PAPER TECHNOLOGY INTERNATIONAL

PAPERTECHNOLOGY INTERNATIONALINTERNATIONAL

PAPER THE JOURNAL OF THE BIOFOREST PRODUCTS SECTOR

VOLUME 60, NUMBER 1 SPRING 2019

FEATURING: A.CELLI PAPER; PROCSIM; QCL SCIENTIFIC; SCHÄFERROLLS

PRACTICAL: COD MEASUREMENT; FORGED YANKEES; ROLL COVER LIFE; STEAM CONTROL

RESEARCH: MEMBRANE TECHNOLOGY; NOVEL HAND SANITIZER; SPLICING TAPE ADHESIVES

COLUMNS: CPI; LETTER FROM INDIA; NEWS; ORDERS; STANDARDS

THREE DECADES OF SUPPORT FOR THE DEINKING COMMUNITY

Features 10........ Novel technology for fast COD analysis 14........ CPI: Industrial Strategy 16........ Steel Yankee Shells – The Seamless Option 20........ Increased service life at calender ...... applications 22........ Doing nothing against your high ...... operating costs?

24........ Membranes for Papermaking Wastewater ...... Purification

28........ Water-Soluble Pressure-Sensitive Adhesives 34........ Electric Dryers – Hand Hygiene risks 40........ Greener hand sanitizer products 45........ Conference / Exhibition / Meeting Reports

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Volume 60 Number 1

Spring 2019

ContentsPublished by PITA 5 Frecheville Court, Bury, Lancs BL9 0UF Tel: 0300 3020 150 Tel: +44 161 746 5858 (from outside the UK) Fax: 0300 3020 160 email: info@pita.co.uk website: www.pita.co.uk Editor Daven Chamberlain St Johns House Spring Lane Cookham Dean Berks SL6 9PN Tel: 0300 3020 159 email: editor@pita.co.uk

Advertising Manager Graham Sutton Tel: 0300 3020 154 Email: graham@pita.co.uk European Representative Nicolas Pelletier RNP 16 Rue Bannier – 45000 Orleans, France Tel: +33 6 82 25 12 06 Fax: +33 2 38 42 29 10 email: europe@pita.co.uk Designed and typeset by Upstream Ltd, Deepcar, South Yorkshire Printed by Mixam UK Watford, Herts

As the recent INGEDE Symposium showed, interest in deinking technology remains high, not least because of the ever changing demands being placed on mills by new printing methods. In addition, with the quality of recovered paper showing a general decline, improvements in the science of deinking becomes ever more important for maintaining raw material quality for graphical and tissue manufacturers.

© PITA reserves all copyrights for the contents of this Journal. Technical papers may also carry first-authors’ copyrights jointly with the Association. None of the contents may be extracted, circulated, or re-published without permission.

Registered Number*2928961 England Limited Liability. ISSN 0 306-252X

FRONT COVER PICTURE

2 ........ Comment 4 ........ Industry News 6 ........ News Bytes 13 ........ Standards Update 23 ........ Compendium of Recent Orders 32 ........ New Book Releases

36 ........ A Letter from India 38 ........ People in the News 39 ........ Obituary 43 ........ News Bytes Stop Press

Advertising List ABB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axchem . . . . . . . . . . . . . . . . . . . . . . . . . . 21 CPI Health & Safety . . . . . . . . . . 2 MIAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Paper & Biorefinery . . . . . . . . . . .33

Paper Middle East . . . . . . . . . OBC

Paper One Show . . . . . . . . . . . . . . . 35

Pilz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PITA – Events 2019 . . . . . . . . . . . .30

PITA – Food Contact . . . . . . . .IFC

PITA – Wastewater . . . . . . . . . IBC

SchäferRolls . . . . . . . . . . . . . . . . . . . . . . 5

SinoPaper 2019 . . . . . . . . . . . . . . . . . 44

Solenis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Spraying Systems . . . . . . . . . . . . . 15

TechnologieKring . . . . . . . . . . . . . . 34 Zellcheming . . . . . . . . . . . . . . . . . . . . . 37

A.Celli . . . . . . . .6, 8, 16-19, 23, 46 ABB . . . . . . . . . . . . . . . . . .5, 8, 23 ÅF . . . . . . . . . . . . . . . . . . . . . . . . .8 Andritz . . . . . . . . . . . . . . .6, 23, 45 Archroma . . . . . . . . . . . . . . . . .5, 8 BASF . . . . . . . . . . . . . . . . . . . . . .8 BTG . . . . . . . . . . . . . . . . . . .23, 45 Cellutech . . . . . . . . . . . . . . . . . . .6 Duran Machinery . . . . . . . . . . . .8 Emtec . . . . . . . . . . . . . . . . . . . . . .8 E.ON . . . . . . . . . . . . . . . . . . . . . . .5

GLV . . . . . . . . . . . . . . . . . . .5, 8, 9 Greycon . . . . . . . . . . . . . . . . . . .23 Hanchang . . . . . . . . . . . . . . . . . . .9 Hydac Technology . . . . . . . . . . . .5 Kadant . . . . . . . . . . . . . . . . . . . . .9 Kemira . . . . . . . . . . . . . . . . . . . . .5 Koenig & Bauer Group . . . . . . .8 Metso . . . . . . . . . . . . . . . . . . . . . .9 Omya . . . . . . . . . . . . . . . . . . . . . .9 Oradoc . . . . . . . . . . . . . . . . .45, 46 Pesmel . . . . . . . . . . . . . . . . . .4, 23 PMP Group . . . . . . . . . . . .8, 9, 23 PMT . . . . . . . . . . . . . . . . . . . . . .23 Pöyry . . . . . . . . . . . . . . . . . . .8, 46

Procsim . . . . . . . . . . . . . . . . .22-23 Pulpeye . . . . . . . . . . . . . . . . . . . .23 QCL Scientific . . . . . . . . .5, 10-13 Renaissance Chemical . . . . . . . .5 Rotex . . . . . . . . . . . . . . . . . . . . . .9 SchäferRolls . . . . . . . . . . . . .20-21 Solenis . . . . . . . . . . . . . . . . . . .8, 9 Statkraft . . . . . . . . . . . . . . . . . . .23 Techno Paper . . . . . . . . . . . . . . .46 Toscotec . . . . . . . . . .6, 7, 8, 23, 45 Valmet . . . . . . . . .5, 6, 8, 9, 23, 45 Voith . . . . . . . . . . .6, 7, 8, 9, 23, 46 Woollard & Henry . . . . . . . . . . .5

Supplier Index

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Reduction of energy consumption is an objective goal. It reduces not only CO2 emissions, but also the operating costs. One tonne of paper consumes up to 2 tonnes of LP steam. This represents almost 80% of the energy consumption in the Mill. The price for LP steam moves between 20 and 40 £/ton. Reducing steam con-sumption by 10% for annual average production of 200,000 tonnes represents reduction of operating costs by around £1M. Could the drying process efficiency be higher? The current control approach is predominantly based on PID control technique. Because of process long dwelling time (the process reaction on control variable change takes several min-utes), the PID controllers must be even slower to avoid process destabilisation. This causes off production and, of course, inef-fective energy consumption. However, the main reason of this inefficient energy usage is the fact that generally the controllers are working independently of each other. Paper machine effi-ciency was investigated by world-leading universities Cam-bridge and Manchester. The investigation results were presented at TAPPI PaperCon 2011. The steam consumption could be decreased by 20%! How to increase drying process efficiency? The precondition is to get more information from the process. Instead of equipping the paper machine with expensive gauges, the existing process values, which are linked by a system of physical formulas, allows the derivation of countless new pro-cess values. This system so-called “first principal model” is based on the technical parameters and functions of installed equipment and creates a “virtual process”. Two nearly identical processes (real and virtual) are effectively running in parallel. Difficult-to-measure process variables are derived from the virtual process, which increases process stability, speeds-up control reactions and enables the papermaker to coordinate all control loops as one unit. What does the digitalisation mean? The digitalisation is a mathematical decomposition of the entire process into the elementary processes. This new control technique combines process values from the field instrumentation together with a set-up of physical equations and equipment parameters creating a virtual twin of the real process. It represents an ar-tificial brain, which is based on functional “cooperation” between machinery and paper technology. This technique applies all avail-able information to find the best possible production path for all working conditions, saving energy in each individual production step and in each sub-process with stress on the global solution. This technique automatically checks and optimises all control activities in the virtual future, and only then controls the real process using the best set points.

Reduction of steam consumption at the press section: The weak point of many paper machines is the lack of informa-tion about web dryness after the press section. This fact disables continual observing efficiency and control of press section equip-ment (steam box, felt, felt washing, suction roll). The virtual pro-cess continuously calculates web dryness after the press section with precision near to that of the final scanner. This important information enables efficient control of press section functions, which reduces paper machine steam consumption by more than 5%. Reduction of steam consumption at the heat recuperation: Not well maintained efficiency of the heat recuperation is the second weak point. Polluted heat exchangers, unbalanced fresh and exhaust air, unnecessary high temperature and low humidity of exhaust air cause steam loss over 5% in most of the paper ma-chines. The virtual process continuously calculates dew point of exhaust air as important information to control efficiency in the heat recuperation area, which reduces paper machine steam consumption up to 4%. Reduction of steam consumption in the drying process: Grade change is a never ending story! Paper machine start-up after break and over-drying also causes remarkable energy and production losses. The virtual process continuously calculates and saves grade-dewatering parameters. Before the grade change starts, the dryness after press and required steam pressure in dryer are exactly predicted. The grade change time is shortened to the technological minimum. The control results are simulated virtually into the future so that deviations in the real process are corrected before they occur. These functions reduce paper ma-chine steam consumption by more than 3%. Increase of drying capacity: For caution, the steam pressure in the first and last cylinder groups is kept purposely lower on most paper machines, al-though the conditions for flashing steam would allow higher steam pressure values. The reason is unknown cylinder surface temperature, which could be a risk to paper quality. The virtual process continuously calculates surface temperature of each cylinder. Temperature information enables the papermaker to in-crease steam pressure and simultaneously maintain paper quality. This function increases drying capacity up to 5%. Drying efficiency increase: The control of the paper machine is continuously and automat-ically optimised for each grade in the virtual process. Only after this procedure, the optimised set points carry out the process to

PAPER TECHNOLOGY SPRING 2019 NEW INSIGHTS ON APPLICATION OF HIGH-YIELD PULP

Do you really want to forego £1 million and do nothing against your high operating costs?

Peter Fisera, CF ProcSim GmbH.

Barry R. Read, PITA

your high operating costs?

23

the new targets using the best way there. The broke is minimised and the energy losses are limited to a physical minimum. The equipment efficiency changes are continuously monitored and quantified as changes in the specific steam consumption. This is an operational tool to plan and economise maintenance activities.

Benefits of virtual technology: Due to the derived process information and their mutual physical dependencies, the simulation aided control of drying process re-duces steam consumption at least by 10% and increases dry-ing capacity up to 5%. The annual gain of virtual control technology for average production can be estimated at £1 million and Payback is shorter than 6 months.

PAPER TECHNOLOGY SPRING 2019 DOING NOTHING AGAINST YOUR HIGH OPERATING COSTS?

The list below contains a summary of orders reported by a host of major suppliers to the Paper Industry and related sectors since November 2018. Further information on each entry can be found online. Supplier companies wishing to publicise their success in gaining orders should send details to Daven Chamberlain via editor@pita.co.uk. A.CELLI SpA: 1. Berli Jucker Cellox Co. Ltd (Prachinburi plant, Thailand)

Winder 2. Dongguan Jintian Paper Co. (Sichuan Jintian Paper plant,

China) Winder 3. Global Hygiène (Charavines, France) Tissue production line 4. PartexTissue Ltd (Bangladesh) Yankee 5. Shanying Huazhong Paper Industry Co., Ltd (Jingzhou Dis-

trict, China) Two winders 6. Zhejiang Kingsafe Nonwovens Fabric Co. Ltd (Huzhou,

China) Winder (nonwovens) ABB: 1. Anon (East Java) Advanced digital services

ANDRITZ AG: 1. Iggesund Paperboard (Iggesund Mill, Sweden) Modernise

fibreline 2. JSC Volga (Balakhna, Russia) Convert pulp line to TMP 3. Kabel Premium Pulp & Paper (Hagen, Germany) TMP line 4. Melhoramentos Florestal (Minas Gerais, Brazil) Modernise

fibreline 5. Vattenfall AB (Uppsala, Sweden) Biomass boiler plant

BTG: 1. Suzano Papel e Celulose (Limeira unit, Brazil) Instrumen-

tation / Process Control (Fibreline C) GREYCON Ltd: 1. Mohawk (various sites, USA) Software 2. Polímeros y Derivados (Guanajuato, Mexico) Software

(nonwovens) 3. Sima Kraft Industry Co. Ltd. (three mill sites, Thailand)

Software PESMEL Oy: 1. SVEZA Group (Vologda region, Russia) MoU re basic en-

gineering of new pulp mill PMP SA: 1. South India Paper Mills Ltd. (Nanjangud, India) Headbox

& Shoe Press (PM6)

PMT SRL: 1. PT Dayasa Aria Prima (Surabaya, Indonesia) Machine re-

build (PM1) PULPEYE AB 1. Iggesund Paperboard (Iggesund Mill, Sweden) Online sensors

STATKRAFT 1. Norske Skog (Skogn Mill, Norway) Long term power sup-

ply contract 2. Norske Skog (Saugbrugs Mill, Norway) Long term power

supply contract TOSCOTEC SpA 1. Anon (Latin America) TAD tissue production line 2. Marutomi Group (Marutomi Paper, Japan) Tissue produc-

tion line 3. Marutomi Group (Ono Paper, Japan) Tissue production line 4. Smurfit Kappa (Cellulose du Pin Mill, France) Machine re-

build (PM5) VALMET Corp 1. ARAUCO (Arauco Mill, Chile) Pulp line (No.3, MAPA project) 2. Blue Paper SAS (Strasbourg, France) WMS / WIS (PM1) 3. Century Pulp and Paper (Lalkua, India) tissue production line 4. LondonEnergy Ltd. (North London, UK) Modernise water

treatment plant 5. Luzhou Yongfeng Pulp and Paper (China) Steam profiler 6. Mayr-Melnhof Karton (Frohnleiten, Austria) WMS (KM3) 7. Mercer Group (Stendal Pulp Mill, Germany) Online moni-

toring 8. Metsä Tissue (Mänttä Mill, Finland) Automation system up-

date 9. Mondi SCP (Ružomberok, Slovakia) OCC & container-

board lines 10. Papel Aralar (Amézqueta, Spain) Rewinder (nonwovens) 11. Papelera del Principado (Paprinsa, Spain) Control system 12. Pori Energia Oy (Aittaluoto biomass power plant, Finland)

Automation 13. Turun Seudun Energiantuotanto (Naantali, Finland) Com-

bustion plant upgrade 14. Sappi (Saiccor Pulp Mill, South Africa) Bailing line / Cutter

upgrade / Washing & Screening 15. Urumchi Jinghuan Environmental & Energy (Urumchi,

China) EfW boilers VOITH PAPER GmbH & Co KG 1. Hamburger Rieger (Spremberg, Germany) Stock prepara-

tion line (PM2) 2. Laakirchen Papier (Laakirchen, Austria) Stabiliser boxes /

Reel changing system

Compendium of Recent Orders Daven Chamberlain