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TAPPI a showcase of new ideas


May 1, 1999
By Pulp & Paper Canada

INTENTIA: Movex Paper is said to be the first Enterprise Resource Planning (ERP) supply chain management system designed specifically for the paper industry. It integrates business functions with cust…

INTENTIA: Movex Paper is said to be the first Enterprise Resource Planning (ERP) supply chain management system designed specifically for the paper industry. It integrates business functions with customer order fulfillment, production planning and manufacturing information. According to Ted McDermott, director, paper and converting industries, Movex can replace a “whole host of legacy systems that have been strung together with spaghetti code.” Movex has three prime functions. The first takes care of the functional needs of a business. The second provides integration of business, customer order and manufacturing information into one system. The third is to provide an integrated view of the manufacturing floor for better tracking of customer orders improved efficiencies. Movex gives companies access to “better” information allowing them to manage and control their supply chains as well as make better capital investment decisions. In a price-driven, tight margin industry, this is important. Intentia also introduced Enterprise Process Manager, a tool for defining a company’s business processes and configuring the Movex software to these models, accelerating the implementation of Movex ERP software.

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J&L FIBER SERVICES: The OptiGuard CSC (continuous slotted cylinders) is a new line designed to provide a large open area, precise slot width openings and structural integrity. The Optiguard uses an interlocking U-joint design to hold individually contoured heavy-duty rolled bars in place. This allows for slots as thin as 0.1 mm. Also, the steel bars run the length of the cylinder without the need for flow interrupting reinforcing areas. This means the amount of open area is greater than that available with conventional milled slots. Slot widths, pitch and contours can be customized to the client’s specifications. J&L’s Stabilizer refiner plate also made its debut. It features improved load stability, increased energy efficiency, superior tear strength results, shive reduction and reduced process/pulp variability. The plate has a constant-angle, uni-directional design.

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ABB: ABB Automation claims to have the industry’s first online fibre orientation sensor that measures both sides of the sheet — AccuRay Smart Fiber Orientation Sensor. To printers, press runnability is their most important parameter and there is a strong correlation between runnability and proper fibre orientation.The new sensor provides a quick payback, six months or less, and helps save time during grade changes, reducing off grade paper and/or broke. The sensor measures fibre ration and angle using ABB’s patented laser arc polarization measurement principle. ABB Automation’s Nexus quality control system also made its debut. Its three keys are; open access to all information; more integration choices with existing mill systems; expandability to integrate changing technology. The Nexus allows papermakers to achieve connectivity with all control and information systems, regardless of supplier. ABB’s C-E Services has two new products for recovery boilers. The first, DryAsh Fireside Conditioning Treatment, is a dry chemical additive that improves recovery boiler operations by turning sticky ash deposits and slag into a soft porous material that can be removed by sootblowers. The second new product is SmeltGuard, pre-cured floor tiles that are said to improve recovery boiler performance by protecting floor tubes from direct contact with molten smelt.

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JOHNSON CORP.: TechDry is an interactive system of services that offers papermakers a total resource to optimize drying processes. TechDry is designed to allow papermakers increase machine efficiency, eliminate dryer flooding and improve energy efficiency. The system has four components: joints and syphons, steam system, monitoring system (monitors press and dryer conditions for optimal performance) and, advanced controls including an advanced dryer drainage system. Johnson claims that TechDry can help increase paper machine efficiency by 5%, steam use efficiency by up to 30% while reducing maintenance costs. The system can be integrated into a mill’s existing DCS or data interface. Although TechDry seems more suited to newsprint or board grades, Johnson officials said it may be applied to any machine producing any grade. Johnson Corp. has also released an educational CD — Understanding the paper machine dryer section.

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BELOIT: Beloit introduced its latest refiner design, the DD5000. Its benefits include low installation cost, increased flow capacity, improved refiner control, longer plate life, easier maintenance and quicker plate changes. Installation costs are lower because the unit is smaller and features a non-lubricated coupling. The refiner uses a tangential discharge. Beloit used computational fluid dynamics to optimize the flow in the unit, achieving up to 50% more flow. Beloit claims that the use of a variable frequency drive allows the refiner to make smaller changes to the refining energy than any other refiner. A rotor removal device allows a 20% faster change.

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TAPPI: TAPPI has announced an alliance with the Brazilian association, ABTCP. As a result, a jointly-sponsored conference will be held in Sao Paulo, Brazil, October 23-26, 2000. It will focus on the emerging Latin American market. Wayne Gross, executive director of TAPPI, noted that future success depends on cooperative efforts with other national organizations.

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RAISIO: Raibond is said to help reduce paper breaks, improve runnability, improve drainage, keep wire and press felts cleaners and reduce BOD and COD loading. In one newsprint mill, the objective was to reduce dusting without affecting paper machine runnability. By adding Raibond, one newsprint mill was able to reduce kraft content by 2%, increase filler content by 1.5 to 2%. Retention was maintained but required 20% less flocculant and 70% less coagulant.

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ROCKWELL AUTOMATION: The booth featured a full range of products that come under the Rockwell Automation umbrella — Allen-Bradley, Reliance Electric, Rockwell Software and Dodge. Rockwell Automation Drive Systems introduced ControlLogix Systems. The system allows data communication within existing Allen Bradley PLC-5 or Reliance Electric AutoMax controllers. It allows mills to implement advanced communication and motor control technologies into existing drive systems.

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NELES CONTROLS: Neles Controls has a new range of smart valve products and software. The company’s foundation technology is the ND800 digital positioner for control valves. An advanced algorithm in the positioner improves the valves’ speed of response and positioning accuracy to reduce process variability. Neles products include: Valve Manager software, which configures and monitors up to hundreds of control valves from a single remote location; Nelflow, which integrates a control valve and flow meter into a single smart flow control package; Field Browser, a system that makes it possible to monitor smart field devices for operation status and performance changes from any computer location with an intranet or Internet connection.

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PAVILION TECHNOLOGIES: At TAPPI, Pavilion introduced Property Predictor, a component of the company’s Production Chain Optimization technology suite. Predictor is said to facilitate rapid development and deployment of soft sensor models using Pavilion’s Virtual OnLine Analyzer (VOA) technology. Pavilion’s Brenda Westbrook said the technology can look at historical data and determine what’s important. A mill can then build a model for a process and the model will predict process tendencies. Pavilion software can control the process to the point of controlling tendencies. This can lead to shorter grade changeover times, minimized energy use and the possibility of reducing emissions. With
in the Optimization suite, components include Insights, which learns about the process, Property Predictor, which predicts the process, Process Perfector, which controls the process, and Process Optimizer. The technology is applicable to all mill loops but the current focus is on the paper machine and paper properties as well as chlorine dioxide generation. It has also worked with continuous digesters and TMP refiners. Pavilion also announced a sales and marketing alliance with Sterling Pulp Chemicals. The goal is to give clients using ERCO R8 and R10 chlorine dioxide process technology access to Pavilion’s integrated advanced control software application for generator control and optimization.

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JAGENBERG: Jagenberg has developed the Modular Combi-Blade MCB, which offers four different applicator systems for various uses and/or needs. The four systems are: F-NIP 2 applicator roll and convex web run; Jetcoat 3 free flow applicator with convex web run; F-NIP 3 vector pneumatically supported applicator roll with infeed nozzle and linear web run; Jetcoat 3 Vector free flow applicator with linear web run. The company also introduced Jagflex, s special cellular elastomer covering for winder drums. Jagflex is a compressible covering that avoids nip-related stretch in the paper. Winder drums coated with Jagflex lead to greater contact area in the nip of the drum and paper roll. Jagenberg’s redesign of its successful Vari-Top centre drum winder, the Vari-Top II, is ready and designed for very large and heavy rolls of high-grade paper. Design speed is as high as 3200 m/min. Finished roll change takes 35 seconds. Fully encapsulated, the winder is also quiet. It features fully automated machine-wide web threading with integrated wind start-up and a fully automated tambour butt splicer at the unwind station. Finally, the Vari-Flex S two-drum winder made its debut. It has been engineered for small and medium working widths (1.8 to 4 m). Maximum operating speed is 2000 m/min. It is suitable for all papers, from airmail paper to heavy coated board.

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CONSTANT LABORATORIES: The Per Plus (brightness enhancer) and HP Booster (hydrogen peroxide stabilizer) products were introduced. Benefits claimed include higher brightness gains, stronger fibres, less brightness reversion and lower bleaching costs. The products are suitable for mechanical or chemical pulping processes. Suitable for ECF/TCF bleaching processes, the agents are non-oxidizing and non-reducing, are biodegradable, do not contain alkyl phenyl ethoxylates or their derivatives and do not contain heavy metals.

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PCI MEMBRANE SYSTEMS: Membrane filtration technology can help mills close their process loops. The Stora Nymolla pulp mill in Sweden has the world’s largest tubular ultrafiltration membrane effluent treatment plant. PCI designed and manufactured the facility. The company had two new tubular membrane modules on display. The PCI A5 module consists of 69 ultrafiltration membrane tubes, each 0.25 in. in diameter fitted into a stainless steel housing. They are half the diameter of other PCI membranes, yet stronger and can be used without external support. Each 12-ft-long module provides 50 ft2 of membrane area. The compact design means fewer pumps and fittings and less floor space will be required. The PCI C10 module is constructed of lightweight ABS plastic, an economical alternative to stainless steel housings. The large diameter C10 houses more than 100 ft2 of membrane area.

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CORZAN INDUSTRIAL SYSTEMS: A part of B.F. Goodrich, Corzan post-chlorinated polyvinyl chloride industrial pipe and fittings are claimed to offer lower costs, excellent resistance to a broad range of corrosive environments, easy installation, long service life and reduced maintenance compared to metal piping systems. Corzan is resistant to chemicals such as sodium hypochlorite, chlorine dioxide, weak and strong acids and bases. Extruded pipe is available through 12 in. while extruded duct is available through 24 in.

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3M: 3M introduced a thin single coated repulpable tape that is printable. The new splicing tape, 9969, is said to be ideal for butt splicing, hole patching and taping of leading and trailing edges. It can be used with most paper grades through off-machine coaters. Its thin profile travels easily through coaters, nip rollers and supercalenders. The tensile strength of the paper backing, coupled with the shear strength of the adhesive, hold up under pressure at temperatures up to 204C.

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OPTAMAZE: PaperSuite 1.0, claimed to be a tool designed to allow mills to lower costs and reduce wastes while improving manufacturing efficiency and customer satisfaction, was introduced by optAmaze. Company president John Rachlin said the Web-based mill scheduling services are available for a fixed monthly subscription fee and require only a standard Internet connection and a Web browser. The service provides mill schedulers with multiple solution alternatives to reveal trade-offs among competing objectives. These objectives could include minimizing order deviations, machine set-ups and trim losses. PaperSuite 1.0 has two major components: Trim optimization and Transportation load planning.

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THOMPSON EQUIPMENT (TECO): Thompson Equipment Company’s patented GMS (guided microwave spectrometer) system offers online real-time measurement of a variety of process variables. Consisting of an inline waveguide sensor body and electronic controls, the GMS system measures the electrical properties of the process molecules as they pass through the waveguide, providing continuous process measurement information. Potential uses include additive and ash components, kappa number, lignin, water retention value and machine retention.

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AMERICAN PROCESS: Following its success with Pinch technology to help mills cut energy use (PULP & PAPER CANADA, July 1998, p. 17), American Process is introducing its next generation of thermal Pinch technology. Using the same underlying discipline and rigor, the new methodology speeds results and places the emphasis on analyzing the findings in “decision-ready” economic terms. This is achieved by: practical flow diagrams; capital cost/savings analysis; investment grid analyzer.

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HONEYWELL-MEASUREX: The company had lots to say at TAPPI with a host of new products making their debut. First and foremost was the Da Vinci Quality Measurement and Control System. It features a comprehensive selection of scanning and non-scanning measurements. The Precision Measurement Platform is part of the Da Vinci family and includes Precision Non-contacting Laser Caliper Measurements, said to be the first scanning, non-contacting laser-based caliper measurement that provides 0.04 mil absolute accuracy and 0.04 mil zone-to-zone repeatability. Measurement is based on a proximity sensor and two laser triangulation sensors, with proprietary, real-time laser spot alignment to within 4 mil. Also part of the Platform are Precision Basis Weight Measurement and SpectraFoil Non-scanning Wet End Measurement (60 dry weight profile measurements per second), allowing closed loop weight profile control through start-ups, breaks and grade changes. Honeywell-Measurex also introduced Performance Color Control, another member of the Da Vinci system. It allows decoupled control of up to four-color variables. With up to seven supervisory dyes, it provides complete control of paper and paperboard color. The Precision Liquor Sensor for direct, inline measurement of causticizing plant liquor characteristics also made its debut. It has self-cleaning probes for continuous, accurate and reliable measurement of green and white liquor parameters. The sensor is a self-contained, stand-alone microprocessor-based instrument.

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GE: Irving Paper, Saint John, NB, is using GE Industrial Sy
stems’ Innovation Series ac coordinated drive system. This has helped the mill set new productivity records on its PM 2. Since start-up of phase one of a two-part project to convert from a dc to an ac system to allow the production of specialty papers, paper machine production has increased by an average of 6%. Additional Innovation drives were installed in the first quarter of 1999. The drives feature a streamlined design for high reliability and reduced operating costs, a unique heat pipe cooling system, increased power density, high converter operating efficiencies and low noise levels.

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NASH: Nash made a splash with its Splash cooling towers for paper machine vacuum systems. The towers are corrosion resistant, modular in design and require little maintenance The Splash towers are said to solve problems such as dirty water (suspended solids), highly corrosive (acidic) water or a combination of both. The splash series cooling towers are counterflow forced draft coolers of monoblock design. Nash CVN displayed a new shower driver — Rolltech — designed to be cost-effective, reliable and easy to service. It is based upon similar technology used in trash compactors and military applications. The new design has twice the strength and force of previous models and should provide exceptional operating life. Nash also had its Premier 2000 line of vacuum pumps, claimed to be the largest in the world. They are a low-profile design with angled inlets to alleviate space problems. In one mill example, two Premier 2000 pumps replaced four older Nash pumps. Benefits included a 21% reduction in power consumption and a 66% reduction in seal water.

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COGNEX: The SmartView Modular Camera Network (MCN) made its first appearance at TAPPI. It is an automated surface inspection system for detecting, measuring and classifying web defects (holes, scratches, calender cuts, contamination). The system consists of one or more intelligent CCD cameras with camera-based algorithms, a drag and drop Windows NT-based interface, a PC, mounting frame and lighting components. Each camera contains its own CPU and image processing electronics.

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RONNINGEN-PETTER: The company’s business is filters and the pulp and paper industry is its largest market. Since the 1980s, mills have become more serious about closing water loops and many are changing from fresh to recycled water use. This makes filtering a critical issue. In the wet end, as mills move to alkaline papermaking, there are new filters for PCC and bentonite. Also, newsprint mills are now adding pigments. Surface treatment used to be restricted to mills making freesheet or coated groundwood. Now, it’s for everybody. New products from Ronningen-Petter include the AFR High-Flow water filter system. Its benefits include a lower cost per gallon. It can process flow rates as high as 7550 L/min at 250 psi. Its circular configuration features a large inlet and outlet and increased pipe sizes. Therefore, there is more surface area for the filtering media. It applications include white water, vacuum pump seal water, incoming fresh water and recycled water loops. With multiple tubes on the header, there is only one valve to clean the tubes in a backwash-type operation. An indexing flow diverter rotates from station to station, only taking one station off-line at a time. There is a new filtering medium — Accuflux — designed to go with the AFR. The company also introduced the DCF family of mechanically clean-in-place filters designed to remove solids from wet end additives.

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