METSO’S CUSTOMER MAGAZINE FOR THE PULP AND PAPER INDUSTRY pptx

2/2010 METSO’S CUSTOMER MAGAZINE FOR THE PULP AND PAPER INDUSTRYresults SCA Packaging Munksund White liquor quality and capacity up thanks to cutting-edge technology 12 ‘Game-changing’

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No 2/2010 METSO’S CUSTOMER MAGAZINE FOR THE PULP AND PAPER INDUSTRY

results

SCA Packaging Munksund

White liquor quality and capacity up

thanks to cutting-edge technology 12

‘Game-changing’ multilayer

curtain coating technology

– Are you ready? 15

Mondi S´wiecie ECO7

- Economy meets ecology 18

Metso and Tamfelt

join together

- A perfect union formed

for the customers 8

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We are focusing another major effort on rebuilding the pilot paper machines at our Jyväskylä Paper Technology Center Now we will be able to provide, even more flexibly than before, pilot trial possibilities that are at the cutting edge of global development - including ground-breaking paper making technology that will afford our customers superb opportunities to stand out from their competitors.

Our PM 2, the first pilot machine to be rebuilt, now adds a new gap former to its previous former, that allows the production of external packing board at speeds exceeding 2,000 m/min In fact, top speeds of over 2,500 m/min have been attained on the machine during pilot runs PM 1, on the other hand, was rebuilt to be able to more effectively develop energy-efficient solutions for making layered products utilizing cheaper raw materials, for example

We are very well equipped also in the field of tissue making R & D As a matter of fact, our personnel and facilities located in Karlstad, Sweden are unique in the world Nowhere else can tissue processes be studied and developed in the same detail and scale This offers our customers unbeatable opportunities to excel in the market

Our service will also improve in the form of an expanded offering Integration of the paper machine clothing and filter fabric manufacturer, Tamfelt, with Metso at the beginning of this year fulfils our long-term objective Tamfelt’s fabrics complement Metso’s range of products and services, and this allows us to offer more comprehensive and competitive solutions for the needs of our shared customers

From the perspective of product development, we now have unparalleled opportunities to develop machines and machine clothing together, and to add value for our customers through the advances achieved

We believe, therefore, that our key asset will continue to be our ability to provide customers with the industry’s most efficient product and service packages, which will also, in the long run, play a responsible role in caring for our common environment

featured article

Metso and Tamfelt join together

A perfect union formed for the customers

Metso and Tamfelt are both house-hold names identified with high-performing paper and board machines around the world The combination

of the two companies will provide papermakers with access to a more competitive and comprehensive product offering as well as more extensive process improvement and service

packages from one source

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featured article

OVER 210 YEARS OF TAMFELT

From sheep to innovative technical textiles

Founded in 1797, Tamfelt is one of the pioneers of Finnish industry The inspiration for starting up the mill came from Jokioinen Manor, which had

a large herd of sheep The owner of the manor wanted to produce cloth from the wool using the new English machine method

By the 1840s, the mill was the biggest in its field in Finland with more than a hundred workers Due to lack of a water supply, the operations were moved to Tampere where production started under the name of Tampereen Verkatehdas Oy - Tammerfors Klädesfabriks Ab in 1859

The manufacture of machine felts began in 1882 This was the first step that was to take the company away from traditional textiles and into the realms of the paper industry

In 1960, the felt mill’s sales exceeded those of the woolen mill The focus

of production had shifted for good Exports started in 1956 The tion of filter fabrics began in 1965, and from then on the company focused

produc-on technical textiles

In 1981, the name was changed to Tamfelt Corp Internationalization started in the 1990s and the company has plants in Finland, Portugal, Brazil, Poland and China

As of December 28, 2009 Tamfelt has been part of Metso Group

TEXT Marjaana Lehtinen

paper chine clothing (PMC) products of our own

ma-has been under discussion for decades

at Metso The acquisition of Tamfelt was

in fact a natural step since fabrics are an

essential part of a paper or board machine

The larger and faster a machine is, the

more the fabrics and the machine form a

whole This has lead to a situation where

cooperation between a machine supplier

and a PMC manufacturer is a must,” says

Bertel Langenskiöld, President of Metso’s

Paper and Fiber Technology segment

Metso’s predecessor Valmet made a

farsighted decision back in the 1970s to

acquire some of Tamfelt’s shares, and the

companies have been cooperating closely

in product development and customer

Metso for 26 years, for example, as head of the paper and board machines business, as plant manager in Rautpohja, Jyväskylä, and

as head of Metso Paper’s research, ogy and development operations

technol-By late December 2009, Metso had acquired 98% of Tamfelt’s shares, making Tamfelt officially a part of Metso The process

of integrating operations has been ing rapidly ever since Tamfelt now makes

proceed-up the Fabrics business line in Metso’s Paper and Fiber Technology segment

Building bridges

The two technology leaders and full-scope suppliers in their own areas are a strategi-

cally perfect match; there is no overlapping

in their product offerings They know each other well The fact that both companies have their roots in Finland and share the same business culture is expected to make the integration process smoother

“For Tamfelt the worst scenario would have been for Metso to join forces with a foreign PMC manufacturer,” Kerttula ad-mits “Generally speaking, we would have been in quite a challenging situation trying

to grow on our own in the future Metso and its global network provide us with to-tally different opportunities and resources

to take care of our products, improve and sell them.”

cases ever since According to Langenskiöld,

last fall seemed like the right time to move

on to the next stage and deepen the

rela-tionship even further Before that, all other

options had been carefully studied in order

to find the overall best solution for Metso

Out of the possible alternatives, Tamfelt was

chosen as ‘The One’

“Although the two companies had been

‘dating’ for a long time, the proposal was

somewhat unexpected,” recalls Reima

Kerttula, former President and CEO of Tamfelt,

now President of Metso Fabrics business line

Tamfelt’s new owner is no less than Kerttula’s

former long-time employer Before joining

Tamfelt in January 2009, Kerttula worked for

co nt inu e d over l ea f…

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featured article

About 40 percent of the world’s paper is

produced on Metso machines For Tamfelt,

as a relatively small player, this large

installed base creates new opportunities,

especially outside Europe

Kerttula says, “But it also works the

other way around too, since our PMC

products can be found at mills where

there are no Metso machines In fact, after

hearing the news, many customers told us

that Tamfelt can function as a bridge and

bring Metso’s solutions to places where

there aren’t any I believe that this will take

place.”

Filter fabrics, in turn, fit in very well with

Metso’s offering that supports recycling

and improves the environmental

perform-ance and operational eco-efficiency of

cus-tomers’ production processes For example,

its filter bags are used in power plants’ flue

gas cleaning systems

“Filter fabrics complement Metso’s

selec-tion of wear products, not only in the pulp

and paper industry but also, for example,

in the mining and energy industries,”

Langenskiöld adds

More comprehensive

product and service offerings

In recent years, the change in the pulp and

paper industry has directed customers’

demand towards service, maintenance and

optimization of their production

proc-esses The addition of Tamfelt’s products

will further strengthen Metso’s global sales

and service network capabilities

Customers will now have access to a

more competitive and comprehensive

product offering as well as wider process

improvement and service packages from

one source: Metso By starting up their

machines with Metso’s clothing, customers

will gain added value With fewer partners

involved, communication will be more

straightforward and things will be done

faster

“Metso’s target is to provide customers

with a comprehensive solution including

the machine, automation, clothing and

service Having all this in-house helps us

develop the whole paper and board

indus-try,” Langenskiöld continues “Acquiring our own PMC products is one element of our plan to support our customers in improv-ing process performance and results.”

The combination of advanced machine technology and innovative PMC products has already brought success to many customers especially on wide, fast paper machines Tamfelt’s fabrics have contribut-

ed to the achievement of many speed and production world records run with Metso machines, such as Stora Enso Kvarnsveden

“This combination means for Metso’s and Tamfelt’s dedicated and motivated professionals the opportunity to work together to develop and find increasingly efficient solutions for our customers’ needs,"

says Bertel Langenskiöld, President

of Paper and Fiber Technology

PM 12 in Sweden, UPM Changshu PM 1 and APP Ningbo PM 6, both in China

Ability to create totally unique products

Product development between the two companies goes back a long way and is visible in high-performing paper and board machines around the world Innovation has always played key role for both companies – and will continue to do

so now that they are combined

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featured article

In future, product development will be

further intensified and significantly

deep-ened Inside this one Metso family, it will be

possible to create something totally unique

“Cooperation will be closer; there will

be no trade secrets since we now share

the same targets This will accelerate

product development,” Kerttula points out

“However, PMC cooperation with

custom-ers will continue as before Our customcustom-ers

are used to buying a complete PMC

pack-age, including knowhow, training, and joint

product development, not just fabrics.”

Towards more economical,

higher-performance machines

Both Bertel Langenskiöld and Reima

Kerttula are confident about the future

and they are convinced about the many

benefits brought to everybody by this

combination

“It will provide Metso with an

oppor-tunity to develop more economical and

higher-performance machine solutions

We will be able to improve our service

capabilities and offerings globally Our

customers will benefit by getting more

comprehensive service and expertise from

us,” Langenskiöld sums up

“Although the pulp and paper industry

has in the past few years faced some

dif-ficult times, we still consider it a very

impor-tant customer segment at Metso We will

continue to focus on it also in future and will

not leave our customers in the lurch The

acquisition of Tamfelt’s PMC and filter fabric

products is one example of our efforts.”

Riaupaper PM 1 and PM 2 run full speed ahead with Metso fabrics and machinery

Metso’s fabrics have had a significant effect on the dewatering efficiency and runnability of the Metso-supplied Riaupaper PM 1 and PM 2 in Indonesia Both machines produce premium-quality office paper

The press felts have been running successfully on both machines since their start-up in 1998 and 2006, respectively Riaupaper selected a Metso felt package for its PM 2 based on the good experience and results of the cooperation gained on PM 1 and the quality of the fabrics A good fabric reference from another OptiConcept machine in Asia also played an important role in the decision making

The press felts perform outstandingly and have guaranteed premium paper quality throughout the effective felt lifetime Co-operation pro-grams and on-site support have produced results in production by ensur-ing that the right felts are running

The 9,350 mm wire width Metso-supplied machines are among the fastest uncoated woodfree paper machines in the world and they are used as a benchmark by other office paper suppliers In August 2008, PM

2 reached a new 24-hour record of 1,667 m/min, exceeding the design speed of 1,600 m/min by a considerable margin It is one of the top three fastest uncoated woodfree paper machines in the world PM 1 recently set a new speed record of 1,510 m/min It is operating continuously above 1,500 m/min, which is equally clearly above the original design speed of 1,340 m/min

Riaupaper PM 1 SymPress B press section

• Pick-up felt, 1st press and 2nd press: Ecostar

Riaupaper PM 2 OptiPress press section

• Pick-up felt: EcoAqua

• 1st press bottom felt: Aquastar

• 2nd press top felt: Ecostar

For more information visit:

www.metso.com/fabrics

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REPORTING RESULTS

The pressure disc white liquor filter,

PDW, Metso installed at SCA Packaging

Munksund AB during 2008 performs the

same function as the white liquor

sedimen-tation vessel it replaced The vessel and the

PDW both separate white liquor and lime

mud for further use in the pulping process

at the mill But that’s where the comparison

ends

Compared with the corroded and

worn-out sedimentation vessel installed in 1966,

the brand new PDW yields more white

liquor of higher quality

What’s more, the footprint of the PDW is

significantly smaller than that of the

sedi-mentation vessel And it is dimensioned to

allow increased capacity, not only in the future but also currently, when more white liquor than usual is needed for one reason

or another

SCA Packaging Munksund AB, located

in Piteå, Sweden, produces 340,000 tpy of kraftliner from softwood and hardwood, recycled fiber and sawmill chips Kraftliner

is used in the production of industrial packaging, printing applications and high-demand corrugated packaging

Scope of supply

Apart from the PDW filter and auxiliary equipment, Metso supplied the Munksund causticizing plant with a new causticizing

vessel and a green liquor cooler - see Figure

1, showing the causticizing process line.According to Arne Lundman, Building Design Engineer at Munksund, the condi-tion of the sedimentation vessel was such that the government authorities strongly recommended replacing it as it was be-coming an environmental hazard What’s more, he notes, it produced white liquor of poor quality

In his role as a designer at the mill, Lundman was grateful for the 3D computer program Metso is able to offer custom-ers “The PDMS 3D computer program is

of enormous help in designing the layout

of a building to house a PDW It is of great advantage to be able to see what the facility is going to look like and how it will function before it is actually in place,” says Lundman

Lundman and Annette Nilsson, Process Engineer recovery line at the mill, were instrumental in the research conducted into the various technologies and suppliers available for white liquor and lime recovery According to them, they selected the pres-surized white liquor filter technology over the other options because it is the most

AT SCA PACKAGING MUNKSUND

White liquor quality and

capacity up thanks to

cutting-edge technology

TEXT David Wold

Annette Nilsson, Process Engineer recovery line and Per Nilsson, Operator, at SCA Packaging

Munksund AB together with Jonas Lundgren from Metso during start-up of the new PDW filter.

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REPORTING RESULTS

modern technology available today The

fact that Metso staff were involved in the

original development of this technology

contributes to the confidence they have in

Metso as a supplier

“White liquor quality

our first consideration”

“Our first consideration when looking into a

new white liquor facility was quality Metso

guaranteed a solids content of 50 mg/liter

in the white liquor during commissioning

We are now running at 20 mg/liter or less

The former facility ran at a solids content of

50 mg/liter or more This caused cooking

problems and specks in the paper and

board products we produce It also

nega-tively affected paper machine availability,”

says Nilsson

“Our second consideration was

capac-ity, which, before the new installation,

was 2,100 m3 of white liquor/24h The

new installation increased the capacity

to 3,300 m3 /24h This is actually more

than we need for normal operations On

Pressure disc filter PDW is a compact

fully automated machine that produces crystal-clear white liquor and washes lime mud simultaneously.

Fig 1 SCA Packaging Munksund AB causticizing - 3,300 m3 of white liquor/24 h.

Hot water

CondensateCompr air

Green liquor from

smelt dissolver

Weak liquor to dissolverHot water

White liquor to digester 3,300 m3/d

Lime mud filter Weak liquor

storage White liquor storage 1 & 2

Storage

Option 3 Make up silo

Green liquor cooler

Hot waterCold water New equipment

Existing equipment

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Here’s what Munksund expected and what they got

Crystal-clear white liquor. White liquor out of the new PDW at SCA Packaging Munksund AB has a solids content

of 20 mg/liter or less The former facility ran at a solids content of 50 mg/liter or more, which caused pulp

cook-ing problems and specks in the mill’s paper and board products, as well as poor paper machine availability These

problems are now history

Capacity options. The new installation increased the capacity from 2,100 m3 of white liquor/24h to 3,300 m3 /24h,

more than is actually needed for normal operations This gives Munksund the option of running at a higher capacity

if needed, while allowing for additional production capacity in the future Additional discs can be added for even

greater capacity increases

Small footprint The PDW pressurized white liquor filter is a compact, fully automated machine that produces

crystal-clear white liquor and washes lime mud simultaneously The machine’s footprint at Munksund is significantly

smaller than that of the sedimentation vessel it replaced

the other hand, it gives us the option of

running at a higher capacity if we need

to catch up after a stoppage somewhere

in the process It also allows for additional

production capacity in the future

We had some problems with leaking

fil-ter cloths in the beginning and this caused

higher solids content in the white liquor

than we expected But Metso corrected

the problem, and now we are running with

high availability and very acceptable solids

content,” says Nilsson

Produces white liquor

and washes lime mud

The PDW pressurized white liquor filter is

a compact, fully automated machine that

produces crystal-clear white liquor and

washes lime mud simultaneously Its

unit-type shaft, no-blow design, high-pressure

cake washing and cloth cleaning ensure

high specific capacity, high white liquor

purity and minimum maintenance

With an extremely high white uor yield of more than 95%, the PDW eliminates the need for separate lime mud washing and reduces the flow through the green liquor handling, slaking and caus-ticizing These features reduce upstream equipment sizing and facilitate plant upgrading

liq-Filtering in three steps

The PDW filter sequence is carried out in three steps: pre-coating, filtration and washing - see Figure 2

During pre-coating, the vessel is filled with a high flow of causticized liquor to form a lime mud pre-coat on the filter discs, which serves as the active filter me-dium during filtration

Gas lifters prevent sedimentation of the causticized liquor in the bottom of the vessel Discharge scrapers scrape off excess

Causticized liquor from

slaking and causticizing

Compressed air Condensate

White liquor to storage

Lime mud to storage

Fig 2 PDW filter sequence.

lime mud from the filter discs, which is then flushed to a lime mud mix tank.During filtration, cake head washers wash the lime mud cake accumulated on the filter discs Discharge scrapers scrape the washed and dewatered lime mud from the discs It then falls through discharge chutes, where it is flushed with warm water into the lime mud mix tank The slurry from this process is pumped to the lime mud storage tank and the filtrate is pumped to the white liquor storage tank

The scrapers are automatically actuated

at regular intervals to renew the ate layer of the pre-coat This procedure keeps the filter medium free of plugging.The washing sequence cleans the filter cloths on the discs When this sequence starts, the filter feed is interrupted, the scrapers are advanced to their inner posi-tion and the vessel drained When it is empty, the medium-pressure water show-ers located above the scrapers remove the pre-coat and washing is completed

intermedi-An acid wash instead of a water wash is occasionally required to maintain the ca-pacity of the filter This procedure involves discharging acid through the cake wash showers The acid is discharged into the lime mud vessel and then pumped to the lime mud storage tank

Thomas Malmqvist Sales Manager

Tel +46 70 310 53 22 thomas.malmqvist@metso.com

REPORTING RESULTS

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featured article

Multilayer curtain coating has the

potential to revolutionize the art

and science of paper and board

coating, allowing precise,

cost-effective coverage of the base sheet

to get the tailor-made functionality

desired Interest in this technology is

growing rapidly around the world.

‘Game-changing’ multilayer curtain coating technology

Are you ready?

TEXT Hugh O’Brian

simul-taneously in multiple layers in your sheet, precisely where it is needed, and in exactly the right amount And then consider the significant cost advantages of doing it at very high speeds in a clean, quiet, non-contact operation

Actually, you don’t need to imagine this: some papermakers are already ing it! And many more are now actively assessing a revolutionary new coating system to see how they can apply it to existing grades and, perhaps much more importantly, create new products

do-Stig Renvall, Senior Paper Technology Manager (right) says that the advantages of OptiLayer multilayer curtain coater in terms of cost, quality and operational efficiency are very

clear Reijo Kaipainen, Coater Operator, welcomes you to take full advantage of the pilot multilayer curtain coater at Metso's Surface Treatment Technology Center.

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featured article

The technology is Metso’s new OptiLayer

multilayer curtain coating system, which

adds several different coating layers to the

web at the same time in a non-contact

operation with essentially no speed

restric-tions This gives extremely high efficiency

with regard to coating chemicals, machine

runnability, drying efficiency and overall

cost of the process The coating follows the

contour of the sheet for complete and even

coverage of the web

The process was developed by Metso

in close cooperation with the coating

formulation supplier Dow Chemical The

two companies have cooperated in the

development of this technology for paper

and board manufacturing applications

One of the leaders in the use of

OptiLayer is Dong Il Paper in Korea, which

has succeeded in producing and

market-ing a new white liner grade based on 100%

recycled brown stock Thus brown simply

becomes white in a single, cost-effective

coating step No bleaching, no white fiber

Did we miss something?

The results from Korea have certainly got

attention at technical presentations and

conferences held in Europe recently “Many

of the testliner makers we have talked to

appear a bit anxious, or even nervous, that

they might have missed something when

they heard about what Dong Il has been

doing,” explains Timo Saresvuo, Sales

Manager at Metso “Since those results

became public in late 2009 there has been

a very noticeable increase in the level of

interest in the multilayer curtain coating,

and in the trial activity on our Technology

Center pilot line.”

The OptiLayer technology is based on

curtain coating methods that have been

around for a fairly long time What is new

and revolutionary is the multilayer aspect

and its successful commercial application

in installations around the world While there is a fair amount of secrecy sur-rounding some of the installations, two of them, Dong Il in Korea and Jujo Thermal

in Finland, have been willing to discuss their results In both of these cases, the companies have used this new technol-ogy to develop products, processes and functionality that has helped to keep them

a step ahead of the competition

What Dong Il Paper did

At its Ansan mill near Seoul, Dong Il rebuilt

a brown liner machine with the OptiLayer multilayer curtain coater It was therefore able to launch two new grades based on 100% recycled brown fibers, which it calls

WL (White Liner) and CWL (Coated White Liner), taking a market share on the Korean market Although Dong Il had no previous experience with coating, the unit easily started up in December 2008 and has been running very well for more than a year

“The multi-layer curtain coater gives us wide flexibility by putting the right properties

in the right place at the right cost,” explains Jin-Doo Kim, Vice President and Technical Manager at Dong Il “Titanium dioxide for light scattering, for example, can be put in the second layer from the top, which frees up the top layer for printability adjusting and fine tuning This means ratio adjustments for properties like brightness can easily be made

on the run At the same time, the precise curtain coating method gives much lower coating waste and broke.”

Kim says it wasn’t easy to push his ideas through, but he was successful eventually

“Actually,” he says, “many people consider

me a trouble maker! Since I originally came from the fast moving electronics business,

I generally refuse to accept the normal way

of thinking in the paper industry But by questioning the normal mode of doing things, I think we can move forward, and

we must, as it is really a matter of survival

Jujo Thermal used the unique technology to create a new extra-long durability thermal paper grade.

Operating principle of OptiLayer multilayer curtain coater: Coating

colors can be customer tailored to get the optimum function at the right cost.

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featured article

Although producers of liner and cialty grades have been among the most active in adopting the OptiLayer multilayer curtain coating technology, other grades can also benefit Depending on the grade, payback can be very rapid, as short as one year based on some calculations for sav-ings in fiber and coating costs

spe-Replace the airknife on coated board

“Coated board, which has used airknife ing for a long time, could get great benefits from the curtain coating method,” says Renvall “Airknife coating has low efficiency due to inherent runnability and speed limita-tions, as well as other problems such as noise, mist and coating reclaim A curtain coater could provide the same or better coating coverage as an airknife, in a faster, cleaner, quieter and more energy efficient operation.”

coat-High-quality inkjet photo paper is also seen as a grade that could take advantage

of this technology “I am a bit surprised that inkjet photo paper isn’t using this yet,” com-ments Renvall “It is a perfect fit and certainly the right equipment to make it cost effec-tively But perhaps because the OEM printer makers have such a strong hold on the mar-ket and product specs, the paper suppliers don’t dare to consider any other technology

I am sure it will eventually come through.”

“Along those lines,” continues Renvall,

“I don’t think it is too controversial

to say that the paper supply chain is risk-averse No one wants to take risks or try a new product that doesn’t exactly meet the specs that have always been valid for that grade But

if you look at what Dong Il has done in Korea, they just didn’t worry about the specs and launched a new grade that is working very well It might be what you could term

‘politically correct downgrading’

If there are very clear cost, quality and operational advantages, the specs can be adjusted After all, what is more important, specs or profits?”

That’s a good question and it seems pretty clear that this new multilayer curtain coating technology does have the poten-tial to be a ‘game-changer’ Perhaps the bigger question is: How will it impact on your company and your business?

A challenge for everyone

To use the potential effectively will require innovation not only from the paper-makers on the production floor or the technical people working with R&D but also the sales managers who will have

a new improved grade to sell and the higher company executives who must find unique ways of gaining a cost and market advantage over competing products How many paper industry CEOs and CFOs, or even sales managers, know what a mul-tilayer curtain coater is? Now might be a good time for them to find out

Stig Renvall Senior Paper Technology Manager

Tel +358 40 559 1693 stig.renvall@metso.com

The new white coated board from Dong Il,

using only brown fibers for furnish, has been extremely successful in the market.

for the paper industry The only way to stay

alive is to move fast!”

Jujo Thermal pushes innovation as well

Another company that has moved fast is

Jujo Thermal in Kauttua, Finland, which

started up the first commercial installation

in the world of the OptiLayer curtain coater

in 2006 The mill makes high-quality

ther-mal printing papers and was looking for

ways to improve cost efficiency By laying

down several layers at once in the exact

quantity needed with almost no coating

waste, the multilayer curtain coater was the

perfect solution

Technical Director Matti-Pekka Vanninen

comments that the new coater “allows us

to apply a very thin layer that follows the

contour of the web, meaning we apply

exactly what we need in the right place to

get an extremely even coat profile In

addi-tion, since we apply multiple layers at once

in one station, we get improved drying

ef-ficiency as we only need one pass through

the dryers to dry several layers This is very

energy efficient and the entire process gives

us excellent total cost efficiency.”

The incredible shrinking

R&D and tech departments

All of the efficiency and cost advantages that

OptiLayer offers should get a high level of

at-tention from the paper companies However,

a very real barrier to implementation of new

technology in the pulp and paper industry

is the fact that over the past decade or so,

most companies have made drastic cuts in

their R&D and technology staff

Stig Renvall, Metso’s Senior Paper

Technology Manager, is a real expert in

curtain coating He has also worked for a

major US paper producer for many years

“I have seen the situation from both sides

and it is clear that many paper companies

have ‘outsourced’ their R&D activities to the

machine and chemical suppliers over the

past decade So it is a big challenge for the

paper companies, even more so than in the

past, to evaluate and adopt a revolutionary

new technology like OptiLayer But this is so

unique that we are getting their attention,

especially from the fast moving companies.”

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The new line is ideally located to serve customers in Central Eastern Europe, as well as in Germany, Scandinavia and Benelux EUR 305 million investment, combined with a new state-of-the art box plant, strengthens Mondi’s position in the corrugated business by adding lightweight containerboard to its portfolio With ECO7 increasing capacity by 470,000 tons per year, the mill’s production will exceed one million tpy.

“I see Mondi Świecie emerging as the preferred solutions provider for container-board in Europe Customers will automati-cally identify it as the best supplier, and competitors will identify it as the best benchmark We intend to become the cen-ter of competence for Mondi in the field

of corrugating papers,” says Maciej Kunda, CEO of Mondi Świecie SA

Consumption of recycled board in Poland has grown at an annual rate close to double digits Earlier, its raw

container-material was to a great extent imported from Western Europe, mostly Germany

“The fast-growing market, good prospects for the overall economy, the central location, a good wastepaper sup-ply and a shortage of domestic capacity were the key reasons for Mondi’s invest-ment,” explains Market Intelligence and Research Manager Marcin Szwarc

“I see Mondi Świecie emerging as the preferred

solutions provider for containerboard in Europe,”

says Maciej Kunda, CEO of Mondi Świecie SA.

MONDI ŚWIECIE ECO7

Economy meets ecology

Fast, light and central are the adjectives with which the Mondi Group describes ECO7, its new Metso-supplied lightweight recycled containerboard line PM 7 in Świecie, Poland The line enables cost-effective and sustainable production with

no compromises on quality or performance.

TEXT Maiju Salenius and Marjaana Lehtinen PHOTOS courtesy of Mondi

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featured article

Maximum quality,

minimum environmental impact

In ECO7, economy has been designed to

meet ecology: maximum product quality

is achieved with minimum environmental

impact

The recent investments have enabled

Mondi to minimize its carbon footprint

substantially For example, CO2 emissions

have been reduced by more than 100,000

tpy, in addition to the 400,000 tpy already

reduced earlier Despite the increase in

paper production, this translates into a CO2

emission reduction of over 60%

Quality standards for recycled fiber

ECO7’s furnish is 100% recycled fiber When

the line reaches its full capacity, the total

recycled paper consumption will increase

to around 900,000 tons per year, equating

to over 40% of the wastepaper collected

in Poland

“Mondi is by far the biggest buyer of

brown grades in Poland, so the sources of

our raw materials reflect the structure of

the country’s collection system The paper

originates from industrial collection, retail

chains, corrugators and collection points

that buy material from individuals and

small enterprises,” says Marek Skorwider,

Purchasing Director, Recovered Paper

According to OCC Manager Andrzej

Błażejewicz, an analysis of the quality of the

recovered paper over several years has

al-lowed the mill to develop quality standards for its raw materials purchases Supplier training has brought good results and reduced problems during recovered paper processing in the recycled fiber (RCF) line

during the previous project also influenced the decision in favor of Metso,” points out Project Manager Maciej Janeczek, refer-ring to a rebuild project in which Metso converted Świecie’s sack paper machine

PM 1 for two-ply kraftliner

“Mondi always seeks to cooperate with partners capable of providing reliable and proven services This approach is especially important for strategic investments,” he continues

With a design speed of 1,800 m/min and

a capacity of 470,000 tpy, the wide PM 7 is one of the world’s fastest containerboard machines Its efficiency

8.6-meter-“Our positive experience during the previous project also influenced the decision in favor of Metso,” points out Project Manager

Maciej Janeczek (left), referring to a rebuild project in which Metso converted Świecie’s sack paper

machine PM 1 for two-ply kraftliner Metso's Project Manager Juha Hentunen on the right.

One of the world’s fastest containerboard machines

ECO7 represents a very large Metso livery, extending from the RCF line to the OptiConcept machine line It also includes

de-a comprehensive de-automde-ation pde-ackde-age with the latest and best-quality control and diagnostic measurement technology

“Metso was selected to deliver the new line because they offered a techni-cally advanced and proven concept at a competitive price Our positive experience

and short production cycles facilitate shorter lead times as well as high and fast availability of standard grades The product range encompasses lightweight recycled fluting and testliner from 75 to 140 g/m2 The maximum speed achieved so far on

100 g/m2 fluting is 1,400 m/min

Technological factors hidden in all sections

“The key factor in the production of lightweight fluting is an efficient paper

Trang 20

featured article

A USEFUL TIP

Take full advantage of

the supplier’s experience

A new line, new technology – so many things to learn, not only by

new recruits but also by existing staff It pays to take full

advan-tage of the supplier’s in-depth expertise and experience gained

from other deliveries That’s what Mondi Świecie did in training

almost a hundred of its people working on ECO7

“Approximately 60% constituted experienced people, in

particu-lar specialists and managers from other production departments

within the mill A special training schedule was developed for each

new employee, together with training materials and an

acclima-tization package,” explains Jarosław Ożóg, Director of Human

Resources

In addition, the new employees also received training by Metso,

as well as hands-on training They also took part in the pre-start-up

inspection and system commissioning

“The Metso people did a great job teaching and helping the

operators and maintenance staff to understand the machine The

hands-on approach proved most successful, with our people

work-ing alongside the Metso team every day,” says PM 7 Production

Manager Piotr Kowalkiewicz “It is much easier to learn from the

ex-perience of others than from your own mistakes Routine problems

for the Metso people were new to the operators on site In my

opin-ion, this approach enabled us to complete a good start-up phase

and gave us the opportunity to develop production efficiently.”

And he goes on: “The new line contains very modern and

automated equipment, which, in general, is easier to operate The

extensive DNAhelp tool allows a much faster response in case

of problems This is a high-speed paper machine, so everything

happens much faster – and the response to problems has to be

extremely quick As one operator said, ‘This machine does not

for-give mistakes and negligence’, so it has to be treated with respect

In general, working with ECO7 demands a lot of attention, but it

also gives a lot of satisfaction to all the maintenance and

In the SymRun pre-dryer section, tier web guidance and a smoothly operat-ing threading system provide for run-nability The advanced film transfer by the OptiSizer size press completes the sheet strength and helps to maintain good run-nability A double-tier group installed at the end of the SymDry after-dryer section contributes to good flatness properties

single-Entire line capacity managed with one single winder

OptiReel Plus reel enables the mill to duce jumbo reels with a weight of 100 tons and a diameter of 4.6 meters The produc-The produc-tion capacity of 470,000 tpy is handled by one single winder, the WinDrum Pro The robust and utmost reliable winder design combines all the latest advanced winding features, such as automatic splicing, knife adjusting, set changing and core loading.The whole production line is con-trolled by a metsoDNA DCS/QCS system According to Raniszewski, it offers very reli-able and helpful diagnostic tools that make

pro-Marcin Szwarc Andrzej Błażejewicz Maciej Janeczek Robert Raniszewski

Trang 21

featured article

problem-solving much easier and faster

than with their other machines

“The machine features the best available

technology and is designed to operate

with low water and energy consumption

The machine concept is flexible and allows

optimization of the furnish composition

and other factors, depending on market

needs,” Janeczek adds

A project can be fun

The amount of work during the installation,

testing and start-up phases of such a

pro-duction line is massive Doing everything

right and on schedule calls for high staff

motivation and good cooperation with the

main supplier on site

“The process was accomplished through

partnership and trust For our people, this

project was ‘fun’ and a constant challenge,

so it was easy to sustain high motivation

Metso also prepared a good team That’s the whole secret,” Raniszewski states

“Commissioning was a very intensive period for all the testing teams, including Metso, Mondi and various contractors

They all performed excellently,” adds PM 7 Production Manager Piotr Kowalkiewicz

“Of course, we had good and bad days, but

we were always able to solve the problems and push the process forward.”

The good feelings about the project are mutual: Metso’s team also greatly enjoyed cooperating with Mondi Świecie’s team

Customers impressed by runnability on corrugators

Production has been very promising in the first months after the start-up and has ex-ceeded the estimated volumes And what’s best, the feedback from the customers has been extremely positive

“We started to produce marketable quality within a few days The paper quality was according to the standard accepted

by our customers A series of tests on rugators also confirmed good runnability and strength of board in view of ECT and FCT With the papers produced by ECO7, our customers can run their corrugators

cor-at maximum speed and efficiency,” says Technical & Marketing Service Manager Marek Motylewski

“The most recent 4-month production run has already exceeded our planned start-up curve Our new lightweight recycled paper has been well received by our customers They are impressed by its excellent runnability and other distinc-tive characteristics, including consistent technological parameters and profiles, improved printability, and increased speed and capacity.”

Juha Hentunen Project Manager Paper business line

Tel +358 20 482 5030 juha.hentunen@metso.com

Piotr Kowalkiewicz Marek Motylewski Jarosław Ożóg

After the intensive commissioning period, the first jumbo reel was produced on September 1, 2009.

Trang 22

REPORTING RESULTS

New TwinRoll Evolution cuts

discharges and costs at Zellstoff-

und Papierfabrik Rosenthal

The pulp mill owned by Zellstoff- und Papierfabrik Rosenthal GmbH (ZPR)

located in Blankenstein an der Saale, Germany is proud to claim itself as

one of the most modern kraft pulp mills in Europe The mill’s continuous

investment in the latest technology of the highest technical standard

available supports this contention.

TEXT David Wold

Early in 2009, ZPR launched a project to

improve brown-stock washing Project goals

were numerous Among them was the

instal-lation of two new wash presses to reduce

wastewater discharges into the Saale River

and to reduce the fees ZPR is obliged to pay

under German legislation for such discharges

TwinRoll Evolution wash press

meets tough specifications

Expectations for the wash presses also

included low maintenance requirements

and high availability, reduced

consump-tion of bleaching chemicals and enhanced

prospects for increasing the production

of bleached pulp from 328,000 to 400,000

ADT p.a in the future

To meet these tough specifications, ZPR selected a new generation twin roll wash press that Metso has dubbed the TwinRoll Evolution for installation in its brown stock fiber line, and a TwinRoll TRPBZ wash press

in the bleach plant

While retaining the best features of previous generations, the new TwinRoll Evolution wash press significantly en-hances performance It does this through

a number of innovative design tions that increase capacity by as much

modifica-as 30%

“At ZPR technical staff play an important part in making decisions regarding pur-chases of new equipment We are always eager to get the latest technology with

the highest technical standard available," says Adolf Koppensteiner, Manager at the mill

“We are also very keen on achieving high availability and low maintenance requirements, and we expect the TwinRoll Evolution wash press will set a new standard in this direction.”

Adolf Koppensteiner, Mill Manager, Rosenthal

GmbH (left) and Lars Dahlqvist, President, Metso

Paper Sundsvall AB, unveil the first TwinRoll Evolution during a ceremony in Sundsvall.

Technical benefits of the brown-stock washing project

The new TwinRoll Evolution wash press is installed between the knotter and an older TwinRoll wash press positioned before the oxygen stage The TwinRoll TRPBZ wash press is installed before the Z-stage in the bleach plant This configuration permit-ted removal of the peroxide stage in the bleach plant See Figure 1 and Figure 2.The technical benefits of this project include additional closing of the filtrate loops, cleaner pulp into the ozone stage, better temperature control of the pulp into the Z-stage in the TCF sequence Furthermore, it also enables operating in the future without ozone in the ECF-bleach sequence

“The TwinRoll Evolution press worked

as planned during start-up Though there were some small hiccups, the start-up

of this new machine actually went even better than expected There were no unplanned stoppages

The first TwinRoll Evolution in operation at Rosenthal GmbH, Germany.

Trang 23

REPORTING RESULTS

“In terms of performance, the press easily

achieves the mill’s targeted production

level of 1,050 t/d, and not once during trial

operation was the outgoing pulp

concen-tration below the 32% level stipulated in

the contract,” says Koppensteiner

Cost savings

The reduction in fees ZPR is obliged to

pay for discharges into the river under

German legislation is a major cost saving

Recirculation of PO filtrate to the OP stage

cuts peroxide consumption Recirculated

PO filtrate increases the pH value before

the OP stage to reduce caustic soda

con-sumption

The additional washing equipment in the

brown-stock fiber line has made it possible

to reduce the dilution factor As a result the

dry solids content of the weak black liquor

has increased and the low-pressure steam

consumption for evaporation has been

reduced Replacing the old ozone stage

fluffer with a new plug shredder and ing the final P-stage up-stream towers has reduced energy consumption Removing old equipment in the bleach plant also saves maintenance expenses

remov-“The annual cost savings from the washer project are considerable The capital expenditure is low and the payback time is expected to be less than two years,”

Koppensteiner emphasizes

Development for the better

By definition, evolution means developing into something better, and this is exactly what the TwinRoll Evolution press repre-sents Although this new generation wash press employs many of the same compo-nents as previous twin roll presses, such

as a modular design to simplify the design structure and help cut delivery times, this generation performs even better

The principal benefit of the TwinRoll Evolution press is its significantly greater

capacity over a wider feed consistency range, compared with previous presses

At the same time, the TwinRoll Evolution delivers greater washing efficiency, main-tained at higher capacities

Modularization also positively affects maintenance costs When there are several TwinRoll presses in the mill, the quantity of spare parts to be stocked is reduced sig-nificantly The rolls are the same as those used on the fourth generation TwinRoll presses

“After this modernization, we will have a total of six TwinRoll presses in our mill Of course, being able to stock interchangeable spare parts was an important consideration when we chose the TwinRoll Evolution press The press also offers a high degree of safety for staff,

a wide capacity range, and automated systems for optimum operation,” says Koppensteiner

New equipment Demontage Relocated

P P D

PO Q

BT

HD

5000 m3 z

Q

HD Q

1200 m3 O2

I O2 II

BT DIG

BT

HD

5000 m3 z

Q

HD Q

1200 m3 O2

I O2 II

BT DIG

HD

BT

Magnus Danielsson Manager, Machine Design and Product Manager Washing Fiber business line

Tel +46 60 16 55 36 magnus.danielsson@metso.com

offset effluent charges.

Figure 2 New fiber line after rebuild.

Trang 24

REPORTING RESULTS

HiRun runnability blow boxes are used for

improving sheet support at the single-tier

dryer groups of high-speed paper and

board machines The latest HiRun blow

box design includes features that improve

performance and decrease energy

con-sumption Now some of these technical

improvements are also available as an easy

upgrade package for existing HiRun blow

boxes This HiRun upgrade service can be

carried out at the customer’s mill

concur-rently with regular blow box overhaul

Fast upgrade during

maintenance shutdown

Stora Enso Sachsen Papier PM 1 in

Germany produces newsprint with a wire

width of 10 m and a production speed of

1,750 m/min The mill was among the first

in adopting HiRun technology in 2003 A

total of seven HiRun blow boxes placed at

the start of the dryer section are currently

HiRun upgrade service saves

energy at Sachsen PM 1

TEXT Paavo Sairanen

“The performance of Metso’s service team was very professional and the improvement achieved in energy efficiency is of great importance to our mill,”

says Uwe Commichau, Mechanical Maintenance Manager, Sachsen Papier.

Air flow reduction

provides remarkable savings in fan power need.

ensuring the runnability of the machine’s newsprint production

All HiRun blow boxes were upgraded at the mill’s annual maintenance shutdown

in December 2009 In addition to eral maintenance and upkeep, the target was to save electric energy The scope of service included an upgrade of the blow box edge areas as well as a complete box overhaul (including replacement of coanda profiles and labyrinth seals) The end covers were replaced with new ones

gen-in this upgrade, gen-includgen-ing an improved end sealing arrangement These new end covers also include a service hatch at the tending side that enables faster and easier VacRoll cleaning

50% energy savings

The improved end sealing arrangement reduces air consumption, thus creating savings in air fan electricity use Fan power

HiRun blow box before and after upgrade.

Paavo Sairanen Global Product Manager

Air Systems Service Tel +358 50 317 3873 paavo.sairanen@metso.com

Before

After

consumption was reduced by nearly 50% after final setup while blow box perform-ance remained at the same level as before the HiRun upgrade service

This upgrade service is available for all HiRun blow box models The redesigned blow box construction is a standard fea-ture for new HiRun blow boxes

Trang 25

PRODUCTS AND SOLUTIONS

New generation blow boxes

for improved runnability

and electricity savings

Most of the severe runnability problems

at the dryer section are caused by the fact

that wet paper has tendency to stick to

the hot dryer cylinder surface This is due

to adhesion forces and aerodynamics in

the opening nip These forces are

increas-ing with machine speed By directincreas-ing the

counter forces with blow boxes to just the

right zones in the pocket area, it is possible

to improve the runnability

Also, energy aspects have been carefully

taken into account when improving our

runnability systems One example of this is

the development of the SymRun Plus blow

box, which replaced the previous SymRun

HS model This improvement leads to

about 50% lower electricity

consump-tion due to the smaller air flows and other

modifications in the blow box design

The same type of improvement has

recently been carried out on the HiRun

runnability system With certain

construc-tional modifications to HiRun blow boxes,

the energy usage of the system can be

reduced by about 30% In addition to this,

an even bigger reduction in the fan energy usage has been possible with our newest HiRun blow box model – and without compromising sheet runnability or tail threading efficiency This state-of-the-art design uses 40% less electricity to create the same supporting force for the paper sheet against the dryer fabric than the previous model

These remarkable results (Figure 1) in energy savings have been possible by re-thinking the equipment construction and

carefully researching the paper web iour, especially in the opening dryer nip

behav-Additional energy savings with new ways to run the air system

In addition to the above savings given by new energy-friendly equipment, it is also possible to re-think the ways of running the whole air system By controlling the air systems in a new way, it is possible to achieve big energy savings in the dryer section runnability This kind of adjustment can be done both for runnability boxes and for vacuum rolls in the dryer section

For the VacRoll system, for example, this kind of optimizing process means that the ductwork is designed so that the system can be divided into separate vacuum zones in the machine direction Generally,

at least two VacRoll fans with variable speed drives are needed for the system in order to be able to minimize the energy consumption in a proper way

With such main arrangements in the air system, it is now possible to optimize the vacuum levels in the machine direction so that sheet runnability remains excellent but fan energy usage is lowered dramatically

The highest vacuums are needed at the beginning of the dryer section, where the sheet is weakest When going towards the dry end of the dryer section, the vacuums can be reduced without causing any harm

to the sheet This enables less fan power to

be used in the latter part of the dryer section

Of course, the possibility to carry out this kind of adjustment successfully also depends on the paper grade and produc-tion speed But even quite small reductions

in air flows are known to be very beneficial

in the energy respect if the adjusting is done by using variable speed drives for the fan motors The dimensioned full air flows and fan power are, however, normally needed for successful tail threading

Figure 2 schematically shows the principle

of this new way of running the runnability air system with optimized air flows in the machine direction By adjusting the VacRoll air flows accordingly it is possible to achieve even 50% savings in fan power consumption

Pekka Saarikivi Product Manager, Air systems

Tel +358 20 482 4352 pekka.saarikivi@metso.com

New ways to run with less energy

TEXT Heli Anttila and Pekka Saarikivi

Development towards more sustainable paper production is a continuous process An

important part of this development is the overall tendency to reduce the drying section

energy usage Several improvements have recently led to new and more energy-efficient

runnability systems at the dryer section And what is also important is that, in spite of the

lower energy usage, the performance of the new runnability systems is even better than

before, resulting in higher productivity from the papermaking line

Figure 2 Principle of the optimized way to run the dryer section air system

100 80 60 40 20

Figure 1 Positive results of the recent

development projects for SymRun Plus and the newest HiRun blow boxes

Trang 26

PRODUCTS AND SOLUTIONS

Thanks to development work, a direct drive implemented with the permanent-magnet

motor technique is nowadays a very significant alternative for paper machine drives Gears

are not required in the permanent-magnet motor technique because the motor produces

the required torque at the roll’s rotation speed

Metso provides drive solutions for various

pa-per machine concepts and roll constructions

Drive solutions traditionally include electric

and mechanical drives Mechanical drives are

implemented with different gear solutions,

depending on the structure of the roll or the

cylinder The gears reduce the electric

mo-tor’s rotation speed to one suitable for the

rolls and cylinders These gears are placed

either outside the machine on a separate

foundation or in the machine mounted on

the frame structures or the roll structure

A direct drive enables a gearless drive solution with lower energy consumption

A direct drive implemented with a permanent-magnet motor can be used to replace a traditional separate gear solution

In this case only the permanent-magnet motor is located outside the machine, on its own foundation The mechanical en-ergy produced by the motor is transmitted

to the roll through a drive shaft The higher efficiency of space-saving direct drives

also saves energy, making the investment repayment time shorter

The compact DrivePro machine integrated drive can also be installed on the tending side

In co-operation with ABB, Metso has gone the extra mile regarding a drive solution based on a permanent-magnet motor

In the new DrivePro machine integrated drive solution, the permanent-magnet motor is directly mounted on the roll shaft

or the dryer cylinder shaft This solution is

New DrivePro machine integrated drive

Drive solutions implemented with the permanent-magnet motor technique reduce number

of maintenance items and save energy

TEXT Mikko Pitkänen and Sanna Sirén

Due to its compact structure, the

DrivePro machine integrated drive is a good choice for paper machine rebuilds.

intended particularly for paper machine applications It is suitable for positions in a production line where the motor’s power transmission capacity and rotation speed range are sufficient

Since the motor is liquid-cooled and the bearings are lubricated with circulation oil, it can also be used as a drive solution for the dryer section, inside the hood A DrivePro machine integrated drive can be installed on both new production lines and machines to be rebuilt The solution saves a considerable amount of space since mechanical drive components are not needed This is a very significant ad-vantage for rebuilds in particular The high efficiency and motor power factor make it possible for smaller frequency converters and cables to be used, and also results in lower energy consumption

Mikko Pitkänen Product Manager, Mechanical Drives

Tel +358 40 556 2509 mikko.pitkanen@metso.com

The advantages of a direct drive equipped

with a permanent-magnet motor include

• high torque at low rotation speeds

• improved control accuracy

The advantages of a DrivePro machine integrated drive

• can be installed on the drive or tending side

• no mechanical drive components – saves space

– fewer items requiring maintenance – no separate foundations

• oil-lubricated bearings

• low noise level

• quick and easy to install

A direct drive implemented with a permanent-magnet motor can be used to replace a

traditional separate gear solution The DrivePro machine integrated drive saves space, and the

number of maintenance items is reduced since there are no mechanical drive components

Tiêu đề	Metso’s Customer Magazine for the Pulp and Paper Industry
Trường học	Metso Paper Inc.
Chuyên ngành	Pulp and Paper Industry
Thể loại	Magazine
Năm xuất bản	2010
Thành phố	Jyvaskyla

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Số trang	52
Dung lượng	9,59 MB