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World Pulp & PaperTHE INTERNATIONAL REVIEW FOR THE PULP AND PAPER INDUSTRY

2011

WORLD PULP & PAPER 2011

Pulp Paper Cover.indd 1 02/03/2011 09:15

IDEAL LOCATIONSThe Setúbal site is situated just 4kmfrom the port town of Setúbal, makingtransportation of finished goods veryefficient. The mill produces 530,000t/a of bleached pulp (primarily fromthe preferred Eucalyptus globulusfibre). Cacia is midway up the nation ofPortugal, about 8 km from Aveiro andvery close to the sea. “Cacia is in theheart of our country’s eucalyptusforests,” says Nordeste. “The proximityof this raw material is a key advantagefor us.” Cacia’s production of 285,000t/a is primarily designed for specialapplications such as décor papers,specialty coated papers, and tissue.“Portucel can actually trace its roots

back to the start of the Cacia mill in

the 1950s,” Nordeste says. “By 1957,a team of experts made the Cacia milla world pioneer with the production ofsulphate bleached eucalyptus pulp.Our people have an innovative spirit,combined with knowledge that hasbeen accumulated over decades.”

VALUE-ADDED PULPING + ENERGYThe Portucel Soporcel Group isresponsible for about 51% ofPortugal’s total electricity producedfrom renewable forest biomass.“Renewable energy is a key focus inthe world,” Nordeste says, “and is amajor focus for us. It is important forus to be players in this industry toensure that order is maintained in themarket.

Enerpulp, Portucel Soporcel Group’ssubsidiary for power production, istaking advantage of available biomassto generate additional ‘green’ revenuefor the Company at two mills. Two newbiomass boilers, recently supplied byANDRITZ, are performing extremelywell, according to mill management.The Portucel Soporcel Group is one

of Portugal’s largest generators ofenergy from renewable forest biomass.In the years between 2002 and 2009,the group achieved a significant 26%reduction in emissions of CO2. Due to a significant increase in

energy needs to accommodateincreased paper production, the Grouprecorded a 34% increase in emissionsin comparison with the previous year.With a focus on renewable energy,Portucel Soporcel Group started up twoANDRITZ biomass-fuelled power plants(one in Cacia and the other in Setúbal)which produce a net of around 167GWh/a.What is unique is that none of the

energy generated by the boilers is usedby the mills. This is not permittedaccording to Portugal’s directives for‘green energy’ credits, so the electricityis sold directly to the national grid. “Even without these boilers, we are

energy self-sufficient at Cacia,” saysJosé Manuel Nordeste, Mill Manager atthe Cacia pulp mill. The situation is abit different at Setúbal, according toPulp Mill Manager Óscar MonteiroArantes. “The installation of a new andvery large paper machine at our siterequires some purchase of power,” hesays. “However, the extra margin wereceive for green energy still makes itattractive.”

BIO-GENERATION

By Robert Puhr, Andritz Pulp & Paper

WORLD PULP&PAPER 26

A tale of two mills: Bio-generation comesnaturally to Portucel

Forestryresourcesare ourlifeblood.There is apotential

threat if welet otherscontrol theresource, orsimply burnit, before we

can addvalue to it

“One of the strongest references for ANDRITZ was the new recovery boiler they installed at this mill in2006.” José Nordeste, Mill Manager, Cacia

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“Forestry resources are our lifeblood.There is a potential threat if we letothers control the resource, or simplyburn it, before we can add value to it.”The interest in boiler technology and

services has been on the rise in theIberian Peninsula, according to AnssiMarttila, ANDRITZ’s Pulp EngineeredServices Area Manager for the region.“We have worked for many years incooperation with Portucel Sorporcel ontheir strategic investments and on-going service,” he says. “This hasgiven us the opportunity tocontinuously improve our service andspare parts availability – and to trulyhave a local presence in Portugal.With abundant resources and thebusiness incentives improving, this willcontinue to be an active area for us.”The ANDRITZ biomass boiler project

consisted of the supply of two identicalboilers with a total production capacityof 49.75 MWth. According to JukkaKari, Project Manager, the boilers aremid-size (58 t/h, 93 bar, and 472º C).Portucel Soporcel’s scope included thecivil/structural work and part of theelectrification and automation.“ANDRITZ basically providedeverything above the foundations fromthe fuel feeding conveyor to the mainsteam header in the turbine-generatorplant,” Kari says. Contracts weresigned in February 2008 the boilerswere mechanically complete in the fallof 2009.

VALUE-ADDED AT SETÚBALThe Group has made considerableinvestments in upgrading the mill inSetúbal, which was originally startedup in 1967. Arantes says that the total

WORLD PULP&PAPER 27

Standing in front of the new Cacia biomass boiler are (left to right) António Gomes, Site Project Director,José Henriques, ANDRITZ agent, and José Nordeste, Cacia Mill Manager.

PAP3p26-29Andritz_Layout 1 03/03/2011 13:22 Page 27

BIO-GENERATION

WORLD PULP&PAPER 28

recent investment is more than €650mfor a new paper machine, newcombined heat/power plant (CHP),fiberline and boiler retrofits, and thenew biomass boiler. When consideringthe start-up of a steam turbine for thebiomass cogeneration plant at theFigueira da Foz mill in the third quarterof 2010, the Group has completed awide-ranging investment programmeamounting to approximately €900m. “We use about 350,000 t/a of

biomass as a fuel here at the mill,”Arantes says. “About 80% of our logsare debarked at the mill.” In addition to providing green energy,

the removal of forest waste has anotherlarge benefit: a reduction in forestfires. “In the summer, this region is hotand dry, which increases the risk offorest fires considerably,” Arantesexplains. “By removing the waste fromthe forest floor, we actually reduce therisk and impact of fires. We do notremove everything however. Ourforestry experts know where they canremove without damaging the soil.”As for the boiler itself, Arantes has

this to say: “ANDRITZ kept all thecontract milestones on-time or aheadof schedule. We started up the boilerand the start-up was withoutcomplication. It went into service quitesmoothly, which is a good indication ofthe cooperation between ANDRITZspecialists and our own project team.There is good flexibility to burndifferent biomasses with differentmoistures.”

RECOVERY BOILER RETROFITAn ANDRITZ recovery boiler installedat Setúbal in 1978 was due for aretrofit. Portucel Sorporcel decided tohave part of the boiler bank rebuilt, inaddition to replacing portions of theeconomisers and superheater for the2200 tds/d unit. ANDRITZ won the bid. “This was a large retrofit project,”

says Timo Lamberg, Project Manger forANDRITZ. “We installed 856 newtubes in the boiler bank, and both the

first and second economiser sections.”The economiser sections were

massive, about 25 m high andweighing 22 tonnes per assemblyblock. “In order to dismantle the verylarge sections and put in the newones, we had to rent one of the largestconstruction cranes available in theregion, this one coming from Spain,”Lamberg says. Shutdown for the retrofit work began

in October 2008 and the recoveryboiler was commissioned in November.

EXCELLENT REFERENCE AT CACIAThe recovery boiler at Cacia alsoplayed a key role in deciding thebiomass power boiler project forANDRITZ, according to Nordeste.“One of the strongest references for

ANDRITZ was the new recovery boilerthey installed at this mill in 2006,”Nordeste says. “We would not be ableto make the other improvements to thefiberline and the rest of the mill withoutthis boiler operating well, as our twoold units were at end-of-life.”Nordeste, by his own admission, is

“a product of Portucel.” He hasworked 30 years in the mill, rising froma process engineer to Mill Manager. “You can make big mistakes in

handling and burning eucalyptusbark,” Nordeste says. “It comes inlong, stringy strips and must be cutcorrectly. Our first biomass (bark)boiler started in 1987, so it is nothingnew to us.”Another challenge is that you never

know what you receiving with the

Above: By removing biomass waste from the forest floor, Portucel Soporcel groupis actually reducing the risk and impact of fires. The mill uses about 350,000 t/a ofbiomass as fuel at the Setúbal mill.

Above: An interior view of the ANDRITZ biomass boiler.

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WORLD PULP&PAPER 29

“We see allkinds ofincoming

contaminantsin terms ofmetals,

concrete,and otherthings. Youneed a veryrobust andreliable

boiler systemto handle it”

“We started up the boiler without difficulty. There is goodflexibility to burn different biomasses with differentmoistures.” Óscar Arantes, Pulp Mill Manager, Setúbal

The ANDRITZ biomass boiler project for Portucel Soporcel consisted of the supplyof two identical boilers with a total production capacity of 49.75 MWh. Shownhere is the boiler installed at the Setúbal mill.

Grupo Portucel Soporcel With annual production capacity of 1.6 million tonnes of paper and 1.4million tonnes of pulp, the Portucel Soporcel Group is among the largestEuropean producers of uncoated woodfree paper, as well the largestEuropean producer of bleached eucalyptus kraft pulp. The Group has three mill sites in Portugal -- Setúbal, Figueira da Foz, andCacia. A new world-class paper machine at the Setúbal mill started up inAugust 2009. It has annual capacity of 500,000 tonnes. The Group alsomanages some 120,000 ha of forest plantations, most of which is eucalyptus.The forests are PEFC certified. The origins of the Group date back to the 1950s (Companhia Portuguesa deCelulose) at Cacia producing raw pine pulp. In 1976, Portucel (Empresa deCelulose e Papel de Portugal) was incorporated as a result of thenationalisation of the cellulose industry. With a view to restructuring the paperindustry, Portucel acquired Papéis Inapa in 2000 and Soporcel in 2001. In2004, Semapa of Portugal acquired a majority stake of Portucel.Over the years, the Group has pursued a strategy of developing its ownbrands, including Navigator, which is the world's best selling brand in thepremium office paper segment. Thanks to the use of renewable forestry biomass fuel, Portucel SoporcelGroup is Portugal's leading producer of energy from this source.

biomass, according to António Gomes,Project Director and now the mill’sProduction Manager. “We see all kindsof incoming contaminants in terms ofmetals, concrete, and other things,” hesays. “You need a very robust andreliable boiler system to handle it.”Flexibility in handling varying fuels

and moistures is also key. “We neededa very flexible boiler to handle therange of biomass and the ranges ofmoisture,” he says. “Depending uponthe season, we go from 45% moisturein the spring to 60% in the winter.”As with Setúbal, the boiler project

proceeded without a glitch. The boilerwas mechanically complete inSeptember 2009 and wascommissioned and started up in a verysmooth fashion.The assessment of ANDRITZ? “To

me it is quite simple,” Nordeste says.“The equipment works well. TheANDRITZ people know what they aredoing and the process knowledge isthere. And, if something goes wrong,ANDRITZ has the willingness andcapacity to make it right.”

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