value through efficient fibre supply and new pulp mill concepts, pauliina tukiainen
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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
Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013
Knowledge platform
for new value chains
New growth
opportunities
Radically improved resource efficiency
Intelligent and resource efficient production technologies
Future Biorefinery
Customer solutions for the future
FuBio JR1: Future Biorefinery
EffTech: Intelligent and
resource-efficient production
technologies
FuBio JR2: Future Biorefinery –Joint
research 2
EffFibre:
Value through intensive and efficient fibre supply
EffNet: Efficient Networking towards Novel Products and
Processes
FuBio Cellulose: Future Biorefinery – Products
from Dissolved Cellulose
RAMI: Radical market
innovations
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
4 Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013
EffFibre
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
5
Competitiveness through tailored raw materials
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
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
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
EffFibre
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
25.11.2013
EffFibre
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
25.11.2013
EffFibre
Concept of High-Yield Chemical Pulping
11
Preferred Raw material: Softwood (Pine, Spruce)
FT-OD = Flow-through O-delignification
Herbert Sixta
EffFibre
Two-stage kraft oxygen-alkali pulping process
GGM stabilization and Xylan
solubilization. 7-11,7 % yield
increase
High alkalinity
cooking (HA) 14 12 10 8
50
60
70
T
ot Y
ield
, %
od
w
Lignin, % od pulp
HA-PS
Reference + 11.7 %
Challenge for equipment suppliers
constant EA, high L:S Transfer to
commercial scale
Selective K-removal from 60 to 15
feasible, while preserving yield
advantage from cooking
Novel
CSTR-O-stage
Separation into hemi-rich and
lignin-rich fractions in high yields.
Re-precipitation in O-stage to be
optimized
Utilization of dissolved
polysaccharides
Herbert Sixta
EffFibre
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.
25.11.2013 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
• 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.
Pulp mill concepts
25.11.2013 Pauliina Tukiainen
EffFibre
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
15
EffFibre
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.
25.11.2013 Pauliina Tukiainen
17
Acknowledgements
Finnish Bioeconomy Cluster FIBIC Oy 25.11.2013
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