BORREGAARD - A MODERN BIOREFINERY - Creating value from … · 2012-05-16 · Chlor alkali. plant....

Updated: 03.08.2007 - Page1

Karlstad, November 18, 2009Ove Bartholsen

Technical Service ManagerBorregaard ChemCell

BORREGAARD - A MODERN BIOREFINERY- Creating value from wood

Outline

1. The Borregaard Bio-refinery

2. Future Bio-refinery consideration

3. BF 2010 – Securing our future


Borregaard presence

Head office

Production

Sales office

Borregaard Wood based chemicals in an integrated concept

VANILLIN

LIGNIN

SPECIALTY-CELLULOSE

ETHANOL

Bio energy (bark, side streams from the production, biogas from the waste water treatment)

Wood

1000 kg

50 kg 3 kg

400 kg

400 kgWoodyard

Digester

Etanol-plant

Vanillin-plant

Lignin-plant

Bleeching plantDrying machine

Applications (end products)

Cellulose Lignin Vanillin EthanolConstruction materials Concrete additives Food Car careCosmetics Animal feed Perfumes Paint/ varnishFood Dyestuff Pharmaceuticals Pharmaceutical industryTablets Batteries Bio FuelTextiles BriquettingFilters MiningPaint / varnish


Borregaard Biorefinery


The crucial question:Are we better of in the middle of a commodity value chain at the mercy of the politicians ?

Distributor

Biofuel - a possible new value chain for us ?

Raw material supplier

Biorefinery(diesel, ethanol)


Cost efficiency

2. generation with C5 fermentation

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

Spruce (Norway) Wheat (Europe) Corn (U.S) Sugar Cane(Brazil)

Ethanol per square

meter/year

• Biomass growth is a big challenge in Scandinavia

Updated: 01/12/2009 - Page8

Biorefinery options - profit considerations

BioMaterials- Polymers- Composites

BioChemicals- Flavours- Monomers- Proteins-Fine chemicals-Speciality chemicals

BioFuel- Bioethanol- Biodiesel- Biogas

BioEnergy-Electricity/Heat- Liquid Fuels- Pellets

Co

st/p

rice

Low

High

Cre

ati

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valu

es

Low

High

BIOREFINERY

Updated: 01/12/2009 - Page9

Biorefinery options - profit considerationsReduce feedstock price & increase product price





Co

st/p

rice

Low

High

Cre

ati

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valu

es

Low

High

BIOREFINERY

Updated: 01/12/2009 - Page10

Biorefinery options - the incentive paradox





Co

st/p

rice

Low

High

Cre

ati

ng

valu

es

Low

High

BIOREFINERY

Economy of sugarplatform biorefineries

February 09

Raw materialcost

Total sales value

Updated: 03.08.2007 - Page12

Biorefining: Our definition

• The pursuit of the unique properties of our raw materials – not the destruction of them

BF 2010

AGENDA

Production Flow – Borregaard Sarpsborg

Fine Chemicals

also ethyl vanillin

Powerstation

Wood

SO2-plant

Water works

Chlor alkaliplant

Incineration facilities Purification

Salt Sulphur Oil Bio- Bark Sortedmass waste

El powerProcess-

waterCaustic Bleach- Chlor.

soda chem /HClSO2 Steam Steam Bio gas

Raw materials

Ethanol LigninSulphitelye Lye

Glomma

Lye

SALE SALE SALE SALE SALE

CelluloseDigesting Vanillin

Water Purified water

SALESALE

Bleaching

Drying

BF2010:Improved operations and reduced complexity

• Central control room and new organization• Powerful combination of cost reductions and competence development• Construction startup in Q4 2009

Energy works

Drying machineBleachPlant Ethanol Plant

Lignin Plant

Vanillin Plant

Digesting Plant

Chloro-Alkaline Plant

Control Central

SHIFT REDESIGN

Kilde: UCDS

The future organization will be build around the operator– all other functions will support this role

Conceptual design of consoles in the new CCR- developed by operators and plant management

1

2

3

4

5

67

8

Three geographic areas with allocated operators and maintenance personnel

NorthBase: Digester

SYD

WestBase: Bleach

EastBase: Vanillin

Technology and people

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NOV DES JAN FEB MAR APR u20 u21

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DAMP

Uakseptabelt

Tvilstilfelle

Akseptabelt

DAMP

Status: Tag: Beskrivelse Oppstartbetingelser:

Start sekvens H,P,B -trinn gruppestart B5008 -sjekk F5006.3 fettsmøreaparat Ikke vernsjekk C5012 air lift Ikke vernsjekk C5008 avtrekk filterhette Ikke vernsjekk C5008 avtrekk filterhette Ikke vernsjekk F5006.1 skruen Ikke vernsjekk P5033 duksprits Ikke vernsjekk F5006 filter Ikke vernsjekk P5016 spedning innløpskasse Ikke vernsjekk P5017 spedning tårntopp Ikke vernsjekk X5008 tårnskrape Ikke vernsjekk M5008 mikser bunn B5008 Ikke vernsjekk P5019 hypopumpe Ikke vernsjekk P5031 H2O2 pumpe Ikke vernsjekk P5029 A/B NaOH pumpe Ikke vernsjekk P5270 Borol før M5008 Ikke vernsjekk P5025 SO2-vann sugesiden P5017 Ikke vernsjekk HSV6089 drenering trau til B6001 stengtsjekk HSV6090 dren. masseledning til B6001 stengtsjekk HSV5313 masseventil inn i B5008 åpensjekk LIC 6001 nivå i massetank B-6001 < 80%sjekk LIC5077 nivå bakvannstank B5014 > 60%sjekk P6010/11 sperrevann driftsjekk P6006 spedning skruen fra B6007 driftinfo. V1 -vann Fingervann F5006 ikke i startsekvensenstart F5006.3 fettsmøreaparat startstart C5012 air lift + 0 sek. startstart C5008 avtrekk filterhette + 0 sek. startstart F5006.1 skruen + 0 sek. startstart P5033 duksprits + 0 sek. startk i FIC5072 d i k ilå i 15 %

start P5033 duksprits + 0 sek. start

aktiver FIC5072 spedning skruen ventilåpning 15 %sjekk F5006.1 skruen normal strøm

aktiver FIC5072 spedning skruen OP 100% hvis strøm > 43 amp F5006,1start F5006 filter < 43 amp. F5006.1 + 5 sek. startsjekk F5006 sjekk strøm normal strøm < 43 amp.

aktiver V1 -vann fingervann F5006 OP 20% i startsekv. + 20min etter st.P5002aktiver V1 -vann fingervann F5006 OP 100% hvis strøm > 43 amp F5006

start P5016 spedning innløpskasse v/normal strøm F5006 + 3 sek. startstart P5017 spedning tårntopp + 5 sek. start

aktiver FIH5066 mengde spedning tårntopp ?? m3start X5008 tårnskrape v/ ?? M2 5066 + 3 sek.

aktiver X5008 tårnskrape strøm < 23 ampstart M5008 mikser bunn B5008 v/ normal strøm X5008 + 6 sek. start

aktiver TCV5132 temp vaskevann ramper seg opp til SP når P5002 i driftaktiver FCV5071 mengde vaskevann ramper seg opp til SP når P5002 i drift

start P5034 hypopumpe v/resept 2,3,5,8,11,16,19,22+ P5002 starteraktiver XXXX ventil hypo åpnes når P5034 starteraktiver FCV5025 hypo dosering i st. pipe v/resept 2,3,5,8,11,16,19,22+ P5002 starter

start P5025 SO2-vann sugesiden P5017 v/resept 2,3,5,8,11,16,19,22+ P5002 starteraktiver ACV5070 SO2-vann sugesiden P5017 kjøres denne ventilen bare i man.??

start P5031 H2O2 pumpe v/resept 7,9,12,14,15,17,21,23+ P5002 starteraktiver FCV5291 H2O2 i skruen F5005.1 v/resept 7,9,12,14,15,17,21,23+ P5002 starter

start/går P5029 A eller B NaOH pumpe start når P5002 starteraktiver FCV5292 NaOH i skruen F5005.1 aktiver når P5002 starter

start/går C5270 avtrekk tårntopp hele tiden v/resept 12(2),13,18,26,27start/går C5271 avtrekk tårntopp hele tiden v/resept 12(2),13,18,26,27

start P5270 Borol før M5008 v/resept 12(2),13,18,26,27+ P5002 starteraktiver XXXX ventil borol åpen v/ borolaktiver FCV5854 Borol før M5008 v/resept 12(2),13,18,26,27+ P5002 starteraktiver SIC5219 turtall F5006 aktiver når P5002 starter

From complexity….to overwiev and stability

From complex startup procedures….to startbuttom

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u11 u12 u13 u14 u15 u16 u17 u18 u19 u20

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BLEKERIET

Uakseptabelt

Tvilstilfelle

Akseptabelt

Blekeriet totalt per time

From stress….to control

Manning development

600

550

500

450

400

2009 2010 2011 2012

Control center

Retirement

New org.

Retirement + average

Dismissal

Wanted scenarioCa. 530

Competence development - case, SKR

Competence

2005 – jan. 2009 jan 2009 – juli 2009 Aug ’09

Water purification / Effluent treatment

Boilerhouse

Alva

Basic competence

New competence

Target

Bark 4. plant?

BF2010Organizational development and productivity improvements

Organizational development• New common control room

– Operate the plant from one central control room

– An organization build around the operator

– Focus on competence development

Improvements:• Lower manning:

– 200 man-years• Improved production:

– Increased and better production– Optimized maintenance– Lower energy consumption, optimal

steam production– Reduced overtime and sick leave

200

500

800

1100

1998

1999

2000

2001

2002

2003

2004

2005

2006

2007

E2008

P2011

4006008001000120014001600180020002200240026002800

Man-years Sales

Sales in mill. NOKMan-labour year

BORREGAARD - A MODERN BIOREFINERY - Creating value from … · 2012-05-16 · Chlor alkali. plant....

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