spectrumNo. 28 / 2-2013 MAGAZINe OF pulp & paper

STARTING UP BIG in Brazil (Page 12)

FOSSIL FUEL-FREE Gasifier boosts green energy (Page 6) CLEAR ADVANTAGE ShortFlow deaeration (Page 22) REINCARNATED PM Second Hand machine (Page 36) GREEN POWER SHOW New biomass boiler in UK (Page 40) 2 Contents 3

06 10 18 22 The growth trifecta Market growth comes by expanding in one of three ways: customer base, 12 products offered, or geography covered. ANDRITZ continues its strategy to expand in all three.

trifecta is a situation when three ele- For example, you will read in the interview relocate and convert an MG machine to a ments come together at the same with José Grubisich, President and CEO of state-of-the-art packaging machine (page A time. The word comes from a bet- Eldorado Brasil (page 12), that this market 36). 40 ting term (“perfecta”). As you might guess, pulp producer sees his company growing trifecta winners are rare and the payout is more with a specific customer base (tissue) Market growth is also the result of expand- large. and in a specific geography (Asia). We at ing our services, such as rebuilds and ret- ANDRITZ share this view. We have our most rofits. Our success comes not only from We are business people and stewards of modern pulping technology in Brazil, most bolt-for-bolt rebuilds to OEM specs, but our shareholders’ money – not bettors at of our tissue machines in Asia, and have also by adding our own special technology a race track. Still, it makes sense to invest recently expanded our presence in China to to improve upon the “old” installation. You contents in the controlled expansion of our products include competence centers for plastic film can read about the work at Varel (page 33) and locations to align ourselves with the production and R&D for nonwovens. to upgrade the performance of a dewater- new dynamics of this in- ing press and expand the drying capacity of 03 Management Message 12 A start-up starts up ... BIG 33 Keeping it simple. dustry. It is not a risk to Another area of growth is packaging an existing packaging machine. Eldorado Brasil Making it profitable. do so. It is more of a risk grades. We expanded our product line to 04 News, Orders, Start-Ups Papier- und Kartonfabrik Varel 18 Taking the load off NOT to do so. include not only new machines, but also the As mills are transitioning to higher margin relocation and modification of secondhand products and/or higher efficiencies, these 06 Gasification helps mill Stora Enso 36 A reincarnation in machines. In the next issue, we plan to re- transitions require changes to the technol- go fossil fuel-free Russian packaging port on the new machine at Zellstoff Pöls in ogy. We at ANDRITZ have the expertise to Metsä Fibre 22 Five Star’s clear advantage SFT Group Wuzhou Special Paper Austria (high-strength grades for shopping assist – with new, rebuild, upgrade, or re- 10 Benefits of polysulfide 40 Green Power show bags, medical packaging, and food pack- location. We hope you will continue to take Preparing for the future 26 Iggesund Paperboard aging). In this issue, you can read about maximum advantage of this expertise in the cooking Stora Enso Metsä Fibre a project with the SFT Group of Russia to coming year. 30 New OCC line in Malaysia Muda Paper Karl Hornhofer (standing) and Humbert Köfler.

On the cover: Olavi Filipecki, Woodyard Project Manager for ANDRITZ Brasil, stands at the top of the new stacker/reclaimer at Eldorado Brasil’s greenfield pulp mill. The ANDRITZ fiberline, largest in the world, is in the background. (Complete story begins on page 12).

SPECTRUM is published by: Editorial Director: General information and Copyright: ANDRITZ AG Robert Puhr You will see the use of both “tonnes” Stattegger Strasse 18 [email protected] and “tons” in this publication: tonnes for 8045 Graz, Austria Editorial Board: metric units and tons for American units. Phone: +43 (316) 6902 0 Bjørn Hansen, Minna Heinonen, Pirjo Nousjoki, Robert Puhr, Ursula Upanne, Spectrum is published in five languages; Karl Hornhofer Humbert Köfler [email protected] Manuela Wagner, Carina Weissensteiner, Elisabeth Wolfond English, Chinese, Russian, Japanese, and Member of the Executive Board Member of the Executive Board Editor-in-Chief: Contributing Writers: Portuguese. Copyright© ANDRITZ AG Pulp & Paper – Capital Systems Pulp & Paper – Service and Units Bjørn Hansen AK Bolhassan, Martin Koepenick, Robert Puhr, Mark Rushton 2013. All rights reserved. No part of this [email protected] Contributing Photographers: publication may be reproduced without Project Director: Riku Isohella, Christopher Rausch, Thomas Wedderville, permission of the publisher. Pirjo Nousjoki Otmar Winterleitner, iStockphoto [email protected] Layout & Design: INTOUCH Werbeagentur & Internetagentur, Austria spectrum.andritz.com Address Changes: [email protected] 4 News 5

Highlights of new orders

Complete Lines Complete Lines Chuetsu Pulp & Paper AND SYSTEMS AND SYSTEMS Takaoka, Japan O2-stage and bleaching modernization with Haskell Co. for Drax Xuan Yuan Industrial Development ACE/BrainWave. News USA Dobrush, Belarus Chipping and screening lines for two pellet Woodyard, 450 t/d P-RC APMP plant, stock Celulosa Beira Industrial Celbi plants. preparation, and machine approach system. Figueira da Foz, Portugal Cooking and screening line upgrade, new pre- Rentech Emami Paper evaporator and rebuild of pulp drying line. Largest MC pumps Canada (two locations: Atikoken, Ontario and Balasore, India Wawa, Ontario) Two OCC lines, deinking line, stock prepara- Domsjö Fabriker AB Wood pelleting systems (hammermills, pelletiz- tion, machine approach system, new headbox, Domsjö, Sweden ers, and coolers). and coating equipment. Rebuild of boiler to reduce fouling behavior and in the world enhance efficiency 20%. Stora Enso Zhejiang Jingxing Paper The pulp feed to a new washing line for a and testing at ANDRITZ’s workshop in Graz. Skoghall, Sweden Zhejiang Province, China Papelera Guipuzcoana de Zicuñaga Fiberline modernization (incl. TurboFeed and Two PrimeLineST tissue machines incl. Zicuñaga, Spain mill was massive – 4,400 t/d. Moving that Efficiency of the pumps was documented at DD washers); sludge dewatering line; belt press PrimeDry Steel Yankees. Upgrade of evaporation plant with Duct much pulp requires some very large pumps 74% (BOP) at a consistency of 8%. This is rebuild. Stripper and the first modular box-type surface – the largest ever made by ANDRITZ, and the far above the industry average (which is be- Shin-Ei Paper condenser. largest MC (medium consistency) pumps in low 70%) and the best efficiency ever mea- Mjölby-Svartadalen Energi Shizuoka Province, Japan Mjölby, Sweden Two PrimeLineCOMPACT machines incl. PT Suparma the world. sured for an MC pump. The pumps were also EcoFluid BFB biomass boiler, fuel handling, flue PrimeDry Steel Yankees. Surabaya, Indonesia tested at 12% consistency and were able to gas cleaning, and steam turbine. FibreFlow drum pulper. ANDRITZ received the order for six MC pump the equivalent of 7,200 t/d. key equipment, upgrades, Suzano Papel e Celulose and modernizations Weyerhaeuser pumps early this year and has shipped the São Paulo, Brazil Gdansk, Poland units. Although ANDRITZ’s MC pumps can The MC pumps are equipped with the New cooking plant, evaporation plant upgrade, Stora Enso Flash dryer and curing bin expansion. handle consistencies up to 16%, the units SMARTSEP system, which removes air from and methanol liquefaction plant. Oulu, Finland for this mill will operate in the range of 7% the pulp suspension while returning fiber to Fiberline modernization including new pre-steaming chip silo and DD washer. consistency. the pump. Degassing control is so incredibly simple. When the pump is running, the de- The customer counted on a quick deliv- gassing valve is open; when the pump stops, ery from ANDRITZ. Only four and one-half the valve closes. months were required for manufacturing Highlights of new start-ups

Complete Lines Complete Lines ENCE AND SYSTEMS AND SYSTEMS Navia, Spain Evaporation plant capacity increase. Metsä Fibre Nine Dragons Paper Industries 70 trucks Joutseno, Finland Quanzhou, Fujian Province, China Chuetsu Pulp & Paper Polysulphide cooking and MOXY plant. 1,000 t/d OCC line; paper machine approach Satsuma-Sendai, Japan World’s largest single polysulfide cooking line. systems; broke handling system. MVR pre-evaporator. and one First MVR system in Japan. JK Paper Ganzhou Hwagain Rayagada, Orissa, India China UMKA AD Fabrika Kartona to Major kraft mill modernization (woodyard, PrimeLine tissue machine with complete stock Umka-Beograd, Serbia vessel Stock preparation system. fiberline, white liquor plant, evaporators, and preparation plant incl. PrimeFlow headbox, recovery boiler). PrimePress XT shoe press, PrimeDustEx W Considerable fiber savings from ANDRITZ dust removal, PrimeReel advanced reel system, FibreWash. the North Mondi Frantschach and machine control system. St. Gertraud, Austria Vipap Videm Krsko Recovery boiler. Kamenskaya Paper & Board Krsko, Slovenia Recently, the equipment for JSC Arkhan- Tver Region, Russia Deinking system upgrade. gelsk Pulp and Paper Mill’s new semi-chem- Graphic Packaging International Relocated and rebuilt packaging machine ical pulping line in Russia, was shipped from ANDRITZ semi-chemical digester reaching its destination port of Arkhangelsk Macon, GA USA (secondhand); new 800 t/d recycled fiber line Sappi Paper and Packaging (Courtesy of APPM’s “Bumazhnik” newspaper) EcoFluid BFB biomass boiler. and approach flow system. Ngodwana, South Africa ANDRITZ workshops to the site – on 70 Rebuild of pulp drying plant (wire/press section, trucks and one ship. In late May, the con- The other equipment shipped by truck in- Once installed, the new plant will produce key equipment, upgrades, new shoe press, dryer, heat recovery, cutter, tinuous steam-phase digester (75 tonnes) cluded the chip washing equipment, refin- 1,000 t/d of semi-chemical pulp out of and modernizations and baling line). left Antwerp, Belgium and reached its des- ers, washers, screw presses, gas treatment birch and aspen as raw material. Start-up OAO Ilim Group Sappi Fine Paper North America tination port at Arkhangelsk. From there, it system, as well as instrumentation and con- is scheduled for the fourth quarter of 2014. Koryazhma, Russia Cloquet, MN USA travelled by river barge to the mill site. trol systems. Lime stone kiln, white liquor plant, and recovery Pulp drying modifications (wet end, press, boiler modernization. cutter/layboy, and baling line). 6 Metsä Fibre Metsä Fibre 7

Gasification helps mill go Mill Manager Risto Joronen (left) with Kari Salo, Managing fossil fuel-free Director of Carbona. Metsä Fibre’s Joutseno mill tackled the last step in its quest to be free of fossil fuels. A biomass gasifier from ANDRITZ delivers sustainable, renewable fuel for the he availability of low-cost biomass Manageable risks at this mill was a key driver for us The project was designed to replace all the lime kiln, replacing natural gas. Tchoosing gasification technology,” natural gas required for fueling the lime kiln says Pertti Lehmonen, Metsä Fibre’s Project (600 t/d capacity) with renewable, sustain- Manager. “We have a woodyard, but no able biofuel. The kiln was the remaining bark boiler at the Joutseno mill, so we have piece of production equipment running plenty of wood residuals available.” on natural gas. To this end, ANDRITZ pro- posed a complete 48 MW gasification plant And the selection of ANDRITZ as the tech- – including the biomass handling system, a nology supplier? “This mill site has lots of belt dryer, the feed system, circulating fluid- equipment from ANDRITZ and also an on- ized bed (CFB) gasifier, ash handling equip- going service contract,” Lehmonen contin- ment, auxiliary systems, and a replacement ues. “We have worked together for a long gas burner for the existing lime kiln. “This time and have very good cooperation.” was a complete delivery from the founda- tions up,” says Kari Salo, Managing Director The ANDRITZ The drive for fossil fuel-free of Carbona, specialist in the gasification 48 MW gasification “One of our company targets is to make technology. plant at Joutseno (foreground) all our mills carbon dioxide-neutral,” says includes biomass Metsä Fibre’s Vice President and Joutseno “The kiln burner is critical,” Lehmonen says. handling system, dryer, feed system, Mill Manager, Risto Joronen. “The Joutseno “We thought this might be a risk area. The CFB gasifier, ash mill was a good place to start. Similar de- product gas (biofuel) burns differently and handling, and the gas burner for the velopment is underway at our other three is delivered in higher volumes than natural lime kiln (back- mills in Finland.” gas.” After start-up, Lehmonen says that ground to left). the burner has performed quite well and Metsä Fibre is no stranger to bioenergy. there are no worries about its continued It accounts for approximately one-fifth of performance. “That was one risk that never all wood-derived electricity generated in materialized,” he says. Finland. As for the gasifier itself, Metsä Fibre was “The motivation for doing this is both envi- convinced that the ANDRITZ Carbona tech- ronmental and economic,” says Lehmonen. nology was not a risk. “Although it is the “We replaced natural gas with green energy critical item in the plant in terms of pro- from a very low-cost fuel source. It was a duction, we were quite comfortable with smart move for us now, but will appear even ANDRITZ’s experience and knowledge,” smarter when energy prices rise in the future.” says Joronen. 8 Metsä Fibre Metsä Fibre 9

The other big question at the beginning was The motivation is sulfur oxides (SOx ) is easily accomplished how the non-process elements (NPEs) in both environmental without adding post-combustion cleaning the gasifier gas would affect lime quality equipment. ANDRITZ CFB gasifiers have or the entire chemical recovery loop. “The and economic. We replaced been in operation since the 1980’s. The chemicals in a modern mill, including in- natural gas with a low-cost technology has been upgraded over the organics, are recirculated over and over,” green fuel.” years to satisfy today’s demands for reli- Joronen explains. “These inorganics could ability and efficiency. Pertti Lehmonen build up and cause a dead load in the sys- Project Manager tem. We didn’t know for sure if the small Metsä Fibre The biomass fuel at Joutseno is a com- proportions of ash formed during gasifica- bination of pine, spruce, and birch bark. tion would cause us problems.” tures, and residual carbonates are almost Moisture content averages about 50% identical. (maximum 60%). ANDRITZ delivered a According to Lehmonen, this risk also has complete biomass handling and conveying been quite manageable. “Our lime is a The gasification plant system, including the fuel receiving pocket, slightly different color now,” he says, “but Circulating Fluidized Bed is a state-of-the bark screen, and conveying system to the the quality is the same. For the NPEs, we art technology for the partial combustion of gasifier, as well as the feeding system to Inside the CFB gasifier, which operates at about 750-800° C. The biomass is a combination of pine, spruce, and birch bark. just open up the loop a bit and everything fuels of differing qualities (such as woody the gasifier. The feed system conveys fuel The large duct on the left feeds air to the gasifier. ANDRITZ delivered a complete biomass handling and conveying system. seems to be in balance.” biomass). The gasifier operates at about to the dryer at a rate of roughly 22 t/h. This 750-800° C. The turbulent intermixing in equates to 175,000 t/a of bark. In fact, if you look at charts showing opera- the fluidized bed compensates for fuel qual- tions before and after (natural gas vs. gas- ity fluctuations, accommodating low-grade The bark is dried in a belt dryer from of biomass. The heat sources for the dryer One of our targets is Targets met ifier gas) there is virtually no change in lime fuels with variable moisture and ash content. ANDRITZ, with an evaporation/drying rate are hot water (waste water from the mill’s to make all our mills “This is a new kind of fuel for our lime kiln kiln operations. Production rates, tempera- The management of nitric oxides (NOx ) and of 12 t/h. Drying increases the calorific value processes) and also low-pressure steam and there are new things to learn about from the mill. Wet biomass enters the dryer carbon dioxide-neutral.” maximizing the secondary heat from our and is fed uniformly across the 8 m wide Risto Joronen bleaching line,” Joronen says. “We didn’t Wet biomass is dried in a belt dryer from ANDRITZ, with an evaporation/drying belt. Drying air is heated indirectly to about Vice President and Mill Manager have much experience about these things. rate of 12 t/h. Drying increases the heating value of the biomass fuel. Metsä Fibre 95° C in heat exchangers arranged above But we are fast learners!” the dryer belt. The warm air flows gently through the biomass without displacing it According to Joronen, the new gasification from the belt, and absorbs its moisture. plant improves the efficiency of renewable Moisture is reduced from the 50% level to energy usage and further improves environ- about 15% in the dryer. This equates to a mental performance. “Joutseno is the first fuel feed of about 11 t/h to the gasifier. carbon dioxide-neutral facility in Finland during normal operations,” he says. Develop and optimize The plant was started up in 2012 and some Lehmonen lists the technical targets that modifications were made to the bark feed- have been met: replacing fossil fuels, using ing system of the belt dryer. According to cheap biomass residue for fuel, controlling Joronen, the mill has been relying solely on NPEs in the biogas, keeping kiln capacity the gasification plant to fuel the lime kiln for at its high level, improving the kiln’s flame the last six or seven months. radiation and heat transfer, and keeping re- sidual carbonate low, etc. Lehmonen says that the modifications in dryer bark feeding and particle size have Heikki Valtokari, Sales Manager, ANDRITZ Wood “And on the environmental level, we can Processing improved the plant operation. The main say that we are reducing CO2 emissions by challenge now is to improve the utilization It seems that the small things are important, about 200 t/d, or 72,000 tonnes per year. of secondary heat in the bark dryer. “We can according to Salo. “The bark handling and On top of that, we are realizing a short pay- improve our economics considerably by us- processing is critical,” he says. “We have back time on the investment.” ing more of the hot water from the bleach made adjustments to optimize the particle plant instead of the more costly LP steam,” size, feed rates, and some other things to CONTACT Kari Salo he says. get the maximum performance.” [email protected] 10 Metsä Fibre Metsä Fibre 11

The distinctive orange color of polysulfide liquor. Conventional cooking liquor is white.

Markku Lankinen, ANDRITZ Sales Manager for tions are not expensive to implement, but white liquor plant (left), with Risto Joronen, Joutseno Joutseno sees Mill Manager, in front of the MOXY reactor in the are critical.” polysulfide cooking preparation plant.

Johan Engström, ANDRITZ R&D Manager for The poly process cooking technology, oversaw the modifications to Markku Lankinen, ANDRITZ Sales Manager Joutseno’s digester to take full advantage of the benefits of polysulfide cooking liquor. for white liquor plant, explains that the MOXY process converts the sodium sulfide in conventional white liquor into sodium polysulfide with some sodium thiosulfate polysulfide – forming the characteristic orange liquor. “But before this step,” he says, “the white liquor is filtered to the highest possible de- gree by a polishing filter to prevent prema- cooking ture fouling of the catalyst.” Metsä Fibre’s Joutseno mill in Finland started up the The polished white liquor is pumped to the top of the MOXY reactor, where com- world’s largest single polysulfide cooking line. The pressed air is also introduced. The mixture technology for the preparation of polysulfide cooking of air and white liquor is blown through liquor, and the digester modifications to take advantage activated carbon catalyst. The catalyst is of it, were delivered by ANDRITZ. Polysulfide cooking collaboration and a shared target,” he says. arranged in layers, designed to prevent helps us deliver a “But in development work, where we are formation of channels. The catalyst is also trying something unique, it is absolutely surface-treated with Teflon to make it water ccording to Metsä Fibre’s Vice The polysulfide pulp that has real benefits critical. We benefit from the give-and-take repellent and to lengthen its life. “Joutseno cooking plant President and Joutseno Mill delivered by for papermakers.” and sharing of knowledge.” can control its process to obtain just the Manager Risto Joronen, who was ANDRITZ is the right level of polysulfide,” Lankinen says. A Risto Joronen largest in the world. Vice President and Mill Manager also the Project Director for this develop- It is a relatively More than a simple scale-up Metsä Fibre ment with ANDRITZ, the use of polysulfide compact layout. The Joutseno mill, capable of producing As orange liquor is pumped from the reac- Shown here are cooking liquor enables his mill to improve the polishing filter, about 2,000 t/d, is the largest single soft- tor, it passes through an air separator before pulp qualities that offer a real benefit to MOXY reactor, and new focus on increasing fiber yield of soft- wood line in the world. By volume, the poly arriving at a storage tank. The polysulfide papermakers. storage tanks. woods, and overcoming bottlenecks in the plant at Joutseno is almost three times reacts with carbohydrates in the wood at recovery cycle without major capital invest- bigger than any other plant ANDRITZ has the beginning of the cooking process to sta- “Since we started polysulfide cooking, our ments, is causing mills to take a new look.” delivered. “Scaling up presented us with bilize them against alkaline decomposition. customers are noticing a reduction in spe- some challenges,” says Johan Engström, cific energy required to refine our pulp and Not traditional R&D Manager for cooking technology at Running well they are seeing some enhancements in fiber “This was not a traditional mill-supplier proj- ANDRITZ. “It wasn’t just a factor of making “The project implementation was quite bonding,” Joronen says. “The bonding im- ect,” Joronen says. “It is a high-profile proj- the physical size of the vessels and piping good,” Joronen says. “We kept the time provement is due to the retention of certain ect for us because it impacts pulp quality. bigger. There is considerable science and schedule, starting up in May of this year. hemicellulose materials in the pulp.” From white to orange so the idea is not new.” In 1973, Mead Our people have been studying this for sev- process expertise involved.” The MOXY process started up perfectly. Polysulfide cooking stabilizes and pre- Corporation introduced a white liquor oxi- eral years. About one year ago, we decided We produce 9,000 m3/d with an excellent For its own part, Joutseno has increased serves the carbohydrates (hemicelluloses) dation process (MOXY process) in which to implement it at Joutseno. We collabo- The effectiveness of polysulfide liquor is level of polysulfide. There were a few small fiber yield, which reduced the solids in the in wood. This improves yield. The most ob- sodium sulfide was converted into polysul- rated on process development and have dependent on the concentration, tempera- adjustments on the digester after start-up, black liquor, which in turn reduced the load vious difference in polysulfide cooking liquor fide with the help of an active catalyst (coal) been full partners with ANDRITZ. This kind ture, retention time, and where it is intro- but nothing significant. We can report that on the recovery boiler. Like many mills, is its unique orange color. and air. of collaboration is very important to us.” duced into the cooking process, Engström we lost almost zero pulp during the start- Joutseno is recovery-limited. So, this is a explains. “Since polysulfide cooking can be up. The digester is running very well now big benefit. “The increase in yield and over- “Polysulfide cooking has been around for Mäkelä explains that while the process is Mäkelä can cite several examples of how performed at lower impregnation tempera- at full speed.” all pulp production makes the investment many years,” says Mika Mäkelä, ANDRITZ proven, it has not been used that often. “We this type of relationship is beneficial to both tures, we modified the Joutseno digester in polysulfide economically beneficial,” Project Manager. “The first patent for poly- delivered plants in past years to Canada, partners. “In almost any project, we face by adding heat exchangers and altering the CONTACT Fiber Technology Division Joronen says. sulfide pulp cooking was granted in 1943, Japan, and other countries,” he says. “A challenges that are best resolved with close cooking liquor circulations. The modifica- [email protected] 12 Eldorado Brasil Celulose S.A. Eldorado Brasil Celulose S.A. 13

A start-up starts up... n December 2012, Eldorado Brasil inau- gurated the biggest single pulp line mill I(1.5 million tonnes) near Três Lagoas, Mato Grosso do Sul state. Total investment in forests, plant, and infrastructure was more than US$ 3 billion.

As President and CEO José Carlos Grubisich views it (see side story on page 17), while the first line propels the company to being the fifth largest producer of bleached hardwood pulp, it is only the beginning. “We designed this site to support three lines in parallel, pro- BIGYou would think that the people at Eldorado Brasil. ducing roughly five million tonnes of pulp per would stop and take a breather. This start-up company year,” he says. (formed in late 2009) just built a new mill on an empty plot of land and started up the world’s largest pulping ANDRITZ delivered the woodyard (three chipping lines), the fiberline (digester, wash- line (which has already produced over 1 million tonnes ing, screening, and bleaching), the two-ma- of prime quality pulp). But, work is underway to secure chine pulp drying plant with baling lines, and an environmental permit for a second line – which at two the white liquor plant. Plus, the IDEAS pro- million tonnes per year will be roughly 30% larger than cess simulator and web-based training tools, which the project team called “a great benefit the first. for fast start-ups.” 14 Eldorado Brasil Celulose S.A. Eldorado Brasil Celulose S.A. 15

View of the massive Eldorado mill from the woodyard. The new 360-degree Stacker-Reclaimer is in the foreground. ANDRITZ delivered the two-machine pulp drying plant with automated baling lines.

The right time of nominal capacity for several weeks while smiling. “We have not lost one tonne of pulp pany went bankrupt in the middle of the Timing, according to Eldorado Industrial work was being performed on the stacker- due to the plant. It is not a bottleneck, it project),” Neto says, “but they were able to and Technical Director Carlos Monteiro, reclaimer. There was no chip storage. I’ve does not cause environmental problems, keep the schedule with very few problems was excellent. “New pulp projects were fro- Our timing was never seen this level of sustained output and it does not require special attention. during erection. We are very satisfied.T his zen during the economic crisis,” he says. excellent. Pulp from a woodyard.” That means it is running quite well.” huge kiln (the largest in the world) is running “We felt if we could move quickly, we could pricing is good and the with no problems.” get good pricing from suppliers and start up Pulp quality – excellent Pasquale Neto, Eldorado’s General Project before other announced lines.” devaluation of the Real The fiberline features the world’s largest Manager for Recovery/Power, evaluates the According to Alfredo Cunningham, against the US dollar is Lo-Solids digester and a DD Washer based project. “ANDRITZ had considerable chal- ANDRITZ Brasil’s Project Manager for the Guilherme Araujo, Mill Manager, adds, “In in our favor. This puts us bleach plant. “We are very pleased with the lenges with the civil contractor (the com- white liquor plant, there is one other kiln of the last year, mill closures took about 1.2 in a good position.” quality of the pulp and the stability of the million tonnes of pulp from the market. fiberline,” Monteiro says. “Last month, we Pulp pricing is good, and the devaluation Guilherme Araujo produced 100% top quality and, in fact, set Mill Manager of the Brazilian Real against the US dollar Eldorado Brasil a record for the fastest achievement of qual- has worked to our favor. This puts us in a ity – 43 days to reach 95% top quality on a good position to satisfy our debt obligations 30-day moving average. Our daily produc- and achieve a good payback on the overall tion record so far is 4,752 admt.” investment.” second line. According to Araujo, 100% of because we found that our wood density is Carlos Monteiro, Eldorado’s Industrial Eldorado’s forests have received certifica- not what we predicted it would be,” Araujo ANDRITZ is adjusting some of the lines at and Technical Director The right place tion and are in compliance with FSC (Forest says. “But there has been no problem sup- the top circulation of the digester to re- (front center) and his team planning the In terms of logistics, Eldorado is well po- Stewardship Council) norms. plying the fiberline.” duce vibration. “Keep in mind this digester second line. Left to right sitioned. “About 50% of our production is HUGE,” says Newton Kozak, ANDRITZ around him: Pasquale Neto, João Carlos moves by train and the other 50% by river A forest technology center is being built in The ANDRITZ woodyard has three chipping Brasil’s Project Manager for the fiberline. Tonelli, Gilson Martins, barge and train,” Araujo says. “The barges the Três Lagoas area. “We want to increase lines with log loading decks and horizontally “The chip pumps are large and the impact and José Carlos Kling. come back loaded with purchased wood, our fiber productivity,” Araujo says, “and will fed HHQ-Chippers, gyratory chip screens, of any air in the system is magnified due to so this is very cost efficient.” use biotechnology to develop clones that and a large stacker-reclaimer system that the size. But all the problems are manage- are more dense so that less land area is provides a consistent flow of chips to the able. We used the experience from other Forest resources are close by. Plantings be- required. Our goal is to get about 55% yield massive digester. “There initially were projects to make modifications during erec- gan in 2006 and Araujo estimates that it cur- in the digester.” some problems with the stacker-reclaimer,” tion so disruptions have been minimal.” rently takes about 150,000 ha to support Araujo says, “but these have been resolved. the mill (25,000 ha per year with a six-year Well-operating woodyard The three chipping lines are perfect – they Almost forgotten – the white liquor plant growth cycle). The company is planting over “We had some concerns with whether the run well. As an example, we fed the digester “We almost forget about the white liquor 50,000 ha per year in anticipation of the woodyard would be of sufficient capacity directly from the chipping lines at 70-90% plant – which is a compliment,” Araujo says 16 Eldorado Brasil Celulose S.A. Eldorado Brasil Celulose S.A. 17

this size (165 m length and 5.5 m diam- cer game where everyone runs around in a eter) now under construction. “This how- tight group chasing the ball. My job is to get ever is the first that we have delivered with people to stay in position and pass to one five bearing supports,” Cunningham says. another. That is what we are doing now – Other technology in the white liquor plant positioning people in the right jobs.” is the LimeGreen filter (green liquor filter), the LimeWhite white liquor filter, and the “Our team goal was to produce 4,237 LimeDry system to wash and dry lime mud, admt/d on a 30-day moving average,” Interview with improving heat consumption in the LimeKiln Monteiro says. “We achieved that in August. and reducing emissions. With ANDRITZ’s continued support and a few small modifications, I expect we can get Kid’s football to 1.65 million tonnes per year.” José Carlos Araujo says that the start-up was a time of high excitement, high activity, and long With that, Monteiro pauses to reflect – hours. “My job during a start-up is kind of something he has not had the luxury of do- Grubisich, like being a soccer coach,” he says. “With ing for the last couple of years. “Think about all the new operators, it was like a kid’s soc- it,” he says. “This began as an empty site President and CEO of Eldorado Brasil near Três Lagoas in March 2010. I joined Our goal was to the company in January of that year, and in produce 4,237 t/d on about two years we built the world’s largest Are there any advantages to being a Are there best practices from other in- we think we can increase the capacity of able to attract very skilled, competent, and pulping line. It started up on schedule in newcomer in this business? dustries you can bring to the pulping this line by about 15% during our shutdown committed people to our company. Our a 30-day moving average. December 2012 and we are planning the “There are certain advantages to being a industry? in 2014 with only minor investments (to 1.7 project was implemented on time, below We achieved that. I fully next one. Not bad!” ‘newcomer.’ The Pulp & Paper industry is “My experience is in the chemical and ener- million tonnes). And we are already prepar- budget, and has started up well. On an expect we can do better.” a very competent and robust industry. By gy industries. Coming from this background ing to get the environmental licenses for a annual basis, we are already producing nature, it is capital intensive with very low I see opportunities to introduce best prac- second production line which will produce about 1.45 million tonnes a year with close Carlos Monteiro CONTACT returns, and has a strong, conservative tices relating to health, safety, and the envi- two million tonnes per year, and we plan to to 100% export quality. We have received Industrial and Technical Director Luis Bordini Eldorado Brasil [email protected] culture with preconceived paradigms and ronment. While the chemical industry deals bring this on-stream in 2017. Last year, we very good feedback from our customers. conclusions. In general, the global industry with complex, and potentially dangerous, started an aggressive planting program for does not have a strong pattern of product materials, the focus on safety is comple- this second line. We also think there will be The second line will allow us to take ad- development, the technology evolves in mentary to what I have seen in the pulping additional demand in the market to justify a vantage of the infrastructure we have al- marginal steps, and there have been no ma- industry. third production line in 2020 or 2021. That ready built and will allow us to reduce our jor innovations in the setup of the industrial is a clear vision and strategy we have for the investment cost. This will make it an even footprint or in market approach. The market orientation of other industries end of this decade. more competitive project when we take – getting closer to customers – can be ap- advantage of the synergies. If we continue When you approach as a newcomer – with plied here as well. There are opportunities to attract the best brains and spirit to our new eyes and new ideas – you may be able also to streamline the supply chain so that company, we will be well prepared for the to address issues in a new way. And, you is has more of a ‘pull’ effect, rather than the When you approach future. Alfredo Cunningham, ANDRITZ white liquor may be able to find new opportunities. ‘push’ we traditionally see.” as a newcomer, you plant project man- We chose the best available technology ager (left) and Murilo may be able to address Sanches da Silva, One major opportunity for Eldorado is our What are your plans for growth? issues in a new way. for this mill. ANDRITZ is one of the most Eldorado Recovery forestry operations. This is an area that can “I have a very positive view of this sector. well-regarded technology suppliers in the Island Superintendent, in front of the lime kiln, benefit greatly from technology and inno- The pulp market is growing globally and And, you may be able industry with its experience and financial one of the largest in the vation. We need new varieties of eucalyp- will keep growing as disposable income to find new opportunities.” strength. And I think ANDRITZ has been world. tus with higher cellulose content per cubic increases in high-population countries. José Carlos Grubisich able, with our own team, to execute the meter; we need more mechanization in Consumers of disposable paper prod- President and CEO project according to what we agreed at the planting and harvesting; and we need more ucts rarely go back to more traditional Eldorado Brasil beginning. The decision to have ANDRITZ sustainable, competitive operations. This products. as a partner will lead us to maximum asset knowledge will help Brazil be an even more optimization and operational excellence as competitive platform for pulp, panelboard, Eldorado has a very ambitious growth We have had a very good experience with we move to becoming the lowest cost pro- and lumber.” strategy. We just started up one line and this first line. Even as a newcomer, we were ducer in the world.” 18 Stora Enso Biomaterials Stora Enso Biomaterials 19

Focus on evaporators The evaporation plant (or in the case of looked at was to replace the evaporators,” Sunila, TWO evaporation plants) is a logi- says Jarmo Rinne, Development Director at cal place to look for improvements, says Sunila. “However, this would have been a Kari Nikunen, Sunila’s Production Manager, very costly solution.” because it handles a considerable volume of water, and the secondary condensates Which brings us to ANDRITZ and the impor- from evaporation contributed about 20% of tance of good timing. the mill’s COD load. Timing was excellent (Left to right): One evaporation line was installed in 1972; According to Nikunen, “While we were Kari Nikunen, Production Manager; the other (from ANDRITZ) in 1983. The older analyzing the best solutions for the COD Jukka Peltonen, line did not have modern condensate seg- loading issue, we had a meeting with Reijo Project Manager; Reijo Korhonen, regating and stripping capabilities, so the Korhonen and his colleagues on another ANDRITZ; and condensate, laden with methanol (MeOH) topic. “We mentioned our COD challenge Otto Greis, ANDRITZ in front of Duct Stripper and sulphur compounds, was not useful. to him and he told us about a product they equipment. “We tried to use it in the bleach plant,” were developing, the Duct Stripper.” Nikunen says, “but the odor was too in- tense, indicating a high level of volatile or- Korhonen told about the first installation of ganic compounds.” the Duct Stripper at Metsä Fibre’s Joutseno mill. “Joutseno was a retrofit installation as So, all of the condensates at Sunila were well,” Korhonen says. “Their goal was to re- fed to the effluent treatment system for duce fresh water consumption by purifying processing, contributing to the volume and lower quality condensate (B-condensate) COD loading problems. “One scenario we so it could be used as process water.” Taking the load off Stora Enso’s Sunila mill reduces effluent COD load, conserves water, and taps “free” energy with this unique evaporator feature.

new and patented development Manager for Evaporation. “The Duct Stripper fluent treatment plant and wanted to lower from ANDRITZ, the Duct Stripper, is designed for evaporators with segregative the COD load and water volume going A helps the Sunila mill in Finland cut lamellas – the type used in ANDRITZ evapo- into the plant. We did not have a specific the water volume and COD loading to its rators which separate cleaner condensate evaporator project in mind, but were look- effluent treatment plant impressively. The from concentrated streams,” he says. ing at all kinds of scenarios for reducing purified condensates are used as process COD.” water in the fiberline. Green energy, created This new development came at exactly the from the stripped methanol, now burned right time for the good people at the Sunila COD (chemical oxygen demand) is one in the dedicated NCG burner, is an added mill in Finland. Jukka Peltonen, Project indication of water quality in that it mea- bonus. Engineer and Stora Enso’s manager for this sures the amount of organic compounds We did not have a specific evaporator The Duct Stripper came to our atten- unique project, explains. in the water leaving a mill. In Finland and The Duct Stripper can add a highly effec- most other countries, COD limits are rou- project in mind, but were looking at all tion at the right time. It is an effective tive weapon to any pulp mill’s arsenal for “Environmental compliance and good stew- tinely tightened by authorities. “We like to be kinds of scenarios for reducing COD.” and relatively low-cost solution for us.” solving effluent challenges, according to ardship drive us to continually reduce our ahead of the trend,” Peltonen says. “Plus, Jukka Peltonen Kari Nikunen Reijo Korhonen, Director of Development emissions and effluent,” Peltonen says. “We we want to have a margin for error in case Project Engineer Production Manager for ANDRITZ Services and Product Group were getting close to the limits on our ef- there is a process disturbance.” Stora Enso Biomaterials, Sunila Mill Stora Enso Biomaterials, Sunila Mill 20 Stora Enso Biomaterials Stora Enso Biomaterials 21

As Rinne says, “The more ANDRITZ told us, the more it sounded like a good fit for us. We knew that this would be a development project and that we might encounter prob- lems. Especially since we have two evapo- I am now seeing ration plants and high condensate volumes. the advantages But still, the concept was good – and the of the Duct Stripper timing was excellent!” providing an additional,

The Duct Stripper concept free fuel source for us. Otto Greis, a Process Development Engi- It helps us save money.”

neer at ANDRITZ specializing in evapora- Kari Nikunen tion systems, gives an overview of the Duct Production Manager Stripper technology. Stora Enso Biomaterials, Sunila Mill A birds-eye view of the ANDRITZ evaporator line (in the foreground) that contains the Duct Stripper. “The Duct Stripper collects secondary con- densates and sprays them into a secondary vapor duct in the evaporator train,” Greis According to Greis, only minor modifica- it didn’t work – we could always switch it explains. “The volatile organics are stripped tions are required to the evaporator. “But off. Plus, we have worked with ANDRITZ by the vapor flow in the duct. Mills that have there are major advantages in terms of for many years and we know each other.” (Left to right): Nikunen and Peltonen of Stora Enso with Korhonen and Greis of ANDRITZ in front of Duct installed it are experiencing a 60-85% re- methanol and COD recovery – and fresh Stripper equipment that has been added to the ANDRITZ evaporator line installed in the mill in 1983. Benefits of the duction in such compounds in the vapor water consumption,” he says. According to Greis, “We had to study how Duct Stripper duct. The stripped compounds and vent best to handle these condensates. It was gases are handled in the conventional way Let’s do it! not as simple as taking one condensate The methanol, sulphur, and other volatile effluent flow from the evaporators by about For one mill, the most important issue and can be used as a substitute fuel for Greis and his colleagues studied the Sunila stream from one evaporator and putting it organic compounds which are removed in 60%, with a methanol flow reduction of is to reduce the environmental load. the lime kiln or recovery boiler. The clean process and felt that the Duct Stripper through the Duct Stripper.” the vapor at these three locations are routed about 75%. This corresponds to a savings For another mill, it is to reduce fresh condensate, which is heated in the vapor could help. “We made some preliminary inside the evaporator’s lamellas and treated of about 5.5 m3 of fresh water per tonne water usage by optimizing the reuse of duct (from 60-90° C), can be used for pulp calculations about how much the COD The main work was performed while the separately. The methanol is recovered and of pulp. condensates. For another, it is to re- washing, recausticizing, or as make-up wa- load could be reduced and felt that it would evaporation plants were in full operation. used as a fuel in the NCG boiler. duce energy costs. The patented Duct ter for white liquor production. It is a simple be worthwhile to proceed,” Nikunen says. Then the tie-ins were made during the mill’s “By the end of this year, we hope to reduce Stripper helps with any – and all – of and flexible solution.” “There were no big technical risks for us if annual shutdown (October). “When we first did the project, we were fresh water consumption even further, these issues. mostly concerned with the COD loading,” hopefully to 7.2 m3/t,” Nikunen says. “After The ANDRITZ solution takes the A-conden- Nikunen says. “Now I am really seeing the the start-up in January 2012, we found Optimal condensate quality and vol- sates from both evaporation plants to the advantages of the Duct Stripper providing some limits with the condensate separa- ume from the evaporation plant has bleach plant. This now makes up about 30- an additional, free fuel source for us. It helps tors. At our next shutdown, we will make millwide benefits: 35% of the water used in the bleach plant, us save money.” small adjustments that will enable us to replacing an equal amount of fresh water. collect the maximum amount of the clean less overall effluent volume

Clean conden- The B-condensates from both evaporation Good work – more to do condensate at all three positions, so we get lower fresh water consumption sate from the Duct plants, plus some dirty condensate from “We now see that the methanol and sulphur the full benefit of this technology.” lower water treatment costs Stripper makes up most of the water the cooking plant, are collected in a feed- compounds have been transferred to the for brownstock ing tank and sprayed at three places in the foul condensate, as it should be, and that What would Sunila have done if the Duct And energy savings are obtained by: washing. Shown are Nikunen back end of the ANDRITZ evaporator line. our A and B fractions are much cleaner,” Stripper was not yet on the market? Additional methanol as a green fuel in (foreground) and This Duct Stripper condensate is used for Peltonen says. “We routinely use these hot, the lime kiln or recovery boiler Peltonen at a wash press. brownstock washing. clean condensates in our fiberline, saving “We had some ideas how to tackle the Duct Stripper condensate is heated fresh water and energy. We have a lower COD challenge,” Nikunen says, “but luck- up economically by secondary vapor According to Rinne, “Almost all of the wa- volume of water to process in the treatment ily this Duct Stripper came to our attention ter in the wash press is now provided by plant, and there is less COD in the liquid at the right time. It is an effective and rela- The Duct Stripper is included in all new the Duct Stripper condensate. The combi- stream.” tively low-cost solution for us – and certainly ANDRITZ evaporation plants sold. It nation of A-condensate and Duct Stripper easier to implement.” is delivered as a retrofit for existing condensate has allowed us to reduce our The Duct Stripper has allowed Sunila to lamella-based multiple-effect evapo- process water intake by about 20%, which substitute clean condensate to reduce CONTACT ration plants. Reijo Korhonen is quite significant.” fresh water demand – which has reduced [email protected] 22 23

Glassine paper: Five Star’s clear advantage

uzhou Special Paper’s new facil- is glassine, a very thin, usually translucent, The Zhao family’s Five Star Group’s Wuzhou Special Paper launched an initial success has ity in Quzhou (Zhejiang Province) paper used in food services, packaging, largely been built 80,000 t/a specialty line in the fall of 2012 with glassine in China is located near its sister and other specialty products. In addition, around cup stock paper as the flagship product. ANDRITZ’s pioneering W and packaging company, Wu Xing Paper, which operates the machine produces a limited amount of grades. In 2010, the ShortFlow deaeration system, the first in China, aids three machines producing specialty prod- wallpaper base stock and blueprint grades. family made a bold decision to pioneer ucts from cup stock to packaging grades. the mill in producing this glass-like sheet. It also again with domestic Now producing over 320,000 t/a, the Zhao “Our specialties focus, with a range of prod- production of provides the flexibility required for frequent grade glassine. Zhao Yunfu, family, owner of both mills, continues to ucts and frequent grade changes, made President of the Five changes while consuming less energy and chemicals. develop as a homegrown specialty paper us an ideal candidate for the ANDRITZ Star Group (left), and his son-in-law, producer. ShortFlow deaeration system,” says Zhao Zhao Lei, General Lei, General Manager of both Wuzhou Manager, are holding samples of their new Zhao Lei, General Since launching their paper enterprise in Special Paper and Wu Xing Paper. “Flexibility Manager of Wuzhou glassine paper. At Specialty Paper (left), with 2002, the Zhao family has looked for mar- in meeting customer requirements is one of center the happy, prosperous Buddha Wu Xiaoyan, Marketing ket opportunities where growth is strong, our core goals. The compact, multi-tasking Specialist with ANDRITZ made of yew wood. China, in front of the and imported products are high. They cap- ShortFlow system helps us switch from one ANDRITZ ShortFlow tured a formidable share of the cup stock grade to another very quickly. This way we dearation system. At this mill, extreme grade business, including self-serve containers can respond fast and efficiently to a wide changes from glassine of noodle dishes found at railway stations, range of customers.” to wallpaper base stock Because we have invested in the and blueprint grades hap- small shops, and supermarkets throughout pen fast. The ANDRITZ China. The ShortFlow difference best technology, we can modify ShortFlow deaeration technology provides this Complete deaeration of stock and wire our products according to customer flexibility. More recently, the family decided to delve water is standard practice on high-speed specifications.” deeper into specialty grades: this time by paper machines, particularly those pro- producing low basis weight glassine grades ducing printing and writing grades. Air Zhao Yunfu President – with the flexibility to switch to higher weight removal, at least partially, has become in- Five Star Group specialties on short notice. So, the flagship creasingly important for other grades as product of the Wuzhou Special Paper mill well. 24 Five Star Group-Wuzhou Special Paper Five Star Group-Wuzhou Special Paper 25

We see a window of opportunity in China for glassine grades. Many of our customers now use glassine products inside of their packaging.” Papillon stock Zhao Chenjia, Finance Leader prep refiners reduce Five Star Group energy costs and gently treat the fiber to ensure desired properties in the sheet.

Even though the Five Star Group began only a decade ago, their Wu Xing operation is A complete paper machine approach system from ANDRITZ is also in Headquartered in Quzhou, Zhejiang Province, China, Five Star’s Wuzhou already a leading producer of cup stock. Shown are Zhao Lei, General Manager (left), with his place. A ModuScreen headbox screen plays an important role in deliver- Special Paper and Wu Xing Paper are located near their customer base. wife Zhao Chenjia, Finance Leader. ing stock to the new machine.

“There are many applications where com- condenser is required. Deaeration perfor- use our products inside their packaging ity to slow the passage of air. Brand lead- grade changes and less transitional paper blending system, machine screens, broke plete deaeration is not essential, such as mance can be easily adjusted to match the packages.” ers of cookies and snacks like us for these or broke, less defoaming chemicals and handling, and stock refiners. specialty and packaging grades,” says requirements of the paper machine and the reasons.” biocides are required. Energy consumption Ari Pelkiö, Chief Technology Manager for grade being produced. This fast penetration in the domestic mar- goes down, too. These are all benefits that Look for more pioneering and growth stock preparation and machine approach ket is a direct result of Five Star Group’s Short response every papermaker wants.” Looking forward to growth in glassine paper systems at ANDRITZ. “However, removal According to Jiang Weiqiang, for Fiber success in the pressure sensitive label “Critical to our ability to be competitive is sales, as well as the production of addition- of air and entrained gases in the wire water Preparation, ANDRITZ China, “The ShortFlow market. Five Star supplies this label stock quick grade changes,” says Zhao Lei. “This While Pelkiö is quick to point out that the al cup stock capacity at the mill, Wuzhou offers big benefits even for these grades. deaeration solution at Wuzhou Special to factories in China and elsewhere. “Our is challenging because our basis weights ShortFlow technology is not suitable for Special Paper is already considering instal- The ShortFlow deaeration system is an Paper simplified their ability to produce high customers have learned to expect consis- range from 30 to 80 gsm, and sometimes applications that require complete de- lation of a second machine. advanced solution for partial air removal, quality paper with minimal energy consump- tent high quality, and appreciate our ability even higher. The ShortFlow deaeration aeration (for example printing and writ- combining the functions of the white wa- tion. And, with small tank volumes. The sys- to meet their needs for short runs,” Zhao system is a principal reason for our good ing grades on large, fast machines), it is “Since we are a family, we are able to make ter silo and deaeration into one compact tem itself is compact with a small footprint. Yunfu says. “Because we have invested sheet formation no matter what the grade, beneficial for grades where partial de- important decisions quickly,” says Zhao Lei. unit.” It does not require a special mezzanine. in the best technology from stock prepa- and the flexibility we have in making quick aeration is sufficient, such as specialties “We are all in this business together, so we Only short piping runs are needed because ration through supercalendering, we can changes.” and packaging. “For Wuzhou’s machine share the credit when it’s deserved, and we The patented ShortFlow deaeration system this compact unit is placed next to the wet modify our products according to customer running at about 750 m/min and produc- accept responsibility when we don’t meet collects water from the wire and former in end.” specifications.” Being smaller and simpler by design means ing these specialty grades, it is a perfect goals. a deaeration tank, where a vacuum is ap- less flow volume, which contributes to sim- match at a much lower investment,” he plied. Water from the machine is transferred Clear potential “We see a window of opportunity in China plified operation. That is the essence of the says. “Two generations give us another advan- to the deaeration tank through transition Zhao Yunfu, President of the Five Star for glassine grades,” adds Zhao Chenjia, ShortFlow deaeration technology according tage,” concludes Zhao Yunfu. “Perhaps you pipes and enters the tank through a vacuum Group, says, “China consumes more than Finance Leader, who is the wife of Zhao Lei to Ari Pelkiö, Chief Technology Manager for Another factor in the success at Wuzhou will see even a third generation at Five Star space above the liquid in order to prevent air 100,000 tonnes of glassine paper annually, and daughter of Zhao Yunfu. “In addition to stock preparation and machine approach Special Paper is clean pulp, achieved a few years from now.” submergence. Unlike a traditional deaera- but only 50% is made domestically. We our labels, many customers can now use systems at ANDRITZ. “The smaller vol- with the stock preparation system from tor, such as the ANDRITZ Deculator, boil- have already secured a large contract with our glassine products inside of their pack- ume of deaerated water represents a huge ANDRITZ. In addition to delivering the ing point vacuum is not required. A single a leading label producer, and have locked aging. Food products especially benefit simplification compared to conventional ShortFlow deaeration system, ANDRITZ CONTACT Fiber Preparation Systems vacuum pump system is sufficient and no in business with various food brands which from glassine’s grease resistance and abil- systems,” he says. “In addition to faster provided thick stock screening, a stock [email protected] 26 Stora Enso Renewable Packaging Stora Enso Renewable Packaging 27

Wood 2012 prepares Skoghall for the future The Wood 2012 project replaced an old woodyard at this Stora

Enso mill in Sweden – improving the fiber supply and creating a Eva Reiner, Skoghall Project Manager modern, safe wood processing operation. ANDRITZ delivered the key production equipment in the woodroom.

his EUR 90 million investment mod- of the equipment was at end-of-life. Logs where a new chip screening room would ernized the fiber infrastructure at were fed to the debarking drum by an over- be constructed. In total, around 5 km of TSkoghall, one of the world’s larg- head crane. Authorities advised us that it conveyor belts were built. est manufacturers of packaging board for would have to be replaced in 2012 as it foodstuffs. It is estimated that one in six had reached the limits of safe operation.” “The relocation was definitely worth it,” paperboard packages in the world con- Reiner says. “Storage volumes of logs and taining liquid is made from paperboard Another challenge was that the capacity of chips increased dramatically, and more produced at Skoghall. In addition, the mill the old woodroom was too small and a sig- logs can be delivered directly to the mill produces CKB, a paperboard for packag- nificant amount of chips were purchased. without being reloaded at wood terminals. ing dry foodstuffs. The integrated pulp mill “Our chip supply was affected by seasonal About 45,000 m3 of wood can be stored produces 330,000 t/a of kraft and 260,000 factors,” Reiner explains. Eva Reiner and here now, corresponding to a full week’s t/a of CTMP. Stefan Marklund, production.” ANDRITZ A better location Sweden’s After the Wood 2012 investment, chip According to Reiner, by moving the wood General Service In the starting blocks Manager for capacity and quality increased, while the processing operations from a cramped lo- wood processing, “At first we looked at a two-line concept, overall operation was made more efficient. cation inside the mill to land adjacent to inspect the new but this would have had too much capacity ANDRITZ Waplans Skoghall consumes about 2.3 million m³ the mill, she and her team could create ad- debarking drum. and the investment cost would be high,” of logs and sawmill chips per year. After equate space for log receiving, chipping, The hydrostatic Reiner says. “So, we finally decided on one components in the the project, the mill’s capacity to produce storage, and conveying. drum replace rub- large debarking drum with two chippers – chips increased 40% to about 1.9 million ber tires or steel one for CTMP chips and one for kraft mill wheels. m3 per year. “A big challenge for us was finding the right chips.” location for a modern woodyard,” Reiner Equipment at end-of-life says. “It was decided to utilize some land We were running into a In order to meet the schedule for overhead It was in 2008 that the mill began plan- just north of the mill (site of a former sawmill dead end with our old crane shutdown, Skoghall would have to ning for a new wood processing facility. and a paper chemical preparation plant).” woodroom. Much of the do the tie-ins during the annual shutdown “We were running into a dead end with equipment was at end-of-life.” in November. So, backing off that date, the our old woodroom,” explains Eva Reiner, A 700 m long conveyor bridge, partially planning team determined that the project Skoghall’s Project Manager. “It was built in over water, would be required to transport Eva Reiner would need to start in the spring of 2011. Project Manager Wood 2012 1971 and modernized in stages, but much chips between the new site and the mill, Stora Enso Renewable Packaging, Skoghall Mill Skoghall received Board approval for the 28 Stora Enso Renewable Packaging Stora Enso Renewable Packaging 29

chips during a knife change on one of the is 345 m3 sub/h under bark for kraft and chippers. The chippers are provided with 265 m3 sub/h for CTMP. HQ-Plus knife systems and the mill has a knife service contract with ANDRITZ. Recently, Skoghall ordered an online Scan- Chip analyzer from ANDRITZ and is in the ANDRITZ also delivered the bark and wa- process of installing it now. According to ter handling systems for the woodroom. Marklund, “ScanChip helps operators pro- Bark is crushed with ANDRITZ BioCrusher, duce consistently high chip quality while pressed to reduce moisture, and then con- minimizing unwanted chip fractions or veyed to the mill’s biomass boiler. waste. It includes the world’s first optical chip analyzer that works online. Chip sam- Problems solved ples are taken at regular intervals. Through “This project solved a number of problems laser triangulation, the computer measures for us,” Reiner says. “First, it improved our the length, width, and thickness of each Reiner (left) and Marklund in the new fiber supply and put more of it in our direct woodroom at Skoghall. sample chip with absolute exactness. Op- control. We can handle up to three railway erators can calibrate knife chipping angles, There are two parallel HHQ-Chipper units at Skoghall – one for kraft and Reiner and Marklund talk with operators in the modern control room. one for CTMP chips. A unique switching arrangement allows logs to be easily deliveries per day instead of just one. Chip fine-tune feed rates, and determine exactly conveyed to either of the chippers depending on production needs. quality is much improved since we are now Chip quality is much when to make knife changes. This will help using state-of-the-art production equip- improved since we are Skoghall get maximum yield from their ment.” now using state-of-the-art wood raw material and improve their profit- investment in April. “We were in the starting first major project at the mill. “ANDRITZ livery includes a 60 m long PowerFeed in- production equipment.” ability.” blocks ready to go, just waiting for invest- is certainly well-known to me,” she says. feed conveyor, where the logs are sprayed Performance tests were recently com- ment approval,” Reiner says. “As soon as “The company has good technology and to wash away impurities. Hot water is used pleted. The debarking drum performed Eva Reiner CONTACT Project Manager Wood 2012 Stefan Marklund we got it, we signed contracts with suppli- has made some good improvements to in the winter time to de-ice the log surface. well in quality and capacity. The capacity Stora Enso Renewable Packaging, Skoghall Mill [email protected] ers – and they began immediately on the that basic technology over time.” Reiner work.” and her team visited the ANDRITZ refer- An ANDRITZ Waplans type debarking

ence site in Varkaus, Finland (another Stora drum (5.5 m diameter and 42 m length) With its new woodyard, Skoghall can now On time, high quality Enso mill), where they met with the mill pro- is used for debarking. This Waplans drum handle up to three railway deliveries per day instead of just one. From an implementation point of view, Rein- duction team. has a single drive and two hydrostatic sup- er is pleased with the work of ANDRITZ. port units. The hydrostatic design replaces “The erection proceeded well,” she says. Scope of the project rubber tires or steel wheels. “The drum “We had a good and open relationship with All the wood used at Skoghall comes by literally floats on water as it rotates,” say Taisto Salakka (ANDRITZ Project Manager) road or rail. Transporting wood by rail is Stefan Marklund, ANDRITZ Sweden’s Gen- and his team. The woodroom started up more economical. “The Wood 2012 proj- eral Service Manager for Wood Process- well and on time. We faced some challeng- ect gives us the opportunity to increase the ing, “with very low wear and high reliability. es together during the checkout phase, proportion of wood that comes by rail to Most of the mills in Sweden prefer this type and we have had some challenges after the mill,” Reiner says. “A significantly larger of drum design.” start-up, but ANDRITZ has been very sup- woodyard also provides logistics improve- portive. We get good support from their lo- ments that save us money.” After the debarking process (up to 6 m cal people as well.” length logs), it is a rather unique switching Log stacker trucks are now used instead arrangement where the logs can be easily The wood processing operation started up of an overhead crane. “The trucks weigh conveyed to one of two ANDRITZ HHQ- as planned in November 2012. “We cut the 80 tonnes each and can lift an entire load Chippers – one for CTMP and the other conveyors from the old woodroom and then of logs from a train or truck,” Reiner says. for kraft. “We run the CTMP chipper about started up the chip handling equipment on “Our operators are multi-disciplined and 25% of the time,” Reiner says. the mill side on November 5, 2012,” Reiner rotate jobs. They now have a new skill – says. “Then we brought the new systems stacker truck drivers!” Logs are fed horizontally into the HHQ- on this side online on November 8, 2012.” Chippers. CTMP chips are cut to a length The investment also brought a de-icing of 23 mm and kraft chips to 28 mm. The This was Reiner’s first experience work- system to the mill for the first time, with the beauty of this switchable input to the chip- ing with ANDRITZ and was, in fact, her equipment coming from ANDRITZ. The de- pers is that the mill can keep producing 30 Muda Paper Muda Paper 31

New OCC line

ANDRITZ supplied a full OCC line – from pulper to thickener – for “Satay Town” as well as the machine approach system, headbox screen, and the silo design for PM6 which produces cor- packaging rugated medium.

The fact that we are producer located upstream of a water catchment area Muda Paper is a well-known name in the Malaysian ensures that our wastewater market and has been a pioneer in producing many discharge quality is packaging grades in the region. Muda selected Standard A.” Soi Gar Lock ANDRITZ to supply a new OCC processing line Mill Manager for its Kajang mill. Muda Paper, Kajang Mill

ajang, a town just 21 km from the selecting the site of the government area ensures that our The most difficult task was to match-mark Malaysian capital of Kuala Lum- near Sungai Chua. wastewater discharge quality is Standard all the parts so that they could be properly Kpur, is known as “Satay Town,” “Paper mills require big A,” says Soi Gar Lock, Mill Manager of reinstalled. In total, 120 containers were famous among tourists and locals alike volumes of water,” says Ang Lee Yang, Muda Paper. used to ship the dismantled machine to for its skewered barbecued meat. A few Advisor to Muda Paper. “So, when our Malaysia. townships have been developed in Kajang, Chairman visited this site, his first priority The Kajang Mill takes full advantage of the such as Sungai Chua, where Muda Paper’s was to see the nearby river.” waste paper resources in nearby Kuala The impact of the US economic recession Kajang mill is located. Lumpur. The waste paper supply is able to also slowed the installation of PM6 at its The presence of a 2.5 acre pond further provide the raw material for PM6. Prior to new home. During the recession, Muda Muda Paper started its presence in Penang influenced the decision to build the mill the installation of PM6, the mill consumed Paper’s sales dropped by 30%. Installation in 1964 and is considered a Malaysian pio- near Kajang. Using a channel and gravity about 500,000 tonnes of waste paper ev- of PM6 began in late 2009. The process neer producer of various paper grades such to flow water into the mill, it lowered costs ery year. was completed in December 2010. The as testliner, corrugated medium, laminated and promoted energy efficiency at the be- start-up began the following year and pro- chipboard, coreboard, grey chipboard, yel- ginning. Later, the pond was filled in with PM6 – From Wales to Kajang duction has been going since. low wrapping paper, insertion paper, manila dirt and now the building for PM6 is on top Coming from a small town in Wales, PM6 paper, and machine-finished kraft paper. of it. was previously owned by the St. Regis A team from Muda Paper evaluated po- Ang Lee Yan, Advisor to Muda Paper Group. It was connected to a pulp mill op- tential suppliers. “We put ANDRITZ on our Soi Gar Lock, Mill Manager at Muda Paper The merger of the two mills, Tasek and With the environment in mind, the man- eration, so it would have to be reconfigured shortlist because they had very good refer- Kajang, six years ago formed Muda Pa- agement of the Kajang Mill has ensured for the production of Muda Paper’s pack- ences, especially in China,” Mr. Soi says. per. With a recently installed second-hand The Kajang Mill that the quality of water discharges from aging grades. The machine was purchased “Initially, we had an opinion of ANDRITZ as The situation changed after ANDRITZ Chi- machine (PM6) at the Kajang mill, the pro- Tan Sri Lim Guan Teik, Chairman of Muda the mill meets the highest standard, with at the end of 2007. However, the disman- being high-ranking and high-priced. Many na was established and began to build up duction capacity of Muda Paper is now Holding, played an important role in deter- an investment of RM 30-40 million (EUR tling was put on hold for five months until years ago they proposed some modifica- capabilities. A positive factor, according 500,000 tonnes per year, 300,000 of which mining the location of Kajang mill. He and 7-9 million) spent on treatment of waste- the end of the winter season in Wales. In tions for us, but at that time our suppliers to Mr. Soi, was the quality of ANDRITZ’s comes from the Kajang mill. his team surveyed several locations before water. “The fact that our mill is upstream June 2008, the dismantling of PM6 began. were mainly from Japan and Taiwan.” proposal and the cost structure permitted 32 Muda Paper 33

Soi Gar Lock, by delivering some of the key equipment Mill Manager (left), from China. The appointment of a local and Huo Xianzhao, Sales Manager for sales agent, Ro-Quip Engineering, also ANDRITZ China, in- convinced Muda Paper to take a new look spect the corrugat- ing board produced at ANDRITZ. on PM6. Keeping The OCC project with ANDRITZ ANDRITZ supplied a full OCC line – from pulper to disc filter – to process furnish for the production of corrugated medium. it simple. ANDRITZ also delivered the machine ap- proach system, headbox screen, and the silo design for PM6.

The capacity of the LOCC (local old cor- Making it rugated containers), AOCC (American old corrugated containers), and MW (mixed waste) line is 600 admt/d. The furnish is dedicated to PM6, running at 650 m/min profitable. with a basis weight range of 105-180 gsm.

The pulping is accomplished with an ANDRITZ has been very responsive. To enable this cartonboard producer to increase ANDRITZ FiberSolve pulper. Following the Any problem we encounter, they are production of containerboard, ANDRITZ pulper is a high-density cleaner plant (Ahl- ready and able to help.” retrofitted a Twin Wire Press and supplied new Cleaners) to remove coarse contaminants, Ang Lee Yang, Muda Paper Advisor drying cylinders. The retrofits were not complex, followed by a coarse screening plant (Modu- Screen units). A ModuScreen is also used but exceptionally effective. for fiber fractionation and then the stock is fed into a low-consistency cleaner plant start-up, Mr. Ang was impressed with the ANDRITZ succeeded in installing the OCC ANDRITZ replaced more than 30 cast iron dryer before fine screening and thickening in an responsiveness of the local organization. line in the shortest possible time with a very cylinders with new steel ones to increase the ANDRITZ disc filter. Rejects are dewatered, “The local agent provides us good support smooth start-up, and the usual ANDRITZ throughput of PM4. while the clean stock is fed into a Modu- and service,” explains Mr. Ang. “And also quality. An important element of the start- Screen headbox screen before entering very fast response because this is always up was the training of the mill’s operators he Varel mill is located in the north- of testliner, fluting, and white-top, Varel’s “We make it a point to periodically improve PM6. important.” and maintenance people to maintain the western corner of Lower Saxony management decided to invest in a ca- our key machines to obtain the newest quality and minimize wear. Tin Germany. It is one of the largest pacity expansion of PM4, a 5.10 m wide technological advantages and increase The start-up went smoothly and was on Mr. Ang was particularly impressed when paper and board producing facilities in machine producing a wide range of gram- our output and quality,” Wollschläger says. time. On October 22, 2010, the pulper ANDRITZ China hand-delivered some The relationship between Muda Paper and Europe – using recycled fiber to produce mages (100 to 200 g/m2). “This helps us extend the life, and the eco- began operation. Within one-half hour, the spare parts needed for the project. “In ad- ANDRITZ for this project was one of ef- 850,000 t/a of paper and board on its four nomic return, on our existing equipment.” rejects handling system was activated. dition to reliable equipment,” he says, “one ficient supplier and satisfied customer. It production lines. Uwe Wollschläger, one of the four manag- Stock was being fed to the storage tower important consideration is long-term ser- is like the situation of a satay seller and a ing directors of the mill, and his colleagues Working within constraints in a matter of hours that same day. PM6 vice. ANDRITZ has been very responsive. satisfied diner who comes back again for Even with this high level of output, mill sought advice from ANDRITZ and what The project scope around PM4 included began operation with stock from the new Any problem we encounter, they are ready more delicious skewered barbecued meat management was eager to increase pro- could be upgraded to increase throughput of expanding the amount of pulp available OCC plant on the wire on October 28, and able to help.” which has made Kajang famous among lo- duction of testliner and white-top liner. PM4. ANDRITZ had been a supplier of tech- (by eliminating bottlenecks in the dewa- 2010. cals and foreign tourists. ANDRITZ assisted in the expansion. nology and services to Varel for many years, tering process) and extending the drying Future collaboration delivering a Twin Wire Press for dewatering capacity of the machine. Like virtually any Good support Happy with the stock preparation technol- Market-driven recycled fiber in the stock preparation plant retrofit and upgrade project, the work at In addition to the support and training ogy and ANDRITZ China’s service, Mr. Soi CONTACT Based on marketing studies showing in- in 1987, as well as screens, screen baskets, Varel would be constrained by space and Fiber Preparation Systems from ANDRITZ during commissioning and hinted at future collaboration. For its part, [email protected] creased demand for the higher grades and refiner plates on a regular basis. time. 34 Papier- und Kartonfabrik Varel Papier- und Kartonfabrik Varel 35

According to Oliver Kern, Varel’s Produc- tion,” Laatz says. “Older presses have a tion Manager: “We have been happy with rigid wedge zone where the inlet and out- Extended drying capacity the Twin Wire Press as it has been operat- let gaps are fixed. We have an innovation “With PM4 now upgraded, we see about ing well for many years. While we needed for this which is standard on new press- approx. 40% capacity increase,” Kern to increase throughput from approximately es, but can also be retrofitted to existing says. “We expect to be able to go even fur- 220,000 to 300,000 tonnes, we also need- ones.” (Left to right): ther when we see the right signals in the Karsten Laatz, ed to maintain the outlet dryness of at least ANDRITZ’s Service market.” 30%.” That innovation is called a Floating Wedge. Sales Manager for Germany; Hartmut Laatz explains: “In our design, the bot- Langner, Varel’s Replacement of more than 30 of PM4’s The other potential complication, accord- tom part of the wedge is fixed and the top Paper Production cast iron dryer cylinders with new steel Manager; Oliver ing to Kern, was that the drying capacity part is separated from the machine frame Kern, Varel’s ones manufactured by ANDRITZ – together expansion on PM4 would be constrained so that it can self-adjust to the pulp mat. Production with the addition of more cylinders – led to Manager; and by the location of other downstream ma- At the outlet end, the top wedge virtually Georg-Michael a considerable improvement in throughput chinery. “We were not going to move our floats on the mat. This allows smooth, fine Sautter, ANDRITZ’s and efficiency of the machine. Director of Sales slitter rewinder operation,” he says. “So the adjustments of the inlet gap and the dewa- for paper and space limit for machine extension was no tering pressure.” board machines in According to Georg-Michael Sautter, Di- front of the newly more than 15 meters.” rebuilt drying sec- rector of Sales for ANDRITZ’s paper and Variations in the flow or consistency of the tion of PM4. board machine business, the cylinders Dewatering upgrade We make it a point to pulp feed are compensated to increase were custom-designed to fit the Varel ma- ANDRITZ had a ready solution for expand- throughput, consistency, and process sta- chine. “Due to the special design of our ing the capacity of the old Twin Wire Press periodically upgrade bility. This helps increase the effectiveness manufactured steel cylinders, compared to while maintaining the high outlet dryness our machines to obtain the of the disperging system. the old cast iron ones, Varel can now use required. According to Karsten Laatz, newest technology.” the width of the cylinder surface to create a ANDRITZ’s service sales manager for Ger- According to Ewald Kulhanek, Product uniform drying profile across the sheet, es- many, “One key to increasing capacity in Uwe Wollschläger Manager for wire machines at ANDRITZ, pecially at the edges,” Sautter says. “These Managing Director an older press is to modify the wedge sec- Papier- und Kartonfabrik Varel the drive roll system was also upgraded. cylinders have a high-performance design “Usually, the outlet dryness of the press will Seamless installation to increase drying rates without increasing drop as production of the machine is in- “It is a simple solution, but one that has energy consumption.” ANDRITZ rebuilt Varel’s Twin Wire Press which was installed in 1987 to increase capacity from approximately 220,000 creased,” he says. “The drive load required worked perfectly for us,” comments Hart- to 300,000 tonnes while maintaining the desired outlet dryness. This included an upgrade to a Floating Wedge design, for increased production rates will be high- mut Langner, Paper Production Manager Sautter explains that steel is a better heat rebuild of the drive roll press nip, a new wire regulation system, and re-cladding of all the press rolls. er, making it impossible to transmit enough at Varel. “We got the results that we ex- conductor than cast iron (5-7% improve- torque by the angle of wire wraps only. The pected, and in the time required. Good ment). “Fewer steel cylinders are required wires will start to slip.” communications and good cooperation than cast cylinders to achieve the same with ANDRITZ helped us work seamlessly.” drying capacity,” he says. This was a real So, ANDRITZ´s solution was to rebuild the advantage for the PM4 project, since existing drive roll to a drive roll press nip Service and upgrade work on the Twin Wire space was limited. Then, too, there is the system. Nipped drive rolls create a stron- Press was completed in June 2012. “ANDRITZ safety issue. Even the smallest crack in a ger grip on the wire which, in turn, increas- did virtually all the work on-site, with the cast iron unit can be potentially dangerous es outlet dryness due to the additional exception of the re-cladding and grooving due to the explosion tendency of cast. The high-performance nip. of the rolls,” Langner explains. “The actual elasticity of steel is a major safety factor.” time for the rebuild was about one week. Actually, the entire drive system was im- The work was completed without delays.” “The ANDRITZ upgrades to our Twin Wire proved. Each drive roll is now driven by its Press and the upgraded drying cylinders own gearbox, motor, and frequency con- “We are now getting considerably in- are simple and effective,” Kern says. “It is troller. The master drive is speed-controlled creased production, precisely along the amazing to think sometimes just how much from the production rate setpoint and con- lines we originally demanded,” Kern points keeping it simple really works.” trol of the slave drives is synchronized. In out. “We are seeing greater efficiency in the addition, the upgrade included the addition disperger following the upgraded press. of a new wire regulation system and the The filtrate from the press is very constant

re-cladding of all press rolls with stainless and stable, so the processes utilizing this CONTACT steel. Three of the press rolls were grooved filtrate as dilution water have improved. Karsten Laatz, Service [email protected] to handle the higher filtrate quantities cre- ANDRITZ’s innovations are performing just Georg-Michael Sautter, Sales, Paper & Board Machines ated by higher production. as expected.” [email protected] 36 SFT Group SFT Group 37

A reincarnation in Russian packaging The SFT Group and ANDRITZ have completed a remarkable project together. They took on a major challenge of dismantling a graphic paper machine in Finland, transporting it, and reincarnating it as a packaging machine in Russia.

PM originally came from Finland, where it produced machine-glazed kraft paper. ANDRITZ integrated parts of the old machine, including The SFT Group produces 460,000 t/a of paper and board and 460 million m2 of corrugated packaging. It is vertically integrated from recovered paper collection to converting. sections that required refurbishing and upgrading, with its own paper machine technology to deliver a state-of-the art packaging machine.

s soon as you enter the gates of the Working towards this goal, Roman Stein- SFT Group’s Kamenskaya paper berg, Director for Investments for the SFT Amill midway between Moscow and Group, explains the latest project. “We St. Petersburg, you come to the realization We needed more needed more capacity, but a brand new that this is no ordinary manufacturing site. capacity, but a brand machine was out of the question due to the This mill has been through a huge amount new machine was out of capital required,” he says. “So we kept a of change. The signs and relics around the close eye on the secondhand market, and the question due to the Left to right: Raisa mill speak of a very colorful past. The mill eventually a shuttered graphic paper ma- Zaikova, Kamenskaya started in 1799 as a writing paper plant capital required.” chine in Finland came to our attention.” Paper Mill; Karl Eickhoff and Klemens and has been bought and sold a number of Roman Steinberg Unger, ANDRITZ; and times. Once it was lost as part of a gamble. Director for Investments The machine came from UPM’s Kymi mill, Roman Steinberg, SFT Group SFT Group; check It was even completely dismantled, moved, where it produced machine-glazed kraft pa- the formation of the and re-erected in the Ural Mountains. per. With a trim width of 4.6 m and speed finished product. of 1,050 m/min, the machine seemed to Stability arrived when the SFT Group be the perfect choice for the SFT Group’s bought the mill in 2003. The Group cur- expansion requirements. The decision was rently produces 460,000 t/a of paper and consumers, and more consumption means fibers used in containerboard production – made to purchase what was to become board, and 460 million m2 of corrugated more packaging.” the quality of the raw material is excellent. PM7 at Kamenskaya. packaging. Stepan Khomyakov, CEO of the SFT Group, says: “Our Group is focused To meet this growing need, the SFT Group’s Stability doesn’t mean standing still ANDRITZ was chosen as the company that on the packaging business – vertically in- products are used for packaging every- The SFT Group has high ambitions: to pro- would be instrumental in handling the com- tegrated with wastepaper collection, mills, thing from food to televisions. Because the duce some 700,000 tonnes of paper and plex project. Says Steinberg, “We chose and converting facilities. It is a challeng- Russian recovered paper market is under- board and 800 million m2 of corrugated ANDRITZ because we had a successful ing business, but a good business. Russia developed – with a collection rate of only packaging annually by 2018, which will association with the company, and they is becoming more and more a country of 5% per household and a high ratio of virgin make in number one in Russia. were capable of taking the whole project 38 SFT Group SFT Group 39

from dismantling in Finland to erection and optimizing in Russia, and everything in between.” We were told by “We needed a master plan” a consultant that ANDRITZ received the order in June 2011 this project would take a and soon afterwards dismantling of the minimum of three years. machine began. But, this was no ordinary dismantling, according to Klemens Unger, Together with ANDRITZ, we Lead Project Manager for ANDRITZ. “Not completed it in 23 months.” ANDRITZ also delivered a new recycled fiber only did the thousands of parts from this Raisa Zaikova processing line and machine approach system with 1970’s machine have to be painstakingly Executive Director a capacity of 800 t/d to bring high-quality stock to PM7’s new headbox. catalogued and marked for re-assembly,” Kamenskaya Paper Mill Unger explains, “but all the parts needed to be checked and overhauled quickly to keep the very tight time schedule.” shut down for five years, there were quite a rent technology from ANDRITZ with refur- few parts that needed rework.” bished and upgraded sections from the Karl Eickhoff, Senior Vice President, old machine. “It was not just a matter of Second Hand Solutions, and a key player The transportation of the machine to its new putting old and new together,” Eickhoff in the project explains: “For a complex proj- home in Russia took place in November and explains. ect like this, we developed an overall master December of 2011. The logistics required Left to right: Sergey Semyonov, Kamenskaya Paper Mill Technical Maintenance Manager; Mikhail Kozlov, plan document where we basically broke 280 containers and 20 specially adapted “The UPM machine contained equipment Kamenskaya Paper Mill Production Manager; Roman Steinberg, SFT Group Director for Investments; Raisa Zaikova, the machine down into functional sections, trucks for the two-day journey. After the from Metso, Voith, Honeywell, and others,” Kamenskaya Paper Mill Executive Director; Karl Eickhoff, ANDRITZ; and Klemens Unger, ANDRITZ, in front of PM7. and then analyzed each part to make sure civil work, which included the dismantling explains Unger. “It was our challenge to It was a challenge to integrate parts from various suppliers with ANDRITZ paper machine technology. we could salvage as much as possible from of two old paper machines, installation of integrate parts from these various suppli- ANDRITZ delivered a new recycled fiber “ANDRITZ Automation’s control systems the old machine. The goal was to save the PM7 started in May 2012. ers with our own ANDRITZ paper machine processing line with a capacity of 800 t/d of have contributed to our quality improve- SFT Group as much money and time as technology. But the result speaks for itself.” 20% mixed waste and 80% OCC. ANDRITZ ment,” says Steinberg. “We can control the possible, while still getting the parts ready Turbo-boosting and future-proofing also installed a new machine approach quality more easily. This is not only notice- in time for installation.” To help establish the Kamenskaya mill as a In the press section, a PrimePress X shoe system, including three-stage headbox able to our customers, but to our competi- world class packaging producer, ANDRITZ press was installed to obtain maximum screening, a save-all disc filter, and under- tors as well. We are seeing signs that they Overhaul of the old machine began in added its own technology to turbo-boost dryness and improve sheet properties. machine pulpers. want to follow us down this route, and al- August 2011 in Finland. “In the case of this the production line. The machine was built More improvement in drying comes with ready they are offering special deals. This machine,” says Eickhoff, “since it had been up to state-of-the-art by integrating cur- an extension of the original dryer section, Commissioning of the machine began in project shows that the SFT Group is having adding new and refurbished dryers, and March of this year, and the first paper was a major influence on the market.” installing a PrimeRun web stabilization sys- on the reel June 11, 2013. tem. ANDRITZ also upgraded the winding Working together – we create the future ANDRITZ Automation integrated existing and new features into its DCS and QCS systems. diameter up to 2.7 m and automated the roll “We are already influencing Before this project, the Kamenskaya mill transportation and reel spool return. the Russian market” was rarely visited by others from around Raisa Zaikova, Executive Director of the the world, and English was mostly unrecog- Russia is There was also some future-proofing in- Kamenskaya Paper Mill, says: “This was a nized. Steinberg explains, “With ANDRITZ becoming more corporated into the wire section of the ma- very big project for us, but it was one of involved, the many meetings about the of challenges but both teams were com- and more a country chine. Since the SFT Group’s plan is to pro- the biggest of its kind for ANDRITZ as well. project were a new arrangement for us. mitted and both shared a common vision.” duce a two-ply liner, ANDRITZ lengthened In terms of the timeline, we are completely ANDRITZ was patient with us, sharing their of consumers, and more the dewatering area of the wire to allow for delighted. We were told by a Finnish consul- knowledge. We reached a common under- It seems the project can be summed up with consumption means the addition of a top layer forming unit in tant that this project would take a minimum standing. I can’t say that the team speaks the SFT Group’s own mission statement: more packaging.” the future. of three years. Together with ANDRITZ, we English now, but they can communicate well “Working together – we create the future.” completed it in 23 months. We are delighted with the assistance of Google Translator!” Stepan Khomyakov CEO The end result, according to Eickhoff, is with the quality, and so are our customers. SFT Group a state-of-the-art system. “Not only the We are not yet up to the design speed 1,050 “This was not just an equipment supply packaging paper machine itself, but the m/min, but we know that ANDRITZ will help deal,” Unger remarks. “A true spirit of part- CONTACT Paper and Board Machines entire line,” he says. As part of the project, us achieve that in the near future.” nership was a common goal. Yes, it was full [email protected] 40 Holmen Group Holmen Group 41

he drive to Iggesund Paperboard’s showcase examples of manufacturing petitive market to be in. Environmental ex- Workington Mill, part of the Swedish valuable products in the greenest and cellence and sustainability have become THolmen Group, takes you through leanest way possible. And underneath the increasingly important to the buyers of some of England’s most dramatic and nat- gleaming mill façade is the centerpiece of such board products. ural scenery – mountains, lakes, and spar- Workington’s own “green power show” – a kling streams flowing down to the coast of new biomass boiler supplied by ANDRITZ. Ola Schultz-Eklund, who has been Man- the Irish Sea. Situated on the edge of the aging Director of the Workington Mill for 12 county of Cumbria – the “Lake District” as Luxury board years, has overseen many of the changes it is more popularly known – the Workington Over the years, Workington has developed that have taken place at the mill. “Making Mill sits right in the middle of what can only a reputation for satisfying the higher end paper and board in the modern world is a be described as a “green power show.” of the luxury board market. In fact, some tough business,” Schultz-Eklund says. “You Wind turbines dot the shoreline, generating of its top-of-the-range bright white boards have to be lean to survive – even when you power for energy giant E.ON. Renewable are used for the glitzy celebratory side of are in a niche business like we are. We have energy is very big around here. life – including the packaging of choco- continually invested in product quality while lates and champagne or example – under making sure we are as lean as possible. In Iggesund’s Paperboard’s mill with its brand its Incada brand. Important to supplying that space of time, we have become the new woodyard may look to the uninitiated this market is the ability to produce good benchmark for quality and printability in the just like any other big new factory. However, solid boxboard with the potential to print, boxboard market.” In March 2013, Iggesund Paperboard’s new biomass to those in the know, this is one of Britain’s foil block, and emboss. It is a highly com- boiler came online with the result that the mill is now virtually fossil fuel-free. The bubbling fluidized bed boiler and complete woodyard were delivered by ANDRITZ. 42 Holmen Group Holmen Group 43

Anna-Maija Harju, ANDRITZ Product Engineer for power systems Our competitiveness The right strategy was being affected The Holmen Group decided in 2011 to by poor power and steam boost the efficiency and profitability at Workington by investing in a new biomass output. Now we are energy power boiler. The boiler would not only self-sufficient, even reduce the amount of purchased energy, exporting to the grid.” making the mill self-sufficient with self- Ola Schultz-Eklund generated green energy, it would allow the Managing Director company to participate in the UK govern- Workington Mill ment’s program where green energy pro- ducers can sell their Renewable Obligation Certificates (ROCs) to companies which continue to use fossil fuel. Says Schultz- Eklund, “There is no doubt that this project was the right strategy for the future of this mill. It would make us more sustainable, more efficient, more profitable – and would open up new revenue streams.”

In March of that year, the Board approved the investment. By early April, the contract (Left to right): Mikko Hänninen, ANDRITZ Boiler Commissioning Engineer; Manne Koskinen, ANDRITZ delivered the biomass receiving and handling system as part of Manne Koskinen, ANDRITZ Woodyard Technician, talks for PB 195 was in place with ANDRITZ. The ANDRITZ Woodyard Technician; Timo Nieminen, Workington’s Power Plant Manager; the project. This included a chipping line for logs and a crushing line for wood with an operator as they observe wood chips being fed to the and Ville Virtanen, ANDRITZ Commissioning Engineer in the boiler house. waste. The A-frame building in the background stores 20,000 m3 of biomass. BFB boiler. design called for a fuel input of 147.5 MW. The Workington Mill uses around 800,000 t/a of wood, mostly from In terms of steam flow, the boiler would Scotland and northern England. produce 195 t/h on wood-based biomass and 98 t/h with natural gas. Steam pressure ceiving and handling system. This included No option for delays the project for me, the way that Spanish, the retraining in the art of power and steam self-sufficient in terms of energy – and that was targeted for 102 (a) at a temperature all the equipment for receiving and storing The plan was to allow 24 months for the Polish, Swedish, and Finnish technicians generation. “This project has been an amaz- by doing so, they have cut carbon emis- of 540° C. biomass fuel up to a capacity of 1,000 m3/h complete project from demolition of exist- – at one time 400 contractors – worked ing experience for me,” says Williams. “We sions by more than 190,000 t/a. Or, as they as well as all the conveying equipment to ing buildings to start-up. Crucially there alongside the British mill team, and very watched as the boiler was built, then fired like to tell customers, “We cut our annual The ANDRITZ version of Bubbling Fluidized supply the boiler. Part of this delivery was was a strict deadline – the new boiler had impressively got the job done.” up. It was incredible to see how the suppli- emissions by 60,000 automobiles a year.” Bed technology was chosen specifically for the installation of a horizontally fed HHQ- to be synchronized to the national grid by ers sped up towards the end to make the the Workington mill as it had the flexibility Chipper for chipping logs, and a horizontally February 15, 2013. The pressure was re- The first gas firing of the ANDRITZ boiler start-up deadline. The learning curve for us Schultz-Eklund concludes: “This project to deal with the variety of biomass available fed crushing line for other wood wastes. ally on. took place on December 22, 2012. This has been steep and fast, but the ANDRITZ has had some immense challenges, but in the mill – recycled sawmill chips, bark, The storage facility delivered by ANDRITZ was followed by the first solid fuel firing team has been great in helping us move up ultimately we went from a situation where effluent cake, and washings. is an A-frame structure with a capacity of “There was quite a lot of work to be done on February 1, 2013. “But the really good the curve. They are very knowledgeable and our competitiveness was being affected by 20,000 m3 of biomass. before the installation could begin, as we day came on February 15, 2013 when we professional.” really poor power and steam output to a Anna-Maija Harju, ANDRITZ Product had to decommission one of our board ma- synchronized to the grid and reached our situation where we are self-sufficient and Engineer, says: “Our BFB boiler technol- The A-frame building is an essential ingre- chines, remove it, and demolish the build- goal,” Nieminen says. “We were completely Have the targets been hit? “Absolutely!” ex- even exporting power to the national grid.” ogy fits perfectly for Iggesund Paperboard dient in the whole mill operation as it helps ing to make way for the power plant,” says operational and producing power in April, claims Nieminen. “We use the same amount because of its versatility in firing different regulate the moisture content in the wood Timo Nieminen, Workington’s Power Plant and took over the boiler from ANDRITZ on of energy in production that we used a year Clearly, Iggesund Workington is the bright- biomass fuels and sludges. The design in a range of 37-57% depending on the ma- Manager. “Then there were foundations to May 15th.” ago, but now it all comes from renewable est star in the Cumbria area’s “green power maintains combustion and evens out fluc- terials. The mill at Workington uses around pour and construction of all the housing for sources. Our team has achieved great show.” tuations caused by varying fuel qualities. 800,000 t/a of wood, a combination of saw- the new boiler.” Throwing down challenges things. The boiler availability has been near The technology is very environmentally mill chips, roundwood, energy crops, and The Holmen Group, it seems, likes giving 100% since we took it over. With the con- friendly, with emissions that are below, and other biomass, mostly from Scotland and As Nieminen recalls, there was a sudden challenges to its employees as well as its tinued support of our supplier partners, we sometimes far below, EU, domestic, and lo- northern England. flurry of activity around the mill as the dead- suppliers. Instead of importing a group of intend to keep uptime high.” cal regulations.” line began to loom in the distance. “A whole biomass energy experts to run the new From the A-frame, the chipped and crushed host of different nationalities began arriving power plant, Holmen selected team mem- The Workington Mill management and work As a follow-on in May, ANDRITZ received the biomass is transferred into two holding silos to concentrate on their part of the project,” bers from the Workington Mill. This included force make it abundantly clear that they are CONTACT Seppo Hulkkonen order from Workington for the biomass re- before entering the boiler. he says. “This was a really intriguing part of Bill Williams, Lead Technician, who enjoyed extremely proud of the mill being entirely [email protected] Service is more than having the right tools ... it is also about having the right people

Specialized tools are important, replacement parts to comprehensive but having the right service peo- maintenance programs – helps pro- ple is even more crucial. Our peo- tect and extend the life of your equip- ple are skilled at raising the produc- ment and lower your lifecycle costs. tion efficiency of your mill. We help The right tools – the right people. you maintain, repair, and upgrade Good reasons that ANDRITZ should your assets. Our expertise – from be your service partner.

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