New ways to use recovered paper Lynn PM 7

Transcription

1 VPZ_1003 I En I Content: heisimo I Design: S2 I Print: MA I New ways to use recovered paper Lynn PM 7 Voith Paper Holding GmbH & Co. KG St. Pöltener Straße Heidenheim, Germany Tel Fax paper@voith.com Find your regional contact at: II

2 Placement of an order is always a tough decision. In this case, however, we decided in favor of Voith because we had the feeling that the overall concept was right. We have a lot of confidence in the Voith technology. The cooperation between the teams was excellent. I have rarely experienced so little friction with a project as with this one. Dr. Wolfgang Palm, CEO of Palm Paper m/min, t/a, mm A maximum operating speed of m/min, a production capacity of metric tons p. a. and a wire width of mm. These were the three factors driving the design and systematic realization of the King s Lynn PM 7. The site location and the associated customization of the technology to meet local requirements had a great impact on this successful project. 1 Lynn PM 7: integrated solutions for economic efficiency. 2 Dr. Wolfgang Palm, CEO of Palm Paper. However, it s not just these three parameters that testify to the successful implementation of this brand new greenfield facility to the northeast of London. The plant s special features also include the cutting-edge configuration of its secondary fiber treatment facility and its highly environmentally friendly and cost-efficient deinking plant, tailored to the specific characteristics of the recovered paper sourced from within the UK. The complete production process from the arrival of the raw material to the point where the finished rolls leave the mill rely on a process control and monitoring system that has set a new benchmark for design and accuracy. The following pages provide an overview of the completion of this paper mill. The plant s economic efficiency is all the more remarkable because it opens a new chapter in the history of newsprint production in England being customized to fit local circumstances. Why a new production line in Britain? And why in King s Lynn? The planning and realization of the Lynn PM 7 project were based on strategic considerations, which in one stroke targeted the elimination of two market problems: insufficient domestic production of newsprint in Britain compared with demand, and the shortfall in recycling the growing surplus of used paper. Even the major British newspaper publishers did not view importing newsprint and exporting recovered paper as a sensible long-term economic solution. It was in their own interest to safeguard their supply of paper under reliable conditions. Therefore, they encouraged Palm Paper to make its most significant investment and expansion this side of the English Channel. King s Lynn was favored as the site due to its proximity to London and excellent infrastructure. From the very beginning, the community of King s Lynn was very much behind the project. 2 3

3 Largest TwinDrum in the world for deinked pulp t deinking stock treated every day 2 MultiScreen screens with C-bar screen baskets. 3 Drum feed, bale feed, automatic bale wire removal, bale opener. It s crucial to be heading in the right direction from the very outset. That is why the stock preparation unit, as the very first step in the production chain, plays a key role in securing a consistent annual output of t of premium quality newsprint. The deinking plant in King s Lynn is currently the largest of its kind and is designed for a stock output of t/d (oven-dry). A TwinDrum pulping drum supplies material to two deinking lines. The 35 m long TwinDrum, the largest of its kind to date, is cutting-edge technology in many respects, especially given its very high defibering efficiency. Furthermore the TwinDrum has a huge pulper capacity for recovered paper. Compared with conventional single stage drum pulping solutions, the chemical consumption can be reduced by % and specific energy by around 20 %. The two deinking lines operate concurrently. Along with recycling standard newspapers and magazines, the King s Lynn mill also handles flexographic newsprint from the domestic market. This printing process places stringent requirements on stock preparation. Above all, the waterbased printing inks used in flexographic printing cause problems in the conventional deinking process. As the source material has a printing content of %, the deinking facility at King s Lynn is designed with a very high tolerance thanks to proven stock preparation machines combined with a specially developed intelligent process control system. The stock preparation unit is backed by supply and disposal components with a capacity and function that ensure the reliable operation of the plant. This includes a feeding system dimensioned specifically for bales and loose papers and a fully automatic rejects system including separation, shredding and dewatering. Four microflotation units ensure highly efficient cleaning of the water systems. 5

4 Until the end of the 18 th century, King s Lynn was an important port city. Highlights Since the successful start-up of the PM 7, King s Lynn in the county of Norfolk 140 km northeast of London has been one of the key production sites in Britain for high-quality newsprint made from 100 % secondary fibers. This also makes it one of the largest recycling centers for waste paper. 2 Even today, many very well preserved buildings testify to the city s heyday as a Hanseatic League member. 3 The Palm Paper mill site in King s Lynn. Voith scope of supply Stock preparation Deinking with TwinDrum pulping drum, two EcoCell flotation lines, EcoDirect dispersing system, peroxide bleaching system, Deltapurge water treatment, reject dewatering and transport systems. Automation Hydraulic and pneumatic systems, machine-level control, software programming, OnControl process control system, OnC DriveCommand drive control, OnQuality quality control system, OnView information system. King s Lynn in England King s Lynn Great Britain: km 2, 61 million inhabitants of whom 7.5 million live in London. Around press publications comprising local and international daily and weekly newspapers, 600 trade journals and 500 magazines. This city at the mouth of the Great Ouse in the arm of the North Sea known as the Wash was once a distinguished member of the Hanseatic League. It therefore looks back on a long history of trading relations with the continent. Its location and good transport links were also key factors in Palm s choice of location. Relative to its population, Britain has the largest readership of newspapers and magazines in Europe. The demand for newsprint is correspondingly high. Until now, a large part of this demand has been covered by imported paper. Recovered paper has even been exported as the raw material for paper production. The King s Lynn paper mill has shifted this supply and demand pattern. The plant s technology and enormous capacity offer the opportunity for a much more economic and environmentally compatible cycle between paper production, printing industry, readers and paper recycling. The benefits of the short distances involved are obvious. Wet End Process EcoMizer cleaning, MultiScreen screening, VoithVac air extraction, Machine Pulper fiber preparation. Paper machine MasterJet II G headbox with ModuleJet, DuoFormer TQv, DuoCentri NipcoFlex with fourth press, TopDuoRun dryer section, two EcoSoft Delta calenders, Sirius reel, basic and detail engineering. Winder Two VariTop. Auxiliary units Machine and plant air systems, steam and condensate systems, lubrication systems and mechanical drives. Clothing Forming fabrics: PrintForm HS, PrintForm HQ. Press felts: PrintFlex V2, PrintFlex V3, PrintFlex 02 Planar. Dryer fabrics: PrintTech Q2. Rolls EvoTec and CarboTec rolls, SolarFlow suction rolls, SkyLine doctors. Roll covers WebMax, BlackStone S, TerraSpeed, WebNet, NanoPearl, TerraGloss. Press sleeves QualiFlex QX 95. Services Plant and electrical engineering, supervision of installation, commissioning and staff training. 6 7

5 The whole is greater than the sum of all parts Twelve thousand machine parts were installed in King s Lynn during the fifteen month construction period for the new paper mill. After challenges with the site s subsoil in the once marshy mouth of the Great Ouse River had been overcome, the associated delays in the construction phase could be counterbalanced by a faster installation time for the technical systems. The PM 7 went into operation three weeks earlier than planned. Thanks to the Lynn PM 7, Palm Paper has become the leading supplier to the British market in terms of quality and is now supplying virtually all publishers in the United Kingdom. The overall configuration of the Lynn PM 7 is based on tried, tested and improved modules of the One Platform Concept. It meets the ambitious goals for premium quality for both standard newsprint and improved paper grades to achieve complete customer satisfaction. The example of King s Lynn shows that a consistent overall concept from fiber treatment to water recovery precisely tailored to the specific features of the location is a sustainable, future-proof and successful solution. VariTop winder The rolls from the PM 7 are reeled up and cut on two state-of-the-art VariTop winder units with a design speed of m/min. Depending on customer requirements roll widths of 0.4 to 3.6 m and roll weights of up to 10 t are possible. The two VariTop winders with unwind splice, automatic blade positioning and finished roll changer are designed so that the roll can be wound in a set with different core materials such as aluminum, board or plastic. Sirius reel Using Sirius reeling technology, the paper is wound in a careful and controlled manner up to a roll diameter of more than 4 m. The reel master rolls are more than 10.5 m wide and weigh 125 t. When the desired roll circumference is reached, the paper is transferred automatically and with minimal waste to the next available reel by EcoChange reel change system. EcoSoft Delta calender Even if the paper web leaves the press section with a uniform surface quality, the two EcoSoft calenders provide the option of additional paper smoothing if the customer requires it. This ensures that both sides of the web can be printed simultaneously without any detectable difference between first form and perfecting printing, even in the case of sophisticated color photo reproduction. A smooth roll run is therefore guaranteed, even on state-of-the-art printing machines operating at high speeds. TopDuoRun dryer section 36 drying cylinders with optimum runability and low energy consumption ensure stable drying of the entire web draw via the TopDuoRun stations with their eight dryer groups. DuoFormer TQv and DuoCentri NipcoFlex press The latest generation of the TQv former with the proven alternating arrangement of dewatering elements produces an extremely symmetrical sheet formation. The sheet is compressed and the water removed from the paper mechanically in the downstream DuoCentri NipcoFlex press. Dry contents in excess of 50 % are achieved using the NipcoFlex shoe press. In combination with the EcoSoft calender, the separate fourth press helps achieve an excellent surface quality and homogeneous surface condition on both sides of the paper. Voith Advanced Wet End Process As a link between the stock preparation and headbox, the Advanced Wet End Process has a major influence on production stability and paper quality. The component ComMix, for stock mixing in the HC stock range, and HydroMix, for mixing the HC stock in the white water, form the basis for uniform stock consistency and thus a consistently good basis weight cross profile in the paper machine. In addition, the vat volumes and thus energy consumption can be reduced. The integrated overall concept Technical Data Start-up: 2009 Wire Width: mm Production: t/year Basis Weight: 42,5 48,8 g/m paper mill recovered paper printers consumers 1 DuoFormer TQv with MasterJet headbox 2 DuoCentri NipcoFlex with 4th press 3 TopDuoRun dryer section 4 EcoSoft Delta calender 5 Sirius reel 6 VariTop winder

6 The information system provides the perfect overview. 2 The process control system was tailored optimally to the machine. 3 The robust Voith LSC Scanner for operation in challenging operating environments signals The key to quality assurance for Lynn PM 7 is the Voith automation system. It takes more than just laying 600 t of copper cable to be able to process the paper machine s more than input and output signals. It also requires sound process know-how to tailor the control system to the entire production line. The order also included control of the 64 drives of the PM 7 within the process control system. Voith integrated the OnC DriveCommand software, which was developed for this purpose, into the process control system to ensure simple operation of the entire system, from water treatment to headbox through to winder. This close intermeshing of automation and paper machine played a key role in the fast start-up of the PM 7. The OnQ quality control system serves to meet the most stringent quality requirements. As well as the OnQ EnviroScan scanner for measuring paper moisture in the dryer section and Voith LSC scanners upstream of the reel, the quality control system comprises several other modules such as OnQ ModuleJet actuators, OnQ ModuleSteam steambox and OnQ GradeControl Color for color control. The interaction of these components ensures that all key paper web parameters are logged and controlled. The user-friendly OnView information system helps Palm maintain an overview of machine, process and quality data. Even after start-up, the Lynn PM 7 continues to stand out as pioneering technology. The latest installation of Voith LSC QuantumSens, the first non-contacting caliper measurement, provides accurate data without causing holes or other defects thanks to its patented multipoint measuring process. 12

7 7 000 m² of fabrics and more than m² of roll covers 1 2 Fabrics and roll covers are constantly in direct contact with the paper web. This means they have a considerable impact on paper quality and machine efficiency. From start-up, the performance of Voith forming, pressing and drying fabrics continue to be an integral part of the machine to maintain the highest paper quality, says Stephan Gruber, Managing Director Production at Palm in King s Lynn. Voith supplied all start-up fabrics and remains the main supplier for all covers and clothing. In addition, Voith will carry out the roll service for the PM 7. Forming Dryer The SSB design from the PrintForm range used for the top and bottom wires is setting benchmarks with respect to good running properties and paper quality as well as high wear resistance and stability. The WebMax fiber-reinforced roll cover is ideal for high mechanical loads. The BlackStone S hard rubber roll covers on the guide rolls are extremely wear resistant and easy to doctor. The PrintTech Q2 dryer fabrics have proven effective on all positions in the dryer section. They are easy to install and combined with web control and cleaning systems ensure good running properties and excellent heat transfer from drying cylinder to paper web. Press Calender 1 Optimally tailored to one another: fabrics and roll covers. 2 Voith fabrics are in constant contact with the paper. PrintFlex V3 features a long felt service life and very good dewatering capacity in the pick-up position. This technology also operates successfully on the first bottom felt position. The Voith Planar non-woven design chosen for the NipcoFlex press is achieving outstanding results in operation. Excellent sheet release on the center press roll is guaranteed through the use of a TerraSpeed thermal coating. WebNet technology, a bonding layer between the SolarFlow roll cover and the roll, ensures improved thermal resistance and much greater resistance to chemical and mechanical loads. The NanoPearl composite calender roll covers ensure excellent surface condition and provide maximum wear resistance and high operational reliability. The TerraGloss roll cover with SkyTop T doctor blade plays a crucial role in paper quality. The improvement in quality in the paper surface is so considerable that the use of a second calender stack is no longer necessary for all paper grades. 15