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Karin Lindgren, Innventia
Production of Chemicals and Materials in Future Pulp Mill Biorefineries Karin Lindgren, Innventia
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INNVENTIA AB Staff 270 Swedish R&D company Serving customers globally
Pulp, paper, packaging, printing, new materials and biorefining New process solutions and new sustainable products, with greater value than today’s main products, are necessary for maintaining profitability in a mature industry. STFI-Packforsk holds a unique position. The key for success is the combination of Scientific research at high international level and the implemention of results in contract assignments, training courses as well as testing and analysing. Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Chemical pulping process
This slide shows the kraft pulping process and I will briefly go through the parts as some of you is not familiar with the pulping industry. Basically, it starts with the wood yard where the chips are prepared. The digester area is here where the delignification of the fibers takes place. After the cooking the pulp is separated from the black liquor that consist of cooking chemicals and dissolved organic material. Then the pulp is washed, oxygen delignified and bleached. The chemical recovery starts with the evaporation where the dry solid content of the black liquor is increased from about 15% to 70-80% sometimes even higher. In the recovery boiler the black liquor is burned to regenrerate cooking chemicals and produce steam for the mill. In a modern market pulp mill there is an excess of energy that could be used for power generation in a condense turbine. Finally we have the recaustisizing area where the white liquor is prepared. In the lime kiln there is a need for fuel where often oil is used. When a pulp mill would like to increase its capacity they expand the part that is the bottleneck. The most expensive part is the recovery boiler and this is the reason why many mills has a bottleneck in the recovery boiler. Peka på alla delar Increase production, recovery boiler expansion new or rebuild Self sufficient in energy Energi Överskott, condensing turbine Source: Aker Kvaerner Lindgren Italic 4
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Biorefinery – Simultaneous production of fibres, energy and chemicals
Increasing costs Energy and wood Decreasing trend prices on pulp Biorefinery is the solution Handling of large volumes of biomass New pulp mill products New efficient separation processes Add “side” processes Innventia approach Kraft/soda pulp mill platform Focus on the major components Efficient separation process and mill integration Lignin carbon fibres Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Cellulose
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Wood/plants- a mine for valuable polymers Cellulose
Softwoods Hardwoods Agro/annual Spruce Pine Birch Euca. glob. Euca. urogr. Bagasse Cellulose % 44 45 51 50 Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Cellulose Products NanoCellulose Kraft Pulp Fibres Fibre PLA Composite
Transparent Films Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Lignin from black liquor - LignoBoost
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50% of the wood ends up in cooking liquor
Cellulose products Pulp Wood to kraft pulp mill Carbohydrates Black liquor Extractives Lignin 55-60 % of energy goes into the black liquor Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Wood/plants – a mine for valuable polymers - lignin
Softwoods Hardwoods Agro/annual Spruce Pine Euca. glob. Euca. urogr. Hemp Bagasse Lignin, % 27 28 24 29 25 22 Physical/chemical properties vary with species and process Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The LignoBoost process
Lignin IN Replacement of fossil fuel in lime kilns 50 L fuel oil ptp can be saved Lignin OUT Recovery Boiler Evaporation Lime Kiln Digester Wood Wood Chips Bleaching Pulp/Paper Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The LignoBoost process
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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LignoBoost lignin – a new material
Typical composition, % C Na Ash S N Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Kraft lignin Ligno-sulphonate Solubility Alkali Water Ash content 1% 25% Sugar content 2% 10% S 3% 5%
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Metso filter in Innventias lignin demo plant
VPA 1040 24 chambers 1-1.2 t lignin/h Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Fossil fuel in pulp mill lime kilns
In Sweden ca tonne oil/year Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Carbon fibres - High value application of lignin
Construction material in composites Light Weight High Strength and Modulus High Resistans to Heat and Corrosion Expensive Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Oil or renewable Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Manufacturing process of carbon fibres
Raw material Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Carbon fibres from lignin
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Lignin can make difference
ton pulp/year 10% lignin extracted = ton … ton carbon fibres …can replace 40 % steel in cars Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Activated carbon from lignin
Water and gas cleaning Main industrial source coal Physical and chemical activation Surface area up to 3000 m3/g Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Phenols from lignin Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Hemicellulose from black liquor, chips, saw dust and forestry residues
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Wood/plants – a mine for valuable polymers - Hemicelluloses
Softwoods Hardwoods Agro/annual Spruce Pine Birch Euca. glob. Euca. urogr. Hemp Bagasse Xylan, % 9 8 26 21 16 29 28 Glucomannan, % 19 18 3 4 2 Glucomannan degrades in alkali Xylan is relatively stable in alkali Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Chip leaching* for salt and hemicellulose removal
Developed for pre-treatment prior to kraft pulping Leaching liquor (acid or alkaline) Wood chips Chip kidney To processing pulping pelletizing gasification Polymeric hemicellulose and inorganic ions *Protected by patents: WO2004/050983, US2005/ , WO03/046276 Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Xylan from black liquor
Industrial ultrafiltration trials with in-line ceramic membrane 2007 Laboratory membrane filtration unit at Innventia since 2003 Principal outline of mill trial: Wood chips Unbleached pulp Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Polymeric Xylan from black liquor
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Potential hemicellulose applications
Fiber additives Gas barriers O H C ( Z ) SW fibre Other applications Hydrogels Polymers (PLA) Xylitol, furfural Sugar acids Emulsifiers Carboxymethylation 4-5 times higher surface charge Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Wood xylan feedstock for lactic acid and PLA
Hemicelluloses (glucomannan and/or xylan) Acidic or enzyme hydrolysis Pentoses and hexoses Fermentation or alkaline oxidation Polylactide (PLA) Polymerization Lactic acid Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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2G Ethanol from forestry residues
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2G Ethanol Acid/enzymatic pretreatment OR Alkaline preteatment
can handle all wood/forestry residues/annual plants good separation of cellulose and lignin established technology Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Alkaline route from wood to ethanol
Forestry Residues Ethanol Alkaline fractionation Hydrolysis, Fermentation & Distillation CO2 Lignin Separation Chemicals Recovery Sulphur-Free Lignin Energy Recovery Electric Power Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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2G Ethanol- Alkaline Process Will it work in practice? Yes!
Tested in mill and pilot scale trials 70 t soda pulp produced 40 m3 pulp suspension used 700 litres of ethanol produced S-free lignin produced Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The Future Wood/Agri Pulp Mill Biorefinery - many options available
Integrated Energy System Pulp & Cellulose Fibre processing Pulpwood Black liquor Heat & Power Chemicals and materials Primary treat-ment Conver-sion Forestry/agri residues Conver-sion Biofuels Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Possible time frame for commercialization
2- 5 years > 5 years Lignin Fuel oil replacement Pellet additive Dispersant Activated carbon Benzene Phenol Carbon fibres Xylan Gas barrier Fibre surface additive Lactic acid, PLA Polyesters Forestry residues 2G EtOH and S-free lignin High quality pellets Syngas FT-diesel/DME Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The pulp mill biorefinery
Energy Chemicals/Materials Phenols Carbon fiber Binders Dispersants Activated carbon Lignin Lignin Cellulose Bark Forestry residues DME Ethanol FT-diesel Biooil Heat Electricity Solid fuel Lignin Hemi- cellulose Fiber additives Barriers Hydrogels Cellulose Fibers Derivatives Nanocellulose Extractives Functional polymers Bioactive compounds Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Thank you for the attention
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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