ZERO EMISSIONS AND ZERO WASTE - 18 CIRCLETOZERO - ANDRITZ GROUP
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Magazine of Pulp & Paper // No. 42 / 2021 Something old and A circular bioeconomy A big step forward something new // 24 at Södra Mönsteras // 28 at Vajda Papír // 40 ZERO EMISSIONS AND ZERO WASTE CircleToZero 18
Contents
05 Management Message 36 Taking Control // Resolute Clermont
06 Spotlight On 40 A Big Step Forward // Vajda Papír
08 Optimizing The Evaporation Process // Suzano 46 It All Worked // Julius Schulte Trebsten
10 Cooperation and Commitment // Stora Enso Oulo 48 Safe Hands // PKVarel
14 Highest Quality At Lowest Energy // PrimeLineTAD 50 Going Full Circle // Klabin WSA
18 Towards Zero Emissions And Waste // CircleToZero 54 A Boost For The Lime Kiln // TechNews
22 Autonomy As A Side Product // Smart Woodyard 57 Small Change – Big Difference // TechNews
24 Something Old And Something New // Mondi Swiecie 60 Good In A Crisis: Start-Up On Time // Volga Paper
28 Forming A Circular Bioeconomy // Södra Mönsteras 63 Streamlining Health & Safety Reporting // HSE Column
34 The Latest Advancement // TwinFlo Prime 64 Did You Know That …
CircleToZero:
AUGMENTED REALITY CONTENT
TOWARDS ZERO EMISSIONS
To view videos, illustrations and picture galleries in a more AND ZERO WASTE
direct and lively way, we added augmented reality to several
articles! Download our ANDRITZ AR APP on our website
or in the AppStore/PlayStore!
AT PULP AND PAPER MILLS
SCAN THE MARKED PAGES AND
EXPERIENCE THE ENHANCED CONTENT. Cover Story // 18
4 SPECTRUM No. 42 / 2021
08 14 The CircleToZero
Journey Has Begun
ANDRITZ recently launched its CircleToZero initiative to minimize emissions and waste
while creating value at pulp mills.
The circular bioeconomy is increasingly being seen as a valuable concept in the mitigation of climate
change as well as addressing future raw material scarcity. Around the world the message is getting through
that recyclable products derived from renewable resources are the only way forward for the future. It is
also clear that these products must be produced at facilities that are maximized in efficiencies for climate-
friendly manufacturing – creating minimal, or preferably zero, emissions and waste.
30 36 As most professionals working in the production of pulp and paper will know, our
industries are already showcase examples of producing recyclable, biodegradable
products made from renewable resources. In fact, pulp and paper industries around
the world are already recognized as being at the very heart of the circular bioecon-
omy. And when it comes to production, pulp and paper industries have come a long
way in a short time on major improvements to environmental issues at mills. The fact is,
a modern pulp mill is already very efficient in terms of chemical and water consump-
tion and the recovery as well as regeneration and reuse of these vital resources.
With the CircleToZero initiative, we are moving into a new future dimension that not
only focuses on creating an environmentally sound mill, but one that is truly circular in
its use of side streams, turning what was once waste into valuable bio-based prod-
ucts or vital resources for reuse in production.
CircleToZero – A DESTINATION AND A JOURNEY
A good example of the CircleToZero initiative put into action is ANDRITZ A-Recovery+,
44 50 54 an innovative concept to improve the resource efficiency of the chemical recovery
cycle. In this issue there are two of the latest success stories; one at Södra’s Mönsterås
pulp mill in Sweden, which is now producing commercial quality biomethanol, and
Klabin’s latest installation of a sulfuric acid plant at its Ortigueira mill in southern Brazil.
Both of these installations are and will be utilizing side streams to either create value
through new bio-based products, or will generate major savings by recycling and
refining chemicals for their own use at the mill.
These two installations are prime examples of what can be done to maximize existing resources by closing loops
and eliminating emissions and waste. This is why ANDRITZ has launched the CircleToZero initiative; not only has the
initiative been designed to help our customers address climate and raw material resource issues, it has also been
designed to ensure that maximum efficiencies can be obtained along the way. The ultimate aim of C ircleToZero is
to develop environmental and economic value hand-in-hand in close cooperation with our customers.
CircleToZero is the ultimate destination; however, at ANDRITZ we are well aware that this is going to be a
long and challenging journey, full of collaboration and positive activity. We are also aware that this journey
will certainly involve deeper partnerships with new, innovative business models. We have already started our
CircleToZero journey; we welcome you to join us!
SPECTRUM is published by: Pirjo Nousjoki, Dietmar Scherer, Minna Sinijärvi, General information and copyright:
ANDRITZ AG Ursula Suppanen, Manuela Wagner, Copyright© ANDRITZ AG 2021. All rights
Stattegger Strasse 18, 8045 Graz, Austria Elisabeth Wolfond reserved. No part of this publication may Yours sincerely,
Phone: +43 (316) 6902 0 Contributing Writers: be reproduced without permission of the
E-Mail: spectrum@andritz.com Peter Gaide, Minna Keinonen, Robert Puhr, publisher. Due to legal considerations, we must
Editor-in-Chief: Bjørn Hansen Mark Rushton, Gary Thomson inform you that ANDRITZ AG processes your
bjoern.hansen@andritz.com Contributing Photographers & Providers: data for the purpose of informing you about
Project Director: Carina Weissensteiner Lars Behrendt, Croce & Wir, Riku Isohella, the ANDRITZ GROUP and its activities. Find out
carina.weissensteiner@andritz.com Toni Pallari, Christopher Rausch, Daniel Vegel, more details about our privacy policy and your
Editorial Consultant: Klabin, Mondi, Södra, Suzano, Volga rights on our website: andritz.com/privacy.
Mark Rushton, mark@editorialservicesdirect.com Layout & Design: You can easily unsubscribe from receiving
Editorial Board: INTOUCH Werbeagentur und printed SPECTRUM magazine here: Lauri Pehu-Lehtonen
Aline Gomes, Tamara Huber-Huber, Internetagentur, Austria andritz.com/unsubscribe/spectrum. Director, A-Recovery+
Recovery and Power
On the cover: CircleToZero (page 18) ANDRITZ.COM/SPECTRUM ANDRITZ PULP & PAPER
6 SPECTRUM No. 42 / 2021 No. 42 / 2021 Spotlight On 7
World’s first PrimeFilter D
SPOTLIGHT ON disc filters started up!
ANDRITZ has successfully started up next-generation disc filter tech-
nology with eight PrimeFilter D disc filters at Malaysia Lee & Man Paper
Manufacturing Limited, Selangor Darul Ehsan, Malaysia.
Complete LC pulping system with The new PrimeFilter D is the latest ANDRITZ innovation in thickening and
several design upgrades started up fiber recovery, enabling the mill to handle higher feed consistencies and
higher-freeness pulp, even in the most demanding applications, while in
at Papeleira Coreboard, Portugal
parallel offering significant improvements in operation and maintenance.
Malaysia Lee & Man Paper ordered a total of 15 PrimeFilter D disc filters
for their four kraft paper production lines, applied as stock thickener and
Despite the challenging circumstances caused by the pandemic, a The system also comprises a detrashing pump, FibreGuard saveall disc filters in the white-water system of the PM water loops. After
complete continuous LC pulping system was started up successfully detrasher, FibreWash Drum, cleaners, and a RejectCompactor successful start-up of the first eight units, start-up of the remaining seven
at Papeleira Coreboard, Portugal, via remote support from ANDRITZ. for further treatment of rejects. machines is planned for completion by the end of the year.
The new LC pulping system installed features several design Papeleira Coreboard processes LOCC with a line capacity of Malaysia Lee & Man Paper Manufacturing Limited, established in May 2018,
upgrades: 300 bdmt/d and a reject content of up to 10% to produce differ- is one of the production locations of Lee & Man Paper Manufacturing Ltd. For further information,
ent types of coreboard. The company is part of Arteche Paper and has four wet pulp production lines and four paper production lines, visit our website:
• FibreSolve FSR pulper with advanced rotor design for efficient Holding and manufactures pulp, paper, and cardboard, focusing with an annual capacity of 300,000 tons of packaging paper. andriz.com/primefilterd
slushing at lowest fiber loss and highest availability on 100% recycled paper and cardboard as raw material for its
production.
• Advanced ANDRITZ TrashTrap for reliable separation and
removal of heavy and light rejects early in the process
• State-of-the-art ragger that allows – in combination with
the new pulper rotor design – superior forming, handling, and
Contact us for further information:
andritz.com/stockpreparation Leverage the potential
of your screw press
removal of pulper rags or fiber.prep@andritz.com
In many fiber preparation plants, efficient dewatering is essen-
tial for overall process performance. If a pulp screw press lacks
efficiency, it might create a production bottleneck for the entire
process. ANDRITZ has a comprehensive portfolio of spare and
wear parts for all major screw press brands, as well as innovative
solutions for screw press retrofits and upgrades, including:
• New screw shaft with tailor-made geometry
• Shaft exchange program (one-to-one)
• Customized screen baskets and plates for each application
• Highly wear-resistant screw flight protection
• Coated body plates for longer shaft lifetime
OPTIMIZATION TARGETS
Depending on customers’ specific needs, ANDRITZ can supply the
right combination of upgrade products and customized machine
settings, while optimizing the economical effort needed.
• Savings of specific energy consumption: 30 – 50% For further information,
• Capacity increase: by up to 30% visit our ANDRITZ Screw press service website:
• Outlet dryness increase: 5 –10% b.d. andritz.com/screwpress-service
8 SPECTRUM No. 42 / 2021 No. 42 / 2021 Suzano 9
SUZANO OPTIMIZES
THE EVAPORATION André Ferreira, Specialist Engineer, and Marcos Donadio, Recovery and Eduardo Correia and Aline Martins, both OPP Local Analysts from ANDRITZ
PROCESS
Utilities Manager, from Suzano
The main task of the control logic defined “The team of engineers, the manage- also making use of the Metris technology
was to observe the electric current for the ment, and the pulp production opera- to create a blower information panel that
IN PARTNERSHIP WITH ANDRITZ pumps that transport the concentrated tions team worked very closely with the will help us in assessing problems as well as
liquor to the recovery boiler. The output ANDRITZ experts. We have a great rela- supporting operation and maintenance in
data were also used to correct the ref- tionship with everyone at the mill and agile decision-making,” says Donadio.
erence current, with the temperatures of there is a real spirit of cooperation. We
the steam generated in each evapora- are always looking for ways to improve Ahead of this new industrial revolution,
tion vessel as safety information and pre- the processes together.” Aguiar evaluates how Metris technology
venting any interlock in the process. has helped the plant to have one more
Suzano’s pulp mill in São Paulo has generated significant savings in the
For André Ferreira, Specialist Engineer, Suz- competitive difference in its market. “The
plant’s evaporation process by using the Metris UX technology from Throughout the project, the Metris Data ano, the partnership in joint development Metris technology offers several tools and
ANDRITZ for the digital transformation of its processes. Analytic application was also used to of the solution was the decisive factor, “We alternatives for data analysis and simu-
evaluate, monitor, and validate the held some meetings with the local ANDRITZ lation that make it easier to find better
In total, Suzano has 11 industrial plants using Metris – ANDRITZ Digital Solutions to standard deviation of burning solids in responses by the controls on a daily basis, staff and explored a variety of control sce- results. Besides the technology, the con-
throughout Brazil, with each one bearing impact the quality of the final product. recovery boilers by around 30%, generat- so from these results doing the proper narios for a solution to the problem of cept of ANDRITZ teams working together
the name of the city where it is installed. ing savings of 55,000 USD/month. modifications. high standard deviation of the burning with customers generates a unification
The Suzano plant, located in the city of Claudio Nunes Aguiar, Pulp Executive Man- solids in the recovery boilers. After defin- of efforts and synergy with tremendous
Suzano (SP), has played a globally signifi- ager, Suzano, explains how this has hap- This partnership brought the technical “In addition, the Metris Machine Learning ing the control methodology, we planned potential for generating new projects and
cant role in the history of pulp production pened at the Suzano mill, “In recent times, knowledge of the engineers, the participa- application was very important to validate the implementation and testing stages.” ideas, such as performance improve-
as it was at this plant that pulp production due to the greater demands from our tion of the management, and the practi- the correlation of the transfer pump cur- ments, cost reduction, reduction of pro-
from eucalyptus fiber began. This change internal customers, we have implemented cal knowledge of the Suzano operators rents used in the new logic with the boiler MORE IIOT INNOVATIONS FOR cess variability, and quality gains. As soon
revolutionized the industry, which previously projects with the objective of reducing the together with ANDRITZ experts, making it burning and evaporation solids, showing THE FUTURE as one project is finished, another auto-
depended on pine for pulp production. variability of pulp quality. Metris has helped possible to define a control logic that, after that this correlation is suitable for control This partnership work, paired with the matically begins, generating a virtual flow
us to build correlations between the manu- the planning and testing stages, managed purposes,” says Aline Martins, ANDRITZ. Metris technology, led to an experience of continuous improvements.”
But this production site did not stop inno- facturing process parameters and the final to reduce both the standard deviation and that did justice to the entire history of
vating there. In 2015 it was the first to sell pulp quality in order to optimize the runabil- increase the average solids in the boiler. Marcos Donadio, Recovery and Utilities innovation at the Suzano plant. Donadio In addition to the evaporation project,
Eucafluff™, an innovative and sustainable ity conditions of the paper machines.” Manager at the Suzano plant, says that comments on this experience, “It was very there are around 40 more projects uti-
solution that is applied in absorbent hygiene This perfect teamwork between ANDRITZ an important differentiation for this result satisfactory because, at each weekly lizing the Metris technology, focusing on
products, bringing more comfort and well- MAJOR SAVINGS and Suzano, combined with Metris UX tech- was “the follow-up and involvement of follow-up meeting, we could see the optimizing the processes at the Suzano
being to the consumer thanks to the unique One of the high-impact processes for nology, led to the elaboration of the main the production team supporting the local improvements happening, through feed- plant, work that will continue to make his-
characteristics of eucalyptus fluff pulp. guaranteeing production quality is the logic control algorithms. The main Metris UX ANDRITZ team with important feedback back conversations with the operators tory thanks to the partnership between
evaporation of black liquor in pulp pro- applications utilized for this project were to improve the control algorithm during and the local ANDRITZ team.” ANDRITZ and the Suzano professionals,
With a history of innovation references in duction. Suzano and ANDRITZ have Data Analytics (for graphical analysis and the implementation and testing phase.” which is driven by results.
the pulp and paper market from the very developed a successful system for stan- controls monitoring) and Machine Learn- With many plans for the future of this plant,
beginning, the Suzano plant is once again dardizing the control of steam addition ing (which uses big data to make the stud- This intense collaboration had a high use of IIoT technologies does not stop here.
CONTACT
heading towards the future, living Indus- in the first evaporation effects, obtaining ies through clusters, to find opportunities impact on best use of the technology, “We’ve started a project to optimize the Luiz Vega
try 4.0 and IIoT by optimizing its processes greater plant stability and reducing the based on the evaporation process history). according to Eduardo Correia, ANDRITZ, flow of steam in recovery boilers, and we’re luiz.vega@andritz.com
10 SPECTRUM No. 42 / 2021 No. 42 / 2021 Stora Enso Oulo 11
EFFICIENT PROCESSES AND HIGH-QUALITY PRODUCTS ARE CREATED THROUGH
COOPERATIONANDCOMMITMENT
ANDRITZ played a major part in Stora Enso’s Oulu mill Stora Enso dur- “Our clear-cut goal is to be the market leader in terms of
success in reaching a new era as the mill was converted ing the Oulu quality. Our pulp has to live up to this goal; that is, it must
from fine paper to kraftliner production. The virgin fiber- mill conversion be better than any other producer’s. The process solutions
project. It con- must, for their part, ensure that we are constantly able to
based kraftliner produced by the mill will serve the strongly
verted the fiberline produce premium quality. We reflected the technical solu-
growing global packaging market. of Stora Enso’s Oulu mill to pro- tions of various suppliers against this goal.” This is how
duce unbleached high-kappa Klaus Leppänen, Area Manager responsible for Stora Enso’s
The conversion of the production line at Stora Enso’s Oulu years. In that time, the exten- pulp, upgraded the pulp drying fiberline in the investment project, responds when asked
mill was a major undertaking, as the project will also sive mill area has undergone an machine, and modernized the what were the main reasons behind their decision to select
increase the capacity of the pulp mill and the pulp dry- almost complete transformation stock preparation. ANDRITZ also ANDRITZ as the supplier of production technologies and
ing line. Kraftliner, made of unbleached sulphate pulp, is with the help of some 200 suppliers. supplied a significant number of key process equipment.
used in food, fruit, and vegetable packaging that requires process pumps to various areas of
strength, high quality, and purity. The former paper machine was con- the mill and was responsible for the “The starting point of all our operations is that we are the
verted to the production of kraftliner, rebuild and capacity increase of best on the market, both in the production of market pulp
“The online shopping boom has led to increasing con- and the pulp mill was converted to the lime kiln. and kraftliner. In pulp and packaging board production,
sumption of packaging materials. Demand for kraftliner produce unbleached pulp. Changes
is constantly growing, while the need for coated printing were also made at the mill to achieve
paper is decreasing at an accelerating rate,” says Juha considerable improvements in the
Mäkimattila, Mill Director, Stora Enso Oulu. treatment of odorous gases and waste-
water as well as chip storage. Environmental “The old production was ARI SAARNIO
Stora Enso, Project
He says that the company is on the right track to respond to the
current global trends related to the environment, changing life-
investments totalled approximately 40 MEUR.
in progress until September Director, OCO Project
styles, urbanization, growing demand of bio-based products, “Specialization in premium quality and high-price products 2020, so the construction,
replacement of plastic, and growth of the packaging market. will continue to be the backbone of our business. The com-
petitiveness of our products is based on the use of the best testing, and commissioning
FROM WHITE TO BROWN PULP possible raw material. With the investment at the Oulu mill,
related to new production
Converting a mill from fine paper to kraftliner production our processes are now efficient and highly competitive,”
does not happen overnight. In fact, this challenging, multi- says Mäkimattila. had to be completed in
phase conversion project took several years to complete.
The total investment budget was approximately 350 MEUR. ANDRITZ was among the suppliers responding to the
just over two months.”
The implementation of the project itself took just under two strict quality production performance goals set by
12 SPECTRUM No. 42 / 2021 No. 42 / 2021 Stora Enso Oulo 13
“A new mill can be KL AUS LEPPÄNEN
Stora Enso, Area Manager
premium quality cannot be achieved by
designed completely in Fiberline, Woodhandling
talking; it requires cutting-edge technol- 3D. A mill conversion
ogy and expertise,” says Pekka Kylliäinen,
Project Manager responsible for Stora requires people to
Enso’s drying machine in the project.
travel to the site
CONVERSION OF THE VARK AUS and work there.”
MILL STILL FRESH IN MIND
ANDRITZ has proven experience in imple-
menting similar modifications at Stora The upgrade project included a rebuild of the complete pulp drying line.
Enso’s Varkaus mill in 2015–2016 and also
with its Imatra mill’s new drying line in 2017.
The successful conversion project in Kylliäinen, for his part, had had previous process performance to perfection and schedule,” Saarnio says. “Because of the Even without the COVID-19 pandemic, “The COVID-19 pandemic posed a whole
Varkaus, where a paper machine was experience cooperating with ANDRITZ in guarantee the customer world-class quality. COVID-19 pandemic, we also had to cre- the project standards would have still new set of major challenges to the proj-
converted to produce kraftliner, was still connection with the implementation of ate additional remote control rooms from been high. Discontinuation of old pro- ect, but we were able to solve all issues and
fresh in mind at Stora Enso. On the other the new drying line at the Imatra mill. “Shared experiences, desire to learn, and which the facilities were commissioned.” duction, extensive dismantling work, and achieved our original goals in terms of pro-
hand, they also had an equally clear rec- cooperation are all very important factors making new installations all have required duction and quality,” Mäkimattila concludes.
ollection of the challenges encountered in “One of the great innovations is the in this. We continuously stressed the fact BUILDING A NEW MILL VS. overlapping and coordination among
Varkaus. Based on previous experiences, ANDRITZ automatic tail threading system that the project was a joint venture. This REBUILDING AN EXISTING ONE several operators within a tight schedule.
CONTACT
Stora Enso and ANDRITZ joined forces in for the drying machine, which has proved way, we were able to utilize each person’s Saarnio emphasizes that a project such Nor was compromising safety an option Jorma Olkkonen
the Oulu project and created functional to be both functional and reliable. This competence and experience to the max- as the one undertaken at the Oulu mill, at any point of the project. jorma.olkkonen@andritz.com
renovation concepts for both the fiberline equipment has also increased the safety imum and got them to fully commit them- where an existing mill is converted to new
and the drying machine. level of the drying line,” says Kylliäinen. selves to the project,” Leppänen says. production, is dozens of times more chal-
lenging than constructing a similar mill
”One of the lessons we learned in Varkaus TECHNOLOGY, BUT ABOVE ALL , Kylliäinen agrees, “Everyone’s contribution from scratch. Costs are saved, but the
was the fact that washers operate differ- HUMAN COOPERATION is so important in process development. amount of work involved is tenfold.
ently with high-kappa pulp. Furthermore, When it comes to rebuild projects such as The solution will not be good if the supplier
high-kappa pulp requires mechanical the one that took place at Stora Enso’s only picks up standard pieces off the shelf “Connecting old equipment to new is
defibration to achieve a good level of Oulu mill, off-the-shelf technology alone is and arranges them in line. The know-how extremely challenging. When construct-
quality. We reviewed the old washing line not enough. People carry out the work, and of both parties is required. Production pro- ing a new mill, the testing and commis-
in Oulu and found that we would not be cooperation is needed to find solutions to cesses are always different, and you have to sioning work alone can take up to six
able to utilize all of the existing technology the most demanding technical challenges really understand what is required to create months. In our project, the old production
in the new production,” Leppänen says. when the goal is to tune the production a functional solution. This is where profes- continued until September 2020, so the
sional skills and cooperation weigh in.” construction, testing, and commission-
ing related to new production had to be
PROJECT WORK CARRIED OUT completed in just over two months.” THE ANDRITZ DELIVERY:
IN THE SHADOW OF COVID-19 • Conversion of the fiberline to produce high-Kappa unbleached
Ari Saarnio, Project Manager responsible “Many of the challenges and details that pulp, including cooking modernization with new TurboFeed™ chip
for the conversion project at Stora Enso, is are involved in mill conversions became feeding system, Diamondback™ chip silo, and new impregnation
satisfied with the outcome of the project evident at the project planning stage. I vessel. The delivery also included a new DD-Washer™ for brown
and also with the fact that such a large- consider it important that we were able stock washing, new screening plant, and new refiners.
scale project was completed within bud- to discuss the details together well in
get and also almost on schedule, even advance and find solutions to the most • Rebuild of the complete pulp drying line, including modernization
though the work was carried out in the demanding issues,” says Jorma Olkkonen, of the wet-end with new headbox and shoe press, modernization
shadow of the COVID-19 pandemic. Project Manager at ANDRITZ. of the drying section, and upgrade of the baling line.
“When the first news of COVID-19 carried The remote connections implemented by • Installation of the latest innovation in dewatering – three Vertical
from abroad, we were quick to respond. ANDRITZ in Graz, Kotka, and Växjö were Screw Thickeners, dilution conveyor system, MC-pump, and rebuild
We immediately turned our attention used to plan and monitor the progress of of the broke screening system.
to our Chinese deliveries, and made the project and production. This has facil-
plans on how to get them all delivered. itated the flow of information between • Rebuild and capacity increase of the lime kiln.
This is another example of our excel- Stora Enso and ANDRITZ and has allowed
lent cooperation with ANDRITZ. In the for situations to be handled remotely • Significant amount of process pumps to all areas of the mill.
end, we received all of the equipment on without having to travel to the site.
The delivery also included a new DD-Washer for brown stock washing,
new screening plant, and new refiners.
14 SPECTRUM No. 42 / 2021 No. 42 / 2021 ANDRITZ PrimeLineTAD 15
ANDRITZ PrimeLineTAD
Highest Quality
at lowest possible
Energy Input
ANDRITZ experts give a complete overview of its PrimeLineTAD View video footage of this
report in our augmented
(Through Air Drying) technoloy for the production of premium tissue products: reality App!
FOR FURTHER INFORMATION
Joseph Guadagno: Vice President Tissue and Air Systems, North America SEE PAGE 3
Stefano Marenco: Director PrimeLineTIAC and R&D Tissue The TAD section of the ANDRITZ tissue pilot plant in Graz, Austria
Paul Richards: Senior Technology Manager Tissue
Can you give an overview of the ANDRITZ in general, and specifically on the US dewatering of the base sheet before the needs of the specific customer. The com- When we first started down this route, JOSEPH GUADAGNO: The process air
TAD concept; please include anything inter- market. Over the next two years, a con- sheet transfers to the TAD section. At the plete air handling system has been devel- we typically offered a single large diam- system is used to transport hot air through
esting about the development timeline? cept was conceived and engineered and pick-up, there is the possibility of running a oped and engineered using CFD, compu- eter TAD drum but have since developed the paper sheet with a uniform tempera-
by early 2003 ANDRITZ had its first order speed differential to tailor the quality and tational fluid dynamics analysis, by our our standard machine to the two drum ture and pressure profile. There are different
PAUL RICHARDS: ANDRITZ only entered for a TAD machine. sheet structure according to customer North American colleagues in Canada. arrangement to optimize the overall energy ways to properly mix the air and optimize
the TAD machine market in mid-2000, fol- needs, before the sheet passes over the efficiency of the process for our customers. the supply air temperature and pressure
lowing the breakdown and closure of the The ANDRITZ PrimeLineTAD comprises a “shaping” or “moulding” vacuum box to The sheet is then transferred to the Yankee profile uniformity to the TAD drum. For this
Beloit Corporation. While others looked to 2- or 3-layer headbox with dilution con- lock in the sheet structure. Next, the sheet cylinder for application of dry crepe before Can you share details about the hood purpose, we developed specially designed
acquire the technology, ANDRITZ focused trol that delivers the stock to a modi- is dried over two patented TAD drums passing over the recently developed and and air system and what sets the ANDRITZ static mixers, guide vanes and perforated
on the experience of the personnel in an fied C-wrap twin wire former. The former in series, up to anything between about patented active air foils and being wound PrimeLine TAD concept apart from com- screens that are incorporated into the
effort to further grow into the TAD market is adapted to allow vacuum assisted 75% and 90% dryness, depending on the using the linear center-wind assisted reel. petitors? ductwork and the TAD supply hoods.
“Of course, various types of heat JOSEPH GUADAGNO “One of the main purposes STEFANO MARENCO
Vice President Tissue and Director PrimeLineTIAC
recovery can be implemented Air Systems, North America of the trial is to produce and R&D Tissue
ANDRITZ ANDRITZ
to reduce overall energy paper reels that are
consumption. Our goal is to then converted by the
make the highest quality customer into the
tissue and towel products final products.”
with reduced energy input.”
16 SPECTRUM No. 42 / 2021 No. 42 / 2021 ANDRITZ PrimeLineTAD 17
The process air is transported through optimize the drying capacity of the sys- evelopment of the UCTAD, or Un-Creped
d PAUL RICHARDS “One of the key areas of
Senior Technology
the large insulated ductwork by the vari-
able speed supply fans that deliver the
tem. With the proper control of exhaust
air pressure, moisture, and temperature,
TAD, process. The Yankee, a traditional
part of any Tissue Machine, was only
Manager Tissue interest in this technology
ANDRITZ
required air mass to the sheet. A natural the optimal energy use can be achieved really a carrier, allowing a percentage of is clearly a reduction of
gas-fired burner is installed after each together with extended life of your TAD dry crepe to be put into the end prod-
TAD supply fan to heat the air supplied fabrics, both which represent a significant uct. Today, depending on the technology the drying energy.”
to the sheet and to increase its drying operating cost. being used and the manufacturer, the
potential. The supply air ducts are con- dryness after the TAD can be significantly
nected to the TAD hood modules with Of course, various types of heat recov- lower. In fact, ANDRITZ and its custom-
articulating joints that permit the TAD ery can be implemented to reduce over- ers are constantly making efforts to push
hoods to retract, allowing access during all energy consumption. Our goal is to these boundaries and are evolving with
fabric change, sheet breaks, or clean- make the highest quality tissue and towel the chemistry suppliers to allow higher
ing and inspections during maintenance products with reduced energy input. moisture to the Yankee. This movement
shutdowns. of the drying balance is a major step in
Can you talk in-depth about energy reducing the energy demand for drying. and higher volumes. All of this protects Can customers see the TAD concept in reduction of the drying energy. Much of the
The wet and dry end TAD hoods are con- savings, and perhaps provide some the other system components, such as action, and see some samples produced current effort is directed at how we might
structed of two independent, retractable numbers? From the time of the development of our the TAD fabric, while allowing smaller of their own products? achieve a higher reduction of the overall
halves, with perforated nozzle plates that first TAD machine to the current offer- overall system components and com- drying energy, without increasing the net
allow proper airflow distribution into the PAUL RICHARDS: TAD by its very nature ing, we have reduced the drying energy monality between the system sizes. STEFANO MARENCO: The PrimeLineTIAC energy input. Obviously, our goal here is to
space between the TAD hood and TAD is rather energy intensive, which is one of demand in the range of 15 – 20% by the (Tissue Innovation and Application Cen- make deep cuts into the overall net energy.
drum. The supply air is “pulled through” the key reasons the market has devel- simple use of a second TAD drum, albeit Taking this line a little further, our drive is ter) pilot machine at our facility in Graz,
the sheet by negative pressure within the oped so much in the US, where energy smaller diameter drums. This allows a now to further push the balance of the Austria is currently configured in TAD STEFANO MARENCO: We are also
TAD drum. is traditionally so much cheaper than in more controlled and targeted use of the drying towards the Yankee, with a target mode. We are running trials with our cus- focusing our research on technical solu-
other regions. What we are seeing today, hot air in the drying process. We can use around 65% max solids to the cylinder. tomers and one of the main purposes of tions that can increase the overall effi-
Moisture removed from the sheet is however, is an interest from regions where much hotter air for the first air system, This can only be achieved in conjunction the trial is to produce paper reels (small ciency of the TAD machine with a more
then partially evacuated to the atmo- energy is much more expensive, but which also has a lower permeability of with our customers and our partners in rolls of 600 mm width) that are then con- compact design in order to reduce the
sphere using the TAD exhaust fan. The air where a market can still be developed if the tissue sheet, where the pressure drop the chemical side of our industry. Finan- verted by the customer into the final building footprint and the civil construc-
exhausted to the atmosphere is replaced a way can be found to reduce the energy is considerably higher. Then in the sec- cially, however, if such a movement can products. The tissue makers can then run tion costs for this technology.
with fresh air make-up. The TAD supply consumption. ond system, where the sheet is drier and be realized, then the energy efficiency of market analyses and product quality tests
fan pushes the TAD return air back into more open, we can use lower the drying process could finally be at an to predict the interest of the consumer or For more information please visit
the pre-dryer supply air duct system in Historically, TAD was made with a dryness temperatures optimal level. Once all the “free water” market potential for a new product. www.andritz.com/tissue or contact us at
this continuous drying cycle. after the TAD of around 95% – one of the has been removed and only intercellular tissue@andritz.com
reasons that led to the water is left, the impingement process is Can you give us some insights on any
Thus, controlling the TAD supply air prop- much more efficient from a drying per- ongoing R&D work on the TAD concept?
erties like mass flow, temperature, and spective.
CONTACT
absolute humidity, we PAUL RICHARDS: One of the key areas Stefano Marenco
Another recent addition to energy sav- of interest in this technology is clearly a stefano.marenco@andritz.com
4 ing opportunities comes from devel-
6 5 opments in vacuum technology. Using
blowers instead of traditional liquid ring
pumps provides a hot air source that can
be used for preheating a portion of the
2 3 incoming air as it enters the system.
3 Another possibility, probably more popu-
lar in places where gas supplies are more
Key components
of a PrimeLineTAD limited or infrastructure is not yet avail-
tissue machine: able, is the use of steam (heat exchang-
1 1 Headbox
ers) as a heating medium. The system
temperatures lend themselves to con-
2 C-wrap twin wire former sideration of such heat exchangers,
especially in situations where an excess
3 Drum(s)
of steam is available, such as near pulp
4 Steel Yankee plants, etc.
5 Centerwind reel
6 Cleaning module
TAD-drum installation at the ANDRITZ tissue pilot plant
18 SPECTRUM No. 42 / 2021 No. 42 / 2021 CircleToZero 19
CircleToZero™ is a global ANDRITZ initiative
with the goal of achieving zero emissions
and zero waste at the same time as
creating financial growth for customers.
For pulp and paper producers, this means
eliminating unused industry side streams,
turning them into new value-added
products and achieving zero emissions and
zero waste production.
ANDRITZ is inviting customers, partners, and the research com-
munity to join a shared journey towards a more sustainable soci-
ety and to meet the industry growth demands set by the transi-
tion into a fossil-free circular bioeconomy.
Pulp and paper production creates multiple gaseous, solid, and
liquid side streams. Their elimination, reduction, purification, and
conversion are a continuous challenge, requiring new technologies
and solutions with clear environmental and financial payback.
The journey towards this has already started. ANDRITZ is currently
helping its customers to use less fresh chemicals and water as
well as reducing industrial emissions and waste. It is doing this by
increasing resource and operational efficiency and turning tra-
ditionally unused side streams into new commercial products. In
addition, these actions dramatically reduce pollution to air, land,
and water as well as reduce traffic and logistics around the mill.
CircleToZero WHAT IS CircleToZero?
Towards Zero Emissions
The pulp and paper industries play a key role in the transition
and transformation towards a fossil-fuel free circular bioecon-
omy. By developing circular operations to eliminate unused side
streams, and creating new value-added bio-based products,
it can be the global leader in zero emissions and zero waste
industrial processes.
and Zero Waste at
CircleToZero brings together the continuous development
and improvement of existing ANDRITZ technology solutions to
achieve this leadership position with clear environmental and
financial benefits.
Pulp and Paper Mills
CircleToZero is a collaboration-driven process, where we share
innovations, develop new solutions, and contribute to the posi-
tive financial returns and environmental impact of the whole
industry – together with our customers, research institutes, and
other partners.
WHY CircleToZero?
The pulp and paper industries are growing. Growing while
achieving zero emissions and zero waste together with higher
overall resource efficiency is the main driver for sustainability
of the industry. Regulations, capital and customer demand all20 SPECTRUM No. 42 / 2021 No. 42 / 2021 CircleToZero 21
require solutions to resource scarcity, miti- processing technologies make it possible Looking at the current side streams, FROM AMBITION TO investment set out purely to reduce emis- The technologies and environmental
gating climate change, and the need to to produce new value-added bioproducts ANDRITZ has identified several CircleToZero SUSTAINABLE RE ALITY sions is rarely financially feasible. and financial evidence already exist for
create more added value while using less from wood fiber itself, including dissolving opportunities for elimination, reduction, ANDRITZ recognizes that creating eco- CircleToZero, enabling us to make the
natural resources. pulp and micro crystalline cellulose. and further use in and outside the mill. nomic and environmental value is not ANDRITZ has strong customer support best decisions for short- and long-term
without its challenges. Alongside cus- and partnerships to turn CircleToZero sustainability.
Pulp and paper production creates tomers and partners, CircleToZero aims solutions into a reality. Collaboration will
multiple gaseous, solid, and liquid side to change this. be crucial to grasp the wealth of oppor-
streams. These side streams include, for GASEOUS SIDE STRE AMS CircleToZero OPPORTUNITIES tunities at stake and develop innovative CONTACT
instance: Turning CircleToZero into reality will be business models together. Building on Naveen Chenna
Nitrogen oxides • NOx reduction technologies naveen.chenna@andritz.com
fueled by achieving immediate bottom- technology expertise, ANDRITZ will pro-
Gaseous side streams: Nitrogen oxides, line savings, identification of new business vide its customers with gap analyses and
Sulfur dioxide • SO2 removal technologies
sulfur dioxides, odorous gases, and car- and investment opportunities, and the recommendations for existing mills to View video footage of this
bon dioxide ability to comply with tightening adapt and is also able to demonstrate a report in our augmented
Odorous gases • Odorous gas handling and treatment
regulations. CircleToZero payback time close to zero for new proj- reality App!
Solid side streams: Dregs and grits, Carbon dioxide • BioCO2 utilization with hydrogen to can solve the age-old ects, if properly planned ahead with the FOR FURTHER INFORMATION
sludge, ash and gasifier bottom ash, produce biomethanol problem where an CircleToZero approach. SEE PAGE 3
reject fibers, and lime mud
Liquid side streams: Filtrates, raw metha-
nol, condensates, sulfate rich streams, SOLID SIDE STREAMS CircleToZero OPPORTUNITIES
and crude sulfate turpentines
Dregs and grits • Source of alkali
Currently, the ANDRITZ A-Recovery+ con- • Conversion into fertilizers by removing
cept unleashes the economic potential hazardous components WALKING THE TALK:
of the many traditionally unused side
streams. These include purifying raw Sludge • Conversion into pellets
CircleToZero IN ACTION
methanol into commercial quality bio- • New product development WITH ANDRITZ A-RECOVERY+
methanol, the on-site production of sul-
furic acid, and recovery of kraft lignin. Ash and gasifier bottom ash • Purification and reuse outside the mill With existing and developing technologies, CircleToZero can bring opportunities for
• Gasifier bottom ash as new raw new and lucrative bio-based products by converting and utilizing side streams.
CircleToZero OPPORTUNITIES material In this issue of SPECTRUM, there are two prime examples of the CircleToZero
CircleToZero opportunities for developing initiative being put into action using the A-Recovery+ concept from ANDRITZ:
both circular operations and new prod- Lime mud • Purification and reuse
ucts in the pulp and paper industry are: • Source of alkali Södra Cell recently started up the world’s first biomethanol plant at its Mön-
sterås pulp mill in southern Sweden. Using the A-Recovery+ concept from
1. Circular operations. CircleToZero is ANDRITZ, the mill extracts methanol from the pulp process, and now has the
achieved by applying higher efficiency capacity to produce 6.3 million liters of commercial quality biomethanol. The
and closed loops throughout the mill-
LIQUID SIDE STREAMS CircleToZero OPPORTUNITIES biomethanol is then sold as a substitute for fossil-based methanol to be used in
wide production. Future opportunities the transport sector.
Filtrates • New strategies to handle filtrates
include reducing fresh water usage by
• Recirculation of purified filtrates
increasing the recyclability of used water Klabin recently ordered a sulfuric acid plant for its Ortigueira mill in southern
• Reduced fresh water usage that is aim-
– towards a Zero Liquid Discharge mill, Brazil. Again using the ANDRITZ A-Recovery+ concept, the mill will use sulfur-con-
ing towards the Zero liquid discharge mill
process wide capturing of biogenic CO2, taining gases – which are usually burned in the boilers or lime kiln – to produce its
and further utilization of captured carbon own sulfuric acid at the same time as controlling the sodium and sulfur balance
Raw methanol • Purification and reuse in and outside
dioxide in the creation of new products. of the mill. The result will be major savings on chemicals including sulfuric acid,
the mill
but also drastically reducing consumption of sodium make-up chemicals.
• New revenue generation
2. Value added products. There is a sig-
nificant opportunity for C ircleToZero in Condensates • Reuse of condensates The concept of A-Recovery+ is to look at all the chemical cycles in a mill as a
replacing fossil-based products with • Fresh water usage reduction whole and examine where further use, possible recycling, or the refining of dif-
new wood-based products and materi- ferent side streams can take place. Ultimately, the goal is to further use the side
als by utilizing the existing side streams in Sulfate rich streams • Extraction of sulfate to reduce the fresh steams to create more value by producing bio-based products to either be
a better and more efficient manner. The water usage used at the mill or sold on the commercial market.
replaceable materials include plastics,
composites, textiles, industrial bio-chem- Crude sulfate turpentine • Purification and reuse outside the mill
icals, and biofuels. Also, ANDRITZ fiber • New revenue generation22 SPECTRUM No. 42 / 2021 No. 42 / 2021 Smart Woodyard 23
AUTONOMOUS SYSTEMS
Autonomous operation of wood processing systems
OPTIMIZATION SYSTEMS
Optimizing process & equipment performance, production, and profitability
DIAGNOSTICS SYSTEMS
Process and equipment diagnostics, condition monitoring, and prediction
SMART WOODYARD
Autonomy as
a side product
Utilizing deep process knowledge and with many years of successful deliveries to w
oodyards
around the world, the ANDRITZ Smart Woodyard has combined all its experience with the
latest in IIoT technology. The result is an ongoing revolution of the woodyard.
The ANDRITZ Smart Woodyard’s
concept and product portfolio are
based on three levels of intelligence.
Digitalization of the woodyard is nothing Moncada says having a woodyard running and ultimately the woodyard is easier to The levels and systems within the Smart of providing successful solutions for
new – ANDRITZ provided various platforms
and technical solutions using digitaliza-
successfully means first decreasing the
variation across the board. “This variation
operate, meaning you don’t need highly
skilled operators constantly in place.
Woodyard portfolio have an emphasis
on modular, upgradable products with
woodyard operations. Recent deliveries
include woodyard solutions to Bracell,
BENEFITS
tion for a number of years in its constant could be in the size of logs, the species, futureproofing firmly in mind. A
pplications Brazil, and Arauco’s MAPA project in Chile. The emphasis of smart solutions in
efforts to help customers to save wood and how the inventory is managed, or dry wood “Another major benefit of a smart are suitable for both greenfield and wood processing is to optimize the
increase yield. In fact, the w
oodyard is an mixed with wet wood. All these examples woodyard, with variation minimized, is the existing woodyards. ANDRITZ recently received two Smart whole operation using the latest tech-
area in which ANDRITZ has vast experience are where there is a possibility of wood loss safety aspect. Less stoppages mean less Woodyard orders from Metsä Fibre for nologies. The main focus areas are:
for pulp and paper customers, but also in or interruption of woodyard processing. operators going into the danger zone to “As a starting point for an existing mill, the its bioproduct mills in Finland, Äänekoski
• Getting the most out of wood
MDF and biomass power generation appli- unblock the bottlenecks.” customer really needs to understand its and Kemi:
raw material
cations – indeed, ANDRITZ has w oodyard “If you have variation in the woodyard, woodyard operation,” says Moncada. “Cus-
• Best possible chip quality
operations running through its veins. ultimately there is loss of yield, as well THREE LEVELS OF tomers need to identify where they have the Metsä Fibre Äänekoski signed a three-
• Increased availability: Increased
as production interruptions, and when “INTELLIGENCE” most hold ups and we can provide the year contract with ANDRITZ for debarking
production line efficiency
Wayna Moncada, Director Wood Process- fluctuations are high, there is usually one ANDRITZ Smart Woodyard’s concept right module for that particular area. process optimization using smart
• Situation awareness and
ing Digitalization, ANDRITZ, says, “Lately the problem after another and it is just a case of and product portfolio are based on instruments enhanced with oversized chip
predictability: Real-time and
autonomous woodyard has become some- where the next problem will arise. In a smart three levels of intelligence; the floor level, “We are quite aware that total autonomy and bark content in chip flow detection
transparent production awareness
thing of a goal, along with the autonomous mill, where variations are minimized, you are which covers a wide range of individual cannot take place all at once at existing equipment. The agreement will operate
through decision support walls
fiberline and autonomous drying area. But always ahead of any upcoming problems. In smart products including machine and mills, so with a modular approach a mill under the ANDRITZ Synergy model for the
and smart mobile devices
digitalization is about much more than other words you will never chase information, process diagnostic devices, for instance, can solve one problem area and then mill’s three debarking lines.
• Improved safety: Automated
autonomy; it’s about what the c ustomer information will always chase you.” aC hipperEKG, or ChipSCAN; the second add on another module later. We can
woodyards mean less operator
really wants and needs: harvesting the level is optimization systems for sub then tie in each island as the evolution of Metsä Fibre Kemi, has ordered two
interaction is required
right wood, getting better yield from wood, “The economic benefits of a smart wood- processes, which contain lower-level the woodyard takes place.” fully autonomous logyard cranes for its
getting the best quality pulp, maximizing yard can be huge,” says Moncada. “There products; and the third level contains planned mill in Finland. The cranes will be
uptime, and predicting shutdowns. are wins from better yield, better quality autonomous systems, which are built SMART WOODYARD – the first autonomously operated logyard CONTACT
products, less stoppages, and higher with lower level optimization systems or REFERENCES AND ORDERS cranes in the world, and will feature Wayna Moncada
wayna.moncada@andritz.com
“Once we get these right, autonomy uptimes. There is also the opportunity with dedicated technology such as in the ANDRITZ Smart Woodyard has many ref- artificial intelligence to optimize log
simply comes as a side-product.” to better predict maintenance issues autonomous crane system. erences globally and has vast experience handling and minimize wood losses. andritz.com/smartwoodyard24 SPECTRUM No. 42 / 2021 No. 42 / 2021 Mondi Swiecie 25
Something
OLD
Mondi Swiecie is one of the largest Compared to a green field project, the pre- model reflected the actual operation and
integrated pulp and paper produc- work prior to the investment decision was could accurately predict changes in the
ers in Poland. The mill produces some the key to a successful project. The proper digester conditions as the chips moved
500,000 t/a of pulp for consumption on understanding of equipment performance through the vessel.
five of its six paper machines – the sixth and existing bottlenecks required detailed
machine, PM 4, produces paper from 100% analysis including comparing the current Besides the full understanding of the pro-
recovered material. In total, the mill pro- results to estimated equipment perfor- cess, the mechanical condition of equip-
duces 1.5 million t/a of a mixture of corru- mance. ANDRITZ performed an audit in ment was the second important key in
gated board, kraftliner, and sack papers. co-operation with mill people at Swiecie evaluating the needed changes and total
and something
in 2014 to get a full understanding of the budget. The Swiecie mill provided excel-
NEW
Mondi Swiecie contacted ANDRITZ in 2012 possibilities to achieve the set targets. lent equipment lists to ANDRITZ, including
to discuss its intention to increase kraft a comprehensive evaluation about the
pulping capacity by 100,000 t/a with the The mill’s daily laboratory data and DCS condition and usability of each piece of
ultimate aim of producing more virgin- data were used for the analysis and cal- equipment.
based grades on two recently rebuilt culations of the existing conditions. The
paper machines. The management at digester and washing area were mod- Mondi Swiecie’s Pulp Production Engineer,
the mill had a deep understanding of the elled and simulated using simulation pro- Wojciech Jazdziewski, says, “We were
underlying potential at the site when they grams. By modelling the existing situation very impressed by how deeply ANDRITZ
estimated that two old parallel fiberlines, and predicting the potential, the follow- experts and engineers studied our exist-
originally installed in 1972, still had room ing parameters were collected as the ing situation for this project. They were
for a major capacity increase. basis for the simulations: not simply looking to provide a mechani-
cal solution, for instance, bigger pumps or
Marcin Bocian, Mondi Swiecie’s Pulp Man- • Physical size and design of the larger areas of screens. They dug really
ager, explains, “As part of our Green Proj- digester area deep, addressing the pulp quality, as well
A major pulp capacity
ect at the mill, our target was to increase • All flows as taking into account further capacity
the capacity of the digesters by a further • All temperatures increases in the future.”
150 tonnes per day to reach 750 tonnes • All available wood and pulp
increase at Mondi Swiecie
per day of pulp from each digester. Of parameters Aki Muhli, ANDRITZ Technical Specialist and
course, we needed to achieve this with- Process Engineer for the Swiecie project,
out any negative impact on pulp quality. In the simulation of the situation inside the says, “There is no doubt that the mill was
We also wanted to increase the freeness digester, the following were considered: pushing the limits with the digesters and
Mondi Swiecie’s integrated mill in Poland needed to increase its pulp and stability of the kappa number at the washing lines, and we looked closely at
capacity by 25% to meet growing demand from its five five paper same time as reducing alkali losses. • Chip column compaction how best to approach the challenge and
machines using virgin fiber. The solution was a complex but hugely • Friction forces of liquor and chip flows to get the most out of it. During the sales
“Before the project we were running up to • Kappa, alkali, and temperature profiles and engineering phase, we looked at the
successful combination of utilizing older equipment at the same time as 650 tonnes per day of good quality pulp, different options, and we visited a couple
installing new, state-of-the-art technology from ANDRITZ. but everything was overloaded, includ- The main objective of this simulation was of references in Finland with the Swiecie
ing the digesters and washing lines. “The to assess how closely the theoretical team to see what best solution would fit.”
digesters are over 40 years old, and they
were originally designed for just 250 t/d,
so we were already pushing the limits.”
Diamondback™
REPAIR, UPGRADE, OR REPLACE? chip bin bottom
In the Mondi Swiecie case, it turned out that and chip meter-
the best solution was a mixture of upgrad- ing screw provide
uniform chip flow.
ing and replacing old technology with new.
In the cooking area, the main focus was to
upgrade the existing main equipment and
to add new auxiliary equipment, such as
heat exchangers, to provide the needed
capacity and conditions for the future
capacity. On the other hand, in the wash-
ing area the most economical solution
turned out to be a third line so that each of
Sureflow™ screens the lines would handle 500 t/d production.
were installed for
increased capacity
and extraction flows.You can also read
