Caledonian mill replaces fossil fuels with biomass

SMALLER CARBON FOOTPRINT FOR CALEDONIAN

text: Tuovi Similä
photos: Eric Howard, KWP

The new biomass-fired power plant at UPM’s Caledonian paper mill in Irvine, Scotland, supports not only UPM’s but also the Scottish Government’s targets to fight climate change. Supplying the biomass required by the mill is also of great economic importance for the region’s forest sector.

Caledonian’s biomass power plant started up in May this year, a month ahead of schedule. The investment, worth some EUR 88 million, is the mill’s biggest since its construction 20 years ago.

The new power plant will supply all the steam the mill requires for production and half of its electricity needs. Biomass and side products arising from production are mainly used as fuel. The new biomass plant replaced the old fossil fuel-fired facility, which is why the mill’s carbon dioxide emissions will decrease by 75,000 tonnes in a year. Caledonian, the only mill in the UK to do so, manufactures LWC paper, which is used mainly in magazines and catalogues.

Caledonian’s biomass plant is a continuation of UPM’s determination to increase its carbon-neutral output. Over the last 10 years, the company has been able to reduce carbon dioxide emissions in production by 25%.

Scotland has ambitious climate targets

Scotland’s recent Climate Change Act sets a target of an 80% reduction in greenhouse gas emissions by 2050.

“My cabinet colleagues and I are determined to make Scotland the green energy capital of Europe using our nation’s vast natural energy potential to create a sustainable, low-carbon economic future. It is clear that this ambition is well-founded, for we have some of the best sources of renewable energy in Europe and already we generate a fifth of our electricity from renewables,” says Scotland’s Energy Minister Jim Mather.

”We have some of the best sources of renewable energy in Europe and already we generate a fifth of our electricity from renewables,” says Scotland’s Energy Minister Jim Mather.

“Our climate target of reducing CO2 emissions by 80% has been clearly supported by UPM in the building of the new power plant. This facility is precisely the kind of action we need industry to take,” Mather says.

”With one of the largest ever Regional Selective Assistance grants of GBP 10 million the government clearly recognises the importance of these types of high quality projects.” Mather further emphasises that the Caledonian investment will have a huge benefit for the Scottish economy and provide a major contribution to the region’s forestry sector.

“When you combine the benefits of the new plants with the paper mills’ use of certified timber, you have a very powerful message which customers can positively relate to,” says Gordon McLean.

Project exceeded expectations

Gordon McLean, Energy and Engineering Manager at the Caledonian mill, has good reason to be pleased with the highly successful project. “It even exceeded our expectations. The start-up was seamless and we were virtually on full load from the first day,” McLean says. The UK operates a green certificate incentive system to promote renewable energy. The Caledonian mill was able to join the system once the new biomass plant was completed.

McLean thinks that “green” energy is also important in the marketing of paper too. “When you combine the benefits of the new plants with the paper mills’ use of certified timber, you have a very powerful message which customers can positively relate to.”

”We are also continuously looking for new alternative biomass fuel streams, e.g. from recycled wood,” says Peter Whitfield.

Supply of biomass ensured

The new plant requires 380,000 tonnes of biomass fuel annually. Responsibility for the purchase of fuel lies with UPM Tilhill, which also sources the 280,000 tonnes of pulp wood needed by the paper mill. Tilhill is not the only company needing biomass in Scotland, and competition for this fuel is becoming tighter. There are already a number of biomass users in Scotland, and plans are in place for the construction of numerous facilities that will run on renewable energy.

Tilhill has prepared for tougher competition by concluding 10-year supply contracts. “In addition, we have developed a method for brash baling and currently only Caledonian’s CHP can process and burn this material. We are also continuously looking for new, alternative biomass fuel streams, e.g. from recycled wood,” says Peter Whitfield, Timber Operations Director at Tilhill.

Tilhill is also able to harvest stumps for fuel. Permission for this was obtained as a result of extensive dialogue with stakeholders. “Stumps, however, account for only a modest proportion, about 5% of the total biomass input. Although methods of harvesting and transport have improved during the year, the costs are still very high,” Whitfield points out.

Tilhill harvests and trades some 2 million tonnes of wood fibre per annum across the UK. The biomass for fuel comes not only from the company’s own harvesting operations but also from a number of other sources, such as chips from sawmills. The average haulage distance for the biomass into the plant is 100 kilometres.