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GLV_portucel_fine4

Rui Vinhas
Rui Vinhas

Portucel Viana, a paper mill in Portugal owned by Europac Group, partnered with GL&V Sweden to rebuild and upgrade its refining systems. The goals of the project were to increase paper production capacity while saving energy in the refining process and increasing pulp strength. GL&V replaced old refiners with new higher efficiency models, which reduced energy consumption from over 300 kWh/tonne to around 120 kWh/tonne, saving over 80 kWh and cutting the payback period to under two years. The improved refining helped Portucel Viana develop pulp strength properties needed for its kraftliner product.

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Europac Group/ Portucel Viana, Portugal: Refining is very important for us Portucel Viana Mill, part of the Spanish Eu- ropac Group, and GL&V Sweden realised a major refining project to save energy and increase the pulp strength in the mills re- fining processes. The partnership provided excellent results at a very critical process stage in Portucel Vianas marketing mis- sion. The Europac Group is a leading compa- ny in the packaging sector in the Iberian Peninsula which is dedicated to the elabo- ration of paper, corrugated cardboards and packaging to offer the widest range of products to its customers. The integration of the companys activities makes it possi- ble to cover the whole corrugated card- board production chain. Europac Group re- lies on 29 industrial installations and some 1,300 employees in Spain, Portugal and France. The aggregate sales in 2007 equalled EUR 526 million. Portucel Viana is the major paper mill in the Group to produce kraftliner. It is lo- cated in the city of VIANA do Castelo in Portugal. The mill started up in 1973 with a capacity of 136,000 tonnes/a. Since then the mill has changed rapidly over the years. Today Portucel Viana produces Por- toliner brand kraftliner, basis weight 115 300 g/m2 , some310,000 tonnes/a. It has 310 employees. Portucel Viana is a fully in- tegrated paper mill with contin- uous pulp cooking, a recycled fibre plant, recovery island, power boiler (second under construction), one gas and one steam turbine to produce 27 MW of power which is sold outside the mill and one paper machine with auxiliary equip- ment. Its raw materials include pine, eucalyptus wood and old corrugated containers. The mill is located close to the sea in an area where forestry has a very impor- tant role in the local economy. The raw material mix for kraftliner is 70% virgin fi- bre (80% pine and 20% euca) and 30% re- cycled fibre. The power production raw material mix is 15% biomass, 37% natural gas and 48% black liquor. Portucel Viana has increased its pro- duction capacity step-by-step by imple- menting various technological improve- ments. The latest investments in 2008 increased the kraftliner production capaci- ty to320,000 tonnes/a. The overall capac- ity of this product in Europe is one million tonnes. Their kraftliner brand Portoliner is marketed mainly to Spain (its main mar- ket), Portugal, Germany, France and Italy. In late 2009 the mill will introduce a new product. Recycled fibre use will in- crease in the future. To reach its commer- cial targets the mill has invested in short circulation and the paper machine. The re- fining system has been rebuilt and upgrad- ed and the paper machine has been up- dated with a new topformer. The challenge is that to be able to achieve this new product you need to im- prove the furnish. Europac is not so well known in the marketplace but it will be in the future, says Jos辿 D. de Castro Carrero, Managing Director of Portucel Viana. Your obvious partner in pulp and paper
2 Portucel Viana chose GL&V as its partner to rebuild and upgrade its refining systems. The refining rebuild was part of the whole paper making investment. The main tar- gets were to achieve a higher paper pro- duction capacity and at the same time save energy in the refining process as well as increase the pulp strength. In 2005 we decided to increase the refining capacity, it was a necessity, explains Jos辿 D. de Cas- tro Carrero. We turned to the technology providers and after a very tight competition GL&V won this project. We decided to co-operate with GL&V to rebuild this refining system because the overall power consumption in the whole refining process was very high. So we replaced the old Beloit-Jones refiners in the top layer refining system with new models and bought four new 42 DD速 4600 units from GL&V. All of them are working more or less at full power. The old systems were operated by two lines with six 34 refiners. Even with this power consumption there was a lack of refining capacity. At the same time no- load power was very high more than 30% of the total power. We also made changes on the bottom ply refining line in order to decrease no- load power. We changed three old refiner rotors from 46 to 42 utilising GL&Vs re- finer upgrade package DD速 4600. We wanted to have similar refiner plates on both top and bottom plies in order to save Picture above Pedro Campos: During the time we were installing refiners one at a time we were at around 200 kWh/paper. Now we are around 120 kWh/ tonne of paper so we have saved 80 kWh/tonne of paper. Picture next Specific energy consump- tion per tonne of bone dry tonne of fibre and per tonne of paper. 400 350 300 250 200 150 100 50 0 Jan.06 Feb.06 Mar.06 Apr.06 May.06 June.06 July.06 Aug.06 Sept.06 Oct.06 Nov.06 Dec.06 Jan.07 Feb.07 Mar.07 Apr.07 May.07 June.07 July.07 Aug.07 Sept.07 Oct.07 Nov.07 Dec.07 Specific Energy Consumption kwh/BDt kwh/t paper
3 in storage expenses. Now we are running top and bottom plies with the same disk pattern. Its important to us because we have what we call a swing refining process. We have three available refiners for the top ply even if only two are working and three refiners for the bottom ply plus one swing refiner. We can run it, if there are any prob- lems, either for the top or bottom ply. We made these changes step-by-step and we could see with every refiner we were installing that energy consumption was decreasing. The change was very clear and the sav- ings in energy and money can also be measured in euros. You may ask why the refiner is so important for us. The main property for our type of prod- uct is the strength, so we are looking at the strength, mainly using burst and SCT testing. When we get the pulp from our digester plant with its poorly devel- oped strength prop- erties, we have to refine the pulp. It is very demanding. We have to refine a great deal to achieve higher strengths, says M叩rio Santos Amaral, Production Manager. Our target is to reach around 6 kPam2 /g on the top ply at a Schopper- Riegler value of 35 and we can show you the results. This was the target when we turned to GL&V. All the same targets ap- plied to the bottom ply but we left the SR value because the bottom ply represents more or less the overall grammage. The bottom ply represents more or less 70% of the basis weight so we are not able refine a great deal. We cannot develop the Schopper-Riegler value too much because then we would have problems with the grammage on the forming section. It is a very heavy ply. We want to reach a SR val- ue of 25 for the bottom ply with slightly less fibre development. We can see that we have improved the strength properties and energy savings by a factor of 2.5. The payback time of this project is less than two years. Thats why the refining is very impor- tant for us. Its the most important strength development tool that we have. The refining process is also important because we do not have any size presses. We only have cationic starch on the stock but not surface sizing. At the moment we do not refine the recycled fibre. However, we are working with GL&V on how to pro- ceed in this area. GL&V: Can you tell us about the rebuild project changing the new rotor systems with GL&V? This was our first experience with GL&Vs splined rotor systems. In 2005 we upgrad- ed, step-by-step, all three of our old 46 re- finers with 42DD速 4600 Equa-FloTM up- grade packages. After that we decided to install totally new 42DD速 4600 refiners on our top-plyline. However, when we had both the rebuild project and a new installation going on at the same time there was no need to shut down the paper machine dur- ing this operation. On the contrary it was very easy to achieve, says M叩rio Amaral. Before the refining rebuild project we used more or less 300 kWh power per bone dry tonne of pulp for the top ply with these systems and now we use 230 kWh. This curve shows us the specific energy consumption before the project as 320 kWh/bone dry tonne of pulp. During the time we were installing refiners one at a time we were at around 200 kWh/paper. Now we are around 120 kWh/tonne of pa- per so we have saved 80 kWh/tonne of pa- per. states Pedro Campos, Paper Ma- chine Superintendent. GL&Vs scope of delivery: - Four 42DD速4600 refiners - Three 42Equa-flo splined upgrades for upgrading existing refiners to DD速4600 refiners - Refiner plates and spare parts - Split delivery during 2006 and 2007 - Start-up services
For more information visit us at www.glv.com GL&V Pulp and Paper Division: Experience Innovation Solution GL&V Pulp and Paper, a division of the Canadian based company GLV Inc., is a global enterprise in technology and processes for manufacturing of pulp and paper as well as in production and treatment of fresh, process and waste waters. The GL&V Pulp and Paper group is one of the largest suppliers of pulp and paper production equipment and a world leader in equipment rebuilds, upgrades and optimization. GL&V Pulp and Paper group provides complete solutions for production and management of fresh and process waters as well as for efficient treatment of waste waters and effluents in the pulp and paper industry. The GL&V technology and processes are designed for accomplishing the lowest capital and operating experience combined with the highest feasible total efficiency of the supplied components and process systems. Sweden GL&V Sweden AB P.O. Box 100 S-129 22 Stockholm Tel: +46 8 522 444 00 Fax: +46 8 522 444 99 Spain GL&V Sweden AB C/Santuario No. 5 - 3 Dcha. E-47002 Valladolid Tel: +34 983 520 982 Fax: +34 983 520 982 Russia GL&V Sweden AB Office 603, Business center APOLLO 8A Dorolyobova pr., 197198, Saint-Petersburg Ph: +7 (812) 635 88 50 Fax: +7 (812) 635 88 51 France GL&V France SARL 22, rue Pierre Mend竪s France F-77200 Torcy Tel: + 33 1 60 17 28 26 Fax: + 33 1 60 05 86 12 Finland GL&V Sveden AB PO Box 161 (Sinikalliontie 9) FIN-02631 Espoo Tel: +358 10 425 0640 Fax: +358 10 425 0649 Portugal GL&V Sweden AB Pra巽a Almirante Reis, 27, 4th Room B 2900-585 Setubal, Portugal Tel: +351 265 550 613 Fax: +351 265 550 614

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GLV_portucel_fine4

  • 1. Europac Group/ Portucel Viana, Portugal: Refining is very important for us Portucel Viana Mill, part of the Spanish Eu- ropac Group, and GL&V Sweden realised a major refining project to save energy and increase the pulp strength in the mills re- fining processes. The partnership provided excellent results at a very critical process stage in Portucel Vianas marketing mis- sion. The Europac Group is a leading compa- ny in the packaging sector in the Iberian Peninsula which is dedicated to the elabo- ration of paper, corrugated cardboards and packaging to offer the widest range of products to its customers. The integration of the companys activities makes it possi- ble to cover the whole corrugated card- board production chain. Europac Group re- lies on 29 industrial installations and some 1,300 employees in Spain, Portugal and France. The aggregate sales in 2007 equalled EUR 526 million. Portucel Viana is the major paper mill in the Group to produce kraftliner. It is lo- cated in the city of VIANA do Castelo in Portugal. The mill started up in 1973 with a capacity of 136,000 tonnes/a. Since then the mill has changed rapidly over the years. Today Portucel Viana produces Por- toliner brand kraftliner, basis weight 115 300 g/m2 , some310,000 tonnes/a. It has 310 employees. Portucel Viana is a fully in- tegrated paper mill with contin- uous pulp cooking, a recycled fibre plant, recovery island, power boiler (second under construction), one gas and one steam turbine to produce 27 MW of power which is sold outside the mill and one paper machine with auxiliary equip- ment. Its raw materials include pine, eucalyptus wood and old corrugated containers. The mill is located close to the sea in an area where forestry has a very impor- tant role in the local economy. The raw material mix for kraftliner is 70% virgin fi- bre (80% pine and 20% euca) and 30% re- cycled fibre. The power production raw material mix is 15% biomass, 37% natural gas and 48% black liquor. Portucel Viana has increased its pro- duction capacity step-by-step by imple- menting various technological improve- ments. The latest investments in 2008 increased the kraftliner production capaci- ty to320,000 tonnes/a. The overall capac- ity of this product in Europe is one million tonnes. Their kraftliner brand Portoliner is marketed mainly to Spain (its main mar- ket), Portugal, Germany, France and Italy. In late 2009 the mill will introduce a new product. Recycled fibre use will in- crease in the future. To reach its commer- cial targets the mill has invested in short circulation and the paper machine. The re- fining system has been rebuilt and upgrad- ed and the paper machine has been up- dated with a new topformer. The challenge is that to be able to achieve this new product you need to im- prove the furnish. Europac is not so well known in the marketplace but it will be in the future, says Jos辿 D. de Castro Carrero, Managing Director of Portucel Viana. Your obvious partner in pulp and paper
  • 2. 2 Portucel Viana chose GL&V as its partner to rebuild and upgrade its refining systems. The refining rebuild was part of the whole paper making investment. The main tar- gets were to achieve a higher paper pro- duction capacity and at the same time save energy in the refining process as well as increase the pulp strength. In 2005 we decided to increase the refining capacity, it was a necessity, explains Jos辿 D. de Cas- tro Carrero. We turned to the technology providers and after a very tight competition GL&V won this project. We decided to co-operate with GL&V to rebuild this refining system because the overall power consumption in the whole refining process was very high. So we replaced the old Beloit-Jones refiners in the top layer refining system with new models and bought four new 42 DD速 4600 units from GL&V. All of them are working more or less at full power. The old systems were operated by two lines with six 34 refiners. Even with this power consumption there was a lack of refining capacity. At the same time no- load power was very high more than 30% of the total power. We also made changes on the bottom ply refining line in order to decrease no- load power. We changed three old refiner rotors from 46 to 42 utilising GL&Vs re- finer upgrade package DD速 4600. We wanted to have similar refiner plates on both top and bottom plies in order to save Picture above Pedro Campos: During the time we were installing refiners one at a time we were at around 200 kWh/paper. Now we are around 120 kWh/ tonne of paper so we have saved 80 kWh/tonne of paper. Picture next Specific energy consump- tion per tonne of bone dry tonne of fibre and per tonne of paper. 400 350 300 250 200 150 100 50 0 Jan.06 Feb.06 Mar.06 Apr.06 May.06 June.06 July.06 Aug.06 Sept.06 Oct.06 Nov.06 Dec.06 Jan.07 Feb.07 Mar.07 Apr.07 May.07 June.07 July.07 Aug.07 Sept.07 Oct.07 Nov.07 Dec.07 Specific Energy Consumption kwh/BDt kwh/t paper
  • 3. 3 in storage expenses. Now we are running top and bottom plies with the same disk pattern. Its important to us because we have what we call a swing refining process. We have three available refiners for the top ply even if only two are working and three refiners for the bottom ply plus one swing refiner. We can run it, if there are any prob- lems, either for the top or bottom ply. We made these changes step-by-step and we could see with every refiner we were installing that energy consumption was decreasing. The change was very clear and the sav- ings in energy and money can also be measured in euros. You may ask why the refiner is so important for us. The main property for our type of prod- uct is the strength, so we are looking at the strength, mainly using burst and SCT testing. When we get the pulp from our digester plant with its poorly devel- oped strength prop- erties, we have to refine the pulp. It is very demanding. We have to refine a great deal to achieve higher strengths, says M叩rio Santos Amaral, Production Manager. Our target is to reach around 6 kPam2 /g on the top ply at a Schopper- Riegler value of 35 and we can show you the results. This was the target when we turned to GL&V. All the same targets ap- plied to the bottom ply but we left the SR value because the bottom ply represents more or less the overall grammage. The bottom ply represents more or less 70% of the basis weight so we are not able refine a great deal. We cannot develop the Schopper-Riegler value too much because then we would have problems with the grammage on the forming section. It is a very heavy ply. We want to reach a SR val- ue of 25 for the bottom ply with slightly less fibre development. We can see that we have improved the strength properties and energy savings by a factor of 2.5. The payback time of this project is less than two years. Thats why the refining is very impor- tant for us. Its the most important strength development tool that we have. The refining process is also important because we do not have any size presses. We only have cationic starch on the stock but not surface sizing. At the moment we do not refine the recycled fibre. However, we are working with GL&V on how to pro- ceed in this area. GL&V: Can you tell us about the rebuild project changing the new rotor systems with GL&V? This was our first experience with GL&Vs splined rotor systems. In 2005 we upgrad- ed, step-by-step, all three of our old 46 re- finers with 42DD速 4600 Equa-FloTM up- grade packages. After that we decided to install totally new 42DD速 4600 refiners on our top-plyline. However, when we had both the rebuild project and a new installation going on at the same time there was no need to shut down the paper machine dur- ing this operation. On the contrary it was very easy to achieve, says M叩rio Amaral. Before the refining rebuild project we used more or less 300 kWh power per bone dry tonne of pulp for the top ply with these systems and now we use 230 kWh. This curve shows us the specific energy consumption before the project as 320 kWh/bone dry tonne of pulp. During the time we were installing refiners one at a time we were at around 200 kWh/paper. Now we are around 120 kWh/tonne of pa- per so we have saved 80 kWh/tonne of pa- per. states Pedro Campos, Paper Ma- chine Superintendent. GL&Vs scope of delivery: - Four 42DD速4600 refiners - Three 42Equa-flo splined upgrades for upgrading existing refiners to DD速4600 refiners - Refiner plates and spare parts - Split delivery during 2006 and 2007 - Start-up services
  • 4. For more information visit us at www.glv.com GL&V Pulp and Paper Division: Experience Innovation Solution GL&V Pulp and Paper, a division of the Canadian based company GLV Inc., is a global enterprise in technology and processes for manufacturing of pulp and paper as well as in production and treatment of fresh, process and waste waters. The GL&V Pulp and Paper group is one of the largest suppliers of pulp and paper production equipment and a world leader in equipment rebuilds, upgrades and optimization. GL&V Pulp and Paper group provides complete solutions for production and management of fresh and process waters as well as for efficient treatment of waste waters and effluents in the pulp and paper industry. The GL&V technology and processes are designed for accomplishing the lowest capital and operating experience combined with the highest feasible total efficiency of the supplied components and process systems. Sweden GL&V Sweden AB P.O. Box 100 S-129 22 Stockholm Tel: +46 8 522 444 00 Fax: +46 8 522 444 99 Spain GL&V Sweden AB C/Santuario No. 5 - 3 Dcha. E-47002 Valladolid Tel: +34 983 520 982 Fax: +34 983 520 982 Russia GL&V Sweden AB Office 603, Business center APOLLO 8A Dorolyobova pr., 197198, Saint-Petersburg Ph: +7 (812) 635 88 50 Fax: +7 (812) 635 88 51 France GL&V France SARL 22, rue Pierre Mend竪s France F-77200 Torcy Tel: + 33 1 60 17 28 26 Fax: + 33 1 60 05 86 12 Finland GL&V Sveden AB PO Box 161 (Sinikalliontie 9) FIN-02631 Espoo Tel: +358 10 425 0640 Fax: +358 10 425 0649 Portugal GL&V Sweden AB Pra巽a Almirante Reis, 27, 4th Room B 2900-585 Setubal, Portugal Tel: +351 265 550 613 Fax: +351 265 550 614