Corrosion damage and in-service inspection of retractable sootblower lances in recovery boilers

Several reports of accidents involving serious mechanical failures of sootblower lances in chemical recovery boilers are known in the pulp and paper industry. These accidents mainly consisted of detachment and ejection of the lance tip, or even of the entire lance, to the inside of the furnace, towards the opposite wall. At least one of these cases known to the author resulted in a smelt-water explosion in the boiler. In other events, appreciable damage or near-miss conditions have already been experienced. The risk of catastrophic consequences of the eventual detachment of the lance tip or the complete lance of a recovery boiler soot-blower has caught the attention of manufacturers, who have adjusted their quality procedures, but this risk also needs to be carefully considered by the technical staff at pulp mills and in industry committees. This paper briefly describes the failure mechanisms that prevailed in past accidents, while recommending inspection and quality control policies to be applied in order to prevent further occurrences of these dangerous and costly component failures. Digital radiography, in conjunction with other well known inspection techniques, appears to be an effective means to ensure the integrity of sootblower lances in chemical recovery boilers used in the pulp and paper industry.

Comparative assessment of the pulping potentials of soda and mea processes for the development of paper-pulp from sugarcane bagasse

Pulping trials were carried out using MEA and the soda process comparing their pulping potentials. The operating conditions such as the concentration of the cooking liquor (50%, 75%, 100%) for MEA and (10%, 15%, 20%) for NaOH, the maximum cooking temperature (150oC, 160oC, 170oC) and cooking time (60, 90, 120minutes) for both processes were investigated systematically to establish optimal pulping conditions. The agro-biomass used in this investigation is Sugarcane Bagasse viewed as alternative raw material for pulp and paper production. The lignin content of Bagasse (19.5%) was low; indicating that Bagasse should be easier to pulp. The optimum cooking conditions (independent variables) for MEA pulping were 75% MEA concentration, 150oC cooking temperature and 90 minutes cooking time. Excel 2013 was used to analyze the effect of independent variables on yield of bagasse pulp and properties of furnished paper from MEA process in comparison with the Soda process which include tear index, tensile index, burst index and folding endurance with errors less than 15% in all cases. The Kappa number range (12.7-16.9), viscosity (270-870 ml/g) and brightness (62.1-93.2%) of bagasse pulp are appropriate for high-brightness printing and writing papers. The physical properties of furnished paper, tear index (13.4 mN.m2/g), tensile index (71Nm/g), Burst index (4.8 KN/g) and folding endurance (82) recommend the cellulosic pulp from Sugarcane Bagasse obtained from the MEA process for strengthening the virgin fiber in recycled papers and also for developing certain types of printing and packaging papers. Due to the awareness towards the negative impact of kraft mill’s effluent to the environment recently, soda pulping started to regain its popularity among the pulp mills especially non-wood based pulp mills. MEA process is more economically attractive given its high pulp yield, despite the significant increase in chemical demand for bleaching. MEA pulping is a good alternative to soda pulping furnishing high pulp yield with less cooking temperature, i.e. 150oC, thereby saving a considerable amount of energy with less odoriferous pollutants and pollution load associated with the soda process.

The economics of forest bioeconomy: new results

We examine the emerging forest bioeconomy as an integrated multi-product industrial ecosystem, where the traditional pulp mills allocate the use of side streams to independent biochemical companies manufacturing bioproducts in the vicinity of the pulp mills. Biochemical companies benefit from the proximity by receiving wood-based side streams at lower costs and pulp mills from having a new source of revenue from selling side streams. We focus on the economic interaction between the pulp mill and the biochemical company, and study the impacts on the use of wood and profits under perfect and imperfect competition. We demonstrate that the new industrial ecosystem uses more wood than traditional pulp mills, but, depending on the side stream, it may promote cascading use of wood-based side streams.

Hydrothermal Carbonization of Chemical and Biological Pulp Mill Sludges

A modern pulp mill generates a variety of different by-products and waste streams, some of these can be recycled, refined, sold, or used on-site for energy production. However, some, such as chemical and biological sludges produced in wastewater treatment cannot be reused or disposed of easily, mainly due to their high moisture content and poor drying characteristics. Tightening legislation regarding waste disposal as well as the growing need to increase the process efficiencies of pulp mills act as driving forces to find environmentally friendly and energy-efficient techniques for pulp mill sludge treatment. This study summarizes the current methods for pulp mill sludge handling and evaluates the potential of hydrothermal carbonization (HTC), a conversion process through which wet organic substrates can be transformed into a carbonaceous material (hydrochar). Depending on the process parameters, the material’s structure is modified, enabling hydrochar use in energy, soil conditioning and adsorption applications. The sludges were hydrothermally carbonized at 180, 200, 220 and 240 °C for 3 h. The hydrochar and liquid products’ main properties were analyzed. Their potential applications were also evaluated. The effective treatment of sludges from the pulp industry with HTC could transform energy-demanding waste into a value-added source of materials.

Addressing production bottlenecks and brownstock washer optimization via a membrane concentration system

Advancements in membrane systems indicate that they will soon be robust enough to concentrate weak black liquor. To date, the economic impact of membrane systems on brownstock washing in kraft mills has not been studied and is necessary to understand the viability of these emerging systems and their best utilization. This study investigated the savings that a membrane system can generate related to brownstock washing. We found that evaporation costs are the primary barrier for mills seeking to increase wash water usage. Without these additional evaporation costs, we showed that our hypothetical 1000 tons/day bleached and brown pulp mills can achieve annual savings of over $1.0 MM when operating at higher dilution factors and fixed pulp production rate. We then investigated the impact of increasing pulp production on mills limited by their equipment. In washer-limited mill examples, we calculated that membrane systems can reduce the annual operating cost for a 7% production increase by 91%. Similarly, in evaporator-limited mill examples, membrane systems can reduce the annual operating cost for a 7% production increase by 86%. These results indicated that membrane systems make a production increase significantly more feasible for these equipment-limited mills.

Lignin functionalization strategies and the potential applications of its derivatives – A Review

Lignin is one of the most important and widespread carbon sources on Earth. Significant amounts of lignin are delivered to the market by pulp mills and biorefineries, and there have been many efforts to develop routes for its valorization. Over the years, lignin has been used to produce biobased chemicals, materials, and advanced biofuels on the basis of its variable functionalities and physicochemical properties. Today, lignin’s applications are still limited by its heterogeneity, variability, and low reactivity. Thus, modification technologies have been developed to allow lignin to be suitable for a wider range of attractive industrial applications. The most common modifications used for this purpose include amination, methylation, demethylation, phenolation, sulfomethylation, oxyalkylation, acylation or esterification, epoxidation, phosphorylation, nitration, and sulfonation. This article reviews the chemistry involved in these lignin modification technologies, discussing their effect on the finished product while presenting some market perspectives and future outlook to utilize lignin in sustainable biorefineries.

Removing the Bottleneck on Wind Power Potential to Create Liquid Fuels from Locally Available Biomass

In order to reduce global greenhouse gas emissions, renewable energy technologies such as wind power and solar photovoltaic power systems have recently become more widespread. However, Japan as a nation faces high reliance on imported fossil fuels for electricity generation despite having great potential for further renewable energy development. The focus of this study examines untapped geographical locations in Japan’s northern most prefecture, Hokkaido, that possess large wind power potential. The possibility of exploiting this potential for the purpose of producing green hydrogen is explored. In particular, its integration with a year-round conversion of Kraft lignin into bio-oil from nearby paper pulp mills through a near critical water depolymerization process is examined. The proposed bio-oil and aromatic chemical production, as well as the process’ economics are calculated based upon the total available Kraft lignin in Hokkaido, including the magnitude of wind power capacity that would be required for producing the necessary hydrogen for such a large-scale process. Green hydrogen integration with other processes in Japan and in other regions is also discussed. Finally, the potential benefits and challenges are outlined from an energy policy point-of-view.

Effect of polysulfide pulping process on the energy balance of softwood and hardwood kraft pulp mills

Polysulfide pulping is a method to increase the pulp yield in a kraft pulp mill. Higher production is in the core of pulp mill process development, but modifications in cooking raise questions on their effects on the other parts of the process. This study focuses on the impacts of polysulfide pulping on the energy use and production of kraft pulp mills. The impacts are estimated by calculating and analyzing the steam and electricity balances of reference softwood and hardwood mills. Energy generation using residual biomass is an essential part of the operation of a kraft pulp mill, and often a notable source of income. The results show that implementation of polysulfide cooking affects both energy consumption and production. Higher hemicelluloses content of pulp cooked using polysulfide liquor means that less organic material ends up in the black liquor. Subsequently, the recovery boiler energy production suffers. The reduced steam production together with increased steam consumption decreased electricity production, corresponding to a decline in sellable electricity of 22.4 % in the hardwood mill and 28.4 % in the softwood mill. The study shows that increasing the pulp production by investing in polysulfide cooking in stand-alone kraft pulp mills can be economically feasible.