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Paper Technology Journal think in paper – The future of paper begins at Voith Paper. News from the Divisions: LEIPA-Schwedt PM 4 – LWC production line of the new generation. Maxau PM 6 – A challenging project and its implementation. Bohui BM 1 – A benchmark in China for the paper industry worldwide. 19 Innovative Trends in Automation. Paper Culture: Deep-frozen, dried – and saved. Contents EDITORIAL Foreword think in paper – The future of paper begins at Voith Paper 40 years of Voith in São Paulo – a reason to celebrate NEWS FROM THE DIVISIONS Thai Kraft Paper Industry, Wangsala – Significant cost savings by upgrading the approach flow systems of 4 paper machines to Voith C-bar technology LEIPA-Schwedt PM 4 – LWC production line of the new generation Four: the winning number! Successful start-up of the world’s most modern LWC paper machine with Voith Fabrics Contribution by our partner BASF – Using paper chemicals intelligently yields top performance Maxau PM 6 – A challenging project and its implementation Like Phoenix out of the ashes – UPM Shotton PM 2 was rebuilt at the end of 2003 and now achieves ambitious goals Velsen PM 2 with new drive concept – When gearwheels become superfluous New frontiers – new paper mill at Yaslik in Turkmenistan Reader opinion survey – twogether customer magazine: helpful, useful, interesting, or…? SAICA PM 10 – another complete production line for the Spanish packaging paper manufacturer Bohui BM 1 – A benchmark in China for the paper industry worldwide Amcor Cartonboard – Australasia Petrie Mill invests in the future Voith Silent Technologies – SeaLencer The two Offline Janus MK 2 at Chenming/Shouguang show their strength Highest Coating Quality with Cast Coating Technology Voith Process Solutions – Wet End Process Analysis as the foundation of an optimization of paper quality and process stability Prozess analysis for stock and water loops – a well-proven process optimization and development tool Innovative Trends in Automation Development trends in non-contact eb drying systems Field Service Specialist PikoTeknik Oy in Finland – one year with Voith Paper now PAPER CULTURE Deep-frozen, dried – and saved Highlights 1 2 4 6 10 15 18 20 24 28 30 33 34 36 40 42 44 46 48 52 56 60 64 66 70 1 Dear Customer, Dear Reader, The 19 th issue of the twogether magazine in front of you clearly depicts the wide array of products and services Voith Paper Technology offers and successfully supplies to its worldwide customer base. On the one side of the spectrum is the world-class installation of the LEIPA LWC production unit in Germany that performed from the very beginning to its expectations. Using 100% recovered paper as raw material, it is a trendsetting novelty in its product segment. Voith Paper Technology supplied the engineering as well as all the equipment starting from the recovered paper handling to the roll wrapping and transportation system. It is the success of the One Platform Concept in combination with the Process Line Hans Müller Package (PLP) that allowed seamless project management, start-up and commissioning as well as process optimization. On the other side of the spectrum is a small paper production line supplied to Turkmenistan for the production of printing and writing paper based mainly on cotton linters as raw material. Voith Fabrics contributes its part to a demanding puzzle together with our Rolls and Roll Cover Division to make sure that throughout the production process the web is in touch with optimally engineered surfaces be it rolls, fabrics or felts. Looking back at our business year 03/04 we owe thanks our customers for the continued support and confidence in us. This past business year has been one of our best. We will invest approx. 50 Mio Euro into a new Paper Technology Center to continue our support of an industry which we are convinced will play an important role in the advancement of mankind and its standard of living. Hans Müller on behalf of the Voith Paper Technology team 2 think in paper – The future of paper begins at Voith Paper On October 26, 2004, the foundation-stone for a unique project for the future by Voith Paper was laid in Heidenheim: the Paper Technology Center (PTC). With the laying of the foundationstone the go-ahead was given for the world’s largest and most modern paper research center, which will commence operations in a year from now. With an investment totaling around 50 million euros, the PTC marks the highest single investment made so far in Anja Lehmann Corporate Marketing anja.lehmann@voith.com 19/05 the field of research and development in Voith’s corporate history. 3 Approximately 60 guests from politics, industry and the press were invited to Heidenheim for this historic event. Dr. Hermut Kormann, President and CEO of the Corporate Management Board of Voith AG, and Dr. Hans-Peter Sollinger, Member of the Corporate Management Board of Voith Paper, together with the mayor of Heidenheim, Bernhard Ilg, welcomed the guests and jointly embedded an annual report, coins and a Heidenheim daily newspaper in mortar in the prepared foundation-stone. The Paper Technology Center opens up completely new dimensions in research & development at Voith Paper. “The PTC, as a milestone, marks a highlight in our development from machine builder to process and service supplier”, Dr. HansPeter Sollinger explained to the audience. At this research unit it will, for the first time, be possible to test and optimize the complete paper production process under real conditions in advance – from the furnish to the machine configuration, the automation system and machine clothing from Voith Fabrics up to the final product. With the Paper Technology Center, it is intended to recognize customer requirements and the challenges of the paper industry at an even earlier stage and to implement future-oriented solutions. The engineers and scientists will be concerned with, among other things, increasing the share of recovered paper, raising productivity and quality as well as reducing energy requirements. Other points of emphasis of the research will be the reduction of the water requirements and closed water cycles in paper production. All these subjects and many more will make the paper production process of the future more economical and, at the same time, protect natural resources. With the Paper Technology Center, Voith Paper will further expand its role as a leader in technology and innovation. Laying the foundationstone: (from right to left): Dr. Hermut Kormann, Dr. Hans-Peter Sollinger, mayor Bernhard Ilg. 19/05 4 40 years of Voith in São Paulo – a reason to celebrate The celebration starts with a press conference on September 16, 2004. Mrs. Martina Mann (left), a daughter of Hans Voith, and her niece Ofelia Nick (right) visit the school Friedrich von Voith. In September, Voith celebrated 40 years of the Brazilian subsidiary company. Even before its establishment here, Voith already took part in crucial projects for the Brazilian market through its partnership with Bardella. The prediction of Mr. Hugo Rupf, Voith agement Board, Dr. Michael Rogowski, AG president at the time could not be Chairman of the Supervisory Board and more correct. Today, Voith Brazil is the Mr. Friedrich-Karl Finck, Corporate Com- center of competence and manufacture munications, as well as by the directors for several products, exporting not only of the four Voith companies in Brazil. capital assets but also technology and They offered to the Brazilian and foreign know-how. The events related to the cele- journalists an optimistic and enriching Guilherme Nogueira bration of 40 years of Voith Brazil were scenario about the new plans and busi- Voith São Paulo guilherme.nogueira@voith.com attended by distinguished visitors, in- ness foreseen for the country. The jour- cluding customers, members of the Voith nalists left the event very impressed, not family, Voith AG directors, Brazilian au- only by the corporation history, but also thorities and foreign authorities, stress- by the figures related to investments, ing the importance of Voith Brazil and its production and orders. cooperators to the Brazilian society, as well as to the Voith Group. An unforgettable night Press Conference One of the events for the celebrities was the gala dinner held at the Credicard Hall 19/05 The conference was attended by Voith AG Theater on September 16th. The highlight representatives Dr. Hermut Kormann, of the evening came from Mrs. Martina President and CEO of the Corporate Man- Mann, who, in a touching speech, told 5 the story of her involvement with Brazil, Tropical sun and samba rhythm and a lot of beer. Joy and excitement contagiously involved all the participants. including the occasion when she first came to the country on a trip with her Besides the gala dinner, the guests were parents in the 1950’s. Fifteen years later, invited to visit the Voith São Paulo facili- Affected by the samba school rhythm, she became involved in meeting the chil- ties, where a special meeting place, in- the grand-daughter of Hans Voith, Ofelia dren of the school named after her cluding a presentation hall, was built, to Nick, described Brazil and the Voith sub- grand-father, Friedrich von Voith, assist- meet the tour guides and enjoy a special sidiary: everything is very different, beau- ed by the Labor Project, sponsored by lunch. tiful, and everybody is happy and receptive, and she also would like to learn how Voith. The employees of the Brazilian subsidiary to dance samba. The governor of the São Paulo state, had their celebration day too. On Septem- Mr. Geraldo Alckmin, was also present at ber 18th, Voith offered an Open Doors In a speech to the employees, Mr. Jo- Credicard Hall. He mentioned in his party to the employees and their families. hannes Hammacher, representing the speech the importance of Voith to the de- Around 10,000 people attended the event. Voith family, said in Portuguese: “Always velopment of Brazil, creating employ- There was music, raffles, live perfor- remember that Voith cannot exist without ment, income, wealth, and playing a great mance of samba dancers, souvenirs, you. Brazil will always have a special social role. playing activities for children, barbecue place in the hearts of the Voith family.” 19/05 6 1 Thai Kraft Paper Industry, Wangsala – Significant cost savings by upgrading the approach flow systems of 4 paper machines to Voith C-bar technology Gerhard Veh Fiber Systems gerhard.veh@voith.com The Siam Pulp and Paper Public Company Ltd is Thailand’s oldest and largest producer and converter of packaging and fine papers. Companies in the Group include the paper mills SKIC (Siam Kraft Industry Co) Bangpong, TKIC (Thai Kraft Paper Industry Co) Wangsala, TUPI (Thai Union Paper Industries) Wangsala and Bangkok, as well as TPC (Thai Paper Co.) Bangpong. The paper mill UPPC in Calumpit, Philippines also belongs to the Group. Günter Held Fiber Systems guenter.held@voith.com 19/05 Voith Paper and Siam Pulp and Paper have enjoyed a close and trustful partnership for decades. A number of Voith stock preparation lines and paper machines are installed in the customer’s mills. Upgrading the stock approach flows of PM 4, 5, 6 and 7 in Wangsala To keep up with the constantly increasing demands on paper quality and at the 7 Fig. 1: Thai Kraft Paper Industry, Wangsala. Fig. 2: Layout of the stock approach flow systems for PM 4, 5, 6 and 7. 3 2 Fig. 3: Screen upgrade package for the backliner of PM 6, consisting of C-bar basket, MultiFoil rotor and belt pulley. Approach flow system Thai Kraft PM 4 Approach flow system Thai Kraft PM 5 Approach flow system Thai Kraft PM 6 and 7 Paper grade: CA 112 g/m2, EK 95 g/m2 Paper grade: KL 125/150/185/230 Paper grade: KA 150/230 From stock storage chest From stock storage chest From stock storage chest PS36 PS36 PS36 PS30 PS36 Headbox Headbox Topliner Headbox Topliner PS30 PS36 PS36 To broke chest PS12 PS24 PS12 From stock storage chest PS36 Headbox To broke chest PS12 Filler From stock storage chest PS30 Headbox PS30 Filler PS30 From stock storage chest To broke chest PS12 From stock storage chest PS12 To broke chest PS30 PS30 Headbox Headbox Backliner same time reduce production costs, Thai Kraft initiated an optimization programme for the approach flow systems in Wangsala. This involved upgrading all the competitor pressure screens in the approach flow systems of PM 4, 5, 6 and 7 to Voith C-bar technology. Up till then the screens all operated with rotors with four continuous foils each, together with milled baskets. Despite large slot widths of 0.45 mm, the mill could only achieve the required throughputs by running the screens with very PS12 PS30 Backliner PS30 high rotor speeds which meant a high specific energy consumption. Energy savings using C-bar technology This resulted in disturbing pulsations, while screening efficiency was not sufficient for the high paper qualities demanded by the market. In addition, the rotors and screen baskets exhibited very heavy wear. Trial delivery for PM 6 backliner The optimization phase began in February 2002 with a trial delivery of two optimization packages for the screens in the backliner system of PM 6 approach flow (Fig. 3).These were upgraded to Voith MultiFoil rotors and 0.30 mm C-bar slotted baskets. At the same time the rotor speed was reduced by 29 %. Motor load dropped immediately by 47 % from 75 to Fig. 2 shows the approach flow layouts of PM 4, 5, 6 and 7 together with the paper grades produced. PM 6 and 7 are identical. 19/05 8 4 Location Machines Topliner 1st stage 2 x size 36 2 x 92 2 x 57 2 x 35 588,000 PM 4 1,354,920 kWh/year 2nd stage 1 x size 12 16 12 4 33,600 PM 5 1,873,200 kWh/year 1st stage 2 x size 30 2 x 74 2 x 40 2 x 34 571,200 PM 6 1,797,600 kWh/year 2nd stage 1 x size 12 21 20 1 8,400 PM 7 1,797,600 kWh/year 3rd stage 1 x size 12 21 20 1 8,400 Total 6,823,320 kWh/year Backliner 1st stage 2 x size 30 2 x 75 2 x 40 2 x 35 Overall cost savings Euro 103,600 per year Filler Power consumption [kW] before after
P Paper grade: KA 150/230 40 kW, representing energy savings of 588,000 kWh per year. In view of this enormous reduction in energy and the technological improvements described in the following, the mill completely converted the approach flow systems of PM 4, 5, 6 and 7 to C-bar technology. Energy balance for PM 6 and 7 Fig. 4 shows the energy balance for the approach flows of PM 6 and 7, – a total saving of 1,797,600 kWh per PM and year. Overall energy balance for PM 4, 5, 6 and 7 The energy balance shows overall energy savings of 6,823,320 kWh per year for all four approach flows (Fig. 5), representing energy cost savings of approximately Euro 103,600 per year. Overall energy balance in the light of the Kyoto Protocol At this point it is interesting to consider the significant reduction in energy requirements in the light of the reduced CO 2 emissions and the Kyoto Protocol. The following observation is based on 100 % power supply from a coal-fired power station. Certain parameters such as the relationship between energy output in the form of electrical and thermal energy and primary energy input (overall power station efficiency) and the relationship of electrical energy to thermal energy output (power coefficient), are based on values taken from similar plants and therefore may vary from those in Wangsala. The fol- 19/05 kWh saved per year (350 days) Total energy savings 588,000 Total 1,797,600 lowing estimate is therefore intended to give an idea of the additional potential cost savings as a result of the savings in electrical energy. The following figures have been used as basis: Based on the positive trial results with PM 6 in Wangsala, PM 4 was the first paper machine to be completely upgraded, achieving an impressive increase in stickies removal efficiency. ● CO 2 emission from coal combustion per kWh primary energy = 0.335 kg CO 2 ● Overall power station efficiency = 75 % ● Power coefficient = 0.5 ● Expected emission charges = between Euro 5 and Euro 12.5 per ton CO 2. For example, stickies removal efficiencies of 13 % and 34 % in the first screening stage of PM 4 improved to 63 % and 75 % respectively. The residual stickies content dropped to less than half the original value (Fig. 6). The previously mentioned energy saving of 6,823,320 kWh per year is equivalent to a primary energy requirement of 27,293,280 kWh per year. The resultant CO 2 emission amounts to 9,143 metric tons per year. Assuming an emission charge of Euro 8 per ton CO 2 for the emission certificates, an additional savings potential of Euro 73,146 per year is possible. Technological improvements by upgrading to C-bar The following describes the improvements in quality obtained in terms of stickies removal efficiency. In the backliner trials for PM 6, the stickies removal efficiency was improved from 25 % to 63 %. This can be attributed to the following: ● MultiFoil rotor speed reduced by 29 % ● Gentle operation of the MultiFoil rotors ● High screening efficiency of the C-bar basket thanks to its flow-optimized profile ● Slot width reduction from 0.45 mm to 0.30 mm. The resultant reduction in deposits on the drying cylinders and doctors significantly reduced the number of paper breaks and considerably increased the overall production efficiency of PM 4. The same very welcome improvements were also obtained on upgrading the approach flow systems on the other PM’s 5, 6 and 7. The optimization with C-bar technology also reduced overall fibre losses. Taking PM 4 as an example, overall fibre losses (Bauer McNett R 14 / R 30 / R 50) dropped from 0.4 % to less than 0.1 % (Fig. 7). There was not much change in CSF accepts freeness either compared with the inlet values, despite the significantly reduced slot width. This was a further welcome factor. Overall fibre losses were much lower than the forecast and guaranteed values, providing a further appreciable cost savings advantage. The reduction in overall fibre losses from 0.4 % to 0.1 % means a savings in raw material of 1,507 b.d. metric tons per year. Raw material costs in Thailand are about Euro 85 per metric ton and pro- 5