Low Cost And High Yield Kenaf Pulp For Paper

Industry
- Case Study Of Kenaf Market Pulp Mill Project In Vietnam
Eric Chao Xu
Andritz Inc, USA
Dieter Teubner
Andritz AG, Austria
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Location: Phuong Nam, Long An Province, Vietnam
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Economic And Social Features
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
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Kenaf At Phuong Nam, Vietnam
- Transfer on Water-Ways
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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
o
C
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.
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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 winterspring rice crop and summerautumn kenaf crop covers
23,000 hectares.
Ricegrowing 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 ong, Binh
Phong Thanh, Binh Thanh and Tan Thanh.
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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.
Summerautumn rice crop may be cultivated from April to May, and harvested in
J uly 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 Thanh, with total
of 139,684 hectares
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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.
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Profit Comparison Among Different Options
- Based on price in 2006
Options
Summer- Autumn
kenaf crop for
dry fiber
Summer- Autumn
rice crop
Summer- Autumn
kenaf crop for
pulp-making stalk
Total cost to grow kenaf to get
dry fiber (VND/hectare)
5,380,000
Total cost to grow kenaf to get
kenaf stalk (VND/hectare)
4,780,000
Total cost to grow rice
(VND/hectare)
5,650,000
Yield (ton/ hectare) 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
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Kenaf At Phuong Nam, Vietnam
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Kenaf At Phuong Nam, Vietnam
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Kenaf At Phuong Nam, Vietnam
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Kenaf At Phuong Nam, Vietnam
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Kenaf At Phuong Nam, Vietnam
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Kenaf At Phuong Nam, Vietnam
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Basic Characteristics of Kenaf
Whole Kenaf Kenaf Bast Kenaf Core
Fiber Length mm 1,28 2,6 0,6
Fiber diameter 20 30
Lignin content % 13,2 7,7 17,4
Cellulose % 54,4
Alpha Cell % 37,4

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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
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P-RC APMP Processing at Andritz pilot plant:
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Comparison of Kenaf, Jute and Aspen
Material CSF
(ml)
Tensile
(N.m/g)
Bulk
(cm
3
/g)
Burst
(kPa.m
2
/g)
Brightness
(%ISO)
LSC
(m
2
/g)
Opacity
(%)
NaOH
(%)
H
2
O
2
(%)
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
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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.
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P-RC APMP Pulp From Whole Kenaf (Pilot Trial)
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About P-RC APMP
Fundamental concept of P-RC APMP (4 steps):
AP pretreatment Refining 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:
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
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Process Flowsheet
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P-RC APMP Pulp From Kenaf
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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%
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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.
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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.
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Latest Picture from Mill Site At Phuong Nam, Vietnam
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Latest Picture from Mill Site At Phuong Nam, Vietnam
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Latest Picture from Mill Site At Phuong Nam, Vietnam
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Latest Picture from Mill Site At Phuong Nam, Vietnam
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Latest Picture from Mill Site At Phuong Nam, Vietnam
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Latest Picture from Mill Site At Phuong Nam, Vietnam