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ANDRITZ to deliver DCS checkout and Operator Training Simulator (OTS) for Bracell’s “project Star”, Brazil


ANDRITZ Brasil Ltda., part of international technology Group ANDRITZ, has received an order to supply dynamic simulation solutions for Bracell’s announced expansion project – called “project Star” – for their pulp mill in Lençois Paulista, SP.

The new mill will have a flexible line designed primarily to produce dissolving pulp.

The scope of supply encompasses the dynamic models, DCS checkout, and Operator Training Simulator (OTS). ANDRITZ’s proprietary simulation tool IDEAS™ will be used to model the following process areas: fiber line, pulp drying machine and recovery boiler supplied by ANDRITZ, as well as the white liquor plant (including biomass gasification) and evaporation plant (including recrystallization) supplied by other vendors.

The simulated models will be used to test and verify process design concepts, identify and correct errors in the control logic, and provide realistic, hands-on training modules for the operators, helping Bracell to achieve a faster and smoother start-up. This proven approach not only reduces plant start-up time. The OTS also provides an ongoing virtual test platform that allows both training of new operators as well as re-testing of experienced operators. Different scenarios are configured within the OTS, such as plant startups/shutdowns and reactions to process upsets.

In addition, the simulator will allow operators to be trained on the core processes in a risk-free environment prior to operating the real plant so they can respond to abnormal operations quickly and effectively once the plant is in full operation.

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International technology group ANDRITZ offers a broad portfolio of innovative plants, equipment, systems and services for the pulp and paper industry, the hydropower sector, the metals processing and forming industry, pumps, solid/liquid separation in the municipal and industrial sectors, as well as animal feed and biomass pelleting. The global product and service portfolio is rounded off with plants for power generation, recycling, the production of nonwovens and panelboard, as well as automation and digital solutions offered under the brand name of Metris. The publicly listed group today has around 29,500 employees and more than 280 locations in over 40 countries.

This ANDRITZ division focuses on automation, electrification, and instrumentation systems, helping mills to release their full potential. It supplies dynamic simulation, patented advanced control solutions and operator training tools with focus on simulation (IDEAS), electrical equipment and controls, operator training, and system optimization (BrainWave, ACE).

Bracell is part of Singapore-based RGE. It began operations in Brazil with the acquisition of BSC (Bahia Specialty Cellulose) and Copener (Florestal) in Bahia. In 2018, operations were expanded with the acquisition of Lwarcel Celulose in Lençois Paulista, São Paulo. This is also the location of the “STAR” project.

A global leader in the production of specialty cellulose, Bracell’s operations are supported by the sustainable cultivation of eucalyptus and state-of-the-art factories. The annual installed production capacity is 750,000 tons of pulp, and the company employs almost 7,000 people in two different Brazilian states.

The “Star” project is an ambitious effort by Bracell to expand its production capacity from the current 250,000 tons per year by another 1.25 million tons in order to reach 1.5 million tons per year. The expansion work has already begun and should be completed by the end of 2021


Bracell’s “project Star” site, Lençóis Paulista pulp mill in São Paulo, Brazil

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Susan Trast
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