Hayat moving at world class speeds
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Hayat moving at world class speeds
Hayat moving at world class speeds Advantage™ DCT® concept Valmet has over 200 years of industrial history and was reborn through the demerger of the pulp, paper and power businesses from Metso Group in December 2013. Hayat moving at world class speeds Aim for the stars and you will hit the moon! Mr. Kemal Arslan project manager for Hayat Kimya san. AS, recalls the negotiations: “We maybe pushed too much the performance guarantees values. We asked Metso* to run the guarantee test at 2100 m/ min at a sheet basis weight of 15 gsm on the wire. We also stretched the values for the paper quality.” In September 2009, nine month after start-up the young and ardent TM 2 crew took a shot at the performance tests. They missed the moon but indeed hit the stars! ”We made the tests ourselves”, says Kemal Arslan, “with our regular machine crew.” No extraordinary means and measures were taken prior to, or during, the test. The settings of the tissue machine, utilities and support systems were as usual. We met all the performance guarantee values in one day when running at a speed of 2100 m/min. Half an hour may have been lost in stabilizing the sheet. Then we made production for eight hours, remaining on guaranteed values.” World class speed tissue machine No. 2 at Hayat Kimya. The machine is a Advantage DCT 200 TS The Hayat group in Turkey was established in 1938. The company has two business divisions, wood panel board and consumer products. Besides tissue, consumer products include hygienic and cleaning products. The group turnover is 1,6 billion USD. Half is generated from panel board and half from the consumer products. Challenging targets Mr. Lütfi Aydin, Paper Group Director, was the first man on board when Hayat decided to venture tissue paper production in 2004. He remembers: ”It was indeed very difficult to find the technical staff and Mr. Lütfi Aydin, Paper Group Director, organized and started Hayat’s tissue paper production. * Operating as Valmet from Jan 1 2014 establish the work processes in a company which has had no experience in the paper industry. Very few qualified and experienced people were available. However, looking at the results, I would say that our hiring process turned out to be very successful.” Lütfi Aydin and his team did not hesitate to implement advanced concepts in their first plant such as a co-gen plant for electricity production and generation of steam and hot air for the tissue machine. Lütfi Aydin: “In December 2005, after vigorous efforts of my team, we started up our TM 1. Meanwhile, we were carrying out the erection and test runs of the co-gen system consisting of 2x7.5 MW Gas Turbines, as well as 10 machines in our new converting plant. In the converting plant, we were running these jobs with only one experienced Manager and three experienced technicians while the rest of the operators were unexperienced. Our task ahead was to produce 47 different converted tissue products, in a total amount of 400.000 cases, by March 2006 for launching in early April. On March 22 we loaded the first truck with a big applause. On April first the products were on the shelves and we were all very pleased and proud. Tissue production was off and running within the Hayat Group!” We met all the performance guarantee values in one day when running at a speed of 2100 m/min. Kemal Arslan, Project Manager, Hayat Kimya san. AS 3 Following the go-ahead from Metso (Valmet), Hayat made the demanding performance guarantee tests on their own. Mr.Yasar Guloglu, Production Engineer (left) and Mr. Sabri Cakmak, Automation Chief Engineer assumed the hands-on responsibility for the test. Hayat Kimya proved to be a successful newcomer on the Turkish market. In 2009 75% of the tissue machine production was converted and the market share had reached 26%. A converting percentage of 75% triggered the decision to proceed with a new machine, TM2. Lütfi Aydin: “On this project, the situation was different. All learning gathered from the first project had given us a good experience base, which was very useful in the up-coming negotiations and work processes. After a number of reference visits and long lasting technical meetings with three machine suppliers we ended up choosing Metso (Valmet). The contract was signed on November 10, 2009.” Mr. Rolf Tellack, Project Manager, Metso Metso accepted to join in our plan and go for the tough schedule. Optimistic time schedule went realistic Hayat’s spirit of moving at a rapid pace is obviously not limited to the tissue machine: Lütfi Aydin continues: “It surfaced at the second project meeting that we and Metso had a different view on the expected start-up date. “By industry standards”, said Mr. Rolf Tellack, Project Manager, Metso, “I would predict March 2011, provided there would be no major problems”. Our plan for start-up was set for December 2010. This target seemed very optimistic and hardly realistic, even to our boss. However, Metso accepted to join in on our plan and go for the tough schedule. Rolf Tellack made an excellent job coordinating the team efforts in trying to reach the goal. On December 18, 2010, 13 months and 8 days after signing the contract, we made start-up!” “The ground conditions on this site are not the best” according to Kemal Arslan: “I would estimate that we lost 3-4 months due to extensive piling work and concrete reinforcements. Therefore in our mill layout work we tried to keep the ground space requirement to its minimum. The result has been a very compact mill concept. As one example I can mention that their engineering of the stock prep system lowered the amount of piping length by 30% compared with TM1. Production capacity, efficiency, paper quality and experience of co-gen were the main decisive factors for us when selecting Supplier. The co-gen experience, not being least important. Together we made improvements over our existing TM1 system. We accomplished a system for faster and safer start-ups of the tissue machine and thus higher efficiency. Two to three months into the project we all felt that we had made the correct decision on the supplier for TM2.” Mr. Hayrettin Kutluok, Production Manager Mr. Kemal Arslan, Project Manager Pushing boundaries Saleable paper from first hour As mentioned above the contract values for speed performance was set at an unusually high level. “I understood this first later,” admits Kemal Arslan, “when expert visitors said that they did not believe it!” Jan Erikson Vice President. Metso Tissue, comments: “During our pre-project meetings and during the final negotiations, our confidence in the capability of the Hayat team had gradually built. We certainly know our machine in detail, its robustness, stability and its capability of producing a sheet as to the specified paper properties within the whole speed range of the machine. However, in order to reach the very top performance, a large number of operating parameters are to be set correctly for each speed level. We manage this with the Metso Automation System. In the end thou, the machine needs to be in the hands a skilled crew, willing to push the boundaries. We believe we saw this at Hayat.” Speeds in the range of 2000 m/min are easily made visible and do indeed impress both the person on the street and the professional tissue maker. However, what counts, bottom line, is the production, the amount of cases out the door. Mr. Hayrettin Kutluok, Production Manager: “The machine take over went very smoothly. We started up at 1500 m/min and we had saleable paper on the reel within the first hour. During the first eleven months we produced 60.700 tons. Our budget for this time period was 53.300 tons! Net time efficiency was 96%”. On December 18, 2010, 13 month and 8 days after signing the contract, we made start-up! Lütfi Aydin, Paper Group Director, Hayat Kimya san. AS Co-gen plant consisting of 2 x 7,5 MW gas turbines integrated with TM2 (to the right) 4 5 MetsoIQ SteamProfiler Metso Paper IQ Select Even and stable conditions The contracted scope of supply consists of: tissue machine, air system, process ventilation stock preparation, automation and engineering. Process, tissue machine and drive controls are by Metso DNA. Quality controls system is Metso PaperIQ. The tissue machine Advantage DCT200 includes two options, which “have been very valuable tools to us” says Kemal Arslan: “The headbox dilution profiling system and the MetsoIQ steam profiler. We have a very good basis weight profile throughout the speed range of the machine. The steam profiler on the suction pressure roll just ahead of the nip improves the moisture profile of the sheet. With a more even profile we can increase the average moisture content in the sheet by one to two percent. That, in turn, means the same increase in production. Every system, that improves the evenness cross machine, also improves the efficiency. Even basis weight and moisture profiles give an even coating which gives an even creping which stabilizes the sheet .. and so on.” 6 Looking at the jumbo rolls off the machine, there is no doubt that there are very even and stable conditions across the machine width. The rolls look more like good flat grade paper rolls than jumbo rolls of soft high quality tissue. From being a newcomer to becoming a forerunner. In order to grow reasonable fast into the marketplace, Hayat introduced products of a different concept. Hayat launched both bath tissue and kitchen towel as three ply products into the targeted segment, which proved to be very successful. Soon three ply tissues were marketed also by competitors. Hayat’s latest innovative product is bilateral tissue and towel. New is a different embossing pattern on each side of the plied sheet. The product will soon be on the shelves and will be recognized for having very high numbers as to bulk and softness. Determined business expansion In conjunction with the purchase of TM2 for Turkey, Hayat ordered a duplicate equipment package to be installed outside Turkey. Start-up is estimated in September, 2012. “We are implementing the same project, engaging the same teams, Metso’s as well as ours”, says Lütfi Aydin. “Including the last mentioned, we have since 2004 installed three tissue lines, each with a capacity of 70.000 tpy. In the near future we will go ahead with two other projects, one in Tataristan, Russia, the other in Mersin, Turkey, planned to start tissue production in 2014 and 2015 respectively. Both machines in these projects will be integrated with a 60.000 tpy DIP-line for each machine. By the end of 2015 Hayat Kimya expects to operate 5 large tissue machines with a total production capacity of 350.000 tpy. Excellent quality jumbo rolls. Concept is mixed. Reeling on spools as well as split reel winding on cores Tissue Machine Main Data Type Advantage DCT 200TS Production (at 17,5 gsm) 225 ton/24 hours Sheet design 2-layer Paper width on reel 5 600 mm Max. operating speed (yankee speed) 2 100 m/min Basis weight range on reel 120 - 45 gsm Creeping ratio range 5 - 25 % Yankee diameter 18 ft (5 500 mm) 7 For more information, contact your local Valmet office. www.valmet.com e-mail: use generic e-mail adress (paper.service@valmet.com) Specifications in this document are subject to change without notice . Product names in this oublication are all trademarks of Valmet Corporation. © Valmet Corpotation. 0000 VI EN 2014. The Hayat Kimya mill site. The co-gen plant in front of TM2. To the right, in the distance, Hayat is building an automated ware-house, which will be one of the largest in the world.