Knowledge for Excellence in Quality and Costs

Transcripción

1 Eucalyptus Pulp & Paper Process Consultant Biomass Renewable Energy / Environmental P&P Knowledge for Excellence in Quality and Costs Joaquín Fernández Ruiz jfernandez@eucaprocess.com Mobile : Knowledge for Excellence in Quality and Costs 1

2 Who we are Eucaprocess is an expert consulting firm focuses on process improvement and optimisation in the Pulp and Paper making sector using different types of Eucalyptus. It also provides consulting services on renewable energy production using biomass (wood waste and SRWC short rotation woody crops). We seek to apply our expert knowledge to pursuing excellence in cost savings, improving product quality and maintaining environmental performance, all with minimal investment. It draws on wide experience in Operations, Engineering, Research and Development in Eucalyptus Pulp Mills and in Biomass Renewable Energy plants in the Iberian Peninsula and Uruguay, and extends through a network of contacts with top forestry and energy consultants. We seek to assist our clients by involving ourselves and monitoring the proposed solutions to ensure optimal implementation. Professional Profile Industrial Engineer, MBA, with extensive professional experience leading teams in the areas of Operations, Engineering, R & D and Technology in mills and areas of Chemical Industry, Pulp and Paper, Renewable Energy (Biomass and Biorefinery), in both the Iberian peninsula and Uruguay. In continuous contact with the problems of producing pulp using different Eucalyptus (globulus basis). Specialist in Fibre Line process and automation (experience in Suomi-Finland). Staunch advocate of integrating Management Systems - total Quality, Environment and Safety - with Operations and continuous Cost Reengineering. With a strategic vision of innovation, knowledge, management and creativity, providing responsibility, dedication and commitment, and human skills to create effective work teams in order to service clients solutions. Joaquín Fernández Ruiz Eucaprocess Manager jfernandez@eucaprocess.com Mobile : Linkedin: Knowledge for Excellence in Quality and Costs 2

3 Expert consulting services 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines CHIP AND WOOD YARD COOKING / DIGESTERS WASHING OXYGEN DELIGNIFICATION ECF TCF BLEACHING SCREENING AND PULP DRYING Page.-4 Page.-5 Page.-6 Page.-7 Page Pulp Quality Control, problem solving. P&P Environmental control PULP QUALITY P&P ENVIRONMENTAL PROCESS CONTROL Page.-9 Page Optimisation of Eucalyptus pulp refining (Paper production) Page Renewable Energy Production with Biomass Page Development of the Biorefinery concept Page.-13 associated with Biomass 6.- Strategic Consulting, Technologic Benchmarking Page.-14 Knowledge for Excellence in Quality and Costs 3

4 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines CHIP AND WOOD YARD Wood yard management, with a mixed Eucalyptus sources, import/export. Wood processing for digester section, influence on pulp quality (physical and optical properties). Assessment and technical advice on chipping and debarking systems. Chip size and quality. Analysis of the effects of using dry wood. Measurement and control systems (mass, density) log and chip stocks. Control of losses due to bark, fines and oversizes. Chip quality measurement systems, application SCAN standars. Chip cargo management. Knowledge for Excellence in Quality and Costs 4

5 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines COOKING / DIGESTERS Review of cooking conditions (temperature, H-factor, Active Alkali charge, liquor circulation, chip size, basic density, chips and liquor charge, liquor-wood ratio, heating ramp, blowing, ESQUEMA SIMPLIFICADO cooking yield).. DIGESTOR CONTINUO ASTILLAS COCCION VAPOR 11 ata PREVAPORIZADO IMPREGNACION LAVADO ALTA TEMPERATURA LEJIA BLANCA ENFRIAMIENTO AGUA TEMPLADA LEJIA NEGRA A EVAPORADORES PASTA A BLOW TANK Influence on quality, costs and gas emissions. Database of different species of Eucalyptus wood: E.globulus, E.urograndis, E.grandis, E.maidenii, E.bicostata, E.saligna, E.dunnii, E.camaldulensis. Cooking conditions simulator for each species of Eucalyptus, in order to obtain specif final results: Kappa number (join or separate cooking). Steam saving. Steam leveling in the batch cooking. Condensation blow gases, non-condensable gas circuit, diluted and concentrated. Knowledge for Excellence in Quality and Costs 5

6 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines WASHING OXYGEN DELIGNIFICATION Optimisation and automation of counter-current washing. Mass balances, dilution factor, displacement ratio (E10). Improved quality through washing efficiency (Nº stages). Analysis and evaluation (experience) of different washing systems (technology): Presses Vacuum Filters Diffusion Equipment Compaction Baffle Filters COCCION/LAVADO/DESLIGNIFICACION Ejemplo DIGESTOR PFW (CCA-3560) CCA-4060 CONTINUO 6 5 CCA-3560 CCA-3560 DPA-1532 TPRW CCA-3560 VFA R1 DIF R2 P1 TAD 1 P2 TAD LAV Water saving analysis, effluent and condensate recycling. Influence on Quality, Environment and bleaching costs. Energy savings. Oxygen Delignification: revision control parameters (1 o 2 stages), carry over, retention time (channelling/tracers), consistency, temperature, Alkali charge, O 2 used. Additives: trial and assessment support (drainage agents, anti-foaming, pitch dispersing agents, microbicides, talc, phosphonates, chelating products). Cost savings. NPE ( non process elements ): recirculation and drainage. Electrostatic precipitator ash leaching. Knowledge for Excellence in Quality and Costs 6

7 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines ECF TCF BLEACHING Bleaching sequences assessment: TCF, ECF (low AOX), ECF. Alternatives depending on the end AOX target, Eucalyptus wood used, water quality, etc. Bleaching stages (D 0, D, EO, EOP, PO, POP, Z, P aa ), process condition audit: ph, Temperature, Consistency, channelling, towers technology and mixers. Close bleaching water circuit, effluent recirculation proposals, purges. Influence on quality (pitch, brightness) and scale (oxalates). Support to define optimal automatic control strategic (brightness and residuals). Knowledge for Excellence in Quality and Costs 7

8 1.- Process Improvement on Eucalyptus Cellulose Fibre Lines SCREENING AND PULP DRYING Pressurised Screening (in Washing or Drying), technology selection support according to available investment, quality (slots, holes) and expected savings. Assessment of design, circuit and cyclone spare parts. Separation of plastic and light particles. Tanque de Descarga EJEMPLO Esquema Depuración Presurizada en cabecera SEPARACIÓN DE NUDOS DEPURACIÓN PRIMARIA DEPURACIÓN SECUNDARIA DEPURACIÓN TERCIARIA Pasta a LAVADO TRATAMIENTO RECHAZOS DEPURACIÓN (Lavador y Prensa) TRATAMIENTO NUDOS (Lavador) Tanque Nudos Tanque Rechazos Depuración 1ª Nudos a Impregnador Revision of wet zone process conditions: Consistency Machine weight profile Dryness in each stage Fabrics and Felts treatment Vacuum system and layout Technology selection: former, head-box and presses. Steam and water savings (steam tempering control). Knowledge for Excellence in Quality and Costs 8

9 2.- Pulp Quality Control, problem solving. P&P Environmental control PULP QUALITY Quality: : pulp impurities (shives, pitch, cinders, plastic, microbiological slimes),analysis methods, systematic improvement plans (with or without investment).testing of new additives: assessment, monitoring and support. Optical properties: : brightness, yellowing and reversion (TCF pulp). Brightness stability with different Eucalyptus mixes. Internal and surface brightness, fisheye (lumps), storage problems. Pulp Dirt Count Rise problems: Fenton reaction with iron and hydrogen peroxide in TCF pulp. Strenght Properties,, influence of wood mixture, simulator. Best technologies recommendations: dryness measurement, weight and traceability of pulp bales, on-line measurement of impurities and brightness. Quality Systems: : implementation of an innovative system of annual Quality plans and systematic improvement. Setting objectives and monitoring all affected departments: operational and staff (Maintenance, R&D, Engineering, Environmental, Safety). Complementary to and in support of ISO- 9002, TQM (Total Quality Management systems). POLITICA Y OBJETIVOS METAS Ejemplo INFORME DE SEGUIMIENTO PROGRAMA DE GESTION DE LA CALIDAD ACTUACIONES Y DESARROLLO 1.- MEJORA CONTINUA Mejorar los Indices de Calidad de la Pasta por Limpieza y Blancura Reducción de impurezas en la Pasta Parque de Madera Digestores Lavado Deslignificación Blanqueo Rotación Astillas Inversión nueva Criba Granulometría Astillas Astillas de Importación Antraquinona DPTO. SEGUIMIENTO TRIMESTRAL % CUMPLIMIENTO RESPONSABLE 1º Trim. 2º Trim. 3º Trim. 4º Trim. 3ºTrim 4ºTrim P.Madera 0% 25% Laboratorio P.Madera 80% 100% Ingenieria Laboratorio 0% 100% P.Madera 80% 100% Producción 70% 100% Producción 80% 100% Inversión Nuevo Digestor Ingenieria Producción 40% 50% Condiciones de Cocción I+D Revisión Informes Producción 90% 90% I+D Blanqueo I+D Proyecto Segregación Producción 40% 80% Efluentes Ingenieria Filtración Lejía Blanca Producción 0% 20% y L.B. Oxidada Ingenieria Reducción Incocidos Producción 60% 100% y astillas blanqueadas Ingenieria Medición Incocidos Laboratorio 0% 50% Producción Presencia partículas Producción 0% 30% metálicas Análisis de naturaleza Laboratorio 10% 50% de impurezas Knowledge for Excellence in Quality and Costs 9

10 2.- Pulp Quality Control, problem solving. P&P Environmental control P&P ENVIRONMENTAL PROCESS CONTROL Environmental Systems: advisory services on BREF compliance (Reference Document on Best Available Techniques in the Pulp and Paper Industry / IPPC European Commission). Liquid Effluents, closed circuit (quality influence: TCF and ECF pulps). Internal measures to reduce COD, BOD, color, conductivity. Condensate stripping control. Waste water treatment, activated sludge. Technological assessment, benchmarking, startups, optimisation (reactors, clarifiers, filters, temperature, colour, suspended solids..) EJEMPLO ESQUEMA TRATAMIENTO GENERAL DE EFLUENTES NUTRIENTES CAL o NaOH TRATAMIENTO SECUNDARIO (BIOLOGICO) DECANTADORES BIOLOGICOS (SUCCIÓN) 50% EFLUENTES ALTA DQO ( ppm DQO) TORRE TANQUE SELECTOR REACTOR BIOLOGICO ENFRIADORA MEZCLA TRATAMIENTO PRIMARIO FI 2 50% DECANTADOR PRIMARIO FI 1 50% 50% EFLUENTES DE BAJA DQO ( ppm DQO) 50% ESPESADOR BIOLODOS 100% FILTRO BANDAS ESPESADOR PRIMARIO EFLUENTE FINAL CENTRIFUGA A CALDERA DE BIOMASA SECADO TERMICO DE LODOS Waste reduction, internal reuse. Concentrated and diluted gases, process strategy. Control parameters, gaseous effluents, on-line stack measurements. Knowledge for Excellence in Quality and Costs 10

11 3.- Optimisation of Eucalyptus pulp refining (Paper production) Pulp refining strategy recommendations using different species of Eucalyptus, for energy cost reduction and improved paper quality. SISTEMA DE REFINO SEPARADO TINA Fibra Larga SWD TINA Fibra Corta HWD REFINO REFINO REFINO REFINO TINA Rotos TINA Mezcla a máquina deflaker REFINO Influence of different types of wood. 70 Grado de refino, ºSR Pino Eucalipto Abedul Acacia Energía de refino, W Hardwood and Softwood mixing. Commercial-Technical support for Eucalyptus pulp makers (E.Urograndis, E.globulus, E.grandis, E.maidenii, E.dunnii),, with different specialty paper manufacturers: Claims (outsourcing). After-sales service. Improvement plans with the customers. Technical Pulp spokesman. Definition of product technical specifications. Knowledge for Excellence in Quality and Costs 11

12 4.- Renewable Energy Production with Biomass Biomass crushing plant Technology (design, difficulties, flexibility), Best Available Technologies (BAT) for BFB (Bubble Fluidized Bed Boilers) combustion (materials, heat recovery ash..), benchmark plants in Scandinavia. Fuels: analysis (database) and results, influence on plant design (corrosion, sintering ashes). Drying curves, increased GCV. Ash utilisation studies (Spain / Sweden). New biomass plant projects: support on industry knowledge, support on technical offers, new biomass plants. Relations with technologists. Initial feasibility studies, thermosolar- biomass hybrid plants (from the biomass viewpoint). Energy crops and energy production plants. Business model, cost, sensitivity analysis, strategic factors, risk analysis. Evaluación de Productividades SRWC (Ejemplo) A B Media Secano C D E F Media Regadío t. /ha/año Contacts with internationally recognised forestry consultants, (partnership interest projects). Contacts with public and private Centres in relation to biomass. Woody energy crops (SRWC Short rotation coppice woody), advice on genetic improvement, silviculture (species of interest with maximum yield kwh / ha / year), and forest machinery adapted to SRWC. Knowledge for Excellence in Quality and Costs 12

13 5.- Development of the Biorefinery concept associated with Biomass Benchmarking and contacts in biomass gasification (Pulp & Paper sector) (for instance: Lime Kiln with biomass gasification in Sweden, new developments in bio-fuel production with lignin gasification). Other contacts: gasification and gas motors, second wood transformation plant technology. Technical contacts life-cycle analysis and carbon footprint, participation in the European project, Biorenew. Monitoring of new technological applications in Biorefinery (transfer P&P industry experience), Nordic Wood Biorefinery Congress , approved reports. MADERA Eucalyptus PARQUE MADERA Alternativas Proceso Kraft BIOREFINERÍA DESCORTEZADO ASTILLADO Corteza CALDERA CORTEZAS Vapor Astillas O 2/ NaOH -L.B. Ox. H 2O 2 / O 2/ NaOH / ClO 2 COCCIÓN TAMIZADO PRELAVADO DESLIGNIFICACION POSTLAVADO BLANQUEO SECADO OXIGENO ECF / TCF Licor Negro -BIOMASA/ RESTOS FORESTALES -CULTIVOSENERGÉTICOS LEÑOSOS HIDROLISIS Astillas Licor Blanco PROCESO KRAFT EVAPORADORES L.N. TRATAMIENTO BIOLOGICO EMBALADO CALDERA BIOMASA GASIFICACIÓN BIOMASA Licor Negro Celulosa Concentrado Na 2SO 4 TRATAMIENTO FISICO-QUIMICO ALMACEN PASTA CAUSTIFICACIÓN Licor Verde CALDERA L.B. RECUPERACION PASTA ECF / TCF Hemicelulosas Ca CaCO 3 Vapor Licor Negro HORNOS CAL TURBOCOMPRESOR Concentrado VAPOR a Proceso ELECTRICIDAD a Proceso/ Mercado PRECIPITACIÓN LIGNINA Ultrafiltración BLGMF Gasificación L.N. Fuel Motores BLGCC Gasificación L.N. Ciclo Combinado Fs& Ts Fischer ADITIVOS PRODUCTOS QUÍMICOS COMBUSTIBLES BIODIESEL BIOETANOL VAPOR ENERGÍA ELÉCTRICA Assessment of experience and offer relating to biofuel production from microalgae. Other solutions, use of hemicelluloses, (fermentation and ethanol production), lignin derivates (lignosulfonates), cellulose fibre nanotechnology. Innovative experiments in Sweden and Finland. Knowledge for Excellence in Quality and Costs 13

14 6.- Strategic Consulting, Technologic Benchmarking Joint Technical Direction and Project Management. Technology and Process Selection for plant retrofits and green-field mill projects. Support with engineering companies, operation and technology fact-finding trips. Analysis and cost savings: Chemicals and Additives, cellulose yield losses, Energy, Packaging, fixed and semi-fixed (consumables/fungibles). R&D plans, medium and long term assessment. Connection between forest strategy with Eucalyptus species and paper properties and applications. Knowledge Management: development of innovative plan for the Pulp & Paper Industry. ANALISIS DEL CONOCIMIENTO Actividad: CELULOSA Area de Innovación: COCCION ACLARACION ESQUEMAS Y LEYENDAS Analysis Mill organisation, training levels. Tipos de conocimientos: COCCION Automatización optimización y control Conocimiento Maderas para Cocción Teoría química de la Cocción Operativa Gral. Digestores (y/o MTO) Influencia Cocción propiedades Papeleras Ingeniería en Proyectos de Cocción AUT DCS + Ing+Mto.Elec MAD Fcas. + DIT TEO Lab. y/o CIT OPE Planta Fcas. (MTO) PAP CIT + DCL+LAB ING Ofic.Téc. "Experto" compendio de teoría, "Experto" conocimiento teórico y Alto Potencial de desarrollo práctica,ingeniería,automatización experimental Planta Piloto,contacto con como especialista en Cocción visitas,experiencia y casuística. Fcas.,Congresos, visitas y estado del arte Nombre Nombre 30 Nombre AUT MADTEOOPE PAP ING 12 AUT MADTEOOPE PAP ING 12 AUT MADTEOOPE PAP ING 12 Edad (Posibilidad de dar o recibir formación) Nombre 30 Antigüedad (capacidad transmisión "Cultura" ENCE) 55 AUT MADTEOOPE PAP ING 12 Años en puestos relacionados Tipos de Conocimientos (alta especialización) Consultants on Quality, Environment and Safety system integration with Operations. "Management Systems, should work for operations, improving quality and reducing costs" Environmental Systems: BREF compliance advisory consultants. Consulting services on laboratory optimisation, cost reduction and automation. Expertise in industrial accident and incident cause investigations. Risk Management Technical support in the definition of business risk. Knowledge for Excellence in Quality and Costs 14