FiberSpectrum Issue 15 - No.1/2007 The Magazine of Andritz Pulp&Paper

“This money pipe was a present to us from the bank during our groundbreaking. It’s a reminder to keep on schedule so we could turn the valve and start the flow of money.” Riia Ratnik, CFO of Estonian Cell

Winning the world’s respect at Estonian Cell – Page 4 FiberSpectrum A message from Andritz Pulp & Paper Management The Magazine of Andritz Pulp & Paper “Bernhard Rebernik − a visionary man helping ideas take shape” Contents On April 1, 2007, Bernhard Rebernik, who “vendor.” We know that every project in have more time to spend with family, use had been Member of the Managing Board every mill has its unique challenges. It is my season opera tickets, brush up my of Andritz since 1991, retired on reaching our job to understand what is important to Italian, and go on ski mountain tours. But, 3 Management message age 65. When he took over responsibility different customers in different regions. I do not plan on disappearing from Andritz for Andritz’s Pulp & Paper business completely. I have agreed to serve as a 25 years ago, the position of Andritz being This successful development of Andritz’s consultant to Andritz, working on certain 4 Winning the world’s respect a well-recognized global supplier of com- pulp and paper activities was to a great projects and staying in touch with certain Estonian Cell is showcase for latest BCTMP technology plete systems was only a vision. extent the result of Bernhard Rebernik’s customers and partners. steady efforts and ability to build a good When Bernhard became head of team. I would like to take this opportunity It gives me particular pleasure to see 10 A refined approach to rebuilds Pulp & Paper Technology, Andritz had to express my appreciation to him and for my younger colleagues develop and Rebuilds and upgrades keep productivity high at Augusta Newsprint very few products it could call its own. his achievements for Andritz. thrive. I congratulate Karl Hornhofer The majority were licensed, or purchased (Capital Equipment) and Humbert Köfler and resold. Our vision was to expand (Service) on their appointments as new 14 Upgrading a mill step-by-step globally by providing the best technology, board members responsible for the Pulp complete production lines, and compre- and Paper Business Area. Both were Carefully crafted master plan for eliminating bottlenecks at Zellstoff Pöls hensive services at a fair price. Products members of my team, and I hold them in had to be developed and capabilities very high esteem. Please extend the good 20 SC-A Plus puts Summa on top acquired to put all the pieces in place. cooperation and trust to our younger man- Wolfgang Leitner agement team. Competition fosters major grade change at Stora Enso’s Summa mill So Bernhard took our few “star” products (President & CEO) (twin wire press, etc.) into the global With many thanks and kind regards, market. Through acquisitions, we added “My first love was – and still is – 24 Being a good neighbor well-known names such as Sprout-Bauer, the excitement of learning.” Suzano’s location is driving force for odor reduction technology Kone Wood, Durametal, Hymac, Ahlstrom Machinery, ABB Fläkt Industries, Fiedler, With retiring comes a sense of ac- and Küsters. Step-by-step we were able complishment for all that our team Bernhard Rebernik 28 News from the world of Andritz to reach our vision of being a supplier has achieved together, and a sense of (Member of the Managing Board, retired) “from wood to paper.” gratitude for having met so many brilliant, committed, and fascinating people in the The acquisition of Ahlstrom Machinery global Pulp & Paper community. FiberSpectrum is published by: in 2000/2001 was an important step that added chemical pulping, and recycled I am grateful that through our many Andritz AG fiber capabilities. From then on, Bernhard customers/partners we have been able Stattegger Strasse 18 Contributing Writers: and Markku Hänninen expanded upon to develop technologies that achieve A-8045 Graz, Austria Jens Kellersmann Tel: +43 316 6902 0 Robert Puhr Andritz’s position as a reliable supplier of the highest capacities, fastest machine [email protected] complete production systems for all types speeds, lowest energy consumption, Contributing Photographers: of pulp and certain grades of paper. lowest chemical consumption, Managing Editor: Croce & Wir and most advanced automa- Gudrun Schaffer Dieter Brasch Several key orders confirmed our strategy tion in the industry. Many of [email protected] Riku Isohella was correct. The ones that come to mind you took the risks and the Robert Puhr Editor: are Aracruz Fiberline C, Veracel, CMPC, extra effort with us – helping Robert Puhr Graphic Design: Botnia in Uruguay, Estonian Cell, us push the envelope for the [email protected] Gudrun Schaffer Marusumi in Japan, TAD tissue machines entire industry. [email protected] in the USA, seven modern tissue ma- Editorial Team: chines in China, new deinking technology, The work years have Petra Binder Pirjo Nousjoki and the most energy-efficient mechanical passed quickly. It has been Bjørn Hansen Mia Passi Minna Heinonen Olavi Pomoell pulping systems in the world. These or- a pleasure to be part of this Alice Jeloschek Harri Soila ders showed that customers accepted our challenging industry. Thank Jens Kellersmann Manuela Wagner approach on a world-class level. you for so many years of Sara Koller good cooperation and excel- Today, Andritz can bring considerable lent personal relationships. You will see the use of both “tonnes” and “tons” in this publication: tonnes for metric units resources from under one roof to each and tons for American units. Unless otherwise noted, metric units are used. customer’s unique situation. This means I have now retired from day- Copyright © Andritz AG 2007. All rights reserved. it can be a “partner” instead of just a to-day management. Now I will No part of this publication may be reproduced without permission of the publisher.

2 AS Estonian Cell | FiberSpectrum 15 – 01/2007

◄ The Andritz RotaBarker™ in the woodyard is a new innovation. It is especially suited for debarking frozen logs in a dry process without costly de-icing. No water is used in the process. the world’s respect Winning Wood losses are minimal.

Though heavily forested, Estonia is not known as a producer of pulp and paper. The people at AS Estonian Cell wish to change all that. Their new BCTMP mill is a highlight of industrial development in Estonia. It is among the most modern in the world – showcasing several new innovations from Andritz – and holds itself to very high environmental standards.

Remember the first time you ever set turn – an infectious gift from your host northeast Estonia, just a short distance foot inside a mill? Whether you were a and tour leader, Lauri Raid, Production from the Baltic Sea. youngster, or a young university gradu- Manager of AS Estonian Cell. ate, or an adult – you were no doubt fascinated by the sights. Perhaps There is no doubt that Raid loves what Major investment you were intimidated by the massive he does. “When I was studying pulp moving machinery, and in awe of the and paper at the university, I dreamt of The € 153 million investment by hard-working people who operated the a time when there might be a greenfield Austria’s Heinzel Holding, Norway’s complex equipment. There was so mill in Estonia,” Raid says. “I didn’t Larvik Cell, and the European Bank for much to learn, and so much to master! really think it would really happen, Reconstruction and Development is the though. You can imagine how happy second-largest direct foreign invest- Walking through this greenfield I was when this project was an- ment in Estonia. bleached chemi-thermo mechanical nounced!” pulp (BCTMP) mill in Kunda, Estonia The owners selected RWE Industrie- brings those same feelings to the sur- The “project” that Raid is referring to Lösungen of Germany, now a division face again – the newness and the ex- is the Estonian Cell mill designed to of MAN Ferrostaal, as the turnkey citement are reflected in the eyes of the produce 140,000 t/a of hardwood mar- contractor in April 2004. ▲ About 50% of Estonia is forested. Estonian Cell utilizes 100% aspen fiber to ▲ Joe Masella, Project Director for KSH Solutions (left), and Peter workers. Enthusiasm awaits at every ket pulp. AS Estonian Cell is located in produce its high-quality bleached chem-thermo mechanical market pulp. Masloch, Deputy Project Director for RWE Industrie-Lösungen (now part of MAN Ferrostaal).

“The idea was to have a turnkey con- the General Site Manager, with overall Aspen (populus tremula) accounts for Estonian Cell is a showcase for Andritz’s P-RCTM APMP technology. The process produces pulp with high quality mechanical and optical characteristics while reducing energy consumption. Lauri Raid, Production tractor with full responsibility, one major responsibility for the site activities. The 7.3% of the nation’s wood volume. Manager at Estonian Cell, in front of the mainline refiners (Andritz S2070 series) at the mill. ▼ supplier for technology, and somebody Andritz team, including wood process- Roar Paulsrud, one of the owners of else to handle the balance of the plant ing experts from Finland, drying experts Estonian Cell, developed the idea (water, effluent, power, etc.),” says from Austria and Sweden, and mechan- of establishing an aspen pulp mill in Heinz Günther Grollman, a Vice Presi- ical pulping experts from Austria, came 1999 as he bought aspen from Esto- dent with RWE. to Kunda in May 2005. “It was like nia through his Norwegian company, running a small company,” Unger says. Larvik Cell. One of Larvik’s subsidiar- According to Grollman, Andritz was “We had to build our infrastructure, hire ies is responsible for wood purchasing. involved very early in the technical dis- sub-suppliers, handle the accounting, Long-term purchase agreements are in cussions and contributed significantly and personnel.” place with the state-owned RMK and to the process design and technologies with Nor-Est Wood, a private company. employed. It was natural then that Unger certainly has the credentials Both suppliers have FSC certifica- Andritz would become the technology for the job – having been with Andritz tion. Estonian Cell’s annual demand supplier. YIT of Finland was selected for 40 years and having supervised at full capacity is 380,000 m³ of aspen to deliver the raw water and effluent projects literally around the world. pulpwood. The Andritz technology treatment facilities. KSH, a subsidiary “Even after all these years, it is very gives the mill flexibility in handling lower of RWE, was responsible for basic and exciting for me personally to help new quality wood. detail engineering, as well as delivering regions and countries develop. This is the balance of the plant. an important achievement for Estonia.” A showcase for technology Johannes Galos was the Andritz Project Director. Galos coordinated the Aspen as wood source As Project Director, Andritz’s Galos has overall project and was the primary liai- a unique overview perspective of And- son with the customer (RWE) and client Estonia is a richly forested nation. Over ritz’s technology. “It is really a source (Estonian Cell). Johann Unger was 50% of its territory is covered with forest. of pride for me to see how our technol-

4 5 AS Estonian Cell AS Estonian Cell | FiberSpectrum 15 - 01/2007

ogy can help a mill meet its challenges From the woodyard, the chips are in so many ways,” Galos says. conveyed to the main mill, which showcases Andritz’s P-RC™ APMP For example, the challenge for Esto- (Preconditioning Refiner Chemical / nian Cell is to get the maximum good Alkaline Peroxide Mechanical Pulping) quality fiber from the supply of aspen technology. According to Christian logs, says Heikki Valtokari, Andritz’s Laser, Andritz’s Project Manager for the Project Manager for the woodyard Mechanical Pulping delivery, the APMP delivery. This involves not only yield process “produces pulp with high qual- (minimum wood losses), but the ability ity mechanical and optical characteris- ▲ The two-stage flash dryer at Estonian Cell is ▲ The slab press is the largest in the world. This newly designed unit by Andritz is capable of producing to screen out off-spec wood early in the tics, with reduced energy consumption, designed for 500 t/d peak capacity. 500 admt/d. process. The line includes debarking, and easily bio-degradable effluents. chipping, screening, chip storage and There are no sulfur compounds to deal reclaim, bark, and fines handling. with.”

Valtokari explains that the wood sup- Laser walked through the main process After the pulp is dried to a dryness design capacity producing prime quality ply includes short or long logs (3 to steps: chip washing, impregnation, of about 88%, it is transported to the pulp. Acceptance occurred on Sep- 6 m), which can be frozen or unfro- HC refining, screening, reject refining, Andritz bale finishing line. The slab tember 1st and Estonian Cell took over zen. These are processed in differ- and HC bleaching before the pulp is press is a new design from Andritz. operations from the turnkey contractor ▲ Riia Ratnik, Chief Financial Officer for Estonian ent campaigns so the process can be flash-dried and baled. Andritz delivered “This was not just a matter of scaling up RWE. Cell. “Nature and the forests are so much a part of optimized. The variable speed drives all the major systems for each process an old design,” says Thomas Radauer, Estonia’s history.” installed on both the PowerFeed™ and step. Andritz’s Senior Product Manager. “We Since then, there have been a series the RotaBarker™ provide the flexibility had to completely re-think the design to of performance tests by grade, as well to process the logs with varying condi- Impregnation is done in two stages achieve high capacity.” as tests of the woodyard equipment tions. (Impressafiners and vertical twin-screw and water treatment plant, according impregnators). Mainline HC refining The result is a new press with a feed to Riia Ratnik, Chief Financial Officer The RotaBarker™ dry debarking uses two large Andritz S2070 refin- chute and pre-compaction unit on for Estonian Cell. Ratnik was the first process releases bark from the logs ers. Four screens (two primary, one top. In the pre-compaction unit, the employee hired by Estonian Cell in and immediately discharges the bark, secondary, and one reject) comprise descending pulp flocs form a mat August 2004. Johannes Galos, Andritz Project Director (left), ▼ Margus Kohava, Mill Manager, in the warehouse. preventing contact with the debarked the screening room. Rejects are coordinated the overall project. Galos is shown between two belts, while the excess air “Our customers are giving very good feedback log surface. This eliminates the need handled in an Andritz TwinFlo™ refiner. discussing production with Igor Nasimov, Drying is discharged through the belts via suc- Ratnik moved back to Estonia from her about pulp quality.” to wash the logs before chipping. The The pulp is thickened with a disc filter Line Operator at Estonian Cell. ▼ tion boxes. From the pre-compaction job as a controlling manager for a retention time of the logs in the before moving to the HC peroxide unit, the fiber mat enters the distribution German automotive supplier to be part RotaBarker™ is short compared to the bleaching system. The bleached pulp chute and then the press itself. The of the project. “When I came to the in- time needed in a conventional drum. is dewatered in a large twin wire press compressed pulp, at 88% dryness, is dustry, I thought that making pulp would and then fluffed before drying. conveyed to the baling for wrapping, ty- be simple compared to discrete manu- Debarked logs are chipped to optimum ing, stacking, and forming export units. facturing. Now I know better. It re- size in the horizontally-fed The two-stage flash drying unit, accord- quires continuous optimization. There HHQ-Chipper™, what Valtokari calls ing to Kurt Olsson, is designed for are so many variables, you sometimes “the centerpiece of the woodyard,” due 500 t/d peak capacity. Olsson is a On schedule, on budget can’t even foresee them all.” to its influence on chip quality. Bark Senior Project Manager for Andritz’s is treated in a Hooper™ bark shred- fiber drying unit in Sweden. “Flash dry- The contractual start-up date for the Ratnik and her team are using their der and is sold as bio fertilizer and/or ing is typically used for mechanical pulp mill was April 24, 2006. millwide information system to analyze biofuel. because a web of pulp would not be consumption and manufacturing costs strong enough to dry on a sheet dryer,” “The planning and construction of this to identify opportunities for improve- The chip silo stores about two days Olsson says. “The technology gets its mill were big achievements, but one ment. “One area of focus, which will be of production. Chips pass through an name from the speed with which the of the most important achievements a continuous process, is the optimiza- Andritz screen with decks for accepted pulp is dried. The pulp enters the dryer for me was the production of the first tion of costs,” she says. “At first we chips, oversize chips, and fines. The at about 48% dryness and is trans- pulp bales on March 23rd,” says Margus were concerned with making produc- portion of accepted chips fed to the silo ported by the hot air as it is being dried. Kohava, Mill Manager. tion. Now we must shift our attention to exceeds 90%. Oversize chips are sent Total time from input to output is about consumption, energy, chemicals, etc. to to the re-chipper and fines are sent one minute. The dryness at output is Another important milestone was the fine-tune our costs.” to a separate pile to be recovered as about 88%. By recirculating the air we Provisional Acceptance test. By con- biofuel. conserve energy.” tract, the mill had to run for 72 hours at

6 7 AS Estonian Cell

As part of its scope of delivery, Andritz supplied fully integrated distributed controls for the Estonia entire Estonian Cell mill. In addition, an Andritz ▲ The greenfield Estonian Cell mill is designed to ▲ Christian Laser, Andritz’s Project Manager for the BaleMatic™ system automates the pulp finishing After centuries of Danish, Swedish, produce 140,000 t/a of hardwood market pulp. Mechanical Pulping delivery. line. The systems can be monitored and German, and Russian rule, Estonia It is located in northeast Estonia, just a short supported online from a remote Andritz Automation attained independence in 1918. distance from the Baltic Sea. service center. ► It was forcibly incorporated into the Soviet Union in 1940 and regained its freedom in 1991, with the col- lapse of the Soviet Union. Since the Johann Unger, Andritz General Site Manager, was in charge of the overall site activities. “It’s like running a last Russian troops left in 1994, small business. It’s wonderful when everything comes together at the start-up!” ▼ Estonia has been free to promote economic and political ties with Estonian Cell is in a good position with “Nature and the forests are so much products than it will in the future. Western Europe. It joined both regards to energy costs, thanks to a a part of our history,” Ratnik explains. “One of the advantages of the tech- NATO and the EU in the spring of long-term agreement with the state- “Our mill design is such that the noise nology is that we can be flexible in 2004. owned Eesti Energia company, accord- level at the gate is 55 db during the day producing products that are tailored to ing to Ratnik. “Still, there are things we and 45 db at night. The average noise our customers,” he says. “However, we The forests have always played a can do to fine-tune the energy con- level in a home is 50 db. I think people have to rationalize our grade mix. We key part in Estonia’s survival. During sumption of the refiners,” she says. are surprised at how quiet this mill is.” just need to find out what gives custom- the Russian occupation, groups of ers the most benefit from our pulp.” Estonian freedom fighters (the “For- “Cost optimization requires good stabil- “It is perhaps surprising that the est Brothers”) hid in the forests for ity of production,” Ratnik says. “Many government made our permit levels years, and from these deep hide- days, we run at 90-100% of design. for water treatment stricter than most “Learning every day.” outs, raided and attacked the foreign Our target is to run at 90% for the year. Scandinavian mills,” says Kersti Luzkov, occupiers of their country. We know we can reach the target, Estonian Cell’s Technology Manager. “We wish to show the Western world but there are still days when we have “We have a complex permit which that a small country is able to build The capital city, Tallinn, was estab- operational surprises.” places limits on every hour of produc- and operate a modern mill,” Raid says. lished in 1154 amidst the pagan tion.” Luzkov oversees the company’s “When the world finds out we can lifestyle and rituals that pervaded “The first year, we have been able to four laboratories (water, wood, analyti- produce a high-quality product in an en- the area. One of the world’s oldest show positive financial results,” the cal, and pulp labs) that monitor quality vironmentally friendly way, and create universities, the University of Tartu, CFO explains. “Two of our owners are and environmental impact. “We built an jobs, we hope they will respect what we was started in Estonia in 1632. very experienced in the pulp and paper 11 km pipeline from our effluent plant to are doing here.” Wooden buildings of this period were business, which is a big help to us. They the Baltic Sea,” she says. “The last sawn from the rich Estonian forests. understand what it takes to succeed.” 2.5 km is under the sea. The fresh wa- “This greenfield mill has been a major A short time later in 1664, a Swed- ter demand per tonne of pulp is about accomplishment,” Kohava adds. “The ish company built the first pulp and 14 m3. To my knowledge, these figures project was well-managed. It met all paper mill in Estonia, once again A respect for nature are very low.” the agreed time schedules and costs. taking advantage of the vast forests It started up as scheduled. Everything for commercial production of paper. “Estonia has very little experience and went as planned. However, when history in pulp production,” Kohava Fine-tuning grades and you build up a mill, all the small and Modern forest management may says. “We have had two very old operations separate parts need to be fine-tuned. have its roots buried in the rules chemical pulp mills in the country, and Our employees are gaining experience created over 400 years ago. It was only one is operating today. It was built The Heinzel Group handles the world- every day. We are all learning every forbidden to cut and use trees in in 1938.” wide sales and trading of Estonian day!” a zone bordering the coastline in Cell’s output. “We are getting very order to protect the land from ero- “The biggest local concern before this good feedback about our pulp quality sion of the Baltic Sea. Trees for new mill was built was that it would be from both Heinzel and our customers,” ►► find out more at boats, firewood, and buildings were similar to the old chemical pulp mill Kohava says. “But since this mill is so www.fiberspectrum.andritz.com cut from deep in the forests and near Kehra,” Raid says. “People were new, we are still developing our final transported to the shoreline villages concerned about potential pollution and products in cooperation with them.” for use. noise.” Kohava admits that Estonian Cell is making more products and different

8 Augusta Newsprint Company | FiberSpectrum 15 – 01/2007 A refined approach to rebuilds

The TMP plant at Augusta Newsprint Company was installed in 1983. Since installation, the 11 Andritz Twin™ 50 refiners have produced over six million tons of TMP and there has never been a major failure of the equipment. The mill attributes this to a methodical refiner rebuild program which it initiated with Andritz in the 1980’s. “There is too much at stake here to entrust our refiners to any other supplier,” says a maintenance supervisor.

Masters of newsprint

In addition to being home to the prestig- ious professional golfers Masters Tour- nament, Augusta, Georgia is also home to Augusta Newsprint, a joint partner- ship between Abitibi-Consolidated Inc. and the Woodbridge Company Ltd. In 2004, Abitibi-Consolidated added 2.5% to its 50% holdings to become the ma- jority owner and operator. ▲ One of four Andritz Twin™ 50 refiners in the secondary position at Augusta Newsprint. The TMP plant produces 1100 t/d for the mill’s two newsprint machines. When the mill was opened in 1966, the furnish was provided by a groundwood mill. There are two paper machines, one of 1966 vintage and the other installed during the expansion in 1983. This expansion also saw the addition of the TMP plant. One eye on the energy meter

The 1100 t/d TMP mill has four lines When ANC’s TMP plant is running wide

of refiners consisting of primary and ▼ Brian Norris, Pulp Mill Manager, says, “I want a rebuilt refiner to operate like it was new. I want the start- open, it is quite power intensive. secondary Andritz Twin 50 units each up to be trouble-free. And, I don’t want any issues at all.” “Electrical energy accounts for 23% of driven by a 12,000 horsepower 13.8 kV our production costs,” Norris says. synchronous motor. In addition there ▲ David Martin (left), Maintenance Mechanical Superintendent, with Billy Watts, Andritz’s Service Account Manager. “I’ve grown to depend upon Billy. I can call him with any question or problem and he’ll get the are three reject refiners also having One interesting aspect in the pulp mill answer for us.” 12,000 horsepower motors. The main- control room is a computer system that line refiners are pressurized (55 psi) displays real-time electricity pricing to Everything mechanical in a mill either “Andritz people know what to do,” and the reject refiners operate with alert operators. They adjust TMP pro- wears out or breaks down over time. explains David Martin, Maintenance atmospheric outlets. duction rates to minimize the average The key is knowing when to service the Mechanical Superintendent for ANC’s cost of purchased energy. equipment, who to entrust the service pulping areas. “They spend their ca- In 1989, the groundwood mill was to, and what to do during the rebuild. reers engineering and working on refin- replaced by a 90,000 t/a recycled facil- “This is critically important during the ers. They have the drawings and know ity which adds about 30% secondary utility’s peak power hours in the sum- Augusta Newsprint Company (ANC) the dimensions. They understand the fiber to the furnish. “Today, we pro- mer,” Norris says. “We don’t have has determined the when and the who. metallurgies, whether it’s safe to weld duce about 420,000 tonnes per year of that much of a inventory buffer and They rely upon Andritz experts to deter- on it or not.” standard newsprint from southern pine the newsprint machines keep running. mine the what. and recycled newspaper and maga- That’s why it’s important for us to have “The maintenance experts have a more zines,” Norris says. “The majority of all the refiners ready to run at a sec- “Based upon our experience, we detailed view,” says Brian Norris, Pulp the output is 27.7 lb. (45 g/m2) basis ond’s notice so the paper mill has the schedule a rebuild of the refiner’s Mill Manager, “but when you ask me weight. Publishers want a lighter sheet stock it needs.” rotating assemblies every third year, what I want from a rebuild, the answer so they can get more newspapers out and a rebuild of the housing, tubes, is simple. I want the refiner to operate of a tonne. This puts more pressure on “At this mill, when we need four lines to etc. every sixth year,” says David Usry, like it was new, I want the start-up to us both technically and in a productivity run full-out, we have to do it, especially Maintenance Supervisor and a 26-year be trouble-free, and I don’t want any sense.” because of the power pricing arrange- veteran of the company. issues at all.” ment,” says Martin.

10 11 Augusta Newsprint Company

Too much at stake Not just a rebuild After a few headaches, Stover and his On-going support colleagues did a cost analysis to see David Williams spent 18 years in the Ed Stover, who retired in February of how much they were saving by doing TMP plant before recently moving to this year after 24 years with the mill, rebuilds themselves. “With all the “Andritz has the experience and “When we get a rebuilt refiner back the paper machine maintenance area. has a long history of experience with logistics and transport, plus our own has always been there for us,” says from Andritz,” Martin says, “we know “I prefer maintenance over operations,” the refiners and with Andritz. “Because people’s time, we really weren’t saving Dave Williams, an Augusta mainte- it’s ready to run.” Williams says. “I’ve got grease in my I worked for Sprout at one time, I had anything,” Stover says. “From a cost nance professional. “When we have veins.” the knowledge to do refiner rebuilds,” standpoint, it was about equal to send a question, they give us the answer. Refiner rebuilds are just one of the Stover says. “So for the first four or five the units to Andritz.” They deliver what they promise.” services that Andritz performs for Williams remembers the original Twin™ years, we did the rebuilds ourselves.” Augusta Newsprint. Augusta has 50 Model 1 refiners installed at ANC. According to Stover, the logistics of When customer equipment arrives teamed with Andritz for control up- “The Model 1 had a cavity behind the managing the rebuilds became a real Good cooperation at Andritz’s rebuild facility in Muncy, grades, refiner plate improvements, plate holder for balance water. This re- burden. “I had to send my rotors to one Pennsylvania (USA), it is dismantled and upgrades of its dewatering duced the amount of hydraulic pressure place, the plate holders to a different One of the added benefits of Andritz’s and carefully inspected. The results screw presses. During the last needed, but we had problems with it. place, and the casings to still another rebuild service is having access to are compared to the latest specifica- screw press rebuild, the units were So, one of the first changes we did was location. Trying to keep track of all that, “the latest and greatest,” according to tions and reported to the customer. upgraded with replaceable wear move to the Model 2 on the mainlines. and managing the vendors to meet Stover. “Anything new they come up “Andritz people know what to do,” shoes, extending the life between The power tubes eliminate the balance their deliveries was a headache.” with, they ask us if we want to include says David Martin, Maintenance Me- rebuilds. The original solid design water, are much easier to maintain, and it in the rebuild. This way, over the chanical Superintendent. “They have screen baskets were replaced with a have really extended the machine life “The other thing that always worried years, we improved the hydraulic the drawings and know the dimen- split design to reduce maintenance between rebuilds.” ▲ David Usry, Maintenance Supervisor at Augusta, me,” he continues, “was the inter- cylinders, upgraded the ribbon feeders, says, “We have too much at stake with the rebuilds significantly improved bearing life, and sions. They understand the metallur- time and costs. to risk it. Andritz gives us good service – why go changeability of components. With 11 gies, whether it’s safe to repair or if a “Quite honestly,” he continues, “we anywhere else?” refiners, we want to match parts of one enhanced the metallurgy of the rotating component should be replaced.” “We’ve done a number of upgrades have too much at stake with the pres- refiner to another. I resisted going to discs themselves. We could not have over the years,” Martin says. “For sures and steam flows. Andritz has the other suppliers because they all done this with a third-party supplier.” Everything is done with the aim instance, we’ve worked with Andritz the experience and have always been tend to make changes to the original of returning the equipment back to upgrade the refiner plates and re- there for us. When we have a ques- design. If Andritz makes a change to “It has been really important to us to to OEM standards. Final run-off, finer controls on a regular basis. We tion, they give us the answer. When the design, they document it so that if have such a good cooperation with balancing, and hydrodynamic testing continue to look at ways to improve we have a request, they respond. They we ever need parts, they know what is Andritz,” Martin says. “I’ve grown to are performed to ensure the equip- production and control, especially if stand behind their warranties – they needed and have it readily available.” depend upon Billy Watts (Andritz Cus- ment is “production ready.” we can reduce energy consumption deliver what they promise.” tomer Service rep) as an extension of in the process.” our mill personnel.” Usry agrees. “Before moving into supervision, I was a mechanic for many “It’s true that price is a major consid- years. A machine shop can guess at eration,” Martin concludes, “but so is the dimensions and feel-fit, but Andritz knowing that what we’re buying is going has the actual drawings and the specs. to work.” Mike McLaughlin (right), Head of Andritz’s Automation group in North America, was part of the start-up From my experience with Andritz – their team when Augusta installed their refiners in 1983. Here he discusses refiner control with Mike Harrell, dependability, their turnaround times, Pulp Mill Operator at Augusta Newsprint. ▼ and their expert recommendations – ►► find out more at why go anywhere else? We’re just not www.fiberspectrum.andritz.com willing to risk it.”

◄ A technician performs a visual inspection of Augusta Newsprint’s Twin™ 50 refiner before it is rebuilt at Andritz’s Muncy, PA (USA) facility.

12 13 Zellstoff Pöls AG | FiberSpectrum 15 – 01/2007 Upgrading a mill step-by-step

“When you upgrade a mill, you have to rely heavily on your own knowledge,” says the Director of Engineering and Maintenance at the Zellstoff Pöls mill in Austria. “You also must rely on supplier- partners with excellent knowledge.” The Pöls mill is working steadily to increase pulp capacity. One of its latest investments is a white liquor plant supplied by Andritz. Record pulp production was achieved in the first month after start-up.

What do lime kilns, chip bins, slak- to 10 years. The target was to not only The old lime kiln, which was installed in ▲ Zellstoff Pöls is one of the major producers of ECF bleached softwood pulp in Central Europe. Environ- ers, high-pressure feeders, twin wire upgrade the pulp mill, but to add a large 1983, was tremendously overloaded. mental excellence is still a strong attribute. About 600 homes in the Pöls community are heated through a district heating network connected to the mill’s process systems. presses, lime mud filters, and pulp dry- paper or board machine. In 1997, it was upgraded to bring its ers have in common? capacity to about 290 t/d of lime. The One interesting aspect of the white liquor plant is the architecture of the facility itself. The exterior walls are “We did most of the studies ourselves,” price for this capacity increase was designed in a “sandwich” structure to more efficiently heat and cool the building’s interior. Walter Sommerbauer knows – and so Kreuzer says. “Our people know best short refractory life, high energy con-

do the people at Heinzel Pulp’s mill in how to run the mill and where the ob- sumption, and NOx emissions that were Pöls, Austria. stacles are in our path. We defined the pushing the limits. Pushing the capac- steps for upgrading the pulp mill to ity in the kiln also created fluctuations Sommerbauer is Andritz’s Customer 450,000 t/a, adding a board machine in in white liquor quality which caused Service Manager at the Pöls mill. As the range of 350,000 t/a, and installing problems in the cooking plant. Andritz has been a technology and a biomass power plant with 60 MW service partner with Zellstoff Pöls on a thermal load (or 20 MW electricity load).” “With this background, and with our series of projects to de-bottleneck and goals set on production of 450,000 t/a upgrade, it has been Sommerbauer’s The first step of the concept to upgrade of pulp,” Bauer says, “we decided to role to coordinate the communications the pulp mill was approved by the invest in a new larger kiln.” and make sure the customer is happy. Heinzel Group. Because of the size of the proposed expansion, the next step The investment decision was made in “We work with a variety of techni- was to do an environmental impact as- June 2005 to replace the old kiln and

cal specialists, coordinated by one sessment. This process was protracted recaust equipment. “Then we started ▼ Bernhard Bauer (left), Project Manager, with Michael Bauer, Assistant Production Manager, in front of the representative from one company,” to about two years and cost Pöls a to send our inquiries and check refer- new Andritz kiln. says Siegfried Gruber, Head of Project couple of million euros. ences for potential suppliers,” Bauer Engineering at Pöls. “We see many says. ▲ Josef Kreuzer, Director of Engineering and Maintenace. “We have a master plan for faces, but it’s all one Andritz.” “We finally received the environmental upgrading the mill step-by-step.” permit in July 2005,” Kreuzer says. Since the mill is nestled so closely to “And now each day we are moving the small community, special efforts The master plan forward.” are taken to reduce noise and the environmental impact of the mill. The “This mill has a lot of potential,” says Most of the mill’s main equipment is Pöls evaluation team visited several Josef Kreuzer as he looks out over the now sized to sustain 1300 t/d average mills, including UPM’s Wisaforest mill Zellstoff Pöls complex from his of- production, with the capacity to handle in Finland, to see Andritz’s white liquor fice window. Kreuzer came to Pöls in 10% peaks. Plans are in place to up- plant in operation. 2002 after meeting Alfred Heinzel and grade or replace the remaining equip- learning about plans for expanding the ment step-by-step. “The recovery island of Wisaforest Zellstoff Pöls mill. was very clean and very impressive,” says Michael Bauer, Assistant Produc- “Mr. Heinzel explained to me his long- Removing a big bottleneck tion Manager from Zellstoff Pöls (no term goal to become one of the largest relation to Bernhard Bauer). “One of pulp, paperboard, and paper traders “We had been increasing our pulp pro- the advantages that we saw in doing and to be a respectable market pulp and duction to the point where the biggest business with Andritz was our ability paperboard manufacturer in Europe,” bottleneck was our kiln and recausticiz- to single-source the whole white liquor Kreuzer says. “He asked me to be a ing equipment,” says Bernhard Bauer, plant from one supplier. We also liked part of the team and I gladly accepted.” Project Engineer at Pöls. Bauer was the new technology of the LMD-Filter™ the Project Manager for the new Andritz for drying lime mud. The filter has cer- The first task was to prepare a concept white liquor plant that replaced the old tain benefits in that it produces a higher for what the mill could look like in five technology. quality lime and lowers the emissions.”

14 15 Zellstoff Pöls AG

Fiberline upgrades

Zellstoff Pöls installed its continuous Initially, Pöls experienced some prob- ▲ Part of the scope of Andritz’s delivery was this CD-Filter which produces ▲ The two-stage washing capability of the LMD-Filter™ from Andritz is meet- digester in 1983. The digester had a lems with bridging between the first and excellent white liquor purity. ing the mill’s requirements for lime mud dryness and low emissions perfectly, vibrating chip bin as part of the feed- second cone sections of the silo. “The according to Michael Bauer, Assistant Production Manager. ing system. The design capacity at problems were most evident in the win- the time was 620 adt/d, according to ter time,” says Gruber. “After analysis “Originally, Andritz proposed using con- couldn’t push the schedule even though “This included all plant software and the Siegfried Gruber. we came to the conclusion with Andritz ventional filtering technology,” Michael some of the logistics were complex,” burner safety system. Soon, we hope that our silo was not tall enough.” Bauer says. “But, when we met with Bauer says. “For example, transport of that Pöls will install our BrainWave® Today, after a series of upgrades, the the specialists in Kotka, they presented the kiln shell (the longest section being adaptive and predictive controllers digester produces about 1150 adt/d. The bin was extended by 2.3 m in 2003 the idea of a two-stage LMD-Filter™ to 57 m long by 4 m diameter) required to get tighter control of the kiln. This Plans are to increase capacity even fur- and two deflector rings were installed to obtain better quality lime mud and also carefully orchestrated steps with the controller and the Kiln ACE® optimiza- ther to 1300 t/d over the next few years. control the compaction of the chips in Furnish is 70% spruce and 30% pine. the bottom of the silo for better steam reduce H2S emissions.” transport companies and authorities for tion software will help Pöls reduce their ▲ The fiberline at Pöls has been upgraded several its 2500 km journey from Finland. We energy costs and improve the lime penetration. “After this rebuild, the times over its life and currently produces about In 1997, Andritz was selected to up- silo really operated well,” Gruber says. 1150 adt/d. Andritz supplied a Diamondback® chip “As you can see, we are in the middle weren’t going to delay that.” quality even further.” silo to upgrade the feed to the digester. of a village here,” Bernhard Bauer says. grade the chip feeding system with a In 2005 the bin was extended another “We have to think carefully about emis- The kiln shell sections arrived on-site in Erection was completed at the end Diamondback® chip bin. Gruber says 2.5 m to increase capacity and a third sions from our processes.” January 2006. “There were days when of August 2006 and commissioning the old chip bin became very mainte- deflector ring was installed. Pöls has the temperature would be -20° C,” began. The first burner start occurred nance-prone due to its vibrating, mov- the first Diamondback® bin in the world “This is the first two-stage lime mud Bauer says. “And, lots of snow. Condi- in October. At Bauer’s request, Andritz ing parts. with three deflector rings. “We can have filtering system in the world,” says tions were not the best, but everyone brought its most experienced commis- a load in the silo of about 250 tonnes of Michael Bauer. “When Andritz present- did a good job.” sioning and start-up team to Pöls. The Diamondback® has no moving chips now and fill it completely.” ed the concept, we said why not try it? parts, relying instead upon gravity and Previously, we had four washing stages Due to the tight schedule and tough its unique geometry to pre-steam and for the lime mud. We developed this conditions, Andritz offered to have its White liquor party transport the chips. two-stage system together with Andritz Project Manager remain on-site at Pöls and it meets our needs perfectly.” from the first delivery in 2006. “I was “Our original plan was that we would able to better coordinate with Finland begin production in October 2006 and and with the local suppliers to ensure we were on time – so it was excellent,” A challenging schedule that we stayed on schedule,” says Erkki Bernhard Bauer says. When the first Osmonsalo, Project Manager from white liquor from the new system filled The original project plan was to com- Andritz. the white liquor tank, the team could ® plete the installation of the white liquor finally celebrate. “We had a white liq- ▲ Looking over the Diamondback chip bin system plant in 20 months. In the background, “It was the right decision to have Erkki uor party with our own version of white are Walter Sommerbauer, Andritz Customer Serv- ice Manager (left), and Siegfried Gruber, Head of Pöls had applied for revisions to its en- on-site,” Bauer says. “It’s perhaps a liquor,” Bauer laughs. “This was also Project Engineering for Pöls. vironmental permits in order to increase little unusual for the project manager very fine!” production. However, the permitting to be on-site all the time, but it really process took longer than expected. helped.” The Andritz white liquor plant is de- signed to produce 5700 m3/d of white ◄ Shown from left to right: “Due to these delays, we had only 16 In April, the instrumentation and auto- liquor for Zellstoff Pöls’ fiberline. The Front: Josef Kreuzer, Director of Engineering and months to complete the project, includ- mation equipment was installed. The kiln is designed for 440 t/d of reburned Maintenance; Walter Sommerbauer, Customer ing engineering,” Bernhard Bauer says. work was performed by the Andritz lime. Service Manger from Andritz; Michael Bauer, Assistant Production Manager; Heinz Kaiser, “We put the challenge to Andritz if they Automation group in Graz. Rudolf Product Engineer; Eduard Mayerl, Assistant would be able to complete the project Mayböck, Senior Engineer in the Elec- “The lime mud filter has worked exactly Production Manager. in 16 months instead of the planned 20. trical and Automation group, supervised as we hoped,” Michael Bauer says. They promised they would do it.” the work for Andritz. “With the old system on a good day Middle: Harald Trummer, Head of Maintenance; Bernhard Bauer (standing), Project Engineer. we could reach 75% dryness. With Unfortunately, in 2005, the Pöls com- “We were responsible for the power the new LMD-Filter™, we can exceed Rear: Jürgen Rieger, Assistant Production munity suffered through a hard winter – supply, distribution, instrumentation, 80%.” Manager; Alois Jammerneg, Product and Start- up Engineer Dewatering & Bleaching; Bruno not the ideal time to be doing civil, and controls for the recausticizing Prenoler, Project Engineer; Siegfried Gruber, structural, and erection work. “We equipment and the kiln,” Mayböck says. Head of Project Engineering; Manfred Enzinger (standing), Maintenance Planning.

16 17 Zellstoff Pöls AG

In October 2006, after the start-up of Improved pulp drying the new white liquor plant, Zellstoff Pöls Rebuilding achieved record pulp production, about 1400 t/d. Normal daily production is key equipment Pöls has both flash and sheet drying In 2005, Andritz began work to install about 1100 t/d. systems operating in the mill. While a new fan pump, rebuild the dryer it produces about 13,000 t/a of its to increase the steam pressure, and “This is very unusual,” Bauer says. Andritz was selected to rebuild own specialty paper on a small ma- to replace the gearboxes and drives “Usually after a start-up, there is an the high-pressure and low-pres- chine at the site, the majority of pulp on the press. A new lubrication in- adjustment period where production ▲ Manfred Enzinger, Maintenance Planning of Zellstoff Pöls (left), discusses the benefits of the low- sure feeders for the digester’s feed is dried and sold to market under the spection system has been added to may suffer. Especially with a new white pressure feeder after the rebuild with Walter Sommerbauer, Andritz Customer Service Manager. system even though Pöls had been ORION brand name. Capacity of increase bearing life. The rebuilt twin liquor that the fiberline had to adjust for, using another vendor for years, ac- the flash dryer is 378 t/d. wire press is now the world’s fastest this is quite an achievement.” cording to Harald Trummer, Head of – operating at 145 m/min. Maintenance for the mill. Before 1997, Pöls had an old fourdrinier drying machine, accord- “The target after the rebuild was to A good partnership from “We had been routinely sending the ing to Jürgen Rieger, Assistant Pro- achieve 785 t/d production from the both sides units to the original manufacturer duction Manager at Pöls. In 1997, dryer,” Rieger says. “In reality, we’re in Sweden,” Trummer continues, the machine was overhauled to add running at about 830 t/d now. So, “Today, we have realized about 50% of “but we began to have problems an Andritz wet end (including a twin I would say the upgrade has been the total investment to reach the with cracks re-appearing inside the wire dewatering press), add new very successful.” 450,000 t/a level of production,” feeder and in the housing. The coils in the Fläkt dryer, and install a Kreuzer says. “We have upgraded the time between rebuilds was getting new cutter. Production increased “We have also experimented with digester including the fiberline, upgrad- shorter. This indicated to us that from 520 to 690 t/d. many felts and wires in different ed the drying lines, built the new white there were problems with the overlay positions on the press,” says Rieger. liquor plant, upgraded the recovery welding, which is the most critical In 2000, Andritz rebuilt the twin wire “Andritz made improvements to the boiler, etc. We are now at a level of step in the rebuild. Also, the commu- press too. felt conditioning system and modi- 375,000 t/a.” nications was not very good, as the fied the side plates on the twin wire supplier did not keep us informed In 2004, some small improvements press so that we now get record life Kreuzer points with pride to the time about what steps they were taking to were made to the dewatering unit out of our wires – about one year. efficiency in the Zellstoff Pöls mill. repair the feeders.” (changing from steel to rubber rolls, The wire and felt suppliers are not so “Our total time efficiency in 2006 was etc.). Andritz also performed an happy with this, but it’s good for us!” 96%, including the May shutdown,” he Andritz was invited to bid on the audit of the dryer and proposed says. “This is based upon 365 days next rebuild and won the order. The some upgrade suggestions to boost total potential operation, so equipment first test was rebuilding a high-pres- production to 800 t/d. availability is outstanding. We have sure feeder in 2003. “We checked production, maintenance, and technical the work very carefully, since it was people from our side working with ex- done nearby in the Graz facility,” perts from Andritz’s side. This, to me, Trummer explains. is a good partnership because every- one is involved and working toward our Based upon the initial success, Pöls common goals.” now entrusts Andritz with rebuilding its low-pressure feeders, too. “The communications between the ►► find out more at two companies has been very good,” www.fiberspectrum.andritz.com Trummer says. “The rebuild work, too, has been excellent.”

◄ Andritz provided a major rebuild to the sheet drying machine by installing a twin wire dewatering ◄ “This is a good partnership.” Walking together press and making other modifications. The dryer’s are (left to right) Manfred Enzinger, Maintenance capacity is now about 830 t/d. Shown are Heinz Planning, Walter Sommerbauer of Andritz, and Kaiser, Project Engineer (left) and Jürgen Rieger, Harald Trummer, Head of Maintenance for Zellstoff Assistant Production Manager at Pöls. Pöls.

18 19 Stora Enso | FiberSpectrum 15 – 01/2007 SC-A Plus puts Summa on top

In Latin, the word “summa” means “highest.” Stora Enso’s Summa mill was motivated to stay on top of its competition by “re-inventing” itself with a new grade structure. Andritz was there to help. The centerpiece of a major machine rebuild is the new multi-nip calender from Andritz Küsters.

With sales to more than 70 countries, “We had to deal with the cost of three Radical changes Stora Enso has developed a global pro- machines, while our production was duction strategy designed to increase approximately down to one and a half Making that kind of shift in grade struc- efficiency and profit. The strategy is machines,” Mäkimattila says. “We final- ture requires some radical changes. The focus to PM2’s rebuild was the finishing section. ▲ Above: The Andritz Küsters PrimeCal ProSoft calender system consists of two pairs of frames with five rolls each, including PrimeRoll MHV zone- based not only upon an analysis of its ly had to shut down PM1 completely.” This was not a problem for the team controlled rolls. ▼ Below: An operator checks the profiles on the ProSoft system. Paper widths up to competition, but also upon the capa- at Summa. They were accustomed to 7.3 m can be calendered at production speeds up to 1600 m/min. bilities of each of its mills around the change and willingly looked at ways to world. This balance of internal team- Time for new thinking continuously improve. The necessary work and internal competition provided changes to stock preparation, PM2, the momentum for the Summa mill to Since the future was not going to be in and paper finishing were planned and move from standard newsprint to value- standard newsprint, Summa’s Produc- executed with precision. added SC-A Plus grades to stay one tion Manager Antti Outinen reasoned step ahead of the competition – inter- that adding SC-A Plus grades to the The first changes were to the fiber nally and externally. product range would add value for the preparation area. Here, Andritz played company. With the advantage of the a significant part in optimizing the TMP “Competition is what keeps our mills Scandinavian spruce fibers, and his plant with Summa specialists. Andritz efficient, our costs low, and our quality team’s dedication to continuous im- also supplied a new peroxide bleaching high,” says Juha Mäkimattila, Mill Man- provement, the outcome looked promis- stage to increase the stock brightness. ager for the Summa mill. “The idea is ing. Now to convince top management Consumption of bleaching chemicals that every mill is measured not only by to make the investment. and fresh water use was reduced as its results, but also by its prospects for the brightness of the pulp was in- growth and competitiveness.” Stora Enso invested € 90 million to pre- creased. pare Summa for the new grades – add- The Summa mill was founded in 1953 ing a new peroxide bleaching stage, The main changes were to the paper on the south coast of Finland near new quality-based tools to regulate a machine itself. PM2, originally built Hamina. The first paper machine start- stock fractionation system, and a new in 1958, had been modernized in the ed production in 1955. PM2 followed PrimeCal ProSoft multi-nip calender to 1990’s and again in 2000. An interest- three years later, and a third machine produce machine-finished (MF) papers. ing part of the rebuild was the imple- was added in 1972. The mill has been mentation of the “Firewall Concept,” producing standard newsprint for years. Today, Summa’s PM2 produces SC-A developed by the Summa team. With Plus under the brand name MagniPress it, operators could allocate different Bulky, and MF magazine paper under feedstock qualities to PM2 and PM3 Then came Langerbrugge the SilvaPress name. The volume ratio and optimize the product quality of both in the paper is decisively improved – machines. If for any reason the stock 3 ▲ “Competition is what keeps our mills efficient,” When Stora Enso built the new PM4 at reaching more than 1.0 cm /g. This, did not match the quality requirements says Juha Mäkimattila, Mill Manager for Stora Langerbrugge in Belgium, it created plus a roughness below 1.5 pps and a for SC-A Plus, it would be used for Enso’s Summa, Finland mill. a modern and massive newsprint gloss higher than 45%, create a paper other grades. production line. Other mills in the Stora with excellent printability, according to Enso network could not compete with Stora Enso’s key customers. The focus of the rebuild was PM2’s the size, speed, and efficiency of the finishing section. “We wanted to install Langerbrugge machine (10.3 m width A dozen customer companies were the best possible calendering system,” and 2000 m/min design speed). invited to test the paper in its early Mäkimattila explains. “That’s why we stages. The 15% increased bulk, selected Andritz Küsters. Their calen- The new machine created a challenge the smoothness that gave the feel of dering system was proven at Langer- for Summa, as standard newsprint coated paper, and the economic advan- brugge. The online calender achieves production at the mill was no longer an tage of reduced grammage were quite high temperatures, perfect nip-load, option for growth. convincing. and excellent steam regulation. With

20 21 Stora Enso

that reference, we trusted Andritz bottom-to-top route – also making the for the paper to travel through the Excellent results Küsters’ competence.” Summa machine unique. calander – a trip which it completes in Stora Enso only 1.8 seconds. Besides the capacity figures, the paper Once the contract was signed, the work specifications are very satisfying to Summa was fulfilled in about 12 months. The Impressive machine One other aspect of the design is the Summa. For the basis weight range PrimeCal ProSoft calender was manu- MultiMaster control system, which produced (48-60 g/m2), D65 brightness Location: factured in Germany and assembled The PrimeCal ProSoft calender con- monitors the important components of is 75% and gloss is 45%. Hamina (southern coast of before it was dismantled and delivered sists of two pairs of frames, each carry- the calender and regulates the drive of Finland – 150 km from Helsinki) to Finland for final erection. ing five rolls. The top and bottom rolls every single roll. The adjustment with The smoothness stays at 1.5 µm and are PrimeRoll MHV zone-controlled MHV technology offers even more pos- the volume is up to 1.1 cm3/g. The re- Product range: rolls. Also in each stack are two heated sibilities to improve the paper and the build of the PM2 contributes to a posi- SC-A plus, MF magazine, Design stage steel rolls and a conventional roll. machine’s performance. tive development in results, according newsprint and bulky paper to Summa management. Right from the design stage of the While the conventional rolls must only Brand names: project, Andritz Küsters played a signifi- be manufactured precisely, the thermo Smooth start-up “The more complex the technology MagniPress Bulky, cant part in the process. Several test roll’s most important qualities are con- gets, the more important it is to train SilvaPress, NewsPress, runs at the company’s Technical Center sistency in temperature and resilience. After a smooth assembly and start-up, our operators to monitor the machine’s ExoPress, LibroBook in Krefeld, Germany helped Summa to The PrimeRoll MHV (Multi-HV technol- the system was handed over to Stora parameters,” Mäkimattila says. “The determine the specifics of SC-A Plus ogy) rolls weigh 33 tonnes each, have a Enso Summa in March 2005. Accord- ▲ Production Manager Antti Outinen is proud of the project does not end with taking over Raw material: Spruce fiber unique combination of fiber preparation, Summa’s paper and the technical parameters for product width of 7.3 m, and operate at ing to the mill, all expectations have the delivered systems. We want to own “Firewall Concept” and a high-tech finishing their machine rebuild. a production speed of 1600 m/min. been fulfilled. Originally designed at maintain a long-term partnership with at Paper machines: section. a roll temperature of up to 180°C, the least those suppliers who built the core PM2 6720 mm trim, 1200 m/min, Andritz Küsters had to redesign its The two-stack construction of the calander today reaches 190°C. Produc- components.” 183,000 t/a ProSoft concept a little to be able to 580-tonne calender system ensures an tion speed of 1600 m/min, paper width PM3 7650 mm trim, 1500 m/min, retrofit it to Summa’s machine. At extraordinary high rigidity of the entire up to 7.3 m, and nip loads to 500 kN/m 230,000 t/a Langerbrugge, the paper web is trans- machine. complete the picture. Approximately ►► find out more at ferred to the first calender stack from 183,000 tonnes of paper (7.6% more www.fiberspectrum.andritz.com Personnel: 430 employees above. However, at Summa the usual The whole system is 7.5 m high and than originally calculated) are produced top-to-bottom route was not practical. has a length of 9.5 m between the feed- on PM2. Significant machine structural changes ing system and transfer to the winder. were avoided by using a rather unusual That makes a distance of about 48 m

◄ Shown from bottom to top on the Andritz twin wire press in the new peroxide bleach plant are Vesa Holm, Supervisor, Harri Taipale, Production Engineer, and Jorma Latva-Kokko, Production Manager, at the Summa mill. In total, there are five such presses in the bleach plant, which is designed to produce 560 admt/d of 80+ ISO brightness on TMP grades.

The unique combination of bulk and high brightness in Summa’s SC-A Plus MagniPress Bulky grades is very much in demand by Stora Enso’s customers. ►

22 23 Suzano Papel e Celulose | FiberSpectrum 15 – 01/2007 Being a good neighbor

Suzano Papel e Celulose and the city of Suzano have been interconnected since the mill was founded in 1924. “Most of the people working here are living in this same community,” says the mill’s pulp production manager. Its location in the community and proximity to São Paulo require Suzano to keep emissions and effluents within very strict limits. Andritz helped the mill be a good neighbor by installing technology to reduce the odor from Suzano’s two recovery boilers. Good neighbors. Residents of Suzano walk the streets in front of their The cities of Suzano and Mogi das Cruzes, with their combined 630,000 homes. In the background is one of the recovery boilers that now benefits inhabitants, completely encircle the integrated mill owned by Suzano Papel e from Andritz technology to reduce odor. ▲ Celulose. ▲

This is a story of two Suzanos cooking liquor is burned for chemical 860 tds/d of black liquor. The CBC “The Andritz Dissolving Tank Vent Gas – the city and the company. and energy recovery. (Mitsubishi) boiler was installed in 1987 (DTVG) system solves the odor and and burns 1540 tds/d. particulate problems in a unique way,” Suzano, the city, is 45 km from São “TRS gases are the source of the pulp Cruz explains. “Rather than try to scrub Paulo in Brazil. With its 270,000 mill odor,” Shimura says. “It’s what our Shimura explains, “After combustion, the TRS from the dissolving tank gases inhabitants, and the 360,000 population neighbors refer to when they talk about the black liquor turns into molten ash and then vent them, we condensate the of nearby Mogi das Cruzes, the cities the smell of the mill. To be good neigh- that collects in the bottom of the recov- moisture out of the gases so they can encircle a large integrated pulp and bors, we have to do everything possible ery furnace. This molten ash (smelt) be used in the recovery boiler. Today, it The Andritz DTVG technology installed at Suzano paper mill. to eliminate the bad smells.” flows into a dissolving tank. The smelt is very common to feed the gases from conditions the gases in the smelt dissolving tanks is mixed with weak white liquor from the the dissolving tank to the recovery boiler so they can be burned in the recovery boilers. TRS emissions from the tanks are eliminated. ▼ Suzano, the company, owns the mill. The main sources of TRS are the recausticizing plant.” as part of the combustion air. This has The mill is one of four that Suzano digesters, the evaporators, the lime kiln, many advantages, including oxidizing Papel e Celulose owns in Brazil. the incinerator, and the recovery boilers. “Typically, the vent stack from the dis- the TRS compounds in the recovery fur- Suzano is one of South America’s larg- According to Shimura, TRS is currently solving tank is a major TRS emissions nace and eliminating particulate coming est integrated pulp and paper produc- measured at five points: the two lime point,” explains João Guilherme Heinz from the vent stack.” ers. It was, in fact, the first company to kilns, the incinerator, and the two recov- Cruz, an Andritz Service Engineer for utilize 100% eucalyptus for the produc- ery boilers. recovery boilers and evaporators. “The “Andritz has very good technology and tion of printing and writing grades. concentration of TRS emissions from a the equipment is high quality,” Morais dissolving tank vent stack can be five says. “We checked Andritz’s references The city and the company are inter- “We have been on a step-by-step to ten times higher than in the recovery in this area and were satisfied that they twined. “Most people who work here, program to address each source of TRS boiler’s flue gases. The vent stack is could do the job.” live here,” says José Alexandre de over the years, since we are located in also a significant source of particulate Morais, Manager of Pulp Production, the city,” Shimura says. As part of the emissions.” In the DTVG system, vent gases from Recovery, and Utilities. “I also live near upgrade program, Andritz retrofitted one the dissolving tank are cooled and here with my family. The reason the mill of Suzano’s kilns and the recausticizing “That smell is not acceptable to our washed in the scrubber. Gas enters the can survive in this location is that we plant in 2002-2003. This included the community,” Ito says. We knew we lower section of the scrubber vessel and work very closely with the local com- installation of a new slaker, two reac- would have to stop venting the gases to passes through stainless steel pack- munity.” tors, and retrofitting the kiln with Sector the atmosphere and close the system.” ing material and a direct-contact heat Coolers and an LMD section. transfer surface. The packing material is kept wet with water that is circulated José Alexandre de Morais, Suzano’s Manager of Pulp Production, Recovery and Utilities. ▲ Tough on TRS Burning instead of venting through a heat exchanger. A significant Removing the last portion of the gas condenses when it The location of the mill close to the of the odors Most dissolving tank emissions are con- passes through the packing material. cities of Suzano and Mogi is part of the trolled by wet gas scrubbers, where the Excess water is returned to the smelt reason for the strict TRS permit limits, “Prior to 2005, the biggest remaining TRS is washed from the gases before dissolving tank. according to Isaias Shimura, a Process odor was coming from the dissolving they are vented to the atmosphere. In Engineer in the Recovery and Utilities tanks of our two recovery boilers” says Suzano’s case, since the mill did not Before leaving the scrubber vessel, the department. Total Reduced Sulfur Mario Hiroshi Ito, Project Engineer at wish to vent gases from the dissolving cooled gas passes through a demister (TRS) is a measure of the total concen- Suzano. tank into the atmosphere, the decision to remove water droplets from the gas. tration of bad-smelling sulfur com- was to go with Andritz technology for From the scrubber, the gases are trans- pounds released when pulp is cooked, The smallest recovery boiler, a burning the gases in the recovery boiler. ported by a fan to the tertiary air system washed, evaporated, or when the spent Götaverken model built in 1973, burns of the recovery boiler.

24 25 Suzano Papel e Celulose

In order to keep the gas ducts dry and Before the first project was fully com- the gas/air temperature high, fresh missioned in November 2005, Suzano Suzano Papel e Celulose make-up air is heated and mixed with asked Andritz to retrofit the second the cool vent gases. recovery boiler (the CBC unit installed in 1987). “This technology eliminates the need Eighty-three years ago, Leon Feffer With the addition of a second pulp line for scrubbing chemicals, reduces the For this installation, Suzano wanted to began investing in the pulp and pa- at its Murcuri mill (to be completed in chances of plugging the scrubber, and retain as much equipment as possible, per industry in Brazil. Eventually, he 2007), Suzano will increase its produc- also can recover wasted thermal en- so the existing fans and heat exchang- sold all his assets to build a paper tion of pulp by one million tonnes per ergy,” Cruz says. “It is an effective and ers were included in the Andritz DTVG mill near São Paulo. Feffer took year. Andritz is providing the wood- less costly solution.” design. Additional heat exchangers the name of the town, Suzano, to yard and a 3160 t/d fiberline (washing, were installed by Andritz to handle the become the name for his company. screening, and bleaching systems) on Looking inside the condensing scrubber vessel capacity for circulating and cooling In the 1950’s, Suzano became a pio- an EPC basis for the Murcuri project. on the CBC boiler are Isaias Shimura, Recovery Process Engineer for Suzano (left) and João First success leads to waters. neer in the development of eucalyp- Guilherme Heinz Cruz, Service Engineer for follow-on project tus pulp and was the first to use this Suzano has embarked on a unique Andritz. ▲ In the first quarter of 2006, the basic en- fiber for printing and writing grades. program, the Beekeeping Development In early 2005, Suzano contracted with gineering was completed for the project. Program, to offer jobs and income gen- Andritz to install the first DTVG system During the scheduled boiler shutdown in eration through honey production in the Milton Roberto de Mattos Carreiro, Supervisor of Today, the Suzano Group is still on the older, smaller Götaverken boiler July, Andritz did as much as possible to Recovery and Utilities (left), and João Guilherme majority-owned by the Feffer family. regions near the company’s plantations. (installed in 1973). Andritz delivered the prepare the tie-ins to the existing boiler Heinz Cruz, Service Engineer for Andritz. ▲ The Group is active in Pulp & Paper It turns out that eucalyptus flowers project on a modified EPC basis, ac- systems. In early October, construction and Petrochemical sectors. Suzano are excellent for beekeeping. Suzano cording to Morais, with Suzano provid- started. Twenty days later, the DTVG Papel e Celulose has revenues of trains local residents and provides the ing the civil works and instrumentation. system was started up. Everything was about US$ 1.42 billion and produc- materials (hives, protective clothing, “The project was completed on sched- operational by November 2006. tion capacity of 640,000 tons of and other materials). Beekeeping is ule and the overall performance has pulp and 1,080,000 tons of paper. It one of 40 such programs developed been very good,” Morais says. “The produces coated papers, uncoated by Suzano which reach out to 630,000 flows, temperatures, and burning of the ►► find out more at papers, paperboard, and bleached people. gases in the recovery boiler have been www.fiberspectrum.andritz.com eucalyptus kraft pulp. no problem for us.”

◄ Discussing the performance of the Andritz DTVG technology are Suzano’s team (left to right): Marcos Abdalla, Project Coordinator for both installations, Mario Hiroshi Ito, Project Engineer, Marcos Pessotta, Recovery and Utilities Coordinator, and José Alexandre de Morais, Suzano’s Manager of Pulp Production, Recovery and Utilities.

The Andritz DTVG technology was first installed on this 1973-vintage Götaverken recovery boiler. Based upon the success of this project, Suzano immediately ordered a system for their second boiler (a CBC unit installed in 1987). ►

27 New Orders ► Complete Lines ► Key Equipment ► Upgrades and Modernizations

Wood Processing Upgrades & Modernizations Mondi Packaging Upgrades & Modernizations Fiber Preparation Stora Enso (Kvarnsveden Mill) Stambolijski, Bulgaria Borlänge, Sweden Stora Enso (Varkaus Mill) Holmen Paper (Braviken Mill) Complete Lines & Systems Evaporation plant upgrade Complete Lines & Systems Sludge dewatering system Varkaus, Finland Norköpping, Sweden Temple Inland Chip presteaming: Diamondback® chip bin, Chip washing system 900 admt/d, Shandong Chenming Paper Aracruz Celulose Asia Pulp & Paper Diboll, Texas, USA TurboFeed® system and vapor reboiler RT- pretreatment 800 admt/d Shouguang, Shandong, China Turnkey tree length debarking, portal crane Barra do Riacho, Brazil TwinFlo 72 refiner Complete deinking line and stock Haikou, Hainan, China Recovery boiler upgrade Stock preparation components for 6 tissue MeadWestvaco preparation system machines Sappi Saiccor Evadale, Texas, USA Norske Skog Saugbrugs Smurfit Kappa Umkomaas, South Africa Downflow Lo-Solids® cooking Halden, Norway Swedish Tissue (LPC Group) Nettingsdorf, Austria August Krempel Chipping/chip handling Bleach plant upgrade for high brightness Kisa, Sweden Evaporation plant upgrade Kuppenheim & Zwönitz, Germany Recovery paper grades Stock preparation system for tissue machine Key Equipment Papillon™ refiners for unbleached kraft pulp Repeat order, already 90 Papillon refiners Pulp Drying & Finishing ICT Poland Tokai Pulp & Paper (Shimada Mill) Complete Lines & Systems Panelboard sold since 2002 Kostrzyn, Poland Shizuoka, Japan Ence (Pulp Mill Navia) Upgrades & Modernizations Complete Lines & Systems Stock preparation system for tissue machine Help bin Navia (Asturias), Spain Norske Skog Saugbrugs Pitkyaranta Pulp Works Recovery boiler and power boiler Industria de Compensados Guararapes Halden, Norway Karelia, Russia Lee & Man Paper Sappi Austria First recovery and power boiler package Palmas, Brazil HydroDrain™ Wet end rebuild Hongmei, Guangdong, China Gratkorn, Austria supplied by Andritz Pressurized refining system for MDF with Thickener for low-freeness broke OCC line for PM12 with 1,000 t/d capacity Bark shredder 384 t/d capacity Jari Celulose Lwarcel Celulose e Papel Asia Pulp & Paper Almeirim, Para, Brazil Phoenix Pulp & Paper Yanzhou Heli Paper Industry Lencóis Paulista, Brazil Industria de Compensados Sudati Perawang, Indonesia Dryer upgrade Khonkaen, Thailand Yanzhou, Shandong, China Ash leaching chloride removal Stock preparation components for 12 tissue Palmas, Brazil Stock preparation system 3 CenterScrew™ slewing screw reclaimers First chloride removal system based on ESP Pressurized refining system for MDF with machines for chip handling ash bleaching Mechanical Pulping 384 t/d capacity Confidential customer USA Tissue Machines Sappi Saiccor Sun Paper Complete Lines & Systems Homanit Polska Umkomaas, South Africa Complete deinking line & stock preparation Yangzhou, Shandong, China Stora Enso (Kvarnsveden Mill) Karlino, Poland system (for new tissue machine) Complete Lines & Systems Help bin MVR Zedivap evaporator Borlänge, Sweden Pressurized refining system for HDF (MDF) with 576 t/d capacity Hunan Hengan Living Paper Products PHC bleach plant for SGW Shandong International Paper & Sun Fiberline Key Equipment 4th order from Homanit Changde City, Hunan, China Coated Paperboard CrescentFormer, 5.55 m working width Confidential customer th Complete Lines & Systems Yanzhou, Shandong, China 5 order from Hengan Group Confidential customer Finland Shangqiu Dingsheng Wood Industry Complete stock preparation and approach UPM-Kymmene (Kymi Mill) China PHC bleach plant for TMP Shangqiu, Henan, China flow system for coated board 2 TMP reboilers Pressurized refining system for MDF with Swedish Tissue (LPC Group) Kuusankoski, Finland Kisa, Sweden ® 312 t/d capacity TurboFeed chip feeding system and Nanning Jinglang Pulp Key Equipment Tissue machine, 3.37 m working width ® UPM-Kymmene (Kymi Mill) Diamondback chip bin Nanning, Guangxi, China First PrimePress XT shoe press Kuusankoski, Finland P-RC™ APMP system OMO Wood Papierfabrik Palm Eltmann, Germany Domtar Industries Vapor reboiler Lagos, Nigeria Key Equipment Pressurized refining system for MDF Sludge dewatering system ICT Poland Ashdown, Arkansas, USA Kostrzyn, Poland ® Petrozavodskmash with 192 t/d capacity TurboFeed chip feeding system, Jilin Chenming Paper Tissue machine, 5.55 m working width ® Shklov, Belarus Abitibi Consolidated Diamondback chip bin and flash tank Jilin, Jilin, China 3rd order from ICT Group TMP reboiler Sichuan Shengda Forestry Industry Snowflake, Arizona, USA RETRO-fit™ upgrades HC-mixer, HC-discharge system ® Chengdu, Sichuan, China FibreFlow drum pulper Confidential Customer SFK Pulp Stora Enso (Varkaus Mill) Pressurized refining system for MDF Petrozavodskmash Georgia-Pacific USA St-Félicien, Quebec, Canada Varkaus, Finland with 384 t/d capacity Shklov, Belarus Muskogee, Oklahoma, USA Tissue machine, 5.5 m working width Blowline pressure diffuser system Vapor reboiler Heat recovery system FibreFlow® drum pulper (reboiler, engineering, cyclone and PSD) Bajaj Eco-tec Products Upgrades & Modernizations Key Equipment Upgrades & Modernizations Kundarkhi & Paliakalan, India Mondi Packaging South Africa Toscotec Ence (Pulp Mill Navia) Two pressurized refining systems for MDF Sichuan Yong Feng Paper Felixton, South Africa Europe (confidential) Navia (Asturias), Spain with 228 t/d capacity each Muchuan, Sichuan, China FibreFlow® drum pulper, coarse screening Yankee Dryer machining and completion Evaporation plant upgrade First order to Andritz in India for processing Screening and MC components bagasse as raw material

28 29 Recent Start-ups ► Complete Lines ► Upgrades and Modernizations ► Key Equipment

R. Dan & Co. Wood Processing Upgrades & Modernizations Shandong He You Group Sappi Saiccor Manila, Philippines Yu Cheng, Shandong, China Umkomaas, South Africa UPM-Kymmene (Tervasaari Mill) Headbox Complete Lines & Systems MDF pressurized refining system PrimeCal Hard 1x2, PrimePress X Valkeakoski, Finland with 624 t/d capacity JSC Arkhangelsk Pulp and Paper Mill StiroX white liquor oxidation system 3rd order Paper & Board Machines Arkhangelsk, Russia Complete Woodyard Key Equipment Upgrades & Modernizations Start-up 11/2006, final acceptance 02/2007 Shandong Qixing Panel Board Metsä-Botnia (Äänekoski Mill) Zouping County, Shandong, China Zhangzhou Liansheng Paper Äänekoski, Finland MDF pressurized refining system United Fiber System Zhangzhou City, Fujian, China Green liquor clarifier with 312 t/d capacity 3 PrimeFlow SW (single wire) headboxes, Ale Ale, South Kalimantan, Indonesia Chip Mill one with PrimeProFiler F, 6.2 m slice width Pulp Drying & Finishing Upgrades & Modernizations PrimeCoat Film with air turn (film press) Raw material: primarily planted acacia mangium; the mill’s environmental Egger Holzwerkstoffe Brilon Upgrades & Modernizations Paper Finishing compliance is on par with internationally Brilon, Germany accepted practices SCA Graphic Sundvall AB (Östrand Mill) Plug screw feeder, ribbon feeder and refiner Complete Lines & Systems Timrå, Sweden for MDF pressurized refining system (840 t/d) Flash dryer upgrade Naini Papers Limited Fiberline Kashipur, U.S. Nagar, India Fiber Preparation Ence (Pontevedra Mill) 1 PrimeRoll S with hydraulic system Complete Lines & Systems Pontevedra, Spain Key Equipment CMPC Celulose Pulp drying plant rebuild, 3.0 m working Lee & Man Paper Manufactoring Naciamento, Chile width Celhart Donaris Kwun Tong, Hong Kong, China Complete fiberline Braila, Romania PrimeCal Soft 1x2, PrimeCal Hard 1x2 Deflaker for virgin fiber pulp Indah Kiat Pulp & Paper (Perawang Mill) Recovery Riau, Indonesia Ma´anshan Tianfu Pulp machine rebuild SCA Hygiene Products Ma´anshan City, Anhui, China Complete Lines & Systems Mannheim, Germany PrimeCal Hard 1x2 Refiner for virgin fiber pulp CMPC Celulose Panelboard Hebei Yongxin Paper Naciamento, Chile Hartija Complete Lines & Systems Luannan, Hebei, China Recovery boiler Kocani, Macedonia PrimeCal Hard 1x2, PrimePress X Fibraplac Chapas de MDF Stock preparation components for virgin Smurfit-Stone Container Rio Grande do Sul, Brazil fiber pulp Zhangzhou Liansheng Paper Florence, South Carolina, USA MDF pressurized refining system Zhangzhou City, Fujian, China Evaporation plant with 504 t/d capacity, chip washing system JTI Yelets PrimeCal Hard 1x2 Yelets, Russia Weyerhaeuser Sita Rohstoffwirtschaft Refining equipment Valliant, Oklahoma, USA Hochheim/Main, Germany Ventilation and Drying for Recovery boiler Tissue and Paper/Board CVP pilot plant with 90 t/d capacity Paper Finishing High Energy Recovery Boiler (HERB) New process - special raw material treatment Machines Complete Lines & Systems Abitibi Consolidated Daxinganling Luzhou Shengxing Key Equipment Cartiere Marchi Kenogami, Québec, Canada Panelboard Toscolano, Italy Georgia-Pacific Palatka TMP heat recovery system Harbin, Heilongjiang, China PrimeCal Hard 1x2 Palatka, Florida, USA MDF pressurized refining system High temperature hood and process air Chemical Systems with 312 t/d capacity system Repeat order JK Paper Complete Lines & Systems Songdah, Gujarat, India PrimeCal Hard 1x2 Georgia-Pacific Ricon CMPC Celulose Taishan Weilibang Wood Industry Ricon, Georgia, USA Taishan, Guangdong, China Naciamento, Chile Delkeskamp Verpackungswerke High temperature hood and process air Complete white liquor plant Two MDF pressurized refining systems system with 312 t/d capacity each Nortrup, Germany EPC delivery PrimePress X 4th order

30 31 www.andritz.com Starting with a piece of land.

Once you select the site, the real If your first call is to Andritz, the remaining challenge of building and operating a mill challenges get easier. Andritz has the integrated begins. Put the challenge to Andritz. technology, the project management experience, and the service support to bring your mill to life – and keep it running. For complete production lines to complete chemical or mechanical pulp mills – our track record is exceptional.

We accept the challenge! PP.fs.15.en.06.07