paper middleast n°20 13
DESCRIPTION
The bilingual Arabic/English trade magazine dedicated to the paper, board and tissue industry in the MENA region. Bu ENP Publishing GroupTRANSCRIPT
Edito
The State of Kuwait is among the smallest states on the Arabian Gulf Sea, and the number of the paper mills is comparably little.
The GCC economies, in particularly the Kuwaiti econo-my likewise most of the world economies, show a conti-nuous increasing in the markets demand.
The paper industries showed a fast growth and develop-ment indexes, but also a rise in terms of the production following the rise in the raw materials prices which are most of the time imported.
Recent studies undertaken by the local bodies repre-sented primarily by the Kuwaiti Ministry for Commerce & Industry, and the Public Authority for Industry showed that the domestic consumption of paper in the GCC has increased by more than 37% during the seven past years.
The study resulted on stressing on the need to present a significant quantum leap mainly through those indus-tries: the paper rolls and cardboard boxes industries that form the backbone of the paper and packaging industries and which are most of the time unavailable in the local market, thus, extensively and largely imported.
As a result, these bodies joined forces in creating oppor-tunities for new investors encouraging them to take ad-vantage by establishing paper related projects.
In the following pages, we are going to highlight on one of the relevant paper mills in Kuwait; the United Paper Industries CO., through the discussion we had with the General Manager Mr. K. Gopal.
But before I leave you to explore its content, I regret to inform you with deep sorrow, that Paper Middleeast magazine lost one of its young reporters from Egypt, Mr. Yasser Zakaria.
May his soul rest in peace, and to all a long and healthy life!
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The Magazine dedicated to the Pulp, Paper and Tissue Industry in the Middle East
Rima [email protected]
N°20 - Spring 2013
Head Office / PublisherENP [email protected], rue Stanislas Julien - 45000 OrléansFranceTél. +33 238 42 29 00
PublisherSTÉPHANE RICHARD
Editor in chief
LebanonRIMA DIB
Correspondants
SyriaAHMED AL SLEEBA
JordanRAMI HOURANI
Advertising Middle [email protected]: +961 32 24 953
International AdvertisingSTÉPHANE RICHARD
[email protected]ÇOIS HÉNIN
[email protected]: +33 238 42 29 00Fax: +33 238 42 29 10
Graphic DesignersELHAM EL MASRY GHALI
SIMON & PARTNERS
SubscriptionMATHILDE SEVESTRE
Diffusion : 3.000 ex.Algeria, Bahrain, Egypt, Iran, Irak, Jordan, Kuwait, Lebanon, Morocco,Oman, Qatar, Saudi Arabia, Syria, Tunisia, United Arab Emirates, Yemen
www.groupenp.com
Official Media Partner
PAPER MIDDLEASTpulp, paper, tissue
magazine
2013
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16 High quality liquid ring vacuum pumps: less water and less energy consumption
18vacuum system for the new PM2 paper
Technology
20 Service on-site for cylinders of the paper industry
Focus Kuwait - United Papers Industries CO.
22 Gopal on the light
Events
28 Starpack - 500 Students from Lebanon, Egypt, Palestine, & Jordan in StarPack 2013 Promoting Industrial Culture among the Youth
30 It’Tissue (Italy) - When tissue can be fun
6 Europac opens a corrugated packaging plant
6 Turkey’s Hayat Kimya starts tissue produc-tion at Zencan mill
6 Metso receives repeat order for two com-plete tissue lines from Hayat Kimya
8 Mondi starts new industrial bags plant in Sulaimaniyah
8 Germany’s GapCon to supply turn-key tissue plant to Tunisie Ouate
9for Kartonsan Karton Sanayi ve Ticaret, Turkey
10 Yasser Zakaria in our hearts...
Special Pumps & Valves
11
13
14medium consistency technology operating successfully
Contents
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Paper Middleast 20Summer 2013
Advertisers Index
Ashland . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2, 67BTG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9, 64Coldwater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29FAM Ingenieria. . . . . . . . . . . . . . . . . . . . . . . 13, 54Hannecard . . . . . . . . . . . . . . . . . . . . . . . . . . 25, 62Kadant Lamort . . . . . . . . . . . . . . . . . . . . . . . . . . 27
MIAC 2013 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4PaperME. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50PMT Italia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7RIF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Souche Papers. . . . . . . . . . . . . . . . . . . . . . . . 32, 51
News
MOROCCO
Europac opens a corrugated packaging plant
Spain’s Europac has expanded into North Africa. The fi rm announced lately that it ope-ned a corrugated packaging facility in Tangier,Morocco.At present, the facility concentrates on the pro-duction of heavy-duty boxes for industrial cus-tomers. According to the fi rm management, the plant can produce up to 15 million m²/yr.However, Europac was set for further growth in the country by seeking to complete the installa-tion of two converting lines to produce conven-tional boxes.“The packaging facility in Tangier is the fi rst step of a more ambitious industrial project in Morocco, which will enable us to strengthen our position on the country’s packaging market gradually.” Euro-pac’s president, José Miguel Isidro, said in a statement.Carlos Larriba, General Manager of Europac Packaging, added: “Morocco is a relevant market for Europac due to the important role of the agri-cultural sector for the country’s economy. Moreo-ver, the geographical proximity and the existing links between Iberian and French companies and Morocco will create important commercial and logistical synergies that will enable us to continue developing our business as a global packaging pro-vider.“RISI
IRAN
Turkey’s Hayat Kimya starts tissue production at Zencan mill
The Turkish tissue manufacturer Hayat Kimya has started commercial production at its new tissue mill in Zencan in Iran.The Zencan mill houses one machine with a ca-
pacity of 65,000 tones/yr of tissue, a trim width on reel of 5,600 mm and a maximum speed of 2,200 m/min. Some 250 people work at the factory. The paper produced in late April and early May was already saleable and the com-pany reached a speed of 2,000 m/min within two days of the fi rst startup, Aydin said. Hayat Kimya will sell both converted products and jumbo rolls from the Zencan mill. The com-pany started up a converting plant with a BRT rewinder for making facial tissue and colored napkins on May 13. Due to strong demand on the Iranian market, Hayat Kimya will sell all the products domestically for the time being, Aydin said.Hayat Kimya operates one mill in Izmit, nor-thwestern Turkey, where it houses two ma-chines with a combined capacity of some 135,000 tones/yr of tissue. The company has plans to expand its operations in Turkey with a new plant in Mersin in the south of the country and to build a new factory in Yelabuga in Russia. It has contracted Metso to supply two 70,000 tons/yr tissue PMs for these projects. The Rus-sian mill is supposed to start up in the second half of 2014 and the Turkish plant in late 2015.RISI
TURKEY
Metso receives repeat order for two complete tissue lines from Hayat Kimya
Metso has received a repeat order for two com-plete tissue production lines for the Turkish Hayat Kimya A.S. Each production line will in-clude an Advantage DCT 200 TS tissue machine, and they will be installed at the company’s new mill sites near the city of Alabuga, Tatarstan, in Russia, and in the city of Mersin in southern Turkey. The start-up of the tissue machine to be installed in Russia is planned for the second half of 2014, and the second tissue machine will start up in Turkey at the end of 2015. The value of the order will not be disclosed.
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News
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«Metso has been a reliable and trustworthy partner for our previous installations and we are pleased to continue our good cooperation also in this new pro-ject,» says Lütfi Aydin, Director, Paper Group, Hayat Kimya.
“We at Metso are very impressed with how Hayat has developed. Only seven years ago they were a newcomer in the tissue industry. Today Hayat is a global player in the tissue market and is also the current holder of the world speed record for tissue machines. The world class results show the strength of our partnership,” says Jan Erikson, Vice Pre-sident, Sales, Tissue Mills business unit, Metso.
IRAQ
Mondi starts new industrial bags plant in Sulaimaniyah
Mondi recently started full production at its new industrial bags plant in Sulaimaniyah, northern Iraq. Together with local partner, Kaso Group, this green fi eld project is set to strengthen Mon-di’s industrial bags business in the expanding Middle East and North Africa region (MENA). This is the fi rst industrial bags plant in Iraq, and
will serve the growing cement industry which is rebuilding the country. «We are proud to announce the opening of our new green fi eld plant in Sulaymaniah,» says Issa Azar, Regional Manager MENA Mondi Indus-trial Bags. This project coincides with Mondi’s strategy to support our customers’ expansion in emerging markets. «Having Mondi’s industrial bags plant close to our cement factories strengthens our long term business relationship and is impor-tant for good logistics and supply management,»states Rozhgar Barzan, Procurement-Sourcing Manager, United Cement Company - Lafarge Iraq.
«Iraq is now one of the Middle East’s growing countries and the construction industry is helping to rebuild the nation», explains Abdel Hafez Abki, Managing Director of Mondi Kaso Iraq. «The new plant further strengthens Mondi as a reliable industrial bags partner in the region», he adds. Omar Ismail, Managing Director of Mass Iraq Co. for industrial investment illustrates: «We are pleased with the startup of Mondi’s bags factory in Iraq and are looking forward to further construc-tive cooperation between both companies.»RISI
TUNISIA
Germany’s GapCon to supply turn-key tissue plant to Tunisie Ouate
Tunisie Ouate, a well known and reputable tissue producer in Tunisia, and GapCon has recently signed a contract for the supply of a Turn-Key Tissue Plant.The contract covers, but is not limited to, stock preparation equipment, a complete Econ-
Yahya Kigili, Chairman of Hayat Group, (in the middle) and Lütfi Aydin, Director, Paper Group of Hayat Kimya, (right) have agreed with Björn Magnus, Sales Manager, Metso, on the delivery of two new tissue lines for Hayat Kimya. In second row (from left) Kemal Tahir Yildirim, Purchasing Manager, Hayat Kimya, Haluk Arican, Metso re-presentative, and Muammer Timur, Paper Project Coordinator, Hayat Kimya.
News
SOFTTM tissue machine and winder including all auxiliaries. The new machine will produce high quality toilet paper, facial, napkin and kit-chen towel with the capacity of 70 tpd, which will enable Tunisie Ouate to expand their pro-duction capacity to meet the market growth in Tunisia and abroad. Mr. Abdelaziz KOOLI, the Director General, stated that by choosing GapCon, «Tunisie Ouate has found a trustworthy and highly motivated and competent supplier.»Even though the future «brand» is not yet known to the market, the project team for Tu-nisie Ouate has decades of experience in the tissue supply industry. GapCon has the «tools» and «drive» to become an important player in the tissue world, supplying high tech, innova-tive and energy effi cient machines contributing to the development of the industry.Source: RISI
TURKEY
ANDRITZ to rebuild board machine for Kartonsan Karton Sanayi ve Ticaret, Turkey
International technology Group ANDRITZ will upgrade Board Machine 2 and the related stock preparation systems for Kartonsan Kar-ton Sanayi ve Ticaret A.S. in Izmit, Turkey. The upgrade will increase production of duplex and triplex board from 100,000 to 160,000 t/a. The start-up is scheduled for the second quarter of 2014.ANDRITZ’s scope of supply comprises:
min at a paper width at reel of 3,650 mm),
News
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including a PrimeFlow SW headbox with dilu-tion control; rebuild of the fourdrinier wire and press sections with a PrimePress X shoe press; a new hood and air system; and rebuil-ding the pre- and after-dryers, hard calendar, and coating sections.
(capacity: 140 t/d).
line with deinking fl otation unit and thicke-ner disc fi lter for an additional white ledger capacity of 85 t/d.
with a capacity of 380 t/d.
kener.
the four-layer approach system and a dilution water screen.
start-up, training, and spare and wear part packages for the entire equipment supply.
With this order, ANDRITZ PULP & PAPER is confi rming its position as a leading supplier for major rebuilds of paper and board lines.
Yasser Zakaria in our hearts...
For more than 15 years he was able to build a unique name in the paper industry, and took his success out of the local market in Egypt to the Arab countries, and was known by leader suppliers and machine manufacturers in the paper, board and tissue industries in Europe, India, China and so on.
Yasser Zakaria who had a dream of establishing a company that gives ser-vices to the paper industry, and so he was able to build a group of companies give complete solutions in different aspects such as technical services, engi-neering consultants, installation and supplying all that is related to the paper
industry. Also he established Arab Paper Academy, one of its kinds in the Arab Countries that gives training courses to prepare a qualifi ed new generation of paper makers.
His death was a shock for his family, as well for all of his friends and customers around the world. He peacefully died, and left a well-known name in the local and international market, so conti-nuing his footsteps was very essential to achieve his dreams. His wife along with all his companies stuff after a new reconstruction in the companies’ managerial structure decided to continue work and never stop, to keep his success as it always was with all the suppliers and customers inside and outside Egypt, so that Yasser Zakaria Group can always be in the paper industry and related to it as it always was.
Wet end of a PrimeLine paper machine
Value added services to boost global pump services market
Advantages such as improved productivity and time savings promote greater adoptionAn augmentation in value added services (VAS) and integrated solutions are poised to give a fillip to the global pump services market.“There has been a continuous reduction of in-house manpower across all industries, with end users requiring a stable system with minimum initial outlay and operator intervention,” noted Frost & Sullivan’s Industrial Automation and Process Control Programme Manager Ashwin Annareddy. “VAS offer advantages of reduced operating costs, increased asset availability, and minimised maintenance costs.”
New analysis from Frost & Sullivan finds that the market earned revenues of $13.36 billion in 2012 and estimates this to reach $17.55 billion in 2016. The research covers maintenance, re-pair, and overhaul (MRO), installation and com-missioning services (I&C), decommissioning, and VAS.
A higher degree of automation in pumps are en-couraging end-users to buy integrated solutions comprising pumps, frequency drives, valves, logic controllers, and automation software.
“While these integrated solutions offer multiple advantages, they also require personnel with the expertise to operate them,” stated Annareddy.“With the design of pumps and systems becoming increasingly complex, service providers are expec-ted to have greater opportunities in the areas of MRO, I&C, and decommissioning. Specialist ser-vice providers and distributors are set to continue their dominance.”
However, end-user adoption of advanced pump services as well as technology, especially for VAS, has lagged. A conservative mindset has hampered the uptake of new technologies and services despite their ability to enhance produc-tivity and save time.
“This approach is poised to change in the long-term as the end-users realise the importance of these
services,” concluded Annareddy. “VAS, such as condition monitoring, predictive maintenance, and advanced diagnostics, are fast gaining acceptance and will account for a significant portion of the market.”
Sulzer Pumps launches newperformance service
Reduces cost of ownership in the pulp and paper in-dustry Sulzer Pumps has launched a new Pump Performance Expert service for customers in the
pulp and paper industry. This new global ser-vice will contribute not only to reducing custo-mers’ Total Cost of Ownership (TCO) but also to achieving significant benefits in their existing and future processes.The Pump Performance Expert Service focuses on MC® (medium consistency) applications, agitation and mixing applications, tower chan-neling and discharge. This service is applicable for both the installed bases of Sulzer Pumps and other Original Equipment Manufacturers (OEM). By applying our in-depth knowhow and expertise in diagnostics and regular mill surveys our customers can achieve extensive
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Pumps & Valves >> News
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Pumps & Valves >> News
performance improvements in mixing, agitation and pumping applications.Through this service, customers will significant-ly benefit from simplified applications, energy savings and more flexible processes with re-duced chemical consumption, operation costs, maintenance and process down time. Custo-mers will gain from a wide range of savings in pumping, mixing, agitation and tower manage-ment applications, all in one package. Additio-nally to this service, Sulzer Pumps offers large mill and corporate wide agreements to further reduce TCO.
AESSEAL - 30 consecutive years of growth
The ingrained ethos of putting customers at the heart of its business has powered AES Enginee-ring Ltd to its 30th consecutive year of sales and profit growth.
Its annual results for the year to December 31 2012 show that the company, parent to the AESSEAL Group, pushed up sales during the year by 6.4%, to £131.9m. After allowing for acquisitions and exchange differences the com-pany reports that like for like sales growth was a healthy 8.2%.
A global player, Yorkshire-based AESSEAL is the world’s fourth-largest designer and manu-facturer of mechanical seals for a wide range of industries, including oil and gas, food, water, mining and pharmaceuticals. And even as it marks its continued growth, it is working on plans for further expansion.
The past year saw earnings before interest, tax, depreciation and amortisation (EBITDA) rise to £23.8m. Activities in its key strategic market of oil and gas also grew, by 26% in 2012, on top of the previous year’s 49%.
The group reports it has expanded in the UK and around the world, especially in emerging
markets, that it is “well positioned to take ad-vantage of the higher growth rates in markets outside of Europe and the USA” and will be continuing to strengthen its network where-ver it sees opportunities for accelerated deve-lopment, including sub-Saharan Africa and the Middle East. AES Engineering Ltd employs more than 1,600 people worldwide, of whom nearly 600 are in the UK and Ireland and more than 330 in Rotherham.AESSEAL, whose Global Technology Centre HQ is in Rotherham, South Yorkshire, had net assets of £64,150,000, 17.2% up on 2011’s £54,727,000. It also increased the stock it holds to £25.3m, up 6.3% from 20011’s £23.8m, ena-bling it to give customers even faster service.The group’s expanding pump business, Bed-ford-based AESPUMP, also made excellent pro-gress, including acquisitions in Denmark and The Netherlands. Sales rose to £9.3m in 2012, an aggregate growth of 30% on 2011.
Stephen Shaw, group engineering director, said: “Our investment in research and development over the past five years has seen the product range deve-lop more than any other seal company worldwide during that period.”
Group founder and managing director Chris Rea, OBE, said: “Over the past three years the group has continued to develop as a reliability-fo-cused business, with exceptional sales growth of complementary products such as our bearing pro-tection and seal support system ranges alongside emerging complementary services and consultancy support capabilities. In addition, our objective of offering a high-quality alternative for compressor dry gas mechanical seals is now a reality.”
“The group’s purpose is to put customers at the heart of our business through providing exceptio-nal customer service. Our customers have suppor-ted the expansion of our products, processes and the globalisation of our business. We believe this growth will continue in 2013 and beyond as long as we continuously improve every aspect of our business that brings a benefit to our customers.”
Pumps & Valves
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Reject pumps forpulper-cleaning systems
What is a reject pump, what is its purpose and where is it used?The answer to this three-fold ques-
tion is set out below.
A reject pump is a specially-designed non-cho-kable pump configured to handle liquid/solid mixtures that are extremely contaminated by materials of various sizes and types. The size, rotor-configuration and housing design of the special pump described here ensure its perfor-mance as an absolutely-reliable feed pump for use in automatic pulper-cleaning devices and similar systems. One familiar application of pulper-cleaning devices is their use in material-handling systems that involve, for reasons of cost, the treatment of pulp containing unsorted, highly contaminated waste paper. The pulper rotor takes up and fragments the bales of waste paper, but not contaminants such as variable quantities of plastic debris, shards of glass, small stones, wood splinters or other wood-waste residues, metal items such as the mecha-nisms from ring-binders, fragments of rubber from car tyres, or many other items. All of these undesired additional components, which can unfortunately be present in large quantities, must be efficiently and cost-effectively remo-ved, preferably as part of a continuous process. Automatic pulper-cleaning systems are avai-lable in various configurations, although they
all have one basic element in common: the feed pump, referred to as the “reject pump” for our purposes, which supplies the pressure needed to ensure the reliable functioning of the cleaning system, thus allowing the required feed quantity to be supplied, while ensuring the proper fragmentation of larger plastic and woo-den elements, and also the processing of rust-resistant cast steel.The FAM reject pump described above is of extremely robust construction, as it has to work with absolute reliability in 24/7 operation. The system runs at low speed, within a range of 300-650 rpm, with a maximum flow-rate of 18,000 litres per minute and a water column of 18 metres or more.The FAM reject pump provides a reliable and increasingly-vital disposal or feed device for the system concerned, whether it is a pulper-cleaner or any system designed to handle li-quid/solid mixtures containing components of various sizes.The author of this article also designed the reject pump, which is likewise manufactured under his supervision and management control. The pump is already in use all over Europe, and initial units are now also in operation in Asia, Africa and America. Modern Karton, a compa-ny based in Corlu, Turkey, has been using four FAM reject pumps successfully for substance-processing purposes since 2007.
Pumps & Valves
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ANDRITZ MC pump:Cutting-edge medium consistency technology operating successfully
Medium-consistency (MC) pumps are used to pump stock in bleaching lines, pulp lines, and recycled fiber lines.
These pumps are highly process-critical and thus, decisive to project success as the entire pro-duction volume of a plant runs through them. The development project for the new ANDRITZ medium-consistency pump was launched in 2004 by the centrifugal pumps department in Graz, Austria, together with ANDRITZ Finland. In intensive development work, a highly sim-plified and extremely customer-friendly system
with high efficiency was finally created. “Ihave followed the deve-lopment project for the new ANDRITZ MC pump since its launch in 2004. This pump has reached a development status that makes it the best solution for pulp lines,” says Jorma Paa-si, Director of Global Engineering and Bu-siness Development at ANDRITZ.
Keep it simple
First of all, the development team tackled the question of how to simplify the pump system as much as possible – as required by the market. This led to the development of a single-shaft so-
lution, with the required components (conditio-ner/fluidizer and pump impeller) mounted on a shared shaft. In addition, the vacuum pump that is usually a part of the pump system was eliminated for the majority of applications.
Higher efficiency
After this first development stage, optimization of the pump continued with a focus on further increasing the efficiency. In 2005, the MC test stand for pump development went into opera-tion at the development center for fiber techno-logy at ASTRÖ in Graz and has never stopped operating for more than five days in a row! This intensive work on the pumping medium was the key to success. In 2007, the new MC pump (with a single-shaft design and no vacuum pump) was launched on the market and the first unit went into operation at Zellstoff Pöls AG in Pöls, Austria. “Feedback from the customer was very positive, who especially praised the higher effi-ciencies, the robustness of the pump, and elimina-tion of the vacuum pump,” says Ludwig Michal, Head of pump development. Siegfried Gruber, Head of technical planning at Zellstoff Pöls AG: “We installed the pump, switched it on, and have never had to give it another thought since then.”
New separation stage
“We knew that we were heading in the right direc-tion and continued to concentrate all our efforts on product optimization. The pump was already wor-
International technology Group ANDRITZ has had a tried-and-tested product for pumping medium-consistency pulps in the pulp and paper industry in its portfolio for over 20 years. A new MC pump has been developed in order to meet the market’s need for simple control and ever higher throughputs. The pump has already achieved excellent results in industrial applications.
The ANDRITZ MC pump:efficiencies of over 70% and very easy handling
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king perfectly – with all of the advantages descri-bed – within the design range (nominal capacity). Then our main concern was to meet the special re-quirements that arise, for example, when new pulp production plants are being put into operation.”explains Ludwig Michal. In such cases, the MC pump often has to convey pulp with a lower fiber content (lower consistency), which makes control difficult. MC pumps need constant ven-ting via a degassing line. Complex control sys-tems had to be used to control degassing, and very often they did not work satisfactorily. This led to fiber loss, unstable pump operation, and blockages in the degassing line.
In order to eliminate these difficulties and sim-plify control, the pump team developed an in-novative system: SMARTSEP. With this system, the air is removed from the pump by a separa-tion impeller and the fibers removed with the air are returned safely to the pump at the same time. This guarantees that there is no fiber loss, and control of the degassing valve is incredibly simple: pump running – valve open; pump not running – valve closed.
As part of optimizing the entire MC pump, the efficiency was also further increased. At design capacities of over 2,000 tons of pulp per day at a consistency of 12% (e.g. long-fiber sulfate pulp), efficiencies of over 70% are achieved, which are significantly above industrial average.
Operating successfully
At one of the world’s largest single pulp lines operated by UPM in Fray Bentos, Uruguay, en-ergy savings of 7 to 15% were achieved with the new ANDRITZ MC. Control of the pump was highly simplified by using SMARTSEP. There have been no problems whatsoever with degas-sing, and also no fiber losses since start-up in November 2010.At the Mondi Syktyvkar mill in Russia, new-generation ANDRITZ MC pumps were installed in the course of mill modernization. A major challenge facing ANDRITZ was to integrate the new equipment into the existing plant and make it all work. “The ANDRITZ MC pump, with its easy handling, contributed towards suc-cessful start-up,” confirms Mika Makela, Project Manager for the Mondi Syktyvkar Step Fiber-line Project at ANDRITZ.In the Fibria Jacareí pulp plant in Brazil, an existing medium-consistency pump was re-placed by an ANDRITZ MC pump. In spite of the higher pumping capacity, the existing motor could still be used. This gave the customer en-ergy cost savings of over one-third.
In autumn 2013, we will achieve another mi-lestone in pumping of MC pulp: A fiber line in Indonesia will start up the first 3 units of the world’s largest MC pumps. These pumps have an efficiency of 73% (BOP) and willconvey 4400 ADMT/d through the wash press line. With the MC pump, fiber lines can be up-graded to a capacity of up to 6500 ADMT/d.
MC pump at the workshop in Graz, Austria
Advantages of the new ANDRITZ MC pump at a glance
Excellent efficiency (> 70%), significantly higher than the indus-trial average, thus low energy consumption Very easy control and complete avoidance of fiber losses at all operating points thanks to the SMARTSEP system Simple and cost-efficient design without vacuum pump in most applications.
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High quality liquid ring vacuum pumps: less waterand less energy consumption
In a paper mill, the simple action on liquid ring vacuum pumps and its maintenance al-lows high energy savings. If the mill counts
six or seven vacuum pumps, for example, it is possible to lower the energy consumption from 23.000 kWh to 19.000 kWh. So states SAFEM, a family company established since 1964 in Tolo-
sa, Spain. SAFEM is a specialist in manufactu-ring liquid ring vacuum pumps and accessories for the paper industry, under its own brand. As a complement to this activity, the company re-pairs liquid ring vacuum pumps from all brands of the market and carries out studies and tes-ting, for instance performance tests, pumps ins-tallation checking, etc. Thanks to these actions, the electricity consumption can be reduced by 10% to 30% if the adjustment of the pump is correct. In addition, air intake flow can be im-proved significantly. And these elements have all together a strong impact on the drying sec-tion in the paper mill.
The Basque company SAFEM repairs and manufactures liquid ring vacuum pumps and accessories for the paper industry, with a clear difference against its competitors from Asia: all pieces are made out of cast iron, funded in local foundries. The quality and maintenance service given to this equipment are key issues for getting better energy efficiency in the paper mills where it is used.
Piece to be mechanized. In the background: mechanical workshop. Liquid ring vacuum pumps final finish.
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SAFEM manufactures 150 to 200 pieces per year, under order. Its main markets are Spain, France, North Africa (Algeria, Morocco), Rus-sia, Poland, Czech Republic, Latin America and Asia.
Repairs are carried out in the workshop of the company, lo-cated in Lasarte, near Tolosa, Spain. The mechanical works-hop occupies a surface of 900 m2, to which are to be added the boilermaker premises’ 250 m2.SAFEM owns the following ma-chinery: three boring machines (for the mechanizing of casing and headers), two turning lathes (mechanizing of shafts, cones and rolls), two milling machines (drilling of cones, tops), a press and a balance. The clients can get a replacement pump as a loan while their own pump is been repaired in SAFEM’s workshop.
Cast iron makes the difference
SAFEM’s main com-parative advantage lies in the fact that all products are made out of cast iron, produced in local foundries, as a difference to its competitors from Asia. This features gives the liquid ring vacuum pumps a higher quality and longer life-time. Other strength of the company is the high level of service; as an example, the point men-tioned previously: SAFEM lets as a loan spare pumps to its clients, completely free of charge. In addition, the range of products is very wide, with 14 different models, ranging from 20m3/hto 17.000 m3/h (7 tonnes).Among the main projects that SAFEM recently achieved are the construction of a complete equipment for a phosphate mill in Tunes, the fabrication of a liquid ring vacuum pump SA-FEM VP 2000 T2 for a new pulp machine, or two vacuum pumps VP 2000 T1 for an Italian tissue machine manufacturer.
Stock of mechanized pieces.
Vacuum pumps for loan. In the background: testing bed.
Liquid ring vacuum pump SAFEM VP 2000 X (7 tonnes).
Pumps & Valves
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PM2 was a turnkey project, with the va-cuum system and implemented tech-nology specified by the paper machine
manufacturer. Nash was in continuous contact with the paper machine manufacturer during the tender phase. Together, they developed the optimal solution for this challenging task, and the flexibility of the Nash solution and its en-ergy efficiency eventually impressed and won over thecustomer.
Flexibility for the vacuum
Many paper machines produce only a single paper weight (e.g. 80 g/m2, similar to copy paper) or weights within a very tight range. In such cases, only minor modifications to vacuum requirements are needed as production condi-tions, and thus the vacuum levels themselves, are kept relatively constant.
In contrast, the ZellstoffPöls PM2 focuses on «MG» or «machine glazed» papers (a paper with very high strength), and incorporates the pro-duction of paper basis weights between 28 and 120 g/m2. This wide product spectrum places high demands on the flexibility of the vacuum system, as the method of drying has to adapt to each paper grade.
For Gardner Denver Nash, the project repre-sented an ideal opportunity to prove its high level of expertise in vacuum systems for paper machines. The major challenge was adapting the vacuum at the various suction points for each specified paper weight and the required drying needs. This was accomplished through the use of frequency converters that allowed for «fine adjustment» of the speed and the vacuum level to meet the specific requirements of the paper grade produced. The customer provided the list of vacuum requirements, but the speci-fication of suitable pumps, the determination of the number of pumps and their assignments to the various suction points were the responsibi-lity of the Nash team in Nuremberg.
ZellstoffPöls, in Austria, is the largest manufacturer of high quality, chlorine-free bleached long-fiber sulphate pulp in Central and South Eastern Europe. For the new PM2 paper machine, Nash is supplying the vacuum system for dewatering in the wire section and the press section.
NASH 2BE4 liquid ring vacuum pumps with v-belt drive are also used at the PM2.
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In a first step, the required number and capa-city of the liquid ring vacuum pumps were calculated for ensuring the requisite operatio-nal flexibility of the vacuum system. It had to be taken into consideration that strongly fluc-tuating vacuum levels are often applied at the various suction points in accordance with the grammage to be produced. All Nash pumps are driven with a frequency converter for «fine ad-justment» purposes. In this way, the motor and pump speed - and thus the vacuum level of the pump - can be exactly controlled and precisely adapted to the specific requirement.
Efficient use of energy
An important reason that the Nash concept was accepted was the energy efficiency of the ma-chines implemented. Optimal dewatering of the paper in the Forming and Press sections (where Nash vacuum pumps are used) reduces energy (steam) consumption in the Dryer section.
The customer’s specification was clear; focus on energy efficiency. Efficient operation of both the paper machine and the vacuum system result in lower energy consumption and lower operating costs. The alternative concept (low purchase costs that result in high energy costs over the operating life) was not deemed interes-ting by the customer.
The project covers a scope of supply of five 2BE4 pumps of various sizes, all operated with frequency converters. The pumps will be provi-ded in standard cast iron material construction with polyisoprene coating.
Finally, the decision that Nash was the superior vacuum supplier for their new paper machine was due to convincing arguments from about the product’s flexibility, energy efficiency and insensitivity to water.
Technology
20 papermiddleast
Service on-site for cylindersof the paper industry
All machines for the production and su-perficial treatment of paper are equip-ped with one or more big size cylinders.
These cylinders have a paramount importance in the production process, some of them are the real heart.
For their size , weight and, most of all, for their position in the production plants, these rolls, once installed in the machine are never remo-ved for the whole production cycle or often for the entire machine lifecycle.
Among the most important positions we quote the most widespread :
We should also include those cylinders which, in spite of their average dimensions, in most cases are not disassembled from the machines, for example:
Any routine or specially – made maintenance of these cylinders has to be effected therefore di-
the complete range of activities is generally grouped under the wording “ Service On Site “. It is curious that English language generically identifies in the initials of these three words the international acronym SOS for First Aid: by
chance the request of service of maintenance and/or repair on site of these big cylinders is very often characterized by emergency situa-tions and reduced service time with the target to avoid to excessively reduce the production efficiency of the plant.
Among the operations of Service on Site for big rolls in a paper machine we can list for example:
profile-
lized on specially worn out areas
Additionally the activities of diagnostics on site are not of minor importance, for example:
-tions of the rolls and their structural integrity,
pressure and thus to binding safety norms.
The essential requirements to effect this type of
the utmost reduction of the service times
comparatively easy to install on site which do
papermiddleast 21
not require the need to dismantle a number of parts from the paper machine, at the same time ensuring repeatability and accuracy
personnel, capable to understand the requi-
from feasibility study to management of logis-tics and / or temporary export of the portable machinery to the actual service.
and grinding technology, new abrasive media and materials for thermal coatings, with a complete vision based on direct experience on the field.
The requirements are therefore really at 360 °
involved professional profiles have to be senior,
Started my career in the year 1975 in main-ly manufacturing and also as a consultant to a number of Paper Mills in India.
Paper runs in the family, my father was a lea-ding paper technologist in India and so it was only natural that I followed in his footsteps.
During my career spanning for 37 years, I have held different responsibilities from Production Manager to General Manager in medium to large paper mills in India and abroad.
My foreign experience was in Union Paper Mills, Dubai where I was the Production Mana-ger and was responsible for in commissioning the first Brown paper in UAE (Dubai) in the year 1988.
A year before, I held the responsibilities of de-veloping a project in ELF company in Egypt, being the Operations and Production Manager at the mill. That was in 1997.
United Paper Industries Company is dif-ferent from the other paper mills in the region in that it produces Industrial packaging grades (Sack Kraft paper) used in Cement and Multi-layer bags along with the conventional packa-ging grades like Test Liner, Fluting and Kraft Liner.
United Paper Industries is supplying to some of the Gulf (KSA, UAE) and Asian (Sri Lanka, India) countries and hope to supply the entire Middle East region.
I previously was in charge of the Technology Department at United Paper Industries Co,. Kuwait, and today I hold 2 positions; the Gene-ral & the Mill Manager at the company.
United paper Industries Company has ensured that all environmental requirement are met and water consumption per mt of paper is as low as 3-4 m3/.
Paper Industry in Kuwait is better compared to other regions in the Middle East. Being a small
22 papermiddleast
United Papers Industries CO.
Gopal on the light
Focus Kuwait
Name
Birth Place
Education – Under Graduate
1972Post Graduate
1975Position
Experience
Interests
Message to deliver
papermiddleast 23
market and is well served by local suppliers, the import is mainly to cater to special grades like coated box board, pure Kraft and coated papers.
Like any other Industry price swings due to imports from Europe has a damaging effect on local prices. The only way to beat the competi-tion is to be more competitive.
Since paper is a non oil based industry, sup-port from the Government in reducing the Port charges (Continuous usage) to make export market more competitive will definitely help the local companies.
A message to all our readers : Consume more paper so that the Paper Industry can survive, otherwise like in Europe and elsewhere, times will be very tough.
Being a family man, would like to spend maxi-mum time with them and on occasional holiday in Europe and Asian countries.
United Paper Industries CO. in depth
United Paper Industries Company was esta-blished in 1999 and the plant was commissio-ned in 2001.
Reason foreseen to start this paper mill was to cater to the multilayer bag industry for Cement and chemicals...etc.
As there were no other paper manufacturers for this product, it was thought prudent by the late Chairman Abdulla Al Dikheel to go ahead with this project. His vision has borne fruit through the present chairman Dikheel A. Al-Dikheel as K. Gopal explained.
A good Japanese Second hand paper machine was found and using European consultants the project commenced.
To ensure that the automation and control level was at its highest, ABB Italy was engaged thru ABB Kuwait to provide all necessary Drives, DCS, and QCS requirements.
United Papers Industries CO. is one of the most contributing businesses to the economy of Kuwait backed-up with its other sisters compa-nies that deal with paper products and others:
1. International paper Products is a High Qua-lity Printing and lamination for board.
2. Burgan Shoes that deals with the Foot wear.3. Carpet Industry for Domestic.4. Carton Industries Co. a Carton box Manu-
facturer. 5. Kuwait Paper Sack Factory; a Cement bag
manufacturer.
Paper Machine 1 (PM1)
UPI’s mill includes one machine (PM1) with the following specifications:
24 papermiddleast
SANO Iron Works, Japan is the supplier. The machine was installed in the mill’s location in Kuwait in 1999, and the start up was esta-blished in 2001.PM1 has the capacity to produce an average of 100 mt/day of paper and has 230 cm of width and a 300 mpm as an operating speed.
Production Range
UPI’s PM1 machine is capable of producing dif-ferent ranges of paper:
Half of the mill production is consumed in the local market of Kuwait, while the second half is exported to the Kingdom of Saudi Arabia, the United Arab Emirates, Iraq, Jordan, India and Sri Lanka.
Supplier of the machine
The mill uses both waste paper and virgin pulp for the production process. Local companies and the USA supply the need of the mill of waste paper, while Canada and Russia supplies the virgin pulp. Other providers supply the mill with the stock preparation, drives, and other instruments and equipments, such SANO, ABB, Kadant Lamort and others:
Stock Preparation - Therma Black Clawson (Ka-dant Lamort, France) Drives - ABB, ItalyInstruments - ABBElectrical and Automation - ABBScanners - ABBMotors - ABBGear Boxes - SANO, JapanPumps - Ahlstrom, FinlandWires - Albany, Seden Utilities - DONLEE, USA/Thermax, India / AT-LAS Copco
Steam & Condensate system, Hood & P/v - A.V. Engineering, Italy
The UPI management supervises the pro-duction process at the mill that is built on an area of 29000 m2. The core of the company is put together with the networking staff, which hands in hands make sure to apply the vision and objectives of the founder.
More than 115 employees including the Admi-nistration personnel put their efforts to deliver distinguished products to the customer, wor-king in different sections and department; the Process, the Mechanical, or the Instrumenta-tion & Control System, the Electrical Depart-ment and the Utilities.
In order to follow up and get updated with the latest technology in the paper field, through meeting with the paper professionals from around the world, the management makes sure to participate and attend the seminars and ma-jor paper events in the Middle East and Asia held in this respect. Therefore, UPI takes part in Paper Arabia – Dubai, UAE, Paperex – New Delhi, India and Asia Paper – Bangkok, Thai-land. Progress Chart (Production and Sales):
Production is the core of the business. Main-taining a high and stable level of production, controlling and improving the quality are a major issue that the Production in Charge P.K.Mohanty is taking in hand.The production and the sales rates both are 2 indexes going together. A good balance is an index of high performance, where leakage is downsized to the minimum, as shown in the table below:
Quality Substance
The mill current project
Rebuild of Paper Machine 1
The rebuild of paper machine (PM1) has been envisaged keeping product quality in mind and increased production for pay back purposes.A lot of OEMs were considered but UPI sett-led on with PMT, Italy for the upgrading. Four main areas were considered namely, press, size press, pope reel and dryer section. In this the PMT patented AEGO shoe press was conside-red without any open draw to achieve paper dryness in excess of 52%.
Description 2010 2011 2012 2013 (till 2nd quar-ter)
Production (Mt) 17000Sales (Mt) 17000Quality
- - - -
26 papermiddleast
The AEGO film size press was considered for achieving high solids in the size press resulting in high stiffness in Test liner, Fluting and Kraft liner grades. AEGO pope reel was considered to achieve large jumbo reel (Excess of 2.5 mts in dia) and perfect winding to cater to modern high speed corrugators.
In order to increase drying capacity, new 8 BAR drying cylinder will replace the existing low pressure cylinders.
In the wire part existing dry suction boxes will be replaced with Duoflow and Trivac suction element to cater to increased machine speed.
To improve CD/MD ration of physical proper-ties of paper, UPI is considering using hydroline & Varioline drainage element to increase acti-vity on the wire table and improve properties in CD.
After the rebuild United Paper Industries Com-pany will be one of the first paper mills in the world to have a Clupak Unit and Size press in the same paper Machine.
Below are the figures on the speed and the pro-duction capacity reached after the rebuilt:
Future Project
UPI management is planning to undergo a new project at its mill location. The project will answer the need of the increasing market de-mand on specific products. Therefore, and in order to fulfill this need, the mill will acquire a double layer unit. This se-cond layer machine will be able to produce two layers of Test liner and Fluting grades. With this fact, two advantages will be reached; one is by improving the quality of the paper produced;
Description PM1
company should identify and target different markets for it to maintain its position and en-hance its performance as a market leader. Therefore, differentiating is the key, and UPI was able to differentiate itself from other key players in the local and in the regional market by producing a unique item the Sack Kraft pa-per.
Moreover, the high operation indicator on pro-duction and sales on one hand and the determi-nation to plan for new projects on the other are evidence on UPI’s understanding of the com-mitment to the values and vision in order to reach the desired goals and in order to compete in the market. Last but not least, UPI’s General Manager K. Gopal concretizes these values and goals through his expertise and skills. He believes that the only way to beat the competition is to be more competitive. He also calls people to consume more paper, and asks the government to reduce the port charges as a call for support for local companies to survive.
Wishing the best for this industry and for those who believe to make it a better one!
second because the double layer unit will make it possible for the mill to introducing a new pro-duct to its basket of grades; which is the White Top Liner.
Conclusion
The need to cater another industry pressed the late Chairman Abdulla Al Dikheel to evolve a vision that was concretized by establishing United Paper Industries. The need became a vision, and reaching the set goals gave UPI a colossal entity.Through the sections of this report on UPI mill and management, we become more aware of the fact that in a very competitive market, a
papermiddleast 27
Events >> Starpack
28 papermiddleast
500 Students from Lebanon, Egypt, Palestine, & Jordan in StarPack 2013Promoting Industrial Culture among the Youth
Lebanon Student StarPack unleashed the creativity and talents of 500 students from 17 universities in Lebanon, Egypt,
Jordan, and Palestine. Lebanon Student Star-Pack 2013 Award Ceremony took place under the patronage of his Excellency the Lebanese Minister of Industry, Mr. Vrej Sabounjian on April 23, 2013 in the UNESCO Palace.
Ms. Soha Atallah, LibanPack Director, inau-gurated the ceremony and highlighted the fol-lowing: “We celebrate the fifth anniversary of LibanPack, and this year creates a major chal-lenge for LibanPack as starting 2013 LibanPack became self sustainable and financially inde-pendent from UNIDO. Lebanon Student Star-
Pack began in 2010 with 90 students and ever since, it has extended beyond the borders of Lebanon to Jordan, Egypt, and Palestine.
Dr. Fady Gemayel, President of LibanPack sta-ted: «Our ambition is for Lebanon to become a regional hub for packaging in the Middle East and this has been evident from the impact Li-banPack has on the region specifically with the participation of students from Arab countries for StarPack. By organizing StarPack, LibanPack is working on developing the packaging indus-try in Lebanon and opening new horizons for the young generation.”
papermiddleast 29
Mr. Ziad Bekdache, Vice President of the Asso-ciation of Lebanese Industrialists stated that: «Packaging is as important as the quality of the product itself and many companies are more aware of its signi-ficance to attract potential customers looking to pur-chase something new and distinguished.”
During the ceremony, H.E. Mr. Sabounjian stated that “LibanPack has become a reference in the world of packaging and we consider StarPack one of the main activities of the center since they provide an opportunity for students to present their ideas to interested indus-trialists and opens doors for securing jobs.”Furthermore, he stressed on the impor-
tant marketing role for packaging besides its functional role for protection.
The competition awarded two categories: vi-sual category and structural category where university students improved the packaging of Lebanese products. Most of the projects tack-led the structural aspect of packaging to make it easy to handle by the consumer and in the supply chain. Furthermore, a prize for Sustai-nable Packaging was awarded by BankMed and a prize for Creative Design Award was awarded by Unipak, a member of Indevco group.
Events >> It’s Tissue
30 papermiddleast
When tissue can be fun
Where on earth can you start your day with a smooth espresso on a sunny terrace, then sit in a 14th century
convent transformed into a modern auditorium, listening to prominent speakers debate about their vision of the industry, before enjoying a buffet of one of the finest European gastrono-mies, next visiting factories of some innovative tissue machinery manufacturers, and finishing your day wandering around the small streets of a historical city and settling down to enjoy an outdoor jazz concert?
The Lucca Valley in Italy is the place. It’s Tissue is the event.
Those who experienced the very first edition of this unique event will certainly remember it. The initiative is based on an open-house concept, driven by 12 leading companies (see box below) specialized in the tissue production and converting process, has been a complete success.
They joined forces and managed to gather around 700 tissue professionals from the five continents. Obviously many locals and Euro-peans were present, but the event also attrac-ted many producers coming from more dis-tant countries like Japan, Korea, Indonesia, and China. Nationals from Bolivia, Venezuela,
Mexico, Brazil and the US were also repre-sented, as well as Middle Eastern and African investors from Turkey, Dubai, Congo, Angola and Morocco.
During a full week, they were invited to visit the companies of their choice around the valley, whilst being given explanations of the added-value of the latest technology with live demons-trations. Transportation and logistics were impeccable and the visits as much pleasant as they were instructive, thanks to a dedicated and most welcoming staff.
The welcome reception took place in Cinquale, an elegant seaside resort. About 300 guests ga-thered for this exceptional social time, including a fantastic dinner followed by a memorable performance from Tony Hadley, the former lead singer of Spandau Ballet, the famous 80’s romantic band for those who are old enough to remember.
And those wishing to extend their stay had the opportunity to join a cultural and gastronomic program of guided tours.
This event is set to take place every three years. The organisers promised it will be even better in the future. We look forward to it.
papermiddleast 31
It’s Tissue Network
Members:A.Celli: engineering, design, development and manufacture of complete Tissue Sys-temsElettric80: conditioning and warehousing sytsemsFabio Perini: converting and packaging linesFutura: tissue rolls converting linesGambini: tissue converting linesMTC: tissue converting machinery Omet: paper converting machines PCMC: paper converting equipmentsPulsar: conveying and packaging solutionsRecard: complete tissue machinesTMC: tissue packaging machinesToscotec: paper machines and technologies
Supporting companies:
www.groupenp.com
32
wwww.groupenp.com
Cinquale
Tony Hadley
Spandau Ballet
A.Celli
Elletric80Fabio Perrini
Futura MTC
Omet PCMC Pulsar
Recard TMC
Toscotec
Rockwell AutomationHenkelFanuc
SKF
Sustainability BankMed
UNIPAK Creative Design Award
ALBA
AUST
LibanPack
LibanPack
Strapack
Starpack
Graphic Design
Starpack
kcapnabiL
Lebanon Student StarPack 2013
StarPack
LibanPack
PMT
Shoe
PMT AEGO
AEGO
AEGO
DuoflowTrivac
Clupak
PM1
Therma Black Clawson
Kadant Lamort, France
ABB
ABB
ABB
ABB
ABB
SANO
Ahlstrom
Albany
Donlee, USA/ Thermax,
India/ Atlas Copco
A.V. Engineering
ABB
ABB
DCSQCS
PM1
PM1
SANO IRON WORKS
Union Paper Mills
ELF
Gardner Denver Nash
Nash
Nash
Nash
2BE4
Nash
Nash
Nash
Nash
ZellstoffPöls
Nash
PM2 ZellstoffPöls
Nash 2BE4
V
ZellstoffPöls
Nash
SAFEM
SAFEM
SAFEM VP 2000 T2
VP 2000 T1
SAFEM VP 2000 X
SAFEM VP 2000 T2
VP 2000 T1
SAFEM VP 2000 X
SAFEM
SAFEM
SAFEM
SAFEM
SAFEM
SAFEM
FAM
AES
AESSEAL
AESSEAL
AES
AESSEAL
¹
AESPUMP
Sulzer Pumps
Sulzer Pumps
MC®
Sulzer
Sulzer Pumps
AESSEAL
AES
ANDRITZ PULP
& PAPER
http://www.chinapaperchem.com/en/
Risi
ANDRITZ
Kartonsan
ANDRITZ
Kartonsan
Karton Sanayi ve Ticaret
Prime Flow SW
shoePrime Press
X
Mondi
Mondi
Mondi
Mondi Kaso
Iraq
Mondi
Mass Iraq Co.
Mondi
Risi
CapCon
Tunisie Ouate
Tunisie Ouate
CapCon
EconSOFT
Tunisie Ouate
CapCon Tunisie Ouate
Tunisie Ouate
CapCon
Metso
Hayat Kimya
Metso
Hayat Kimya
.Metso
Metso
MONDI
Mondi
Kaso Group
Mondi
Hayat Kima
Hayat Kima
Hayat Kima
BRT
Hayat Kima
Risi
Metso
Hayat Kimya
Metso
.Hayat Kimya
DCT 200TS
Europac
Europac Europac
Sulzer Pumps
AESSEAL
FAM
SAFEM
Nash
ZellstoffPöls
Libanpack
Europac
Hayat Kima
Metso
Hayat Kimya
Mondi
CapCon
Tunisie Ouate
ANDRITZ
Kartonsan
www.groupenp:com
36, rue Stanislas JulienF- 45000 Orléans France
www.groupenp.com
2013
