Displaying items by tag: metso

Metso and Arcelor Mittal Tubarão, located in Espirito Santo State, Brazil, have signed a service contract covering approximately 2,000 automatic and safety valves. The contract also includes intelligent tools for preventive and predictive maintenance and maintenance planning activities. It expands the existing contract and is one of the largest for Metso’s valve operations in South America.

Arcelor Mittal Tubarão is a world leader in the semi-finished steel market, accounting for 12% of global slab sales. It is also one of the largest companies in Brazil.

With Metso’s intelligent tools, the steel plant staff is able to monitor and analyze valve condition while the process is running. Conventional methods require stopping the process and removing or dismantling the valves for closer inspection.

“Constant awareness of overall valve condition prevents unexpected breakdowns, which can result in stopping the process completely, which is extremely costly. The customer can plan the maintenance schedule in advance, so any disruption to the process is kept to a minimum. In addition, the staff can focus maintenance activities on those valves needing it most,’’ explains Tercelino Leite, Service Manager, Automation business line, Metso.

As Metso’s strategy is to offer knowledge-based services close to its customers, the company is continuously growing its global service network. Currently Metso operates 31 service centers globally for valve maintenance. Investing in service capabilities is demonstrated in the large service contracts Metso has won from large global companies such as Arcelor Mittal and Petrobras.

Arcelor Mittal is the world's leading integrated steel and mining company, with operations in more than 60 countries. In 2010, Arcelor Mittal had revenues of USD 78 billion and crude steel production of 90.6 million tons, representing approximately 8% of world steel output.

Metso acquires Fabco Inc. (Fabrication Company of Maine), located in Winthrop, Maine, USA. The acquired business, employing 20 persons, will be affiliated to Metso's Paper and Fiber Technology segment - Filtration Services, as of November 1, 2011. The value of the transaction is not disclosed.

The acquisition will complement Metso’s current services, technology and product offering to the pulp industry in North America, and is in line with Metso's strategy to increase the level of business in the services sector.

Fabco Inc. has been manufacturing and servicing filtration components for the pulp and paper industry for over 30 years. The filtration solutions are offered for different parts of the paper mill; woodyard, pulp mill, paper machine, and waste water treatment. Some of the key manufactured products are disc filter sectors, drum filter covers, belt press belts, sector covers, vibrating & polishing filter screens and recausticizing products.

Metso DNA is again leading the way by being the first in the world to introduce new control applications that enhance productivity and profitability in energy industries, pulp and paper industries, and as a new area, mining and construction industries. Metso is the first to introduce embedded machine condition and runnability monitoring within process controls. Metso DNA has also been strengthened with new control applications, such as winder controls, power plant turbine controls and machine condition monitoring. As well, Metso is pioneering usability in process control work.


Metso DNA meets diverse mining and construction industry needs

Metso is a leading supplier in mining and construction machinery. This expertise is now combined with scalable Metso DNA automation systems that adapt to the diverse mining and construction industry needs, from single machine controls to entire plant-wide automation and information management systems.

An example of Metso's new offering is the new crushing plant control room solution that connects crushers and screens together, ensuring the effective management of the entire plant from a pleasant and safe control room. The Metso DNA user interface provides production information to ensure a proper and rapid response to plant events. Automatic controls stabilize the process and allow the operators to monitor the plant as a whole.

"As an example of the services, we offer performance studies for crushing plants, using Metso's multi-disciplinary teams of experts, to determine the present level of the plant and process efficiency, and to estimate the improvement potential and benefits from optimization and automation, including ROI calculations. As another example, our machine condition monitoring solutions can reduce plant and machine downtime as well as help avoid safety and environmental hazards," says Mikko Mäkinen, Product manager of minerals applications in Metso's Automation business line.

New solutions for increased efficiency for energy industries

Metso DNA now offers one system for power producers, which includes energy management, plant information management, controls for the boiler, turbine and Balance of Plant, safety integrated systems, as well as emission management.

The integration of applications for turbine control, turbine protection and turbine management into the Metso DNA automation system provides customers with easy and cost-efficient maintenance, and reliability-based redundant process controllers. Metso's pulverized coal-fired combustion optimization manages control reactions to dynamic upsets, such as changes in mill configuration or load demand.

The sootblowing optimization tool calculates, stores and displays the boiler heat transfer characteristics that indicate fouling and deposit accumulation on heat transfer surfaces. It also defines the economically optimal sootblowing sequence. Another new application, machine condition monitoring, has been developed for the condition monitoring of rotating machines, such as flue gas fans, feed water pumps and turbines.

For pulp and paper makers, a single system for all controls

Metso DNA now offers pulp and paper makers a single system for all controls, from the fiber line to baling information, and from headbox to winder.

The new Metso DNA now offers winder controls, which increase the transparency between the winding process and papermaking process controls. The new winder controls enable operators to follow paper profiles through the winder controls, which improve both the runnability and productivity of the winding process.

Metso has also further developed its Metso DNA pulp mill information management offering and upgraded its bale tracking solution for the baling line. The newest application in Metso's pulp mill information management system, Metso DNA Bale Tracker, takes bale tracking to a new level. The new solution is based solely on the Metso DNA automation platform, which makes bale tracking and marking even more reliable. All online quality data needed for each and every bale is also available, thanks to full integration with Metso's Quality Control System (QCS) and Process and Quality Vision (PQV).

Machine condition and runnability monitoring

Mechanical condition monitoring is a part of preventive maintenance for wearing components, such as shafts and bearings, which need to be monitored for possible replacement needs. The new mechanical condition monitoring solution from Metso includes rotating machinery vibration measurements and analysis carried out as part of the automation system. Condition and runnability monitoring has traditionally been a separate system, mostly utilized by maintenance specialists. Thanks to Metso DNA Machine Monitoring, the same information can be shared with machine operators in the control room.

Good usability enables positive emotions and feelings

In addition, Metso is pioneering usability in the process control work. Metso DNA takes a new approach to usability by regarding emotions and feelings as part of the process control work. "Despite being fact-based by nature, process control work at pulp and paper mills includes a lot of feelings connected with solving situations. When all the aspects of business and production processes are under control, people in various tasks can enjoy feeling in control of their work," explains Jaakko Oksanen, Product Manager for Metso DNA.

An example of usability is that Metso DNA is the only system in the world from which the user receives the process data in real time and retrospectively from the same user interface, with one push of a button.

"The user can easily access all the data collected during his/ her absence, for example, over the weekend. Traditionally, the history of this information required separate applications, and data analysis was difficult. This is one example of how we have taken usability into consideration with subsequent positive emotions and positive user experience," Jaakko Oksanen explains.

Metso DNA can be developed, maintained, and upgraded throughout its life cycle

Metso's long experience in automation systems dates back to 1979. So far Metso has delivered thousands of systems to various process industries globally.

Metso DNA is a single automation system for all functions - process, machine, drive and quality controls. It also covers information management and mechanical and field device condition monitoring. Metso DNA is scalable from a single stand-alone controller to mill and plant-wide systems in global organizations.

The unique feature of Metso DNA is its single system architecture enabling lifelong compatibility and upgradeability. This means significant advantage for Metso's customers since Metso DNA enables step-by-step system upgrade paths to develop their systems according to changing process needs.

All Metso automation systems delivered after 1988 can be upgraded with new applications as a whole or in sections. Existing equipment and applications can be used in the upgraded system. The system network may also contain different generation subsystems or even different generations of products within a single system, meaning that new product features can be easily added.

Metso DNA is supported by global network of local experts.

Metso will supply a new fiberline for chemical cellulose for Sappi’s Ngodwana mill in South Africa. Start-up is scheduled for the first half of 2013. The value of the order will not be disclosed.

Metso’s delivery will include the design and supply of the main equipment for the new fiberline, from cooking to bleaching. The batch cooking plant is to be designed according to the prehydrolysis process and TwinRoll wash presses will be used in all washing positions.

The equipment to be supplied, together with Metso’s experience and know-how of this type of special pulp, will enable Sappi to produce high-quality chemical cellulose pulp for the growing market.

The new fiberline will produce around 215,000 air dried tonnes chemical cellulose hardwood pulp per year. In addition to the cooking plant and fiberline which will be new, Metso will also supply equipment for the upgrade of wood handling, evaporation and recausticizing as well as a new ash leaching system.

The main part of the order is included in Paper and Fiber Technology’s third quarter 2011 orders received and the evaporation and ash leaching equipment delivery in Energy and Environmental Technology’s third quarter 2011 orders received.

Sappi is today the world’s largest producer of chemical cellulose with a production capacity of approx. 815,000 air dried tonnes per year from the Saiccor mill. The Ngodwana mill located in the Mpumalanga province of South Africa will convert all of its market pulp production to chemical cellulose.

The new Metso-supplied tissue line of AK GIDA SAN ve TİC A.Ş in Turkey was successfully started up on August 29, 2011. The tissue line was installed in the company’s new mill in Pamukova, which is located in Sakarya province. On August 29 AK GIDA SAN produced tissue for the first time in a brand new plant with a complete Metso tissue machine.

With 500,000 m² of production area, AK GIDA SAN. ve TİC. A. Ş. currently produces some 400 different dairy products at the Pamukova facilities. The tissue plant covers 170,000 m². The new tissue line will produce 60,000 tons a year of high-quality facial, handkerchief, toilet and towel grades at a speed level of 1,600 m/min to 2,000 m/min. The raw material for the new line is virgin fiber. The production line is optimized to save energy and enhance final product quality.

Technical information

The Metso delivery comprised a complete tissue production line including a stock preparation system and an Advantage DCT 200 tissue machine. The tissue machine is equipped with an OptiFlo II TIS headbox, a press, a Metso Yankee cylinder, an Advantage AirCap hood, an Advantage WetDust dust management system and an Advantage SoftReel L reel. The stock preparation system comprises OptiSlush VM and HP pulpers, OptiFiner refiners and ProMS machine screens.

The delivery further contained an extensive automation package with Metso DNA machine and process controls, Metso consistency measurements, Metso IQ quality controls with IQ Fiber Measurement and a Neles valves package. Complete engineering, installation supervision, training, start-up and commissioning were also included in the delivery.

AK GIDA SAN ve TİC A.Ş is very satisfied with the delivery and the cooperation with Metso. Both parties look forward to maintaining the cooperation in the further expansion of AK GIDA SAN ve TİC A.Ş.



The first tissue jumbo roll produced at AK GIDA SAN ve TİC A.Ş.

Metso is strengthening its product offering by certifying valve products according to the latest widely accepted fire-safe standard - API 607 6th edition.

The plan is to replace all former fire-safe certificates and to widen the range of Metso fire-safe certified products in order to better serve our customers' needs and requirements and to expand the applications for our product range.

At present, the testing plan applies mainly to Neles ball valves - such as the new D1F-, D2- and X-series valves - as well as L6-butterfly valves and Finetrol-valves. The burnt valves have been selected to achieve as much coverage as possible in terms of size and pressure class with a single test.

State-of-the-art testing facilities

The new tests, to meet the requirements of API 607 6th edition, will be carried out by Metso using its own highly sophisticated fire-safe equipment to test and certify valve products. This equipment, which can be used for valves up to sizes 8" and pressures up to150 bar, is located in the new state-of-the-art laboratory facilities at the Metso Valve Technology Center (located in the Greater Helsinki region), which was opened in September 2011.

The new laboratory is part of a major investment by Metso aimed at raising standards in valve production and service throughout the many industries we serve.

Safety, and fire safety in particular, is a top priority for Metso and all equipment at the new Valve Technology Center incorporates the latest safety features needed to minimize risks related to high temperatures and pressures, and only fully trained laboratory personnel are permitted to carry out such tests.

Metso Batch Cooking Optimizer plays an important role in the control of raw materials and energy flows

Metso will supply an advanced batch cooking optimization solution to the specialty cellulose pulp mill of AV Cell Inc. in Atholville, Canada. The startup is scheduled for the end of the fourth quarter in 2011.

The delivery includes Metso Batch Cooking Optimizer SI with a Modified Cooking Factor control along with Metso's AT analyzer for the automatic measurement of SO2.

Metso Batch Cooking Optimizer is designed to manage the pulp quality and production rates, including digester scheduling. It plays an important role in the control of raw materials and energy flows, as well as such variables as production rate, wood species, Kappa level, and disturbance management.

The model-based quality control automatically adapts itself to changing process conditions and automatically affects the long-term Kappa number deviation. Over the past decades, Metso has delivered dozens of batch cooking optimizers to pulp mills around the world, also for the production of dissolving pulp.

AV Cell will use the solution especially to control the quality of its dissolving grade chemical pulp in its batch digesters. The mill's entire capacity of 119,000 tons is exclusively used by the AV Group's viscose staple fiber units in India, Thailand, Indonesia and China.

Part of the AV Group, AV Cell Inc. is a member of the pulp and fiber business of the Aditya Birla Group. Tembec Inc, a leading integrated forest product company in Canada, owns a nominal 5% holding in AV Cell Inc.

By adopting Metso Kappa Analyzer technology, Billerud Karlsborg will benefit from faster and more accurate measurements to help improve pulp quality and optimize chemical usage

The Karlsborg mill in Sweden is installing a Metso Kappa Q to replace two old kappa analyzers in its bleached softwood kraft fiberline. With five sample points, pulp lignin content and brightness as well as fiber properties and shive content measurements, the Metso analyzer technology will provide opportunities for improved process optimization and quality control.

"The selection of supplier and analyzer was entirely based on the analyzer's performance and opportunities as well as Metso's well known organization for service, spares and support," states Peter Carlsson, Project Manager at the Billerud Karlsborg mill. Start-up is expected to be completed during October 2011.

Unique two-point calibration method

The Metso Kappa Q utilizes patented sweep technology to measure kappa and brightness with a unique two-point calibration method. Fiber and shive analysis at an early stage of pulping helps the user to produce more uniform pulp and provide more precise information for pulp grading and grade differentiation for various end use purposes.

Pulp production at Karlsborg dates back to the start of the 20th century. Today Billerud Karlsborg is one of the largest businesses in the region (Norrbotten), producing 130,000 tonnes of sack and kraft paper as well as 170,000 tonnes of market pulp. The mill comprises a pulp line, a paper machine, a coating machine and a drying machine for market pulp. Karlsborg is one of the Europe´s leading suppliers of white sack paper. White kraft paper and bleached long fibre sulphate pulp for sale on the open market are also produced at Karlsborg.

Metso has signed a roll service agreement with Holmen Paper for their Hallsta Paper Mill in Sweden. The value of the agreement will not be disclosed.

With this three-year agreement, which became effective as of September 1, 2011, Metso will be responsible for all mechanical roll services at the Hallsta Paper Mill. Roll grinding and part of mechanical roll maintenance will be carried out at Metso’s workshops in Borlänge and Karlstad, Sweden. A Metso maintenance engineer will be based at the Hallsta mill to serve as a link between Metso and the mill. Metso’s workforce will also include two maintenance technicians.

Daniel Peltonen, Technical Manager at the Hallsta Paper Mill, says: “We have high expectations for this agreement, and not just regarding the quality of roll grinding and maintenance efficiency. We also expect it to have positive effects on productivity.”

Holmen Paper was established 400 years ago and is one of Europe’s leading manufacturers of printing paper. The three paper machines at the Hallsta Paper Mill produce MF magazine paper and a range of special qualities of wood-containing printing paper. The annual production capacity is 670,000 tons.

UV measurement is now a standard part of Metso's inline brightness sensors to optimize chemical costs at DIP/RCF plants. The previous two inline brightness sensor models, Cormec5 and Cormec5 X, with different measurement capabilities will merge and become one. The new inline sensor with an enhanced measurement capability will carry the name Metso Cormec5 X. In addition to brightness and UV+ brightness, it also measures other important optical pulp properties, such as residual ink and color.

Metso Cormec5 X with its UV measurement has been well received by European DIP/RCF plants. Fluorescence and UV+ brightness values are typically used for measuring the quantity of the optical brightening agent (OBA) in the incoming raw material and for OBA dosage control in stock preparation. As OBAs are fairly expensive and can be harmful to health, mills have been able to optimize their chemical costs with continuous inline measurement information while achieving set quality targets. In addition, the mills have been able to ensure that specific grades, such as tissue and hygienic papers, do not hold any chemical residues.

The UV-based measurement can be used together with the industry standard brightness, effective residual ink content (ERIC) and CIELAB color measurements to achieve full benefit from a single-point inline measurement. Based on experiences at paper mills, Metso Cormec5 X has also proven its capabilities in paper machine approach systems when controlling OBA and color dosage during web breaks and process startups when measurement results from a scanner are not available. During a normal run, it provides fast feedback for paper machine quality controls together with traditional scanner measurements.