Low Cost And High ig h Yield Yield Kena K enaff Pulp For Paper Industry - Case Case Stud Study y Of Kenaf Market Market Pulp Mill Project In Vietnam Vietnam
Eric Chao Xu Andritz Inc, Inc, USA Dieter Teub Teubner ner Andritz AG, AG, Austria
Location: Location : Phuong Nam, Long An Province, rov ince, Vietna Vietnam m
Location: Location : Phuong Nam, Long An Province, rov ince, Vietna Vietnam m
Economi con omi c And Socia Soci al Fea Features tu res
Infrastructure :
Transportation:
water .
A network of waterway is widespread development over the
region thanks to irrigational channel system. The average density of channel system is 50 meters length of chanel per hectare. It is very convenient for cultivation work and kenaf transportation.
Land,
Highway 62 is lying Southwest (on the right side of Vam Co Tay
river), passing through kenaf cultivated area.
National power network is available to all communes in the region.
Irrigational system of the cultivated area is very efficient and functions well
Population, labour :
Hoa and Tan Thanh:~ 187,000 people. 140,000 of them capable of doing cultivation, and have experienced with kenaf cultivation since 1975.
farmers in this region are skillful
Kenaf At Phuong Nam, Vietnam - Transfer on Water-Ways
Natural features
Climate: tropical monsoon two seasons per year: dry season and rainy season rains come from middle of May and end in late October. average temperature: 26.6 to 27.7 oC sun shine is very good and lasts from ~ 7.5 hours per day in average climate is suitable for cultivating two crops of kenaf: winter-spring crop gets seeds and summer-autumn crop gains fibre average yield of kenaf can reach 50 to 55 tons (wet) per hectare. Terrain, Land : Terrain slopes down gradually from north to south: suitable for mechanization Land divided into two main kinds of soil: alkaline soil and grey soil Alkaline soil: plentiful humus and nitrogenous on top soil of 15 to 20 cm Grey soil: slightly mixing of sand and rich soil, with rich humus of 1.5 to 2% on topsoil of 10 to 15cm.
Kenaf Cultivation Situation In Long An Province (1)
The province has 86,031 hectares for planed agricultural cultivation 35,636 hectares of forest 18,017 hectares for the rest In the agricultural cultivation area, Rotation of winter–spring rice crop and summer–autumn kenaf crop covers 23,000 hectares. Rice–growing area has 45,224 hectares. There are 2 to 3 rice crops. Area of other plants is 17, 807 hectares. Cultivated kenaf area spreads over 3 districts: Thanh Hoa, Tan Thanh and Moc Hoa In Thanh Hoa district: 4 communes namely Thanh Phuoc, Thanh Phu, Tan Hiep and Thuan Nghia Hoa In Tan Thanh district: stretches out 3 communes, Kien Binh, Nhon Hoa and Tan Binh In Moc Hoa, cultivated kenaf area spreads in 4 communes: Binh Hoa Đong, Binh Phong Thanh, Binh Thanh and Tan Thanh.
Kenaf Cultivation Situation In Long An Province (2)
Late September or early October, flood waters come slowly. It takes 1 month for the plain to be covered under water. As soon as the flood water recedes in November, winter-spring rice crop is cultivated. It will be harvested in February and March next year. Summer–autumn rice crop may be cultivated from April to May, and harvested in July to August. For kenaf, summer-autumn crop is cultivated in May and harvested in September in order to avoid flood Because the flood comes slowly, over a period of 2 to 3 months. There is plentiful water source, which is supplied from Vam Co Tay River. It runs through rivers and channels and finally comes into kenaf cultivation area Total area consists of 3 districts: Thanh Hoa, Moc Hoa and Tan T hanh, with total of 139,684 hectares
Kenaf Cultivation (According To Vietnamese Method)
Kenaf growing period: 145 to 150 day
Length of kenaf stalk: 3 to 3.5 meters when harvested
Average yield: 50 to 55 tons of fresh kenaf stalk per hectare Farmers sow kenaf seed manually. A suitable seed density is approximately 14 kilograms per hectare.
After sowing, water is pumped to cultivated the field and left it there for 5 –6 hours to soak the seeds. Then, water is let running off, but the land is kept wet enough for sprouting.
Kenaf-harvesting steps: cutting – plucking leaves off trunk – bundling up - drying transfer.
Profit Comparison Among Different Options - Based on price in 2006
Options Total cost to grow kenaf to get dry fiber (VND/hectare)
Summer- Autumn kenaf crop for dry fiber
Summer- Autumn rice crop
5,380,000
Total cost to grow kenaf to get kenaf stalk (VND/hectare)
4,780,000
Total cost to grow rice (VND/hectare) Yield (ton/ hectare)
Summer- Autumn kenaf crop for pulp-making stalk
5,650,000 2.5 (dry fibre)
3.2
50 ton kenaf stalk / hectare
Sale price (VND/ton)
3,200,000
2,200,000
170,000
Total incomings (VND/hectare)
8,000,000
7,040,000
8,500,000
Profit (VND/hectare)
2,620,000
1,390,000
3,720,000
Kenaf At Phuong Nam, Vietnam
Kenaf At Phuong Nam, Vietnam
Kenaf At Phuong Nam, Vietnam
Kenaf At Phuong Nam, Vietnam
Kenaf At Phuong Nam, Vietnam
Kenaf At Phuong Nam, Vietnam
Basic Characteristics of Kenaf
Fiber Length mm
Whole Kenaf
Kenaf Bast
Kenaf Core
1,28
2,6
0,6
20
30
7,7
17,4
Fiber diameter µ Lignin content %
13,2
Cellulose %
54,4
Alpha Cell %
37,4
Pilot Trials At Andritz R&D Centre At Springfield, OH, USA
Before designing the pulping process, several pilot plant trials were conducted to
Investigate suitability of kenaf for value-added pulp grade like P/W
Compare different process configurations and identify the best one
Provide basic process data for system design and engineering
P-RC APMP Processing at Andritz pilot plant:
Comparison of Kenaf, Jute and Aspen
Material CSF Tensile Bulk Burst Brightness LSC Opacity NaOH H2O2 3 2 2 (ml) (N.m/g) (cm /g) (kPa.m /g) (%ISO) (m /g) (%) (%) (%) Kenaf 220 36 2.5 1.6 70 67 92 3.3 2.5 Jute 230 38 2.8 1.7 69 69 93 3.4 2.6 Aspen 200 27 2.5 1.1 71 53 88 3.0 1.5
Pilot Trials At Andritz R&D Centre At Springfield, OH, USA
Results demonstrated kenaf is suitable for production of the high-quality market P/W grade pulp
Pulping process is based on advanced P-RC APMP technology which uses alkaline peroxide solutions in combination with mechanical refining energy to produce high-quality pulps at low energy consumption
The process is free of sulphur-containing chemicals and, hence, leads to better bio-degradability of the mill effluents than conventional BCTMP process that uses sulphite chemicals.
P-RC APMP Pulp From “ Whole” Kenaf (Pilot Trial)
About P-RC APMP
Fundamental concept of P-RC APMP (4 steps):
AP pr etreatment
AP treatment
Refining
Under this basic concept, a number of different design options can be developed and applied for a wide range of different situations:
Refining
Different impregnation system, depending on how difficult raw material to be macerated Different refining strategies, depending on energy and pulp quality request Different bleaching strategies, depending on how difficult to develop brightness
This technology proven to be flexible in handling changes in raw materials (HWD and annual fibers) and in producing different pulp grades/products
Process Flowsheet
P-RC APMP Pulp From Kenaf
Basic Design Data
Production
300 admt/d
Pulp type
P-RC APMP Market pulp
Raw Material
100 % Whole Kenaf
Freeness
150 -250 ml CSF
Final brightness
80% ISO
Pulp Yield
>80%
Effluent Treatment
Combined waste water from the pulp mill is treated in 2-stage biological waste water treatment plant with anaerobic reactors in the primary and an aerobic activated sludge system as secondary stage.
The biogas generated in the anaerobic reactors, mainly consisting of methane, is used as additional fuel for the operation of the flash dryers and covers approx 40% of the total energy demand of the flash dryer.
Fiber sludge and/or biological excess sludge from the bio treatment separated in pre sedimentation and final sedimentation is dewatered on a sludge press and sent to deposit. The purified waste water is discharged to Vam Co Tay river.
Conclusions
Using kenaf as fiber source for pulp and paper industry not only will help to slow down the excessive exploitation of the tropical rain forests, but also will reduce the dependence on imported raw materials in some of Southeast Asian countries on long term
Results from Andritz R&D pilot plant at Springfield Ohio, USA, have demonstrated that kenaf is suitable for low cost, high yield chemical mechanical pulping and can be used for value-added paper and paperboard applications
With implementation of Phuong Nam kenaf P-RC APMP market pulp mill project in Vietnam, Andritz has set a milestone in utilization of annual fibers for production of chemi-mechanical pulps. This will help to secure the fiber supply with an “environmental friendly” technology also in other countries with limited wood supply.
Latest Picture from Mill Site At Phuon g Nam, Vietnam
Latest Picture from Mill Site At Phuon g Nam, Vietnam
Latest Picture from Mill Site At Phuon g Nam, Vietnam
Latest Picture from Mill Site At Phuon g Nam, Vietnam
Latest Picture from Mill Site At Phuon g Nam, Vietnam
