Experiences on mill scale with enzymes

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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
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Content

• Introduction Smurfit Kappa Roermond Papier
• Fluctuations long term
• Fluctuations short term
• The effect of enzyme treatment on the paper
  production performance
• Conclusions

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Introduction Smurfit Kappa Roermond Papier
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Production facilities Europe

• Operations
• Mills/Depots (42)
• Solid Board (14)
• Paper Sacks (13)
• Corrugated Plants (230)
• Graphic Board (2)
• Specialities (15)
• Generating employment for approx. 34,000

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(No Transcript)
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Mill key information

• 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

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Logistics 2006

• 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

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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 4,750 m3/day 130,000 civil
  equivalent

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Kappa Roermond Papier
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Evolution of the recovered paper utilisation and
the recycling rate in Europe (CEPI 2002)
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Price fibres
(

)
average 2003
300
250
200
Virgin Fibre
150
100
50
Recycled Fibre
0
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Effects of recycling

• Fibre damage
• Change in physical properties
• Change in surface properties
• Accumulation of additives

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Fibre damage

• Fibre shortening
• Minor influence
• Creation and accumulation of fines
• Great influence on process and product

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Identification of fine particles inrecycled
fibre pulp
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Identification of fine particles inrecycled
fibre pulp
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Identification of fine particles in recycled
fibre pulp
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Ash content Mixed (PM2)
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Ash content Mixed (PM2)
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Ash content Mixed (PM2)
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Ash content Mixed (PM2)
22
20
18
?
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Asch content ()
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Germany
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10
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1970
1975
1980
1985
1990
1995
2000
2005
2010
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Fines in head box
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Examples Paper properties
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Examples Paper properties
Specifications
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Examples Paper properties
Excess of raw material/additives
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Energy consumption
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Energy consumption
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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

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Influence of enzymes (cellulase) ondewatering
speed
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Prevention - Compression refining
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Washing
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Sustainable paper production in the future

• Zero emission strategy

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Raw Material Recycled Paper

• 94 Paper fibre
• 5 Organic material
• 1 Inert, inorganic material (metal, glass, sand
  etc.)

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Upgrading Recycled Paper

• Fluting Testliners
• Secondary fuel - Rofire

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Process Scheme
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The Rofire Rational

• Better use of valuable raw materials
• Advanced separation process
• Useful, new product with good market conditions

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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

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Rofire and the Economics

• Rofire average price 15 /ton
• Equivalent coal 50
• Equivalent natural gas 90
• CO2 reduction

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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.

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Return of investment

• Savings on reject costs
• 4.000.000,- a year
• A pay-back of 2 years on the described
  installation
• Based on landfill costs of 160,-/tonne
  (Netherlands 2003)

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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.

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A paper mill has different costumers, depending
on the point of view
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Core competence from different views