Customer case:

APP's OKI Pulp and Paper Mill - record breaking key technology

Oct 14, 2019

APP’s OKI Pulp and Paper Mill in Indonesia had its start-up in late 2016. Being one of the largest in the world, the mill has hit several pulp production world records ever since. Valmet’s delivery scope comprised of key technology, including pulp drying and baling, evaporation, ash treatment, biomass drying and gasification, a lime kiln, green liquor handling, mill wide NCG collection and biomass boilers. Both pulp dryers, as well as the ash crystallizer, are the largest machines ever built, with the largest production capacity.

APP has partnered with Valmet on major projects in the past, and we expected and received the same good level of cooperation in all areas of the project.

David Kerr, General Manager of OKI Pulp and Paper Mill

Summary

Location	South Sumatra, Indonesia
Customer challenge	Meet the growing demand for pulp with a cost-efficient and sustainable new production line.
Solution	New pulp mill with key technology from Valmet: Pulp drying and baling: Pulp dryers largest ones in the world - 10.6 meters wide No capacity limitations on dryers Production record for both machines combined 8,630 tonnes in one day Pulp drying line featuring several new technologies Baling lines with extensive safety features Evaporation: The largest evaporation plant in the world with design capacity of 2,900 tons of evaporated water per hour Exceptionally high dry solids The condensate treatment system is designed to enable 100 percent reuse of condensates in mill processes Ash treatment: World's largest ash crystallization plant Fully energy-integrated in the evaporation plant, optimizing the steam balances Biomass dryer and gasification Biomass dryer utilizes mill waste heat Two CFB Gasifiers - producing product gas from acacia bark with capacity of 110 MW each Lime kiln Two lime kilns with a length of 140 meters each Using biogas (gasified acacia bark) as fuel Green liquor handling Green liquor from the lime kiln is cleaned in Valmet OptiClear high rate clarifiers to increase the efficiency of the recausticizing process Mill wide NCG collection Collection and handling of non-condensable gases (NCG)(odorous and hazardous gases) Biomass boilers Two 302 MW(thermal) BFB power boilers using bark, sludge and coal as fuel
Results	The project was a success, with highly skilled specialists from across the globe working closely together as a team - regardless of any language barriers. The mill has an annual production of 2.8 million tonnes of bleached hardwood pulp.
Keywords	Chemical pulping, Complete pulp mills, Greenfield project, New lines, Indonesia, Asia Pacific

World records at OKI pulp mill

APP’s OKI pulp and paper mill in Indonesia is one of the largest in the world. The mill has broken several world records since its start-up in 2016, while delivering top quality. The success of the project lies in the mix of the best pulp expertise and a true team effort.

Project success is built on experts working together

"The OKI pulp mill project was special in many ways," tells Johan Schotte, who was Valmet’s project director in the project.

Ash crystallization at the OKI mill

At the APP OKI pulp and paper mill the recovery boiler ash is treated in an ash crystallization plant to keep potassium and chlorine at the desired low levels in the mill’s recovery cycle.