2015-05-12 abu dhiab concepts for wlc and budget
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Abu Dhiab Concepts for WLC and BudgetTRANSCRIPT
1Stock Preparation References for White Lined Chipboard | Ravensburg | 2012-04-10
Stock Preparation Conceptsfor White Lined Chipboard
2
Content
1. Stock Preparation Conzept for WLC2. WLC Technology
3. OPC Board Machine Layout4. Forming Section
5. Press Section
6. Dryer section
7. Surface Sizing
8. Pre- Calandering
9. Coating Section
10. Coating Drying
11. Reel
12. Winder
13.BUDGET INDICATION
3
1. White Line Chipboard (WLC)Raw material categories
70% LBKP/ 30% NBKP
100% ONP/OMG
100% MWP/OCC
100% MWP/OCC
70% LBKP/ 30% NBKP
100% ONP/OMG
100% MWP/OCC
70% LBKP/ 30% NBKP
70% LBKP/ 30% NBKP
100% ONP/OMG
100% MWP/OCC
100% MWP/OCC
70% LBKP/ 30% NBKP
100% ONP/OMG
100% MWP/OCC
100% ONP/OMG 70% LBKP/ 30% NBKP
WLC
4-layer
WLC
5-layer
Top layer
Underlayer Top
Middle layer
Back layer
Top layer
Underlayer Top
Middle layer
Back layer
Underlayer Back
White back Grey back Diagram
1
2
2
2
1
1
1 1
1
2
3
2
2
3 3
3 3
3
100% ONP/OMG
4
HC
Cle
anin
g
Raw
Mat
eria
l Han
dlin
g
Stock Preparation Line for BKPfor Toplayer and white Back Layer WLC
Ref
inin
g
Make-up Water from PM
LC P
ulpi
ng
Diagram 1
5
Stock Preparation Loop
Clear filtrate PM Disc Filter
White water
HC
Cle
anin
gLC
Pul
ping
IC C
lean
ing
Thi
cken
ing
SF
Coa
rse
Scr
eeni
ng
Fra
ctio
natio
n I Dew
ater
ing
LF
Dis
pers
ion
LF
Thi
cken
ing
LF
To PMF
ract
iona
tion
II
LC S
lot S
cree
ning
Reject Approach flow
30% LF
70% SFRaw
Mat
eria
l H
andl
ing
RejectHandling
SludgeHandling
Reject from Line for Underlayer
Diagram 2
Stock Preparation Line for MWP/OCCfor Middle Layer WLC
6
Stock Preparation Loop
Clear filtrate PM Disc Filter
White water
HC
Cle
anin
g
Dru
mP
ulpe
r*
IC C
lean
ing
Thi
cken
ing
SF
Coa
rse
Scr
eeni
ng
Fra
ctio
natio
n I Dew
ater
ing
LF
Dis
pers
ion
LF
Thi
cken
ing
LF
To PMF
ract
iona
tion
II
LC S
lot S
cree
ning
Reject Approach flow
30% LF
70% SF
Raw
Mat
eria
l H
andl
ing
RejectHandling
SludgeHandling
Reject from Line for Underlayer
Diagram 2
Ref
inin
g LF
Stock Preparation Line for MWP/OCCfor Middle Layer WLC – Optional Module
* Single Release required
7
Process Water
Treatment
LC S
lot S
cree
ning
IC C
lean
ing
MC
Hol
e S
cree
ning
HC
Cle
anin
g
Flo
tatio
n
HC
Pul
ping
Thi
cken
ing
Dew
ater
ing
Dis
pers
ion
SludgeHandling
Clear Filtrate from PM Disc Filter
Raw
Mat
eria
l Han
dlin
g
Process Water
Treatment
WW II from PM R
educ
tive
Ble
achi
ng
Diagram 3
to Reject Handling in Middel layer
Stock Preparation Loop
Stock preparation line for ONP/OMG for Underlayer WLC
8
9
2. Cartonboard Technology for WLC Grades
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Cartonboard Technology
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Overview board grades
SBS
Top ply:BKP (HW+SW)
middle: BKP, [(B)CTMP], Broke
Back ply: BKP (HW+SW)
Back coat: Blade Coater
Pre coat: Blade CoaterTop coat: Blade Coater
FBB
Top ply: BKP (HW+SW)
middle: BKP, BCTMP, Broke
Back ply: BKP
Pre coat: Blade Coater
Pre coat(Middle coat: Blade Coater)
LPB
Top ply:BKP (HW+SW)
middle: UBKP, CTMP, Broke
Back ply: (U)BKP
Sizing: Filmpress
Pre coat: FilmpressMiddle coat: Blade Coater
Top coat: Blade Coater
WLC
Top ply: BKP (HW+SW)
middle: MW, OCC (GW), Broke
Back ply: ONP, DIP
Pre coat(Middle coat: Blade Coater)Top coat: Blade Coater
(Top coat: Blade Coater)
Top coat: Blade Coater
Sizing: Filmpress
Sizing: Filmpress Sizing: Filmpress
Sizing: Filmpress Sizing: Filmpress
Pre coat: Blade CoaterSizing: Filmpress
Undertop ply: DIP
Polyethylene
PolyethyleneAluminumPolyethyleneaseptic application
SUS
middle: UBKP, CTMP, Broke
Back ply: UBKP (SW)
Pre coat: Blade CoaterTop coat: Blade Coater
Sizing: Filmpress
Back coat: Blade CoaterSizing: Filmpress
Top ply:BKP (HW+SW)
Can be single ply! Virgin fiber based Recylced fiberbased
12
Overview Cartonboard marketWorldwide
Total production capacity to / year 56.639.061
Number of board machines 659
Mean BM capacity to / year 85.947
Mean technical age of BM years 30
Mean BM speed m/min 287
Mean width at reel mm 3.021
Source: Fisher database; FisherSolve™ Status 2012 Q1
13
White Lined Chipboard (WLC)
Grammage / range Characteristics End-use examples
200 – 550 gsm - stiffness (bulk) - cereals and snacks - hygiene - bakery- creasing and - foodstuffsfolding properties - household & industrial
- good printability products- good runnability - froze foods (ice cream)
- garden goods- toys - heavy duty outers- direct food contact - non-direct food contact
WLC is common in regions where virgin fiber is scarce (e.g. Central & Eastern Europe) and where the packaging price has to be kept at minimum.
14
3. OPC Board Machine Layout
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Machine concept
OPC 150 means 150.000 to/a (web width reel= 3,75m, voper. max.= 600m/min)
16
OPC concept
Headbox : Top, Undertop and Back Ply: MasterJet ProMiddle ply: MasterJet Pro with ModuleJet II (100mm)
Forming Top, Undertop and Back Ply with same number of dewatering elements
Section: Middle Ply: with DuoFormer D II for dewatering and formation
Press Section: OPC 150: 1st Press: Roll Press, double felted with 4 uhle boxes2nd Press: NipcoFlex Press, double felted with 4 uhle boxes 3rd Press: Smoothing Press, fix roll at print side
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OPC concept
Dryer Section OPC 1501st dryer group slalom2nd dryer group slalomrest double tier
Surface sizing both concepts with SpeedFlow (no coating considered)
Pre- calender both concepts with 1x2 rolls EcoCal Calender (200°C surface temperature ) Option 1: with moisturizer (Module Pro RS), Option 2: with Flexitherm Coil (EcoCal Plus)
18
OPC concept
Blade coating OPC 1502x print side coating(mainly for India, China 3x print side coating)1x reverse side coating
Post- Calenderboth concept with 1x2 rolls EcoSoft calender (200°C surface temperature). Thermo rolls are changeable with pre- calender
19
OPC concept
Reel OPC 150Master Reel up to 3,2m reel diameter
Winder OPC 1501 Slitter winder type VariFlex , reel transport manually per hall crane
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Summary OPC concept
• The concept considers the main two board grades (WLC & FBB).
Adaption for LPB or Artboard can be done very simple and fast.
• The OPC standard covers almost 70% of the total inquiries of new BM
projects
� faster layout and offer
• Standardized machine layout + machine calculation worldwide
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4.Forming Section
22
Headbox� Fiber orientation important for curl and twist properties
� Profile adjustment
– manually on outer plies
– dilution control in middle ply (2 sigma bone dry bw ≤ 0,6 %)
– slice control for lower requirements (2 sigma bone dry bw ≤ 1,2 %)
� High throughput range (max. flexibility)
Forming section� Create ply layout for strength and surface properties
� Create MD/CD properties
� Utilize furnish economically
Forming Section Requirements
23
basi
s w
eigh
t [g/
m²]
speed [m/min]50035 1200
200
100
300
400
500
600
700
800
1000
Forming ConceptsDesign Limits for Board Machines
24
State of the art forming section
middle PlyDuoFormer D IIHB with 25mm
Reverse Ply
HB with 25mm
HB with 25mm spacing
Print Ply
All headboxes are equipped with• Edge Module (Option) • Lamella Technology
New ModuleJet Technology
Wide operating window
Stable & reliable sheet forming up to 1.000mpm possible due to the relevant hard- & software components
25
Why is lamella technology required?
� High basis weight in middle ply with low consistency leads to a large headbox lip opening
� Large lip opening results in high macro turbulences (poor formation & roughness)
� Only lamella technology can reduce macro turbulences and have a positive effect on formation and sheet roughness
� Improves jet quality
� Eliminates tiger stripes
� Improves (lower) MD/CD ratio
26
DuoFormer D II
27
DuoFormer DReferences of a proven Hybrid Forming concept
~ 230 installations
28
DuoFormer D II
29
DuoShake
30
Where to install DuoShake in multi-ply BM?
Example 210 g/m² base board
Improvement potential
Ply
basis weight
Headbox
consistencyFormation MD / CD
50 g/m² 0.35 % + +
125 g/m² 0.70% ++ ++
35 g/m² 0.30% o +
Top ply
middle ply
Back ply
31
Advantages with DuoShake
• Improves formation
• Reduction of MD/CD ratio (curl, twist, converting)
– bending stiffness
– tensile strength
• Also very useful to decouple the interaction of formation andMD/CD ratio of the drag/rush curve
• More even CD profile
32
5. Press Section
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Press Concepts Overview
Machine speed [m/min]
Pro
duct
ion
1000 > 1000
Print side bottom
Print side top
600
34
State of the art press for board application1st Press Nip
NFP, 2xfeltedLLmax= 800kN/m
2nd Press NipNFP, 2xfelted
LLmax.= 800kN/m
3rd Press NipSmoothing
LLmax= 80kN/m
Pick-up Suction Rolls
1 & 2
Transfer Suction Box
OnQ ModuleSteamMoisture Profiling (100mm spacing)
3rd Press NipPrint side with ceramic cover and swimming roll on bottom
side
Vacuum conveyor belt
� closed web run + full web width transfer through the press!
35
Alternative Press Section for high smoothness requirements 1st Press Nip
NFP, 2xfeltedLLmax= 800kN/m
2nd Press NipNFP, 2xfelted
LLmax.= 800kN/m
3rd Press NipSmoothing
LLmax= 80kN/m
Pick-up Suction Rolls
1, 2 & 3
Transfer Suction Box
OnQ ModuleSteamMoisture Profiling (100mm spacing)
3rd Press NipPrint side with ceramic cover and swimming roll on bottom
side
Vacuum conveyor belt
36
Technology Feature / Benefit Analysis
Feature BenefitPRESSING
1st shoe press prepared for use with a shorter shoe (150mm)
Better control of ply bondHigher densification of outer layers possible
Fine adjustment in critical transferareas Ideal for high basis weight range, less rewetting
Uninterrupted shoe surface design Stability and longer sleeve lifetime
Transfer suction box with 3 slots Accurate control of web run
Loadable doctoring of sleeve Longer sleeve lifetime
Profiling steam box between 1st and 2nd press nips
Early profiling and dryness development = better runnability after press
Vacuum conveyor tail threading to therope carrier system
More efficient than blow-pipes (especially for high basis weights, >250gsm)
37
6. Dryer Section
38
General arrangement
1st Group3 Cyl.
8th Group14 Cyl.
3rd Group 14 Cyl.
4th Group 14 Cyl.
6th Group 14 Cyl.
7th Group14 Cyl.
2nd Group 4 Cyl.
5th Group 14 Cyl.
covered drying cylinder to prevent fiber picking
Fabric Cleaners (DuoCleaner Express)
Single tier design for runability reason
Mech. Sheet Breakes after each second Dryer Group
39
Technology Feature/Benefit Analysis
Feature BenefitDRYING
62°C Hood dew point High energy saving
Accessible design of pocket Faster cleaning after sheet break
Pocket ventilation by blow doctorsUp to 4% higher performance
Proven fabric cleaning concept Longer fabric lifetime
First 3 cylinders contacting top and back side are non-stick coated Less cylinder contamination at start of drying
Web knock-off device after each 2nd dryer group
Less sheet in drying section = Faster cleaning = faster start-up after sheet break
Teflon shoe for condensate removal in drying cylinder
Thinner condensate layer = better heat transfer
Smooth heating curve Reduced risk of delamination
40
7. Surface Sizing
41
Concept
SpeedFlowAfter Dryer Section
Covered drying cylinder after starch application
Optional Fabric Cleaners (DuoCleaner
Express)
DiskCutter
42
Speedy- Family
SpeedSizer SpeedFlow SpeedSizer AT
Application system Application system Application system
43
Technology Feature/Benefit Analysis
Feature BenefitSIZING
Without metering beam heating Energy saving, faster profile response
Simple metering rod clamping unit
Full access for cleaning without risk of tube damage
Air-turn with low air consumption Energy saving
44
Pre- Calendering
45Cartonboard Technology | Markus Freutsmiedl, c4pt | 2014-02-03 | confidential
Guangxi BM1
46
Pre- Calendering ConceptPrint Side Top
Moisturizer ModuleProTM RS
Nipcorect™ Rollfor caliper profiling
FlexiTherm™ Roll
Induction heating system
References: Bohui BM3, Liansheng BM8 & Rizhao BM12
47
Pre- Calendering ConceptPrint Side Bottom
Dry End Rewetting with Moisturizer
EcoCal Plus hard nip calender withinductive heating system
Flexitherm Roll (oil-heated roll)
ModulePro RS, optional RD (Moisturizer)
FlexiTherm Coil(inductive external heating)
Nipcorect Roll (Caliper profiling)
Reference: Guangxi BM1
48
EcoCal Calender
� Uniform nip pressure over the full sheet width
� Caliper calibration of base board for preparation of coating
� Uniform CD-temperature by continuous oil circulation
� Back side smoothening
� Simple design
� Use of various shell material possible
� Simple grinding
49
Technology Feature/Benefit Analysis
Feature Benefit
CALENDERING
Moisturizer ahead of HNC Less bulk loss (up to 2%)
Higher smoothness due to ironing effectNipCorect caliper profiling Less energy, fast caliper response, no glossy or
smooth stripes
50
8. Coating Section
51Cartonboard Technology | Markus Freutsmiedl, c4pt | 2014-02-03 | confidential
Guangxi BM1
52
Coating Concept
Precoat Premium side
Middle coat Premium side
Back side CoatingReverse side
Final coat premium side
Curl Correcting Group
53
Coater
Coater with roll applicator Coater with JetFlow F
Application system with roll Application system with JetFlow F
54
DynaCoat with roll applicatorEdge deckle design
55
DynaCoatJetFlow F Applicator
15° C 5° C
Flow strip cover cooling ducts 15°C- Is required for offset coating colorat high temperatures or on-line coating
Flow/gap strip cooling ducts 5°C- Gap strip is required for offset coating color at high temperaturesor on-line coating
56
9. Coat Drying
57
Voith is the only full-scope supplier ofnon contact drying and web guiding systems
• Voith can provide all state of the art systems for non-contact drying applications from its own product and manufacturing program
• No compromises are made when drying concepts are planned, designed and offered to our customers
58
HCB Turn
59
• short web run• simplified tail threading• low risk of picking
at guiderolls
• long web run• motor driven guide rolls• risk of picking at
guide rolls
Conventional Concept Module Concept
Modern Coat Drying Equipment
60
qDry Pro
61
Technology Feature / Benefit Analysis
Feature BenefitCOATING
New qDryPro drying systems High energy efficiency
All coat layers with IR Less risk of mottling, especially final coat
All rolls chrome coated Easier cleaning = less contamination = less quality loss
Well proven web run Runnability & product quality
Flexible curl control Due to the additional dryer group 12 after Coater 4
Self-learning coating kitchen More accurate dosing of additives
Filtering without slotted screens Longer run-times of the filter elements
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10. Finishing
63
Post Calendering to Reel
1x2 Soft Nip Calender
Cooling Air Cap
Sirius
64Cartonboard Technology | Markus Freutsmiedl, c4pt | 2014-02-03 | confidential
Guangxi BM1
65
11. Reel R
eel D
iam
eter
(m
)
Machine Speed (m/min) / Quality Requirement
Sirius reel Ø up to 4,6
MasterReel reel Ø up to 3,2
66
Roll handling
67
12. VariFlex for Coated Board
� Less bulk loss
� Gloss difference low or zero
� No steel drums in contact with board
� Drums and rider roll covered with special flexible rubber, low abrasion
� Easy operation and maintenance
� High degree of automation
� Centric core position, good roll runability in further process
68
Fibre saving by Bulk savings with soft cover of winder drums
WINDER - Soft Cover Technology brings 1% Bulk
Bulk loss without Soft Cover 1%
Percent BCTMP necessary to compensate 1 % bulk loss 2%
Board Board
Steel drums Elastomer covered
drum with ElaCare
69
Technology Feature/Benefit Analysis
Feature BenefitREELINGCentre drive reeling concept Larger parent reel diameter while maintaining
qualityReel diameter up to 4.6 meter Less parent reels per year = less loss = more
saleable production!
WINDINGSoft covered drums Less bulk loss
Gravity reel transport to winder Reel transport without overhead crane
Rotation maintains reel qualityOTHERVacuum conveyor tail threading High reliability with higher basis weight
70
71
139.500.000
7.500.000
15.000.000
3.000.000
15.000.000
90.000.000
9.000.000
Approach Flow / Broke / Paper Machine / Winder / Finishing / Au xiliaries
EURItemized Plant Equipment
13. Budget Price Indication
Equipment Stock Preparation (from pulping to mixing chest)
Electrification & Automation
Tanks, Pipes, Valves, Steel Construction, Cranes, Hoists, etc.
Services (engineering, installation supervision, training, start-up)
Pipes on Pipe Bridges
Total Investment Budget (+10% / -15%)
The Budget indication is for a machine with a design speed of 7 00m/min,3.750mm web width on Reel. The average Basis weight calculat ed for theproduction is 250g/m², resulting in a annual net. productio n of approx.200.000t/a.
72
Itemized Plant Equipment
Not included in the Budget
Fresh Water Treatment
Power Plant / Steam Generation
Effluent Treatment Plant
Civil Works
The Budget indication is for a machine with a design speed of 7 00m/min,3.750mm web width on Reel. The average Basis weight calculat ed for theproduction is 250g/m², resulting in a annual net. productio n of approx.200.000t/a.