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Business AreasPulp and Paper055Fiber Preparation SystemsIn the Fiber Preparation Systems Division, Andritz cannow perform full-line production trials and testing forrecycled fiber applications in its Graz pilot plant. Theplant is capable of receiving customer raw materials,processing the fibers (including deinking if necessary),and producing the final pulp. Future research work willconcentrate on different aspects of residuals (sludge/rejects)and water handling technologies to further reduceenvironmental impact.Mechanical PulpingTechnologies and equipment to process alternative rawmaterials (different species of pine, a variety of hardwoods,and annual plants) have been developed.In chemi-mechanical pulping, development has concentratedon mill-scale optimization of the advancedP-RC APMP process. Results that had been achievedin pilot plant work were confirmed or surpassed in actualmill operation.New pre-treatment and high-consistency refining technologieswere developed to allow for the use of alternativewood species in the RTS TMP process. Pulps ofvery high quality have been produced with these processesand specific energy consumption has been reducedby 20–30% compared to standard TMP.Major drivers in equipment development are productivityimprovements and increased production capacities.Following these requirements, new machine sizes withlarger capacities were introduced to the market. Availabilityand ease of maintenance for refiners and dewateringmachines have been improved. New methodsto increase replacement intervals of refiner plates havebeen successfully introduced.Customer requirements include sophisticated processcontrol. The new Andritz Bleach Commander usesmodeling and predictive control strategies to better controlthe bleaching process – minimizing quality deviationsand maximizing the production of “on-grade” pulp.Chemical consumption is optimized to the target brightness,which reduces bleaching costs.Pulp DryingTechnology development in the Pulp Drying Division continuesto focus on lowering the investment cost per tonof pulp produced. The main R&D thrust is to producea single drying line with production of 4,000 t/d basedupon successful Twin Wire Former technology. The relatedspecific design capacity was reached on the Division’sfull-scale pilot machine. In addition, developmentis underway to continually improve the machinery’s uptimethrough easy/fast sheet threading and process conditionmonitoring.A highly sophisticated process simulator for the entiresheet drying line has been developed. This is used foroperator training and DCS checkout prior to start-up.This simulation approach ensures fast production rampupsafter the line is started. The simulator also contributesto continuous optimization of the plant.Work on the new slab press was completed, givingAndritz full-line capabilities for mechanical market pulpmills. The first commercial installations of this press wereat Estonian Cell, Estonia and Phuong Nam, Vietnam.Tissue MachinesFor optimum “hands-on” operator training, the TissueMachines Division developed a tool to provide dynamicsimulation of all mass and energy flows in a tissue orTAD plant. Operators can virtually run the future paperproduction line and change settings in a safe, virtualenvironment.The shoe press technology has been proven in 13 tissuemachine installations around the world. One of its latestfeatures is “machine direction” shoe movement. Thisadditional functionality results in gaining more bulk orachieving higher post-press dryness, giving the operatormore flexibility. Record speeds of over 1,900 m/minhave been achieved with a shoe press.A further development of the reel concentrated on the improvementof the centerwind. A centerwind reel is mainlyused in TAD machines to retain the volume and waterabsorption properties for bulky heavyweight tissue andtowel grades. The new PrimeReel Centerwind controlsvery low nip loads sufficient for crease-free winding.Furthermore, it allows winding of larger diameter rolls toincrease productivity.A stable sheet transfer in the area between the crepingdoctor at the Yankee cylinder and the reel is criticalto runability. The PrimeRun system of sheet transfercomponents ensures better runability, especially withlightweight tissue at high machine speeds.Paper Mill ServicesA new wedge wire basket with the brand name Bar-Tec was successfully introduced, with a focus on optimizationof the screen basket production process andthe application of new profile types and wires to ensurehighest quality and maximum stability.Building on the LemaxX Spiral TM success in Andritz/Durametal’s core Double-Disc refiner plate business, thelow consistency product line is now pursuing growthin the conical refiner plate market. The first field trialsof LemaxX Spiral C TM , the latest development for thehigh performance, value-added conical market, haveproved very successful; product launch is expected during2006.Development programs were designed for Bauer DoubleDisc Refiners in order to address the seal and bearingproblems of those machines. They are a guideless andtrammable rebuild kit for the Twin 60 to ensure parallelplate gap over the service life, and a Keraloy hard facingproduct to increase service life of compression plugscrews (MSD, chip press, etc.).The modern Refiner Protection System (RPS) developedfrom Andritz was upgraded with additional security functions.Furthermore, it was improved in a way to enablethe condition monitoring with this system.New SCP wear shoes for both the high pressure andthe low pressure zones were developed, targeting increasedlifetime and thus reducing maintenance costson screw presses. The new wear shoes are available forall Andritz and competition screw presses.ANDRITZ Annual Report 2005