Global paper-based packaging solutions provider Smurfit Kappa is rebuilding the dryer section of paper machine 6 (PM6) at its existing paper mill in Nettingsdorf, Austria.

Scheduled to be completed in the second quarter of 2019, the rebuild is expected to improve production and energy efficiency while reducing the environmental impact.

The ground-breaking ceremony on the rebuild of recovery boiler was held in October 2018, with completion scheduled for 2020, while the new steam turbine is expected to be installed by 2022.

Objectives of the modernisation

Smurfit Kappa’s paper mill modernisation is part of the company’s €134m ($152m) Future Energy Plant Project announced in July 2017 with an aim to increase the production and supply of high-quality, sustainable containerboard to its customers.

The investment plan also includes reconstruction of a new recovery boiler and installation a new and more efficient steam turbine, which will reduce CO2 emissions at the plant by 40,000t.

Paper machine PM6 upgrade details

The PM6 papermaking line currently consists of a total of 63 dryers. It produces lightweight, high-strength containerboard with 7.4m reel trim while operating at a speed of 1,100mpm.

The rebuild includes the replacement of two out of 63 dryers with new TT SteelDryers and the installation of an additional three TT SteelDryers.

“The rebuild is expected to improve production and energy efficiency while reducing the environmental impact.”

The TT SteelDryer has a standard operating pressure of 12 bar, while its standard diameters are 1.25m, 1.5m, 1.8m, and 2m. It has a high heat transfer rate and delivers higher drying capacity.

The existing 34-year old steambox at the plant was recently replaced with new Valmet IQ Steam Profiler to reduce steam consumption for the PM6.

Nettingsdorf paper mill details and sustainable features

Established in 1851, the Nettingsdorf paper mill is one of the biggest producers of containerboard in Europe. It produces two main products Nettingsdorfer Kraftliner brown (K) and Ceiling Paper (TDP) with an annual production of 450,000t of paper a year. The facility employs approximately 360 people.

The new HERB recovery boiler being built at the plant will recover energy from biomass and provide a high power-to-heat ratio. It uses vertical air system to reduce NOx, CO, SO2 and TRS emissions. It also features a smelt spout robot, a process simulator, and an advanced soot-blowing control system.

The pre-evaporation plant heated by ANDRITZ’s mechanical vapour recompression (MVR) technology is expected to increase the mill’s energy efficiency and evaporation capacity. The clean condensate produced by the MVR units can be reused in other processes to reduce freshwater consumption.

The mill earned Quality Management System ISO 9001, environmental management system ISO 14001, hygiene management system EN 15593, ASI management system ISO 45001, PEFCTM, and FSC® certifications.

Contractors involved with Smurfit Kappa’s paper mill modernisation

ANDRITZ received a contract to supply a HERB recovery boiler and a pre-evaporation plant for Smurfit Kappa’s paper mill modernisation at Nettingsdorf, in June 2018. The contractual scope includes delivery of mechanical equipment, automation, electrification, and instrumentation.

Smurfit Kappa company Nettingsdorfer Papierfabrik awarded a contract to Toscotec to rebuild the dryer section of the PM6 at Nettingsdorf mill in October 2018. The company will provide erection supervision, commissioning, and start-up assistance for TT SteelDryers.

Marketing commentary on Smurfit Kappa

Founded in 1934 in Dublin, Ireland, Smurfit Kappa manufactures a wide range of papers and paper-based packaging for packaging applications. It also provides recycling solutions for corrugated packaging and papers.

The company operates 350 production facilities in 33 countries with 45,000 employees worldwide. It produces seven million tonnes of paper and recycles 6.2 million recovered papers a year.

Smurfit Kappa generated €8.6bn ($9.8bn) in revenue in 2017.