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2016 THE INTERNATIONAL REVIEW FOR THE PULP AND PAPER INDUSTRY WorldPulp Paper putting it all together Material Flow How Concept simulations Roll handling Stretch packing www.pesmel.com Pesmel Pesmel has 35 years of history and expertise working with customized roll handling packing and storage system deliveries. Our unique Material Flow How concept has all the elements required to create the optimal handling system from winders to dispatching allowing paper mills to take full advantage of their production capabilities. We consider every customer to be unique and each project is planned and executed according to specific individual requirements using the most suitable technology for the solution required. The key to an optimally functioning finishing system is a smartly and well-engineered system layout and that knowledge is Pesmels Material Flow How. Our competence is based on four cornerstones innovation ability system and engineering know-how and of course flexibility. We lead the way as a single source supplier of bespoke finishing systems from engineering and manufacturing all the way to our global 247 service. Kraft packing Storing Dispatching 2016 Buckman Laboratories International Inc. All rights reserved. Youmayalreadyknowthat Oxamine for influent is more stable so it works harder longer than bleach chlorine gas and bromide treatments to control microbiological activity and save you money. You may also know that it has less impact on the environment. But did you know that the Oxamine microbicide program comes with proprietary feed equipment designed for industry- leading safety Its the only technology on the market with all these advanced safety features. LEAK DETECTION ABUILT-IN SEPARATOR to keep active ingredients apart in the case of a line break or other issue AUTOMATIC FLUSHING in case power is lost REGULAR INSPECTION by Buckman personnel to ensure efficient safe operation Protect your equipment your people the environment and the bottom line. Contact your Buckman representative or visit buckman.com and see just how easy it is to switch to Oxamine. AN INFLUENT MICROBICIDE SO GOOD IT CAN EVEN HELP KEEP YOUR SAFETY RECORD CLEAN. 9Capacity and the Maturation of the paper Industry By Rod Fisher President Fisher International. 16A single approach for a multifaceted result when processing recycled fibre By Niklas Tunell Area Sales Manager NS America Cellwood Machinery AB 22By David Cowles Global Business Manager-Nanotechnologies GLV USA Inc. 26All roads lead to nekoski By Ian Fenton Miltton Ltd. on behalf of Mets Fibre CONTENTS WORLD PULPPAPER 3 Krima HDS Installation World Pulp Paper 2016 DESIGNER MIKE PIROZEK EDITORIAL ENQUIRIES 44 0 1983 761909 EMAIL COLINREMPRODUCTIONS.CO.UK PUBLISHER COLIN SMITH MANAGING DIRECTOR DANIEL ROSE ADVERTISING ENQUIRIES REM PRODUCTIONS TEL. 44 0 1904 672222 FAX. 44 0 1904 672030 EMAIL COLINREMPRODUCTIONS.CO.UK WPP IS PUBLISHED BY REM PRODUCTIONS 7 ST SAMPSONS SQUARE YORK YO1 8QT UNITED KINGDOM. PRINTING AND COLOUR ORIGINATION CHERRY DESIGNS ALL RIGHTS RESERVED. REPRODUCTION IN WHOLE OR IN PART IS STRICTLY PROHIBITED WITHOUT WRITTEN PERMISSION FROM THE PUBLISHER. THE VIEWS EXPRESSED IN THE PUBLICATION ARE NOT NECESSARILY THOSE OF THE PUBLISHER OR OF WPP. REM PRODUCTIONS 2016 30Fine Tuning A Well-Tuned Mill By Robert Puhr Ad Hoc Communications 35Simply Better Board at Korea Paper By Timo Koivisto and Martin Koepenick Aikawa Fiber Technologies 41Pulp mill optimisation no longer pulp fiction By Abhijit Badwe and Ramesh Satini ABB Pulp and Paper Control Systems Singapore 48 By Ramon Roh Omya International AG FibreFine - The Newest Tool in the Papermakers Toolbox Increasing efficiency of liner machines through the use of mineral primary fillers Strong bonds lead to unique possibilities in business as well as in chemistry. And thats precisely why weve acquired AkzoNobels paper chemicals business. Additional expertise. A broader technology base. Greater presence where you need us most. It all adds up to a winning partnership with a shared commitment to innovation. Weve extended our capabilities so you can extend yours. Lets work together to build value into paper. www.kemira.comextend-your-capabilities 52Novel total dewatering concept improves water removal and paper machine runnability By Wim van den Brink Applications Project Manager Luc VanderAuwera Laboratory Team ManagerPatric Bierganns RD Manager and Paul Knight Market Manager Solenis 56Better hygiene in food-packaging board at reduced risk of rejected tonnage and machine corrosion By Dr. Marko Kolari Senior Principal Scientist Microbiology Biotechnology RD and Technology EMEA Juha Rintala Marketing Manager Deposit Control Pulp Paper EMEA Kemira Oyj Finland 62Advanced Diagnostic Strategies for Optimal Biocontrol By Liliya Lund Lead Chemist Laura Rice Corporate Scientist Elisa Luth Senior Microbiologist NALCO Water an Ecolab Company 66Solving Volatile Fatty Acids Issues in Recycled Packaging Operations By David R Jones Industry Specialist Buckman 71Single point Kappa measurement gives double-sided savings By Mark Williamson Journalist Engineer 75Coarse or fine A suitable design By Franz Kiefer and Jochen Pirig Heimbach GmbH Co. KG 78C iFilm coating starch Customer focused development of nature- derived binder for cost effective coating of Paper and Board By Dr. Andreas Becker Cargill Technology Manager Industrial Andreas Voigt Cargill Senior Specialist Paper Applications Solutions 82Better tissue bonding whilst using less adhesive is now achievable By Dave Kouwe Marketing Director Spraying Systems Co. CONTENTS WORLD PULPPAPER5 85Internal logistics at the core of the mills processes By Kaj Fahllund Vice President Paper and Converting Pesmel Oy 90Innovative solutions to increase operator safetyin the winder deck area By Mikko Rantanen CEO MoveRoll Oy 94ZELLCHEMING-Expo 2016 current challenges and developments in the pulp and paper industry By Christina Pantermehl Project Manager Mesago Messe Frankfurt GmbH Cellwood Machinery AB Box 65 SE-571 21 Nssj Sweden Phone 46 0380 760 00 Telefax 46 0380 141 23 E-mail salescellwood.se www.cellwood.se a member of the Cellwood Group CELLWOOD MACHINERY KRIMA GRUBBENS ALGAS Energy Efcient Fiber Strength Development Stickies and Dirt Reduction Wet Strength and Bleaching Capability New or Rebuilds of both UTM and Bale Pulpers. Unparalleled Reliability and Energy Savings For All Your Water Treatment Needs Water Reuse Water Energy and Chemical Savings Despite some concerns over its comparative economic slowdown China still continues to play a huge role in industry growth FOREWORD According to Rod Fisher of Fisher International paper board and tissue demand is generally up in Asia Africa the Middle East and Latin America see his excellent Industry Trends article these areas therefore remain very important targets for many of the worlds leading supply companies. Despite some concerns over its comparative economic slowdown China still continues to play a huge role in industry growth and with World Pulp Paper - Chinese Edition now a fully recognised source of information by industry specifiers in the region our writers and advertisers are able to convey their message and wisdom directly to them through this unique platform. This year promises to be very exciting indeed We have our stand at the International Pulp Paper Week and Bioeconomy Innovation Forum in Stockholm in May where World Pulp Paper alongside its sister publication World Biomass will be promoted. In addition we shall also be exhibiting at the Zellcheming Conference and Expo in Frankfurt in late June. Our team looks forward to welcoming both new and long-term clients to our booths and to discussing future initiatives to present their product and service offerings through our publications. With my usual thanks to our article contributors for their excellent input I send my best wishes to you all for a successful year ahead. Colin Smith Publisher WORLD PULPPAPER 7 World Pulp Paper 2016 Welcome to World Pulp Paper 2016 COATING CLEANING SHOWER TRIMMING NOZZLES AUTOMATED SPRAY CONTROL STANDARD CUSTOM SHOWERS Spraying Systems Deutschland GmbH Grossmoorkehre 1 D-21079 Hamburg Germany Phone 49 040 766 001-0 Fax 49 040 766 001-233 E-Mail infospray.de Internet www.spray.de Spraying Systems Sverige AB Rlsgatan 6A S-802 91 Gvle Sweden Phone 46 26 17 65 50 Fax 46 26 12 62 68 E-Mail infospraying.se Internet www.spraying.se ADVANCED SPRAY TESTING MORE THAN 90 SALES OFFICES WORLDWIDE. FIND OUT AT WWW.SPRAY.COM SPRAY OPTIMIZATION STRATEGIES FOR EVERY AREA OF YOUR MILL Spraying Systems Co. P.O. Box 7900 Wheaton Illinois 60187-7901 USA Phone 1 630 665-5000 Fax 1 630 260-0842 E-Mail infospray.com Internet www.spray.com SSF Spraying Systems Finland Oy Juurakkokuja 4 FI-01510 Vantaa Finland Phone 358 30 650 50 Fax 358 30 650 5405 INDUSTRY TRENDS WORLD PULPPAPER 9 Everyone has a pretty good idea of what paper demand is doing in regions where population and GDP are growing. While there certainly are cycles with ups and downs the trend in total paper board and tissue demand is generally up in Asia Africa the Middle East and Latin America. Figure 1 shows how steadily total capacity has been responding to demand growth. But what about regions where growth has slowed or even turned negative What will happen to investment and the stock of capacity we have now Is investment in new capacity over The answers come from an interplay of trends in demand between grades and By Rod Fisher President Fisher International Capacity and the Maturation of the Paper Industry The trend in total paper board and tissue demand is generally up in Asia Africa the Middle East and Latin America Figure 2. Europes distribution of grades is more even than North Americas Figure 1. Steady growth over the past 10 years reflects increasing global demand INDUSTRY TRENDS the quality of existing assets which will now be examined in more detail. First a few facts Figures 2 and 3 show how much capacity there is now in Europe and North America U.S. and Canada by grade. Next it is necessary to look at how capacities are likely to change in percentage terms over the next 20 years. Figures 4 and 5 show that the capacities of some grades will need to grow and others will have to contract. What is interesting is how each region will make the required adjustments up and down. How much will come from new investment how much from repurposing and how much from closures There are significant differences between Europe and North America that will determine how capacity changes play out in the future. For example Figure 6 shows the bias in Europe towards new capacity investment even during periods of slow or negative demand trends. In the last 15 years European paper companies built five times the amount Figure 5. North America has many repurposing opportunities for pulp mills that now serve printing and writing machines Figure 4. Europe will lose almost the same amount of capacity in some grades as growth replaces in other grades Figure 3. North Americas largest grades are containerboard and tissue There are significant differences between Europe and North America that will determine how capacity changes play out in the future WORLD PULPPAPER10 WORLD PULPPAPER 11 of new capacity as did North American operators. One of the reasons for this difference is that the industry in Europe was built and continues to operate today on an export strategy. So even if domestic demand in Europe declines European producers still tend to expect to export and therefore to invest. An obvious result is that the European stock of assets is considerably newer than that found in North America as shown in Figure 7. The consequence of this however is that some European assets are considerably more competitive than others Figure 8. This will be important as will be demonstrated later. As demand growth rates in some grades decline the need for closures in those grades increases. Which brings us to another factor determining the future of investment consolidation. As Figure 9 shows the European industry is significantly less consolidated than it is in North America. Whereas large companies in As demand growth rates in some grades decline the need for closures in those grades increases Figure 7. Continued European investment has made its assets more competitive Figure 8. The North American containerboard cost curve is flatter than Europes Figure 6. Europe has continued investing in new capacity even with declining demand INDUSTRY TRENDS North America have closed unneeded capacity for strategic reasons European producers tend not to have that luxury. Bankruptcies have been and will continue to be a relatively more common way for Europe to adjust its supply-demand balances. Figure 10 shows that North America has become less reliant on slow- or negative-growth grades. Where fibre is concerned the North American industry is characterised by a heavier reliance on virgin fibre for the products it makes. Unless this were to change and there is intriguing evidence that it could the North American industry has more flexibility than Europe when it comes to repurposing its assets as demand patterns change. Figure 11 shows that there could even be a need for moreFigure 10. Europe relies more heavily on declining grades than North America Figure 9. Fragmentation impedes Europes ability to adjust its supply-demand balance Whereas large companies in North America have closed unneeded capacity for strategic reasons European producers tend not to have that luxury WORLD PULPPAPER12 WORLD PULPPAPER 13 virgin fibre than is made today. We will continue to see repurposing of pulp mills in North America from Printing and Writing grades into those such as fluff and dissolving pulp where demand may grow growth in imports of virgin fibre for tissue manufacturing substitution of recycled containerboard for virgin and a threat from FBB to SBS. Lastly it is necessary to mention the likelihood the need even for some capital investment in North America. Despite low demand growth rates low enough to justify disinvestment in new capacity there will be new investment in the region. As Figure 12 clearly shows a huge amount of North American capacity has reached a critical age. In comparison Figure 13 shows just how new the capacity is in the rest of the world. To remain competitive globally and to maintain margins there will be opportunities for Figure 11. In the long run demand for virgin fibre in North America is likely to increase Figure 12. A large portion of North American assets are nearing the end of their economic lives ...it is necessary to mention the likelihood the need even for some capital investment in North America INDUSTRY TRENDS WORLD PULPPAPER14 North American producers to replace seriously ageing equipment with newer assets whose manufacturing costs are significantly lower. FisherSolve measures the long-term staying power of every paper asset in the world revealing that some assets will continue to get investment because they can remain competitive while others will be allowed to close because reinvestment in them is no longer cost effective. Figure 14 shows how to think about which ones will get support in the future those that are neither too new to need investment nor too old to justify it and among them those whose asset quality competitive environment and grade potential confer long-term viability. The paper industry is so capital intensive that every decision made by its managers can have large financial and strategic consequences. This means data-driven decision making is a critical component in maximising the value of the industrys assets. The examples and thought processes in this article should help inspire industry professionals to capitalise on the data analytics and expertise available in the marketplace today in order to make the best possible decisions for the industrys stakeholders of the future. ABOUT FISHER INTERNATIONAL INC. Fisher International supports the pulp and paper industry with business intelligence and strategy consulting. The data and analyses for this article were drawn from FisherSolve the paper industrys premier BI resource. For more information please visit www.fisheri.com Figure 13. The rest of the world may out-compete North America unless its fleet is modernised Figure 14. The bubble chart identifies assets most likely to participate in the next wave of investment ...a huge amount of North American capacity has reached a critical age With the largest installed base of recovery boilers in the U.S. and a continued commitment to the pulp paper industry Babcock Wilcox BW provides comprehensive solutions for a mills power and steam requirements regardless of OEM. BWs boiler solutions can help improve unit performance increase solids processing capacity reduce emissions and achieve reliable power production. 2016 The Babcock Wilcox Company. All rights reserved. is essential for uninterrupted operations. Reliable and clean power and steam production Recovery and power boilers Boiler upgrades modications and parts Boiler pressure parts Superheaters Economizers Smelt spouts Black liquor guns Air systems Field service engineers for tuning and technical advisement Sootblowersboiler cleaning equipment Ash handling systems Continuous emissions monitoring and data acquisition systems RECYCLED FIBRE PROCESSING WORLD PULPPAPER16 Mills incorporating waste paper in their process have often struggled for a long time with many different issues. The more obvious are the actual contaminants accompanying the waste paper. However more recently the fibre properties can start to degrade as well as fluctuate more. Amongst other things this is due to less sorting and more mixing of different grades making it largely impossible for the mills to source the correct furnish. Companies spend significant extra time and money in order to secure a furnish mix that will not only give them the By Niklas Tunell Area Sales Manager NS America Cellwood Machinery AB A single approach for a multifaceted result when processing recycled fibre As the tacky contaminants reach the machine there will be downtime to handle wire felt and doctor blade changes desired end quality but also keep the production upsets to a minimum. As the tacky contaminants reach the machine there will be downtime to handle wire felt and doctor blade changes as well as cleaning. Often it will also mean a heightened reject rate of the finished product andor defects therein which lowers the value of the same. Mills also tend to have to run higher basis weights on their specific grades to meet strength targets this is mainly due to a fibre source with less physical strength and not enough installed refining capacity to correct it. The solution can be found with the KRIMA HDS Hot Dispersion System which in one single system achieves the same as a complete stock preparation and approach flow upgrade. THE KRIMA HDS Paper is a product which we all use on a daily basis. As raw material and energy prices continue to fluctuate and rise it becomes increasingly important to have the correct tools with which to handle these changes. The KRIMA Hot Dispersion is one important component Figure 1. Krima HDS Installation Hot Dispersion makes good economic sense and achieves a return upon investment in a comparatively short time in a modern stock preparation plant and is crucial when trying to meet todays demands for quality. The aim of dispersion is to distribute the contaminants in the waste paper to a non-visible size. With a vast number of installations now operating Hot Dispersion makes good economic sense and achieves a return upon investment in a comparatively short time. The HDS is the solution in order to optimise the performance flexibility and operating cost on varying degrees of both raw material and required results. It has a capacity to operate at temperatures up to 120C 248F. HDS produces the best dispersing result on all kinds of dispersible contaminants in waste paper. It is also the most flexible dispersing system. The discharge of the Screw Press KSR does not need to be pressurised as the downstream Plug Screw is designed to seal the system. Retention time through the system is 2 minutes time which enables all fibres as well as contaminants to be uniformly heated all the way through it is also enough for in-line bleaching and a high reduction of spores and bacteria in the pulp. DIRT AND SPECKS Due to the temperature the high consistency at plus 30 and the design of the HDS the dirt reduction efficiency will be very high. Normally it will be in the 85 to 95 range depending on raw material quality and previous treatment. The fibres and contaminants are heated to a point where they are soft and flexible. This will enable a stronger dispersion without the risk of excessive fibre shortening and freeness drops. The dispersion of dirt and specks is made possible due to the fibre-to-fibre friction as well as friction against the disperser plates. The HDS will ensure full and uniform heating of all fibres and contaminants this will in turn guarantee the efficiency. TACKY CONTAMINANTS The high temperature up to 120 deg. Celsius plays an even more important role in dispersion of tacky contaminants. On top of that high consistency at plus 30 and the design of the disperser makes the reduction efficiency of tacky contaminants outstanding. The contaminants are heated to a point where they are soft and can be dispersed over a large amount of fibre surfaces with fibre-to-fibre friction and friction against the disperser plates. WORLD PULPPAPER 17 Figure 2. Speck reduction before and after RECYCLED FIBRE PROCESSING WORLD PULPPAPER18 The HDS capability of uniform heating due to retention time is a crucial part in maximising the efficiency. After passing the plates the pulp is diluted and cooled this will stabilise the contaminants in a non-tacky state. Later increases in temperature will not reactivate the tackiness and the contaminants will go with the paper through the machine without adhering to wires felts rolls or dryer cans. The installation of an HDS will lead to higher yield through less reject and less fines creation as well as less additives for stickie control on the machine and less down time for solvent cleaning. BACTERIA AND SPORES Retention time at high temperatures and high consistency at plus 30 sets the reduction of bacteria and spores at a very high level. Normally it will be some 99 thus dramatically reducing the need for biocides etc. PHYSICAL PROPERTIES Further developments have the added benefit of significant fibre development in regards to strength. This is made possible by the treatment at both high consistency and temperature. The flexibility of the fibre under these conditions allows for a controlled defibrillation that results in very high strength development without excess creation of fines. In full scale installations as well as pilot plant trials the following improvements have been seen on average 40 tensile 60 Burst and 20 Tear. The energy needed to reach these levels of strength development is very small. The disperser consumes about 35-40 kWhMTon 1.75 2.0 hPd STon. This energy can easily be saved in the low consistency refining stages. Mills today see that with a Krima they can compensate for the lower quality fibre source and keep their raw material costs in check. In many cases mills today are adding basis weight to the sheet to keep within specifications and to compensate for lower quality fibre. By adding an HDS system not only will a clean sheet be produced but the strength will be improved so that the basis weight can be reduced back to normal levels again. ENERGY There is a widespread misconception that dispersion uses a lot of energy. That might be true for some technologies both new and old but when it comes to the HDS nothing could be further from the truth. There are basically 2 energy inputs into the system electrical and steam. As already mentioned the electrical energy used in the HDS is almost always saved in refiners and deflakers. As for the steam it is important toFigure 3. Importance of time and temperature In many cases mills today are adding basis weight to the sheet to keep within specifications and to compensate for lower quality fibre WORLD PULPPAPER 19 especially so on lower basis weights. The HDS is very efficient at separating these bundles and clusters giving the mill a better opportunity to manufacture a better stronger and more uniform product. This deflaking capability of the Krima Disperser is well illustrated in broke handling systems running wet strength and coated broke. BROKE HANDLING Handling wet strength broke normally means use of steam and chemicals. This leads to an energy and environmental impact not acceptable by most producers today. If a Krima HDS is installed in the final parts of the stock prep a side stream of broke can be fed to it. By cutting out chemicals and steam in the pulping stage as well as shortening pulping batch times by 4 to 8 times a pump-able high flake content pulp is produced. This is then fed to the Krima HDS for full deflaking without any need of chemical additives. This results in a full yield and very economical broke handling. BENEFITS AND SAVINGS Furnish cost normally a significant factor. Due to a very efficient sequence YP bleaching significant chemical savings will be realised. Yield there are either no or very minimal rejects in dispersion. Solvent chemical usage on the machine for cleaning. Biocide usage as temperature will eliminate bacteria and spores. Reduction or elimination of refining energy used due to excellent strength development across the Disperser. Less rejected product from the machine due to a more stable quality and a police-like function of the disperser. Improved overall quality and brightness ... small fibre bundles that have not been separated in traditional stock preparation systems will make their way onto the machine mention that the location of the HDS is crucial. Sited at the very end of stock preparation with minimal storage time before the machine the uniformly heated pulp will aid in drainage and pressing allowing for significant savings in the dryer stages and chests. The HDS will also act as a water loop divider keeping the stock prep water from the machine water and thus keeping the latter at a higher quality and more stable temperature. Let us not forget that the heating in the HDS is performed at high consistency in a fully sealed and insulated system making it far more efficient than a chest or hood. UNIFORMITY AND FORMING It is rather common that small fibre bundles that have not been separated in traditional stock preparation systems will make their way onto the machine. This leads to uneven forming which impacts strength and uniformity Case Study 1 A North American board mill conducted their due diligence including trials at Cellwoods pilot facilities in Sweden. The results of the trials were the basis for their decision to install a complete KRIMA HDS. The type of board produced had been severely affected by tacky contaminants and especially bleed through spots that showed up in dryer sections as well as later in converting. Following the HDS installation these problems were eliminated. Another positive effect was strength development as seen on the furnish with 80 OCC and 20 Mixed areas included 40 Tensile Index development this at the same time as a 17 increase in Tear. This they were able to reduce the basis weight on the production it also made it possible to back off low consisten- continuously delivers top quality results with high availability and very low maintenance needs and costs. Figure 4. Strength development in board mill Case Study 2 A North American tissue mill producing a wide variety of wet strength towel qualities had issues with high energy usage as well as high chemical hypochlorite consumption. In addition significant amounts of steam was used to be able to pulp these wet strength grades. Due to the environmental permits they were restricted in the amount of broke that could be processed as each ton required a lot of hypochlorite. After trials with Cellwood a Krima UCD dispersing system was installed. Today they are running very short batch times in the pulper just enough to be able to pump the flaky pulp to the Krima. The UCD system then treats the pulp and produces a completely de-flaked pulp which can be sent directly to their separate machines. This gives the mill a big flexibility in broke handling and takes away the need to run it through their regular stock preparation. Other benefits are lower energy levels per ton treated and best of all no more chemicals. Figure 5. Wet strength towel before and after UCD Case Study 3 A mill producing newsprint and fine paper was planning to convert the newsprint portion into OCC based light weight liner. The stock preparation was designed with ample cleaning and screening but very little refining. To handle the new challenges they had considered installing more cleaning screening and LC refining. In the end they decided to just install a Krima HDS to tackle all issues. It resulted in a strong sheet and as the Mill manager described it the cleanest sheet on the market. A test was carried out coating before and after samples to show the bleed through rate there was a significant difference. There are many mills planning this type of shift in their production and the HDS could well provide the answer one system one project and problems solved Figure 6. Before and after bleed through the deflaking capability of the Krima Disperser is well illustrated in broke handling systems running wet strength and coated broke RECYCLED FIBRE PROCESSING WORLD PULPPAPER20 www.heimbach.com As a machine clothing expert we deliver specic solutions for each paper machine and every position. You can rely on our experience to help make the correct design choices when it comes for example to converting your machine to packaging papers. With a tailor-made clothing package from Heimbach you can reach longer life times and achieve more economical production. Why not get in touch with us Power to your Packaging Clothing from Heimbach helps achieve improved productivity FIBRE PROCESSING WORLD PULPPAPER22 During the last decade paper producers have continually pushed more ash and alternative fibre sources to improve costs and satisfy market demands. These changes have caused sheets to be less robust than their low ash virgin fibre counterparts. In addition to the increase in chemistries used Cellulose NanoFibril CNF Technology has begun to be deployed for additional strength and modified sheet properties. CNF has been a talking point within the industry for many years however the FibreFine System now allows the papermaker to produce CNF pulp using known industry equipment. In addition to adding CNF internally at a stock chest we now have the ability to add CNF on the surface using the Hydra-Sizer Applicator. FIBREFINE SYSTEM The heart of the FibreFine System is GLVs DD6700 Disk Refiner. It was designed with high efficiency and optimum fibre development in mind. CNF production is optimised using proprietary plate design and GLVs Anti-Plate Clash System APCS. This results in the ability to provide optimum fibre development at the lowest energy while maintaining plate integrity. The DD6700 technology has the unique advantage of having 50 more capacity as compared to similar sized refiners. This allows installation of smaller refiners with less energy demand and less cost to maintain. This technology and operation is very Cellulose Nano Fibrils CNF is forced out of a narrow slot in the applicator and is applied as a full-width curtain onto the wet stock. These units come By David Cowles Global Business Manager-Nanotechnologies GLV USA Inc. FibreFine - The Newest Tool in the Papermakers Toolbox similar to products already in most paper mills and existing machinery can be adapted to produce CNF. FIBREFINE HYDRA-SIZER APPLICATOR The Hydra-Sizer technology features a special applicator that is positioned on the Fourdrinier with an adjustable structure and an additive supply system. A liquid dispersion of in two versions a linear model which applies CNF at a constant rate across the machine width and a profiling version which can vary the addition rate in a number of distinct zones across the machine. One of the key benefits of the Hydra-Sizer applicator is the near 100 retention of your CNF solution and being able to apply it on one side of the sheet for specific property modification. Figure 1. FibreFine System Cellulose NanoFibril CNF Technology has begun to be deployed for additional strength and modified sheet properties 164 61 11 30 -20 0 20 40 60 80 100 120 140 160 180 Porosity Int. Bond Stiffness Tensile Tear Bulk -6 -6 FIBREFINE PAPER RESULTS INTERNAL ADDITION With the use of FibreFine produced CNF papermakers have several options for sheet modification. Typically internal dosage would be 25 to shift the sheet performance the desired amount. With CNF present typically the sheet will close up develop higher bond higher stiffness and have increased tensile. Tear results can vary and bulk will decrease slightly. Figure 3 shows the results from a pilot machine run of an 80 gsm sheet. These results are from CNF addition with no additional modifications such as fibre substitution or ash increase. The increase in strength could translate directly to a possible lighter weight sheet in many packaging applications. Additionally options for improved performance in specialty sheets should be considered. Many release or medical packaging grades could benefit from higher bond values. Another option afforded to the papermaker using CNF is to increase the level of sheet ash. In another pilot machine trial we have seen that with the addition of 5 CNF added internally 46 additional ash can be added to the sheet and maintain MD tensile and internal bond. These trends appear to be maintained across The increase in strength could translate directly to a possible lighter weight sheet in many packaging applications softwood less virgin purchased pulp or substitute in more recycled fibre. CNF will also help papermakers as the secondary fibre sources become weaker with lower strength potential. In figure 4 you will see the internal bond gain while using OCC CNF. Use of CNF incorporated into the sheet provides todays paper industry with many options that are not centered on chemistry. Although some chemistry adjustments may be required for production optimisation the natural WORLD PULPPAPER 23 a wide range of ash loadings ranging from 10 to 30. This opens many options for the papermaker trying to balance budget with performance. A third option while using CNF is to introduce a lower cost fibre. Using the FibreFine System any fibre source can be processed into CNF. As an example we have processed OCC into CNF with positive strength results. This lower cost fibre substitution could easily benefit mills struggling with fibre costs. Extrapolating this concept out one could choose to use less Figure 2. GLV_Hydra-Sizer Figure 3. UMaine trial results Figure 4. Internal bond 0 20 40 60 80 100 120 140 160 Control 1 2.50 5 Ft-lb1000 CNF CNF Internal Addition Change From Control 80 GSM Sheet CNF Internal Addition Internal Bond FIBRE PROCESSING WORLD PULPPAPER24 strength benefits of a CNF sheet help lower the on-going struggle some mills have with VOCs and various permit limits. FIBREFINE PAPER RESULTS SURFACE APPLICATION The use of the Hydra-Sizer Applicator in the FibreFine System gives the papermaker many options to create new grades or enhance current ones. By adding a CNF layer on the surface sheet characteristics can take on almost pre-coated value. We have seen Gurley Porosity values 30 times greater than the control. Sheffield Roughness values have been decreased by over 10 while STFI increased by 9.5. See figure 5 for a comparison between a regular sheet surface and one with CNF applied. One can see by this dramatic comparison how the new CNF covered sheet provides a drastic leap forward in grade creation. In addition to closing up a sheet making it smoother and stronger CNF addition can act as a pre-coat for several different types of coatings. The CNF surfaced sheet gives the papermaker a unique opportunity when it comes to applying various specialty or barrier coatings. The CNF sheet can help lessen the chemistry needed for certain barrier properties while making the sheets more environmentally friendly. Just a small reduction in some of the barrier coatings could translate into huge savings andor lower VOC levels. This concept is demonstrated with KN Ink Absorbency testing. As you can see adding CNF internally does influence absorbency however notice the difference when the CNF is applied to the sheet surface. Allowing your premium coating to remain on the surface where it is needed could provide many benefits for the papermaker and the converter. SUMMARY Although Cellulose NanoFibrils have been around for a long time the FibreFine System pushes the benefits toward the average papermaker. We can now employ refining machinery that every papermaker is comfortable with. Through our knowledge and equipment design energy costs continue to drop for CNF production. Should you wish to create a whole new grade line or just improve your economics CNF now affords the papermaker a new eco- friendly tool in their toolbox. The CNF surfaced sheet gives the papermaker a unique opportunity when it comes to applying various specialty or barrier coatings Figure 6. KN Ink Stain Test Figure 5 BIOPRODUCT DEVELOPMENTS WORLD PULPPAPER26 Mets Fibre is currently constructing the most significant facility to hit the European pulp industry in decades. But dont call it a pulp plant the new bioproduct mill will expand pulp production into new exciting areas and brings the Nordic perspective on sustainable use of raw materials into the 21st century. Along with Mets Group its parent company Mets Fibre has long made sustainability a byword. Everything the company does involves sustainability from the products it delivers to its customers all the way back to the By Ian Fenton Miltton Ltd. on behalf of Mets Fibre All roads lead to nekoski It is this modern conscientious and very Nordic view of wood as a raw material which has served the company well for decades forest. Every one of these products is safe and recyclable and the main raw material employed to make them is renewable wood from sustainably managed northern forests. And of course the company makes exclusive use of the best available technology in its production. It is this modern conscientious and very Nordic view of wood as a raw material which has served the company well for decades keeping it at the forefront of pulp production in matters such as material and energy efficiency water usage and emissions. But developments are afoot centred upon the companys new construction at nekoski in Central Finland which will constitute the storys next thrilling chapter. WELCOME TO THE BIOECONOMY At the heart of the new facility is the concept of the bioeconomy. Riikka Joukio Mets Groups Senior Vice President of Sustainability and Corporate Affairs explains the origins of the term and its signal importance to nekoski. I was introduced to the idea of the Figure 1. nekoski bioproduct mill bioeconomy over five years ago she begins when the Confederation of European Paper Industries CEPI was preparing its roadmap to a low-carbon economy. It was identified as a future- focused movement towards the use of renewable raw materials. Whereas elsewhere in Europe the bioeconomy is mostly associated with agriculture the concept is more relevant to forestry in Finland. The idea gradually emerged that the forest industry was an essential part of the bioeconomy and new products and technologies were being envisioned. Wood as a renewable raw material began to gain new significance. As a result Finland prepared a national bioeconomy strategy with development of the bioeconomy as one of its key projects. The definition of bioeconomy has become more modern and inspiring seeking to reduce national dependence on fossil resources facilitate economic development and create new jobs. These are all among the principle targets of the new nekoski mill. The bioproduct mill in nekoski is one of the largest investments in the bioeconomy in Europe enthuses Riikka Joukio. Its a prime example of combining the old and the new. It will produce pulp but the other constituents of the wood will also be separated out during the production process. These side streams will be used to manufacture a wide selection of bioproducts and the pulp will be processed into wholly new products. WHAT IS A BIOPRODUCT MILL There has been a great deal of publicity about Mets Fibres investment in the new facility and the term bioproduct mill has dominated the proceedings. Riikka Joukio has offered one definition and Mill Manager Camilla Wikstrm expands upon it highlighting the important distinctions setting nekoski apart from every other pulp-producing mill in the world today. All the fundamental differences stem from the very first planning stages says Camilla Wikstrm during which we set out our aim to look at the facility from a wider industrial perspective. We considered the idea of different WORLD PULPPAPER 27 The bioproduct mill in nekoski is one of the largest investments in the bioeconomy in Europe Figure 2. Whereas elsewhere in Europe the bioeconomy is mostly associated with agriculture the concept is more relevant to forestry in Finland BIOPRODUCT DEVELOPMENTS WORLD PULPPAPER28 types of partners making use of the side streams an area which is already active to a more limited extent at other mills of ours and began strengthening the technical processes needed to make this a defining feature. This emphasis gave rise to the idea of a thriving ecosystem surrounding the nekoski mill. The production process of pulp gives rise to a number of by-products explains Riikka Joukio. Some of these amount to side streams that we can make use of ourselves for energy production for example and then there are those that are either too small or best suit a business that we are not active in. With an ecosystem of other companies these opportunities can be captured in a way that encourages innovation and entrepreneurship as well as benefitting the local communities and society at large. Today the bioproducts of a pulp mill in addition to pulp are tall oil turpentine and bio-energy Camilla Wikstrm points out which can amount to around 10 per cent of the whole operations turnover. The idea with this new concept is to double this to about 20 per cent in the first stage. Potential new products from the side streams of the bioproduct mill include product gas sulphuric acid textile fibres biocomposites lignin products fertilisers and biogas. In some cases existing partners will extend their cooperation to capitalise on these resources. In others Mets Fibre is collaborating with universities and other research bodies to establish further processes and production paths with the aim of signposting the next phase of products to be derived from the bioeconomy. But while these possibilities are boundless in 2017 when the new mill begins operations the side streams of the mill will already generate a great deal of bioenergy. In fact the nekoski bioproduct mill will increase the total share of renewable energy in Finland by more than two percentage points. The role of Mets Group as a bioenergy producer is already significant and altogether 16 per cent of the renewable energy used in Finland comes from the company. The nekoski bioproduct mill will increase the total share of renewable energy in Finland by more than two percentage points Figure 3. Mill Manager Camilla Wikstrm Figure 4. Now more than ever there is abundant potential to market pulp as a genuinely sustainable product based on a renewable raw material WORLD PULPPAPER 29 production capacity nearly three times higher than the mill currently occupying the site it will operate within all the same emission limits and wastewater conditions of the existing environmental permit. Its sulphate emission into water will be around 15 per cent lower than those of the current mill. As the bioproduct mill will operate close to vast water resources its water needs will not impede any other parties access to or usage of water. Emissions of odorous gases will also be reduced significantly. Perhaps most impressively of all not only will the new bioproduct mill be completely self-sufficient in terms of electricity it will in fact produce 2.4 times more electricity than it consumes representing 2.5 per cent of all electricity production in Finland. Naturally this also completely alleviates the need for any fossil fuels. JUST THE BEGINNING All told nekoski will be the most energy-efficient pulp mill in the world. And it is fair to say that this is just a starting point. As those familiar with the company will know Mets Fibre emphasises continuous improvement in its operations with its personnel constantly at work to improve both material efficiency and all the various sustainability metrics mentioned above. With such an impressive range of achievements already in evidence right at the beginning how does the company see nekoskis future potential Riikka Joukio demonstrates the same trust in Mets Fibres experts that the company has placed in them for many years I really trust Finnish pulp and paper engineers. They always find a way to do things a little bit better. And this emphasis on continuous improvement particularly in terms of sustainability goes all the way up to our top management. At nekoski Mets Fibre has generated huge achievements in the field of sustainability both on a company level and for the pulp industry in general. Now more than ever there is abundant potential to market pulp as a genuinely sustainable product based on a renewable raw material. It might be too early to say how things will progress from here but the direction has been firmly set. All told nekoski will be the most energy- efficient pulp mill in the world BENCHMARK EFFICIENCY AND RAW MATERIAL USAGE Even the enormous scope of the nekoski development its importance to the European bioeconomy and all the innovative conceptual thinking underpinning its implementation cannot overshadow the facilitys most important properties - its sustainability credentials. These are numerous and challenging to summarise succinctly. Despite a Figure 5. do things a little bit better says Riikka Joukio VERACEL CELULOSE WORLD PULPPAPER30 By Robert Puhr Ad Hoc Communications Fine Tuning A Well-Tuned Mill A passion for continuous improvement still attracts industry attention Figure 1. The Veracel mill produced over 10 million tonnes of pulp in 9.5 years almost 20 over the mills design capacity When the Veracel mill started operating in Brazil in 2005 it was pre- ordained to be one of the worlds most advanced bleached pulp mills and also a reference site for sustainability and operational excellence. A passion for continuous improvement from the smallest process details to large activities such as an innovative maintenance program still attracts industry attention. Veracel is a partnership of two major leaders in the pulp and paper industry Fibria and Stora Enso. Ari Medeiros mill is in a very good position and is also in a very good condition. But it is challenging to stay on top as this is a single-line mill. We must run continuously and at a high level of performance especially when coming out of a shutdown or blackout or whatever. In response to the challenges Veracel has suceeded in producing over 10 million tonnes of pulp in 9.5 years almost 20 over the nominal design capacity. A REFERENCE FOR EXCELLENCE According to Medeiros Veracel was for the best this industry can offer. And after 10 years of operation it is still one of the most competitive in terms of costs quality environmental performance and forest productivity. operational excellence Medeiros operations over the years we know that big gains are less common. But we are pushing for even the small gains that when taken together can equal a big one. others come to watch and learn trained eight operating teams from other mills here. People come to see what we are doing here. We dont mind. Anyone can buy the same equipment the difference is in the knowledge and skill of the people. PIONEERING MAINTENANCE CONTRACT When Veracel signed a contract for maintenance activities at the mill it contract of its kind in the pulp sector similar results to the Frey Bentos mill Medeiros says. Veracel rapidly became an reaped through outsourcing My core business is to produce pulp Focusing on maintenance would only detract from my core interest. WORLD PULPPAPER 31 Figure 3. OPP Optimisation of Process Performance is a combination of sophisticated software and processequipment knowledge from experts in ANDRITZ and the client organisation. Veracel was a pioneer in using OPP Figure 2. A specialist from ANDRITZ Maintenance Solutions to produce pulp to innovate better commodity Medeiros explains. detract from my core interest. Initially Veracel hired four different maintenance companies mechanical electrical and instrumentation lubrication and general building were four different approaches four different management groups and we had not established any penalties or bonuses so Veracel took all the risks. In 2011 it was decided to put all maintenance activities with one company. After negotiations with nine selected. Maintenance Manager for the Veracel helps Veracel know exactly what costs ourselves to integrate with their Coordinators in the mill process areas so the communications is very direct maintenance expenses and we centralised the decisions with one and they control their costs tightly quality or safety. It has been a win-win for the two companies I think. According to both Costa and Medeiros the relationship is improving year by lessons learned to improve operations together they say. such a contract is whether the maintenance provider will do everything it needs to do to keep the mill running reliably or will it try to skip certain things in order to make more on trust. has experience in maintenance but I didnt know about the quality of the contract Veracel had the best results in the companys history. Results in 2013 were also good. Last year we had one disruption that cost us tonnage but it was not the fault of maintenance. We are in a very good position this year so our expectation is that in 2015 we will have the best results in our history once environmental and safety. different maintenance scenarios that outsourced maintenance is the best way to get good results for the mill. made and I am in favour of it continuing. VERACEL CELULOSE WORLD PULPPAPER32 Things improved dramatically with zero capital investment and I became a big believer FINE TUNING BIG GAINS FROM USING NEW TOOLS ago in Brazil called OPP Optimisation pioneer in adopting this tool according to Kleverson Figueiredo OPP Specialist OPP is a combination of sophisticated software methodology knowledge database on-site specialists and processequipment knowledge from project in 2007 Medeiros recalls was to optimise the DD Washers in the bleach plant. As a result of the work Veracel increased production from 2900 to dramatically with zero capital investment and I became a big believer Medeiros says. perfectly we moved on to the other three washers in bleaching and then the four in the brownstock area. In the following years we have developed new algorithms and control strategies for chemical consumption temperature better control each stage in the for a variety of smaller and easily measurable projects to reduce chemicals increase electrical generation optimise the recovery boiler project for electricity generation had the control loops and improved the programming using multi-variable controls and fuzzy logic to increase the electrical output from the boiler and turbo-generator plant Figueiredo range of about three million dollars per year. a half-percentage point here and a half-point there adds up to real money at the end of the year. ALWAYS SOMETHING TO IMPROVE UPON powerful than it was eight years ago when we started Medeiros says. techniques. I think that we are on the leading edge of using these tools but eventually they will be used in all pulp mills. In his 31 years of working in pulp mills are doing things today that I could not savings of chemicals the improvements in safety the energy gains these are all important things to keep Veracel ahead. Medeiros and his team have some ideas about what they will do next including a couple of large projects that may take up to a year to prove in simulation before operators and getting their opinions and feedback so that we can improve he human knowledge is incredibly important. Figure 5. I can say is the millwide contract Veracel had the best results in the companys history. Ari Medeiros Veracel COO Figure 4. The answer is right here. Smart chemistry doesnt have to be complex. Sometimes all it takes is a conversation. So we work closely with you to analyze your process and water chemistry challenges. Then we connect with the right technologies that can help you achieve your goals. Experience the simplifying power of collaboration at solenis.com Together into the future with our portfolio inspired by your needs Omya is your solution provider fulfilling todays and tomorrows requirements based on CaCO3 . For printing writing papers and packaging. Omya International AG CH-4665 Oftringen paperomya.com www.omya.com 41 62 789 21 91 SERVICE - Technical service - Expertise - Analytics LOGISTICS - Delivery reliability - Flexibility - Distribution network - Tankfarm warehouses PRODUCTION - Secured raw material supplies - State-of-the-art technologies - ISO certified quality control INNOVATION - Interdisciplinary - Research network - Solution oriented - Fundamental research PRINTING WRITING PACKAGING - Mineral fillers - Coating pigments - Additives - Tailor-made solutions APPROACH FLOW SYSTEMS WORLD PULPPAPER 35 Flying into Seoul Korea you land at one of the best rated airports over the last decade Incheon International Airport. Just before landing you can see the Sihwa Lake Power plant one of the largest tidal power facilities in the world. And close by you can see the Siwha Industrial Park where Korea Paper sets a high standard for corrugating medium linerboard and white top. What all three enterprises have in common is advanced technical competence and an unwavering commitment to achievement at the highest performance level possible. While Korea Paper operates on a much smaller scale than the airport or tidal power plant they have the same intense Korean motivation to succeed. Says Ryu Jin Ho President CEO Korea Paper Koreans are known for working long hours and being committed to continuously hitting higher targets. After many years of effort and investmentand some difficult times we now produce over 400000 tons of high quality liner and white top very efficiently. No one could have imagined that our rebuilt machine could reach this quality level using 100 recycled furnish. Simplification of our approach system has been vital to our transformation adds Lee Dai Young Managing Director By Timo Koivisto and Martin Koepenick Aikawa Fiber Technologies Simply Better Board at Korea Paper By eliminating countless tanks and silos we gained control of the wet end and reduced consumption of water energy and chemicals. Mill Manager Korea Paper. By eliminating countless tanks and silos we gained control of the wet end and reduced consumption of water energy and chemicals. DECADES OF EVOLUTION Korea Paper began in the 1970s to meet the growing demands for packaging in the region. They produced 200000 tpy of linerboard and medium grades covering a wide range of grammages from 180 to over 400 gm2. They had a steady flow of business until a crisis period from 1999 to 2004 when they faced severe challenges to survive. Investing heavily from 2004 to 2007 they reached 300000 tons per year. All grades attained the targeted quality goals. BREAKING PAPER MACHINE CAPACITY LIMITS In order to reach 410000 tpy with the same machine much had to be done. In 2012 investments included a new former improvements in dewatering and most importantly a new compact approach flow system. The result New high value products including white top liner productivity gains faster grade changes. Figure 1. Ryu Jin Ho President CEO Korea Paper APPROACH FLOW SYSTEMS WORLD PULPPAPER36 A central and deliverable aim was deaeration assuring smoother runnability machine speed over 1000 mmin Continues Lee Dai Young As part of a major paper machine rebuild a new wet end approach system was needed to address our production capacity increase goals quality and also the benefits of freeing up space in a crowded work area. HIGHER OUTPUT EFFICIENCY BASED ON SIMPLICITY A central and deliverable aim was deaeration assuring smoother runnability machine speed over 1000 mmin. AFT supplied the complete approach flow system for all three plies. None of the typical large tanks are required which allowed for the complete system to be installed on the paper machine floor eliminating the need for mezzanines. The new system includes three POMp 730 series degassers two POMheaders and three POMlock C suction leg sealing. The three POMp degassers were positioned for the back ply filler ply and top ply systems. Two POM mixing headers allow different fibres to be kept separately top vs. back. In addition to the equipment AFT also delivered basic engineering 3D conceptual engineering operator training start-up supervision and performance testing. The start-up went smoothly with the POM system handling grade testing from the minimum to maximum grammages without issue. Figure 2. Lee Dai Young Managing Director Mill Manager Korea Paper Figure 3. The POM system handles all three layers and also includes 3 POMp 730 Degassers and 3 POMlock C units WORLD PULPPAPER 37 Notes Kim Jinhong Representative Director Oh Yang Patech Co. Ltd. for AFT The fact that the POM wet end saved capital by eliminating the need for seal pits silos and chests is a great starting point. Best of all however is better process stability and quicker response to control changes. BUBBLE TROUBLE With the traditional approach system more had to be done in wastewater treatment which meant a focus of time and higher use of chemicals. Lots of bubbles in the whitewater and wastewater treatment often call for an overload of defoamers. Changing over to the POMp degasser however meant that the entrained air reduction of about 70 eliminated much of the foam without chemicals. With less demand on the wastewater system we have more time to focus on other important issues says Lee Dai Young. Now we use about half the defoamers that similar mills employ in Korea. WATER USE DROP DRAMATIC Lee Dai Young being a strong advocate for simplicity suggests that lower water consumption is fundamental to the productivity and quality gains. Fewer problems happen when tanks are gone. Contaminants and deposits dont have a chance to build up as they did before. A closed system with less entrained air is also easier to clean. Water volume was decreased by over 50. More importantly all of the problems that are created because of huge water volumes and what grows in various tanks became history. He continues As you decrease water use you can control better. You make adjustments faster. Your good ideas are not diluted in the vast liquid volume which you dont need. FREQUENT GRADE CHANGES To satisfy a wide range of customers Korea Paper makes frequent grade changes which include colour and grammage changes. The normal procedure is step by step but now dramatic changes are possible in a short period of time. Sometimes an important customer needs a particular With the traditional approach system more had to be done in wastewater treatment which meant a focus of time and higher use of chemicals Figure 4. Kim Jinhong left Representative Director Oh Yang Patech Co. Ltd. for AFT with Keiji Yasuda small space. Korea Paper saved capital by eliminating the need for seal pits silos and chests. Best of all the compactness led to better process stability and quicker response to control and grade changes. grade with very short turnaround time adds Ryu Jin Ho. Because of our smooth and flexible operations we can respond quickly when it matters. The POM system takes away a lot of stress and gives us a new advantage. Grade change time is faster because thick stock and white water systems purge quickly. Figure 5. Greater control is now the norm with a simpler wet end approach APPROACH FLOW SYSTEMS WORLD PULPPAPER38 ...all of the problems that are created because of huge water volumes and what grows in various tanks became history Figure 6. they are planning a second mill at a strategic location about an hours drive away. They also own four converting facilities and utilise half of their production themselves. THE FUTURE A new box plant is planned for next year adding to the one already in place. Looking to 2018 a new mill focused on lightweight grades will become a parallel operation with similar output. A POM system will be part of that line as well. Korea Paper is positioned to grow domestically and in Southeast Asia and the Middle East. Our team has earned a reputation for quality delivery and flexibility concludes Ryu Jin Ho. Korea Paper Lee Jinkuk Chief of Production Lee Dai Young Managing Director Ryu Jin Ho CEO Byon Dae Bok Quality Environment Figure 7. Korea Paper PM1 was rebuilt in 2012 to produce 3-ply board grades. A - www.xelorex.com We create chemistry that makes stability love changes. trademarkofBASFSE XELOREX is the innovative 4-in-1 solution for papermaking. Retention drainage fixation and strength are achieved with significantly better results than those obtained with conventional wet-end chemicals. It also reduces wet-end complexity and total cost of operations. This way XELOREX opens up new perspectives in papermaking. When cost-efficient production results in superior paper quality its because at BASF we create chemistry. ECHOONLINE thenewhomeof fibreintelligence. Offering an up-to-date view into the world of pulp and other bioproducts. www.metsabre.comecho PULP MILL OPTIMISATION WORLD PULPPAPER 41 When Mondi the global paper and cardboard producer decided to modernise their largest pulp mill in Poland they chose ABB as partners to help improve and optimise the mills two pulp production lines. For this undertaking ABB developed an advanced process control solution based on model predictive control and soft sensors. The modernisation resulted in an improvement of 56 By Abhijit Badwe and Ramesh Satini ABB Pulp and Paper Control Systems Singapore Pulp mill optimisation no longer pulp fiction One of the first things that the newly formed Mondi Swiecie did was look for ways to improve the pulp mills production process Advanced process control at the largest pulp mill in Poland has increased productivity and stabilised the processes in the cooking and pulp washing lines in a way that conventional methods of DCS control could not percent in pulp quality as well as standardised solutions that can now be offered to other pulp mills. In 2011 Mondi embarked on a project to look for ways to improve pulp quality and chemical usage enhance production and reduce cost for its two pulp production lines in the Mondi Swiecie pulp mill. A number of factors played a role in this search. One was the companys policy of reducing the environmental impact of its operations and in pulp mills this means cutting the use of heat energy and chemicals. A second factor was the requirement to improve the quality of the product. Mondi Swiecie mostly makes containerboard corrugated packaging and industrial bags which are surprisingly high-tech products. Thirdly there were the universal goals Producing consistently high-quality pulp with advanced process control PULP MILL OPTIMISATION WORLD PULPPAPER42 for further processing. HOW TO IMPROVE THE PROCESS The challenge was to make the process work more efficiently and to higher tolerances without replacing anything except the control system that operated the existing equipment. The key to this was to optimise the operation of the two lines digester and brown stock washing stages. The first step was to audit and analyse the control loops then develop an advanced process control APC action plan based on model predictive control MPC and soft sensors. THE COOKING PROCESS For the digester the key variable for product quality is the Kappa number this measures the lignin level in the pulp and thereby indicates how well the chips have been cooked. This number of all industrial processes increasing production volumes and decreasing production costs. In 2011 Mondi Swiecie awarded ABB a contract to improve the quality and efficiency of its pulp mill. To better understand the challenge involved in this task it pays to take a closer look at how the pulp process works. SEPARATING CELLULOSE The raw material for cardboard and paper is of course wood. The purpose of the pulping process is to separate the valuable cellulose fibres in wood from the lignin and hemicellulose polymers that bind them. Traditionally this was done by physically beating the wood but nowadays chemical methods are used not least because they better preserve the integrity of the cellulose. The process begins by stripping the wood of its bark turning it into chips screening the chips to achieve a roughly similar size impregnating them with chemicals and feeding them into a pressure cooker the digester. In the sulphate process used at Swiecie the chips are mixed with a solution of sodium hydroxide and sodium sulphide known as white liquor this is then pressurised and heated to a temperature of about 160 C with steam from coal-fired boilers. After a few hours the material takes on the consistency and colour of porridge the amount of alkali in the sodium hydroxide decreases as it is turned into sulphates and carbonates as a result of reacting with the lignin in the wood. At the end of the process the pulp is squeezed out of the digester through an airlock called the blow line. The sudden depressurisation results in the rapid expansion of the cellulose fibres which helps to separate them. They are then suspended in a liquid that is known to pulp workers as brown stock. The next stage of the process is to wash the brown stock to remove the cooking chemicals now referred to as black liquor together with the degraded lignin and hemicellulose. After progressing through a number of tanks the extracted liquid is reduced and its sodium and sulphur compounds recovered to make more white liquor. Meanwhile the clean cellulose pulp is bleached if necessary and then pressed and heated to remove water after which it is ready to be cut and rolled or bailed The challenge was to make the process work more efficiently and to higher tolerances without replacing anything except the existing control system Figure 1. Digester APC WORLD PULPPAPER 43 ABBs APC solution maintains the chip level by optimally manipulating the digester bottom scraper speed and the pulp flow out of the digester length of time the chips are exposed to a given concentration of effective alkali and to keep the concentration of alkali the same throughout the digester vessel. The APC is also able to maintain a consistent production rate of pulp. Finally a log of the collected data is packaged into concise reports complete with measurements of key performance indicators. Another important variable in the continuous cooking process is the level of chips inside the digester. Variations in this chip level leads to non-uniform cooking disturbances in the overall liquor balance of the process and non- uniform pulp flow at the digester outlet. ABBs APC solution maintains the chip level by optimally manipulating the digester bottom scraper speed and the pulp flow or blow flow out of the digester. While the APC is handling these complex measurements making real- time predictions about the process and implementing optimal control actions the ABB Extended Automation System 800xA distributed control system DCS handles the basic controls such as liquor and chip flows temperature pressure etc. It also performs the vital job of controlling the H-factor that is the rate at which the lignin is being dissolved. As this is largely a function of temperature the amount of heat applied to the digester has to be closely controlled. A variance from the optimal of just a couple of degrees can make a big difference to the quality of the pulp. The obvious advantage of the APC and the DCS is that the outcome meets all of the customers requirements for this step of the pulping process. The fact that just the right amount of steam has is difficult to control for two reasons. Firstly because all the chips that are fed in have different moisture content and physical characteristics. Secondly the Kappa number cannot be physically measured in the digester but only after the chips have passed through it and entered the blow line. This is a problem because it is essential to know what the Kappa number is before this point. The pulp has to stay in the oven for just the right amount of time long enough to yield as much cellulose as possible but not so long as to break down its physical structure. Therefore to maintain a steady process with minimal variations in the quality of pulp the Kappa number has to be arrived at by taking continuous measurements of the various process variables before the chips enter the digester and feeding these numbers into a mathematical model or soft sensor that considers the multiple nonlinear process effects. As shown in Figure 1 this is what ABBs solution does. The advanced process control scheme employs a soft sensor based on ABBs Inferential Modelling Platform that yields soft measurements of the Kappa number from a series of process-variable measurements. These measurements are tracked using a tracking function that creates a virtual model of the chips on their journey through the digester. Along the way measurements are derived from the chips characteristics and these are fed into the model to predict the Kappa number in every zone of the digester. The soft sensor is deployed online and yields real-time virtual measurements of quality variables such as the Kappa number that are then used by a model predictive controller to optimise the cooking process to decide the Figure 2. Control overview washing APC PULP MILL OPTIMISATION WORLD PULPPAPER44 development of a specific action plan for implementing the APC system. The implementation phase involved the deployment of the pulp tracking function in the DCS followed by the development of online soft sensors to model the Kappa number. Subsequently step tests were carried out on the process to develop mathematical models for use in the model predictive controller this was then commissioned tuned and handed over to the mill operators. The APCs are currently in the sustain phase in which ABB helps Mondi maintain the optimal performance of the APCs by performing quarterly audits remote monitoring and online retuning. A similar approach was followed for the implementation of the APC in the washing area. THE RESULT This work was carried out in phases between August 2011 and December 2013 by which time the system had been completely installed and tested. During this process the pulp mills engineers were kept fully engaged to make sure they were confident in using the APC and were able to adapt their working and training practices to make best use of it. Once the entire system was up and running it was possible to arrive at some quantitative measures as to how well the objective had been fulfilled Variations in the Kappa number in the digester were reduced by 56 percent meaning that the APC The first step was to audit and analyse the control loops then develop an advanced process control action plan based on model predictive control and soft sensors been added and just the right volume of white liquor or alkali injected means that as much waste as possible has been squeezed out of the process. And as the maximum amount of highest quality cellulose has been produced the quality and quantity criteria have been met as well. THE BROWN STOCK WASHING PROCESS This is the second key area where optimisation can be achieved through an APC system. As with the digester the data is gathered on a continuous basis so that soft sensors can give predictive readings of what is taking place. The aim in this stage of the process is to control the levels in the numerous filtrate tanks so that just the right amounts of fresh water are added for each ton of brown stock to be washed also known as the dilution factor. If an optimal value for this variable can be continuously solved for then the maximum quantity of the cooking chemicals can be recovered and the minimum amount of energy used in the evaporators. The alkali losses will also be reduced. This is achieved by the brown stock washing see Figure 2 which computes the optimal dilution factor at each washing stage based upon pulp conductivity measurements at various locations in the process. At the same time it ensures that the levels in the filtrate tanks are within their specified ranges. As with the digester the information gathered throughout the operation is presented to the control room in the form of key performance indicators. THE IMPLEMENTATION METHODOLOGY The approach followed to achieve Mondis objectives was based on ABBs Advanced Services philosophy diagnose implement and sustain Figure 3. The diagnose phase involved performing a detailed audit of the process and control loops at Mondi Swiecie which led to the Figure 3. APC implementation approach WORLD PULPPAPER 45 The approach followed was based on ABBs Advanced Services philosophy diagnose implement and sustain Figure 5. Reduction in residual alkali variation 2 SigmaFigure 4. Reduction in Kappa Variation 2 Sigma Figure 6a. Chip level with no APC Figure 6b. Chip level with APC Figure 6c. Process stability is greater when APC is on Figure 6. Figure 6. APC stabilises chip level Figure 6d. APC leads to reduced digester chip levels has helped produce pulp of a consistently high quality Figure 4 Variations in residual alkali fell by 48 percent implying a better utilisation of white liquor in the cooking process Figure 5 Variations in the digester chip level were cut by 40 percent Figure 6 resulting in reduced variations in the blow flow Figure 7. This has led to much more stability in the pulping and washing processes. A 30 percent reduction in alkali losses in the washing process was achieved Figure 8 The volume of fresh water used in the washing area and consequently steam consumption by the evaporators were both reduced Washing filtrate and blow tank levels were stabilised resulting in a reduced carbon dioxide and effluent load The obvious advantage of the APC and the DCS is that the outcome meets all of the customers requirements Figure 7. APC stabilizes blow flow Figure 8. APC reduces alkali losses in brown stock washing Figure 8a. Before APC The whole process of solving the optimisation problem and having that solution validated by the mill itself has made it possible for ABB to offer standardised solutions to other pulp mills these solutions are now called OPT800 CookC for continuous digesters and OPT800 Wash for brown stock washing. Finally the APC solution has proved to be a door opener not only for other APC opportunities but also for System 800xA DCSs as well. One recent example is a DCS order for the worlds largest pulp and paper mill which is being set up in Indonesia. One of the key customer considerations was to have a proven APC solution on top of the DCS the Mondi Swiecie project provided this.Figure 8b. After APC WORLD PULPPAPER46 PULP MILL OPTIMISATION Automation solutions to optimize berline productivity and protability through industry leading expertise delivered by people with global reach. Chemical Pulping expertise close to you Single point solutions for enhanced process control Optimized results for sustainable economic impact Please contact your local sales ofce for more information BTG Instruments AB instrumentsbtg.com www.btg.compulping Pulping Innovation Relax its in control MINERAL PRIMARY FILLERS WORLD PULPPAPER48 In contrast to graphic papers fillers have generally not been used on testliner and kraftliner qualities up to now despite the fact that significant increases in production and energy savings can be achieved through the use of mineral fresh fillers. While the consumption of graphic paper qualities in Europe dropped by 1.4 from 29.6 to 29.2 million tons between 2012 and 2014 packaging paper achieved growth of 2.6 from 35.6 to 37.6 million tons in the same period 1. In addition to the positive developments in volume it was and remains possible to achieve pleasing results in terms of sales prices. However the cost pressure is also increasing for these qualities and the current situation on the waste paper market with regard to deteriorating quality limited availability 2 and volatile prices 3 makes planning more difficult for the producers. In the long term the situation will be exacerbated by the fundamental changes in the recycling circuit. This is in addition to increasing requirements in terms of smaller batch sizes or functional properties such as mineral oil barriers. A further increase in packaging paper volumes is expected in the near future. By Ramon Roh Omya International AG Increasing efficiency of liner machines through the use of mineral primary fillers While the consumption of graphic paper qualities in Europe dropped packaging paper achieved growth This is due to an increasing shift from classic sales channels towards packaging-intensive online mail order and a drive towards environmentally friendly and sustainable packaging methods. With the targeted introduction of fillers in testliner or kraftliner products Figure 1. World recovered paper demand by major grade million tonnes Figure 2. Price of bulk grades in the European market EurosTonne FOB dealer Source RISI 2014 development of global demands for various waste paper qualities Source RISI 2014 development of the European market price for various waste paper qualities With the targeted introduction of fillers in testliner or kraftliner products manufacturers can achieve cost benefits and increase capacity manufacturers can achieve cost benefits through increased production or energy savings even at todays full load capacities This also has a continued positive effect on product sustainability. By selecting suitable spherical fillers such as calcium carbonate very positive results can be achieved even at low volumes of between 3 and 6 . Tests have proven the feasibility of increasing production or saving production costs while having as little impact on product quality as possible Increased production output Reduced steam consumption Low impact on strength properties such as the short compression test SCT ring crush test RCT or burst resistance Reduced porosity Bendtsen In contrast to fine papers where high filler volumes some far in excess of 10 lead to increased porosity these results show a more compact structure with reduced porosity. A possible reason for this is the improved drainage capacity of the fibrous suspension in the wire section and a more homogeneous sheet in general with a more uniform starch absorption. Consequently a significant reduction in glue consumption can be expected in the further processing of the product which brings with it additional cost benefits. Significant improvements in brightness whiteness and chromacity were not observed with the volumes used. CASE STUDY Results of practical trials at Thurpapier Model AG Various filler qualities were tested in a two-part practical trial. In the first part 6 and 4 gm of fresh filler was added with a base weight of 100 gm. At a constant production volume it was possible to reduce the steam pressure for the dryer section by 5 and 3 respectively. Strength properties such as SCT RCT or burst resistance did not change significantly. Porosity was reduced by around 5 . WORLD PULPPAPER 49 100 100 Production th Steam Pressure bar Reference - 18 100 100 Production parameter 100 94.1 97.8 93 94 95 96 97 98 99 Trial - 24 Trial - 22 100 100 Short Compression Test CD kNm Ring Crush Test kNm Reference - 18 96.6 97.4 Quality parameter 100 90.0 93.3 89 90 91 92 93 94 95 96 97 98 99 Trial - 24 Trial - 22 100 Burst Strength kPa Air Permeability Bendsten mlmin Reference - 18 94.8 96.6 Quality parameter 100 95.2 95.5 Trial - 24 Trial - 22 100 93 94 95 96 97 98 99 All percentages in the key relate to the determined total ash content MINERAL PRIMARY FILLERS WORLD PULPPAPER50 The second part of the trial was carried out with the goal of utilising the savings made in steam consumption for increasing the machine speed and was thus carried out with a base weight of 110 gm. As expected it was possible to increase the production output by more than 3 through the addition of 5 primary filler. Changes in strength properties remained within the levels seen as part of general measurement or process fluctuations. As in the first part of the trial the porosity was significantly reduced. a 1 increase in production is possible for each percentage point of fresh filler added These results allow the conclusion that a 1 increase in production is possible for each percentage point of fresh filler added and thus confirms the concept. In terms of economic benefits adding fillers to testliners and kraftliners through the use of a suitable calcium carbonate is a very interesting approach for manufacturers. This relates not only to savings in energy and raw materials but far more importantly to the clear potential for increasing production by using a primary filler. These positive results will be checked further in extended long-term trials in the near future. Figure 3. increase in production is possible 100 Production th Steam Pressure bar Reference - 15 102.2 103.7 Production parameter 100 100 100 99 100 101 102 103 104 Trial - 18 Trial - 20 110 100 Short Compression Test CD kNm Ring Crush Test kNm Reference - 15 100.7 106.3 Quality parameter 95.5 100 105.5 80 85 90 95 100 105 Trial - 18 Trial - 20 100 Burst Strength kPa Air Permeability Bendsten mlmin Reference - 15 96.4 96.8 Quality parameter 98.4 100 89.2 70 75 80 85 90 95 100 Trial - 18 Trial - 20 DECISION CHAIN supports the Pulp Paper Industrys Because sooner or later youre going to want Rich Data Smart Analytics and Expert Consulting ANALYSIS PLANNING How big is the market and how is it growing How is capacity changing How competitive are we Is there protability in exporting How do nancial performances compare Which regions have the most potential OPERATIONS PRODUCT DEVELOPMENT How does asset efciency compare Where are cost improvement opportunities What else can the machine make How do environmental performances compare What new products does the market need most How competitive can we be in each new product SALES MARKETING Where are the best margins to be found How cost-competitive is each asset How attractive is the market for a new product Whats in the pipeline and wheres the best ROI Is sales well prepared Whos a star and whos not INVESTMENT MA ASSET DISPOSAL What should be sold repurposed or closed Which competitors should be targeted Whose products and locations t best Where should capital be spent and why Who has a long-term viability problem and who will survive 50 Water Street So. Norwalk CT 06854 USA 1 203 854 5390 www.sheri.comBETTER INTELLIGENCE. BETTER DECISIONS. FisherSolveTM 5 10 15 20 25 11 61 158 184 111 97 88 175 237 53 53 120 188 244 143 390 75 170 193 125 55 76 81 75 74 232 187 105 0 200 400 600 800 1000 1200 1400 0 Cumulative Production FST CostUSDperFST Overhead Materials Labor Energy Chemicals Pulps Raw Material Fiber Few Machines Are Best in all Cost Categories. Investment Will Change Competitive Positions 19 Operate for cash Invest in cost reduction Divest or close High Fiber Line Competitiveness Low HighPMCompetitivenessLow Repurpose the PM Competitiveness of Mills Fiber Lines versus Paper Machine Suggests Strategy Nine Dragons 14 Nippon 3 Oji Holdings 5 PCA 3 RockTenn 10 G-P 7 Mondi 4 IP 20 APP 7 Total 61354836 FMT Market Shares by Grade Segments Paper Machine Width Inches TPDTrimWidth More productive Less productive Our Efciency in Tons-per-Trim Width versus Key Competitors 0.131 0.485 0.673 1.187 0.398 0.843 0.859 Total Carbon Emission and Cumulative Production Cumulative Production FST per Year x1000000 0 2 4 6 8 10 12 14 CarbonEmissionSTCOeq.perFST 0.000 0.500 1.000 1.500 2.000 2.500 3.000 3.500 4.000 0.000 CO from Transportation CO from Purchased Electricity CO from Fossil Fuel Combustion CO from Raw Materials Cumulative Production FST CarbonEmission.STCO2eq.perFST Carbon Footprint versus Key Competitors in Each Grade Class Headbox Hydraulic Dilution Control 1997 Voith Master Jet GVoith Type SubType Model Year Built Original Supplier Current Supplier Former Press Assembly Press Assembly Press Assembly Dryer Dryer Dryer Size Press Dryer Calender Stack Coater-On Machine Twin Wire_Gap Roll Press Roll Press Shoe Press Drum Drum Drum Film_press Drum Hard Nip Rod Roll Blade Double Nip Double Nip Straight Through Two Tier Two Tier Two Tier Metering_rod Two Tier xxxx Metering 2001 1997 1997 2001 1997 1997 1997 1997 1997 1997 1997 Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith Voith DuoFormer TQv DuoCentri I DuoCentri I NipcoFlex CombiDuoRun CombiDuoRun CombiDuoRun SpeedSizer CombiDuoRun xxxx Speed Coater Headbox Hydraulic D Former Press Assembly Twin Wire_Gap Roll Press R D y Press Assembly Dryer Shoe Press Drum S T y Size Press D Film_press D M TDryer Drum T xCalender Stack Hard Nip Coater-On Machine Rod MC t O M hi R d x M Calender Stack Hard Nip Machine Capabilities Available for Product Development Project Forecast ShortTon Asian White Top Linerboard Capacity Growth Historical and Forecast 1 1 2 2 3 3 4 4 4 4 4 5 6 6 7 8 8 8 Total Average Ranking and Cumulative Production Cumulative Production FST per Year x1000000 0 5 10 15 20 25 30 ViabilityIndexRankingValue 0.0 2.5 5.0 7.5 10.0 0.0 FST Per Year Viability Benchmarking Assets at Greatest Risk Analysis of Logistics Product Portfolios and Costs Suggests Three Candidates C1S Label 21 Carbonless 11 Greaseproof 1 Label 0 Cover and Total 9902135 FMT Liquid Packaging 24 Finished Products Made on Other Machines Like Ours Paper Machine Width Centimeters MTPDcm Widths and Productivities of Machines Making the Target Grade Today MassEnergy Balance Model Flow Sheet Key Financial Ratios versus Competitors with Bankruptcy Probabilities Target Higher Cost Competitors in Selected Areas 49 54 38 74 148 56 53 43 99 149 0 200 400 600 800 1000 1200 1400 1600 1800 CostUSDperFST 0 50 100 150 200 250 300 350 400 450 0 -50 Cumulative Production FST CostUSDperFST Transportation Overhead Materials Labor Energy Chemicals Raw Material Fiber Us Them Energy Energy Lower Energy Prices Alone Could Make Them Competitive OPTIMAL DEWATERING WORLD PULPPAPER52 1. INTRODUCTION The efficiency of overall water removal during papermaking is critical for good runnability quality and cost-effective paper production. Water removal occurs in three areas on the paper machine the forming press and drying sections. It has long been accepted that the most cost-effective dewatering takes place in the forming section. As a result it is advantageous to remove as much water as possible during web formation. The cost and effort of removing water increases considerably throughout the production process so it is imperative though often difficult to find the right balance. 2. BACKGROUND 2.1. Optimal dewatering is dependent on the size of the flocs created at various stages of the process. Large flocs in general have the potential to drain well in the wire section but tend to hold a substantial amount of water when entering the press section. This water can be very difficult and crucially expensive to remove in the pressing and drying sections of the paper machine. By Wim van den Brink Applications Project Manager Luc VanderAuwera Laboratory Team Manager Patric Bierganns RD Manager and Paul Knight Market Manager Solenis Novel total dewatering concept improves water removal and paper machine runnability A well-designed laboratory test can provide useful information about the dewatering process without incurring the high cost and risks associated with full-scale evaluations Therefore one has to consider a certain balance between floc size and water removal in the wire section and press dryer sections. In particular small micro flocs or flocs with a more open structure tend to favour water removal in the press and dryer sections. Controlling floc size with the aim of optimising dewatering becomes even more difficult when producing high basis weight paper and board 250 gsm. A well-designed laboratory test can provide useful information about the dewatering process without incurring the high cost and risks associated with full-scale evaluations of many different retention and drainage programs. 2.2. Test Methodologies Traditional laboratory retention and drainage testing can be done with tools such as Drainage Freeness Retention DFR Dynamic Drainage Analyser DDA see Figure 1 and Vacuum Drainage Tester VDT. In general VDT differentiates itself from gravity drainage testing Schopper Riegler Britt Jar DFR by providing information related to the sheet moisture content as it enters the press section of the paper machine. For cases where one is most interested in obtaining highly reproducible dewatering rate data following treatment with different chemical programs DDA is the recommended tool. Unfortunately none of the described methodologies provides accurate predictive values regarding the potential of efficient water removal in the press and dryer sections during full-scale machine trials. Nor do they fully capture or predict the behavior of polymer programs. Hence there is a need for a predictive laboratory or field method that can simulate wet-end drainage press dewatering and water removal in the drying section. 3. TOTAL DEWATERING CONCEPT 3.1. The Challenge Polyethyleneimine PEI has been the benchmark for retention and drainage for higher basis weight recycled packaging grades. In an effort to reduce total operating costs heavy weight paper and board producers have been searching for new technologies that allow them to Simulation of overall water removal in heavy weight paper and board optimise water removal whilst increasing productivity and maintaining product quality. 3.2. New Method Simulates Overall Water Removal Acknowledging the market requirements for a breakthrough in dewatering Solenis committed resources to the development of a new laboratory methodology referred to as the Total Dewatering Concept. The approach uses many of the traditionally available laboratory tools such as the DDA laboratory sheet presses and the laboratory sheet dryers. To better emulate the customers processes the new laboratory method incorporates improvements in press and dryer dewatering simulation Fig. 2. Starting with a sheet formed in the DDA the goal is to measure the performance of a range of dewatering programs during the different stages of papermaking. The method measures the sheet weight and sheet dry solids at each individual process step drainage pressing and several drying steps and can even be used with a range of target process parameters such as final sheet moisture energy required or drying time. Developed at Solenis Krefeld Technical Centre this new method evaluates and ranks the dewatering performance of existing products but it can also be used as a tool to develop new more effective products. 4. A CASE-ORIENTED APPROACH 4.1. Introduction The value of the Total Dewatering Concept has been demonstrated first at the Mayr Melnhof production WORLD PULPPAPER 53 ... there is a need for a predictive laboratory or field method that can simulate wet- end drainage press dewatering and water removal in the drying section Figure 1. Dynamic Drainage Analyser DDA OPTIMAL DEWATERING WORLD PULPPAPER54 facility in Neuss Germany. A number of drainage technologies had been thoroughly evaluated by the experienced technical team at the mill. Trials on the paper machine revealed that the incumbent PEI program gave the best performance despite data from traditional lab testing that showed otherwise. The Total Dewatering Concept developed by Solenis was then applied to studying the dewatering characteristics of the furnish. Simulating each step in the dewatering process gave an insight into the optimum floc structure required to effectively manage water removal at each stage Fig. 3. Once this was established it was then possible to develop novel polymers that enhanced each dewatering step. 4.1. Collaboration with Mayr Melnhof Mayr Melnhof Neuss Mill was established in 1911. Today it has the largest and most modern recycled fibre folding carton board machine in Europe. The grades produced at the Neuss mill are characterised by consistently high quality and application safety making them perfect for use in the food and non-food packaging sector. It achieves these results with the following machine characteristics 4-ply Fourdrinier machine producing folding carton board Different furnishes in each ply Production 55 tonnes per hour Grammage range 180 to 375 gsm Machine speed 425 to 850 metres per minute Mid Ply 100 Recycled Packaging As the basis weight of the mid ply increases control of dewatering in the press and dryer sections becomes critical. The initial trials at Neuss focused on replacing PEI in the mid ply. The application of the Total Dewatering Concept was used to select the most effective polymer for managing dewatering during forming pressing and drying. PerForm PC303LM was found to give the best results especially after pressing. Based on these findings the mill at Neuss implemented a program in which overall water removal in the mid ply is controlled by a post- screen injection of up to 3.5 kgT polyethyleneimine 70 reduction and up to 850 gT PerForm PC303LM dosed via Solenis PerForm VMax 1000 injection system. The actual dosages vary according to the grade being produced. 4.3. Program Results Following the successful application in the mid ply the program has now also been extended to the outer plies PerForm PC303LM up to 400gT dosed via PerForm VMax1000. Such has been the success of the program that it will soon be adopted by other similar machines. The application of the Total Dewatering Concept was used to select the most effective polymer for managing dewatering during forming pressing and drying Figure 2. Pressing Results WORLD PULPPAPER 55 The implementation of the PerForm PC303LM program has resulted in more stable running conditions on the paper machine efficiency. Benefits of Improved Dewatering Improved paper machine runnability Improved ply bond results on specific grades Lower total operating costs Reduced retention treatment costs by up to 75 The authors wish to extend a special thanks to the Mayr Melnhof Neuss mill which collaborated extensively with Solenis to demonstrate the success of this new methodology and polymer- based program. REFERENCES 1 Risnen K. O. Paulapuro H. and Karrila S. J. The Effects of Retention Aids Drainage Conditions and Pretreatment of Slurry on High- Vacuum Dewatering A Laboratory Study Tappi J. 78 4 140 1995. 2 Maunier C. O. and Ramarao B. V. Effect of Flocculation on Pulp Drainage Characteristics Proc. TAPPI 1996 Engineering Conf. 221. 3 Kufferath W. Dewatering Process on the Paper Machine Deut. Papierwirt. 1983 163 1983. 4 Risnen K. Karrila S. and Maijala A. Vacuum Dewatering Optimisation with Different Furnishes Paperi Puu 78 8 461-467 1996 5 Britt K. W. Unbehend J. E. and Shidharan R. Observations on Water Removal in PapermakingTappi J. 69 7 76-79 1986 6 Lindberg L. Pulsed Drainage of Paper Stock Svensk Papperstidn. 73 15 451-454 1970 7Baldwin. L. High Vacuum Dewatering Paper Technol. 38 4 23-28 1997 8 Retulainen E.Condebelt Press Drying and Sustainable Paper CyclePaperi Puu 85 6329-333 2003 9 Wahlstrm B. Wet Pressing in the 20th Century Evolution Understanding and Future Pulp Paper Can. 102 12 81-88 2001 10 Hubbe M.A. Tripattharanan T. Heitmann J.A. and Venditti R.A. The Positive Pulse Jar PPJ Aflexible Device for Retention Studies Paperi Puu 86 2004 accepted 11 Ahrens F. Alaimo N. Nanko H. and Patterson T. Initial Development of an Improved Water Retention Value Test and its Application to the Investigation of Water Removal Potential TAPPI 99 Proc.37-47 TAPPI Press Atlanta 1999 It is anticipated that the Total Dewatering Concept will support the development of novel polymers to improve dewatering at each stage of the papermaking process. 5. Conclusion The development of the Total Dewatering Concept and subsequent application to real papermaking processes has yielded significant benefits for the Mayr Melnhof mill in Neuss. The implementation of the PerForm PC303LM program has resulted in more stable running conditions on the paper machine and total operating costs have been greatly reduced through the reduction in polymer consumption. The Total Dewatering Concept can be applied in all cases where paper producers are seeking to optimise water removal in their processes whilst maintaining or improving the paper properties quality and overall machine Figure 3. Total Dewatering Concept Results INTRODUCTION Recent advances have taken some of the mystery out of bacteria problems. Many mills that have been close to the allowed hygiene limits can now run with less worry about specs and potential costs. Board grades which are used for packaging of dry or fresh food milk or other liquids for human consumption have strict requirements regarding the hygienic quality of the packaging board. If they are not tightly controlled minute micro-organisms present in hygienic grades like liquid packaging board LPB or food-grade folding box board can be extremely costly. For example if part of a shipment of these grades is out of spec for hygiene the converter may reject the whole lot. A two-day outbreak of bacterial spores on a board making machine can lead to the loss of thousands of tons of finished LPB at a cost approaching millions of Euros. This is clearly a much bigger financial loss compared to for example a non-food grade machine where slime growth on machine surfaces means smaller losses in terms of downtime tonnage and money. To ensure that the hygienic quality of the final board meets the required BACTERIAL CONTROL MEASURES By Dr. Marko Kolari Senior Principal Scientist Microbiology Biotechnology RD and Technology EMEA Juha Rintala Marketing Manager Deposit Control Pulp Paper EMEA Kemira Oyj Finland WORLD PULPPAPER56 Better hygiene in food-packaging board at reduced risk of rejected tonnage and machine corrosion specifications manufacturers need to apply high-performance microbe control programs on their board machines. Over the past decade Kemira has emerged as one of the leading global suppliers of microbe control solutions to the hygienic board industry. Based on numerous RD programs and mill trials we now have a better understanding of how to control process conditions and avoid process situations that cause sporulation. Recent results with new applications in mills show that we are clearly on the right track in taking some of the mystery out of these frustrating and costly disturbances. This report summarises some of the things we have learned which can help you keep your board within the hygiene Many mills that have been close to the allowed hygiene limits can now run with less worry about specs and potential costs Figure 1. Microscope pictures of paper machine bacteria Cells of Deinococcus geothermalis growing on steel surface 1a and cells of Rubellimicrobium bacteria growing in process water 1b. These non-spore formers do not endanger hygiene of board as they are all killed by heat of dryer section. Fig 1c. A mature spore just being released from a Bacillus cell. If present in wet paper web these spores will survive alive into the dry finished board. B A C WORLD PULPPAPER 57 High hygiene can only be achieved through very close cooperation between the biocide supplier and the mills production personnel specifications. Beside the scientific facts which we have discovered we have also concluded that high hygiene can only be achieved through very close cooperation between the biocide supplier and the mills production personnel. HYGIENE CONTROL IS ALL ABOUT SPORE CONTROL Depending on end uses board machines have various hygiene targets for food packaging. Many specifications are based on a maximum acceptable level of aerobic bacteria in the final dry board. For example LPB for milk products normally must contain less than 250 CFU of living aerobic bacteria per gram in dry board. In reality however we have found the quantity of aerobic bacteria in the final dry board depends on bacterial spores only. These spores are thermo-tolerant forms of bacteria sleeping cells and when they are mature they can survive the heat of the dryer section whereas vegetative growing bacteria cells and incomplete spores are destroyed by heat. Therefore spores are the real bad guys regarding food board hygiene. Figure 1 gives additional examples of this. Figure 1a shows a scanning electron microscope picture of cells of non- spore forming paper machine bacteria Deinococcus geothermalis growing on stainless steel surface. Figure 1b shows vegetative cells of Rubellimicrobium bacteria in process water. None of these vegetative cells can endanger hygiene of final board as they are effectively killed by the heat of the drier section. Figure 1c shows a transmission electron microscope picture of a mature spore just being released from a Bacillus cell. If present in wet paper web these thermo- tolerant spores will survive through the heat of the dryer section and are alive in the dry finished board. Hygiene control is all about spore control. TROUBLE ON THE MACHINE DESPITE HIGH BIOCIDE LEVELS In our work with hygiene in mills we have observed several food-packaging board machines that were running significant amounts of biocides but were still having difficulties in meeting strict end-product hygienic specifications. So despite intense use of biocides these machines were still periodically suffering from bursts of elevated levels of bacterial spores thus endangering the hygiene of the food-packaging board. Adding to the mystery some machines can run every day with high amounts of vegetative bacteria in process water and still not experience hygiene issues in board. In deeper studies on one board machine for example we observed an interesting phenomenon. In one process tank the total quantity of vegetative bacterial cells remained at essentially the exact same level for three consecutive days. However on day 1 the amount of spores was below detection limits on day 2 they jumped to very high levels and then on day 3 they were again below detection limits. Thus the vegetative cells were at stable levels but the spores were fluctuating from day to day. RD ON SPORE CONTROL Our RD programs aimed at reducing contamination in food-board mills have given us unique insight into the mechanism of sporulation what triggers it and what controls it in the board making process. This learning and new understanding in turn has supported the successful application of biocide solutions on hygienic board Bacillus Brevibacillus and Paenibacillus Among all aerobic bacteria that are capable of growing in the process of a board machine only these three genera are aerobic spore-formers A spore is inactive resting thermo-tolerant form of bacteria that resists the dryer heat Similar to other bacteria these prefer to grow multiply by simple cell division they make spores only if needed One cell produces only one spore of a threat to survival Killing of a mature spore requires a huge amount of biocide not economically affordable Prevention is the best approach stop bacteria from making a spore BACTERIAL CONTROL MEASURES WORLD PULPPAPER58 One of our key findings is that the total quantity of vegetative cells and spore counts do not directly correlate machines. One of our key findings is that the total quantity of vegetative cells and spore counts do not directly correlate. Some process tanks can contain higher bacterial counts but not spores whereas another tank that may look fine based on low total bacteria count is really surprisingly high in spore content. RUNNING CLOSE TO THE EDGE Based on the experience and knowledge gained through both RD studies and numerous mill trials we are now confident that we have good solutions that can control hygiene issues. We have worked in many mills that having experienced hygiene troubles had tried and failed with other biocide solutions before we got involved. When we came in and worked closely with the mill team we were able to get them comfortably and consistently within specifications. Figure 2 below gives a typical before and after picture regarding spores. We have also observed many machines that run barely within specifications or put simply close to the edge. This leads to a fairly nervous situation for the mill management operations and sales teams. Achieving superior hygiene on a board machine requires complete cooperation between the mill and the partner taking care of dosing and monitoring of microbe control products ensuring that problems are anticipated and dealt with in a proactive way. Success also requires careful monitoring of all raw materials coming into the process including pulp and all chemicals. It may seem like an excessive amount of initial hard work but the payback to the mill in terms of reduced lost tonnage is very significant. In addition the mysterious and frustrating outbreaks of spores are reduced leading to improved peace of mind for the mill management. CORROSION RISKS OF INTENSIVE BIOCIDE PROGRAMS Another issue that unfortunately does not receive much attention until it is sometimes too late is the corrosion of machinery and components. We know of over 30 paper and board machines that have experienced dangerous and costly corrosion issues due to intense use of biocides. Machine corrosion due to biocides is a very real risk especially in food packaging board machines which are often using biocide-intensive control strategies due to the hygiene requirements. It is thus extremely important to understand and mitigate any potential corrosion risks especially when applying an intensive biocide program. We have conducted basic research on vapour phase corrosion mechanisms in paper machines to improve both understanding and control. Like hygiene corrosion on paper machines is very complex. In all of our laboratory studies steel plates were located above containers of flowing white water in a manner that only vapour phase contact occurred. Different oxidising biocides were then dosed at equal total active chlorine concentration and the subsequent corrosion of the steel coupons was measured. There were two key Figure 2. Development of bacterial spore content in finished board during a period of correcting the hygiene situation green line by applying a new control philosophy WORLD PULPPAPER 59 findings first at equal dosage level in terms of active chlorine content the different species of stabilised chlorine compounds demonstrate corrosion rates of widely different magnitudes. Secondly laboratory experiments can never fully demonstrate the true corrosion potential in vapour phase in an individual paper machine due to machine specific moisture conditions and in-situ reactions of chemicals in white water. Therefore we developed an on-line probe for measuring changes in vapour phase corrosion rate. This probe is sensitised so that it corrodes all the time and responds to chemical changes in vapour phase thereby giving a possibility to observe changes and react before corrosion occurs in the machine. More information on biocides and corrosion is shown in Figures 3 and 4. As a result of studies both in the laboratory and mills we have created a complete package to reduce corrosion risks to machines while at the same time ensuring hygiene in the board products. CONCLUSION Safely achieving hygienic conditions on a food packaging board machine is not simple. The mechanisms of contamination and corrosion are both complex and require expertise for control. We have shown that there is no direct correlation between the level of aerobic bacteria and the level of spores the true enemy as they can survive the heat of the dryer and contaminate your finished product at a high cost. Kemira has gained significant market share within hygienic board by successfully controlling spore formation mechanisms. Close co-operation among our Sales Applications and RD groups with the board mills has provided customers with clear competitive advantages stable production combined with continuous improvement in hygienic quality. Long-term control of bacterial spores on a board machine requires special competence to select the best control strategy for each individual machine. There is no universal spore control philosophy that best fits all machines Figure 3. Kemira CorrStrix on-line data from a folding boxboard machine. A new biocide program was started after shutdown with no other changes done in the wet-end of this board machine. The average rate of vapour phase corrosion at dryer section reduced by over 75 when compared to the previous biocide program. The complete package for hygiene control Kemira FennoClean Corrosion-safe biocide products in the machine On-line monitoring tools for of biocides such as CorrStrix Know-how and products for controlling spore formation Centralized data management and analysis tools KemConnect for follow-up Systematic co-operation with customers enabling continuous improvement in hygienic quality Safely achieving hygienic conditions on a food packaging board machine is not simple. The mechanisms of contamination and corrosion are both complex and require expertise for control BACTERIAL CONTROL MEASURES WORLD PULPPAPER60 Long-term control of bacterial spores on a board machine requires special competence to select the best control strategy for each individual machine in the world. We have seen numerous machines where this one-size-fits- all strategy has failed and when subsequently called in to help we have been able to correct the situation by applying a different philosophy and understanding to control spore formation. Kemiras toolbox to combat spores in food-packaging board is unique and the most comprehensive on the market. It includes patented products and treatment concepts such as FennoClean D patented Global annual production of hygienic board is approximately 14 million tons of which liquid packaging board LPB makes up about 5.5 million tons. Depending on end-uses of the board grades these machines have different hygiene specs and targets. Machines with the strictest targets follow the Dairyman standard with aerobic bacteria content of max. 250 CFUg of dry board. This is also the maximum accepted level according to FDA legislation for milk packages in the US market. The most common target setting in food- packaging grades is aerobic bacteria content of max. 1000 CFUg of dry board. FennoClean qSpore FennOx and CorrStrix are trademarks or registered trademarks of Kemira Oyj or its subsidiaries. diagnostics such as qSpore and patented on-line monitoring tools such as Kemira FennOx and CorrStrix. When applied correctly these can help you take the mystery frustration and costs of contamination out of your food packaging board machine. a Slime on frames b - c Clean headbox however if unaware of potential corrosion risks the intense biocide usage can create costly corrosion issues d Corrosion damages. More information about corrosion safe use of biocides in the article. A C D B Some people think the word partnership is just a buzzword. We have a different perspective we think it is the best way to do business. Whether you are executing a rebuild or a new installation you want your project to be on time within budget and safe. And you want the equipment to perform at a high level for a long long time. ANDRITZ is known as a manufacturer of high-quality equipment. A closer look reveals that we also build high-quality relationships supporting you technically mechanically and personally Heres a fresh perspective on what it means to be partners. throughout the lifetime of your equipment. We are your technology and service partner. When you need a fresh perspective on what true partnership means let ANDRITZ open up new possibilities for you. www.andritz.com We accept the challenge BIOCONTROL DIAGNOSTICS WORLD PULPPAPER62 INTRODUCTION Papermaking systems utilise several raw materials that introduce microorganisms into the machine system. This includes virgin wood fibre recycled fibre freshwater starch dyes and other chemical additives. Microorganisms proliferate in the warm nutrient-rich environment of the papermaking system and diverse microbial communities result. Inadequate control of microbial growth allows for the formation of surface deposits that slough leading to filter or nozzle plugging and defects e.g. spots or holes or breaks in the sheet. Microorganisms can also proliferate in the felts and machine fabrics negatively impacting water removal and machine or operational efficiency. Traditional key performance indicators including conventional plating techniques and oxidant residuals often indicate adequate dosing and control. However deposition defects and breaks may still be prevalent. There is a need for monitoring tools that provide more accurate information regarding microbial growth and biofilm formation in industrial water systems and allow for more rapid determination of the contribution of microorganisms to sheet defects. The presence of microorganisms in sheet defects and By Liliya Lund Lead Chemist Laura Rice Corporate Scientist Elisa Luth Senior Microbiologist NALCO Water an Ecolab Company Advanced Diagnostic Strategies for Optimal Biocontrol Many traditional monitoring approaches do not provide enough information to respond in a correct or timely manner to an upset situation ability to determine the location of problematic deposits in the process would allow for rapid implementation of the most appropriate microbial control strategy Figure 1. Such information can be acquired through the use of quantitative polymerase chain reaction qPCR techniques. Optimised treatment strategies reduce the volume of treatment chemical required to control problematic deposits. PROBLEMS WITH TRADITIONAL MONITORING TOOLS Many traditional monitoring approaches do not provide enough information for the papermaker to respond in a correct or timely manner to an upset situation. Techniques such as plate counts and adenosine triphophsate ATP measurements fail to represent and discriminate between the different microorganisms present in a sample. Analysis of microbial population using conventional plating techniques is labour intensive time consuming and relies on the ability of an organism to grow on a defined or selective medium. Moreover lengthy incubation periods negate any possibility for pro-active control or preventative measures related to microbial growth in the process. While plating allows for a basic level of identification of organisms it requires that the organism is viable. The need for viable bacteria and lengthy Figure 1. MAP is used to determine the contribution of bacteria to sheet defects and holes and target treatment based on the type and quantity of DNA detected MAP utilises quantitative polymerase chain reaction qPCR to provide accurate timely and representative information about the population of microorganisms in any given sample incubation times limit the value of this approach as a problem solving tool especially when it comes to analysis of sheet defects and felts. A more rapid method for detecting microbial growth in process waters is by measuring the amount of ATP. While it is possible to quantify microbial activity in a sample with the use of the ATP assay the reaction is unable to discriminate between ATP that is produced by one type of microorganism compared to another and it does not detect organisms that are viable but inhibited. Another disadvantage is that this method cannot be used to determine microbial contribution to sheet defects because most organisms are not viable following exposure to the heat of the dryer section. In contrast to plating and ATP measurements ninhydrin staining and Fourier transform infrared FTIR spectroscopy can be used to assess microbial contribution to sheet defects. These methods are not quantitative indicating the potential presence or absence of microorganisms. They are also non-specific preventing the ability to identify the source of contamination or process location where growth is not adequately controlled. Furthermore these methods are prone to false positive or false negative results caused by chemical additives that interfere with the test method and detection limits. In addition if bacteria are detected in the defect it is not possible to tell which organism is responsible for the defect and what part of the process it originated in. METAGENOMIC ANALYSIS PROTOCOL MAP MAP is a Nalco patented technology that fills technological gaps left by traditional monitoring approaches. This technology provides the ability to quantify and identify microbial DNA present in the papermaking process Figure 2. All living things contain DNA which is a robust molecule capable of surviving conditions found in papermaking systems. Once detected microbial DNA is broken down into groups of bacteria that are known to cause problems in a papermaking environment 1. Total bacterial load of the sample The general bacterial population present in a sample 2. Primary biofilm-formers Bacteria capable of colonising clean machine surfaces 3. Adaptive biofilm-formers Bacteria that exhibit tolerance to some biocontrol programs 4. Fresh water bacteria - Bacteria including filamentous bacteria that enter the papermaking process with raw water 5. Fungi 6. Sulfate-reducing bacteria Bacteria that reduce sulfate to form hydrogen sulfide gas 7. Spore-formers Bacteria that have the propensity to form spores when experiencing an external stress e.g. nutrient depletion or biocides. MAP utilises quantitative polymerase chain reaction qPCR to provide accurate timely and representative information about the population of microorganisms in any given sample. By focusing on the potential problem developed by uncontrolled growth of these problematic organisms more WORLD PULPPAPER 63 Figure 2. corresponding to a problematic organism. BIOCONTROL DIAGNOSTICS WORLD PULPPAPER64 The root cause of sheet defects is notoriously difficult to determine Figure 3. Utilising MAP to resolve a product quality issue 3.1. was microbiological 3.2 bacteria in the process. 3.3. successful WORLD PULPPAPER 65 Patented DNA-based monitoring strategies are available to provide more accurate information regarding microbial growth and biofilm an appropriate chemical for their elimination. CUSTOMER EXAMPLE A coated freesheet mill was experiencing product quality issues due to an outbreak of sheet defects. Onsite biomonitoring using traditional plating and ATP tools did not indicate a microbiological problem. Analysis of sheet defects with MAP showed that the root cause of the problem were problematic bacterial species including adaptive and filamentous biofilm-formers Figure 3-1. Following a process survey the location of these bacteria in the process was identified to determine the most responsive addition point for the biocide Figure 3-2. Subsequent MAP testing confirmed eradication of problematic bacteria from the process Figure 3-3. CONCLUSION Conventional plating techniques and oxidant residuals may indicate adequate biocide dosing and control of microbial growth while deposition defects and breaks remain prevalent. Patented DNA-based monitoring strategies are available to provide more accurate information regarding microbial growth and biofilm formation in industrial water systems. These strategies allow for rapid analysis of the contribution of microorganisms to deposit formation and can be used to rapidly determine whether or not deposits containing microorganisms are contributing to defects. Quantitative PCR techniques allow for rapid analysis of sheet defects to determine the contribution of microorganisms to quality issues. This new approach has been demonstrated to allow for a more proactive diagnosis of problems leading to improved machine efficiency and product quality Figure 4. precision can be applied to the design and deployment of microbial control programs. CONNECTION BETWEEN MACHINE DEPOSITS AND SHEET DEFECTS The root cause of sheet defects is notoriously difficult to determine. High temperatures in the dryer section desiccate all microbial contaminants making them impossible to analyse using traditional plate counts or ATP techniques. The burden of identifying whether the defect is microbial or chemical in nature then falls on mill personnels experience FTIR or ninhydrin spray. The experience of mill personnel can be subjective and FTIR and ninhydrin spray detect chemical groups that are not unique to microorganisms. All of these approaches can result in inaccurate information that may lead to an improperly treated process. DNA is a robust molecule that can withstand extreme conditions of the dryer section. MAP makes it possible to detect bacterial DNA in sheet defects and identify problematic species present therein thus making it possible to determine with certainty whether the root cause of the problem is chemical or bacterial in nature Figure 1. Based on the type and quantity of microorganisms present their origin can be traced back to a specific source in the process. IDENTIFICATION OF HOT-ZONES OF PROBLEMATIC BACTERIA IN THE PROCESS Once the root cause of a sheet defect has been recognised as microbiological and the implicit bacterial species identified it is important to eliminate the source of these bacteria from the process. Using MAP to perform a thorough process survey allows for the type and quantity of target bacteria to be determined to track their origin back to a specific location or raw material source in the process or locations that serve as proliferation zones for these bacteria. TARGETING THE MOST EFFECTIVE CHEMICAL TO THE MOST RESPONSIVE ADDITION POINT When the identities and location of problematic organisms are known it is possible to accurately target the right chemicals to correct the problem. Knowing which organisms are present makes it easier to select Figure 4. MAP Technology allows for proactive diagnosis of microbial problems leading to targeted treatment strategies that and quality MICROBIOLOGICAL SOLUTIONS WORLD PULPPAPER66 INTRODUCTION All grades of paper can have a problem with odour. The problem can be in the paper or as part of the operation. The cause of odour problems fall into two main groups chemical and microbiological. The microbiologically- caused problems occur more often than the chemical- and this is especially so with recycled packaging grades. When investigating an odour problem an understanding of the possible causes is important. There are various lab methods to identify the odour forming gas. Identifying the source of the odour is an important first step in the problem solving process. Once the source has been identified then a solution can be implemented. The solution can include process changes as well as a treatment program. This article focuses on volatile fatty acids VFAs and the issues they can cause in recycled packaging grades. RECYCLING PACKAGING When looking at the packaging industry as a whole VFAs are more of a problem in 100 recycled operations. If you think about the pulps used in virgin packaging such as unbleached kraft NSSC and sulphite it is clear that the pH and temperatures that are used in these processes result in good microbial control. With old corrugated containers OCC you have a number Identifying the source of the odour is an important first step in the problem solving process. Once the source has been identified then a solution can be implemented of factors that result in more microbial contamination. These include outdoor storage and single stream recycling. With single stream recycling there is more chance of the recovered board to be contaminated with food matter. The food matter will contain microorganisms and also serve as food for the microbes. The other factor that has led to more VFA issues is the tightening or closing up of water systems in packaging mills. As packaging companies look to reduce fresh water use save energy and reduce effluent there is less and less opportunity to remove or wash out undesirable compounds. This is a factor that affects all types and grades of pulp and paper. VOLATILE FATTY ACIDS What are VFAs and where do they come from VFAs are fatty acids with an aliphatic tail of less than six carbon atoms. Table 1 lists the various VFAs and the odours they produce. The most common types of VFAs found in recycled packaging operations would be acetic propionic and butyric. Many different types of bacteria can produce VFAs these include both facultative and strict anaerobic bacteria. Facultative anaerobic bacteria can survive with or without oxygen while strict anaerobes thrive in no or low oxygen conditions. One example of a VFA producing bacteria is the Clostridium genus. These are obligate anaerobes meaning that oxygen is toxic to them. They are also endospore formers. Some bacteria form an endospore this is a spore that is formed inside the bacterial cell that contains the genetic material. This spore is released when the cell dies and is very resistant to hostile environmental conditions. They will survive prolonged boiling for example. Once conditions are again favorable to the bacterias growth the spores wake up and start to grow. The presence of endospore forming bacteria is a factor that needs to be considered in a control program. What are the issues that can be caused by VFAs These fall into a few areas the first is odour which can be in the final product or in an area. There can be complaints from neighbours or from the workers in the mill. Odour in the final product can be a very serious issue that can lead to loss of business and can put a mills future in jeopardy. Some packaging customers have limits on the VFA level in the sheet that need to be met by the board producer. DIAGNOSTIC METHODS In problem solving any odour issue you first need to determine the type of gas or gases that are producing the odour. There are various tests that can be done By David R Jones Industry Specialist Buckman Solving Volatile Fatty Acids Issues in Recycled Packaging Operations in a lab. For example a gas sample can be tested with gas chromatography mass spectrometry using thermal desorption and the resulting spectra is compared to a database to determine which gases are present. There are odour panels and professional smellers. These are people who have trained themselves to be able to identify different odours. There are many references in the literature that give more information on methods. There are monitors available that can detect gases and identify them. In some cases these can be programmed to store an odours profile in memory. If there is a limit to VFAs in the final product in most cases these samples are sent to an outside lab for testing. In the mill there are commercially available test kits to test for VFAs in stock and water samples. While the final product testing may be required the in-mill test can be used as a monitoring tool. The in-mill test will give immediate results while the outside lab test will have a time delay. The other area of testing is the microbial enumeration or detection methods. It is important to understand the nature of Improving process conditions is important but in the case of VFA control this will not provide the complete answer of anaerobic bacteria a good control tool is oxygen. Improving mixing in chests and tanks to keep oxygen levels up will help control the anaerobes. This is an economical option. Good cleaning and housekeeping is also important. If a layer of solids is allowed to build up in the bottom of a chest then anaerobic conditions can result. The aerobic bacteria in the layer will use up the oxygen. Once the oxygen level is low then anaerobic bacteria growth will start. In the same vein leaving water and pulp sitting unused in tanks should be avoided. Again this can lead to anaerobic conditions. It is always important to audit the process to identify unfavorable process conditions and as much as possible to design them out or at least minimise them. Improving process conditions as mentioned above is important but in the case of VFA control this will not provide the complete answer. A microbial control program will be required. One aspect of VFA producing anaerobic bacteria control is the endospores that were mentioned earlier. A portion of an endospore producing bacterial population will always produce endospores. One bacteria will produce WORLD PULPPAPER 67 microbial testing. There is no one test that will test for all the different types of microorganisms especially with odour where it is important to identify the different types of microbes that are causing the odour. When in the problem solving stage a number of different tests may be necessary to help identify the microbes present and audit the system. This article will not discuss in detail the wide range of tests available but will focus on the VFA producing anaerobic bacteria. A common test for bacteria is what is commonly known as the standard plate count. This widely used method tests for aerobic bacteria which will grow on nutrient agar at a temperature of 36 C. Therefore if you are looking for anaerobic bacteria this test will not detect them. You need to use a more specific test such as using reinforced clostridial medium. This tests for clostridial species as well as some other anaerobic bacteria. It is more a yesno test in that you do not end up with a count of the population. CONTROL OPTIONS It was mentioned earlier that in most cases a control program will involve process changes as well as the use of a microbial control program. In the case Table 1. Volatile Fatty Acids Common Name Systematic Name Odour Formic acid Methanoic acid Pungent solvent like nail polish Acetic acid Ethanoic acid Vinegar Propionic acid Propionic acid Body odour Butyric acid Butanoic acid Rancid butter vomit Isobutyric 2-Methylpropanoic acid Rancid butter Valeric Pentanoic acid Fruit like Isovaleric 3-Methylbutanoic acid Body odour MICROBIOLOGICAL SOLUTIONS WORLD PULPPAPER68 one endospore. When environmental conditions become more hostile then the percentage of the population that produce an endospore will increase. The result is that you could kill all of the living bacteria and leave the endospores. Once conditions are again favorable for bacterial growth the same problem will occur. Choosing the right type of control program is important. There are two main types of biocides the organic based and inorganic. The organic products contain an active that is toxic to microbes. It is important to choose the right active for the type of microbe that needs to be controlled. A biocide active that is very effective at reducing an aerobic bacteria population may have little effect in reducing the population of an anaerobic bacteria. Thus it is important to choose the right active or actives for the type of microbe that needs to be controlled. Application program design is also important. Flow rates have to be set so that the kill concentration for that specific active is reached. In addition some actives require more contact time to be effective and this needs to be reflected in the biocide application strategy. One of the downsides in using organic biocides is that they may not penetrate the biofilm to reach the anaerobic population. Also they may not be able to penetrate a pulp build-up at the bottom of a chest. Buckman has the required information for all of the actives in our biocide product line and uses computer models to determine cycling up of the product to ensure that the effective concentration is reached. Inorganic microbicides are mainly in the chlorine family different types include chlorine gas hypochlorite and chlorine dioxide. There are also products such as peracetic acid and peroxide. The chlorine products can be effective but there are limitations especially in a packaging operation. The chlorine products are oxidisers. They will oxidise organic matter inorganic reducing matter and biological matter including bacteria. They have to satisfy the total demand to be effective. For recycled packaging mills the demand will be higher than that found in a 100 virgin bleached kraft fine paper operation. The result is that the traditional inorganic products can be expensive and less than effective. OXAMINE Buckmans Oxamine family of products can be used to control microbes. The Oxamine products are a proprietary mixture of ammonium compounds that when mixed with hypochlorite at precise molar ratios and the correct pH produce the biocidal active. Because Oxamine is already combined it is not affected by the typical oxidant demand of the system. The active itself is biocidal and is able to greatly reduce the population of both aerobic and anaerobic bacteria. The precise mixing of the two components is extremely important to safely produce the required active. If the correct molar ratio is not maintained then other compounds can be produced that are not biocidal. Buckman has developed a PLC controlled sophisticated feed system that maintains the correct ratio to ensure that the biocidal active is produced. In addition it is important that the Oxamine and hypochlorite do not mix together in When environmental conditions become more hostile then the percentage of the population that produce an endospore will increase Figure 1. Oxamine Feed System WORLD PULPPAPER 69 Problem solving involves a good understanding of the various causes of odours and the testing methods that are required to identify the type of odour and its source the neat form as this can produce toxic gases. Both products are mixed with water in the system to safely produce the desired active. The feed system has a solid partition in the middle. The Oxaminer and hypochlorite are separated by this partition. If there is a leak in the system the two neat products cannot get into contact with each other. The feed system is designed with safety first in mind. The system includes Pre-rinse and post-rinse cycles Alarms that trigger wash sequence and shutdown Lowhighno chemical flows Low or no dilution water flow Loss of air pressure Loss of power Emergency rinse in case of power failure Leak-proof casing with integrated spill sensors Back-up water source for emergency flushing Thus if there is any interruption in operation the system will automatically shut down and flush. Figure 1 is a diagram of an Oxamine feed system. Traditional chlorine products are controlled to a free chlorine measurement. In the case of Oxamine a total chlorine measurement is used. An example is an alarm in the system that will send a text to a Buckman associate or to mill personnel informing them of the alarm. Case Study 1 A 100 recycled packaging mill was receiving complaints from neighbours about odour coming from their effluent plant. The odour included VFAs. An Oxamine program was started and there has been a marked reduction in complaints over the period of one year. Case Study 2 A 100 recycled packaging mill needed to be below a target VFA level in some of their board grades. An Oxamine program was started that treated both the pulp and the water system. ATP measurement showed a tenfold decrease in total microbial population and final product testing confirmed that the VFA levels were well below target. Case Study 3 A mill needed to reduce the VFA levels in their final product. An Oxamine program was started and there was an almost immediate reduction in VFAs. Chart 1 shows the results. Another benefit of this program was that odour in the mill was reduced. CONCLUSION Odour problems in pulp and paper take many forms. Volatile fatty acids are becoming more of an issue in recycled packaging operations. The two main reasons for this include the use of recycled paper with its contamination and the closing up of water systems. Both of these result in higher microbial populations. Problem solving involves a good understanding of the various causes of odours and the testing methods that are required to identify the type of odour and its source. In the past various organic and inorganic type microbicides were used to control VFAs they could be expensive and not always effective. The introduction of Oxamine by Buckman has given the recycled packaging operation a tool that can effectively control VFA levels whether it is an odour issue or a final product requirement. Buckman has safe well designed feed systems to ensure the correct and safe application of Oxamine. Oxamine has proven effective in controlling a wide range of microbial issues including VFA control in a number of recycled packaging mills.Chart 1. Case study 3 VFA levels We have the smartest roll handling solutions that increase and saving SIMPLY THE SMARTEST We have the smartest roll handling solutions that increase and saving Pienteollisuustie 3 B FI-06450 Porvoo Finland Tel 358 400 610 764 E-mail infomoveroll.fi www.moveroll.com KAPPA ANALYSIS WORLD PULPPAPER 71 Papermakers in an integrated kraft containerboard mill know very well they have to adapt their papermaking operations to compensate for incoming variations in Kappa number. Usually with manual Kappa testing they adjust refining levels and machine speeds to react to changes in drainage and drying rates to avoid web breaks and to maintain strength tests. However with some inherent human variability in testing plus potential time delays of over two hours machine tenders are BTGs online Kappa analyser at Green Bay Packagings Arkansas Kraft Division permits Kappa number and pulp yield increases plus improved runnability on the containerboard machines. By Mark Williamson Journalist Engineer Single point Kappa measurement gives double-sided savings ...machine tenders are always playing catch-up reacting to old tests runnability can suffer always playing catch-up and reacting to old tests with some extra testing variability that is built in. Machine runnability can suffer. Green Bay Packagings integrated kraft pulp and containerboard mill in Morrilton Arkansas has found a solution to this dilemma by investing in a BTG Single Point Kappa Analyser SPK-5500. This analyser serves a unique function since both pulp mill and paper mill operators value it and rely upon it to stabilise their operations and quality. It is difficult to think of another measurement that has that this double impact. As a result pulp mill operators have become better at controlling Kappa and have stabilised and increased its level and the pulp yield. Moreover the papermakers have adapted the operation of their machines based on real-time information. The result is a good ROI on both sides of the mill. The fibre line with five batch digesters feeds two Green Bay Packaging Arkansas Kraft Division KAPPA ANALYSIS WORLD PULPPAPER72 board machines that currently produce 1331 tons per day of linerboard and corrugating medium. DELAYS IMPACT FIBRE QUALITY AND RUNNABILITY The mills reasoning for the initial trial installation is explained in the internal justification document Because of the small sample size and frequency of the test there is not enough information to react in real-time to variations in chip supply or the cooking process. These tests are performed manually every two hours by the pulp mill lab operator and take about an hour to complete. This delay in feedback of what is occurring during the process has proven to have a negative impact on fibre quality and board machine runnability. Based on the need for more accurate and real- time information a trial Single Point Kappa SPK analyser was installed during the May 2014 annual outage in the pulp mill. The SPK analyser automatically takes multiple online samples 12 per hour which provide a continuous feedback of the Kappa number. Jack Williamson former pulp mill superintendent and now operations manager at the Green Bay Packaging Wisconsin mill explains the previous dilemma for the pulp mill and downstream machine crews The One snapshot every two hours is not a good indication of variation. The swings really give the paper makers problems. suited to unbleached kraft pulp mills. The analyser provides an accurate on-the-spot reading in a few minutes and there is no need for the additional delays and complexity of remote sampling devices valves and sample transport lines to a central analysis unit. The SPK is mounted directly in the process flow and performs all the necessary operations for sample measurement including screening washing and measurement of the pulp fibre lignin content using absorption of ultra-violet light. It is a simple and direct measurement with an improved sampling frequency of 10 to 12 samples per hour with the SPK compared to 2 or 3 samples per hour with the multi-point analyser. Figure 1 shows that the SPK analyser is installed at the inlet of the screen accepts tank after the hot refining and screening. At this location the analyser shows trends in the blow Kappa numbers from the digesters. With the frequent sampling Lee says it is possible for the operators to determine which digester the pulp is coming from since the interval between blows of the five digesters averages 2.25 hrs. The first signs of an incoming blow are recognised by the meter after about 15 to 20 minutes process delay and the blow progress is followed thereafter. Results highlights - Operators adjust cooking conditions to reduce Kappa variations by more than 50 allowing an increase in target Kappa number - Pulp yield increase of 1 means 300000y in wood and energy savings - Board machine operators rely on real-time readings to adjust - Reduced web breaks on board machines have been documented manual tests were subjective and varied from tester to tester and shift to shift. The online measurement would remove the testing subjectivity and help us to improve runnability and keep the machine speed up. With high Kappa we would run into refining limitations and problems with strength tests. With low Kappa we had to reduce machine speeds. Sean Lee pulp mill superintendent adds One snapshot every two hours is not a good indication of variation. The swings really give the paper makers problems. SIMPLE DIRECT MEASUREMENT Unlike multi-point Kappa analysers that are used typically in bleached kraft pulp mills the SPK-5500 is purposely designed for a single point online measurement that is particularly Figure 1. SPK installation in the fiber line process WORLD PULPPAPER 73 AVOIDS OVER CONTROL The SPK measurement was evaluated over a five month period in 2014. The advantages of a quick measurement update are shown in Figure 3 which clearly indicates that the SPK has avoided the two hour delay with the manual tests. At that point in time the operators were making downward machine speed adjustments for lower Kappa number but the data was two hours old. The same is true for the speed resumption period. Figure 4 shows how the manual and the online Kappa number variation sigma decreased over time as the pulp mill operators became more familiar with the measurement and how to control the cooking process. The variation of data in Figure 4 shows a consistent gap between manual tests and online measurements although both decreased as the pulp uniformity became better. That gap between manual and online tests implies that the extra human testing variability was inherent in the manual tests. Since the operators now use the online measurement the extra variability of the manual tests is no longer a factor. Lee confirms that the SPK numbers are an accurate tool for evaluating pulping process performance I have recently started using the K average and standard deviation of the SPK as the indication of how we are running compared to our yearly goals and I have discontinued using the manual test numbers he says. Recent data provided by Lee shows that the average online measurement sigmas for six months up to January 2016 were 2.63. That is better than 50 reduction from the initial trial numbers. Lee says The operators are making fewer and smaller changes to the liquor-to-wood ratios and that means more consistent pulp for the machines. A Green Bay Packaging report shows that liquor to wood ratio changes were reduced from 84month to 44month. Variability in the tests was causing us to over-control now we have cut the changes for better control adds Williamson. The board machine operators get a heads-up warning of changes well in advance and the swings are much less. As an indication of operator acceptance the machine tenders call to see Since the operators now use the online measurement the extra variability of the manual tests is no longer a factor Figure 2. Single Point Kappa SPK Analyser installed Figure 3. The SPK analyser eliminates the two hour delay with manual testing and updates the reading twelve times per hour. Machine speed changes are now based on current data. KAPPA ANALYSIS WORLD PULPPAPER74 During the trial the break events on the No.1 linerboard machine were tracked 41 breaks were saved what is wrong if the measurement is offline for half an hour for preventive maintenance. We call them in advance to get permission to take it offline. Thats how critical it is jokes Williamson. HIGHER YIELD FEWER WEB BREAKS During the trial period the average Kappa number was raised about three points now it is run consistently at a target of 98. In all fairness this increase is not entirely due to the SPK measurement. The mill also invested in wood chipping operations to get more even chip size and more uniform cooking. Williamson has no problem crediting the SPK with one point Kappa increase. In fact he says they could not have made the full three point shift without it. He estimates that a one point increase means 300000 savings in wood costs and energy savings in the recovery operation since there is less black liquor in the loop with a lower liquor-to-wood charge. During the trial the break events on the No.1 linerboard machine were tracked. Forty-one breaks were saved according to an internal report that resulted in a payback of 8 to 16 months depending on the operating period chosen. No.1 machine was rebuilt with a new press section in 2015 and that in itself would be expected to improve productivity. It is therefore difficult to isolate the effects of the Kappa measurement. However considering how the operators rely on the measurement to avoid breaks Williamson has no problem extrapolating the initial trial results to today. Lee adds his thoughts on the benefits Fewer breaks mean more uptime and more total production. Increased reliability is a major focus going forward and the SPK goes a long way to reducing those breaks from a fibre furnish standpoint. The whole mill is sitting on the BTG measurement Williamson concludes. Figure 4. Kappa number variations were reduced during the trial period. Over six months to January 2016 the sigma values averaged 2.63 - more than 50 reduction from the trial start. PRESS FELT ADVANCES WORLD PULPPAPER 75 As a specialist and market leader for non-woven and multi-axial press felts Heimbach has proven press felt technology pre-existing woven fabric or non-woven fabric structures can be combined with a multi-axial non-woven structure. These flexible and adaptable Atrojet modules are the dawn of a new era in press felts said Franz Kiefer who together with his colleague Jochen Pirig both Strategic Product Managers supervised the R D project launched in 2011 from the very beginning. The development project amalgamated not only the experience gathered over the years at Heimbach but also the results of a series of field trials with customers in Europe and Asia. The main focus was on an expansion of the spectrum of yarn material and counts. In this respect we no longer wanted to be limited commented Jochen Pirig. The actual objectives were clearly formulated Fast start high dewatering and high service lifetime. As the first manufacturer in the world to combine a multi-axial non- woven structure with conventional woven bases the company from Dren revolutionised its proven press felt technology and can now offer tailored flexible and adaptable base combinations in its Atrojet product line. The name chosen for the new product By Franz Kiefer and Jochen Pirig Heimbach GmbH Co. KG Coarse or fine A suitable design the crux of the matter is the lamination and the knowledge of how the process parameters are kept constant line is no accident the suppliers want the paper manufacturer with the innovative Atrojet felt design to discover new shores Atrojet technology is globally unique and can be adapted to the individual requirements of each application. To achieve this Heimbach designed a specific paper side Atrojet base module and combined it with existing base modules. The resulting multi-axial non-woven base offers far greater flexibility in the composition of both yarn and twisted yarn structure than conventional non-woven or woven structures. The selection of a suitable base in the substructure enables tailored felt designs. Understandably Messrs Kiefer and Pirig would rather not reveal too many details of their secret part of the manufacturing process but they are prepared to confirm that the crux of the matter is the lamination and the knowledge of how the process parameters are kept constant. Figure 1. Franz Kiefer left and Jochen Pirig Strategic Product Managers at Heimbach PRESS FELT ADVANCES WORLD PULPPAPER76 GLOBALLY UNIQUE The success of Atrojet is down to an incredible flexibility of both yarn material and yarn counts. Whether from very high dense yarns with thin twisting or monofilaments or from more moderate or low yarn counts Heimbach tailors each module to fit closely to the felt properties requested by the customer. Atrojet technology also enables the processing of different yarn geometries. The uniformly directed MD yarns are characterised by high symmetry and precision spacing. This homogeneous structure enables key felt characteristics to be emphasised and improved. The uniform machine direction MD yarn structure has a positive effect on the absorption of tensile forces in turn this gives enhanced strength and makes a major contribution towards an economical service life. With its particularly dense MD yarn structure Atrojet has far greater surface contact and homogeneity than conventional bases. This brings about a more even power transmission in the press nip and results in very uniform dewatering as well as a uniform paper CD profile. Atrojet designs can also have a positive influence on paper surfaces in regards to its smoothness and printability. This is of importance for the graphic paper sector and also in packaging field where the demands on printability are continuously growing. More open felt designs usually improve void volume retention and allow particularly effective cleaning of the press felt. This is particularly important for machines with a larger range of paper grades and a selection of different raw materials. The uniformly directed MD yarns are characterised by high symmetry and precision spacing Figure 2. Atrojet module Figure 3. With its uniform machine direction yarn structure Atrojet has far greater surface contact than conventional bases. This leads to more even pressure transmission at the press nip resulting in very steady WORLD PULPPAPER 77 TISSUE IN FOCUS The production of tissue paper makes extremely high demands on the press felta high degree of dewatering must be achieved at extremely fast running speeds. Also a new press felt has to reach optimal performance within just a few hours. Another consideration is when drying energy requirements gas and steam consumption demand greater consideration than in the production of graphic papers. The fine fibre batt layers typically used means that tissue felt has a tendency toward compacting and contamination. Here Atrojet press felts can have a particularly positive effect thanks to their tailored adaptation. This makes them ideal for use in the tissue sector one with very specific manufacturing requirements. The adaptability of the yarn structure enables the implementation of an extremely compact and very fine Atrojet module. This can for example be combined with an open substructure. REDUCING ENERGY REQUIREMENTS An Atrojet press felt used in tissue production opens opportunities for actively optimising energy requirements the fine homogeneous Atrojet MD yarn structure enables fast start-up and the highest possible dewatering. The best possible contact area yields optimum pressure transfer and contact pressure on the Yankee cylinder. Selecting an open-textured roll side base enables the press felt to be cleaned more efficiently it also improves the resistance to compacting and contamination thus potentially increasing the service life of the felt. Unsurprisingly Heimbach take an optimistic view of their market share potential given the growth currently being experienced in the tissue sector. With this product we wish to make future inroads into the tissue sector to a much greater degree than we have so far confirmed Mr. Kiefer. AT THE CUTTING EDGE The paper industry is our pacemaker summarised Jochen Pirig. The range of raw materials is constantly expanding as is the range of products. He considers Atrojet to be a product that meets the needs of the future because this felt does not need to be changed even when changing between batches of raw materials or rapidly changing recipes and grammages. Many of the customers in whose premises Heimbach conducted test runs have already placed repeat orders the potential for this new technology seems to have been recognised. The company has invested a seven-figure Euro sum in its Olten facility in Switzerland. Within the Heimbach Group the Olten facility is considered a competence centre for multi-axial products in web technology. Atrojet production at Olten should be in full swing by the end of the first quarter 2016. Franz Kiefer and Jochen Pirig are certain Atrojet represents the next evolutionary step in felts sector. Here we are presenting the product that will dominate through the next decade Selecting an open- textured roll side base enables the press felt to be cleaned more efficiently Figure 4. Atrojet press felt consisting of batt module and the Atrojet module combined with a woven base in the substructure COATING STARCH ADVANCES WORLD PULPPAPER78 The papermaking industry and especially the coated graphical papers have to face various challenges. Europe is an aging society in a mature market showing quite limited growth rates. The lifestyles of people are changing rapidly especially with regards to the work environment e.g. home offices and flexibility of people communication and electronic media as well as social networking and on-line shopping to name but a few. For the paper industry these trends led to an increasing consolidation combined with rationalism of companies their production processes and product portfolio. During the crises in 20089 the graphical paper industry was hit heavily and a further decline of about 3 on the average for that year is expected for the future. As a result the paper industry in Europe is now focusing on cost optimisation at maintained quality. The trend towards a greener and more environmentally sustainable paper making process led to an increased use of starches in coating during recent years. Papermakers realised that by using classical coating starches cost optimisation had reached its boundaries. Today some further developments of nature-derived cost effective coating binders remain possible thanks By Dr. Andreas Becker Cargill Technology Manager Industrial Andreas Voigt Cargill Senior Specialist Paper Applications Solutions C iFilm coating starch Customer focused development of nature-derived binder for cost effective coating of Paper and Board The partnership between paper producers and their suppliers is an essential component of product innovation to close cooperation between the papermaker and a starch supplier who is fully aware of their clients specific requirements. PARTNERING THROUGH INNOVATION The partnership between paper producers and their suppliers is an essential component of product innovation. Exchanging ideas and experiences with people from paper production and RD is key as the understanding of customers needs is one of the most important ways to develop the best solution. At Cargill based on our very good experience in paper coating combined with customer knowledge and valuable feedback from our customers we have been able to focus our development on the main product requirements that need to be met maximise coating solids minimise synthetic binder content and improve coating colour rheology all without compromising on paper quality. TECHNICAL OPTIMISATION We know paper coating requires fine-tuning of multiple parameters to optimise runnability and performance e.g. coating colour rheology water retention coater adjustment. It is about taking a holistic view rather than looking at the effect of starch in isolation. Advanced instrumentation techniques allow us to understand the rheological behaviour of starch its interactions with other coating colour components and interactions between the coating colours and the base WORLD PULPPAPER 79 CASE STUDIES These results enabled us to assess the coater runnability confirmed by the following trials and case studies. Case Study 1 A double coated woodfree paper 150gm finish quality was blade pre-coated at 70 solids with a standard recipe containing 50 of the total binder- employed classic starch plus 50 latex. In order to reduce costs the pre-coat formulation was optimised to 65 C Film coating starch plus 35 latex. Due to the aforementioned benefit in extending the working range similar coater runnability was observed whilst surface strength as represented by IGT and ISIT measurements was kept constant. An overall good print quality was confirmed during commercial print trials. Case Study 2 LWC offset 60gm finish quality in MSP application at machine speeds 1400mmin. and coat weights of 8g ...rheology is key to ensuring smooth runnability at the coating heads paper. The positive effects seen in the new products were revealed in coating colour formulations by measuring water retention high shear viscosity as well as intrinsic coating structure. In order to optimise a coating colour binder system rheology is key to ensuring smooth runnability at the coating heads. For example if a customer is utilising a binder composition of 53 latex combined with 47 classical coating starch B and wants to enhance binding power with a classical starch C perhaps with a view to replacing more latex with more of this starch he would be faced with much higher blade pressure due to higher high shear viscosity of the coating see Figure 1. In most of the cases the consequence would be dilution of the coating. ONE STEP FURTHER WITH C iFILM COATING STARCH Compared to the classical coating starch C the newly developed C iFilm coating starch has even higher binding power it also affects lower coating colour high shear viscosity than both classical coating starches B and C. With this excellent property C iFilm coating starch allows the binder system to be adapted towards more starch and less latex for example 46 latex combined with 54 C iFilm coating starch will maintain high-shear viscosity of the originally used coating composition containing the classical coating starch B. Not only is high-shear viscosity important as the rheology parameter for the coating application Visco- elasticity is also influencing the coater runnability. It is commonly known that starch produces more elasticity in a coating formulation than latex. However C iFilm coating starch is also beneficial in that respect. No increase in measurement of the elastic part was recorded for the coating composition employing 46 latex combined with 54 C iFilm coating starch when compared to the coating composition originally used containing the classical coating starch B. Thus rheology disturbances at the coaters in other words misting at the MSP or bleeding at the blade are less likely. Based upon these facts it can be concluded that the operating window as shown in Figure 2 can be extended by the utilisation of C iFilm coating starch. Therefore either coating solids can be increased whilst maintaining the starchlatex ratio or higher starch utilisation is possible to replace a synthetic binder at constant coating solids whilst ensuring the overall performance is kept high. COATING STARCH ADVANCES WORLD PULPPAPER80 has become faster and bigger in order to achieve longer and smoother production runs. The binder type and content have been optimised to meet these demands coupled with the cost aspect as mentioned before. The skilled specialists and scientific experts at Cargill have focused their developments on specially designed starches for high stability beneficial coating rheology at high solids coating combined with superior binding power. With our products made from renewable natural resources C Film C iCoat and C iFilm coating starches we have been able to increase the utilisation of our naturally derived and specialised products on a step-by-step basis in the coating binder composition. m per side a standard coating system employing 45 latex plus 55 classic starch was tested and compared to a recipe containing 35 latex plus 65 C iFilm coating starch. During a run no rod spitting or misting were observed. Rheology measurements of high-shear viscosity represented by ACA measurements as well as rod pressures were comparable. Due to a higher starch quantity the OBA carrier function was improved CIE Whiteness whereas there were no differences observed in the glossprinting gloss surface strength and mottling. The newly developed starch was able to simplify the coating formulation only one synthetic binder instead of two show improved binding power it was possible to replace 2.5 parts of latex by 2 parts of the C iFilm coating starch whilst giving superior coater runnability without comprising the quality of paper produced. SUMMARY As shown in Figure 3 the coating colour binder composition has developed significantly over 30 years. The formulations and the production portfolio of paper grades have both become very much more simplified whilst at the same time the machinery ... the coating colour binder composition has developed significantly over the last 30 years AFT MaxSaver Screen for maximum ber recovery High Capacity and deaking more ber recovered More stickies removal with MacroFlow2 screen cylinder Experience PowerWave rotor elements to lower energy use Longer life with early removal of heavy debris www.aikawagroup.com salesaikawagroup.com A new spray system developed for the application of foamed adhesives for tissue or towel lamination is now available multi-ply tissue manufacturers can now effectively preserve tactile properties and virtually prevent the occurrence of ply mismatch. The patented PlyAble Tissue Lamination System uses unique spray technology to precisely apply foamed adhesives to tissue or towel lamination. This innovative technology jointly developed by Spraying Systems Co. and H.B. Fuller Company is designed to replace knurling wheels hot-melt or water-based adhesive systems and provides better tissue bonding using less adhesive. By leveraging H.B. Fullers micro foaming PlyABLE adhesive the patented application process uses a proprietary nozzle to reduce saturation whilst maximising bond strength and reducing waste. The PlyAbleTissue Lamination Spray Systems and Self-Cleaning Header Spray Systems are fully automated systems including cleaning cycles that can eliminate clogging and ensure optimal performance. They are ideal for applying adhesives lotions brighteners scents antimicrobials and other additives to personal care items such as tissue and hygienic products. The PlyAble Tissue Lamination System automatically cleans nozzles in place to ensure clog- free performance thus eliminating the excessive maintenance time required for conventional systems. Between parent roll changes the By Dave Kouwe Marketing Director Spraying Systems Co. Better tissue bonding whilst using less adhesive is now achievable multi-ply tissue manufacturers can now effectively preserve tactile properties and virtually prevent the occurrence of ply mismatch exteriors of the air atomising nozzles are cleaned by full cone nozzles mounted inside the header to remove buildup. Water is then passed through the air passages that feed the nozzles to ensure unobstructed air flow. The cleaning cycle is then repeated a second time Figure 1. The system uses an Allen Bradley PLC-based spray controller with HMI touchscreen to provide closed-loop flow control. As your line speed changes spray volume is automatically adjusted to ensure maximum bond strength. to remove any remaining residue. It is programmable and typically lasts 30 to 60 seconds. It can be programmed to run during unscheduled stoppages such as sheet breaks and should it prove necessary the cleaning cycle can also be triggered manually. Figure 2. Special nozzles optimise foaming and reduce bearding. Plate-mounting allows quick and easy removal from the header. Fluid and air passages are flushed during cleaning cycles. The nozzle on the left is used for starch-based adhesives and the nozzle on the right is typically used for PVA-based adhesives. TISSUE LAMINATION SYSTEMS WORLD PULPPAPER82 The system uses closed-loop control to eliminate over- or under- application of coatings and the associated quality problems The system uses closed-loop control to eliminate over- or under-application of coatings and the associated quality problems. A positive displacement pump a flow meter and a customer- supplied line speed signal are used to automatically adjust the application rate based upon line speed. SPECIFICATIONS OF THE PLYABLE TISSUE LAMINATION SYSTEM Spray Header - 6.5 x 7.5 165 x 190.5 mm. Lengths up to 144 356 cm - Two headers may be placed together for wider coverage spans - No nip required S wrap only Typical Spray Distance 6 to 14 154.2 to 355.6 mm depending on nozzle selection Fast Rewinder Speeds Up to 3000 ft. min 914.4 mmin Application Rates 5 to 30 mgft.2 54 to 323 mgm2 Figure 3. The patented self-cleaning spray header features air atomising nozzles positioned just 6 to 14 inches 154 to 355.6 mm from the tissue web. Headers are custom fabricated to precisely fit your machine Figure 4. PlyAble Tissue Lamination Spray Header with patented plate- mounted nozzles which allows quick and easy removal from the header Figure 5. Side view during automatic cleaning cycle Figure 6. Side view with nozzles in spraying position KEY BENEFITS TO THE CUSTOMER Precise application of foamed adhesives on all types of multi- ply tissues for excellent bonding without affecting the drape or softness of the material Prevents ply mismatch and maximises bond-strength Reduces over application of adhesive and saturation of tissue Reduces wasted adhesive and scrap Reduces misting and the associated clean-up of nozzles header and other equipment Improves worker safety Reduces maintenance downtime nozzles are automatically cleaned both internally and externally after every stoppage Plate-mounted nozzles are easier to remove and clean More efficient operation means lower operating costs compared to hot-melt and water-based spray systems TISSUE LAMINATION SYSTEMS WORLD PULPPAPER 83 The platform for the European pulp paper and supplier industry Fibers in Process Exhibition and Congress with 111th Annual General Meeting Frankfurt a.M. Germany 2830 June 2016 Patron ZELLCHEMING e.V. Get your free entry ticket now at zellcheming-expo.com Exhibition with unique industry overview along the process chain of the pulp and paper production as well as ber based materials Extensive fringe program at the market place Fibers in Process with free lecture forum Parallel held congress with the topic Raw materialsbers the extended added value 111th Annual General Meeting of the association ZELLCHEMING e.V. Variety of networking opportunities outside the exhibition stands INTERNAL LOGISTICS WORLD PULPPAPER 85 In any paper mill the processes can be divided into three main areas fibre preparation paper making machinery and finishing material flow a tricycle that works best when correctly balanced. In this instance material flow means everything from the slitter winder deck to the mills shipping dock. Of these three main areas pulping and paper making are process technologies to which the paper makers are educated for whereas By Kaj Fahllund Vice President Paper and Converting Pesmel Oy Internal logistics at the core of the mills processes ...logistics system layouts are always separately tailored for each mill using base modules the finishing material flow is left with less attention. However material flow-related conveying packing and storing operations are internal logistics that are vital for smoothly flowing mill processes. These processes demand a different set of skills know-how of material flow. The key to cost-effective internal logistics is a well-engineered system layout that saves space and minimises Figure 1. Material flow from slitter winder to shipping is one of the key processes of every mill along the stock preparation and paper making line itself the amount of equipment utilised. In order to create this a vision of an optimal system is required as a basis for the material flow layout engineering. A common layout engineering mistake is to place too much focus on details at an early stage by jumping directly to component application. This hinders your ability to see the big picture what is really needed and why. It is safe to say that no two mills are identical so therefore logistics system layouts are always separately tailored for each mill using base modules. This requires in-depth understanding of processes and engineering as well as a flexible attitude when searching for the optimal solution. Pesmel specialises in the creation of layout concepts for paper mill internal logistics specifically for how material moves inside the mill. They have developed the concept of Material Flow How that comprises solutions for roll handling packing storing and dispatching all combined with tailored engineering. Their system engineering process is flexible and easily controlled by in-house engineers in mechanical electrical automation and ICT areas. When the whole system is delivered by one supplier all parts talk with each other and the production flow can be guaranteed. INTRENAL LOGISTICS WORLD PULPPAPER86 It is often the case that there are not one but several possible layout solutions SYSTEM ENGINEERING OF A FUNCTIONAL MILL CONCEPT The production of goods naturally takes the centre stage at paper mills but attention must be paid to internal logistics in order to avoid bottlenecks in the production process. The system engineering of a paper mill begins by defining the must-dos for the internal logistics specific grade-related handling needs required buffering capacity between production and shipping packing method selection based upon the actual needs of the mill preferred automation level CUTTING EDGE SOLUTIONS When a customers site is first visited by an internal logistic specialist the customer may not necessarily be able to put into words what they want or even know exactly what they need. In these situations the ability of the service provider to listen to and then sensitively interpret the precise needs of the customer is crucial. When the connection between the customer and the service provider is uncomplicated it is possible to start looking for the optimal layout concept. It is often the case that there are not one but several possible layout solutions. The consultants when visiting the mill and making their assessments can see beyond the current state and envisioning what would be achievable in that environment. Concept suppliers differ from machine suppliers as they are able to deliver tailored solutions that include all aspects of the mills Figures 2a 2b. Appropriate handling methods are always tailored according each mills individual needs 2a 2b WORLD PULPPAPER 87 material flow process. By seeing the big picture they can provide the most suitable solutions across the entire finishing process. Conversations with customers to ensure a genuine understanding of needs are a prerequisite for finding and selecting the most suitable solution for each case. The key is to start this communication early enough before other decisions ones that will limit the layout options are taken. Pesmel differs from many other players in the concept engineering phase with their 3D illustrations and animations enabling them to verify and demonstrate solutions in a very tangible manner. Three-dimensional layout concepts are much easier to understand when compared to a stack of 2D illustrations even for engineers who have spent most of their careers with two-dimensional illustrations. Our 3D illustrations are the first steps on the path which can end with full-scale simulations with actual production data. Simulation study is a vital tool for assessing the practical situation and planning the layout concept at the start of the project. The real situation is simulated with the correct product measures capacities and equipment layouts in order to identify the possible bottlenecks and to analyse the total capacity of the mill. With this information the customer is able to optimise their machine purchase a process that can deliver large cost savings. Simulation studies provide guidelines as to what kind of roll handling packing storing and dispatching systems will be built. Such studies can also create a foundation for an upper level control system which in By seeing the big picture concept suppliers can provide the most suitable solutions across the entire finishing process Figure 3b. Simulations help verify the proposed systems capabilities Figure 3a. Animations show the flow of a proposed system. 3b 3a Figure 4. As well as the layout plan the packing concept should be selected on a needs basis. Above is a fully automated OptiWrap kraft wrapping concept - perfect for sensitive grades INTERNAL LOGISTICS WORLD PULPPAPER88 Simulation study is a vital tool for assessing the practical situation and planning the layout turn can help in the practical planning and subsequent operation of a new installation. IOT SERVICES HELP IN OPTIMISING THE MILLS OPERATIONS IoT or the Internet of Things means the connection between various equipment vehicles and buildings that is created with sensors software and network connectivity. This makes it possible to collect and exchange data between the various objects and to remotely monitor and control them. The collected data can be refined into usable form through analysis and it is possible to create different kinds of reports and other resources which help to improve the production and cost- efficiency of the mill. A paper mill is full of sensors that are controlled by programmable logic controllers PLCs. With the help of IoT it is easier to collect and analyse data than ever before. For example the mills service manager can use IoT software to identify and anticipate the equipments and systems need for spare parts and maintenance as well as planning actual maintenance schedules. With the help of the software maintenance personnel no longer need to constantly inspect the equipment - their work becomes easier and cost savings can thus be created. When fewer personnel are needed to ensure the smooth running of the mill operating expenses can be lowered. SUMMARY Pesmel delivers the FlowCare IoT software as a part of the system installation. FlowCare is a part of Material Flow How working together with machinery and other equipment Figures 5a 5b. Simulation models are built according to real systems adjustable parameters they help to verify the proposed concepts capabilities with real production data Figure 6. With IoT software customer mills are able to collect and analyse system data for operational and maintenance purposes automation and data systems. FlowCare primarily works in the internal network of the mill and is fully operated by the customer. FlowCare enables the customer to collect and analyse equipment data for operative and maintenance purposes. The application can be downloaded to a smart phone tablet or PC allowing the customer to follow the operation of any single machine in the mill monitor the overall technical operation of the mill find bottlenecks in production optimise the timeliness of maintenance work by spotting maintenance needs in advance 5a 5b These are just a few of GLVs cost saving solutions to your existing equipment. GLV also provides process equipment and upgrades for fiberlines stock preparation recycle systems and paper machines. Contact your local GLV representative to review our www.glvpulppaper.com 2016 GLV. ALL RIGHTS RESERVED. Reduce your operating cost... with GLVs cost saving solutions Celleco Twister Hydrocyclone Handles up to 2 feed consistency with up to 50 less energy. TamPulper Rotor New impeller upgrade reduces energy consumption and pulping time while still providing the same high performance. FibreFine System A unique refiner based technology for the production and application of Cellulose NanoFibrils CNF. DD 6000 Refiner Provides 50 higher capacity and significantly better tensile strength properties at the same specific energy consumption. g p ROLL HANDLING SAFETY WORLD PULPPAPER90 Compared to the end of last century the amount of work-related accidents in paper mills has notably dropped. One possible explanation for this may be that in the course of the last two decades more and more stakeholders in the pulp and paper industry have committed to the ambitious goal of zero accidents. In order to reach this goal a wide range of different measures has been implemented. A few examples a potential safety hazards in paper mills have systematically been analysed and counter measures have been taken b paper mill staff have conscientiously been educated on occupational safety c guidelines on safe use of paper mill equipment have been published. d paper equipment manufacturers have recognised safety as an important factor for product development and the general level of automation in paper mills has increased. However in a work environment that is characterised by heavy equipment use of toxic chemicals and handling of heavy loads safety hazards do still exist and accidents do still occur. Such hazards are for instance malfunctioning machinery uncontrolled rolling heavy paper rolls falling heavy objects unexpected start-ups and inadequate safeguarding or dangerous working methods. Since paper mill staff often deal with heavy loads By Mikko Rantanen CEO MoveRoll Oy Innovative solutions to increase operator safety in the winder deck area Since paper mill staff often deal with heavy loads accidents and injuries often tend to be more severe than in other industries accidents and injuries often tend to be more severe than in other industries. Thus the goal of innovative product development has to be to increase operator safety by as much as possible. SAFETY HAZARD WINDER DECK AREA In terms of paper finishing the winder area has always had an unfavourable reputation for operator safety. For instance severe injuries may be caused by being crushed between rolls when loading contact with sharp slitter knives both access to and too close contact with nip points unexpected descents of rider rolls unexpected ejection of paper rolls and collision with or getting crushed between paper rolls on the winder deck. Ejected rolling paper rolls whether expected or not - can pose a significant security and health risk on the winder deck. Since winder decks usually have a declining angle the paper rolls pick up speed and operators may be hit by or crushed between them. Winder decks are traditionally equipped with steel roll stops. Often the rolling paper rolls will hit these steel stops with great force which causes the rolls to bounce back and forth heavily. This multiplies the accident risks for operators on the winder deck and increases the risk for material damage. Finally uneven flooring on winder decks may cause paper rolls to move in unexpected directions making the risk of getting hit or crushed even greater. Not only does this increase accident risks for operators on winder decks but it also increases the amount of manual labour. Pushing heavy paper rolls by hand is an ergonomic problem that should not be overlooked since this kind of heavy manual labour poses severe strain to the operators back. INNOVATIVE SOLUTION TO INCREASE WINDER DECK SAFETY MoveRoll a paper roll handling equipment supplier from Finland addressed these issues more than three years ago by developing the patented Zero Energy Receiver that cushions rolls gently and reduces their kinetic energy on average by more than 75 . The soft cushions decrease paper roll damage while the reduction of kinetic energy improves the safety of operators on the winder deck. For more information about the Zero Energy Receiver see our article in World Pulp Paper2015. Feedback from paper mills and system integrators showed that the Zero Energy Receiver is a very effective solution to reduce kinetic energy of paper rolls. This positive feedback made MoveRolls engineers ask further questions How can we increase operator safety on winder decks further How can we improve the cushioning and roll speed reducing effects of the receiver even more and thus lower the risk of WORLD PULPPAPER 91 Pushing heavy paper rolls by hand is an ergonomic problem that should not be overlooked Figure 1. Braking Pad on winder deck Figure 2. MoveRoll Braking Pad Braking method ROLL HANDLING SAFETY WORLD PULPPAPER92 accidents and roll damage Answers were found in the development of two new products MoveRoll Winder Deck and MoveRoll Braking Pad. The Winder Deck consists of MoveRoll horizontal pressure conveyors that have been specially modified for the winder deck application and of a Zero Energy Receiver in the same width as the installed conveyor modules. After ejection from the winder pressure elements guarantee the controlled transport of the rolling paper rolls. That way unexpected changes in rolling direction are avoided and the roll speed can be controlled. The receiver cushions the rolls reduces their kinetic energy and stops them gently into the next conveying device. The concrete length and width of this winder deck solution always depends on winder width and the paper mills specific needs. Adjustments can be made so that several roll stop stations and roll stop sections can be incorporated and that rolls can be sorted. The winder deck solution can be fully fenced so that operator access during operation is excluded. In addition the system is equipped with sensors that stop the rolls automatically on the conveyor if a fence door is opened during operation. Should operators have a need to enter the winder deck for labelling work for example the winder deck conveyors transport the rolls to a safe processing area which increases safety and reduces ergonomic hazards. 75 METRES WIDTH AND 10 METRES CONVEYING LENGTH In 2015 the system integrator Advanced Dynamics - in cooperation with MoveRoll - installed the first large scale winder deck application in a paper mill located in Southern USA. The No-Impact roll transfer deck consists of 20 MoveRoll horizontal conveyor modules with a total width of 75 metres and conveying length of 10 metres a Zero Energy Receiver of the same width and a category 3 safety perimeter. The old winder deck of the mill had become antiquated with steel stops that caused the rolls to bounce back and forth heavily meaning too much ergonomically unfriendly and potentially unsafe manual work for the operators. The goal of the mill was to minimise operator interaction with the rolls remove inefficient equipment and to make a safer work place. Today the mill enjoys smooth rollset handling 12000 kg - automatic or by pushbutton and without roll damage or unsafe operator interaction. Peter Hanna Director of Advanced Dynamics comments Compared to the old system safety and low cost of ownership have been the biggest The winder deck solution can be fully fenced so that operator access during operation is excluded Figure 3. MoveRoll winder deck installation in Southern USA WORLD PULPPAPER 93 improvements. The old bump and bang roll handling system was beating up the old equipment causing high maintenance costs and wasting energy with antiquated pneumatics. The MoveRoll system solved both problems. AN EASY SOLUTION TO IMPROVE SAFETY For different reasons not all paper mills are able to change the whole winder deck area. However there are still ways to increase operator safety and to reduce material damage. One of them is MoveRolls patented Braking Pad which reduces roll speed or can in low speed applications actually stop rolls completely. The Braking Pad is based on the same basic principle as the Zero Energy Receiver a combination of soft material air exhaustion and absorption of kinetic energy. Depending on the length the Braking Pad consists of a certain amount of cushions. The Pad is portable and can for instance be placed on flat surfaces. On passing over it the speed of paper rolls decreases up to 05 ms. The braking occurs through trapped pressure in other words air exhausts from the front edge of the pad and partially compresses against the back side of it. The Pad can easily be placed on the flat flooring of old winder decks e.g. on winder decks with separation stoppers before and after separation stations. Since winder decks are high speed applications the use of two lines of Braking Pads is recommended each located a certain distance from the other. In doing so roll speed and roll bouncing can be reduced most efficiently. The Braking Pad is one of the most innovative products that we have developed so far. You just place it on the deck and it will reduce the roll speed and increase operator safety comments Mikko Rantanen MoveRolls CEO. Reduction of roll speed minimisation of roll bouncing and decrease of manual roll pushing can be achieved by Braking Pads on winder decks. Thus increased operator safety on winder decks can be achieved even in situations where the whole winder deck area cannot be modernised. Figure 4. Paper roll bouncing freely 2 vs MoveRoll Braking Pad 1 Figure 5. MoveRoll Braking pad applications winder deck without stopers 1 and winder deck with stopers 2 However.. there are ways to increase operator safety and to reduce material damage ZELLCHEMING EXPO 2016 WORLD PULPPAPER94 From 28 - 30 June 2016 ZELLCHEMING-Expo will take place at the fairground in Frankfurt a. M. Germany. The event is the only trade exhibition of the European pulp paper and supplier industry that takes place in Germany Europes biggest paper manufacturing nation. Visitors can find a wide product range along the process chain of pulp and paper production as well as the fibre based materials sector. Organised by Mesago Messe Frankfurt GmbH the event last year offered more than 150 exhibitors the opportunity to present their products and solutions to an experienced audience. 41 of the exhibitors are based outside of Germany and are spread across 14 different countries. The top 5 foreign exhibitor countries in 2015 were Finland Sweden Italy the USA as well as Switzerland. More than 1800 visitors from 31 different countries were recorded as attendees at the show. With the first exhibition being staged in 1987 ZELLCHEMING-Expo is an event with a long history and tradition. For both exhibitors and visitors the event has become an annual platform to meet and the place to be. ZELLCHEMING-Expo is for me like a family reunion and I am looking forward to this event every year says Thomas Villforth managing director of Villforth Siebtechnik. This year along with key players such as Valmet or Voith numerous exhibitors have registered for the upcoming event. The last preparations are running at full speed says Simone Pfisterer Vice President Mesago Messe Frankfurt GmbH. We are looking forward to a successful show MORE THAN JUST AN EXHIBITION ZELLCHEMING-Expo offers a comprehensive and attractive framework program. An essential part of the event is the Fibres in Process ZELLCHEMING-Expo market place that is organised and run by the publishing house Deutscher Fachverlag. The market place is a dialog platform that unifies practice research and science. It offers visitors By Christina Pantermehl Project Manager Mesago Messe Frankfurt GmbH ZELLCHEMING-Expo 2016 current challenges and developments in the pulp and paper industry Figure 1. Networking in the exhibition hall of ZELLCHEMING-Expo 2015 For both exhibitors and visitors the event has become an annual platform to meet and the place to be Visitor Statements to ZELLCHEMING- Expo 2015 Xerium Ernst Kerschhofer Vice President Sales Services Austria ZELLCHEMING-Expo - the event where the paper industry meets. Tate Lyle Pedro de Lima Account Manager Industrial Starches Germany In any case a worthwhile event which I visited a whole day and will visit again in 2016. Neenah Gessner GmbH Siegfried Fuchs Director Technology Process Development Germany ZELLCHEMING-Expo offers a great opportunity for networking. The cost performance offer concerning excellent lecture series and parallel held exhibition is very good. the opportunity to get in contact with exhibitors apart from their exhibition stands to debate industrys current challenges and developments. The three topics Technology Services Materials Processing and Research Development will in the focus. Represented universities and institutions give an insight into future trends of the industry and show their current research projects and innovative developments. In free lectures and panel discussions at the trend lounge the heart of the market place experts of the industry take up current topics and demonstrate the direction that the industry is taking in the future. EVENT PROMISES CAREER OPPORTUNITIES Whether graduates students young professionals or experts ZELLCHEMING-Expo 2016 offers different potential career opportunities for its visitors. At the Fibres in Process ZELLCHEMING-Expo market place graduates can become familiar with exhibiting universities and research institutions learn about the latest research projects as well as The evening events on the first two exhibition days enable participants to have time for some intense networking GmbH Maschinenfabrik. The After Fair is the evening event which takes place at the end of the first exhibition day. It gives visitors and congress participants the opportunity to continue their discussions with exhibitors in a relaxed atmosphere after the end of the exhibition. Good food drinks and live music as well as a small fringe program await the participants. Following the second exhibition day the Summer Evening organised by the ZELLCHEMING e.V. association gives all participants of ZELLCHEMING- Expo further opportunity to establish new contacts and develop existing ones. Besides culinary delicacies and live music various award presentations also take place on this second evening. PARALLEL HELD CONGRESS TOPIC RAW MATERIALS FIBRES - THE EXTENDED VALUE This years ZELLCHEMING-Expo congress which runs parallel to the exhibition will be focusing upon a highly topical issue Raw materials fibres - the extended added value. Subject areas to be covered include WORLD PULPPAPER 95 employment training possibilities be they further or initial. On the second exhibition day a free guided tour for students takes place as organised by the Department Paper Technology and Mechanical Process Engineering of the University Darmstadt. During the tour which lasts about two hours participants have the opportunity to begin networking with potential employers. Visitors who are searching for a new work challenge will take great interest in the Jobs Careers area where exhibitors present their current employment vacancies. EVENING EVENT PROVIDES EXCELLENT NETWORKING OPPORTUNITIES The evening events on the first two exhibition days enable participants to exchange views and have time for some intense networking with experts from science and industry. Many exhibitors appreciate this opportunity The After Fair as well as the Summer Evening provided great opportunities to establish many efficient business contacts reports Erich Kollmar Managing Director Gebr. Bellmer Figure 2. A scene from last years ZELLCHEMING-Expo 2015 The entrance hall at the After Fair evening event. ZELLCHEMING EXPO 2016 WORLD PULPPAPER96 fibre-based substrates of the next generation innovative materials for a bio-based economy and the almost endless possibilities of a newly defined forest industry. The international paper market is constantly changing. In order for the story to be a positive success it is important to continue to identify future markets early and to try to anticipate customer requirements for fibre- based materials. Innovations will be needed to develop new fibre-based solutions. An intensive exchange between research training and the industry are just as important as a closer collaboration with the materials industry. Today corporate industry leaders are already paying great attention to waste and by-products of the material use of wood as can be seen with the development of new bio- based products and services. The shift towards the bio-economy is a great opportunity for the paper industry in terms of achieving the highest added value for wood by-products whilst simultaneously making an important contribution to a more sustainable bio- based economy. CONGRESS PROGRAM IS BASED ON THREE EVENT ELEMENTS The congress builds a bridge between research and industrial applications in the manufacturing process. Congress participants have the choice between three different event elements. In the Business Forum well-known speakers provide current and exclusive insights into the innovation and development sector. One particular highlight this year will be the keynote presentation by Dr. Joachim Schnbeck member of the Executive Board of the technology group Andritz A look at sustainability and adaptions made in the pulp paper industry. In his lecture Mr. Schnbeck will speak about the most important current reference contracts advanced technologies their application and what contribution suppliers firms can make towards the Today corporate industry leaders are already paying great attention to waste and by-products of the material use of wood ZELLCHEMING-Expo 2016 Data Facts Date Venue 28 30 June 2016 Frankfurt am Main Germany Exhibition Ground hall 11.00 Opening hours exhibition 28-29 June 0900 1800 hrs 30 June 0900 1530 hrs Opening hours congress 28 June 1400 - 1800 hrs 29 June 0900 1800 hrs 30 June 0915 1245 hrs Forest Industry. Solution-oriented lectures on the subject of waste paper are part of the Application Forum an event element that celebrates its premiere in 2016. The highlight of this forum will be the panel discussion on the second day of the exhibition Waste paper sorting and application requirements for waste paper and challenges for the processing a forum to be moderated by Markus Grne head of the stock market news division of the German TV channel ARD. The well-established Cellulose Chemists Symposium offers experts from research and industry the possibility to exchange knowledge and share their experiences about polysaccharide research in particular cellulose and new materials. Besides these event elements in a further session Paper Fibre World 2030 a topic first explored in 2015 is once again on the agenda with presentations of the latest findings on this subject. Depending upon the time of reading registration for the ZELLCHEMING- Congress may still be possible. The whole congress program the registration and further information can be found at zellcheming-expo.com congress. Figure 3. The Summer Evening event which follows the second exhibition day World Class Efficiency Sulzer product innovations are based on the very latest pumping and mixing knowledge. The products in our full- line portfolio demonstrate the highest applications. Core competencies are based on long- term partnership programs with key customers and research institutes. www.sulzer.com pulppaper-processes See how Sulzer can help you win more opportunities. Visit us at IWB16 MIAC16 Papfor16 and ABTCP16. MAKING WATER WORK HARDER FOR YOU MINIMIZING Water MAXIMIZING Results OPTIMIZING Costs REDUCE REUSE RECYCLE