Reference story New biomass boiler at Iggesund Workington, UK Green power show

www.andritz.com Fossil fuel free board mill ANDRITZ EcoFluid boiler

CONTENTS

Fossil fuel free board mill 02

Scope of supply 03

Green power show 04

Luxury board 05

The right strategy 06

Throwing down challenges 07

Biomass feeding system to the BFB boiler New biomass boiler island for Iggesund Paperboard is located in Workington in Cumbria, United Kingdom. Photograph courtesy of Holmen Group. In March 2013, Iggesund Paperboard’s new biomass boiler came online with the result that the mill is now virtually fossil fuel free. The bubbling fluidized bed boiler and complete woodyard were delivered by Scope of supply ANDRITZ. BFB boiler and complete woodyard

ANDRITZ delivery to Iggesund Workington Technical Data Ash handling system inside the BFB boiler plant consisted of a bubbling fluidized bed Biomass handling cap.: 1,000 m3/h boiler island including biomass handling, Storage volume: 20,000 m3 crushing, chipping, screening, A-frame stor- Steam output: 195 t/h age, biomass feeding, ash handling, and Steam pressure: 102 bar(a) flue gas cleaning with ESP. Steam temperature: 540° C Heating value: 6.5-11.6 MJ/kg The BFB boiler can utilize forest residues, recycled sawmill chips, bark, sludge, and sawdust. The plant uses natural gas for start-up and load burners.

“We use the same amount of energy The first test firings were conducted be- in production that we used a year tween late 2012 and early 2013. The mill be- The boiler’s design is based on ANDRITZ’s well- ago, but now it all comes from re- proven Bubbling Fluidized Bed (BFB) technology com- came fully operational in the spring of 2013. bining high fuel efficiency with excellent environmental newable sources.” performance.

Timo Nieminen Power Plant Manager Workington Mill

02 03 he drive to Iggesund Paperboard’s to those in the know, this is one of Britain’s to print, foil block, and emboss. It is a highly Workington Mill, part of the Swedish showcase examples of manufacturing valu- competitive market to be in. Environmental THolmen Group, takes you through able products in the greenest and leanest excellence and sustainability have become some of England’s most dramatic and natu- way possible. And underneath the gleaming increasingly important to the buyers of such ral scenery – mountains, lakes, and sparkling mill façade is the centerpiece of Workington’s board products. streams flowing down to the coast of the Irish own “green power show” – a new biomass Sea. Situated on the edge of the county of boiler supplied by ANDRITZ. Ola Schultz-Eklund, who has been Managing Cumbria – the “Lake District” as it is more pop- Director of the Workington Mill for 12 years, ularly known – the Workington Mill sits right in Luxury board has overseen many of the changes that have the middle of what can only be described as Over the years, Workington has developed a taken place at the mill. “Making paper and a “green power show.” Wind turbines dot the reputation for satisfying the higher end of the board in the modern world is a tough busi- shoreline, generating power for energy giant luxury board market. In fact, some of its top- ness,” Schultz-Eklund says. “You have to be E.ON. Renewable energy is very big around of-the-range bright white boards are used for lean to survive – even when you are in a niche here. the glitzy celebratory side of life – including the business like we are. We have continually in- packaging of chocolates and champagne or vested in product quality while making sure we Iggesund’s Paperboard’s mill with its brand example – under its Incada brand. Important are as lean as possible. In that space of time, new woodyard may look to the uninitiated to supplying this market is the ability to pro- we have become the benchmark for quality just like any other big new factory. However, duce good solid boxboard with the potential and printability in the boxboard market.”

04 05 Anna-Maija Harju, ANDRITZ Product Engineer for power systems

The right strategy Our competitiveness The Holmen Group decided in 2011 to boost was being affected by the efficiency and profitability at Workington poor power and steam out- by investing in a new biomass power boiler. put. Now we are energy self- The boiler would not only reduce the amount sufficient, even of purchased energy, making the mill self- exporting to the grid.” sufficient with self-generated green energy, it would allow the company to participate in Ola Schultz-Eklund Managing Director the UK government’s program where green Workington Mill energy producers can sell their Renewable Obligation Certificates (ROCs) to compa- nies which continue to use fossil fuel. Says Schultz-Eklund, “There is no doubt that this project was the right strategy for the future of this mill. It would make us more sustainable, more efficient, more profitable – and would open up new revenue streams.”

In March of that year, the Board approved the (Left to right): Mikko Hänninen, ANDRITZ Boiler Commissioning Engineer; Manne Koskinen, ANDRITZ delivered the biomass receiving and handling system as part of Manne Koskinen, ANDRITZ Woodyard Technician, talks investment. By early April, the contract for PB ANDRITZ Woodyard Technician; Timo Nieminen, Workington’s Power Plant Manager; the project. This included a chipping line for logs and a crushing line for wood with an operator as they observe wood chips being fed to the 195 was in place with ANDRITZ. The design and Ville Virtanen, ANDRITZ Commissioning Engineer in the boiler house. waste. The A-frame building in the background stores 20,000 m3 of biomass. BFB boiler. The Workington Mill uses around 800,000 t/a of wood, mostly from called for a fuel input of 147.5 MW. In terms of Scotland and northern England. steam flow, the boiler would produce 195 t/h order from Workington for the biomass receiv- No option for delays on wood-based biomass and 98 t/h with ing and handling system. This included all the The plan was to allow 24 months for the and Finnish technicians – at one time 400 con- project has been an amazing experience for ing so, they have cut carbon emissions by natural gas. Steam pressure was targeted for equipment for receiving and storing biomass complete project from demolition of existing tractors – worked alongside the British mill me,” says Williams. “We watched as the boiler more than 190,000 t/a. Or, as they like to tell 102 bar (a) at a temperature of 540° C. fuel up to a capacity of 1,000 m3/h as well buildings to start-up. Crucially there was a team, and very impressively got the job done.” was built, then fired up. It was incredible to see customers, “We cut our annual emissions by as all the conveying equipment to supply the strict deadline – the new boiler had to be syn- how the suppliers sped up towards the end 60,000 automobiles a year.” The ANDRITZ version of Bubbling Fluidized boiler. Part of this delivery was the installation chronized to the national grid by February 15, The first gas firing of the ANDRITZ boiler took to make the start-up deadline. The learning Bed technology was chosen specifically for of a horizontally fed HHQ-Chipper for chipping 2013. The pressure was really on. place on December 22, 2012. This was fol- curve for us has been steep and fast, but the Schultz-Eklund concludes: “This project has the Workington mill as it had the flexibility to logs, and a horizontally fed crushing line for lowed by the first solid fuel firing on February ANDRITZ team has been great in helping us had some immense challenges, but ultimately deal with the variety of biomass available in other wood wastes. The storage facility deliv- “There was quite a lot of work to be done be- 1, 2013. “But the really good day came on move up the curve. They are very knowledge- we went from a situation where our competi- the mill – recycled sawmill chips, bark, effluent ered by ANDRITZ is an A-frame structure with fore the installation could begin, as we had February 15, 2013 when we synchronized able and professional.” tiveness was being affected by really poor cake, and washings. a capacity of 20,000 m3 of biomass. to decommission one of our board machines, to the grid and reached our goal,” Nieminen power and steam output to a situation where remove it, and demolish the building to make says. “We were completely operational and Have the targets been hit? “Absolutely!” ex- we are self-sufficient and even exporting pow- Anna-Maija Harju, ANDRITZ Product Engineer, The A-frame building is an essential ingredient way for the power plant,” says Timo Nieminen, producing power in April, and took over the claims Nieminen. “We use the same amount of er to the national grid.” says: “Our BFB boiler technology fits perfectly in the whole mill operation as it helps regulate Workington’s Power Plant Manager. “Then boiler from ANDRITZ on May 15th.” energy in production that we used a year ago, for Iggesund Paperboard because of its versa- the moisture content in the wood in a range there were foundations to pour and construc- but now it all comes from renewable sources. Clearly, Iggesund Workington is the bright- tility in firing different biomass fuels and slud- of 37-57% depending on the materials. The tion of all the housing for the new boiler.” Throwing down challenges Our team has achieved great things. The boiler est star in the Cumbria area’s “green power ges. The design maintains combustion and mill at Workington uses around 800,000 t/a of The Holmen Group, it seems, likes giving chal- availability has been near 100% since we took show.” evens out fluctuations caused by varying fuel wood, a combination of sawmill chips, round- As Nieminen recalls, there was a sudden flurry lenges to its employees as well as its suppli- it over. With the continued support of our sup- qualities. The technology is very environmen- wood, energy crops, and other biomass, of activity around the mill as the deadline be- ers. Instead of importing a group of biomass plier partners, we intend to keep uptime high.” tally friendly, with emissions that are below, mostly from Scotland and northern England. gan to loom in the distance. “A whole host energy experts to run the new power plant, and sometimes far below, EU, domestic, and of different nationalities began arriving to con- Holmen selected team members from the The Workington Mill management and work local regulations.” From the A-frame, the chipped and crushed centrate on their part of the project,” he says. Workington Mill. This included Bill Williams, force make it abundantly clear that they are biomass is transferred into two holding silos “This was a really intriguing part of the project Lead Technician, who enjoyed the retraining extremely proud of the mill being entirely self-

As a follow-on in May, ANDRITZ received the before entering the boiler. for me, the way that Spanish, Polish, Swedish, in the art of power and steam generation. “This sufficient in terms of energy – and that by do- First published in SPECTRUM, issue 28

06 07 Biomass power for sustainable production and profits

Green energy solutions from ANDRITZ. contents. ANDRITZ delivers complete solu- vices enable conversion of existing boilers Using biomass fuels for power generation tions – from biomass receiving to fuel feed- to biomass firing and co-firing. ANDRITZ offers important environmental and eco- ing to combustion (boilers or gasifiers) to has been a leading technology and service nomic benefits. The key is to design a flex- ash handling to on-going service. BFB and partner for forest products companies for ible solution, capable of handling the vari- CFB boilers from ANDRITZ are proven in in- many decades. Talk to us about sustain- ations in biomass materials and moisture stallations around the world. Rebuild ser- able, renewable solutions.

CONTACT

AUSTRIA FINLAND ANDRITZ AG ANDRITZ Oy ANDRITZ Oy Stattegger Strasse 18 Tammasaarenkatu 1 Askonkatu 9 G 8045 Graz, Austria 00180 Helsinki, Finland 15100 Lahti, Finland www.andritz.com Phone: +43 (316) 6902 0 Phone: +358 (0)20 450 5555 Phone: +358 (20) 450 5555 [email protected]

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