NEXT-GENERATION BIOPRODUCT MILL

IN ÄÄNEKOSKI

Metsä Group has built the world’s first next-

generation bioproduct mill in Äänekoski.

With a value of EUR 1.2 billion, it is the largest

investment of the forest industry in Finland.

The construction of bioproduct mill began

in May 2015 and the large-scale project

progressed as planned – on schedule and

according to the budget. The mill began

operations in August 2017.

The mill is producing 1.3 million tonnes of pulp

per year. Most of the pulp will be exported,

mainly to Europe and Asia. The bioproduct mill

is manufacturing softwood and birch pulp for

board, tissue and printing paper and speciality

products. The pulp deliveries from the new mill

to customers began in early September 2017

and the mill will achieve its nominal capacity

in summer 2018.

The world consumption of softwood pulp is

increasing steadily, most rapidly in China.

The bioproduct mill is strengthening Metsä

Group’s position in the global softwood pulp

market. This quarantees long-term reliability

and meeting the needs of our customers.

The new Äänekoski mill is called a bioproduct

mill since it is increasing the product portfolio

with new bioproducts, generating excess

bioenergy, and using no fossil fuels. The mill is

utilising 100 per cent of its wood raw material

as well as production side streams.

THE WORLD’S FIRST NEXT-GENERATION BIOPRODUCT MILL

DID YOU KNOW?That the bioproduct mill is creating more than 2,500 jobs throughout the value chain in Finland, with 1,500 of them being new jobs.

P U L P P R O D U C T I O N

million tonnes per year

1.3

BIOPRODUCT MILL IN BRIEF

I N V E S T M E N T

EUR billion

1.2

E L E C T R I C I T Y S E L F - S U F F I C I E N C Y

%

U S E O F W O O D

million cubic metres per year

6.5 S H A R E O F S E R T I F I E D

W O O D

%

90

U S E O F F O S S I L F U E L S

E L E C T R I C I T Y P R O D U C T I O N

% terawatt hours per year

0 1.8 240

THE ECOSYSTEM CREATED BY THE BIOPRODUCT MILL IS UNIQUE IN THE WORLD.

TOP-CLASS ENVIRONMENTAL EFFICIENCY

ustainability and environmental responsibility are an integral part of Metsä Group’s daily

operations. We use renewable northern wood as a raw material, utilise the best available technologies in production, and take care of our employees’ safety and well-being.

The bioproduct mill represents the highest levels of energy, material

C H E M I C A L O X Y G E N D E M A N D ( C O D C R )

The information is based on statistics from Metsä Fibre, the Finnish Forest Industries Federation and the Swedish Forest Industries Federation and company reports. The COD load of the bioproduct mill is based on a prediction for 2018 onwards.

COD is a value that is used to monitor the quality of wastewater and its organic load on waterways.

kg/tonne of pulp

E F F L U E N T S

SODIUM

13 00015 000 17 00012 000

Tonnes/year (SO4) Tonnes/year (Na)

and environmental efficiency in the world. Even though its production capacity is nearly three times higher than the previous pulp mill of Äänekoski, the bioproduct mill is operating within the same emission limits and wastewater conditions of the previous mill´s environmental permit.

Its emissions are not affecting the recreational or other use of

Bioproduct mill Previous mill

SULPHATE

Metsä Fibre’s mills Swedish pulp mills Finnish pulp mills

BAT lower limit BAT upper limit

S

20

15

10

5

0

Biopro

duct m

ill

Jouts

eno

Kemi

Raum

a

750

1,050

1 ,800

GWh/a

Use of fossil fuels210

Electricity generation

Sold electricity

Own electricity use

E L E C T R I C I T Y P R O D U C T I O N

the natural water system. Its sulphate emissions into water are around 15 per cent lower than those of the previous mill.

The noise generated by the mill site is not exceeding the reference values. The mill’s odorous gases are processed into sulphuric acid, which the bioproduct mill needs in the manufacturing of, among other things, the important bioproduct tall oil.

Maximal energyefficiency

Equipment for the new mill was selected based primarily on energy efficiency, low water consumption and low emissions. The mill is producing 1.8 TWh of electricity per year, which represents 2.5 per cent of all electricity production in Finland. The mill is annually producing 2.4 times more electricity than it

consumes. The high level of electricity self-sufficiency (240 per cent) is based on the mill’s size and on its highly advanced technology. The bioproduct mill is increasing the share of renewable energy in Finland by more than 2 percentage points.

T H E B I O P R O D U C T M I L L’ S E L E C T R I C I T Y P R O D U C T I O N I S E Q U A L T O T H E A N N U A L

C O N S U M P T I O N O F

electrically heated single-family houses

in Finland.

times as much energy as it needs.

T H E M I L L I S P R O D U C I N G

2.4 100,000THE MILL IS NOT

USING ANY FOSSIL FUELS.

Bioproduct mill Previous mill

THE MILL CONCEPT MAXIMISES SOLD BIOENERGY

0 500 1,000 1,500 2,000

365

95

270

0

12.

15.

14.

9.

8.

3.

7.6.

5.

4.13.

10.

OUTSTANDING EFFICIENCYThe core of Metsä Group’s bioproduct mill lies in the world’s most efficient pulp mill. Production side streams are used to produce other bioproducts and bioenergy.

FIBRE LINEProduction of pulp fibre

1. Debarking plant2. Chip piles3. Digester4. Washing5. Bleaching6. Drying7. Automated pulp

distribution center

RECOVERY LINEEnergy production and recycling of chemicals

8. Evaporation plant 9. Recovery boiler and turbine 10. Recausticising 11. Lime kiln 12. Bark gasification plant 13. Sulphuric acid plant 14. Water treatment plant 15. Mill office 16. Wastewater treatment plant

2.

16.

11.

1.

FOSSIL-FREE PRODUCTION PLANTThe bioproduct mill is not using any fossil fuels, as it is generating all of the bioenergy that it needs from wood and side streams. The fossil fuel for the lime kiln is replaced with producer gas from gasified bark.

MORE THAN A PULP MILLThe bioproduct mill is using 6.5 million cubic metres of pulpwood per year to produce 1.3 million tonnes of softwood and birch pulp. The wood and production side streams are utilized 100 per cent for bioproducts and bioenergy. Bioproducts are making up 20 per cent of the mill’s net sales, even in the first phase.

THE MOST EFFICIENT RECOVERY BOILER IN THE WORLDA significant share of all renewable energy produced in Finland is generated when black liquor, consisting of wood and cooking chemicals, is combusted in a recovery boiler in pulp production. This process converts the cooking chemicals into a reusable form. The bioproduct mill is the most energy-efficient pulp mill in the world, as its equipment solutions are based on highly advanced energy technology. The mill is producing 2.4 times as much electricity as it uses.

Pulp

Tall oil and turpentine

Various forms of bioenergy

Product gas from bark to biofuel for the mill

Sulphuric acid from odorous gases to be used by the mill

Biogas and biopellets from sludge to be used as fuel in transport and industry

Biocomposites from pulp

New biofuels from surplus bark

Fertilisers and earthwork materials from dregs and ash

New bioproducts from lignin

New textile fibres from pulp

PULPWOOD

PULP

UTILISATION OF MAIN AND SIDE STREAMS

TRADITIONAL BIOPRODUCTS

NEW BIOPRODUCTS ALREADY AGREED UPON

NEW CONCEPTS UNDER DEVELOPMENT

Sludge

Bark

Odorous

gases

Dregs and ashes

Bioenergy

Lignin

Turpentine and tall oil

Pulp upgrading

THE NEW BIOPRODUCTS EXPANDING THE PRODUCT RANGE

xpanding the product range to completely new bioproducts was a central principle in

the design of the bioproduct mill. So far, the production of product gas, biogas and sulphuric acid have been started in the mill´s ecosystem. The mill is also producing traditional

E

Product gas

Bark-derived product gas is produced for the mill’s own use, whereby the mill is fully free of fossil fuels. The renewable product gas is replacing some 45,000 m3 of heavy fuel oil a year.

Sulphuric acid

Metsä Group has developed a concept in which the odorous gases of the bioproduct mill are converted into sulphuric acid, to be used as a raw material by the mill. This represents a significant step towards more closed chemical cycles.

Biocomposites

Aqvacomp Oy is producing biocomposite as a substitute for plastic, which combines pulp fibre and plastic. It can be used in the electronics and automobile industries. The first plant is integrated to Metsä Group’s Rauma pulp mill.

Biogas

The biogas plant that Eco-Energy SF Oy has built at the bioproduct mill is the first in the world to make use of the sludge generated in pulp produc-tion. The plant produces biopellets and approximately 20 GWh of biogas a year, which is equal to the annual fuel consumption of roughly 1,800 passenger cars.

biochemicals, such as tall oil and turpentine, and bioenergy. The share of bioproducts manufactured from side streams represents 20 per cent of the mill’s net sales and continue to grow gradually. We are studying several processes and product paths and will implement them gradually.

Upgrading of lignin and manufacture of textile fibres from pulp are progressing at the research stage.

Metsä Group is researching the manufacture of textile fibres from pulp. The manu-facture of wood-based textile fibres using environmentally friendly method based on ionic liquid technology is a long-term research process.

he importance of wood is increasing globally. Forest management, wood supply,

sawmills and pulp mills constitute a cluster that is a unique success factor for Finland. Metsä Group’s business areas make up a strong value chain. In its various phases, we fully utilise wood as pulp, wood products, board, tissue paper and bioenergy, for example.

On this strong foundation, we have builtthe bioproduct mill that is the largestwood-processing plant in the NorthernHemisphere.

Its core consists of the world’s most efficient pulp mill, and a network of companies manufacturing various types of bioproducts will broaden around this nucleus. These companies will convert pulp production side

streams into bioproducts that offer higher added value than before. This will support the competitiveness of the mill complex and increase supply in the growing market for wood-based bioproducts. The ecosystem created by the bioproduct mill is globally unique.

UNIQUE BIOECONOMY ECOSYSTEM

T

of the raw materials and side streams

T H E B I O P R O D U C T M I L L A N D T H E N E T W O R K O F C O M P A N I E S

A R E U S I N G

100 %

Botnia Pulp:1.3 million

tonnes of pulp per year

Botnia Biochemicals:

Tall Oil and Turpentine

New Bioproducts:BiogasSulphuric acidProduct gas

Bioproducts in research phase:Processed lignin productsTextile fibres

Increases the share of renewable energy in Finlandby more than2 percentage points

2,500employed

throughout value chain in Finland

Total investment

EUR 1.2 billion

Increases the value of Finnish exports byEUR 0.5 billion per year

The annual impact of more than EUR 0.5 billion on Finland’s income

Unique Industrial Ecosystem

Value for Finnish Society

Network of companies utilizing pulp and process side-streams in the production of a variety of new bioproducts

Significant added value for Finnish economy, industry and employment

Metsä Board

CP Kelco Äänevoima

Specialty Minerals

EcoEnergy SF

Metsä Group Äänekoskibioproduct mill

1.8 terawatt hours

of bioelectricity per year

Use of fossil fuels

0%

240% energy self-sufficient

GROWTH FOR FINLAND

WHY THE BIOPRODUCT MILL WAS BUILT IN ÄÄNEKOSKI?

he bioproduct mill is the largest investment ever made in the forest industry in Finland. It has

a significant effect on the Finnish natio-nal economy by providing new jobs and economic growth.

The employment effect of bioproduct mill throughout the value chain in Finland is 2,500 jobs, including 1,500 new jobs. The most significant emplo-yment effects are expected to be in the forest industry and transport. The mill will increase the value of exports by around EUR 0.5 billion per year. The bioproduct mill is diversifying the structure of the Finnish forest eco-nomy and bioeconomy and expanding their product range by introducing new bioproducts that offer high added value. Northern wood – a sustainable choiceThe bioproduct mill is significantly increasing the use of Finnish wood. The use of pulpwood is increasing by

E M P L O Y M E N T I M P A C T

jobs in the whole value chain in Finland

I N C R E A S E S T H E V A L U E O F F I N N I S H

E X P O R T S A N N U A L L Y

EUR billion

0.5

2,500

• The global demand for softwood pulp is increasing steadily, by around two million tonnes by 2025, most rapidly in China.

• Metsä Group has strong roots in Äänekoski, where pulp production began in 1937.

• The new bioproduct mill was built on the present mill site, where it serves the existing forest industry. The bioproduct mill replaced in 1985 opened pulp mill which was nearing the end of its life cycle.

• Metsä Board’s board mill is located in the same integrated mill complex as the bioproduct mill.

• Äänekoski has a good geo-graphical location in terms of availability of raw material.

more than four million cubic metres per year, or around 10 per cent. Most of the wood used by the bioproduct mill is acquired from sustainably managed Finnish forests. The wood used as raw material at the mill is fully traceable, and 90 per cent of it has PEFC or FSC certification.

H I S T O R Y O F T H E Ä Ä N E K O S K I I N T E G R A T E D M I L L S

19061906– 2011 Paper production

19371937– 1984 Sulphite pulp mill

18991899–1986 Sawmill

1899 Board production

T

WHY THE BIOPRODUCT MILL WAS BUILT IN ÄÄNEKOSKI?

19611961– 1985 Sulphate pulp mill

19661966– New board mill 1985

1985–2017 Previous pulp mill

2017

2017– Bioproduct mill

METSÄ FIBRE OYP.O. Box 3002020 Metsä, Finland tfn. +358 10 4612metsagroup.commetsafibre.com

bioproductmill.comtwitter.com/biotuotetehdas

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