Fray Bentos mill status

Eugenio García Sami Saarela

2 EGa 03.11.2008

Milestones of the pulp mill project

Eucalyptus plantations established in Uruguay at the beginning of

1990’s by UPM-Kymmene and Shell (Compañia Forestal Oriental)

Botnia purchases 60 % of Forestal Oriental (early 2003), today a fully

owned subsidiary of Botnia

Botnia S.A. founded (October 2003)

Preliminary Environmental Authorization (February 2005), the project

starts

Fibre line installation starts in November 2006

Readiness for start-up in September 2007

Final Environmental Permit in October 2007

Start-up November 9th, 2007

Reaching the nominal capacity of the mill (as 30 days average) 145

from the start-up

3 EGa 03.11.2008

Key data of the mill

Capacity 1000 000 ADT/year of fully bleached eucalyptus pulp

Target brightness 89 – 92 % ISO, ECF-bleaching

Raw material mixture comprises of E. Grandis, E. Dunnii and E. Maidenii

Basically the entire raw material supply comes from the plantations of Forestal Oriental within max. distance of 200 km from the mill, wood usage > 3 million s-m3

The entire fiberline and chemical recovery process delivered by Andritz

4 EGa 03.11.2008

Process and equipment

Woodhandling

Fiberline

Recovery

Effluent treatment

5 EGa 03.11.2008

Woodhandling

Debarking in the forest

Two parallel chipping lines at the mill (capacity 2 x 330 s-

m³/h)

Final debarking (diameter 4 m, length 15 m debarking

drums)

Chippers of horizontal feeding (HHQ-ChipperTM)

Two chip piles (diameter 106 meters, capacity 93 000

s-m3)

Gyratory screening of chips

6 EGa 03.11.2008

Fiberline

7 EGa 03.11.2008

Basic features of the fiberline

Cooking:

Process Lo-Solids® Downflow

Diamondback® chip silo, Turbofeed® chip feeding system (three

chip pumps in series)

Brown stock washing:

Three DD-washers in parallel (DD4580.3)

Oxygen delignification:

Two stages 10 + 60 min residence time

Bleaching:

Sequence (A/D)-Eop-D-P

Drying of pulp:

Two parallel drying machines, capacity 2 * 1800 ADT/d

Twin Wire Formers

8 EGa 03.11.2008

Chemical Recovery

Evaporation plant:

7 effects, capacity 1100 tons water/h

Recovery boiler:

Combustion capacity 4450 tons/d

Steam values: pressure 94 bar (g) and temperature 490 oC

Vapor generation capacity 182 kg/s

Electric power generated with two 70 MW turbines

White liquor preparation:

X-Filters for green liquor filtration, disc filters for the the white liquor filtration

Lime kiln with the capacity of 830 tons CaO/d

9 EGa 03.11.2008

Effluent treatment

Activated sludge biological treatment, for ca. 73 000 m3/d effluent

flow:

Coarse screening to remove bigger particles

Primary clarifier to remove solids (mainly fibers) from the high

solods stream

Safety and equalization basins (three 25 000 m3 basins in

parallel)

Cooling tower for temperature control

Aeration basins (rwo in parallel)

Secondary clarifiers (two in parallel, dia. 65 m)

Excess sludge disposal system

10 EGa 03.11.2008

Effluent treatment plant

11 EGa 03.11.2008

Botnia FRB Key Figures

Cumulative production up to

21/04/09 : 1358578 tons

Record day production up to 31

Oct: 3890 t/d (25/01/09)

1000000 TONS in moving 12

month just reach

PRIME GRADE %

99,798,1 98,1

98,899,9 99,7 99,8 99,2

10098,9

97,9

99,5 99,4

97,3

87

80

85

90

95

100

105

JANUARY

FEBRUARY

MARCH

APRIL

MAY

JUNE

JULY

AUGUST

SEPTEMBER

OCTOBER

NOVEMBER

DECEMBER

JANUARY

FEBRUARY

MARCH

AVAILABILITY %

75,681,1

92,8 95,3 94,7

83,7

96,392,7

97,8

89,9

65,9

99,9 97,593,4 92,3

0

20

40

60

80

100

120

JANUAR

Y

FEB

RUAR

Y

MARCH

APR

IL

MAY

JUNE

JULY

AUGUST

SEP

TEM

BER

OCTO

BER

NO

VEM

BER

DECEM

BER

JANUAR

Y

FEB

RUAR

Y

MARCH

12 EGa 03.11.2008

13 EGa 03.11.2008

Botnia FRB Production: Nov’07- actual

DAILY PRODUCTION (month average)

2 2 0 32 0 72

2 2 2 2

2 54 12 6 11 2 59 3

2 2 0 1

2 9 4 5

2 6 8 7

2 8 9 22 8 0 7

2 59 1

3 154 3 1543 0 2 3 2 9 6 9

1000

1500

2000

2500

3000

3500

12.200

7

02.200

8

04.200

8

06.200

8

08.200

8

10.200

8

12.200

8

02.200

9

MONTH

TO

NS

/DA

Y

14 EGa 03.11.2008

Botnia FRB Production: Nov’07- actual

MONTHLY PRODUCTION

3 0 .8 9 2

78 .3 3 2

6 6 .0 3 5

9 1.3 0 9

8 3 .2 9 2

57.0 0 4

9 7.76 2

75.58 7

9 2 .0 3 4

9 7.771

8 6 .76 68 7.0 2 3

8 0 .3 9 878 .78 3

6 4 .2 3 1

6 8 .2 8 9

6 4 .4 3 8

0

20.000

40.000

60.000

80.000

100.000

120.000

11.2007

01.2008

03.2008

05.2008

07.2008

09.2008

11.2008

01.2009

03.2009

MONTH

PR

OD

(T

ON

S)

15 EGa 03.11.2008

Botnia FRB quality trends

16 EGa 03.11.2008

ISO Brightness (%)

DM2 BRIGTHNESS

86

87

88

89

90

91

92

93

21

/01

/20

08

04

/02

/20

08

18

/02

/20

08

03

/03

/20

08

17

/03

/20

08

31

/03

/20

08

14

/04

/20

08

28

/04

/20

08

12

/05

/20

08

26

/05

/20

08

09

/06

/20

08

23

/06

/20

08

07

/07

/20

08

21

/07

/20

08

04

/08

/20

08

18

/08

/20

08

01

/09

/20

08

15

/09

/20

08

29

/09

/20

08

13

/10

/20

08

27

/10

/20

08

10

/11

/20

08

24

/11

/20

08

08

/12

/20

08

22

/12

/20

08

05

/01

/20

09

19

/01

/20

09

02

/02

/20

09

16

/02

/20

09

02

/03

/20

09

16

/03

/20

09

30

/03

/20

09

13

/04

/20

09

DM1 BRIGTHNESS

85

86

87

88

89

90

91

92

93

21/0

1/20

08

21/0

2/20

08

21/0

3/20

08

21/0

4/20

08

21/0

5/20

08

21/0

6/20

08

21/0

7/20

08

21/0

8/20

08

21/0

9/20

08

21/1

0/20

08

21/1

1/20

08

21/1

2/20

08

21/0

1/20

09

21/0

2/20

09

21/0

3/20

09

17 EGa 03.11.2008

Dirts on pulp (mm2/kg)

DIRT DM1

01234567

21/0

1/20

08

21/0

2/20

08

21/0

3/20

08

21/0

4/20

08

21/0

5/20

08

21/0

6/20

08

21/0

7/20

08

21/0

8/20

08

21/0

9/20

08

21/1

0/20

08

21/1

1/20

08

21/1

2/20

08

21/0

1/20

09

21/0

2/20

09

21/0

3/20

09

21/0

4/20

09

DIRT DM2

0

2

4

6

8

10

12

21/0

1/20

08

21/0

2/20

08

21/0

3/20

08

21/0

4/20

08

21/0

5/20

08

21/0

6/20

08

21/0

7/20

08

21/0

8/20

08

21/0

9/20

08

21/1

0/20

08

21/1

1/20

08

21/1

2/20

08

21/0

1/20

09

21/0

2/20

09

21/0

3/20

09

21/0

4/20

09

18 EGa 03.11.2008

Viscosity (mL/g)

VISCOSITY DM1

0

200

400

600

800

100021

/01/

2008

21/0

2/20

08

21/0

3/20

08

21/0

4/20

08

21/0

5/20

08

21/0

6/20

08

21/0

7/20

08

21/0

8/20

08

21/0

9/20

08

21/1

0/20

08

21/1

1/20

08

21/1

2/20

08

21/0

1/20

09

21/0

2/20

09

21/0

3/20

09

21/0

4/20

09

VISCOSITY DM2

0

200

400

600

800

1000

21/0

1/20

08

21/0

2/20

08

21/0

3/20

08

21/0

4/20

08

21/0

5/20

08

21/0

6/20

08

21/0

7/20

08

21/0

8/20

08

21/0

9/20

08

21/1

0/20

08

21/1

1/20

08

21/1

2/20

08

21/0

1/20

09

21/0

2/20

09

21/0

3/20

09

21/0

4/20

09

19

19 EGa 03.11.2008

Successes and bottlenecks

20 EGa 03.11.2008

Successes

Good production figures

Good learning curve of operators and engineers. Effective

organization

Emissions under permit limits and most parameters have already

achieved long term average targets (expected to be reached about 3

years after start up)

Good and even pulp quality

Safety

21 EGa 03.11.2008

Performance tests

Wood Handling: chips production accepted

Fiberline: done, but line needs more tunning on digester and

brownstock washing to achieve guarantee figures.

Drying machines: done and accepted

Evaporation: done

Boiler: done

22 EGa 03.11.2008

Bottlenecks

White liquor plant:

• Had been bottleneck until September

• Green liquor filtration (due to bad quality welding of recirculation

pipes), and to much solids in the circulation

• White liquor filtration (learning what parameters affect WL filtrability,

adjusting slits and correcting start up procedure)

• Lime kiln bricks

• Now very good production level

Evaporation:

• Bottleneck during May and June

• Hydroblasting and acid washing of effect 2 performed in June and

periodical boil outs have improve situation

23 EGa 03.11.2008

Bottlenecks

Drying machines: • Bottleneck for short periods, due to side deckers on wet end

worn out, felts changes and cutter jams. Availability problems

Fiberline: • Bottleneck for short periods, due to lower than expected

availability.

• Main problems: chip pums, steam nozzles leakages, combi screens operability, unstable consistencies, corrosion D2 control valve, fiber reinforced pipes breaks.

• It is present bottleneck together with RB

Recovery Boiler: • It is present bottleneck if fiberline is in steady operation

24 EGa 03.11.2008

Process and availability optimization

challenges

25 EGa 03.11.2008

Wood and wood handling

Minimizing cost of handling

Amount of bark. Have effects on: quality of product, availability of the

area and in the future whole mill, and gasifier.

Dryness of wood: Have effect on cooking. To check logistic chain.

More efficient use of water.

26 EGa 03.11.2008

Fiberline

Digester parameters fine tunning to get stable discharge (kappa and

consistency) at blow line and stable higher pulp viscosity

To check yield: TDS/ADT very high (there are other reasons also:

high dead load at liquor circulation, high ashes recirculation)

Digester bottom & brownstock washing improving continues

Improving availability issues: chips pumps problems

Desing/operation of screening

• Consistency control

• Tank agitation and pipes desing

• Rotors and baskets

Sand separation

Better control of consistency along the line

Better understanding of the effect of key parameters on papermaking

characteristics.

27 EGa 03.11.2008

Drying machines

Moisture and basis weight control after drying machines optimization ongoing

Sectional drives (situation it is better)

Fabrics (to develop the suppiers) to improve durability and runnability

Dryer threading still some problems, have improved

Pick up rolls water splashing ( dealing with the issue, some modifications next shutdown)

Screening improvement (sand separation and secondary accepts to primary accepts)

28 EGa 03.11.2008

Evaporation and boilers

EVAPORATION

not important continuous problems.

Future situation depending on better reduction efficiency at boiler

and optimizacion of caustizicing efficiency

RECOVERY BOILER

Learning to run Recovery Boiler with higher reduction efficiency and

lower carbon to green liquor

Chloride and potasium removal: corrosion and plugging at

continuous high load.

Some construction issues.

29 EGa 03.11.2008

WLP and Lime Kiln

WLP

Design/construction issues at X filters

To optimize caustizicing efficiency

LIME KILN

Brick lining design

To maximize hydrogen burning

Help for success of gasifier project

30 EGa 03.11.2008

Electricity and ETP

ELECTRICITY

to achieve optimum distribution between selling for chlorate

production and the national grid

Load shedding:

• Changes in the program to shed only what it is necessary

• Changes in the priorities between areas

ETP

Treatment of domestic effluents

31 EGa 03.11.2008

Summary of challenges

Improving availability of whole mill to improve quality stability,

increasing production, lowering cost and lowering even further

emmisions; overcoming bottlenecks.

Continue with test runs on wood handling, fiberline & recovery

Understanding effect of key process parameters on

papermaking properties of pulp

Improving bales quality

32 EGa 03.11.2008

Environmental figures – March 2009 – Effluent

33 EGa 03.11.2008

Effluent discharge - COD

COD (DQO) - Kg/ADT

0

2

4

6

8

10

12

14

16

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 8 Kg/ADT

Permit limit (annual): 15 Kg/ADT

Target 2009 (annual): 5 Kg/ADT

COD (DQO) - ton/d

0

10

20

30

40

50

60

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 56 ton/d

34 EGa 03.11.2008

Effluent discharge – BOD5

BOD5 (DBO5) - Kg/ADT

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 0,3 Kg/ADT

Permit limit (annual): 0,7 Kg/ADT

BOD5 (DBO5) - ton/d

0,0

0,5

1,0

1,5

2,0

2,5

3,0

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 2,6 ton/d

35 EGa 03.11.2008

Effluent discharge - AOX

AOX - Kg/ADT

0,00

0,02

0,04

0,06

0,08

0,10

0,12

0,14

0,16

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 0,08 Kg/ADT

Permit limit (annual): 0,15 Kg/ADT

AOX - ton/d

0,00

0,10

0,20

0,30

0,40

0,50

0,60

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 0,56 ton/d

36 EGa 03.11.2008

Effluent discharge – P Total

P Total - Kg/ADT

0,000

0,004

0,008

0,012

0,016

0,020

0,024

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 0,012 Kg/ADT

Permit limit (annual): 0,020 Kg/ADT

P Total - ton/d

0,00

0,01

0,02

0,03

0,04

0,05

0,06

0,07

0,08

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 0,074 ton/d

37 EGa 03.11.2008

Effluent discharge – N Total

N Total - Kg/ADT

0,00

0,04

0,08

0,12

0,16

0,20

0,24

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 0,15 Kg/ADT

Permit limit (annual): 0,20 Kg/ADT

N Total - ton/d

0,00

0,10

0,20

0,30

0,40

0,50

0,60

0,70

0,80

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 0,74 ton/d

38 EGa 03.11.2008

Effluent discharge - TSS

TSS (SST) - Kg/ADT

0,0

0,2

0,4

0,6

0,8

1,0

1,2

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Long Term Average (IFC, annual): 0,7 Kg/ADT

Permit limit (annual): 1,0 Kg/ADT

TSS (SST) - ton/d

0,0

0,4

0,8

1,2

1,6

2,0

2,4

2,8

3,2

3,6

4,0

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

Permit limit (monthly): 3,7 ton/d

39 EGa 03.11.2008

Effluent discharge - Flow

Effluent flow (Caudal de efluente) - m3/ADT

0

10

20

30

40

50

07/08 08/08 09/08 10/08 11/08 12/08 01/09 02/09 03/09 04/09 05/09 06/09 07/09 08/09 09/09 10/09 11/09 12/09 Avg

2008

Avg

2009

BAT (annual): 30 - 50 m3/ADT

Target 2009 / LTA (annual): 25 m3/ADT