Being asked to think outside of the box is a phrase that can stir up dread when solutions to problems are few and far between. For most industries, the rising cost of coal and anthracite is a challenge that is especially hard to solve, but ever so prudent considering a mill’s dependency on energy.
But true to what is increasingly becoming the norm at Sappi, a quick-thinking innovative team has come up with a solution that will not only save Sappi ZAR300 million per year in energy costs but is better for the environment too. With one solution, the team has succeeded in bringing Sappi closer to two of its goals: increased profitability and decreased pressure on the environment.
How did they do it?
Albert Olivier, Strategy Manager of Fibre and Coal at Sappi Ngodwana Mill, and his team developed a lower cost, greener solution using a biomass, Lignosulphonate and coal slurry to replace coal and anthracite. The result is a fuel rod that beats coal in performance.
A pilot plant was erected at Sappi Lomati Sawmill in Barberton, to produce this 100% green fuel rod, which is an entirely new product for the domestic market.
But true to what is increasingly becoming the norm at Sappi, a quick-thinking innovative team has come up with a solution that will not only save Sappi ZAR300 million per year in energy costs but is better for the environment too. With one solution, the team has succeeded in bringing Sappi closer to two of its goals: increased profitability and decreased pressure on the environment.
How did they do it?
Albert Olivier, Strategy Manager of Fibre and Coal at Sappi Ngodwana Mill, and his team developed a lower cost, greener solution using a biomass, Lignosulphonate and coal slurry to replace coal and anthracite. The result is a fuel rod that beats coal in performance.
A pilot plant was erected at Sappi Lomati Sawmill in Barberton, to produce this 100% green fuel rod, which is an entirely new product for the domestic market.
The rods are made in five steps:
Step 1: Bennet Shabangu, supervisor at the Fuel Rod Plant, starts the production process by feeding raw sawdust into the steam reactor. This puts the product under high pressure in order to create a steam explosion of the fibres during the sudden release of the product into the blow tank.
The rods are made in five steps:
Step 1: Bennet Shabangu, supervisor at the Fuel Rod Plant, starts the production process by feeding raw sawdust into the steam reactor. This puts the product under high pressure in order to create a steam explosion of the fibres during the sudden release of the product into the blow tank.
Step 2: The steam exploded bio-mass excretes into the fan press to squeeze out the steam condensate in order to increase the consistency of the product. The biomass is moved to the heaters to dry before it goes to the extruder.
Step 2: The steam exploded bio-mass excretes into the fan press to squeeze out the steam condensate in order to increase the consistency of the product. The biomass is moved to the heaters to dry before it goes to the extruder.
Step 3: Mangaliso Mhlanga feeds the extruder with biomass to produce the fuel rods.
Step 3: Mangaliso Mhlanga feeds the extruder with biomass to produce the fuel rods.
Step 4: The fuel rods are dried under infrared dryers. This is not the ideal drying mechanism as this is only for pilot testing and will be replaced with more economical drying methods once a market for the new product is established.
Step 4: The fuel rods are dried under infrared dryers. This is not the ideal drying mechanism as this is only for pilot testing and will be replaced with more economical drying methods once a market for the new product is established.
Step 5: Product is bagged in 5kg bags for distribution. The Lomati plant can currently produce a ton of fuel rods a day. Once a market for domestic heating and cooking is established, capacity will increase. A commercial plant is currently under construction at Tugela Mill with the intent to replace coal at the Stanger, Saiccor and Tugela mills in KZN. The next phase will see a 500,000 ton per annum plant erected to replace coal at Ngodwana. Pilot plant can do a ton a day. Once market is established a larger plant will be established.
Step 5: Product is bagged in 5kg bags for distribution. The Lomati plant can currently produce a ton of fuel rods a day. Once a market for domestic heating and cooking is established, capacity will increase. A commercial plant is currently under construction at Tugela Mill with the intent to replace coal at the Stanger, Saiccor and Tugela mills in KZN. The next phase will see a 500,000 ton per annum plant erected to replace coal at Ngodwana. Pilot plant can do a ton a day. Once market is established a larger plant will be established.
During the trials the team conducted burn tests to compare the efficiency of the fuel rods with charcoal and braai briquettes. A comparison was done between 1kg biomass fuel rods, 1kg hybrid fuel rods, 1kg charcoal and 1kg braai briquettes, to braai 1kg wors. The team found that that the fuel reached ready state, braai condition quicker, within 25 minutes, compared to charcoal that takes 50 minutes. The fuel rods also braaied the wors far quicker than the charcoal.
During the trials the team conducted burn tests to compare the efficiency of the fuel rods with charcoal and braai briquettes. A comparison was done between 1kg biomass fuel rods, 1kg hybrid fuel rods, 1kg charcoal and 1kg braai briquettes, to braai 1kg wors. The team found that that the fuel reached ready state, braai condition quicker, within 25 minutes, compared to charcoal that takes 50 minutes. The fuel rods also braaied the wors far quicker than the charcoal.
Olivier said he was proud of the production team that took on this new challenge and delivered. “Thank you Lomati for your support and teamwork. This includes all from the General workers to General Manager.”
Olivier said he was proud of the production team that took on this new challenge and delivered. “Thank you Lomati for your support and teamwork. This includes all from the General workers to General Manager.”
