Displaying items by tag: metso

With a skilled crew and through dedicated hard work Hayat Kimya A.S. in Turkey have succeeded in their efforts to break the world speed record for tissue machines. The record of 2,210 m/min was set on June 1, 2012 during a 24-hour production run by their TM 2 tissue machine at the company’s mill in Yeniköy near the city of Izmit in Turkey. The machine, which was started up on December 18, 2010, is an Advantage DCT 200 TS supplied by Metso.

The Advantage DCT 200 TS machine is equipped with an OptiFlo headbox with a Metso IQ Dilution Profiler, a Metso IQ Steam Profiler, a Metso Yankee cylinder, an Advantage AirCap hood for co-generation, an Advantage WetDust dust management system, an AdvantageRun sheet transfer system and an Advantage SoftReel L reel. The process is controlled with a Metso DNA system. Stock preparation equipment and engineering were also supplied by Metso.

The world speed record was achieved through excellent management and operational skills in combination with Best Available Technology (BAT).

Lütfi Aydin, Paper Group Director, Hayat Kimya, says: “The cooperation with Metso has been beyond excellent and both parties did their utmost to make the project successful. The results clearly show that the efforts were worthwhile on both sides. This cooperation will extend to cover new projects in the future.”

“We are not surprised that Hayat Kimya managed to break the world speed record. Our confidence in the capability of the Hayat team has been high since our project started in 2009. We certainly know our machine in detail, its stability, production efficiency and speed capability. However, in order to reach the very top performance a machine needs to be in the hands of a skilled crew willing to push the boundaries. We have certainly seen that at Hayat,” Jan Erikson, Vice President, Sales, Metso states.

Hayat Kimya A.S. is part of the Hayat Group. The Hayat Group primarily operates in the chemicals, hygienic products, paper and wood-based industries. The Hayat tissue facilities have a paper production capacity of 135,000 tonnes and a converting capacity of 100,000 tonnes per year.

Metso has signed several contracts for supplying automation technology for greenfield waste-to-energy plants in Italy, Estonia and the UK. Modern automation solutions will play a major role in managing these new plants successfully. Plant operators will able to maximize incineration capacity, keep combustion and steam production stable, as well as maintain high process availability. Extensive, employee-empowering automation will ensure that waste burns safely and emissions stay low.

Metso has extensive experience in supplying automation and information management applications to waste-to-energy plants that run on industrial, municipal and wood waste or sludge. The company has a long track record of deliveries to roughly a hundred waste-to-energy and biomass combustion plants around the world.

CNIM chooses Metso's automation for greenfield waste-to-energy plants in Italy, Estonia and the UK

Metso has recently received three orders for Metso DNA automation systems for greenfield waste-to-energy plants from the CNIM Group. The latest order is for the North Hykeham plant in Lincolnshire, UK. It was preceded earlier this year by similar orders for waste-to-energy plants in Turin, Italy, and Maardu, Estonia. CNIM, the European leader in construction of waste-to-energy plants, acts as a contractor in all these projects.

At these plants, Metso DNA will provide one system for all process controls and plant information management. The integrated process automation system covers all plant processes from boilers to turbines. High-level reliability is ensured through an integrated TUV certified safety solution.

The North Hykeham waste-to-energy plant is owned by the Lincolnshire County Council and will be operated by the Waste Recycling Group. It will have an electric output of 13.1 MWe and a thermal output option up to 10 MWth. With an annual capacity of 150,000 tons of household and similar waste, and it will provide electricity to around 15,000 houses and the national grid. The plant is scheduled to go on line in spring 2013.

The Turin waste-to-energy plant owned by Trattamento Rifiuti Metropolitani will have a thermal output of 206 MW and an electric output of 56 MWe. It will be able to handle 421,000 tons of household and similar waste annually, with three incineration lines and provide electricity to around 150,000 houses and district heating to about 17,000 houses. The plant will go on line 2013.

The waste-to-energy plant in Maardu, owned by Eesti Energia, will have a thermal output of 50 MW and an electric output 17 MW. Using up to 220,000 tons of municipal, industrial and construction waste annually it will supply district heating to 500,000 inhabitants. The plant will go on stream in 2013.

Established in 15 countries, the CNIM Group designs and produces turnkey industrial solutions and offers expert research, expertise and operations services in the fields of environment, energy, defense and industry. The group has 3,000 employees, and its turnover was 633 million euros in 2010.

Hitachi Zosen Inova AG goes for Metso DNA to fulfill customer requirements in the UK

Metso has also signed an agreement with Hitachi Zosen Inova AG to supply automation for two lines at a greenfield waste-to-energy plant being built by SITA South Tyne and Wear Ltd. in Tees Valley, Billingham, UK.

The waste-to-energy lines under construction at the North East Energy Recovery Centre will each have the capacity to incinerate 152,000 tons of waste per year. They will feature grate-fired boilers with a thermal performance of 2 x 45.85 MW and rated turbine capacity of 24.2 MW with a live steam temperature of 410°C. The plant will start commercial operation in the autumn of 2013.

Metso's delivery scope consists of a Metso DNA distributed control system, a Metso DNA information management system, on-site commissioning, trial run support, training and spare parts. To boost system availability, there will be a remote service connection between the plant and Metso. Metso's delivery will take place in September 2012.

With advanced solutions, the operators will be able to manage operations and information efficiently at the plant. The system includes, DNA Report, an umbrella application for all Metso DNA reporting and analyzing tools, and solutions that use historical data stored in the DNA Historian database. It includes tools for report development, calculations, trending, alarms & events analysis, manual data entry and an operator log book. One example of the tools is Tracer, a process history analyzing tool combining traditional trends with alarms and events in the same graphic with a common timeline.

Metso was chosen as the supplier for the plant based on its good track record from five earlier projects with Hitachi Zosen Inova at A.S.A. Zistersdorf in Austria, BIR Bergen in Norway; Riverside and Newhaven in the UK and Vaasa in Finland.

"Compared with other systems in use in our previous projects, we immediately understood that Metso DNA is a flexible, state-of-the-art and easy-to-operate system. It fulfills our customers' requirements," says Jean Bilger, Head of Electrical and Control, Hitachi Zosen Inova. "Our engineers especially like the easy expandability and flexibility of Metso DNA."

Bilger appreciates Metso's way of working. From the first offer to the final startup, Metso's people have proven to be professional and proactive partners. "We have a high level of trust in all the departments of Metso we have dealt with, from the sales team to the project engineers and startup team."

SITA UK is a leading recycling and resource management company with specialist knowledge and experience in all areas of recycling, waste and resource management. www.sita.co.uk.

Zurich-based Hitachi Zosen Inova is one of the world's leading international specialists in energy-from-waste installations. Created from the former Von Roll Inova, the company offers customers all over the world reliable, customized thermal waste processing solutions. With more than 75 years of experience and over 470 reference installations, Hitachi Zosen Inova provides the entire range of services from developing, designing, planning and constructing installations right through to maintenance and modernization. Since 2010, Hitachi Zosen Inova has been part of the global industrial group Hitachi Zosen Corporation. www.hz-inova.com.

Metso and Wärtsilä have agreed that Wärtsilä’s holding in their MW Power joint venture will be acquired by Metso. Metso currently owns 60 percent and Wärtsilä 40 percent of MW Power. The arrangement is subject to permission from the EU competition authorities. The owners estimate completion by the end of July 2012. The value of the agreement will not be disclosed.

Founded in 2009, MW Power has been part of Metso’s corporate structure. “In the future, Metso will develop MW Power’s business as part of its comprehensive power generation solutions offering for the international market,” says Jyrki Holmala, President of Metso’s Power business line.

MW Power supplies small- and medium-sized heat and power plants for European market, and focuses on renewable fuel solutions. Its main customers are municipalities, process industries and utilities. The company has a total of 250 employees in Finland, Scandinavia, the Baltic area and Russia.

Metso will rebuild the white top kraftliner machine at the Piteå mill of SCA Packaging Munksund AB in Sweden. The rebuilt production line will be fully operational during 2013. The value of the order will not be disclosed.

The main target of the rebuild is to increase the share of the production of value-added white top kraftliner products. As a result of the rebuild, SCA Packaging Munksund will be able to increase its total annual white top kraftliner production from the current level of 110,000 tonnes to 165,000 tonnes and the total kraftliner production from today’s 360,000 tonnes to 415,000 tonnes.

“The investment in the rebuild facilitates increased production of white top kraftliner, a strong specialty paper for the corrugated board industry which is experiencing a high growth rate. The investment is in line with the company’s strategy, which is to increase production and sales of products and services with a higher degree of refinement that add value to our customers,” said Jan Johansson, President and CEO of SCA, in a press release after the investment decision.

Metso’s delivery will comprise a rebuild of the approach flow system, headbox, forming, press and dryer sections as well as of the board machine ventilation system.

The 7.01-m-wide (wire) PM 1 produces white top kraftliner in the basis weight range of 115-200 g/m² and unbleached kraftliner in the range of 170-440 g/m² at the design speed of 1,100 m/min.

The order is included in Metso’s Pulp, Paper and Power first quarter 2012 orders received.

Metso's unique offering of products and solutions to improve safety and productivity in the oil & gas industry is now complemented with a range of control valve innovations which will be presented at Hall 9.0. Stand B21 at ACHEMA. There will be short info sessions daily on the stand in English and German. ACHEMA 2012 will be held 18-22 June in Frankfurt, Germany.

Improved version of famous Q-Trim

Noise and vibration generated by control valves constitute a typical environmental issue in process plants and their surroundings. Further improvements to Metso's famous Q-Trim™ noise reduction technology that will be on show at ACHEMA 2012 have resulted in advanced noise and vibration control in challenging applications. These solutions help process industry customers improve personnel and plant safety while simultaneously increasing efficiency and reliability.

Third generation valve diagnostics from Metso

New Metso Valve Manager™ represents state-of-the art, 3rd generation valve diagnostics which is capable of processing the collected diagnostics information to visualize the condition of the valve in question with five different indices: Control performance, Valve condition, Actuator condition, Positioner condition and Environmental conditions.

With processed and visualized diagnostics information the maintenance managers and engineers and process operators are capable of making educated decisions concerning the control valve maintenance without deep valve know-how. Unexpected shutdowns can be avoided and the control valve performance can be maintained at optimum level by continuously monitoring the condition of the installed base at the plant or mill and by taking the necessary preventive actions based on the available diagnostics information. Also, with the help of the diagnostics, the available maintenance resources can be more efficiently allocated during shutdowns.

When so called preventive or schedule based maintenance strategy is followed, many valves are often needlessly maintained during shutdowns. By focusing the maintenance actions on the valves really needing maintenance, significant maintenance cost savings can be achieved through reduced spare part purchases and reduced need for maintenance resources.

Metso's new Valve Manager is available for the Neles ND9000 series intelligent valve controllers.

New features and services for intelligent emergency shutdown valves

New additions to Metso's market-leading intelligent emergency shutdown valves (iESDs) enhance the reliability and availability of emergency shutdown valves, and are designed to reduce plant safety costs efficiently and help customers maximize process plant uptime. Metso's valve sizing and selection software Nelprof® is the world's first valve selection software for safety valve optimization providing improved efficiency for safety valve selection process.

The Metso Valve HealthCare program supports the customer's preventive maintenance ensuring reliability of the critical emergency valves and helping to fulfill SIL requirements. Service is based on regular checking of valve conditions and analysing of diagnostics. The checking and reporting of recommended maintenance actions is done by Metso's certified service technicians.

The service reveals the condition of the critical valves and helps to avoid unexpected incidents affecting safety, environment or production. The service brings savings in maintenance costs by focusing on the valves needing attention or maintenance actions. Possible problems and degradation in performance are notified early to ensure time for maintenance planning.

On-going investments in global presence

Besides offering an extensive product offering, Metso is also investing in its global portfolio and presence to constantly improve services to customers in oil & gas and power. Just recently, Metso announced the acquisition of a globe valve technology and service company, Valstone Control Inc., in South Korea and established a new supply and service center in India. Currently, Metso is expanding its valve production premises in the US. Last year, Metso opened a new valve technology center in Finland, and another one in 2010 in Shanghai, China. In addition, Metso has high-class industrial valve facilities in Brazil and Germany.

Experienced in valves

Metso is the leading valve solutions and services provider. Metso's Flow Control solutions include control valves, automated on/off and emergency shut-down valves, as well as smart positioners and condition monitoring. Metso's world-leading brands include Neles, Jamesbury and Mapag.

Due to Metso's strong position in advanced valves technology, services are a major part of the offering. For example, customers like Petrobras and Arcelor Mittal have awarded Metso with large service contracts. For valve customers alone, Metso already has 32 service centers around the globe. 

On September 14, 2011, Shanghai Orient Champion Paper started up their new Metso-supplied tissue production line, TM 7, at their facility in Jinshan outside Shanghai, China. Now, less than eight months after the start-up of the first Advantage DCT machine, a second Advantage machine was even more successfully started up on April 26, 2012 at the same site. Due to the excellent cooperation between Shanghai Orient Champion Paper and Metso the TM 8 machine started up smoothly on schedule.

Metso’s scope of delivery included two complete tissue production lines, featuring one Advantage DCT 100+ and one Advantage DCT 135+ tissue machine. Each of the lines includes stock preparation systems, comprehensive Metso DNA automation systems and Metso IQ quality control systems with steam profiler and auxiliaries. Each of the machines is equipped with an OptiFlo headbox, a Metso Yankee cylinder, an Advantage AirCap hood, an Advantage WetDust dust management system for enhanced working environment and a ValReel reel.

The Advantage DCT tissue machine concept is developed for fast installation and start-up. These two installations were no exception. The TM 7 performance test was carried out two months after start-up. Within 10 days of the start-up the machine was up to guaranteed speed. The machine is designed for a production speed of 1,800 m/min.  The start-up of TM 8 exceeded all expectations and the machine started up smoothly and timely. It is now operating with ease producing high-quality tissue paper.

“It has been a privilege for the Metso site crew to work together with the Shanghai Orient Champion Paper employees. The start-up crew led by Metso’s Niklas Ryman showed great professionalism when the “paper on” order was given. Without the skill and hard working attitude of the Shanghai Orient Champion Paper employees and the Metso crew the outcome would not have been this successful,” says Stefan Ziegel, Project Manager, Metso.

Just like for the start-up of TM 7, for the start-up of TM 8, too, a traditional inauguration ceremony was held to celebrate the new family member in Shanghai Orient Champion Paper’s machine park in Jinshan, Shanghai.

The rapidly growing Shanghai Orient Champion Paper currently operates six smaller tissue machines and converting lines at the Jinshan mill. The two new Metso machines add another 70,000 tonnes to the mill’s production capacity.

Shanghai Orient Champion Paper Co., Ltd. is part of the CIMIC Group which operates companies in various businesses. The CIMIC Group has operations in consumer goods, real estate, building materials, education, electronics and communications industries.

Metso has reached an agreement with Airtherm Corporation, USA after an apparent patent infringement by Airtherm in a patent owned by Metso.

The Metso product protected by this patent is the so called Advantage WetDust system whereby the dust in a paper and tissue making line is entrained into a dust collector where water is injected directly inside the dust collector.

Airtherm have agreed to discontinue any further sales of the wet dust collection system protected by Metso’s patent. Airtherm Corporation have also agreed to pay for a onetime license for systems already sold.

The patent in question is the US Patent No. 6,176,898 issued in 2001 entitled “Method and System for Collecting and Handling Dust in a Paper Machine Environment”.

Metso has received an order for a new Metso IQ quality control system from Stora Enso Skoghall. The system will be installed on BM8, one of the largest board machines in the world with an annual production amount of over 400,000 tons. The order was placed after careful evaluation, since Stora Enso places high demands on availability. One of the main criteria for the choice of supplier was to minimize the risk of production losses, both during the project phase and during normal operation of the board machine.

The delivery includes four scanners with the latest sensor versions, Metso Moisturizer IQ for the drying section, a reconstruction of the coating stations for automatic profiling with the new actuators, Metso IQ Dilution Profilers, plus MD and CD controls.

Metso is responsible for delivery, installation and performance. Installation and commissioning will take place in three phases starting in October 2012. The last stage will be carried out during the autumn shutdown in 2014.

"We are pleased and proud of this extensive order and consider it a privilege to work with Stora Enso Skoghall," Says Maria Dotzsky, Regional Director at Metso Automation.

Metso IQ quality control system, including high-level intelligent control applications, optimizes the cross-machine performance of papermaking processes. It integrates process quality management, measurements and profile controls, resulting in faster startups and grade changes, reduced dryer breaks and better runnability with stable short circulation to improves the uniformity of the wet sheet. (www.metso.com/metsoiq)

Metso IQ profilers provide effective profile management, improve production and runnability, and ensure better paper quality and printing properties. Metso's profilers feature advanced self-diagnostics and compact designs for easy maintenance and installation. (www.metso.com/automation/pp_prod.nsf/WebWID/WTB-041026-2256F-5F91A) 

Metso IQ system deliveries have reached a record level. With proven successful installations over the years, Metso's market share has grown significantly to over 30%.

When Metso introduced its first advanced architecture PaperIQ quality control system in the mid-1990s, the company set in progress a resolute course to be a major contributor to the stability and profitability of its customers' papermaking operations. More than 15 years later and with over 1,000 QCS scanners delivered, the long-term investment in QCS technology, engineering skills and application development has paid off handsomely.

New Metso paper, board and tissue machines are equipped with Metso IQ systems. However, the substantial growth in Metso system deliveries is coming from replacing the so-called legacy systems, many of which were installed over the past twenty years. Just over 40% of the Metso IQ systems recently sold worldwide have replaced systems originally delivered by other vendors. In North America, that replacement rate was near 50%. Other growth areas for Metso include the replacement of CD profilers and CD controls.

Metso has introduced many new system enhancements in recent years to improve the return on investment from new system installations and therefore encourage customers to update their QCS technology. The now-standard MD and CD multivariable predictive controls have provided better machine stability and bottom-line results. New developments in sensor technology include Metso IQ Laser Caliper, which has a major market share in SC paper and many other grades, and Metso IQ Fiber non-nuclear fiber weight measurement for tissue machines. More than 50 Metso IQ Fiber sensors have been installed. New imaging-based sensors for formation, fiber orientation and surface topography, as well as a new pressure-based porosity sensor, are recent additions to the measurement capabilities.

Metso IQ systems have also become easier and less costly to service than previous generations with the addition of extensive predictive maintenance diagnostics. This makes the total cost of ownership over the system lifespan considerably lower.

Metso feels poised to achieve even better results in years to come. "In order to achieve the same success this year, we have to be even more competitive with our product performance, with our total quality, and naturally with product costs. Our total offering and industry specific concepts, such as Pulp, Paper, Tissue and Board, show our expertise and help differentiate us from our competitors. It is going to be a hard competition, but both our offering and the company are in good shape for it," concludes Juha Koistinen, Vice President, Control & Measurement Solutions.

Metso IQ quality control system including high-level intelligent control applications optimize the cross machine performance for papermaking processes. It integrates process quality management, measurements and profile controls resulting faster startups and grade changes, reduced dryer breaks and better runnability with stable short circulation improving uniformity of the wet sheet. (www.metso.com/metsoiq)

Metso IQ profilers provides effective profile management, improves production and runnability through to better paper quality and printing properties. Metso's profilers feature advanced self-diagnostics and compact designs for easy maintenance and installation. (www.metso.com/automation/pp_prod.nsf/WebWID/WTB-041026-2256F-5F91A)

Metso’s Mika Viljanmaa receives Marcus Wallenberg Prize for ground-breaking work on metal belt calendering

Mika Viljanmaa, who works as Development Manager in Metso’s Järvenpää unit in Finland, has been awarded the prestigious 2012 Marcus Wallenberg Prize for his work on metal belt calendering in paper and board making. Viljanmaa will receive the prize at a ceremony in Stockholm, Sweden on October 1, 2012.

According to the Board of the Marcus Wallenberg Foundation, “The 2012 Marcus Wallenberg Prize has been awarded to Mika Severi Viljanmaa for his ground-breaking development of metal belt calendering technology resulting in better paper print surfaces with less fiber materials and higher production efficiency”. Furthermore, the invention also paves the way for applications in other paper machine sections with the opportunity of becoming a wider platform technology expected to substantially enhance production efficiency, competitiveness and sustainability of paper and board making.

Metal belt technology improves quality and efficiency, with less raw materials and energy

Metal belt technology has made a major breakthrough as a revolutionary new calendering concept for papermaking. Calendering is done to improve the paper surface and thus print quality. Compared with conventional calendering, advanced long nip metal belt calendering technology enables manufacturing of paper and board with better surface properties at a desired level of stiffness and bulk, but with 3-10% less fiber raw material; in addition it decreases energy consumption and yields higher production efficiency.

It is also suitable for low-cost fibers such as recycled fibers and thus enables development of new cost-competitive paper and board products. The new concept is compact, making it ideal for rebuilds to increase capacity by removing existing production bottlenecks such as yankee dryers or wet stacks.

Mika Viljanmaa

Mika Viljanmaa, M.Sc., born in 1966, joined Valmet Corporation (now Metso) in 1996 as a development engineer at their Järvenpää unit, where he also completed his Master’s thesis for the Helsinki University of Technology. Since 2003 he was in charge of calendering research and development at Metso Paper and since 2009 he has been responsible for R&D in surface treatment technology.

Viljanmaa is a highly prolific innovator, with a total of 120 protected inventions. 57 of these are related to metal belt technology and Viljanmaa is the sole inventor in 12 of them.

Mika Viljanmaa has guided several thesis works related to metal belt calendering and has presented conference papers on the subject.

The Marcus Wallenberg Prize

The Marcus Wallenberg Prize is an international prize that was established in 1980. Each year the prize recognizes a single research breakthrough by one scientist or a small group of collaborating scientists. The selected breakthrough will have a significant effect on the forestry and forest products industries.

In addition to rewarding the winner, the prize is also intended to encourage further research around the world. The prize sum is SEK 2 million. For more information, please visit www.mwp.org.

In 1999 the prize was awarded to former Valmet (Metso) engineers Pekka Eskelinen, Raimo Virta and Vesa Vuorinen for their pioneering development of a unique air blowing technology for stabilizing paper webs aerodynamically at high speeds.