express
Fiber&Paper
Metso Paper news magazine dedicated to lifecycle support Issue No.3 2004
CTMP line and the
world’s first OptiStream
roll finishing line to be
supplied to Shandong
Huatai Paper in China.
Page
The new composite cover
CalTiger offers a new
dimension in cover selection
for demanding calendering
applications.
New active tools for high-speed
winding and a truly remarkable
12-second set change impressed
Francisco Carilla, Project
Director at SAICA.
4
Page
6
Page
SymBelt
M-real Kirkniemi places repeat orders for BowMaster
conventional curved spreader rolls
due to their insufficient spreading
efficiency. Wrinkles on sheet edge
areas were a particular problem.
In addition, conventional spreader
roll maintenance intervals are quite
short: on PM 3’s coater they were
less than 4 years due to the high operating speed. The maintenance of
conventional spreader rolls is fairly
expensive, too. However, one useful thing with conventional curved
spreader rolls is that in case of roll
failure, this kind of extensively
bowed roll can temporarily be used
as a non-rotating spreader bar,” explains Jari Tiura.
BowMaster, Metso’s state-of-theart paper spreader roll based on
advanced composite materials,
is still going strong. Fifty rolls
have now been sold worldwide,
and thirty of them are already
running. One of BowMaster’s
customers is M-real Kirkniemi
mill in southern Finland,
who use BowMaster rolls on
both their PM 1 and their
PM 3 off-machine coater.
Kirkniemi’s PM 1 runs at 13001340 m/min, producing 170,000 t/y
of ULWC coated wood containing
grade in the range 45-60 g/m2. The
PM 3 off-machine coater operates
at 1700-1750 m/min. The mill has
plans to increase the coater speed
to 2000 m/min within the next two
years. The PM 3 coater produces
350,000 t/y of coated special fine
paper in the 40-70 g/m2 range.
Jari Tiura, Mill Production
Manager, has experienced conventional curved spreader rolls in use
at the mill. “Every now and then
we had wrinkle problems with
two
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Condebelt containerboard grade for Asian markets
Kim Jin Doo, Mill Manager of
Dong Il Paper, South Korea.
Metso Paper and the Dong Il Paper
mill at Ansan city in South Korea are
striving to produce a new grade for
Asian containerboard markets. The
BM 1 at Dong Il is currently running
at 700m/min with a basis weight
range of 180-400g/m2. Metso Paper
has previously delivered a Condebelt
drying process, rebuilds for the wet
end and a production monitoring
system for the BM 1. The step-bystep improvement plan continues
with the press section rebuild and a
new size press after the Condebelt
drying process.
The SymBelt rebuild for BM 1’s
press section increases the board
dryness after the press, and also improves runnability and speed. The
production costs were lowered due
to the reduced steam consumption
in the drying section and also as a
result of the board being dryer after the press. “The SymBelt press is
technically and mechanically a very
good device,” states Kim Jin Doo,
the Mill Manager at the Dong Il
Dedicated to lifecycle support
8
Jari Tiura, Mill Production Manager,
(left) and Tommi Hevonoja,
Production Superintendent of PM 1,
from the Finnish Kirkniemi mill are
both satisfied with BowMaster’s
operation on their coater.
STEP-BY-STEP IMPROVEMENTS CREATE NEW
Paper mill. He also adds that “we
saved time by carefully planning
the installation and by making advance preparations for the start-up.”
The total shut-down time was just
twelve days and the machine was
running at normal speed and production again within 24 hours after
start-up. Kim Jin Doo reasons that
“the co-operation with Metso Paper
worked well since we have a good
relationship and deep understanding of each other”.
In addition to the SymBelt rebuild,
the machine is being supplied with a
size press in July 2004. This will secure the adhering of the glue between
different box layers as well as improve the surface quality of the board
with coating. Coating enables further
development of the new Condebelt
white top grades. The machine is
using Korean OCC as the primary
raw material with ash content often
exceeding 14%. The process is very
challenging but the customers are
satisfied with Dong Il Paper’s product.
“Our customers are impressed by the
board’s profiles, formation and even
quality,” Kim Jin Doo clarifies.
The mill is planning to further
develop the white top grades and
run the machine with modern
equipment to respond to the growing needs of containerboard markets in Asia. §
FOR MORE INFORMA T I O N
juha.a.leppanen@metso.com
Tel. +358 20 483 8845
Rebuild of KL 1000 control system
ensures trouble-free production
The rebuild of the KL 1000
winder control system at
Stora Enso Veitsiluoto has
substantially improved the
usability and reliability of
the mill’s PM 2. The rebuild
extends the lifecycle of the
winder and creates a solid
base for future upgrades of
other parts and functions.
The Stora Enso Veitsiluoto integrated
mill in Kemi, Finland is the world’s
northernmost paper mill, producing
865,000 tons of office and coated
mechanical paper per annum. The
6.5m wide PM 2 is one of four paper machines at the mill. PM 2 produces copy paper with a basis weight
of 80 g/m². The line is equipped
with one KL 1000 two-drum winder,
which was delivered by Metso Paper
(Valmet) in 1985.
S7 replaces S5 in
just four days
The delivery included a rebuild of the control and operating systems. Additionally,
the winder control room was
relocated and the winder was
equipped with monitoring
cameras. The original Siemens
S5 control system was replaced
with a Siemens S7 system during the rebuild that was carried out over four days in
8
the summer of 2003. According to
Aarne Suojärvi, Project Manager at
the Stora Enso Veitsiluoto mill, the
new control system has been functioning excellently ever since the
successful start-up.
two
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8
WindControl enables winder control
via a PC screen and keyboard or
from an operating panel at the winder.
Metso Paper has concentrated on
user-friendliness, an example
of which can be seen in the
use of symbols instead
of written text on
the keyboards
and panels.
THE HEART OF SHOE PRESSING
During the years, Metso Paper
has continuously improved
shoe press technology with a
view to further enhancing the
reliability and runnability of the
operation. Today the SymBelt
roll, the heart of the shoe press,
is more user-friendly than ever.
Metso Paper’s SymBelt roll: A
proven design with over 15 years of
experience. Continuous development
work has led to easier, faster and
even more reliable installation as
well as smoother belt operation.
SymBelt continues to improve
To meet customer demands, Metso
Paper has improved the belt clamping segments with new threads and
bolts and installation tools. This enables easy, fast and even more reliable installation as well as smooth
belt operation. In addition, the
new-design, belt-draping pipe with
reinforced brackets and screwed
connections facilitates better belt
installation and more reliable functioning.
One important development step
in the SymBelt’s operation is the
new doctoring solution, BeltDoc.
BeltDoc with a maintenance-free internal support shoe provides excellent and smooth belt doctoring results for different speeds and grades.
Furthermore, the SymBelt sealing has been developed to reach
the demands of higher speed machines. A new type of lip seal and
seal counter ring together ensure
reliable and long-standing sealing.
Toward smarter shoe pressing
Hydraulic belt stretching provides
even tension for the entire belt lifetime. The belt indexing does not
influence the belt tension and the
process is very reliable, thanks to a
longer support distance of moving
heads and sliding parts. New covers
for head sliding necks ensure reliable belt stretching and smooth head
operation.
Reduced hydraulic connections
and a multi coupling plate offer a
simplified and more compact design,
while the present one-zone loading
system with edge controls requires
no more than three hydraulic connections for nip loading. §
F O R M OR E IN F OR M A TI ON
jori.onnela@metso.com
Tel. +358 20 482 6168
express
one
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dear
reader
Tissue production is fundamentally a sound and
excellent business that boasts particularly stable
global growth. Metso’s process delivery and
technology businesses currently produce some 40
percent of the world’s total tissue output. Metso’s
target is to maintain its position as the number one
supplier of equipment and services to tissue markets.
Metso Paper has actively launched its Process Services business for tissue customers. This business model serves Metso
Paper’s entire installed base. As is well known, Metso Paper
is the intellectual property owner of all Beloit delivered tissue
machines, and the Process Services business serves deliveries
under Metso’s former company banners including KMW and
Valmet, and now Metso.
The Process Services business provides installed base solutions ranging from simple replacement parts to technical
de-bottlenecking solutions to improve tissue makers’ productivity, quality, operational and energy costs. Metso’s technical
solutions are born from the combination of the world’s most
comprehensive library of machine data and technology together with supreme tissue technical expertise from Metso’s
employees. This wealth of knowledge and experience is further complemented by Metso Paper’s world-class tissue pilot
facility that provides tissue makers with a controlled full scale
testing ground for their new products.
Metso’s long and rich history dates back to 1891 with the
very first paper machine delivery. Our pioneering efforts have
continued through the centuries and decades resulting in innovations such as the current Thru-Air Drying technology.
Metso owns technologies that have been developed internally
through RTD efforts as well as acquired technologies such
as Beloit’s.
The latest examples of Metso’s creativity include the all
new, Advantage DCT100, Advantage Thru-Air 100 and
Advantage STT machines which cover the range of Dry Crepe
to Thru-Air dried production and incorporate the latest tissue-making features offered in the market today. Metso’s
Advantage Shoe Press also provides tissue makers with tissue quality advantages not available in conventional shoe
presses.
Metso Paper is committed to its customers with presence
around the world and offerings that provide tissue makers
with the highest competitive advantage in their business. /
8
Wrinkle free paper quality
provided by BowMaster on
the Kirkniemi PM 1 sizer.
To solve their spreading related
problems Kirkniemi decided to start
using new BowMaster roll technology for paper spreading.
Wrinkles removed
The first BowMaster roll at Kirkniemi
was taken into use on the PM 3 offmachine coater, positioned after the
1st sizer used for coating. The roll,
started in February 2003, operates
right after an infrared heater, where
high temperatures increase the demands set for roll reliability.
Jari Tiura mentions that in that
spreader roll position the mill used
to have continuous wrinkle problems which required constant adjusting. “The BowMaster roll has
reduced these problems remarkably,” he says.
one
1
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8
Old control system problematic
The mill’s maintenance team initiated the project because spares for the
old control system were no longer
available. In addition, there had been
plenty of unplanned stops on the
winder caused by the outdated control system. By upgrading the control
system, the mill wanted to ensure a
trouble free winder operation.
Operators prefer WindControl
“Like in all other projects, the
Winder Operators were skeptical
about the rebuild in the beginning.
In a high-speed application such
as this, the BowMaster roll is dimensioned to operate on a speed
area above the roll’s first nominal
frequency. Kirkniemi find that when
the coater speed is accelerated over
this nominal frequency area a temporary rise in roll vibration level appears. This does not, however, cause
any problems for paper production.
“In fact,” says Jari Tiura, “after taking BowMaster in use, the coating
machine has been less sensitive to
start-up breaks.”
Excellent spreading effect
One year after the successful startup of BowMaster on the coater, Kirkniemi installed a second
BowMaster roll on their PM 1, in
a position before the second sizer
used for coating. The roll has now
run continuously for 8 months.
“On the PM 1 sizer we used to
have occasional wrinkle problems,”
comments Jari Tiura, “but these
have now been eliminated with the
BowMaster roll.” Tommi Hevonoja,
Production Superintendent of PM 1,
adds that the visual spreading result
is excellent, and sheet movement is
now more stable.
The rubber cover used on the
BowMaster roll in this application is cleaned with a wet sponge.
“Cleaning takes a bit more time, but
the cleaning intervals are about the
same as with conventional chromium coated curved spreader rolls,”
says Tommi Hevonoja.
However, the resistance remained
slight due to thorough training,
the user-friendly user interface and
the well-functioning control system” explains Suojärvi. “The operators quickly adopted the computer-based WindControl operating
system. They find that the control
panel’s illustrative symbols make
the system more user-friendly”.
Winder Operator Matti Kuoppala
is happy with the modern, easy to
use operating system that has become an essential tool in his work.
He particularly appreciates the feature that enables exact winding to
the accurate roll diameter or roll
length.
The latest BowMaster start-up
was also on PM 1, in a position before the reel. In the past, the mill
has had some problematic cases
of wrinkles at the reel. “After the
BowMaster start-up there hasn’t
been any indication of these problems,” Tommi Hevonoja explains.
Solution to demanding paper
spreading applications
Kirkniemi got BowMaster rolls to
improve operations in problematic
spreader roll positions. According
to Jari Tiura, BowMaster has fulfilled the mill’s expectations. The
roll spreading effect has been excellent. With just a couple of years running experience with BowMaster it
is still a bit early to evaluate roll
reliability, but so far the rolls have
been maintenance free.
After the successful start-up and
operation of these three BowMaster
rolls, Kirkniemi have now placed an
order for two more rolls. They are
happy to recommend Metso Paper’s
BowMaster to other papermakers,
too, as a solution to demanding paper spreading applications. §
FOR MORE INFORMATION
kari.roysko@metso.com
Tel. +358 40 839 8621
All goals accomplished
The rebuild of the KL 1000 control system improved the usability and reliability of the winder.
Furthermore, the WindControl
operating system significantly improved the winding reproducibility,
which is now in a totally different
class to the former manual operations. All goals for the rebuild set by
the mill have been fully met. §
FOR MORE INFORMATION
tommi.vuoristo@metso.com
Tel. +358 20 482 7297
The Winder Operator’s
desk before the rebuild.
The Winder Operator’s desk after
the rebuild. Matti Kuoppala, Winder
Operator at Stora Enso Veitsiluoto,
appreciates the WindControl
operating system’s numerous features.
New TMP line start-up for Stora Enso Varkaus
M ARCO MARCHEGGIANI
Fiber&Paper
President, Tissue Business Line
express
Fiber&Paper
Published by Metso Paper, Inc.
P.O. Box 587, FIN-40101 Jyväskylä, Finland
Tel. +358 20 482 150, Fax +358 20 482 151
In June, Stora Enso’s Varkaus
Newsprint Mill in Finland startedup a new TMP pulping line supplied
by Metso Paper. The design capacity of the TMP (thermomechanical
pulp) line is 600 tons per day, with
a maximum capacity of up to 700
tons per day. Metso Paper delivered
all of the main process technology
for chip washing, main line refining and screening, rejects thickening, refining and screening, steam
separation, heat recovery and post
refining.
Out with the old
and in with the new
The new TMP line is a complete
replacement for the former stone
groundwood pulp (SGW) plant.
“The take-over of the new line took
place exactly on schedule and we
were able to shut down the SGW
plant just two days later,” recalls Production Manager Matti
Leppänen from the Varkaus Mill.
The mill has two paper machines,
PM 2 and PM 4, for directory and
newsprint papers with an annual
Editor-in-Chief: Juha Kinnunen
Managing Editor: Riitta-Maija Peltovuori
Contributors: Björn Engström, Ulf Eriksson, Nathalie Faure,
Leena Färm, Eero Halmari, Björn Johansson, Anna-Riina Kirjavainen,
Anna Koskinen, Markku Käppi, Marika Lindeman, Jan Lindström,
Päivi Luoto, Kristiina Löfgren, Jari Marttinen, Elisangela Melo,
Vanda Molitor, Kirsi Mäntylä, Janne Märkälä, Heike Picker-Hess,
Riitta Pöntynen, Riitta Räisänen, Jori Sipari, Eric Tetreault, Susan
Trast, Alpo Tuomi, Martti Tyrväinen, Jorma Vänttinen, Stephanie
Wang, Tim Warriner.
English language editor: Bellcrest Language Services Oy
Lay-out and art work: Non-Stop Studiot Oy, Paul Hitchman
Printing: Libris Oy. Printed on Galerie One Silk 100 g/m2
production capacity of 280,000
tons. The new TMP line feeds both
of these paper machines.
The investment in Varkaus,
known as the Warma project, concentrated on enhancing paper quality by improving the products’ opacity and strength properties.
Good pulp quality
“The feedback from the paper machines has been very positive since
the beginning. The TMP pulp from
the new line has already proven its
ability to produce the desired paper
properties”, says Leppänen.
Wood handling modernized
The Warma project also included
the modernization of wood handling operations at the mill. Metso
Paper supplied a Camura GS chipper and a bark removal conveyor to
the wood handling line. The modernized line secures a constant chip
flow to the new TMP line. §
Published in September 2004
© Copyright Metso Paper, Inc.
All rights reserved.
Reproduction permitted quoting
“Fiber&Paper Express” as source.
2
Metso Paper news magazine
Production Manager Matti Leppänen and Supervisor Mauri
Mättö from the Varkaus Mill by an RGP main line refiner.
FOR MORE INFORMATION
mechanical.pulping@metso.com
OptiLoad TwinLine races to the market!
PILOT CALENDER AT COATING TECHNOLOGY
CENTER (CTC) ALREADY IN FULL OPERATION
The inauguration festivities of the
OptiLoad TwinLine calender and
Future Printing Center (FPC) included
the cutting of the ribbon: Manager
of CTC Päivi Miettinen in action.
OptiLoad multinip calendering represents Metso Paper’s leading calendering technology. This claim is
backed by the over 50 references
sold all over the world. Metso Paper
has recently introduced the latest
member to the OptiLoad family, the
OptiLoad TwinLine, to meet the demands of high speed calendering on
top quality printing papers.
Technology for high speed
and superior quality
The market is creating a demand for
faster and more efficient production
processes, in order to keep paper
mills profitable in an ever-tightening
competitive environment. For example, the new OptiLoad TwinLine
calender enables the cost efficient
upgrade of traditional newsprint
machines to high speed on-line SCproduction, the quality of which can
be optimized close to coated LWCpapers.
This new generation calender
can lend its superior calendering
capabilities to both uncoated and
coated printing papers. Besides
providing excellent tools for controlling two-sidedness and paper
profiles, OptiLoad TwinLine also
demonstrates outstanding operational flexibility.
Swing running modes allow the
papermaker to use all the nips in the
stacks or to select the nip arrangement best suited to the paper being produced. This allows the mill
to produce both matte and glossy
grades with the same calender.
For SC-paper applications, the
OptiLoad TwinLine dual stack configuration splits the calender into two
separate stacks and re-moisturizes
between them. This allows papermakers to keep moisture levels coming into the first stack low enough
to eliminate the risk of paper blackening and the loss of critical optical
properties, while ensuring required
end moisture levels even with high
thermo roll temperatures. On-line
moisturizing combined with high
calendering temperatures creates a
moisture gradient. This combination
results in paper surface properties
such as gloss, porosity and absorption that are far better than those
achievable with traditional multinip
calendering.
OptiLoad TwinLine at CTC
– a real multipurpose calender
The first OptiLoad TwinLine calender was inaugurated in mid January
of this year, at Coating Technology
Center CTC (owned by Ciba Specialty
Chemicals, Omya and Nordkalk), in
Raisio, Finland. According to Päivi
Miettinen, Manager of CTC, the pilot installation has drawn the attention of many customers interested to
learn the potential benefits OptiLoad
TwinLine can bring to their specific
grade. “Feedback from customers
has been very positive,” Miettinen
explains. “The new pilot calender
has been able to fulfill the research
needs of customers, from SC and
coated grades to even newsprint and
multi-ply board! Flexibility and versatility were among the key reasons
to invest in the OptiLoad TwinLine
pilot calender.”
Three new OptiLoad TwinLine
calenders will start-up next year
Metso Paper has already received
three other OptiLoad TwinLine
calender orders in addition to
CTC. The first production scale
OptiLoad TwinLine will start-up
next year. Two other OptiLoad
TwinLine calender start-ups are also
scheduled for next year, on the new
PM 12 at Stora Enso Kvarnsveden
mill in Sweden. This will be one of
the world’s largest paper machines,
and will produce top quality SC-paper. §
FOR MORE INFORM A T I O N
pekka.linnonmaa@metso.com
Tel. +358 40 594 1006
The OptiLoad TwinLine pilot
calender at the Coating Technology
Center (CTC) in Raisio, Finland.
Tissue Makers
meet at Metso Paper in Karlstad
Members of the European Tissue
Symposium (ETS), representing a
majority of tissue paper producers
throughout the EU, had its Spring
Meeting at Metso Paper in Karlstad,
Sweden between June 10 – 12.
Out of the world estimated annual tissue production of some 20 million tons, Western Europe produces
some 5 million tons of paper tissue
per year. The main grades are toilet
paper, kitchen towels and facial tissue, of which the ETS members are
the main producers. These products
have very special characteristics that
appeal directly to the consumers and
therefore create an especially close
relationship between the paper tissue manufacturers, their customers
and the consumers.
The Brussels-based trade organization serves its members by
providing quality guidance in these
relations and by preserving and defending this characteristic with public authorities.
Metso Papers Tissue Business in
Karlstad hosted the event and was
given the opportunity to present its
resources and also some local culture and entertainment. §
FOR MORE INFORMAT I O N
bjorn.engstrom@metso.com
Tel. +46 54 17 1203
Forming section improvements
for more profitable boardmaking
Two of the biggest challenges for
profitable boardmaking are continually higher customer expectations for end product quality, and
the special features of the various
board grades themselves. Increased
board machine speeds have also demanded better water handling for
the short circulation, and called for
improvements of web forming conditions. Metso Paper’s extensive
forming section product range offers customized solutions to accommodate the specific needs and wishes of every board manufacturer.
Customized forming
section solutions
Aside from traditional foil boxes
and vacuum boxes, Metso Paper’s
product line includes a highvacuum flat-cover HiVac suction
box for customers contemplating
quality, speed, production or maintenance upgrades. A movable forming board at the forming stage gives
a cost-effective way to improve formation.
In addition to traditional forming section operations and control
equipment, such as additional operator stations, breast roll lifting equipment, fabric replacement equipment
or stretchers and guides, Metso
Paper’s recent product development
work includes OptiCleaner Wet, a
forming fabric cleaner, WetMist, a
mist collector, and VacuDoc, a suction roll air doctor.
Optimization improves
boardmaking profitability
Web forming conditions at the forming section of a board machine have
a material impact on the structure
of the end product, particularly its
formation, which can only be greatly influenced at the forming stage.
Ideally, forming section production should be optimized with various forming section analyses, such
as runnability, production capacity, board quality, production safety
and cost analyses.
Stock that leaves the headbox in
a very turbulent and homogenous
state flocs up quickly in the forming
area as turbulence dies down. As
microturbulence of dewatering elements in the forming section loosens up the structure of the fiber web,
forming retention also decreases.
Formation-improving components
include various types of agitators,
such as a breast roll shaker, and different types of foil configurations.
Metso Paper’s FormMaster breast
roll shaker has a particularly favorable effect on formation.
Among other new products, the
MicroJet starch sprayer for increased plybond strength deserves
a mention. Another product to remember is forming board moving
mechanism, which allows for easier
adjustment of the slice jet impact
point. §
FOR MORE INFORMATION
kari.humalajoki@metso.com
Tel. +358 20 482 5992
Coating preparation capacity increased by 35% at
Stora Enso Grycksbo PM 10 – Metso PaperChem DryFeed
“The investment of DryFeed gives us
the edge for several years to come, both
quality and capacity wise.” says Tomas
Andersson, Superintendent of raw
materials from Stora Enso Grycksbo.
The Stora Enso Grycksbo mill is situated close to the city of Falun in the
Swedish Dalarna. Paper production
at the Grycksbo mill started in 1740;
today the mill produces wood free
and matt coated grades with three
machines. The Grycksbo PM 10 is
the newest machine, with a start-up
year of 1957. Over the years PM 10
has been rebuilt several times, the
latest rebuild was in 1999 when the
new coater was installed. At that time
Metso PaperChem was awarded the
contract to expand the coating color
kitchen originally delivered in 1987.
The mill has continuously optimized
the production process, and has further increased production capacity by
20% since the 1999 rebuild. A new
rebuild on the coating color kitchen
was inevitable in order to cope with
the increased coating color demand.
Metso PaperChem made a process study at the mill focusing on the
coating preparation capacity. The
conclusions made after the process
study were clear: the highest capacity increase would be achieved by
installing the new DryFeed process on the existing batch mixer.
The DryFeed process developed by
Metso PaperChem is specially designed for adding and pre-mixing
dry raw materials into the coating
mixer. Dry raw materials are typically used in order to achieve a higher dry solids content in the coating
color. The most commonly used dry
added chemical is CMC (Carboxyl
Methyl Cellulose). DryFeed solves
all the typical problems related to
the dry addition of components. It
enables good homogenity of the
additive flow, excellent pre-mixing
with no agglomerates, and most
importantly a significant capacity
increase.
The Stora Enso Grycksbo mill has
been using dry CMC since the previous rebuild in 1999. This meant that
the basic equipment needed for powder metering and pigment metering
was already available. Installation
of the DryFeed process was done
during a short maintenance break
on PM 10, the installation time was
roughly 10 hours. The time needed
for process optimization, i.e. setting
the right dosing speed for the CMC
and pigment, optimization of the
addition order and determination of
the coating color quality, was carried out the next day.
The main investment target was
to increase the coating color pro-
duction capacity. Another critical
issue is coating color quality i.e.
when the batch is ready virtually
no agglomerates are allowed in the
final color. The coating color quality after the DryFeed process was
installed was thoroughly checked
by measuring the screening residues,
viscosity and dry solids content of
the coating color.
The results of the process rebuild
were spectacular, coating color production capacity was increased by
35%, cutting the batch time from
75 minutes (before rebuild) to 55
minutes. The coating color quality was improved by decreasing the
number of agglomerates to zero and
decreasing the coating color temperature by 5 °C.
"We have never before been able
to achieve such a capacity increase
in any process with such a short
maintenance break. This investment
gives us the edge for several years
to come, both quality and capacity
wise. The whole DryFeed process
is easy to understand and the crew
at the coating kitchen have already
adopted the process. The commitment of Metso personnel to optimize
the process alongside the operators
was also of great importance," says
Tomas Andersson, Superintendent
of raw materials. §
FOR MORE INFORMATION
john.bergman@metso.com
Tel. +358 2048 24037
Wide range of automation and field solutions to
Stora Enso Kvarnsveden’s new world-class SC paper line
Metso Automation will supply Stora
Enso’s Kvarnsveden mill in Sweden
with a wide range of automation
and field solutions. This turnkey delivery is for a new production line
for high-quality SC paper being supplied by Metso Paper. With a capacity of 420,000 tons per year, the
new PM 12 line will be one of the
largest in the world. The start-up is
scheduled for the end of 2005. The
automation order is part of Metso
Paper’s total order that was an-
nounced on April 20, 2004.
Metso Automation’s delivery includes a full range of automation
solutions for the paper machine and
for two off-line twinline calenders.
These solutions include a metsoDNA machine control and a process
control system with process historian, a PaperIQ quality control system, profiling actuators, a Sensodec
6S condition and runnability monitoring system, a DNAforesight web
runnability monitoring camera
system, and a CCRV monitoring
camera system. Metso Automation
is also delivering Kajaani analyzers
and complete field instrumentation,
including amongst other things
Neles valves. All the systems are delivered on a turnkey basis including
engineering, installation, start-up
services and training. §
FOR MORE INFORMATION
matti.tapio@metso.com
Tel. +358 20 483 8040
3
Shandong Huatai Paper selects Metso Paper’s CTMP and roll finishing lines
Metso Paper will supply a
new CTMP line, a complete
bale pulping line and an
OptiStream roll finishing line
to the Shandong Huatai Paper
Co., Ltd mill in Dong Ying City,
Shandong Province, China.
The lines are scheduled to
start-up in December 2005.
CTMP line for mechanical
pulp production
The CTMP line will manufacture
high-quality BCTMP pulp (bleached
chemi-thermomechanical pulp) for
standard newsprint, high brightness
newsprint and LWC paper production. Chinese Poplar will be used as
raw material for the line.
The CTMP line is based on
Metso Paper’s proven high-capacity CD-refiner concept. The line will
include all of the core process technology required for chip washing,
main-line refining and screening,
reject refining, pulp washing, highconsistency bleaching and steam
separation.
Proven process for
high-yield pulping
Vice President Tian Zhiding explains that Shandong Huatai selected Metso Paper’s CTMP process on
the grounds of high reliability, advanced technology and easy operation. “CTMP is a globally proven
process for high-yield mechanical
pulping, and there are many successful CTMP references in operation. The large operating window of
the CTMP process gives us operational freedom. The process meets
our targets in producing hardwood
BCTMP pulp for high quality newsprint and LWC. The large conical
CD refiner in the main line can effectively guarantee sufficient energy input to improve the pulp qual-
ity. The high consistency bleaching
technology in combination with efficient pulp washing will ensure efficient bleaching, and save the consumption of chemicals.”
Higher quality at lower cost
“The CTMP process combines improved paper properties with a lower production cost,” continues Tian.
“We are targeting maximum bulk
and opacity at brightness levels of
up to 82 % ISO and freeness levels
below 150 ml CSF. Using high bulk
BCTMP in the furnish improves the
formation, bulk, surface smoothness and opacity of the finished paper. The lower production cost is
obtained by the very high bulk and
high yield of the BCTMP compared
to chemical pulp.”
Metso Paper has received
three CTMP line orders from the
Shandong Province within the past
12 months. §
FOR FURTHER INFORMATION
hakan.dahlin@metso.com
Tel. +46 60 16 54 07
Europe
The CTMP line delivery contract
was confirmed by (left to right)
President Li Jianhua of Shandong
Huatai and Vice President, Sales,
Håkan Dahlin of Metso Paper.
The Huatai mill is situated in Dong
Ying City, Shandong Province, in the
lower reaches of the Yellow River
and the eastern region of the North
China Plains. The Huatai Group is a
publicly listed large-scale company
comprised of paper mills, chemical
industry facilities, printing houses,
thermoelectricity power plants, tree
plantations, and trade and service
industries. The company has several
paper machines and produces newsprint, fine paper, special printing papers, coated board and tissue. The
Huatai Group is the biggest newsprint producer in China, producing
some 800,000 tons of various mechanical papers per annum.
OptiStream roll finishing line
The world’s first OptiStream
roll finishing line will be
supplied to the new PM 11
newsprint machine. Shandong
Huatai Paper selected Metso
Paper following the successful
delivery of a winder and roll
wrapping and handling systems
in 2001 for the mill’s PM 9.
Continuous production flow
OptiStream integrates finishing operations and information management into one seamless entity and
ensures a continuous flow of production and information. The extensive scope of Metso Paper’s
OptiStream delivery includes two
WinBelt winders with automated
transfer rails and a core handling
system, an OptiCart parent reel
cart, a StreamLine wrapping machine and roll handling system. The
processing, recording and reporting
of shipping roll data is performed exclusively by the Metso RollControl
system. The finishing room layout
has been jointly designed by Metso
Paper and the mill.
A convincing solution
Sun Changgeng, Vice General
Manager of Pulp and Paper Company
Huatai Group, believes that sourcing all of the finishing equipment
from one supplier is highly beneficial. Metso’s machines are not only
well engineered and reliable, the
OptiStream solution links together
the highly automated machines and
assures that all segments of the roll
finishing system combine seamlessly,
ensuring efficient paper production
right from the start-up.
Highly automated
WinBelt winders
The trim width of the highly automated WinBelt winders is 9.8 meters. The winders are equipped with
automatic set change, automatic
slitter positioning and automated
core handling and gluing. Metso’s
delivery also includes automated
parent reel transfer rails from the
paper machine to the winder.
The decision to purchase WinBelt
winders was based on the positive
results from the WinDrum winder at
the mill’s PM 9. According to Wang
Chunran, Project Engineer of finishing operations, the runnability of the
WinDrum is excellent. He is pleased
that Metso Paper will deliver the
winders and roll wrapping and handling system for the new line.
Pulp drying line
to Ripasa, Brazil
High capacity StreamLine
wrapping machine
The roll wrapping and handling systems are designed for a capacity of
160 rolls/hour. The fully automatic
StreamLine multistation wrapping
machine is equipped with four industrial robots and overlap wrapping. StreamLine can be controlled
by a single operator, who monitors
production flow and handles material replenishment.
The cornerstone for an optimally
functioning finishing line lies in
a well-designed, efficient layout.
Metso Paper is able to provide mills
with invaluable layout expertise.
FOR FURTHER INFORMATION
ilkka.tuomenoksa@metso.com
Tel. +358 40 528 0779
Kappa Kraftliner Piteå mill gearing up
to growing demand for white top linerboard
Kappa Kraftliner Piteå is the biggest
kraftliner mill in Europe, producing
640,000 tons a year of various linerboards. They have five different
corrugated material qualities from
brown liner to white top liner, including mottled liner and high quality coated linerboard, all under the
same Royal Kraftliner brand. PM 1
produces brown kraftliner and PM 2
is dedicated to the increasing production of white top liner. A major
proportion of the production goes
to customers in Europe.
Anneli Burman and Lars Bergström
are satisfied with the last two years’
co-operation between Metso Paper
and Kappa Kraftliner Piteå.
4
Metso Paper news magazine
The demand for white top linerboard has increased in recent years
and the market for white top applications is growing faster than for
brown. This is due to the market
trend for more promotional packaging and high quality printing in corrugated board. Kappa Kraftliner Piteå
mill has prepared for the growing
demand for white top liner with continuous investments and co-operation with Metso Paper for their PM 1
and PM 2 in the last two years.
The biggest recent investment in
PM 1 was carried out in 2002 for
increased production and drying
capacity. At the same time as the
rebuild of PM 1, PM 2 had a quality targeted rebuild. Both rebuilds
were end results of a machine analysis done by Metso Paper in 2001.
“The scope of the rebuilds was well
optimized after the machine analysis,” points out Lars Bergström,
Superintendent of PM 2. The production of both machines has now
been successfully increased and optimized for linerboard markets.
Metso Paper was selected as the
machine supplier for both rebuilds
after the analysis, thanks to the
unique headbox technology, good
co-operation, and excellent references from Munksund mill. PM 2 was
supplied with a new dilution headbox and wire section reconstruction. “The profiles of PM 2 were
significantly improved with the new
headbox,” says Bergström. “We
achieved the quality targets straight
after start up, so I am very pleased
with Metso Paper’s work.” Due to
some other small investments PM 2
is now also more efficient. PM 2 is
running with half reduced breaks,
mainly thanks to Metso Paper’s
well functioning transfer box in the
top wire.
For PM 1 the target was to increase the production capacity by
removing the machine’s runnability and drying capacity bottlenecks.
“Together with Metso Paper we chose
the optimal rebuild solution for
9% drying capacity increase,” says
Anneli Burman, Superintendent
of PM 1. Runnability issues were
solved with small but essential slalom group modernizations for the
first drying section, runnability blow
Kappa Kraftliner Piteå is located
in the north of Sweden. It is the
biggest kraftliner mill in Europe with
640 000 tons annual production.
Metso Paper will supply Ripasa
S/A Celulose E Papel in Brazil with
a complete pulp drying line for its
Limeria mill in the state of Sao Paulo.
The pulp drying line delivery will include bleached stock screening and
wet end, airborne dryer, cutter-layboy and pulp baling systems. The
drying line is dimensioned for a 760
adt a day capacity, and has a trim
width of 3,9 m and a design speed
of 200 m/min. The line is furnished
with combi and shoe presses for optimum dryness prior to the airborne
dryer. In addition, Metso Paper will
also provide training, erection- and
start-up supervision services.
The new drying line is scheduled
to start up mid 2005.
In recent years Metso Paper has
received several corresponding complete pulp drying and baling system
orders. The drying line at VCP
Jacarei mill in Brazil was started up
late 2002, Arauco Valdivia line in
Chile early this year, and the most
recent start up was at Stendal mill
in Germany this summer. §
FOR MORE INFORMATION
jukka.sampi@metso.com
Tel. +358 400 590 968
Pulp drying line at Arauco Valdivia in Chile.
boxes, and ropeless tail threading
before the second drying group. In
addition a pope pulper was added
to handle the increased production.
Overall the cooperation between
Kappa Kraftliner Piteå and Metso
Paper has been working well in recent years. “People are always easy
available, the technological solutions for the board machines are
innovative, and Metso Paper works
flexibly,” states Bergström. §
FOR MORE INFORMATION
goran.tranberg@metso.com
Tel. +46 54 17 1461
Strengthening cooperation between
paper makers and machine suppliers
Europe is a traditional and very important market for Metso Paper’s pulp and paper machinery services and rebuilds. Such services are necessary to maintain and
improve the performance of existing installations. Incorporating these services into
the purchase contract for a new line creates a solid foundation for cooperation
with the machine supplier throughout the production line’s lifecycle. Particularly in
European paper mills, the trend is moving towards stronger cooperation between
paper makers and machine suppliers. Our customers want to concentrate on their
own core business - paper making - and are willing to outsource the maintenance
work of their production lines to service specialists such as Metso Paper. This level
of cooperation demands mutual commitment and deep trust, and can only be successful if it proves to be beneficial for both parties.
Metso Paper is usually recognized as a supplier of state-of-the-art high-speed
paper and board machines. We are proud of this reputation and maintain our
position in this very challenging market by means of constant development and increasing effort. Because of our status, it is easy to assume that Metso Paper is simply a service supplier for large and high-speed machines, but this is not the case.
Most of our services and products are suitable for all production lines, regardless of the speed or width of the machine. In order to stay competitive in the
future, we must develop specialized products and services for paper, board and
tissue machines. The market will call for more and more products and services
for big machine lines and smaller machines alike. Our target is to not only hold
a strong position in terms of our own installed base, but to also be a preferred
service supplier for other paper and board customers too, irrespective of who
originally delivered the machine.
The key elements in a successful partnership are availability, fast response,
reliability, professionalism and open communication. How can Metso Paper develop these characteristics to be even better in the future? We have to train and
educate our people continuously as we are doing today, but the most effective
way is to listen to our customers and to learn from them. Both positive and
negative feedback is the only way to develop our way of working to match our
customers’ needs, and we now challenge you to provide this kind of feedback.
We hope that this new issue of Fiber&Paper Express will bring our new
thoughts and ideas on service and rebuilds to your attention! /
Senior Vice President, Process Services, Paper Business Line
jari.vahapesola@metso.com
Tel. +358 20 482 5260
New Service Center strengthens
Metso Paper’s Korean presence
Dedicated to lifecycle support
“UPM-Kymmene Shotton mill
in the UK rebuilt the machine
calenders on its PM 1 (2003)
and PM 2 (2002) because of
a planned increase in the
amount of deinked pulp (DIP)
in the base paper. Shotton
increased DIP production
capacity in 2003 and at the
same time started producing
newsprint from 100 % recycled
fiber (earlier ~60 %),” explains
Timo Heinonen, operations
director at Shotton.
“Rebuilding the Shotton PM 1 and
PM 2 machine calenders was a good
decision,” says Timo Heinonen
(left), operations director at UPMKymmene Shotton. Next to Heinonen
is Graham Sutton, Managing Director
at Metso Paper Limited in UK.
J A R I V Ä H Ä P E SOLA
Metso Paper has expanded its aftermarket operations in Korea by establishing a new Service Center in
Daejeon, about 150 km south of
Seoul. The new center is centrally
located with regard to the country’s
pulp and paper industry.
The Daejeon Service Center provides the Korean pulp, paper, board
and tissue industry with traditional
spare parts service as well as roll
service and maintenance.
The development of the local aftermarket operations demonstrates
Metso Paper’s commitment to lifecycle support.
In his speech at the opening
ceremony of the Service Center,
Kim Luotonen, the Ambassador
of Finland in Korea, pointed out
Metso Corporation’s standing as an
all encompassing service house for
the global paper and pulp industry.
In today’s world, where meeting
deadlines is of paramount importance, Metso’s clients can benefit
from procuring entire integrated
processes from one supplier.
Metso Paper’s Area President
for the Asia-Pacific region, Kaj
Lindroos, remarked in his speech
that Metso Paper undergoes constant modernization in order to
serve its customers better. One example of this is the increased focus
on geographical area management.
The Daejeon Service Center will
strengthen Metso Paper’s local pres-
Machine calenders on newsprint lines PM 1 and PM 2
in Shotton were rebuilt to meet the requirements of DIP
The current trend in newsprint production is to use as much recycled
fiber as possible. Since recycled fiber
has gone through several production processes in its lifetime the fiber
is easily moldable and easy to calender. This is where traditional machine calenders in newsprint mills
become hard to control.
Standard DIP based newsprint
requires mild calendering with low
linear loads, which is not easy to
handle with traditional 4 to 6-roll
machine calender stacks. “The dead
weight of the rolls adds up to calendering loads which are too heavy,
and the sheet gets too smooth,”
explains Timo Heinonen. “The
Shotton 4-roll stacks were rebuilt
by reducing the roll amount to two,
making a single nip formed by two
deflection compensated SYM-rolls.
The new configuration with reduced
roll amount has enabled the minimum loading to be decreased to a
level better suited for DIP newsprint.”
The former pneumatic loading
systems were replaced with more
precise hydraulics. All calender
rolls were overhauled and modified
for double oil circulation, which
had a beneficial influence on rolls’
temperature profiles. The rebuilds
included some changes to the hydraulic systems as well as the installation of new doctors to insure the
cleanliness of the roll surfaces. The
Metso is no stranger to
the Korean market
Metso Paper supplied the first paper
machines to Korea in the 1980s. In
all, Metso has made approximately thirty major machine deliveries
to the country. Machines manufactured by Metso Paper produce
about one fourth of the paper and
board in South Korea. §
FOR MORE INFORMATION
harri.haavisto@metso.com
Tel. +358 40 596 4700
Ropeless tail threading with SingleForce Plus
ence and improve its capability to
serve the Korean paper industry.
A seminar for Korean paper
making professionals
Before the grand opening, there
was a half-day seminar in which
Ari Leppänen, Area Vice President,
Paper Business Line, gave a presentation on the shoe press in the 3rd
press position.
Kyoung-seop
Kim,
Metso
Paper Korea’s Product Manager,
talked about the advantages of the
BowMaster roll for web spreading
and also spoke about mechanical roll
maintenance products. Ari Telama,
Area Vice President, Process Services,
explained the benefits of co-operation agreements and maintenance
outsourcing.
controls on PM 1 were upgraded
to metsoDNA to meet the requirements of the new loading system.
The calender rebuilds were implemented in two separate phases
in 2002 and 2003 before the 100%
DIP process was started at the end
of 2003. The modified calender
configuration also worked well in
the period before the 100% DIP
process. “We carried out some pilot trials at the Metso Technology
Center in Järvenpää before the rebuilds, in order to define the right
calender configuration. Rebuilding
the existing machine calenders was
a good decision. We have reached
the desired quality and the results
have met our expectations,” says a
satisfied Timo Heinonen.
Metso Paper has rebuilt a large
number of machine calenders with
somewhat varying scopes depending on the targets. The need for a
rebuild may arise from a change in
paper grade or furnish, vibration
problems, change in production
speed, etc. §
SingleForce Plus compensates for the forces affecting
the tail particularly in the opening nip area.
Constantly increasing paper machine speeds and safety regulations
set further demands on tail threading. With this in mind, Metso Paper
has developed a new solution to
boost the tail threading process:
SingleForce Plus provides more reliable ropeless tail threading for single-felted dryer groups.
Well-managed tail threading
SingleForce Plus operates as a tail
threading zone vacuum booster for
single-felted dryer groups. It operates together with SingleForce, a
compressed air operated tail threading system, where vacuum is created with the help of blow boxes and
VacRolls or TailVac rolls SingleForce
Plus is applicable with SymRun HS
blow boxes.
Forces affecting the tail in singlefelting can complicate the threading
process, especially in the opening
nip area. The high vacuum zone
created by SingleForce Plus compensates for these forces and thus
prevents the tail following the dryer
cylinder surface.
SingleForce Plus provides improved machine line efficiency
by increasing the threading process reliability even with varying
speed, basis weight, moisture or
dryer cylinder temperatures. As a
compressed air operated system,
SingleForce Plus requires less maintenance, spares and wearing parts,
making the threading process more
economical. §
FOR MORE INFORMATION
kari-matti.laitinen@metso.com
Tel. +358 20 482 5907
VERACEL PULP MILL PROJECT INCLUDES SIGNIFICANT AMOUNT OF
Neles valves and Kajaani analyzers
FOR MORE INFORM A T I O N
esa.karki@metso.com
Tel. +82 11 359 7038
The ribbon cutting in the
opening ceremony.
Metso Automation will deliver
Neles valves and Kajaani analyzers
worth over six million euros to the
Veracel pulp mill project in Brazil.
The start-up of the mill is scheduled
for mid 2005.
Metso Automation provides the
mill with more than a thousand
automated Neles valves - on a complete fiber line and white liquor
plant by Andriz, a boiler plant by
Kvaerner, evaporators by Confab
and on a water treatment process
by Centroprojekt. Over 600 critical flow control applications are
furnished with Metso Automation’s
latest digital valve controller technology ND9000 and Hart communications.
The Kajaani analyzers will be
included in the controls of the fiber
line and white liquor plant. The
fiber line delivery includes kajaaniKAPPAi and BRITEi analyzers for
delignification and brightness control. Several kajaaniPOLAROXi
residual sensors, kajaaniCORMECi
and pH measurements with kajaaniFiltratePistons are also included to
provide measurements for bleaching
line standard controls. In the white
liquor plant, the automatic process
titrator kajaaniALKALi will handle the critical liquor analyses for
causticizing process monitoring and
control. The chosen technology is
specially designed for the production of high quality pulp with minimum environmental impact.
With a designed annual capacity
of 900,000 tons of bleached softwood market pulp, Veracel’s greenfield pulp mill will be the largest in
the world.
Veracel Celulose S/A is a joint
venture of Aracruz Cellulose S/A,
the world-leading producer of short
fiber eucalyptus pulp, and Stora
Enso, the second largest paper producer in the world. §
FOR MORE INFORMATION
marcelo.motti@metso.com
Tel. +55 15 219 1300
ilpo.miettinen@metso.com
Tel. +358 20 483 160
janne.tolonen@metso.com
Tel. +358 20 483 121
5
paper
extreme
A SPOT OF LIGHT READING?
World’s largest published book weighs 60 kg
The world’s largest book was published in December 2003, when author
Michael Hawley, a scientist at the Massachusetts Institute of Technology
(MIT), revealed his monumental book “Bhutan: A Visual Odyssey Across
the Kingdom”. The tome has 112 pages, measures 1.5 by 2.1 meters (5 by
7 feet) and weighs 60 kg (133 pounds). For each copy, a full U.S. gallon
(3.8 liters) of ink is used.
Hawley did not set out with the intention to produce the world’s largest book. However, while working at MIT’s Media Lab with a specialist
digital printer, he discovered the spectacular quality of large digital images.
His first idea was to create a 5-by-7-foot wall that would enable the owner
to change the picture every day. But then he realized there was an old-fashioned mechanism that might work - a book. The result is a showcase of a
variety of new digital, photographic and printing techniques.
Image processing and printing for the book demanded considerable
computing power. Each page image is close to two gigabytes in size, pushing the envelope of computer and printer capacity. Each copy requires 24
hours of printing time.
The book’s assembly posed its own problems. Traditional bookbinding
methods are inappropriate for a book of this size so a special binding machine combining western and oriental bookbinding techniques was created.
Each copy of “Bhutan: A Visual Odyssey Across the Kingdom” costs
approximately USD 2,000 to produce. Five hundred limited edition copies
are being produced, but the book is not being sold in a traditional way. It
is offered to people who make a donation of at least USD 10,000 to a nonprofit educational charity. Proceeds will benefit Bhutanese schools, scholars
and educational programs. Each copy will be built expressly for the recipient. The book is supplied complete with an easel-like display stand. §
Forming section performance optimization
The forming section is one of the
most important and complicated
parts of a board machine. It produces
the basic structure of board plies,
combines them with one another,
and removes more than 90% of the
web’s water content. Reliable forming section operation is a prerequisite for the efficient manufacture of
quality products; it thus also plays
a role in determining the financial
performance of a mill.
Metso Paper offers a broad selection of products that can assist
in the maintenance, testing, tuning,
development, upgrading, servicing, learning, and optimization of
a board machine’s forming components and process. All of these products can be further customized and
combined into very comprehensive
cooperative service packages for the
board machine forming section.
This cooperation can entail the
continuous contractual optimization and development of the customer’s process and related costs,
or it can also be based on ad hoc
problem solving, condition testing
or investment-specific assistance.
Each customer can freely choose
the level of partnership with Metso
Paper that best suits their needs.
Tests and analyses
Metso Paper’s basic tools for investigating the condition and operation
of a forming section consist of various tests and analyses. They help
customers reduce their operational
risks, lower shutdown and operating
costs, and improve efficiency. They
also provide useful background in-
formation for possible quality, speed
or volume upgrade projects.
Examples of Metso Paper’s
tests and analyses for
the forming section
Process-oriented tests and analyses
Runnability study
Efficiency audit
Stock and board sample analyses
Process analyses
Wet end chemistry audit
Tail threading audit
Slice jet speed profile measurement
IR camera analysis
Doctoring study
Ventilation audit
Automation-oriented
tests and analyses
Guide and stretcher test
Machine automation audit
Process automation audit
Steam box study
Break automation audit
Mechanically-oriented
tests and analyses
Alignment checks
Roll audit
Suction roll crack inspection
Corrosion study
Vibration study
Foundation plate leveling
measurements
Mechanical drive condition
measurements
Ceramics audit
Other tests and analyses
Lubrication study
Washing/cleaning study (shower
and cleaning analysis)
Reliability (applied RCM) analysis
Maintenance audit
Shutdown audit
Optimization
The forming section can
be optimized with respect
to aspects such as:
◗ runnability: breaks/
profiles/cleanliness
◗ production capacity:
maximum gross production
◗ board quality: formation, profiles
◗ safety: operator safety, risks
◗ costs: maintenance/operating
costs/raw materials/energy
◗ environment: water
consumption, noise, smell
◗ shutdown control: planned/
unplanned shutdowns
Metso Paper and its network of
cooperative partners can provide
experienced technical experts and
tested tools and methods for all of
the above, including laboratory facilities and pilot machines. §
FOR MORE INFORMATION
ari.hiltunen@metso.com
Tel. +358 20 482 5212
The optimization of a forming
section can proceed in steps.
Successful GradeMatic start-up at
Felix Schoeller in Titisee-Neustadt
Metso PaperChem has supplied a chemical management system
to the Felix Schoeller Group in Neustadt, Germany, consisting
of an unloading station for chemicals, chemical storage, a
GradeMatic unit and a supply system for the size-press.
The new surface size preparation
system was a part of rebuild of the
PM 18 making it possible to produce new grades at the machine.
The surface size used at Felix
Schoeller is very expensive and chemical losses are also difficult to manage, therefore Felix Schoeller decided to invest in a continuous surface
size preparation system with small
volumes. The surface size is also
quite complicated to prepare and
therefore a trial run was conducted
in Raisio at Metso PaperChem’s pilot-plant. GradeMatic facilitates the
possiblity of altering the component
dosing order, which is not typical
with continuous coating color preparation. Overall, the trial proved to
be very successful and convinced
the project team that the right process solutions had been made.
Entrained air in surface size has a
negative impact on the final product
quality. With GradeMatic, coating
color is prepared in a closed pressurized process, meaning that no air
is mixed into the product. This was
one of the GradeMatic unit’s most
important features as far as Felix
Schoeller was concerned.
In accordance with the millstandard, the whole delivery was
automated with the Siemens PCS7.
The size kitchen delivery also comprised a recipe handling system.
The available space for the supply system and size kitchen was
very restricted, and the installation
had to be completed in limited time.
GradeMatic is a small and compact
unit and is delivered as a pre-installed
unit. This together with sound preengineering made it possible to reduce the required work on site.
According to Michael Haffke,
who was the Project Manager,
Technology, during the delivery and is
currently the Factory Manager of the
Technocell Mill, Osnabrück, the Felix
Schoeller project production team is
very satisfied with the results of the
project. The co-operation with Metso
PaperChem worked well right from
the very beginning through to the installation, start-up and training. §
With GradeMatic, coating color is
prepared in a closed pressurized
process, meaning that no air
is mixed into the product.
mikael.furu@metso.com
Tel. +358 2048 24010
6
Metso Paper news magazine
FOR MORE INFORMATION
SAICA orders
WinDrum Pro
from Metso Paper
S.A. Industrias Celulosa Aragonesa
(SAICA) has placed an order with
Metso Paper for a high capacity WinDrum Pro winder. The
WinDrum Pro winder will be delivered to the SAICA mill located
in Zaragoza, Spain for use on their
corrugating medium and testliner
machine. Start-up of the winder is
scheduled for December 2005.
The highly automated WinDrum
Pro winder has a trim width of 7.8
meters and its operating speed is
2500 m/min. The winder is equipped
with automatic set change, automatic slitter positioning, automated
core handling and gluing and automated parent reel transfer rails from
the paper machine to the winder.
The winder’s capacity is further
increased by Metso’s Continuous
Winding automated function package, which permits fully automatic
winding as long as there are new
parent reels available.
WinDrum Pro winders give paper mills the ability to meet industry
production demands by increasing
winder throughput. New active
tools for high-speed winding coupled with a truly remarkable 12-second set change can increase winder
capacity by up to 15%.
Leading technology
prompts selection
Metso Paper’s superior winding
technology convinced SAICA to
select WinDrum Pro. According to
Francisco Carilla, Project Director,
the high capacity of the winder, the high level of automation
which allows one-man winder operation, the fast set change and the
increased winding speed were all
important factors in their decision.
Equally important was the ability
to reduce vibration by adjusting the
gap between the front and the rear
drums.
“Metso Paper is one step ahead of
other suppliers in winding technology.”
Francisco Carilla, Project Director at
SAICA, explains the reasons for choosing
WinDrum Pro winding technology.
SAICA in brief
SAICA is one of the leading manufacturers of testliner in Europe, producing over 1.5 million tons per
year. The company has five mills
and seven paper machines located
throughout Spain and France. §
FOR MORE INFORMATION
tapani.nyman@metso.com
Tel. +358 20 482 7392
HOW A BOARD MACHINE ANALYSIS LED TO A MODERNIZATION PROJECT
− The rebuild of BM 7 at Oudegem
Papier in Belgium by Metso Paper
Oudegem Papier in the Belgian town
of Dendermonde produces fluting,
testliner, carton and core board on
their three board machines, with a
total annual production of approximately 350,000 tons. The No. 7
machine, supplied by Voith in 1996,
manufactures approx. 150,000 t/
year of fluting. The machine has a
maximum speed of 770 m/min and
a wire width of 5600 mm.
In November 2003 Oudegem
Papier ordered a comprehensive
machine analysis from Metso Paper.
In the analysis, bottlenecks were
determined in the areas of capacity,
runnability, maintenance and board
samples, as well as in the wire and
press sections, size press and reel.
The mill was very pleased with
the results of the analysis: bottlenecks were revealed in detail and
the extent of the planned modernization could therefore be fixed with
definite targets.
A machine analysis gives a sound
basis to optimize a rebuild. Among
other benefits it makes it possible to
determine to what extent existing
structures and other components
can be reused. The aim of the modernization in this case was to improve runnability, increase efficiency
and to upgrade product features.
In June 2004 Oudegem Papier
ordered the first part of the rebuild
of BM 7 from Metso Paper. The rebuild is planned in two stages. The
first stage in October 2004 will include a new mist collector, two new
trim suction boxes, the rebuild of
the press section with transfer suction boxes and press nip blow boxes, new spray pipes after the second
press, and a TailJet water cutter
after the dryer section. The second
stage in December 2004 will comprise a new pick-up roll with spare
shell, save-all, doctor and modification of suction box of transfer suction roll. §
FOR MORE INFORM A T I O N
two are from 1969 and one from
1974. Two of the presses have already been fitted with new feed
motors and one has the new valve
block. The third press will change
feeding motors and new valve
blocks will replace the old camshaft
operating unit on the other two.
This upgrade will increase capacity by 10-15% and, as in Vallvik,
maintenance will be made easier.
The Rottneros mill produces both
ground wood pulp and CTMP and
is one of the world-leading producers
in these two categories, due largely to
the fact that the mill can deliver tailor-made pulp quality according to
customer requirements.
Supervision is included in the deliveries at Vallvik and Rottneros. §
FOR MORE INFORM A T I O N
marika.levander@metso.com
+46 60 16 58 12
board machine fourdrinier on the
front and back side in a location
where the web has drained enough
for the trim to be blown off from
the surface of the fabric.
Metso Paper’s new trim collecting
system, TrimRecovery, has been
designed for the efficient and costeffective recovery of trim that can
be reused as fiber raw material for
multiply board machines.
TrimRecovery allows for the
controlled recovery of the most
expensive top-quality trim of the
fiber raw material so that it can be
reused. The system effectively prevents the trim from being mixed
with the stock system. The trim
collecting system is installed at the
Dedicated to lifecycle support
Patent pending
The new trim collecting system
consists of a trim squirt, a blowoff blow nozzle and a trim collector. The trim squirt cuts the trim
reliably and neatly. The trim, having been cut with the blow-off blow,
is directed from the surface of the
fabric to the trim collector. Metso
Paper has applied for a patent on
the TrimRecovery system.
Due to substantial savings in raw
materials and low running costs, the
typical payback time for the investment in TrimRecovery is about four
months. §
Water buffer volume bigger than stock volume
require additional water treatment.
Net production efficiency in
closed paper mills without effective
water management could be noticeably lower than in similar mills with
an open water system. In such cases,
water management solutions could
normally increase the runnability to
an acceptable level.
At mills with high or normal fresh
water consumption levels, good efficiency can normally be achieved
without any additional kidneys.
Internal kidneys are only necessary
if runnability is expected to be low.
When reaching low or extremely
low fresh water consumption levels, ultrafiltration is required and
additional purification to improve
the runnability is carried out with
microflotation.
If salt removal efficiency is the
key issue, part of the permeate originating from ultrafiltration plant can
still by treated with nanofiltration.
Ultrafiltration technology has
great potential in helping to improve paper machine runnability
and to decrease the fresh water consumption. The aerobic bioreactor
system seems to be already accepted
as a standard solution for the new
European paper mill effluent treatment plants.
By combining state-of-the-art
technologies and solutions in the
right way, water consumption and
the environmental load of paper mills
can be significantly reduced. §
Careful steps lead to effective water management. Metso Paper
has invested heavily in the development of water management
solutions for pulp and paper making processes.
paperchem.info@metso.com
Recommended actions
20 m3/t
10 m3/t
keijo.ruonala@metso.com
Tel. +49 6157 9455 0
TrimRecovery system
offers substantial savings
TrimRecovery system cleans
trim area effectively.
Effective closure of the mill’s water
system requires new thinking, combining the pulping department, paper machine and effluent treatment
operations. The best solutions need
a mill-wide technical and economic approach. Although savings or
losses due to runnability and product quality are much more critical
for mill profitability than the water
treatment costs, it should be borne
in mind that well-organised water
management can provide the possibility to turn water costs into savings.
The traditional approach to
waste water treatment in European
mills has been to collect all process
waters in one central effluent treatment system and then recycle the
cleaned water back into the process. The new method calls for sepa-
15 m3/t
Vallvik and Rottneros upgrades
to increase baling line capacity
When the fiber line at Vallvik Bruk
AB in Sweden increased its capacity, the old PFC-type slab presses
installed for flash dryed pulp a bottleneck. Now the two PFC-presses
from 1974 and 1980 will be upgraded to handle today’s high production levels.
The upgrading consists of valve
blocks, press forms and feeding
motors. Capacity is expected to increase by 10-15% and maintenance
will be made much easier with
the introduction of the new valve
blocks.
The Vallvik mill produces chemical pulp and its output consists of
three types of bleached, long-fiber
sulphate pulp: elemental chlorine free, totally chlorine free and
unbleached kraft pulp. The production capacity at Vallvik is 190,000
tons per year.
Rottneros mill in Sweden has
four PFC-presses, one of which, no
longer in operation, is the original
prototype delivered by Sunds AB in
1967. Of the three running presses,
New approach to closing the water system
Recycling and cleaning of save all clear filtrates
Minimizing the long loop water volume
Minimizing the salts at chemicals and process
0 m3/t
Available Metso Water Management Technologies
All fresh water to paper machine
Effluent treatment with FlooBed
and OptiDaf
Counter current principle for all process water
All make up water from clean to dirty
Stable process conditions; No temperature or pH variations
Waste water out from pulp mill
Separate water loops for different departments Removal of stickies and ash with OptiDaf
Efficient pulp washing before paper machine
5 m3/t
rate compact and specialized water
treatment modules inside the different process loops and a common
reject and sludge treatment system
with FlooBed – an efficient biological treatment.
Basic steps that describe the most
important process arrangements
have to be carefully followed before
additional water treatment is constructive. For example, fresh water
is used only where water quality is
the most critical factor. The remarkable developments in membrane filtration, biofilm processes and thermophilic biological treatment has
made it possible to minimize fresh
water consumption by using new
process arrangements. When the
water consumption level is down
to 10 m³/t paper, a limit is reached
where basic process arrangements
White Water treatment with OptiDaf
White Water treatment with OptiFilter CR
Extractives removal with OptiFilter CR
FlooBed biokidneys for Pulp Mill
Salt removal with OptiFilter nanofilter
FOR MORE INFORMATION
D’well done Maule!
CombiDoc
LATEST SHOE NIP CALENDER ORDER TO CHILE
EFFICIENT COUCH ROLL DOCTORING
FOR PAPER AND BOARD MAKERS
Metso’s fifth OptiDwell shoe
nip calender will start-up in
Cartulinas CMPC Maule in
Chile in mid 2005. It will be
part of the extensive rebuild
ordered by CMPC for its
folding boxboard machine
BM 19, originally started up in
1998. Cartulinas CMPC S.A. is
an affiliate of Empresas CMPC
S.A. and has manufactured
and marketed world-class
folding boxboard since 1951.
Besides the OptiDwell shoe nip calender, Metso will supply a new dilution controlled headbox for the filler
ply as well as two new SymBelt shoe
presses for the press section. The existing pond sizer will be converted
to ValSizer metering size press technology and drying capacity will be
increased to meet the higher speed
needs. In addition, the existing twodrum winder will be replaced with a
WinBelt winder.
The 5 meter wide BM 19 currently produces folding boxboard
(FBB) with a Yankee cylinder, which
bottlenecks the production line both
in terms of capacity and production flexibility. The Yankee cylinder
process works only within a narrow
speed and basis-weight window.
With OptiDwell it will be possible
to replace the current pretreatment
with Yankee cylinder and increase
the capacity of the board line significantly – in Maule’s case from
600 tons/day to 900 tons/day (max.
speed after rebuild 650 m/min).
The OptiDwell precalendering
process is based on sufficient dwell
time and high calendering temperature. OptiDwell precalendering will
enable the development of excellent
surface properties, equal to those
achieved with the existing Yankee
cylinder.
Metso has for a long time been at
the forefront of developing long nip
calendering. Besides being applied
as a precalender for coated grades,
the OptiDwell shoe nip calender
can also be used as a final calender
for paper and board. Raw material
savings can be obtained thanks to
OptiDwell’s unique bulk preserving
capability, which is based on low
nip pressure and a long nip dwell
time. Due to the uniform surface
smoothness the print quality is also
exceptional.
Shoe nip calenders have been
delivered to two board machines in
Korsnäs mill, Sweden, the first already in 1994. Two other OptiDwell
shoe nip calenders are also currently
running, one for uncoated board
and one for specialty paper. §
FOR MORE INFORMATION
tarja.hamalainen@metso.com
Tel. +358 40 596 4800
With the OptiDwell shoe nip calender it is possible to increase board
line capacity without compromising end product quality.
The air blade in the 1st blade
position boosts the under pressure
between the shell and the blade
providing a more effective
doctoring result for suction rolls.
Metso Paper’s latest doctoring solution, the CombiDoc doctor, combines foil/air doctor benefits with a
conventional doctor blade for competent suction roll doctoring. This
doctor is designed to ensure troublefree operation by providing clean
roll surfaces as well as well-controlled web take-off for both paper and
board machines.
Improved runnability
CombiDoc consists of two blades
mounted on a single doctor save-all
beam or integrated at the bottom of
the couch roll save-all. A foil or alternatively an air blade operates as
the first blade removing water rimming on the suction roll surface and
effectively sucking water out from
the shell holes. The first blade’s operation is based on the under pressure created between the shell and
the blade. The second blade is a
conventional doctor blade, which
removes the rest of the water sucked
out by the first blade.
One of CombiDoc’s advantages
is an increased dry content over the
couch roll, resulting in improved
press section runnability. In addition, CombiDoc improves the moisture profile by preventing uneven
rewetting and also decreases fabric
plugging. §
FOR MORE INFORM A T I O N
FOR MORE INFORMATION
kari.humalajoki@metso.com
Tel. +358 20 482 5992
tuomo.juvakka@metso.com
Tel. +358 20 482 5902
7
Looking locally
Metso CalTiger
− A NEW DIMENSION IN CALENDER COVERS
Over the last few years, the calendering process has gone through a
revolutionary transition. Today, a single on-line multinip calender
can manage the production of a modern paper machine compared
to two to three off-line supercalenders. In order to meet the everincreasing efficiency requirements from the overall paper making
process, calendering speeds are continuously accelerating. This
pressurizes papermakers to increase process temperatures and
loads in order to maintain or even improve the paper quality.
Metso CalTiger 92 & 94
Application: soft
calenders, supercalenders,
multinip calenders
Material: Special composite
Color: Sky blue
Hardness: 92 ShD and 94 ShD
Thickness: 20 – 25 mm
Surface finish: Ra 0.4 µm regular
Transition temperature:
155 °C (310 °F ) for CalTiger
92 and 175 °C (350 °F)
for CalTiger 94
Maximum loading: over 80
- 100 MPa (11600-14500 PSI)
Benefits:
◗ Homogeneity, no
pinholes, no porosity
◗ Improved strength and
impact resistance
◗ Low wear
◗ Long re-grinding intervals
◗ High temperature resistance
◗ Superior smoothness
◗ Repairability
Two LWC machines ran record
runs on the second week of June in
Italy and Finland. First a new world
speed record was supplied by PM 9
at Cartiere Burgo S.p.A. in Verzuolo,
Italy. Only four days later PM 4 at
UPM Rauma mill in Finland set a
new world speed record.
10-11 June, 2004: Burgo PM 9
The Metso Paper supplied PM 9 at
Cartiere Burgo S.p.A. in Verzuolo,
Italy set a new world record for
LWC production speed. During a
24-hour period between June 10th
and 11th, PM9 – which was supplied by Metso Paper and startedup at the end of November 2001
– was run at an average speed of
1860 m/min. PM 9 is one of the
world’s largest LWC paper production lines. The machine has a
design speed of 2000 m/min and a
wire width of 10 450 mm.
Cartiere Burgo S.p.A. produces
remarkably high quality LWC and
woodfree coated paper. It is also
one of Europe’s largest producers
by production quantity. The company’s production plants are situated in Italy and Belgium.
15-16 June, 2004:
UPM Rauma PM 4
The Metso Paper supplied PM 4 at
UPM Rauma mill in Finland has
set a new world speed record. The
paper making line ran at an average speed of 1881 m/min for a period of 24 hours, producing lightweight coated paper with a basis
weight ranging from 54 to 60 g/m2.
The speed record was set between
June 15th and 16th 2004, during
normal production.
The record-breaking machine
was supplied by Metso Paper in
1998. The machine has a design
speed of 1800 m/min and a wire
width of 10.1 meters.
UPM is one of the world’s leading forest product companies. The
company’s businesses focus on
magazine papers, newsprint, fine
and specialty papers, converting
materials and wood products. The
company’s turnover in 2003 was
close to EUR 10 billion, and personnel numbered approx. 35,000.
UPM’s shares are quoted on the
Helsinki and New York stock exchanges. §
FOR MORE INF O R M A T I O N
Burgo: juha.immonen@metso.com
Tel. +358 20 482 6092
Rauma: olavi.kupari@metso.com
Tel. +358 40 547 1954
The Product Vault is your source
for digital Metso Paper product
materials in different languages.
Keep yourself up-to-date on
Metso Paper’s lifecycle support,
from maintenance services, process
improvements and rebuilds to new
installations – visit the Vault. §
Unsurpassed properties
CalTiger has the highest temperature resistance in all composite cal-
FOR MORE INFORMATION
juhani.partanen@metso.com
Tel. +358 204 82 7645
Metso - Beloit seminar for UK customers
A two-day seminar was held on the 23rd and 24th June to present
possibilities for process improvements that can be applied to Beloit
paper machine installations. Metso’s market-leading paper making
expertise and technology, together with a deep understanding of
the design philosophy behind the original Beloit equipment, means
that the company is uniquely positioned to service this area of
opportunity. Furthermore, Metso Paper retains ownership of all
drawings, patents, designs and intellectual property from the Beloit
Corporation, following the acquisition of the group in the year 2000.
Attendees at the seminar
included production,
maintenance and engineering
professionals from the
majority of UK mills
utilizing Beloit technology.
Presentations were given by Metso
specialists from Germany, Sweden,
Finland and the UK, covering all aspects of the machine from headbox
to winder, and including specific
solutions to such problem areas as
suction roll maintenance, overhauls
and upgrades and innovative developments in doctoring technology.
informative and enjoyable for both
delegates and organizers alike.
Local Metso management look
forward to the forthcoming “Roll
Academy” training session for UKbased roll maintenance engineers,
which is to be held in Germany and
France during the autumn. Metso
looks forward to seeing as many
delegates there as possible. §
Product Vault available on Metso Paper website
Metso Paper’s upgraded Product
Vault is now available on our
website, www.metsopaper.com.
The choice is yours
The CalTiger cover is produced in
92 ShD and 94 ShD. CalTiger 92
is the premium choice for the supercalendering of printing paper
grades and for the softcalendering
of coated paper and board grades.
CalTiger 94 is the premium choice
for on-line and off-line multinip
calendering, and for supercalendering and soft calendering requiring
excellent wear resistance from the
cover.
The seminar also looked at some
of the ways that Metso Paper’s
various support services and machine survey / audit programs can
assist papermakers, regardless of
the process technology employed.
Many participants appreciated the
opportunity to learn about these
simple and cost-effective solutions
to the problems that they have endured for many years.
The local sales support team, the
“Metso Dream Team”, was also
introduced as a regular point of
contact for UK papermakers for all
their technical support, equipment
and service needs.
The venue for the seminar was
The Last Drop Village Hotel &
Conference Centre, which is well
known to North West UK papermakers as it has hosted numerous
technical meetings over the years.
All in all, the event proved to be
Metso Paper, Inc. F&P Ex/EN/EU 3/2004
LWC machines set world records in June
Roll covers must also keep pace with
these developments as the process
requirements set are ever more demanding. The type of polymer roll
covers used in the modern calendering process is significant. The Metso
CalTiger offers a new dimension in
cover selection for demanding calendering applications.
A tiger represents speed, resilience and superiority, just like our
composite calender cover CalTiger.
It has a high surface quality, withstands the highest loads and temperatures, and is fully repairable.
ender covers. Their transient temperatures are very high allowing for
increased running temperatures.
CalTiger covers boast superior
homogeneity, are non-porous and
do not contain pinholes or voids,
resulting in the best possible paper
smoothness and gloss.
The
CalTiger’s
new composite
longevity
CalTiger
is duecover
to its
is suitable
multinip
calenders,
strength
andfor
high
marking
resistance.
soft calenders.
Itssupercalenders
running costs and
are low,
thanks to its
unbeatable durability and grindable
cover thickness, and the fact that the
cover is also band repairable. Highquality paper is assured by this smooth
and self-smoothing cover surface with
low wear and profile deterioration.
Metso Paper has carried out trials
with a band-repaired pilot calender
roll. In calendering, the repaired half
of the roll reacted the same as the
original half. There was no difference
in the achieved paper properties such
as smoothness or gloss while comparing the paper from under the original
cover to that of the band-repaired
cover. The results were uniform with
SC, LWC and fine paper grades.
Paper makers have long been
waiting for a cover like the CalTiger
and it has already generated a great
deal of interest. Feedback from the
mills that have been using the first
CalTiger covers is very encouraging.
CalTiger covers are manufactured in Järvenpää, Finland and in
Appleton, WI, USA. §