Long-term partnership provides results
Metso supplied JSC Segezha Pulp and Paper Mill in Russian Karelia with an extensive rebuild of their PM 9 production line for extensible sack kraft paper. The rebuilt production line started up in summer 2008.
The Segezha Pulp and Paper Mill is located in northwestern Russia in the Republic of Karelia, about 700 km north of St Petersburg. Segezha, which is owned by the InvestLesProm Group, is the only Russian manufacturer of semi-extensible sack paper. The PM 9 rebuild has strengthened Segezha’s position in the industry and provides the paper sack factories of Segezha Packaging with good-quality paper. Together with a rebuild of PM 10, also carried out by Metso, the modernization of PM 9 increases Segezha’s annual capacity of semi-extensible sack paper to 250,000 tons.
The 7.1-meter-wide PM 9 is a sack paper machine that was originally delivered by Metso (Valmet) in 1972. The rebuild allows a potential increase of the machine’s production speed to 750 m/min and a daily capacity of 550 tons. But speed and capacity were not the primary objectives: “The main target was quality improvement,” says
Vladimir Ermakov, Executive Director of JSC Segezha Pulp and Paper Mill.
 | Long-term cooperation
The Segezha Pulp and Paper Mill selected Metso as a result of good experience gained in the high-consistency refining project of 2002 and subsequent modernization of PM 10 and stock preparation by Metso in 2004. “We have been working with Metso for a long time now. A total mutual understanding has been reached during our collaboration. All questions have been solved very fast and decisions have been taken promptly,” says Vladimir Ermakov. “A supplier's credibility forms the basis of a successful project. We have already had work experience with Metso so, as the saying goes, if it ain’t broke don’t fix it! We were already familiar with the technology and operation mechanism so this enabled us to avoid the challenges we faced during the modernization of PM 10.” |
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“A supplier's credibility forms the basis of a successful project. We have already had work experience with Metso so, as the saying goes, if it ain’t broke don’t fix it,” says Vladimir Ermakov, Executive Director of JSC Segezha Pulp and Paper Mill.
Rebuild project tasks and scope
The first steps in the project were taken by a team of specialists from Metso working with mill personnel to conduct an audit and performance review of the machine and stock preparation systems. The audit identified which of the existing structures and components could be reused and which were in need of repair. Maintenance and replacement recommendations were also agreed to help avoid unplanned shutdowns and enhance the efficiency and runnability of the machine. Based on the final report presented to the mill, Metso was selected to rebuild the refining line, wire and drying section of PM 9 and to supply the automation and engineering.
Proven expertise
The production of semi-extensible sack paper relies on good stock preparation to provide the exceptional combination of strength and porosity needed in the final product. High-consistency refining is the answer, creating micro-compressed curly fibers that result in higher stretch and tensile energy absorption values. An RGP 262 refiner fed by a TRPW-1532 twin roll dewatering press provided the best solution.
The mill already had good experience of a similar arrangement using an earlier generation of twin roll press in the PM 10 rebuild. Metso also supplied a new seal water unit and broke thickener, together with auxiliary equipment such as pumps, field instruments, manual and automatic valves, piping, tanks and agitators to complete the stock preparation modernization. Erection supervision, start-up assistance and operator training were included in the delivery.
The modernization of the paper machine included a FormMaster breast roll shaker and a rebuild of the dryer section to improve drying capacity and moisture profiles. FormMaster improves formation as it shakes the breast roll in a CD direction and breaks unwanted flocks by creating shear forces on the web. Based on the good results with PM 9, the mill has ordered a second FormMaster for PM 10.
The PM 9 line, like that of the PM 10, is now equipped with new, highly modern automation: a metsoDNA control system and PaperIQ quality control system. A new moisturizing profiler, IQAquaPro, was also installed on the machine.
The production of semi-extensible sack paper relies on good stock preparation to provide the exceptional combination of strength and porosity needed in the final product. At Segezha an RGP 262 refiner fed by a TRPW-1532 twin roll dewatering press provided the best solution.
Installation
The rebuild operations of PM 9 commenced and went according to the schedule. “A complete mutual understanding was reached between the project managers. All questions were solved promptly. The erection supervisors
Hannu Lipsanen and
Jaakko Lattu were always ready to provide any advice and assistance to our installation contractor specialists. There was a businesslike and well-intentioned atmosphere at the erection site,” explains
Aleksander Sivkov, Project Manager. In June 2008, PM 9 was restarted with the production of semi-extensible sack kraft paper.
Results
The investment focused on increasing the mill's competitiveness in international markets. The immediate results were impressive, and the quality properties specified in the contract were achieved straight away after the start-up. “Now we mainly concentrate on exports. Deliveries to Europe have increased,” says Vladimir Ermakov.
“The quality improvement was evident after the first stage of the rebuild. It is especially obvious on the standard paper,” explains
Zinaida Pugina, PM 9 and PM 10 Stock Preparation Manager.
“Now we can produce both paper and board with a basis weight range of 50-125 g/m2 thanks to the rebuild of the wire and drying section equipment of the PM 9,” says Vladimir Ermakov. “Now it is possible to say that the first stage rebuild goals have been met. No one else in Russia is producing such good-quality sack paper which is also highly rated in Europe. We haven’t had any quality complaints from our customers. Such successful results have been possible due to Metso’s equipment and technology!”
Recognized for quality
The award ceremony for winners of “The Best Exporter of 2008” competition was held in Moscow on June 3, 2009, by the Ministry of Foreign Affairs of the Russian Federation. Among the 56 winners, the Segezha Pulp-and-Paper Plant, Inc., (InvestLesProm Group) was awarded with the prize for the best exporter in the industry (pulp and paper industry).
“Now we can say that the first stage rebuild goals have been met. No one else in Russia is producing such good quality sack paper which is also highly rated in Europe” says Vladimir Ermakov.
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