Closing the loops

Alfa Laval solutions for the pulp and paper industry

Alfa Laval provides a broad range of process equipment thatdeals with many of the key challenges faced by the pulp andpaper industry.

High-efficiency Alfa Laval solutions are easy to integrate intopulp and paper manufacturing processes to improveprofitability and strengthen your company’s environmentalprofile.

Paper – the multifunctional solutionPaper and paper products are used forcountless purposes – with newspecialty products constantly underdevelopment. Examples include● the boom in packaging innovation as

a key feature of branding and marketing activities

● the resurgence of paper bags because paper is generally more environmentally acceptable than plastic

● the proliferation of giveaway dailies and new-format freebie newspapers and magazines.

Companies are therefore eager toensure that their pulp and paperoperations are kept efficient enough toseize the new business opportunitiesthat arise.

Environmental profilePaper products provide a moreenvironmentally acceptable solutionthan any of the obvious alternatives.

However, this also means that theindustry has to tackle the fact that its

Alfa Laval solutions for the pulp and paper industry 3

basic production processes involve theuse of extremely large quantities ofboth energy and water.

Cutting down these quantities is one ofthe keys to reducing costs, improvingprofitability and maintaining a positiveenvironmental profile.

Alfa Laval solutions make thedifferenceAlfa Laval solutions make a hugedifference to● your environmental profile● your bottom lineby providing technologies that enable you to close the loops in your pulp and paper manufacturing processes.

Paper forever

Water loop

Utilities and

chemicalsloop

By-productsloop

Energy loop

Alfa Laval solutions make thedifference

● boost energy recovery● reduce wastewater treatment costs● reduce water consumption● separate and purify by-products

cost-effectively● improve utilities management● reduce chemicals costs.

Energy is the keyLarge amounts of energy, in the formof heat and electricity, are required forall the processes involved in pulp andpaper manufacturing.

Reducing the overall consumption ofenergy is therefore a prime focus,leading to careful consideration of heatrecovery solutions.

Alfa Laval heat transfer equipmentenables you to recover maximum heatenergy from most process fluids –

4 Alfa Laval solutions for the pulp and paper industry

Optimizing energy recoveryAlfa Laval equipment for the pulp and paper industry enables you to

recover as much energy as possible - and thus reduce your

energy costs.

fibrous or not – with low installation,operating and maintenance costs.

Uniquely efficientThe closer the temperature approachbetween two fluids in a plate heatexchanger, the more heat is recovered.As illustrated below, Alfa Laval heattransfer equipment enables you toachieve as close a temperatureapproach as possible.

Alfa Laval heat exchangers feature aspecial plate design that providesmaximum thermal efficiency. Along withthe fully counter-current flow, thisenables you to achieve maximum heatrecovery.

This means a much smaller heattransfer surface area is needed toachieve any given capacity. Alfa Lavalheat exchangers are therefore muchsmaller than traditional shell-and-tubeheat exchangers. This space-savingfootprint also cuts back on installationcosts.

Heat transfer efficiency

Energy loop

Cut energy costs by one thirdThe Mississippi River Corporation (MRC)– an American recycle pulp mill – is amajor energy consumer. With energycosts at an all-time high, the companyneeded substantial reductions.

Part of the solution was heatexchangers to recover heat from a hotwhite water stream. But shell-and-tubeheat exchangers were ruled outbecause of fouling and cleaning issues.

“We selected three Alfa Laval spiralheat exchangers because of their highthermal efficiency and ability to handlefluids containing fibres and particles.This heat recovery system has reducedour energy costs by one third,” saysTanya Richardson, MRC’s processmanager.

Alfa Laval solutions for the pulp and paper industry 5

UPM relies on wide-gap technologyUPM is one of the world leaders in forest products, and has installed more than 30Alfa Laval wide-gap plate heat exchangers in its many plants – both chemical andmechanical pulp mills, and paper mills. These heat exchangers are used toimprove heat recovery from process streams such as bleaching filtrates, PGWfiltrates, white water and wastewater.“Energy is expensive, and rising energy prices mean that any investments in energyefficiency are easily recouped. We particularly appreciate the wide selection of heatexchanger products from Alfa Laval – they meet all our needs,” says MikkoSaarela, responsible for process development and related investments at the UPMmill in Kaipola, Finland.

Dealing with fibrous fluids

● Alfa Laval wide-gap plate heat exchangers are specifically developed for operating with fibrous fluids.

● Alfa Laval spiral heat exchangers feature a single-channel flow. Any deposits or tendency to clogging are simply flushed out.

Close your energy loop

● Maximize heat recovery● Prolong operating efficiency● Reduce maintenance costs● Reduce installation costs● Add processing flexibility.

Self-cleaning effect: any deposits that restrict thechannel cross-section increase the fluid velocity atthat exact point. The deposits are thereforeimmediately flushed away.

Standardplate heatexchanger

Spiral heatexchanger

Fibrecontent

Extra-wide

Compabloc

Wide-gapplate heat exchanger

A wide spectrum of efficient heat exchangers to cope with different levels of fibre content.

Fibrous fluids no problemOperators of pulp and paper mills oftenhave to deal with the fact that one orboth process fluids contain fibres andsolid matter.

With Alfa Laval equipment, this is nohindrance. You benefit from a full rangeof heat exchangers fully capable ofhandling fibrous fluids while stillproviding high thermal efficiency andthus maximum heat recovery. Fullaccess on both sides also ensureseasy cleaning, should this provenecessary.

● Standard Alfa Laval plate heat exchangers are ideal for extracting heat from fluids with limited fibre content.

● Alfa Laval Compabloc heat exchangers feature a unique wholly welded design, and are thus gasket-free. This is a major advantage with aggressive fluids.

6 Alfa Laval solutions for the pulp and paper industry

Efficient water managementAlfa Laval equipment paves the way for better wastewater management

and enables you to reduce water consumption

in pulp and paper processing.

Alfa Laval provides both the processequipment and the know-how to helpyou minimize water consumption andoptimize the economics of yourwastewater treatment.

Reduced wastewater treatment costAlfa Laval drum thickeners anddecanter centrifuges are ideal for boththickening (reducing sludge volume byup to 90%) and dewatering (usingcentrifugal force to remove even moreliquid from the solids).

Alfa Laval sludge treatment equipmentand solutions add up to● lower operating costs due to

reduced polymer consumption, no filter aids and fully automated operation

The production of pulp and paperdemands water in large quantities forvirtually all the processes involved.Even with some recycling, pulpprocessing and paper making stillrequire large quantities of fresh water.

Influent

Thickening

Dewatering

Primary treatment

Effluent cooling

Aeration

Dewatering

Return

Secondary treatment Tertiary treatmentClean waterto mill

Ultra filtration &reverse osmosis

Typical example of Alfa Laval equipment in a pulp and paper wastewater treatment plant.

Water loop

Reduced wastewater treatment costs

● reduced installation costs due to compact size

● minimum disposal costs and maximum water recovery due to higher cake dryness and clearer effluent

● prolonged service life with the help of on-the-spot local service, backed by comprehensive Alfa Laval maintenance and spare parts services.

In addition to enabling you to treat andrecycle wastewater with the utmostefficiency, Alfa Laval also provides theequipment that makes it possible to reducewater consumption at your plant.

Alfa Laval solutions for the pulp and paper industry 7

Close your water loop

● Reduce wastewater treatment costs● Improve water balance● Reduce cleaning water

consumption● Reduce cooling water consumption.

Less cleaning water, improvedproduct qualityIn the pulp and paper industry, all tanksand process systems need regularcleaning. The traditional solution is todo this manually, using large quantitiesof cleaning water and disruptingproduction for long periods.

The more modern, highly efficientalternative is to install Alfa Laval rotaryjet heads inside the vessels and tanks.This means there is no need for staff toenter tanks, and efficient cleaning takesminutes rather than days, with nodisruption of production. This rapid,automated cleaning method alsoreduces biocide use and results in abetter environmental profile.

And because the cleaning is moreeffective, you can maintain higherproduct quality levels.

Meeting the requirementsIn 2004, a new biological effluent treatment plant was taken into use at M-realSverige AB, Husum Mill, Sweden. The new plant treats all process effluents fromthis pulp and paper mill, which produces uncoated and coated fine paper fromhigh-quality, bleached market pulp.M-real was looking for the most efficient, economical way to handle sludge fromthe biological treatment and therefore ordered a hydrolyzing system from KvaernerPower AB, Environmental System.Part of this system involves increasing the dry content of the biological sludgebefore hydrolyzation. To meet these demands, an Alfa Laval ALDEC G2 90decanter centrifuge was chosen.

Closed-circuit cooling loop – Stora Enso Corbehem MillRebuilding the PM5 magazine at the Stora Enso Corbehem Mill in France hasnow gone into the third stage. The project manager for this stage is Mr Dehay,PM5 line manager, who says, “We appreciate the solution that Alfa Lavaldesigned. Combining five air liquid coolers with one plate heat exchanger met our requirement for a completely closed cooling water loop.It also enables us to use river water when needed during the hot season.This provides very good operating economics as well as high flexibility,reliability and safety.”

Reduced water consumption

Closed-circuit cooling waterA considerable volume of cooling wateris normally required for the manycooling and condensing duties in pulpand paper plants.

This consumption can be drasticallyreduced using closed-circuit cooling.You can do this with● indirect cooling using standard Alfa

Laval heat exchangers● indirect condensing using AlfaCond,

Compabloc or spiral heat exchangers.

Fresh water and air can both be usedas the cooling medium, depending onwhether Alfa Laval plate heatexchangers or air coolers are used.

8 Alfa Laval solutions for the pulp and paper industry

Water loop

By-productsloop

Closing the loops in pulp

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Water loopDecanter centrifuge – forsludge dewatering, etc.Drum thickener – for sludgethickening, etc.Membrane filtration – forcondensate polishing, etc.AlfaVap – for effluentconcentration, as steamconverter, etc.Air liquid cooler – for closed-circuit cooling water, enginecooling, etc.Rotary jet head – for cleaningpulp storage towers, wire pitcleaning, pigment tankcleaning, etc.

By-products loopSpiral heat exchanger – asturpentine condenser, etc.Membrane filtration – for ligninextraction, lignosulphonateextraction, etc.Disc stack centrifuge – for talloil separation, lignosulphonateextraction, etc.

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Energy loop

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Utilities and chemicals loopGasketed plate heat exchanger– as oil cooler, etc.Decanter centrifuge – for greenliquor dregs dewatering, etc.Disc stack centrifuge – for lubeoil purification, turbine oilpurification, etc.Compabloc plate heatexchanger – as chlorinedioxide heater, gas cooler, etc.Membrane filtration – forpigment recovery, etc.AlfaNova – for steam andcondensate systems, etc.

Energy loopAlfaNova – for steam andcondensate systems, etc.Automatic filter – for particleremoval prior to plate heatexchanger, etc.AlfaCond – as condenser inspent liquor evaporation plant,etc.Gasketed and wide-gap plateheat exchanger – as filtratecooler, for shower water heatrecovery, etc.Compabloc heat exchanger – as steam condenser, etc.Spiral heat exchanger – as effluent cooler, for whitewater heat recovery, etc.

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A focus on recovering high-value pulpand paper by-products can improvethe overall economics of your plant.

Alfa Laval expertise and experience,covering the complete spectrum of

10 Alfa Laval solutions for the pulp and paper industry

Boost the value of your by-productsSpecial Alfa Laval equipment for the pulp and paper industry

enables you to fine-tune your extraction of key by-products,

ensuring better quality and greater value.

A consistent combination of separationtechnologies to match your processrequirements.

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Disc stack centrifuge

Microfiltration

Ultrafiltration

Reverse osmosis

Decanter centrifuge

Boost your by-product value

● Make by-product extraction more efficient

● Reduce operating costs● Minimize downtime and

maintenance.

By-productsloop

Unique lignosulphonate solutionBIOTECH Paskov in the CzechRepublic produces lignosulphonateextracted from the spent sulphiteliquor supplied by the nearby millowned by Biocel Paskov. The plantuses Alfa Laval plate-and-frameultrafiltration modules to extract andconcentrate the lignosulphonate. Toimprove the water balance, thepermeate is recycled back to the pulpmill.

The installation at BIOTECH Paskov isfully automated and requires nodetailed supervision. Furthermore, theinstallation is scalable. After four yearsof fully satisfactory operation, capacityhas been expanded by as much as32%, simply by adding extra plates.

different separation technologies, meanthat we can help you determine themost efficient equipment configurationfor your by-products.

Alfa Laval has developed andimplemented unique solutions for by-products such as● turpentine – using the Alfa Laval

spiral condenser● tall oil – using a specially developed

type of Alfa Laval disc stack centrifuge integrated into continuous acidulation plants

● lignosulphonate – extracted and purified using Alfa Laval membrane filtration technology.

Alfa Laval solutions for the pulp and paper industry 11

Utilities and chemicalsUtilities and chemicals play a critical role in pulp and paper operating

costs. Alfa Laval equipment helps reduce your consumption of both.

Power plant systemsPulp and paper processing plants needconstant energy inputs. The powerplants providing these must thereforeoperate with zero downtime.To meet this need, Alfa Laval providesexceptionally efficient, reliableequipment for use in power plants.Examples include coolers for generatoroil and turbine oil, preheaters forcondensate and steam condensers forturbines.

Steam and condensate systemsBecause of their compactness,efficiency and reliability, Alfa Laval heatexchangers are widely used in steamand condensate systems.To cope with your requirements inthese high-temperature and/or high-pressure applications, Alfa Lavalprovides a wide range of heavy-dutyheat exchangers, including bothgasketed and semi-welded designs, inaddition to fully welded plate heatexchangers.

Oil treatment systemsAlfa Laval separation equipment isused to remove any particles orimpurities, including water, from lubeoils used for the paper rolls.Similar Alfa Laval separation equipmentis used to clean many other fluids usedin paper plants, including turbine oil,diesel fuel oil and hydraulic oils.

Chemical and pigment recoverysystemsAlfa Laval separation technologies arealso used to help reduce yourchemicals costs.One common application is thedewatering of the green liquor dregs ina chemical pulping process.Dewatering the dregs enables you tocut back significantly on sulphateconsumption.Customized solutions that combinedifferent Alfa Laval core technologiesare also frequently used to improvepigment recovery.

Smooth running at Italian paper millIn 2001, Cartiere Burgo SpApurchased a PM9 lightweight-coatedpaper line for its Verzuolo paper mill inItaly. Several different Alfa Lavaltechnologies were integrated into thisMetso Paper installation, including twoSU 300 separation units for purifyingboth wet-end and dry-end oil, andseveral gasketed heat exchangers foroil cooling.

“Lube oil treatment is a serious issuein a modern paper mill,” says MrMartina, maintenance supervisor. “OurAlfa Laval equipment has enabled usto reach a high level of purification,while keeping maintenance costs to aminimum,” he adds.

Utilities andchemicals

loop

Reduce your utilities and chemicalsconsumption

● Use Alfa Laval equipment specially designed for high-temperature and/or high-pressure duties

● Boost lube oil quality● Cut back on consumption of

sulphates

The best tools for the jobAlfa Laval provides an exceptionally comprehensive range of

high-efficiency equipment for the pulp and paper industry.

Standard plate heat exchangersAlfa Laval provides a complete range of plate heat exchangers with fully counter-current flow and high turbulence. These units provide maximum heat recoverywith a minimum of investment and installation costs. Full access to the heattransfer surfaces also keeps service and maintenance costs to a minimum.

Air coolersAlfa Laval compact air coolers enable you to cool cooling water and process fluidswith high heat transfer efficiency, extremely low power consumption, low risk ofcorrosion, no bacteriological problems, low noise levels and with a minimum ofmaintenance.

Plate condensers and evaporatorsAlfaCond plate condensers and AlfaVap plate evaporators are specially designedfor condensing and evaporation.They combine the benefits of compact, efficient plate heat exchangers with the lowpressure drop required for these duties.

Wide-gap plate heat exchangersAlfa Laval wide-gap plate heat exchangers are specially designed to handle fibrous fluids.The design combines the benefits of compact, efficient plate heat exchangers with aspecial plate pattern that helps prevent clogging.

Spiral heat exchangersAlfa Laval compact spiral heat exchangers feature a single-channel design thatresults in a self-cleaning effect. This makes them particularly suitable in foulingapplications.Spiral heat exchangers are also ideal for condensing duties.

Fully welded plate heat exchangersAlfa Laval Compabloc heat exchangers are fully welded, which means no gasketsbetween the plates.Compablocs are ideal for use with chemically aggressive fluids or for dutiesfeaturing high pressures and/or high temperatures, such as condensers, reboilersand steam heaters.

Fusion-bonded plate heat exchangersAlfaNova fusion-bonded plate heat exchangers have no gaskets in contact withthe process media. This makes these 100%-stainless steel units ideal for high-pressure, high-temperature duties.

12 Alfa Laval solutions for the pulp and paper industryindustry

Alfa Laval solutions for the pulp and paper industry 13

Disc stack centrifugesAlfa Laval disc stack centrifuges are highly efficient centrifugal separation units idealfor separation involving small particles and droplets and with medium concentrationsof solids. They are often supplied as fully automated integrated modules.

Decanter centrifugesAlfa Laval decanter centrifuges combine high separation efficiency with the ability tohandle greater concentrations of solids for dewatering. These units are availablefully automated, and require very little supervision.

Membrane filtration systemsAlfa Laval provides a complete spectrum of cross-flow membrane filtrationtechnologies, from microfiltration to reverse osmosis.Alfa Laval membrane filtration modules are available in both plate-and-frame andspiral configurations.

Drum thickenersAlfa Laval drum thickener equipment reduces the water content of large processflows prior to dewatering.Use of an Alfa Laval drum thickener before any specialized dewatering equipmentalso improves the operating economics of the dewatering installation.

Tank cleaning jet headsRotary jet heads clean tanks or process equipment by casting jets of cleaningmedia against the walls. The nozzles rotate in both vertical and horizontal axes,providing a criss-cross spray pattern.

Automatic filtersAlfa Laval back-flushing filters give your heat exchangers extra protection againstclogging and fouling. Automatic self-cleaning by back-flushing takes place with nointerruption to your process operations.

14 Alfa Laval solutions for the pulp and paper industry

Worldwide commitment to NonstopPerformanceSuccess in the highly competitive pulp and paper industry depends on

your operations performing exactly as required – no matter what.

Performance partnersTo be a front runner in your part of thepulp and paper industry, you needstrong support from your serviceprovider. Not just to solve problems asthey arise, but also to help youoptimize the performance of yourparticular industrial processes.

At Alfa Laval, we are 100% committedto the total service concept that we callNonstop Performance. Thisencompasses everything fromsupplying a single spare part to all themany aspects of our role as long-term“performance partner”, worldwide.

The cornerstones of our Alfa LavalNonstop Performance concept are● outstanding service● unique expertise● being easy to do business with.This means Alfa Laval tailors aPerformance Agreement to meet yourspecific service needs, to minimizeyour maintenance costs and maximizeyour plant uptime.

Everywhere you need themAlfa Laval Performance Agreements areglobal in scope. This means that nomatter where in the world your plant issituated, the service you receive fromAlfa Laval service engineers or AlfaLaval service centres will be of thesame high standard.

Alfa Laval has sales offices or othersales representatives in over 100countries.

We employ a staff of about 2,000people in our Parts and Service divisionand operate approximately 50 certifiedservice centres, located worldwide.

Alfa Laval Performance Agreements

● Maximum operating safety● Maximum plant uptime● Optimized plant operation● Premium Partnership● 2,000 technicians positioned

worldwide to meet your service requirements.

Alfa Laval in briefAlfa Laval is a leading global provider ofspecialized products and engineeredsolutions.

Our equipment, systems and servicesare dedicated to helping customers tooptimize the performance of theirprocesses. Time and time again.

We help our customers to heat, cool,separate and transport products suchas oil, water, chemicals, beverages,foodstuffs, starch and pharmaceuticals.Our worldwide organization worksclosely with customers in almost 100countries to help them stay ahead.

How to contact Alfa LavalUp-to-date Alfa Laval contact details forall countries are always available on ourwebsite atwww.alfalaval.com/pulpandpaper

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