and thermodynamic models • Chip scale mass transfer • Digester hydrodynamics • In-depth knowledge on the existing and possible new cooking processes. • Model enables to explore modifications and development ideas related to chemical pulping. EffFibre 25.11.2013 Tukiainen
  • 14. Pulp mill concepts • • 25.11.2013 Comprehensive techno-economical evaluations of entire industrial concept cases The applied research on unit operations of high kappa pulping paths way to the piloting and industrial demonstration of more effective high kappa pulping technology. Pauliina Tukiainen • • The results of the pulp mill concepts provide a solid basis for further development towards new industrial solutions, generating value and new business opportunities for the industry. Pulp mill concepts – Two-stage kraft oxygen-alkali pulping process – New Reinforcement Pulp manufacturing concept (URMAS) – Sulphur lean concept – Lignin separation cooking concept – Energy mill concept (EneMi) – High yield nucleophile cooking – H2O2 boosted cooking
  • 15. Competence impacts & networking • Annual EffTech/EffFibre/EffNet Seminar • Over 20 Thematic workshops and seminars organized • Over 50 International Conference presentations and posters • 30 scientific publications (peer reviewed) • 14 MSc thesis finished • 15 PhD thesis ongoing • Networking within Finland and expanded international cooperation – Short and long term research visits – Student exchange – The collaboration with research groups EffFibre 15
  • 16. Impact of the results Intensive forestry – more efficient production of forest-based raw materials – Intensive forest management would dramatically improve the profitability of forestry in Finland. Potential for up to 50 per cent increase in harvesting. – Technological solutions to improve productivity and cost effectiveness of mechanized timber harvesting and forest regeneration. – New opportunities for tree breeding. Up to 50% higher volume growth. Modern pulp mill is an efficient biorefinery – Profitable pulp mills enable renewal: Novel Two-stage Kraft Oxygen-alkali Pulping Process has potential for 7-10% yield increase – Techno-economical and phenomenon modeling has given tools for developing new pulping and bio refinery process concepts. The results provide a solid basis for further development towards new industrial solutions, generating value and new business opportunities for the industry. EffFibre 25.11.2013 Pauliina Tukiainen
  • 17. Acknowledgements Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013 17