Pinola Kraft Soap Technology

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Transcript of Pinola Kraft Soap Technology

Technology overview

The Pinola technology platform provides kraft pulp mills with a seamless solution encompasing weak black liquor from the digester through to high quality crude tall oil production.

Efficient separation of soap and suspended solids from black liquor, producing a clean black liquor and a concentrated tall oil soap.

Produces high quality crude tall oil (CTO) with the highest yield.

Technology overview

Technology overview

UNIT 21 Acidulation &

Separation

UNIT 22: CTO Drying &

Cooling

UNIT 23: Gas Scrubbing

UNIT 24: Acid Water

Neutralization

UNIT 25: Cleaning in

Place

UNIT 11: Clarification

UNIT 12: Purification

UNIT 12: Purification

BLiSS

BLiSS Light

TOPP

UNIT 26: Conditioning

Technology overview

Solids accumulated at bottom of the tank

Black liquor 4-10 g TO/kg DS

Black liquor feed 20-25% DS15-40g TO/kg DS0,06% solids

Soap skimmed from top of the tank with entrained black liquor

Existing tank soap separation system

Soap

Soap skimming tanks

Technology overview

Concentrated sulphate soap(≥ 60% TO)

Clarified black liquor: < 1g TO/kg BL DS

SolidsBlack liquor feed20-25% DS15-40g TO/kg DS0,06% solids

New BLiSS system

High Speed Centrifugal Separator

Scaleable Technology

Soap

Clarified Black liquor < 1g TO/kg DS

Black Liquor feed 20-25% DS15-40g TO/kg DS0,06% solids

BLiSS system

Soap buffer tank

To solids tank or heavy black liquor stream

Suspended Solids

Black liquor return

85 m3/hr.

85 m3/hr.

85 m3/hr.

Concentrated soap (≥ 60% TO)

Technology overview

Black liquor 4-10 g TO/kg DS

Black liquor feed 20-25% DS15-40g TO/kg DS0,06% solids

Solids

Black liquor150-400g TO/kg DS

BLiSS Light systemConcentrated soap (≥ 60% TO)

Soap skimming tanks

Black liquor return

X m3/h

Black liquor flowX/10 m3/h

To evaporators

To recovery boiler

Technology field trials

Test No.

Flow m3/hr

BL DS (%)

g TO / kg BL DS

g TO /kg soap

Feed before BLiSSBlack liquor 22.5 13.8 -

Results after BLiSS1 Black liquor 1.5 - 0.9 -1 Soap 1.5 - - 6422 Black liquor 2.5 - 0.9 -2 Soap 2.5 - - 603

Field trials conducted at Billerud Gruvön mill, Sweden October 2009: 3m3/hr black liquor

Technology field trials

Field trials conducted at Billerud Gruvön mill, Sweden April & May 2011: Average black liquor flow c:a 70m3/hr

Technology field trials

Concentrated soap (diluted with water)

Cleaner black liquor

Removed suspendedsolids

3 Phase Separation

Technology field trials

Key Field Trial Results (extract from report)

Sample ID

Date Time Sample Location Black liquor flow rate (m3/h)

g TO / kg BL DS

1 2011-04-15 Feed 72 7,7

2 2011-04-15 After separator 72 0,7

5 2011-05-02 19:10 Feed 62 5,48

6 2011-05-02 21:10 After separator 68 1,71

B 2011-05-03 21:30 Feed 5,51

A 2011-05-03 21:30 After separator 1,51

C 2011-05-04 07:15 Feed 9,39

D 2011-05-04 07:15 After separator 1,99

E 2011-05-04 13:50 After separator 75 1,20

F 2011-05-04 15:00 Feed 73 8,39

G 2011-05-04 15:05 After separator 73 1,29

0,7 g TO / kg DS < Black Liquor < 1,99 g TO / kg DS(i.e. c.a: 70 - 90% reduction of g TO/ kg BL DS)

Technology field trials

Tankseparated

soap”BLiSSed”

soap

250ml to 230ml in ~1hr

250ml to 200ml in ~1hr

Acidulated soap separation efficiency

Key process metrics

(1) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008, tabel 4.1.

TANK SYSTEM PINOLA BLiSS

RESIDENCETIME

Days.Scandinavian mills vary from 14 to 31 days. (1)

Minutes.Residence time < 2mins. (2)

BLACKLIQUOR

”Dirty”. Poor separation.Average, 4.2 g TO / kg BL DS.(3)

Clean (”BLiSSed” Black Liquor)Excellent separation. < 1 g TO / kg BL DS. (2)

TALL OILSOAP QUALITY

”Aged” due to long residencetime. Entrained black liquor.

Fresh (”BLiSSed” Soap) due to shortresidence time.

TALL OILCONC.’N

45 – 55% w/w. (4)

Average 51%, Scandinavian mills.≥ 60% w/w. (2)

(4) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008 Attachment B & C.

(2) Source: Field trials May 2011, Billerud, Gruvön, Sweden.

(3) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) report 1078 Nov. 2008, Fig 3.6

SEPARATIONEFFICIENCY

Poor. Gravity decantation. Excellant. Centrifugal force. 1g vs > 4000g

Key process metrics

(5) Source: Värmeforsk (Swedish Thermal Engineering Research Institute) 1078 Nov 2008, Executive summary.

TANK SYSTEM PINOLA BLiSS

TALL OILYIELD

Estimated 30 000 MT or > 10% of existing Swedish production is lost. (5)

≥ 10% higher yield of TO from black liquor to the tall oilproduction plant. (2) >30 000 MT can be recovered.

SUSPENDEDSOLIDS

Builds up in tanks.In black liquor to the evaporatorIn soap to the splitting plant.

Majority removed in a separate stream.

EVAPORATIONUNIT

Fouling. Increase energy usage. Downtime.

Reduced fouling.Reduced steam consumption.

RECOVERYBOILER

High loading from residues, soap. Reduced loading.Stable operation.Better heat transfer.

(2) Source: Field trials May 2011, Billerud, Gruvön, Sweden.

Summary of Benefits

1. Reduced scaling of evaporators=> Increased availability=> Reduced steam (energy) consumption=> Increased pulp production capacity

2. Improved capacity of recovery boiler=> Increased pulp production capacity

3. Reduced build up on recovery boiler tubes=> Increased energy efficiency

4. More soap captured=> Increased CTO production

5. Less black liquor in soap => Reduced chemical usage in CTO production

6. Easier separation of acidulated soap products => Increased CTO production yield.

Technology overview

UNIT 21a: Acidulation

UNIT 22a: CTO Drying

UNIT 23: Gas Scrubber

UNIT 24: Acid Water Neutralising

UNIT 25:CIP (Cleaning

in Place)

UNIT 21b: Separation

UNIT 22b: CTO Cooling

UNIT 26: Conditioning

TOPPTall Oil Production Plant

Technology overview

TOPPTall Oil Production Plant

The Pinola TOPP solution is a modernisation of the Alfa Laval Celleco tall oil plant which utilises a high speed centrifugal separator.

Unit 26 Unit 21a Unit 21b

Unit 22aUnit 23 & 24Unit 25 Unit 22b

TOPPTall Oil Production Plant Benefits & Performance guarentees

The performance guarantees achieved bythe Pinola TOPP solution:

1. CTO recovery yield > 97%

2. Water content < 1 %

3. Ash content < 0,2%

4. Max. Temp 70 deg C

5. H2S gas to atmosphere < 20ppm

6. Highest possible acid number. No acid number degradation due to the short residence time.

The technology improvements offered bythe Pinola TOPP solution include:

1. Higher CTO yield

2. Higher CTO quality.

3. Reduced acid consumption

4. Improved pH control

5. Continuous & fully automated

6. Cleaning In Place system

7. Closed system. No H2S gas leakage.

8. Lower installed power

TOPPTall Oil Production Plant Reference plant

Södra Cell mill Värö Sweden, capacity 5MT CTO / hr. Commissioned April 2012.

TOPPTall Oil Production Plant Reference plant

TOPPTall Oil Production Plant Reference plant

TOPPTall Oil Production Plant Reference plant

Optimum solution

Combined economical benefits

Increase in revenue due to increase in crude tall oil production.

The Pinola technology guarentees:1. Increased TO concentration in soap by 10% w/w.2. Increased CTO recovery by 12% w/w (from 85% (1) to 97%).

Tank system PINOLA ( BLiSS + TOPP)Soap recovered from black liquor (kg) 100 100Tall oil concentration in soap 50% 60%Tall oil available (kg) 50 60CTO recovered from soap 85% (1) 97%CTO (kg) 42,5 58,2

Total increase in CTO production 36,9%

Other potential cost savings:1. Steam (energy) costs at evaporator unit and recovery boiler.2. Maintenance costs at evaporators.3. Maintenance costs at recovery boiler.4. Chemical costs.

Other potential revenue increase:1. Increased pulp production capacity.

(1) Average in Scandinavia: Source Värmeforsk (Thermal Engineering Research Institure) report 1078 Nov. 2008

TOPPTall Oil Production Plant

o Adhesiveso Bio-energyo Bio-lubricantso Coatingso Consumer Products

• Air Fresheners -Automotive

• Air Fresheners - Home and Industrial

o Personal Care• Make-Up• Skin Care• Sun Care

Crude Tall Oil end products

o Detergent Cleanerso Fuel Additiveso Mining/oil field

additiveso Polymer Additiveso Printing inkso Road markingo Road Constructiono Tires and Rubber

Contributing to a sustainable future !

Sal PassanisiBusiness DevelopmentP: +46 8 50 57 11 25M: +46 703 573 800E: sal@head-engineering.se