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Pulp-Paperworld

Issue no.4 June 2011

Abb’s Customized Control system Showcases its Power in HIGH - END Projects

Pcc production in China

MCC Paper Yinhe mill Excels in quality and energy efficiency Kelheim Fibres to present viscose specialitites and new Paper Competence Centre at Zellcheming

pic source: Sun Paper


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inerolo, May 2nd, 2011, during Tissue World in Nice, CMPC Tissue S.A. signed a major service contract with PMT Italia S.p.A. for improving the energy efficiency and performance of nearly all of their Latin American Tissue Machines. In short, PMT Industries (a subsidiary of PMT Italia S.p.A.) will retrofit at least ten (10) Yankees of varying sizes in CMPC’s tissue mills in Argentina, Chile, Uruguay, Colombia, Mexico and Brazil with new head insulation in order to optimise the drying and energy efficiency throughout their tissue production organization. With this order, PMT solidifies its status as the premier supplier of Yankee technology worldwide – for retrofit, service as well as new Yankees. The development was

driven by the rapidly increasing price of energy supplies as well as environmental and safety concerns. Addressing all those needs was accomplished by focusing the attention on the need for greater efficiency by reducing energy consumption, but without detriment to output. CMPC will in the future benefit from a design which was developed to ensure that the increase in efficiency does not come at the expense of the machine operation, and the smooth external finish helps with cleanliness on the dryer end, and improves safety in the event that water sprays onto the end face of the Yankee. By retrofitting these Yankees, CMPC is improving their production cost structure, while at the same time further focusing on the environment by ensuring a more efficient and energy saving

production process throughout their whole tissue production organization. The total cost of the project cannot be disclosed, but it is expected that payback is in less than a year for each Yankee retrofit. Present at the signing were (from left): Mr. Carlos Hirigoyen (Director of Industrial Development at CMPC Tissue S.A.), Mr. Tomas Anderson (Tissue Sales Mgr, PMT), Mr. Luca Nugo (CEO, PMT), Mr. Giampiero Miglietta (COO, PMT), Mr. Gonzalo Contreras (Manager of Projects Administration, CMPC Tissue S.A.) and Mr. Reinaldo Uribe Arancibia (Manager of Production Process Development, CMPC Tissue S.A.). source : PMT industries


ABB’s customized control system showcases its power in

high-end projects Recent interview, Chen Linfeng, Sales Director of ABB Pulp & Paper China

ABB SOLVES THE PROBLEM OF OFF-MACHINE COATER AUTOMATION CONTROL, AND DELIVERS LARGE-SCALE PAPER PROJECTS TO SUN PAPER AND HUATAI. Each papermaker obtained tailor-made, world-leading technology and equipment, including drive control systems and high-efficiency frequency conversion motors, which not only ensure the smooth and efficient operation of the production lines, but also realize energy savings and emission reduction.


In January this year, ABB comIn China, along with Huatai’s pleted the commissioning of a PM8, there are two other producPMC800 multi-drive control system tion lines with large off-machine in a high-end coated paper project coaters. These at Huatai Paper. Installed on the lines are lomill’s PM8, a machine with an ancated at the APP nual production of 700,000 tons, the Dagang mill and system met Huatai’s design require- Sun Paper. ments – it solves the problem of Production off-machine coating automation lines of this type control, ensures the smooth and are commishighly efficient operation of the sioned at the avproduction line, and realizes energy erage rate of one savings and emission reduction. every three years. There are only two off-machine So far, there are coaters of the same type in China, several dozen and each is equipped with ABB such production lines in the world. drive systems. Commissioned in The difficulty lies in the control of 2004 and 2005 respectively, each is the off-machine coater, particularly operating well. the flying splice control. While the Lin Shuming, head of ABB Pulp off-machine coater operates at and Paper North Asia, said: “It india designated speed, this control cates that, by integrating unique method is applied so that online innovative technologies, ABB’s cusroll-changing can proceed without tomized service model successfully shutdowns. passed the test of China’s ABB (www.abb.com) is a leader in power high-end paper projects. ” and automation technologies that enable Optimal utilization of utility and industry customers to improve advanced technology performance while lowering environmental During a recent interimpact. The ABB Group of companies operview, Chen Linfeng, Sales ates in around 100 countries and employs Director of ABB Pulp & about 124,000 people. Paper China, said that ABB tailored the drive control system PMC800 installed on Huatai’s Meeting this challenge requires PM8 according to customer requiredrive equipment that has control ments and specific application precision down to a millisecond needs.. The drive system on Huatai’s level (1-10 ms), along with extenPM8 and coating machine is by far sive cooperation and experience one of the most complicated drive between the drive supplier and systems used today in the paper equipment supplier. Because ABB industry. The system includes 223 meet these key requirements, it exdrive sections, 241 AC frequency ecutes most similar drives projects conversion motors and 10 AC800M worldwide. controllers ,as well as additional At Huatai, there are numercontrol equipment. It provides AC ous tension control points on the drive and control for specific parts production line. When the speed on of the production line, including the production line varies, it is very the paper machine, rewinder, offdifficult to precisely control the tenmachine coater, super calendar and sion. The maximum speed of PM8’s winder.

coater is 2100 meter/min, which is the extreme speed of the machine and motor. But ABB’s leading drive control technology ensures the production line will operate smoothly and continuously even under such high speeds. This prevents the waste of items such as paper and paint that occur when the coater shuts down, and it also saves the additional labor, water and electricity needed to clean the coater.. To minimize energy consumption, ABB installed customized motors with optimization design on various parts of Huatai’s production line, including the winder, rewinder, super calendar and coater. This kind of motor is much smaller and lighter than standard motors. Its design is optimized according to a piece of equipment’s specific load requirements, so that control and efficiency are optimized. But the overload multiples are high enough to prevent high energyconsumption “light load drives”. The current installed power of paper machines in China’s paper industry is dramatically higher than it was in the past. This renders the 400V motor, which was previously prevalent, unable to meet new industrial demands. As a result, ABB promotes its 690V grade low voltage motor – the ABB M3BP is the most high-efficiency AC motor in the industry. It is the first batch of motors to obtain China’s authentication of energy-saving product, with an efficiency level of IE2. So far, these new motors have been used in new projects at mills that include the APP Dagang mill, Lee Man Papers, and Huatai Paper. “It has higher voltage than the

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400V motor, so there is less heat loss due to smaller current, contributing to energy-saving,” said Linfeng. The efficiency of ABB’s standard motor is 3.8% higher than that of a normal motor. On Huatai’s PM8 production line with total installed power estimated to be 390,000 kW, this motor can annually save nearly 5 million yuan in electricity costs and almost 3700 tons of coal, a very outstanding amount. Problem-solving with the world’s best combined service resources In terms of technology, PM8 is the most complex paper machine in China -- or even the world. So ABB selected its best global service team to ensure the project’s smooth implementation. During project execution, ABB Finland sent its principal engineers to meticulously oversee the software and equipment design work, key technology, project progress, etc. They worked with a Chinese team consisting of highlyskilled engineers who are experts in different aspects of the automation. These Chinese specialists could fully utilize local service and equipment manufacturing systems to provide Huatai with the most efficient and high-quality service possible.

Said Linfeng: “Engineers from ABB Finland and China cooperated by contributing their strengths and advantages, which overcame many technical difficulties, accomplished the project meeting its schedule, quality and quantity requirements, and achieved customer satisfaction.” In the past, projects at APP Dagang were usually accomplished by ABB’s European engineers. Now a Chinese local service team dominates the PM8 project. Linfeng added: “Currently, the most challenging and state of the art paper equipment and projects in the world can be seen in China. The transition from participation roles to leadership roles indicates that ABB China’s local team is gradually growing up. Such localized customized service leads to the formation of long-term strategic cooperation and partnerships between ABB and its China customers. ABB has many customers similar to Huatai, such as, Sun Paper, Lee Man Paper, APP, HengAn, Nine Dragons Paper and Shan Ying Paper. ABB finds the best cooperation points with these customers, and establishes long-term partnerships. HengAn Paper has 15 paper machines, and ABB provided drive control systems

and integrated automation control systems for 14 of them. The automation and electrification equipment of 16 paper machines and 3 pulp mills of Lee Man Paper all come from ABB. This is due to the tailormade service, which provides a very cost-competitive plan.” Shuming said: “The paper industry is a high energy consumption industry. ABB’s automation technology could significantly help customers improve energy efficiency, and realize green environmental production and sustainable development. Shandong Huatai Corporation is a world-leading paper enterprise. The long-lasting cooperation between ABB and Huatai demonstrates the mutual trust between the two partners, raising excellent cooperation model and energy-saving example for the industry.” For more information please contact:

Jing Guan – Communication Manager, Pulp & Paper, North Asia Tel: + 86 10 64231317 Fax: +86 10 6423 1626 Email: jing.guan@cn.abb.com

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INTRODUCING BOXRUNNER A NEW STRADDLE CARRIER FROM KONECRANES

Terminal quayside container unloading operations need to be linked flexibly with yard stacking operations. The new Boxrunner straddle carrier from Konecranes is the flexible link between ship-to-shore cranes and automated yard cranes.

Konecranes Boxrunner – container handling flexibility, speed and safety at your fingertips. © Konecranes Oyj Abp


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he new Konecranes Boxrunner straddle carrier offers unique container handling performance to two distinct container handling operations. The first is represented by large container terminal operators that are adopting automation technology for greater efficiency. The second is represented by a potentially diverse range of companies that do not have container handling as a core competence, and yet handle incoming and outgoing materials in containers – often using trucks and trailers or customengineered, stationary gantry cranes. Boxrunner can be a much more effective solution for their container handling needs. Boxrunner is the product of Konecranes’ long experience in the straddle carrier business and a deep understanding of the needs of container handling operations. The design process started by asking a number of key customers the question: “What are the characteristics of the perfect straddle carrier?” Their answers inspired the Boxrunner’s principle performance and ownership characteristics i.e. speed, outstanding handling, durability, operator friendliness , low maintenance with long service intervals, and a low total cost of ownership. “We listened to our container handling customers and incorporated their feedback resulting in the launch of this special machine, the Boxrunner, a uniquely advanced straddle carrier,” says Jens Andreas, General Manager, Konecranes Straddle Carriers. “It provides the industry’s highest lifecycle value in the role it was designed for.” The Boxrunner is a machine for professionals who care about longterm benefits based on lifecycle cost calculations that take into account performance metrics, fuel efficiency and maintenance interval length.

Quayside flexibility The Boxrunner gives large container terminal operators a flexible and efficient means of moving containers from ship-to-shore (STS) cranes to the automated stacking cranes (ASCs). The key word here is flexibility. Boxrunner can deal with almost any requirement during this phase of the operation e.g. boosting STS unloading speed to maximum or handling containers of different ISO sizes. The Boxrunner is adapted to handle all ISO container sizes, stacking two-high at high speed. “We have a very simple formula for delivering customer value,” says Andreas. “We maximize the productivity of uptime and minimize the cost of downtime with the Boxrunner, thus boosting the productivity of our customers’ operations.”

Konecranes designs and manufactures Boxrunner’s key components in-house to make sure they work together flawlessly. The new straddle carrier is built around a very rigid structure that provides excellent handling performance and direct steering. Powered by a dieselelectric (DE) drive and rope hoist system, the Boxrunner is offered as a 50 t twin twenty lift machine and as a 40 t single lift machine that can travel at 30 km/h with a 25 m/ min hoist speed. “Boxrunner is a technologically advanced machine that is truly driver-friendly and maintenance-friendly,” says Jost Dämmgen, Sales Manager, Port Cranes. “We want to deliver high-

performance, high-quality vehicles to our customers. The Boxrunner exceeds expectations for drive feel and performance, and meets expectations for reliability, safety and maintenance.”

Unique Konecranes technology The Boxrunner uses Konecranes’ unique rope and drum hoisting system, a proven technology from the company’s popular rubber tired gantry cranes (RTGs) and rail mounted gantry cranes (RMGs). It also has an electronic-hydraulic system with four-cylinder steering for less tire wear, fewer spare parts, a greaseless gantry and very low maintenance. The driver’s cabin is a model of ergonomic design providing excellent visibility. Its simple controls and displays help to ensure safety, accuracy and speed. “With space in short supply at ports and quays, the Boxrunner is an excellent choice because it can take on several roles, eliminating the need for other container transport equipment. It is very stable and has excellent straight driving characteristics thanks to its 4-axle steering system. Comparatively speaking, every operator that has tested the Boxrunner has been impressed by its superior drive feel and sense of control aided by innovative and intelligent displays. Moreover, we offer our customers outstanding service packages,” says Andreas. As a major global player in the design, manufacture, delivery and servicing of container handling equipment, Konecranes is pleased to offer its new Boxrunner straddle carrier to demanding customers worldwide and expects to make the first delivery during Q1/2011. article source : /ins industrial news service


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


Cartaspers® PSM enables efficient processing of recycled paper

(Photo: Clariant)

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apermakers using recycled paper in their production process can wave goodbye to “stickies” and look forward to cost-efficient manufacturing with Clariant’s pioneering Cartaspers® PSM. Cartaspers® PSM liquid from Clariant, a leading supplier of Optical Brighteners, Colorants and Chemicals for the paper market, prevents the clogging-up of machine clothing with “stickies”- the resin and adhesive particlesinherent in wastepaperand caused for example by address labels or envelope edges. Downtime, due to “stickie” contamination, is practically eliminated and the amount of hydrocarbon cleaning solvent, for dissolving and removing the contaminants, is reduced by up to 90%. Clariant’s patented Cartaspers® PSM liquid is available globally and is easy to use. It is added to the shower water during the paper production process

and adsorbs on the machine clothing to provide a repellent protective layer. This allows the“stickies”to be rinsed away before they can build up and contaminate the fabrics. These combined benefits bring significant performance and sustainability advantages to the capital intensive papermaking business, where machines need to run continuously to be profitable. Cartaspers® PSM is a nonionic, readily biodegradable (OECD 301 A 97% - 28 days), hydrophilic polymer with high affinity for hydrophobic surfaces. The product is a water-based polyester dispersion, with the ability to modify the surface energy of nonpolar substances. It can be combined easily with other papermaking additives and is suitable for use in hard and soft water. It can be used in pulping and fiber preparation, wet-end applications and for the surface treatment of paper to increase inter-surface adhesion and improve printability.

From an environmental perspective, Cartaspers® PSM meets the requirements of Nordic Swan and EU Ecolabel schemes and complies with the US Food & Drug Administration (FDA) for food packaging materials. The reduction in the use of cleaning solvent also benefits mill staff, who are exposed to fewer solvent emissions. “Cartaspers® PSM liquid is a powerful opponent in the control of stickies, keeping machinery free of such contamination. This cuts drastically both the amount of downtime and the need for large quantities of solvent, for a much more efficient production process,”comments John Cowman, Technical Manager of the process chemicals group, Clariant Production UK Ltd. “These are important factors for paper mills looking for cost reduction and efficiency improvements. Our customers tell us this is exactly the product they have been waiting for!” Cartaspers® is a registered trademark of Clariant.


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y c n e i c ffi ye g r e n e d n fine a y t coated i n l u a e d qu g in op -gra n i investin s lier of t l f p o p e p u s e c t s g r Ex a leadin decisive om the first yea coming fr o o k th e ill t ults y. f be Paper m d ser vices. Res nergy efficienc s goal o e it h f o in Y it n gy a and e e MCC In pursu technolo , per formance hina, th g C in k in a r y e pap aper m qualit latest p xcellent e e t a ic Metso’s d ation in o f o p er

Li Shujian, General Manager of MCC Yinhe Paper:

“As the leading technology and services supplier in the pulp and paper industries worldwide, Metso can also meet the requirements of traditional Chinese enterprises on their way towards becoming high technology mills.”

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production line has a design speed of 1,300 m/min and produces around 200,000 The new 5.8m-wide tons of uncoated fine paper annually. With a compact design concept from headbox to reel,

plus related stock preparation and air systems, the paper machine showcases Metso’s latest technological advances in cost efficient paper making. These include, for instance, a hybrid former and a closed hood. Also featured in the machine is an extensive automation package.

A leap into top-notch technology Located in Linqing City in the mostly rural Shandong Province, the Yinhe mill was long a traditional local company lacking hi-tech machinery. After joining the MCC (Metallurgical Corporation of China) Paper Group, the mill decided to invest in a new production line to enable a capacity increase and quality upgrade, with the aim of becoming a leading producer of uncoated fine paper in China. Today, the Yinhe mill employs around 6,000 people and produces mainly 70/80 g/m2 copy paper and 60-100 g/m2 offset paper. “The market demanded that we develop from a middle-grade producer to a top-level one. Accordingly, to complete our range, we needed to invest in new technology – that is, if we wanted to become one of the biggest fine paper producers in China,” says Li Shujian, General Manager of MCC Yinhe Paper. “Metso had good references as a fullscope supplier for the global pulp and paper industry, with a range extending across all grades. Our biggest challenge was our lack of project experience and technology expertise, but Metso’s intensive

support and well-established local services ensured smooth project execution all along the way.” Quality comes first “Our target market is the top-level offset paper market, so the quality of our products should always come first,” says Sun Chengbo, Assistant General Manager and Manager of the High-Grade Fine Paper Mill. “Customer expectations must be fulfilled without exception.

“So far, the feedback from end users has been gratifying. By using Metso’s latest technological advances we have been able to ensure stable quality, which is what they value most. The ValFomer shoe blade hybrid former, for instance, permits a minimum of two-sidedness compared with conventional gap and hybrid formers, and this translates into superior printing characteristics.”

Top quality of the end product is controlled regularly at Yinhe mill.

Resource savings

20%

34%

Electricity

46%

Water Steam

Benefits from energy efficiency The introduction of new technology has resulted in significant energy savings at the Yinhe mill. Compared to past figures, electricity consumption has decreased by 20% per ton of paper, while steam consumption has dropped by 34%. Water consumption has been reduced by 46% due to closed circulation and the ability to reuse effluent water for pulp washing. Moreover, the mill can now boast remarkably low chemicals’ consumption and fiber loss. Even gas consumption has decreased to one third that of the former production lines. Not surprisingly, Shan Liwei, Vice Manager of the High-Grade Fine Paper Mill, expresses great satisfaction with the energy efficiency and environmental soundness of their new line. “There are many highlights in the new line, starting from stock preparation which consumes about 30-40% of all the electricity in the paper making process. Thanks to the Metso refining system with low energy consumption, we have achieved electricity consumption levels of 400 kWh/t for refining in copy paper production, which is well below the industry standard.

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Sun Chengbo, Assistant General Manager and Manager of the High-Grade Fine Paper Mill

“Currently, our main product is 60-100 g/m2 fine paper and the new machine handles grade changes well. The entire grade change process takes just 10 minutes for the selected products.”

1

2

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With Metso OptiPress we can achieve approximately 50-51% dryness in the press section. This is a significant increase in dryness compared to the earlier situation. Generally, increasing dryness by 1% in the press section saves 5% of steam in the dryer section. For us, increased dryness means remarkable savings in steam,” Shan Liwei explains. “Also, the ValHood closed hood and related ventilation system, as well as Metso’s efficient heat recovery system enable us to keep our steam consumption per ton at a low level.” “To summarize, it is not the individual technological advances alone, but the sound design of the entire production line that helps keep energy consumption at such a low level,” Shan concludes. More capacity with less cost To further improve operating efficiency is one of the key issues at Yinhe. After reaching its design speed of 1,300 m/min, the production line’s next goal is 1,350 m/min. The speed is progressing, step by step.

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“This Metso line is our first advanced paper machine ever, and we have had worries about the start-up and operation, as well as about how our employees will manage with this technology. But the new line has achieved all our expected production goals. The design capacity of 791 tons per day has actually turned out to be 795 daily tons,” says Sun Chengbo. “The highest speed we have reached up to now is 1,305 m/min and we are heading towards 1,350 m/min,” he continues. His positive opinion is shared by Shan Liwei, who praises the Metso line for its good operational performance. “Right from the start-up Metso’s new line has performed well. If any operating problems arise, they are immediately solved by Metso’s experts. To further optimize capacity and energy efficiency, Metso carried out energy consumption measurements, which increased our highest daily output up to 880 tons per day for 100 g/m2 fine paper, while still decreasing water, electricity and steam consumption,” says Shan.

1 Shan Liwei, Vice Manager of the High-Grade Fine Paper Mill: “As for energy efficiency, there is a world of difference between the new line and the old one, which was characterized by high costs and low capacity.” 2 Jin Like, Automation Manager: “The benefits of optimal automation levels are countable, including easy operation and maintenance, fewer quality problems and flexible grade change procedures.” 3 Jiang Liansheng, Vice Automation Manager.

Optimal level of automation for top-level grades Metso’s delivery to Yinhe also included a full automation package. According to the mill’s Automation Manager, Jin Like, a high level of automation is a clear must when targeting top-level paper grades. He points out that the main advantage of Metso’s automation solution is that it integrates all the process, quality and machine con-


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Like a bullet train, the new line with its target speed of 1,350 m/min creates quite a contrast to the old 500 m/min machines.

trols into one and the same metsoDNA platform, which enables seamless communication between all processes during operation. Jiang Liansheng, Vice Automation Manager, emphasizes the benefits gained from the PaperIQ quality control system, the Sensodec condition monitoring system and the Kajaani analyzers. “Our two PaperIQ scanners measuring basis weight, moisture, ash content, color and caliper are worth their weight in gold in terms of improving our product quality. The Sensodec pulse, light and trigger sensors monitor vibrations in bearings, rolls and fabrics, enabling efficient maintenance and avoiding unplanned outages. When the Kajaani analyzers are used for on-line calculations, they minimize errors and save labor,” says Jiang Liansheng.

Modular machine concept meets market needs in China

“Even though the pace is still relatively slow, fine paper consumption keeps increasing in China. The market trend is favoring middle and high-level products, which means that production technologies should improve correspondingly,” says Li Shuijan, commenting on the paper industry market outlook in China. “Today’s paper industry in China faces demands for technologies that will help save costs, reduce energy consumption and increase operational efficiency and product quality, with less environmental damage.” Metso’s new modular paper machine concepts provide an easy and convenient way to improve operational efficiency at paper mills in China. Ready-engineered packages offer low risks and a Minimized cost per ton from start up for mills striving for higher levels of technology. The modular concept permits optimized investment and operating costs with short investment payback times. “This is a sure way to future upgradability,” says Liu Jingwei, Vice President, Marketing and Communications, from Metso Paper China. To serve the needs of the Chinese market, Metso has established three modern and extensive service centers in China: Wuxi in Jiangsu province. Guangzhou in Guangdong and Zibo in Shandong province. The newest center in Zibo offers a wide range of roll maintenance services and roll covers.

Jussi Kairus Project Manager Tel. +358 40 551 9253 jussi.kairus@metso.com

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Tailor-made for Paper Applications: Kelheim Fibres to present viscose specialitites and new Paper Competence Centre at Zellcheming

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s the only European manufacturer of viscose short cut fibres for paper applications, Kelheim Fibres GmbH has become firmly established within the paper industry. Newly developed speciality fibres perfectly adapted to the needs of paper manufacturers add to Kelheim’s already broad range of products. Bellini, for example, is an ultra-flat fibre which excels in particular as a result of its extremely high self-bonding properties. Even an addition of only 5% of Bellini fibres in a paper ensures a significantly higher tensile strength and resilience in the end product. Tests carried out by the Graz University of Technology* have specifically shown more than twice the number of double folds in papers containing Bellini compared to the control paper. In addition the results for elongation, tear length and tear resistance could each be improved by more than 20%.

Due to its unique cross section, Kelheim’s Danufil® fibre is ideally suited to control the porosity of a paper. Depending on the pulp used, the addition of 10% Danufil® fibres achieves a decrease of a paper’s density by 10% - but at the same time the air permeability (porosity) according to Bendtsen rises by almost 90%. Danufil® fibres are therefore used for all products which request a fast exchange or passage of air and liquids; typical end uses are tea bags, cigarette papers, filter papers or papers for vacuum cleaner bags. Along with Bellini and Danufil® Kelheim Fibres presents at this year’s Zellcheming a range of speciality fibres which have been particularly developed for the paper industry. At the same time, the fibre specialists focus has been first and foremost on tailor-made new developments generated in close cooperation with the customer.

For this purpose Kelheim Fibres has extended its in-house Paper Competence Centre. With the new Bellini therefore is an ideal partner for all challenging pilot plant with inclined wire technology all kinds speciality paper end uses – but also an interesting of fibres, pulp and – if required – different additives choice in view of the worldwide growing demand can be processed to papers with surface weights for paper and the subsequent necessity to recycle from 20-200g/m2. The new inline dryer enables the papers: by adding Bellini fibres a paper’s properties production of larger samples. can be optimised so as to increase the proportion of recovered paper used, yet at the same time maintain Kelheim Fibres can therefore quickly prove the the quality of the end product – an ecologically and economically attractive aspect. results of their fundamental research in cooperation


with the Institute for Paper-, Pulp- and Fibre Technology of the Graz University of Technology in innovative paper products. The new Paper Competence Centre is also available for Kelheim’s customers’ own trial work. Test runs on big production plants are expensive but with the new pilot plant the customers can make the first steps in developing innovative papers – and engineer these new products in close cooperation with Kelheim’s R&D fibre experts. * paper made of eucalyptus pulp with 5% Bellini fibres versus paper made of 100% eucalyptus pulp

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Mondi’s Color Copy

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ondi’s Color Copy has earned a reputation with professional and office printers as a top quality digital colour laser paper. Recognized by FOGRA for excellent runnability and smooth surface characteristics, ranked No. 1 for performance in Western Europe according to the EMGE cutsize survey, it has become known as a top quality paper for brilliant full colour printing. This year, the global paper and packing manufacturer chose to highlight Color Copy’s haptics with its Feel the Difference Campaign and the slogan, “Only the best quality feels this good”. The new ads feature a Color Copy-clad man or woman reclining on a smooth sheet of Color Copy — a fun visual metaphor that suggests Color Copy is smooth enough to surround oneself in. “As part of our 2011 Feel the Difference Campaign, our new ads emphasise the smooth feel of Color Copy and the pleasant, tactile experience it offers together with an element of luxury to illustrate that it is a high quality, premium paper,” explains Johannes Klumpp, Marketing and Sales Director Mondi Uncoated Fine Paper. “In addition to the information on our Color Copy website and Facebook page, customers will also find stickers on 100 gsm A4 Color Copy reams with details about our new online game.” Since the launch of the campaign in February, visitors have been flocking to the Mondi Color Copy website (www.mondigroup.com/colorcopy) and Color Copy Feel

the Difference Facebook page (http://apps.facebook.com/ color-copy-game/) to try out the new online game. Three animated printing machines release printouts of “soft/ smooth” and “hard/rough” pictures. Players collect points by catching and dragging the “soft/smooth” Color Copy printouts to the filing box before they hit the ground. The game will stay online until August. As a monthly highscore prize, Mondi has been giving away an apple iPod nano and those participants with overall high scores can register to take part in a prize draw to win a Sony Vaio Subnotebook.

A step ahead of the rest

In 1989, Color Copy became the first paper in the world, specially designed for digital colour laser systems. The brand has since expanded and become the world’s first CO2 neutral colour laser paper. Professional and office users now have an entire portfolio of Color Copy papers to choose from, including Color Copy style, Color Copy glossy, Color Copy coated silk, Color Copy Xeikon reels and the latest addition, Color Copy indigo. Color Copy indigo received HP’s 3-star certification, which is the highest performance rating for HP Indigo digital presses and indicates the best performance in terms of runnability, fixing and blanket compatibility. “Indigo technology is optimal for professional printers. During the paper production process a special primer is applied to the paper so HP’s ElectroInk will later adhere properly. This has another major advantage over papers that must be pre-primed at the printer’s – Color Copy


indigo and DNS® indigo have an unlimited shelf life. Meaning that you will still achieve exceptional print results on an Indigo machine even if your paper is in storage for a few years,” explains Johannes Klumpp. The special primer guarantees 100% ElectroInk adhesion. The layer of the ElectroInk is also much thinner in comparison to other digital inks, which leaves the natural haptics of the paper intact – much like the offset lithographic process. Characteristic of digital printing technology, HP’s Indigo presses facilitate flexibility in print applications. HP recommended Color Copy indigo particularly for photo books because of its smooth surface and highquality full-colour print results.

Green never looked so good

In addition to being a fully CO2 neutral paper Color Copy is part of Mondi‘s eco-friendly Green Range of papers. It is FSC® certified and has earned the EU Ecolabel, making it an environmentally friendly choice for professional or office users, knowing that their high impact presentations, promotional material, direct mailings, business plans, or print proofs were produced with strict environmental considerations.


Improve your bottom line! Your daily production problems are our challenge - get expert advice and tailor-made complete solutions from BTG.

Talk to the experts! www.btg.com

info@btg.com


NEW 3D IMAGING TECHNOLOGY BOOSTS THE USE OF MILL BROKE IN THE PAPER INDUSTRY In terms of paper industry, Numcore has for now focussed on optimizing the use of mill broke. The dosing of broke is an important stage in the paper manufacturing process, as broke is constantly generated, and fluctuations in dosing, particularly in coated broke, may disrupt the wet-end process. The measurement device is being used as part of a pilot in a few paper and corrugated board mills and is connected to, in addition to the mills’ own monitoring systems, Numcore’s IT system. The device was realised as a CoreApus flow-through sensor with electrodes that continuously measure the electric conductivity differences in the various phases of the flowing mass. The 3D image produced by the device can only be generated, however, using inverse calculation, i.e. highly advanced mathematical modelling, which is where Numcore’s core knowledge lies. “The pilot devices are highly important product development tools for us, as the measuring data they generate allows us to precisely pinpoint the actual correlation between changes in mass flow and specific production problems. This has helped us to develop the modelling such that the data generated by the measuring device can be used to directly regulate the production process and boost its efficiency,” explains Jukka Hakola, Numcore’s Vice President of Sales and Marketing. Close inspection of broke dosing One of the pilot mills is Stora Enso’s Veitsiluoto paper mill in Kemi, Finland, where Numcore’s measuring device has been installed in the broke dosing stage of Paper Machine 5, which manufactures magazine paper. The broke consists of both base paper and coated broke. “Here we can regulate the refining and total amount of broke as well as the proportion of base and coated paper broke to an extent that the quality of the base paper and the runnability of the paper machine improve,” says Jukka Hautamäki, Process Development Manager, Veitsiluoto Mill, Stora Enso. He says immense demands are being placed on the measuring device, because the machine’s runnability was already very good. “Numcore’s technology is simple to

use and it was easy to install the sensor in the process. The sensor generates approximately 20 indices, which are displayed on the operator’s monitor and can be integrated alongside other machine parameters in our Savcor Wedge process analysis system. This allows us to seek correlations between, for example, the brightness of a base paper and the degree of refinement in specific broke.” In the spring, progressive tests involving gradual changes to broke refining will be carried out. The changes will be compared with indices generated by the measuring system, with the quality of the base paper and with the runnability of the machine. “In the tests, we will work the machine to an extent that we will be able to see what the measurement device actually sees. The tests will be conducted until the end of April, at which time we will be able to see how well the device meets the special demands of our production processes. The ultimate goal is to use the device for automatic broke dosing,” says Hautamäki. Major savings possible Another pilot mill is Powerflute Savon Sellu Oy in Kuopio, which manufactures corrugated board. There, Numcore’s device measures the mass flow from the mixing tank. “Thanks to the measuring device, we have already noticed that certain changes in mass flow clearly correlate with breaks that happen later on in the process. If we can determine as early as possible that there is the risk of an impurity in the process which will later on lead to a break, we are more efficiently able to regulate the process and thus avoid the break,” says the mill’s Operations Manager, Martti Laatikainen. According to him, the mill is particularlyconcerned with changes in the amount of broke and variations in the amount of fines in the pulp. “If the device helps us to find out the causes of breaks, it would bring us major annual savings. For that reason we were happy to take part in the development work for the measuring device,” says Laatikainen. /ins


14

15

PCC Production in China

On June 2nd, 2010 IMERYS Pigments for Paper produced their first full scale, plant batch of PCC in China. The new joint-venture PCC plant (formed with Tiger Forest and Paper Group) is on the site of the Yueyang Paper Company in Yueyang, Hunan Province, a subsidiary of Tiger Group. Yueyang Paper has recently installed two paper machines that have a combined 400k ton capacity to produce copy and LWC paper. Yueyang Paper is keen to produce paper of the highest quality to compete in both the domestic and export paper markets. This requires PCC which would improve the opacity, brightness and bulk of their paper. Tiger Forest and Paper Group decided that they needed an experienced supplier of PCC that could meet their needs. IMERYS was chosen to form a joint venture with one of Tiger’s subsidiaries, Antai Trading Company, to supply the high quality PCC needed to support their expansion plans. Plant design, construction and commissioning was supported by key groups in the Pigments for Paper team. Global support from engineering, carbonate processing, and technical service personnel was enlisted to supplement to local IMERYS China team for the project. The Yueyang Project team and all supporting members overcame many difficulties along the way. This was the first developmental capital project in the paper group after the 2008 financial crisis. In addition the plant construction and commissioning was to be delivered in a record breaking 10 months after project approval. The valuable on-the-ground experience gained during this project will make Imerys a stronger team and even more capable of dealing with future growth projects in the Asia region. The JV, Yueyang IMERYS Antai Minerals Company, is managed jointly, in the spirit of partnership, by both IMERYS and Antai personnel. Wang Ruihua, General Manager from Antai is the acting General Manager. Stone Shi, previously the plant manager of our Changshu plant in China producing wet ground calcium carbonate and having a kaolin makedown facility, transferred to Yueyang as the Operations Manager for the new JV. In total, there are 23 members within the new IMERYS team in Yueyang.

IMERYS Pigments for Paper

2010/08/11 03:35

Yueyang Background Story In 2010, Asian printing and writing paper production growth is forecast to accelerate to 6%, translating into 2.5 million tonnes of additional output. China will contribute more than half of the increase (1.33 million tonnes) due to the installation of several new machines. RISI is projecting growth within China of 19,387 million tonnes of new capacity within the printing and writing sector over the next 15 years. Tiger Forest and Paper Group is a state-owned enterprise in China and is a controlling stakeholder in Yueyang Paper. Yueyang Paper is listed on the Shanghai Stock Exchange. Yueyang Paper currently has a production capacity of 780,000 metric tonnes per year of CWF, UWF, LWC and Newsprint. This makes it one of the largest paper producers in China. The Group's principal activities are the manufacturing and selling of paper, paper products and chemical pulp from wood and reed. The main products are pigment finished offset paper, offset newsprint, bright and coloured newsprint, surface sized newsprint and slightly coated newsprint. Other activities include export of products and technology and import of materials, measuring equipment, machinery equipment and technology for production use.

About PCC

The second raw material, carbon dioxide, is the most important of the greenhouse gases. It is mainly created by burning fossil fuel in a power boiler. A PCC plant is connected to the power boiler stack from where the purified flue gas can be used in the manufacturing process. The amount of carbon dioxide used in the process is the same as that released in the calcination of the limestone. This means that the carbon footprint of the whole process is basically a function of the energy used. The calcium hydroxide and the carbon dioxide react together in a carbonator tank, forming the desired PCC crystal shape and size. The production process is flexible and the same plant can often produce several crystal types for different end uses.

The PCC Production Process Limestone 20-80mm

PM

Precipitated Calcium Carbonate, is a man made mineral chemically similar to GCC, Ground Calcium Carbonate, but different in shape.

Calcining

Unlike most of the other IMERYS products, PCC is manufactured and not mined. At the heart of the process is precipitation where PCC particles are formed in a carefully controlled environment in a carbonator tank under vigorous mixing (see diagram right).

Board of Directors

CaO

900 - 1200 ºC

CO2

Slaking

Water

CO2 + Air General Manager

Finance Director

Operations Manager

Maintenance

Shift Leaders & Workers

QC&Tech Services Manager

QC Shift Staff

Accountant

Purchasing & Logistics Officer

Industrially, PCC is produced from two main raw materials, quick lime (CaO) and carbon dioxide (CO2) gas. Quick lime is calcium oxide, which has been produced by burning limestone (CaCO3) at extremely high temperatures of about 1000 °C. This calcination process removes carbon dioxide and all organic impurities from the limestone and transforms it into a reactive substance. In a PCC plant, calcium oxide is first converted to calcium hydroxide (milk of lime) by mixing it with water in a slaker.

“Lime Milk” –15 weight-% Ca(OH)2

Carbonising

PCC ca 16.5% torrh.

13.2% Ca(OH)2 Low solids needed to produce the right crystal form and to avoid high viscosity

Screening To remove unreacted limestone and Ca(OH)2 aggregates.

Exoterm reaction –1700 kƒ/kg CaO

www.imerys-paper.com


14

15

PCC Production in China

On June 2nd, 2010 IMERYS Pigments for Paper produced their first full scale, plant batch of PCC in China. The new joint-venture PCC plant (formed with Tiger Forest and Paper Group) is on the site of the Yueyang Paper Company in Yueyang, Hunan Province, a subsidiary of Tiger Group. Yueyang Paper has recently installed two paper machines that have a combined 400k ton capacity to produce copy and LWC paper. Yueyang Paper is keen to produce paper of the highest quality to compete in both the domestic and export paper markets. This requires PCC which would improve the opacity, brightness and bulk of their paper. Tiger Forest and Paper Group decided that they needed an experienced supplier of PCC that could meet their needs. IMERYS was chosen to form a joint venture with one of Tiger’s subsidiaries, Antai Trading Company, to supply the high quality PCC needed to support their expansion plans. Plant design, construction and commissioning was supported by key groups in the Pigments for Paper team. Global support from engineering, carbonate processing, and technical service personnel was enlisted to supplement to local IMERYS China team for the project. The Yueyang Project team and all supporting members overcame many difficulties along the way. This was the first developmental capital project in the paper group after the 2008 financial crisis. In addition the plant construction and commissioning was to be delivered in a record breaking 10 months after project approval. The valuable on-the-ground experience gained during this project will make Imerys a stronger team and even more capable of dealing with future growth projects in the Asia region. The JV, Yueyang IMERYS Antai Minerals Company, is managed jointly, in the spirit of partnership, by both IMERYS and Antai personnel. Wang Ruihua, General Manager from Antai is the acting General Manager. Stone Shi, previously the plant manager of our Changshu plant in China producing wet ground calcium carbonate and having a kaolin makedown facility, transferred to Yueyang as the Operations Manager for the new JV. In total, there are 23 members within the new IMERYS team in Yueyang.

IMERYS Pigments for Paper

2010/08/11 03:35

Yueyang Background Story In 2010, Asian printing and writing paper production growth is forecast to accelerate to 6%, translating into 2.5 million tonnes of additional output. China will contribute more than half of the increase (1.33 million tonnes) due to the installation of several new machines. RISI is projecting growth within China of 19,387 million tonnes of new capacity within the printing and writing sector over the next 15 years. Tiger Forest and Paper Group is a state-owned enterprise in China and is a controlling stakeholder in Yueyang Paper. Yueyang Paper is listed on the Shanghai Stock Exchange. Yueyang Paper currently has a production capacity of 780,000 metric tonnes per year of CWF, UWF, LWC and Newsprint. This makes it one of the largest paper producers in China. The Group's principal activities are the manufacturing and selling of paper, paper products and chemical pulp from wood and reed. The main products are pigment finished offset paper, offset newsprint, bright and coloured newsprint, surface sized newsprint and slightly coated newsprint. Other activities include export of products and technology and import of materials, measuring equipment, machinery equipment and technology for production use.

About PCC

The second raw material, carbon dioxide, is the most important of the greenhouse gases. It is mainly created by burning fossil fuel in a power boiler. A PCC plant is connected to the power boiler stack from where the purified flue gas can be used in the manufacturing process. The amount of carbon dioxide used in the process is the same as that released in the calcination of the limestone. This means that the carbon footprint of the whole process is basically a function of the energy used. The calcium hydroxide and the carbon dioxide react together in a carbonator tank, forming the desired PCC crystal shape and size. The production process is flexible and the same plant can often produce several crystal types for different end uses.

The PCC Production Process Limestone 20-80mm

PM

Precipitated Calcium Carbonate, is a man made mineral chemically similar to GCC, Ground Calcium Carbonate, but different in shape.

Calcining

Unlike most of the other IMERYS products, PCC is manufactured and not mined. At the heart of the process is precipitation where PCC particles are formed in a carefully controlled environment in a carbonator tank under vigorous mixing (see diagram right).

Board of Directors

CaO

900 - 1200 ºC

CO2

Slaking

Water

CO2 + Air General Manager

Finance Director

Operations Manager

Maintenance

Shift Leaders & Workers

QC&Tech Services Manager

QC Shift Staff

Accountant

Purchasing & Logistics Officer

Industrially, PCC is produced from two main raw materials, quick lime (CaO) and carbon dioxide (CO2) gas. Quick lime is calcium oxide, which has been produced by burning limestone (CaCO3) at extremely high temperatures of about 1000 °C. This calcination process removes carbon dioxide and all organic impurities from the limestone and transforms it into a reactive substance. In a PCC plant, calcium oxide is first converted to calcium hydroxide (milk of lime) by mixing it with water in a slaker.

“Lime Milk” –15 weight-% Ca(OH)2

Carbonising

PCC ca 16.5% torrh.

13.2% Ca(OH)2 Low solids needed to produce the right crystal form and to avoid high viscosity

Screening To remove unreacted limestone and Ca(OH)2 aggregates.

Exoterm reaction –1700 kƒ/kg CaO

www.imerys-paper.com


Europe & International

Uncoated Fine Paper

Corrugated

Bags & Coatings

Only the best quality feels this good.

ber one The num ser paper: colour la

quality st print e h ig H ity • runnabil e e fr le • Troub eutral • CO 2 n

Color Copy. The highest paper quality is an important requirement for perfect print results. Feel the smooth and pleasant surface of the Original and participate to win great prizes at: www.colorcopy.com

SOLUTIONS. FOR YOUR SUCCESS. www.mondigroup.com/colorcopy www.colorcopy.com

53810_Mondi_CC_210x297_engl_bulletp_PLWCI.indd 1

17.01.11 15:52


Pulp-paperworld magazine issue 4