sami paper machine improvements

Paper MachineImprovements1° Seminario LatinoAmericano deTecnología Valmet 2016Sami HartikainenSenior Product Sales Manager

Today’s Challenges in Paper Making

Industry challenges

Volatile rawmaterial andenergy costs

Globalindustrialcompetition

Rising laborcosts and skillsshortages

Increasingenvironmental andsafety requirements

Constantchanges inmarket conditions

Global megatrends

How to keepequipment andprocessesrunning reliably

How to optimize theperformance of industrialprocesses to get themost out of the least

How to ensureprocesscompetitiveness withlatest innovations

How to getthe rightexpertisewhen needed

Digitalization

How to best utilizethe opportunitiesof IndustrialInternet

April, 2016 © Valmet2

INTERNAL

ü Our solutions are based on the uniquecombination of process technologies,services and automation – to your benefit.

ü We develop the solutions in closecooperation with you to match your needs in:– Safety and sustainability– Production efficiency– Energy efficiency– Raw material efficiency– Maintenance efficiency– Cost efficiency– Optimized quality

Customer

Solutions toyour needs

April, 2016 © Valmet3

INTERNAL

Solutions to ring up the ROI

13 June, 2016 © Valmet | Sami Hartikainen4

Energy efficiency

Quality improvement

Safety

Break management Trouble shooting

Dryness improvement

Runnability improvement

Draw control

Qualityimprovement


ü RetroDilution headboxü Vane RetroFit for headboxü FormMaster, breast roll

shakerü VacuBalance, vacuum

assistanted forming boardü Adjustable foilsü Doctoring solutionsü Fabrics

RetroDilution headbox

Main Reasons for Upgrading an ExistingHeadbox

ü Better basis weight profile withoutcompromising fiber orientation profile

ü Short startup time after shutdownsand long breaks

ü Improved efficiency– Quick grade changes– Less broke, especially in edge areas

ü Slice lip release and possibilityto optimize orientation profile

19 May, 2016 © Valmet7

RetroDilution dilution control upgrade

Investment Arguments

ü A cost-effective way to converta slice lip-controlled headbox to adilution-controlled one

ü Provides the performance of a state-of-the-art dilution headbox– Extensive improvement in paper quality– Better runnability for the entire machine line

ü Estimated shutdown period is just2 to 3 days

ü Can be installed on-site duringplanned annual shutdown



Manifold tubebank outlet

New parts


RetroDilution Upgrade Components

New Parts – Dilution Circulation

ü Dilution circulation piping with dilution pump and screenü Dilution header with specially developed dilution valves and dilution actuatorsü Dilution element to be installed between manifold tubes and main headerü Scope of automation package defined with customer

19 May, 2016 © Valmet10


Dilution recirculation

Dilution pump

White water

Dilution water screen

Dilution feed

Dilutionheader

New Controls

19 May, 2016 © Valmet11


Dilution circulation controls

Quality controls

Vane Retrofitfor Headboxes withoutVanes

Vane Retrofit for Headboxes

ü Benefits– Lower tensile strength ratio– Reduced tendency to produce

streaks– Fine-tuned formation

ü Applications– Headboxes with no vanes– All paper grades– All machine sizes

19 May, 2016 © Valmet13

Improved paper quality

A special vane holder enables the use of avane in the headbox. The vane increasesturbulence in the slice channel and reducesfiber orientation in the machine direction.


Typical challengesü Headboxes originally

dimensioned for highheadbox flow rates.

ü Smaller slice openings (lesspressure loss in theturbulence generator, highcontraction leading to higheracceleration affects fiberorientation in the slicechannel).– Tensile strength ratio increases

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Lower tensile strength ratio

HorizontalGap Forming

VerticalGap Forming


Typical challenges oflow flow rates:ü Low turbulence in the slice

channel– Poor formation

ü Dirt accumulation in the slicechannel

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Improved formation and cleanliness with vanes

Fourdriniers,Hybrids

HorizontalGap Forming

VerticalGap Forming

Improved Paper andBoard Properties withFormMaster 120

Better Paper and Board Properties withFormMaster 120

ü Better visual propertiesü Improved formation

– Possibility to optimize furnish, refiningand headbox consistency

ü Improved strength propertiesü Lower MD/CD tensile ratioü Easy to useü Low power consumptionü No external reaction forcesü Improved safety and usability


FormMaster is a self-balancing breastroll shaker. Forces are transferred tothe breast roll through a connectingrod. Shaking forces are generated byrotating eccentric mass pairs.

Cost Savings with FormMaster 120

ü Less refining– Same strength and formation level

with optimized refining

ü Higher headbox consistency– Same formation level with higher

consistency

ü Raw material savings– Same strength properties with lower

basis weight– Minimized starch usage

ü Reduced steam consumption indrying process


Segezha Pulp andPaper, RussiaPM 9 and PM 10

FormMaster service agreement

• High equipment availability• Significantly reduced

unplanned shut-downs

Results

Vladimir Bolshakov,Technical Director

”FormMaster is an outstanding equipment whichallows us to produce high quality sack paper tobe competitive. I can say that the reliability ofFormMasters has undoubtedly improved sinceDecember 2013 as a result of control fromValmet and close co-operation between trainedmill personnel and Valmet specialists.”

PM 9 PM 10Grade High quality

sack paperHigh qualitysack paper

Wire width (mm) 7050 7050

Production speed(m/min)

730 850

FormMaster service agreementCase: Segezha Pulp and Paper, PM 9 and PM 10, Russia

13 June, 201620 © Valmet | Sami Hartikainen

Valmet Shaker 20

Spring loaded Valmet shaker 20

ü Valmet shaker 20– all reaction forces impacting on the

foundations– limited ratio of shaking intensity– low cost alternative

ü Spring support– breast roll bearing housing is supported

by springs made of stainless steel orglass fiber

– roll is making pendulum motion whichcan affect negatively on fiberorientation profile

– limited life time with stainless steelsprings, glass fiber under development

– low cost alternative


VacuBalance

Challenges of Fourdrinier forming

ü Target: first-class formingquality on a Fourdrinier tablewith high dewatering capacity

ü Challenge: high table activityon the forming board – stockjump - that limits both thespeed and the slice opening


Novel vacuum-assisted forming board

ü VacuBalance is a new vacuum-assisted forming board design whichefficiently absorbs the jet impact energy and enables fast non-pulsating drainage through a high open area cover


VacuBalance vacuum-assisted forming boardFor improved initial dewatering

ü Stabilizes jet impingement andprevents stock jump– optimized jet landing and VacuBalance

geometries

ü Freezes the slice jet and producesexcellent layer coverage

ü Provides high dewatering capacityü Orientation and formation controlled

simultaneously

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Vacuum-assistedforming board

Conventionalforming board


• Minimized pulsation• Minimized stock jump• Very high dewatering capacity• Very wide operation window• Excellent for layering

• Sensitive for stock jump• Heavy pulsation• Low dewatering capacity• Fixed operation window• Not suitable for layering

Runnabilityimprovement


ü Press open draw reductionü Perforated UhleBox coverü Felts/Beltsü Doctoring solutionsü Roll coversü Press geometry optimizationü Runnability blow boxesü Drive upgrades

Press open drawreduction

Open draw reductionCase South Africa

May 19, 2016 © Valmet | Author / Title29

• Grade White Top Liner• Wire width 5500 mm• Reel width 4910 mm• Design speed 1000 m/min• Basis weights 115-250 g/m²

Main data

• Draw through press section can bereduced 20% (e.g. from the current 2,5%(1,7%+0,8%) down to 2,0%)

• reduction is total from the center roll to the1st dryer cylinder and can be spilt betweenthe two open draw as mutual agreed.

Target/quarantee

Scope• New brackets and cylinders

TS/DS• New large diameter lead roll• Spacers for the transfer

suction roll relocation

• PressRun blow boxes• Installation advising• Start-up assistance

Valmet perforatedUhleBox cover

Cost-saving Felt Conditioning Solution

ü Cost savings and benefits through– Increased dewatering at a lower

vacuum level than a slotted cover– Better runnability– Better profiles– Lower friction - lower press drive load– Longer felt lifetime – longer felt change

interval

ü Additional savings with vacuumsystem and felt optimization– Reduced vacuum => energy savings– Possibility to use seamed felts


Perforated Uhle box, vacuum system and felt optimization

Cost-saving Felt Conditioning Solution

ü Long dwell time in the vacuum zone– Full support over the cover area

ü Optimized tight drilling pattern and highopen area– Vacuum is continuous over the whole drilled

area– Optimized drilling pattern for good moisture

profile– Cover structure doesn’t block easily by furnish

ü Durable SolidCoat hard coating– Expected life timesü Recycled furnish: 3-4 yearsü LWC: 4-5 yearsü Semi-Chemical Fluting: +10 years


Perforated uhle box cover based on SolidCoat technology

HiRun P web stabilizerfor perforated rollapplications

INTERNAL

Conventional stabilizers in perforated roll conceptsProblems reported by papermakers

19 May, 201634 © Valmet | HiRun Runnability Systems, HiRun P

At higher vacuum (max 1500 Pa)seals are in contact with fabric

Wearing of seals and fabricHigh number of seal changesExtra costs

Clear needforimprovement

At lower vacuum (< 800 Pa)Press-to-dryer draw is highNumber of web breaks is highMachine speed increase is limited

Cleaning of the stabilizerStabilizers need to be taken out of themachine for cleaning

INTERNAL

HiRun P - Rebuild conceptNow available for perforated rolls

19 May, 201635

Main benefits:

ü Based on proven HiRun blow boxtechnology

• Adjustability

Long lifetime of seals

Easy control of vacuum

Draw reduction

• High vacuum

Stable web run

© Valmet | HiRun Runnability Systems, HiRun P

Upgrading ProReleaseto HiRun technology

INTERNAL

Upgrading old stabilizers to HiRun technologyEconomical on-site upgrade service

19 May, 2016 © Valmet | Upgrading ProRelease to HiRun technology37

Upgradedstabilizer withimprovedfeatures

Valmet’sHiRun Module

OriginalStabilizer

INTERNAL

Upgraded stabilizer with HiRun featuresBenefits

19 May, 2016 © Valmet | Upgrading ProRelease to HiRun technology38

High vacuum

Correct positionof labyrinth seal

Adjustablelabyrinth seal

• > 3 kPa• Less draw• Web stability

• Minimized fabric bendingwith high vacuum

• Minimal wear of seals

• Optimal vacuum betweenrelease zone/pocket

• Minimal wear of seals

Drive upgrade, silentdrive

INTERNAL

Silent drive implemented with direct driveGearless solution with permanent magnet motors

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Cylindersand leadrolls are

driven fromthe drive pin

Cylindersand leadrolls are

driven fromthe drive pin

Nogears

Nogears

INTERNAL

Silent drive implemented with separate gear

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INTERNALSilent drive implemented with direct driveBenefits

High torqueat low

rotationspeeds

High torqueat low

rotationspeeds

Fewer itemsrequiring

maintenance

Fewer itemsrequiring

maintenance

Nocirculationlubricationsystem forthe gears

Nocirculationlubricationsystem forthe gears

Improvedefficiency

Energysavings

Improvedefficiency

Energysavings

Improvedcontrol

accuracy

Improvedcontrol

accuracy

Noseparate

gears

Noseparate

gearsLessspareparts

Lessspareparts

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Drynessimprovement


ü Straight drilling for theCouch roll

ü SteamBox/SteamShoeü Perforated UhleBox coverü Felts/Beltsü Nip load optimizationü Doctoring solutionsü Roll coversü Nip geometry optimization

Higher Dryness withOptimized Couch RollDrilling

INTERNAL

19 May, 2016 © Valmet | Author / Title45

Higher Dryness with Optimized Couch RollDrilling

Backgroundü Development of forming fabrics

to 2 or 3 layersà No hole countersinking needed

as the fabric allows internal flows(”countersunk” fabrics)

ü The rewetting effect of countersunkholes becomes more significant athigher machine speeds

Countersinking vs. straight drilling in suction roll shells

Countersunkdrill hole

Straight-throughdrill hole

Web

Fabric Water

Suction box

Rewetting

SteamShoe

SteamShoeSolution for increased web dryness after press section

ü Increase web dryness after presssection gives:– Increased web wet strength and better

runnability

– Reduced drying section steam consumption

or

– Increased production by increasing machinespeed

ü Application:– For all press section geometries– Suitable for all speeds board and

paper grades– Suitable for all machine sizes

© Valmet | Sami Hartikainen47

SteamShoe is ejecting steam to felt before apress nip. Heating the felt improves waterremoval from paper web. Steam has a perforatedexchangeable cover which is perforated. Coverhas a radius to improve penetration to felt..

13 June, 2016

Drawcontrol


ü TrimSquirt, formerü TrimSuction boxesü TrimRecoveryü Suction pick-up roll

modernizationü Speed controlü Press open drawsü Air blows and ventilationü Runnability boxesü Roll coversü Process chemistry

TrimSquirts

TrimSquirt web edge cutting deviceFor sharp-featured and reliable edge trim cutting at the forming section

ü Provides high-quality edges with non-turbulent and precise needle jet

ü Single, double or triple nozzleoperation

ü Easy service– Nozzle adjustment during run (MD angle and

multi-jet nozzle rotation)– Nozzle replacement one nozzle at a time– The equipment rotates to the service position

during fabric change

50 13 June, 2016 © Valmet | Sami Hartikainen

TrimSquirt web edge cutting deviceOptions

ü Localized cutting water and mistcollection system underneath thewire (option)

ü Cleanup mist shower for squirts(option)

ü Electrical position indication incontrol room (option)

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Clean-up mistshower

Mist collection saveall13 June, 2016 © Valmet | Sami Hartikainen

Dearator tank for cutting water

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Water feed in

Water feed out

Manual overflow valve

Manual flushing valve

• When can be applied• if no tank at the moment

• What it gives• Remove air from cuttingwater• Secure trim cutting in allsituations

Trim cutting water module

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• When can be applied• if old pump, normally over capacity = ”high” electricity cost

• What it gives• Cutting water feed always in good condition• Possibility to get high pressures• Duplicate systems in one unit give security• correct production amount, no over capacity

TrimBoxes

INTERNAL

TrimBox Trim Suction Boxes

Applications:ü Small suction boxes located under the

pick-up roll on the forming section– Both on the front and back side

of the machine

Main features:ü Ensure that the edge trims follow the

fabric down to the couch pit instead offollowing the felt to the press section– Prevent possible felt damages– Prevent edge flipping– Ensure better runnability

ü Minimized fabric wear on the edgesdue to high-quality mechanical parts

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for reliable trim control

INTERNAL

TrimBox Trim Suction Boxes

ü Effective solution that enables increaseddraw between the forming and presssections

decreased draw in the press open gapü Compact design

– Can be installed in applications with limited space– Less modifications to surroundings

ü Improved safety and usability– Due to the new design manual adjustment can

be performed outside the running machine

ü Non-corroding stainless steel frame withhard SolidCoat coating– Very durable solution– Recoating through exchange unit service

19 May, 2016 © Valmet56

Benefits

TrimRecovery

TrimRecovery

ü The solution recovers andreuses the higher quality andmore expensive top andback plies separate from themiddle ply

ü The solution keeps the topand back plies from windingup in the middle ply pulper

ü The solution consists of edgesquirt, guiding tube andrelease blow

Trim collecting system

TrimRecovery

ü Edge Squirt cuts the trimü Air blow releases the trim off from the wire into the guiding tubeü Water shower accelerates removed web edge speed inside the

guiding tubeü Guiding tube leads the web into a desired course

Trim collecting system

Edge squirt

Guiding tube

Release blow

TrimRecovery

ü Significant raw material savingsü More operating profit with less

production costü Reliable trimming and outstanding

cutting performanceü Reduction of disturbances at the sheet

edgesü Effective operating controlsü Improved and more consistent

runnability

Outstanding advantages

Suction pick-up rollmodernization

Edge flutter of paper into the pressnip might cause sheet breaksSuction pick-up rolls can be modifiedto extend the vacuum zone on theends to assure the paper is adheredto the bottom of the pick-up felt

Suction pick-up roll modernizationImproved pick-up & web handling

Roll modernization for improved :+ Pick-up

+ Tail threading

+ Web handling (less breaks)

+ Runnability

+ Quality

25.03.2015/ K. Kuusela

After modernization

Before modernization

Axial seal

End deckle

Axial sealEnd deckle

Suction pick-up roll modernizationImproved pick-up & web handling

High vacuum zone

Low vacuum zone

Suction pick-up roll with two vacuum zones

25.03.2015/ K. Kuusela

Energyefficiency


ü Perforated UhleBox coverü Vacuum system upgradeü Roll coversü SteamBox/SteamShoeü Nip load optimizationü Break managementü Tail threading

Vacuum systemupgrade

Vacuum System Benchmarking

ü Until today over 100 machines screenedü Total estimated saving potential is over

35 MW/about 70 machinesü Pre-engineering about 30 machines,

verified savings about 15 MWü Achieved savings with system

improvements, total today over 10 MW

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For identifying machines with electrical energy saving potential

0

5000

10000

15000

20000

25000

30000

35000

40000

1 11 21 31 41 51 61 71 81 91 101 111

Estim. kW

Pre-Eng. kW

Actual kW

Cumulative Estimated Energy savings at PM

Machine Number

Ene

rgy

Sav

ing,

KW

2008 2009 2010 2011 2012Time

Energy savings can be achieved more than 50% of machinesOften required modifications are relatively small compared to savings

Tail threadingRopeless single dryer group w/o vacuum roll

New Patented Ropeless Tail Threading SystemNip Ventury Booster

ü Doctor or Nip Blow pipe needed as usual– Takes Tail from Cylinder surface

ü Closing Nip has New Ventury Technology– Creates high vacuum with mill pressure air– Tail will be fixed to the fabric surface

ü Vacuum will stay under the tail inside the fabric

ü Doctoring blade will prevent the air going to the closing nip– Prevents air moving with the cylinder rotation


Doctor blade

Air blow

Vacuum area

Breakmanagement


ü Pick-up optimizationü Pick-up controlsü CleanCutü Tail threadingü Break detectorsü Broke conveyoursü Doctoringü Web break analysis,

cameras

Pick-up optimization

Mechanical movement to hydraulicPick-up

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• Pick-up penetration ~12 mm (adjustment0…25 mm)

• Pick-up open position 100 mm• Service position• All positions with mechanical stopper or

locking

Two hydraulic cylinders withlocking arrangement per side

Situation• Problems to achieve the right position when

start-up• Difficulties to run the machine, breaks• Needs an accurate control in order to reduce

the time of start-up.

Target• Pick-up roll accurate operation• Avoid manual operation

Pick-up controls

Pick-up sequence

ü In the ideal case the whole web transfers from Former to PressSection as a single sheet, but quite often that’s not the reality.Transfer can take 2-5 second and the web is ripped to many piecescausing possible :– Felt damage– Roll cover damages– Belt lost

ü The risk can be minimized by improving Pick-up Sequence

CleanCut

CleanCutClean web threading from the wire to the press


Safety


ü Felt Moisture MeasuringBeam

ü Tail threadingü Maintenance, roll/fabric

changeü Walkwaysü Safety audits

Fabric ReplacementSolution for SeamedFelts

Fabric Replacement SolutionRoll up and change – at the same time

ü Fast and easy fabricreplacement solution forseamed fabric

ü Improves working safety

ü Effective due to shorterfabric replacement times

© Valmet | Sami Hartikainen13 June, 201678

Fabric Change Device’s Componentsfor Seamed Fabric

© Valmet | Sami Hartikainen13 June, 201679

New fabric• holders with brakes

Winding device for old fabric• a pneumatic drill can also beused for turning

Change device inserted into themounting sleeves of the dolly

Movable platform dolly for thebasement• can be secured in place

Troubleshooting


ü Air bubblesü iRoll Portable Liteü Wrinkles, creasingü Flutteringü Runnabilityü Tail threadingü Audits

Air bubble removal with perforated suction boxBenefits

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Efficientoperation

• Effective perforated cover ensureeffective vacuum level to keep the webin good contact with the press felt

• Utilized for separate presses toprevent possible air bubbles in theclosing nip

• Quick start-up of the new press felt• Improved sheet edge control

Easymaintenance

• Due to cover design easy to keepclean and open

Excellentrunnability

© Valmet | Runnability systems19 May, 2016

Slottedcover

Perforatedcover

Suction box installed at theclosing nip of the separate

press

iRoll Portable Lite

Wireless data transferred from roll to receiverand to monitors or automation system

Rollcover

Roll body

Signal processingmodule & transmitter

Wireless power supply system(option). Battery system as standard.

Receiver

Sensors on the rollbody for measuring nipload or tension profiles

Connection toautomationnetwork by usingopen protocols

What is iRoll?

ü iRoll is an online profilemeasuring tool for improvingnip profiles, parent rollhardness profiles and tensionprofiles as well as printer andconverter satisfaction

ü iRoll can be used on paper,board, pulp or tissueproduction machines

ü iRoll has sensors under the rollcover for measuring nip load orweb tension profile in CD andMD

© Valmet83 19 May 2016

sami paper machine improvements

Services