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magazine

Edito

PAPER MIDDLEAST pulp, paper, tissue

The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East

N°20 - Spring 2013 Head Office / Publisher ENP SA info@groupenp.com 36, rue Stanislas Julien - 45000 Orléans France Tél. +33 238 42 29 00 Publisher STÉPHANE RICHARD stephane.richard@groupenp.com Editor in chief Lebanon RIMA DIB rima.dib@groupenp.com Correspondants Syria AHMED AL SLEEBA ahmed.sleeba@groupenp.com Jordan RAMI HOURANI rami.hourani@groupenp.com Advertising Middle East rima.dib@groupenp.com Tel: +961 32 24 953 International Advertising STÉPHANE RICHARD stephane.richard@groupenp.com FRANÇOIS HÉNIN francois.henin@groupenp.com Tel: +33 238 42 29 00 Fax: +33 238 42 29 10 Graphic Designers ELHAM EL MASRY GHALI SIMON & PARTNERS Subscription MATHILDE SEVESTRE mathilde.sevestre@groupenp.com Diffusion : 3.000 ex. Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco, Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen www.groupenp.com

T

he State of Kuwait is among the smallest states on the Arabian Gulf Sea, and the number of the paper mills is comparably little.

The GCC economies, in particularly the Kuwaiti economy likewise most of the world economies, show a continuous increasing in the markets demand. The paper industries showed a fast growth and development indexes, but also a rise in terms of the production following the rise in the raw materials prices which are most of the time imported. Recent studies undertaken by the local bodies represented primarily by the Kuwaiti Ministry for Commerce & Industry, and the Public Authority for Industry showed that the domestic consumption of paper in the GCC has increased by more than 37% during the seven past years. The study resulted on stressing on the need to present a significant quantum leap mainly through those industries: the paper rolls and cardboard boxes industries that form the backbone of the paper and packaging industries and which are most of the time unavailable in the local market, thus, extensively and largely imported. As a result, these bodies joined forces in creating opportunities for new investors encouraging them to take advantage by establishing paper related projects. In the following pages, we are going to highlight on one of the relevant paper mills in Kuwait; the United Paper Industries CO., through the discussion we had with the General Manager Mr. K. Gopal. But before I leave you to explore its content, I regret to inform you with deep sorrow, that Paper Middleeast magazine lost one of its young reporters from Egypt, Mr. Yasser Zakaria. May his soul rest in peace, and to all a long and healthy life!

Official Media Partner

2013 Rima Dib rima.dib@groupenp.com

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4 papermiddleast


Contents

Paper Middleast 20 Summer 2013

5L^Z 6

Europac opens a corrugated packaging plant

6

Turkey’s Hayat Kimya starts tissue production at Zencan mill

6

Metso receives repeat order for two complete tissue lines from Hayat Kimya

8

Mondi starts new industrial bags plant in Sulaimaniyah

8

Germany’s GapCon to supply turn-key tissue plant to Tunisie Ouate

9

 5+90;A[VYLI\PSKIVHYKTHJOPUL ( for Kartonsan Karton Sanayi ve Ticaret, Turkey

10

Yasser Zakaria in our hearts...

16

High quality liquid ring vacuum pumps: less water and less energy consumption

18

-SL_PISLHUKLĄJPLU[!5HZOZ\WWSPLZH vacuum system for the new PM2 paper THJOPULH[ALSSZ[Vă7€SZ

Technology 20

Service on-site for cylinders of the paper industry

Focus Kuwait - United Papers Industries CO. 22

Gopal on the light

Events 28

Starpack - 500 Students from Lebanon, Egypt, Palestine, & Jordan in StarPack 2013 Promoting Industrial Culture among the Youth It’Tissue (Italy) - When tissue can be fun

Special Pumps & Valves 11

5L^Z

13

9LQLJ[W\TWZMVYW\SWLYJSLHUPUNZ`Z[LTZ

30

14

 5+90;A4*W\TW!*\[[PUNLKNL ( medium consistency technology operating successfully

7HWLY*SHZZPÄLK

Advertisers Index Ashland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 67 BTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 64 Coldwater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 FAM Ingenieria . . . . . . . . . . . . . . . . . . . . . . . 13, 54 Hannecard . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 62 Kadant Lamort . . . . . . . . . . . . . . . . . . . . . . . . . . 27

MIAC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 PaperME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 PMT Italia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 RIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Souche Papers. . . . . . . . . . . . . . . . . . . . . . . . 32, 51

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News

MOROCCO

Europac opens a corrugated packaging plant Spain’s Europac has expanded into North Africa. The firm announced lately that it opened a corrugated packaging facility in Tangier, Morocco. At present, the facility concentrates on the production of heavy-duty boxes for industrial customers. According to the firm management, the plant can produce up to 15 million m²/yr. However, Europac was set for further growth in the country by seeking to complete the installation of two converting lines to produce conventional boxes. “The packaging facility in Tangier is the first step of a more ambitious industrial project in Morocco, which will enable us to strengthen our position on the country’s packaging market gradually.” Europac’s president, José Miguel Isidro, said in a statement. Carlos Larriba, General Manager of Europac Packaging, added: “Morocco is a relevant market for Europac due to the important role of the agricultural sector for the country’s economy. Moreover, the geographical proximity and the existing links between Iberian and French companies and Morocco will create important commercial and logistical synergies that will enable us to continue developing our business as a global packaging provider.“ RISI

IRAN

Turkey’s Hayat Kimya starts tissue production at Zencan mill The Turkish tissue manufacturer Hayat Kimya has started commercial production at its new tissue mill in Zencan in Iran. The Zencan mill houses one machine with a ca6 papermiddleast

pacity of 65,000 tones/yr of tissue, a trim width on reel of 5,600 mm and a maximum speed of 2,200 m/min. Some 250 people work at the factory. The paper produced in late April and early May was already saleable and the company reached a speed of 2,000 m/min within two days of the first startup, Aydin said. Hayat Kimya will sell both converted products and jumbo rolls from the Zencan mill. The company started up a converting plant with a BRT rewinder for making facial tissue and colored napkins on May 13. Due to strong demand on the Iranian market, Hayat Kimya will sell all the products domestically for the time being, Aydin said. Hayat Kimya operates one mill in Izmit, northwestern Turkey, where it houses two machines with a combined capacity of some 135,000 tones/yr of tissue. The company has plans to expand its operations in Turkey with a new plant in Mersin in the south of the country and to build a new factory in Yelabuga in Russia. It has contracted Metso to supply two 70,000 tons/yr tissue PMs for these projects. The Russian mill is supposed to start up in the second half of 2014 and the Turkish plant in late 2015. RISI

TURKEY

Metso receives repeat order for two complete tissue lines from Hayat Kimya Metso has received a repeat order for two complete tissue production lines for the Turkish Hayat Kimya A.S. Each production line will include an Advantage DCT 200 TS tissue machine, and they will be installed at the company’s new mill sites near the city of Alabuga, Tatarstan, in Russia, and in the city of Mersin in southern Turkey. The start-up of the tissue machine to be installed in Russia is planned for the second half of 2014, and the second tissue machine will start up in Turkey at the end of 2015. The value of the order will not be disclosed.


News

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News

Yahya Kigili, Chairman of Hayat Group, (in the middle) and Lütfi Aydin, Director, Paper Group of Hayat Kimya, (right) have agreed with Björn Magnus, Sales Manager, Metso, on the delivery of two new tissue lines for Hayat Kimya. In second row (from left) Kemal Tahir Yildirim, Purchasing Manager, Hayat Kimya, Haluk Arican, Metso representative, and Muammer Timur, Paper Project Coordinator, Hayat Kimya.

«Metso has been a reliable and trustworthy partner for our previous installations and we are pleased to continue our good cooperation also in this new project,» says Lütfi Aydin, Director, Paper Group, Hayat Kimya. “We at Metso are very impressed with how Hayat has developed. Only seven years ago they were a newcomer in the tissue industry. Today Hayat is a global player in the tissue market and is also the current holder of the world speed record for tissue machines. The world class results show the strength of our partnership,” says Jan Erikson, Vice President, Sales, Tissue Mills business unit, Metso.

will serve the growing cement industry which is rebuilding the country. «We are proud to announce the opening of our new green field plant in Sulaymaniah,» says Issa Azar, Regional Manager MENA Mondi Industrial Bags. This project coincides with Mondi’s strategy to support our customers’ expansion in emerging markets. «Having Mondi’s industrial bags plant close to our cement factories strengthens our long term business relationship and is important for good logistics and supply management,» states Rozhgar Barzan, Procurement-Sourcing Manager, United Cement Company - Lafarge Iraq.

«Iraq is now one of the Middle East’s growing countries and the construction industry is helping to rebuild the nation», explains Abdel Hafez Abki, Managing Director of Mondi Kaso Iraq. «The new plant further strengthens Mondi as a reliable industrial bags partner in the region», he adds. Omar Ismail, Managing Director of Mass Iraq Co. for industrial investment illustrates: «We are pleased with the startup of Mondi’s bags factory in Iraq and are looking forward to further constructive cooperation between both companies.» RISI

IRAQ

TUNISIA

Mondi starts new industrial bags plant in Sulaimaniyah

Germany’s GapCon to supply turn-key tissue plant to Tunisie Ouate

Mondi recently started full production at its new industrial bags plant in Sulaimaniyah, northern Iraq. Together with local partner, Kaso Group, this green field project is set to strengthen Mondi’s industrial bags business in the expanding Middle East and North Africa region (MENA). This is the first industrial bags plant in Iraq, and 8 papermiddleast

Tunisie Ouate, a well known and reputable tissue producer in Tunisia, and GapCon has recently signed a contract for the supply of a Turn-Key Tissue Plant. The contract covers, but is not limited to, stock preparation equipment, a complete Econ-


News

SOFTTM tissue machine and winder including all auxiliaries. The new machine will produce high quality toilet paper, facial, napkin and kitchen towel with the capacity of 70 tpd, which will enable Tunisie Ouate to expand their production capacity to meet the market growth in Tunisia and abroad. Mr. Abdelaziz KOOLI, the Director General, stated that by choosing GapCon, ÂŤTunisie Ouate has found a trustworthy and highly motivated and competent supplier.Âť Even though the future ÂŤbrandÂť is not yet known to the market, the project team for Tunisie Ouate has decades of experience in the tissue supply industry. GapCon has the ÂŤtoolsÂť and ÂŤdriveÂť to become an important player in the tissue world, supplying high tech, innovative and energy efďŹ cient machines contributing to the development of the industry. Source: RISI

TURKEY

ANDRITZ to rebuild board machine for Kartonsan Karton Sanayi ve Ticaret, Turkey International technology Group ANDRITZ will upgrade Board Machine 2 and the related stock preparation systems for Kartonsan Karton Sanayi ve Ticaret A.S. in Izmit, Turkey. The upgrade will increase production of duplex and triplex board from 100,000 to 160,000 t/a. The start-up is scheduled for the second quarter of 2014. ANDRITZ’s scope of supply comprises: s5PGRADEOFTHEMACHINEDESIGNSPEEDM min at a paper width at reel of 3,650 mm),


News

Wet end of a PrimeLine paper machine

including a PrimeFlow SW headbox with dilution control; rebuild of the fourdrinier wire and press sections with a PrimePress X shoe press; a new hood and air system; and rebuilding the pre- and after-dryers, hard calendar, and coating sections. s2EBUILDOFTHEDEINKINGLINEFORWHITELEDGER (capacity: 140 t/d). s5PGRADE OF THE BACKLAYER STOCK PREPARATION line with deinking otation unit and thickener disc ďŹ lter for an additional white ledger capacity of 85 t/d. s2EBUILDOFTHEEXISTING/##-IXED7ASTELINE

with a capacity of 380 t/d. s"ROKEPULPERADJUSTMENTANDNEWBROKETHIC kener. s4HREEPRIMARYANDTWOSECONDARYSCREENSFOR the four-layer approach system and a dilution water screen. s%NGINEERING SUPERVISION COMMISSIONING start-up, training, and spare and wear part packages for the entire equipment supply. With this order, ANDRITZ PULP & PAPER is conďŹ rming its position as a leading supplier for major rebuilds of paper and board lines.

Yasser Zakaria in our hearts... For more than 15 years he was able to build a unique name in the paper industry, and took his success out of the local market in Egypt to the Arab countries, and was known by leader suppliers and machine manufacturers in the paper, board and tissue industries in Europe, India, China and so on. Yasser Zakaria who had a dream of establishing a company that gives services to the paper industry, and so he was able to build a group of companies give complete solutions in different aspects such as technical services, engineering consultants, installation and supplying all that is related to the paper industry. Also he established Arab Paper Academy, one of its kinds in the Arab Countries that gives training courses to prepare a qualiďŹ ed new generation of paper makers. His death was a shock for his family, as well for all of his friends and customers around the world. He peacefully died, and left a well-known name in the local and international market, so continuing his footsteps was very essential to achieve his dreams. His wife along with all his companies stuff after a new reconstruction in the companies’ managerial structure decided to continue work and never stop, to keep his success as it always was with all the suppliers and customers inside and outside Egypt, so that Yasser Zakaria Group can always be in the paper industry and related to it as it always was. 10 papermiddleast


Pumps & Valves >> News

Value added services to boost global pump services market Advantages such as improved productivity and time savings promote greater adoption An augmentation in value added services (VAS) and integrated solutions are poised to give a fillip to the global pump services market. “There has been a continuous reduction of inhouse manpower across all industries, with end users requiring a stable system with minimum initial outlay and operator intervention,” noted Frost & Sullivan’s Industrial Automation and Process Control Programme Manager Ashwin Annareddy. “VAS offer advantages of reduced operating costs, increased asset availability, and minimised maintenance costs.” New analysis from Frost & Sullivan finds that the market earned revenues of $13.36 billion in 2012 and estimates this to reach $17.55 billion in 2016. The research covers maintenance, repair, and overhaul (MRO), installation and commissioning services (I&C), decommissioning, and VAS. A higher degree of automation in pumps are encouraging end-users to buy integrated solutions comprising pumps, frequency drives, valves, logic controllers, and automation software. “While these integrated solutions offer multiple advantages, they also require personnel with the expertise to operate them,” stated Annareddy. “With the design of pumps and systems becoming increasingly complex, service providers are expected to have greater opportunities in the areas of MRO, I&C, and decommissioning. Specialist service providers and distributors are set to continue their dominance.”

services,” concluded Annareddy. “VAS, such as condition monitoring, predictive maintenance, and advanced diagnostics, are fast gaining acceptance and will account for a significant portion of the market.”

Sulzer Pumps launches new performance service Reduces cost of ownership in the pulp and paper industry Sulzer Pumps has launched a new Pump Performance Expert service for customers in the pulp and paper industry. This new global service will contribute not only to reducing customers’ Total Cost of Ownership (TCO) but also to achieving significant benefits in their existing and future processes. The Pump Performance Expert Service focuses on MC® (medium consistency) applications, agitation and mixing applications, tower channeling and discharge. This service is applicable for both the installed bases of Sulzer Pumps and other Original Equipment Manufacturers (OEM). By applying our in-depth knowhow and expertise in diagnostics and regular mill surveys our customers can achieve extensive

However, end-user adoption of advanced pump services as well as technology, especially for VAS, has lagged. A conservative mindset has hampered the uptake of new technologies and services despite their ability to enhance productivity and save time. “This approach is poised to change in the long-term as the end-users realise the importance of these papermiddleast 11


Pumps & Valves >> News

performance improvements in mixing, agitation and pumping applications. Through this service, customers will significantly benefit from simplified applications, energy savings and more flexible processes with reduced chemical consumption, operation costs, maintenance and process down time. Customers will gain from a wide range of savings in pumping, mixing, agitation and tower management applications, all in one package. Additionally to this service, Sulzer Pumps offers large mill and corporate wide agreements to further reduce TCO.

AESSEAL - 30 consecutive years of growth The ingrained ethos of putting customers at the heart of its business has powered AES Engineering Ltd to its 30th consecutive year of sales and profit growth. Its annual results for the year to December 31 2012 show that the company, parent to the AESSEAL Group, pushed up sales during the year by 6.4%, to £131.9m. After allowing for acquisitions and exchange differences the company reports that like for like sales growth was a healthy 8.2%. A global player, Yorkshire-based AESSEAL is the world’s fourth-largest designer and manufacturer of mechanical seals for a wide range of industries, including oil and gas, food, water, mining and pharmaceuticals. And even as it marks its continued growth, it is working on plans for further expansion. The past year saw earnings before interest, tax, depreciation and amortisation (EBITDA) rise to £23.8m. Activities in its key strategic market of oil and gas also grew, by 26% in 2012, on top of the previous year’s 49%. The group reports it has expanded in the UK and around the world, especially in emerging

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markets, that it is “well positioned to take advantage of the higher growth rates in markets outside of Europe and the USA” and will be continuing to strengthen its network wherever it sees opportunities for accelerated development, including sub-Saharan Africa and the Middle East. AES Engineering Ltd employs more than 1,600 people worldwide, of whom nearly 600 are in the UK and Ireland and more than 330 in Rotherham. AESSEAL, whose Global Technology Centre HQ is in Rotherham, South Yorkshire, had net assets of £64,150,000, 17.2% up on 2011’s £54,727,000. It also increased the stock it holds to £25.3m, up 6.3% from 20011’s £23.8m, enabling it to give customers even faster service. The group’s expanding pump business, Bedford-based AESPUMP, also made excellent progress, including acquisitions in Denmark and The Netherlands. Sales rose to £9.3m in 2012, an aggregate growth of 30% on 2011. Stephen Shaw, group engineering director, said: “Our investment in research and development over the past five years has seen the product range develop more than any other seal company worldwide during that period.” Group founder and managing director Chris Rea, OBE, said: “Over the past three years the group has continued to develop as a reliability-focused business, with exceptional sales growth of complementary products such as our bearing protection and seal support system ranges alongside emerging complementary services and consultancy support capabilities. In addition, our objective of offering a high-quality alternative for compressor dry gas mechanical seals is now a reality.” “The group’s purpose is to put customers at the heart of our business through providing exceptional customer service. Our customers have supported the expansion of our products, processes and the globalisation of our business. We believe this growth will continue in 2013 and beyond as long as we continuously improve every aspect of our business that brings a benefit to our customers.”


Pumps & Valves

Reject pumps for pulper-cleaning systems

W

hat is a reject pump, what is its purpose and where is it used? The answer to this three-fold question is set out below. A reject pump is a specially-designed non-chokable pump configured to handle liquid/solid mixtures that are extremely contaminated by materials of various sizes and types. The size, rotor-configuration and housing design of the special pump described here ensure its performance as an absolutely-reliable feed pump for use in automatic pulper-cleaning devices and similar systems. One familiar application of pulper-cleaning devices is their use in materialhandling systems that involve, for reasons of cost, the treatment of pulp containing unsorted, highly contaminated waste paper. The pulper rotor takes up and fragments the bales of waste paper, but not contaminants such as variable quantities of plastic debris, shards of glass, small stones, wood splinters or other woodwaste residues, metal items such as the mechanisms from ring-binders, fragments of rubber from car tyres, or many other items. All of these undesired additional components, which can unfortunately be present in large quantities, must be efficiently and cost-effectively removed, preferably as part of a continuous process. Automatic pulper-cleaning systems are available in various configurations, although they

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all have one basic element in common: the feed pump, referred to as the “reject pump” for our purposes, which supplies the pressure needed to ensure the reliable functioning of the cleaning system, thus allowing the required feed quantity to be supplied, while ensuring the proper fragmentation of larger plastic and wooden elements, and also the processing of rustresistant cast steel. The FAM reject pump described above is of extremely robust construction, as it has to work with absolute reliability in 24/7 operation. The system runs at low speed, within a range of 300-650 rpm, with a maximum flow-rate of 18,000 litres per minute and a water column of 18 metres or more. The FAM reject pump provides a reliable and increasingly-vital disposal or feed device for the system concerned, whether it is a pulpercleaner or any system designed to handle liquid/solid mixtures containing components of various sizes. The author of this article also designed the reject pump, which is likewise manufactured under his supervision and management control. The pump is already in use all over Europe, and initial units are now also in operation in Asia, Africa and America. Modern Karton, a company based in Corlu, Turkey, has been using four FAM reject pumps successfully for substanceprocessing purposes since 2007.


Pumps & Valves

ANDRITZ MC pump:

Cutting-edge medium consistency technology operating successfully International technology Group ANDRITZ has had a tried-and-tested product for pumping medium-consistency pulps in the pulp and paper industry in its portfolio for over 20 years. A new MC pump has been developed in order to meet the market’s need for simple control and ever higher throughputs. The pump has already achieved excellent results in industrial applications.

M

edium-consistency (MC) pumps are used to pump stock in bleaching lines, pulp lines, and recycled fiber lines. These pumps are highly process-critical and thus, decisive to project success as the entire production volume of a plant runs through them. The development project for the new ANDRITZ medium-consistency pump was launched in 2004 by the centrifugal pumps department in Graz, Austria, together with ANDRITZ Finland. In intensive development work, a highly simplified and extremely customer-friendly system with high efficiency was finally created. “I have followed the development project for the new ANDRITZ MC pump since its launch in 2004. This pump has reached a development status that makes it the best solution for pulp lines,” says Jorma Paasi, Director of Global Engineering and BuThe ANDRITZ MC pump: siness Development efficiencies of over 70% and at ANDRITZ. very easy handling

lution, with the required components (conditioner/fluidizer and pump impeller) mounted on a shared shaft. In addition, the vacuum pump that is usually a part of the pump system was eliminated for the majority of applications.

Higher efficiency After this first development stage, optimization of the pump continued with a focus on further increasing the efficiency. In 2005, the MC test stand for pump development went into operation at the development center for fiber technology at ASTRÖ in Graz and has never stopped operating for more than five days in a row! This intensive work on the pumping medium was the key to success. In 2007, the new MC pump (with a single-shaft design and no vacuum pump) was launched on the market and the first unit went into operation at Zellstoff Pöls AG in Pöls, Austria. “Feedback from the customer was very positive, who especially praised the higher efficiencies, the robustness of the pump, and elimination of the vacuum pump,” says Ludwig Michal, Head of pump development. Siegfried Gruber, Head of technical planning at Zellstoff Pöls AG: “We installed the pump, switched it on, and have never had to give it another thought since then.”

Keep it simple New separation stage First of all, the development team tackled the question of how to simplify the pump system as much as possible – as required by the market. This led to the development of a single-shaft so14 papermiddleast

“We knew that we were heading in the right direction and continued to concentrate all our efforts on product optimization. The pump was already wor-


king perfectly – with all of the advantages described – within the design range (nominal capacity). Then our main concern was to meet the special requirements that arise, for example, when new pulp production plants are being put into operation.” explains Ludwig Michal. In such cases, the MC pump often has to convey pulp with a lower fiber content (lower consistency), which makes control difficult. MC pumps need constant venting via a degassing line. Complex control systems had to be used to control degassing, and very often they did not work satisfactorily. This led to fiber loss, unstable pump operation, and blockages in the degassing line.

MC pump at the workshop in Graz, Austria

In order to eliminate these difficulties and simplify control, the pump team developed an innovative system: SMARTSEP. With this system, the air is removed from the pump by a separation impeller and the fibers removed with the air are returned safely to the pump at the same time. This guarantees that there is no fiber loss, and control of the degassing valve is incredibly simple: pump running – valve open; pump not running – valve closed. As part of optimizing the entire MC pump, the efficiency was also further increased. At design capacities of over 2,000 tons of pulp per day at a consistency of 12% (e.g. long-fiber sulfate pulp), efficiencies of over 70% are achieved, which are significantly above industrial average.

Advantages of the new ANDRITZ MC pump at a glance sExcellent efficiency (> 70%), significantly higher than the industrial average, thus low energy consumption sVery easy control and complete avoidance of fiber losses at all operating points thanks to the SMARTSEP system sSimple and cost-efficient design without vacuum pump in most applications.

Operating successfully At one of the world’s largest single pulp lines operated by UPM in Fray Bentos, Uruguay, energy savings of 7 to 15% were achieved with the new ANDRITZ MC. Control of the pump was highly simplified by using SMARTSEP. There have been no problems whatsoever with degassing, and also no fiber losses since start-up in November 2010. At the Mondi Syktyvkar mill in Russia, newgeneration ANDRITZ MC pumps were installed in the course of mill modernization. A major challenge facing ANDRITZ was to integrate the new equipment into the existing plant and make it all work. “The ANDRITZ MC pump, with its easy handling, contributed towards successful start-up,” confirms Mika Makela, Project Manager for the Mondi Syktyvkar Step Fiberline Project at ANDRITZ. In the Fibria Jacareí pulp plant in Brazil, an existing medium-consistency pump was replaced by an ANDRITZ MC pump. In spite of the higher pumping capacity, the existing motor could still be used. This gave the customer energy cost savings of over one-third. In autumn 2013, we will achieve another milestone in pumping of MC pulp: A fiber line in Indonesia will start up the first 3 units of the world’s largest MC pumps. These pumps have an efficiency of 73% (BOP) and will convey 4400 ADMT/d through the wash press line. With the MC pump, fiber lines can be upgraded to a capacity of up to 6500 ADMT/d.

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Pumps & Valves

High quality liquid ring vacuum pumps: less water and less energy consumption The Basque company SAFEM repairs and manufactures liquid ring vacuum pumps and accessories for the paper industry, with a clear difference against its competitors from Asia: all pieces are made out of cast iron, funded in local foundries. The quality and maintenance service given to this equipment are key issues for getting better energy efficiency in the paper mills where it is used.

I

n a paper mill, the simple action on liquid ring vacuum pumps and its maintenance allows high energy savings. If the mill counts six or seven vacuum pumps, for example, it is possible to lower the energy consumption from 23.000 kWh to 19.000 kWh. So states SAFEM, a family company established since 1964 in Tolo-

Piece to be mechanized. In the background: mechanical workshop. 16 papermiddleast

sa, Spain. SAFEM is a specialist in manufacturing liquid ring vacuum pumps and accessories for the paper industry, under its own brand. As a complement to this activity, the company repairs liquid ring vacuum pumps from all brands of the market and carries out studies and testing, for instance performance tests, pumps installation checking, etc. Thanks to these actions, the electricity consumption can be reduced by 10% to 30% if the adjustment of the pump is correct. In addition, air intake flow can be improved significantly. And these elements have all together a strong impact on the drying section in the paper mill.

Liquid ring vacuum pumps final finish.


Stock of mechanized pieces.

SAFEM manufactures 150 to 200 pieces per year, under order. Its main markets are Spain, France, North Africa (Algeria, Morocco), Russia, Poland, Czech Republic, Latin America and Asia.

Vacuum pumps for loan. In the background: testing bed.

Repairs are carried out in the workshop of the company, located in Lasarte, near Tolosa, Spain. The mechanical workshop occupies a surface of 900 m2, to which are to be added the boilermaker premises’ 250 m2. SAFEM owns the following machinery: three boring machines (for the mechanizing of casing and headers), two turning lathes (mechanizing of shafts, cones and rolls), two milling machines (drilling of cones, tops), a press and a balance. The clients can get a replacement pump as a loan while their own pump is been repaired in SAFEM’s workshop.

Cast iron makes the difference SAFEM’s main comparative advantage lies in the fact that all products are made out of cast iron, produced in local foundries, as a difference to its competitors from Asia. This Liquid ring vacuum pump SAFEM VP 2000 X (7 tonnes). features gives the liquid ring vacuum pumps a higher quality and longer lifetime. Other strength of the company is the high level of service; as an example, the point mentioned previously: SAFEM lets as a loan spare pumps to its clients, completely free of charge. In addition, the range of products is very wide, with 14 different models, ranging from 20m3/h to 17.000 m3/h (7 tonnes). Among the main projects that SAFEM recently achieved are the construction of a complete equipment for a phosphate mill in Tunes, the fabrication of a liquid ring vacuum pump SAFEM VP 2000 T2 for a new pulp machine, or two vacuum pumps VP 2000 T1 for an Italian tissue machine manufacturer.

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Pumps & Valves

-SL_PISLHUKLĄJPLU[! 5HZOZ\WWSPLZH]HJ\\TZ`Z[LTMVY [OLUL^74WHWLYTHJOPUL H[ALSSZ[Vă7€SZ ZellstoffPöls, in Austria, is the largest manufacturer of high quality, chlorine-free bleached long-fiber sulphate pulp in Central and South Eastern Europe. For the new PM2 paper machine, Nash is supplying the vacuum system for dewatering in the wire section and the press section.

P

M2 was a turnkey project, with the vacuum system and implemented technology specified by the paper machine manufacturer. Nash was in continuous contact with the paper machine manufacturer during the tender phase. Together, they developed the optimal solution for this challenging task, and the flexibility of the Nash solution and its energy efficiency eventually impressed and won over the customer.

Flexibility for the vacuum Many paper machines produce only a single paper weight (e.g. 80 g/m2, similar to copy paper) or weights within a very tight range. In such cases, only minor modifications to vacuum requirements are needed as production conditions, and thus the vacuum levels themselves, are kept relatively constant. In contrast, the ZellstoffPöls PM2 focuses on «MG» or «machine glazed» papers (a paper with very high strength), and incorporates the production of paper basis weights between 28 and 120 g/m2. This wide product spectrum places high demands on the flexibility of the vacuum system, as the method of drying has to adapt to each paper grade. 18 papermiddleast

NASH 2BE4 liquid ring vacuum pumps with v-belt drive are also used at the PM2.

For Gardner Denver Nash, the project represented an ideal opportunity to prove its high level of expertise in vacuum systems for paper machines. The major challenge was adapting the vacuum at the various suction points for each specified paper weight and the required drying needs. This was accomplished through the use of frequency converters that allowed for «fine adjustment» of the speed and the vacuum level to meet the specific requirements of the paper grade produced. The customer provided the list of vacuum requirements, but the specification of suitable pumps, the determination of the number of pumps and their assignments to the various suction points were the responsibility of the Nash team in Nuremberg.


In a first step, the required number and capacity of the liquid ring vacuum pumps were calculated for ensuring the requisite operational flexibility of the vacuum system. It had to be taken into consideration that strongly fluctuating vacuum levels are often applied at the various suction points in accordance with the grammage to be produced. All Nash pumps are driven with a frequency converter for «fine adjustment» purposes. In this way, the motor and pump speed - and thus the vacuum level of the pump - can be exactly controlled and precisely adapted to the specific requirement.

The customer’s specification was clear; focus on energy efficiency. Efficient operation of both the paper machine and the vacuum system result in lower energy consumption and lower operating costs. The alternative concept (low purchase costs that result in high energy costs over the operating life) was not deemed interesting by the customer. The project covers a scope of supply of five 2BE4 pumps of various sizes, all operated with frequency converters. The pumps will be provided in standard cast iron material construction with polyisoprene coating.

Efficient use of energy An important reason that the Nash concept was accepted was the energy efficiency of the machines implemented. Optimal dewatering of the paper in the Forming and Press sections (where Nash vacuum pumps are used) reduces energy (steam) consumption in the Dryer section.

Finally, the decision that Nash was the superior vacuum supplier for their new paper machine was due to convincing arguments from about the product’s flexibility, energy efficiency and insensitivity to water.

papermiddleast 19


Technology

Service on-site for cylinders of the paper industry

ll machines for the production and superďŹ cial treatment of paper are equipped with one or more big size cylinders. These cylinders have a paramount importance in the production process, some of them are the real heart.

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chance the request of service of maintenance and/or repair on site of these big cylinders is very often characterized by emergency situations and reduced service time with the target to avoid to excessively reduce the production efďŹ ciency of the plant.

For their size , weight and, most of all, for their position in the production plants, these rolls, once installed in the machine are never removed for the whole production cycle or often for the entire machine lifecycle.

Among the operations of Service on Site for big rolls in a paper machine we can list for example:

Among the most important positions we quote the most widespread : s9ANKEECREPINGCYLINDERS s#REPINGCYLINDERSAND-ONOGLAZINGCYLINDERS s$RYINGAND#OOLING#YLINDERS We should also include those cylinders which, in spite of their average dimensions, in most cases are not disassembled from the machines, for example: s7INDER$RUMS s2EWINDER"ACKING2OLLS Any routine or specially – made maintenance of these cylinders has to be effected therefore diRECTLYONTHEMACHINE FROMSKILLEDPERSONNEL the complete range of activities is generally grouped under the wording “ Service On Site “. It is curious that English language generically identiďŹ es in the initials of these three words the international acronym SOS for First Aid: by 20 papermiddleast

s&ACE GRINDING WITH CYLINDRICAL OR CROWNED proďŹ le s4HERMALCOATINGOFTHEFACE FULLFACEORLOCAlized on specially worn out areas s2EPAIROFDEFECTSONTHECYLINDERFACE s'RINDINGANDORTHERMALCOATINGOFJOURNALS s$YNAMICBALANCING Additionally the activities of diagnostics on site are not of minor importance, for example: s$IMENSIONALANDGEOMETRICALCHECKINGS s4HICKNESSMEASUREMENT s6IBRATIONANALYSIS s.ON DESTRUCTIVE TESTINGS TO CHECK THE CONDItions of the rolls and their structural integrity, IN PARTICULAR THOSE SUBJECT TO INTERNAL STEAM pressure and thus to binding safety norms. The essential requirements to effect this type of SERVICEDIRECTLYATTHE#USTOMERARE s4ECHNICALRELIABILITYOFTHESERVICEASLONGAS the utmost reduction of the service times s5SE OF MACHINERY AND PORTABLE EQUIPMENT comparatively easy to install on site which do


not require the need to dismantle a number of parts from the paper machine, at the same time ensuring repeatability and accuracy s3PECIALIZED AND CUSTOMER ORIENTED OPERATING personnel, capable to understand the requiREMENTSOFTHE#USTOMERANDBECOMEPARTNER IN ALL STEPS OF THE PROJECT OF ON SITE SERVICE from feasibility study to management of logistics and / or temporary export of the portable machinery to the actual service.

s#ONTINOUS DEVELOPMENT OF NEW MACHINERY and grinding technology, new abrasive media and materials for thermal coatings, with a complete vision based on direct experience on the ďŹ eld. The requirements are therefore really at 360 ° AS IN ORDER TO MAKE THESE TYPE OF SERVICES ALL involved professional proďŹ les have to be senior, MIXINGBOTHTECHNICALANDCOMMERCIALSKILLS

papermiddleast 21


Focus Kuwait

United Papers Industries CO.

Gopal on the light

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Paper runs in the family, my father was a leading paper technologist in India and so it was only natural that I followed in his footsteps.

Education – Under Graduate

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tarted my career in the year 1975 in mainly manufacturing and also as a consultant to a number of Paper Mills in India.

During my career spanning for 37 years, I have held different responsibilities from Production Manager to General Manager in medium to large paper mills in India and abroad. My foreign experience was in Union Paper Mills, Dubai where I was the Production Manager and was responsible for in commissioning the ďŹ rst Brown paper in UAE (Dubai) in the year 1988.

United Paper Industries is supplying to some of the Gulf (KSA, UAE) and Asian (Sri Lanka, India) countries and hope to supply the entire Middle East region.

A year before, I held the responsibilities of developing a project in ELF company in Egypt, being the Operations and Production Manager at the mill. That was in 1997.

I previously was in charge of the Technology Department at United Paper Industries Co,. Kuwait, and today I hold 2 positions; the General & the Mill Manager at the company.

United Paper Industries Company is different from the other paper mills in the region in that it produces Industrial packaging grades (Sack Kraft paper) used in Cement and Multilayer bags along with the conventional packaging grades like Test Liner, Fluting and Kraft Liner.

United paper Industries Company has ensured that all environmental requirement are met and water consumption per mt of paper is as low as 3-4 m3/.

22 papermiddleast

Paper Industry in Kuwait is better compared to other regions in the Middle East. Being a small


market and is well served by local suppliers, the import is mainly to cater to special grades like coated box board, pure Kraft and coated papers. Like any other Industry price swings due to imports from Europe has a damaging effect on local prices. The only way to beat the competition is to be more competitive. Since paper is a non oil based industry, support from the Government in reducing the Port charges (Continuous usage) to make export market more competitive will definitely help the local companies. A message to all our readers : Consume more paper so that the Paper Industry can survive, otherwise like in Europe and elsewhere, times will be very tough. Being a family man, would like to spend maximum time with them and on occasional holiday in Europe and Asian countries.

United Paper Industries CO. in depth United Paper Industries Company was established in 1999 and the plant was commissioned in 2001.

As there were no other paper manufacturers for this product, it was thought prudent by the late Chairman Abdulla Al Dikheel to go ahead with this project. His vision has borne fruit through the present chairman Dikheel A. Al-Dikheel as K. Gopal explained. A good Japanese Second hand paper machine was found and using European consultants the project commenced. To ensure that the automation and control level was at its highest, ABB Italy was engaged thru ABB Kuwait to provide all necessary Drives, DCS, and QCS requirements. United Papers Industries CO. is one of the most contributing businesses to the economy of Kuwait backed-up with its other sisters companies that deal with paper products and others: 1. International paper Products is a High Quality Printing and lamination for board. 2. Burgan Shoes that deals with the Foot wear. 3. Carpet Industry for Domestic. 4. Carton Industries Co. a Carton box Manufacturer. 5. Kuwait Paper Sack Factory; a Cement bag manufacturer. Paper Machine 1 (PM1)

Reason foreseen to start this paper mill was to cater to the multilayer bag industry for Cement and chemicals...etc.

UPI’s mill includes one machine (PM1) with the following specifications: papermiddleast 23


SANO Iron Works, Japan is the supplier. The machine was installed in the mill’s location in Kuwait in 1999, and the start up was established in 2001. PM1 has the capacity to produce an average of 100 mt/day of paper and has 230 cm of width and a 300 mpm as an operating speed.

Steam & Condensate system, Hood & P/v - A.V. Engineering, Italy

Production Range UPI’s PM1 machine is capable of producing different ranges of paper: Quality

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Half of the mill production is consumed in the local market of Kuwait, while the second half is exported to the Kingdom of Saudi Arabia, the United Arab Emirates, Iraq, Jordan, India and Sri Lanka.

The UPI management supervises the production process at the mill that is built on an area of 29000 m2. The core of the company is put together with the networking staff, which hands in hands make sure to apply the vision and objectives of the founder. More than 115 employees including the Administration personnel put their efforts to deliver distinguished products to the customer, working in different sections and department; the Process, the Mechanical, or the Instrumentation & Control System, the Electrical Department and the Utilities.

Supplier of the machine The mill uses both waste paper and virgin pulp for the production process. Local companies and the USA supply the need of the mill of waste paper, while Canada and Russia supplies the virgin pulp. Other providers supply the mill with the stock preparation, drives, and other instruments and equipments, such SANO, ABB, Kadant Lamort and others: Stock Preparation - Therma Black Clawson (Kadant Lamort, France) Drives - ABB, Italy Instruments - ABB Electrical and Automation - ABB Scanners - ABB Motors - ABB Gear Boxes - SANO, Japan Pumps - Ahlstrom, Finland Wires - Albany, Seden Utilities - DONLEE, USA/Thermax, India / ATLAS Copco 24 papermiddleast

In order to follow up and get updated with the latest technology in the paper ďŹ eld, through meeting with the paper professionals from around the world, the management makes sure to participate and attend the seminars and major paper events in the Middle East and Asia held in this respect. Therefore, UPI takes part in Paper Arabia – Dubai, UAE, Paperex – New Delhi, India and Asia Paper – Bangkok, Thailand. Progress Chart (Production and Sales): Production is the core of the business. Maintaining a high and stable level of production, controlling and improving the quality are a major issue that the Production in Charge P.K.Mohanty is taking in hand. The production and the sales rates both are 2 indexes going together. A good balance is an index of high performance, where leakage is downsized to the minimum, as shown in the table below:


Description

2010

2011

2012

2013 (till 2nd quarter)

Production (Mt)







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Sales (Mt)







17000

Quality

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The mill current project

Rebuild of Paper Machine 1 The rebuild of paper machine (PM1) has been envisaged keeping product quality in mind and increased production for pay back purposes. A lot of OEMs were considered but UPI settled on with PMT, Italy for the upgrading. Four main areas were considered namely, press, size press, pope reel and dryer section. In this the PMT patented AEGO shoe press was considered without any open draw to achieve paper dryness in excess of 52%.


To improve CD/MD ration of physical properties of paper, UPI is considering using hydroline & Varioline drainage element to increase activity on the wire table and improve properties in CD. After the rebuild United Paper Industries Company will be one of the ďŹ rst paper mills in the world to have a Clupak Unit and Size press in the same paper Machine. Below are the ďŹ gures on the speed and the production capacity reached after the rebuilt: Description

The AEGO ďŹ lm size press was considered for achieving high solids in the size press resulting in high stiffness in Test liner, Fluting and Kraft liner grades. AEGO pope reel was considered to achieve large jumbo reel (Excess of 2.5 mts in dia) and perfect winding to cater to modern high speed corrugators. In order to increase drying capacity, new 8 BAR drying cylinder will replace the existing low pressure cylinders. In the wire part existing dry suction boxes will be replaced with Duoow and Trivac suction element to cater to increased machine speed. 26 papermiddleast

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Future Project UPI management is planning to undergo a new project at its mill location. The project will answer the need of the increasing market demand on speciďŹ c products. Therefore, and in order to fulďŹ ll this need, the mill will acquire a double layer unit. This second layer machine will be able to produce two layers of Test liner and Fluting grades. With this fact, two advantages will be reached; one is by improving the quality of the paper produced;


company should identify and target different markets for it to maintain its position and enhance its performance as a market leader. Therefore, differentiating is the key, and UPI was able to differentiate itself from other key players in the local and in the regional market by producing a unique item the Sack Kraft paper.

second because the double layer unit will make it possible for the mill to introducing a new product to its basket of grades; which is the White Top Liner.

Conclusion The need to cater another industry pressed the late Chairman Abdulla Al Dikheel to evolve a vision that was concretized by establishing United Paper Industries. The need became a vision, and reaching the set goals gave UPI a colossal entity. Through the sections of this report on UPI mill and management, we become more aware of the fact that in a very competitive market, a

Moreover, the high operation indicator on production and sales on one hand and the determination to plan for new projects on the other are evidence on UPI’s understanding of the commitment to the values and vision in order to reach the desired goals and in order to compete in the market. Last but not least, UPI’s General Manager K. Gopal concretizes these values and goals through his expertise and skills. He believes that the only way to beat the competition is to be more competitive. He also calls people to consume more paper, and asks the government to reduce the port charges as a call for support for local companies to survive. Wishing the best for this industry and for those who believe to make it a better one!

papermiddleast 27


Events >> Starpack

500 Students from Lebanon, Egypt, Palestine, & Jordan in StarPack 2013 Promoting Industrial Culture among the Youth

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ebanon Student StarPack unleashed the creativity and talents of 500 students from 17 universities in Lebanon, Egypt, Jordan, and Palestine. Lebanon Student StarPack 2013 Award Ceremony took place under the patronage of his Excellency the Lebanese Minister of Industry, Mr. Vrej Sabounjian on April 23, 2013 in the UNESCO Palace.

Ms. Soha Atallah, LibanPack Director, inaugurated the ceremony and highlighted the following: “We celebrate the fifth anniversary of LibanPack, and this year creates a major challenge for LibanPack as starting 2013 LibanPack became self sustainable and financially independent from UNIDO. Lebanon Student Star28 papermiddleast

Pack began in 2010 with 90 students and ever since, it has extended beyond the borders of Lebanon to Jordan, Egypt, and Palestine.

Dr. Fady Gemayel, President of LibanPack stated: «Our ambition is for Lebanon to become a regional hub for packaging in the Middle East and this has been evident from the impact LibanPack has on the region specifically with the participation of students from Arab countries for StarPack. By organizing StarPack, LibanPack is working on developing the packaging industry in Lebanon and opening new horizons for the young generation.”


tant marketing role for packaging besides its functional role for protection.

Mr. Ziad Bekdache, Vice President of the Association of Lebanese Industrialists stated that: «Packaging is as important as the quality of the product itself and many companies are more aware of its significance to attract potential customers looking to purchase something new and distinguished.”

The competition awarded two categories: visual category and structural category where university students improved the packaging of Lebanese products. Most of the projects tackled the structural aspect of packaging to make it easy to handle by the consumer and in the supply chain. Furthermore, a prize for Sustainable Packaging was awarded by BankMed and a prize for Creative Design Award was awarded by Unipak, a member of Indevco group.

During the ceremony, H.E. Mr. Sabounjian stated that “LibanPack has become a reference in the world of packaging and we consider StarPack one of the main activities of the center since they provide an opportunity for students to present their ideas to interested industrialists and opens doors for securing jobs.”Furthermore, he stressed on the imporpapermiddleast 29


Events >> It’s Tissue

When tissue can be fun

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here on earth can you start your day with a smooth espresso on a sunny terrace, then sit in a 14th century convent transformed into a modern auditorium, listening to prominent speakers debate about their vision of the industry, before enjoying a buffet of one of the finest European gastronomies, next visiting factories of some innovative tissue machinery manufacturers, and finishing your day wandering around the small streets of a historical city and settling down to enjoy an outdoor jazz concert? The Lucca Valley in Italy is the place. It’s Tissue is the event. Those who experienced the very first edition of this unique event will certainly remember it. The initiative is based on an open-house concept, driven by 12 leading companies (see box below) specialized in the tissue production and converting process, has been a complete success. They joined forces and managed to gather around 700 tissue professionals from the five continents. Obviously many locals and Europeans were present, but the event also attracted many producers coming from more distant countries like Japan, Korea, Indonesia, and China. Nationals from Bolivia, Venezuela,

30 papermiddleast

Mexico, Brazil and the US were also represented, as well as Middle Eastern and African investors from Turkey, Dubai, Congo, Angola and Morocco. During a full week, they were invited to visit the companies of their choice around the valley, whilst being given explanations of the addedvalue of the latest technology with live demonstrations. Transportation and logistics were impeccable and the visits as much pleasant as they were instructive, thanks to a dedicated and most welcoming staff. The welcome reception took place in Cinquale, an elegant seaside resort. About 300 guests gathered for this exceptional social time, including a fantastic dinner followed by a memorable performance from Tony Hadley, the former lead singer of Spandau Ballet, the famous 80’s romantic band for those who are old enough to remember. And those wishing to extend their stay had the opportunity to join a cultural and gastronomic program of guided tours. This event is set to take place every three years. The organisers promised it will be even better in the future. We look forward to it.


It’s Tissue Network Members: sA.Celli: engineering, design, development and manufacture of complete Tissue Systems sElettric80: conditioning and warehousing sytsems sFabio Perini: converting and packaging lines sFutura: tissue rolls converting lines sGambini: tissue converting lines sMTC: tissue converting machinery sOmet: paper converting machines sPCMC: paper converting equipments sPulsar: conveying and packaging solutions sRecard: complete tissue machines sTMC: tissue packaging machines sToscotec: paper machines and technologies Supporting companies: s2OCKWELL!UTOMATION s(ENKEL s&ANUC s3+&

papermiddleast 31


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2013


Paper MiddlEast n°20 13  

The bilingual Arabic/English trade magazine dedicated to the paper, board and tissue industry in the MENA region. Bu ENP Publishing Group

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