John Wilkie Paper Mill Services Ltd. · The mill produces wood-free coated paper for web-offset...

Paper machine year 1971, rebuilt 2012, major upgrades over the years, Manufacturer Escher Wyess/Beloit/Metso. Deckle 4890 mm, speed 1070 m/min, capacity 240,000 tons, grammage range 80 -200, Dilution headbox Symflo D by Metso, Foudrinier wet end with top Belform topformer. Tri-nip press part with steambox and a separate fourth press. Inline

coaters Optisizer and two Opticoat jet coaters. Grades. Full details, drawings and photos are available on request.

telephone 0044 (0)1764 685 267 mobile 0044 (0)796 772 6501 email: [email protected] Office: Maryfield, St Fillans, Perthshire, UK, PH6 2NF

John Wilkie Paper Mill Services Ltd.

Nijmegen Mill 2013-10-0412 Paper Mill Nijmegen

Paper production

General production flow diagram

John Wilkie Paper Mill Services Ltd. telephone 0044 (0)1764 685 267 mobile 0044 (0)796 772 6501 email: [email protected]


Paper production

The mill produces wood-free coated paper for web-offset applications on a single paper machine (PM7). Coating applications are inline. The mill operates in five shift 24/7 continuous mode. PM7 was originally manufactured in 1971 by Escher-Wyss with subsequent rebuilds in 1974, 1981, 1991, 2001, 2007 and 2012. The current production capacity is around 240.000m t.p.a. in the grammage range of 80 – 200 gr/m2 with surface properties matt, silk and gloss. In the automated stock preparation the dry bales of pulp are dewired, processed and re-pulped for transport to the wet end of the paper machine.

Papermachine:

PM07 is equipped with headbox (Symflo D concept), fourdrinier with topformer (Belform concept), trinippress-section with a separated 4th press, pre-dryer section (with 39 drying cylinders of which 33 are steam heated). The inline coating equipment consist of double sided film coater and two blade coaters operated in a stiff blade mode. Coating drying installed after each coating application is gas heated infra-red, high velocity hot air drying and steam drying. Stainless steel winding station venta and chevron grooved.

Finishing:

Re-reeler.

Two supercalanders (Voith Sulzer), width 5,1m, to produce the targeted surface and gloss characteristics for the silk and gloss grades, at speeds of up to 750 m/min, linear load of max. 290 kN/m, temperatures between 60c and 100c in maximum 11 nips (12 rolls).

Two slitter winders (Jagenberg Vari-plus and Jagenberg Vari-flex) where the reel is produced on customer order with desired diameters and variable width of the reel between 200mm and 2500mm.

Reel wrapping machine

Doctor-winder

Storage and dispatch area:

Storage capacity of finished goods approximately 10000 tons.

Truck loading finished good via six loading docks.



Papermachine PM07



Technical Facts

Year of construction 1971

Last Rebuild 2012

Major upgrades 1974,1981,1991,2001, 2007

Manufacturer Escher Wyss / Beloit / Metso

Width 4.89 m

Speed 1070 m/min

Capacity 240,000 tons NPV

Grammage range 80 - 200 g/m2

Headbox Dilution headbox Symflo D, Metso

Forming Part Fourdrinier with Beloit Belform topformer

Press Part Tri-nip, steambox and separate fourth press,

Inline coaters Opti-Sizer, 2* OptiCoat Jet

Paper machine PM07



Technical Facts

Stock preparation


Last Rebuild 2012

Manufacturer Metso

Capacity 90 bales/hr into 2 pulpers (22.5 t virgin fiber/hr)

Installed equipment • Automatic unit de-wiring and de-stacking

• Automatic bale de-wiring (max. 3 wires each side)

• Metal detection

Bale transport and storage

equipment

• Automatic transport to storage conveyors

• 6 storage lines (each 12 bales)

• 1 outsourcing line (metal detection) for manual care and restore

again automatic to the storage line

Automation Full automatic demand of 2 pulpers taking batches (mix of 4 qualities

of bales)

Pulpers Pulper 1 and pulper 2

Pulp storage each pulper 50 m3

Pulp UnitLoading

UnitDewiring

BaleDewiring Metal

Detector

Bale Sorting



Technical Facts

Refining

Refiner line 1 Refiner line 2 Broke line

Max. flow

capacity

4000 l/min 4000 l/min 4000 l/min

Magnet-trap Redundant Redundant -

Pulp storage

capacity

160 m3 125 m3 1,700 m3 (2 x 150 m3, 400

m3, 2 x 500 m3 )

Type of refiners • 2x: Sproud Waldren

(350kW) 26 inch

• 1x: Voith TF3E

(900kW) 40 inch

• 2x: Sproud Waldren

(350kW) 26 inch

• 1x: GL&V (800kW) 40

inch

Type of deflacor • 2x: Deflacor (Escher

Wyss E2K

Automation • Recirculation control

possible

• Control of specific

energy based on flow

rate of fibers

• Recirculation control

possible

• Control of specific

energy based on flow

rate of fibers

• Balanced control of

coated / uncoated flow

of broke (set points)

related to fresh fibers



Technical Facts

Headbox


Manufacturer Metso

Type Symflo D

Slice width 5220 mm

Wire width 5410 mm

Design speed 1300 m/min

Max slice flow 72 m3/min

Min. slice flow 43.8 m3/min

Pressure drop 60 Kpa

Pressure drop with max slice flow 82 Kpa

Pressure drop with min slice flow 32 Kpa

Slice horizontal adjustment 0 – 25 mm

Micro adjusters 44 pcs

Dilution valves 86 pcs

Remarks:

• Headbox was equipped with a retro

vane for laminating slice flow during

last rebuilt in 2012.



Technical facts

• Fourdrinier with Beloit Belform topformer

• Cantilever system

• Open / closed forming board

• Arc foils: 10 pcs

• Suction boxes with low vacuum: 3 pcs

• Free dewatering zone: ±10 m

• Length of wires:

Bottom wire: 33.15 * 5.39 m

Top wire: 16.08 * 5.45 m

Wire section

Schematic wire section



Technical facts

Trinip 1st press 40 kN/m

2nd press 60 kN/m

3th press 80 kN/m

Ceramic Centre roll, double doctored

Press covering Poly Urethane

Fourth Press 4th press maximum linear load 120 kN/m

Bottom roll Poly Urethane

Counter roll Ceramic, double doctored

Steam-box Installed after 1st press facing 2nd press

Steam-box is operating in both Machine Direction and Cross Direction mode

Press section



Technical facts

• Amount of cylinders: 39 divided in 6 groups

• 33 Steam heated cylinders

• First 6 bottom cylinders equipped with hot air dryers

• Steam system manufacturer: Langregler (Voith)

– Cylinders equipped with stationary siphons

– Dryer section 5 steam pressure: 4,6 bar(g)

– Other drying section steam pressure: 3,8 bar(g)

• Group 1 and 2 single felted

• Group 3 to 6 double felted

• Drive configuration: Silent drive

• First 3 dryer groups were rebuilt in 2012

– New sheet stabilizers and PV systems were installed (EVG)

– First 2 dryer section rope less tail threading

– Optimisation of heat recovery

Pre drying section



Technical Facts

Online Film coater


Manufacturer Metso

Type OptiSizer, film coater

Coating system Optidozer

Coat weight range per side 3 – 14 g/m2

Linear load 5 – 20 kN/m

Profile control / actuators 36 pcs (every 75 mm)

Automation QCS Since 2012 rebuilt

Role diameter 915 mm



Technical Facts

Inline Blade coaters


Manufacturer Valmet

Type OptiCoat Jet

Quantity 2 pcs

Sheet width 4960 mm

Blade tip angle 0o – 45o

Blade beam angel 10o – 70o

Jet angle 25o – 40o

Coat weight range per side 11 – 16 g/m2 per side

Profile control / actuators 70 pcs (every 75 mm)

Automation QCS Since 2012 rebuilt

Role diameter 915 mm



Drying & Winding

Impression



Technical Facts

QCS PM07


Manufacturer Metso

Quantity 4 pcs

Measurements Moisture, Weight, Ash, Coatweight



Technical Facts

• Batch oriented preparation of three different coatings simultaneously

• 3 dissolvers (10 m3/each)

• 10 sorts of raw-materials possible in each batch (1 – 3 m3)

• Binder cooking facility integrated inside total installation

• Storage tanks for each coating recipe before coating stations (10 m3/each)

• At each coating station there are 2 storage tanks 2 m3/each for flexible switch over to next coating

• Upgrade complete automation/batch control in 2010 by GAW /Automation-X

Coating kitchen



Technical Facts

Speed 2000 m/min

Sheet width 5100 mm

Rolls Steel winding drum Venta grooved

Reel Rewinder



Technical Facts

Super Calanders

Super Calander SK08 Super Calander SK09

Year of construction 1981 1985

Manufacturer Voith Sulzer Woith Sulzer

Width 5.1 m 5.1 m

Speed 750 m/min 750 m/min

Pressure 290 N/mm 290 N/mm

Temperature 60 – 100 oC 60 – 100 oC

Number of rolls 12 rolls (4 heated steel rolls) 12 rolls (4 heated steel rolls)

Number of nips 11 11

QCS system

Manufacturer Metso Metso

Build in 2012 2012

Measurements Caliper, Gloss Caliper, Gloss



Supercalander



Technical Facts

Slitter Winders

Vari-Plus Vari-Flex Doctor-Winder

Year of construction 1991 1998 1972

Manufacturer Jagenberg Jagenberg Jagenberg

Width 5.1 m 5.0 m 2.1 m

Speed max. 2000 m 1800 m 800 m

Capacity 36 reels /day

Number of reels 11 (8 stations and

possibility to block

winding)

11 1

Number of knives 12 + 2 12 2

Min. diameter of reels 780 mm -- --

Max. diameter of reels 1300 mm 1525 mm

Reel width min. 420 mm (block:

2x210 mm)

200 mm

Max. reel weight 3200 kg --



Slitterwinders

Impression



Technical Facts

Reel Wrapping machine 2


Manufacturer Lamb AG

Reel width 390 – 2500 mm

Speed Average 80 reel / hour

Min. diameter reel 780 mm

Max. diameter reel 1350 mm



Technical facts

Automation

Automation level Machine is divided in functions and based on PLC controls by Siemens. Most

parts are Siemens S7-400 systems programmed by Step 7

Field level Using profibus DP networks for distributed I/O, Motor control, Frequency

converters

MES / ERP level PLC’s are connected by Ethernet

PLC’s exchange signals to each other. Clock synchronization

Scada level WINCC V5; Server / client solution; Redundancy (hot standby)

HMI level Siemens panels (Protool, WinCC Flexible)

Other systems Drive System

Reel Wrapping machine

Web break monitoring

Web Quality monitoring

Web Quality System

Signal / profile trending

Coating Kitchen

control by Siemens PCS7

control by Siemens PCS7

Webvision of Papertech

Parsytec

Metso QCS

Aspen Process Explorer

Automation X (GAW)



Technical Facts

Boilers

Boiler 6 Boiler 5 Boiler 7

Description High pressure - -

Manufacturer Standard Fasel-

Lentjes

Siller en Jamart Standard Fasel-

Lentjes

Installed 1987 1976 1987

Fuel Natural Gas Natural Gas Natural Gas

Rated Pressure [bar(g)] 80 10 10

Steam Temperature [oC] 510 185 185

Capacity [t steam/h] 60 25 25

Operation mode Continuous Cold standby Hot standby



Technical facts

Turbines

Turbine Steam Turbine 3 Gas Turbine Diesel generator Diesel generator

Type G25 Gas * Diesel Emergency

diesel set 1 **

Diesel Emergency

diesel set 2 **

Manufacturer AEG Kanis Siemens SGT 200 Man / Unilec Deutz Gruppo

Installed 1978 2005 1977 1992

Motive Steam: 80bar inlet and

4 bar exhaust

Motive: Natural gas

Exhaust hot gas to No.

6 boiler

Output 10,500 kW 5,700 kW 125 kVA 200 kVA

Generator

Type

Manufacturer AEG SU

100014x4RD

GEC Unipak GD

710D

Voltage 10,500V 10,500V

[*] Siemens SGT 200 Gasturbine is replaced by an identical gasturbine in 2005. Year of Manufacturing of this turbine is 1997.

[**] The emergency diesel sets are used for emergency lighting, critical equipment and can bring the other generators on-line if

required.



Technical facts

• All generation is on 10 kV and this voltage is used as site distribution voltage. The central 10 kV

distribution board, onto which both generators feed, supplies the mill through a double connection to local

10 kV panels from which the power is transformed to lower voltages for machine use.

• The internal plant distribution system provides a double connection from the main double bus-bar 10 kV

board to a single bus-bar arrangement to local 10 kV panels with complex interconnection between

boards to maximize the security of the power supply to the production areas. In a few cases single power

supplies only are provide, for instance to the PM7 coater.

• The power system of the mill can operate independently of the grid system. Two power lines enter the

site at 10 kV and connect to the main 10 kV board. These lines are rated at 400 A each, which limit the

power supply to approximately 12 MW.

Single line electrical diagram



Technical facts

Wastewater treatment

Design capacity Actual laod


Capacity / load 75,000 pollution units (population

equivalents)

30,000 pollution units (based on

COD)

Hydraulic load 600 m3/hr = 14,400 m3/day 200 m3/hr = 4,800 m3/day

Sludge loading 0,14 – 0,28 kg BOD/kg sludge. day 0,09 kg BOD/kg sludge. day

Load CO 4,300 kg/day

Load total Nitrogen 13 kg/day

Load suspended solids 5,900 kg/day

Efficiency 94% (based on COD)

Operating temperature 35 – 40 oC



Technical facts

Buildings - Area and available Cranes

Building

No.

Building name Area app. m2 Occupancy Crane No. Crane

Tonnage

Paper production

859 Pulp pre process PM7 240 Broke processing

827 Pulp pre process PM7 1,440 Cellulose handling 10

35

2 t

2,5 t

861 Chemical pulp storage 240 Process stock cellulose bales

828 PM building PM7 6,204 PM07 11

12

46

2x20 t

2x20 t

1x5 t

Finishing

829, 863 Calendering machine hall 3,200 Storage (jumbo reel),

Supercalenders,

Slitterwinders

25

26

27

29

30

40

52

32 t

32 t

2x4 t

2x20 t

2x4 t

2x20 t

2x22 t t

826 Former coater hall 1,196 Storage of packing material 13

14

15

2x3 t

2x3 t

2x4 t

830 Reel wrapping hall 2100 Reel wrapping machine 57

63

5,5 t

1,6 t



Technical facts


Building

No.


Tonnage

Warehousing

864 Reel storage building 1,400 Storage of finished goods

831 Reel storage building 5,000 Storage of finished goods 58 6 t

813 Chemical pulp building 3,240 Storage of cellulose fiber

874 Chemical pulp storage 1,800 Storage of cellulose fiber

810 Clay building 810 Storage of cellulose and

empty barrels



822 Ex. Paper finishing PM5 2,800 Storage of finished goods,

packing material

08

09

Not certified

Utilities

808, 809 Purification plant 1 and 2 528 Water make-up plant

857 Energy building 1,260 Gasturbine, HP boiler 24 16 t

819 Boiler building 1,560 Boilers, boiler water make-up



Technical facts


Building

No.


Tonnage

Miscellaneous

820 Ex. Pulp pre process PM5 2,800 Contractor area

821 Ex. PM5 building 4,738 Contractor area, offices 03

04

5 t

10 t

824 Offices 1,428 Offices, canteen, comp. room

860 Main offices 1,215 Offices

811 Roll storage and repair 238 Storage of rolls and related

parts, roll repair

20

47

64

2x10 t

5 t

2x12,5 t

815 Maintenance workshop 1,500 Technical warehouse,

offices, workshop

16 1x10 t + 1x6,3 t



Tank No. Volume Content Agitator

757 8 m3 Afranil Yes

251 100 m3 Empty Yes


253 100 m3 Litex No

450 27 m3 EKA Yes

734A 20 m3 Catiofast No

734B 20 m3 Catiofast No


263 400 m3 Hydro.95 Yes

265 1000 m3 Harmilithe Yes

221 900 m3 Hydro.75 Yes

261 200 Empty Yes

264 400 Hydro.95 Yes

739A 20 Basoplast Yes

739B 20 Basoplast Yes

List of major storage tanks

Tank No. Volume Content Agitator

254 100 m3 Styronal No

222 900 Empty Yes

255 60 Empty Yes

256 60 Empty Yes

452 27 Sterecol No

451 20 Tinopal No

249 30 Sachtoklar No



Schematic Paper Machine 7

Wire section and Press section




Pre dryer section 1 till 6




Sizer & unidryer & drier section 7




Coater 1 & dryer section 8




Coater 2 & dryer section 9




Pope reeler



Schematic Super Calander 8



Schematic Super Calander 9



Contact details

Nijmegen Paper Mill

• Operational, technical and practical issues

Mill Director

Wayne Thomas

[email protected]

Office +31 (0)24 371 0600

Management Assistant

Ellen Bouwmeester

[email protected]

Office +31 (0)24 371 0601

Site visits can be arranged with the site

responsible persons but are subject to

approval by Sappi Fine Paper Europe

Sappi Fine Paper Europe

• Commercial and ownership issues

Chief Executive Officer

Berry Wiersum

[email protected]

Office +32 (0)2 676 9712

Executive Secretary

Marleen Pousset

[email protected]

Office +32 (0)2 676 9711

Director Manufacturing

Mat Quaedvlieg

[email protected]

Office +32 (0)2 676 9703

Executive Secretary

Kian Ping Ng

[email protected]

Office +32 (0)2 676 9714

Director Project Management

Thomas [email protected]

Office +32 (0)2 6769787


THIS INFORMATION IS THE TITLE OF JOHN WILKIE PAPER MILL SERVICES LTD AND SHOULD NOT BE COPIED OR FORWARDED TO A THIRD PARTY WITHOUT CONSENT.

FOR YOUR GENERAL INFORMATION WE HAVE TO INTIMATE THE FOLLOWING TO YOU:This schedule has been prepared solely for guidance and does not constitute (and at no time shall be deemed to constitute) an offer or contract or any part of an offer or contract. Additionally, no warranty is given to the accuracy of any measurements, specifications or other details whatsoever given within this schedule. Whilst every reasonable effort has been made to verify any statement, description, or comment made within this schedule, for the avoidance of doubt it is emphasised that any prospective purchaser must make their own enquiries and satisfy themselves.

John Wilkie Paper Mill Services Ltd. · The mill produces wood-free coated paper for web-offset...

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