Head Engineering AB White Papers

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