Saving Energy Improving Technology Voith Paper Fiber & Environmental Solutions Ravensburg / Germany Eugen Loderer TAPPSA Conference Cape Town 23rd Sept. 2010

Voith Paper Fiber & Environmental Solutions Ravensburg / Germany Contacts South Africa: Hennie Alberts Tel: +27 11 418-4016 Cell: +27 824550049 e-mail: hennie.alberts@voith.com

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

IntensaPulper IP-V (Virgin) Pulper for Virgin Fiber title, author short name | 2007-08-xx | 4

1. How can energy be saved? - Avoid flow losses! Excentricity instead of flow resistant directional baffles Conventional IntensaPulper IP Durchmischung ist wichtig! Partikel müssen zum Rotor gebracht werden, das kann eine Konzentrische Strömung nicht, ein Partikel würde sich dauerhaft im Kreis bewegen. Umlenkung der Strömung mit Strömungsbrecher zur Pulpermitte kostet Energie. Es entstehen Wirbel. PB: Avoid unnecessary turbulence Siehe auch Folie Farbtestbeweis. title, author short name | 2007-08-xx | 5

1. How can energy be saved? - Avoid flow losses!- Color test 5 sec 10 sec 15 sec Conventionel Intensa Pulper links ist der Pulper mit 4 Baffles ausgestattet, rechts ist die Auflösegarnitur exzentrisch ohne Baffle. Bei 6% SD wird in aufgelöstem Zellstoff in die Mitte Tinte hinzugegeben. Filme sep anhängen. bzw beide filme in ein flash Erkenntnis: Durchmischung in der IPV Variante ist schneller. IPV ist schon durchgehend blau, im anderen sind die Einflüsse der Baffles deutlich zu sehen. Mixing by excentricity, instead of baffles title, author short name | 2007-08-xx | 6

Investigate your savings! stellvertreted für IP V mit verstellen der Schieber kann die individuelle Situation gezeigt werden. Investigate your savings! title, author short name | 2007-08-xx | 7

Intensa Technology - Rebuild - A Chance for any Pulper Intensa Technology - Rebuild Low Energy Consumption in Pulping

Intensa Pulper Rebuild - Deflector and other components create a very good vortex and the suspension is guided to the center

Modifications by INTENSA components for existing pulpers ③ Bale Breaker ②** Intensa Deflector ④ Double Cone Bottom (option only) ① Rotor Modification **2 = to guide suspension and to improve vertical movement of suspension down to rotor title, author short name | 2007-08-xx | 10

Projects at a Glance Customer in Thailand Pulper type UP10 Furnish AOCC and LOCC Tonnage 404 bdmt/day Operation Continuous Operation volume 38 m3 Installed power 710 kW Power consumption 590 kW in average Consistency 3,5% Scope of supply: Intensa Deflector Rotor Modification Rotor cap with Eddy Cross Installation on site Startup supervision Measurement before and after rebuild title, author short name | 2007-08-xx | 11

Results of rebuild-ROI calculation Customer in Thailand Before After Power consumption 590 kW Consistency 3,5% 4,6% Capacity 404 t 548 t Net volume 38 m3 Specific energy input 15,5 kW/m3 Specific energy consumption 35,1 kWh/t 25,9 kWh/t Cost saving per year (with 350 days per year) 42.350 €/year No change 31% increased 34% increased No change No change 26% of savings ROI ≈ 13 months title, author short name | 2007-08-xx | 12

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

Energy savings with Eclipse ...replaces step rotor Outlook in Screening Energy savings with Eclipse ...replaces step rotor

Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor Low energy Rotor to keep the current performance of Step Rotor Step Rotor Eclipse Rotor 12.5 mm Gap 5 mm Gap title, author short name | 2007-08-xx | 15

Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor Development of Power Consumption vs. Rotor Tip Speed up to minus 30% power consumption (kW) at 20% higher throughput level for Eclipse Rotor Power consumption [kW] Rotor tip speed [m/s] title, author short name | 2007-08-xx | 16

Development of Spec. Energy vs. Rotor Tip Speed Eclipse Rotor: Energy saver for DIP applications Head to head trials: Current Step Rotor vs. Eclipse Rotor Development of Spec. Energy vs. Rotor Tip Speed up to minus 45% specific energy at 20% higher throughput level for Eclipse Rotor Spec. energy [kWh/t] Rotor tip speed [m/s] title, author short name | 2007-08-xx | 17

Eclipse Rotor: Energy saver for DIP applications Eclipse Performance Higher throughput performance up to 20% Specific energy reduced up to 45% Similar thickening factor for both Rotor types Up to 30% higher screening efficency Operational recommendation For rebuild and new installation instead Step Rotor Rotor tip speed 18 to 20 m/s Stock consistency 2,0 to 4.5 % Rotor-Screen Basket gap 5 mm Basket combination: All hole types title, author short name | 2007-08-xx | 18

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

Guangzhou DIP 2 retrofit in 2005 rotor and screen basket situation before and afterwards reduction of power consumption increasing of sticky removal efficiency

Rotor Situation Ahlström Screen F4 before and after upgrade Rotor Situation before upgrade Rotor Situation after upgrade title, author short name | 2007-08-xx | 21

Old Screen Basket and New C-bar Screen Basket New C-bar Screen Basket with much higher open area Screen Basket old title, author short name | 2007-08-xx | 22

Reduction ofPower Consumption in First Stage: Situation before upgrade: Installed power: 2 x 132 kW rotor speed: 550 rpm power consumption: 2 x 110 kW Situation after upgrade: Installed power: 2 x 132 kW rotor speed: 440 rpm power consumption: 2 x 80 kW Annual savings in energy at 350 running days a year: 504.000 kWH / year @ 0,07 €/kWh = 35.280,-- €/year title, author short name | 2007-08-xx | 23

Sticky removal efficiency before upgrade: 1st Stage: ηSticky 60% title, author short name | 2007-08-xx | 24

1st Stage: ηSticky 74% Sticky removal efficiency after upgrade: title, author short name | 2007-08-xx | 25

The High Capacity Screen Basket for Stock Preparation C-bar™ Q The High Capacity Screen Basket for Stock Preparation

C-barTM Q Profile width [mm] Relative open area [%] C-barTM S 3.3 100 2.7 ~120 length unit length unit Standard bar C-barTM S Narrow bar C-barTM Q (previous SQ) More bars at given length  higher number of slots  higher open area title, author short name | 2007-08-xx | 27

C-barTM Q – Results of mill tests: Influence on sticky removal 10 20 30 40 50 60 70 80 90 100 1 1,2 1,4 1,6 1,8 2 Slot velocity [m/s] Sticky efficiency [%] C-barTM Q C-barTM S Sticky efficiency at same slot velocity seems to be same with C-barTM S and Q Sticky efficiency is better with lower slot velocity B&P DIP title, author short name | 2007-08-xx | 28

C-bar™ Q Baskets - Summary Increased Production with same slot size – C-bar™ Q provides up to 20% more capacity than C-bar S basket Improved Quality – Higher screening efficiency at low slot velocities NDura material assures basket strength and lifetime (add. we offer chromium layser) Basket Wear Measurement Tool – repeatable method for measuring basket wear over time – developed by Voith – value added “C-bar™ Q just one part of Voith‘s “ screening toolbox“ title, author short name | 2007-08-xx | 29

C-bar™ / MF Rotor Combination Best screening efficiency / sticky and dirt removal title, author short name | 2007-08-xx | 30

C-bar™ / MF Rotor Combination title, author short name | 2007-08-xx | 31

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

HW-Cleaner HCL5 – I and EcoMizer Technology

Technical Data HCL5-I: Size HCL5-I Max admissible operation pressure 4 bar Max admissible operation temperature 70°C Pressure drop: Inlet  Outlet 1.5 – 2.0 bar Inlet flow range 380 – 470 l/min Min required accept pressure 0.1 bar Dilution water flow 30 – 60 l/min Max Inlet stock consistency ≤ 3 % Schematic of the HCL5-I title, author short name | 2007-08-xx | 34

HW cleaner HCL5-I with EcoMizer Technology Customer’s benefits EcoMizer feature for the HCL5 allows: Minimum number of cleaners. Minimum number of stages. Hydraulically optimized head design for maximum production and efficiency. High concentration of contaminants in the reject Minimum fiber losses. Fine cleaning at consistencies up to 3 % without reduced operational reliability. Transparent reject chamber easy inspection of reject flow. title, author short name | 2007-08-xx | 35

EcoMizer™ Technology Principle Back-flushing of fibers to the accept Specific adjustment of reject consistency possible Flow on cone wall remains unchanged So reduction of reject without affecting separation efficiency title, author short name | 2007-08-xx | 36

EcoMizer™ Technology Influence on sand separation Fiber losses [%] 90 94 92 98 96 100 10 15 20 5 25 30 35 Sand removal [%] conventional cleaner (without back-flushing water) cleaner with tangential water injection EcoMizer™ Cleaner title, author short name | 2007-08-xx | 37

Rebuild to EcoMizer technology Example: Stock prep Newsprint – A500T -1- 246 68 17e 4e 1e 26 8 not needed anymore existing cleaner rebuild to EcoMizer™ Inlet Accept Before Energy 1.040 kW Fibre losses 3,67 t/d Reject 6,6 t @ 45% ash 7-stage cascade Energy Fibre losses 40.000 € 343.000 € Savings 383.000 € /year After Energy 945 kW Fibre losses 1,2 t/d Reject 4,3 t @ 72% ash 5-stage cascade 1st step fibre loss reduction title, author short name | 2007-08-xx | 38

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

LowEnergyFlotation 50% Energy Savings EcoCell LowEnergyFlotation 50% Energy Savings

LowEnergyFlotation The most efficient flotation concept, which saves up to 50% of energy Target: Reduction on energy consumption compared to standard applications by up to 50% at same quality demands. How: Modification of injector technology Optimized injector hydrodynamics Optimized EcoCell hydrodynamics High efficiency pumps title, author short name | 2007-08-xx | 41

Products for Saving Energy and Improving Technology: 1. Pulper 2 Products for Saving Energy and Improving Technology: 1. Pulper 2. Coarse Screening 3. Slot Screening 4. Cleaning 5. Flotation 6. Refining

Refining with PLURALIS – optimize your CEL title, author short name | 2007-08-xx | 43

PLURALIS – Advantages of a new concept Small bars & optimized grooves = more bars @ same diameter More bars = more cutting edge length (CEL) More CEL = lower SEL = lower refining intensity possible Energy savings against standard designs = 10 – 20 % possible Specific edge load [J/m] = Net refining power [kW] Cutting edge length [km/s] Refining intensity title, author short name | 2007-08-xx | 44

lower Energy @ same Technology PLURALIS design = reduction of specific edge load SEL by increase of CEL b b g b = bar width g = groove width more CEL g lower Energy @ same Technology title, author short name | 2007-08-xx | 45

Advantages by using Pluralis fillings save Energy = COST SAVINGS boost Quality = TECHNOLOGY 50 20 40 60 80 100 200 300 Total spec. energy [kWh/t] Tensile index [Nm/g] 40 Freeness [SR] 30 20 10 100 200 300 Total spec. energy [kWh/t] I would like to show as an example the influence of the cutting angle on the fibre treatment of southern pine kraft pulp. Left hand side the development of drainage vs. energy is shown, right hand side you can see the development of tensile index vs. drainage. The drainage increase at the beginning very slow while the strength develop its values very quick. Higher drainage rates requires less energy but increase the strength not so quick. Using 60° instead of the 20° more energy is required. For example 25 % more energy results in 15% more strength. To save energy a small angle would be helpful Lets have a look to the other fillings parameter  Fillings type Spec. edge load Pluralis 1 J/m Common Bleached Brazil Eucalypt pulp title, author short name | 2007-08-xx | 46

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