Prediction of heat transfer on kraft recovery boiler

Työssä tutkittiin Andritz-Ahlstrom toimittamien soodakattiloiden lämmönsiirtoa ANITA 2.20- suunnitteluohjelmalla feedback- laskentaa apuna käyttäen. Data laskentaan saatiin kattiloiden takuukokeissa mitatuista arvoista. Mittaukset on suoritettiin Andritz-Ahlstromin henkilökunnan toimesta tehdashenkilökunnan avustuksella. Feedback -laskenta tapahtui mittaustulosten perusteella, joten tiettyä virhettä luonnollisesti esiintyi. Aluksi laskettiin taseet molempien ekojen yli erikseen sekä molemmat yhdessä Excel-taulukkolaskentaohjelmalla. Täältä saatiin oletettu savukaasuvirtaus kattilassa. Tämän jälkeen lämpöpintoja muokattiin todellisuutta vastaaviksi yleislikaisuuskerrointa muuttamalla (overall fouling factor). Kertoimet ovat liikkuivat noin 0.4 ja 1.6 välillä riipuen kattilan tyypistä ja ANITAn oletuksesta lämpöpintojen likaisuudelle. Havaittin että yhtä varsinaista syytä lämpöpintojen eroavaisuuteen oletetusta ei saatu. Syitä toiminnan poikkeamiseen oli monia. Mm. etukammion koolla havaittiin olevan suurtakin vaikutusta tulistimien, etenkin savukaasuvirrassa ensimmäisen tulistimen toimintaan. Yleisesti todettiin muiden tulistimien vastaavan oletettua toimintaa. Keittopinnan ja ekonomiserien toimintaa tutkittiin hivenen suppeammin ja havaittiin niiden toimivan huomattavasti stabiilimmin kuin tulistimien. Likaisuus kertoimet oletetusta vaihtelivat noin ±20 %.

Measurement Problems and Problem-Solving in Kraft Pulping

Tämän työn tarkoituksena on koota yhteen selluprosessin mittausongelmat ja mahdolliset mittaustekniikat ongelmien ratkaisemiseksi. Pääpaino on online-mittaustekniikoissa. Työ koostuu kolmesta osasta. Ensimmäinen osa on kirjallisuustyö, jossa esitellään nykyaikaisen selluprosessin perusmittaukset ja säätötarpeet. Mukana on koko kuitulinja puunkäsittelystä valkaisuun ja kemikaalikierto: haihduttamo, soodakattila, kaustistamo ja meesauuni. Toisessa osassa mittausongelmat ja mahdolliset mittaustekniikat on koottu yhteen ”tiekartaksi”. Tiedot on koottu vierailemalla kolmella suomalaisella sellutehtaalla ja haastattelemalla laitetekniikka- ja mittaustekniikka-asiantuntijoita. Prosessikemian paremmalle ymmärtämiselle näyttää haastattelun perusteella olevan tarvetta, minkä vuoksi konsentraatiomittaukset on valittu jatkotutkimuskohteeksi. Viimeisessä osassa esitellään mahdollisia mittaustekniikoita konsentraatiomittausten ratkaisemiseksi. Valitut tekniikat ovat lähi-infrapunatekniikka (NIR), fourier-muunnosinfrapunatekniikka (FTIR), online-kapillaarielektroforeesi (CE) ja laserindusoitu plasmaemissiospektroskopia (LIPS). Kaikkia tekniikoita voi käyttää online-kytkettyinä prosessikehitystyökaluina. Kehityskustannukset on arvioitu säätöön kytketylle online-laitteelle. Kehityskustannukset vaihtelevat nollasta miestyövuodesta FTIR-tekniikalle viiteen miestyövuoteen CE-laitteelle; kehityskustannukset riippuvat tekniikan kehitysasteesta ja valmiusasteesta tietyn ongelman ratkaisuun. Työn viimeisessä osassa arvioidaan myös yhden mittausongelman – pesuhäviömittauksen – ratkaisemisen teknis-taloudellista kannattavuutta. Ligniinipitoisuus kuvaisi nykyisiä mittauksia paremmin todellista pesuhäviötä. Nykyään mitataan joko natrium- tai COD-pesuhäviötä. Ligniinipitoisuutta voidaan mitata UV-absorptiotekniikalla. Myös CE-laitetta voitaisiin käyttää pesuhäviön mittauksessa ainakin prosessikehitysvaiheessa. Taloudellinen tarkastelu pohjautuu moniin yksinkertaistuksiin ja se ei sovellu suoraan investointipäätösten tueksi. Parempi mittaus- ja säätöjärjestelmä voisi vakauttaa pesemön ajoa. Investointi ajoa vakauttavaan järjestelmään on kannattavaa, jos todellinen ajotilanne on tarpeeksi kaukana kustannusminimistä tai jos pesurin ajo heilahtelee eli pesuhäviön keskihajonta on suuri. 50 000 € maksavalle mittaus- ja säätöjärjestelmälle saadaan alle 0,5 vuoden takaisinmaksuaika epävakaassa ajossa, jos COD-pesuhäviön vaihteluväli on 5,2 – 11,6 kg/odt asetusarvon ollessa 8,4 kg/odt. Laimennuskerroin vaihtelee tällöin välillä 1,7 – 3,6 m3/odt asetusarvon ollessa 2,5 m3/odt.

Cost-Efficiency of Birch Sprinkling in Kraft Pulping

Työn tavoitteena oli selvittää koivun kasteluvarastoinnin kannattavuus selluteollisuudessa. Lisäksi tutkittiin, kuinka kastelu vaikuttaa puuaineeseen varastoinnin aikana ja kuinka koivun kasteluvarastointi vaikuttaa puun kuorintaan ja haketukseen, keitettävyyteen, vaalenevuuteen sekä sellun laatuun. Enocellin puukentälle rakennettiin kasteluvarasto, jossa varastoitiin 40,000 m3sob koivua. Kastelu oli päällä huhtikuusta lokakuuhun asti. Kastelun vaikutusta puuaineen muutoksiin arvioitiin lahotutkimusten avulla. Tehdaskoeajoissa verrattiin tuoretta, kasteluvarastoitua ja kuivavarastoitua koivua. Puuaines säilyi lähes muuttumattomana yhden kesän kasteluvarastoinnissa. Kastellulla koivulla terveen puun osuus oli yli 85 % kesän lopussa, kun se oli alle 20 % kuivavarastoidulla koivulla. Kuorinnan puuhäviö laskee selvästi kastelukoivulla ja myös hakkeen laatu oli parempaa kuin kuivavarastoidulla koivulla. Kastelukoivulla hakkeen kuoripitoisuus oli vain 0.13 %. Kuoren kuiva-aine oli 12 prosenttiyksikköä alhaisempi kuin kuivalla koivulla, mutta kuoren lämpöarvossa ero oli vain 1 €/ADt. Varastointimenetelmällä ei ollut vaikutusta hakkeen keitettävyyteen, mutta tuoreella puulla keitettävyys oli parempi kuin varastoidulla puulla. Sellun asetoniuutepitoisuus oli samalla tasolla tuoreella ja kastellulla puulla. Kuivalla syyspuulla uutetaso oli korkeampi, vaikka hartsisaippuan annostusta nostettiin 10 kg/ADt. Betulinolitaso oli kastellulla puulla erittäin alhainen puun hyvän kuoriutuvuuden vuoksi. Kastellun ja tuoreen puun vaalenevuus oli parempi kuin kuivalla puulla. Aktiivikloorin kulutus oli 3 – 4 kg/ADt alhaisempi kuin kuivalla syyspuulla. Puun varastoinnilla ei ollut vaikutusta sellun laatuun. Koivun kasteluvarastoinnin kannattavuus on erittäin hyvä. Tuotantokustannukset määritettiin tuoreelle, kastellulle, kierrätetylle sekä kuivalle koivulle. Kasteluvarastointi laskee tuotantokustannuksia noin 10 €/ADt verrattuna kierrätettyyn koivuun. Kuivavarastoidun puun käyttö nostaa tuotantokustannuksia noin 5 €/ADt verrattuna kastelukoivuun. Kierrätetyn ja kuivavarastoidun puun kustannusero johtuu kierrätyskustannuksista. Kasteluvarastolle, jota käytettiin kesällä 2004, takaisinmaksuaika on vain 0.4 vuotta. Jos tavoiteltu takaisinmaksuaika olisi kaksi vuotta, niin perusinvestointi 80,000 m3sob varastolle voisi maksaa noin 370 k€.

Ozonólise das ligninas organossolve e kraft eucalipto. Parte II: cinética nos meios ácido e básico

Organosolv and kraft lignins were treated with ozone both in basic and acid media and the reaction was studied kinetically. In contrast to reported studies, ozone was more efective in basic medium. Kraft lignin was degraded faster than organosolv lignin in both media but in the basic medium the rate of reaction was very much faster than in the acid one: for kraft lignin, the observed degradation was 93% for 2 min of reaction in the basic medium and 56% for 10 min of reaction in the acid medium; for organosolv lignin, 47% and 25%, respectively, in the same times. Higher phenolic hydroxyl groups contents increase the reaction rate.

Offdesign operation of kraft recovery boiler

A model to solve heat and mass balances during the offdesign load calculations was created. These equations are complex and nonlinear. The main new ideas used in the created offdesign model of a kraft recovery boiler are the use of heat flows as torn iteration variables instead of the current practice of using the mass flows, vectorizing equation solving, thus speeding up the process, using non dimensional variables for solving the multiple heat transfer surface problem and using a new procedure for calculating pressure losses. Recovery boiler heat and mass balances are reduced to vector form. It is shown that these vectorized equations can be solved virtually without iteration. The iteration speed is enhanced by the use of the derived method of calculating multiple heat transfer surfaces simultaneously. To achieve this quick convergence the heat flows were used as the torn iteration parameters. A new method to handle pressure loss calculations with linearization was presented. This method enabled less time to be spent calculating pressure losses. The derived vector representation of the steam generator was used to calculate offdesign operation parameters for a 3000 tds/d example recovery boiler. The model was used to study recovery boiler part load operation and the effect of the black liquor dry solids increase on recovery boiler dimensioning. Heat flows to surface elements for part load calculations can be closely approximated with a previously defined exponent function. The exponential method can be used for the prediction of fouling in kraft recovery boilers. For similar furnaces the firing of 80 % dry solids liquor produces lower hearth heat release rate than the 65 % dry solids liquor if we fire at constant steam flow. The furnace outlet temperatures show that capacity increase with firing rate increase produces higher loadings than capacity increase with dry solids increase. The economizers, boiler banks and furnaces can be dimensioned smaller if we increase the black liquor dry solids content. The main problem with increased black liquor dry solids content is the decrease in the heat available to superheat. Whenever possible the furnace exit temperature should be increased by decreasing the furnace height. The increase in the furnace exit temperature is usually opposed because of fear of increased corrosion.

Hemicellulose extracted Kraft pulp as a raw material of paper

The transformation of a traditional pulp mill into an integrated forest biorefinery utilizing wood-derived biomass presents a promising opportunity for enterprise revival of the pulp and paper industry by offering new sources of revenue and significantly improved industry profitability. One proposed next generation process step for an integrated forest biorefinery is the extraction of hemicelluloses, allowing the co-production of pulp and ethanol or chemicals. The extraction of hemicelluloses, however, will likely have downstream effects on pulp quality. In the literature survey an overview of the integrated forest biorefinery and possible next generation technologies implementable in such facility were reviewed. Moreover, some hemicellulose extraction methods suitable for the co-production of pulp and hemicellulose products were looked into in more detail. Also, an overview on the significance of pulp’s hemicellulose content on papermaking properties of pulp fibers was made. In the literature it is stated that the hemicellulose content of pulp affects on many papermaking properties of pulp fibers, hornification and paper strength properties in particular. In the experimental part the goal was to investigate what effects alkaline hemicellulose extraction after bleaching has on the papermaking properties of birch Kraft pulp. It was discovered that tested pulps, normal and hemi-poor birch Kraft pulp, were different in many ways regarding to pulp properties. Differences were observed in both physical and chemical characteristics. Furthermore, clear distinctions were seen in tested paper properties, especially in strength properties, between the handsheets made from hemi-poor or normal birch Kraft pulp. Hemi-poor and normal birch Kraft pulps were also compared as a raw material of laboratory made copy paper. Based on this comparison, usage of hemi-poor birch pulp as the raw material of copy paper does not drastically deteriorate its quality.

Gasification of Black Liquor as a Way to Increase Power Production at Kraft Pulp Mills

The study is focused on the opportunity to improve the power performance from black liquor at Kraft pulp mills. The first part of the paper includes an overview of a traditional recovery system, its development and indication of the integral drawbacks which provoke the search for more efficient methods of black liquor treatment. The second part is devoted to the investigation of black liquor gasification as a technology able to increase electric energy generation at pulp mills. In addition, a description of two most promising gasification processes and their comparison to each other are presented. The paper is based on a literature review and interviews of specialists in this field. The findings showed that while the modern recovery system meets demands of the pulp mills, pressurized oxygen-blown black liquor gasification has good potential to be used as an alternative technology, increasing the power output from black liquor.

The role of bound chlorine in the brightness reversion of bleached hardwood kraft pulp

Our previous paper showed fragmentary evidence that pulp brightness reversion may be negatively affected by its organically bound chlorine (OX) content. A thorough investigation on eucalyptus kraft pulp led to the conclusion that OX increases reversion of certain pulps but this trend is not universal. Alkaline bleaching stages decrease reversion regardless of pulp OX content. Pulps bleached with high temperature chlorine dioxide revert less than those bleached with conventional chlorine dioxide in sequences ending with a chlorine dioxide stage but similarly in sequences ending with a final peroxide stage. The use of secondary condensate for pulp washing decreases reversion.

A influência dos ácidos hexenurônicos no rendimento e na branqueabilidade da polpa kraft

This study investigated the impact of pulp hexenuronic acids (HexAs) content on pulping yield by changing cooking reaction temperature. The bleachability of pulps containing variable amounts of HexAs was also investigated. The cooking at 170 ºC produced pulp of kappa number, HexAs and screen yield of 16.2, 49.4 mmol/kg and 50.2%, respectively, whereas the cooking at 156 ºC resulted pulp of kappa 17.0, 61.3 mmol/kg HexAs and 50.8% screened yield. The pulp produced at lower cooking temperature also showed better bleachability as evaluated by the total amount of active chlorine required to achieve 90% ISO. The sequence OA HT D(EP)DD showed the lowest bleaching performance among all.

Branqueamento de polpa celulósica kraft de eucalipto com peróxido ácido ativado por molibdênio

Optimum conditions to run the P Mo stage for bleaching eucalyptus kraft pulp were 90 ºC, pH 3.5, 2 h, 0.1 kg/t Mo and 5 kg/t H2O2. The P Mo stage efficiency increased with decreasing pH (1.5-5.5) and increasing temperature (75-90 ºC), time (2-4 h), and hydrogen peroxide (3-10 kg/t) and molybdenum concentration (0.1-0.4 kg/t). The implementation of the P Mo stage, as replacement for the A stage, decreased total active chlorine demand of the OAZDP sequence by 6 kg/t to reach 90% ISO, both in laboratory and mill scale. Such practice resulted in decreased bleaching chemical costs to produce fully bleached pulp of 90% ISO.

Previsão das propriedades físicas do papel kraft por espectroscopia no infravermelho próximo (NIR) e regressão por mínimos quadrados parciais (PLS)

The main objective of the present work is represented by the characterization of the physical properties of industrial kraft paper (i.e. transversal and longitudinal tear resistance, transversal traction resistance, bursting or crack resistance, longitudinal and transversal compression resistance (SCT (Compressive Strength Tester) and compression resistance (RCT-Ring Crush Test)) by near infrared spectroscopy associated to partial least squares regression. Several multivariate models were developed, many of them with high prevision capacity. In general, low prevision errors were observed and regression coefficients that are comparable with those provided by conventional standard methodologies.

Influência dos atributos do solo sobre a qualidade da madeira de Pinus taeda para produção de celulose Kraft

Neste trabalho foram analisados os efeitos dos atributos do solo sobre a qualidade da madeira de Pinus taeda para produção de celulose Kraft, em áreas da Klabin, em Telêmaco Borba-PR. Foram estudados oito sítios com árvores de 12 anos de idade, selecionados pelo tipo de solo, textura e vegetação primária. Para caracterização dos sítios foram realizadas coletas de amostras em três horizontes, tendo sido coletadas amostras indeformadas e compostas, analisando-se as seguintes variáveis no solo: densidade global, porosidade total, macroporosidade, disponibilidade de água, fertilidade e granulometria. Selecionaram-se cinco árvores médias por sítio, nas quais foram medidos as alturas total e comercial e o DAP e retirados discos, sendo este material ensaiado quanto a densidade básica, composição química, características morfológicas dos traqueídeos e produção de celulose Kraft. Com relação às propriedades da madeira, os atributos físicos do solo demonstraram ter maior influência. De modo geral, as madeiras provenientes de sítios com texturas mais argilosas apresentaram menores valores de densidade básica; maiores teores de extrativos e lignina; menores teores de holocelulose e celulose; traqueídeos mais curtos, mais largos, com paredes mais finas e com diâmetros do lúmen maiores; e menor rendimento em celulose. A partir destes resultados, concluiu-se ser possível a previsão de propriedades da polpa através da análise das características da madeira associada às condições edáficas reinantes.

Influência da densidade básica da madeira na qualidade da polpa kraft de clones hibrídos de Eucalyptus grandis W. Hill ex Maiden X Eucalyptus urophylla S. T. Blake

Foram estudados dois clones de Eucalyptus com densidades básicas de 447 e 552 kg/m³. O processo kraft foi utilizado para a produção de celulose, tendo sido aplicadas diferentes cargas de álcali para se obterem polpas com número kappa 18 ± 0,5. As polpas foram branqueadas pela seqüência ODEopDD, a alvuras de 90 ± 1% ISO, e refinadas, sendo suas propriedades físico-mecânicas e ópticas analisadas. A madeira de baixa densidade mostrou-se mais recomendável para a produção de celulose, por ter apresentado maior rendimento depurado, viscosidade da polpa mais elevada, ter requerido menor carga de álcali no cozimento, ter proporcionado menor teor de sólidos no licor residual e menor consumo de reagentes químicos no branqueamento. As propriedades mecânicas e estruturais das polpas não foram afetadas significativamente pela densidade básica das madeiras.

Utilização de surfactantes, na polpação kraft de madeira de eucalipto, como auxiliar na remoção de extrativos lipofílicos

Problemas de deposição de "pitch" em fábricas de celulose e de papel são atribuídos aos extrativos lipofílicos existentes na madeira. Uma das maneiras mais eficientes de controlar essa deposição é através da remoção de seus precursores do sistema, logo que possível, nas etapas de cozimento, lavagem da polpa marrom e pré-deslignificação com oxigênio. O uso de surfactantes como aditivos da polpação tem sido investigado, mas há grande deficiência de informações técnicas, e a aplicação industrial é, ainda, incipiente. A proposta deste trabalho foi analisar a viabilidade de minimizar a deposição de "pitch", intensificando a remoção de suas substâncias precursoras na etapa de polpação pelo uso de tensoativos sintéticos com propriedades umectantes e solubilizantes. Foram testados 20 princípios ativos de surfactantes em cozimento kraft convencional de madeira de eucalipto. Os resultados, alguns estatisticamente significativos, apontaram redução do teor de substâncias lipofílicas na polpa marrom. Foi observado que a remoção dos extrativos lipofílicos da madeira é afetada, inversamente, pelo teor de óxido de eteno na molécula do surfactante. Outros parâmetros de cozimento, como deslignificação, rendimento, teor de rejeitos e viscosidade da polpa, foram também avaliados.

Bleached kraft pulp production from Pinus tecunumanii (Eguiluz e Perry)

The use of 12-year-old Pinus tecunumanii (Eguiluz e Perry) grown in Colombia was evaluated for bleached kraft pulp production. Kraft pulps of kappa number 30 ± 1 were produced, and oxygen delignified and bleached to 90% ISO with ECF processes. The bleached pulps produced under optimum conditions were evaluated with regard to their strength properties. Pinus tecunumanii wood required low effective alkali charge to reach the desired kappa number and the unbleached pulp showed high oxygen delignification efficiency and bleachability when a OD(EO)DED sequence was used. The bleached pulps presented good physical-mechanical properties, which are comparable to those obtained with more traditional pines such as Pinus taeda and Pinus radiata. The results demonstrate that this tropical pine species is a suitable raw material for bleached kraft pulp production