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PULP-PAPERWORLD Issue 6 - November 2011

EMERSON’S Smart Wireless technology The ROSEBERY Group’s project for De La Rue

ABB hosts Paper Students BTG "No more soup"... MONDI SCP’s PM18 beats own world record Photo © Korsnäs Gävle, Gävlebukten, Sweden


December 2011 Contents 4

4. New tissue felt technology helps improve operational performance and reduce energy consumption 7. The Rosebery Group are please to announce the recent completion of their first project with their new client De La Rue 10. No more soup…optimising your tissue mill chemistry 13. ABB Showcases Its Products, Services and Teamwork for Visiting Students

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15. Walki-4E technology: a new, sustainable way of producing RFID antennas 17. Emerson announces first global users exchange in Europe 18. Emerson’s Smart Wireless technology helps meet environmental requirements at paper mill in Sweden

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22. ABB retains leading distributed control system market share worldwide for 2010 26. BTG Americas partners with Ashland Water Technologies to improve wet end optimization 28. Mondi SCP’s PM18 beats own world record as fastest paper machine of its kind. Publisher Melin-Jones Media Hjulsta Backar 25 Stockholm Sweden Tel: +46 8 12093201 Editor Ian Melin-Jones email: ian.melin-jones@pulp-paperworld.com


Xerium Technologies Unveils Advanced Tissue Felt Technology

Xerium Technologies, Inc. , a leading global manufacturer of industrial textiles and rolls used primarily in the paper production process, today announced full global availability of Impact TS, advanced tissue felt technology, as part of its clothing (PMC) technology designed to help customers improve operational performance and reduce energy consumption, which are vital to the manufacturing of tissue grades.


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ith Impact TS, Xerium continues to take the lead in advancing the technology of PMC, which is critical to tissue machines' overall energy efficiency and product quality as it is produced. PMC products are highly engineered synthetic textile belts that are used to transport raw paper along the length of the paper-making process, as it is formed, pressed, and dried, keeping in constant contact with the paper as it is formed. "Through innovations such as Impact TS, we continue to lead the market with technological solutions that boost efficiency and lower the cost of manufacturing paper," said Stephen R. Light, President, Chief Executive Officer and Chairman. "Time and again we earn our customers' loyalty by developing products with measurable return on investment." Impact TS incorporates a unique combination of innovative raw materials, highly compressible base structure elements, topped with our premium needling technology delivering outstanding press performance. Impact TS technology utilizes hydrophilic base yarns aligned perfectly parallel in order to provide an ideal combination of pressure uniformity, exceptional dimensional stability and immediate nip saturation. These unique features provide immediate startup, lower energy consumption and optimum steady-state performance. About Xerium Technologies Xerium Technologies, Inc. (NYSE: XRM) is a leading global manufacturer and supplier of two types of consumable products used primarily in the production of paper-clothing and roll covers. The Company, which operates around the world under a variety of brand names, utilizes a broad portfolio of patented and proprietary technologies to provide customers with tailored solutions and products integral to production, all designed to optimize performance and reduce operational costs. With 31 manufacturing facilities in 14 countries around the world, Xerium has approximately 3,400 employees.

mpact ts


Paptech Finland 2012 – a new meeting platform for Finnish pulp and paper professionals!

Paptech is a new event concept for the pulp and paper industry which provides an intimate, targeted and businessoriented platform. This is a two-day forum where suppliers and buyers meet and do business in a creative and relaxed atmosphere and where quality counts more than quantity. There will be inspiring seminars, a stimulating social programme and focused matchmaking.

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Exhibiting is easy – you just book an all-inclusive stand package and show up to do business! Paptech will attract high quality visitors including the key decision makers of the Finnish pulp and paper industry. Welcome to Wanha Satama, Helsinki, March 21-22, 2012. Find out more on www.paptech.com


The Rosebery Group complete first contract for De La Rue

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he Rosebery Group are please to announce the recent completion of their first project with their new client De La Rue, one of the foremost experts in Cash Management. De La Rue is the world’s largest integrated commercial security printer and papermaker and a leading provider of cash sorting equipment and software solutions to central banks worldwide. In preparation for a strip out of PM9 to make ready for refurbishment, De La Rue needed to relocate the Broke Chest on PM8. The Rosebery Group undertook the decommissioning/commissioning of the plant, which was completed within the allocated timescales and to the value of circa £70k. Peter Arnold, Project Manager from Rosebery’s said, “This was a relatively straight forward small project with De La Rue. However, we hope to be able to work further with this valuable client long into the future and that we have made a good impression at this stage.” A future project for Rosebery’s is the relocation of the Perini Line from Barrow Mill to Flint Mill for Kimberly Clark. In order to make room for the Perini Line to be received, a Breting Machine from

Flint has to be relocated to KC Bilbao, Spain. As well as decommissioning and commissioning the plant, Rosebery’s will also provide the design engineering for power supplies and loadings on site. The process will be completed within an allotted 2 month tight schedule and within budget to a total cost of circa £120k. Pete Arnold, Leading PM for the project commented, “Our previous experience in this sector proves invaluable time and time again. Clients such as KC know they can rely and trust us to complete the schemes designated to us. This enables ease of programming on their behalf for the fuller programme, which we know is of incredible importance to them. We may only be one spoke on the wheel, but we do see and appreciate the bigger tasks that our client’s have to complete.” Further new projects are in the pipeline for The Rosebery Group within the paper/pulp/recycling sector. Should you have any queries or think we can assist with any of your requirements, please contact Christine Suckley, New Business Consultant on 0151 357 1066, Christine.suckley@rosebery.co.uk.


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No more soup......optimising your tissue mill chemistry

by Ian Padley Tissue Applications Manager

Imagine a typical scenario faced by a tissue machine operator where chemistry has got out of control. Your machine is using a recycled fibre furnish and making some towel grades; but you are finding it very difficult to reach the wet tensile specification. This important end-user property is delivered by a chemical, a cationic polyamide-epichlorhydrin in fact, but you don’t know that, just that it is ‘wet strength resin’. So, if the lab test for wet tensile is low, lets just add some more, OK? Well, no. Perhaps when the next shift arrives, there will be foam overflowing the wire pit. Felt dewatering is suddenly quite poor, but we don’t see that, what we see is wet streaky Yankee coating, poor crepe, web breaks and repeated blades changes. And still the wet tensile is poor. Maybe the new shift operator has seen this before, they shut down, clean the felt, drop the backwater, restart on fresh water and less wet strength resin, and for a while things may be better. Or maybe he just turns up the antifoam pump and things can then get even worse!

starch, coagulants and de-bonder chemicals all work like this. Already we can see the complexity of several charged functional polymers competing for space on the fibre! However, the furnish stream may also have the so-called ‘anionic trash’ comprising pitch, stickies, fines or ash which will quickly eat up the cationic additive before it can react with the fibre. Now the solution to this might be to neutralize the trash with a non-functional cationic polymer, but how to do this in the right place and right amount?

What really happened here? The problem with chemistry is that we tend to see only end effects, not visual things like when troubleshooting the mechanical operation of the machine. If we understood a little bit of paper mill chemistry, we might speculate that we had some poor waste rich in anionic trash in the furnish. This trash consumed the wet strength resin before it reacted with the fibre, but by increasing the resin pump, we put more un-reacted chemical into the system, filling the felt, creating foam and destabilising the Yankee coating. But we still don’t know for sure. What we have is a chemical soup we need to unravel, not just to save chemical cost, but to improve the machine operation, as every tissue maker knows that any chemical imbalance will eventually end up on his or her Yankee. Paper fibres are inherently anionic or negatively charged, due to the carboxyl functional groups on the fibre. Many functional chemicals will have the opposite cationic (positive) charge and thus we have an electrostatic attraction between fibres and chemical we can exploit to put the chemical where it needs to be, i.e. on the fibre. Wet strength, some dry strength,

Mütek SZP-10 System Zeta Potential


The key to good chemistry management therefore is objective measurement, and the techniques most often applied measure the minute electrical charges on furnish and chemicals. For many years, papermakers have known about the Mütek PCD (Particle Charge Detector) for measurements of the soluble or fine particle charge. The PCD lab instrument is also

available as an online analyzer and can not only measure the residual chemical in solution but also the troublesome anionic trash. A more recent development is the Mütek SZP-10 (System Zeta Potential), an off-line technique to measure directly the charge on the fibre. The higher this negative charge is, the better it will retain the cationic additive.

Wet end survey

To exploit these techniques trained technicians would build a map of SZP and PCD charge for all the stock and water streams, noting chemical additions and modifying these to get the best results. They ask the questions: • • • •

Which furnish stream has the highest chemical retention potential? How much anionic trash is present? How much fixative is needed to neutralize the trash? Did my functional additive retain on the fibre?

And so a new chemical control strategy, based on measurement, not guesswork, is built. By using these means we can control chemical usage, optimise first pass retention and even improve the crepe efficiency. So, back to our opening story. In fact this describes the case in a Middle East tissue mill which ended up with a typical chemical soup. BTG experts patiently mapped this and suggested the appropriate actions to change addition points and control trash and retention. Not only was this client able to optimize their chemical dosages, they also were able to achieve much improved tissue machine operation with stable quality and fewer web breaks, thus reducing to just weeks the payback time for the initial investment in instrumentation and training. This story is repeated many times for customers who decided to stop guessing and start to measure their chemistry and ‘get out of the soup’. BTG is committed to helping clients achieve significant, sustainable gains in business performance. We accomplish this through our world-class people, market-leading technologies, industry expertise and a passion for results. We are present throughout the pulp and paper-making operation, from the digester and bleaching plant, through the pulping and wet end processes to the final coating or creping of the paper, as well as in printing and converting.


Is ABB committed to pulp and paper? Absolutely.

Maximizing the performance of your mill by adding cutting edge technology or simply fixing what’s broken is what you should expect from your automation and electrification partner. As an industry pioneer and leader in pulp and paper, ABB will always meet or exceed your expectations regardless of the age or history of your system. We did it yesterday and we will do it tomorrow. That is our pledge. www.abb.com/pulpandpaper


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ABB Showcases Its Products, Services and Teamwork for Visiting Students

BB, the leading power and automation technology group, recently hosted 40 students from the TAPPI student chapters at Miami University and Western Michigan University at ABB Westerville in Ohio. The students left with a very positive impression of ABB and its products. On October 14, ABB staff met with the students, introduced them to ABB’s pulp and paper business, and demonstrated how the company’s products and services help papermakers. “Not only did all the visitors get excellent presentations about ABB’s business, products, technology and services, they were also particularly impressed by ABB’s teamwork,” said Shin-Chin Chen, a corporate executive engineer with ABB’s Pulp and Paper Division in Westerville. “These students will remember ABB for a long time.” The students took part in presentations on ABB’s pulp and paper technologies, led by experienced ABB staff including Charlie Young,

Steve Sturm, John Spachman, Andy Broomfield, Randy Niemeyer, Kevin Starr and Don Gillespie. The presentations covered measurement technology, actuator technology, control system technology, and project delivery and service. Åke Hellström, a retired ABB chief engineer, explained how ABB’s integrated Quality Control System helps create quality paper and demonstrated ABB’s System 800xA. Summing up their visit to ABB, many of the students commented that it had exceeded their expectations. Student advisors reported that the feedback they received was 100 percent positive. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 124,000 people. For more information please contact: Pulp and Paper Business Unit Eamon Devlin Mobile: +353 87 689 1109 email: eamon.devlin@ie.abb.com


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Walki-4E technology: a new, sustainable way of producing RFID antennas

he manufacturing of RFID antennas through the process of etching is now being challenged by a new patented technology: Walki-4E, a new way of producing flexible circuit boards efficiently and sustainably. This is possible through a dry production process, involving no liquid chemicals and using paper as the substrate. It also allows for computer to antenna production and extremely accurate laser cutting of the circuit board patterns. The traditional way of producing RFID antennas by etching has for a long period undergone only modest development. Walki, a leading producer of technical laminates, looked for ways to simplify the manufacturing process, while making use of their knowledge in lamination. “We think that Walki-4E technology is the first feasible alternative to etching and that it will bring new dimensions of cost efficiency and sustainability to the industry,” says Sami Liponkoski, Global Product Manager at Walki. In brief, the idea is to make a special laminate of aluminium and paper substrate, then aluminium foil is cut in patterns using a laser. The technology can be used for any production of flexible circuits boards, ranging from RFID antennas to boards for radiators and flexible displays. The first product to be launched using Walki-4E technology is Walki-Pantenna, a UHF RFID antenna. One step shorter The four E’s of Walki-4E stand for efficient, exact, economical and ecological. Compared with etching, the technology eliminates a whole step from the tag production process or from the converter’s process, thus combining efficiency and economy. “Since paper is used as a substrate, the RFID manufacturers can leave out the insertion of the PET inlay into paper, a necessary step when the antenna has been produced by etching. Moreover, the computer to antenna production method speeds up design and development, an advantage especially when it comes to producing short series, involving a fewer number of antennas,” Sami Liponkoski says. Cost efficiency comes hand-in-hand with environmental benefits. The dry process does not involve any chemicals, thus resulting in process residue that is easily recyclable. The absence of liquid chemicals also leaves the RFID manufacturers with a product, the ready antenna, that is 100 % recyclable. “Since the antenna is free from plastics, made of paper and aluminium only, it is easily recycled in a fibre recycling process, where metal detectors sort out the aluminium.” Sami Liponkoski says. Towards digitalisation The precision of the laser cutting of the patterns allows for smaller chips, greater repeatability in the production

process and higher accuracy of the antenna. “This does not only overcome certain accuracy problems that etching brings, but also gives new possibilities for developing the antennas and the chips,” Sami Liponkoski says. Digitalisation of the production process, i.e. computer to antenna production, brings efficiency and allows for an endless number of variations in the patterns. “Our vision is that the antenna production eventually will be completely digital. Laser cutting can speed up the production process by ten times, and taking into account the development that laser technology undergoes every year, the possibilities of producing flexible circuit boards with lasers are almost limitless,” Sami Liponkoski says. Walki’s first product, Walki-Pantenna, will be ready for mass production in 2012. “We are now in the ramp-up phase for our new production line in Pietarsaari, Finland, and we are looking forward to introduction in the market. There is a lot of interest in our product and we strongly believe it has the capacity to change the industry,” Liponkoski says.

Walki-4E technology is a new way of producing flexible circuit boards using a dry process and paper as the substrate, the first real alternative to the wet, chemical based process of etching.

Computer to antenna production and laser cutting of the flexible board patterns allow for a speedy production process and extremely high accuracy. An example: the laser cuts with an accuracy of 20 microns while a human hair has the thickness of 100-120 microns.


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EMERSON ANNOUNCES FIRST GLOBAL USERS EXCHANGE IN EUROPE

hree day event in Düsseldorf, Germany aims to help Emerson users improve efficiency and reduce costs with enhanced automation Emerson announces the first Global Users Exchange in Europe. Themed “Exchanging Ideas. Creating Solutions”, the three day event will run from 29-31 May 2012 at the Hotel Maritim, Düsseldorf, Germany. Tailored to meet the needs of users in Europe, the Middle East and Africa, delegates will learn about best practices and see how colleagues are meeting new regulatory requirements, increasing yields, improving efficiency and reducing costs with enhanced automation. The European event will follow the same format as the October 2011 Emerson Global Users Exchange held in Nashville, USA. The event will include workshops, presentations, industry forums, short courses, technology exhibits and product roadmaps. Delegates will be able to choose from themed presentations in English, German and Russian. “We are delighted to announce the details of the first Global Users Exchange for our many users across Europe and others who will join

us from other regions,” said Bob Sharp, President, Emerson Process Management Europe. “The Emerson Global Users Exchange is much more than an industry-leading technical conference. It is a community of manufacturing leaders committed to extracting the most from their automation investment and sharing their learning with each other.” The event also provides an opportunity for delegates to understand what their peers, other suppliers and customers in the industry are doing to compete in these dynamic times. Attendees will be provided with a unique opportunity to touch and experience the breadth of innovative Emerson technologies – all in one place. An important element of the event is the opportunity it provides to network with other delegates and industry leaders to make the right connections. Delegates will also be able to meet with the experts behind the technologies and learn how innovative technologies can be put to work. The Emerson Global Users Exchange organisation is now looking for users to share their experiences

and expertise with their process automation peers by giving a presentation, workshop or short course at the event. Presenting at the Global Users Exchange provides a unique opportunity for users to showcase their company and its successful operational practices. For more information about the event, including how to submit presentations, the conference programme and venue please visit: www.emersonexchange.org/emea Emerson Process Management (www.EmersonProcess.com), an Emerson business, is a leader in helping businesses automate their production, processing, and distribution in the chemical, oil and gas, refining, pulp and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences, and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management, and maintenance services. Its brands include PlantWeb™, Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel™, Ovation™ and AMS Suite.


Korsnäs Gävle, Gävlebukten, Sweden

Emerson’s Smart Wireless technology helps meet environmental requirements at paper mill in Sweden

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osemount® wireless conductivity transmitters help prevent discharge of chemicals into local environment

Korsnäs Gävle is using Emerson Process Management’s Smart Wireless conductivity and temperature transmitters to collect critical leak-detection monitoring data at its board and paper production unit at Gävlebukten, Sweden. Improved monitoring enables the company to verify its compliance with environmental monitoring legislation. Water from heat exchangers at the Gävlebukten plant is carefully monitored prior to its return to the sea. Small internal leaks may result in the discharge of hazardous chemicals into the local environment. Any leak of acids, bases, or salts will raise the electrical conductivity of the water and is easily detected using a conductivity sensor. A renovation project within the utilities section meant that I/O supporting existing instrumentation was to be removed. Korsnäs Gävle therefore needed an alternative way to transmit the required measurements to the main control room.

“Initially we considered installing new cable runs, but the process would have taken too long and would have delayed the planned renovation project,” said Peter Hallenberg, Project Leader Process Automation, Korsnäs Gävle. “The application presented a great opportunity for us to install and evaluate Emerson’s Smart Wireless technology, which takes advantage of the IEC 62591 (WirelessHART®) communication standard.” The Smart Wireless solution that Korsnäs Gävle installed includes a Rosemount® Analytical 6081-C transmitter connected to a conductivity probe. The transmitter sends the measurement data via a Smart Wireless Gateway to the existing control and data acquisition systems, where it is used to ensure compliance with the environmental monitoring legislation. Korsnäs Gävle also needed to establish new continuous monitoring of emissions from aerated basins and ponds. Twenty-two new sensors measuring pH, dissolved oxygen, and water temperatures had to be installed and connected to the central monitoring system. There were no available cable runs, and new cable infrastructure presented a considerable challenge and


cost at €200 per metre. To meet this challenge, Korsnäs Gävle installed six Rosemount wireless transmitters, each with four available inputs, to relay data from the analytical sensors. The wireless instruments provide the necessary data to meet the environmental requirements. “Less than two months after ordering the Smart Wireless devices, the whole system was fully operational. That is very fast for implementing 30 new measurement points,” said Hallenberg. “Now that the network is in place,” he added, “we have also found that adding additional devices becomes very simple.” Specifically, Korsnäs Gävle has installed seven Rosemount 648 wireless temperature transmitters to automate the monitoring of water temperatures in wastewater pits that feed the aerated basins and ponds. A further eight Rosemount wireless transmitters will be installed to identify plugged filters on two wood chip digesters within the main processing section of the plant.

About Emerson Process Management

Emerson Process Management (www.EmersonProcess.com), an Emerson business, is a leader in helping businesses automate their production, processing, and distribution in the chemical, oil and gas, refining, pulp

and paper, power, water and wastewater treatment, mining and metals, food and beverage, life sciences, and other industries. The company combines superior products and technology with industry-specific engineering, consulting, project management, and maintenance services. Its brands include PlantWeb™, Syncade™, DeltaV™, Fisher®, Micro Motion®, Rosemount®, Daniel™, Ovation™ and AMS Suite.

About Emerson

Emerson, based in St. Louis, Missouri (USA), is a global leader in bringing technology and engineering together to provide innovative solutions to customers in industrial, commercial, and consumer markets through its network power, process management, industrial automation, climate technologies, and tools and storage businesses. Sales in fiscal 2011 were $24.2 billion. For more information, visit www.Emerson.com Rosemount is a mark of Emerson Process Management legal entities. WirelessHART is a mark of the HART Communication Foundation. All other marks are the property of their respective owners.

Emerson’s Rosemount Analytical 6081-C transmitter sends measurement data via a Smart Wireless Gateway to the existing control and data acquisition systems


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ABB retains leading distributed control system market share worldwide for 2010 A

RC study states that new projects in heavy process industries, power generation contributed to overall market growth In the newest version of ARC Advisory Group’s “Distributed Control Systems Worldwide Outlook,” study, ABB retained its leading worldwide market position in this core automation market. According to the study, the DCS (distributed control system) market in 2010 rebounded from 2009; the overall market for DCS (distributed control system) increased by 3.3 percent, in part due to an increase of new projects in the heavy process industries. ARC forecasts that market growth, while improved compared with 2009, will not reach peak 2008 levels until next year, and then will resume normal slow but steady growth. The increase in new projects in the heavy process industries such as oil & gas and petrochemical, as well as a resurgence in power generation projects, helped to drive global demand for DCS in 2010. Many of the larger projects that contributed to 2010 growth were booked throughout 2009. ABB booked a number of large process industry and power generation orders, which included major greenfield projects as well as system upgrades and expansions for existing installations. “Innovation, quality products, extensive industry

knowledge and application expertise has enabled ABB to establish a large and loyal customer base,” said Barry Young, Principal Analyst at ARC and author of the report. “ABB brings together a product, system and service capability that allow them to deliver complete automation and production solutions across a broad range of industries.” According to the study, ABB was also the regional market share leader for Latin America, Europe/Mid East/Africa (EMEA), and the worldwide leader in key global verticals including Upstream Oil & Gas, Pulp and Paper, Mining and Metals, and Cement and Glass. The report also notes that the DCS business has continued to be primarily a services business over the past few years, with combined project, engineering and operational services accounting for more than half of total revenues. In particular, the Main Automation Contractor (MAC) approach, in which the automation vendor manages the overall project and includes a strong project execution and services component, continues to grow stronger and expand in scope. “ABB’s deep process industry knowledge, extensive global and local resources, and world-class services organization provide the project execution capabilities needed to successfully manage complex


projects as the Main Automation Contractor,” said VeliMatti Reinikkala, head of ABB’s Process Automation division. “In addition, we offer our customers a diverse portfolio of DCS solutions to help any process perform better, from the smallest operation to large integrated operations.” ABB’s portfolio of DCS includes its flagship System 800xA Extended Automation platform, Symphony Plus control system, Freelance process control system for small to medium process applications, as well as its prior generation systems. All ABB control systems offer a secure evolution path forward to next generation technologies to protect and enhance the control system investment over its lifetime. Additional information on the DCS Worldwide Outlook, as well as other studies on the global automation market, is available at www.arcweb.com Founded in 1986, ARC Advisory Group has grown to become the Thought Leader in Manufacturing and Supply Chain solutions. ARC analysts have the expert industry knowledge and first-hand experience to help clients find the best answer to complex business issues. ARC focuses on simple yet critical goals: improving clients’ return on assets, operational performance, total cost of ownership, project time-to-benefit, and shareholder value. Further information can be obtained from ARC, Three Allied Drive, Dedham, MA 02026, 781-471-1000, Fax 781-4711100, E-mail info@arcweb.com, Web www.arcweb.com. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 130,000 people.


There for you! BTG is present throughout the Pulp & Paper process and committed to helping you achieve significant, sustainable gains in business performance.

Contact us today to learn how we can help improve your bottom line! www.btg.com

info@btg.com


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BTG Americas partners with Ashland Water Technologies to improve wet end optimization Article by Michael Molter Applications Specialist at BTG.

A new wet-end optimization solution is saving one North American mill hundreds of thousands of dollars every year, with ROI well under three months from installation.

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round the world, most paper mills struggle to automate wet end defoamer addition rates. Quite aside from the cost overhead of unnecessary chemical additives, excessive use of defoamer can lead to problematic production issues including quality (sizing) and machine runnability (deposition). Unfortunately, traditional manual control approaches, including the simple visual observation of foam levels, often fall short and result in over-use of additives. But new tests by BTG and partner Ashland Water Technologies (AWT) show that combining accurate and reliable online measurement technology with closed loop control gives papermakers a highly effective tool for stabilizing free and dissolved air levels in the wet end and automating defoamer addition rates. BTG and AWT are working together to offer papermakers a closed loop defoamer control approach based on BTG’s GAS-60 Gas Analyzer combined with Ashland’s defoamer product technology and extensive application knowledge. Initial installations in North America have been in linerboard production, because of the often higher defoamer dosages and stock variability in these processes. For mills, the new approach is helping cut costs through defoamer optimization while delivering substantial improvements in final product quality.

Defoamer cost savings at large US kraft mill

One of the first applications of the new BTG/ AWT system has been in a large southern US kraft mill producing linerboard on two high speed Fourdrinier machines. The mill had been experiencing problems with sheet quality when the table turned ‘foamy’ – causing process control teams to habitually over-use defoamer to prevent this from occurring. Over the years, mill operators had learned that excessive wire pit foam was a strong indicator that the table would begin to get foamy and sheet breaks and defects would soon follow. Observation of the wire pit had thus become the basis for decisions on defoamer addition. Manual entrained air tests revealed that the problem was in fact related to high levels of entrained air in the head box. But since there was no way of knowing when the period of high entrained air was at an end, subsequent defoamer reductions were only slowly implemented, if at all. This poor control strategy had led to routine excessive defoamer use. Together, teams from the mill, AWT and BTG successfully applied the GAS-60 measurement in a continuous closed loop defoamer control approach, reducing defoamer costs while maintaining product quality. The installation was set up to measure headbox samples from both paper machines, with a feedback control loop to the defoamer pump applied within the thick stock loop.


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TG and Ashland trained operators on how to interpret and use the measurements sent from the GAS60 to the DCS. Although the analyzer was not initially connected to the mill’s DCS and not used in a control loop, after a short introductory period, the operators quickly gained confidence and began using the entrained measurement to adjust defoamer dosage. The use of manual control resulted in a gradual decrease in defoamer dosing, as operators quickly became comfortable with the system (see the first ten data points in Figure 1: No Control). Following the tie-in to the DCS, the closed loop control strategy resulted in additional optimization of defoamer (see the next ten data points in Figure 1: Closed Loop Control).

Figure 2 below shows that the mill’s key issue – defoamer use versus budget – was reduced to a new standard level by implementing continuous entrained air measurement and closed loop control of defoamer addition. For the mill, the result was annual savings of hundreds of thousands of dollars – a recurring economic benefit reflected in savings in defoamer chemicals of 31.6% and a very impressive ROI of less than three months.

The partnership between BTG and Ashland Water Technologies shows that an expertly implemented GAS-60 Gas Analyzer can make a major positive impact on a papermaker’s bottom line. Almost one year after the installation, the GAS-60 continues to keep the mill’s defoamer performance levels in line with values demonstrated during the trial period – and below budget!


Mondi SCP’s PM18 beats own world record as fastest paper machine of its kind.

The world’s fastest running paper machine with a single shoe press, PM18, achieved a new speed record on August 9th 2011, producing 1620 metres of paper/minute.


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ince the start-up of PM18 eight years ago, the operations team at Mondi SCP in Ružomberok, Slovakia have reached two world records for speed. Mondi SCP set the first world record for PM18 in 2009 and surpassed it by 20 meters/minute on August 9th, 2011 with a new speed record of 1620m/min.

Paper Company Environmental Index and the 2010 PPI Award for Mondi SCP Mill’s Environmental Strategy of the Year. Its renowned brands such as Color Copy, DNS®, IQ, MAESTRO®, NAUTILUS®, BIO TOP 3® or Snegurochka are used in office environments on laser or inkjet printers and by professional printers on digital or offset presses to create brochures, transactional material, folders, invitations, business cards, letterheads or other high-impact communication.

PM18 is the largest paper machine at Mondi SCP mill, producing over 10 million A4 sheets every hour. The mill’s managing director, Roman Senecky, commented on his team’s success and hard work stating, “Today’s record is tomorrow’s production target. Our team deserves a big thank you for their latest achievement. From wood processing to pulp production, cutting and About Mondi proper logistics of the paper – the end success is being Mondi is an international paper and packaging Group, able to satisfy our customers.” with production operations across 31 countries and revenues of €6.2 billion in 2010. The Group’s key The mill’s smallest and oldest machine, PM16, has also operations are located in Central Europe, Russia maintained its top performing position as a Metso and South Africa and as at the end of 2010, Mondi benchmark leader on lowest percentage in break employed 29,000 people. time, shut-down time and broke among uncoated fine paper machines. PM16’s ranking in 2010 marks the Mondi is fully integrated across the paper and paper machine’s fourth consecutive standing as Metso packaging process, from the growing of wood and the Benchmark top performer in these categories. manufacture of pulp and paper (including recycled In response to the successes of PM 16, Mondi SCP paper), to the conversion of packaging papers into paper division director Franz Aigner comments, “It is corrugated packaging, industrial bags and coatings. not all about technology. This is proven by the fact that The Group is principally involved in the manufacture same machines reach various outputs. What makes a of packaging paper, converted packaging products and major difference is having skilled people on board.” uncoated fine paper (UFP). About Mondi Uncoated Fine Paper Mondi Uncoated Fine Paper is a business unit of Mondi, a leading international paper and packaging company. In 4 paper mills in Europe, Russia and South Africa, Mondi Uncoated Fine Paper produces office and professional printing papers with the environment in mind. It complies with the strictest international certification standards and regularly earns recognition for this policy such as the #1 position in WWF’s 2010

Mondi has a dual listed company structure, with a primary listing on the JSE Limited for Mondi Limited under the ticker code MND and a premium listing on the London Stock Exchange for Mondi plc, under the ticker code MNDI. The Group has been recognised for its sustainability through its inclusion in the FTSE4Good UK, Europe and Global indices in 2008, 2009 and 2010 and the JSE’s Socially Responsible Investment (SRI) Index in 2007, 2008, 2009 and 2010.


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Pulp-paperworld Magazine Issue 6  

Pulp and Paper Industry magazine

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