Operating experience of the worlds largest lime kiln Roberto - PowerPoint PPT Presentation

Operating experience of the world’s largest lime kiln Roberto Villarroel Eldorado Brazil Sao Paulo, BRAZIL Honghi Tran University of Toronto Toronto, ON, CANADA The 7th International Colloquium on Eucalyptus Pulp Vitoria, Brazil, May 28, 2015

Site Location TrêsLagoas – MS 20º45’04” S Highway BR 158 -km 231

Eldorado Mill Project Fev 2010 Start-Up Nov 2012 Inaguration Dez/2012 Learn Curve Ago/2013 1.000.0000 ton/y Out/2013 Pulp Capacity 1.5mtpy

Eldorado Design Wood Handling 1.200 m³s/h Cooking 5.100 tsa/d Bleaching 4.750 adt/d Drying 5.022 adt/d Evaporation 1.600 tH2O/h Recovery Boiler 6.800 tds/d Power Boiler 120 t/h Causticizing 15.700 m³/d Lime Kiln 1.200 t/d Boiler Feedwater Treatment 630 m³/h Effluent Treatment 6.500 m³/h

Lime Kiln Reburnt Lime inventory 2 silo 3000 tonne 1 silo: 200 tonne Fresh Lime Bin 1silo 1000 tonne Purge by Lime milk to effluent in balance : 7,8Kg/Adt Fuel: • Fuel Oil / (Natural gas) • Methanol • Hidrogên

Lime Kiln Volume 1200 2011 Design Eldorado 1000 2011 Operating Production, t CaO/d 1993 Operating 800 600 400 200 0 0 1000 2000 3000 4000 Kiln Volume, m3 Global Survey on Lime Kiln Operation, Energy Consumption and Alternative Fuel Usage-Pulp & Paper Centre - University of Toronto - December 28, 2009

Main Dimensions Cylinder Size: 5.5 m diam. x 165 m long Number of Supports: 5 Rotation 1.36 rpm Slope: 2.0 % Cyclone (LMD) Size: 5.5 m diam x 15.9m overall height

Size Comparison

Size Comparison

Size Comparison

Lime Kiln-burning Zone 9.8” 2,5”

Lime Kiln Advanced Control Strategy control in stable operation Feed End Temperature Firing Hood Temperature Excess Oxygen/emissions

Lime Kiln Advanced Control • Lab measure residual CaCO3 and Operator input every 4-8 hrs • Kiln temperature profile is managed by ACE • Production rate can de controlled by ACE automatically . • ACE tries to minimize the fuel consumption based on target quality. • Residual Carbonate target is set by the operator • Emissions Limits are set by the operator

Operation Stabibity Production TPD Lime 1400 1200 1000 800 TPD LK production 600 400 Average production 200 0 0 30 60 90 120 150 180 210 240 270 300 330 360 Day (Nov2013-Nov2014)

Energy Consumption Kiln Heat Rate Heat Rate-Op 10000 Avg-in Operation" MJ/tonne CaO 7500 5000 2500 0 0 30 60 90 120 150 180 210 240 270 300 330 360 Days ( Nov 2013- Nov 2014)

Lime Mud Solids Content Solids Content of mud-to-Kiln 90 85 Mud Solids % 80 75 DS%-Op Avg 70 65 0 2000 4000 6000 8000 samples ( Nov 2013-Nov 2014)

Quality Lime Availability (%) 100 95 Availability 90 85 80 75 0 2000 4000 6000 8000 10000 samples ( Nov 2013-Nov 2014)

Operation Issues Global Survey on Lime Kiln Operation, Energy Consumption and Alternative Fuel Usage-Pulp & Paper Centre - University of Toronto - December 28, 2009

Emissions (?) NOx Emissions 600 500 400 mgr/Nm3 300 200 100 0 0 100 200 300 400 Day ( Nov 2013-Nov2014)

Thermal efficiency O2 vs Gas Temp. 25 350 300 20 250 15 200 O2 O2 150 10 Temp C 100 5 50 0 0 0 50 100 150 200 250 300 350 400 Título do Eixo

Refractory Damage • After 274 Day after the first Outage 10m in burning zone was replace (27/09) • 8 day out of operation • Displacement of refractory rings- sensitive • Complex Lime mud strategy (truck)

Refractory Damage Refractory(10m) 0.8 MMUS$ Fuel Oil -0.7 MMUS$ Transp. Int. 0.1 MMUS$ Transp ext. 0.8 MMUS$ Purchased Lime 1.1 MMUS$ Total 2.2 MMUS$

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