RAW MATERIALS OF THE FUTURE FOCUS OF FIBER RAW MATERIALS GROUP 2016-2020

MICHIEL ADRIAANSE PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

Roadmap Fiber Raw Materials

•

General trends regarding fiber raw materials

•

Industry ambition

•

Groups of raw materials

•

Approach ‘Paper calculator’; participation

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 2

Starting points Fiber Raw Materials • PfR remains the key raw materials in the NL • Quantity and composition of PfR will keep changing • There is a growing market for alternative fibres (annual plants) • Side-streams find increasing value • Paper mills develop more and more into MIMO mills with extra business interests • Cooperation along chains and between sectors offers more and more opportunities • New business models create new opportunities PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 3

“Added value out of biomass” “ ‘We are taking the maxiumum out of biomass/natural raw materials’ 100% closing of biobased product cycles • 100% reusability or recyclability of all components

• Integrated use of raw materials The paper and board industry is still in the year 2020 the market leader in the Netherlands in the field of non-food biobased products and services From fighting over resources to distributing fractions PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 4

Fiber raw materials 3 “flavors”;  Paper for Recycling

> 2.2 Mt/yr  Wood (virgin cellulose) >90% bought, 1 mill has own production  Alternative fibres from new sources new installations are being installed /invested in PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 5

Paper for Recycling

1/2

 White grades •

Strong decrease of production Graphic Papers (2007 > 2013; -/-23%)

•

Repercussion on availability of ‘Medium and High Grades‘

•

Need for diversification (Virgin; Alternative fibers) and flexibility

 Brown grades •

Slight increase of production Packaging Papers

•

Sufficient availability of ‘Ordinary Grades’

 General •

Non-paper components content keeps rising; (known and new!)

•

Offer of previously “non-recyclable” raw materials

•

Risks of fiber “inbreeding”, “asphyxiation” and “image” PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 6

New fibers from new (regional) sources 

Agro- & Horticultural waste (eg. sugar beets and tomato plants) •

Limited volumes and challenging logistics

•

Processing with existing infrastructure

•

(High-value) niche applications and utilisation of all fractions “necessary”

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 7

The example of tomato 1 tonne of dry stem fibres is lost under a load of: Fraction

Amount per t plant [%]

Amount per t fibre (dm) [ton]

Contribution per to fibre [€/tonds]

Fibers

10

1

~ € 100,-

Other dry matter

14

1,4

~ - € 50,-

Plant juice

76

7,6

~ - € 100,-

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 8

The example of tomato; Where is the leverage you need? “A complete utilisation is necessary for a profitable business case”

stems (v)ezel

Fractionation and valorisation of all fractions

Using the entire barrel of Biomass PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 9

New fibers from new (regional) sources 

Agro- & Horticultural waste (eg. sugar beets and tomato plants) •

Limited volumes and challenging logistics

•

Processing with existing infrastructure

•

(High-value) niche applications and utilisation of all fractions “necessary”



Specially cultivated plants (eg. miscanthus, hemp) •

Potentially!

•

Requires high values “unlocking” and intersectoral fraction utilisation



Industrial residues (eg. diapers, manure, wastewater treatment sludge) •

Fractionation and separate utilisation necessary

•

Risks of sensitive image



Not utilised natural plants (eg. grass, reed) •

Implemented cases with high image value

SHEET 10

Paper calculator

1/3

All raw materials for papermaking are characterized by a strong inhomogeneity and greatly varying compositions - Paper for Recycling - Wood - Annual plants

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 11

PAPER CALCULATOR

2/3

Selection assessment for Raw Materials

Main requirements of the paper industry for raw materials Product quality

Process performance

Economic efficiency

Quality parameters for paper production PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 12

Paper calculator

3/3

How are all components brought into the business case? – – – – – –

Price Quality Energy requirements (for „unlocking“ and processing) Process aids requirements Value of various fractions ……

Raw material

->

Fibre in paper

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 13

PROJECT OUTCOMES • • • • •

Comparison of the various raw materials (groups) Taking “all“ aspects int consideration Potential effect of options „Rough“ business cases Follow-up of most promising case(s) in new project(s) • Until mid-2017

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 14

PARTICIPATION POSSIBILITIES Participating: • Declare interest • Which raw materials are most interesting ? • Still more parameters to add? Expectations: • In-kind contribution • Contribution of own experiences (never directly shared; only collectively examined!) PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 15

THIS PROJECT IS MADE POSSIBLE PARTLY BY:

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

SHEET 16

MICHIEL ADRIAANSE +31(0)6 47047024 [email protected]

PLATFORM VEZELGRONDSTOFFEN– DOORWERTH - 3 FEBRUARI 2016

PAPER WITH ADDED PERFORMANCE INTRODUCTION

MICHIEL ADRIAANSE PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

STARTING POINTS Raw materials: • become more scarce; competition & prices ↑ • PfR remains the most important raw material in the NL • Quantity and composition of PfR change; Diminishing – increasing content of “non-paper” components – increasing content of inorganic components – decreasing ONP/OMG and mechanical pulp

raw material quality

End product: higher requirements • grammage reduction Increasing • better properties/additional functionality product • increased use of process chemicals (known and new!) demands PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

SHEET 2

Mechanical treatment • Optimization conventional refining • Compression refining • Fiber extrusion

Performance grid

Pulp Remove unusable components Separate 'disturbing' components Fractionation and separation (fibers, fines, fillers, ink, stickies, ….)

Upgrading

Mechanical

composition

Chemical

Add useful components Adding value-adding fibers • Alternative fibres • Higher grades Paper for Recycling • Internally available streams

Application of additives: • Starch • Nano-cellulose • Enzymes • Chemical modification of fibers PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

SHEET 3

PROJECT OUTCOMES • Comparison of the various options • Utilising previous project outcomes and industrial experiences • Potential effect of options • „Rough“ business cases • Follow-up of most promising case(s) in new project(s) • Until mid-2017 PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

SHEET 4

PARTICIPATION POSSIBILITIES Participating: • Declare interest • Which option is more interesting ? • Still more comparable cases to add? Expectations: • In-kind contribution • Contribution of own experiences (never directly shared; only collectively examined!) PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

SHEET 5

THIS PROJECT IS MADE POSSIBLE PARTLY BY:

PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

SHEET 6

MICHIEL ADRIAANSE +31(0)6 47047024 [email protected]

PLATFORM VEZELGRONDSTOFFEN – DOORWERTH - 3 FEBRUARI 2016

PRESENTATION

ESKA POWER PROJECT REJECTS GASIFICATION FACILITY A

HOOGEZAND GRONINGEN THE NETHERLANDS

Creating Energy Solutions For The Future

PRESENTATION

CONTENTS LEROUX & LOTZ TECHNOLOGIES

COMPANY OVERVIEW ●

Combustion Technologies Eska Power Project PROJECT BRIEF ● LLT SOLUTION ●

Creating Energy Solutions For The Future

KEY DATA Start of Business Total Staff Locations

Business Units Turnover Parent Company Workshop

Creating Energy Solutions For The Future

LEROUX & LOTZ TECHNOLOGIES 1946 205 France Nantes [44] Grenoble [38] Poland Elbląg Heat & Power and Industries 54 M€ in 2014 Groupe ALTAWEST 17,000 m2 (Nantes) 1,000 m2 (Elbląg)

OVERVIEW

Creating Energy Solutions For The Future

Groupe ALTAWEST

CORE BUSINESS ●

HEAT & POWER DIVISION

BOILER ISLANDS

Complete “chute to stack” delivery for

Biomass Waste to Energy

●

WATER TUBE BOILERS

●

REVAMPING EXISTING BOILER PLANT

1-150 MWth 10-50 MWth

Design, manufacture and installation for wide range of waste heat gases including incineration & gasification of MSW, RDF, SRF, biomass 5-200 MWth Complete overhaul and betterment of existing plant with holistic approach covering all aspects of your facility

Creating Energy Solutions For The Future

PRESENTATION

CONTENTS LEROUX & LOTZ TECHNOLOGIES

COMPANY OVERVIEW ●

Combustion Technologies Eska Power Project PROJECT BRIEF ● LLT SOLUTION ●

Creating Energy Solutions For The Future

COMPETENCE

THERMAL CONVERSION

….is the use of heat, with or without the presence of oxygen, to convert a feedstock into other form of energy….

● DIRECT COMBUSTION

excess air -> heat (CO2+H2O)

● GASIFICATION ● PYROLYSIS

limited air -> syngas (CO, H2, CH4, CO2)

Creating Energy Solutions For The Future

no air

-> oil/gas/char

COMPETENCE

SYNGAS APPLICATIONS

Minimal Gas • Direct Firing in Boiler with a Burner Cleaning

Extensive • Gas Engine Gas Cleaning • Gas Turbine Further Processing Creating Energy Solutions For The Future

• Chemical Production • Substitute Natural Gas

COMPETENCE

COMBUSTION TECHNOLOGIES

COVERING A WIDE RANGE OF TECHNOLOGIES

● ● ●

FLUIDISED BED SPREADER STOKER MASS BURNING

(*) both for combustion and gasification Creating Energy Solutions For The Future

Bubbling [BFB] and Circulating [CFB] (*) Rotating Grate and Vibrating Grate

Step Grate, Moving Grate

PRESENTATION

CONTENTS LEROUX & LOTZ TECHNOLOGIES

COMPANY OVERVIEW ●

Combustion Technologies Eska Power Project PROJECT BRIEF ● LLT SOLUTION ●

Creating Energy Solutions For The Future

ESKA POWER PROJECT

PROJECT BRIEF

To generate steam by utilizing waste paper rejects Gasification 3.5 tph 16 bar

Creating Energy Solutions For The Future

Brief Technology Rejects Throughput Steam Parameter Emissions

ESKA POWER PROJECT ~ Early 2000’s 2006 2008 June 2010 Dec 2011 Feb 2013 2013 Feb 2014 Feb 2014 Jan 2015 Summer 2016 Oct 2016

Creating Energy Solutions For The Future

TIMELINE

First Ideas developed Ecofys Study “Converting Rejects – from P&B Industry to energy on own site” Tauw Report “Producing” Energy from Cardboard Paper Waste (master thesis) Arcadis Report “Feasibility Study On Site Processing Coarse Rejects at Eska” Eska Submission Environmental Permit (Omgevings Vergunning) Issue of Omgevings Vergunning by Provincie Groningen Several appeals Discussion with LLT commence Raad van State confirms validity Omgevings Vergunning Contract Award Commencement Commissioning Expected Completion

Eska Hoogezand AEREAL VIEW Residential Area Pulper

Gasification Facility Existing Boiler House

Residential Area

ESKA POWER PROJECT

LLT SOLUTION

Technology Airblown Circulating Fluidized Bed System Components Fuel Preparation (crane, shredder, magnetic + non-magnetic separator) Storage & Dosing (c/w reclaim system, conveyors and surge bin) Gasifier Syngas Combustion System Heat Recovery Steam Generator Fluegas Treatment System

Creating Energy Solutions For The Future

ESKA POWER PROJECT Flue Gas Treatment System

LLT SOLUTION Combustion System & Boiler Fuel Preparation, Handling & Storage

CFB Gasifier

Creating Energy Solutions For The Future

LEROUX & LOTZ TECHNOLOGIES Gasification

THANK YOU

Prepared Fuel to Storage

Creating Energy Solutions For The Future

Leroux & Lotz Technologies 10 rue Irene Joliot Curie magnetic separator 38000 EYBENS FRANCE Telephone +33 4 76 14 77 70 Mobile +33 6 27 33 42 78 E-mail [email protected]

Thermal Fiber Detection

Thermal Fiber Detection

Introduction Studio diip Product design and computer vision For 5 years, now with 5 people Situated in Leerdam, the Netherlands

Thermal Fiber Detection

What is Computer Vision “Recognizing relevant information from images by acquiring, processing, and analyzing them”

Expertise - Artificial intelligence - Image processing - Communication and networking - Mathematics and geometry - Hardware & camera knowledge

Thermal Fiber Detection

Theory

Goal: Detect paper fibers in reject stream to increase efficiency of washing cycle Partners: KCPK, DS Smith De Hoop, SolidPack

Steps - Detect temperature differences with thermal cam - Extract background and waste water - Isolate paper fiber areas - Determine relative density - Output to systems in control room

Thermal Fiber Detection

Setup

Setup: Dual camera (thermal and regular color) IP67 rated casing Network connected, PoE

Thermal Fiber Detection

Algorithm

Video

Thermal Fiber Detection

Setup

Setup: Shows relative fiber amount in reject stream Per shift or per day Shows live feed from color camera Data connection for long term analysis

Thermal Fiber Detection

Status

Current status: First setup operational Running trials at DS Smith De Hoop Finetuning connections Analysing results

Interested? Contact me: [email protected]

Innovative solution to separate mineral from organics in P&B sludges

Extract Value from Sludge KCPK Seminar Feb 3rd, 2016

KCPK seminar

Introduction: Why to work on mineral and organic separation in P&B sludges ? 2

WHY SEPARATING MINERAL AND ORGANICS IN SLUDGES ?

P&B SLUDGE VALORISATION

• P&B Sludge valorisation needs • Ash content increase in raw materials • Reject handling and deposit cost increase • To be able to develop higher value of each component mineral and organic

• Mineral can disturb P&B while some organic can give benefits • . 3

P&B SLUDGE VALORISATION

WHY SEPARATING MINERAL AND ORGANICS IN SLUDGES ? • Ash content level is increasing in end products and water circuits due to an increase of the waste paper inorganic content. • Sludge volume coming from DAF / Deinking cell in DIP has the tendency to increase. • However, an ash control/ reduction need to be done with the highest selectivity to limit Fiber and fines losses at the lowest operating cost. • Fines has to be preserved as they are important for mechanical and to some extent optical properties. •. 4

Market trends Focus on PW market Filler consumption trend in P&B (ctp source)

Fillers Trend in Recycling Paper

6

Market trends: a challenge for the ONP OMG mix

Market trends: a challenge for mechanical pulp

Some Fines are FINE: Fines analysis versus TMP pulp

9

Some Fines are FINE: Fines analysis

10

SLUDGE VALORISATION KADANT STRATEGY How to apply it ? Which product & Process ?

DEVELOP PROCESS TO SEPARATE MINERALS AND ORGAINIC FROM SLUDGES

YIELD SAVING STRATEGY

VALUE ORGANIC AT THE MAXIMUM IN P&B PROCESSES FIND BIOREFINERY VALUE FOR MINERAL EXTRACTED

.

11

1. GO TO NEW SPLITTING PORCESSES 2. FINES ARE FINE 3. VALUE MINERAL

KCPK SEMINAR 2016

SEPARATION MINERAL & ORGANIC IN SLUDGES 12

Kadant with Multisplit screen An expert in fractionation by Screening Kadant Multi Split Screen Pilot machine tested during boost eff project

Kadant after Noss acquisition

An expert in fractionation by Hydrocyclone

Kadant Frationator cleaner Pilot machine tested during boost eff project

MULTI SPLIT TECHNOLOGIES FRACTIONATION STRATEGY & PRINCIPLE

Why fines are important?: Fibrils

Flakes Luukko et al ‘99 Higher specific surface area finesFibrills

High specific surface area Increase sheet density & mechanical strength properties Do not promote optical properties

Low specific surface area Do not increase sheet density & mechanical properties. Poor bonding ability, cause sheet defects (linting) But promote optical properties

Hydrocyclone Fractionation

True in 100% pure state

Lower specific surface area finesFlakes

Fines fractionation 46

44

f2

43 42 41 f1 SGW f1 SGW & f2 SGW f2 SGW

40 39 38 0%

10%

20%

30%

40%

% added Mean fibre width

f2 TMP

30.0

f1: 21.9 µm S.Acc:23.8µm f2: 26.4 µm

Screen accepts f1 TMP

20.0 %

Tensile Index (N.m/g)

45

10.0

0.0

5-7

7-9 9-12 1217

1723

2330

3041

4156

Fibre width class (µm)

56- 75-> 75

50%

f1

Kadant with new MAK C family An expert in selective & Sludge flottation MAK-C S 120 Plug & Paper Test in “Real” size in mills: Impact on yield Impact on efficiency Impact on quality

Impact of MAK-C on efficiencies.(1) A wide range in terms of adjustment for froth height in MAK-C cell allows to achieve the optimal running conditions.

And it is controlled with only 1 valve.

MAK C Improved design Colum zone Collision Drainage and contact time

Reject control

Air Air

Injection zone

Air

Mixing zone Collision

Air

Air

MAK-C : Mix of Multi Aerated & Column flottation Cell

Impact of MAK-C on efficiencies.(2)

NEW MAK C Cell versus Tank Flottations: Comparative analysis

22

2016: Kadant Technology Center

KCPK SEMINAR 2016

TEST RESULTS ON 2 TYPE OF SLUDGE’S

24

Extract value from sludge

Extract value from sludge’s process Micronisation process & Fiber recovery

Target is dispersed agragate and recover Fiber

FIBER FRACTION

MINERAL SEPARATION

Target is to have a mineral fraction as pure as possible

MINERAL

POWER BONDING GENERATION

Target is to generate a high power bonding fraction and a mix residual fraction

FINES SEPARATION

FRACTION

POWER BONDING FRACTION RESIDUAL MIX FRACTION

SLUDGE 1 coming from DAF from packaging mill

SLUDGE 2 coming from Tissue mill with Deinking

TAKE AWAY MESSAGE Sludge 1 OCC LESS THAN 0.3% OF FIBER NO FIBRE TO RECOVER

MINERAL FRACTION PURITY UP TO 75% Mineral without post chemical treatment

BONDING FRACTION NO BONDING POTENTIAL FRACTION DECREASING PROPERTIES MIX RESIDUAL FRACTION VERY POOR VALUE

15 TO 40% OF THE FEED FRACTION

SLUDGE 2 coming from Tissue mill with Deinking Initial Sludge

Fibre fraction

Filler fraction

Fines fraction

SLUDGE 2 Bonding Fines/ Flakes before separation process

SLUDGE 2 Bonding Fines/ Flakes before separation process

SLUDGE 2 Bonding Fines after separation process

SLUDGE 2 Bonding Fines after separation process SLUDGE 2 DIP 100%fibres 99% fiber+1% DIP original sludge 2 after fibre separation 99% fiber+ 1% Fine bonding fraction sludge 2 95% fibre+ 5% Fine bonding fraction sludge 2

SLUDGE 1 OCC

Bonding index 100 103 110 115

Bonding index

100%fibres

100

99% fiber+1% OCC original sludge 1

95

99% fiber+ 1% Fine bonding fraction sludge 1

95

Sludge 2 DIP ABOUT 16% OF FIBER TO RECOVER THIS FRACTION IS ABOUT 20% OF FEED FIBER RECOVERY INTEREST

MINERAL FRACTION PURITY

UP TO 85% Mineral without post chemical treatment

BONDING FRACTION VERY GOOD BONDING POTENTIAL 10 TO 15% OF FEED MASS

MIX RESIDUAL FRACTION VERY POOR VALUE 10 TO 15% OF THE FEED FRACTION

CONCLUSIONS

OCC SLUDGE’S

SLUDGE 1

DIP TISSUE SLUDGE’S SLUDGE 2

• NO BIG INTEREST TO DEVELOP A EVS Process “Extract Value from Sludge” • Unless interest outside paper industry from the mineral fraction.

• A MAJOR INTEREST FOR EVS PROCESS • GOOD FIBRE VALUE Design without weld • GOOD MINERAL FRACTION POTENTIAL VALUE • VERY PROMISING BONDING POWER VALUE • VERY LOW FINAL RESIDUAL MIX, over 85 TO 90% OF SLUDGE HAVING FOUND INTERESTING VALUES

alain.las[email protected] [email protected] [email protected]

Questions