Valeria Lundberg

Converting a kraft pulp mill into a multi-product biorefinery: techno-economic analysis of a case mill

In this case study, we investigated the conversion of an existing Swedish kraft pulp mill to the production of dissolving pulp, with export of electricity, lignin, and a hemicellulose stream suitable for upgrading. By increasing the level of heat integration of the mill, it was possible to achieve self-sufficiency in terms of steam and to produce significant amounts of excess steam. The excess steam could facilitate the integration of a lignin separation plant or be used for power generation. The production of dissolving pulp requires a higher input of wood that is required for the same level of pulp production as is achieved with kraft pulp. For the studied mill, the batch digester was the main limitation for pulp production. Nevertheless, if the digester capacity was increased, then the level of pulp production could be maintained. In addition, the recovery boiler, causticization plant, and evaporation plant had sufficient capacities for preserving the same production level upon conversion, and could easily be upgraded to a certain degree through relatively simple measures for an increase in pulp production. However, increasing pulp production beyond that limit required extensive upgrades or investments in new equipment, which negatively affected annual earnings. Annual earnings were found to be also dependent upon the level of heat integration, type of by-product, and the costs for lignin and electricity. However, our results suggest that the optimal process configuration is more dependent upon other factors, such as the long-term vision of the company and policy instruments.

Energy Analysis for Conversion of a Kraft Pulp Mill into a Dissolving Pulp Mill

Currently, kraft pulp mills in Europe and North America are facing several challenges and have been forced to think along new products and new business areas. One opportunity is the conversion of chemical pulp mills into dissolving pulp mills by extracting hemicellulose prior to digesting via pre-hydrolysis. From the extracted wood chips, the more valuable dissolving pulp can be produced whereas the hydrolysate can be upgraded to high-value products. In this paper, pinch analysis is used to evaluate the consequences in the energy balance and utility system of a kraft mill converted into dissolving pulp production as well as to identify the potential for heat integration within the host mill itself, between the host mill and the pre-hydrolysis unit and with a hemicellulose upgrading process. The results show that proper heat integration within the host mill itself, and between the host mill and the pre-hydrolysis unit gives significant amounts of surplus steam which could be exported to a hemicelluloses upgrading process, used for power generation or to facilitate lignin extraction.

High Solids Loading in Ethanol Production – Effects on Heat Integration Opportunities and Economics

Production of lignocellulosic ethanol still suffers the drawback of high production cost. Methods for making the process more cost efficient are therefore of high importance for commercialising large-scale production. One way of improving the process economics is to ensure efficient heat integration within the process, thereby reducing process energy costs. Another opportunity to improve production costs is to design the process for high solids loading in the bioreactors. By operating the process with higher solids concentrations (so-called high-gravity), water flows through the process will be reduced, which would enable smaller equipment and lower energy demand for downstream separation and purification of the ethanol product. However, problems with pumping and mixing are also likely to occur due to higher viscosities. Furthermore, the yield will be lower due to increased concentration of inhibitors. In addition, the opportunities for heat integration within the process will be affected. In this paper, the effect on heat integration opportunities of the high gravity concept is investigated for ethanol production in a stand-alone process in which fractionation of the softwood raw material is assumed to be achieved with steam explosion. Estimations of how the process economics will be affected are also provided.

Enlarging the Product Portfolio of a Kraft Pulp Mill via Hemicellulose and Lignin Separation - Process Integration Studies in a Case Mill

Increased energy and raw material prices along with contracting markets for kraft pulp, have highlighted the need for the pulp industry to enlarge their traditional product portfolio with new value-added products via the implementation of biorefinery concepts. In this paper, we have investigated potentials for enlarging the product portfolio of a kraft pulp mill by extracting hemicellulose prior to digesting and in this way, converting to dissolving pulp production. A case study has been performed on a Swedish kraft pulp mill, in order to evaluate the consequences of the original mill configuration, level of heat integration and choice of by-products produced have on the overall profitability of the mill upon conversion to dissolving pulp production. For the mill studied, the batch digester is identified to be the bottleneck for both kraft and dissolving pulp production. If the digester capacity is increased by e.g. purchasing new effects, the pulp production could be maintained. The results from the energy study indicate that dissolving pulp production is more heat demanding than kraft production. However, by increasing the heat integration of the mill, it is possible to, not only become self-sufficient in terms of steam, but also to produce significant amounts of excess steam. The steam excess facilitates integration of a lignin separation plant or can be used for power generation. The net annual profit was evaluated for varying prices of electricity and lignin. For the economic conditions studied, lignin separation was always better than power generation, if lignin can be priced as oil.