HEAD Engineering AB Complete project delivery for the process industry
About Established 1982. Located in Gamla Stan, Stockholm, Sweden.
Business model: Propriety technology. Turnkey process plants & process equipment. Engineering services. • Technical consulting, Feasibility studies, Project management, EPCm, Commissioning and Training. Scope of services: From conceptual design To turnkey process plants.
Technology overview The Pinola technology platform provides sulfate (kraft) pulp mills with a seamless solution for clarifying black liquor,soap managementand production of to high quality crude tall oil.
Efficient separation of soap and suspended solids from black liquor, producing a clarified black liquor and a concentrated tall oil soap.
Produces high quality crude tall oil (CTO) with high yield.
Technology overview
Technology overview
BLiSS
TOPP
UNIT 11: Clarification
UNIT 12: Purification
UNIT 20: Conditioning
UNIT 27 Solids removal
UNIT 24: Gas Scrubbing
UNIT 26: CTO Cooling
UNIT 21 Acidulation
UNIT 22 Separation
UNIT 25: CTO Drying
BLiSS Light UNIT 12: Purification
UNIT 23: Acid Water Neutralization/CIP
Technology overview Existing tank soap separation system
Soap mechanically skimmed from top of the tank. Soap with entrained black liquor Black liquor feed 20-30% DS 15-40g TO/kg DS 0,06% solids
Black liquor 4-10 g TO/kg DS
Solids accumulated at bottom of the tank
Soap skimming tanks
Technology Overview BLiSS system Black liquor return Black Liquor feed 20-30% DS 15-40g TO/kg DS 0,06% solids 85 m3/hr. *
* Trial underway to increase flow to 100 m3/hr
High Speed Centrifugal Separator
Soap
Soap buffer tank Clarified Black liquor < 1g TO/kg DS
Suspended Solids
Concentrated soap (â&#x2030;Ľ 60% TO)
High Speed Centrifugal Separator
To heavy black liquor tank
Scaleable Technology BLiSS system Black liquor return Black Liquor feed 20-30% DS 15-40g TO/kg DS 0,06% solids 85 m3/hr.*
High Speed Centrifugal Separator
Soap
Concentrated soap (â&#x2030;Ľ 60% TO)
* Trial underway to increase flow to 100 m3/hr 85 m3/hr.
Soap buffer tank Clarified Black liquor < 1g TO/kg DS 85 m3/hr.
Suspended Solids
High Speed Centrifugal Separator
To solids tank or heavy black liquor stream
Technology overview BLiSS Light system
Concentrated soap (â&#x2030;Ľ 60% TO)
Black liquor return
Black liquor 150-400g TO/kg DS
Black liquor feed 20-30% DS 15-40g TO/kg DS 0,06% solids
Black liquor flow X/10 m3/h
High Speed Centrifugal Separator
X m3/h Soap skimming tanks
Solids To recovery boiler Black liquor 4-10 g TO/kg DS To evaporators
Technology field trials Field trials conducted at BillerudKorsnäs, Gruvön mill, Sweden October 2009: 3m3/hr black liquor
Test No.
Flow m3/hr
Feed before BLiSS Black liquor
1 1 2 2
Results after BLiSS Black liquor Soap Black liquor Soap
1.5 1.5 2.5 2.5
BL DS (%)
g TO / kg BL DS
g TO / kg soap
22.5
13.8
-
-
0.9 0.9 -
642 603
Technology field trials Field trials conducted at BillerudKorsnäs, GruvÜn mill, Sweden April & May 2011: Average black liquor flow c:a 70m3/hr
Technology field trials 3 Phase Separation Concentrated soap (diluted with water)
Removed suspended solids
Clarified black liquor
Technology field trials Key Field Trial Results (extract from report) Sample ID
Date
1
Time
Sample Location
Black liquor flow rate (m3/h)
g TO / kg BL DS
2011-04-15
Feed
72
7,7
2
2011-04-15
After separator
72
0,7
5
2011-05-02
19:10
Feed
62
5,48
6
2011-05-02
21:10
After separator
68
1,71
B
2011-05-03
21:30
Feed
5,51
A
2011-05-03
21:30
After separator
1,51
C
2011-05-04
07:15
Feed
9,39
D
2011-05-04
07:15
After separator
1,99
E
2011-05-04
13:50
After separator
75
1,20
F
2011-05-04
15:00
Feed
73
8,39
G
2011-05-04
15:05
After separator
73
1,29
0,7 g TO / kg DS < Black Liquor < 1,99 g TO / kg DS (i.e. c.a: 70 - 90% reduction of g TO/ kg BL DS)
Technology field trials Acidulated soap separation efficiency 250ml to 200ml in ~1hr
â&#x20AC;?BLiSSedâ&#x20AC;? soap
Tank separated soap
250ml to 230ml in ~1hr
Field trials: Separation Times ml CTO = f(time)
ml CTO 100 90 80 70 60
1. GN okt 2009
50
2. SS okt 2009
40 30 20 10 0
Time, min 0
20
40
60
80
100
120
140
160
180
Technology field trials Work on a full scale field trial was started in October 2012 at BillerudKorsnäs, Gruvön mill, Sweden. The black liquor flow will be c:a 100m3/hr.
The trial received financial support from the Swedish energy agency as well as from the stake holders, BillerudKorsnäs and Alfa Laval. The trail is expected to be completed by the end of May 2013
Key process metrics TANK SYSTEM
PINOLA BLiSS
RESIDENCE TIME
Days. Scandinavian mills vary from 14 to 31 days. (1)
Minutes. Residence time < 2mins. (2)
SEPARATION EFFICIENCY
Poor. Gravity decantation
Excellant. Centrifugal force. 1g vs > 4000g
BLACK LIQUOR QUALITY
Dirty. Poor separation. Average 4.2g TO / kg BL DS. (3)
Clarified Excellent separation. < 1 g TO / kg BL DS. (2)
SOAP QUALITY
”Aged” due to long residence time. Entrained black liquor.
Fresh soap. Minimal black liquor content.
TO CONTENT IN SOAP
45 – 55% w/w. Average 51%, Scandinavian mills. (4) Estimated 30 000 MT or > 10% of existing Swedish production is lost. (5)
≥ 60% w/w. (2) ≥ 10% higher yield of TO from black liquor to the tall oil production plant. (2)
SUSPENDED SOLIDS
Builds up in tanks. In black liquor to the evaporator. In soap to the splitting plant.
Majority removed in a separate stream.
(1) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008, tabel 4.1. (2) Source: Field trials May 2011, BillerudKorsnäs, Gruvön, Sweden. (3) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008, Fig 3.6 (4) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008 Attachment B & C (5) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) 1078 Nov 2008, Executive summary. .
Summary of Benefits 1.
Removed suspended solids & soap from black liquor I. => reduced scaling at the evaporators (1) a. => increased availability, reduced downtime b. => increased heat transfer efficiency c. => increased pulp production capacity II.
=> increased capacity at the recovery boiler (1) a. => increased pulp production capacity
III.
=> reduced build up on recovery boiler tubes a. => increased availability, reduced downtime b. => increased heat transfer efficiency
2.
More soap recovered from black liquor I. => increase in CTO recovery.
3.
Less black liquor in soap I. => reduced chemical usage during CTO production.
4.
Well homogenised soap I. => easier separation after acidulation a. => increased CTO production yield.
(1) Tall Oil Soap Recovery. C. Douglas Foran, Arizona Chemical Company. 7th Dec 2006.
TOPP Tall Oil Production Plant
UNIT 20 Conditioning
Technology overview
UNIT 27 Solids removal
UNIT 24 Gas Scrubber
UNIT 21 Acidulation
UNIT 22 Separation
UNIT 23 Acid Water Neutralising/CIP
UNIT 25 CTO Drying
UNIT 26 CTO Cooling
TOPP Tall Oil Production Plant
Technology overview Unit 20
Unit 21
The Pinola TOPP solution is a modernisation of the Alfa Laval Celleco tall oil plant which utilises a high speed centrifugal separator.
Unit 27
Unit 22
Steam injector
Unit 23
Unit 24
Unit 25
Unit 26
TOPP Tall Oil Production Plant
Benefits & Performance guarentees
The technology improvements offered by the Pinola TOPP solution include:
The performance guarantees achieved by the Pinola TOPP solution:
1.
Higher CTO yield
1.
CTO recovery yield > 97%
2.
Higher CTO quality.
2.
Water content < 1 %
3.
Reduced acid consumption
3.
Ash content < 0,2%
4.
Improved pH control
4.
Max. Temp 70 deg C
5.
Continuous & fully automated
5.
H2S gas to atmosphere < 20ppm
6.
Cleaning In Place system
6.
7.
Closed system. No H2S gas leakage.
Highest possible acid number. No acid number degradation due to the short residence time.
8.
Lower installed power
TOPP Tall Oil Production Plant Södra Cell mill Värö Sweden, capacity 5MT CTO / hr. Commissioned April 2012.
Reference plant
TOPP Tall Oil Production Plant
Reference plant
TOPP Tall Oil Production Plant
Reference plant
TOPP Tall Oil Production Plant
References
Swedish & Finnish mills that have a CTO plant based on the high speed centrifugal separator technology. The plants are of the Alfa Laval Celleco design unless noted otherwise. 1.
Nordic Paper, Bäckhammar mill
9.
Stora Enso, Kemi mill
2.
BillerudKorsnäs, Gruvön mill
10. Stora Enso, Oulu mill
3.
BillerudKorsnäs, Skärblacka mill
11. Södra Cell, Värö mill (PINOLA TOPP)
4.
Rottneros, Vallvik mill
12. Metsä-Fibre, Äänekoski mill
5.
BillerudKorsnäs, Gävle mill
13. Metsä-Fibre, Kaskinen mill
6.
Mondi, Dynäs mill
14. Domsjö, O-vik mill
7.
Stora Enso, Skutskär mill
8.
Stora Enso, Varkaus mill
Optimum solution
Combined benefits TANK SYSTEMS vs. Pinola Technology Platform: BLiSS + TOPP Soap Separation
Tanks
Pinola BLiSS
Soap content in BL
2.2 – 9 g
< 1g
51% w/w (1)
60% w/w
Entrained black liquor
Minimal black liquor
Tanks
Pinola TOPP
Ave. 85% (1)
> 97%
Chemicals**
130%
103%
Scrubber load
130%
103%
160 max.(1)
167 (2)
-
35.3
Large volume. Hours. Manual.
30mins. Automated.
Long dead time
Fully automated
Tall oil content in soap Tall oil soap quality*
CTO Production Recovery yield
Quality (acid number) Quality (Rosin acid) Cleaning In Place (CIP) Automation
* Fresh soap from BLiSS splits substantially easier than aged soap from tank systems. ** If acidic water is returned back to medium liquor (1) Source: Värmeforsk report 1078 Nov. 2008, Attachment B & C. (2) Source: CTO from fresh soap at BillerudKorsnäs, May 2011
Combined economical benefits Increase in revenue due to increase in crude tall oil production. The Pinola technology guarentees: 1. Increased Tall oil concentration in soap to 60% w/w. 2. Increased CTO recovery yield by 12% w/w (from 85% (1) to 97%). Soap recovered from black liquor Tall oil concentration in soap Tall oil available (kg) CTO recovered from soap CTO (kg)
(kg)
Total increase in CTO production
Tank system 100 51% (1) 51 85% (1) 43,3
PINOLA ( BLiSS + TOPP) 100 60% 60 97% 58,2
~ 34%
Other potential cost savings: (2) 1. 2. 3. 4. 5.
Improved evaporator performance. Improved recovery boiler performance. Maintenance/downtime costs at evaporators. Maintenance/downtime costs at recovery boiler. Reduced chemical costs.
Other potential revenue increase: 1.
Increased pulp production capacity.
(1) Average in Scandinavia: Source V채rmeforsk (Thermal Engineering Research Institure) report 1078 Nov. 2008 (2) Tall Oil Soap Recovery. C. Douglas Foran, Arizona Chemical Company. 7th Dec 2006.
Project References
References
Swedish Energy agency: October 2012 (ongoing) Field Trial. Pinola BLiSS.
Location: BillerudKorsnäs, Gruvön mill, Sweden.
Capacity: 90 ~ 100 m3/hr
Scope: • •
Cooperation between Billerud & Alfa Laval Engineering, Installation, commissioning and operating of BLiSS plant.
Arauco Group: August 2012 Feasibility study. Pinola technology.
Location: Arauco pulp mill, Chile.
Scope: Crude tall oil production.
• • •
Study to upgrade of existing to 3.5 t CTO/hr or new plant Minimise sulphuric acid consumption. Use of sodium sesquisulfate as acidulation media.
Scope: Soap handling system. •
Improvement in black liquor and soap quality.
References
BillerudKorsnäs AB: July 2012 Field Trial. Pinola dynamic tall oil reactor, D-TOR500.
Location: Skärblacka mill, Sweden.
Scope: •
Supply of dynamic tall oil reactor for their field trials.
BillerudKorsnäs AB: July 2012 Supply. Pinola dynamic tall oil reactor, D-TOR500ds.
Location: Gruvön, Sweden.
Capacity: 500tpd
Scope: •
Equipment supply.
Ilim Group: Feb. 2012 Field Trial. Pinola BLiSS 3m3 /hr.
Location: Koryazhma mill, Russia.
Scope: •
Engineering, Trial, Final report.
References
BillerudKorsnäs AB: June 2011 Field Trial. Pinola dynamic tall oil reactor, D-TOR.
Location: Gruvön mill, Sweden.
Scope: •
Supply of dynamic tall oil reactor for their field trials.
Södra Cell AB: June 2011 Pinola TOPP5000. Tall Oil Production Plant.
Location: Värö, Sweden.
Capacity: 5 t CTO / hr
Scope: Turnkey project delivery. • • • •
Engineering. Procurement. Construction management. Commissioning & Handover.
References
Vinnova: April 2011, Field Trial. Pinola BLiSS.
Location: BillerudKorsnäs, Gruvön mill, Sweden.
Capacity: 75m3/hr
Scope: • •
Cooperation between Billerud & Alfa Laval Engineering, Installation, commissioning and operating of BLiSS plant.
SunPine AB: 2010, Production plant: Raw tall Diesel
Location: Piteå, Sweden.
Capacity: 15 t RTD / day
Scope: Consultant engineer: • • •
Process de-bottlenecking. New spray condenser. Trials on tall oil de-salting.
Vinnova: 2009, Field Trial. Pinola BLiSS, 3m3/hr.
Location: BillerudKorsnäs, Gruvön mill, Sweden.
Scope: • •
Cooperation between Billerud & Alfa Laval Engineering, Installation, commissioning and operating of BLiSS plant.
Contributing to a sustainable future !
Sal Passanisi Business Development P: +46 8 50 57 11 25 M: +46 703 573 800 E: sal@head-engineering.se