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Updated: 03.08.2007 - Page1
Karlstad, November 18, 2009Ove Bartholsen
Technical Service ManagerBorregaard ChemCell
BORREGAARD - A MODERN BIOREFINERY- Creating value from wood
Outline
1. The Borregaard Bio-refinery
2. Future Bio-refinery consideration
3. BF 2010 – Securing our future
Updated: 03.08.2007 - Page3
Borregaard presence
Head office
Production
Sales office
Borregaard Wood based chemicals in an integrated concept
VANILLIN
LIGNIN
SPECIALTY-CELLULOSE
ETHANOL
Bio energy (bark, side streams from the production, biogas from the waste water treatment)
Wood
1000 kg
50 kg 3 kg
400 kg
400 kgWoodyard
Digester
Etanol-plant
Vanillin-plant
Lignin-plant
Bleeching plantDrying machine
Applications (end products)
Cellulose Lignin Vanillin EthanolConstruction materials Concrete additives Food Car careCosmetics Animal feed Perfumes Paint/ varnishFood Dyestuff Pharmaceuticals Pharmaceutical industryTablets Batteries Bio FuelTextiles BriquettingFilters MiningPaint / varnish
Updated: 03.08.2007 - Page5
Borregaard Biorefinery
Updated: 03.08.2007 - Page6
The crucial question:Are we better of in the middle of a commodity value chain at the mercy of the politicians ?
Distributor
Biofuel - a possible new value chain for us ?
Raw material supplier
Biorefinery(diesel, ethanol)
Updated: 03.08.2007 - Page7
Cost efficiency
2. generation with C5 fermentation
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
Spruce (Norway) Wheat (Europe) Corn (U.S) Sugar Cane(Brazil)
Ethanol per square
meter/year
• Biomass growth is a big challenge in Scandinavia
Updated: 01/12/2009 - Page8
Biorefinery options - profit considerations
BioMaterials- Polymers- Composites
BioChemicals- Flavours- Monomers- Proteins-Fine chemicals-Speciality chemicals
BioFuel- Bioethanol- Biodiesel- Biogas
BioEnergy-Electricity/Heat- Liquid Fuels- Pellets
Co
st/p
rice
Low
High
Cre
ati
ng
valu
es
Low
High
BIOREFINERY
Updated: 01/12/2009 - Page9
Biorefinery options - profit considerationsReduce feedstock price & increase product price
BioMaterials- Polymers- Composites
BioChemicals- Flavours- Monomers- Proteins-Fine chemicals-Speciality chemicals
BioFuel- Bioethanol- Biodiesel- Biogas
BioEnergy-Electricity/Heat- Liquid Fuels- Pellets
Co
st/p
rice
Low
High
Cre
ati
ng
valu
es
Low
High
BIOREFINERY
Updated: 01/12/2009 - Page10
Biorefinery options - the incentive paradox
BioMaterials- Polymers- Composites
BioChemicals- Flavours- Monomers- Proteins-Fine chemicals-Speciality chemicals
BioFuel- Bioethanol- Biodiesel- Biogas
BioEnergy-Electricity/Heat- Liquid Fuels- Pellets
Co
st/p
rice
Low
High
Cre
ati
ng
valu
es
Low
High
BIOREFINERY
Economy of sugarplatform biorefineries
February 09
Raw materialcost
Total sales value
Updated: 03.08.2007 - Page12
Biorefining: Our definition
• The pursuit of the unique properties of our raw materials – not the destruction of them
BF 2010
AGENDA
Production Flow – Borregaard Sarpsborg
Fine Chemicals
also ethyl vanillin
Powerstation
Wood
SO2-plant
Water works
Chlor alkaliplant
Incineration facilities Purification
Salt Sulphur Oil Bio- Bark Sortedmass waste
El powerProcess-
waterCaustic Bleach- Chlor.
soda chem /HClSO2 Steam Steam Bio gas
Raw materials
Ethanol LigninSulphitelye Lye
Glomma
Lye
SALE SALE SALE SALE SALE
CelluloseDigesting Vanillin
Water Purified water
SALESALE
Bleaching
Drying
BF2010:Improved operations and reduced complexity
• Central control room and new organization• Powerful combination of cost reductions and competence development• Construction startup in Q4 2009
Energy works
Drying machineBleachPlant Ethanol Plant
Lignin Plant
Vanillin Plant
Digesting Plant
Chloro-Alkaline Plant
Control Central
SHIFT REDESIGN
Kilde: UCDS
The future organization will be build around the operator– all other functions will support this role
Page 17
Conceptual design of consoles in the new CCR- developed by operators and plant management
1
2
3
4
5
67
8
Three geographic areas with allocated operators and maintenance personnel
NorthBase: Digester
SYD
WestBase: Bleach
EastBase: Vanillin
Page 19
Technology and people
0
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200
NOV DES JAN FEB MAR APR u20 u21
Ala
rmer
per
tim
e
DAMP
Uakseptabelt
Tvilstilfelle
Akseptabelt
DAMP
Status: Tag: Beskrivelse Oppstartbetingelser:
Start sekvens H,P,B -trinn gruppestart B5008 -sjekk F5006.3 fettsmøreaparat Ikke vernsjekk C5012 air lift Ikke vernsjekk C5008 avtrekk filterhette Ikke vernsjekk C5008 avtrekk filterhette Ikke vernsjekk F5006.1 skruen Ikke vernsjekk P5033 duksprits Ikke vernsjekk F5006 filter Ikke vernsjekk P5016 spedning innløpskasse Ikke vernsjekk P5017 spedning tårntopp Ikke vernsjekk X5008 tårnskrape Ikke vernsjekk M5008 mikser bunn B5008 Ikke vernsjekk P5019 hypopumpe Ikke vernsjekk P5031 H2O2 pumpe Ikke vernsjekk P5029 A/B NaOH pumpe Ikke vernsjekk P5270 Borol før M5008 Ikke vernsjekk P5025 SO2-vann sugesiden P5017 Ikke vernsjekk HSV6089 drenering trau til B6001 stengtsjekk HSV6090 dren. masseledning til B6001 stengtsjekk HSV5313 masseventil inn i B5008 åpensjekk LIC 6001 nivå i massetank B-6001 < 80%sjekk LIC5077 nivå bakvannstank B5014 > 60%sjekk P6010/11 sperrevann driftsjekk P6006 spedning skruen fra B6007 driftinfo. V1 -vann Fingervann F5006 ikke i startsekvensenstart F5006.3 fettsmøreaparat startstart C5012 air lift + 0 sek. startstart C5008 avtrekk filterhette + 0 sek. startstart F5006.1 skruen + 0 sek. startstart P5033 duksprits + 0 sek. startk i FIC5072 d i k ilå i 15 %
start P5033 duksprits + 0 sek. start
aktiver FIC5072 spedning skruen ventilåpning 15 %sjekk F5006.1 skruen normal strøm
aktiver FIC5072 spedning skruen OP 100% hvis strøm > 43 amp F5006,1start F5006 filter < 43 amp. F5006.1 + 5 sek. startsjekk F5006 sjekk strøm normal strøm < 43 amp.
aktiver V1 -vann fingervann F5006 OP 20% i startsekv. + 20min etter st.P5002aktiver V1 -vann fingervann F5006 OP 100% hvis strøm > 43 amp F5006
start P5016 spedning innløpskasse v/normal strøm F5006 + 3 sek. startstart P5017 spedning tårntopp + 5 sek. start
aktiver FIH5066 mengde spedning tårntopp ?? m3start X5008 tårnskrape v/ ?? M2 5066 + 3 sek.
aktiver X5008 tårnskrape strøm < 23 ampstart M5008 mikser bunn B5008 v/ normal strøm X5008 + 6 sek. start
aktiver TCV5132 temp vaskevann ramper seg opp til SP når P5002 i driftaktiver FCV5071 mengde vaskevann ramper seg opp til SP når P5002 i drift
start P5034 hypopumpe v/resept 2,3,5,8,11,16,19,22+ P5002 starteraktiver XXXX ventil hypo åpnes når P5034 starteraktiver FCV5025 hypo dosering i st. pipe v/resept 2,3,5,8,11,16,19,22+ P5002 starter
start P5025 SO2-vann sugesiden P5017 v/resept 2,3,5,8,11,16,19,22+ P5002 starteraktiver ACV5070 SO2-vann sugesiden P5017 kjøres denne ventilen bare i man.??
start P5031 H2O2 pumpe v/resept 7,9,12,14,15,17,21,23+ P5002 starteraktiver FCV5291 H2O2 i skruen F5005.1 v/resept 7,9,12,14,15,17,21,23+ P5002 starter
start/går P5029 A eller B NaOH pumpe start når P5002 starteraktiver FCV5292 NaOH i skruen F5005.1 aktiver når P5002 starter
start/går C5270 avtrekk tårntopp hele tiden v/resept 12(2),13,18,26,27start/går C5271 avtrekk tårntopp hele tiden v/resept 12(2),13,18,26,27
start P5270 Borol før M5008 v/resept 12(2),13,18,26,27+ P5002 starteraktiver XXXX ventil borol åpen v/ borolaktiver FCV5854 Borol før M5008 v/resept 12(2),13,18,26,27+ P5002 starteraktiver SIC5219 turtall F5006 aktiver når P5002 starter
From complexity….to overwiev and stability
From complex startup procedures….to startbuttom
0
20
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60
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100
120
140
160
180
200
u11 u12 u13 u14 u15 u16 u17 u18 u19 u20
Ala
rme
r p
er
tim
e
BLEKERIET
Uakseptabelt
Tvilstilfelle
Akseptabelt
Blekeriet totalt per time
From stress….to control
Manning development
600
550
500
450
400
2009 2010 2011 2012
Control center
Retirement
New org.
Retirement + average
Dismissal
Wanted scenarioCa. 530
Competence development - case, SKR
Competence
2005 – jan. 2009 jan 2009 – juli 2009 Aug ’09
Water purification / Effluent treatment
Boilerhouse
Alva
Basic competence
New competence
Target
Bark 4. plant?
BF2010Organizational development and productivity improvements
Organizational development• New common control room
– Operate the plant from one central control room
– An organization build around the operator
– Focus on competence development
Improvements:• Lower manning:
– 200 man-years• Improved production:
– Increased and better production– Optimized maintenance– Lower energy consumption, optimal
steam production– Reduced overtime and sick leave
200
500
800
1100
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
E2008
P2011
4006008001000120014001600180020002200240026002800
Man-years Sales
Sales in mill. NOKMan-labour year