Reduce emissions in pulp & paper with biomass gasification

Suzano is Brazilian pulp manufacturer, facing the challenge of reducing emissions in energy-intensive industrial operations, particularly in thermal systems like lime kilns. The company’s decarbonization strategy includes replacing fossil fuels with renewable sources, focusing on scalable solutions.

Location of the initiative: Ribas do Rio Pardo, Mato Grosso do Sul, Brazil

The initiative involves implementing a biomass gasification plant capable of converting biomass into syngas. This renewable syngas replaces fossil fuels in lime kilns, reducing CO₂ emissions by up to 97%. The plant also generates steam and electricity from lignocellulosic residues—such as black liquor and biomass—, promoting energy self-sufficiency .

Key steps:

1. Collection and preparation of biomass

2. Gasification to produce syngas

3. Integration of syngas into lime kilns

4. Performance and emissions monitoring

Figure 1: Suzano’s biomass gasification plant

Sustainability Impact

Climate

This initiative directly impacts Scope 1 emissions (combustion in lime kilns), and indirectly Scope 2 (electricity generation) and Scope 3 (logistics and inputs). Replacing fossil fuels with renewable syngas reduces CO₂ emissions from lime kilns by up to 97%. Lime kilns emissions represent approximately 35% of Suzano’s scope 1 emissions.

Nature

By valorizing biomass products, the initiative avoids improper disposal and contributes to the conservation of natural resources, reducing pressure on fossil sources and promoting sustainable biomass use.

The facility has the smallest average structural radius of the forest base among Suzano’s operations, with only 65 kilometers between plantation areas and the factory—significantly lower than the structural average of 150 kilometers. This unique feature minimizes logistics costs and the environmental impact associated with pulp transportation.

Social

In addition to generating over 10,000 direct jobs at the peak of construction and thousands of indirect jobs, the development of the new facility stimulated the local economy and contributed to workforce qualification. More than 1,300 individuals were trained for industrial, forestry, and logistics operations, and approximately 300 people were prepared for the local labor market in commerce and services through partnerships with SENAI and SENAC. Beyond the resources allocated to the factory, logistics infrastructure, and eucalyptus plantation areas, Suzano invested over BRL 300 million in a comprehensive set of initiatives, including housing units, a medical center, local infrastructure improvements, and support for social projects. As part of the Basic Environmental Plan (PBA), the Urban Infrastructure Program, approved in 2021 by public and civil society representatives, encompasses 21 projects in health, education, social development, housing, and public safety. Key deliverables include the expansion of the Municipal Hospital and the construction of a Family Health Strategy (ESF) unit, a Shelter House, a Civil Police Station, and a Federal Highway Police (PRF) Operational Unit. Additionally, Suzano promoted voluntary social initiatives focused on sustainable development, income generation, and poverty reduction. These investments were distributed across seven areas: education, income generation, rights protection, infrastructure, health, community relations, and employment. In education, Suzano supported public school quality improvement through teacher training. Income generation efforts included support for family farming, beekeeping, livestock, circular economy, and creative economy. Rights protection actions focused on preventing violence against children, adolescents, and women, considered priority groups in this initiative.

1. Job Creation & Economic Stimulation

• 10,000+ direct jobs during construction and thousands of indirect jobs

• Boosted local economy

2. Workforce Training & Qualification

• 1,300 trained in industrial, forestry, and logistics operations

• 300 trained in commerce and services (with SENAI & SENAC partnerships)

3. Community Investments

• BRL 300M+ in housing, medical center, local infrastructure, and social projects

4. Urban Infrastructure & Public Services (PBA Program)

• 21 projects in health, education, social development, housing, and public safety

• Key deliverables: Municipal Hospital expansion, ESF unit, Shelter House, Civil Police Station, PRF Operational Unit

5. Voluntary Social & Sustainable Development Initiatives

• Focus on seven areas: education, income generation, rights protection, infrastructure, health, community relations, employment

6. Examples of Initiatives

• Education: Teacher training, school quality improvement

• Income Generatio: Family farming, beekeeping, livestock, circular/creative economy

• Rights Protection: Prevention of violence against children, adolescents, women

Business Impact

Benefits

• Approximately 20% increase in pulp production capacity

• Reduced dependence on fossil fuels

• Improved energy and logistics efficiency

• Replication potential in other industrial units

Costs

• High initial investment in gasification infrastructure

• Operational costs depend on stable biomass supply

• Potential access to clean technology subsidies

• Cost minimization through integration with existing processes and internal waste use

Typical Business Profile

Energy-intensive industries, especially in the pulp and paper sector, with access to biomass and interest in Scope 1 decarbonization.

Approach

1. Emissions and biomass availability assessment

2. Design and construction of gasification plant

3. Integration testing with lime kilns

4. Continuous monitoring and operational adjustments

Stakeholders Involved

• Project Leads: Suzano’s engineering, operations, sustainability, procurement teams among others

• Company Functions: Engineering, logistics, procurement, financial planning, operations

• Main Providers: Gasification technology suppliers

• Others: Local communities and biomass suppliers

Key Parameters to Consider

• Mature technology with large-scale application in the sector

• Advanced implementation stage with initial results

• Geographic relevance: regions with biomass availability

• Potential subsidies and tax incentives

Implementation and Operations Tips

Project is already implemented and is running since middle of 2024.

• Ensure continuous biomass supply

• Invest in syngas quality control

• Provide technical training for operational teams

• Monitor emissions and energy performance