Valmet in Circular Economy
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Transcript of Valmet in Circular Economy
Contents
Circular economy in brief Valmet’s position in circular
economy How Valmet applies circular
economy Enabling circular economy
for customers Driving circular economy in
own operations
13 June, 2017 © Valmet | Circular economy2
Circular economy in briefFrom linear to circular chains
A circular economy aims to keep products, components and materials in a continuing cycle instead of disposal.
Waste is minimized or eliminated for example through using side streams in other applications, processes or even industries.
Circular economy creates new business potential across industries through more efficient use of material flows.
13 June, 2017 © Valmet | Circular economy3
Waste
Linear economy Circular economy
Production
Distribution
Consumption
Re-use, repair, recycle
Waste menagement,
resource recovery
Consumption
Distribution
Production
Resource extraction
13 June, 2017 © Valmet | Circular economy4
Valmet’s mission is to convert renewable resources
into sustainable results
Circular economy is inbuilt in Valmet’s solutions
Valmet’s solutions enable its customers to apply circular economy
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Utilization of renewable raw materials by customer
Process technology and services provided by Valmet
We apply circular economy in Valmet’s own and customer operations in different ways
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Resource efficiencyRefers to the efficient use of resources, so that the amount of recources (materials, energy, water, chemicals) needed to produce the products can be reduced.
Closed cyclesRefers to material flows within one production unit/organization/industry aiming at creating closed loop systems with no waste.
Longer circulationRefers to cycles where materials last longer, e.g. their lifecycles are extended, through e.g. more efficient recycling.
Cascaded use across industriesRefers to material flows cascading from one value chain/industry to another e.g. by using sidestreams from one value chain/industry as inputs into another industry.
Main circular economy themes from customers’ point-of-viewResource efficiency Improvement and optimization
of resource efficiency Flexible energy production
Closed circles Chemical and energy recovery
Longer circulation Design enabling reuse and conversion Maintenance and modernization of production technology
Cascaded use across industries New bio-based products
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1. Improvement and optimization of resource efficiency
Concrete examples: Significant savings in energy, water and raw
materials in paper making technologies e.g. OptiConcept M paper and board machines, Advantage DCT and Advantage NTT tissue machines
Measurement solutions and industrial internet enable data analytics to detect production inefficiencies and optimize material use
Performance agreements provide a comprehensive approach to improve mill wide production efficiency
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Resource efficiency can be improved through technology, automation and maintenance
2. Flexible energy production
Concrete examples: Waste-to-energy solutions by fluidized bed boiler
and gasification technologies enable efficient energy recovery
Fuel flexibility with multi-fuel boilers, which can operate on fuel mixtures ranging from 100 % coal to 100% biomass
Wider use of fuel sources by fluidized bed boilers, which can utilize fuels with varying energy value and moisture content
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Valmet’s energy production technologies reduce the need for non-renewable fuels and the amount of waste
3. Chemical and energy recovery
Concrete examples: Recovery island enables efficient recovery of
chemicals and energy in a pulp mill
Sulphur recovery from odorous gases enables on-site production of sulphuric acid
Internal recovery and recycling solutions in production processes e.g. condensate water recycling and paper pigments recovery
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On-site recovery of energy and chemicals allows materials to circulate longer and reduces the need for virgin materials
4. Design enabling reuse and conversion
Concrete examples: Paper machines can be converted to produce
board or other paper grades
Modular design of machines and plants make it possible to replace individual machine parts
Machines can be dissembled and reassembled in another location
Flexible design enables changes based on market needs (e.g. Advantage NTT, multi-fuel boilers)
Modular I/O-cards(* enable system updates without the need to update the core system
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Modular design and smart engineering enable the use of same equipment for other uses
*) I/O-cards = input / output cards
5. Maintenance and modernization of productiontechnology
Concrete examples: Preventive maintenance can be planned utilizing
big data analytics e.g. in roll maintenance
Refiner segments, rolls and certain wear parts are refurbished and used again and again
Individual process parts or complete mills and power plants can be modernized to extend the life time
Boilers can be modified to use another fuel e.g. from coal to biomass
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Equipment lifetime can be significantly prolonged with well planned maintenance and partial replacements
6. New bio-based products
Concrete examples: LignoBoost technology makes it possible to extract
lignin from pulping process side stream, and lignin can be used as raw material for bio-based materials and chemicals
Technologies for bioethanol, biocoal and bio-oil production help to replace non-renewable fuels and materials
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Solutions for new bio-based products decrease the need for non-renewable materials
Valmet’s way to apply circular economy in its own operations
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Resource efficiency Continuous improvement of resource efficiency Maximum utilization of metals Resource efficient supply chain Shared use of assets
Longer circulation Preventive maintenance1
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Valmet’s own operations
Concrete examples: Energy audits, quality and environmental
standards, and LEAN principles are applied to improve efficiency of production operations
Majority of metals sourced is recycled and internally reused e.g. in foundries
Resource efficiency and good environmental management are required from suppliers
Laboratory and piloting facilities are shared with customers
Preventive maintenance prolongs the life time of production equipment
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Efficient use of metals and other raw materials in own production and supply chain
OptiConcept M modular board and paper production line
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A completely new, modular way to build a board or paper machine with• significant savings in energy, water and raw-material usage• built-in safety and usability• smaller carbon footprint through compact design
OptiConcept M modular board and paper production line
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A completely new, modular way to build a board or paper machine with
Built-in safety and usability
Smaller carbon footprint through compact design
Savings in energy, water and raw-materials
30% lower energy consumption
compared to average
Less fiber throughlight-weight end product
30% Saving in fresh water
consumption
Safe and easy daily operations:
70% fewer stairscompared to conventional machine
85% fewer platforms compared to
conventional machine
Safe daily maintenance no need to remove walkway parts
during fabric changes or other maintenance work
Up to 40% less hall space
Up to
430 000 kg less CO2 emissions
Corresponds to a car driving around the world
61 times
Advantage NTT tissue production line
13 June, 2017 © Valmet | Circular economy19
Advantage NTT brings unique flexibility to tissue production with• Fast change from production of plain to textured tissue• Unlimited possibilities for product variations• Premium quality • High capacity and efficiency• Significant savings in energy and fiber
Advantage NTT tissue production line
13 June, 2017 © Valmet | Circular economy20
Advantage NTT brings unique flexibility to tissue production
Plain and texturedtissue production
3 hours’ swing from plainto textured mode
Unlimited possibilities for product variations
50–80%higher bulk plain mode
High softness
Improved waterabsorbency
Energy less than
50%vs. TAD in textured mode
Energy
less or equalvs. DCT in plain mode
Fiber savings
10–20%
Premium quality High capacity and efficiencyFlexibility Energy and fiber
savings
180 tpdplain mode
(2.6 m wide machine)
2,000 m/minplain mode
1,800 m/mintextured mode
Valmet IQ quality management solution
13 June, 2017 © Valmet | Circular economy21
A comprehensive quality management product family for pulp, paper, board and tissue production with • Significant savings in energy, water and raw-material usage
• Consistent end product quality
• Single-window view to optimized machine performance
Valmet IQ quality management solution
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A comprehensive quality management product family for pulp, paper, board and tissue production
Consistent end-product quality
Single-window view to optimized machine performance
Savings in energy,water and raw materials
Up to
40% less reject in grade changes
Annual energy savings up to
600,000 €Up to
75%lower maintenance costs
Consistent quality and up to
10%increase in production
with QCS upgrade
Accurate and stable sheet quality in demanding
conditions
End product quality stabilized through one
optimizer for all production and quality variables
Easy access to information for operators
Easy usability and transparent view into
process
Integrated machine vision solution to identify defects
and quality flaws
Performance Agreements for board andpaper production lines
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Customized improvement programs for the competitiveness andprofitability of the production line• Guaranteed results based on common targets and systematic development
• Benchmarking and finding best practices
• New insights through audits
Performance Agreements for board andpaper production lines
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Benchmarking and best practices
New insights through audits
Guaranteed resultsbased on agreed targets
Typically 4-7 days more availability
Typical production increase
3-10%
Up to 7%energy savings
Comparison to worldwide benchmarking data
Access to Valmet’s expertise and global
resources
Continuous improvement through prioritized actions
Identifying bottlenecks and pointing out focus issues
Typical payback time
6-12 months
Experts are alwaysclose – on-site or
remotely
Customized improvement programs for the competitiveness andprofitability of the production line
Valmet’s multifuel power boilers
13 June, 2017 © Valmet | Circular economy25
With HYBEX and CYMIC boilers, fossil fuels can be replaced with renewables in continuously varying proportions. Our multifuel solutions offer • Fuel flexibility• High efficiency• High reliability• Low emissions
Valmet’s multifuel power boilers
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Possibility to choose the most economic fuel mixture available in the
market
From biomass to waste and coal in any
combination
Possibility to maximize use of low-carbon fuels
Typical boiler efficiency well over 90%
regardless of fuel
High boiler efficiency means lower CO2
emissions
High electrical efficiency even on demanding fuels*
Low primary emissions due to reasonably low
combustion temperature
Easy NOx and SO2control
by injecting ammonia and limestone into the boiler
Reduced CO2emissions with low-
carbon fuels
High efficiency High reliabilityFuel flexibility Low emissions
Typically over 99% of scheduled
operation time
High reliability evenwith demanding fuels
Over 30 years experience in developing
boiler technology and components in
own R&D centers
* based on high steam temperature and pressure
With HYBEX and CYMIC boilers, fossil fuels can be replaced with renewables in continuously varying proportions. Our multifuel solutions offer:
© Valmet | Circular economy
Gasification technology for biomass and waste
13 June, 2017 © Valmet | Circular economy27
Valmet’s gasification technology converts biomass, recycled materials and waste into product gas. The gas can then be burned into energy in a power boiler or a lime kiln with• excellent electrical efficiency
• minimized carbon footprint
• possibility to connect as co-gasifier to existing power boiler
Gasification technology for biomass and waste
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Minimized carbon footprint Possibility to connect as co-gasifier to existing boilerExcellent electrical efficiency
Up to 60%more electricity
from same amount of wastecompared to grate firing
Clean and corrosion free operation even with high
steam parameters
In co-gasification, the gasifier can replace
up to
100%of fossil fuel
Valmet’s gasifiers use onlylow-carbon fuels such as
biomass or waste
Economical and time-efficient investment
Co-gasifier extends existing boiler’s service life
Valmet’s gasification technology converts biomass, recycled materials and waste into product gas. The gas can then be burned into energy in a power boiler or a lime kiln with:
Minimal downtime of existing energy production
LignoBoost lignin separation technologyfor pulp mills
13 June, 2017 © Valmet | Circular economy29
LignoBoost separates lignin from kraft black liquor in pulp making• Reducing the amount of lignin increases pulp production capacity
• Fossil fuels can be replaced with lignin to produce energy
• Lignin can become a new source of income for the pulp mill
LignoBoost lignin separation technologyfor pulp mills
13 June, 2017 © Valmet | Circular economy30
LignoBoost separates lignin from kraft black liquor in pulp making
Fossil fuels replacedwith lignin to produce energy
New sources of incomefor the pulp mill
Increased pulpproduction capacity
Up to 25%
more pulp by removing 25%
of the lignin in the black liquor
50 litersof oil saved
per ton of produced pulp whenfiring lignin in the lime kiln
Lignin is a
CO2neutral fuel
Green energy fromlignin can be profitablysold to the power grid
Lignin can be sold as fuel inthe form of pellets or powder
Lignin can be sold asraw material for bio
products and chemicals