2015-05-12 Abu Dhiab Concepts for WLC and Budget

1Stock Preparation References for White Lined Chipboard | Ravensburg | 2012-04-10

Stock Preparation Conceptsfor White Lined Chipboard

2

Content

1. Stock Preparation Conzept for WLC2. WLC Technology

3. OPC Board Machine Layout4. Forming Section

5. Press Section

6. Dryer section

7. Surface Sizing

8. Pre- Calandering

9. Coating Section

10. Coating Drying

11. Reel

12. Winder

13.BUDGET INDICATION

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1. White Line Chipboard (WLC)Raw material categories

70% LBKP/ 30% NBKP

100% ONP/OMG

100% MWP/OCC

100% MWP/OCC

70% LBKP/ 30% NBKP

100% ONP/OMG

100% MWP/OCC

70% LBKP/ 30% NBKP

70% LBKP/ 30% NBKP

100% ONP/OMG

100% MWP/OCC

100% MWP/OCC

70% LBKP/ 30% NBKP

100% ONP/OMG

100% MWP/OCC

100% ONP/OMG 70% LBKP/ 30% NBKP

WLC

4-layer

WLC

5-layer

Top layer

Underlayer Top

Middle layer

Back layer

Top layer

Underlayer Top

Middle layer

Back layer

Underlayer Back

White back Grey back Diagram

1

2

2

2

1

1

1 1

1

2

3

2

2

3 3

3 3

3

100% ONP/OMG

4

HC

Cle

anin

g

Raw

Mat

eria

l Han

dlin

g

Stock Preparation Line for BKPfor Toplayer and white Back Layer WLC

Ref

inin

g

Make-up Water from PM

LC P

ulpi

ng

Diagram 1

5

Stock Preparation Loop

Clear filtrate PM Disc Filter

White water

HC

Cle

anin

gLC

Pul

ping

IC C

lean

ing

Thi

cken

ing

SF

Coa

rse

Scr

eeni

ng

Fra

ctio

natio

n I Dew

ater

ing

LF

Dis

pers

ion

LF

Thi

cken

ing

LF

To PMF

ract

iona

tion

II

LC S

lot S

cree

ning

Reject Approach flow

30% LF

70% SFRaw

Mat

eria

l H

andl

ing

RejectHandling

SludgeHandling

Reject from Line for Underlayer

Diagram 2

Stock Preparation Line for MWP/OCCfor Middle Layer WLC

6


Clear filtrate PM Disc Filter

White water

HC

Cle

anin

g

Dru

mP

ulpe

r*

IC C

lean

ing

Thi

cken

ing

SF

Coa

rse

Scr

eeni

ng

Fra

ctio

natio

n I Dew

ater

ing

LF

Dis

pers

ion

LF

Thi

cken

ing

LF

To PMF

ract

iona

tion

II

LC S

lot S

cree

ning

Reject Approach flow

30% LF

70% SF

Raw

Mat

eria

l H

andl

ing

RejectHandling

SludgeHandling

Reject from Line for Underlayer

Diagram 2

Ref

inin

g LF

Stock Preparation Line for MWP/OCCfor Middle Layer WLC – Optional Module

* Single Release required

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Process Water

Treatment

LC S

lot S

cree

ning

IC C

lean

ing

MC

Hol

e S

cree

ning

HC

Cle

anin

g

Flo

tatio

n

HC

Pul

ping

Thi

cken

ing

Dew

ater

ing

Dis

pers

ion

SludgeHandling

Clear Filtrate from PM Disc Filter

Raw

Mat

eria

l Han

dlin

g

Process Water

Treatment

WW II from PM R

educ

tive

Ble

achi

ng

Diagram 3

to Reject Handling in Middel layer


Stock preparation line for ONP/OMG for Underlayer WLC

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2. Cartonboard Technology for WLC Grades

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Cartonboard Technology

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Overview board grades

SBS

Top ply:BKP (HW+SW)

middle: BKP, [(B)CTMP], Broke

Back ply: BKP (HW+SW)

Back coat: Blade Coater

Pre coat: Blade CoaterTop coat: Blade Coater

FBB

Top ply: BKP (HW+SW)

middle: BKP, BCTMP, Broke

Back ply: BKP

Pre coat: Blade Coater

Pre coat(Middle coat: Blade Coater)

LPB

Top ply:BKP (HW+SW)

middle: UBKP, CTMP, Broke

Back ply: (U)BKP

Sizing: Filmpress

Pre coat: FilmpressMiddle coat: Blade Coater

Top coat: Blade Coater

WLC

Top ply: BKP (HW+SW)

middle: MW, OCC (GW), Broke

Back ply: ONP, DIP

Pre coat(Middle coat: Blade Coater)Top coat: Blade Coater

(Top coat: Blade Coater)

Top coat: Blade Coater

Sizing: Filmpress

Sizing: Filmpress Sizing: Filmpress

Sizing: Filmpress Sizing: Filmpress

Pre coat: Blade CoaterSizing: Filmpress

Undertop ply: DIP

Polyethylene

PolyethyleneAluminumPolyethyleneaseptic application

SUS

middle: UBKP, CTMP, Broke

Back ply: UBKP (SW)

Pre coat: Blade CoaterTop coat: Blade Coater

Sizing: Filmpress

Back coat: Blade CoaterSizing: Filmpress

Top ply:BKP (HW+SW)

Can be single ply! Virgin fiber based Recylced fiberbased

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Overview Cartonboard marketWorldwide

Total production capacity to / year 56.639.061

Number of board machines 659

Mean BM capacity to / year 85.947

Mean technical age of BM years 30

Mean BM speed m/min 287

Mean width at reel mm 3.021

Source: Fisher database; FisherSolve™ Status 2012 Q1

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White Lined Chipboard (WLC)

Grammage / range Characteristics End-use examples

200 – 550 gsm - stiffness (bulk) - cereals and snacks - hygiene - bakery- creasing and - foodstuffsfolding properties - household & industrial

- good printability products- good runnability - froze foods (ice cream)

- garden goods- toys - heavy duty outers- direct food contact - non-direct food contact

WLC is common in regions where virgin fiber is scarce (e.g. Central & Eastern Europe) and where the packaging price has to be kept at minimum.

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3. OPC Board Machine Layout

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Machine concept

OPC 150 means 150.000 to/a (web width reel= 3,75m, voper. max.= 600m/min)

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OPC concept

Headbox : Top, Undertop and Back Ply: MasterJet ProMiddle ply: MasterJet Pro with ModuleJet II (100mm)

Forming Top, Undertop and Back Ply with same number of dewatering elements

Section: Middle Ply: with DuoFormer D II for dewatering and formation

Press Section: OPC 150: 1st Press: Roll Press, double felted with 4 uhle boxes2nd Press: NipcoFlex Press, double felted with 4 uhle boxes 3rd Press: Smoothing Press, fix roll at print side

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OPC concept

Dryer Section OPC 1501st dryer group slalom2nd dryer group slalomrest double tier

Surface sizing both concepts with SpeedFlow (no coating considered)

Pre- calender both concepts with 1x2 rolls EcoCal Calender (200°C surface temperature ) Option 1: with moisturizer (Module Pro RS), Option 2: with Flexitherm Coil (EcoCal Plus)

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OPC concept

Blade coating OPC 1502x print side coating(mainly for India, China 3x print side coating)1x reverse side coating

Post- Calenderboth concept with 1x2 rolls EcoSoft calender (200°C surface temperature). Thermo rolls are changeable with pre- calender

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OPC concept

Reel OPC 150Master Reel up to 3,2m reel diameter

Winder OPC 1501 Slitter winder type VariFlex , reel transport manually per hall crane

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Summary OPC concept

• The concept considers the main two board grades (WLC & FBB).

Adaption for LPB or Artboard can be done very simple and fast.

• The OPC standard covers almost 70% of the total inquiries of new BM

projects

� faster layout and offer

• Standardized machine layout + machine calculation worldwide

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4.Forming Section

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Headbox� Fiber orientation important for curl and twist properties

� Profile adjustment

– manually on outer plies

– dilution control in middle ply (2 sigma bone dry bw ≤ 0,6 %)

– slice control for lower requirements (2 sigma bone dry bw ≤ 1,2 %)

� High throughput range (max. flexibility)

Forming section� Create ply layout for strength and surface properties

� Create MD/CD properties

� Utilize furnish economically

Forming Section Requirements

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basi

s w

eigh

t [g/

m²]

speed [m/min]50035 1200

200

100

300

400

500

600

700

800

1000

Forming ConceptsDesign Limits for Board Machines

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State of the art forming section

middle PlyDuoFormer D IIHB with 25mm

Reverse Ply

HB with 25mm

HB with 25mm spacing

Print Ply

All headboxes are equipped with• Edge Module (Option) • Lamella Technology

New ModuleJet Technology

Wide operating window

Stable & reliable sheet forming up to 1.000mpm possible due to the relevant hard- & software components

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Why is lamella technology required?

� High basis weight in middle ply with low consistency leads to a large headbox lip opening

� Large lip opening results in high macro turbulences (poor formation & roughness)

� Only lamella technology can reduce macro turbulences and have a positive effect on formation and sheet roughness

� Improves jet quality

� Eliminates tiger stripes

� Improves (lower) MD/CD ratio

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DuoFormer D II

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DuoFormer DReferences of a proven Hybrid Forming concept

~ 230 installations

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DuoFormer D II

29

DuoShake

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Where to install DuoShake in multi-ply BM?

Example 210 g/m² base board

Improvement potential

Ply

basis weight

Headbox

consistencyFormation MD / CD

50 g/m² 0.35 % + +

125 g/m² 0.70% ++ ++

35 g/m² 0.30% o +

Top ply

middle ply

Back ply

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Advantages with DuoShake

• Improves formation

• Reduction of MD/CD ratio (curl, twist, converting)

– bending stiffness

– tensile strength

• Also very useful to decouple the interaction of formation andMD/CD ratio of the drag/rush curve

• More even CD profile

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5. Press Section

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Press Concepts Overview

Machine speed [m/min]

Pro

duct

ion

1000 > 1000

Print side bottom

Print side top

600

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State of the art press for board application1st Press Nip

NFP, 2xfeltedLLmax= 800kN/m

2nd Press NipNFP, 2xfelted

LLmax.= 800kN/m

3rd Press NipSmoothing

LLmax= 80kN/m

Pick-up Suction Rolls

1 & 2

Transfer Suction Box

OnQ ModuleSteamMoisture Profiling (100mm spacing)

3rd Press NipPrint side with ceramic cover and swimming roll on bottom

side

Vacuum conveyor belt

� closed web run + full web width transfer through the press!

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Alternative Press Section for high smoothness requirements 1st Press Nip

NFP, 2xfeltedLLmax= 800kN/m

2nd Press NipNFP, 2xfelted

LLmax.= 800kN/m

3rd Press NipSmoothing

LLmax= 80kN/m

Pick-up Suction Rolls

1, 2 & 3

Transfer Suction Box

OnQ ModuleSteamMoisture Profiling (100mm spacing)

3rd Press NipPrint side with ceramic cover and swimming roll on bottom

side

Vacuum conveyor belt

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Technology Feature / Benefit Analysis

Feature BenefitPRESSING

1st shoe press prepared for use with a shorter shoe (150mm)

Better control of ply bondHigher densification of outer layers possible

Fine adjustment in critical transferareas Ideal for high basis weight range, less rewetting

Uninterrupted shoe surface design Stability and longer sleeve lifetime

Transfer suction box with 3 slots Accurate control of web run

Loadable doctoring of sleeve Longer sleeve lifetime

Profiling steam box between 1st and 2nd press nips

Early profiling and dryness development = better runnability after press

Vacuum conveyor tail threading to therope carrier system

More efficient than blow-pipes (especially for high basis weights, >250gsm)

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6. Dryer Section

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General arrangement

1st Group3 Cyl.

8th Group14 Cyl.

3rd Group 14 Cyl.

4th Group 14 Cyl.

6th Group 14 Cyl.

7th Group14 Cyl.

2nd Group 4 Cyl.

5th Group 14 Cyl.

covered drying cylinder to prevent fiber picking

Fabric Cleaners (DuoCleaner Express)

Single tier design for runability reason

Mech. Sheet Breakes after each second Dryer Group

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Technology Feature/Benefit Analysis

Feature BenefitDRYING

62°C Hood dew point High energy saving

Accessible design of pocket Faster cleaning after sheet break

Pocket ventilation by blow doctorsUp to 4% higher performance

Proven fabric cleaning concept Longer fabric lifetime

First 3 cylinders contacting top and back side are non-stick coated Less cylinder contamination at start of drying

Web knock-off device after each 2nd dryer group

Less sheet in drying section = Faster cleaning = faster start-up after sheet break

Teflon shoe for condensate removal in drying cylinder

Thinner condensate layer = better heat transfer

Smooth heating curve Reduced risk of delamination

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7. Surface Sizing

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Concept

SpeedFlowAfter Dryer Section

Covered drying cylinder after starch application

Optional Fabric Cleaners (DuoCleaner

Express)

DiskCutter

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Speedy- Family

SpeedSizer SpeedFlow SpeedSizer AT

Application system Application system Application system

43


Feature BenefitSIZING

Without metering beam heating Energy saving, faster profile response

Simple metering rod clamping unit

Full access for cleaning without risk of tube damage

Air-turn with low air consumption Energy saving

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Pre- Calendering

45Cartonboard Technology | Markus Freutsmiedl, c4pt | 2014-02-03 | confidential

Guangxi BM1

46

Pre- Calendering ConceptPrint Side Top

Moisturizer ModuleProTM RS

Nipcorect™ Rollfor caliper profiling

FlexiTherm™ Roll

Induction heating system

References: Bohui BM3, Liansheng BM8 & Rizhao BM12

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Pre- Calendering ConceptPrint Side Bottom

Dry End Rewetting with Moisturizer

EcoCal Plus hard nip calender withinductive heating system

Flexitherm Roll (oil-heated roll)

ModulePro RS, optional RD (Moisturizer)

FlexiTherm Coil(inductive external heating)

Nipcorect Roll (Caliper profiling)

Reference: Guangxi BM1

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EcoCal Calender

� Uniform nip pressure over the full sheet width

� Caliper calibration of base board for preparation of coating

� Uniform CD-temperature by continuous oil circulation

� Back side smoothening

� Simple design

� Use of various shell material possible

� Simple grinding

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Feature Benefit

CALENDERING

Moisturizer ahead of HNC Less bulk loss (up to 2%)

Higher smoothness due to ironing effectNipCorect caliper profiling Less energy, fast caliper response, no glossy or

smooth stripes

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8. Coating Section


Guangxi BM1

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Coating Concept

Precoat Premium side

Middle coat Premium side

Back side CoatingReverse side

Final coat premium side

Curl Correcting Group

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Coater

Coater with roll applicator Coater with JetFlow F

Application system with roll Application system with JetFlow F

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DynaCoat with roll applicatorEdge deckle design

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DynaCoatJetFlow F Applicator

15° C 5° C

Flow strip cover cooling ducts 15°C- Is required for offset coating colorat high temperatures or on-line coating

Flow/gap strip cooling ducts 5°C- Gap strip is required for offset coating color at high temperaturesor on-line coating

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9. Coat Drying

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Voith is the only full-scope supplier ofnon contact drying and web guiding systems

• Voith can provide all state of the art systems for non-contact drying applications from its own product and manufacturing program

• No compromises are made when drying concepts are planned, designed and offered to our customers

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HCB Turn

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• short web run• simplified tail threading• low risk of picking

at guiderolls

• long web run• motor driven guide rolls• risk of picking at

guide rolls

Conventional Concept Module Concept

Modern Coat Drying Equipment

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qDry Pro

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Technology Feature / Benefit Analysis

Feature BenefitCOATING

New qDryPro drying systems High energy efficiency

All coat layers with IR Less risk of mottling, especially final coat

All rolls chrome coated Easier cleaning = less contamination = less quality loss

Well proven web run Runnability & product quality

Flexible curl control Due to the additional dryer group 12 after Coater 4

Self-learning coating kitchen More accurate dosing of additives

Filtering without slotted screens Longer run-times of the filter elements

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10. Finishing

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Post Calendering to Reel

1x2 Soft Nip Calender

Cooling Air Cap

Sirius


Guangxi BM1

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11. Reel R

eel D

iam

eter

(m

)

Machine Speed (m/min) / Quality Requirement

Sirius reel Ø up to 4,6

MasterReel reel Ø up to 3,2

66

Roll handling

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12. VariFlex for Coated Board

� Less bulk loss

� Gloss difference low or zero

� No steel drums in contact with board

� Drums and rider roll covered with special flexible rubber, low abrasion

� Easy operation and maintenance

� High degree of automation

� Centric core position, good roll runability in further process

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Fibre saving by Bulk savings with soft cover of winder drums

WINDER - Soft Cover Technology brings 1% Bulk

Bulk loss without Soft Cover 1%

Percent BCTMP necessary to compensate 1 % bulk loss 2%

Board Board

Steel drums Elastomer covered

drum with ElaCare

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Feature BenefitREELINGCentre drive reeling concept Larger parent reel diameter while maintaining

qualityReel diameter up to 4.6 meter Less parent reels per year = less loss = more

saleable production!

WINDINGSoft covered drums Less bulk loss

Gravity reel transport to winder Reel transport without overhead crane

Rotation maintains reel qualityOTHERVacuum conveyor tail threading High reliability with higher basis weight

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139.500.000

7.500.000

15.000.000

3.000.000

15.000.000

90.000.000

9.000.000

Approach Flow / Broke / Paper Machine / Winder / Finishing / Au xiliaries

EURItemized Plant Equipment

13. Budget Price Indication

Equipment Stock Preparation (from pulping to mixing chest)

Electrification & Automation

Tanks, Pipes, Valves, Steel Construction, Cranes, Hoists, etc.

Services (engineering, installation supervision, training, start-up)

Pipes on Pipe Bridges

Total Investment Budget (+10% / -15%)

The Budget indication is for a machine with a design speed of 7 00m/min,3.750mm web width on Reel. The average Basis weight calculat ed for theproduction is 250g/m², resulting in a annual net. productio n of approx.200.000t/a.

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Itemized Plant Equipment

Not included in the Budget

Fresh Water Treatment

Power Plant / Steam Generation

Effluent Treatment Plant

Civil Works

The Budget indication is for a machine with a design speed of 7 00m/min,3.750mm web width on Reel. The average Basis weight calculat ed for theproduction is 250g/m², resulting in a annual net. productio n of approx.200.000t/a.

2015-05-12 Abu Dhiab Concepts for WLC and Budget

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