Experiences on mill scale with enzymes
Final Seminar of Subproject 3 of ECOTARGET
Tuesday 1 April, 2008
at STFI-Packforsk
Ir. Loud van Kessel
Senior Process Engineer
Smurfit Kappa Roermond Papier
Content
 Introduction Smurfit Kappa Roermond Papier
 Fluctuations: long term
 Fluctuations: short term
 The effect of enzyme treatment on the paper production performance
 Conclusions
2
Introduction Smurfit Kappa Roermond Papier
Production facilities: Europe
Operations
Finland
 Mills/Depots (42)
 Solid Board (14)
Russia
 Paper Sacks (13)
Lithuania
 Corrugated Plants (230)
 Graphic Board (2)
Czech Republic
Slovakia
 Specialities (15)
Switzerland
 Generating employment for
approx. 34,000
4
5
Mill key information
6
 Products
Testliners, fluting and chip (Schrenz)
 Customers
Packaging industry
 Production
525,000 ton/year paper
testliner
: 100 - 220 grs/m²
fluting
: 105 - 180 grs/m²
chip
: 90 - 140 grs/m²
15 kt/year Rofire
 Paper machines
3
 Employees
260
Logistics 2006


7
Recovered paper is main raw material

consumption + 570,000 ton/year (22 % of NL)

+ 11,000 tons/week

delivery + 85 lorries/day

stocks: + 3 weeks of production

max. stock capacity 30,000 ton
Produced paper

+ 525,000 ton / year

shipment: + 75 lorries / day

max. stock 18,000 ton
Utilities 2006
 Energy usage
160,000 MWh
 Own power plant
4 turbines 14 MW
producing 114,000 MWh
35,000 household equivalent
 Gas
89 million m3/year
45,500 household equivalent
 Civil water usage
169,000 m3/year
3,550 person equivalent
 Water treatment
8
4,750 m3/day
130,000 civil equivalent
Kappa Roermond Papier
9
Evolution of the recovered paper utilisation
and the recycling rate in Europe (CEPI 2002)
Utilisation
45
56%
40
54%
35
52%
30
50%
25
48%
20
46%
15
44%
10
42%
5
40%
0
38%
1991
10
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
Recycling rate
R.P. Utilisation (Million tonnes)
Recycling rate
Price fibres (€ )
average 2003
300
250
200
Virgin Fibre
150
100
50
Recycled Fibre
0
11
Effects of recycling
 Fibre damage
 Change in physical properties
 Change in surface properties
 Accumulation of additives
12
Fibre damage
 Fibre shortening
 Minor influence
 Creation and accumulation of fines
 Great influence on process and product
13
Identification of fine particles in
recycled fibre pulp
Fibre chunks
14
Identification of fine particles in
recycled fibre pulp
Fibre fibrils
15
Identification of fine particles
in recycled fibre pulp
Ash
16
Ash content Mixed (PM2)
22
20
Asch content (%)
18
16
14
12
10
8
6
1970
17
1975
1980
1985
1990
1995
2000
2005
2010
Ash content Mixed (PM2)
22
20
Asch content (%)
18
16
14
12
10
8
6
1970
18
1975
1980
1985
1990
1995
2000
2005
2010
Ash content Mixed (PM2)
22
20
Asch content (%)
18
?
16
14
12
10
8
6
1970
19
1975
1980
1985
1990
1995
2000
2005
2010
Ash content Mixed (PM2)
22
20
Asch content (%)
18
?
16
14
Germany
12
10
8
6
1970
20
1975
1980
1985
1990
1995
2000
2005
2010
Fines in head box
Fines in headbox
0,58
0,57
0,56
Fines (%)
0,55
0,54
0,53
0,52
0,51
0,50
0,49
16-10-06
20:24
21
16-10-06
21:36
16-10-06
22:48
17-10-06
0:00
17-10-06
1:12
17-10-06
2:24
17-10-06
3:36
17-10-06
4:48
17-10-06
6:00
17-10-06
7:12
17-10-06
8:24
Examples: Paper properties
Berst and SCTd of Fluting 105 grs
1,9
340
1,85
1,8
1,75
300
280
1,7
Berst
SCTd
1,65
1,6
260
1,55
1,5
240
1,45
220
5-jan
22
1,4
5-jan
5-jan
5-jan
6-jan
6-jan
6-jan
6-jan
6-jan
7-jan
7-jan
SCTd (kN/m)
Berstpressure (kPa)
320
Examples: Paper properties
Berst and SCTd of Fluting 105 grs
1,9
340
1,85
1,8
1,75
300
280
1,7
Berst
SCTd
1,65
Specifications
1,6
260
1,55
1,5
240
1,45
220
5-jan
23
1,4
5-jan
5-jan
5-jan
6-jan
6-jan
6-jan
6-jan
6-jan
7-jan
7-jan
SCTd (kN/m)
Berstpressure (kPa)
320
Examples: Paper properties
Berst and SCTd of Fluting 105 grs
1,9
340
1,85
1,8
1,75
300
280
1,7
Berst
SCTd
Excess of raw
material/additives
1,65
1,6
260
1,55
1,5
240
1,45
220
5-jan
24
1,4
5-jan
5-jan
5-jan
6-jan
6-jan
6-jan
6-jan
6-jan
7-jan
7-jan
SCTd (kN/m)
Berstpressure (kPa)
320
Energy consumption
150
100
kg steam / ton
50
0
week
nr.
-50
10
20
30
40
50
8
18
28
38
48
-100
-150
-200
2003
-250
25
2004
2005
5
15
25
Energy consumption
150
100
kg steam / ton
50
0
week
nr.
-50
250 kg steam per ton
10
20
30
40
50
8
18
28
38
> 5 Euro per ton
48
-100
-150
-200
2003
-250
26
2004
2005
5
15
25
Enzymes
 Improved drainability and porosity without strength loss and without
significant loss of mass
 Increased relative bonded area, flexibility and fibrillation without affecting
fibre length
27
Influence of enzymes (cellulase) on
dewatering speed
Increase of the dewatering speed (%)
Influence of enzyme activity on the dewatering speed
25%
20%
15%
10%
5%
0%
0
5
10
15
20
25
Time (min)
28
30
35
40
45
Prevention - Compression refining
Beating degree development
45
o
Beating degree [ SR]
40
35
Speed difference
in PFI-mill [m/s]
30
2
6
12
25
20
15
10
5
0
0
1000
2000
3000
4000
PFI revolutions
29
5000
6000
7000
Washing
Effect of washing on refining curves
Results pilot scale trials
40
Tensile Index [Nm/g]
35
30
25
20
15
Maximum washed (21% loss, 7.4% Ash)
10
Minimum washed (7% loss 14% Ash)
5
Mixed Waste Reference (17% Ash)
0
20
25
30
35
40
Beating degree [0SR]
30
45
50
55
Sustainable paper production in the future
Zero emission strategy
Raw Material Recycled Paper
32
 94%
Paper fibre
 5%
Organic material
 1%
Inert, inorganic material
(metal, glass, sand etc.)
Upgrading Recycled Paper
 Fluting + Testliners
 Secondary fuel - Rofire®
33
Process Scheme
34
The Rofire® Rational
 Better use of valuable raw materials
 Advanced separation process
 Useful, new product with good market conditions
35
Rofire® and Environment (1)
Roermond
 30,000 tonnes less waste disposal p.a.
 16,000 Rofire® p.a.
 12,000,000 m³ natural gas p.a.
 Biomass content 50%
36
Rofire® and the Economics
 Rofire® average price 15 €/ton
 Equivalent coal 50 €
 Equivalent natural gas 90 €
 CO2 reduction
37
Rofire® and Environment
Europe
 1,300,000 tonnes less waste disposal p.a.
 700,000 tonnes Rofire® p.a.
 525,000,000 m³ natural gas p.a.
38
Return of investment:
 Savings on reject costs:
€ 4.000.000,- a year*
 A pay-back of 2 years on the described installation
*
39
Based on landfill costs of €160,-/tonne (Netherlands 2003)
Forbonium
 The biology of the water treatment plant at Roermond Papier has a
lack of the element phosphorous: phosphoric acid is used as a
nutrient.
 A food producer in Holland needs to de-phosphorize baby food
products. There is an emission (waste) of a phosphorous
concentrate.
 Both companies invested in a storage and dosing unit in Roermond
to reduce both on variable costs.
40
A paper mill has different costumers,
depending on the point of view:
Core competence from different views:
Customer
Shareholder
Employee
Neighbourhood
Environment
42