Forward 3/2015

New ecosystem
for bioeconomy 12
Baling line rebuild gives
Södra head start 38
VA L ME T ’S C US T OME R M AG A ZINE | 3/ 2015
Advantage NTT technology
gives new flexibility to
TISSUE
MAKING
at Papel San Francisco
Valmet IQ
Smart way forward in
quality management 50
Editorial
Sustainable innovations
take us forward
Valmet has been included in the Dow Jones Sustainability Index
for the second year in a row. Being ranked among the world’s
300 most sustainable companies shows that we have been able to
constantly improve our sustainability performance.
One of the five focus areas in our Sustainability Agenda is
to offer products and services that enhance our customers’
sustainability. This requires continuous development of new
innovations and our current offering to improve raw material
and energy efficiency.
In this magazine, we discuss some top innovations developed
in close cooperation with our customers. They bring significant
savings in energy and raw material usage and enhance end
product quality, like the Advantage NTT tissue machine. Other
good examples are the foam forming technology being piloted
to enable the creation of lighter board with good strength
properties, the new Valmet IQ automation solution for online
monitoring and optimizing the board- and papermaking
process, and the recovery boiler with record-high steam
generation efficiency to be installed at Metsä Fibre’s
Äänekoski mill.
I hope you will find the articles of this magazine both
interesting and informative.
ANU SALONSAARI-POSTI
SENIOR VICE PRESIDENT
MARKETING AND COMMUNICATIONS
2
FORWARD 3/2015
In this issue 3/2015
We want to
offer products
and services
that enhance
our customers’
sustainability.
22
Smoothing
the way at
Skoghall Mill
Fewer cleaning
shutdowns needed at
the board machine
31
Reliable power
generation
New biomass-fueled power plant inaugurated in Jönköping
2EDITORIAL
4
6
Latest in R&D: Using foam
instead of water in board or
paper web forming
62
NTT TISSUE TECHNOLOGY A WINNER IN MEXICO
First Advantage NTT machine started up at Papel
San Francisco
12 NEW ECOSYSTEM FOR BIOECONOMY
Metsä Fibre builds a bioproduct mill in Äänekoski
16 MORE ELECTRICITY WITH HIGH-POWER
RECOVERY BOILERS
Valmet recovery boilers boost energy production at
Metsä Fibre
18 SUSTAINABLE BOARD MAKING AT ANHUI
SHANYING
Two containerboard machines in full swing in China
22 SMOOTHING THE WAY AT SKOGHALL MILL
Fewer cleaning shutdowns needed at the board
machine
24 SHAPING THE FUTURE WITH TREES
Kazufumi Yamasaki of Nippon Paper in the spotlight
28 EFFICIENT PROCESS MANAGEMENT WITH
MODERNIZED AUTOMATION
Power plant automation renewed at Helen Ltd.
31 RELIABLE POWER GENERATION
New biomass-fueled power plant inaugurated in
Jönköping
34 CARTONES PONDEROSA STRENGTHENS ITS
COMPETITIVE ADVANTAGE
Improved quality, lower costs and more productivity
at target
38 EARLY BALING LINE REBUILD GIVES SÖDRA
HEAD START AT VÄRÖ
First step of a major upgrade project taken
41 VALMET DNA EXTENDS MACHINE CONTROL
LIFETIME AT NYMÖLLA
Nymölla PM 2 started up with up-to-date control
technology
43 INTEGRATED COGENERATION SYSTEM AT LUCART
Optimized energy usage for tissue production
44 TWINROLL MODERNIZES ARKHANGELSK PULP
WASHING PLANT
Three new wash presses improve environmental
impact in Arkhangelsk
46 GROUNDBREAKING GALILEO
Grinding technology with diamonds for mechanical
pulping
48 IMPROVED END PRODUCT QUALITY WITH
RIGHT REFINING
Save energy and
resources with
foam forming
IN BRIEF
Cartiere Ermolli replaced two refiners with
OptiFiner Pro
50 SMART WAY FORWARD IN QUALITY MANAGEMENT
Valmet IQ product family now available
56 ENHANCED EFFICIENCY WITH OPTIRUNNER
DRYER FABRIC
Smart double-warp system for optimized energy usage
58 A NEW SOLUTION TO A CLASSIC PROBLEM
Sludge management problems tackled by
hydrothermal carbonization
59 ON TOP OF THE GAME
Recausticizing filter fabrics are the result of demand
in pulp making
61 IT’S NOT ONLY THE DOCTOR BLADES
Valmet’s doctoring portfolio contributes to
optimization of the papermaking process
62 SAVE ENERGY AND RESOURCES WITH
FOAM FORMING
Latest in R&D: Using foam instead of water in web
forming
64 AROUND THE WORLD
66 ABOUT VALMET
FORWARD 3/2015
3
In brief
Valmet acquires
tissue rewinder
business in Italy
Energy efficiency
meets sustainability
at Skövde
Valmet has completed the acquisition
of Massimiliano Corsini srl’s tissue
rewinder business in Italy. The acquired
company, now called Valmet Pescia,
mainly supplies rewinders for tissue and
non-woven machines, employing 33
persons.
As a result of the acquisition, Valmet
will have a more extensive product portfolio and becomes a stronger technology
and services company in its field. The
acquisition strengthens Valmet’s competitiveness by combining tissue making
equipment from stock preparation to
rewinding, process know-how, automation and services into one customer
value-adding entity.
Skövde Värmeverk’s new biomass-fired power plant in Sweden will feature high energy
efficiency combined with close to zero emissions into the atmosphere. Valmet’s delivery
for Block 4 will cover nearly everything
from fuel feed to stack. It will include a
bubbling fluidized bed boiler plant with a
biomass-fired HYBEX boiler, an electrostatic
precipitator, a flue gas condensing scrubber,
a combustion air humidifier, condensate
treatment, electrification, instrumentation
and automation.
Special attention has been paid to the
plant’s low environmental impact. NOX
emissions are controlled with a selective
non-catalytic reduction system and careful
combustion design. Particulate emissions
are collected by an electrostatic precipitator,
and acidic gases, ammonia and particulates are removed by a flue gas condensing
scrubber.
Södra Cell
Mönsterås pulp
mill upgrades its
evaporation plant
The evaporation plant at Södra Cell’s
Mönsterås pulp mill in Sweden will
be upgraded with Valmet technology.
Increased evaporation capacity and
improved steam economy are the main
drivers for the project, scheduled for
autumn 2016.
“We are satisfied with the technical
concept Valmet has offered us. This will
improve the functioning of the evaporation plant, and increase energy efficiency and our profits,” says Jonas Olander,
Project Leader at Mönsterås.
Valmet will install two tube evaporators, a falling film reflux condenser
and four liquor preheaters. The piping
system will be upgraded and the condensate treatment system improved and
integrated with the evaporation.
ROYAL INAUGURATION
AT OSKARSHAMN POWER
PLANT IN SWEDEN
Jöns Wahlström, Managing Director of Oskarshamn Energi, thanking
the King of Sweden Carl XVI Gustaf and the Crown Princess of
Sweden Victoria for attending the inauguration.
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Oskarshamn Energi’s new biomass-fired power plant
was inaugurated in August. The King of Sweden Carl
XVI Gustaf and the Crown Princess of Sweden Victoria
honored the occasion with their presence.
The new combined heat and power plant will cover
70% of the Oskarshamn municipality’s annual district
heat demand.
The boiler is able to use renewable fuels with moisture content up to 55%. Valmet’s delivery included a
complete power plant, including patented BioGrate
combustion technology, installation, training and
commissioning as well as plant automation. Valmet
also delivered a flue gas condenser and a ventilation
system.
Two Advantage
DCT tissue lines to
China
Valmet will supply two Advantage
DCT tissue production lines and related automation systems to one of China’s leading paper and pulp producers,
Lee & Man Paper Manufacturing Ltd.
The start-up of the two new lines is
planned for late 2016.
Valmet’s Advantage DCT 200HS
tissue lines are designed for production of high quality tissue products. In
2014, the company ordered a similar
tissue line which is planned to start up
at the Chongqing mill later this year. ”We see Valmet as strategic partner
in the development of our tissue
business. Their position as market
leader in tissue machinery made us
confident to repeat our previous order
with Valmet”, says Raymond Lee,
Chairman of the Board, Lee & Man.
Main equipment
for Huanggang
Chenming’s pulp
mill project
Valmet will supply main equipment
to Huanggang Chenming Pulp &
Paper’s new pulp mill in China. The
mill is designed for flexible production
to respond to market developments.
The pulp line can be run to produce
softwood kraft pulp and dissolving pulp
depending on the market needs. The
new mill is expected to start up in 2017.
Two Advantage NTT tissue lines to the
United States and Portugal
Resolute Forest Products Inc. has selected Valmet’s Advantage NTT tissue production technology and Valmet’s automation solution for its new facility in the United
States to manufacture at-home, premium private label tissue paper, including bath
and towel. The new machine will start production in early 2017.
The European tissue brand Renova in Portugal has also ordered an Advantage
NTT tissue production line and an automation system. Renova is the first tissue
producer in Europe to invest in Valmet’s Advantage NTT tissue technology for the
production of textured and plain tissue products.
The new line, to be started up at the end of 2016, will allow Renova to increase
its paper production capacity with 50%.
Valmet maintains
its position
among global
sustainability
leaders
Valmet has been included in the Dow
Jones Sustainability Index (DJSI) for
the second consecutive year. The DJSI
is a sustainability index family which
includes the global sustainability leaders
across industries. Valmet was listed both
in the Dow Jones Sustainability World
and Europe indices.
OPTICONCEPT M
CONTAINERBOARD LINE
TO LEE & MAN
Valmet will supply a complete
OptiConcept M containerboard line for
Lee & Man in China. The new line will
produce containerboard grades out of
100% recycled raw materials. The startup of the machine is scheduled for the
fourth quarter of 2016.
”This repeat order to Valmet
strengthens our long partnership in
this business area”, says Edmond Lee,
CEO of Lee & Man.
The line will be the tenth
OptiConcept M production line to
be supplied by Valmet since the first
delivery in 2012.
FORWARD 3/2015
5
CUSTOMER’S VOICE
GOALS
ACHIEVED
Enrique Zarate
Caro (from the
left) and Dario
Palma of Papel
San Francisco
with Ola
Thomasson and
Johan Rågård
from Valmet.
Moving forward together
Advantage NTT tissue
technology proves to be a
Both the operations and sales people at
Papel San Francisco in Mexicali, Mexico are
happy with their Advantage NTT textured
tissue machine from Valmet. The mill was
initially only looking for conventional tissue
with low energy input. The ability to make
textured grades has worked out perfectly
as an added bonus. Hugh O’Brian
TEXT
for Papel San Francisco
6
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7
CUSTOMER’S VOICE
“WE GET CONVENTIONAL
PRODUCTS AT LOW ENERGY,
AND TEXTURED TISSUE AS
AN EXTRA BONUS.”
B
eing the first in
the world with any
major papermaking
technology is never
easy. The money
involved is big, as
are the risk and the
pressure. However,
if there are any
questions about
Papel San Francisco’s
decision to install
the world’s first Advantage NTT textured tissue machine,
the following statements from the company’s Operations
Director and Sales Director certainly address them.
“We have no regrets at all with our decision to go with
Advantage NTT technology,” states Dario Palma, Operations Director at Papel San Francisco (PSF). “In fact, I am
quite confident that this is the design of the future for conventional tissue, due to the high productivity that comes
with it. This is an extremely energy-efficient machine, with
DESIGN OF THE
FUTURE
Dario Palma,
Operations Director,
is quite confident
that the Advantage
NTT technology is
the design of the
future.
8
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HAPPY
CUSTOMER
Juan Helu (top),
Dario Palma and
Enrique Zarate
Caro confirm
that both the
operations
people and the
sales people are
happy with the
first Advantage
NTT line from
Valmet.
high dryness going into the Yankee and hood, which gives
us previously unheard of productivity. We get conventional products at low energy, and textured tissue as an
extra bonus if the market needs it, with a quick and easy
changeover. For these reasons, I believe Advantage NTT
could replace the crescent former as the new ­standard for
conventional tissue-making in the future.”
From the market side, Sales Director Juan Helu is
equally pleased, but for different reasons.
“The biggest contribution Advantage NTT has made is
that our customers now see us as a complete supplier. The
market perceives a company as a reflection of the products
it sells, and people really like the new NTT products we
are offering under our Level brand. So by raising quality
with the introduction of our Level products, we’ve enhanced our reputation. We have been able to set prices between conventional and through-air-dried TAD ­premium
grades, with people realizing that the Level brand gives
them really good quality at a fair price.”
Energy was the primary focus
Truth be told, PSF originally had no intention of adding an
NTT machine, and in fact they didn’t even know what the
FORWARD 3/2015
9
CUSTOMER’S VOICE
“I’M HAPPY TO SAY
WE HAVE ACHIEVED
ALL THE GOALS AND
GUARANTEES THAT
WERE SET UP FOR
THE PROJECT.”
HEAD OF THE MILL
Enrique Zarate Caro is Mill Manager at Papel San
Francisco’s mill in Mexicali.
technology was. Dario Palma explains the background further.
“We needed to add conventional capacity and, due to
continuously changing energy prices, we decided that our
main focus for a new machine was on reducing energy
consumption. We already had four tissue machines, and
we were talking with Valmet about a new conventional
machine with low energy consumption.”
“At that point, although we had not heard of it, we were
told that the new Advantage NTT configuration gave
the most energy­-efficient tissue production in the world.
That certainly caught our attention. We clearly required
conventional capacity, as our sales department needed
product. So when we heard the energy numbers for NTT
Our sales department
here is extremely
happy that we have the
Level brand, and the
sales numbers for this
textured product have
been very high.
10
FORWARD 3/2015
in conventional mode and were told it could also make
textured tissue, this was an additional ‘bonus’ for us that
clearly made it interesting. The risk was very low and the
upside very positive.”
Running well for over two years
now
The machine, known as Mexicali 6, had a good start-up in
July 2013, making salable paper in the first couple of days.
Of course, says Dario Palma, “it was not a perfect start-up,
as none ever is, but it was smooth and we rapidly achieved
very high speeds.”
The PM 6 tissue machine started in conventional mode
because the company needed that grade for its main market. Eventually the machine moved into textured runs, and
Dario Palma says he is pleased to report that, “the machine
has been completely full for a while now. As of mid-2015,
we have been making about 11% in textured mode and
the remainder in conventional, which is traditionally our
market and what the sales department demands most, at
this point. This is no surprise, as it was always the plan.”
here is extremely happy that we have the Level brand, and
the sales numbers for this new textured product have been
very strong. Right now, the textured grades – meaning
Level – make up 6% of our bathroom tissue sales. It has
rapidly found its place with retailers, including the very
biggest ones, at the top of the market, just below the premium grades like Kleenex and Charmin. But NTT is not a
premium TAD grade and was never meant to be.”
Limitless potential for belt design
Exactly what more Advantage NTT can become is open
to speculation, but the early signs are positive. Dario
Palma says he sees lots of possibilities: “One of the nice
things about NTT is that it basically has limitless potential
with regards to the belt design. Lots of new products can
be produced by changing the belt design, so that offers
high potential for the market. I wish we had more time
to experiment and play around with the potential of this
machine, but the reality is that our sales department needs
the tonnage, so we are limited in our ability to experiment.
Eventually, we expect to have more time to work on new
product development, which we are sure will give us even
more advantages in the market.”
“That will, of course, be for the future. For us right
now, the bottom line is that we got
a very energy-efficient conventional
machine, with textured tissue as a
CONTACT
bonus. Working closely with Valmet,
PERSON
Jan L Larsson
I’m happy to say we have achieved all
Sales Director
jan.l.larsson
the goals and guarantees that were set
@valmet.com
up for the project. There is really not
tel. +1 404 229
4269
much more to be said, as the results
speak clearly for themselves.”
Advantage NTT concept for
high-quality tissue making
Valmet’s Advantage NTT concept is designed for
maximum flexibility and can easily swing between
conventional tissue and high-quality textured tissue
in a few hours.
In standard mode it is possible to produce high
volumes of tissue products with high softness at
low energy consumption.
Textured mode provides the possibility to produce premium quality tissue with 50-100% more
bulk and softness as well as water absorbency.
Fiber savings up to 30% can be obtained due to the
increased bulk.
Market niche just below premium
TAD
PSF has changed from previously being basically a 100%
recycled-based conventional tissue company, to one that
also offers a textured tissue quality near the premium
grades. Filling this gap has given it the important advantage of presenting the company as a complete supplier to
the main retail players in the Mexican market, with good
results.
Juan Helu says the timing of Advantage NTT has been
great since, due to some market adjustments in Mexico,
demand for textured tissue has moved up just as the NTT
tonnage was becoming available. “Our sales department
NEW “LEVEL”
BRAND
Juan Helu,
Sales Director,
is pleased that
people like the
new tissue
products made
with Advantage
NTT technology.
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11
CUSTOMER’S VOICE
Ecosystem for
BIOECOMOMY
M
etsä Fibre Fibre, part
of Metsä Group,
is a world-leading
producer of softwood
pulp for high-quality paper, board
and tissue producers in Europe
and the Far East. In 2017, Metsä
Fibre will begin operations at its
new bioproduct mill in Äänekoski,
Finland. This new mill will produce
1.3 million tonnes of pulp per year,
with impressive performance in the
materials usage and energy. What is
more impressive is that the volume
of the bioenergy and bioproducts,
meaning products besides pulp, will
reach some 20% of the bioproduct
mill’s net sales.
to be created at Metsä
Group’s Äänekoski mill
Metsä Fibre’s new bioproduct
mill will start operation in 2017.
Valmet is contributing with
key technology supplies to the
project.
Ambitious goals for
bioproducts
Timo Merikallio is Project Director
at Metsä Fibre and in charge of the
bioproduct mill project: “We have
very ambitious goals. We are aiming
for the highest possible efficiencies in
energy and materials with the highest
possible environmental performance. Pulp production is what we
know best, and this is where we as a
company will continue to improve
our quality and our operations. But
in this new mill, we will create a network of partner companies who can
work alongside us and develop their
product areas.”
TEXT Andreas Liedberg, Anna Liisa Pennanen and Kaisu Vaalto
Profitable fossil fuelfree operation
Timo Merikallio, Project Director at
Metsä Fibre during a presentation of
the new bio product mill at Äänekoski
city hall, September 2014.
12
FORWARD 3/2015
“The bio products are products that
we will produce using the material
and energy available in the mill. We
will start with products that are relatively well known today, like electricity, turpentine, sulfuric acid and gas
from bark. We will have a recovery
boiler with very good performance
that is a good match with the turbine.
This along with low internal consumption will make it possible for us
to produce 2.4 times the electricity
we need. This means that we will be
able to supply around 2% of the total
electricity in Finland from renewable
sources.
The excess sulfur in the mill will
be converted into sulfuric acid for the
mill’s own use.
A third example of a profitable
technology is bark gasification. The
bark gas will make us totally fossil
fuel-free, and we can also sell the gas
outside the mill. We have good experiences of gasification from another
Metsä mill where the gasifiers we installed helped to make that mill fossil
fuel-free and were profitable. It was
natural for us to choose this technology for our new mill as well.”
“Best of the best”
partner network
“When the new mill is up and running we will tear the old mill down.
This will make 15 hectares of land
available for products that are a little
further into the future, but very exciting. We are examining wood-based
textile fibers together with Itochu
Corporation, part owner in Metsä
Fibre, and we are studying manufacture of biocomposites together with a
small Finnish company.
The layout of the bioproduct mill
has been planned to allow access to
the process areas that we need to connect the new businesses to. We can
extract lignin and produce bio-oil or
bio-coal from bark and dust. Sludges
can be converted to biogas, and we
will find a good way to do business
with a company that is an expert in
this area. We will have large amounts
of hot water so drying the bark, dust
and other materials before they are
converted into biofuels or other bio-
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13
CUSTOMER’S VOICE
products can be done profitably.”
Metsä Fibre’s plans for the mill
extend quite far into the future but as
a pulp mill has a quite long lifetime,
Merikallio explains that it is reasonable that within a few years, production of several bioproducts will be in
place.
“We have planned this new mill
based on our experiences with our
other mills, and we will create a platform for growth for a very long time
to come. We will continue to look for
the best of the best in all areas. We are
not experts in biocomposites, so we
will work with a partner and develop
that business together with them. The
partner will be the expert, the “best
We have planned
this mill based on
experiences with
our other mills,
and we will create
a platform for
growth for a very
long time to come.
of the best” in biocomposites, and
we will focus on being the best of the
best within pulp fibers. This is the
thinking we are bringing to the new
bioproduct mill.”
CONTACT PERSON
Jari-Pekka Johansson
Project Manager
jari-pekka.johansson
@valmet.com
Tel. +358 40 830 4432
UTILISATION OF
MAIN AND
SIDE STREAMS
01.
Bark*
02.
Odorous gases
03.
Lignin
“Forever young”
When asked about his personal driving forces, Timo Merikallio immediately displays a never-ending desire to
learn and improve:
“I love to improve. It is good to be
satisfied only for a short time, and
then start looking for improvements
again. This is not the same as being
unsatisfied but rather to always look
for something better. It means asking
questions, working together to find
new ideas, testing them and turning
them into reality. Trying to become
better brings a lot of fun into the
work because things always improve for us. We won the Excellence
Finland award in 2012 as the result of
years of improvements. We are now
competing on the European level
with other companies that also work
to become the best of the best.
This is a mindset I have summed up
as “forever young”. When you’re young
in your mind, you always ask questions
and look for new ideas. In this sense
I am forever young. It just brings me
more joy to work that way.”
INTEGRATE
OF BIOPROD
Turpentine and
tall oil*
PULPWOOD
04.
Sludge
Valmet will supply key technology to
the Äänekoski bio product mill:
• recovery boiler: 7200 tDS/24h
Clean
water
PULP*
• pulp drying line: 2700 Adt/24h
• gasification plant: 87 MW
• lime kiln: 1200 t/24h
• mill-wide Valmet DNA automation
system
* PRESENT
BIOPRODUCTS
05.
Dregs and
ashes
06.
Pulp
upgrading
POTENTIAL
NEW BIOPRODUCTS
Glauber
salt
T
he manufacture of new
bioproducts in conjunction
with pulp production is a
key starting point in designing and
building the mill. Tall oil, turpentine
The bioproduct will
in
and bioenergy
are traditional byproducts of pulp production. They
Äänekoski will maximize
currently represent around 10 per
use of the incoming
cent of Metsä Fibre’s net sales.
materials and all available
Potential new products from
side streams will
bestreams include producer
side
gas, sulphuric acid, textile fibres,
utilized. Development
lignin products,
of new productsbiocomposites,
will be
fertilisers and biogas.
done with partners
who
We are studying several processes
can focus on becoming
and product paths, which will be
the “best of theimplemented
best”
in phases, possibly even
in 2017 when the mill is launched.
within their field.
Bioenergy*
01.
Producer gas from bark
and sludge to be used as
biofuel for the mill
New biofuels from
bark and energy wood
NEW LAYOUT
The existing
Äänekoski mill in
the foreground,
and in the
background the
new mill. The
harbour and
railrods are right
next to the mill,
which means
good logistics.
05.
03.
New bioproducts
from lignin
02.
04.
Sulphuric acid and
methanol from odorous
gases to be used by the mill
Biogas from
sludge to be used as
a fuel for vehicles
Fertilisers and
earth work materials
from ash
06.
New textile fibres
from pulp
Biocomposites
from pulp
SOURCE: METSÄ GROUP
FACTS ABOUT THE NEW ÄÄNEKOSKI BIO
PRODUCT MILL:
Biggest investment in Finnish forest industry (EUR 1.2 billion)
Pulp production 1.3 million t/a
The share of renewable energy in Finland increases by
approx. 2 percentage points
All side streams of chemicals, energy and water utilized
The share of bioproducts and bioenergy around 20% of the mill’s net sales
Does not increase the environmental load in the Äänekoski area
A partnership network for bioproduct businesses around the mill
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15
CUSTOMER’S VOICE
MORE
ELECTRICITY
Metsä Fibre Oy Äänekoski Bioproduct
Mill, Finland
Metsä Fibre Äänekoski bioproduct mill:
Metsä Fibre Oy Äänekoski Bioproduct
Mill, Finland
· Very advanced, new recovery boiler
by Valmet
· Biggest recovery boiler in Finland
· Highest ever stam parameters
with Valmet’s high-power recovery boilers
The RECOX recovery boiler to be supplied
by Valmet to Metsä Fibre Äänekoski
bioproduct mill will be an advanced highpower recovery boiler with record-high
steam generation efficiency. TEXT Andreas Liedberg
T
he new high-power recovery boiler will be
a key element at the Äänekoski mill in the
production of electricity. It will be the biggest
in Finland, and have a record-high steam
generation efficiency. The steam parameters, pressure of
110 bar and temperature of 515 °C, are the highest applied
for recovery boilers, and this will ensure that the ratio of
steam to electricity will be maximized.
The Äänekoski mill is designed to maximize the
amount of surplus bioenergy for sale. The mill will start
production in the second half of 2017 and the electricity
production is forecasted to be around 2.4 times the mill’s
own consumption. At maximum capacity, the mill will
produce some 2% of the total electricity production in
Finland, all from renewable sources. The predictions indicate a sales volume of 1,050 GWh of electricity per year.
Advanced high-power features
Valmet has a wide range of options when designing
high-power recovery boilers, according to Pekka Siiskonen, Director, Recovery Boilers at Valmet:
16
FORWARD 3/2015
· Capacity: 7200 t ds/24h
· Steam: 363 kg/s, 110 bar, 515 °C
“There are several high-power features we can add to
· Liquor:
Kraft
the recovery boiler
design. We
have both the advanced
Start-up:
tools and the ·experience
to help2017
our customers find the
most profitable concept. Since the high-power features
mean additional equipment and certain material upgrades, a case-by-case profitability calculation is needed to
optimize the design.”
The highest possible availability
As the steam temperature increases, the material corrosion rate tends to increase and proper corrosion control
will become crucial in order to maintain high availability.
More corrosion
resistant High
materialsPower
will be used
and the for
Valmet
options
corrosive non-process
elements
need
to
be
controlled
at
recovery boilers:
acceptable levels.
Siiskonen continues: “Our principle at Valmet is that
High
steam
parameters
our customers· will
get recovery
boilers
with the highest
· High
black
liquorPulp
dryproduction
solids
possible reliability
and energy
efficiency.
is the main focus
for
our
customers.
Having
high
· Feedwater preheatingavailability is therefore our first priority when we design our
· Fully pressurized feedwater tank
high-power recovery boilers.”
Preheating
of combustion
The Metsä·Fibre
Äänekoski recovery
boiler is a good air
· principle.
Vent gas
recovery
example of this
“Theheat
Äänekoski
recovery boiler
will have a wide
range
of
high-power
features.
The concep· Flue gas heat recovery
tual engineering is ready and the project is proceeding at
full speed. This boiler is a leading example of what can be
achieved in terms of high-power recovery boilers. We are
also working on a high-power recovery boiler to a Chinese
customer. This recovery boiler, too, utilizes renewable
resources. We are looking forward to taking both of these
boilers into operation.”
VALMET’S HIGH-POWER RECOVERY
BOILER AT ÄÄNEKOSKI WILL BE
THE LARGEST RECOVERY BOILER
WITH HIGHEST EVER STEAM
PARAMETERS IN FINLAND
· Very advanced, new recovery boiler
by Valmet
· Biggest recovery boiler in Finland
· Highest ever stam parameters
Metsä Fibre Oy Äänekoski Bioproduct
Mill, Finland
· Capacity: 7200 t ds/24h
· Steam: 363 kg/s, 110 bar, 515 °C
Metsä
Fibre
Äänekoskirecovery
Bioproduct
Fibre Oy
Äänekoski’s
·Metsä
Very
new recovery boiler
· advanced,
Liquor: Kraft
Mill,
Finland
boiler
to
be
delivered
by
Valmet
by Valmet
· Start-up: 2017
· Biggest recovery boiler in Finland
· Very
advanced,
new
recovery boiler
Advanced
RECOX
recovery
· Highest ever stam parameters
boiler
by
Valmet
· Biggest recovery boiler in Finland
· Capacity: 7200 t ds/24h
parameters
· Highest ever steam
stam parameters
· Steam: 363 kg/s, 110 bar, 515 °C
· Liquor: Kraft Metsä Fibre Oy Äänekoski Bioproduc
· Capacity: 7200 t ds/24h
· Start-up: 2017 Mill, Finland
· Steam: 363 kg/s, 110 bar, 515 °C
· Liquor:
Kraft
Valmet
High Power options for
· Very advanced, new recovery boiler
· Start-up:
2017
recovery
boilers:
by Valmet
· Biggest recovery boiler in Finland
· High steam parameters
· Highest ever stam parameters
· High black liquor dry solids
· Feedwater preheating
· Capacity: 7200 t ds/24h
· Fully pressurized feedwater tank
· options
Steam: 363
kg/s, 110 bar, 515 °C
Valmet
high-power
for
High Power
for air
· Preheating
ofoptions
combustion
· Liquor: Kraft
recovery
boilers:
· Vent
gas heat recovery
· Start-up: 2017
· Flue gas heat recovery
Valmet High Power options for
· High steam parameters
recovery boilers:
· High black liquor dry solids
· Feedwater preheating
· High steam parameters
· Fully pressurized feedwater tank
· High black liquor dry solids
· Preheating of combustion air
· Feedwater preheating
· Vent gas heat recovery
· Fully pressurized feedwater tank
· Flue gas heat recovery
· Preheating of combustion air
Valmet High Power options for
· Vent gas heat recovery
recovery boilers:
· Flue gas heat recovery
Metsä Fibre Oy Äänekoski Bio
Mill, Finland
· Very advanced, new recovery
by Valmet
· Biggest recovery boiler in Fin
· Highest ever stam parameter
Metsä Fibre Oy Äänekoski Biop
· Capacity:
Mill,
Finland7200 t ds/24h
· Steam: 363 kg/s, 110 bar, 51
Liquor:
Kraft new recovery
·· Very
advanced,
· by
Start-up:
2017
· High
steam parameters
Valmet
· High black liquor dry solids
preheating
· Biggest·· Feedwater
recovery
boiler in Finl
Fully pressurized feedwater tank
of combustion air
· Highest·· Preheating
ever
parameter
Vent
gasstam
heat recovery
· Flue gas heat recovery
·
·
·
·
Capacity: 7200 t ds/24h
Steam: 363 kg/s, 110 bar, 51
Liquor: Kraft
Start-up: 2017
Valmet High Power options fo
recovery boilers:
· High steam parameters
· High black liquor dry solids
· Feedwater preheating
· Fully pressurized feedwater t
FORWARD 3/2015 17
· Preheating
of combustion
air
Valmet
High Power
options for
CUSTOMER’S VOICE
SUSTAINABLE
BOARD
MAKING
at Anhui Shanying
Shanying Paper made the largest
investment in the company’s history by
investing in two new, Valmet-supplied
containerboard lines at its plant in
Ma’anshan, in Anhui Province in China. The
high-quality recycled containerboard lines
have been up and running for more than a
year now, producing 1,000,000 tonnes of
board a year. Marika Mattila and Sara Li
TEXT
T
GOOD COOPERATION.
During the whole project, Shanying
Paper and Valmet experienced very
good cooperation. From left: Jiang
Bo, Valmet Mill Sales Manager, East
China; Zhang Xianrong, Shanying
Paper PM 5 superintendent;
Wang Yong, Shanying Paper PM 6
superintendent and Zhou Fudong,
Valmet Product Engineer.
18
FORWARD 3/2015
he driver behind the investment in two new high-quality production lines
using recycled raw material – PM 5 and PM 6 – was the need to adjust
Shanying Paper’s production structure to fulfill market needs and to be more
competitive.
The concept of PM 5 is based on effective hybrid forming technology, while PM 6 is
based on gap forming technology. Making lightweight containerboard using gap forming
technology is new for Chinese containerboard makers. The most efficient European
containerboard lines making high-quality lightweight end products utilize gap forming
concepts with excellent results. Now, Shanying Paper has taken this step with Valmet’s
technology. “We evaluated Valmet solutions especially from the technology and energy
consumption perspectives and compared them with other suppliers’ solutions. We found
that Valmet can offer the most optimized package for producing lightweight yet strong
containerboard”, says Zhan Zhengfeng, General Manager of Anhui Shanying Paper
Industry Co., Ltd..
Sustainable board making saves both energy and
raw materials
In the containerboard business, the trend is towards lighter yet stronger end products
FORWARD 3/2015
19
CUSTOMER’S VOICE
One supplier providing both machinery and automation
systems can make the board machine run more smoothly
and brings its superiority into full play.
produced using less raw material and energy. “The environmental efficiency of PM 6 in terms of energy consumption
and raw material efficiency is totally beyond our expectations
– much better than the industry standards,” comments Wang
Yong, Mill Manager of Shanying Paper. He continues: “We
have achieved electricity consumption of 450 kWh/tonne and
steam consumption of 1.5 tonnes per tonne of paper, which
makes us very competitive in the market”.
PM 5 has been running successfully since start-up as
well. The most beneficial features of the production line
are the high end product quality, the stability of the process and its overall safety. “The environmental advantage
of this line is its very low water and steam consumption.
The fresh water consumption per tonne of paper is six
tonnes, and steam consumption is 1.5 tonnes,” explains
Zhang Xianrong, Mill Manager of Shanying Paper PM 5.
The material efficiency is very high. “The initial target
of PM 5 was to produce one tonne of paper by using about
1.15 tonnes of waste paper, but we have reached the level
of 1.12 tonnes,” says Zhang Xianrong.
LIU WENMING
Chief Engineer of
Anhui Shanying
Paper Industry Co.,
Ltd., Ma’anshan
factory.
SONG ZHIMING
Maintenance
Manager of Anhui
Shanying Paper
Industry Co., Ltd.,
Ma’anshan factory.
Smart combination of machinery
and automation
THREE
HIGH-CAPACITY
WINDERS.
“We produce
lightweight
containerboard
at very high
speed with an
annual capacity
of 960,000
tonnes, and
three Valmet
winders can meet
two production
lines’ capacity
requirements,”
says Zhan
Zhengfeng.
Shanying Paper PM 5 and PM 6 are equipped with full
Valmet DNA automation systems, including process control
and quality control, as well as condition and runnability
monitoring systems. This kind of extensive overall delivery package from the same supplier enables the design of
highly energy-efficient production lines. It also provides
decision-makers with the data they need to make the right
decisions. One supplier providing both machinery and
automation systems can make the paper machine run more
smoothly and bring its superiority into full play.”
The union of the latest board-making technology and
full automation system saves both money and effort. According to Liu Wenming, Shanying Paper Chief Engineer:
“Automation is the brain of a paper machine, and only advanced systems let the machine produce the best results”.
Experiences after one year
operation
The PM 5 and PM 6 start-ups were successful, with good
results. PM 6 set a 24-hour average machine speed record
of 1,398 m/min only 12 days after start-up. After three
days of operation, the machine was already producing saleable products. “During the installation of both
machines, Valmet’s very professional installation team
provided us with guidance and technical support. Over
one year of operations proves that these machines run
very smoothly and are easy to maintain. Our staff are able
to visit Valmet Wuxi Service
Center for training, which has
improved our technological
CONTACT PERSON
capabilities and ability to mainAri J leppänen
tain two machines”, says Song
Senior Project Manager
[email protected]
Zhiming, Maintenance Manager
Tel. +358 40 558 4946
of Shanying Paper.
ZHAN ZHENGFENG
General Manager of
Anhui Shanying Paper
Industry Co., Ltd.,
Ma’anshan factory.
HIGH-QUALITY
CONTAINERBOARD
MADE OF 100%
RECYCLABLE RAW
MATERIALS.
“The trend in containerboard production
is towards lighter but
stronger end product
with less raw material and decreased
energy consumption.
This can be achieved
by investing in new
technologies,” says
Zhan Zhengfeng.
20
FORWARD 3/2015
PM 5. “The results of analyzing paper samples show that the formation of PM 5
is at a high level. The fibers are distributed very well, and the strength properties
are also very good. The press section has excellent dewatering performance. The
analysis results show that dryness after the press section is around 51.5%, which
is very high. Due to the high dewatering capacity, the operating efficiency is also
high, and water, electricity and steam consumption have fallen accordingly,” says
Zhang Xianrong.
PM 6. “The advantages of gap forming and a double-layer
headbox in PM 6 are obvious. It is easy to maintain and operate and it reduces energy consumption,” says Wang Yong.
FORWARD 3/2015
21
CUSTOMER’S VOICE
BIG SAVINGS
“We now save
an eight-hour
shutdown every
six weeks,” says
Pehr Mithander
(left), Supervisor
of BM 8 at Stora
Enso Skoghall
Mill. Pictured
standing beside
John Fridebring
from Valmet.
By the summer of 2015, the results
were in. Both OptiCleaner Roll and
PressKodiak covers met the customer’s expectations. The new roll
covers have been running well and
have demonstrated lower and safer
temperatures under operation. OptiCleaner Roll has also resulted in clear
maintenance cost savings. “We have
saved an eight-hour shutdown every
six weeks because the new cleaning
device can be maintained while
the machine is running,” says Pehr
Mithander, the supervisor of BM 8 at
Stora Enso Skoghall Mill.
SMOOTHING
THE WAY
at Skoghall
One cleaning
shutdown eliminated
every six weeks at
Stora Enso’s Skoghall
board machine
TEXT Juha Ruotsi, Minea Hara
22
FORWARD 3/2015
S
tora Enso Skoghall’s board
machine BM 8 in Sweden
produces high-quality
liquid packaging board
using a non-felted smoothing press.
At the beginning of 2013, Skoghall
decided to renew their old smoothing
press cleaning device and improve
the roll cover durability, choosing
Valmet’s new OptiCleaner Roll
cleaning device and PressKodiak
press roll cover.
Long experience has shown that
using a traversing cleaning device
for soft rolls in a smoothing press
is vital for effective and productive
operation. Experience with a variety
of roll covers shows that the cover
type makes the difference. In addition
to the extreme wear- and erosion-resistance required by the high pressure
cleaner, the covers need to run safely
without internal water cooling.
EASY
MAINTENANCE
OptiCleaner
Roll can be
serviced while
the machine is
running.
Direct contact with the
web calls for extreme
cleanliness
In many machines producing carton
board grades, the press section has a
non-felted smoothing press nip. As
smoothing press rolls are in direct
contact with the web, roll surface
cleanliness is extremely important for
board quality, machine runnability
and production efficiency. Typical
carton board ingredients, such as the
hydrophobic resins AKD and ASA,
pose roll contamination challenges.
In recent decades, smoothing presses
with soft covered rolls in particular
have had a questionable reputation
due to contamination problems.
Seamless solutions for
reaching a common
goal
One traditional way to improve roll
cover cleanliness is to modify roll
cover release and its non-stick properties. Cleanliness and contamination
problems can also be addressed by
doctoring and traversing high-pressure cleaning devices, or even by
cleaning chemicals using trough
showers.
In order to find a successful solution that works well in a given operation environment, all the components
must be adjusted to work seamlessly
towards achieving a common target.
Take doctoring, for example: gentle
plastic blades do not fully clean the
rolls, but more aggressive carbon
fiber blades with high blade pressure
may destroy the roll cover altogether.
PressKodiak roll cover
– extreme durability
in harsh operating
conditions
During recent years, Valmet has
developed greatly improved polyurethane roll covers for several
applications. PressPolar, PressHusky
and CoteFalcon have been joined by
PressKodiak – Valmet’s latest example
of advanced polymer technology. Probably the biggest benefit of
STORA ENSO
SKOGHALL MILL
IN A NUTSHELL
Stora Enso Skoghall Mill is
located in Värmland, the heart
of Sweden’s Paper Province.
With two board machines fed
by mechanical and chemical
pulping lines, the mill has an
annual production capacity of
800,000 tonnes of paperboard for liquid and foodstuff
packaging. One in every six
beverage cartons in the world
is made of paperboard from
Skoghall Mill.
PressKodiak is its extreme durability
against wear, tear, pressure and chemically harsh environments. It also has
excellent dynamic properties and
can withstand high nip loads without
heating up, resulting in increased
reliability and maintenance savings.
OptiCleaner Roll for
continuous cleaning
during production
Valmet’s OptiCleaner Roll is a modern traversing high-pressure cleaning
device designed for smoothing press
applications. This new device ensures
a reliable cleaning result without
making contact with the roll cover
itself. In addition to excellent cleaning
performance,
it reduces
breaks and
CONTACT PERSON
John Fridebring
leaves no
Product Sales Manager
streaks or
john.fridebring@
valmet.com
markings on
Tel. +46 706 17 78 70
the sheet.
FORWARD 3/2015
23
CUSTOMER’S VOICE
IN T HE SP O T L IGH T
Kazufumi
Yamasaki
Nippon Paper Industries
“Shaping the future
with trees”
TEXT Makoto Saito and Gaurav Ghosh
Nippon Paper Industries Co. Ltd., a world-leading
pulp and paper conglomerate based in Tokyo, is
driving their sustainable business model forward.
“As a comprehensive biomass company, we are
creating value and contributing to better living and
cultural progress. We are shaping the future with
trees,” says Kazufumi Yamasaki, Executive Director
of the Research & Development Division, Technical &
Engineering Division and Energy Business Division.
24
FORWARD 3/2015
Creating new value in a
sustainable way
Over the years, Nippon Paper Industries has been one of the foremost
industrial companies in Japan. The
company prides itself on managing
forests sustainably and pursuing a
variety of businesses by making full
use of renewable wood resources.
“The challenge always remains to
use wood resources effectively in increasingly diverse ways, exploring all
the possibilities of wood and creating
new value to meet society’s needs,”
states Kazufumi Yamasaki.
Business focus a must
for sustainable growth
In Nippon Paper Industries’ strategy,
reviewing and renewing the medium-term business plan to re-align
the business focus for long-term sustainable growth is a key. In the latest
medium-term business plan there are
two main initiatives or focus areas:
“We want to enhance competitiveness in our existing businesses in
order to maintain stable quality and
operation and to reduce costs. Secondly, we will transform our business
structure. We want to expand our
business in growth areas and create
new businesses.”
“The first initiative has seen us
successfully collaborate with Valmet.
An example of this is our steady
cooperation in services and mill
improvements. Also the air dryer nozzle upgrade system and O2
reactor installed at our Ishinomaki
mill are giving excellent results. The
Akita mill is receiving an advanced
process control system from Valmet.
We always have high expectations of
Valmet’s technology and services”.
FORWARD 3/2015
25
CUSTOMER’S VOICE
Nippon Paper has the largest private sector electricity generating
capacity in Japan, with the exception of electricity companies.
Future of biomassbased energy
With the exception of electricity
companies, Nippon Paper has the
largest private sector electricity generating capacity in Japan. “We consistently strive to focus on sustainable
energy resources in line with national
guidelines and regulations. We have a
separate energy division that oversees
opportunities to grow potential
business. The biomass-based energy
sector has been active in recent years,
and we have noticed tangible benefits
from black pellets, although there
have been some challenges. Another
factor has been the acceptance of
hardwood fiber, which is predicted
to outgrow softwood in the long
term. We intend to study digester and
recovery boiler renewal prospects
further with Valmet.”
Local support and
reliable partnerships
are essential
Mr. Yamasaki explains: “Nippon
Paper Industries has been actively
expanding its operations outside
Japan in recent years. This has made
us understand the value of having reliable partners. Experiences
from our mills abroad – Australian
Paper in Australia and Siam Nippon
Industrial Paper in Thailand – show
that getting local support is essential,
not only during the rebuilding phase
but post-start-up as well. Continuous
cooperation allows both partners to
gain deeper insight into each other’s
operations and better know-how.”
“Earlier this year, we rearranged
the maintenance outsourcing of
the Maryvale mill in Australia with
Valmet, opting for a tailor-made technical maintenance service solution,
ensuring a win-win approach for
both partners. In Japan, Nippon Paper Group has a strong maintenance
organization, so the situation here
is somewhat different from overseas
mills. We are also very interested in
new technological evolutions like
the Internet of Things or Big Data
analysis to seek further developments
in the field of maintenance”.
Wood – frontline of
growth strategy
“Going back to our second initiative
– transforming the business structure – the company is committed to
consistently investing in expanding
new business areas and creating new
businesses.”
“Let me raise a few new innovative
products from wood. Cellulose Nano
Fiber is a good example of a new,
wood-based material. There are also
new ideas that have already reached
consumers, like the shift from plastic
boxes to paper ones. Wood-based
chemical products aim to make a
change from oil-base to wood-base.”
“The fact that Valmet offers
solutions throughout the product life
cycle is an interesting value proposition. For example, the LignoBoost
technology for extracting lignin from
wood challenges us as customers
to study and find possible new end
products for our customers. The
future looks interesting,” Kazufumi
Yamasaki concludes.
GOOD
COOPERATION
“We look
forward to
expanding our
SAICA was founded cooperation
in 1943 in with
Zaragoza (Spain). At Valmet
present,across
the
company is one of the
leaders in
businesses.”
the manufacturing of paper for
corrugating with a production
capacity of 2.5 million tonnes
per year.
The company is committed
to consistently investing in
expanding new business
areas and creating new
business.
26
FORWARD 3/2015
FORWARD 3/2015
27
CUSTOMER’S VOICE
Helen Ltd has invested in the future of the
Salmisaari power plant in Helsinki, Finland.
The new automation system by Valmet is
part of the company’s efforts to improve
energy efficiency, increase usability and
reduce emissions. The lifespan of Helen’s
two power plants, Salmisaari A and B,
will increase by 20 years.
More efficient power plant process management with
TEXT Soili Städter
he modernization of
the automation system
and field measuring
instruments in the
Salmisaari A and B power plants, built
in the 1980s, is a major investment in
Finland.
Modernization of the B power
plant included the adoption of the
Valmet DNA automation and safety
interlocking systems as well as the
modernization of the reporting
system. The separate logics were
replaced with the automation system,
and emission reporting was modernized to conform to current requirements.
Modernization of the A power
plant will be carried out later during
2015.
MODERNIZED
AUTOMATION
T
Salmisaari B
modernized first
The Salmisaari B power plant produces 300 MW of heat and 170 MW
of electricity. In the future, in addition to burning coal, the power plant
will increase its use of pellets as fuel.
A catalyst supplied by Valmet is currently being built for the power plant,
and 5–7% of the coal will be replaced
by pellets. The Salmisaari B power
plant is producing approximately
25% of the district heating and 17%
of the electricity in consumed Helsinki. Salmisaari also produces most of
the district cooling in Helsinki.
28
FORWARD 3/2015
Best power plants in
terms of efficiency
“Helen Oy’s Salmisaari B power
plant is highly efficient. It generates
electricity as well as district heating
and cooling for the Helsinki region.
Thanks to this combination of heat,
electricity and district cooling, the
plant’s net efficiency is over 90%.
Power plants that only generate electricity typically only reach a level of
Good project
management starts
with planning
Project Manager Pekka Salimäki
from the Engineering unit is in
charge of the automation project
and acts as the project manager for
the entire project. In addition to the
modernization of the automation
system in the Salmisaari B power
plant, annual maintenance was also
Thanks to this combination of
heat, electricity and district
cooling, the plant’s net efficiency
is over 90%.
40%–45%,” says Jyrki Itkonen, Power
Plant Manager.
Itkonen thanks the professionals
at Helen and Valmet for their part
in the successful completion of the
project. A management team model
developed at Itkonen’s initiative was
adopted along with the automation
and electrification projects. The
model helped to coordinate several
projects and annual maintenance
simultaneously.
carried out and the construction of a
pellet plant began.
Obtaining initial data on the old
automation system may be very challenging. Salimäki says: “Valmet made
a substantial investment in the project
planning, which can be seen in the
positive end result. Project management has been systematic, which is
essential in modernization projects in
particular.”
FORWARD 3/2015
29
CUSTOMER’S VOICE
Reliable
Salimäki is satisfied with Valmet’s
project expertise. From Valmet, Ossi
Lampinen acted as the project manager, and although the project took
place over a couple of years, there
were no personnel changes during
the project. The same experts are
currently working on replacing the
automation system in Salmisaari A.
POWER
“Valmet DNA is quite
the time machine”
Control Room Operator Hannu Karhu says: “For users, the replacement
of a system is a major and challenging
issue. We previously used a console
system, and now we have the latest
technology from Valmet.”
Karhu lists some of its practical
benefits: “We all have our favorite
pages on which the displays are given
in a certain order. When my work
shift begins, I open my page and I
know exactly where to find whatever
information I’m looking for. There is
a great deal of historical data available. By analyzing the causes of events,
we can investigate failures and learn
more from them. Valmet DNA also
manages past events, which makes it
quite the time machine.”
EFFECTIVE PLANNING
According to Pekka Salimäki, the
project planning was extremely
effective.
30
FORWARD 3/2015
The Industrial
Emissions Directive
controls the power
plant’s operations
Valmet’s new control solutions allow
the power plant to optimize boiler
operation. The end result is an efficient and environmentally friendly
process. The Industrial Emissions Directive will set stricter limits in 2016
for sulfur, nitrogen and particulate
emissions from power plants. “The
measurement results gathered by
the Valmet DNA automation system
allow the power plant to manage its
emissions and prevent limit values
from being exceeded. By investigating a failure, we will be able to see its
causes. If necessary, we can change
HIGHLY EFFICIENT
Our power plant is highly efficient,
explains Jyrki Itkonen.
process operation methods to operate
the plant in the optimal way. Furthermore, the reports conveniently
provide the information the authorities require,” says Tom Huovilainen,
Technical Operations Manager.
Huovilainen emphasizes the
importance of the safety interlocking system. “In the previous system,
we had to find the values on paper;
now we can see them directly on the
display. Replacing the separate logics
was a very good thing, as now all the
information is available in the same
system,” he explains.
NEW SYSTEM
Hannu Karhu
explains the
benefits of
the advanced
automation
system.
GENERATION
The project continues
through a service
agreement
In addition to the modernization of
the automation system at the Salmisaari power plants, Valmet DNA
also controls other processes: two gas
turbines, the underground coal storage facility and the operation of the
Kellosaari stand-by power plant. All
of this is controlled from one control
room, which was converted into a
modern workplace, right down to the
ergonomics.
The unified automation system will
help to achieve cost savings in spare
parts, local support and maintenance.
Helen Ltd and Valmet will continue their
cooperation
through
CONTACT PERSON
a service
Olli Koivumäki
Director, Sales
agreement.
[email protected]
Tel. +358 40 749 7314
The new biomass-fueled Torsvik 2
power plant in Jönköping, Sweden,
was inaugurated in April 2015. The
investment has turned out to be just
as reliable as expected.
TEXT Marjaana Lehtinen
A
few years ago,
Jönköping Energi
decided to expand
and modernize its
combined heat and power (CHP)
plant in Torsvik to better meet the
growing district heat and electric
power needs of its owner, the
municipality of Jönköping. The
investment was in fact necessary as
the existing district heat boilers and
related systems were reaching the end
of their life cycles. Another target was
FORWARD 3/2015
31
CUSTOMER’S VOICE
Cost efficiency, high availability and
reliability were the most important
technical criteria when choosing Valmet’s
technology for the power plant.
PHOTO: LEIF GUSTAVSSON
to replace the use of refined bio-fuels
with primary biomass fuels, such as
wood chips.
Cost efficiency, high availability
and reliability were the most important technical criteria when Jonköping
Energy chose Valmet to supply
the technology. Valmet’s extensive
scope included a 100 MW HYBEX
boiler utilizing bubbling fluidized
bed (BFB) technology, buildings, an
electrostatic filter, electrification and
instrumentation, a DCS, a catalyst,
burners and a demi water treatment
plant, all erected and commissioned.
“Availability is very important
since the plant is a big investment,
and it must run when the customers
need heat and power,” says Pontus
Steinvall of Projekt- & Energikonsult
Steinvall AB, who acted as a project
manager on the customer’s side. “As
Jönköping Energi is a rather small
company and such a major investment is a risk, it is very important
that the plant is not only modern and
efficient with low emissions to meet
future demands, but it also features
proven technology to avoid high
risks.”
High availability during
the first winter
Torsvik’s new plant was commis-
ABOUT THE
PLANT
The capacity of the new
boiler at Jönköping Energi
has an output of 100 MW
thermal energy. The new
plant uses roughly 550,000
cubic meters of forest
fuels annually. It produces
approximately 320 GWh of
district heat per year, corresponding to the heating
needs of 17,000 single-family homes. The production
of electricity amounts to
120 GWh/year, covering
the power consumption of
about 25,000 households.
32
FORWARD 3/2015
EXCELLENT
COMBINATION
“New technology
with extensive
training program
was excellent
combination for us.”
says Per Eklund
sioned in the fall of 2014. It serves
as a mid-load unit and runs only
in wintertime when there is a high
demand for district heat. The main
power plant, the waste-fueled Torsvik
1, runs throughout the year.
As the winter of 2014-15 in
Sweden was quite mild and there
were no long sub-zero centigrade
periods, Block 2 could not show
all of its capabilities to the fullest.
Nevertheless, the experience has been
positive. “The plant has been running
with high availability. However, there
is still a lot of tuning to be done to
optimize the production,” Pontus
Steinvall points out.
Sharing the same goal
pays off
The project was characterized by
excellent cooperation between
Jönköping Energi and Valmet. “We
were impressed that the project
was completed on time and within
budget,” says Svante Berglund, Project Manager, Jönköping Energi.
“The Valmet people are easy to
work with. We shared the same goal
and focus throughout the whole
project of building a well-functioning
plant for Jönköping Energi and its
customers,” Steinvall adds. Steinvall
also emphasizes how both Jönköping
Energi and Valmet focused on health
and security issues – and how this
paid off. “By
working
hard and
CONTACT PERSON
with some
Tapani Nummelin
Project Manager
luck, we had
tapani.nummelin
no accidents
@valmet.com
Tel. +358 10 676 3080
and no injuries.”
Training is an investment for the future
at Jönköping Energi
A successful outcome of the investment on the new HYBEX
boiler at Jönköping Energi was further ensured through a
solid educational program. All 24 operators in the six shifts
learned to run the new boiler through Valmet’s classroom and
online product training, accompanied by extensive training in a
simulator.
Simulator training was exciting and
effective
The simulator utilizes the same DCS control system as the
boiler in real life to give realistic training environment. Three
operators were selected to be tutors and to have deeper training for creating different operating scenarios for future new
employees and other operators to learn with.
The employees were excited about the simulator and Per
Eklund, Operating Engineer at Jönköping Energi, is pleased
with results: ”The whole training program, including the DCSbased simulator, is a good investment over time. A couple of
avoided unplanned stops in production gives a fast payoff.”
Per Eklund continues: ”This training program has been
important part of the delivery. It gave the operators a chance
to try the new technology in a safe environment before the
power plant was started up in November 2014. When the operators had finished the training with the simulator they went
straight into production without any transitional problems.” In
addition to the simulator training, all operators also participated in an online course in Valmet WebAcademy.
Training increased the involvement
The level of know-how and skills were also tested after the
training. This created a challenge for the company: how
individuals experience training, learning and testing. Results
varied between low stress and some panic in test situations,
but now the staff is used to testing. ”Our overall aim is that all
employees take responsibility of their own learning. After the
training we perform tests to evaluate the level of competence,
and to see what needs to be improved. The tests are also a
means to awaken an interest among the staff, and to secure
and enhance their level of competence”, says Eklund.
After being responsible for the training in Jönköping Energi,
Per Eklund could see several advantages.
“Firstly, operators are committed and
have started to be more involved with
CONTACT PERSON
Tuula Ruokonen
problems and solutions. Secondly, all
Director, Power
teams now have the capability to start,
Performance and
Components,
operate and stop the production process.
tuula.ruokonen@
The higher level of competence gives them
valmet.com
Tel. +358 10 676 3301
confidence in their jobs and enables them
to think further”, he concludes.
FORWARD 3/2015
33
CUSTOMER’S VOICE
PONDEROSA MANAGEMENT
The management of Ponderosa is keen to maintain
the company’s leadership in the Mexican market.
From left to right: Jesus Mijares Vazquez, Paper
Division Deputy Director; Antonio Rodríguez Demeneghi, Director, Paper Division; and Saul Guzman
Espinoza, Director of Operations.
CARTONES PONDEROSA
strengthens its
competitive
advantage
34
FORWARD 3/2015
MOTIVATED TEAM
The machine production team is very motivated to take advantage of all the benefits the new
equipment brings.
Mexico’s leading producer of coated folding boxboard
has invested in Valmet’s curtain coating and air
impingement drying technology to improve board
quality, lower costs and boost productivity.
TEXT Mark Williamson
C
artones Ponderosa – the
Mexican market leader
– is protecting that
position by investing
in a new Valmet OptiCoat Layer
curtain coating station and OptiDry
Vertical impingement dryer for
its 270,000-ton-per-year folding
cardboard mill in San Juan del Rio,
Querétaro, Mexico. The company
produces over 50% of Mexico’s coated
folding boxboard and is also the
country’s leading exporter. A large part
of the mill’s production is used for the
production of folding boxes for the
food and pharmaceutical industries.
The 3,400 mm-wide machine was
previously rebuilt by Valmet in 1997.
Saul Guzman Espinoza, Director
of Operations, explains the rationale
for the current reconstruction project: “Our clients are requesting cardboard with better printing properties
that require smoother surfaces and
increased resistance, allowing conversion at higher printing press speeds.
We set the objective of improving
product quality and increasing our
market share in the Mexican market,
which is growing at 4% a year. We
also needed to achieve cost savings in
order to be more competitive, while
maintaining a good balance with
quality. Additionally, the increase in
machine speed is intended to lower
our cost per ton,” he says. He also
FORWARD 3/2015
35
CUSTOMER’S VOICE
“Optimum quality was achieved
after just eight hours of operation of
the new curtain coater.”
Complete solution with
short downtime for
implementation
MULTILAYER
COATING
OptiCoat Layer
curtain coating
provides flexible
multilayer
coating in a very
compact size.
points out that there is increased
competition in the Mexican market,
with some European cardboards
appearing on the Mexican market.
Higher quality,
lower costs
The mill took bids for a new coating
station to improve quality and to provide better control over flexibility and
the cost of the mixture of ingredients
that make up the coating. The mill also
looked at options to increase drying
capacity, as the main steam cylinder
dryer section was limiting production
on grades above 350 g/m2.
36
FORWARD 3/2015
The company determined that
curtain coating would provide better
coating and opacity. Being able to
apply more than one coating layer
simultaneously at the same station
would allow higher coating weights
to be applied and permit the most
cost-effective coating formulation.
The OptiCoat Layer curtain applicator design chosen includes the ability
to apply two different coatings. The
two-coating preparation line was
also included in the project. The
curtain applicator replaces the former
three-layer dosing rod application
system in the intermediate part of
The proposals to increase drying
capacity were based on very different approaches. Valmet’s OptiDry
Vertical impingement dryer could
be installed beneath the existing
drying section, requiring only a few
modifications to the machine while
retaining the same footprint. The other option was to add one additional
section to the drying cylinder train.
According to Guzman, “Valmet’s
solution was a complete one that
required only a very short downtime
for implementation.” Valmet also supplied an OptiDry Chill web cooler.
Much of the equipment was installed during 2012 while the machine
was in normal operation. In total, the
project needed only seven days of machine downtime. According to Guzman, “The quality of the new coating
was good from the start, and optimum
quality was achieved after just eight
hours of operation of the new curtain
coater.” Coating recipes developed at
the Valmet pilot plant in Järvenpää,
Finland, were reproduced successfully
with the production machine.
Reduced coating
weight, increased
opacity and coverage
SUBSIDIARY
OF OEM
Cartones Ponderosa
is a subsidiary
of Organización
Editorial Mexicana
(OEM). In the picture
Francisco Vazquez
Torres, CEO and
Director General,
and Paquita Ramos,
Vice President and
Deputy Director
General of OEM.
Guzman says that a very uniform
coating is obtained, better than that applied at the base, resulting in increased
opacity and better coating smoothness.
“Application of the coating is very clean
and the operation is very stable, since
there is no dosing element that can
cause breakage or mark the web. It is
also easy to handle,” he adds.
The mill is now applying a heavier
coating weight in the curtain coater
than in the previous rod station (13 g/
m2 compared to 12 g/m2). The chart
shows how coating applications have
changed in the three stations as well
COATING LAYER WEIGHTS: BEFORE AND AFTER CURTAIN COATING
40
35
Total Coat Weight, grams/m2
the coating system, converting it to
a four-layer application. The first
coating layer is applied by a metering
rod system, and the fourth coating
is applied by either rod or blade,
providing excellent flexibility.
30
2,700 t/a
12
10
25
20
15
Top Layer
12
13
10
5
12
Middle Layer(s)
(Now Curtain)
9
Bottom Layer
0
Before
After
The chart shows how coating applications have changed in the three stations and
how the total coating is reduced from 36 g/m2 to 32 g/m2 , resulting in annual
savings of 2,700 tons. Two different coatings can be applied simultaneously with
OptiCoat Layer coater.
as how the total coating application
has reduced from 36 g/m2 to 32 g/
m2. This reduction of 4 g/m2 of total
coating weight results in annual savings of 2,700 tons of coating material
based on a cardboard with a weight
of 350 g/m2.
OPTICOAT
LAYER
Valmet’s
OptiCoat
Layer curtain
applicator can
simultaneously apply two
coats.
Immediate
productivity gains
The start-up of the OptiDry Vertical
units was equally fast and smooth.
The team in charge of machine
operation was so motivated to make
the machine work under the new
conditions that they took the initiative
to immediately increase the speed of
the machine. “They achieved a speed
increase of 15% in just one hour, while
the Valmet boys were enjoying a coffee
break,” joked Guzman. While running
a typical 350 g/m2 cardboard, the
speed increased by 18%, from 410 to
485 m/min.
When asked about the success of
the project, Guzman says, “We are
very happy with the execution of the
project, which was well coordinated.
Our company grew by participating
in the conceptualization and implementation of this project. We now
have the potential to improve our
quality, capacity and cost flexibility.
Now that there is more competition,
we need this to maintain our leadership in the Mexican market.” FORWARD 3/2015
37
CUSTOMER’S VOICE
The upgraded baling lines at Södra Cell’s Värö pulp mill in Sweden are up
and running, enhancing safety and increasing capacity. They are giving the
mill a head start in its major EUR 400 million expansion project to boost
annual softwood sulfate pulp production capacity from 425,000 to 700,000
tonnes. TEXT Bryan Ralph
EARLY BALING LINE REBUILD
GIVES SÖDRA VÄRÖ
head start
T
he countdown to the Värö mill’s
major pulp dryer upgrade has
begun – a massive new dryer
with double the present capacity
will be installed during the mill shutdown
in May 2016. Valmet was selected in June
2014 as Södra Cell’s main process equipment
supplier for Värö pulp mill expansion, and
proposed that the rebuilding of two of the
mill’s baling lines be brought forward by
one year to minimize disturbances to the
enormous dryer upgrade project. The baling
line upgrades were completed during the
mill’s annual shutdown in April 2015.
Jaime Zamora, manager of the mill’s
pulp drying department and responsible for
the pulp dryer expansion project, says: “We
were the first to complete a major phase of
the mill’s overall expansion project, and it
feels good to have the upgrade of the baling
lines done. Now we can focus on the other
end of the line, from the wet end to the
38
FORWARD 3/2015
cutter. We know there is still a lot of work to
do.”
the availability and reliability issues associated with the old machines.
Part of Södra Cell’s major
investment
Continuity counts in
selection process
As well as upgrades for the pulp dryer,
flash dryer and baling lines, Valmet will
supply a new continuous cooking plant and
upgrades to the mill’s wood handling, fiber
line, evaporation plant, recovery boiler and
recausticizing.
Valmet supplied all
three of the mill’s existing baling lines, and was
contracted to rebuild
two of the baling lines
to enhance capacity,
availability and not least,
safety. New machines
integrated into the existing lines will increase
capacity by eliminating
Jaime Zamora explains that past experience
and continuity were important factors in
selecting Valmet for the line rebuilds.
“There were two ways to go: either you
put in completely new lines or improve what
IN FRONT OF THE
ROBOAPPLYER
From left: Jimmy
Syrén, Process
Engineer, pulp drying
and baling and Jaime
Zamora, Manager of
the mill’s pulp drying
department.
you have. We felt it was best to improve the
current lines. We had already done one rebuild with Valmet in 2009, so we knew what
we wanted to do. There was another good
candidate, but we knew already knew Valmet and we know their equipment very well.
It’s always a challenge to incorporate new
equipment into an existing line, so upgrading now has given us time to get familiar
with the new lines and resolve any issues
before the dryer replacement next year.”
Line one, for flash-dried pulp, now has
three new baling machines from Valmet:
RoboFolder, RoboStacker and RoboStacktyer.
A new separate pickup station for forklifts at
the end of the line has increased the overall
system capacity and flexibility. A new fluffer
from Valmet has been installed before the
FORWARD 3/2015
39
CUSTOMER’S VOICE
Enhanced safety for
operators
For me, the main improvement has
been the safety of the new lines. We
have covered all the known risk and
safety hazards for the operators.
dryer to make drying more efficient and to
lower the energy consumption.
Three new Valmet baling machines –
RoboApplyer, RoboFolder and RoboStacker
– have been incorporated in line two. The
system’s capacity and flexibility has been
improved by building in storage capability
for bales before the bale press and adding
storage of ready units in the loading area
where the forklifts operate.
Smooth installation and
commissioning
Jimmy Syrén, who is responsible for
operations in the baling area, worked with
Valmet on the rebuild in 2009 and found the
experience useful in the recent line rebuild
project.
“It was certainly much easier this time, as
we know the equipment and the people,” he
says. “The key members of both our team
and Valmet’s were the same as last time,
which made collaboration easier. The preparation for electrification of the lines with
both new and old equipment was the main
challenge, but the installation and commissioning went smoothly.”
RoboStacktyer
installation at Värö
mill.
40
FORWARD 3/2015
“The project teams from Södra and Valmet engaged in constructive discussions and
sorted out the technical parameters of the
lines and capacity questions,” states Jaime
Zamora.
The special nature of the contract and
the need to keep costs at fixed levels resulted
in an “open book agreement” regarding the
electrical field installation for the baling
line project. “This is good from our point of
view,” says Zamora, “as it means invoicing
from Valmet is transparent and we can see
exactly what we are paying for.”
The baling line project has now been taken over by Södra Cell, and final acceptance
is scheduled for November.
“For me, the main improvement has been
in the safety of the new lines,” says Jaime
­Zamora. “I believe we have covered all
the known risk and safety hazards for the
operators.”
“When you look at the new lines, almost
everything is fenced off, but we wanted
to find a balance that would ensure safety
while improving accessibility for operators
and maintenance crews. We have three
mills within Södra and we saw a solution at
­Mörrum that felt very open, but very safe.”
“In my opinion, the lines are now more
reliable. However, the new safety features
mean that we need to change our way of
thinking and operating the machines, and
that can be a bit frustrating before we fully
learn how to use the new equipment.”
“Valmet helped us to find the right safety
solution for the two lines, and I would say
that their safety
know-how was
the most imporCONTACT PERSON
Andreas Lindstedt
tant knowledge we
Sales Manager,
received from Valmet
Pulp Solutions
andreas.lindstedt@
on this project,” Jaime
valmet.com
Tel. +46 70 576 54 98
Zamora concludes.
Start-up was
very successful.
Production was
sellable from the
second reel on,”
says Peter Fleron,
Paper Technician.
“The runnability
of the machine
was excellent right
from start-up”.
Valmet DNA
extends
lifetime
of paper machine control at Nymölla
In May, Stora Enso Nymölla in Sweden
successfully started up its paper machine
PM 2 with up-to-date control technology.
Valmet’s delivery comprised machine control
programmable logic controllers (PLCs),
replacement with Valmet DNA, an upgrade of
the existing Valmet DNA system, and a single
window operator interface in Valmet DNA for
new sectional drives. TEXT Anna-Riina Ahonen
N
ymölla mill in Sweden has two
paper machines and a pulp mill.
The mill has been using Valmet
DNA to control its processes for years.
Detailed analysis and
careful testing required
Valmet DNA has a unique feature: its compatibility with earlier generations of systems. Many
competing systems need to be completely
replaced, but Valmet DNA can be upgraded
piece by piece, as all generations are fully compatible and can also be integrated into other
suppliers’ systems. In this project, the Siemens
S5 machine control system for PM 2 was
replaced with Valmet DNA and connected to
the existing Valmet DNA automation system.
The machine control system replacement was
installed and started up during a seven-day
production shutdown. Stora Enso already had
good experience of this kind of system replacement at their other mills.
“The start-up was a complete success. Production was sellable from the second reel on,”
says Peter Fleron, Paper Technician. “The
runnability of the machine was excellent right
from start-up. I can’t recall a previous time
when we have experienced 33 hours of continuous production without breaks, although
we were not running at full speed.”
Juha Koivisto, Project Manager, Valmet
Automation, is grateful to the start-up team for
their good work. “We had a very good team in
this project. They are skilled and hard-working
professionals. We had people from a variety of
Valmet locations and functions. The cooperation with all parties involved was good.”
“Project follow-up is also very important,”
Juha continues. “We were able to keep to the
planned schedule. I want to emphasize the significance of the factory acceptance (FAT) test.
It is important for customers and us because
it enables smooth, rapid start-up and project
takeover. I’m glad to be working on another
project with Nymölla. We are delivering an
VALMET’S DELIVERY SCOPE:
• Pre-study of the existing PLC
• MCS application with function descriptions and interlock diagnostics
• Common engineering and diagnostic tools with all functions in DNA
• Complete documentation with field
engineering
• Factory acceptance test, installation and commissioning
• New equipment added to existing
service agreement
• Operator and maintenance training
energy efficiency monitoring system for a
two-line pulp mill, three boilers, district heat
production and two paper machines.”
Support from local service
team
“It is important to involve the local service
team in the project to ensure a smooth transition from project to service,” says Roger
Holmedahl, Service Manager, Valmet Automation. “The local service team took care of
setting up the Valmet DNA system, upgrading the system, and training the customer.
Valmet has a 24/7 service contract with
Nymölla including on-call services, spare
parts and additional services, and training
covering Valmet’s DNA system with over
21,000 I/Os for the
whole mill. With
CONTACT PERSON
local knowledge
Roger Holmedahl
Service Manager,
of Nymölla’s DNA
Automation
system, Valmet can
roger.holmedahl@
valmet.com
provide fast, experiTel. +46 70 317 14 14
enced service.”
FORWARD 3/2015
41
CUSTOMER’S VOICE
Valmet presenting Lucart representatives with a silk-screen printing of the cogeneration
system. From left Roberto Benzi, Mill Manager, Lucart Castelnuovo; Danilo Calamari,
Technology Manager Paper Mill, Lucart Group; Franco Pasquini, Engineering Manager,
Lucart Group; and Luigino Furlan, Vice President DCD Technology Unit, Valmet.
THE COGENERATION SYSTEM
Cogeneration is a combined production
of electrical energy and thermal energy
(heat), obtained in special plants using
the same primary energy.
Reduces the natural gas consumption
by 15%–20% a year, correlating to an
estimated reduction of CO2 emissions
of 7,000 tonnes
Reduces NOX emissions into the air by
3.5 tonnes a year
Integrated cogeneration system brings
SIGNIFICANT
ENERGY
SAVINGS
The Lucart Group’s Castelnuovo tissue mill in Lucca paper district in
Tuscany, Italy, is a perfect example of achieving significant energy savings
by installing an integrated cogeneration system. TEXT Laura Scek
42
FORWARD 3/2015
T
issue production processes are
known to be energy-consuming
and require the simultaneous
use of electrical and thermal
energy. Thermal energy – as steam used by
the Yankee cylinder and natural gas as fuel
for the burners of the high-velocity hood –
accounts for up to 70% of the total energy
needed by a tissue machine. Optimizing
energy usage is of the utmost importance.
The existing system as
starting point
When Lucart Group acquired the Castelnuovo Garfagnana mill in 2012, it started to identify improvement areas and found that the
mill’s energy set-up needed to be optimized.
The analysis showed that a technology utilizing the turbine exhaust fumes in the hood
could be the right choice for their needs.
The existing cogeneration system has
now been almost totally rebuilt. The gas
turbine is still in use and produces all the
electricity the site needs. Now it has been
integrated with the Yankee hood air system
and a heat recovery steam generator, and its
flue gases are used to dry the paper without
any further gas consumption. The hood
exhausts are also recovered to obtain all the
steam for the Yankee dryer, and the system
provides the energy needed for the drying
process.
Energy-efficient production
The results show that this has improved
energy efficiency and significantly reduced
CO2 emissions, as well as eliminating drying
costs related to hood burners.
The solutions supplied for the new system
serve to make the most out of the cogeneration plant, considering that the gas turbine
had to be reused.
The equipment Valmet supplied included a new air system with fans, burners,
dampers, ducting, and instrumentation for
the existing hood. The delivery also included
a heat recovery steam generator along with
air/air and air/water heat recovery systems.
Challenges overcome
When asked about the challenges involved
in the project, Franco Pasquini, Engineering
Director of the Lucart Group, mentions the
new technology involved, particularly applying the technology to an existing machine
while keeping production at normal levels.
Pasquini points out, however, that the
expertise, professionalism and vision of
Valmet’s representatives convinced them
that they had made the right choice. They
particularly appreciated the ability of Valmet’s people to always be ready to contribute
to finding solutions; Valmet had an indispensable role.
The system was positively received, both
by the staff operating the machinery and
by all the mill employees. It sends a positive
message about the prospects for the future.
Reduced gas consumption
and emissions
When it comes to environmental sustainability, the Lucart Group is extremely active.
Pasquini emphasizes how the integrated
cogeneration technology is totally consistent
with Lucart’s mission, which focuses on
environmental respect and a commitment
to decreasing energy consumption and
emissions.
“The impact of the technology depends on
the energy set-up and balance in each mill and
varies from case to case. At Castelnuovo Garfagnana, we expect a 15%–20% reduction in
gas consumption, as
well as 8,000 tonnes
less CO2 emisCONTACT PERSON
sions per year. The
Paolo Della Negra
Manager, Sales
feedback from the
paolo.dellanegra@
valmet.com
authorities has also
Tel. +39 345 1497 398
been very positive.”
FORWARD 3/2015
43
CUSTOMER’S VOICE
Arkhangelsk Pulp and Paper Mill in Russia decided to modernize the
washing plant in their bleached pulp production line. The reasons
behind the decision were increased environmental requirements and
the old drum filter battery becoming obsolete.
responded to all our requests. For example,
during the commissioning works they
worked 24 hours a day with many people
involved. They always met our needs”.
TEXT Mihaly Szekeres and Aleksandr Akishin
Vadim Moseev, Line Manager of the bleached
pulp production department, is also satisfied
with the results of the modernization.
“This project brought our long-standing
plans to fruition: the concentration of black liquor for evaporation increased significantly, and
now it is never lower than 17.5%. This helps to
reduce steam consumption for evaporation,
and the washing results have improved as well.
After excluding molecular chlorine some years
ago, we had first-stage, low-consistency bleaching before the project. Now we’ve significantly
increased the consistency of bleaching, which
has given us the opportunity to decrease our
overall water consumption as well,” Vadim
Moseev points out.
“I’d particularly like to highlight the competence of Valmet’s specialists and give credit
to their skills and knowledge of the process. Of
course, there were problems as well. However,
despite the language barrier, we always reached
a common understanding. It was essential that
the project was implemented in a 14-day period from shutdown to the start-up of the digester. It was also important that we managed to
arrange 24-hour work on the site. All the new
equipment was successfully started by pushing
the button – the result of excellent cooperation
during the preparation and implementation of
the project.”
Valmet’s TwinRoll presses are quite popular in Russia. There are more than twenty-five
presses operating in large pulp mills around
the country in a number of washing and
bleaching, high consisteny refining and
­dewatering plants. Now they are also operating at Arkhangelsk Pulp and Paper Mill.
TwinRoll modernizes Arkhangelsk
PULP
WASHING
PLANT
T
he installation of the pulp
washing plant started in summer
2014. All the work for the final
assembly, connection and testing
of the new system were performed during a
two-week shutdown of the plant in October,
which also saw the commissioning work
completed.
Decision to go ahead
without delay
“We have had plans for the washing system
for a long time, but somehow we have
We chose a Valmet
TwinRoll press, which has
a number of advantages
that you can’t get from
other suppliers.
44
FORWARD 3/2015
always put it off for future projects. Finally,
in 2012 we decided that the project simply
had to be implemented without any more
delays. The existing washing plant was in
poor condition and was deteriorating month
by month,” says Pavel Smirnov, Director of
Production Development.
“We selected two suppliers: Valmet and
GL&V. After visiting a number of reference
plants, reading feedback, and analyzing
potential problems, we chose a Valmet
TwinRoll press, which has a number of
advantages that you can’t get from other
suppliers.”
“We wanted to replace equipment, but we
also wanted to optimize the consumption
of water, steam, and bleaching chemicals.
Therefore, we decided to install three TwinRoll presses, which could easily be fitted
with oxygen delignification in future. This
project was connected to the shutdown of
the main production line; this meant that
the project had to be completed within a
strict period of time, because the line had to
be restarted on time.”
Targets achieved
The new line has been working for more
than eight months already. Pavel describes
the results achieved in comparison with the
previous washing plant:
“First of all, water consumption has been
significantly reduced, and consequently, the
amount of liquor sent to the evaporation
station has also decreased. For this reason,
one evaporation station can now be used to
extend the capacity of other facilities. At the
same time, we now have more precise control
over the process, and we can easily change
the process conditions depending on the
prevailing situation. For example, if we want
to adjust the amount of washing water (the
dilution factor) and the amount of liquor for
evaporation, we can easily do this now.
After several months of operation, the
plant has already reached almost all the
guaranteed values. The test period was completed in May, and all the process guarantees
have been successfully fulfilled.
“We have been cooperating with Valmet
for a long time, and so far, the experience has been extremely good. They have
“Long-standing plans come
true”
ARKHANGELSK PULP AND PAPER MILL
Arkhangelsk Pulp and Paper Mill, located in northwestern Russia near
the White Sea, is one of the biggest production facilities of its kind in
Russia and Europe. The mill produces container board, white paper,
exercise books, and bleached market softwood and hardwood pulp.
CONTACT PERSON
Mihaly Szekeres
Senior Manager,
Pulp Solution Sales
mihaly.szekeres@
valmet.com
Tel. 7 921 932 4379
FORWARD 3/2015
45
CUSTOMER’S VOICE
Breaking boundaries
Galileo grinding segments
SAVE ENERGY
WITH DIAMONDS
Galileo is a groundbreaking new grinding
segment concept that cuts production
and energy costs in producing
mechanical pulp.
TEXT Minea Hara
W
ood grinding machines
typically use enormous,
two-meter-wide ceramic
grinding stones. In just
one day, the motor of a grinder consumes
the same amount of energy required to
heat five houses for an entire year. Due to
its structure and the vast amount of energy
consumed, conventional grinding stones
wear out quickly and need to be frequently
sharpened – typically every two or three
weeks.
Almost 15 years ago, Valmet and some of the
world’s leading mechanical pulp producing
customers set out on a joint project to re-invent the way mechanical pulp is ground,
breaking a tradition that has lasted over 100
years. Led by Valmet at its technology center
in Tampere, Finland, the engineering team
came up with a completely new grinding
segment concept that cuts pulp production
and energy costs by 5%–10% in an extremely energy-intensive process.
“The technology was named after Galileo
Galilei, the brave Italian scientist who too
broke boundaries at his time,” says Viljo
Saarinen, Sales Manager for Valmet Grinder
Segments.
With its savings potential and quick
payback time, Galileo truly is groundbreaking. This innovative technology not only
reduces production costs, it also increases
pulp production and leads to more uniform
end-product quality. As Saarinen puts it,
“Galileo breaks conventions in a very traditional industry.”
Grinding with diamonds
Galileo consists of steel segments bolted
onto a steel core. The segments are coated with industrial diamonds, replacing
the conventional ceramic stone surface.
The diamonds are set in a specific, precise
pattern depending on the species of wood
in question, the process conditions, and the
desired pulp quality.
“Galileo engineers accurately determine
the pattern and amount of diamonds per
square centimeter. Since the diamonds are of
equal size, they form a very precise surface,”
Saarinen explains. “Depending on the width,
a grinder can have 120, 150 or 180 Galileo
segments. Each segment contains over
60,000 diamonds, all attached to the desired
position,” he continues. After the initial
installation, the segments are renewed every
six to twelve months, depending on the
process conditions.
Decreases in energy
consumption
The most groundbreaking feature of Galileo
is the significantly reduced energy consumption. The improved grinding can lead to
energy savings of more than 300–500 kWh
per tonne, equivalent to annual cost savings
of over EUR 500,000.
Since the same capacity can be achieved
with fewer machines, using Galileo grinding
segments also leads to savings in overall
energy consumption as well as maintenance
costs. After the first Galileo was installed in
2010, gathered data shows that customers’
pulp production has increased by 25%–50%.
In addition, the end product quality is more
uniform, since the diamond surface retains
its pattern throughout its lifetime.
Costs according to actual
usage
Galileo’s installment payment plan is also
unique: as the payments are based on
realized production and actual savings per
tonne, they never exceed the amount of
savings for the investment.
“Customers only pay for their actual
usage and they can only win. Galileo’s
performance is followed up remotely on a
weekly basis. The reports are shared and
analyzed with the customer, enabling us to
truly develop the grinding process together,”
Saarinen says. The payment plan is yet more
proof of Valmet’s trust in cutting customer’s
costs with Galileo grinder segment concept,
just as promised.
CONTACT PERSON
Viljo Saarinen
Sales Manager, Grinder
Segments
viljo.saarinen@
valmet.com
Tel. +358 40 543 4757
Industrial
diamonds are
set in a specific
pattern .
Final check of the diamond surface.
46
FORWARD 3/2015
The energy-saving Galileo surface ready to be
shipped to the customer.
Attaching the grinding segments after a surface change.
FORWARD 3/2015
47
INNOVATOR’S VOICE
The first OptiFiner Pro wood
fibre refiner in Southern Europe
started up in Cartiere Ermolli mill in
Northern Italy at the beginning of
2014. The new refiner replaced two
existing refiners at PM 1, increasing
the overall refining capacity
significantly and reducing energy
consumption by at least 20%.
LONG HISTORY IN
PAPERMAKING
Cartiere Ermolli’s
mill in Moggio
Udinese, at the foot
of the Carnic Alps,
was founded in 1922.
TEXT Kaisamaija Marttila
C
artiere Ermolli has a long history
in papermaking, as their mill in
Moggio Udinese, at the foot of the
Carnic Alps, was founded already
in 1922. Papermaking in the area started
as early as 1758. Cartiere Ermolli produces
specialty grades for flexible packaging
like food wrapping papers. “When you
create specialty papers like we do, doing
refining right is fundamental,” explains
Gilio Munaro, the Mill Manager at Cartiere
Ermolli. “As raw material, we use both
short and long pure virgin fibers. You do
not want to lose any mechanical properties
of the fiber, so the amount and the quality
of the refining must be right, without any
harmful cutting effects,” he continues.
“When we realized that the capacity of the
existing refining system needed an increase,
it was easy to start searching for a solution
with Valmet. We already had five Valmetsupplied Conflo refiners that perform well,”
explains Operations Manager Loris Not,
about the factors affecting the supplier
selection.
The power of simplicity
Improved paper quality with
right refining
48
FORWARD 3/2015
“Absolutely the most positive part of the
new refiner is its simplicity and the unique
operating principle,” Not says. “Since the
new refiner was installed, it has been easier
to achieve the paper characteristics we need.
The refining process is controlled by suction
roll vacuum, as before, but it’s now much
easier to control the process.” The mill now
achieves the same degree of refining while
using at least 20% less energy with a simultaneously much higher capacity.
“We’re very satisfied with the high
availability of the refiner. The maintenance
is easy and the amount of maintenance work
needed is really low. We’re continuing the
optimization project with Valmet to get the
filling lifetime to an even higher level,” Not
explains.
“I do feel that I have to warn that you
need to be careful if you are used to working
in manual operation,” Not notes, with a
smile. “The OptiFiner Pro refiner is fully
automated, so we noticed that we needed a
NEW REFINER REPLACING TWO OLD.
At Cartiere Ermolli, the new refiner replaced two existing refiners at PM 1, increased overall
refining capacity significantly, and reduced energy consumption by at least 20%. Operations
Manager Loris Not (on the left) and Mill Sales Manager Maurizio Sala of Valmet.
totally new mindset to work with it in order
to get the best results.”
Fit for future
“We are committed to serving our customers in the best possible way and we value
highly the satisfaction of our customers,”
explains Munaro about the future plans
of Cartiere Ermolli. “We’re lucky to have
customers that trust us to continuously improve our end products to better meet their
needs. We see that the new, more controlled
refining process is an advantage for us and
helps when working to reach this target.
This new refiner technology might also open
up possibilities for
us to get even better
production efficiency
CONTACT PERSON
Kimmo Harju
by implementing it in
Product Manager,
Stock Preparation
further positions.”
kimmo.harju@
valmet.com
Tel. +358 40 535 0611
OptiFiner Pro
refiner
OptiFiner Pro is Valmet’s new refining
concept, in which one refiner can
replace two traditional refiners and
deliver 30% electrical energy savings.
OptiFiner Pro refiners are suitable for
all kinds of low consistency refining
applications.
The major difference in the operating principle of the OptiFiner Pro refiner compared to conventional refiners
is the distribution of the fibers in the
refining zone via a shaft which ensures
an equal distribution and homogenous
treatment of the fibers. Due to this
flow-through principle, the size of the
refiner is much smaller than a conventional refiner with a similar capacity.
These are the main drivers for reduced
idle load and similar refining results
with significantly lower specific energy
consumption.
FORWARD 3/2015
49
INNOVATOR’S VOICE
Get inspired
The smart way forward in
QUALITY
MANAGEMENT
Valmet IQ is a new
product family for quality
control and monitoring in pulp and paper.
TEXT Nigel Farrand
50
FORWARD 3/2015
FORWARD 3/2015
51
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Valmet IQ
V
INNOVATOR’S VOICE
to reach your New innovations
quality goals
almet is introducing a totally
new product family for on-line
During the design phase, elements of earlier systems were
quality control and monitoring
totally reassessed and improved where needed, with well
of the paper and boardmaking
working and proven features retained. Valmet’s unique
process. The latest generation
expertise with process, machinery and automation plays a
Valmet IQ is a scalable
great part, as effective quality control stretches all the way
quality management solution
for the
pulp and paper
from stock preparation
to converting.
combining QCS quality control
industry is designed and built with the experience of over 1000 quality
systems, CD cross direction profilers, web monitoring and
A better
scanner
control
by Valmet
in recent
years. It is a customizable
web inspection
systemssystems
in a commondelivered
platform, marking
a
The latest generation IQ Scanner is a stable platform
new milestone
in the era
of qualityinformation
management solutions
quality
control,
and management
solution
for pulp,
paper,
with slim dimensions,
dustproofed
with a more
enclosed
in the paper industry.
shroud for installation on any machine. Incorporating a
Valmet IQ
Measurements
and Scanners
provide accurate and
stable sheet quality
measurements in
demanding machine
conditions, improving
quality and efficiency
while reducing costs.
board and tissue production that helps you reach process and end
combination of new technology with proven scanning
product
as simply, efficiently
and sustainably as possible.
New system
orquality
smart goals
upgrade
innovations developed by Valmet, IQ scanners connect
Today’s paperOur
making
machines are supported
aging, and as oldby
ma-unparalleled
dedication
and process
to existing automation
systems is via an Ethernet
cable with all signal
chines are modernized,
the
smartest
way
forward
is
to
replace
and
measurement
handling
in
the
scanner.
Additional
knowhow means we deliver what you need to improve your business.
the intelligence in the machine with the latest technology
hardware in the cross connection room or control room
instead of trying to maintain obsolete components and strugis eliminated, simplifying installation, maintenance and
Comprehensive
your performance forward
gle to preserve
availability. Valmet IQsolutions
offers a moremove
integrated
operation. With upsets like start-ups, paper web breaks or
yet scalable solution by replacing individual pieces of existing
grade changes, scan speed and scan width can be automatequipment that
or providing
anto
easy
theimprove
devicesperformance
and applications
needed
monitorically adjusted to suit the situation with edge to edge scanpath to entirely
quality management
from theand ning controlled
andnew
optimize
both processsolution
performance
seamlessly
other
automation
systems
all
bywith
precise
sheet
edge detectors.
Thisand
allows
ground up. Easy
connectivity
with
third
party
systems
and
end product quality. From our measurements
regardless
manufacturer.
So
better paper
controlmachines
over the process
withof
minimum
waste and
applications for all paper machinery, regardless of their man- - the highest
whether
you machine
choose aefficiency.
stand-alone IQ solution or
possible
ufacturer, with
guaranteed
compatibility
between different
trol
applications,
all components
of a Valmet IQ
a complete quality management system, you can
generation IQ
productsare
helps
to futureproof
thetogether.
investment
solution
designed
to work
Guar- New measurements
and provides true scalability with room to grow.
- An industry
deliverfirst
theisperformance
the on-line IQpromised.
Softness sensor measuration IQ products helps to future-proof your ing tissue surface properties on-line with a good correlation to laboratory softness. A non-nuclear sensor for
basis weight and moisture measurement provides accurate
measurements without the need for special certification or
radiation safety issues. Valmet’s new topography measurement for fiber orientation- and surface measurements
End product quality
Refined data
with printability
prediction capability has already met
Continuous easy access to operator
Consistent desired quality
with market
success.
Coater operations will greatly benefit
relevant information
Raw material efficiency
from a patented and unique direct coat weight sensor for
Availability
Optimized utilization of fibers, fillers,
CaCO3, Clay
or Latex based coatings and new microwave
Real-time monitoring
andfor
control
of grades
chemicals and water
moisture measurement
is introduced
recycled
process performance
with residual ink.
Energy efficiency
User experience
Savings in energy and instrument air
Business made simple
Valmet IQ is a scalable
quality management
solution combining
QCS, CD profilers, web
monitoring
and web
consumption
inspection
systems in a
Operational efficiency
time for core business tasks
commonLeaving
platform.
Environmental performance
Reduced reject production and process
waste
52
FORWARD 3/2015
Quality made simple
Easy usability,
dependable control and
Situation
based interface
transparent
into interface
process enables operThe new situation
basedview
operator
ators to easily
see theintelligence
existing status under one navigation
Process
bar and provides
comprehensive
visibility
the past
Achieving
quality goals
madeto
simple
through integrated IQ Reporting. Easy to assimilate information means situations can be assessed rapidly and the
Valmet IQ Applications are the core of the system with
joint user interface and intelligent control applications
that let you monitor and optimize machine performance.
Efficient reporting and enhanced user experience
give a clear view of process performance
and product quality at all times.
Valmet IQ Profilers
provide effective
profile management
for improved sheet
uniformity, productivity
and runnability at all
stages of the process.
Valmet IQ Process
and Quality Vision
helps detect quality
defects and identify
their root causes
to achieve better
runnability and high
end quality.
FORWARD 3/2015
53
INNOVATOR’S VOICE
right path to production targets taken the smartest way.
Reports help highlight potential bottlenecks with lost
time analysis keeping track of sheet breaks, shutdown
time and periods of off-spec quality and grade changes.
Several profile windows can be opened at the same time
to evaluate quality property differences between machine
reels, helping users to improve efficiency and increase
production.
Comprehensive IQ profiler family
To get the best out of CD control, state of the art actuators,
comprehensive diagnostics and application knowhow
ensure optimal operation from the headbox to the finished
product. The benefits of effective profile management
are many, extending from improved production and
runnability through to better paper quality and printing
properties. IQ Profilers are capable of providing considerable energy savings as well as conserving raw material and
Situation based interface refines and structures complex data for the
operator.
chemicals. The replacement of a 12 year old steambox on
a North American newsprint machine with an IQ Steam
profiler reduced steam consumption by 3.2 tons per hour
while still improving the CD moisture profile by 25%. A
competitor’s 5 year old sprayboom was replaced by an IQ
Moisturizer to give 4% fiber savings and 5% more production capacity on a liquid packaging board machine.
Web inspection and monitoring
The integration of the Web Inspection System to the IQ
quality map opens many possibilities from improving
machine runnability and speed to base sheet and coating quality evaluations. The higher resolution
cameras and high speed capture technology supported by detection specific
camera and light angles has made fast
identification of defects and quality flaws
a reality. WIS functionality is integrated
with IQ Web Monitoring to enable
operators and process specialists to find
the reasons for breaks, tail feed problems and back track quality defects.
The smart way forward
The completely renewed, more integrated
yet scalable Valmet IQ product portfolio offers all
the technologies and solutions needed to monitor and
optimize process stability and end product quality. Providing a new level of user experience and clear view into
process and product quality at all times, IQ also features
a remote connection to make Valmet expertise available
with on-line help when needed. The road to optimized
production performance and quality has never been
smoother.
54
FORWARD 3/2015
VALMET IQ
Visual inspection
of the sensors and
cleaning of the web
path is much easier
with the new Valmet
IQ system at Mänttä
mill.
Valmet IQ quality control system at Metsä Tissue’s
Mänttä mill performs from day one
With the introduction of the new Valmet
quality management just months away,
the first QCS pilot system was installed at
Metsä Tissue in Mäntta, central Finland, on
paper machine PM 7.
Accurate and dependable
The cooking and baking papers produced on
PM7 are in great demand and downtime for
the new scanner was limited by full order
books to only two days in March 2015. Time
was not the only constraining factor, according to Jyrki Pekkala, Mill Maintenance Manager: “There were only a few centimeters to
spare when installing the new scanner but
everything went amazingly well and we kept
the schedule. The new scanner and meas-
urements operated right from the word “go”
and we were back in production.” Machine
operators were immediately impressed,
commenting that caliper, moisture and basis
measurements are now more accurate and
dependable.
Simplified installation
For Sauli Seikkula, Valmet’s service engineer, the installation of the new design
scanner was pretty straightforward. “It
looks really good too,” he says, “The transparent doors on each end remove a little of
the black box appearance and mill personnel
experienced something of a wow factor seeing it for the first time.” Connection to the
mill’s existing DCS is via an Ethernet cable,
with all signal and measurement handling
in the scanner to eliminate any additional
hardware in the cross connection room or
control room. “In four months, since start-up,
the new scanner has performed well with
no need for any special service actions,”
comments Seikkula.
Compatibility for future
As well as being totally compatible with the
mill’s existing equipment, the new Valmet
IQ system also provides forward compatibility, making future automation investments
easier and more effective. This will ensure
a continued return on Metsä Tissue’s IQ
investment as well as maximize the useful
life of existing equipment.
FORWARD 3/2015
55
INNOVATOR’S VOICE
Improved efficiency for paper
and board making with
OptiRunner
dryer fabric
The demands placed on paper and board machine clothing are high, as the
fabrics have to support the smooth operation of the entire production
line. Dryer fabrics also need to withstand high temperatures, high fabric
wear risk caused by mechanical seals and rolls, as well as high-pressure
cleaning up to 600 bars. TEXT Minea Hara
O
ptiRunner dryer fabric for
single felted groups was
developed with modern
drying sections and devices in
mind. “It has a smart double warp system
to optimize efficiency and save more
energy in one of the most energy-intensive
applications of a paper machine,” explains
Juha Paavolainen, Product Manager for
Forming and Dryer Fabrics at Valmet.
A durable double warp
system
In the drying section, mechanical seals are
placed 10–15 mm from the fabric, leading to
a significant risk of abrasion. Modern seals
are a vital energy-saving factor, but they
require more durable dryer fabrics. “Durability has been the cornerstone of OptiRunner development. Its smart structure works
in harmony with modern blow boxes, and
56
FORWARD 3/2015
we’ve been able to bring additional energy
savings and improved runnability to our
customers,” says Paavolainen.
Maximizing running times
The smart single-layer structure consists
of two separate yarn systems – one on the
paper side and one on the non-paper side. If
one layer wears out, the other remains intact.
The strength of the fabric is about 200 kN/m
(approx. 1,100 PLI), making it extremely
wear- and jam-resistant, with strong warp
loop seams that can hold up to 50 kN/m.
Compared to traditional fabrics, OptiRunner extends running times and fabric
lifetime by an average of 15%–30%.
non-toxic yarns. When choosing Valmet,
our customers get a high-quality product and our expertise at their disposal,”
­Paavolainen says.
In the end, customers want their dryer
fabrics to simply run without problems. “All
our innovations are based on
customer needs. Special atCONTACT PERSON
tention has been paid to easy
Juha Paavolainen
Product Manager
installability, reduced energy
juha.paavolainen@
consumption and maximized
valmet.com
+358 40 559 3177
running times,” Paavolainen
says.
SMARTEST IN
THE MARKET
OptiRunner’s two
separate yarn
systems keep the
fabric running for
a clearly longer
time. Although
the machine side
streak wears off
(above), the sheet
side remains intact
(below).
Less downtime and
stronger seams
With a caliper of 1.5 mm, OptiRunner is
also thinner and lighter than its predecessors, making it easier to install. OptiRunner’s
durable structure also means less downtime
and fewer unplanned shutdowns. Paavolainen explains: “We put a lot of effort into the
seamability of the fabric, since the point of
discontinuity is always the weakest link in
dryer fabrics. In OptiRunner, this area has
been rimmed so that the warp loom seam
structure is stronger when in contact with
mechanical seals.”
Savings potential in
improved efficiency
What’s even cleverer about the double warp
system is its high contact area. Other suppliers’ fabrics can guarantee a total contact area
of 30%–40%, whereas OptiRunner adds up
to 51%. This significantly improves drying
efficiency.
“Both sides have similarly low air carry
surfaces. This results in improved sheet
control and reduced total fan energy costs,
because less air is carried into the blow box
pocket area,” Paavolainen explains. As the
drive power demand is lower, total annual
energy savings add up to EUR 100,000 on a
six- or seven-meter-wide machine. “In relation to other sections, the potential for dryer
fabric savings is huge,” Paavolainen notes.
Developed for the customer
When developing OptiRunner, quality and
safety were key factors. “We use durable,
FORWARD 3/2015
57
INNOVATOR’S VOICE
A NEW SOLUTION
to a classic problem
A
growing number of mills in
the pulp and paper industry
are experiencing sludge
management problems.
Sludge generated by the mills binds water,
which makes it expensive to transport and
dispose of. In addition, there have not been
any energy-efficient methods of incinerating
sludge.
Hydrothermal carbonization (HTC) is
a solution to this problem. Sludge management costs are reduced while also cutting
CO2 emissions.
HTC is a thermochemical process
first described in 1913 by Nobel laureate
Friedrich Bergius. Valmet is now offering
industrial-scale HTC plants for sludge treatment for the pulp and paper industry based
on a continuous HTC process developed by
the German company SunCoal. SunCoal is a
Valmet technology partner and has developed several applications based on HTC.
Sludge reduced by 70%
In the HTC process, organic sludge is
treated at a temperature of 200 °C and a
pressure of 20 bar. The structure of the
sludge is transformed: chemically bound
oxygen and hydrogen as well as intracellular
water are removed. Total sludge mass at the
start of the HTC process can be reduced by
up to 70%, using only 25% of the energy of
thermal drying. The end result is a sludge
press cake that contributes positive thermal
energy when incinerated.
“HTC also cleans the sludge to some
extent, and there is potential for removing non-process elements,” says Peter
Björklund, Process Engineer at Valmet.
SunCoal’s headquarters near Berlin features
a technology center including a lab and a pilot
plant.
58
FORWARD 3/2015
Sludge management problems in the
pulp and paper industry can be solved by
hydrothermal carbonization.
TEXT Kristofer Sjöblom
Valmet builds and
commissions the plant
The first stage involves analyzing a sample of
the customer’s sludge. The sludge is treated
with HTC and then analyzed again. Valmet
then establishes the design criteria and dimensions the plant. Then Valmet builds and
commissions the plant.
“We can provide an extensive list of guarantees that ensures the reliability of the HTC
process,” says Peter Björklund.
Great potential
Valmet has high hopes for HTC. Sales Manager Cecilia Geijer believes that the market
for HTC will grow rapidly:
“The option of sending sludge to landfill
will be limited in the future. Society and
industry must find solutions for reducing
sludge volumes. HTC is a solution that is
both environmentally and financially viable.
It has great potential.”
Cecilia Geijer and Peter Björklund argue
that there is a need for this new technology
all over the world and that it is important to
raise awareness of what Valmet can offer.
“HTC is an interesting option for companies in the pulp and paper industry that
want to reduce the costs of sludge management and meet very strict environmental
requirements. We offer a solution to a
problem that is growing ever larger, as well
as the best possible combination of companies: SunCoal’s cutting-edge competence in
HTC development combined with Valmet’s
extensive experience of process plants and
equipment for the pulp and paper industry.
We have high hopes
and expectations now
that we are providing
CONTACT PERSON
HTC on an industrial
Cecilia Geijer
Sales Manager,
scale,” says Cecilia
cecilia.geijer@
­Geijer from Valmet.
valmet.com
Tel. +46 76 639 76 43
On top
of the game
Innovative
recausticizing filter
fabrics are the
result of demand in
the pulp industry.
TEXT Minea Hara
W
hen a pulp mill customer
invests in recausticizing
equipment, Valmet’s
filter fabrics are most
probably doing the dirty work. With a
unique chain of in-house R&D, laboratory
testing and its own production, Valmet is
the leading developer and manufacturer of
recausticizing filter fabrics.
“Our expertise starts from the premise that we have always collaborated with
leading filter suppliers globally, spreading
and cultivating know-how within the
industry,” explains Antti Mäkinen, Senior
Sales Manager of Valmet. “This cooperation
will continue. Our history includes many
challenges and successes, but Valmet’s role
as a supplier of superior-quality filter fabrics
has not changed,” he says.
Effective recausticizing
with filter fabrics
A variety of products and filters are used in
recausticizing processes within the chemical
pulping industry. The quality of filtrated
green liquor, white liquor and lime mud
depends heavily on the filter fabrics’ ability
to effectively filtrate and recover cooking
chemicals for further processing. “High demands for increased capacity with the existing machinery present interesting challenges
for recausticizing filter fabrics,” says Antti.
Today, the most commonly used recausticizing filters are disc filters, alongside
conventional drum and tube filters. A disc
filter consists of around 200–300 filter bags
and sectors. Each filter bag needs to filtrate
lime mud and white liquor with a good clarity, as well as having excellent mechanical
durability features. The bags need to resist
extreme conditions: high process temperatures, exposure to harsh chemicals and
mechanical stress. Above all, the filter has
to achieve high filtrate clarity for excellent
quality liquor.
“The starting point is to use the most
suitable fabric structure for each application
so that the best possible filtration results
are achieved. The objective, of course, is to
find the most cost-effective solution for the
customer,” Antti explains. In the lime mud
filter, one key factor is that the dry content
of the separated lime mud needs to be ideal
FORWARD 3/2015
59
INNOVATOR’S VOICE
It’s not only the doctor blades,
Waste
Lime slaker
Unfiltrated
green liquor
Green
liquor
filter
Recaustizicing vessel
Unfiltrated
white liquor
Filtrated
green liquor
quor
ite li
d wh
te
Filtra
White
liquor
filter
Weak liquor
Lime mud
washing
filter
Lime mud
filter
it’s the overall approach
Lime kiln
Lime mud
Lime silo
Dregs filter
Weak liquor
Burned lime
Waste
Valmet is the leading developer and manufacturer of filter fabrics for all stages of the recausticizing process.
when it goes to the reburning process. If the
amount of water is even a few percentage
points lower, burning the cake in the lime
kiln requires less energy. “A difference of
3% is enough to create significant energy
savings for the mill,” says Antti.
Many ways to save money
Customers expect a long filter fabric lifetime
without any clogging problems that might
lead to unnecessary maintenance. Antti
explains: “An acid wash is a typical way of
removing dirt particles to prevent them
clogging the fabric. This means that the
machine has to be stopped, production
time is reduced, maintenance costs rise, and
corrosive chemicals may wear out the fabric
– all of which costs money. This, of course,
is something all our customers want to
avoid,” Antti explains, emphasizing operational reliability in filter fabric development.
Valmet’s filter fabrics are always tailor-made
specifically for each filter in the recausticizing process.
“Our goal is to minimize unplanned
downtime. The right direction is found by
listening to the customer already at the mill.
“A difference of
3% is enough to
create significant
energy savings for
the mill.”
Valmet’s advantage is our comprehensive
ability to provide service locally,” Antti continues. Valmet is also the only manufacturer
able to weave fabrics up to 12 meters wide
for lime mud drum filters. “This means we
can supply fabrics for all machines without
any seams. A seamless filter fabric is many
times more durable and wear-resistant, since
it is not exposed to extreme abrasion.”
Up to 10% increase in
filtration capacity
Integrated filter bag and support wire give the
patented two-in-one structure a stable design
(microscopic picture of bottom side).
60
FORWARD 3/2015
Traditional concepts are making way for a
new generation of filter fabrics. The reasons
behind this much-needed innovation are increased capacity requirements, heavier mechanical loads and common goals in finding
easier and faster installation procedures that
save time for customers.
“We have been able to respond to the
changing expectations by optimizing existing filter fabric sections,” says Antti. Valmet’s
research resulted in an innovation in recausticizing filter fabrics: a two-in-one integrated
fabric for white liquor disc filters.
“Our challenge was to develop an
improved product without compromising
quality or reliability. We decided to concentrate on threads, materials and overall
product features, which led to combining
the filter bag and the underwire into a functional, integrated structure,” Antti explains.
In the patented two-in-one structure, thick
support wires are woven to the bottom side
of the fabric, giving the single-layer filter
fabric the same properties as two separate
components.
“The sparse support wire structure hinders
the fabric from full contact to the sector,
increasing filtration capacity by up to 10%,”
Antti says. Compared to conventional disc
filter fabrics, the two-in-one structure is
affordable and easy to install. “Our product
development objectives are really captured
in this product. We continue to lead the way
towards more durable, effective and reliable
filter fabrics. Valmet is the only manufacturer
providing all the filter fabrics required in the
recausticizing processes. Our products
CONTACT PERSON
can be fitted with all
Antti Mäkinen
filters available on the
Senior Sales Manager
antti.makinen@
market.”
valmet.com
Tel. +358 400 637 664
Valmet’s renewed doctoring portfolio focuses
on optimizing the papermaking process by
lowering production and maintenance costs
as well as improving cleanliness. TEXT Kare Väisänen
F
ifteen years ago, paper producers
were after more production, less
downtime and higher machine
speeds, regardless of the costs
of production and sub-processes, such
as doctoring. Today, things are different:
mills are looking for the lowest possible
production costs.
“Furthermore, board-makers have to
tackle cleanliness issues caused by the
furnish base. Environmental regulations are
getting stricter, and the use of fresh water
is being minimized, making cleanliness
even more of an issue,” says Kare Väisänen,
Global Technology Manager for Paper Process Parts at Valmet. “We are responding to
these challenges by renewing our doctoring
portfolio. We want to help mills lower their
production and maintenance costs and
improve their cleanliness.”
Best raw materials at a
competitive price
The price of doctor blades is often the only
criterion for choosing a supplier. This is why
Valmet is now introducing a new range of
cost-effective ValTech blades.
“Our novel production method lets us
use the best raw materials but keep the price
competitive. ValTech products are available
with different carbon contents with superior
performance for positions throughout paperand board-making lines,” Väisänen points out.
Major impact on lower
energy costs
The renewed portfolio includes blades with
low friction featuring a short payback time.
For example, 10% savings in dryer sectional
drive power means free blades in the dryer
section.
Low friction is not the only way to save
energy. Dewatering suction rolls, grooved
press rolls and belts can often be improved
through doctoring with the new solutions.
According to Väisänen, typically about a
0.5% increase in dry content after press can
be achieved, resulting in lower energy consumption in the dryer section or increased
production.
New levels of cleanliness
and reliability
All mills want to reduce the number of web
breaks and unplanned shutdowns. With
some grades, blades do not last throughout
a normal shutdown interval. Other grades
have cleanliness issues in the dryer, causing
a constant need for cleaning. “By choosing
Valmet’s durable, high-performance products, you can significantly reduce downtime,” Väisänen adds.
To ensure trouble-free runnability, blade
holders need to be in good condition. They
have a major impact on how the blades
conform to the doctored surface and how
well they maintain their doctoring efficiency.
“Having the right type of holder in the right
position reduces both the need for cleaning
and maintenance and the time it takes.”
Less capital employed in
stock
One important cost factor is the capital employed in stock, which can be reduced and
rationalized by turning to Valmet for asset
management services. With a consignment
stock or other asset management model,
mills can ensure continuous availability of
precisely the products they need.
More than 10% savings in
total costs
With Valmet’s new doctoring approach, it is
possible to save more than 10% on the total
doctoring-related costs.
“This is gained via superior products,
jointly agreed and monitored KPI´s,
focusing not only on individual blades but
the papermaking process and solving the
bottlenecks on each line with the help of
Valmet´s global and local specialist network,” Väisänen lists. “There are flexible
agreement pricing models, and pricing can
be based on results,
not on the unit prices
CONTACT PERSON
of products.”
Kare Väisänen
Global Technology
Manager
kare.vaisanen@
valmet.com
+358 40 705 2439
FORWARD 3/2015
61
INNOVATOR’S VOICE
Is there a way to create a lighter end product with good strength properties?
Can you save on raw materials at the same time? Could you use less refined
pulps with excellent formation and reduce energy consumption? These are
questions that Valmet’s research and development experts ask themselves
every day. The latest results show that these claims could turn into reality by
using foam instead of water in web forming for more sustainable papermaking.
TEXT Kaisamaija Marttila
“O
ur research and
development work
focuses on improving
energy and raw
material efficiency of the paper or board
machine. We believe that foam forming
technology has a lot to offer in that sense,”
explains Sami Anttilainen, Vice President of
Technology at Valmet. “In recent years, we
have been actively studying foam forming
in a laboratory environment, as well as in
our pilot machines in Finland. To speed
up the research, we have cooperated with
VTT Technical Research Centre of Finland.
Partnering with VTT was a natural choice
for us, as we have a long and successful
history with VTT to test and do research
together,” he continues.
“Foam forming is actually nothing new
in the market. It has conventionally been
used in the non-woven industry. Our recent
studies indicate that foam forming has
several benefits also in boardmaking compared to conventional water forming. The
modifications needed to convert a machine
for foam production are quite cost-effective,”
says Hannu Turpeinen, Senior Technology
Manager.
products utilizing special fibers could see the
light, for example.”
Foam on top of your beer?
Valmet has an extensive set of pilot facilities
that it uses for demonstration trials and
specific projects with customers, as well
as for research. “For us, a pilot machine
is a must,” Cecchini tells us. “People are
naturally skeptical about new things. If
you can test and demonstrate things under
realistic process conditions, that helps with
development, and also makes it easier for
our customers to see the benefits of new
“Yes, there is foam on top of beer,” laughs
Development Manager Juan Cecchini, “But
that kind of foam is not suitable for papermaking because of the phase separation
that takes place. For papermaking, you need
foam that is a simple combination air, water
and the fiber suspension. If you mix it in the
right way and then add a little bit of ‘magic
powder,’ like a foaming agent, it helps to
bind the bubbles and trap the air in in the
multiphase liquid.” Online foam creation
is done with an injector mixer in the
approach flow system. For a stable process,
a method of disposing of drained foam is
also needed, as well as reliable measurements for foam density and fluid flows.
“Controlling the characteristics of the foam
– like bubble size and density – are the key
factors for creating a suitable papermaking suspension and forming conditions,”
Cecchini adds.
Raw material savings?
Save energy and raw materials with
foam forming
in papermaking?
62
FORWARD 3/2015
“The attractive benefit of foam forming
is that you can reduce the headbox flow
while increasing the consistency and still
handling the formation of the paper,”
explains Cecchini. The stock contains large
amounts of air and the fibers are distributed more evenly in the web, improving the
formation of board and resulting in more
consistent properties and appearance. The
most interesting benefit is that the structure
of e.g. cartonboard could become bulkier,
allowing more lightweight products. When
you look at the bottom line, the technology
reduces the use of raw materials and energy,
enhancing sustainability.
“Foam forming can be applied to several
products,” says Turpeinen. “Foam forming could benefit grades where bulk is a
critical asset, like cartonboards. With foam,
bulkier end product can be achieved and
the product can be made lighter. Products
like specialty papers or products with a high
amount of synthetic fibers could benefit
from the improved formation that foam
forming permits. We also expect that with
continuous foam forming, totally new
Seeing is believing
We believe the foam
forming technology
has a lot to offer in
view of energy and
raw material effiency.
technology. It shows how they can achieve
their targets.” Although foam forming is not
yet a ready-wrapped package that you can
just take off the shelf and start using right
away, the benefits are clear: “At Valmet, we
believe in foam forming technology and
the new possibilities it offers our customers.
Does it really save energy and raw materials?
Yes, at least at pilot scale. Hopefully, we will
soon confirm the results at production scale
as well. After we have solved the remaining
challenges, we will see if this really will be a
breakthrough innovation in the paper industry,” Sami Anttilainen
concludes and invites
all to start exploring
CONTACT PERSON
Sami Anttilainen
the possibilities of
Vice President,
Technology
foam forming with
sami.anttilainen@
pilot trials at Valmet’s
valmet.com
Tel. +358 40 768 7854
Technology Center.
FORWARD 3/2015
63
Around the world
Stora Enso Varkaus
orders Valmet
quality management
Valmet will supply pulp mill
and board machine quality
management solutions for
Stora Enso Varkaus mill in
Finland. The orders are an
addition to the extensive
rebuild of the mill’s fine paper
machine supplied by Valmet.
Tissue machine
rebuild in Germany
Metsä Tissue has chosen
Valmet’s Advantage DCT
concept including the Advantage ViscoNip pressing
technology for their tissue
machine TM 1 in Raubach,
Germany. The machine will
start up during the first half
of 2016.
What is happening in the global pulp, paper and energy industries? Around
the world demonstrates some of the events and projects where Valmet has
worked together with its customers to move their performance forward.
Cost-efficient
district heating in
Rovaniemi, Finland
Consumables and roll
service agreement
with Stora Enso
Kvarnsveden
Valmet will supply a district
heat network optimization
solution and a production planning system to
Napapiirin Energia ja Vesi
Oy’s Suosiola power plant
in Rovaniemi, Finland.
With the investment, the
customer is able to control
its district heat production
cost efficiently and boost its
electricity trade.
Valmet will supply paper
machine and fiber line
consumables as well as roll
maintenance to Stora Enso
Kvarnsveden in Sweden. The
five-year agreement started in
July, 2015.
Valmet DNA
automation started
up in South Korea
Automation for
Tallink’s LNGpowered fast ferry
Tallink has ordered a Valmet
DNA distributed control
system for its new LNG-powered ferry. The vessel will be
completed in early 2017 and
will start shuttle operations
between Estonia and Finland.
CS Engineering & Construction has completed its 105
MW biomass power plant in
Danjing City, South Korea. The
plant includes Valmet DNA
automation system (DCS)
and is the largest of its kind
in Asia.
Meet Valmet in Las
Vegas
Come to meet Valmet at the
Power-Gen International
exhibition in Las Vegas, USA,
on December 8-10, 2015.
New FormMaster
introduced for board
and paper forming
OptiConcept M line
started up at Pratt
Industries, USA
The first OptiConcept M
boardmaking line in the USA
has started up at Pratt Industries in Valparaiso, Indiana,
on October 5, 2015. The new
machine, with a wire width
of 6.25 meters and a design
speed of 1,200 m/min, produces corrugated medium.
64
FORWARD 3/2015
New biorefinery
project at Cascades
Norampac Cabano
plant
Cascades will be investing in
a unique solution to extract
hemicellulose, a cellulosic
sugar with high value-added
potential, from wood chips.
The new process, to be built
at the company’s Norampac
Cabano facility in Canada,
will reduce the mill’s environmental footprint and energy
consumption.
LignoBoost plant
now in operation at
Stora Enso’s Sunila
mill in Finland
Stora Enso’s Sunila mill is now
running the Valmet-supplied
LignoBoost lignin separation
plant.The LignoBoost plant is
integrated with the pulp mill
to separate and collect lignin
from the black liquor. This is a
significant step in transforming the Sunila mill towards
an innovative and customer
focused biorefinery.
Valmet has introduced a new
FormMaster 120 breast roll
shaker for board and paper
machine forming sections. It
will improve the board and paper quality giving a smoother
surface and better printability
with reduced raw material
costs and lower power consumption.
Maintenance
technical support for
Australian Paper
Australian Paper has made
a multi-year agreement with
Valmet to provice maintenance technical support at
the Maryvale Mill in Australia.
The agreement will focus on
providing onsite maintenance
technical advice and expertise
to the mill’s maintenance
organization.
FORWARD 3/2015
65
Valmet is a leading global developer and supplier of services and
technologies for the pulp, paper and energy industries. Our 12,000
professionals around the world work close to our customers and are
committed to moving our customers’ performance forward – every day.
About Valmet
Valmet maintains its position
among the world’s sustainability
leaders
Keng Zhen Central
primary school in
China enjoys fresh
water by Valmetdonated water
filters.
Part of Valmet’s
sustainability agenda
Fresh water for the Keng Zheng school
As part of its community
programs, Valmet decided to
address the challenge of fresh
water availability at the Keng
Zhen Central Primary School in
Jiaxian, China. The school’s 550
students and personnel now
enjoy fresh water with the help
of Valmet-donated water filters.
The Keng Zhen Central Primary School is
one of more than 100,000 rural schools in
China. The school is located in a geographically remote area where access to fresh
water is limited. The school has pumped
poor-quality water from underground since
there is no water supply system in the town.
”Our school is located in a mountaineous
66
FORWARD 3/2015
Valmet has been included in the Dow Jones Sustainability Index (DJSI)
for the second consecutive year. The DJSI is a sustainability index family
which includes the global sustainability leaders across industries.
In total 317 companies were included in the DJSI World for 2015-2016.
Valmet was also included in the DJSI Europe index.
”Being included in the Dow Jones Sustainability Index for the second
year in a row is an excellent achievement for Valmet. It shows that we
have been able to constantly improve our sustainability performance.
We have systematically proceeded with our sustainability agenda and
continued to nurture our shared values and global operating principles
which serve as a strong foundation for all of us at Valmet,” says Pasi
Laine, President and CEO of Valmet Corporation.
The annual evaluation conducted by a Swiss investment specialist
RobecoSAM comprehensively reviews the company’s performance with
regard to social, environmental and financial factors.
area, which makes access to fresh water challenging. Our teachers need to walk down
to the valley to get fresh water and carry it
back to the school,” says Zhang Jiangong,
the principal of Keng Zhen primary school.
”Furthermore, due to the saline soil, the
underground water tastes bitter and salty.”
A change that feels and
tastes
The new water filters were installed in the
school canteen to secure the availability of
fresh water for drinking and cooking for
all students and teachers. Shortly after the
installation work, Valmet’s team from Wuxi
and Xi’an travelled back to Jiaxian to see
how the filters work in practice.
“I was very impressed when I saw the first
group of children taste the filtered water:
their immediate reaction revealed that it
actually tasted different, and on top of that,
it will surely have a significant impact on
the overall wellbeing of the students and the
school personnel,” says Wang Hongmei,
Marketing Communications Manager at
Valmet China.”
To ensure proper functionality of the
water filter equipment in the long-term,
Valmet’s donation also included a service
agreement. In addition to the water filters,
Valmet donated second-hand computers
to the students and promised to provide IT
support via the internet.
Collaboration with local
communities
“This project is a good example of Valmet´s
initiatives in local communities. We support
selected programs relating to science, research, education, environmental protection,
nature conservation and youth activities,”
says Xie Daorong, Vice President, China
Operations. Read more: http://www.sustainability-indices.com/
Corporate citizenship is one of Valmet’s sustainability focus areas. We strive to operate
in a socially responsible and globally aligned
manner. Our growing presence in emerging
markets emphasizes our responsibility to
local communities around the world. We aim
to be seen as a trusted local partner and to
build mutual relations with our stakeholders.
Forward
FORWARD
Valmet’s customer magazine
PUBLISHED BY
Valmet Corporation
PO Box 11
FI-02151 Espoo, Finland
Tel. +358 10 672 0000
ADDRESS CHANGES
[email protected]
EDITOR-IN-CHIEF
Anu Salonsaari-Posti
MANAGING EDITOR
Elisa Lomperi
VA L M E T ’ S C U S T O M E R M A G A Z I N E
ASSOCIATE EDITORS
Marianne Kasjan, Marika
Mattila, Kaisamaija Marttila,
Eero Halmari, Pauliina Purola,
Katarina Ahsberg , Anne
Paloheimo-Seppanen, Riitta
Pöntynen, Gunnar Vesterlund,
Kerstin Eriksson, Andreas
Liedberg, Satu Lamminen, Eric
Tetreault, Juha M Virtanen,
John Della-Bosca, Gaurav
Ghosh, Jingwei Liu, Sara Li,
Sofia Forslund, Lisiane Cunha
ENGLISH LANGUAGE EDITOR
AAC Global
LAYOUT AND ART WORK
Neutron Design
PRINTING
Libris Oy
©Copyright
Valmet Corporation
All rights reserved
Printed on MultiArk Silk
115/250 g/m2
Supplement printed on
Lumiforte 115 g/m2
Printed on November 13, 2015
Reproduction permitted
quoting “Forward” as source.
All product names used
herein are trademarks of their
respective owners.
ADDRESSES
Valmet Corporation, customer
data
ISSN
0356-2751 (Printed)
1458-8013 (Electronic version)
FORWARD 3/2015
67
Valmet IQ
e smartest way to reach
your quality goals
e Valmet IQ quality management solution for the pulp and paper industry
is a comprehensive new product family that helps you to reach your process
and end product quality goals. Our products, applications and services cover
all your needs, from replacement of individual equipment to building a full
quality management solution. Each Valmet IQ solution is always based on our
extensive industry knowhow and designed to move your performance forward.
www.valmet.com/iq