Borregaard and Sappi commemorate 20th anniversary of the opening of their lignin extraction plant in South Africa

Type of post: NEWS.

Last week, Sappi issued a press release to commemorate 20 years of a biorefinery investment carried out together with Borregaard: the lignin extraction plant in Umkomaas (KwaZulu Natal, South Africa). Let us seize the opportunity to know more about the history of the facility and its high value-added products that generates export revenues for South Africa and has a positive impact on the environment.

Press release: “Sappi and Borregaard celebrate 20 years of biorefinery investment”, 8/4/2019.

Figure 1. Lignin extraction plant in Umkomaas (taken from Google Maps)

Timeline

1997: LignoTech South Africa was established as a partnership joint venture owned by Borregaard (50%) and Sappi (50%). The plant was designed to generate revenue from a previously-unused component of the effluent stream from Sappi’s Saiccor mill. The location in South Africa was chosen because of the ready availability of a sustainable supply of raw materials, effective infrastructure, highly competent people, the relatively low cost of production and proximity to export markets via the Port of Durban. Its original nameplate capacity was 55 ktons/year.

1998: The plant was commissioned in December.

1999: Officially opening.

2003: First expansion capacity – From 55 to 155 ktons/year.

2008: Second expansion capacity – From 155 to 160 ktons/year.

2017: Third expansion capacity – From 160 to 180 ktons/year.

2018: Borregaard and Sappi agreed on an extension of the finalisation date of the agreement governing the lignin co-operation (from 2027 to 2032) and on a reduction in the annual production capacity for lignin. With effect from 2021, the capacity will be scaled down from the current 180,000 tons to 130,000. The reason is that Sappi's Saiccor dissolving pulp mill, which supplies the lignin raw material, will be expanded in order to increase total cellulose capacity on the site. The expansion will be based on magnesium sulphite technology, whereas the current calcium sulphite capacity will be reduced. The remaining calcium sulphite line will continue to supply lignin raw material to the joint venture.

2019: 20 year after the official opening, LignoTech South Africa continues to benefit all stakeholders and has matured into one of the largest lignosulphonate manufacturers globally.

Products

Lignosulphonates are the end product of an advanced lignin extraction process. Lignin is a natural binding agent found in timber and is released during the pulping process. The released material is enhanced by a process of evaporation, chemical modification and spray drying.

The lignosulphonates produced at LignoTech South Africa are used as binding and dispersing agents in a wide range of agricultural and industrial applications (dust suppression, concrete additives, pelleting agents in animal feeds, mineral granulation…). Biodegradable and non-toxic to both humans and animals, they are the perfect industrial and agricultural additive. LignoTech South Africa’s output is sold in South Africa and exported to countries in Africa, Asia Pacific, the Middle East and South America.

One example of end application is Dustex®, a binding additive that suppresses the formation of dust. It is particularly effective in preventing gravel loss on non-tarred roads, thus limiting the formation of corrugations and improving the quality of the road surface. This in turn, improves road safety, makes traveling more comfortable, decreases vehicle operating and maintenance costs and decreases the cost of road maintenance.