Paper Making & Distribution - Volume 17 Issue 19     IN THIS ISSUE: ABB: benefits of liquid-cooled motor drive inverters Demag: how to manage a 24/7 paper warehouse Heimbach: how to find savings in the press section Honeywell: fibre-orientation measurement on-line

 

 

 

 

 

 

 

 

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VOL 17 ISSUE 19 May/June 2010 VOL 17 ISSUE 19 May/June 2010 ABB: benefits of liquid-cooled motor drive inverters Demag: how to manage a 24/7 paper warehouse Heimbach: how to find savings in the press section Honeywell: fibre-orientation measurement on-line  www.metso.com/fabrics Metso and Tamfelt join together The union brings together two world-class suppliers, both dedicated toproviding real results for the pulp and paper industry through advanced, cost-effective and sustainable solutions. lidi ingbrunionheT etsoMdlthflt clald-orwowtogethertgs elamfTTaand dhthid dedicatboth,suppliersass ogett join t d oted ther aetivecefffecost realrvidingoprom.c.metsowww.solutionssustainablend paandpulptheorffoesultsr m/fabrics advaoughthryindustraper ,anced www.metso.com/fabrics Metso and Tamfelt join together The union brings together two world-class suppliers, both dedicated toproviding real results for the pulp and paper industry through advanced, cost-effective and sustainable solutions. lidi ingbrunionheT etsoMdlthflt clald-orwowtogethertgs elamfTTaand dhthid dedicatboth,suppliersass ogett join t d oted ther aetivecefffecost realrvidingoprom.c.metsowww.solutionssustainablend paandpulptheorffoesultsr m/fabrics advaoughthryindustraper ,anced  CommentContentsii 2 - 9 14 - 15 18 - 23 24 - 25 26 - 28 32 May/June 2010 110 - 12 J J ust days away from the opening of PulPaper 2010 in Helsinki (1-3 June), it looks like this show will play a key part in the marketing plans of many suppliers to the pulp and paper industry. News of press conferences and new product launches are still coming in and there is a definite buzz of optimism surrounding the show. But the same cannot be said for this year’s Zellcheming, with companies who have exhibited for many years not participating. With many mills struggling to reduce overheads and energy costs, the recent increases in raw-material costs have only further hampered the potential for growth this year. And the slow down has not only hit the mills but also the specialist suppliers. Speaking to one company recently I was told that they have had to look long and hard at how to keep highly-qualified staff on the payroll while protecting the company for the long term. With a lack of good-sized projects on the horizon, many such companies are working out how to diversify into new sectors and use existing specialist knowledge to see them through the coming months while retaining key personnel. Many suppliers to the pulp and paper industry are still family owned and have a long history. For these companies it is especially tough to maintain the close working relationships they have with their employees while protecting the long-term future of the company – I wish them all the very best. Vince Maynard Publication manager & editorial controller 2 - 9 Industry News 10 - 12 Heimbach: Finding dramatic savings in the press section 14 - 16 Honeywell: Developing on-line measurement 18 - 23 Projects & Contracts 24 - 25 Product News 26 - 28 Demag: The warehouse that never sleeps 30 ABB: Liquid assets 31 Trading Post 32 People  Volume 17 Issue 19 May/ June 2010 Published under licence by: Hartswood Media ISSN 1479-3989 Vol. 17, Issue No. 19 May/June 2010 Accounts -June Bray Editorial advisor -John Nutting Consultant editor -David Young PAPER MAKING & DISTRIBUTION Industry News Fire hits Metso’s Tissue Technology Center in Sweden M M etso’s Tissue Technology Center Cleaning up and repairs were started at Karlstad in Sweden was hit immediately after the fire was by fire at the end of April. extinguished, said Metso in a release. The fire damaged the roof of the The company is now focusing on Technology Center building, but minimizing downtime of the tissue pilot personnel were not endangered, machine during the roof repairs. The nor was the tissue pilot machine itself machine was expected to be back in or any other vital systems affected by operation within a few weeks. the fire. Source of the fire was not revealed. 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 mill strikes resolved in Sweden Paper workers who had paralysed a number of paper mills with strikes across Sweden in April returned to work when an agreement was reached with industry leaders in April 26. The agreement was reached just before the Swedish paper workers union, the Pappers, were about to go on strike at six more mills. The paper workers and the Forest Industry Association, Skogsindustrierna (SFIF) had failed to agree on a new pay structure following the expiry of a three- year agreement at the end of March. The dispute escalated with a ban on overtime and blockades at a number of mills that started on April 12. Strikes at six mills started four days later. The agreement reached is valid for 22 months and provides salary increases of 3.3 per cent, or just one tenth of a percent more than the agreements reached by the other unions in the Swedish industry. The agreement also covers some improvements in other areas of interest of the paper workers. Marie Arwidsson, managing director of the Swedish Forest Industries, said that the agreement assures the companies competitive power “and that is the most important matter”. The 11day strike is said to have lost the forest industries more than half a billion kronor in export income. Make your waste work harder The tenth Recycling and Waste Management Exhibition (RWM10) takes place at the NEC, Birmingham from 1416 September. Bigger than ever, the three-day show features an indoor and outdoor exhibition of more than 500 exhibiting companies and organisations which are demonstrating the latest technologies and recycling ideas. Entry is free and also gives visitors access to more than 40 seminar sessions offering invaluable legislative and financial advice and first-hand case studies of successful public and private sector projects. Of interest to paper manufacturers, energy from waste, wastewater reuse and carbon efficiency will be tackled in the Energy & Water Theatre. Speakers have already been confirmed from the London Waste & Recycling Board, WRAP, Glenigan, Arup and the BREW Centre for Local Authorities among others. Visitors can register online for fast track entry to RWM 10 and take advantage of the MyRWM Show Planner, a simple online tool which creates a personalised floorplan of relevant exhibitors. Gerry Sherwood, event director of RWM, said: “Green industries are thriving while economic and legislative pressures have made waste, energy and resource management more relevant than ever before. As a result our audience broadens every year.” More information from www.rwmexhibition.com/epress2 2 May/June 2010  PAPER MAKING & DISTRIBUTION Industry News Environmental containerboard line in Poland inaugurated by Mondi M M ondi has added said David Hathorn, chief ideal position to serve achievement and I consider it a lightweight recycled executive of Mondi Group. customers.” benchmark for the future,” said paper to its portfolio Peter Oswald, chief The €305 million project Maciej Kunda, chief executive with the first delivery of executive of Mondi Europe & was completed on schedule of Mondi Swiecie SA. product from its new ECO7 International added: “Today, and within budget. First With a design speed of containerboard paper machine we celebrate the Swiecie saleable paper was produced 1,800 m/min, the ECO7 is at Swiecie in Poland. Mondi success story. Representing the in September last year. claimed to be one of the says the paper machine is its culmination of Mondi’s early “We implemented the world’s fastest containerboard response to the growing trend investment programme, project in 17 months from the machines with capacity of towards lightweight corrugated Swiecie has developed time the first soil was turned 470,000 tonnes a year. Its case material, driven by alongside Poland’s emergence until start-up. The start-up was efficiency and short production demand for higher cost as a powerhouse in the region. exceptionally good. We were cycles facilitate shorter lead efficiency, European The ECO7 enables us to offer producing saleable quality times and the high and fast packaging legislation and cost-efficient and within 48 hours of getting the availability of standard grades. environmental concerns. environmentally-sound solutions first paper on the reel. A-The product range At a recent opening without having to make quality was being produced encompasses lightweight ceremony attended by around compromises on quality and just 24 hours later, only three recycled fluting and testliner 100 customers, the Mayor of performance. In addition, our days after the first paper was from 75 to 140 gsm. Swiecie, Tadeusz Pogoda central location puts us in an produced. It has been a great It also achieves maximum and Mondi Europe & product quality with minimum International Division chief environmental impact. executive Peter Oswald cut Production of one tonne of the ribbon to officially launch paper will consume 20 per the new machine. cent less steam, 30 per cent “The successful start-up of the less electricity and 40 per new recycled containerboard cent less water than machine in Poland was a comparable machines in significant achievement with Swiecie. When it reaches full current performance exceeding capacity, the mill’s total the investment plan. recycled paper consumption Congratulations must be will increase to around extended to the whole team 900,000 tonnes per year. involved in the execution of this Mondi Containerboard, part project, which puts us in a of the Europe & International great position to respond to the Division, is a leading European growing demand for supplier of virgin and recycled lightweight containerboard in containerboard with a network central and eastern Europe,” of eight plants. MONDI’S ECO7 LINE IS OFFICIALLY OPENED AT SWIECIE IN POLAND WITH (LTOR) VEIT SORGER OF THE INDUSTRIALIST ASSOCIATION; PETER J OSWALD, CHIEF EXECUTIVE OF MONDI EUROPE & INTERNATIONAL, TERESA KORYCInSKA, POLAND’S MINISTER OF ECONOMY POLAND, AND MACIEJ KUNDA, CHIEF EXECUTIVE OF MONDI SWIECIE SA. 4 May/June 2010  PAPER MAKING & DISTRIBUTION Industry News Nuclear power proposals in Finland favour bio-energy production Södra announced that it was to increase its price of softwood pulp in Europe by US$20 to $980 per tonne from 1 June. It was the fourth increase since the beginning of February when the price was $860 per tonne. “The pulp market remains solid, with strong demand and low stocks,” said Ulf Edman, president of Södra Cell International. * BASF also increased prices of paper and board dispersions in Europe, the Middle East and Africa by 20 percent following a “dramatic” increase in raw material costs for dispersions. Another pulp price increase from Södra T T he Finnish government has proposed the construction of two nuclear power plants, and that has improved the forest industry’s operating and investment prospects, according to the Finnish Forest Industries Federation. When increasing the share of bio-energy, it is extremely important to safeguard the forest industry’s raw material supply, says the FFIF. But processable wood must not be steered into use for combustion. Said FFIF chairman and chief executive of the Metsäliitto Group Kari Jordan: “The government’s stance on the building of more nuclear power will, when implemented, lead to an improvement in the forest industry’s operating and investment prerequisites in Finland. Building more nuclear power provides the forest industry with the ingredients for developing diverse processing operations and increasing the utilisation of forest energy.” FFIF says that the forest industry’s grid electricity requirements will grow because increasing the value- added input and the manufacture of new products will lead to a rise in electricity consumption. If between three and five bio-refineries are built in Finland, they will together annually consume 1.5-2.5 terawatt-hours of grid electricity. “It is extremely important that the forest industry’s raw material supply is safeguarded in the follow-up drafting of bioenergy subsidy decisions as promised by the Government. Subsidies must not steer processable wood into combustion,” said Jordan. As more wood is processed, the amount of forest biomass going into energy use will also increase. The most cost- effective way to promote Finnish renewable energy production is to look after the development of the forest industry's manufacturing operations. The forest-based sector produces 70 per cent of Finland’s renewable energy. The forest industry invested more than a €1billion into renewable energy production following the previous decision to build more nuclear power. This has tripled the use of forest energy. World’s first biodegradable industrial bag launched What is claimed to be the world’s first biodegradable industrial bag with humidity protection and certified compostability has been launched by Mondi Industrial Bags. The Terra Bag consists of a paper bag with a film for humidity protection. The entire bag is biodegradable and optimised for industrial composting. It meets EN 13432, a harmonised European standard that defines the requirements for packaging recoverable through composting and biodegradation. “Because of its reduced environmental impact Terra Bag perfectly fits the green purchasing endeavours and sustainable development commitment of our customers,“ says Claudio Fedalto, sales & marketing director of Mondi Industrial Bags. “With the compostable Terra Bag you can turn packaging into valuable humus, a great way to manage waste.” The biodegradable film used for Terra Bag is partly made from corn. Joined with sack kraft paper, also made from composted within 12 weeks in renewable resources and biodegradable, these components are said to ideally complement the sustainable industrial packaging solution. The entire bag can be an industrial composting facility after usage. During this process the bag is broken down by micro-organisms finally resulting in humus, suitable for agriculture or gardening. www.pmdmagazine.com May/June 2010 5  PAPER MAKING & DISTRIBUTION Industry News US trails Europe in corrugated basis weights by a fifth P P ackaging trends in Europe are comparable with the US because they occupy 700 similar geographic areas, have similar climates and 650 topographical features, and their containerboard companies supply many of the same global food, beverage and consumer goods companies. But average basis weights of Grams per square metre 600 550 corrugated are now 20 per cent 500 lighter in Europe than the US, as shown in the new study published 450 by RISI, The Future of Lightweight Containerboard in North America. This reflects a proactive 1997 1998 1990 2000 2001 2002 2003 2004 2005 2006 2007 2008 Average Basis Weights United States Italy Europe Wt. Avg Germany Spain France Poland United Kingdom cultural change in Europe, with sustainability high on the agenda and government- backed environmental initiatives with targets and penalties for non-compliance implemented across the supply chain, and supported by trade groups and NGOs. Author of the study and industry expert Sarilee Norton says, "A critical look at the geographic factors, the fibre considerations and the supply chain drivers that distinguish Europe from North America are not different enough to continue to explain a 20 per cent differential in average basis weights. Sustainability, packaging efficiency and cost savings are vitally important considerations to North American corrugated users as well as those in Europe." Since 2000 only three new machines have been built in North America, compared with 32 in Europe. Modern machines, or conversions of existing machines, can produce extra-lightweight containerboard (less than 26#) more quickly and economically. Many corrugators currently operating in North America are fully capable of running extra-lightweight constructions, and an analysis of current North American and European containerboard machine capabilities is included in the study. The evolution of lightweighting, including the technology developments of board machines, corrugators and converting capabilities, provides the containerboard producer and converter perspectives in the study, alongside what the trend towards lighter basis weights means for end-users. The containerboard market is customer-driven and with the largest global retailer, Walmart aiming to reduce five percent of packaging across its supply chain by 2013, the report anticipates that the 'lightweighting' trend will continue, providing an opportunity for corrugators that invest in modern machines offering the speed, quality and versatility needed, to help their customers realise their packaging strategies. The Future of Lightweight Containerboard in North America provides a detailed analysis of the 'lightweighting trends', a history of corrugated, and capacity forecasts of the North American Containerboard market until 2014. More information from – In North America: Sara Girtz Tel:1 770.373.3001 Email: sgirtz@risi.com. In Europe: Tea Tuuli. tel: 32.2.536.0743 Email: ttuuli@risi.com. In Asia: Levi Li Tel: 86.139.1714.6037 Email: lli@risi.com In Latin America: Luis Sucupira Tel: 55.11.3848.9051 Email: lsucupira@risi.com Metso purchases Viconsys’ machine vision systems business The web inspection and web Energy and Environmental expanded service will fit well to Viconsys is known as a break system business of Technology Segment. Metso's global sales and industry benchmark and global Finnish-based Viconsys has Metso’s objective is to service network. Through this market leader in the machine been bought by Metso. The complete the automation network, Metso is able to vision technology. Within three business, which employs 30, product and service offering to improve its customer service for years, it has completed more will be affiliated into Metso’s the paper industry. The existing and new customers. than 100 product deliveries. 6 May/June 2010  PAPER MAKING & DISTRIBUTION Industry News Recovery for Södra after a year of crisis Paper, pulp, forest products and energy giant Södra reported dramatically improved financial results for the first quarter with sales of SEK4,575 million (US$598m), up 21 per cent on the same three months of 2009 when the market was in the depths of the recession. Net profit was a more healthy SEK382m ($50m) after write offs and write downs of SEK298m ($39m), compared with a loss in the first quarter of last year of SEK59m ($7.7m). “2010 began with a continued recovery after a year suffering the adverse effects of the recession,” said chief executive Leif Brodén. “Profits were boosted by increased deliveries and higher prices in the pulp and sawn timber products areas. “In the course of a single year we have gone from the shadow of the recession and the dramatic events it entailed to a position where all our business areas comply with or almost comply with return requirements. “Although we are not exactly in a boom, we have moved from recession to prosperity.” Sales in the pulp business were up by 19 percent to SEK2,615m ($342m). The period was characterised by relatively low stock levels and high deliveries, said Södra. Production increased compared with the same period last year, which was influenced by market-related stoppages at the Norwegian pulp mills. The market also strengthened as a result of the earthquakes in Chile, which reduced pulp supplies. www.pmdmagazine.com LEIF BRODÉN A leading manufacturer of custom-designed fabrics and belts used in the production of paper and paperboard, Albany International Corporation reported first quarter sales of $213.9 million, an increase of 2.2 percent compared to the first quarter of 2009. The Albany, New York, global company also turned round net loss in last year’s first quarter of $18.9 million into a profit of $4.3 million this year. Last year’s loss included a GAAP restructuring charge of $17.2 million which this year was $3.1 million. Paper machine clothing (PMC) remains the biggest sector of the company’s sales which were up 3.8 per cent to $144.4 million. Chief executive Joe Morone said that first quarter revenues are usually dampened by seasonal effects but this year January was the weakest month in recent memory. “In PMC, global sales were only 3.8 percent higher than Q1 2009; excluding exchange rate effects, sales were flat,” he said. “The weakest spot for PMC in Q1 was Europe, where sales were down 9 percent compared to the previous year. This weakness was offset by quarterto- quarter sales increases of 52 percent in Asia-Pacific and 2 percent in the Americas. Most of our other businesses followed a similar pattern. “In contrast to sales, orders in Q1 2010 were well ahead of Q1 2009. In PMC, orders can be an imprecise indicator of future sales, and in Q1 2010, they may have been inflated by inventory restocking by our customers. Nonetheless, Q1 2010 orders in PMC were 23 percent higher globally than in Q1 2009. Orders were especially strong in Asia-Pacific, increasing 64 percent above orders in Q1 2009, when that region hit bottom. In the Americas and Europe, orders were 18 percent and 22 percent higher, respectively. “Q1 results leave one important question unanswered: what levels of revenue should investors expect as our end-markets continue to recover from the recession? Given the seasonal effects, abnormally low January sales, and the strong order patterns, it is clear that Q1 sales do not provide a reliable indication. Historically, Q2 is generally free of negative seasonal effects, and it should also be free of any inventory effects that could have inflated Q1 order levels. Barring any unusual disruptions to economic activity, Q2 should provide a good indication of the post-recession, near-term revenue potential in PMC, Doors, EF, and PrimaLoft.” Albany International turns round first quarter performance Modifications that have created the world’s first fossil-fuel-free pulp mill have been completed at Södra Cell’s mill in Sweden. Södra Cell has invested SEK600 million (US$78.4 million) at Värö over the past few years and these mean that the pulp mill will now be free from fossil fuels. These include a new evaporation plant – for a more energy-efficient mill; feed water preheating – to produce more electricity; heat transfer from flue gases for more district heating; and bark drying – providing and optimum fuel for district heating supplies The investments form part of an investment programme which has been ongoing since 2002, worth SEK 1.7 billion ($222m) to date. World’s first fossil-fuel-free pulp mill May/June 2010 7  PAPER MAKING & DISTRIBUTION Industry News Metso Technology Center opens in Shanghai M M etso’s Technology Center in China was officially inaugurated at the end of May, providing what the company calls the world’s newest and most modern valve factory and supply center along with facilities for the production, assembly and testing of process automation systems. The centre at the Shanghai Waigaoqiao Free Trade Zone also includes premises for Automation business line’s sales, project and engineering units in China. Initially with 250 staff, the centre will be expanded in 2013 and employ an additional 400. With a strong presence in China, Metso says it will provide better service to energy, oil and gas, and pulp and paper customers, especially in China and Asia Pacific. It also enables the development of a global supply chain for valve production. Metso made its first deliveries to China back in the 1950s, starting its own operations through a joint venture in the 1980s. Today, Metso operates in 16 different localities in China, where it has about 2,600 employees. Another world record for Dagang PM3 in China Another world speed record for woodfree papers has been set by Gold East Paper’s PM3 at Dagang in China. In April the machine, which was supplied by Voith Paper, achieved an average speed of 1,800 m/min during the production of double-coated fine paper with a basis weight of 90 g/m² over a period of 25 hours. The operating time efficiency was 91 per cent. This is the sixth time that the PM3 has set a world record: last August it achieved a best-ever speed of 1,770 m/min. PM3 produces coated fine paper in a basis-weight range of 80-128 g/m² on a wire width of 10,600 mm. Based on the proven One Platform Concept, the machine is equipped with a SpeedSizer and two DynaCoat coating units. The Tandem NipcoFlex press is equipped with QualiFlex press sleeves in both positions. One sleeve in the first press had set a running time record of its own with 329 million nip passes. During the world record run Dagang PM3 was running with forming fabrics and press felts as well as roll covers from Voith Paper. Started up in May 2005, the mill’s entire process technology has been supplied by Voith Paper, from stock preparation to winder. 8 May/June 2010  PAPER MAKING & DISTRIBUTION Industry News International Paper strengthens its position in China G G lobal leader in the paper and packaging industry, International Paper has agreed to purchase SCA's packaging business in Asia for $200 million in cash, subject to post-closing adjustments. International Paper expects to complete the purchase in the second quarter of 2010, subject to regulatory approval of the transaction in China. “We’re buying good facilities at a good price as well as gaining an excellent team of 4,500 employees,” said Paul Brown, president of IP Asia. “SCA’s facilities complement our existing converting system of 12 corrugated box plants, which are principally in China. The combination strengthens our packaging business in Asia and will make it more competitive, more profitable and better able to serve customers.” The SCA packaging business in Asia, which is primarily in China, consists of 13 corrugated box plants and two specialty packaging facilities. . Sales in the first quarter for International Paper were $5.8 billion, 1.7 percent up on the same period in 2009 but down on the last quarter of 2009, when they were $6.0bn. The Memphis, Tennessee- based global forest products, Efficiency software specialist acquired by Honeywell Honeywell has agreed to acquire Matrikon Inc, which specialises in software that helps industrial manufacturers operate their plants safely, reliably and efficiently. The acquisition, valued at US$142 million, is expected to strengthen Honeywell’s position in the high-growth oil and gas and power value chains. Matrikon will be integrated into Honeywell Process Solutions, which is part of Honeywell’s Automation and Control Solutions business group. “Our industrial customers want their plants to run well in any economy, and Matrikon’s products help do that,” said Norm Gilsdorf, president of Honeywell Process Solutions. “Combining Matrikon’s technology and expertise with Honeywell’s industrial platform expands our offering to help customers continue to improve plant performance. This is a great addition to our business.” printing papers and consumer products manufacturer made a net loss of $162 million, compared with a net profit last year of $257m. But operating profits in the first quarter were $20 million, up from an operating loss of $147 million in the fourth quarter of 2009. “We started the quarter with an extreme run up in fibre costs in North America but ended with costs peaking in March and now moderating,” said chief executive John Faraci. “The strong results of our European businesses helped offset higher input costs in North America. Importantly, we JOHN FARACI exited the quarter in North America seeing improved cost and fibre availability, stronger operations, improving demand and the further realization of our previously announced price increases – setting us up for a significantly better second quarter.” Core handling & core cutting Core strippers & butt roll unwinders Roll saw Core cutters Battery roll movers Your partner in core and waste roll handling www.cfenordic.com Phone+46(0)346-450500 www.pmdmagazine.com May/June 2010 9  Heimbach PAPER MAKING & DISTRIBUTION Heimbach PAPER MAKING & DISTRIBUTION Finding dramatic savings in the press section Though press felts represent less than one per cent of overall paper line costs, their impact on running and energy costs is significant. Olli Kääpä* explains why A A fter the cost of raw materials, energy represents the next largest cost on a paper manufacturing line. Depending on the paper grade, it’s between 20 and 30 percent of the total. So there is always motivation for optimising the process. The largest energy cost is the drive to the vacuum pumps. By optimising their adjustment the costs of the other ‘consumers’ on the line can also be reduced to a minimum. The essential requirement for this is bringing about a nip dewatering. Additionally, on fast machines the laws of physics conflict with Uhle box dewatering: there is just not enough dwell time available. In addition, the water has to be pulled from the horizontally-running felt at an angle of 90 degrees vertically into the slot (Figure1). Depending on the paper grade, some 10-20 per cent of the power consumption is required for FIGURE 2: VACUUM REDUCTION: POWER SAVING FIGURE 1: UHLE BOX DEWATERING creating vacuum for the various dewatering elements, around 25 per cent of this vacuum capacity is usually required for the Uhle boxes. So the optimisation of the Uhle box vacuum can alone save more than €1 million each year, subject to the ‘correct’ dewatering techniques being applied. Figure 2 shows that with a high- speed newsprint machine the felts can be run throughout their whole life at a significantly lower vacuum (20-40 kPa) than was previously the case (45-75 kPa), without any problems. In many cases, at least one of the watering pumps can be shut down shortly after the start for the remainder of the felt life, subject to the use of appropriate felts for the correct style of dewatering. Advantages of thecost balance Permanent savings of between 100 and 300 kW per felt from the reduction in vacuum energy plus or minus a saving of around 100 kW from the drive to the press rolls as a result of reduced braking of the felts plus or minus a saving of drive energy, lubricating and sealing 10 May/June 2010  HeimbachPAPER MAKING & DISTRIBUTION HeimbachPAPER MAKING & DISTRIBUTION water from the elimination of a water-ring pump results in savings/yr of circa €1,000,000. Nip dewatering, theoptimal clothing One felt specially designed for nip dewatering is Heimbach’s non-woven ATROCROSS layered felt (Figure 3). Its key features are a no yarn system in the Z-direction; high openness combined with low free volume; life-long minimal base compressibility, especially active water removal from the sheet and fast barrier-free water flow through the felt. The special feature of the base is the cross-directional alignment of the upper layer. This causes the layer to function as a micro-foil, which ‘shovels’ the water very quickly from the sheet into the felt (Figure 4). This also leads at low specific pressure to a high level of saturation and reduces the risk of further water take-up (oversaturation, crushing, rewetting). For all of these reasons the non-woven felt from Heimbach has proved in practice to be an extremely fast starter, a pronounced nip dewaterer and an active energy saver. Example; start-up phase An example with a machine (56 g/m2, 10.5 m) shows two different dewatering systems with two different felts. Figure 5, left, shows the typical dewatering of a very open, conventional woven felt. During the start-up phase the felt dewaters FIGURE 3: ATROCROSS FROM HEIMBACH almost exclusively through the Uhle boxes and returns to the nip with too low a saturation level: its start-up dewatering suffers considerably and the machine must be run more slowly and with higher energy consumption. This felt also shows indications of fatigue towards the end of its life: in addition to the sinking level of Uhle box dewatering the high compaction/density level will cause the weak nip dewatering to fall again. These two time periods of inadequate dewatering – the ‘cost triangles’ in Figure 5 – impacts not only energy costs but also the level of production. In contrast Figure 5, right, shows the ideal dewatering with an ATROCROSS felt: immediately high nip dewatering results in start-up with merely residual dewatering through the Uhle boxes, significantly increased total dewatering with virtual ‘fatigue-resistance’ throughout its life. Result is that the machine can run on average 100 m/min faster during the start-up phase. • FIGURE 4: ATROCROSS FROM HEIMBACH: NIP DEWATERING May/June 2010 11  Heimbach PAPER MAKING & DISTRIBUTION Heimbach PAPER MAKING & DISTRIBUTION FIGURE 5: COMPARSON: DEWATERING DEVELOPMENT The calculation below is restricted to the additional production. Energy saving or increased production from fewer shuts/breaks and lower felt costs from longer life are to be added. Advantages for the cost balance A 100 m/min higher start-up speed provides a 3,528 kg/h production increase which results in an additional 84.67t production/day. At €650/t this works out at €2,293/h or €55,037 increased turnover/day. Rounding these figures up for a year with 11 felt changes and only one day startup phase each gives increased production of 931.4t with a value of €605,410. If the relevant production remains unchanged there would be comparable savings. Example: moisture profile Based on a machine (80 g/m2 woodfree, 1400 m/min, 10 m) the comparison is made between the moisture profiles from the Uhle box dewatering with a previous woven felt and from the nip dewatering with a non-woven felt. The even profile curve of the non-woven felt is clearly visible. So the end moisture per sheet could be raised, for example by 1 per cent to between 4 and 5 per cent. Advantages for the cost balance Production (at 85 per cent efficiency) totals 493,776t/yr. Pulp component at 4 per cent end moisture equals 473,776 t/yr – at 5 per cent end moisture resulting in production of 468,841 t/yr. The saving is 4,935 t pulp per year which at €550/t means a saving of €2,714,250 per year. Example: break rate On the above machine, by the introduction of nip dewatering with a Heimbach non-woven felt the dry content after the press could increase typically from 49 to 50 per cent. This can increase the wet strength of the sheet by around 6 per cent. The result is that the break rate could lower typically by around100 breaks/year. The calculation is limited to the increased production. Energy savings, also in the dryers, are to be added. Advantages for the cost balance Assume production of 57.1 t/h. 100 fewer breaks per year each with 20 minute shut means that 33.33 hours are gained production time multiplied by 57.1 t/h equals 1,903t extra production which at €800/t gives €1,522,400 increased turnover. Example steam consumption Also based on the above machine, the nip dewatering with the non-woven felt and the higher dry content achieved can reduce the steam consumption in the dryers by about 5 per cent. Advantages for the cost balance With a daily production of 1,371t the steam consumption is around 1,300 t/day. With a steam saving in the dryers of 5 per cent this gives 65 t/day times the cost of €45/t steam results in €2,925/day. Multiplied by 350 days this gives €1,023,750 in savings per year. In the event that the steam saving is used for the production, an additional sales value of several million euros could also be achieved. Conclusion In relation to total paper production costs, the cost of press clothing represents less than 1 per cent, so is insignificant. However, its importance for the process, for the sheet quality goes technologically and economically far beyond the cost relationship, as proved by the example calculations. This fact demonstrates that it is not the lowest price for the clothing, but its degree of efficiency that should be the determining factor. The felt that pays for itself to the greatest degree – by fulfilling all technical parameters – is the most economical, independent of its purchase price. * Olli Kääpä (Dipl-Ing) is vice president of sales at Heimbach GmbH & Co KG, Email: olli.kaapa@heimbach.com 12 May/June 2010  The Valve World Expo presents continual growth, outstanding innovations and the highest level of technology at the new Düsseldorf location as of 2010. Valves and the entire palette of accessories, as well as the preceding and succeeding technologies take centre stage. The Valve World Conference, as the most important event of the industry, analyses the future of the markets against the background of fascinating developments and scientific evaluations. Düsseldorf turns it on! www.valveworldexpo.com Now get all the congress and trade fair information daily on your mobile! Simply use the QR-Code Reader of your camera phone. Sponsored by: Supported by: www.valveworldexpo.com Now get all the congress and trade fair information daily on your mobile! Simply use the QR-Code Reader of your camera phone. Sponsored by: Supported by: 7th Biennial Valve World Conference & Expo Düsseldorf, Germany 30 Nov - 02 Dec 2010  Honeywell PAPER MAKING & DISTRIBUTION Developing on-line measurement Fibre orientation on-line measurements from Honeywell have improved board quality on the BM3 line at StoraEnso’s Fors Mill in Sweden. Antti Paavola* explains S S toraEnso Fors mill’s management approached Honeywell in 2007 when it was looking for an on-line fibre orientation angle measurement system. A year earlier, Honeywell had released a new generation camera-based formation analyzer. Utilizing this platform, a novel sensor to measure this property was already in development pipeline. Once the prototype sensor was available Fors provided a CD sample strip. This was then analyzed in the Honeywell Kuopio development laboratory for fibre orientation angle profiles of both top and back side of the board. Layers were then separated by Fors mill laboratory and TSO angle profiles were measured. Comparing sensor prototype measurements with mill TSO measurements provided encouraging results and increased enthusiasms in the project’s development. See Figure 1 and Figure 2 Installation of sensors In the spring of 2008 laboratory testing was completed in Kuopio and sensors for beta installation were built. Fors decided to purchase a new base scanner and DaVinci system application version upgrade for new sensor installation for BM3. After the new scanner and version upgrade was successfully completed two FotoFiber fibre- orientation angle sensors were installed on the base scanner before coating on opposite sides on the board. See Figures 3, 4a & 4b. Initial results Startup after installation of the sensors was successful and both were measuring as expected. After completion of sensor setup of online measurement parameters, first online profiles were observed. The mill continued with layer separation ANTTI PAAVOLA FIGURE 1: COMPARISON OF TOP LAYER LAB TSO AND ONLINE MEASUREMENT. CORRELATION R2 = 0,979 14 May/June 2010  HoneywellPAPER MAKING & DISTRIBUTION FIGURE 3: COLOUR MAP OF LOWER SURFACE FO ANGLE PROFILES AT MACHINE STARTUP WITH ZERO SLICE, FOLLOWED BY MULTIPLE SLICE OPTIMIZATIONS (OLDER PROFILES NEAR BOTTOM). and TSO angle profile measurement. This gave excellent material to fine tune and further improved on-line measurement performance. After confidence was gained for measurement results some interesting process test were conducted. Focusing on quality with on-line measurements StoraEnso is now using on-line fibre orientation measurements in every day operation to manage board flatness. This is particularly important after grade changes, when flatness issues are likely to occur. Measurement provides instant feedback of changes and operators have learned to observe measured fibre orientation profiles and make corrective actions to top and bottom headbox slice screws accordingly. User experiences Henrik Näslund, process engineer in StoraEnso Fors has been following new sensors closely. Commenting on the measurement performance, he said: “On-line fibre orientation measurements are found to be reliable and repeatable. We are utilizing these measurements in our daily operation to keep board flatness under control.” Oskar Skärgård, production manager of the • FIGURE 2: COMPARISON OF BOTTOM LAYER LAB TSO AND ON-LINE MEASUREMENT. CORRELATION R2 = 0,896 FIGURE 4A & 4B: GRADE CHANGE (POINTED BY AN ARROW) AFFECTING FIBER ORIENTATION PROFILES ON TOP (LEFT) AND BOTTOM (RIGHT) LAYERS. S-SHAPE PROFILES APPEAR ON BOTH TOP AND BOTTOM LAYERS AFTER GRADE CHANGE. FIBER ORIENTATION ANGLE PROFILES HAVE DIFFERENT SIGNS, WHICH TYPICALLY INCREASE THE PROBABILITY FOR FLATNESS ISSUES. May/June 2010 15  Honeywell PAPER MAKING & DISTRIBUTION • board mill, has gained experience of utilization of new measurements: “With these measurements we can reduce control action response time, dramatically. Instead of two hours of waiting for sample cut, layer separation and TSO analysis, we now get instant feedback and can make much faster corrective actions when needed.” Next steps The co-operation continues. StoraEnso Fors and Honeywell have signed an agreement to develop control application to manage board flatness. With this step completed, StoraEnso Fors will make further steps towards even better board quality. * More information from Antti Paavola, Product Manager, Automation & Control Solutions, Honeywell Process Solutions, Sensor Technology and Control Applications, Sensor Technology Center, Pulp,Paper,Printing, PO Box 1001, Viestikatu 1-3, FIN-70600 Kuopio, Finland. Tel: 358 20 752 2817. Mobile: 358 40 723 9397. Fax: 358 20 752 2400. www.honeywell.fi Email: antti.paavola@honeywell.com The StoraEnso Fors board mill is located in the south of the province of Dalarna in central Sweden, about 170 km north west of Stockholm. Fors mill produces 390,000 tons a year of fully-coated folding boxboard on two board machines repesenting15 per cent of StoraEnso’s total consumer board manufacturing. Raw material is CTMP sourced from integrated production at Fors Mill and chemical pulp from Stora Enso pulp mills. Product palette is targeted for high end consumer packaging purposes, such as cigarette, chocolate and confectionery boxes, frozen food packaging and graphic materials. PRODUCTION MANAGER OSKAR SKÄRGÅRD (LEFT) AND PROCESS ENGINEER HENRIK NÄSLUND StoraEnso Fors Mill THE STORAENSO FORS MILL 16 May/June 2010  Fast Start-up – the Solution: Fast Start-up – the Solution: atrocross Heimbach – wherever paper is made.  Projects & Contracts PAPER MAKING & DISTRIBUTION Metsä-Botnia’s mill at Kemi in Finland has ordered a recausticizing plant from Metso. It will replace an existing operation with the new one scheduled to start up in the autumn of 2011. The recausticizing equipment will comprise of a clarifier, a decanter centrifuge, a green liquor cooler, a slaker, causticizers, a PDW filter (pressure disc filter for white liquor) and storage tanks. The new recausticizing plant is designed for 7,000 cu m of white liquor per day. The delivery also includes basic and detail engineering for piping, erection and start-up. The new plant will lower maintenance costs and improve the efficiency and environmental performance at the Metsä-Botnia Kemi mill. It will be the first recausticizing plant to be delivered by Metso to Finland. Oy Metsä-Botnia Ab is part of the Metsäliitto Group. Metsä- Botnia operates four mills in Finland and is one of Europe’s top producers of chemical pulps. Production capacity of the Kemi mill is 590,000 tons of kraft pulp per year. Total production of Metsä- Botnia, which is 17 per cent owned by UPM-Kymmene Corporation, is 2.4 million tons per year. Metsä-Botnia’s Kemi mill orders recausticizing plant THE DEAL SIGNING: BERTEL LANGENSKIÖLD, PRESIDENT, PAPER AND FIBER TECHNOLOGY, METSO (LEFT) AND ISMO NOUSIAINEN, SENIOR VICE PRESIDENT, PRODUCTION, METSÄ-BOTNIA, SIGNING THE CONTRACT FOR THE DELIVERY OF A METSO RECAUSTICIZING PLANT TO METSÄBOTNIA’S KEMI MILL. ALSO PRESENT WERE (FROM THE LEFT) EBBE ÖSTER, PROJECT MANAGER, THOMAS MALMQVIST, SALES MANAGER, JUHANI SIPILÄINEN, SENIOR SALES MANAGER, PETRI LASSILA, SENIOR PRODUCT MANAGER FROM METSO, AND LAURI VERKASALO, MILL MANAGER, JOUKO YLIVIUHKOLA, MATERIALS MANAGER AND ILKKA SAIKKONEN, PROJECT MANAGER FROM METSÄ-BOTNIA. A Metso defibrator system is being installed by Siempelkamp Group at PT Sumatera Prima Fibreboard’s mill in Indonesia. With start up expected in 2011, the project will include all the key machinery for an EVO 56 Defibrator system, related motors, a control system as well as supervision of installation and start-up. PT Sumatera Prima Fibreboard’s new thin board line will be located adjacent to the existing plant at Palembang in South Sumatra, Indonesia. Production will cover board thicknesses from 1.5 mm to 12 mm with a maximum defibrator capacity of about 30 dry ton/h. Raw material will be mainly acacia and rubber wood. It will make PT Sumatera Prima Fibreboard the largest producer of MDF in Indonesia. It’s the first EVO 56 system at the mill. The Siempelkamp Group is an international supplier of equipment to industry in the mechanical and plant engineering, nuclear technology and foundry markets. PT Sumatera Prima Fibreboard gets its first Metso defibrator system 18 May/June 2010  easy as Looking for better papermaking control? Imagine papermaking technology that is easy to operate, service and maintain at a lower overall cost. Honeywell’s papermaking solutions offer fast scanning and processing speeds, superior measurement, high resolution cross direction profile control and a comprehensive suite of quality control applications. These integrated solutions can vastly simplify control and increase production efficiency, producing the highest quality paper with reduced raw material, energy and maintenance costs. To learn more, visit us at PulPaper 2010 booth #6f37. We make it easy. See innovative papermaking technology at booth #6f37 at PulPaper 2010 in Helsinki, Finland. © 2010 Honeywell International, Inc. All rights reserved.  Projects & Contracts PAPER MAKING & DISTRIBUTION NewPage Corporation signs ABB to improve reliability C C oated paper manufacturer NewPage Corporation has signed up ABB’s Reliability Consulting in a deal that covers the US- based company’s 10 mills in North America. The first phase of the multi-million dollar deal includes strategic planning, world-class reliability benchmarking and implementation design. “In order to improve our shareholder profitability, we sought a company who could help implement a new phase of operational excellence across ten diverse sites,” said George Martin, senior vice president of NewPage’s paper operations. “Because of ABB’s ability to drive and deliver common best practices at multiple mills, we selected ABB as our reliability partner.” ABB’s Reliability Consulting group (a part of Global Consulting) More containerboard making technology for Amcor in Australia Amcor Packaging has expanded the B9 containerboard line project at its Botany Mill in Sydney, Australia. The main order from Metso for a containerboard line is scheduled to start up during the second half of 2011. The order, the value of which is not being revealed, will include all main process equipment and control systems for the mill and includes control valves and instrumentation as well as complete mill engineering and electrification with Metso drive controls. The extended scope of supply and project implementation method will benefit Amcor significantly, says Metso. The B9 machine will be built to produce recycled testliner from 80 to 200 g/m2. In addition to high-quality testliner, the line will have capacity to produce liner at lighter weights to enable innovation. It will deliver significant environmental benefits with lower usage of energy and water, says Metso. Amcor Packaging (Australia) Pty Ltd is part of global packaging manufacturer Amcor Limited which offers a broad range of plastics, fibre, metal and glass packaging products, along with packaging- related services. It has annual sales in excess of A$14 billion (about €9.5 billion) with 35,000 employees worldwide. It has 300 manufacturing sites in 43 countries. provides a service by reducing costs and maximising production efficiency. It benchmarks existing processes and implements methodologies to build, improve and sustain world-class reliability. “ABB Reliability Services drives customer profitability through improved maintenance and reliability,” said Magnus Pousette, head of ABB Reliability Services North America. “By bringing proven best reliability practices to our customers, we add new value to their bottom line.” NewPage Corporation is the largest coated paper manufacturer in North America, based on production capacity, with $3.1 billion sales in 2009. The Miamisburg, Ohio-based company’s product portfolio includes coated freesheet, coated groundwood, supercalendered, newsprint and speciality papers. Renewable fuels for SCA’s Östrand pulp mill SCA in Sweden has ordered a new lime kiln with fuel handling and white-liquor filtration equipment from Group Andritz. Theequipment for SCA’s Östrand pulp mill is part of its BioLoop project, in which the mill will change its systems from oil to renewable fuels. SCA says this will enhance the environmental friendliness of the mill. Fuelled by wood dust, the lime kiln will contribute to lower chemical and maintenance costs. The existing power boiler will be fitted with new wood dust burners. The white liquor filter is scheduled to be started up in the spring of 2011, and the lime kiln in the following autumn. For the pulp mill at SCA Packaging Obbola, Andritz Pulp & Paper will supply green liquor and dregs handling equipment, including a LimeGreen filter and a LimeFree centrifuge, and also a lime mud filtration system. This delivery includes process electrification and instrumentation, as well as modification of the existing control system for the new process equipment. Start-up is scheduled for spring 2011. Global hygiene and paper company SCA develops and produces personal-care products, tissue, packaging solutions, publication papers, and solid-wood products sold to around 100 countries. Automation system for Stora Enso’s pulp bleaching line in Finland Stora Enso’s pulp bleaching line at its Oulu mill in Finland is current one on the pulping line dating from the 1980s. having an automation system installed by Metso. The line produces Objective is to increase the mill’s operational efficiency and bleached pulp, part of which is used as raw material in the multi-extend the its life. coated art paper made at the integrated paper mill, and part of Stora Enso is the world leader in forest industry which is sold the to market as pulp. sustainability that offers its customers solutions based on The metsoDNA CR automation system will replace the renewable raw materials. Sales last year were €8.9 billion. 20 May/June 2010  Projects & ContractsPAPER MAKING & DISTRIBUTION Successful start up for Porstendorf’s upgraded board machine A A fter installation of a long nip style press in the board machine operated by Kartonfabrik Porstendorf GmbH in Germany, MultiFlex V3 press felts from Voith Paper were installed for start-up. The decision had been made to introduce a clothing manufacturer which had not supplied the mill at Porstendorf. The new press has now been running for a number of weeks and all technological specifications have been met or surpassed, says Voith. “Especially noteworthy is the 52 per cent dry content achieved and the width shrinkage which was reduced by more than 10 per cent,” said plant manager Steffen Söll. With a 2.32m net width and a speed of 80m/min, the board machine produces 40,000 tons of chipboard per year. At the beginning of the year, the two previous reversed presses were replaced by a long nip style press giving press loads up to 500 kN/m. A straight-through press was positioned at the end of the press section for setting the desired surface characteristics. The goals of the conversion were: improvement of the energy balance, reduction of production disturbances due to vapourisation bubbles and improvement of ply bond strength. The success of MultiFlex V3 is said to be based on Voith Paper’s speciality for meeting challenges in the press section, the well-proven Vector technology. This comprises a tri-axial non-woven base fabric structure that provides elasticity in all three spatial directions for excellent compaction resistance and self-cleaning properties. It also has high active void volume for controlled dewatering and handling large amounts of water. Even pressure distribution leads to more uniform drying whilst the multi-axial structure provides low flow resistance and maintained permeability. The rebuild of Kimberly Clark’s tissue machine TM2 at the Enstra Tissue Mill in South Africa was completed by Voith in February. The order covered structure refurbishment including installation and supervision service and to ensure improved operational reliability the framing was given a general overhaul and main framing parts were replaced. Kimberly Clark Enstra produces tissue products with various basis weight ranges and furnishes on two tissue machines. Built in 1976, TM 2 produces tissue with a web width of 3,450 mm. Enstra Tissue Mill’s tissue line 2 rebuilt by Voith Optimize your overalltissue productivity! The TTC - Total Tissue Capability - concept combines our Duroblade® high-performance blades Instruments closed loop control application expertise to deliver the results you need to maintain your competitive edge! Contact your local BTG sales representative to learn more about how implementing the TTC concept in your mill can lower your costs while raising productivity. Talk to the experts - and start raising your productivity today! www.btg.com See us at PulPaper, stand No. 6f20 and Zellcheming, stand No. 947  Projects & Contracts PAPER MAKING & DISTRIBUTION Voith Paper system solves misalignment problems at ABB Pucaro A A BB Pucaro’s mill at Roigheim in Germany was able to solve predominant profile problems at the reversed suction press and in the second press by using NipSense, a static real-time nip measurement system from Voith Paper. “Misalignment of the two presses was first detected with NipSense measurement results. Then Voith Paper immediately suggested corrective measures in a very good report. Since we carried them out we have increased product quality and we can operate the paper machine at maximum speed again,” said production supervisor Martin Gotthardt. ABB Pucaro manufactures 75 to 670g/m² electrical insulating paper at a machine speed of 65 m/min. NipSense is a static real-time measurement of events in the nip of two rolls. It consists of a measuring mat with highly sensitive sensors and an electronic module that is connected to a Voith First tissue line for Turkish dairy products manufacturer Turkey’s AK GIDA SAN ve TC is having a new tissue line supplied by Metso at its new mill at Pamukova in Sakarya province for start up in the second quarter of 2011. With a width of 5.6m and a design speed of 2,200 m/min, the new line will produce 60,000 tons a year of high-quality facial, handkerchief, toilet and towel grades produced from virgin fibre. It will consist of a complete tissue production line including a stock preparation system and an Advantage DCT 200 TS tissue machine. This will be equipped with an OptiFlo headbox, an Advantage ViscoNip press, a Metso Yankee cylinder, an Advantage AirCap hood adapted for co-generation, an Advantage WetDust dust management system and an Advantage SoftReel reel. The stock preparation system will comprise OptiSlush pulpers, OptiFiner conical refiners and OptiScreen machine screens. The project will also include an extensive automation package with metsoDNA machine and process controls, a PaperIQ Plus scanner and quality controls. Complete engineering, installation supervision, training, start-up and commissioning will also be included in the delivery. With a 140,000 m2 manufacturing facility, AK GIDA SAN ve TC AS currently produces a range of 400 dairy products at the Pamukova facilities. laptop computer with NipMaster software. The sensor mats have up to 32 sensors in the cross direction and by default, the distance between the sensors is 325mm. Intelligent microchips for condition monitoring of the sensors and connections are part of the Voith NipSense technology ensuring that calibration is not required. The current nip widths are recorded and displayed in real time and the measurement data are updated continuously. The change of nip width during measurement can be followed on the screen to enable precise analysis of the closing operation. The line load setting and also the adaptation of corrections on swimming rolls can be displayed in real time. The NipMaster software controls the NipSense measurements whilst at the same time visualizing and analyzing the measurement data of the sensors. Finally, NipMaster calculates the required crown correction for optimal nip proportions. Advanced Metso controls for M-real in Finland M-real’s Joutseno and Kaskinen mills in Finland are to be supplied with Metso’s quality control systems and and kajaaniMAP analyzers. The mills produce bleached chemi-thermomechanical pulp (BCTMP) with a total capacity of nearly 600,000 tons per year. Commissioning is expected later in 2010. The systems will combine the mills’ existing metsoDNA automation products with the kajaaniMAP analyzer for freeness, fibre length and shives measurement, and an Advanced Quality Control (AQC) system. The combination will reduce variation in BCTMP quality, control and reduce energy required for refining, increase plant production and ease the operators’ work. M-real is Europe’s leading board supplier and a major paper producer and provides its customers with high-quality board and paper for consumer packaging. The company’s global sales network serves brand owners, carton printers, publishers, printing houses, merchants, and office suppliers. The company’s sales in 2009 were €2.4 billion employing around 4,900. Improvements to Yuen Foong Yu’s PM1 by PMT Taiwan’s Yuen Foong Yu is having the PM1 paper machine at its Hsin Wu mill rebuilt by PMT Italia, with completion scheduled for the first quarter of 2011. The rebuild is focusing on improving paper quality to the highest standards. The paper machine has a 5.25 m-wide wire section and produces testliner grades in the basis weight range of 130-340 g/m2 at a maximum operating speed of 800 m/min. The project will include the installation of a new PMT M4 headbox with dilution system for the back ply and the rebuild of the two existing headboxes, implementation of the wire section to a three-ply fourdriniers configuration, a new film size press along with new after dryer section, and new calendering arrangement and automatic spool loading on the existing reel. Sheet runnability will be improved in critical areas of the dryer section and tail threading will be completely new through film size press to the reel. MCS will be implemented according to the new paper machine configuration. 22 May/June 2010  PAPER MAKING & DISTRIBUTION Product news NOV Mono celebrates its 75th anniversary A A leading provider in Europe of progressing cavity pumps, parts, grinders and screens, NOV Mono celebrated its 75th anniversary in May. Paul Naylon, group managing director at NOV Mono, commented: “The progressing cavity (PC) pump has come a long way since its invention by French creator René Moineau in the 1930’s and, as the UK’s only licensee of this simple and effective pumping principle, we’ve taken a front row seat in its development over the past 75 years. “Originally the preserve of the water and wastewater industry, over the years Mono has introduced PC pump technology to a great many different sectors, revolutionising processes, minimising costs and improving efficiency. We are constantly striving to develop this technology to meet the changing needs of the many different markets in which we operate, which is why we have gone from strength-tostrength. “Major innovations over the years have included the Mono Flexishaft, which eliminates the need for a double universal joint or gear joints, the Compact C range of PC transfer pumps, the Heimbach adds shoe press belts to its portfolio Yamabelt shoe press belts are to be distributed exclusively to the European paper industry by Heimbach. Modern paper and cardboard mills are increasingly furnished with shoe press technology. The belts (press covers for shoe presses) made by Japan’s Yamauchi will be integrated into the Heimbach paper machine clothing product portfolio and complement its Webmover transfer belts, enabling it to offer customers a complete range of clothing for all positions of the paper machine. A specialist in the production and application of felts for shoe presses, Heimbach says that its sees many promising opportunities to optimise the combined use of felts and belts. Yamauchi is a pioneer in shoe press belt technology and a major supplier to the domestic market. Following considerable investment in modernisation and capacity expansion at its Kanuma production site, Yamauchi is now able to utilise the Heimbach distribution network in Europe to bring the advantages of Yamabelts to market. Muncher range of disintegrators and the latest addition to the family, our revolutionary EZstrip maintain-in-place PC pump. “These high performance products are used in sectors such as food and beverage, oil and gas, and chemical and pharmaceutical, as well as water and wastewater.” Products in Mono’s current pump portfolio can handle capacities in excess of 400 tonnes per hour and pressures in excess of 70 bar (1,000 psi). These pumps are complemented by additional ranges of grinders, screens, packaged pumping systems and solar pumps. Mono has also developed a comprehensive range of Mono Universal Parts for use in other brands of progressing cavity pumps. These have been designed to be used in seepex®, Netzsch, PCM, Allweiler, Robbins & Myers, Bornemann and Orbit pumps. Originally formed in 1935, Mono’s continual development of product innovations and business practices has seen it thrive into the company it is today. The NOV Mono Group has 700 authorised distributors across the globe and employs more than 640. For more information visit: www.mono-pumps.com. Paper Making & Distribution VOL 17 ISSUE 18March/April 2010 Stora Enso's Kvarnsveden mill: aiming for 1 million tonnesHeimbach: How press felts impact saturationREDD: Reducing forest loss and climate changePropapier: Huge PM2 line in Germany starts up :Layout 1 19/4/10 20:18 Page 1 www.pmdmagazine.com May/June 2010 23  PAPER MAKING & DISTRIBUTION Product news A revolution in LC-refining technology Continuous measurement of the former water weight Although water weight and the corresponding dry content at the end of the forming section are key parameters for the best operation of the former, in most paper mills they are only occasionally measured, using hand held devices. But these important parameters are constantly changing – such as the settings of the vacuum productivity. In the case of elements or the condition of multi-ply headboxes, runability the forming fabrics – so the is enhanced by optimizing the water weight should be couching of single layers on the continuously monitored. To basis of the measurement. enable this Voith Paper has weight, an optimum water Furthermore, optimal developed OnQ FormingSens, weight can be continuously dewatering of the forming a sensor that measures the defined to ensure sustained fabrics over their entire service water weight continuously process improvements. This life leads to energy savings. using high-frequency leads to efficiency increases in OnQ FormingSens microwave technology with the several areas: the start-up contributes to increased safety highest level of accuracy. process following shutdowns is at the paper machine: thanks Through real-time shortened as a result of faster to the completely harmless measurement of the water threading and thus increases microwave technology, the radioactive sources used in many handheld measurement devices are eliminated. In addition, since measurement is done online there is no danger to the operators, as there is with the usual manual measurement process. Due to its large measurement range, the sensor can be used for nearly all grammage and former types. OnQ FormingSens has a contact surface made of smooth, low-abrasion ceramic material. Long-term field tests have shown that the sensor does not cause any wire wear or leave marks on the paper. Another benefit is low operating costs, because the sensor has no moving parts and is completely maintenance free. The refining stage in stock- preparation plays a crucial role in developing fibre properties for paper production, greatly affecting the runnability of the paper machine and paper quality. Metso has introduced a low consistency refining system with its OptiFiner Pro refiner. Unlike conventional refiners, OptiFiner Pro feeds the stock evenly across the bars directly in the refining zone where fibre treatment occurs. All of the stock is treated equally, providing a higher refiner loadability and better energy efficiency. High flexibility in operation is gained as well as easier installation owing to the smaller physical size. In its best configuration, one OptiFiner Pro can replace two traditional refiners and still deliver electrical energy savings of 20 per cent. The new design is suitable for all kinds of LC- refining applications including short hardwood fibres as well as recycled fibres requiring fibrillation at low refining intensities. In conventional refining, fibres have to travel the full length of the refining zone and suffer excessive impacts leading to increased fines, weakening of the refined fibres and inefficient delivery of energy to the fibre. Some fibres, as much as 70 per cent THE NEW OPTIFINER PRO REFINER IS COMPACT AND EASY TO INSTALL in a disc refiner for instance, may not be treated at all. The new OptiFiner Pro increases the number of fibres that receive proper refining treatment and, because of the high utilization of the refining area and all refining bar lengths, refiner treatment intensity is much higher than any other refiner. No-load power, which as much as 40 per cent of applied power in a conventional refiner, is consumed by viscous drag effects of the rotor and increases with both diameter and rotational speed. OptiFiner Pro uses a smaller rotor because of the improved fibre flow, reducing the no-load power by almost half. The design permits a remarkably higher installed power and throughput, further raising the refining efficiency. The improved performance of OptiFiner Pro enables refining with a reduced number of more compact refiners, thus reducing investment and maintenance costs significantly. The high energy efficiency provides operational cost savings and supports sustainable development with lower entire life cycle cost and less environmental stress. More information from Petteri Soini. Email: petteri.soini@metso.com. Tel: 358 40 565 6293. 24 May/June 2010  PAPER MAKING & DISTRIBUTION Product news New technology for monitoring press fabric performance T T he production of very low grammage graphics paper at Portucel Soporcel’s new PM4 line, the world’s fastest of its type, exposed the risk of the follow to become wetter and more clogged. Knowing the reliability of the well-proven Cristini’s PresScan microwave portable moisture meter, and its performances, Portucel Soporcel decided to apply this new technology to scan and monitor the press fabrics performance on the PM4. It used a newly developed diagnostic system called PermFlow DUOFIX which allows the monitoring of the press fabric’s moisture and water permeability. A record sampling speed of 1,500 per second makes the system the fastest-ever moisture meter, with a potential resolution of 2cm on a machine running at 2,000m/min. The system uses microwave planar sensors, a technology developed by Cristini that is more accurate than microwave injection of water through a resonance cavities. special nozzle, the system is Through the innovative use also able to detect at high of the microwave tecnology, speed (256 sps) the press in conjunction with a precise fabric water permeability. A sensor also enables the precise measurement of the press fabric surface temperature. The system consists of three measuring heads (one for each press fabric) for the cross- machine scan of the press fabrics. A ceramic plasma coating protects the exposed area from high fabric wear. The use of the PermFlow DUOFIX diagnostic system brings advantages such as: • a reduction of the paper web breaks, connected to the press fabric clogging; • an accurate evaluation of the press fabric performance; • an optimization and reduction of the machine energy consumption, trough vacuum optimization in the press section; • a prediction of press vibrations, trough high speed FTT analysis of the press fabric barring. More information from www.cristini.com Safety monitoring for harsh environments A universal remote input/output (I/O) module has been launched by Honeywell for its Safety Manager platform that allows process manufacturers to integrate more safety devices while simplifying installation and maintenance. The module is said to be ideal for facilities that must cost effectively integrate equipment, units and other assets that are spread over wide geographic areas. Plants and mills use Honeywell’s safety-instrumented system (SIS) platform, Safety Manager, to share critical safety information with process control systems. This system helps them prevent and mitigate safety incidents by protecting equipment, monitoring for fire and gas leaks, and maintaining critical control functions. The new Safety Manager Remote I/O module is designed for the harsh environments. An increasing focus on safety has led to a greater need for SIL (Safety Integrity Level) certified systems that can operate in these tough environmental conditions. Safety Manager’s remote I/O module is SIL-3 certified, byGermany-based TÜV Rhineland. The remote I/O module also helps facilities more easily expand Safety Manager. Typical I/O modules are wired to control rooms through junction boxes and marshalling cabinets. By using soft- marshalling, the Honeywell Safety Manager Remote I/O module can be mounted close to the process unit, eliminating the need for marshalling panels and homerun cables, and reducing or eliminating field auxiliary rooms. This reduces overall capital expenditure, engineering cost as well as maintenance costs. Each channel of the universal, high-density module can individually be configured to a different I/O type, which provides manufacturers more flexibility to design safety solutions that are uniquely suited to their needs. “Process manufacturers today are paying closer attention to safety applications for a variety of reasons, including a growing list of regulations and widespread reports of industrial safety incidents around the world,” said Erik de Groot, marketing manager for Honeywell Process Solutions. “Adding universal, remote I/O to Safety Manager gives process manufacturers an alternative and cost effective path to comply with these regulations, and to prevent or mitigate an incident.” More information from Zakia Demaghelatrous. Tel: 971 50 818 5369. Email: zakia.demaghelatrous@honeyw ell.com or Guy McGerr. Tel : 44 207 067 0337. Email: Gmcgerr@webershandwick.com www.pmdmagazine.com May/June 2010 25  Demag Cranes PAPER MAKING & DISTRIBUTION THE PROCESS CRANES GENTLY TRANSPORT THE ROLLS OF PAPER BY MEANS OF VACUUM LIFTING DEVICES The warehouse that never sleeps Mondi’s mill at Swiecie in Poland covers the entire value chain from the processing of recovered paper to the production of corrugated paper. Its recent €300 million investment covering both papermaking and a corrugated line includes the PM7 paper making machine, the output of which is accommodated by a roll shipping store. Germany’s Demag Cranes & Components installed the fully automatic crane-served store and in so doing has successfully strengthened its presence in Eastern Europe. Rising industrial production in recent years has increased demand for suitable packaging materials, and plastics for packing are being replaced by corrugated paper as an environment-friendly alternative, because it can be fully recycled. Construction of the PM7 paper machine at Mondi Swiecie SA is the Mondi group’s response to higher demand for light-weight paper types based on recovered paper. Swiecie will supply markets in Central and Eastern Europe, Scandinavia and neighbouring Western European countries. High-speed production The PM7 machine produces fluting and testliner papers in grammages from 75 to 140 g/m². With a speed of 1,800 m/min and an annual capacity of 470,000 t, it is one of the fastest container board machines in the world. The tasks of channelling, efficiently storing and making ready for shipping are performed by a automatic paper roll shipping store supplied by Demag with three process cranes in two bays that are controlled by a Demag warehouse management computer. After passing through the rewinder, the machine-width rolls of paper are cut to specific customer diameters measuring between 700 and 1,600 mm and widths of up to 3,500 mm. The rolls of paper are then transferred to the conveyor system. They are then strapped, measured, Output from Mondi’s new PM7 paper machine at Swiecie in Poland is managed using an automated warehouse with cranes and control systems from Demag. PMD reports ’ 26 May/June 2010  Demag CranesPAPER MAKING & DISTRIBUTION provided with a printed label and transported to the storage area. The conveyor line passes through the two parallel storage areas in the middle of the building, which measures some 90m in length. The warehouse management computer decides whether the rolls are to be transported to the automatic store, to the small stacker-served store or direct to the shipping points. Maximum storage capacity achieved For automatic storage of rolls, there are two identical bays in the warehouse: the first, Zone 1, accommodates rolls measuring up to 2,800 mm in width; in Zone 2, rolls measuring up to the maximum width are accommodated. The infeed points of the automatic store were installed in the middle of the bays parallel to the conveyor belt, where the vacuum lifting devices on the cranes pick up the rolls, weighing up to 5.2t, and transport them to the assigned storage locations. The transport line at the level of the paper machine is 7.5m above the store floor level. Since the loads are picked up by a vacuum lifting device from above, the rolls can be stacked close together at heights of up to 15m. The store is based on a space-saving grid layout, which enables up to 1,541 stacks to be created – with maximum roll diameters, plus 100mm. At a theoretical full capacity, the store can accommodate 34,700t of paper. The storage operation continues around the clock according to the machine capacities. Process cranes with high handling rates Three double-girder overhead travelling cranes operate in the automatic store. In storage zone 1, one crane performs all transport operations: the parallel storage zone 2 is served by two other cranes. While their working areas are defined, the cranes can cross into the other half of the store to complete transfer operations. • AT FULL CAPACITY THE WAREHOUSE HOLDS 34,700 TONNESOFPAPER THE CONVEYOR LINE PASSES THROUGH THE CENTRE OF THE 90M LONG STORAGE ZONES May/June 2010 27  Demag Cranes PAPER MAKING & DISTRIBUTION • The three identical crane installations have a span of 29.2m and are fitted with multi-purpose winch units (MPW). Frequency-controlled drives provide for variable speeds in three axes – and make it possible to carefully position the rolls of paper. Cranes travel lengthwise at speeds of up to 120m/min and across up to 80m/min, as well as with hoist speeds up to 100 m/min, provide for high handling rates. With more than 100 roll cycles per hour, the crane installations are responsible for storage of the output of PM7 and staging of the rolls of paper prior to shipping. The crane motions are controlled by the warehouse management computer in such a way that the operating sequences are timed for optimum performance. For the retrieval operation, the cranes deposit the rolls of paper at defined transfer points. They are then labelled and transported to Level 0 by the conveyor system and a load elevator. There are six stations available for loading trucks and a further one for loading rail wagons. Warehouse management system in control The warehouse management computer (WMC) is connected to the host system operated by Mondi as an autonomous unit. By comparing the theoretical and actual dimensions, both of these systems share information on the measured roll data and the positions of the rolls. The other monitoring and control functions are performed entirely by the WMC, such as: • Control of the crane installations • Visualisation of the current system status via external terminals • Continuous inventory including the storage locations • Control of the conveyor system • Control of the information displays for the operators Strategies for optimised inventory management The Demag warehouse management system modules can be adapted to specific customer processes. For this purpose, the system features storage strategies for optimised inventory management of the stored rolls of paper. Mondi aims to create stacks containing only one type of material in the store: The system reports information on a roll to be stored to the warehouse management computer, including specific data such as the customer, paper grade, grammage, roll width and delivery date. The WMC consequently triggers a multiple-stage search for storage locations with optimum travel paths. After it has received retrieval information from the Mondi host computer, the Demag warehouse management computer identifies the relevant rolls according to strategic criteria and triggers operation of the crane systems. During periods with low handling rates, the warehouse management system prepares the retrieval operations for the following day. For this purpose, the crane installations also create new stacks, which make it possible to retrieve items quickly on shipping day. Mondi Swiecie’s new PM7 line produces lightweight paper which is the basis for the production of corrugated paper and packing material. It uses only recycled paper as a source and with the commissioning of the PM7 line demand increased to 900,000t per year, which is 40 per cent of the paper recovered in Poland. Around half of PM7’s annual output of 420,000t is supplied direct to Mondi’s neighbouring corrugated paper plant. A paper recycling installation, the PM7 paper machine, the corrugated paper plant and the automatic paper roll shipping store form a total investment of €305 million at Swiecie. This represents a considerable increase in the production network operated by Mondi Corrugated Packaging, which has five of its 18 European plants in Poland. More information from Demag Cranes & Components, PO Box 67, 58286 Wetter, Germany. Tel: 49 2335 92-7788. Fax: 49 2335 92-7200. Email: info@demagcranes.com THE HONEYCOMB STORAGE PATTERN FACILITATES OPTIMUM UTILISATION OF THE AVAILABLE STORAGE AREA RECYCLED PAPER AS A SOURCE 28 May/June 2010  PulPaper UpdatePAPER MAKING & DISTRIBUTION French Finnish at PulPaper 2010 French pulp and paper sector goes to Helsinki for PULPAPER 2010 U U BIFRANCE, the French Agency for International Business Development, will present 13 companies on the French pavilion at PULPAPER, the international trade show for the pulp, paper, board and converting industry, which will take place in Helsinki from 1 to 3 June 2010. PULPAPER, which is the leading European trade show for the paper industry, takes place every other year, alternating with SPCI, the Swedish trade show for the paper industry. In 2007, PULPAPER welcomed 16,000 visitors from 78 countries, primarily from Europe and Asia ( China , Indonesia and India ). In 2010, the event will take place in Helsinki ( Finland ) from 1 to 3 June. French Pavillion In Finland , the timber and paper sector is a key industry, and the country is renowned for its expertise in pulp and paper. PULPAPER is a key event for European companies and the French Pavilion will showcase the expertise of innovative French companies in the paper industry. French manufacturers of machinery for the paper and cardboard industry generate 80% of their turnover through exports around the world. French companies are present at each stage of the production process, from engineering and pulp production to finished products. The 13 French companies on the French Pavilion represent all sectors of the industry and will be presenting their latest innovations during the trade show. The following companies will take part in the French Pavilion. ABB France specialises in coating preparation for use in papermaking (www.abb.com/pulpandpaper), while ABK Machinery SA designs and manufactures complete machines and specialised equipment for the paper and board industry (www.abkmachinery.com). B A Systèmes supplies Automatically Guided Vehicles (AGVs) to leading multinational companies in the paper and printing industry (www.basystemes.com). Clextral will present its Bivis machines, which process a wide variety of raw materials into quality pulp (www.clextral.com). CTP (Centre Technique du Papier) is an R&D centre for the production and converting industry for pulp, paper and board (www.webctp.com). For its part, Durum is a leading specialist in the manufacturing and application of hardfacing products and parts for the paper industry (www.barratgroup.com). IBC is an international provider of training courses for the pulp and paper industry (www.ibcppc. com). Pall Corporation is a leading specialist in filtration, separation and purification, providing analyses and solutions for fluids used by the pulp and paper industry (www.pall.com). Rai-Tillieres produces wove dandy rolls, marking rolls, filtration belts and shrinkable covers for use by the paper industry (www.raitillieres.com). Solaronics Bekaert offers a range of non-contact drying solutions for paper manufacturers (www.bekaert.com). Symop, the French Association for Manufacturing Technologies, brings today 220 companies, including specialists in manufacturing for the paper industry (www.symop.com). Tecofi designs and manufactures industrial valves and accessories with applications in sectors including water, HVAC, and the pulp and paper industry (www.tecofi.fr). Finally, Thermopap offers complete drying and energy- saving solutions for papermakers (www.thermopap.com). About UBIFRANCE UBIFRANCE is the French Agency for International Business Development, and is part of France ’s export-support framework. As the partner of reference for French companies wishing to export, UBIFRANCE offers a complete range of services based on the provision of information about export markets, about legal issues and regulations, and about international finance and tenders, while also supplying sectorial data. In addition, UBIFRANCE offers export advice and targeted support to companies’ commercial activities, such as exploratory visits, partnership meetings, foreign exhibitions and international press communication. Finally, UBIFRANCE runs the International Postgraduate Programme (VIE) for employing qualified personnel and young graduates outside France . For further information, please go to: www.ubifrance.fr UBIFRANCE is organising the French Pavilion at PULPAPER, which will take place in Helsinki from 1 to 3 June 2010. For further information about the PULPAPER trade show, please go to: http://www.finnexpo.fi/pulpaper/intro/ Ms Kate AMBLER - Press Officer UBIFRANCE Press Office in London Tel: +44 (0) 207 024 3640 kate.ambler@ubifrance.fr May/June 2010 29  ABB PAPER MAKING & DISTRIBUTION Liquid assets Getting the best efficiencies from paper machine drives depends on taking a total system approach. ABB showed Vince Maynard the process at the Stora Enso Kvarnsveden mill In the last issue of PMD magazine I reported on my visit to the Stora Enso Kvarnsveden mill in Sweden. This month I take a more in-depth look at the involvement of ABB and some of equipment put in place to improve energy savings. The mill features novel liquid-cooled inverters as part of optimised energy management processes. Paper mill managers can use the following analysis to review their own facility’s electrical drive systems. Total system Obtaining energy efficiency from electrical drive systems in paper mills at ABB involves using a total system approach called PMC800. Vital to this is ensuring that there is high availability of the entire systems of drives in the mill. Each of driven motors should also be connected to more energy efficient mechanical arrangement, that is, direct drive. It is also important to be mindful of the dimensioning of the motors (without sub optimising motor-inverter combination), having drive controls together with the varying and cyclic processes, and selecting motors with high efficiency Power components In selecting motors, it must be ensured that they are direct drive with permanent magnets rather than a geared version of a traditional AC-motor. These must have the optimum number of poles for the application, in other words they are gearless AC rather than permanent magnet motor. Certain motors improve the total performance by having controlled motor cooling fans or liquid cooling. The supply transformers should have high efficiency and quality, with the correct configuration for parallel transformers. Losses will be reduced if the appropriate cooling systems for the inverters are used, either liquid or air. Equally important is to ensure the cabling is correctly dimensioned to reduce power losses, including the distances between transformers, drives and motors. Control methods ABB offers advanced and patented functions developed to increase availability of paper machines, by reducing web breaks and loss of production and loss of energy. Key aspects for consideration include: • Application supports drive firmware with special functions • Encoderless control possible in main drives and demanding applications • Acceleration/deceleration optimisation in winders and dryers • Adaptive load share control • Adaptive load compensation • Errorless tension control and measurement • Optimated motor fan control Example – PMC800 WinderOptimized Dimensioning • Standard products: These are based on catalog data with 150 per cent over-loadability during acceleration. With optimum selection of high efficiency products, the sum of calculated losses is 80 kW and the total efficiency is 84 per cent. • PMC800 Standard: with ABB catalogue products selected, but taking into account detailed data on the equipment and application, as well as information on loading, cooling, and system behaviour, losses are reduced to 69 kW and efficiency rises to 86 per cent. • PMC800 Optimized: With further refining, the design of the motor is modified so that its electrical performance matches the specific application. Otherwise standard catalogue equipment is used. Losses are further reduced to 67 kW and efficiency increases to 86.5 per cent. • This demonstrates that, in this case, optimization can increase efficiency by 2.5 per cent, delivering annual savings of around 13 kW x 8,700 h = 110 MWh. 600 500 400 300 200 100 0 100 90 80 70 60 50 40 30 20 10 0 Standard PMC800 PMC 800 Products Standard Optimized Output (kW) Losses (kW) Eff% Total Power (kW) Total Efficiency (%) Losses (kW) 30 May/June 2010  ABBPAPER MAKING & DISTRIBUTION Case PM Drives - Cooling arrangements In contrast to liquid-cooled inverter cabinets, air-cooled versions require additional heat exchangers in which additional losses can be incurred. Typically: Air cooled PM and winder drives • Installed motor power 15.3 MW • Nominal running load 10.7 MW • Drive heat losses (calculated) 391 kW (from NRL) • Air transfer and cooling eq. power 180 kW (for 1,800 m3/min) • Optimated motor fan control €358, 000 • Alternative with liquid cooling • Losses to air 8 kW (= no additional cooling needed) • Losses to water 383 kW • Water transfer and cooling same as (capacity Ø10 deg C, 560 l/min) ext. piping & control for A/C equipment ext. piping & control for A/C equipment • Additional investment cost €10,000 (longer cooling pipes) • Space savings air cooled versus liquid cooled • A/C equipment room (~200 m3) -€22,000 (110 €/m3) • Length reduction of drive cabinets (~15m) -€20,000 • Total investment cost reduction -€390,000 (>10 per cent of the total system investment) • Energy savings for three years -€284,000 (180kW A/C eq; 6c/kWh) • Energy savings for 15 years (PV, 5 per cent) -€1 million approx. As shown, liquid-cooled inverters for controlling the electric-redundant, compared to liquid-cooled with savings in both drive powered drives have more efficient heat-transfer systems. Because efficiency and space savings. And because there is no radiated of this the heat exchangers used with air-cooled systems become heat, the conditions in the plant are improved for workers. 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KWI(UK)LimitedCambrianBusinessParkBromfieldIndustrialEstateMold,FlintshireCH71NJUnitedKingdomt:+44(0)1352700224f:+44(0)1352700396e:office-uk@kwi-intl.comwww.kwi-intl.comTechnologiesforwater&wastewatertreatment Roll Manufacturing and Roll Covers To advertise here call: +44(0)1732 505724 www.pmdmagazine.com .................................................... ........................................ ................................................ .................... ................................................................ .............................................. ............................................................ .......................................... Advertisers page index and web information ABB BC www.abb.com BTG 21 CFE Nordic 9 www.cfenordic.com Christini 3 www.cristini.com Heimbach 17 Honeywell 19 www.honeywell.com Metso IFC www.metso.com Pulpaper 2010 IBC www.pulpaper2010.com Valve World 2010 13 www.valveworldexpo.com May/June 2010 31  People PAPER MAKING & DISTRIBUTION Independent Scottish papermaker Tullis Russell is to set up its own sales company in Spain following a number of years sales growth in the Iberian market. The creation of Tullis Russell Iberia coincides with its long-term agent, Luis Rodriguez of Copacel, retiring. The new sales company will be managed by Josep Gonzalez and will continue to work out of the same office at St Cugat near Barcelona. Gonzalez previously held senior sales positions at Torras Papel and Antalis and has more than 22 years experience in the paper industry. Tullis Russell’s sales and marketing director Malcolm Sinclair confirmed that the company's ambitions were to further develop their sales in Spain and Portugal. “Iberia now represents a core part of our business and we are sure that with Josep and our own sales organisation we can continue to build on the solid foundations laid through the hard work and commitment of Luis over the last 17 years,” Sinclair said. Tullis Russell to set up sales company in Spain Specialist engineering project management company Projen has appointed Simon Forshaw as its head of projects. Forshaw joins Preston Brook, Cheshire-based Projen plc from James Fisher & Sons PLC with a successful track record of delivering outstanding results. In his most recent position as commercial director he was responsible for the strategic and operational leadership of James Fisher's Strategic Asset Management Business Unit, building relationships with blue chip organisations globally. In addition he also had functional leadership for the major projects business, developing and delivering long term sustainable revenues in engineering, procurement, construction and management (EPCM) projects. "These are exciting times for us - the success and growth of Projen is a result of the company successfully continuing to grow within its expanding markets but also reflects the determination, expertise and professionalism of its staff,” said Projen’s managing director Martin Seabrook. “We welcome Simon Forshaw to Projen at this exciting time and look forward to his seeing contribution to the ongoing success of the company.” Simon Forshaw is a chartered engineer, a Fellow of the Institute of Engineering and Technology and gained his BEng from the University of Salford. Projen has a diverse client base which includes a substantial number of large blue chip organisations. The company's record for client retention is exceptional and by ensuring that client expectations are exceeded and company standards are maintained Simon will help to reinforce Projen's market position. Forshaw appointed head of projects at Projen JOSEP GONZALEZ Paper Making & Distribution www.pmdmagazine.com  Welcome to PulPaper 2010– the global meeting place! Welcome to PulPaper 2010– the global meeting place! Meet the suppliers at one of the largest and most international exhibitions for the pulp and paper industry. Be inspired at the technical conference on the theme ”implementing the new rise” covering topics like bio energy, resource efficiency, sustainable solutions and technological breakthroughs. The conference is organized by PI in co-operation with AEL. Mingle with colleagues and industry people from all over the world at the social activites, among them a new social event, the PulPaper 2010 Party. Visit PulPaper 2010 – this year’s most important global meeting place offering the best possible business opportunities for all participants in the pulp and paper industry. The offcial figures for 2007 amounted to 16,102 visitors from 78 countries and 700 exhibitors from 33 countries in 273 exhibition stands. PulPaper 2010 is open: Tue Jun 1 – Wed Jun 2, 9 am–5 pm. Thu Jun 3, 9 am–4 pm. Registerasavisitorandseemoreinformationabouttheevent:www.pulpaper2010.com Organised by Adforum and Paper Engineers’ Association in co-operation with The Finnish Fair Corporation.  Should you expect support 25 years later? Absolutely. Should you expect support 25 years later? Absolutely. Maximizing the performance of what you have, adding cutting edge technology to existing systems or just fixing something that’s broken are all things pulp and paper companies should expect from their automation and electrification partner without regard to the age of the system. The expectations for an industry pioneer like ABB have never been higher and we can meet those expectations. www.abb.com/pulpandpaper 

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