Production of Chemicals and Materials in Future Pulp

Report
Production of Chemicals and Materials in
Future Pulp Mill Biorefineries
Karin Lindgren, Innventia
INNVENTIA AB
 Staff
270
 Swedish R&D company
 Serving customers globally
 Pulp, paper, packaging, printing, new materials and biorefining
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Chemical pulping process
Source: Aker Kvaerner
Lindgren Italic 4
Biorefinery – Simultaneous production of
fibres, energy and chemicals
 Increasing
costs
– Energy and wood
 Decreasing
trend prices on pulp
 Biorefinery is the solution
–
–
–
–
Handling of large volumes of biomass
New pulp mill products
New efficient separation processes
Add “side” processes
 Innventia
approach
– Kraft/soda pulp mill platform
– Focus on the major components
– Efficient separation process and mill integration
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Lignin carbon fibres
Cellulose
Wood/plants- a mine for valuable polymers
Cellulose
Softwoods
Cellulose %
Hardwoods
Agro/annual
Spruce
Pine
Birch
Euca.
glob.
Euca.
urogr.
Bagasse
44
44
45
51
50
44
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Cellulose Products
NanoCellulose
Kraft Pulp
Fibres
Fibre PLA
Composite
Transparent
Films
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Lignin from black liquor - LignoBoost
50% of the wood ends up in cooking liquor
Cellulose products
Wood to kraft
pulp mill
Pulp
Carbohydrates
Black liquor
Extractives
Lignin
55-60 % of energy goes into the black liquor
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Wood/plants – a mine for valuable polymers
- lignin
Softwoods
Spruce Pine
Lignin, %
27
28
Hardwoods
Euca.
glob.
24
Agro/annual
Euca.
Hemp Bagasse
urogr.
29
25
22
Physical/chemical properties vary with species and process
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The LignoBoost process
Lignin IN
Lignin OUT
Evaporation
Recovery
Boiler
Replacement of
fossil fuel in lime
kilns
50 L fuel oil ptp
can be saved
Lime Kiln
Digester
Wood
Wood Chips
Bleaching
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Pulp/Paper
The LignoBoost process
Precipitation
Filtration
Filtration &
Displacement
washing
Re-suspending
H2SO4
Wash liquor
Black
liquor
Lignin
CO2
Back to the
evaporation plant
Back to the
evaporation plant
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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LignoBoost lignin – a new material
Typical composition, %
C
Na
Ash
S
N
64 - 66
0.05 - 0.4
0.3 - 1
1-3
0.1
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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OCH 3
OH
OH
HO
HO
lignin
OCH 3
O
lignin
OH
OCH 3
HO
O
O
HO
OH
HO
O
OCH 3
O
HO
O
HO
HO
OCH 3
Alkali
Water
O
HO
OH
1%
25%
Sugar content 2%
10%
H 3 CO
S
O
OH
O
O
O
OCH 3
HO
OH
H 3 CO
OH
Ash content
H 3 CO
OCH 3
OH
OH
O
O
OCH 3
HO
Solubility
HO
O
O
O
HO
OH
OCH 3
OCH 3
OCH 3
O
OH
3%
5%
OH
O
HO
Lignosulphonate
H 3 CO
OH
HO
OCH 3
HO
Kraft lignin
HO
OCH 3
HO
O
HO
OCH 3
OH
O
OCH 3
HO
HO
OCH 3
OCH 3
OCH 3
O
HO
O
CHO
O
HO
OH
O
OH
HO
O
OCH 3
OH
OCH 3
OH
Metso filter in Innventias lignin demo plant
VPA 1040
24 chambers
1-1.2 t lignin/h
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Fossil fuel in pulp mill lime kilns
In Sweden ca 300.000 tonne
oil/year
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Carbon fibres - High value application of lignin

Construction material in composites
Light Weight
 High Strength and Modulus
 High Resistans to Heat and Corrosion

Expensive
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Oil or renewable
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Manufacturing process of carbon fibres
Raw
material
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Carbon fibres from lignin
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Lignin can make difference
650 000 ton
pulp/year
10% lignin extracted … 16 000 ton carbon fibres
= 33 000 ton
…can replace 40 %
steel in 160.000 cars
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Activated carbon from lignin
Water and gas cleaning
 Main industrial source coal
 Physical and chemical activation
 Surface area up to 3000 m3/g

Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Phenols from lignin
OH
R
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Hemicellulose from black liquor,
chips, saw dust and forestry residues
Wood/plants – a mine for valuable polymers
- Hemicelluloses
Softwoods
Hardwoods
Agro/annual
Spruce
Pine
Birch
Euca.
glob.
Euca.
urogr.
Hemp
Bagasse
Xylan, %
9
8
26
21
16
29
28
Glucomannan, %
19
18
3
4
3
2
2
• Glucomannan degrades in alkali
• Xylan is relatively stable in alkali
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Chip leaching* for salt and hemicellulose removal
Developed for pre-treatment prior to kraft pulping
Leaching liquor (acid or alkaline)
Wood chips
Chip kidney
To processing
• pulping
• pelletizing
• gasification
Polymeric hemicellulose and inorganic ions
*Protected by patents: WO2004/050983, US2005/0034823, WO03/046276
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Xylan from black liquor
Industrial ultrafiltration trials with in-line ceramic membrane 2007
 Laboratory membrane filtration unit at Innventia since 2003

White liquor
Principal outline of mill trial:
Wood chips
UF-membrane
Feed
To
evaporation
Retentate
Unbleached pulp
White liquor
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Polymeric Xylan from black liquor
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Potential hemicellulose applications
Fiber additives
Gas barriers
O
O
HO
O
OH
O
HO
O
HO
OH
HO
O
OH
O
OH
O
SW
fibre
O
OH
O
HO
O
OH
OH
OH
O
O
O
HO
HO
O
HO
HO
O
O
HO
OH
O
OH
(Z )
OH
OH
HOOC
O
HO
O
O
O
OH
O
Hydrogels
HO
O
O
OH
OH
O
OH
O
4-5 times
higher
surface
charge
HO
HO
O
OH
O
OH
HO
O
OH
O
HO
O
Other applications
Polymers (PLA)
Xylitol, furfural
Sugar acids
Emulsifiers
Carboxymethylation
HO
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Wood xylan feedstock for lactic acid and PLA
Hemicelluloses
(glucomannan and/or xylan)
Acidic or enzyme
hydrolysis
Pentoses and hexoses
Fermentation
or alkaline
oxidation
Polymerization
Polylactide (PLA)
Lactic acid
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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2G Ethanol from forestry residues
2G Ethanol
 Acid/enzymatic
pretreatment
OR
 Alkaline
preteatment
– can handle all wood/forestry residues/annual plants
– good separation of cellulose and lignin
– established technology
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Alkaline route from wood to ethanol
Forestry Residues
Ethanol
Hydrolysis,
Fermentation &
Distillation
Alkaline
fractionation
CO2
Lignin
Separation
Chemicals
Recovery
Energy
Recovery
Sulphur-Free
Lignin
Electric Power
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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2G Ethanol- Alkaline Process
Will it work in practice? Yes!

Tested in mill and pilot scale trials
70 t soda pulp produced
 40 m3 pulp suspension used
 700 litres of ethanol produced
 S-free lignin produced

Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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The Future Wood/Agri Pulp Mill Biorefinery
- many options available
Pulpwood
Fibre
processing
Black
liquor
Pulp &
Cellulose
Integrated
Energy
Heat & Power
System
Forestry/agri
residues
Primary
treatment
Conversion
Conversion
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Chemicals
and materials
Biofuels
Possible time frame for commercialization
2- 5 years
>
Lignin

Fuel oil replacement
 Pellet additive
 Dispersant
 Activated carbon

Xylan

Gas barrier
 Fibre surface additive

Forestry
residues

2G EtOH and S-free lignin
 High quality pellets

Benzene
 Phenol
 Carbon fibres
Lactic acid, PLA
 Polyesters
Syngas
 FT-diesel/DME
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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5 years
The pulp mill biorefinery
Energy
 DME
 Ethanol
 FT-diesel
 Biooil
 Heat
 Electricity
 Solid fuel
 Lignin
Chemicals/Materials
Lignin
Lignin
Cellulose
 Phenols
 Carbon fiber
 Binders
 Dispersants
 Activated carbon
 Fiber additives
 Barriers
 Hydrogels
Bark
Hemicellulose
Forestry
residues
Cellulose  Fibers
 Derivatives
 Nanocellulose
Extractives  Functional polymers
 Bioactive compounds
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
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Thank you for the attention
Karin Lindgren, Production of Chemicals and Materials in Future Pulp Mill Biorefineries
38

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