suzano pulp and paper mucuri site

Suzano Pulp and Paper

Mucuri Site

2

History

• Paper was invented in China by Tsai Lun A.D 105

• It was introduced in Japan in 610

• In 1150 in Spain

• In 1189 in France

• In 1494 England

• In 1689 in the USA

• In 1798 – invention of continuous paper-making, in France

• In 1803 – Fourdrinier paper-making machine, in Englande

• In 1884 – kraft process in Germany

• In 1911 – First factory with kraft process in the USA

• In 1946 – Bleaching with multple levels

• In 1950 Suzano creats aternatives to imported raw material (DNA innovation)

• In 1961 Suzano starts producing paper in industrial scale with 100% of eucalyptus

History





• In 1494 England









3

History





• In 1494 England









4

START UP

1992 (Pulp - Line 1) > 95% Own

(self-sufficient)

ENERGY CONSUMPTION

1,506 Employees

977 Contractors

1993 (Paper)

2007 (Pulp - Line 2)

Average daily truck movement

Wood – 600

Raw Material - 53

Finished Product - 250

Mucuri UnitMucuri Unit

5

Line 2 (Mucuri Project)

♦ 1st Phase: 2008/2009

� 1.0 million tons - (1.1 million

tons without additional

investments)

♦ 2nd Phase: After 2010

� 1.25 million tons with

investments yet to be defined

Competitive and Profitable GrowthCompetitive and Profitable Growth

Global scale in operationsGlobal scale in operations

6

Installed CapacityInstalled Capacity

TOTAL PULP

PAPER – PRINTING & WRITING

Line 1………………………… 700,000 adt/year

Line 2 ………………………1,000,000 adt/year

MARKET PULP

Line 1…………………………… 500,000 adt/year

Line 2 ………………………… 1,000,000 adt/year

M1 ……………………… …..250,000 t/year

SHEETS – LINE 1

Cutter nr. 1

Cutter nr. 2

Packaging Machine 1

Packaging Machine 2

Baling

100,000 t/year

7

Equipments InstalledEquipments Installed

Final productsFinal products

DRYING – LINE 1

Formation and pressing: Voith

Dryier: Flakt

Cutter: Lamb

Packaging Line: Sunds

Sheet Width: 6m (9 bales)

Capacity: 1,600 Adt/d

Speed: 100 to 180 m/min

DRYING – LINE 2

Formation and pressing: Metso

Dryer: Metso

Cutter: Metso

Packaging Line: Metso

Sheet Width: 9.99 (15 bales)

Capacity: 3,340 Adt/d

Speed: 150 to 250 m/min

PAPER – LINE 1

Formation: Duoformer FM - Voith

Pressing: Tri nip plus fourth press - Voith

Pre-drying: 36 dryers - Voith

Speed Sizer: Voith

Post-Drying: 14 dryers – Voith

Useful sheet width: 7,850m

Speed: 1,200 m/min

Production capacity: 250,000 t/year

8

SHEETS – LINE 1

2 Bielomatik P1185 Cutters Maximum Machine width: 2,220mm

Maximum reel diameter: 1,530mm

Doctor blade maximum grammage: 1,000 gsm

Amount of Unrollers: 6

2 Bielomatik FSW500 Ream PackagersMaximum ream width: 1,000mm

Maximum ream width: 1400mm

Maximum ream height: 80mm

1 Cyklop Baling line

Maximum diagonal pile/stack: 1,700mm


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WOODYARD – LINE 1

BLEACHING – LINE 1

Supplier: Beloit-Rauma and

Andritz

Capacity: 660 m3s/h - 3 chipping lines,

Two with debarking drums

Pile / Autonomy: 52,000 m3 / 2 days

COOKING – LINE 1

Supplier: Metso (Kvaerner)

Process KOBUDO Mari

Digestor with a single vessel, steam phase:

2,200 adt/d

WOODYARD – LINE 2

COOKING – LINE 2

BLEACHING – LINE 2

Supplier: Andritz

Capacity: 840 m3s/h

3 chipping and sieving lines ,with

Stacking and resumption movable system

Circular pile: 94,000 m3 / 3 days

Supplier: Metso

Process: Compact Cooking G2

Cooking steam phase with two vessels: 3,400 adt/d

Supplier: Metso (Kvaerner)

ECF in 4 stages: Dhot D Eop D (PO)

Washing with atmospheric diffusers and press

2,025 adt/d

Supplier: Andritz

ECF in 4 stages: A/D Eop D P, brightness 92 % ISO

Washing with DDWs (drum displacement washer)

3,160 adt/d


Fiber LineFiber Line

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Fiber LineFiber Line

CHLORINE DIOXIDE PLANT – LINE 1

Supplier: LURGI

Capacity:18 ton/d / 54 kA.

Process: Integrated with chlorine dioxide generation,

sodium chlorate electrolysis and hydrochloric acid synthesis

Raw material is chlorine.


Supplier: EKA

Capacity: 25 t/d

Process: EKA Lite – chlorine dioxide from raw material:

sodium chlorate, sulphuric acid and methanol, with sodium

sesquisulfate as by-product, used in the Recovery Boiler.


Supplier: EKA

Capacity: 45 t/d

Process: EKA SCW – with double washing of sesquisulfate

generated as by-product, which reduces consumption of raw

material, specially sulphuric acid.

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Chemical Recovery and UtilitiesChemical Recovery and Utilities

RECOVERY BOILER - LINE 1

STEAM TURBINES – LINE 1

Supplier: METSO

Capacity: 3,200 tss/d of liquor 480 t/h of steam

EVAPORATION – LINE 1

Supplier: APV

Process: Plaques with descending film

Capacity: 580 t/h of evaporation

Final concentration 75%.

RECOVERY BOILER – LINE 2

EVAPORATION – LINE 2

STEAM TURBINES – LINE 2

Supplier: METSO

Capacity: 4,700 tss/d of liquor and 740 t/h of steam

Supplier: Siemens

TG 1: 47 MVA/ 37.6 Mw extraction and counterpressure

TG 2: 47 MVA/ 37.6 Mw extraction and counterpressure

TG 3: 21 MVA/ 16.8 Mw condensation

Supplier: Siemens

TG 4 : 76 MVA/ 60.8 Mw , extraction and condensation

TG 5 : 76 MVA/ 60.8 Mw extraction and

counterpressure

Supplier: Metso

Process: Piping/tubes with descending film

Capacity: 1,100 t/h of evaporation

final concentration 80%.

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Utilities Utilities –– Line 2Line 2

ETAC – Boiler Water Treatment Station

COMPRESSORS

Supplier: Degrémont

Capacity: 360 m3/h

4 reverse osmosis lines

12 x 6 Setup

ETA - Water Treatment Station

Supplier: Degrémont

Capacity: 6,500 m3/h

Aquazur Filter: 10 filters

Supplier: Atlas Copco

Capacity: 5,700 Nm3/h

Quantity: 3 compressors

Pressure: 8 bar

Exempt from oil

COOLING TOWER

Supplier: Vettor


8 cells manufactured in Fire-resistant fiberglass.

Inlet temperature: 45° C

Outlet temperature: 33º C

ETE – Effluent Treatment Station

Supplier: Veolia


Efficiency: 95%

Primary treatment made up of 3 decanters and

2 thickeners.

Settling pond: retention time - 7days

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Industrial UnitIndustrial Unit

Total PulpTotal Pulp

494 587

581

602

578 6

99

1.5

22

664

235 468

408 477

496 577

855

502 578

0

200

400

600

800

1.000

1.200

1.400

1.600

1992 1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008

x 1000 tsa

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Industrial UnitIndustrial Unit

Market Pulp / PaperMarket Pulp / Paper

MARKET PULP

13

22

23

2

31

8

31

8

33

1

35

8

32

9

32

7

39

1

39

3

41

0

39

4

41

7

40

1

47

1

48

7

65

9

0

200

400

600

800

1000

1200

1400

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

PAPER

240

91

161

159 162 2

05

203 213 212 2

11

228 226

229

234 246

250

0

50

100

150

200

250

300

1992

1993

1994

1995

1996

1997

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

2008

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Current ProductionCurrent Production

Line 2Line 2

3.7003.340Drying

3.4503.160Bleaching

3.6003.400Cooking

Current

adt/d

Nominal

adt/dPlant

80 – 90 g/adtOX

>750 dm3/kgViscosity

6,0pH

90,5%ISOBrightness

16

Process Fiber Line 2Process Fiber Line 2

Cooking Cooking –– 3.400 3.400 adt/dadt/d

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18



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Cooking Cooking –– 3.400 adt/d3.400 adt/d

L/W : 4,3 m3/BDTTemp. : 100ºCPressure : atmosphericEA : 8,0 % (as NaOH)

Dil. Factor : 1,5 m3/adtTemp. : 85ºCKappa No. : 17

L/W : 1,8 m3/BDTTemp. : 150ºC

L/W : 5,2 m3/BDTTemp. : 145ºCPressure : atmosphericEA : 8,5 % (as NaOH)

20


Washing, Screening and Bleaching Washing, Screening and Bleaching -- 3.160 3.160 adt/dadt/d

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Temp. : 90 – 95ºC

O2 : 13 – 16 kg/adt

DF : 1,5 – 2,0 m3/adt

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DF : 1,5 – 2,0 m3/adt

- Condensate

- Hot water

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Temp. : 90-95ºC

pH : 3,0

ClO2 : 15-18 kg/adt

Temp. : 85ºC

pH : 10,5 - 11,0

H2O2 : 3,0 kg/adt

Temp. : 75 – 80ºC

ClO2 : 6-8 kg/adt

Temp. : 80ºC

pH : 10,5-11,0

H2O2 : 1,5-2,5 kg/adt

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Water ConsumptionWater Consumption

Sustainability!!!!!

Low Water Consumption

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m3/adt

24,0

How much is that???

??? m3/adt

The opportunity!!!

Total Water Consumption

m3/adt

24,0

How much is that???

??? m3/adt

The opportunity!!!

Total Water Consumption

26



Cooking Washing Bleaching Drying

Liquor

Chips

Hot water

Fresh water

Liquor

Fresh water

Hot water

Condensate

(Hot water)

Hot water

White / hot water(Fresh water)

CookingCooking WashingWashing BleachingBleaching Drying

Liquor

Chips

Hot water

Fresh water

Liquor

Fresh water

Hot water

Condensate

(Hot water)

Hot water


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4(3)

4(3)

10(8) m3/adt) 4(3) m3/adt)

4(1)

4(5)

4(4)

4(4)

4(4)

4(4)

Considerations:- Consistency : 12%- Total wash flow : 8,1 m3/adt- Dilution factor = 1,5 m3/adt

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Cooking Washing Bleaching Drying

Liquor

Chips

Hot water

Fresh water

Liquor

Fresh water

Hot water

Condensate

(Hot water)

Hot water


CookingCooking WashingWashing BleachingBleaching Drying

Liquor

Chips

Hot water

Fresh water

Liquor

Fresh water

Hot water

Condensate

(Hot water)

Hot water


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Decreasing hot water generationDecreasing hot water generation

Temperatureincreasing100 →→→→ 105ºC

Water consumption decreasing

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Water consumption decreasingWater consumption decreasing

m3/adt

24,0

Total water consumption

decreased considering all

others actions in the mill.

20,5 m3/adt

Water Consumption Decreasing

m3/adt

24,0

Total water consumption

decreased considering all

others actions in the mill.

20,5 m3/adt

Water Consumption Decreasing

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