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Presentation for:

Southeastern and VA-Carolina TAPPI Conference

Feb 17th, 2005

Main Menu

Tech Menu

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Bowater Catawba Fiberline, 1500 ADST/D

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Project Information

Order date November 2000

Start-up September 2003

EPC (Equipment - Procurement - Construction) project Andritz: Process Machinery, Process Engineering AMEC: Balance of Plant Engineering Kamtech: Construction

Built on experience from other similar projects in North America, South America and Europe

All proven technology at the time

Cut the cord start-up. All connections to the old fiberline mill were cut.

Project Information

Safety

Total incident rate 1.5 vs industry average of 7.6 ZERO lost time injuries

Start-up 7 days early

Quality Construction quality was good Pulp quality has been excellent since the beginning

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Pressure Diffuser
Stock Outlet Rotating Discharge Scraper ensures uniform flow.

Operation
Wash Header Piping System distributes wash medium evenly. Screen Assembly forms the extraction chamber inside the shell. The stainless steel screen is slightly conical and strokes up and down creating a periodic backflush and wiping action to keep the screen clean.

Pulp enters the stock inlet at the bottom and flows up through an annulus between the outer shell and the screen assembly. The stock exits out the stock outlet at the top.

Wash water moves horizontally from the outside of the vessel to the center chamber and then out the bottom extraction outlet.

The screen moves up with the pulp and then rapidly downstrokes to clean the screen

Shell and Liquor Distribution Assembly, depending on application is designed for 150 or 300 PSIG, and is fabricated of either carbon steel or stainless steel. Extraction Outlet Stock Inlet Hydraulic System

Typical DR Number 0.92 at 2.5 DF

Blowline Pressure Diffuser

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

DD Washer Operating Principle

How it Works

1.5 Stage DD Washer Typical DR 0.94 at 2.5 DF

DD Washer Pulp Cake Formation

Index

Main Menu

Tech Menu

DD Washer Key Features

Hydraulically Full Machine, No Air

Entrainment

Constant Feed Pressure is Used to Ensure

Even Pulp Distribution

Pressurized Wash Water for Positive

Displacement Through the Pulp Cake

Counter-current Fractionated Washing

Between Stages

Vacuum Pump for Final Thickening

Main Menu

Tech Menu

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Screening and Pressure Thickener

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Oxygen Delignification
#2 O2 reactor #1 O2 reactor

Two-stage System

20 + 60 minutes

Kappa reduction 28 to 12

(57% delignification)

2.1 % NaOH

1.8 % O2

No MgSO4 addition

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Knotting and Screening

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Knotting and Screening

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

Advantages of late Knotting and Screening


To Black Liquor Cooler

O2

O2

Knotting and screening can be together, 20 minimizing low 60 min min consistency operation Rejects can be recycled back to before the O2 stage. Improves yield and reduces solids waste. Lo-Level Knots are well washed, and can be burned in hog fuel boiler Feed Cleaner dumping Cleaner spills
Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Main Menu

Tech Menu

Knotting and Screening

Pressure Thickener

Improved DD Washer feed consistency = More stable operation Increased Capacity of DD Washer following Screen Room Creates Separation between Screening and Washing Optimal screening efficiency Optimal washer feed efficiency
THICK STO CK

FILTRATIO N

FEED

Main Menu

Tech Menu

Bowater Catawba Fiberline

Project Information

Flowsheet Overview

Pressure DIffuser

DD Washer

Oxygen Delignification

Knotting and Screening

Bleach Plant

Questions

Bowater Catawba Fiberline

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Bleach Plant

All DD washers
Oxygen Delignification
To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Chips In

Lo-Solids Cooking and BS Washing

Knotting & Screening


DD 3070.1 LC Condensate

All operations at MC consistency


O2
60 min

O2

min stages Upflow-downflow D1 and D2

20

Split filtrate additions and extractions improve chemical Lo-Level consumption at reduced water consumption Feed

No scaling
Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Bleach Plant

D0 30 min.

Eop 60 min.

D1 3 hrs

D2 3 hrs.

Kappa in 12.2

Eop Kappa 2.3

Final Brightness +89 % ISO

No dirt

Chemicals

- ClO2 1.9 %

- H2O2 0.45 %

- O2

0.5 %

- NaOH 1.7 %

Bleach Plant

Water 3800 gal/ADST (16 m3/ADMT)

Steam 3800 lbs/ADST (incl Digester)

Power 230 kWh/ADST (incl Digester)

D0 DD D2 Upflow & Downflow Towers

Eop DD

D1 DD

D2 DD

Screen Room DD

Screen Room Filtrate Tanks

#2 BS DD

Knots and Rejects Drainers

#1 BS DD Control Room Building

The mill was running in all the pictures

Total uptime 98% (including scheduled downtime)

First vessel entry shutdown will be in March, 18 months after start-up

Bleach Plant

Chips In

Lo-Solids Cooking and BS Washing Oxygen Delignification


To Black Liquor Cooler DD 3070 1.5 MCV DD 3070 1.5 MCV

Knotting & Screening


DD 3070.1 LC Condensate

O2
20 min 60 min

O2

Lo-Level Feed

Pump 1500 to PM at 10% consistency


Bleaching
3070.1.5MCV 3070.1.5MCV 3070.1.5MCV White Water

D0
OP

E
60 min 180 min

D1

D2

30 min

180 min

Hot Water To Existing #3 Bleached HD Storage Tank To Existing #6 Bleached HD Storage Tank To Existing #7 Bleached HD Storage Tank To Existing #8 Bleached HD Storage Tank

Bleached HD Booster MC Pump

Pulp Dryer Statistics (after two months)

Pulp Dryer Production

Well above plan

Quality

First quality - 86.8% for the month of September

First quality from 9/7 on - 97.0%.

First six days had high dirt because Dryer HD was

converted from brown to bleach pulp

Comments

The sheet is stronger

Fewer breaks

Higher brightness

Confident that rate can be improved 50 tons per day

because of the pulp

Sent: Thursday, September 18, 2003 3:50 PM To: Jim Vining; Per Klykken; Dana Harkness; Victor Bilodeau; Wylie Gregory Subject: No. 2 P.M. Results

I know you guys are busy right now, but I wanted to tell you your work is really making great things happen on our end! No. 2 is loving the new fiber now that we are on it full time. We are averaging 6% to 7% more TMP than previous runs on high-bright grades. Our strength numbers now are equal to or better than past runs (with much lower TMP percent), so we don't see any downside. We are using no FWA on the high-brites (never before), even with the increase in TMP percent. This means our retention aid and other chemical costs will be greatly reduced. In addition, the extra TMP has raised opacity allowing us to cut TIO2, which will save big $$$'s on coating chemical costs. I know you guys are working hard so I just wanted to share our appreciation looks great from this end! By the way, I got a tour of the new fiberline this week and was very impressed. There is a lot going on in a fairly small (but tall) area. Keep up the good work, and feel free to pass this along to others who are involved in the startup effort.

Jody Watts No. 2 Paper Machine

Bowater Start-up Exceptional Results


Breaking Production records on Pulp machine Using less Long Fiber (softwood) on Paper Machines Bleach Plant Chemicals are already at Guarantee level

ADMT

1,800 1,600 1,400 1,200 1,000 800 600 400 200 0

8/31/03 9/1/03 9/2/03 9/3/03 9/4/03 9/5/03 9/6/03 9/7/03 9/8/03 9/9/03 9/10/03 9/11/03 9/12/03 9/13/03 9/14/03 9/15/03 9/16/03 9/17/03 9/18/03 9/19/03 9/20/03 9/21/03 9/22/03 9/23/03 9/24/03 9/25/03 9/26/03 9/27/03 9/28/03 9/29/03 9/30/03 10/1/03 10/2/03 10/3/03 10/4/03 10/5/03 10/6/03 10/7/03 10/8/03 10/9/03 10/10/03 10/11/03 10/12/03 10/13/03 10/14/03 10/15/03 10/16/03

Day

Since reaching design production on day 9 the average production rate has been greater than the design rate of 1500 admt/d
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