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Lignin Extraction and Recovery Process (LERP)

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Anthony Edgeton

on 29 April 2016

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Transcript of Lignin Extraction and Recovery Process (LERP)

Project Scope
1)
1,000 tpd Kraft pulp mill

2)
10:1 ratio of black liquor to pulp

3)
Hardwood Eucalyptus feed

4)
10% of black liquor treated in process

5)
Negligible thermodynamic losses and constant temperature

6)
Process off-gases sent to existing NCG system


Background
Black liquor is a byproduct comprised of spent pulping chemicals, lignin, and hemicellulose
Burned inside the recovery boiler to generate power and recover the spent pulping chemicals
Size of boiler limits maximum pulp production
Bottleneck
Up to 25% of lignin can be extracted from the liquor via LERP
Decreases heating value of the liquor
Allows for increase in recovery boiler liquor throughput
LERP Process Overview
Project Team
The Kraft Process
Lignin Extraction + Recovery Process
Feed
Digestion
Highly alkaline solution dissolves woodchips into solution
Cellulose is recovered, and sent for further processing
Black liquor is spent cooking chemicals, lignin, and hemicellulose

Chemical Recovery
Black Liquor is burned in a recovery boiler to recover cooking chemicals
Recovery boiler produces steam to generate power for the mill
Recovery boiler steaming limit restricts production for entire mill
Scaling Recovery Boiler
Lignin Extraction
Lowers heating value of black liquor
Generates lignin by-product
$100 million approximate capital cost
Extensive environmental re-evaluation
De-Bottlenecking
Technical
Design
Project
Economics
Market
Analysis
Technical Design
Samantha Hultgren
Project Manager + EHS
Tony Edgeton
Filter Presses + Economics
Mauricio Palen
Process Design + Drawings
Gina Serantoni
Pumps + Material Balance
Jessica Schacht
Market Research
Kevin Weeks
Reactors + Process Specs
Lignin Precipitation Reactor
100-second residence time promotes continuous flow
4-inch Schedule-40 stainless steel piping prevents corrosion from alkaline black liquor and allows high pressure
Pressure controlled to 80 psia
pH controlled to 9.3 with carbon dioxide to maintain 75% conversion
Chamber Filter Presses
Acid Wash
20,000-gallon, glass-lined mixing tank prevents corrosion from acidic conditions
pH controlled between 2.0-3.5 with sulfuric acid

Market Analysis
Marketability of Kraft Lignin
Kraft lignin is 80-95% pure lignin
60% Carbon

Natural and sustainable products
Increasing Market Demand


Current Market
Current Global Kraft Lignin Production:
100,000 lbs/year
Niche market
High grade chemical products
Research and Development
Carbon Fiber
Alternative fuel for industrial use
Co-firing lignin with coal
Reduces coal emissions
Fuel pellet additive
Increases structural integrity
Comparability
Compared to similar biofuels
HV – 11,000Btu/lb
$330/ton
Niche Market
Up to $6500/ton
LERP Minimum Sale Price
$200/ton

Recommendations
Kraft mills that can sell their product for at least $200 per ton should install LERP as an effective method to increase pulp mill capacity.
TCP Consulting Co.
Our Mission…

Total Chemical Products is committed to providing the paper and pulp industry with advanced engineering technology to maximize profitability. We have 5 years of combined experience in research, process and environmental engineering specific to paper and pulp, agriculture, and material science industries. We are committed to providing a quality service with a focus on safety, environmental stewardship, and customer satisfaction.
References
[1]
(2010). Future of lignin in value added products. LigniMatch. Retrieved from https://www.chalmers.se/gmv/EN/projects/previous-projects/lignimatch.
[2]
(2016). Large capacity J-press sidebar filter presses. Evoqua Water Technologies. Retrived from http://www.evoqua.com/en/brands/JWI/Pages/Large-Capacity-JPress-Sidebar-Filter-Presses.aspx.
[3]
Gellerstedt, G., Sjöholm, E., & Brodin, I. (2010). The Wood-Based Biorefinery: A Source of Carbon Fiber? The Open Agriculture Journal TOASJ, 4, 119-124.
[4]
Miettinen, M. (2014). US Patent No. US20130203972A1. UPM-Kymmene Oy.
[5]
Novaes, Evandro, Kirst, Matias, Chiang, Vincent, Winter-Sederoff, Heike, Sederoff, Ronald. (2010). Lignin and Biomass: A Negative Correlation for Wood Formation and Lignin Content in Trees.





[3]
Equipment Costs
CapCost
CEPCI
EAOC
$6 Million
NPV
$8.8 Million
DCFROR
50%
DPBP
2 Years
Operating Costs
Process Water
Equipment Power
Steam Usage
Chemicals
Revenue
Increased Throughput
Fossil Fuel Offset
Sold as Biofuel
Niche Market
TCP
Consulting
Co.

Cash Flow
Profit Sensitivity
Capital Investment
Operating Cost
Revenue
Filter Press 1 [A=900m^2, V=20m^3]
50 Minute Fill Time
45 Minute Discharge
Filter Press 2 and 3 [A=750m^2, V=8m^3]
30 Minute Fill Time
45 Minute Discharge
225 psi
Polypropylene Felt Filters
Full transcript