RECOVERY 2012 – AN INVESTMENT TO GET A MORE ENERGY EFFICIENT AND ENVIRONMENTALLY FRIENDLY SKÄRBLACKA MILL 2013-09-26 Mattias Redeborn

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BILLERUDKORSNÄS IN BRIEF

High performance packaging materials and development of packaging solutions

Sales of approx. SEK 20 billion (Skärblacka 2 billion)

4,400 employees in 13 countries (Skärblacka 640)

BillerudKorsnäs is listed on the NASDAQ OMX Nordic Exchange in Stockholm

OUR THREE BUSINESS AREAS

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PACKAGING PAPER Sack and kraft paper, pulp

CONSUMER BOARD Liquid packaging board, cartonboard

CONTAINERBOARD Fluting, liner

NET SALES: SEK 8.5 BILLION SALES VOLUME : 1,200 KTONNES

NET SALES: SEK 6,1 BILLION SALES VOLUME: 870 KTONNES

NET SALES: SEK 3.1 BILLION SALES VOLUME: 570 KTONNES

OUR PRODUCTION UNITS

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Unit ktons

BEETHAM 45 FRÖVI/ROCKHAMMAR 430 GRUVÖN 685 GÄVLE 700 PIETARSAARI 200 KARLSBORG 300 SKÄRBLACKA 400 TERVASAARI 100 Total 2,860

LATGRAN 400 Total 400

PIETARSAARI

TERVASAARI

GRUVÖN SKÄRBLACKA

KARLSBORG

GÄVLE

FRÖVI / ROCKHAMMAR

BEETHAM LATGRAN

HEAD OFFICE

United Kingdom Latvia

Finland

Sweden

SKÄRBLACKA PROCESS

Wood room

Two fiber lines (batch and continuous digester)

Pulp from batch digester to a bleach plant

Three PMs for kraft pulp and one pulp drying machine

NSSC-digester and a separate PM. Cross recovery.

One evaporation plant, one recovery boiler, green liquor clarifier, white liquor filtration and two lime kilns

BFB power boiler and steam turbine

HISTORY OF SKÄRBLACKA MILL

Pulp production since 1872

1962 A complete new kraft mill and two paper machines was started

1975 New fiber line, paper machine and recovery boiler

1977 Aerated lagoon

1986 Increased pulp production and new pulp dryer

1997 Rebuild of three paper machines and the recovery boiler

1998 New biological waste treatment (LAS)

2000 New wood room

2005 Rebuild of power boiler and new steam turbine

2012-13 Recovery 2012

BEFORE RECOVERY 2012 Above IPPC directive’s requirement for dust emissions (100-200 mg/Nm3)

Energy efficiency below industrial good standard Evaporation plants with 5 and 6 effects Heavy black liquor of 62-64% dry solid content Fossil oil consumption (bark boiler, oil boiler and NCG-incinerators)

Evaporation plant and recovery boiler as bottle-necks for production

High cost for maintenance

RECOVERY 2012 - GOALS

Recovery boiler flue gas dust content according to BAT

Steam consumption in evaporation plant 600 400 MJ/ton

Reduce externally purchased bio fuels with 50%

Increase pulp production (10 000 Adt/y)

Reduce fossil oil consumption

Decrease maintenance cost

Increase availability of recovery boiler (one instead of two washes per year)

Oil boiler out of operation

TECHNICAL SCOPE

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Electro filter Sc

rubb

er

Recovery boiler

Evaporation 1

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Minor parts 1. Firing black liquor tank 2. Moving of loading positions 3. Modified tank farm 4. Gas destruction retrofit 5. Increased power production (turbine) 6. Control room upgrade

Main parts New evaporation plant Recovery boiler upgrade New and retrofitted electro filters New scrubber and stack

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PROJECT HISTORY AND TIME SCHEDULE Several studies 1997, 2004, 2008

Feasibility study October 2010 – May 2011

Environmental permit and ”GO” from board December 2011

Signing of main contracts Nov-Dec 2011

Tie-ins during normal mill shut September 2012 (one week)

Start-up of new ESP December 2012

Start-up of retrofitted ESPs April and July 2013

Start-up of new evaporation plant 2013-05-22

Mill shut for rebuild of recovery boiler 2013-08-31 – 2013-10-07

Start-up of mill and completion of project 2013-10-07

MAIN SUPPLIERS

Electrostatic precipitators; FLSmith

Evaporation plant; Metso Power

Recovery boiler and scrubber; Metso Power

Tanks; ÖMV

Stack; VL Staal

MAIN SUPPLIERS SCOPE OF SUPPLY

Mechanical turn-key with functional responsibility

In-line instruments and control valves included

Steel structures

Not included:

Civil, interconnecting piping, DCS, safety system, electrical and instrumental installation, HVAC

OTHER SUPPLIERS Weak black liquor screen AFT

Medium voltage switchgears ABB

Low voltage MCC Siemens

Transformers Siemens

Medium voltage freq conv and motors Siemens

DCS Siemens

HVAC FTX

Feed water pumps KSB

Process pumps Sulzer and Processpumpar

Control valves Metso automation

Instruments Omniprocess, ABB, Fagerberg, Axel Larsson

Hand valves KSB and Procab

CONSULTANTS AND ENTREPRENEURS

Main consultant Pöyry

Civil design Sweco

Civil project lead/permits Ramböll

Civil Peab

Piping Orab, Caverion

Electrical mounting Bravida

Instrument mounting Caverion

Scaffolding Heab

INSTRUMENTATION

Field instruments according to Profibus PA to get possibility to diagnose status

Instruments in safety system according to 4-20 mA.

Electrical- and instrumental commissioning by BillerudKorsnäs

EVAPORATION PLANT 7 effects

Integrated stripper

Methanol system

Design data: Evaporation amount 500 t/h Heavy black liquor dry solids 75% Stripper capacity 110 t/h

EVAPORATION PLANT

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RECOVERY BOILER New boiler ceiling

New primary superheater

Rebuilt secondary superheater

New water screen

New economizer 5

New air system (secondary+tertiary)

New liquor system with six guns

New ash mixing tank

New oil burners

Dissolving tank off-gases to tertiary air

Rebuilt ash transportation system

New feed water pumps

RECOVERY BOILER PERFORMANCE

Dry solids flow 2060 tds/d

Steam temperature 470ºC

Steam pressure 56 bar(g)

BIOLOGICAL WASTE TREATMENT

How would the waste treatment (LAS) manage a 37 day mill stop?

LAB test during spring 2013 according to SBR (Sequence Batch Reactor)

Same environment and performance as in LAS was established in 10 l reactors

Parameters studied TOC reduction Microscopy Phosphorus Odour

LAB TESTS

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No liquor addition

No air

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No liquor addition

Aeration

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NSSC-liquor last 7 days

Aeration

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NSSC-liquor continously

Aeration

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Minor NSSC-liquor continously

Aeration

6. Reference

Sköts som LAS

6,4 ton TOC/d 1,5 ton TOC/d 0,75 ton TOC/d 12 ton TOC/d

All five reactors performed well and quite similar

Reactors with large liquor addition showed lower TOC-reduction at start-up

Best result if no liquor was added and reactor was aerated

TANK EMBANKMENT

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Environmental permit requires new tanks to be embanked

2,4 m high concrete wall

3400 m3

LESSONS LEARNED

Closer cooperation between civil design and other disciplines

Retrofit of equipment requires time on site

Civil and piping in same 3D-model

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