magazine of & // No. 32 / 2-2015 Montes delPlata//14 CHALLENGES READY FOR Marco MensinkInterview//29 OF FIBRE THE AGE

tuning

Otter Tail Power//38 SCRUBBER BIG STONE Fine passion for continuous A passionforcontinuous improvement keeps this improvement keepsthis Brazilian mill on top // 6 Brazilian millontop//

2 NO. 32 / 2-2015

10 38

Switch on GREEN POWER solutions from ANDRITZ

More and more companies are switch- ing on their GREEN POWER options. ANDRITZ offers a range of technologies for producing solid biofuels, liquid biofuels, and even energy from waste by-products.

We have included several stories in this is- sue of SPECTRUM, highlighted with the GREEN POWER symbol, which show- case our customers’ successes with re- 24 32 newable energy technologies. contents

03 Management Message 20 OPE in Finland 38 Big Stone scrubber Kotkamills and Stora Enso Otter Tail Power 04 News 24 Turkish delight 53 Minimal mercury 06 Fine tuning Kartonsan A.S. ANDRITZ Air Pollution Control Veracel Celulose 29 The Age of Fibre has begun 46 Orders & Start-ups 10 Kiln conversion Interview Marco Mensink Sappi North America 47 Did you know that? 32 Energy and revenue 14 Ready for the next challenge Harmac Pacific Montes del Plata 35 New generation drying TechTalk

On the cover: Fine Tuning ( 6), Cover/page 6: Stokkete - shutterstock.com

SPECTRUM is published by: Editorial Director: General information and copyright: ANDRITZ AG Robert Puhr You will see the use of both “tonnes” and Stattegger Strasse 18 [email protected] “tons” in this publication: tonnes for metric 8045 Graz, Austria Editorial Board: units and tons for American units. Spec- Phone: +43 (316) 6902 0 Bjørn Hansen, Minna Heinonen, Robert Puhr, Regina Puschnig, Dietmar Scherer, trum is published in three languages; Eng- [email protected] Andrea Schlagbauer, Ursula Suppanen, Manuela Wagner, Carina Weissensteiner lish, Chinese and Japanese. Copyright© Editor-in-Chief: Contributing Writers: ANDRITZ AG 2015. All rights reserved. No Bjørn Hansen Thomas Barbieri, Robert Puhr, Mark Rushton part of this publication may be reproduced [email protected] Contributing Photographers: without permission of the publisher. Project Director: Riku Isohella, Robert Puhr, Nilton Souza, Thomas Wedderwille Manuela Wagner Layout & Design: INTOUCH Werbeagentur & Internetagentur, Austria [email protected] spectrum.andritz.com NO. 32 / 2-2015 3

Leading technology vs. technology leadership

Joachim Schönbeck, Member of the Executive Board, Capital Systems. Humbert Köfler, Member of the Executive Board, Service & Units.

Some industries (consumer electronics a customer who is willing to try new con- weight – yet has the power to cope with comes to mind) are constantly driven to in- cepts – so that we can develop a better all sorts of wood species. What makes it troduce leading technology. The latest, the solution in partnership. There are clear ex- better is that it stays sharper longer so greatest, the newest feature. By leading with amples of these kinds of partnerships at knife changes are fewer. Plus, it cuts bet- technology, they try to determine what cus- work – big and small: ter chips. tomers really find valuable. ▪▪ The biggest has to be the 11,600 tonnes ▪▪ Another is OPP (Optimization of Process Given the amount of capital required to oper- of dry solids per day now Performance) which is a powerful comput- ate a pulp and , we find very few being erected in Indonesia. This would er-based tool that gives ANDRITZ process owners wanting to risk their production on replace about four “traditional” boilers – a experts and mill personnel insight into their any equipment that is Serial Number 001. “super tool” for the customer to produce processes like they have never had before. Even the best-funded and technically savvy the highest amount of electricity while re- The OPP actions, usually without capital mills want technology that is proven. covering black liquor. investments, can save staggering amounts of money. We are a technology-intensive company, but ▪▪ The smallest might be emulsion-cooled we understand that the technology we sup- black liquor guns for the recovery furnace. By carefully listening to our customers and ply is only of value to you if it makes your The guns are cooled and cleaned with a then combining inputs from a variety of tech- business better and your life easier. There is water/steam emulsion. What makes them nical sources, we design technology solu- no sense being first with something unless it better is that they last considerably longer, tions that are responsive. Partnering with passes the acid test of helping you improve basically clean themselves, and form bet- customers to prove out these solutions is your business: either by increasing produc- ter liquor droplets to arrive at more stable critical to bringing technology leadership to tion, reducing waste, saving money, or help- boiler operation. the industry. ing you make more money. ▪▪ Then there is TurnKnife IV: the latest knife What’s on your “wish list” of technologies We search for all opportunities where we can system for roundwood chipping. It has to help you work better? We would love to bring our most current technology tools to a new chipping geometry and is light- know.

Joachim Schönbeck Humbert Köfler N4 NO.e 32 / 2-2015 ws New multi-injector design for DIP

ANDRITZ has developed a new multi-injec- modelling the opti- tor design for the primary stage in deink- mum air bubble size ing flotation systems. The multi-injector is and distribution. It in- tailor-made for effective ink removal and corporates a reshaped consumes 50% less energy than previous nozzle geometry, which designs. The new design optimizes the air also reduces the risk of plug- intake in the injector as well as the distribu- ging. The new multi-injector is avail- tion within the flotation cell. It also utilizes able in three ways: a newly developed pump series, which is more energy efficient. 1. In new SelectaFlot flotation systems 2. As a retrofit to existing SelectaFlot units The new multi-injector was designed us- 3. As a retrofit to flotation cells made by other Find out more about the multi-injector at: ing computational fluid dynamics (CFD) to manufacturers. www.andritz.com/flotation obtain the best performance by

EWR extends the wear life of critical chipper parts

ANDRITZ has developed some Extreme ing bedknife changes each year. With fewer Wear Resistant (EWR) chipper parts for hard changes, chipper uptime is enhanced. wear (e.g. logs with sand and/or bark slices) and high capacity chipping applications. With longer intervals between wear parts changes, less maintenance labor hours re- Two examples of the EWR product line are quired, and savings in wood losses, EWR parts bedknives and wear segments (inner and improve equipment reliability and uptime. outer). The expected life of an EWR bedknife is three to four times that of a standard one, Find out how to save money and im- giving a parts cost savings of about 25% per prove throughput with EWR parts by year. Maintenance cost savings are also sig- talking with your ANDRITZ service nificant due to reduced labor hours for mak- representative. NO. 32 / 2-2015 Spectrum News 5

FibreSolve rotor saves energy; easily retrofitted to under-machine and tub pulpers

ANDRITZ engineers used the latest CFD The FibreSolve rotor has a unique studies to develop a better rotor design “pumping vane” which achieves to not only improve pulper efficiency, but optimal circulation by creat- save significant energy in the process (up ing a counter-rotating flow to 30%). pattern that quickly sub- merges incoming material. Historically, pulper rotors have a low pro- FibreSolve also allows pulping file with many cutting edges. As much as at higher consistencies (i.e. up 70-80% of the energy input is required for to 10%). Specific energy is re- these cutting and mechanical forces. Due duced by 25-30% with equal or to this, stock circulation has suffered, as better pulp quality. low profile rotors are only able to create a circular vortex. Mills have tried many solu- Find out more about FibreSolve at: tions, such as baffles and d-walls to im- www.andritz.com/fibresolve prove circulation.

different input materials to a quite small and of separator, the ReSed. By optimizing the Shake, uniform particle size. A hydraulic pendulum geometry of the sedimentation tank and the pusher feeds the material to the cutter. Then, internal flow pattern, a huge increase in ef- the material is cut between a high-speed ro- ficiency has been achieved. Since the cham- shred, and tor with block knives and a static counter ber is completely filled with liquid, problems knife. with floating fibers that can plug the machine separate are avoided. Separate. ANDRITZ tackled the traditional your rejects problems with sand separators (low effi- Find out more about ANDRITZ rejects ciencies, bad filtrate quality, wear, and me- treatment equipment at: chanical issues) and developed a new type www.andritz.com/reject-handling Handling rejects in a safe, efficient, and eco- nomical way is vital to any plant’s continuous ANDRITZ Sediment Separator ReSed. production. ANDRITZ has developed several new products to handle reject treatment.

Shake. The Ballistic Separator ReBal re- moves bulky material from a mixed reject stream. A solid inclined screen plate oscil- lates at 150 rpm to set the material in mo- tion. Spherical or cubic parts roll downwards to the heavy fraction; flat and light materials move upwards to the light fraction. The angle of inclination and machine speed are easily adjusted.

Shred. The ANDRITZ Granulator UG shreds pulp and paper rejects, reducing the size of 6 NO.NO. 32 / 2-2015 Fine Tuning When the Veracel mill started operating in Brazil in 2005, it was pre-ordained to be one of the world’s most advanced bleached pulp mills and also a reference site for sustainability and operational excellence. A passion for continuous improvement – from the smallest process details to large activities such as an innovative maintenance program – still attracts industry attention. NO. 32 / 2-2015 Veracel Celulose 7 Fine Tuning a well-tuned mill

Veracel is a partnership of two major leaders in “We have a very strong focus on operational mill in Uruguay (the first such contract in South the , Fibria and Stora excellence,” Medeiros explains. “Since we America, also with ANDRITZ),” Medeiros says. Enso. Ari Medeiros, Chief Operating Officer, have fine-tuned our operations over the says, “This mill is in a very good position, and years, we know that big gains are less com- From the moment Veracel was born, there is also in a very good condition. But it is chal- mon. But we are pushing for even the small was a concept of outsourcing maintenance. lenging to stay on top as this is a single-line mill. gains that, when taken together, can equal “My core business is to produce pulp – to in- We must run continuously and at a high level of a big one.” novate better, more efficient ways to produce performance, especially when coming out of a a commodity,” Medeiros explains. “Focusing shutdown or blackout or whatever.” “Veracel has long been a place where others on maintenance would only detract from my come to watch and learn,” Medeiros says. “We core interest.” In response to the challenges, Veracel has have, in fact, trained eight operating teams suceeded producing over 10 million tonnes of from other mills here. People come to see what Initially, Veracel hired four different mainte- pulp in 9.5 years – almost 20% over the nomi- we are doing here. We don’t mind. Anyone can nance companies (mechanical, electrical and nal design capacity. buy the same equipment – the difference is in instrumentation, lubrication, and general build- the knowledge and skill of the people.” ing maintenance). “The overall results were not A reference for excellence so good,” Medeiros says. “There were four dif- According to Medeiros, Veracel was originally Pioneering maintenance contract ferent approaches, four different management conceived to be a “showcase for the best this When Veracel signed a contract for ANDRITZ to groups, and we had not established any penal- industry can offer.” And, after 10 years of op- handle all the maintenance activities at the mill, it ties or bonuses, so Veracel took all the risks.” eration, it is still one of the most competitive in was the first millwide maintenance contract of its terms of costs, quality, environmental perfor- kind in the pulp sector in Brazil. “Our expectation mance, and forest productivity. was to have similar results to the Frey Bentos The Veracel mill produced over 10 million tonnes of pulp in 9.5 years – almost 20% over the mill’s design capacity. 8 NO. 32 / 2-2015

A specialist from ANDRITZ Maintenance Solutions inspects a fitting on one of Veracel’s DD Washers.

In 2011, it was decided to put all mainte- The other key element is the quality of the OPP is a combination of sophisticated soft- nance activities with one company. After people. “I’ve known that ANDRITZ has experi- ware, methodology, knowledge database, negotiations with nine different companies, ence in maintenance, but I didn’t know about in-site specialist” and process/equipment ANDRITZ was selected. the quality of the people,” Medeiros says. knowledge from experts in ANDRITZ and the “What I can say is, the first year of the mill- client organization. The first OPP project in Roberto Costa is ANDRITZ’s Maintenance wide contract, Veracel had the best results in 2007, Medeiros recalls, was to optimize the Manager for the Veracel contract. “The con- the company’s history. Results in 2013 were DD Washers in the bleach plant. As a result tract was negotiated with a fixed maintenance also good. Last year we had one disruption of the work, Veracel increased production budget, which helps Veracel know exactly what that cost us tonnage, but it was not the fault of from 2,900 to 3,200 t/d. “Things improved costs will be,” he says. “We have organized maintenance. We are in a very good position dramatically with zero capital investment and ourselves to integrate with their Coordinators in this year, so our expectation is that in 2015 we I became a big believer,” Medeiros says. the mill process areas, so the communications will have the best results in our history once is very direct and efficient.” again. Together.” “We started with a single DD Washer,” Medeiros says. “After it was running per- “We have reduced our budget for main- The major measurement is the amount of pro- fectly, we moved on to the other three tenance expenses and we centralized the duction. There are bonuses and penalties in washers in bleaching, and then the four in decisions with one partner,” Medeiros says. place with ANDRITZ. There are also targets for the brownstock area. In the following years, “On their side, they have a very efficient or- quality, environmental, and safety. we have developed new algorithms and ganization and they control their costs tightly control strategies for chemical consump- without sacrificing our production, quality, or “I have worked in companies with differ- tion, temperature, pH, pressures, and flows safety. It has been a win-win for the two com- ent maintenance scenarios,” Medeiros to help us better control each stage in the panies I think.” says. “Personally, I believe that outsourced fiberline.” maintenance is the best way to get good According to both Costa and Medeiros, the re- results for the mill. I am satisfied with the The value of OPP is that is can be used lationship is improving year by year. “We learn progress we have made and I am in favor of for a variety of smaller and easily measur- together, and use these lessons learned to im- it continuing.” able projects to reduce chemicals, increase prove operations together,” they says. electrical generation, optimize the recovery Fine tuning: big gains from using boiler sootblowing routines, and similar “A big question when you enter into such a new tools things. The project for electricity generation contract is whether the maintenance provider ANDRITZ introduced a service years ago in had significant economics. “We analyzed will do everything it needs to do to keep the mill Brazil called OPP (Optimization of Process the control loops and improved the pro- running reliably, or will it try to skip certain things Performance). Veracel was a pioneer in adopt- gramming using multi-variable controls and in order to make more money,” Medeiros says. ing this tool, according to Kleverson Figueiredo, fuzzy logic to increase the electrical output “It is all based on trust.” OPP Specialist for ANDRITZ. from the boiler and turbo-generator plant,” NO. 32 / 2-2015 Veracel Celulose 9

OPP (Optimization of Process Performance) is a combination of so- phisticated software and process/equipment knowledge from experts in ANDRITZ and the client organization. Veracel was a pioneer in using OPP.

Maintenance on the fiberline.

Figueiredo says. “The economic impact is started,” Medeiros says. “They are working Medeiros and his team have some ideas in the range of about three million dollars with data mining techniques. I think that we about what they will do next, including a per year.” are on the leading edge of using these tools, couple of large projects that may take up to but eventually they will be used in all pulp a year to prove in simulation before they go “We are running better and better, with mills.” live. “A big part of that is training operators more savings,” Medeiros says. “Even a and getting their opinions and feedback so half-percentage point here, and a half-point In his 31 years of working in pulp mills, that we can improve,” he says. “It’s not just there adds up to real money at the end of Medeiros is constantly learning. “We are do- technology – the human knowledge is incred- the year.” ing things today that I could not even have ibly important.” dreamed of back then. The savings of chemi- Always something to improve upon cals, the improvements in safety, the energy “The OPP service today is much more pow- gains – these are all important things to keep CONTACT Luis Binotto erful than it was eight years ago when we Veracel ahead.” [email protected]

What I can say is, the first year of the millwide contract, Veracel had the best results in the company’s history.”

Ari Medeiros Veracel Chief Operating Officer 10 NO. 32 / 2-2015

A project to convert an existing lime kiln from oil to gas firing gave Sappi Skowhegan the opportunity to reduce energy costs in a big way. The LimeFire burner and LimeCool sector cooler were key to the conversion.

Sappi North America’s mill in Skowhegan, Skowhegan is now running on natural gas The switch to natural gas in the kiln re- Maine is a large, integrated complex with instead of oil, a move that is forecast to save places the equivalent of 80,000-100,000 a unique hardwood and softwood pulp about 30% in energy costs in addition to re- barrels of No. 6 fuel oil each year, accord- blend (Somerset Synergy) which is used ducing air emissions. The final stage of the en- ing to Lance Bolduc, Recovery Manager. by its three machines. Annual production ergy project involved converting a 1970’s vin- “ANDRITZ supplied a great cooler and is about 795,000 metric tonnes of paper. tage FLSmidth lime kiln and upgrading it with a great burner,” Bolduc says. “I am very some of the latest technology from ANDRITZ. happy with the design and performance.”

Kiln conversion helps Skowhegan save ener gy NO. 32 / 2-2015 Sappi North America 11

Best guarantee also wanted the flexibility to burn multiple tors would not be able to use their traditional The Skowhegan mill evaluated three suppli- fuels, so that we can select the lowest cost equipment to work inside the kiln. It turned ers for the kiln conversion project. “ANDRITZ fuel in the future.” out that the extra time was not needed be- was the only one who would guarantee NOx cause the kiln was so clean.” emissions at the production rate and quality Concerned about neck-down design that we required,” Bolduc says. “That was the “At the time we made the decision to go with More production: an added benefit biggest reason we chose ANDRITZ.” the ANDRITZ ‘neck-down’ design, there was When you convert to natural gas, you de- a lot of discussion internally,” Bolduc says. crease energy efficiency by about 10% be- ANDRITZ delivered the LimeCool cooler and “The retrofit takes the shell diameter of 11’6” cause the heat value of gas is less than fuel shell section and the LimeFire multi-fuel burn- (3.5 m) down to 6’ 7” (2 m) at the coolers. oil. Sappi’s goal was to convert to 100% er, along with other items such as support Our biggest concern was having the space natural gas without losing any production, rollers, crusher, conveyor, elevator, primary to get equipment in and out during our annual so that is where the LimeCool unit comes in. air fan, and the burner management system. outage to clean the kiln and re-brick when In terms of support services, ANDRITZ also necessary.” “One of the things we did was to visit sev- did some basic, process, and control engi- eral mills to evaluate sector coolers,” says neering, as well as provided erection supervi- Robert Kenny, an Engineering Consultant Gregory Hale, Sappi’s Project Manager. sion and commissioning support. who has worked at the Skowhegan mill for “Competitive coolers were often failing due 16 years, remembers the discussions with to thermal expansion. ANDRITZ coolers are Do no harm ANDRITZ well. “The mill ended up going with robust enough to stand up to the harsh kiln “One of my main criteria for this project was ANDRITZ’s design,” Kenny says. “But, the environment.” that it would do no harm to the existing op- thought was that it would add a couple of eration,” Bolduc says. “We had a decent days to the annual outage because contrac- running kiln and we did not want to go back- wards in any way. Same production. Same save quality. Just do it with a lower cost fuel. We ener gy 12 NO. 32 / 2-2015

The Skowhegan kiln is inside a building. The switch to natural gas replaces the equivalent of 80,000-100,000 barrels of No. 6 fuel oil each year in the kiln.

“Before the conversion, we were running 342 t/d, but we have been able to increase When the kiln started up, operators dialed about 340-350 t/d of product,” Bolduc says. production because the kiln is running so in the shape they wanted and left it there. “Our old satellite cooler was undersized. well for us,” Bolduc says. “That was an “The only time we play with it is during start- Lime coming out of the kiln was very hot added benefit.” up after the annual outage when there is no which meant we were sending away ther- product in the kiln,” Bolduc says. “We make mal energy with the product. With LimeCool, Very flexible burner the flame a little bushier for the heat-up, then we reduced the temperature of the lime Sappi Skowhegan’s operators have been dial it back and don’t touch it. The burner is by about 60% and the secondary air go- very impressed with the new LimeFire multi- outstanding.” ing back to the kiln is considerably hotter. fuel burner and its flame shaping capabili- Putting that thermal energy to work allows ties. “We used to constantly fight with our Ahead of schedule us to produce more lime at a lower overall old lance burners,” one operator says. “We Conversion work started during the an- energy cost.” would often experience flame impingement nual shutdown in October 2014. First mud on the brick. The new burner is very predict- to the kiln began to flow on October 31st. Today, the kiln operates at 375 t/d. “The able. I can go out and adjust the valves to get According to Robbie Diaz, ANDRITZ Project process guarantee from ANDRITZ was for exactly the flame shape I want.” Manager, “We had a very good start-up and brought the kiln online two days ahead of schedule.”

Diaz is complimentary of the project team from Skowhegan. “Sappi runs very profes- sional projects,” he says. “They are consis- tent in their attention to detail and quality. All of the departments – engineering, opera- tions, maintenance, and quality – are active participants. With this kind of attention and support, everyone is motivated to do his or her best work.”

“People talk all the time about teamwork,” Hale of Sappi says. “We had a great group of people on this project with mill process en- gineers, ANDRITZ, operations, and mainte- Gregory Hale, Sappi Project nance. This has been outstanding. We could Manager not ask for a better project.” NO. 32 / 2-2015 Sappi North America 13

Scott Thibodeau, Utility & Recovery Shift Supervisor (standing), discusses perfor- Lance Bolduc, Recovery Manager (left), is shown with Todd Lewick, Burner Project mance of the kiln with Steve Simpson, Senior Operator, in the control room. Manager for ANDRITZ, with LimeFire burner in background.

“The ROI on this project is significant,” the new equipment looked brand new af- “I don’t know of any mill we talked to that Bolduc says. “We did some other things ter one year,” Koskinen says. “And when produces more lime after the natural gas during this project which have paid back as the Sappi Reliability Manager and I went conversion than they did before,” Hale says. well. We can start up easier and we have the into the LimeCool, the only thing he said “We put in the LimeCool and LimeFire, fired capacity to store more product to keep the was ‘Magnificent!’. That is a real tribute to the kiln harder than we had before, pro- kiln running at a stable production rate. We the way that Sappi operates the kiln. First duced more product, and had almost no don’t experience the swings that we used class.” brick loss. This is outstanding.” to. And, we have cut our purchased lime down to a point where I would be uncom- Bolduc says, “We had scheduled 60 hours Bolduc only expressed one concern, “After fortable cutting it any more.” for cleanout and completed the work in 20. the first year of operation, we set the bar We did not have to replace any of the burner so high in terms of the kiln’s performance, I Magnificent! end brick and lost only ¼-inch (7 mm) of re- only hope we can keep it that high!” he says. One year after start-up, Tero Koskinen, fractory in a year. In the past, we would have ANDRITZ’s Erection Supervisor, was in to replace 20 feet (7 m) of brick every year town to inspect the kiln during the an- because we would lose 2-3 inches (5-8 cm) CONTACT Markku Lankinen nual outage. “The inside of the kiln and of refractory at the burner end.” [email protected]

Sappi, a global company headquartered in South Africa, acquired the Skowhegan mill in 1994. Sappi is a leading supplier of coated , pulp, and release paper in the United States- with a produc- tion capacity of 1.3 million tons annually. 14 NO.NO. 32 / 2-2015

Ready for the next challenge

With construction completed, Montes del Plata mill in Uruguay is intently focused on running and maintaining a world-class market . In addition to delivering the production technology, ANDRITZ is now supplying millwide maintenance services as part of a long-term full-service contract. NO. 32 / 2-2015 Montes del Plata 15

Arauco and Stora Enso took advantage of A shift in thinking the decision by the Spanish company ENCE Héctor Araneda, Mill Manager, is leading his to sell its assets in Uruguay near Conchillas team through the transition from “construc- (Colonia region) and formed the 50-50 ven- tion” to “operations.” “This represents a big ture known as Montes del Plata. This gave shift in thinking,” Araneda says. “During con- birth to a greenfield market pulp mill in Punta struction, there were thousands of people Pereira, which has as its goal to be a shin- on-site in constant movement. Now there ing example of high technology, sustainable are a few hundred.” production, environmental safety, commu- nity involvement, and effective maintenance By comparison, the mill scene is calm and outsourcing. business-like. Calm, however, does not mean that nothing is happening. “We have Montes del Plata manages over 145,000 ha of a new and active challenge now,” Araneda forested lands in 11 departments of Uruguay, says. “We need to run stably at full load or including plantations on third-party lands, that even slightly above design. Reliability is a key secures the raw material supply for the 1.3 issue.” million t/a bleached eucalyptus mill. The site on the Rio del Plata (River of Silver) is ideal for Araneda came to his Montes del Plata assign- easy transport of logs and pulp. ment from Arauco’s Valdivia mill in Chile and was responsible for the organization, hiring, ANDRITZ was selected as the main technol- and training of key engineers and operators. ogy supplier for Montes del Plata – providing Montes del Plata did extensive training, since the woodyard, fiberline, pulp drying plant, most of the new engineers had not worked chemical recovery island, and power plant in pulp production before. In addition to 40 on an EPC basis. When the mill became engineers, about 125 operators were hired. operational in 2014, it was calculated that “We split our training into phases, and made it increased the GDP of Uruguay by 1.7% good use of the ANDRITZ IDEAS dynamic compared to 2012. It represents the largest simulator for this training,” Araneda explains. and most important private investment in the “We trained operators to control the virtual country’s history. mill before the real mill was ready.” 16 NO. 32 / 2-2015

Montes del Plata management team (left to right): Dan Holmsten, Manager of Maintenance & Engineering; Héctor Araneda, Mill Manager; Eero Ristola, Production Manager; and Victor Otárola, Enviromental Manager.

Based on progress so far, Araneda is Selling all that we produce sides. We get very good support from the pleased. “I would say we have done well Montes del Plata started feeding chips to the ANDRITZ as we fine-tune each process. We with our selection and training activities,” digester in June 2014. “We are now regularly have good discussions that are focused on he says. “The mill is running very well and reaching our design production and recently solving problems.” the quality of the pulp is excellent.” have been running above design,” Araneda says. “The pulp quality has been superb to Millwide maintenance contract A commitment to Uruguay the point where we are selling all that we are Dan Holmsten, Maintenance & Engineering When Montes del Plata built its organiza- producing.” Manager, worked in Sweden for Stora Enso tion, it made a commitment to hiring and prior to coming to South America. Holmsten training mostly Uruguayans. Only about Running at and above design has given has been part of two greenfield projects (first 3% of the people in the company come Araneda a chance to evaluate the overall Veracel in Brazil and now Montes del Plata in from outside Uruguay. “Most recently, we design of the mill. “I am very happy with this Uruguay). Holmsten’s experiences at Veracel hired 25 young people from the local high mill,” Araneda says. “The overall concept and helped to shape the maintenance model be- schools and trained them to work at the process flows are extremely sound,” he says. ing used at Montes del Plata. mill. They relieve some of the operators “Once we get over the couple of small bottle- for a shift so that operators can partici- necks we have uncovered, I know that we “We have agreed upon a millwide contract pate in training to learn multiple skills.” have a good future.” with ANDRITZ and they are responsible for all ANDRITZ is also hiring and training maintenance activities in the mill with a fixed Uruguayans for its full-service mainte- No looking back maintenance budget,” Holmsten says. “We nance organization. The maintenance Certain parts of the construction project were know what we will pay. We have a partner team of 128 is all local people with the very rough, as schedules and resources be- who will share the risks. And, we are willing exception of one person from Finland. tween ANDRITZ and Montes del Plata were to pay extra if we get good results.” “ANDRITZ has good experience working pushed. “But that period is over,” empha- in Uruguay,” Araneda says, “and it shows sizes Araneda. “We don’t live in the past. We Strategic choice in their ability to build a professional have a very good relationship with ANDRITZ From Holmsten’s point of view, the choice organization.” on both the equipment and maintenance between insourcing or outsourcing main- NO. 32 / 2-2015 Montes del Plata 17

Teamwork in the plant

Carolina Rogberg is Supervisor of the Javier Cabrera is Maintenance Supervisor for “I like working with Carolina and her white liquor plant for Montes del Plata. the white liquor plant and the effluent treat- team,” Javier says. “We work side by The ANDRITZ equipment in the plant is ment plants. His team consists of six people. side and are part of the same team. some of the largest in the world, produc- “Our main focus is on preventative mainte- Once a week, we participate in a meet- ing 13,370 m3 of liquor per day. The lime nance and condition monitoring of the equip- ing with all the supervisors in the recov- kiln is designed to deliver 1,100 t/d of ment. We classify the equipment based on ery area just to make sure everyone is reburned lime for the process. how critical it is to the process, in collabora- informed.” tion with Montes del Plata. The critical equip- Carolina came to Montes del Plata from ment (about 20%) gets regular attention. the steel industry and joined the project in 2007. She supervises a production team of 10 people. “In general, we are operat- ing well and white liquor quality is excel- lent,” she says. “Our one issue is to push production of the kiln. We are coordinat- ing with ANDRITZ to change the burner to a new design in January.”

Carolina says that working with ANDRITZ Maintenance Solutions is easy and natu- Javier Cabrera, ral. “They are very knowledgeable and Maintenance Supervisor (left) the working relationship is excellent,” with Carolina she says. “I meet with Javier daily and Rogberg, Production Supervisor, in the we coordinate our activities.” white liquor plant.

tenance is a matter of strategic choice by that your maintenance partner will have As Holmsten summarizes it, “The main ben- the owners. “If you insource, you need the short-term thinking and just be motivated efit for us is that we have high equipment competence in-house,” he says. “If you to make money,” he says. To mitigate this availability and we can focus on producing outsource, you need a partner who has the risk, the contract with ANDRITZ has a bonus pulp.” competence to build an organization, build component. “That keeps it from being solely the maintenance routines, and manage all about costs, and drives us all to reaching our From corrective to preventive the activities.” performance targets,” he says. “Another key Mauricio Mattos is ANDRITZ’s appointed advantage is that the budget is agreed to Site Manager, responsible for the entire One essential component, Holmsten in- ahead of time. When the cost is known and maintenance team at the Montes del Plata sists, is that there is an incentive for the fixed, you can do the necessary and preven- site. He honed his skills in maintenance maintenance partner to profit from the mill’s tive things which are essential for long-term management while working at the UPM excellent performance. “A potential risk is mill performance.” Fray Bentos mill as part of the team assem-

The pulp quality has been superb to the point where we are selling all that we are producing.”

Héctor Araneda Mill Manager 18 NO. 32 / 2-2015

Instrument Technician Luis Vico checks the calibration of a field transmitter in the fiberline.

bled by Andrés Sommer, the Site Manager “We had confidence that ANDRITZ would do fed to the digester,” he says. “We also or- there and the General Manager for ANDRITZ the planning well and have a good set-up for ganized a program for our maintenance Maintenance Solutions in Uruguay. maintenance based on their experience at people to be actively involved in commis- Fray Bentos,” Holmsten remarks. sioning. They know the equipment and pro- “Maintenance with separate specialist or- cesses intimately.” ganizations is typically more expensive and One of the keys, according to Mattos, there is more difficulty in setting performance was that ANDRITZ maintenance engineers During any start-up and ramp-up, the ac- targets since there is no single organization joined the project team well before the tivities tend more toward corrective actions with accountability,” Sommer says. “As an Montes del Plata mill was built. “We creat- rather than preventative ones. “This is natu- alternative, we offered a full-service contract ed a long-term maintenance plan, entered ral,” Mattos says, “as you have the peaks to Fray Bentos, which has been in force since maintenance routines and spare parts into and valleys during ramp-up. But now we pay the mill started up in 2007.” an SAP database, and staffed a mainte- more attention to preventative actions to put nance organization before chips were ever the mill in steady-state. Less swings, less

Wed to the fiberline

Daner Perez and Eliana Satrano are pro- erator and working his way into supervision. planner during the project phase and was duction and maintenance supervisors “I came to Montes del Plata quite early in the recently promoted to a supervisor,” she says. respectively for the fiberline and chemi- project, so it has been exciting to see the “I love the work, as I love new challenges.” cal plant. At the end of each workday, fiberline evolve,” he says. “After the normal they ride the same bus home and sit hiccups during a start-up and ramp-up, we Any difficulties with being married and side-by-side. Only now, the conversation are running quite well now.” working together? “Not really,” Eliana says. changes from the calibration of a trans- “We are not competitive, and we support mitter on the digester blowline to what The main activities for Daner and his team at each other. That’s really an ideal situation to do about dinner and whose turn it is the moment is focused on optimizing white for maintenance and production.” to give 18-month-old Renata a bath. You liquor consumption. On the maintenance see, Daner and Eliana are not only work side, Eliana and her team are keeping to a Another positive: “If we get a call in the eve- colleagues – they are husband and wife. strict schedule of preventative maintenance ning about a fiberline situation that requires and planning for the next shutdown. maintenance support, I don’t have far to go Daner is one of the few Montes del Plata to get answers,” Daner says. “We can dis- engineers who had prior pulping experi- Eliana came to ANDRITZ Maintenance cuss and arrive at an action plan so we’re ence. He worked for five years at UPM Solutions after working as a lab chief and a ready to work the next morning.” Fray Bentos, starting as a digester op- recovered fiber mill. “I was a maintenance NO. 32 / 2-2015 Montes del Plata 19

Woodyard Mechanic Emanuel Romero changes the chipper knives in the woodyard.

ANDRITZ delivered all the process pumps to the Montes del Plata mill. Shown here is ANDRITZ Robert Prugger, a Technician for ANDRITZ HYDRO during commissioning of a fiberline pump.

disruptions, less emergencies. Plus, we are the younger people here, since I have been in having us in the mill every day with our ac- very actively planning for the next shutdown, through this process before. Mauricio has a cess to all the information within the global which will be our biggest annual opportunity similar role for ANDRITZ on the other side of ANDRITZ organization.” to improve the performance and reliability of the desk.” the equipment. We will have several hundred Contact people in this mill during a tightly orchestrated “We are here to execute proactive mainte- Capital: Johan Engström time period.” nance using our knowledge of equipment [email protected] and processes,” Mattos says. “One of the Maintenance: Monitoring and coaching most important factors is to have excellent Andrés Sommer “My job is to monitor the maintenance per- cooperation with the Montes del Plata pro- [email protected] formance of ANDRITZ and administer the duction team. Dan and I talk daily. All of our contract on behalf of the owners,” Holmsten maintenance teams meet and talk daily with says. “I also play the role of coach to some of their production counterparts. There is value

Eliana Satrano, Maintenance Supervisor (left) with Daner Perez, Production Supervisor in the fiberline.

Dan Holmsten, Montes del Plata Manager of Maintenance & Engineering (seated) with Mauricio Mattos, Site Manager for ANDRITZ Maintenance Solutions. 20 NO. 32 / 2-2015

The recovered fiber plant processes OCC for the production of the Absorbex® product line, with its wide range (140 to 350 g/m2) of un- bleached saturating base kraft grades. Typical applications are decorative and industrial lami- nates and different types of electro-technical products.

“Our latest grade development is Absorbex Eco,” Ukkola says. “The fiber sources are forest industry by-products, sawdust, and recycled fi- ber from our own plant.”

The mill has another machine (PM2) which is currently producing , but is undergoing an over MEUR 100 investment to convert to the production of packaging board grades. The conversion should be completed by mid-2016, according to Tallinen.

A sticky situation The driver for Kotkamills seeking outside coun- sel was a nagging problem with removal from the secondary fiber furnish, according to Ukkola. It was about three years ago when they began discussing with ANDRITZ about this problem. “Stickies were causing us head- aches on the ,” Ukkola explains, “and surface stickies are a definite problem for laminators, as they must produce a perfectly smooth sheet.” improve key key improve OPE with processes

Two case studies show how Timo Tallinen, Technical Director, Kotkamills. mills are using ANDRITZ’s Overall Production Efficiency (OPE) service to increase throughput and quality without major investments.

Case #1: Kotkamills

Kotkamills produces quality products from two facilities in Finland (Kotka and Tainionkoski) and one in Malaysia. We are at the Kotka mill com- plex, which specializes in laminating , matte coated papers, and sawn products. Our hosts include Timo Tallinen, Technical Director, and Teemu Ukkola, Production Manager for PM1 and the recovered fiber plant. NO. 32 / 2-2015 Kotkamills and Stora Enso 21

ies reduction by about 25%. The installation improve machine efficiency and margins by be- of Dolphin rotors also saved energy for the ing able to substitute recovered fiber for virgin.” mill. In the next phase, Kotkamills purchased a rebuild combined coarse/fine screen used Our customers tell us that we make a smooth at another mill. This screen, and the exist- and high-quality sheet,” Ukkola says. “We are in ing broke screen, serve as coarse and fine a quite good situation at the moment, especially screening stages. As a result, stickies reduc- when compared to three years ago.” tion was improved further 18%. “At the same time, we doubled the amount of OCC in our Kotkamills recently renewed the OPE contract furnish from the starting point, and have in- for another three years. “The first three-year pe- creased throughput by 8-10%,” Ukkola notes. riod was a very good learning experience for our people as we improved the quality and pro- “We also improved the short circulation in the duction efficiency of PM1,” Tallinen says. “The cleaner plant,” Selin says. “We installed a fifth targets were achieved. We expanded the scope stage in the cleaner plant. By doing that, we in the new contract to include the chemical pulp Teemu Ukkola, Production Manager (left) with Jukka lowered the fiber losses in the short circulation mill. We have new targets that will keep both Selin, OPE Project Manager at the reel end of PM1. by about 75%.” ANDRITZ and Kotkamills challenged.” Stickies were reduced by 85-90%, permitting a higher use of recovered fiber in the PM furnish. Other areas of the mill have benefited from the Tallinen speaks positively about the meetings OPE actions. “We installed inverters to lower with ANDRITZ experts. “They present new so- When ANDRITZ first proposed an Overall the rotation speed of some of the pumps in lutions for us to consider,” he says. “We now Production Efficiency (OPE) contract, not every- the pulp mill to save energy, and replaced have access to the latest technologies and one at the mill immediately saw the value. As screen baskets and rotors to remove shives techniques, things we can use to retrofit to Tallinen puts it, “We were not all that interested. before they ever get to the paper mill,” Selin our existing equipment. Those meetings, and At that time, we believed we could manage says. “We also recommended a new type of working together, are a very good platform for our processes without suppliers. The more we refiner plate for the pulp mill’s rejects refiner improvement.” talked, however, we learned there were things which has cut energy consumption and im- ANDRITZ could give us that we could not do proved fiber properties. This has improved “It is good to have a sounding board with ourselves.” the quality of the end product and enhanced ANDRITZ on a regular basis when we en- the performance of the paper machine.” counter a process problem or just would like Ukkola agrees. “This is not like contracting for a to discuss production issues,” Ukkola says. regular service or like buying a piece of equip- Clear results and a new contract “They have expertise in all the pulp and pa- ment,” he says. “When you buy equipment, you “Today we are using more recovered fiber in our permaking processes and can bring the right negotiate the best price, put it in, and then you paper furnish and the quality is much better than experts to us when needed.” are on your own to figure out how to operate it it was before,” Ukkola says. “This has helped us in the best way. With OPE we work as a team. ANDRITZ people are like our own employees, working here with the same goals that we have – Selin and Ukkola in the screenroom. to maximize production and minimize the costs. So I think this OPE experience has been very good.”

Analysis and action Says Jukka Selin, OPE Project Manager for ANDRITZ, “At the beginning, we involved some of our best process people to do some root- cause analysis on the stickies problem and to develop solutions. As part of the work, we analyzed where the sand and heavy materials were originating from and did a sand-balance for the mill. We made a lot of improvements in the removal of contaminants.”

As a first step,AN DRITZ suggested changing rotors and baskets in the existing screens to a lower profile design. This step improved stick- 22 NO. 32 / 2-2015

Case #2: Stora Enso, The process areas under contract are cook- ment screens), but ANDRITZ made an im- ing, brownstock washing, and the evapora- portant contribution by helping improve the Veitsiluoto Mill tion plant. cooking process. “When cooking is going Stora Enso’s Veitsiluoto Mill in Kemi is said to well, the downstream processes also im- be the northernmost paper mill in the world. “I was not familiar with OPE when I arrived prove,” notes Ari Pulkkinen, OPE Project We are speaking today with Juha Mäkimattila, here, since I have been working mostly Manager of ANDRITZ at Veitsiluoto. Mill Director and General Manager, and abroad,” Kangas says. “I was curious and Kimmo Kangas, Production Director for Pulp perhaps a bit skeptical about the concept at According to Pulkkinen, “The OPE service Mill, about the results of the OPE service in first.I must say now that I am quite satisfied concept was created by ANDRITZ in Finland the pulp mill. with the approach and the results.” many years ago. Process OPE focuses on improving specific areas in a mill that a cus- The Veitsiluoto complex includes a sawmill, Washing was the driver tomer wants to target. Many of the targets in pulp mill and energy production unit, as The main issue that led to the OPE solution Process OPE can be achieved without capi- well as paper mill producing office papers, was the mill’s brownstock washing process. tal investments, but with ANDRITZ special- magazine papers, and other “It was not running well,” Kangas says, “and ists working side-by-side with mill personnel products. Output from the pulp mill, with its this caused us problems in effluent treatment to reinforce best practices for operations, annual production of 375,000 tonnes of both as we were very close to the permitted levels. troubleshooting, and maintenance.” hardwood and softwood pulp (swing produc- Our consumption of bleaching and make-up tion), is supplemented by production from the chemicals was too high due to poor washing Measurable results nearby Oulu mill. efficiency. It was quite clear that we needed Although Veitsiluoto has made targeted in- to improve in this area.” vestments by replacing certain equipment, Veitsiluoto Mill management signed an OPE which has benefited overall results, Kangas contract with ANDRITZ in December 2012, Mill personnel were aware of some equip- also notes the value of the OPE service on its six months before Kangas arrived at the mill. ment problems in washing (for example an own. “During the three years with ANDRITZ, The first contract was for a three-year period. atmospheric diffuser needed some replace- there have been very positive results. We

Ari Pulkkinen, OPE Project Manager for ANDRITZ (left) with Kimmo Kangas, Production Director for Pulp Mill. NO. 32 / 2-2015 Kotkamills and Stora Enso 23

have gotten a lot of support from ANDRITZ to improve our cooking and evaporation pro- cesses, which have improved washing effi- ciency and reduced our COD load.”

Key Performance Indicators (KPIs) are re- viewed on a quarterly basis and the prog- ress can be clearly seen. “The most impor- tant measurements for us are average daily production, specific energy consumption in the evaporators, and brownstock washing costs, all of which have trended in the right direction”, Kangas says.

Critical to the success, from Kangas’ per- spective, is that his Fiberline Operations Manager, Pasi Pigg, has been the OPE project manager from the mill’s side. “He The Veitsiluoto complex includes a sawmill, pulp mill with energy production unit, and paper mill. Annual output from the pulp mill is 375,000 tonnes of both hardwood and softwood pulp (swing production). The first OPE contract has been very active in motivating and en- was for cooking, brownstock washing, and the evaporation plant. couraging our people – so it has been a very good teamwork,” Kangas says. “Not only en- gineers, but also operators involved.” the scope a little, since the evaporation plant “The main thing I have learned is that the mill is running so well now. The new contract will has to take an active role,” Kangas says. “We Supplier in a different role focus on cooking, washing, and bleaching.” can’t just sit and wait for ANDRITZ people to Mäkimattila came to the Veitsiluoto Mill in come and take care of our problems.” 2008, but has worked at Stora Enso for many From Mäkimattila’s point of view, “I am years in various roles, including Research pleased with the OPE way of cooperation— “We have decided to continue with the con- Director at the Imatra Research Center. “This combining ANDRITZ specialists with our en- tract, and will continue as long as it is bringing is probably the first time in my career where gineers and operators. This sort of system- us clear and measurable results,” Mäkimattila an ‘equipment’ supplier comes to our mill in atic planning and continuous improvement says. “This is a real investment in money and a different role,” he says. “We have very little is very good. We are getting the results that time, so we have to see continuous results.” ANDRITZ equipment in the mill, yet the OPE we expected. We have removed bottlenecks specialists are effective in improving our pro- in cooking, washing, and evaporation. There CONTACT Jari Kapanen cesses. This expertise is appreciated.” have been several technical improvements.” [email protected]

When ANDRITZ first presented the OPE concept to Mäkimattila and his team, they set certain expectations. “The reality is very close to what I was told to expect,” he says. “Very often these type of programs start with the best intentions, but very often the real- ity is something completely different. But in This is a real investment the case of OPE, both companies have been in money and time, so putting resources into the work. We actu- we have to see continuous ally measure the involvement of the people. results.” Another positive aspect is that people at all levels are involved. They understand what we Juha Mäkimattila are doing and why.” Mill Director and General Manager

Contract extension “Based on the results so far, we decided this year to extend the contract for another two years at least,” Kangas says. “We changed 24 NO. 32 / 2-2015

Coated TURKISH DELIGHT NO. 32 / 2-2015 Kartonsan A.S. 25

Increasing capacity 60% and reducing energy costs for its coated board – plus several quality benefits – were the results after ANDRITZ upgraded Kartonsan’s BM2 and stock preparation system in Turkey. For Turkey’s largest white-lined chipboard producer, the 60,000 t/a rise in capacity means strengthening its domestic position and increasing opportunities for export. 26 NO. 32 / 2-2015

Our expectations were high, and the pressure was on us all to get the installation running fully.”

Ümit Özkan Mill Manager

ANDRITZ was selected to rebuild Kartonsan’s ANDRITZ understands the working envi- “A very large project and investment” second board machine (BM2) because of ronment here and has been able to adapt According to Özkan, the BM2 upgrade was a an earlier successful project. BM1 was up- accordingly.” very large project for the mill. The main drivers graded in 2009 from 50,000 to 80,000 t/a by were to increase capacity by raising the ma- ANDRITZ and the collaboration was excellent. Kartonsan, headquartered in Istanbul, is chine speed (from 250 to 450 m/min) for the The two machines are housed at Kartonsan’s Turkey’s largest, and Europe’s fourth largest, lowest basis weights, to reduce energy costs mill in Kullar Köyü, Izmit, Turkey. producer of coated cardboard. Some 25% by installing a shoe press, and to improve the of its sales is exported to 20 countries. The output and quality of the furnish (through re- “Our customers expect high qual- mill’s location on the Gulf of Izmit in the Sea building and upgrading the stock preparation ity and good pricing for our coated of Marmara, about 100 km from Istanbul, is and machine approach system). By utilizing board products, as well as the abil- perfect for logistics. ANDRITZ’s newer technologies for forming ity to deliver promptly,” says Ümit and pressing, the quality of the coated board Özkan, Mill Manager. “We Kartonsan products are used in many indus- itself – with better formation, bulk, stiffness, expect these things from tries from food to pharmaceuticals – mostly and smoothness – would also improve. our suppliers as well. We for packaging. for the duplex appreciate ANDRITZ’s and triplex white-lined chipboard products Gerhard Knes, ANDRITZ Project Director, flexibility and advanced range from 200-500 gsm. All the products explains the ANDRITZ contribution. “BM2 is technical solutions. are multi-coated, with a blade top coat that 3.65 m wide and was first installed in 1986,” Communications provides brilliant printability. Backsides can he says. “We added and replaced compo- are good and be gray or white. nents beginning at the wet end section, start- response time is ing with a new PrimeFlow SW headbox with remarkable. A modest, but solid start dilution control. We rebuilt the fourdrinier and “We started in 1967 under challenging con- press section, and installed our PrimePress ditions at a time when paper production X shoe press. We also replaced the canopy was a state-controlled business,” Özkan hood and air systems, and rebuilt the pre- recalls. “The capacity of the mill was just and after-dryer sections, hard , and 9,000 t/a. In 1986, we started up BM2, coater.” and BM1 was upgraded in 2009. After raising the capacity of BM2 from 100,000 But, actually, ANDRITZ’s work began up- to 160,000 t/a, we can now produce stream of the machine. To meet the increased 240,000 t/a at this mill.” NO. 32 / 2-2015 Kartonsan A.S. 27

demands for furnish quantity and quality, spare and wear part packages for the entire requirements for the rebuilds and upgrades ANDRITZ rebuilt Kartonsan’s recycled fiber equipment supply. In addition, ANDRITZ and designed the power system to accom- processing plant. All of Kartonsan’s coated provided engineering support to complete modate our new requirements,” Özkan boards are made from a blend of care- the rebuild (drives, vacuum systems, steam explains. “Basically, everything had to be fully selected recovered papers and virgin and condensate handling, automation, etc.). renewed – cables, transformers, etc. This fibers to achieve both strength and high required us to shut down the mill to do the brightness. “This investment was initiated in 2012 and work before we could do the equipment completed in late 2014,” Özkan notes. upgrades.” In the stock preparation area, ANDRITZ re- “Before the contract was signed in January built the deinking line for white ledger (ca- 2013, we visited ANDRITZ several times to As ANDRITZ’s Knes explains, “This type pacity: 140 t/d); upgraded the back layer familiarize ourselves with their latest prod- of electrical work could take about three line with flotation deinking and a disc filter ucts and references.” months to complete. But thanks to innova- to achieve an additional white ledger capac- tion and precise planning, we were able to ity of 85 t/d; rebuilt the existing OCC and A need for power do it in seven weeks.” As part of the work, Mixed Waste lines for the base board and “Like any project of this size which involves ANDRITZ replaced 73 AC motors with DC grey back layers (capacity: 380 t/d); adjust- combining new components with existing drives, and installed new Motor Control ed the broke pulper and added a new broke equipment, we faced some challenges,” Cabinets for all low-voltage motors. The thickener; and delivered three primary and Özkan says. detailed planning and close supervision two secondary screens for the four-layer during the execution of this phase of the machine approach system, and a dilution It was uncovered very early that the power project paid off. water screen. requirements for all the upgraded equip- ment was in excess of what the mill cur- Time to optimize There were also the engineering, supervi- rently had available. “ANDRITZ stepped in “Our expectations were high, and the pressure sion, commissioning, start-up, training, and and did a thorough analysis of the power was on us all to get the installation running

BM2 after rebuild.

New PrimePress X shoe press installation to reduce energy costs. 28 NO. 32 / 2-2015

We plan to do optimization and will be work- ing with ANDRITZ to finalize any details for improving quality and efficiency, and lowering our production costs.”

Seeking sustainable performance At Kartonsan, sustainability is the key for long-term performance. The mill recycles up to 99% of its paper in the production process, exceeding the average in Europe. It uses mod- ern techniques to purify and reuse its waste water, generates its own energy, and recovers the turbine exhaust gases to produce steam. The mill was the first in the Turkish paper in- dustry to use the MBR system, which allows 60% of the waste water to be recycled (10,000 m³/d).

“In order to survive in this business one has

(Left to right): Ümit Özkan, Mill Manager; Haluk Iber, General Manager; Gerhard Knes, ANDRITZ Project Director; to constantly invest in new technologies to and Güven Sanli, Production Manager. remain competitive and reduce costs,” says Özkan. “ANDRITZ and Kartonsan have a proven track record, which makes these types fully,” Özkan says. “We were perhaps overly “There are still a few punchlist items we need of upgrades a good match. The support from optimistic in terms of a five-week schedule to to work on together,” Knes says. “It is always ANDRITZ has been excellent. We solve issues get all this done, but got everything done in more complicated when rebuilding a machine, effectively and efficiently and we have found reasonable order.” since you have new technologies working with common ground for success.” older existing equipment. But we plan to get According to Knes, the Factory Acceptance everything done during the next shutdown.” CONTACT Test for the DCS delivered by ANDRITZ was Gerhard Knes conducted at the Graz (Austria) workshop with Özkan agrees. “Right now, we are focused on [email protected] a simulated station. “We did this to ensure that getting our ROI, and getting our products to all the controls would be fully functional once market,” he says. “There is stiff competition. installed at the mill,” he says. “This reduced commissioning time as the automation portion was sort of like ‘plug and play’ ready to go.” New SelectaFlot flotation cell in the back layer line.

The start-up of BM2 took place in September 2014. Initially there was a bottleneck with the pumps feeding pulp to the machine, and the capacity was not as expected. ANDRITZ promptly replaced the pumps with larger ones and adjusted the design of the approach sys- tem to solve the issue.

“After the start-up, we could speed up BM2,” Özkan says, “but we faced a sheet flutter- ing problem in the coating section. ANDRITZ checked the data from the distributed control system and did some root-cause analysis to isolate the problem. After some tweaks of the Air Glide system, we have reached the maxi- mum speed and capacity.” NO. 32 / 2-2015 Interview Marco Mensink 29

THE AGE OF Fibre HAS BEGUN

Interview with Marco Mensink, Director General, Confederation of European Paper Industries (CEPI)

The European industry is extremely dynamic and very ambitious. 30 NO. 32 / 2-2015

An industry in transformation Kappa in the US, or Stora Enso in these new products; bicycle helmets, M. Mensink: “It is clear that the industry Brazil). We also lead the way in product car parts, carbon fiber, cosmetics and is going through transformation in many innovation. Just take a look at what is chemicals – and of course innovation in ways. Overcoming current economic happening in specialities and packaging. paper and board. The list is a long one, challenges, finding new markets, Our companies have become adept and any products that are made out of reinvesting and consolidating – there is at being more agile and flexible, and fossil fuel – our members can make them a lot going on at once. We see a decline adapting to survive.” too. We came up with The Age of Fibre in graphic papers, but an increase in concept because it is the natural next packaging, tissue, and the bioeconomy Challenges and opportunities step from our Roadmap to 2050: a vision area. We are seeing the impact of M. Mensink: “Our biggest challenges in we drafted in 2011 and that is becoming investments, as well as the impact of Europe are the ones of sustainable GDP more and more real.” measures that have been taken over the growth, market conditions, and regulatory last few years. Sometimes painful to uncertainty. Our opportunities are plenty: Breakthrough technologies watch, but progress is being made. All a recovering economy - particularly in M. Mensink: “Breakthrough technologies in all, we see an industry that is fit for the countries like Spain and Eastern Europe. like they are used for products from The future.” And now, the surge in specialities, and Age of Fibre are even more important fiber-based packaging, and products of now than they were a few years ago. Europe’s standing the bioeconomy.” The goal is to exponentially grow the M. Mensink: “I think Europe leads the yield and benefit from fiber that has just world in the forest products industry. The Age of Fibre? been harvested. There is nonstop work At this year’s Paper Week we had M. Mensink: “We have just held one going on in Europe in the areas of guests from all over the world who were of the best ever CEPI Paper Weeks in research, nano-, and micro-fibrillated impressed with the energy, commitment, Brussels. All the work of the companies . We are now moving down from and transparency all our members exhibit over the years is now bearing fruit and fibers to molecules, and we need to be to tackle and solve problems. This is we are seeing papermakers create thinking all the time about maximising the across the board, whether developing and produce value-added products yield from our existing fiber. As always, new products and grades to finding that are not just paper – but are still the major challenge is to get the cost of new markets. The European industry is made out of fiber. We can only facilitate production down in new technologies. extremely dynamic and very ambitious. this transformation. CEPI has created There is nonstop work going on in this European companies are expanding a new publication: The Age of Fibre, area, too.” abroad (for instance Mondi and Smurfit which celebrates some of the best of NO. 32 / 2-2015 Interview Marco Mensink 31

“We have created a new publication, The Age of Fibre, which celebrates some of the best of these new products and innovation in paper and board.”

Industry 4.0 completely different. We cannot predict ABOUT MARCO MENSINK M. Mensink: “The impact of ‘big data’ on the future; however we can be ready for the industry is going to be huge. When whatever it is that gets thrown at us, good Early years you bring data to use for the automation and bad. One of the fantastic aspects of Born 1968, son and grandson of a and management of the complete chain my job is working with members who may Dutch politician; one twin sister from fiber and raw material procurement often be competitors in the market place, Education to printers and end users buying but when put together generate a huge Graduated from Wageningen University products off of shelves, the possibilities spirit of cooperation. Everyone in CEPI, - MSC in Forestry and Business of efficiencies and growth are enormous. including the members and the team, Administration Bring in the ‘Energy Internet’ and you like working towards a future we can all Work life then have a completely new sector. benefit from. And that makes me look first job at Ernst & Young Industry 4.0 represents another huge forward to going to work every day!” consulting in the Netherlands transformation to get the fiber industry to came to Brussels 10 years ago its next stage.” after six years at the Royal NL VNP (the Dutch trade federation Sustainability for the paper industry) M. Mensink: “This is a very, very important Private life area. As The Age of Fibre begins, Married; three children (13,11 managing our raw material resources and 8) becomes even more important for every Hobbies: Managing my son’s step of the supply chain. The paper football team, Belgian beer and industry in Europe has had decades of the sauna experience in this area, and leads the way Passion in managing and maximizing the yield Passionate about innovation, our from our forests, raw material bases, and industry and the CEPI Team natural resources.” (Temporarily gave up my lifetime passion for Dutch national football) Looking ahead M. Mensink: “Think back to three years ago. Due to the economy in Europe, the future looked bleak. Now, things look 32 NO. 32 / 2-2015 Engineering a new source of energy and revenue

A clean energy initiative by the provincial power utility provided the impetus for Nanaimo Forest Products to invest in a biomass electrical generation project. Upon completion, the mill became energy self-sufficient and also gained an additional revenue stream. ANDRITZ AUTOMATION served as the electrical engineering partner. NO. 32 / 2-2015 Harmac Pacific 33

Operating under several different owners, burned in the power boiler,” says Rinus Jellema, generates up to 33 MW of power,” says Russ the Harmac Pacific pulp mill has been a cor- Steam Plant Superintendent. “To create this Lang, Steam Plant Supervisor who repre- nerstone of Nanaimo’s business life. Built in extra energy for the grid, we burn about 40% sented his department as the ultimate “own- the late 1940’s in British Columbia, Canada, more hog fuel, but the fuel is carbon-neutral.” er” of the G4 system on the project team. and named after Harvey Reginald MacMillan “G4 shares some infrastructure with G3, but (Har-Mac), the mill became one of the world’s Global expertise – locally is installed in a new building.” foremost producers of northern bleached Harmac was fortunate to have in its backyard softwood kraft pulp. an office of ANDRITZ AUTOMATION which has Earlier funding from a federal Green supported numerous projects with the local util- Transformation Program allowed Harmac When Pope & Talbot, Harmac’s owner at the ity, BC Hydro, and is well-equipped to provide to complete a series of smaller energy sav- time, filed for bankruptcy in 2007, the mill was Electrical, Instrumentation and Controls (EI&C) ing projects. According to Saul Spearing, shuttered in 2008. That spurred a group of un- engineering and project supervision services Harmac’s Project Manager, “These smaller employed mill workers to put together their own for the G4 project. projects paved the way for us to seek financ- money, and persuade two local investment ing for the turbo-generator project. Each was groups to put up the additional capital required “We have done several projects with ANDRITZ designed to improve our mill operations and (75% of the equity) to purchase the mill, save AUTOMATION in the past five or six years,” says energy efficiency.” as many jobs as possible, and defy the odds. Graham Cant, Electrical Project Supervisor. “Each time, the quality of work and flexibility in EI&C scope Proving the naysayers wrong seven years meeting our requirements has been excellent. According to Tom Spence, ANDRITZ later, the mill is operating well. It recently They have a strong group of guys who really AUTOMATION’s Project Manager, “The new mustered the financing and showed excel- understand power and electrical generation.” turbo-generator is connected to an existing lent dexterity in a project to install a new 13.8 kV system at Harmac. However, to allow 25 MW condensing steam turbo-genera- One of those guys is Bernie Schmidtke, Power for the additional fault current it provides, the tor (called G4 by the mill). Ryan Prontack, Specialist. “Bernie was a huge help on this proj- existing 13.8 kV BUS-1 switchgear had to be Engineering Superintendent, says about ect,” Cant says. “He has more than 25 years’ replaced. Our detail design work for both the the project, “Added to our existing power experience in the design of power and control BUS-1 replacement and the G4 installation generation capacity, G4 allows us to meet systems and really knows cogeneration proj- was occurring at about the same time.” all our electricity needs and also send about ects in British Columbia. He was ANDRITZ’s 190 GWh of electricity each year to BC Engineer of Record and our liaison with BC Spence was involved in much of the work, Hydro’s power grid. This adds a good and Hydro and really helped us through the appli- including the upgrading of BUS-1 switch- predictable revenue stream to help us even cation and review process.” gear. “A lot of the electrical infrastructure out the cycles in the pulp business.” improvement was accomplished when we New power for an older mill did the design for the replacement of one of “The turbine creates energy using steam “We have one backpressure turbine installed the two medium-voltage buses in the mill,” produced from waste wood (mostly bark) in the 1960’s which was recently rebuilt, that Spence says.

Harmac Pacific selected ANDRITZ AUTOMATION to perform Electrical, Instrumentation and Controls engineering for its project to install a new 25 MW condensing steam turbo-generator. The new unit allows the mill to meet all its electricity needs and send enough electricity to BC Hydro’s power grid to light 17,000 homes annually. 34 NO. 32 / 2-2015

(Left to right): Tom Spence, ANDRITZ AUTOMATION Doug Tymos, Steam Plant Operator, checks the readings on a meter on the BUS-1 switchgear. Project Manager; Graham Cant, Harmac’s Electrical Project Supervisor; and Saul Spearing, Harmac’s Project Manager for the G4 project.

In addition to replacement of the switchgear, throughout the project to answer questions or this variability, which flattens our steam de- Harmac’s existing generator G3 electrical address any issues,” Spence says. mand and makes things much more steady connection was relocated. “The necessity to state. Plus, we eliminated the requirement switch generators to different buses required In July 2013, the G4 unit went into commer- for a cooling tower. This has increased our us to revisit the entire power system in this cial operation. Unfortunately, 10 days later, thermal efficiency from the standard 30% for mill,” Spence says. “Virtually every part of the the system came to a full stop due to a sig- a condensing turbine to 42%.” 13.8 kV electrical system was touched, or at nificant mechanical issue with the turbine. least reviewed in depth. This meant we had Corrections were made and the unit started In-depth knowledge to understand and document each system in back up three months later and has been run- “The work we did on this project gives us detail before we designed modifications to it.” ning reliably ever since. so much visibility into what we have now,” Cant says. “We are very confident that our “ANDRITZ AUTOMATION did an outstanding Unique condenser and cooling loop drawings and specifications are up to date. job on this project,” says Spearing. “We had a “We now take all of the mill’s process wa- Considering that the original switchgear was lot of work to accomplish in a very short time- ter and send it through the turbine’s steam installed in 1963, we now have a power net- frame during an eight-day shutdown. Not only surface condenser to warm it before using it work that will serve us well for a long, long did they do the design work, but they were on in the process,” Prontack says. “Before this time.” site continuously helping to get the work done.” project, we had seasonal steam demand, because the water temperatures would vary CONTACT Chris Madin ANDRITZ AUTOMATION did a number of considerably. Now, we have smoothed out [email protected] power and control system studies to ensure that the G4 system would be integrated into the existing mill systems in a safe, economi- cal, and reliable way. They also worked with Harmac to develop a control strategy, with control loop narratives, to help Harmac avoid any instabilities in the steam plant as a result of the addition of another steam turbine. Russ Lang, Supervisor (left), with Rinus Jellema, Steam Plant The bulk of the work, however, was in the Superintendent in front of design and detailed engineering required to the new turbine. write the equipment specs and provide the electrical contractors with proper drawings and work documents. “We had people on site NO. 32 / 2-2015 TechTalk 35

Higher productivity Tech and reliability in Talk “new generation” pulp drying plants

The traditional design for pulp dewatering machines served the industry well for decades. The Twin Wire Press or a Fourdrinier with heavy-duty press (or shoe press) were the de facto industry standards and are still used for smaller capacities where high specific production rates are not of as much importance. A modern pulp drying plant operating in South America.

A huge step forward was realized with the ▪ Increase specific production at the wet end Major developments: introduction of the Twin Wire Former with and 300 bales/h in the finishing area while Combipress and shoe press. The first in- keeping machine size small. Stock approach stallation of this technology at Aracruz (now ▪ Optimize design of the former and press The “new generation” stock approach sys- Fibria) in Brazil created a real buzz in the in- section while using standardized com- tem is based on five to seven stages as fol- dustry. Several other installations followed. ponents as much as possible to reduce lows: three stages of pressurized ANDRITZ Single machines up to 9.3 m working width, spare parts inventory. ModuScreens with Dolphin rotors and an or double lines at slightly narrower widths, ▪ Develop high-capacity upgrades for existing additional two to four stages of cleaners. became the new standards. Equipment, lines that were housed in small buildings. The Dolphin rotors make it possible to save components, and the overall process were ▪ Reduce overall operating costs. 15 - 30% energy at similar levels of screen- optimized to improve production and reli- ▪ Reduce steam and electrical power ing efficiency and fiber loss as traditional ability. Basis weights were increased up to consumption, fiber loss, and water systems. 1,250 g/m² with machine speeds reaching consumption. peaks in the excess of 200m/min. ▪ Reduce maintenance requirements. Major developments: ▪ Make the equipment safer and easier to “New generation” drying plants operate. Pulp dewatering ANDRITZ began a development program to The development program focused on devel- harmonize the individual components in or- The development program yielded significant oping forming and dewatering components der to extract their full potential and increase results in all key processes – beginning with such as: overall plant performance, with the following stock approach and ending with the finishing goals: equipment. 36 TechNO. Talk 32 / 2-2015NO. 32 / 2-2015

“New generation” pulp dewatering.

Headbox. Utilizing Computational Fluid The higher efficiency allows a reduction in the was to achieve sustainable production above Dynamics (CFD) models, the headbox was number of fans and steam coils. A unique 250 bales/h with peaks up to 300 bales/hr modified to include new control valves and the automatic tail threading system provides The development program focused on pro- use of fan beam injection to achieve uniform rapid, safe, and fully automatic threading of ducing a baling line with reduced complex- basis weight profiles. This headbox is capable the dryer. With support systems such as in- ity and standardized components. The new of achieving less than 6 g/m² standard devia- ternal broke nips and a broke detection sys- design increases the conveyor speeds and tion (coefficient of variation of 0.6%, 1σ ) over tem, operation and maintenance of the dryer uses sound isolation techniques to provide the entire working width. is enhanced. low-noise operation. Certain features were also added: a laser scanner safety device and Wedge section. Wedge geometry and open Major developments: bar code positioning on the transfer car; gear dewatering area were improved to increase the pumps with variable speed drives at the bale dewatering speed in the wedge section of the Baling line press hydraulic unit; and electrically operated Twin Wire Former. A conventional ANDRITZ baling line oper- stacker lifting devices. ates at sustainable rates of 220 bales/h with Couch roll with Anti-Rewetting Unit peak production of 250 bales/h. The goal The success of the equipment is proven: (ARU). The same excellent dewatering is for the “new generation” equipment design peak production reached on a recently in- achieved with couch roll + ARU when com- pared to a traditional wire suction roll in this “New generation” sheet dryer. position. The advantage of this couch roll sys- tem is obvious: same results as a wire suction roll, but significantly easier and cheaper to operate and maintain (simpler vacuum plant, less spare parts). It produces a stable pulp sheet with no crushing or wrinkles ahead of the lump breaker nip even at high machine speeds (> 200 m/min).

Major developments: Sheet Dryer With continued innovations in air distribution and impingement, the Sheet Dryer has be- come more efficient per dryer surface area. NO. 32 / 2-2015 TechTalk 37

Automated baling lines in operation, each achieving peak productions above 300 bales per hour. stalled line is 332 bales/h within the first three Current records for specific productions specific production of 455 t/d per meter weeks of start-up. Cycle time was reduced to are all achieved on these new generation working width was achieved in Europe on less than 11 seconds. In terms of reliability, ANDRITZ pulp drying lines. In some cases an ANDRITZ pulp drying line. Customers at the binding equipment produces an average purely mechanical issues needed corrective these plants believe there is potential to in- of 25,000 bindings without operator interven- action. One example of corrective action was crease production even more. tion (with the exception of coil changes). the installation at Eldorado Celulose in Brazil

– the largest single-line pulp mill in the world. CONTACT There were some mechanical issues that af- Klaus Pöschl Major developments: [email protected] fected production and customer satisfaction. Cutter-Layboy However, the plant today runs remark- A conventional ANDRITZ Cutter-Layboy op- ably above design capacity. The erates at 190–225 m/min, with peak speeds world record for A state-of-the-art Cutter- up to 250 m/min. The development program Layboy to match the new generation drying machine. centered around reducing complexity and improving uptime while using standardized components as much as possible. The “new generation” Cutter-Layboy has several en- hancements: an individually driven bottom slitter, traction rolls instead of short tapes, and nip wheels instead of top tapes. The long tape arrangement is independent from sheet / wrapper size. In addition, the electromechani- cal movements in all key positions have been simplified for increased reliability and ease of maintenance. The electromechanical systems for the main table are now separated for im- proved vibration damping and the cutter hood has an efficient noise insulation.

Experience from start-ups and daily operation The overall design of the “new generation” pulp drying plant proved very successful. NO. 32 / 2-2015

Dry scrubbing at Big Stone

With its new Air Quality Control System (AQCS), the Big Stone power plant will reduce emissions of nitrogen oxides, sulfur dioxide, and mercury. Opting for circulating dry scrubbing technology, instead of going the “traditional” route, turned out to be the right choice at the right time. NO. 32 / 2-2015 Otter Tail Power 39 NO. 32 / 2-2015

“The comfortable thing to do would have lating Big Stone Plant (Minnesota, North BART leads to dry scrubbing been to choose the technology that has been Dakota, and South Dakota). Phinney set to The driving force for the project was the around for decades,” says Kirk Phinney. work helping to review all the specs and need for Big Stone to meet upcoming fed- “But we did our homework and concluded layouts, gathering operating data, and eral regulations, including new mercury that the ANDRITZ circulating dry scrubber meeting with technology suppliers to ob- standards, and regulations to reduce haze would help us well into the future. Today, we tain accurate bids for the project. He later over Minnesota’s Boundary Waters canoe have one of this industry’s top performing supported the construction phase and area, a popular outdoor recreational area. retrofit units in terms of SO2 reduction. We served as Commissioning Manager. “It The existing air pollution control system know we made the right decision.” has been very exciting to be involved with on the boiler was a baghouse – effective the project all the way through,” Phinney at removing dust and particulates, but not Phinney is Commissioning Manager for says. gaseous emissions or mercury. the Big Stone air quality control system (AQCS) project. He transferred to Big Phinney’s employer, Otter Tail Power After doing a thorough evaluation of the Stone in hopes of being part of this proj- Company, is the majority (53.9%) owner best available retrofit technology (BART), Big ect – a MUSD 400 investment – and quick- of Big Stone. Otter Tail people staffed the Stone personnel determined the need for a ly became part of Project Manager Mark project and run the 495 MW power plant, dry scrubber. Rolfes’ team. which burns subbituminous coal and has been online in South Dakota since 1975. My how things have changed Rolfes was busy at first obtaining permits The other two owners are NorthWestern “Flue gas cleaning with a dry scrubber and approvals from the three states regu- Energy and Montana-Dakota Utilities. is today an attractive alternative to wet NO. 32 / 2-2015 Otter Tail Power 41

The scrubber vessel’s waste ash pickup point, including the fluidizing air ring and ash transport lines.

(Left to right): Erik Fladhammer, Project Engineer; Kirk Phinney, Commissioning Manager; and Scot Ojard, ANDRITZ Project Manager, inside the scrubber building.

scrubbers, even for large coal-fired boilers,” Spray dry absorber (SDA) technology had the slurry droplets in the scrubber vessel. says Paul Petty, Director of Applications and been the traditional dry scrubbing solu- And SDA is able to remove only about 85-

Technology of ANDRITZ’s air pollution control tion for power plants requiring large SO2 95% of the SO2. “Plants today are looking business in North America. “It was impos- removal rates. The downside of SDA is the to remove 98%+, which before the advent sible to make this statement when I started in potential for corrosion due to the creation of circulating dry scrubbing technology, the business. But much has changed.” of lime slurries and the need to quickly dry was only possible with much more ex- pensive wet scrubbing technology,” Petty said.

“The most important advantage of circulat- ing dry scrubbing is the ability to achieve

this 98%+ reduction of SO2 and other acid gases,” Petty says. “Other important bene- Paul Goettig, ANDRITZ Commissioning Engineer fits are a lower capital cost, simpler design, adjusts an air valve for the lower water use, no wastewater discharge, pulse jet fabric filter. and the ability to remove all pollutants ex- cept carbon monoxide and nitrous oxides in one step.” NO. 32 / 2-2015

Rigorous evaluation metered to recirculate into the scrubber ves- “In simple terms, the contract we have “We went through a very rigorous pro- sel. A portion of this material is diverted into with Big Stone is for everything above the cess to evaluate the technical offerings,” the ash handling system for disposal. foundations for the scrubbing and waste Phinney says. “Our evaluation conclud- ash handling,” says Scot Ojard, Project ed that the circulating dry scrubber had An excellent project Manager of ANDRITZ. further room to perform than the SDA ANDRITZ’s scope included the scrubber and would not put us at the limits of the (34-foot diameter), gas humidification One twist of the ANDRITZ technology is technology.” system, reagent system, gas recircula- that Big Stone is a dual-train configuration tion system, by-product recirculation/ due to its size (practical limit for a single In evaluating suppliers, it came down to removal system, pulse jet fabric filter, train is around 400 MW). This is the first experience. “ANDRITZ had six installa- Powder Activated Carbon (PAC) injection dual-train for ANDRITZ in North America. tions at that time, not a huge number, but system for enhanced mercury capture, and “The SDA supporters told us that we would enough for us to feel confident,” Phinney waste ash removal and storage system. have problems with the dual fluidized beds says. “The other supplier had one.” ANDRITZ also supplied ductwork, piping, fighting each other and the ID fans fight- access points, platforms, logic for the DCS ing each other and things would be out of The ANDRITZ CFB Scrubber controls, and support steel for the scrub- synch,” Phinney remembers. “I can tell you Flue gas is directed into the bottom of the ber and lime silo. that has not been the case.” circulating fluidized bed (CFB) vessel where it is turned upward and passes through a grid of venturis. The hydrated lime and recirculated by-product is introduced be- low the venturis and gets evenly mixed and dispersed into the flue gas. Cooling water spray (which can be wastewater from boiler blowdown) is added above the venture section, independent from the reagent feed. The by-product is collected downstream in a pulse jet fabric filter, then

Allen Narverud, ANDRITZ Manager of Field Engineering (left) and Todd Campbell, Commissioning Engineer near the lime hydration system. NO. 32 / 2-2015 Otter Tail Power 43

“There has never been a worry during this “We are down to the point of finishing sense. They fit the company personality at project,” says Erik Fladhammer, Project punchlist items,” Ojard says. “Plus we Otter Tail very well and we did good work Engineer. “It has been a very good re- recently used our newest computational together.” lationship. The discussions have always flow dynamic model studies to optimize the been open. Scot and his team came up turning vanes at the bottom of the scrub- “The original budget was over MUSD 400 through the technical side. Their sug- ber inlet to improve the dispersement of for the project,” says Rolfes. “The upgrade gestions are practical and it is clear that recirculated by-product materials. This im- is now expected to close out 21% below these guys know how to build and run proves Big Stone’s ability to run efficiently the budget due to our procurements and scrubbers.” at low loads.” engineering work coming in below an- ticipated cost. Plus we have been able to Construction began in Spring 2013. The plant “ANDRITZ gave us excellent performance reduce the contingency reserves. That is went down in early 2015 for a planned outage guarantees for SO2 removal, availability, good news for our customers, owners, and to do all the tie-ins and the extensive boiler and lime consumption,” Phinney says. “If shareholders.” work to increase the surface area. “When we I had to do it all over again, I would do it came back online, we moved along quite the same way and with the same suppli- CONTACT well,” Phinney says. ers – especially ANDRITZ. Their people are Scot Ojard technically smart, practical, and no-non- [email protected]

Hoppers for the pulse jet fabric filter.

A view of the ANDRITZ CFB scubber. NO. 32 / 2-2015

Removing mercury from the emissions of coal-fired power stations can be accomplished with an ANDRITZ-patented system that has synergies with existing air pollution control equipment and downstream processes.

Mercury is a potentially deadly neurotoxin. to operators of coal-fired power plants in tion system,” Kramer says. “Dosing calcium Mercury emissions from coal-fired power order to meet stringent mercury reduction bromide into the boiler is often a sufficient stations are an environmental concern regulations. and easy way to oxidize the majority of the due to the toxicity and persistence of mer- mercury that originates within the boiler.” cury that accumulates in our waterways. “If conventional oxidation in the gas phase is Stringent mercury emission limits in the USA not sufficient to meet the emissions limits, we Other actions taken within the flue gas path and upcoming BAT and IED regulations in offer a well-proven calcium bromide oxida- are often necessary to further oxidize the mer- Europe might present a significant chal- cury downstream of the boiler. “For instance, lenge for some power producers, according we can look at enhanced oxidation within a to Andreas Gruber-Waltl, Team Leader for Selective Catalytic Reduction (SCR),” Kramer Process Development at ANDRITZ. says. “Regardless of the steps taken, much of the oxidized mercury will be caught in the “These limits must be met,” Gruber-Waltl says. Flue Gas Desulphurization (FGD) scrubber.” “We even have to consider clean gas mercury concentrations below 2 μg/m³ STP dry.” Bind and stabilize the dissolved mercury A wet FGD is not only a very efficient way of A holistic approach to mercury control separating acidic components from the flue To meet these limits, ANDRITZ has taken a gas, it is also highly efficient when it comes to “holistic” approach which works in synergy the removal of the oxidized mercury. The mer- with downstream processes. “We started cury is dissolved in limestone slurry in the ab- by looking at the process as a whole,” sorber tower and then removed through the Gruber-Waltl says, “taking into account blowdown process either in a device called not only the various oxidation reactions hydrocyclone or within the waste water path. that make sense in the flue gas pathway itself, but also working in concert with “However, inconsistencies in wet scrubber downstream equipment.” chemistry can actually contribute to return- ANDRITZ developed a new hydrocylone design which ing some of the captured mercury back to Michael Kramer, Process Engineer for significantly reduces fine particles (such as mercury- the flue gas,” Kramer says. “To avoid this, we laden activated carbon) from the underflow. Shown here ANDRITZ, highlights the options available is a small prototype that was built to prove the concept. have to bind and stabilize the dissolved mer- NO. 32 / 2-2015 ANDRITZ Air Pollution Control 45

Michael Kramer, Process Engineer for ANDRITZ (left) and Andreas Gruber-Waltl, Team Leader for Process Development.

cury in the limestone slurry in the scrubber. says. “We have never actually focused on its reduced significantly. “Mercury separation This is accomplished with a new design of design before.” efficiency of up to 95% has been proven,” the hydrocyclone and the addition of either Kramer says. “The gypsum was clean with Activated Carbon (AC) or precipitation agents “Once we focused on the design,” Kramer no black activated carbon particles.” on the other side.” says, “we had the idea to use a clean water wash to eliminate the fine particles in the un- Controlled “mercury sink” Particles in a hydrocyclone are separated derflow. By directing the fines to the overflow, To enhance the mercury transfer to the according to their sedimentation speed. Big they do not affect the gypsum.” wastewater treatment plant and prevent an and dense particles (like gypsum) are dis- increase in mercury concentrations in the charged in the hydrocyclone’s underflow (the The ANDRITZ solution is not simply a water scrubber, ANDRITZ offers an upgrade to Apex flow). The gypsum is dewatered and is injection system. “We re-designed the bot- any mercury reduction system with a clear then ready for commercial use (typically in the tom of the hydrocyclone where we introduce “mercury sink” within the FGD system. With construction industry). the wash water so that it causes minimal its long experience in both FGD design and turbulence,” Kramer says. “Coarse particles dewatering technologies, ANDRITZ can as- Powdered activated carbon (PAC) can be can pass through the sedimentation layer, sist any power plant in creating a controlled injected into the absorber slurry to inhibit re- but fines are caught within it and carried to “mercury sink” in the wastewater treatment emitting the mercury. In this case, the “mer- the overflow.” facility. cury sink” (place where the mercury collects) will be the by-product of the FGD process ANDRITZ did its first tests at its technical cen- Testing at industrial scale – the gypsum. “PAC particles are very fine, ter in Austria. Based on the results, two pat- “We are closing the gap in mercury removal but their specific weight is still higher than the ents were granted: one for the hydrocyclone technology for FGD systems,” Gruber-Waltl fluid´s density,” Kramer says. “So, a standard design itself and one for the process. says. “We have now linked up with a power hydrocyclone cannot separate PAC out of the producer and are testing this technology at underflow. A significant portion of the PAC will Original prototyping tests were conducted industrial scale and expect first results by the end up in the Apex flow, which contaminates with a hydrocycyclone supplier in Germany. end of 2015.” the gypsum and blackens it so that it is com- “Their design was not robust.” Kramer says. mercially unusable.” “Also, the targeted mass transfer point could not be met with their technology.” CONTACT Michael Kramer From auxiliary to star [email protected] “We had always considered the hydrocy- So, the next step was for ANDRITZ to design clone to be an auxiliary piece of equipment its own prototype. Tests with the prototype for us, standing between our FGD and the showed that the amount of mercury-laden wastewater treatment system,” Gruber-Waltl activated carbon in the underflow could be 46 NONO.. 32 / 2-2015 Highlights Recent orders

Complete Lines Vinda Paper, Jiangmen City, Guangdong Province, Cartiere Modesto Cardella, Lucca, Italy AND SYSTEMS China PrimeFlow TW two-layer headbox with Stock preparation and paper machine PrimeProfiler F dilution control; PrimeForm TW Fibria Celulose, Três Lagoas, Mato Grosso do Sul, approach system. gap former for PM 3. Brazil Repeat order (PM 4 has same scope and has EPC delivery of complete production lines for entire Yunnan Jinchen Paper, Huaning, Yuxi City, Yunnan started up). mill: wood processing plant, fiberline, white liquor Province, China C&S (Hubei) Paper, Xiaogan City, Hubei Province, plant, evaporation plant, pulp drying plant, and Stock preparation and save-all disc filter. China recovery boiler. Whitewater recovery upgrade from DAF to save-all Woodyard, fiberline, and white liquor plant will have Hubei Xiangxing Paper, Jianli City, Hubei Province, disc filter. the highest production capacities in the world. China Evaporators will be largest in Western Hemisphere; Paper machine approach system for Dongguan Shunyu Paper, Dongguan City, recovery boiler largest in South America. corrugated board. Guangdong Province, China Headbox screen to upgrade paper machine ap- SCA Östrand, Timrå, Sweden key equipment, upgrades, proach system for corrugated board. Woodyard equipment, pulp drying plant, major and modernizations upgrade to white liquor plant, and extension of the ENCE Navia, Navia, Spain recovery boiler. Mondi Merebank, Merebank, South Africa Optimization of Process Performance (OPP) service. Innovative, energy-saving technologies that sub- Automation upgrade of 3 TMP refiner lines stantially reduce operating costs. Repeat order (1 TMP line already started up). ENCE Pontevedra, Pontevedra, Spain Chenming Huanggang, Chenming, China Optimization of Process Performance (OPP) service. Cooking plant for kraft and ; NCG Phoenix Pulp and Paper, Khonkaen, Thailand treatment system. Lime kiln key equipment (EPS delivery). ANDRITZ is the only supplier with solid references Arcelor Mittal Tubarão, Serra, Brazil and experience in continuous cooking of dissolving Corrigan OSB, Corrigan, Texas, USA Optimization of Process Performance (OPP) service. pulp. Two 32-ton LogPorter portal cranes and two round wood debarking lines with LogAligner technology. POSCO E&C, Pohang, Republic of Korea SCA, Östrand, Timrå, Sweden Waste-to-energy plant. Zellstoff- und Papierfabrik Rosenthal, Blankenstein, Debarking drum modernization. Germany Ibrahim Fibers, Faisalabad, Pakistan Lime kiln upgrade with LimeFlash (lime mud drying). Coal-fired PowerFluid boiler (80t/h steam) for a 20 Iggesund , Workington, Cumbria, UK ProGest Group, Carbonera, Italy MWel power plant. Debarking drum modernization. PrimeFlow headbox, PrimeCoat Film (film press), Nippon Paper Industries, Gotsu Mill, Shimane post-dryer section, and PrimeReel. Prefecture, Japan PrimeDry cylinders completely made of steel. New evaporation plant to replace old multi-effect evaporators. Mechanical Vapor Recompression (MVR) plant for sulfite liquor with comprehensive cleaning features.

Recent start-ups SCA Östrand will double its annual production capacity from 430,000 to 900,000 tonnes and become the largest mill in the world for softwood Complete Lines key equipment, upgrades, kraft pulp AND SYSTEMS and modernizations

Stora Enso, Varkaus, Finland Chuetsu Paper, Takaoka, Japan Fiberline conversion: modernization of cooking, Modernization of oxygen stage and bleach plant brownstock washing, and screening; new refiners (5 DD Washers) and LimeFree centrifuge for white Zhanjiang Chenming Pulp & Paper, China for blowline and rejects. New LimeDry (lime mud liquor plant. 65 MW gasification plant. disc filter) for recausticizing plant. Evaporation New smaller size DD Washers (2 m x 2 m). plant capacity increase. MSE Mjölby Svartadalen Energi, Mjölby, Sweden CMPC Celulosa, Santa Fe, Chile EcoFluid boiler (35 MW); biomass handling sys- UPM-Kymmene, Kuusankoski, Finland Increase availability of the cutter layboy. tem; fuel handling and flue gas cleaning Fiberline modernization and pulp drying plant systems; steam turbine with auxiliary systems. capacity increase and quality improvement. Zhejiang Jingxing Paper, Pinghu City, China PrimeLineST tissue machine with steel Yankee Suzano Papel e Celulose, Suzano, São Paulo, Suzano Papel e Celulose, Suzano, São Paulo, (diameter of 18 feet), head insulation, and steam- Brazil Brazil heated hood. Upgrades to bleaching, pulp machine, and winder New continuous cooking plant for capacity 2nd ANDRITZ tissue machine delivered to this for the production of . increase. customer for high drying capacity at reduced First mill to produce fluff pulp using Eucalyptus - Fast learning curve – only 10 days to reach nomi- energy costs. Eucafluff. nal capacity. NO. 32 / 2-2015 Did you know that… 47 Did you … ANDRITZ holds the dominant position for continuous cooking of dis- solving pulp?

In the last four years, every order for continuous cooking of dissolving pulp has been placed with Know ANDRITZ. ANDRITZ technology is swing-capable, meaning that producers can easily switch between the produc- tion of kraft pulp and dissolving pulp depending on market conditions.

Get more information at: that... www.andritz.com/dissolving-pulp

… ANDRITZ offers technologies for recycling of plastic-containing rejects?

With consumers and industry generating increasing amounts of waste containing plastic, ... Yankee service ANDRITZ saw an opportunity to combine its fiber extends the life of Yankee and rejects treatment expertise with innovative cylinders? pyrolysis technology. The technology involves high-temperature heating of organic materials in A well-maintained Yankee cylinder (steel or cast iron) the absence of oxygen. The plastic turns into a offers improved runnability and increased machine hot gas that is cooled and becomes pyrolysis gas efficiency. Using Life Cycle Management (LCM) or oil – fuel for a mill’s power plant. Remaining techniques, ANDRITZ has focused on the overall added metals can be pressed into blocks and value of the Yankee and offers services through the life recycled in the metals industry. of the product. Yankee Service can include grinding, coating, on-the-run measurements, leak repair, bearing Get more information at: changes, FE analysis, diagnostics, etc. www.andritz.com/pyrolysis

Get more information at: www.andritz.com/yankeeservice Here’s a fresh perspective on improving your bottom-line efficiency.

We focus our technology and services You can benefit from technological leader- We are your technology and service part- on your bottom-line efficiency, so you ship. Our solutions increase throughput, ner. When you need a fresh perspective can profit in virtually any market. reduce waste, improve yield, substitute on raising your bottom-line efficiency – let As your partner, ANDRITZ tries to ensure less costly raw materials, generate power, ANDRITZ open up new possibilities for you. that everything we do helps you increase reduce energy costs, and keep your equip- your efficiency and lower your costs. ment running longer.

www.andritz.com We accept the challenge!