Download as pdf - andritz business areas

092Business AreasEnvironment and ProcessEnvironment and ProcessBusiness Area ManagersComprehensive productportfolio for mechanical andthermal solid/liquid separation.Johannes Kappel | Graz | AustriaSeparation TechnologiesWerner Hölblinger | Graz | AustriaThermal Process TechnologiesANDRITZ Global Top Products 2007

Business AreasEnvironment and Process093[1] The five HBF pressure filtrationlines, each with 168 m 2 filter surface,supplied by Andritz to Alunorte do Brasil,Barcarena, Brazil were started upin 2007 and are in full operation. Theplant dewaters over 700 m 3 of bauxitesuspension per hour, from between 50and 60% to over 85% dry solids.[2] Palm oil has become one of themost popular oils for cooking and forindustrial food processes. Andritz palmoil filter presses are used to separateolein and stearin to meet different productspecifications.[3] Andritz built the world’s largestsludge dryer for the cement industry,in Karlstadt, Germany. The waste heatfrom the cement factory is used for drying,and the dried sludge is used as fuelin the factory. The entire mineral portionis integrated in the cement. Thus, thesludge is sustainably reused, leavingbehind no waste.[4] The belt dryer developed by Andritz3Sys is designed for optimum recoveryof waste heat. The photo shows theplant in Karlstadt.[1][3][2][4]ANDRITZ Global Top Products 2007

094Business AreasEnvironment and ProcessprofilEMarketdevelopmentBusinessdevelopmentThe Environment and Process Business Areacovers a comprehensive range of technologies,products, and services for mechanicaland thermal solid/liquid separation formunicipalities and major industries, suchas coal and mineral processing, chemical/petrochemical, and food processing.The Business Area is a global leader in thisfield and offers comprehensive support,from design to the manufacture of key componentsfor thickening, dewatering, drying,and incineration, as well as erection andstart-up of turnkey plants, including automationand safety engineering.The large installed base of Andritz productsand systems, including more than 10,000centrifuges, more than 10,000 filter presses,and over 100 sludge drying lines worldwide,is serviced from more than 15 dedicatedAndritz service centers in Europe, the Americas,Asia, South Africa, and Australia.During 2007, the market for sewage sludge dewateringequipment developed very solidly, especiallyin Asia and the USA.Project activity for industrial applications for thepetrochemical, minerals, mining, and food processingindustries was very high in most regionsof the world. In parallel, the demand for dewateringequipment to treat industrial sludges remainedat a very high level.Project activity for sludge drying plants mainlyfocused on the UK, Turkey, the Arabic States,and Southeast Asia. Due to rising fuel prices,the demand for refurbishments of drying plantswith combined heat and power solutions, heatrecovery, and plants with combined incinerationhas developed favorably.The rising demand for alternative fuel sourceshas resulted in orders for dewatering of residuesfrom bioethanol production and in high projectactivity for equipment and systems to dry varioussorts of biomass, specifically wood chipsand sawdust, as well as sugar cane bagassefor the production of pellets.In 2007, Sales of the Business Area amountedto 364.5 MEUR, which is a slight decrease comparedto 2006 (366.5 MEUR). In particular, theSeparation Technologies Division showed a verysolid Sales development during the reporting period.EBITA of the Business Area increased to 25.3MEUR in 2007, up 23.4% compared to 2006(20.5 MEUR).Order Intake in 2007 reached 346.9 MEUR, practicallyunchanged compared to the high levelachieved last year (344.2 MEUR). While ordersin the Separation Technologies Division continuedto show good organic growth, Order Intakein the Thermal Process Technologies Divisiondeclined compared to 2006.Key figures Environment and ProcessMEUR 2007 2006 2005 2004 2003Sales 364.5 366.5 289.2 217.9 110.4Order Intake 346.9 344.2 340.1 200.7 110.2Order Backlog as of 31.12. 161.1 179.3 202.2 138.3 113.8EBITDA 30.3 25.6 22.0 12.6 3.3EBITDA margin 8.3% 7.0% 7.6% 5.8% 3.0%EBITA 25.3 20.5 17.7 9.9 1.5EBITA margin 6.9% 5.6% 6.1% 4.5% 1.4%Capital investments 4.9 6.5 6.6 7.9 1.5Employees as of 31.12. 1,350 1,324 1,213 926 428ANDRITZ Global Top Products 2007

Business AreasEnvironment and Process095Major ordersResearchand DevelopmentSeparation Technologies• Two large filter presses will be delivered for atitanium dioxide plant in the Ukraine.• A total of six large filter presses for dewateringof kaolin was ordered by customers in Brazil.• Four Hyperbaric Filters (HBFs) for fine coal dewateringwill be delivered to the Ukraine andChina.• Three centrifuges with a diameter of 1,100 mmwere sold to a customer in Saudi Arabia fordewatering of HDPE (High-Density Poly-Ethylene).• Nine large centrifuges will be delivered tovarious plants worldwide for the productionof melamine; four centrifuges were sold for apotash plant in Russia.• A customer in Korea ordered four large centrifugesfor the production of bisphenol. A similarplant in Taiwan will use the same type ofcentrifuges.• The Division was awarded a contract to deliversix large screens for the storm water overflowsystem of the city of Detroit, USA.• A gold washing company in Russia decided tolook for a new filter press supplier and boughttwo large Andritz filter presses due to their superiorreliability.Thermal Process Technologies• Sodawerke Staßfurth, Germany ordered a1,000 t/d fluid bed plant for conversion of lightsoda ash from the Solvay process to dense ashusing Andritz’s monohydrate process.• The Division was awarded a contract to delivera sludge drying plant with a water evaporationcapacity of 4.9 t/h for the city of Antalya. Thiswill be the first plant of its kind in Turkey.• Schwenk Cement, Germany placed an orderfor a belt dryer plant with a water evaporationcapacity of 10 t/h for Bernburg, Germany; thiscustomer had ordered an 8 t/h plant for theKarlstadt, Germany factory in 2004.• Ticona Germany, a company of the CelaneseGroup, ordered two fluidized bed dryers forPOM, a specialty polymer. The planned extensionof Frankfurt Airport contributed to this projectas this is part of Ticona’s plant relocationfrom Kelsterbach to Hoechst Industrial Park.• A belt dryer plant with a water evaporationcapacity of 3 t/h will be supplied for Radom,Poland; this is the first belt dryer order fromPoland.• A belt dryer with 8.15 t/h water evaporationcapacity was sold to Nuh Cimento, one of thelargest cement producers in Turkey.• A major PVC producer in the USA placed anorder for a turnkey fluid bed drying and coolingsystem for Suspension-PVC (S-PVC), includingmechanical dewatering with Andritz Birdsolid-bowl decanter centrifuges; the plant willbe located in the Midwest of the USA.• The city of Cape Coral, Florida, USA, ordered adrying system (2 lines with 5 t/h water evaporation)for its new wastewater treatment plantexpansion. Similar plants have been constructedby Andritz in Florida at Jacksonville,Pinellas County, Hillsborough County, and BonitaSprings.Research work in the Separation TechnologiesDivision continued to concentrate on the optimizationof the centrifuge product range in orderto further enhance performance and/or reducemanufacturing costs. Another focus area wasthe standardization of the filter press productfamily in order to shorten delivery times and reducecosts.Driven by increasingly stringent requirements forhighly efficient odor control systems, further effortsand tests have been conducted to minimizeodor and TOC (Total Organic Carbon) compoundsin the offgas from sludge drying plants. Especiallyfor sewage sludge with its unpredictable rangeof odorous substances, extensive R&D work isdone to develop a reliable and ecological odorcontrol system that – unlike thermal oxidizers– does not consume further primary energy andcause additional pollution by CO 2.Based on the strong market demand for biomassdrying, the development of a large-scalebelt dryer for biomass with an evaporation capacityof up to 16 t/h has been started with thetarget to achieve utmost energy efficiency byheat recovery from drying gases. This dryer willoperate with nearly closed drying air loops andalso recover the energy from the minimized dryeroffgas stream. It will be able to run on waste heator offgas from other processes as well as fromcombined heat and power plants (CHPs).Also with respect to biomass drying, intensivepilot tests were carried out with a pilot-scale dryingplant to obtain design and feasibility data forbelt drying on various biomass materials such assawdust for pellet mills, spent grain from breweries,rejects, sugar cane bagasse, and bark fromthe pulp and paper industry.ANDRITZ Global Top Products 2007