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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.

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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

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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

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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

[email protected] 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

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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.

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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

[email protected] Tel. +358 20 482 6168

express

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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. /

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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.

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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

[email protected] 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

[email protected] 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.

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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

[email protected]

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

[email protected] 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

[email protected] 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

[email protected] 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

[email protected] 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

[email protected] Tel. +358 20 483 8040

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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

[email protected] 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

[email protected] 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.

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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

[email protected] 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

[email protected] 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 [email protected] 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. §

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[email protected] 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

[email protected] 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

[email protected] 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

[email protected] Tel. +55 15 219 1300 [email protected] Tel. +358 20 483 160 [email protected] 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

[email protected] 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.

[email protected] 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

[email protected] 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

[email protected] +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.

[email protected]

Recommended actions 20 m3/t

10 m3/t

[email protected] 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

[email protected] 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

[email protected] Tel. +358 20 482 5992

[email protected] 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: [email protected] Tel. +358 20 482 6092 Rauma: [email protected] 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

[email protected] 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. §