1. Experiences on mill scale with enzymes Final Seminar of Subproject 3 of ECOTARGET Tuesday 1 April, 2008 at STFI-Packforsk Ir. Loud van Kessel Senior Process Engineer Smurfit Kappa Roermond Papier

2. 2 Content  Introduction Smurfit Kappa Roermond Papier  Fluctuations: long term  Fluctuations: short term  The effect of enzyme treatment on the paper production performance  Conclusions

3. Introduction Smurfit Kappa Roermond Papier

4. 4 Production facilities: Europe Czech Republic Switzerland Slovakia Russia Finland Lithuania Operations  Mills/Depots (42)  Solid Board (14)  Paper Sacks (13)  Corrugated Plants (230)  Graphic Board (2)  Specialities (15)  Generating employment for approx. 34,000

5. 5

6. 6 Mill key information  ProductsTestliners, fluting and chip (Schrenz)  CustomersPackaging industry  Production525,000 ton/year paper testliner: 100 - 220 grs/m² fluting: 105 - 180 grs/m² chip: 90 - 140 grs/m² 15 kt/year Rofire   Paper machines3  Employees260

7. 7 Logistics 2006  Recovered paper is main raw material  consumption + 570,000 ton/year (22 % of NL)  + 11,000 tons/week  delivery + 85 lorries/day  stocks: + 3 weeks of production  max. stock capacity 30,000 ton  Produced paper  + 525,000 ton / year  shipment: + 75 lorries / day  max. stock 18,000 ton

8. 8 Utilities 2006  Energy usage160,000 MWh  Own power plant4 turbines 14 MW producing 114,000 MWh 35,000 household equivalent  Gas89 million m 3 /year 45,500 household equivalent  Civil water usage169,000 m 3 /year 3,550 person equivalent  Water treatment4,750 m 3 /day 130,000 civil equivalent

9. 9 Kappa Roermond Papier

10. 10 Evolution of the recovered paper utilisation and the recycling rate in Europe (CEPI 2002)

11. 11 Price fibres (€ ) average 2003 0 50 100 150 200 250 300 Virgin Fibre Recycled Fibre

12. 12 Effects of recycling  Fibre damage  Change in physical properties  Change in surface properties  Accumulation of additives

13. 13 Fibre damage  Fibre shortening  Minor influence  Creation and accumulation of fines  Great influence on process and product

14. 14 Identification of fine particles in recycled fibre pulp Fibre chunks

15. 15 Identification of fine particles in recycled fibre pulp Fibre fibrils

16. 16 Identification of fine particles in recycled fibre pulp Ash

17. 17 Ash content Mixed (PM2)

18. 18 Ash content Mixed (PM2)

19. 19 Ash content Mixed (PM2)

20. 20 6 8 10 12 14 16 18 20 22 197019751980198519901995200020052010 Asch content (%) ? Ash content Mixed (PM2) Germany

21. 21 Fines in head box

22. 22 Examples: Paper properties

23. 23 Examples: Paper properties Specifications

24. 24 Examples: Paper properties Excess of raw material/additives

25. 25 Energy consumption 200420032005

26. 26 Energy consumption 200420032005 250 kg steam per ton > 5 Euro per ton

27. 27 Enzymes  Improved drainability and porosity without strength loss and without significant loss of mass  Increased relative bonded area, flexibility and fibrillation without affecting fibre length

28. 28 Influence of enzymes (cellulase) on dewatering speed

29. 29 Prevention - Compression refining

30. 30 Washing

31. Sustainable paper production in the future Zero emission strategy

32. 32 Raw Material Recycled Paper 94%Paper fibre 5%Organic material 1%Inert, inorganic material (metal, glass, sand etc.)

33. 33 Upgrading Recycled Paper Fluting + Testliners Secondary fuel - Rofire ®

34. 34 Process Scheme

35. 35 The Rofire ® Rational Better use of valuable raw materials Advanced separation process Useful, new product with good market conditions

36. 36 Rofire ® and Environment (1) Roermond 30,000 tonnes less waste disposal p.a. 16,000 Rofire ® p.a. 12,000,000 m³ natural gas p.a. Biomass content 50%

37. 37 Rofire ® and the Economics Rofire ® average price 15 €/ton Equivalent coal 50 € Equivalent natural gas 90 € CO 2 reduction

38. 38 Rofire ® and Environment Europe 1,300,000 tonnes less waste disposal p.a. 700,000 tonnes Rofire ® p.a. 525,000,000 m³ natural gas p.a.

39. 39 Return of investment:  Savings on reject costs: € 4.000.000,- a year *  A pay-back of 2 years on the described installation * Based on landfill costs of €160,-/tonne (Netherlands 2003)

40. 40 Forbonium  The biology of the water treatment plant at Roermond Papier has a lack of the element phosphorous: phosphoric acid is used as a nutrient.  A food producer in Holland needs to de-phosphorize baby food products. There is an emission (waste) of a phosphorous concentrate.  Both companies invested in a storage and dosing unit in Roermond to reduce both on variable costs.

41. A paper mill has different costumers, depending on the point of view:

42. 42 Core competence from different views: Employee Shareholder Customer Environment Neighbourhood