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PULP & PAPER 055 High Energy Recovery Boilers (HERB ) at pulp mills increase electricity generation from black liquor . As mills continue to close their chemical circulation loops to reduce emissions and generate more electricity, chloride removal is becoming more important. The new leaching-based chloride removal process by ANDRITZ PULP & PAPER offers a lower cost alternative to ash re-crystallization. Technology development in the evaporation business is aimed at producing highly efficient, low (or zero) effluent evaporation systems. These environmentally friendly evaporators and related technologies ensure low energy consumption and minimal raw material losses. Pulp Drying Systems The focus is on increasing the production capacity of drying lines to the target of 600 t/d per meter working width to cover the needs of pulp mills of the future that will produce 1.5 million t/y or more in a single line. This requires new forming and pressing concepts, improved heat transfer within the airborne dryer , and operating speeds of the cutter/ layboy in excess of 300 m/min. For the finishing line, the target is to increase the production rate and improve equipment availability. ANDRITZ service specialists finalizing modernization work in the course of a disc filter rebuild at Stora Enso’s mill in Saxony, Germany.
056 PULP & PAPER Paper Machines Developments in tissue machines include the PrimeDry Steel, made of welded steel, which gives higher performance and is operationally safer than a cast iron Yankee. In the air engineering department, the focus is on energy savings. A new step in heat recovery from the exhaust of Yankee hoods (ReEvaporation) saves up to 25% primary steam by re-evaporating condensate in a heat exchanger using exhaust air. Fiber Preparation Systems R&D work focused on optimizing the new low-consistency pulping systems in wastepaper processing. This is a major step in improving system efficiency and reducing energy consumption. Mechanical Pulping Systems One focus of the division’s R&D work is the testing of new wood species such as eucalyptus, acacia, birch, maple, and also annual plants such as bagasse , reed, or kenaf for mechanical pulping. This supports sustainable development in countries with different wood species or where wood is a rare resource. Further research is being conducted to reduce the effluent flows from all mechanical pulping systems and in the panelboard industry. The goal is to develop low-effluent mills and chemical recovery systems which reduce effluent pollution to the minimum. Minimizing energy consumption remains the main focus in the panelboard industry. In addition, there are ongoing investigations to produce high-quality fibers from annual plants as an alternative to wood chips and other wood by-products. Paper Finishing The main focus of development work has been on shoe rolls for pulp, paper, and tissue applications. For the tissue-making industry, a newly developed shoe roll – the smallest and fastest in the market – has been successfully installed and started up. In calendering technology, a value analysis study was completed. Cost reduction and acceleration of deliveries have been reached through modular calender design which achieves the same functionality as conventional units. A new design PrimeFeeder technology has been introduced that stabilizes the threading process and shortens the time it takes for a paper machine to reach full production after a sheet break. Pulp Engineered Services The leading development program continues to be OPE ® (Overall Production Efficiency), where the target is to enhance production efficiency and maintenance practices in order to secure the highest life cycle profits for customers. Supporting OPE ® is the Life Cycle Profits (LCP) program, which helps to secure and maximize profitable operations for customers. The program consists of several elements, where predictive tools for online diagnostics of pulping processes are being developed. Software tools for improving predictive maintenance are being introduced. Examples: software to determine the most cost-effective timing for changing chipper knives; software to predict the maintenance needs for hydraulic drives; software to ensure the smooth functioning of washers even under difficult, volatile circumstances. Paper Engineered Services The R&D focus is on reducing operating costs of equipment already installed in a customer’s plant. This involves optimizing the machine design to reduce energy consumption and the usage of consumables, to increase reliability, and to reduce maintenance costs. Newly developed technologies have been introduced in the areas of sealing, wear, and machine control, thus enabling customers to profitably operate their existing equipment, regardless of the original manufacturer. For the pulping of stock, broke, and recycled fiber, a development program is in progress to enable up to 20% energy savings for the majority of pulpers installed in mills. Automation Solutions In the automation area, SpectraVision optical sensors were introduced to measure fiber properties continuously without sampling. The sensor requires significantly less maintenance and eliminates the need for intense recalibration often required for competitive units. Advanced process control systems to achieve fully automated production lines were introduced for all process areas of pulp and paper mills. These systems are built using the BrainWave ® model-predictive controller and the expertise of ANDRITZ technologists encapsulated into the ACE (Advanced Control Expert) products. The IDEAS training simulator was augmented using the new Instructor software to monitor the operator’s progress as he/she learns the new processes and to provide a certification process for operators.
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