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Paper Making & distribution Magazine Volume 17 Issue 17

PMD magazine

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Fast Start-up – the Solution: atrocross Heimbach – wherever paper is made. A s we start a New Year it is interesting to see the diversity in news coming from the pulp and paper industry. On one hand there are fines of A$4m being issued by the Australian Federal Court for paper price-fixing and in Russia protesters demanded the premier’s resignation ahead of the official reopening of the Baikal Pulp and Paper Mill after 16 months of inactivity. A little closer to home we also had the news from AbitibiBowater that its Bridgewater Paper Company Limited (BPCL) subsidiary had filed for administration in the UK. The BPCL board of directors only made this decision after all other options to keep these UK operations solvent were exhausted. While production ceased at the Liverpool mill it was reported that it continues to explore its options (including finding a buyer) and are holding discussions with a number of potential interested parties. The mill however is continuing to fulfil customer orders from stock while the sale of the business process continues. Let’s hope it continues, for the 300 or so workers. Looking forward, this year we have the 7th PulPaper exhibition and conference in Helsinki from 1-3 June. This type of event represents a significant investment by those companies whom exhibit and I would urge readers to visit this show. Exhibitors and visitors travel from all over the world to take part in this international event. The last PulPaper show in 2007 attracted more than 16,000 visitors from 78 countries. Along with the exhibition there will also be a high-quality conference under the theme ‘Implementing the new rise’ which will cover topics that the forest cluster has to deal with to maintain its position and improve results in the changing environment. Copies of PMD May/June will also be available at the international media booth and will include our look at bio fuels and energy for the pulp & paper industry. In the next issue (March/April) we will include machine clothing (including rolls, wires, felts, belts, ropes and blades) our annual Shipping, Handling, Wrapping, Ports and Warehousing focus plus Advancements in Tissue Production. Vince Maynard Publication manager & editorial controller 2 - 9 Industry news 10 - 12 Projects & Contracts 13 - 14 Product news 16 - 18 Viconsys: Web imaging helps improve quality 20 - 23 Heimbach: Long-life forming fabrics that cut energy use 24 - 26 Cristini: Improving retentions and sheet planarity 28 - 31 Metso: Energy saving in stock preparation 32 People 32 Trading Post Volume 17 Issue 17 January/ February 2010 Published under licence by: Hartswood Media ISSN 1479-3989 Vol. 17, Issue No. 17 January/February 2010 Accounts -June Bray Editorial advisor -John Nutting Consultant editor -David Young Production -anton.print1@btconnect.com Production editor -Justin Whitsed Publication Manager & Editorial Controller Vince Maynard +44 (0) 1732 505724 Mobile +44 (0) 7747 002286 Fax +44 (0) 1732 860052 E-mail: pmdmagazine@btinternet.com or pmdeditorial@btinternet.com Circulation – circulation@pmdmagazine.com Nordic representative Einar Johansson E-mail einar.johansson@telia.com Publisher -Paul Barrett paulbarrett@pmdmagazine.com Paper Making & Distribution is published under licence by: Hartswood Media Hallmark House 25 Downham Road Ramsden Heath Essex CM11 1PU England T- + 44 (0) 1268 711560 F- + 44 (0) 1268 711567 Repro by: Anton Print Solutions Email: anton.print1@btconnect.com www.antonprintsolutions.co.uk Printed by: Manor Creative, Eastbourne, East Sussex, UK Tel: 02392 661485 www.manorcreative.com Digital Conversion by: Print to Digital PAPER MAKING & DISTRIBUTION Industry News Forest and paper groups lobby at Copenhagen summit R ecognition of responsible management of forests and sustainable use of their resources as part of the push to curb global warming was urged upon the negotiators at December’s Copenhagen climate change summit by the Confederation of European Paper Industries (CEPI) and the Confederation of European Forest Owners (CEPF). The Intergovernmental Panel on Climate Change (IPCC) had recognized the significant potential of forests in mitigating climate change. In its 4th Assessment Report, IPCC concluded that “a sustainable forest management strategy aimed at maintaining or increasing forest carbon stocks, while producing an annual sustained yield of timber, fibre or energy from the forest, will generate the largest sustained mitigation benefit”. Forest owners and the pulp and paper industries called for the IPCC recommendations to be included in an international climate change agreement. European forest owners and industry have implemented sustainable forest management principles. They call for these practices to be recognized in forestry policies to be put in place to achieve national commitments for carbon reduction. To this end, CEPI and CEPF have called for improvements in LULUCF (Land Use, Land Use Change and Forestry) accounting. In a statement they said that the accounting rules need to be practical “as opposed to the current mixture in approaches which is highly inconsistent. They do not send the right forest management signals to a sector, which is critical for achieving a global solution to climate change”. President of CEPF Christer Segerstéen said, “We need supportive policies to enhance the contribution of family forest owners to sustainable forest management and harvest of wood, as a carbon neutral activity with positive climatic effect.” Current negotiations on post 2012 arrangements have a focus on reducing deforestation and forest degradation (REDD) as leading causes of global warming. Forest-based products offer the most efficient and ‘green’ solution for the reduction of emissions and producing renewable energy, thus helping countries to meet their targets, says the CEPF. Teresa Presas, managing director of CEPI, added, “While emissions reduction should remain the priority to mitigate climate change, responsible management of forests and sustainable use of these resources should not be ignored in the endeavour to curb global warming. “Fair and transparent accounting rules applicable not only to forests, but also recognising the benefits of harvested wood products, would support this effort, hence confirming the IPCC conclusions.” PAPER MAKING & DISTRIBUTION Industry News Normal recession’ improves Södra’s finances in 2009 S ödra lurched from economic crisis to one “more resembling a normal recession” towards the end of 2009 said chief executive Leif Brodén when he announced the year-end results. Despite this, sales for 2009 slipped by only 1.9 per cent to SEK16.7 billion (US$2.3bn) and profits after taxes fell by 4.9 per cent to SEK696m ($96m). The company had been impacted by a weak start to the year with price and demand declines and responded with spring shutdowns at its Norwegian pulp mills. Price falls slowed in the second quarter and began to recover after the summer. “During the year we went from a situation of economic crisis to one more resembling a normal recession. Our production units have been running at full capacity since the summer apart from shutdowns in conjunction with planned maintenance,” said Brodén. “We have countered the economic fluctuations with measures in the areas we can affect. We have adapted our production rate. In addition, Södra has performed extremely well in terms of productivity development. In 2009 we implemented 3,400 improvement suggestions from Södra employees, the total effect of which represents an annual profit improvement of SEK 93 million,” he continued. “The total average productivity improvement for the Group was 1.7 per cent, with variations between business units. Södra Timber, for example, increased its real productivity by more than 5 per cent,” said Brodén. After the initial crisis, the second half of the year was characterised by low pulp inventories at producers as well as buyers. In particular, robust demand in China contributed to the stronger balance on the pulp market and the strengthening of Södra Cell’s profit in the second half-year. Smurfit Kappa Group hit by loss in market demand One of the world’s largest integrated manufacturers of paper-based packaging products, Smurfit Kappa managed to withstand the economic downturn in 2009 by maintaining its level of operating profits despite a substantial slide in sales. Net loss more than doubled from 22.8 euro cents per share to 55.8 cents while sales dropped 14 percent to 6.06 billion euros, compared with 2008. Smurfit Kappa Group chief executive Gary McGann said that attention to operating efficiencies helped. “In the context of a significant collapse in market demand and pricing, this outcome demonstrates the benefits of the Group’s ongoing attention to cost and operating efficiency, and a sustained contribution from its Latin American operations which delivered strong profitability and earnings growth in 2009. “In the fourth quarter of 2009, as anticipated, higher raw material costs compressed margins and affected the Group’s profitability. However, this was largely offset by further cost reduction actions and the commencement of the increase in SKG’s European corrugated and kraftliner pricing. On the demand side, the Group has experienced a return to positive volume growth in the last two months of 2009, and continues to see improving order books into 2010. “Early in the new year, a further increase in recovered fibre prices is generating some near-term margin compression within the Group’s system. However, higher input costs combined with the inventory discipline that continues to prevail in the market are supportive of the recent containerboard price momentum, translating in turn into higher corrugated box prices. “The sustainability of the recovery is dependent on continuing supply side discipline in the European market bearing in mind the start-up of a new containerboard machine in the second quarter of 2010. The Group for its part is maintaining its focus on operating efficiency and free cash flow generation. Given that focus, the significant input cost pressures and the extent to which this supports price increases, notwithstanding the near-term margin compression, the Group expects to deliver meaningful overall EBITDA growth in 2010.” . Smurfit Kappa Group said in January that it was in negotiations that would involve SKG acquiring Mondi Group’s corrugated operations in the United Kingdom and Mondi Group acquiring SKG’s European sack converting operations. The transaction would be subject to the normal procedures and conditions attaching to such transactions and was also subject to regulatory clearances. PAPER MAKING & DISTRIBUTION Industry News Ten million tonnes of Kemiart Kraftliner celebrated by M-Real PICTURED AT THE CELEBRATIONS ARE (LTOR): LAURI VERKASALO, VICE PRESIDENT, MILL MANAGER, M-REAL KEMIART LINERS; LEENA YLINIEMI, CUSTOMER SERVICE MANAGER, M-REAL KEMIART LINERS; RISTO AUERO, VICE PRESIDENT LINERBOARDS AND SPECIALITY PAPERS, M-REAL CONSUMER PACKAGING; ROGER VERVOORT, MENASHA PACKAGING CO LLC, USA; STEFANIE KAISER, CHRISTIANSEN PRINT GMBH, GERMANY; PAUL ZELINSKY, SALES MANAGER, KEMIART (US); JOACHIM BERTHEL, SALES DIRECTOR, M-REAL GERMANY; AND MIKA JOUKIO, SENIOR VICE PRESIDENT, HEAD OF M­REAL CONSUMER PACKAGING L eading European primary fibre paperboard producer and a paper supplier M- real reached a milestone in the production of Kemiart kraftliners when the 10 millionth tonne rolled out of the Kemiart Liners mill in January. The event was celebrated with customers, including Christiansen Print GmbH from Germany and Menasha Packaging Co LLC from the USA, in January at the mill in Finland. Capacity of the mill has more than doubled to 375,000 tonnes per annum since production started in 1971, as a result of continuous process development and significant investment. The range now consists of three different coated grades and one traditional white top grade providing a liner suitable for all printing methods including flexo, offset, and screen. Linerboards and Speciality Papers chief at M-real Consumer Packaging, Risto Auero said: “We are proud of our achievement in passing this target, as it reflects M-real’s ability to listen to its customers and foresee the needs of brand owners and retailers. “We have responded to rising demand for shelf-ready packaging, producing high quality kraftliners that provide excellent colour and half-tone reproduction, so vital in maintaining brand image and promoting the product. It goes hand in hand with the recognition that strong but lightweight secondary packaging saves costs and resources by preventing damage and waste at all stages in the supply chain.” When the mill started production it was of brown kraftliner, with mottled kraftliner following four years later. In 1986 the wet end forming and press sections were rebuilt and a new product, white top liner, was launched, with capacity increasing to 280,000 t/a. In 1990 processing was again upgraded and a coating unit added, with production of coated white top kraftliner starting the same year. M-real, part of Metsäliitto Group, had sales of 3.2 billion euros in 2008, with about 5,700 employees. PAPER MAKING & DISTRIBUTION Industry News Cost controls pay off for UPM A revival in demand allied to stringent cost controls have enabled paper products manufacturer UPM to make a turnround its fortunes in the final quarter of 2009 and in its year end results. Net profits in the quarter were 295m euros, compared with a 286m euro loss in the same quarter of 2008. This, despite sales falling 9 per cent to 2.11 billion euros. Earlier losses in the year diluted net profits to 160m euros, compared with a 180m euro loss in 2008. Sales for the year were down 18 per cent to 7.72 billion euros. The company said that it had made fixed cost savings of 300m euros with strong operating cash flow of 1.26bn euros and net debt reduced by 591m euros. Chief executive Jussi Pesonen said: “Demand for all of our products was affected by the global recession, and our sales dropped by 18 per cent during the year, severely impacting the profitability of our operations. Lower sales prices also impacted operating profit negatively. “In Paper and Label businesses, the internal improvements were necessary and they were professionally implemented. In Label, a quick and clear turnaround was achieved. In Plywood and Timber, the markets declined substantially in the course of the year which resulted in extensive production downtimes. Eventually, restructuring in Finland was necessary to improve long-term cost competitiveness of these businesses. “In 2009, the restructuring of Botnia ownership was a major strategic milestone for our company. Now we have not only excellent assets and people in Uruguay, but also a clear structure in our pulp operations, Fray Bentos cash flow in our full control and a solid bridgehead in Latin America. “In 2010 we expect the pulp business to improve, and we can gain the benefits of Uruguayan operations to the full. Also paper deliveries are expected to be higher than last year. However, average price for all paper deliveries will be clearly lower than last year. Demand is estimated to improve in self-adhesive labelstock.” Kimberly-Clark Europe contracts out its transportation Leading tissue manufacturer Kimberly-Clark Europe has contracted out its transport services to Dutch-based SmartWay Logistics. Some 70,000 truckloads will be managed by SmartWay each year to customers in Europe and domestic customers deliveries in France and Poland. SmartWay Logistics will also be responsible for selecting and managing hauliers and providing logistics administration support. The move marks a significant change in the way Kimberly-Clark manages their transportation operations. Historically, Kimberly-Clark managed this portion of their freight using an in-house freight management team based in their European Shared Service Centre. “We selected SmartWay Logistics based on their expertise of the European transportation market and their low cost approach to managing our business,” said Peter Surtees, director of European consumer logistics at Kimberly-Clark Europe. “With SmartWay Logistics driving operational and system synergies we have seen a reduction in empty running with benefits that include lower transport costs and carbon emissions.” Protests at Baikal mill reopening in Siberia Russia’s Baikal Pulp and Paper Mill in Eastern Siberia was due to start production in February after local environmental concerns forced its closure 16 months ago, reports RIA Novosti. Located on the shores of Lake Baikal, the world’s largest freshwater lake, the mill was opened in 1966 with its closure first proposed as a part of Glasnost in the early 1980s. Thousands of protestors gathered prior to the reopening to rally against the mill's reopening. The protests broke out after Prime Minister Vladimir Putin signed a resolution in January that excluded the production of pulp, paper and cardboard from the list of operations banned in the Baikal natural territory, which is a UNESCO World Heritage Site. Putin’s move was criticized by environmentalists who are appealing for a reversal from President Dmitry Medvedev. The campaign during Glasnost to close or convert the Baikal Mill involved the nation's leading statesmen and literary men and forced the Soviet government to promise a halt to pulp production by 1993. The collapse of the Soviet Union in 1991 delayed the decision until 2007. In October 2008 the plant switched over to a closed water cycle, preventing the discharge of waste into the lake. In December 2009, the mill started testing its new equipment. A spokesman said: “Now, production of brown pulp sample consignments is under way. Full production will start in late February.” PAPER MAKING & DISTRIBUTION Industry News Biofuel lime kiln to cut emissions at SCA Östrand Metso biomass power plant for Belgium A new lime kiln is to be installed at SCA’s Östrand pulp mill at Timrå in Sweden. The SEK500 million (US$69m) kiln will increase capacity by 10,000 tonnes of pulp a year while at the same time cutting fossil-based carbon dioxide emissions by 80 percent. The investment will also make further capacity increases possible. With a target start-up before the end of 2011, the kiln will replace two existing oil-fired lime kilns and will use fuel pellets from SCA’s BioNorr plant in Härnösand. Lime kilns play an important role in the production process at sulphate pulp mills. The process produces lime sludge, consisting primarily of calcium carbonate. The lime kiln converts this to calcium oxide (slaked lime), which is then reused in the pulp production process. The Östrand mill’s two lime kilns consume around 17,000 cubic metres of oil per year and significant savings will be made when the oil is replaced with biofuel. The new lime kiln will also lead to lower chemical and maintenance costs. “The new lime kiln will enable us to increase our production and at the same SCA IS ON THE MOVE: THIS IS THE MUNKSUND MILL time, we will achieve a dramatic drop in Östrand’s greenhouse gas emissions,” says Ingela Ekebro, the site’s manager. The pulp plant produces 420,000 tonnes of chlorine-free bleached kraft pulp a year, which is used in the production of printing paper and hygiene products, plus approximately 90,000 tonnes of chemically-treated mechanical pulp, which is used for the manufacture of hygiene products and packaging products. . SCA says a new winder will further improve production capability of its premium product White Top Kraftliner line at the Munksund mill outside Piteå, Sweden. SCA White Top Kraftliner is a product that is showing strong growth in the market, says SCA. “This grade of containerboard has a full-cover white surface layer, which offers very good printing characteristics,” it said in a release. The investment will entail the replacement of the existing winder in order to increase delivery safety and future quality demand. It leads to a somewhat increased production capacity. . A production line for incontinence care products will be built by SCA in Russia where demand for personal care products is showing strong growth. A SEK138m production line for incontinence products will be installed at its plant in Veniov in the Tula district some 180km south of Moscow. The decision entails that SCA – once the plant is in place during 2011 – will be able to substantially cut its import from its plants in Olawa, Poland, or Gennep, Holland. Thereby, high costs for transports and duties will be lowered. Belgian renewable-energy company 4HamCogen is planning to construct a biomass power plant for combined heat and power production (CHP) in the province of Limburg next year. The 30 million euro (US$41m) plant at Ham will be supplied by MW Power, a Metso-Wärtsilä joint venture with the expected start up in the second quarter of 2011. The plant automation system will be delivered by Metso’s Automation business line. With uncontaminated biomass as the primary fuel, the plant will utilize bubbling fluidized bed (BFB) technology. With the new cogeneration plant, 4HamCogen will feed 8.4MW of electricity into the distribution grid and will be able to deliver up to 14MW of heat. 4Energy Invest, the parent company of 4HamCogen, is a Belgian based renewable energy company that aims at creating and managing a portfolio of small to middle-sized biomass-to-energy projects. PAPER MAKING & DISTRIBUTION Industry News Fuel credits boost International Paper’s fortunes A combination of alternative fuel credits, cost reductions and capacity cuts enabled International Paper (IP) to turn a stormy US$1.3 billion net loss in 2008 into a $663 million profit after tax, despite a drop in sales from $24.8bn to $23.4bn in 2009. Much of the loss in 2008 came from special items including a final quarter $1.8bn charge for impairments of goodwill for the company’s US Printing Papers and US and European Coated Paperboard businesses. In the fourth quarter of 2009, Memphis-based IP earned $516m in alternative fuel credits but had to pay a pre-tax charge of $1.0 billion ($638 million after taxes) for restructuring and other charges. These also included a pre-tax charge of $861 million ($525 million after taxes) for shutdown costs for the closures of the Albany, Franklin and Pineville mills announced in the fourth quarter of 2009. Although the year end figures were positive, in the final quarter of 2009 the company made a net loss of $101m compared with a net loss of $1.8bn in the final quarter of 2008. The company also repaid $3.1 billion of debt during 2009. “Despite all the uncertainties we faced at the beginning of 2009 and throughout the year, plus the challenge of rising input costs in the fourth quarter, International Paper overall has delivered solid results,” said chief executive John Faraci. “Our focus on reducing overhead costs, matching our supply with our customer demand and realizing Industrial Packaging synergies gave us the ability to generate record free cash flow and pay down a significant amount of debt while positioning ourselves for 2010.” Speciality paper manufacturer sets up in Moscow Global manufacturer of speciality papers and engineered paper products Glatfelter has opened a sales and distribution center in Russia. The office in Moscow will serve US-based Glatfelter’s Composite Fibers Business Unit (CFBU) customers in Russia and the Commonwealth of Independent States (CIS) including Ukraine, Kazakhstan, Azerbaijan, Georgia and Belarus. At the same time, Glatfelter acquired a number of customer relationships and an existing sales network from distributors of metallized products. General manager of Glatfelter CFBU Martin Rapp said: “This opportunity to expand our global footprint better positions us to serve an important growing market and supports our vision to become the global supplier of choice in specialty papers and engineered products. “It further demonstrates our commitment to provide excellent customer service as a strong local presence in these markets will allow us to work closely with our strategic customer partners to strengthen and grow their businesses.” CPI ‘extremely disappointed’ at CCL relief cuts The UK’s Confederation of Paper Industries said it was “extremely disappointed” that the Chancellor of the Exchequer had planned to cut the rate of relief from CCL for business with Climate Change Agreements will be reduced from 80 to 65 per cent. Justificaton for the measure, said the CPI, was that the move would avoid the submission of full State Aids notifications and will save a one-off compliance cost for business and Government of around £6.5million, contributing additional savings of up to 200,000 tonnes of carbon dioxide over the next five years. Whilst it is true that the rate of CCL levy reliefs on gas and solid fuels would have had to reduce in 2011 to avoid a State Aids notification, the rate of levy relief for electricity would not, and indeed could, have been increased to compensate, said the CPI. David Morgan, the CPI’s Head of Regulatory Affairs, said, “Climate Change Agreements have been proven to work well in improving energy-intensive industries’ energy efficiency and in reducing carbon emissions. Reducing the incentive associated with CCAs, particularly in the light of the current economic downturn, makes no sense whatsoever. CPI proposed to Government that it should make a revenue neutral adjustment of CCL reliefs and supplied data to support this argument but regrettably Government appears to have found the lure of garnering extra revenue by taxing manufacturing industry irresistible.” PAPER MAKING & DISTRIBUTION Industry News UPM Shotton to expand paperrecovery capacity A materials recovery facility being constructed at UPM’s Shotton paper mill, the UK’s largest newsprint producer, will sort dry recyclables such as plastic bottles, cardboard, newspapers, magazines and metals. The facility in North Wales, representing an investment of £17 million, will enable the mill, which currently recovers around 640,000 tonnes of recovered newspapers and magazines a year, to source high-quality paper from co-mingled sources. David Ingham, general manager at UPM Shotton said: “Our vision for UPM Shotton is to be the frontrunner in creating value from renewable and recyclable materials. Building a materials recovery facility at Shotton is a natural step towards this vision. It enables us to provide solutions to our partners in paper recycling and meet UK market needs in processing recyclable materials.” The investment is supported by the Welsh Assembly Government with a £1.7m Single Investment Fund grant and will have up to 150 working on the construction phase of the facility, which will create 160 jobs. UPM is the world’s largest user of recycled fibre in graphic papers consuming annually three million tonnes of recovered paper. Once fully operational, the facility will sort up to 200,000 tonnes of recyclable material of which 120,000 tonnes will be newspapers and magazines ­providing 20 per cent of the recovered paper used as raw material in the mill's paper production. Surplus recyclable material will be recycled by other reprocessors as required. UPM Shotton is a part of the Finnish-based UPM group that produces pulp, paper and engineered materials with worldwide sales of 9.5 billion euros. Research project aims at protecting the Baltic Sea UPM is helping towards cleaning the Baltic Sea, one of the most polluted in the world, by becoming a partner at the Baltic Sea Action Summit. The energy, pulp and paper firm has set up a project that involves the use of charcoal mixed with soil to remove impurities from nutrient-rich water running from agricultural lands into the Sea. “UPM’s corporate responsibility defines minimal waste to landfill and efficient re­use as well as sustainable use of water resources as key responsibility areas. Finding new and innovative solutions to use industry's side products and at the same time finding new ways to safeguard the Baltic Sea is very much in line with our responsibility programme,” said Marko Janhunen, director of corporate responsibility. Recent international research on use of biochar as soil conditioner points out several potential benefits to be achieved. Development of biochar-recycling products for agricultural use offers, therefore, an important technological option. The two-year research programme will be carried out with the University of Lappeenranta and University of Helsinki and preliminary results are expected by the end of the year. . UPM has also joined the United Nations Global Compact’s CEO Water Mandate to confirm its commitment to responsible use of water resources in all its operations. The company’s commitment covers water reduction and minimising the impact of its operations on local water resources and safeguarding natural watercourses in its forests. Pulp and paper mill fined for price fixing A Singapore pulp and paper company has been fined A$4million by an Australian Federal Court for price fixing in the domestic market. Asia Pacific Resources International Limited (APRIL) was accused by the Australian Competition and Consumer Commission (ACCC) of breaching the price fixing provisions of codes relating to the price of copy paper and uncoated woodfree folio paper. APRIL admitted it was part of the AAA Club, a group that had met secretly 18 times with competitors in the four years from December 2000. Average prices were agreed, said the ACCC. “Conduct at AAA Club meetings was an arrangement which arose in circumstances where the participants were seeking to achieve stability in pricing by avoiding competition amongst themselves,” said Federal Court Justice Bennett. Finnlines to open a roro line to Gothenburg Three new roro shipping lines were opened by Finnlines in January for the routes from Helsinki to Gothenburg, from Kotka to Gothenburg and from Gothenburg to Bilbao. The new routes increase the roro network connections operated by Finnlines by one fifth. Two large, modern roro vessels, MS Finnmill and MS Finnpulp, will operate on the new routes. . Port of Helsinki fees will not be increased in 2010. The price list is now available for download at its website port.helsinki@hel.fi SCA’s Mexico tissue plant uses Metso and ABB systems A tissue production line being supplied by Metso for SCA’s new paper-making mill in Mexico will use electrical systems engineered, delivered and commissioned by ABB. Production at the mill, located near Mexico City, is expected to start in the summer or autumn of 2010, with capacity for 60,000 tons a year of high-quality facial, toilet and towel tissue grades. The electrical systems from ABB include intelligent control and monitoring systems for power distribution, the new generation intelligent Motor Control Centers, frequency converters and high efficiency motors as well as a complete paper machine Sectional drives system. “The electrical equipment, that drives the processes, is connected by modern field bus solutions into one functional system. By using the latest new generation products and applications know how the life cycle management and preventive maintenance of the system will be further enhanced,” said ABB’s area sales manager Fredrik Grankull. The delivery includes ABB’s most recent application knowledge for the power distribution and motor control techniques. The intelligent solution enables a higher degree of control and information transfer between the systems. ABB’s Process Industry unit from Vaasa, Finland is responsible for the delivery which includes besides the equipment, project management, engineering and site services. Two paper machines relocated for Chinese Shandong Huatai Paper Shandong Huatai Paper Stock Co is having two paper machines relocated to its subsidiary mills in China by Metso. The 4.45m-wide (trim) PM8 fine paper machine at Mondi Group in Szolnok, Hungary, will be relocated to the Anqing mill of Anhui Huatai Forest Pulp & Paper in Anhui province. Metso will dismantle and pack the paper machine line and supervise the installation and start-up of the relocated equipment. Metso’s delivery will also include a modernization of the machine control system as well as mill engineering services. The start-up of the relocated machine is scheduled for the first half of 2011. The 5.56m-wide (trim) PM8 newsprint machine at the Qiqihar Paper Mill, originally owned by Heilong Paper, in Heilongjiang province, will be relocated to Guangdong Huatai Paper in Xinhui, Guangdong province. Metso’s delivery package comprises engineering and supervision services for dismantling, packing, installation and start-up of the paper machine line. The start-up of the relocated line is scheduled for the end of 2010. Anhui Huatai Forest Pulp & Paper Co and Guangdong Huatai Paper Co are part of Shandong Huatai Paper Stock Co which produces newsprint, uncoated fine paper, coated art paper and tissue with an annual capacity of more than 1.8 million tonnes. Reconditioning, rebuilding and eventual relocating of entire production lines is part of Metso’s service offering for paper machines. It combines machine rebuilding business, project management and automation solutions. As a result of structural changes in the global pulp and paper industry, paper producers in Europe and North America have cut production capacity and closed machines and entire mills. Some of the closed machines have technical operating life remaining, and some of them are relocated to the growing Asian markets, especially to China and India. Production management systems for Pratt Industries P ratt Industries, a leading worldwide producer of recycled paper and packaging materials, recently implemented and commissioned a comprehensive Pulp & Paper Collaborative Production Management (CPM) system delivered by ABB. The cpmPlus system consists of production tracking and quality management functions that are used by all US-based Pratt Industries’ paper mills in Shreveport, Louisiana, Conyers, Georgia and Staten Island, New York. The delivery also includes box plant functionality, integration with Pratt’s global business system, centralized sales order entry, invoicing and distribution as well as multi-mill planning functions, which are used in the head office of Pratt Industries in Conyers. This delivery is in line with the company’s strategy to harmonize its operations globally, and dedication to continuous productivity improvement. This implementation extends the existing systems which ABB had previously installed in their six Australian paper mills. The new CPM system provides Pratt Industries with better production and quality data visibility, centrally managed multi-mill planning and optimization, real-time integration with their box plants and paper mills and a modern IT system architecture. The challenging IT-project was accomplished in 12 months, six months ahead of schedule. “ABB has a strong working relationship with Pratt Industries. This made it easy to get the buy-in from the end users; they expressed their pleasure at how easy and intuitive the new system is and how smoothly the roll-outs went,” said Matti Vartinen, ABB’s project manager for the projects. “Working together in a true partnership has enabled this project to be so successful. The combination of the full scope of supply and the flexibility to match the way Pratt wants to run their business and has greatly accelerated the sustainable return that Pratt Industries has achieved.” said Dennis Fleming, Senior IT Director at Pratt Industries. Front end system for high-density fibre board at Swedspan Polska A front end system for ultra-thin fibre board production is to being supplied to Swedspan Polska in Poland by Metso. Installation at the company’s mill in Bielsk Podlaski, northeast of Warsaw is expected to start in the third quarter of 2010 The project will comprise a system that takes logs from the wood yard through to the EVO Defibrator system along with electrical and process control systems and steel structures. Objective of the system is to deliver high-quality fibre at lowest possible production cost and environmental impact. Swedspan Polska sp. zoo is part of the international Swedspan Group, which was formed as a spin-off from IKEA’s in-house furniture maker Swedwood in 2008. Turkey’s Hayat Kimya to install tissue line A complete tissue production line is being supplied to Hayat Kimya AS in Turkey by Metso. The line includes an Advantage DCT 200TS tissue machine and will be installed in the Yeniköy mill near Izmit. Start-up is planned for the fourth quarter of 2010. Equipment will include a tissue production line including a stock preparation system and an Advantage DCT 200TS tissue machine. The tissue machine will be equipped with an OptiFlo headbox, Metso Yankee cylinder, Advantage AirCap hood adapted for co­generation, Advantage WetDust dust system, Advantage Run sheet transfer system and an Advantage SoftReel L reel. The stock preparation lines will consist of OptiSlush pulpers, OptiFiner conical refiners and OptiScreen machine screens. The delivery will also include an extensive automation package with metsoDNA machine and process controls, PaperIQ Plus scanner and quality controls. Complete engineering, installation supervision, training, start-up and commissioning are also included in the delivery. With a width of 5.6m and a design speed of 2,200 m/min, the new line will have a design capacity of 70,000 tons a year of high-quality facial, toilet and towel grades. Raw material for the new line will be virgin fibre. The production line is optimized to save energy and to enhance final product quality. Hayat Kimya AS is part of the Hayat Group which primarily operates in the chemicals, hygienic products, paper and wood-based industries. The Hayat tissue facilities have a production capacity of 65,000 tons and a converting capacity of 60,000 tons per year. With the new investment the total production capacity of Hayat Kimya will reach 135,000 tons, making it the largest tissue producer in Turkey. Advanced recycled paper mill for SAICA in UK One of the world’s most advanced recycled paper mills is to be built SAICA Containerboard at Partington Wharfside, near Manchester, UK. The new PM11 – scheduled to start up at the beginning of 2012 – will produce 425,000 t/a of high performance lightweight fluting and testliner grades to be used in the manufacture of corrugated boxes. Finnish consulting and engineering company Pöyry will be providing complete plant and civil engineering for the paper mill and stock preparation worth 5 million euros. The 100 per cent recycled fibre-based PM will incorporate the best-available board making technology including low energy and fresh water consumption. The project is a continuation of cooperation between SAICA and Pöyry in a number of projects in Spain and it further strengthens Pöyry’s position as the leading engineering solutions provider for the board making industry. SAICA is Spain’s biggest paper and board manufacturer with paper machines in Zaragoza and El Burgo de Ebro in Spain and in France. Projects & Contracts PAPER MAKING & DISTRIBUTION Elastic calender covers increase smoothness values Arctic Paper in Mochenwangen continues to successfully increase smoothness values by using Voith Paper’s NeoSilk in the soft machine calender of its PM2 line without destabilizing the roll run. “We are absolutely satisfied,” said Kurt Jurczik, Arctic’s director of production and technology, and Harald Nimz, department director of paper production. The paper mill produces 110,000tons/year of book paper, uncoated offset and specialty papers on three paper machines. The NeoSilk line of elastic calender covers was developed in order to improve the paper quality, increase running times and to ensure the thermal stability and optimal operational reliability. Voith Paper says that with its optimized filler systems and resin technologies, NeoSilk offers outstanding wear and abrasion resistance. The running time is thus increased and mechanical defects are reduced. The optimized technology provides for very good marking and barring resistance. China’s Nanning Phoenix Pulp & Paper Co has ordered a high-speed tissue machine from Group Andritz. Start up of the PrimeLine machine to be installed at Guangxi is scheduled for mid 2011. The order, to be fulfilled by Andritz’s Foshan factory, includes the complete stock preparation plant that is also designed for bagasse pulp, a two-layer headbox (PrimeFlow), an EquiDry hood, as well as a PrimeDry Steel Yankee – a high-precision drying cylinder for excellent drying rates at low costs. The PrimeLineTM tissue machine has a design speed of 2,100 m/min and a width of 3.65m. It is Andritz’s 11th high-speed tissue machine in China. Nanning Phoenix orders high-speed tissue machine Alabama River Group’s pulp drying machine to be rebuilt US-based Alabama Pine Pulp is having its market pulp machine at Claiborne in Alabama rebuilt by Metso as the mill converts to roll fluff pulp production. Both a wet-end rebuild as well as the new finishing equipment needed for roll fluff pulp production will be part of Metso’s delivery. It includes a new headbox, steambox, calender, and winder. The rebuild will be completed in stages beginning in the spring of 2010 with the final completion in early 2011. Alabama Pine Pulp is part of the Alabama River Group (ARG), a subsidiary of Parsons & Whittemore Inc, and known worldwide as a leading producer of quality softwood and hardwood market pulps. The Claiborne Mill Complex, located at Claiborne, Alabama, employs 550 and is recognized as one of the largest pulping operations in North America. The mill will begin roll fluff production in the second quarter of 2011. Domtar converts fine-paper line to fluff pulp production North America’s largest manufacturer of uncoated freesheet paper, Domtar Corporation is having the PM5 fine paper machine at its Plymouth mill in North Carolina rebuilt and converted by Metso for fluff pulp production. The project – which is estimated will cost between 15 and 25 million euros – will include a new wet end and a rebuild of the finishing equipment needed for fluff pulp production. It includes a new wire section and a SymFlo headbox equipped with an IQDilutionPro profiling system, an IQSteamPro steambox, a new press section, and dryer modifications including a new hood as well as reel and winder rebuilds. The rebuilt 7.77m-wide machine will produce fluff pulp in the basis weight range of 420-470 lbs/3,000ft2 (684–765 g/m2). With yearly sales in 2008 of $6.4 billion, Domtar Corporation is the second largest in the world based on freesheet production capacity, and is also a manufacturer of papergrade, fluff and specialty pulp. It operates 12 paper mills and eight pulp mills. To find out more on how to advertise or start receiving PMD, please contact Vince Maynard +44 (0) 1732 505724 or email: pmdmagazine@btinternet.com Website: www.pmdmagazine.com Papermaking & Distribution Magazine PAPER MAKING & DISTRIBUTION Product news Digital automation system streamlines practices I n what is described as an industry breakthrough that streamlines 35-year-old engineering practices, a digital automation system from Emerson Process Management offers “I/O on Demand” and Electronic Marshalling. Resulting from a focus on Human Centered Design, the S- series platform is based on the v11 release of the DeltaV digital automation system. DeltaV includes enhancements to all of the systems I/O processing, operator displays, asset management, batch capability and system security. These combined capabilities reduce project complexity, eliminate needless work, and speeds up system commissioning. They are claimed to lift Emerson’s PlantWeb digital architecture to new levels of project and operations performance. Project and operations benefits stem from the S-series I/O on Demand flexibility which allows users to choose among traditional wired, wireless, bussed and Electronic Marshalling. With I/O on Demand, users decide what type of I/O they want – Wireless, Foundation fieldbus, HART, AI, AO, DI, DO, DP, T/C, or RTD. They decide when they want the I/O, whether for late project changes, during start-up, during operation, or temporary installations; and where they want the I/O, whether in a rack room, remote locations, hazardous areas, safety systems, or harsh environments. Further advantages are realised with Electronic Marshalling, a powerful new technology that streamlines design and installation for users. This eliminates two-thirds of the wiring and connections needed by today’s conventional marshalling cabinets. Larry O’Brien, research director at ARC Advisory Group, explained: “There is a significant amount of cost associated with traditional marshalling methods, which can also limit the changes possible in the engineering and design of the system. The new I/O on Demand capability of Emerson’s DeltaV S-series allows users to add or change I/O types whenever project design changes are made, and they can do it no matter where the I/O is located. Even more important than reducing projects costs is the reduced time to start­up achieved by this kind of an approach.” More information from Emerson Process Management, Blegistrasse 21, 6341 Baar, Switzerland. Email: infocentral@ap.emersonprocess. com Web: www.EmersonProcess.eu Kemira Blankophor FWA products to include Fennocide biocide A fluorescent whitening agent from Kemira – global 2.8 billion Europe-based chemicals company – has had its preserving biocide changed to Blankophor urea- and carrier-free product formulations that will be manufactured with Kemira Fennocide BZ 26 D biocide. This will replace currently-used biocides that have been sourced externally due to different regional requirements. “Kemira has broad in-house biocide knowledge, thus, the decision to change the formula to contain Fennocide BZ 26 D was very welcome,” said Christiane Sloan, FWA product line manager. “We are one of the key pulp and paper industry chemical suppliers specializing in water-intensive processes and our product portfolio covers a wide range of biocides which are specifically designed to kill and inhibit the growth of troublesome microbes typically found in paper manufacturing conditions.” Extensive tests and long-term trials were carried out to ensure that the change does not have any impact on Blankophor product quality, effectiveness or specification. The new formulations can be mixed with existing inventories of the current formulations and are marketable world-wide. More information from: FWA: Kemira Germany GmbH. Tel: 49 151 1677 6418. Email: christiane.sloan@kemira.com Biocides: Kemira Chemicals Inc, USA. Tel: 1 678 427 3332. Email: ken.keegan@kemira.com Web: www.kemira.com PAPER MAKING & DISTRIBUTION Product news Handheld communicator supports easy upgrade capability ABB drives show how much energy they are saving Ensuring that a plant or process is working to its optimum performance, while avoiding the cost of external energy measuring equipment, is made possible by an application from ABB that shows how much energy is being used, and saved, in drive systems. The drives’ built-in energy efficiency parameters work out energy savings of the application in kWh and MWh; the cost of the energy saved in local currency; and the carbon dioxide emissions equivalent of the energy saved. All these energy-related measurements are displayed through the control panel’s alphanumeric display and can be accessed by pressing a combination of the soft keys. The energy consumed when a fan or pump is used direct-on­line is compared with the energy used once the drive is W hat is described as the next generation in handheld communicator technology now supports the German language version of both its system software and Easy Upgrade capability. The new 475 Field Communicator provides advanced device diagnostic and troubleshooting capabilities in the field and on the bench, so users can work more efficiently. With a faster boot-up and operating system, jobs can be performed quickly and easily while the new battery ensures days, not hours, of operation. The intrinsically safe 475 Field Communicator supports HART, WirelessHART, and Foundation fieldbus devices. The full-colour LCD display provides an intuitive graphical interface to support trend charts, gauges, and graphics available in enhanced Device Descriptions. The colour display aids troubleshooting through high-contrast images. “The ability to quickly perform configurations and view advanced valve diagnostics in the field from a handheld reinforces Emerson’s commitment to delivering innovative field communicator technology,” said Craig Llewellyn, president of Emerson’s Asset Optimization business. “We continue to develop ways that enable workers to be more productive in the field and easily integrate their field work into the bigger asset management picture. Providing the system software in local languages is another step in helping maintenance and reliability experts work more effectively and efficiently.” More information from Emerson Process Management, Blegistrasse 21, 6341 Baar, Switzerland. Email: infocentral@ap.emersonprocess .com Web: www.fieldcommunicator.com installed and running. The drive then calculates energy savings read way on its built-in screen. set the local energy cost as a (tn/MWh) is used to convert with reference to this baseline Saved money is displayed in reference, while a carbon energy into carbon dioxide and displays it in an easy to local currency after the user has dioxide conversion factor emissions. Web imaging helps improve quality After the installation of a Viconsys integrated system at St Regis Hollins, mill staff took steps to eliminate faults at their upstream sources to dramatically reduced sheet defects, reports Mark Williamson* T he technology of imaging systems for identifying paper web fault and break events has recently been advancing dramatically. The imaging quality and resolution in newer systems has improved so much that originals, installed only a few years ago, seem quite rudimentary in their fault detection capabilities. With older systems, some important web faults are missed, and it is often difficult to find the sources of either quality problems, web breaks, or both. The St Regis Hollins linerboard mill in Darwen, Lancashire, UK, faced these obsolescence issues in two respects: The original web break analysis (camera) system and the web quality inspection systems, installed in 1996, were showing their age and were getting difficult to service. Hardware and software support was hard to find. Moreover, some critical quality faults were not being identified quickly enough. Rather than replace each system independently they chose an integrated web imaging solution from a single supplier: Viconsys Oy, based at Jyväskylä in Finland. In 2006, Viconsys introduced the integrated web imaging system – combining web break analysis cameras and web quality inspection cameras in single system with common hardware, image-analysis software and operator interfaces. Production manager Mark O’Shaughnessy says the Viconsys offering of one integrated system was attractive technically and cost-wise. After the installation of the Viconsys system early in 2009, the mill’s management has taken proactive steps to eliminate faults at its upstream sources and has dramatically reduced sheet defects for the satisfaction of their customers. O’Shaughnessy says the fault frequency was reduced by more than 75 per cent soon after the system start up and has continued to fall. “Critical faults can be counted on one hand,” he says. Quality is everything The Hollins mill produces ‘white top’ linerboard with grammage ranging from 125 to 200 g/m2. The twin forming table machine has maximum trim width of 2,850 mm and a typical operating speed THE QUALITY VISION BEAM, POSITIONED BEFORE THE MACHINE REEL, COMPRISES SIX DIGITAL MATRIX CAMERAS LOCATED ABOVE THE SHEET TO CAPTURE THE WEB DEFECT IMAGES AND THEIR PRECISE LOCATION USING THE COMMON USER INTERFACE AT THE WET END (BELOW) OR THE DRY END (ABOVE), OPERATORS CAN SEE THE ORIGINS OF FLAWS AND HOW THEY PROPAGATE THROUGH THE MACHINE. FINAL PRODUCT FLAWS AND SHEET BREAKS CAN THEREFORE BE RELATED TO THE SOURCE of 550 m/min. The linerboard is converted to folded corrugated boxes used for consumer product packaging and folded trays for product display. In their final use, some products have a white surface and some have high ink coverage. O’Shaughnessy emphasizes that fault-free quality is required for both visual appearance and for their customers’ converting processes. “We aim for a world-class product, so quality is everything. For white-top presentation liners, print quality and appearance is very important. Sheet flaws are also a big issue for runnability in our customer’s high speed corrugators,” he says. But first it is necessary to precisely characterize the flaws and define the causes. The integrated system provides this capability by allowing operators to see the flaws in the finished sheet and at potential upstream sources. “With this system you can narrow down the fault to a specific machine section,” says O’Shaughnessy. “And when you find faults you want to react as quickly as possible,” he says. The integrated system has given machine operators this visibility and quick problem solving capability. The Viconsys system comprises two inter-related imaging techniques: the Quality Vision part and the Process Vision part. The Quality Vision beam, positioned before the machine reel, encloses six digital matrix cameras located above the sheet to capture the web defect images and their precise location. These cameras take an instantaneous snapshot of the full field of view of each camera, so all pixels are captured at the same time. A strobed LED light source illuminates the sheet from an overhead position, from a slightly oblique angle so surface defects are better detected. The pale green light from the LED source is pulsed at a very high rate, adjustable from 50 microseconds down to 3 microseconds. This high image strobing rate ‘freezes’ the sheet image so the image smearing effects caused by sheet movement are minimal, even at high web speeds. Since the high-intensity light source is pulsed and remains on for only a short period the light source beam remains cool and therefore does not need any cooling system. Faults are classified by the system and mapped according the MD and CD location. The frequency of occurrence calculated by the system defines where the fault may be occurring by relating it to roll or fabric rotation speed. The system has a self-learning capability based on neural network technology. So far, 20 important fault types have been defined. Formation of the white top layer, as measured by • THE TRIM SQUIRT AND FORMING TABLE CAMERAS ARE IN A VERY DIFFICULT ENVIRONMENT; AN INTEGRAL WASHING AND WIPING UNIT KEEPS THE LIGHT SOURCE AND THE CAMERA WINDOW CLEAN FOR GOOD IMAGE QUALITY ONE LED-CAM OVERLOOKS THE UPPER (WHITE TOP) FORMING TABLE .the reel Quality Vision cameras, is displayed as a snapshot every 60 seconds so it can be followed by the operators. With this feedback, they can adjust ply weight and ash levels to get the best white top coverage and surface appearance. Process Vision cameras, which use the same digital matrix technology, are located along the machine length at strategic locations where upstream flaws may originate and cause quality or web runnability problems. Using the common user interface at the wet end or the dry end, operators can see the origin of flaws and how they propagate through the machine. Final product flaws can therefore be related to the source. Process Vision cameras are located at the following locations: . Above the reel . After the calender stack . After the size press, looking up through the sheet . After the second press nip, front and back side . After the first press nip, front and back side . At the trim squirts, front and back side . Over the primary forming table before the combining roll, front and back . Overlooking the center of the upper (white top) forming table Spot-on image quality The trim squirt and forming table cameras are in a very difficult environment; the areas are very misty and there is a lot of splashing stock. The cameras here are special LED-Cams in which a LED light source array and the cameras are enclosed in a common housing. An integral washing and wiping unit keeps the light source and the camera window clean for good image quality. O’Shaughnessy says the image quality from these cameras is, “Spot-on. Our guys don’t need to touch them.” Solved many problems As reported by Mark O’Shaughnessy, overall defects have been reduced dramatically and critical faults are at a miniscule level. And repetitive break problems have been solved with the same image analysis capability. Most of the solutions involved looking for clues in upstream locations and taking informed corrective actions. For instance, fiber bundles from the lumpbreaker roll have been eliminated by roll refinishing. White stock blow-off trim debris from the upper forming table has been seen and corrected quickly. Fibre buildup up on the trim squirts is checked regularly. Calender cuts and stamps have been reduced. Stickies have been detected from a faulty screen basket. Dryer picking, water drops, slime holes, doctor debris: the list of problems and solutions goes on. O’Shaughnessy summarizes the impact on how the operators react to the new-found information to solve quality and web break problems: “It allows us to clear up a problem faster, and that can avoid many repeated breaks.” * Mark Williamson is a journalist engineer based in Thornhill, Ontario, Canada More information from Viconsys Oy, Survontie 9, FIN-40500, Jyväskylä, Finland. Tel: 358 106 331 800. Fax: 358 106 331 830. Web: www.viconsys.com Email: info@viconsys.com 7th Biennial Valve World Conference & Expo Düsseldorf, Germany 30 Nov - 02 Dec 2010 Long-life forming fabrics that cut energy use Significant cost savings are possible in the forming section of a paper making machine, explain Ged Leigh and Markus Hemker of Heimbach* T he paper industry faces challenges as business shifts from the traditional markets of North America and Europe to the emerging markets of Asia, which has brought a number of mill closures. Overall, demand is relatively flat in the traditional markets together with falling prices and increased costs. The situation and short-term outlook will certainly remain tough. It is well known that the forming section of a paper making line consumes the least amount of energy when compared to the press section and the dryer section. However, with the correct choice of fabric design and constituent materials, quantifiable and significant cost savings are possible. Technical background Currently, the most common material combination in use for the machine-side wefts (CMD) in forming fabric designs is polyester and polyamide. The main advantages and disadvantages of these materials are described in Figure 1. Forming fabric manufacturers have tried to improve the abrasion resistance of forming fabrics by increasing the amount of polyamide on the machine side. Whilst this approach addresses the abrasion resistance the negative aspect is a (potential) increase in the power consumption due to the increased coefficient of friction of polyamide compared to polyester (see Figure 4). Additionally, an increase in edge curl as well as a decrease in fabric dimensional stability is possible because of the high moisture uptake of polyamide. FIGURE 2: MAIN DESIGN DRIVERS OF DURALON Therefore there has been a need to develop a new material that utilizes the advantages of polyester and polyamide without any of the disadvantages. As a result of extensive laboratory analysis and field trials Heimbach has introduced a material – called Duralon – into its Primobond SSB range of forming fabrics. Duralon fulfills the key criteria of today’s (and tomorrow’s) forming fabrics (Figure 2). Experimental material analysis In order to characterize the constituent material, two main analysis techniques were used – abrasion testing which also includes the measurement of the frictional properties, and laser profilometry measuring the machine-side topography of the fabrics. The analysis was conducted on Primobond SF SSB fabrics. Three fabrics were analysed with different machine-side material components – namely 100 per cent polyester, alternating polyester/polyamide and 100 per cent Duralon. All other fabric parameters were unchanged. Abrasion testing The equipment used was an industry standard Einlehner AT 2000 which utilizes a rotating cylindrical ceramic body made from aluminium oxide. Filler concentration was 0.8 per cent Hydrocarb 50 BG from Omya. From the analysis, we can see in Figure 3 that the caliper loss evolution after each 5,000m step. This clearly shows that the wear rate of the polyester is much higher with an overall caliper reduction of more than 23 per cent. This compares to the polyester/polyamide and Duralon samples which are both similar at around 10 per cent. Measurement of frictional properties In addition to the above abrasion analysis a detailed investigation was undertaken to look at the frictional properties of the three materials previously mentioned. Figure 4 shows the relationship between temperature (typical PM furnish temperature range of 45-55 deg C) and the coefficient of friction (CoF): It can be seen that the coefficient of friction of the Duralon fabric is much lower compared to the polyester/polyamide and the polyester sample. A lower CoF will lead to less drag on the paper machine – meaning lower power consumption and potentially longer life. Laser profilometry The NanoFocus µSurf is a 3D optical measurement system is based on white light confocal microscopy. Since it measures over the entire field of view of the objective, the NanoFocus µSurf is especially suited for fast and easy measurement of microstructures – such as forming fabrics. The analysis looked at the machine-side topography of these designs but for ease of presentation of the results only the polyester/ polyamide fabric and the Duralon fabric will be considered. Figures 5 and 6 show the topographical profile of the machine-side weft (CMD) monofilaments. Both fabrics were soaked in water for 24 hours, so full saturation could take place. The moisture uptake of Duralon is similar to polyester at around 0.3 per cent which ensures that dimensional changes in a wet environment are almost zero. This FIGURE 4: COMPARISON: RELATION OF TEMPERATURE AND COEFFICIENT OF FRICTION compares to the Polyamide 6 which takes up around 9.5 per cent. This fact ensures that the dimensional changes of Duralon in a wet environment are almost zero. The polyester/ polyamide profile (Figure 5) is showing the effect of the higher moisture uptake of the polyamide, highlighted by a significant plane (or height) difference of 38.7 µm between the polyamide and polyester. This plane difference and the CoF differences explains the phenomena that in some applications a fabric starts-up with high power consumption which then reduces as the fabric ‘beds-in’ and becomes worn. Figure 6 shows that the Duralon sample is almost co-planar with a measured variance of only 1.3 µm. Figures 7 and 8 are 3D images of the machine-side weft taken from the Nanofocus analysis and demonstrate the above characteristics. In Figure 7 it is readily apparent that every second monofilament is out of plane – highlighted by the grey colour of every second monofilament. The consequence of this plane difference is a variance in the contact area of the machine side. Figure 8 shows no variance and demonstrates the co-planar machine side of the Duralon containing fabric which translates into an increase in contact area. Measured at a distance of 100 µm from the machine or roll side surface, the Duralon fabric exhibits a 13.79 per cent increase in contact area when compared to the polyester/polyamide fabric.• FIGURE 5: POLYESTER/POLYAMIDE CMD PROFILE: SIGNIFICANT PLANE VARIATION Case study 1• The paper machine with a twin-Fourdrinier former produces Fluting and Testliner at speeds of between 600 and 1,100 m/min with a grammage range of between 90 and 180 gsm. The standard designs on the bottom position were 16 shaft SSB with alternating polyester/polyamide wefts on the machine-side. The design supplied by Heimbach was a 24-shaft Primobond.HD SSB containing exclusively Duralon wefts on the machine side. The power consumption of this PM has always been on the high side, and with high grammages and speed the PM was ‘on the edge’. The fabric guiding has also been a significant problem – which is due to the plane difference / contact area of alternating polyester/polyamide on the machine side. The Duralon containing design was presented to the customer as the solution to both of these key issues, along with a systematic approach to service by Heimbach. Figure 9 shows the average drive load (mill figures) of each fabric on the bottom position over a two-year period. (The final two data points are from after a rebuild to increase machine speed – hence higher numbers. These two data points have not been taken into account for the comparative calculations). The Duralon containing fabrics are showing a significant reduction in drive load in comparison to both competitors (Figure 9). If the drive loads are averaged by supplier we can note a reduction from a high of 69.80 per cent with competitor A to 53.80 per cent with the Duralon containing fabrics from Heimbach (Figure 10). The maximum power capacity for the bottom position drives, namely the couch and the forward drive roll are around 640 kW each and an additional 162 kW for the auxiliary drive giving a total drive capacity of around 1,442 kW. Comparative calculation (based upon the data points in Figure 10) Cost to drive the forming section with polyester/polyamide fabrics (competitor A): 1,442 kW (max. capacity) x 69.80 per cent (drive load) = 1,006.52 kW (drive load) 1,006.52 kW x 24 hours x 350 days x 0.07 euros/kWh = 591,830 euros/year Cost to drive the forming section with Duralon fabrics (Heimbach): 1,442 kW (max. capacity) x 53.80 per cent (drive load) = 775.80 kW (drive load) 775.80 kW x 24 hours x 350 days x 0.07 euros/kWh = 456,170 euros/year Based on the above calculations it is possible to save more than 135,000 euros with Duralon fabrics solely by reducing the power consumption to drive the bottom fabric. Additionally, within the above mentioned two year period the fabric lifetimes have been noted. Compared to the polyester/polyamide fabrics the lifetimes of the Duralon fabrics increased significantly (Figure 11 and 12), achieved mainly due to the better frictional properties of Duralon (Figure 4). Comparative calculation Annual fabric consumption with Polyester/ Polyamide fabrics (Competitor A): 9 fabrics, each 25,900 euros = 233,100 euros Annual fabric consumption with Duralon fabrics (Heimbach): 6 fabrics, each 25,900 euros = 155,400 euros Based on the above calculations it is clearly demonstrated that with Duralon containing fabrics significant annual cost savings are possible: by reducing the power consumption by more than 135,000 euros as well as by reducing the fabric consumption by more than 77,000 euros – a total of more than 210,000 euros. This does not take into consideration the increased production due to the reduction of PM stops to replace the bottom fabrics. Case Study 2 The paper machine measured here has a hybrid former and FIGURE 12: AVERAGE LIFETIMES BY SUPPLIER OVER THE SAME 2 YEAR PERIOD produces copier at around 1,000 m/min with a grammage range of 68-100 gsm. The standard competitive designs on the bottom position were 20-shaft SSB with alternating polyester/polyamide wefts on the machine-side. The design supplied by Heimbach was a 24-shaft Primobond.F SSB containing exclusively Duralon wefts on the machine-side. The main objective of the customer was to improve dry content after the couch. The power consumption had not been an objective – until Heimbach presented the results of the Duralon trial. The key objective to increase dryness was achieved with an average increase of 2-3 per cent. Clearly this is not due to the Duralon material but an effect of good application of the right forming fabric design. Figure 13 clearly demonstrates the reduced electrical current needed by the bottom position running with Heimbach fabrics containing Duralon. Comparative calculation Cost to drive with polyester/polyamide fabrics (competition) 621 kW (drive load) x 24 hours x 340 days x 0.07 euros/kWh = 354,715 euros/year Cost to drive with Duralon fabrics (Heimbach) 414 kW (drive load) x 24 hours x 340 days x 0.07 euros/kWh = 236,477 euros/year The above calculations clearly demonstrates that by using Primobond.F SSB fabrics containing Duralon it is possible to save more than 118,000 euros by the significant reduction in power consumption. Summary The experimental material analysis has described the theory behind the successful practical experiences of Duralon, and has gone some way to explaining the mechanisms of high initial and overall power consumption in the forming section. The two case studies are a reflection of numerous fabric installations rather than isolated instances and demonstrate that it is possible to achieve substantial and quantifiable reductions in power consumption and associated costs through the utilization of this innovative material. * More information from Ged Leigh, Strategic Product Manager (Forming), Heimbach GmbH & Co KG. (email: ged.leigh@heimbach.com) or Markus Hemker, Sales and Service Forming, Heimbach GmbH & Co KG. (email: markus.hemker@heimbach.com) Improving retention and sheet planarity A new structure that binds two longitudinal yarns to each design pattern interval for new family of forming fabrics is described by Marco Bucchi and Clara Rossetti* T he design of a new forming fabric, regardless of the type of paper to be produced, starts by considering the type of machine and the typical features of the product. For the development of the new OptiFlyer, the design team started with the analysis of the customers’ and paper machine needs. An in-depth market study indicated the three most frequent customers’ demands as being: 1. Planarity of the paper sheet 2. Homogeneity of the paper sheet 3. Cost reduction Sheet planarity was undoubtedly one of the main concerns. OptiFlyer characteristics are the best solu­tion to meet this need. Compared to the classic SSB (Surface Stitch Binding) approach, the design team took an innovative direction, in contrast to the latest developments of this family of forming fabrics. OptiFlyer was developed on a high-speed weaving loom using a reduced number of shafts, to afford the maximum binding and thus the best dimensional stability. In fact, the structure binds two longitudinal yarns to each design pattern interval, as opposed to just one of the traditional SSBs (Figure1). This revolution satisfies the first of the three most common concerns as regards the new ever wider and faster paper machines: paper sheet planarity. It is easy to note how the transversal stiffness value of the new concept is comparable to the best currently available on the market, normally found in triple weft designs (Figure 2). The Taber Index of OptiFlyer is steadily around 80 gr/cm for the fine papers design and in excess of 200 gr/cm for packaging grades. Additionally, the double longitudinal binding yarn considerably limits the stretching of the fabric under operating tension, to about 30 per cent less than standard SSBs. In fact, this type of construction also contributes to satisfying the other two demands of the market. With two longitudinal yarns inside the strand of perpendicular yarns, the machine side floating yarn goes over six MD yarns. Compared to the standard SSBs with shorter floating yarn, OptiFlyer offers a double advantage: the fabric has a naturally very small inner void volume, thus a natural and easy dewatering capability (Figures 3-4) which is very important on high speed machines. In fact, with an equal degree of permeability required by the paper machine position, the new design offers a higher number of CMD yarns on paper side, which enhances fines and fibre retention and consequently improves paper sheet homogeneity, hence reducing the consumption of raw materials. OptiFlyer also offers a true one-on-one fabric pattern, but is the only one with all knuckles actually aligned on the same plane. This factor maximises the fibre support index, erasing any possible marking of the sheet. FIG 2: FABRIC CMD STIFFNESS COMPARISON DESIGN 60 Y/CM, 350CFM FIG 3: VOID VOLUME COMPARISON DESIGN 60 Y/CM, 350CFM With a very even surface, fibre distribution is very regular, with a consequent high degree of homogeneity in paper sheet formation. Comparing SSB fabrics with the same fineness, OptiFlyer’s fibre support index is probably the highest in the industry, with values up to 198 FSI (Beran) total for fabrics dedicated to hybrid machines with top formers and greater than 240 FSI total for gap formers (Figure 5). If the customer needs to work with higher dilution in the headbox, the fabric naturally suits this purpose. OptiFlyer’s engineered easy dewatering system, combined with fabric transversal stiffness and limited empty volume, is one of the keys to its success. This was a not easy task, reached thanks to the development and use, for the first time, of Optical Computed Tomography, or OCT. Each peak in the bottom of the fabric represents a natural water passage channel, while the top part shows with great precision the fabric 3D topography. OptiFlyer superior dewatering is obvious compared to SSB designs with similar weaving density. This characteristic translates to excellent dewatering capacity, with no water dragging issues, while the high surface FSI increases retention, resulting in a better coating of the paper sheet. A better paper sheet coating means reduced costs of pulp preparation (ex.: refining) and reduced consumption of chemical products (ex.: retention agents). The OptiFlyer application allows optimising the consumption of chemical products by up to 8 per cent on papers using fillers. What is Optical ComputedTomography? Optical Computed Tomography (OCT) is an innovative technology, developed by the OptiFlyer research team. It consists of producing an axial tomography of the fabric, through the use of a high definition scanner and a powerful customized microscope, with micro controls on the three axes, connected to a PC running dedicated software. The sample is placed under the scanner, where a laser provides the accurate measurement of the surface topography (with resolution of a micron), and thousands of pictures taken at different distances from the sample. Specially developed software then assembles all the pictures with the 3D pattern detected by the laser scanner, and produces 3D images and animations of the fabrics surface (Figure 6), from any point of view. Additionally OCT allows an accurate measurement of the fabric surface topography, yarn dimensions and yarn deformations connected with the weaving process. Through additional software calculations, OCT can predict and measure with excellent precision the surface deformation of the paper sheet forming on the fabric surface. OCT also allows an accurate evaluation of the fabric dewatering capabilities, to accurately measure the dimensions, volume and precise • FIG 4: VOID VOLUME COMPARISON DESIGN 60 Y/CM, 350CFM FIG 5: VOID VOLUME COMPARISON DESIGN 60 Y/CM, 350CFM FIG 6: OPTICAL COMPUTED TOMOGRAPHY FIG 7: OPTICAL COMPUTED TOMOGRAPHY • scattering of the dewatering channels. Thanks to OCT it is possible for the first time to precisely predict the effective fabric dewatering and void volume at the design stage. The scanner developed is now used extensively in the quality assurance control, thanks to the extremely precise 3D mapping of the fabric surfaces. In summary, OptiFlyer allows: 1. Improved planarity of the paper sheet: the binding of two longitudinal yarns and the gap of six produces the highest cross stiffness known today in the SSB approach, resulting in the best maintenance of paper sheet profiles for the entire life span of the fabric. 2. Improved homogeneity of the paper sheet: thanks to an enhanced dewatering capacity and high FSI, a better fibre distribution and maximum sheet coating are obtained with an equal number of wefts. 3. Cost reduction: the reduced empty volume of the OptiFlyer concept offers improved drying of the paper sheet and the reduction of energy costs typical of press and dryer sections. The immediate success of this new design confirms the validity of the initial project and design approach. * Marco Bucchi is sales director and Clara Rossetti is development leader, forming fabrics, at Cristini S.p.A. More information from S.A. Giuseppe Cristini S.p.A., via Bombardieri 5, 24020 Fiorano al Serio (BG) Italy. Tel: 39 035 715111. Fax: +39 035 711451. E-Mail: info@cristini.it Precise handling for your paper reels. Cranes and components by Demag offer optimum speed, precision and ef. ciency for the manufacture and storage of paper and reels. Solutions tailored to meet your needs and comprehensive service provide for economical and reliable handling for a wide range of applications. SUCCESS FACTORS Metso PAPER MAKING & DISTRIBUTION For some time, cost reduction has been the main driver behind the development actions of paper mills and technology suppliers. Energy consumption is and will remain one of the main issues. In recent years, major advances have been made in several stock preparation processes, such as pulping (control of intensity, increased unit capacity), screening (narrow slots, foils in the LC and MC range), dispersion (fillings development for good dispersion, fibre development and reduced energy consumption) and refining (segments and fillings development), with the aim of improving energy efficiency. Although Metso provides tools to optimize energy consumption in all furnish preparation sub-processes, this article will focus on the two most energy-consuming processes –refining and the dispersion of recycled fibres. 1. Improved energy efficiency in refining The cost of energy, and especially of electricity, has – with a few exceptions – steadily increased in recent decades. The single highest electricity consumer in papermaking is mechanical pulp production. This is a well-known fact and several innovations have been made to reduce the electricity cost. In producing TMP for SC or LWC, the typical electricity consumption has been around 3,000 kWh/t, and in producing CTMP for paperboard grades, it has been about 1,100 kWh/t. Metso has been the leader in developing energy-efficient TMP refiner segments. Segment development has reduced the electricity consumed in producing TMP or CTMP for paperboard, SC or LWC grades by 400-600 kWh/t. But as the results of the new TMP and CTMP process and refiner segment solutions have been extensively presented earlier (see IMPC 2001 and 2003), they will not be further discussed here. Paper made from cellulose needs refining in order to achieve the desired strength and surface characteristics. Low consistency (LC) Energy saving in stockpreparation The optimizing of low-consistency refining provides cost savings that are not as high as in mechanical pulp, but worthwhile nonetheless, suggest Håkan Sjöström* of Metso’s Fibre business line and Jaana Sjöström* of Metso’s Paper business line Impact on tensile index by LC-refining 0 10 20 30 40 50 60 70 80 90 100 0 50 100 150 200 250 300 Bleached birch Scandinavian softwood kraft Eucalyptus, different grades TMP, PGW, about 300-500 ml CSF level Eucalyptus, never dried 0 0 ptus, LC-refining energy input kWh/ton TMP, PGW, about 100 ml CSF level Tensile index KN/m/g Stock preparation Short circulation PM’s sectional drives Lubrication and hydraulics Water system Vacuum system Air systems Compressed air system Other Refiners Pulpers Screens Thickeners Deflaker Disc filter Paper mill electricity consumption Fine paper machine, 120 adtpd on reel Stock preparation main equipment electricity consumption 33 % 0.3 % 4.4 % 2 % 3 % 10 % 12 % 1 % 7 % 24 % 8 % 5.5 % 0.6 % 71 % 18.1 % FIGURE 2. FIGURE 1. MetsoPAPER MAKING & DISTRIBUTION refining accounts for about 20 per cent of the whole electricity consumption of the paper machine and about 70 per cent of the energy consumed in stock preparation. The energy consumed in some typical LC refining applications is as follows: • Softwood refining for SC paper reinforcement 150–250 kWh/t • Eucalyptus refining for fine paper 60–120 kWh/t • Post-refining of mechanical pulp for printing papers 30–150 kWh/t • Refining of unbleached kraft for liner, paperboard 150–250 kWh/t The potential energy savings that can be made by optimizing low consistency refining are not of the same magnitude as for mechanical pulp, but they target one of the highest sources of electricity consumption on the paper machine. The type of pulp is one of the major parameters that determine energy consumption in LC refining (Figure 1). Softwood Kraft pulp Fibres with a thick cell wall and low hemi-cellulose content are typically harder to refine. Hardwood is generally easier to refine than softwood; that is, hardwood develops strength (tensile strength) and refining degree faster than softwood. For unbleached kraft pulps, the higher the lignin content (Kappa number) the harder the pulp is to refine. The extreme case is mechanical pulp, which needs a high energy input to produce any change in mechanical properties. The energy requirement in stock preparation is heavily influenced by the selection of pulp grades for the furnish. The overall situation concerning the pulp price and the energy requirement for refining different pulps needs to be optimized for each case. Low consistency refining optimization In recent years the trend in papermaking has been to increase the content of short-fibre raw materials. This has been driven by constant demands to improve printing performance and reduce the costs of the pulp furnish. The trend to replace softwood with hardwood improves formation, opacity and printability, but the furnish changes create challenges for existing stock preparation LC refining lines. Softwood refiners now run with significantly lower production than they were originally dimensioned for. Low loads in softwood refining lines make refining inefficient, unless changes are made in the way of operating. On the other hand, hardwood lines are being heavily loaded as production increases. This poses challenges for refiner loadability, hydraulic capacity and fillings lifetime. The basis of a good refining result is correct dimensioning of the refiners and process conditions. But, although a correctly-sized and well-maintained refiner is a necessary prerequisite, it is the refiner fillings that ultimately determine the refining result. Higher refiner capacity and energy savings with new MicroBar fillings Stock preparation accounts for up to one third of the electricity consumption of the whole paper mill (Figure 2). As low consistency refining accounts for a significant part of energy consumption, it offers huge potential savings. Therefore, developing products to reduce energy consumption has been one of the focal areas at Metso. The key to efficient refining is using correct refiner fillings in correct refining conditions. This ensures that the desired pulp and paper quality will be obtained. Metso’s patented MicroBar design is the first innovation for decades that offers clearly higher refiner capacity with considerably higher loadability in low consistency refining than is possible with any other refiner filling design. The more efficient operation of MicroBar saves refining energy in both short-fibre and long fibre refining. When refining to a certain freeness or strength, the unique combination of a densely designed refining zone and the very long cutting edge of the MicroBar fillings reduces refining energy consumption by up to 10 per cent in hardwood and up to 20 per cent in softwood and mixed pulp applications. Higher refiner hydraulic capacity and loadability The new MicroBar design features special capacity grooves feeding the fibres uniformly to the refining zone. This also makes it possible to double the hydraulic capacity of large refiners. The special • 1. 2. 3. 4. Velocity Filling degree of fibers Edge load 1. blade -fiber impact 2. fiber - fiber friction 3. blade wall - fiber friction 4. refining between blade edges Filling degree of fibers R = 0.86 0 20 40 60 80 100 120 0 10 20 30 40 Volume energy, kWh/m DIP visible dirt specs area, ppm Cs 30% Cs 22% Cs 15% Cs 9% Cs 9% 45 deg FIGURE 3. FIGURE 4. Metso PAPER MAKING & DISTRIBUTION .design of the feeding grooves also makes the design insensitive to fibre length, fibre type and freeness. The longer bar cutting length of the MicroBar design enables an increase in capacity with high loadability, while maintaining the desired fibre quality in hardwood refining. Loadability can be increased by up to 30-50 per cent compared with standard filling designs. Ease of refining The advantages of MicroBar also include the easy runnability of the refiner, including an easy start. The same filling design can be used for refining long, short or mixed Fibres, which reduces the amount of refiner downtime needed for a filling change. The special design of the feeding grooves also means considerably less plugging than with standard fillings. 2. How to select a specific energy level for dispersion of recycled fibres: Dispersing process and mechanisms Recycled fibre pulps are dispersed to improve their apparent cleanliness. The dispersing sub-process is located after screening in all RCF processes, and also after flotation in DIP processes. Thus, most of the impurities have already been removed before the dispersing sub-process, and it is mainly the impurities attached to fibres that are fragmented in dispersing. The dispersing sub­process involves pressing the pulp to a high consistency (25-32 per cent), heating with steam (70-110 deg C), and finally mechanical treatment between a stator and a high-speed rotor (50-70 m/s). The dispersion process typically consumes 40-100 kWh/t of electrical energy, which is a significant portion of the total energy demand of recycled fibre lines. Therefore it is of major interest to paper mills to carefully select a sufficient, but not unnecessarily high, specific energy level for dispersion. The optimum energy level will vary according to the pulp raw material and the final cleanliness targets. What happens inside a high-speed disperger has not been fully explained, but some phenomena that are known from LC refining, HC refining and low-speed kneading processes are thought to be applicable in dispersing (Figure 3). Blade-fibre collisions have an intensive impact on Fibres and ink particles. A conical disperger provides a long retention time and a relatively high number of impact zones and thus a high number of collisions. The velocity of the particles when they collide controls the intensity of each collision. Fibre-fibre friction and blade-fibre friction is dependent on the concentration of Fibres inside the disperger. Most of the space between the fillings may be occupied by steam and the fibre network may thus be very open. Friction can be controlled by the pumping ability of the rotor – in other words, by the design of the rotor and the friction generated by the stator. Friction is the only mechanism in low-speed kneading. Moreover, in dispersing, most of the specific energy is believed to be used in overcoming friction. Finally, there is some refining action between the stator and the rotor. This phenomenon is characterized by the edge-load theory and controlled by the gap between the stator and the rotor. Influence of specific energy and volume energy on dispersing result We carried out experiments that included pulp preparation for the pilot dispersing of DIP and OCC. DIP, consisting of a news magazine mixture, was processed by pulping, coarse screening, flotation, fine screening, thickening and pressing. The preparation of European OCC was simplified to pulping, coarse screening and pressing. All dispersing tests were performed with Metso’s OptiFiner disperger, which is a conical high-speed version. The dispersing energy and pulp consistency were varied at 90 deg C and at 45 deg C. The volume energy was defined as specific energy consumption multiplied by consistency per 100. We measured CSF, fibre length, residual ink (ERIC), dirt, stickies, tensile strength, tear strength and curl. SEC, kWh/t OCC Tensile Index, Nm/g Cs 28% Cs 22% Cs 16% Cs 10% Cs 10% 45 deg 44 45 46 47 48 49 50 51 52 53 54 0 20 40 60 80 100 120 140 Task for DIP dispersion SEC Recommended Comment Ink detachment 25-50 kWh/t Higher SEC causes ink fragmentation. Consistency should be >20% Reduction of dirt specs 35-60 kWh/t Dirt break-down improves with high number of impact zones in the fillings. Reduction of stickies 40-80 kWh/t Temperature >80° C is essential. Incoming stickies content should be >150 mm/kg. Softening & curl 25-40 kWh/t For Tissue. Curl improves in high consistency. High SEC drops CSF and softness. Strength improvement 40-80 kWh/t Tensile can be increased until tear deteriorates. FIGURE 5. TABLE 1. MetsoPAPER MAKING & DISTRIBUTION The decrease in visible dirt specks in DIP correlated well with the specific energy consumption, as is known from practice. Volume energy alone described very well the change in visible dirt (Figure 4), and different consistencies and temperature conditions seemed to influence dirt reduction through their influence on volume energy. Volume energy of 15 kWh/m3 seems to be enough to achieve the available dirt specs reduction. Reduction of freeness (CSF) and improvement of strength correlated well with specific energy, as was also observed in practice in mills. Typically, a tensile improvement of 10 per cent is easily available, and in this case an increase of up to 15 per cent was observed for OCC pulp (Figure 5). Tensile improvement is not dependent on consistency, but with high consistency the same disperger fillings provide an opportunity to use more energy. The energy consumption in our mill references is usually 30-60 kWh/t, and we obtained better quality results than were obtained in the pilot with energy consumption of 90 kWh/t. In the mill cases, the unnecessary friction forces can be lowered and the number of impact zones can be increased. This would suggest that energy consumption does not fully explain the dispersing results and supports the theory of blade-fibre impact. This also means that there is a great opportunity to save energy by selecting optimal equipment and fillings. For good stickies removal in OCC, both high temperature and reasonable energy consumption were required. On the other hand, energy consumption in excess of 90 kWh/t did not improve the reduction of stickies. The generation of curl seemed to depend on temperature and consistency, and the effect of energy input was irrelevant. 3. Selection of specific energy consumption Based on the trial results and mill data, the recommendations for specific energy consumption in the dispersing of DIP and OCC have been summarized in Tables 1 and 2. The selection of energy consumption should be based on knowing the properties of the raw material and the final pulp requirements. The equipment type used should also be taken into account. Therefore, the energy consumption recommendations are expressed as ranges. Before choosing the energy consumption it is important to define the main task or tasks for dispersing. In a modern DIP line for printing paper manufacture, the reduction of stickies should not be the main issue, because macrostickies are removed efficiently by narrow-slotted fine screening. The attached ink content will become low enough with gentle treatment. Therefore, it is typical that dirt speck reduction will define the needed energy. In some cases, an improvement in strength is desirable for good paper machine runnability and for the quality targets of the end product. In such a case, the energy consumption needed might cause fragmentation of the ink. To avoid this, it is advisable to maximize the removal of free ink in flotation prior to dispersion. In recycled fibre plants using OCC, the first question is whether dispersion is needed at all. In the case of North American OCC raw material, the obvious choice is to go with dispersion, due to the waxes included. Typically, strength is often desired, even with European raw material. In such a situation, dispersing could replace the need for an LC refining stage, because in addition to increasing strength, it can also reduce stickies and dirt specks. The intensity of the dispersion process is gradually becoming better understood. The new volume energy theory of CTP was applicable in describing the reduction of visible dirt specks. However, an improvement in strength properties correlates better with energy consumption, while a reduction in stickies correlates with temperature condition. It might be challenging to find one common expression for dispersing intensity, since there are so many mechanisms present. The results suggest that the blade to fibre impact could be an important mechanism in dispersing. To fulfill the most frequent task of dispersing, which is dirt specs reduction, only 30 kWh/t is required when the newest dispersing technology is applied. Literature 1. Vikman, Leskelä, Vuorio, Tyrväinen, Huhtanen IMPC 2003 Quebec Canada, New refiner Segment technology to optimize the aspen BCTMP pulping process, pp91-95. 2. Vuorio, Bergquist. IMPC 2001 Helsinki Finland, New Refiner Segments Technology to Optimize Fibre Quality and Energy Consumption of Refiner Mechanical Pulp, pp565-578. 3. Kumar, S., Fabry, B., Carre, B., Cochaux, A., Julien Saint Amand, F.,Galland, G. Past, Present and Future of Dispersion and Kneading. Progress in Paper Recycling, 16(4), August 2007, pp6-33. 4. Ruzinsky, F., Zhao, H., Bennington, C. Characterizing ink dispersion in newsprint deinking operations using specific edge load. Appita Journal, January 2007, 60(1), pp. 23-28. 5. Pan, J., Nguyen, K. Energy required for detachment of inks from printed newsprint in fibre slurries – Effects of vehicles and aging. Colloids and Surfaces A: Physicochem. Eng. aspects 302 (2007). pp354–359. 6. Hietaniemi, M., Sjöström, J.: Proceedings PTS Deinking symposium, Leipzig 2008. * Jaana Sjöström, Application Engineer, Process Services, Metso’s Fiber business line. Tel. 358 40 508 7723. email: jaana.sjostrom@metso.com Håkan Sjöström, Development Manager, DIP Systems, Metso’s Paper business line. Tel: 358 40 719 8790. Email: hakan.sjostrom@metso.com Task for OCC dispersion SEC Recommended Comment Reduction of waxes and hotmelts 30-60 kWh/t Temperature >80°C is important. Reduction of stickies 40-80 kWh/t High temperature and consistency are beneficial. Hotmelts are included in the reduction of stickies. Reduction of dirt specks 35-75 kWh/t Dispersion will homogenize outlook. Strenght improvement 40-70 kWh/t A significant share of the pulp fractions should be dispersed to see the effect on board machine. TABLE 2. Cronin takes charge at SCA’s packaging business Michael Cronin is taking over the packaging as president of SCA’s European business,” said packaging operations. Jan Johansson, He has more than 30 years SCA’s chief experience within the Alcan executive. “In Packaging and Rio Tinto group his position as President of our where he held various senior European Packaging business positions dealing with complex Michael will have a strong and multicultural. focus on improving our “Michael Cronin has profitability in our packaging unsurpassed experience from operations.” Hook takes over UK water technology business Bob Hook has been appointed contemporary environmental managing director for UK trends such as carbon footprint, business at Veolia Water water recovery and waste to Solutions & Technologies. energy with the aim of meeting “My focus going forward will our clients’ future requirements.” be on delivering exceptional Ole Roesdahl, who has been customer value achieved responsible for the UK business through reliable project delivery for the past three years will and excellent service from our remain with the Veolia Group people,” said Hook. “Our and will become the executive business invests in our vice president of Kruger, technology to meet Nordic Region of VWS global. Bolt joins Parkland Core cutting and slitting managing director Peter specialist Parkland Kelly. “As Area Sales International has appointed Manager, Derek will be Derek Bolt as Area Sales responsible for working Manager. He joins the UK- closely with our sales and based firm from Fife-Tidland marketing staff members to with more than 14 years of help guide product experience from within the development and identify converting industry. optimal strategies and tactics “Derek is a valuable to serve both existing and addition to our team as he new markets. His knowledge brings with him both a and abilities will contribute to technical background and a sustained high growth rate industry knowledge,” said going forward.” Morris to develop business at Hi-Line Compressed air purification his whole working life, starting equipment specialist Hi-line with a technical apprenticeship Industries has appointed Kevin at Denco. He moved to Morris as Business Development Ultrafilter provided more sales Manager, and has responsibilities experience and he then to Beko for OEM accounts, distributors Technologies, the condensate and compressor manufacturers specialists, where he stayed for or suppliers. more than eight years where he Kevin has been involved in had been sales manager for UK the compressed air industry for and Ireland since 2007. PAPER MAKING & DISTRIBUTION We will no longer be sending the printed version of Paper Making & Distribution to countries outside of Europe UNLESS THEY HAVE A PAID SUBSCRIPTION. Please complete the details below if you would like to continue to receive the magazine. 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Post Town/City: ............................................... County: ................................................................................................................... Postcode: ........................................................ Country: .................................................................................................................. Tel: .................................................. Fax: .................................................. Email:.......................................................... ...................... SECTION 1 Type of Business: . a. Paper Merchant . b. Pulp Mill . c. Converter . d. Logistics/Supply Chain Management . e. Paper Agent . f. Integrated Mill . g. OEM . h. Telecommunications . i. Paper Mill . j. Board Mill . k. Distribution Company . l. Other SECTION 2 Job Title: . a. Managing Director . b. Logistics/Transport Manager . c. Production Manager . d. Technical/RAD Director . e. Mill Manager . f. 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