Visy Pulp & Paper – Valmet

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An enduring legacy of sustainable growth

The Pratt family business came to be thanks to a £1000 loan from Richard Pratt’saunt Ida Visboard in 1948.Just as family looks after each other, Visy has grown from strength to strength on the back of looking after its customers needs with great service and innovation.

Leon PrattDie cutting, corrugating

Richard PrattRecycling, paper making, primary packaging

Anthony PrattGlobalisation, USA/Asia logistics, waste-to-energy

1948 – 1968 1969 – 2009 2009 – Current

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Key global numbers

A$4.9bnWORLDWIDE SALES

A$6.6bnWORLDWIDE ASSETS

10000+EMPLOYEES

* Incl Pratt Industries

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Investing in materials transformation

Circular business thinking, to transform materials from waste into useful products, has been at the core of Visy’s business lifecycle for decades…

Footprint of Visy Pulp & Paper Operations1,5 Million tonnes per annum

721 FTE5OPERATIONAL LOCATIONS (TOTAL)

QLD

PAPER MILL 8 (1996) Gibson Island 165,000 tpa

NSW

PAPER MILL 3 (1986) Smithfield 130,000 tpa

PAPER MILL 6 (1989) Smithfield 120,000 tpa

VIC

Head OfficePAPER MILL 2 (1983) Resevior 100,000 tpa

PAPER MILL 4 (1992) Coolaroo 160,000 tpa

PAPER MILL 5 (1989) Coolaroo 145,000 tpa

COGENARATION (2011) Coolaroo 80,000 tpa

COATINGS PLANT (1996) Coolaroo

NSW

TUMUT Kraft Mill 700,000 tpa

VP9 (2000) 280,000 tpa

VP10 (2009) 420,000 tpa

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Tumut Site. NSW

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TUMUT Mill

FTE

305Recycled Waste Paper Used

230,000Tonnes per annum

Paper Production

1,950Tonnes Per Day

Wood Usage

1,850,000Tonnes per annum

= 1 Truck every 5 minutes

Grades

45Types Produced

Power Generation

34 MW/h (44,253 HP/h)

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Tumut Time line of Projects

TUMUTTUMUT

TUMUT

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Mill wide optimization and control

High level process coordination and optimization

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Cooking

Washing

StockPreparation

Bleaching

Targets

Optimization of Board property

boardMachine

Targets

Optimization of Kappa

Targets

Optimization of Causticizing

2012 Quality improvement on both PMs with Valmet Breast Roll Shaker

• Improve board CD strenght properties

• Improve formation• Improve sheet roughness

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Targets

Competitiveness - Visy Tumut gives you both CD and MD strength

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STIF

I / S

CTc

d

Mullen / Burst

Competition

Competition

Visy HPKL

Visy KLVisyProject Target Quality

2015 New grades for VP9 - refining and sizer rebuild project

• Develop new grades for VP9• Further improve the strength

potential of VP9• Possibility for coating and sizing

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Targets

2016 Cooking optimization - Valmet Kappa Analyser

“ For the first time, accurate and reliable Kappa number in over 10 years, and very dynamic correlation. Valmet Kappa Analyzer controls deviation, monitors the chemicals, improves the pulp quality, eventually increase cooking yield. Primary savings in energy and chemicals possible.”

Gary Le Roux Mill Technical Manager

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2017 Causticizing Optimization

Recovery Liquor Analyzer

Advanced Process Control

SolutionsChallenges

Reduce energy cost and chemical cost.

Eliminate production constrains.

Optimize control and eliminate process variations.

Asset performance optimization –better ROI.

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2017 Causticizing optimization - Results

Increase paper

870ADT

in 40days

White liquor volume to digester

reduced 5%Less white liquor to be evaporatedReduce hydraulic load and steam demand on the digesterExtraction liquor dropped

3.65%

No pebble lime purchased – buy CaCO3 instead

High and stable TTA

Reduce scaling significantly

No over liming since control starts

Improved CE% stability

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Production ChemicalEnergy

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Change of Chip pile clearly seen belowMoisture change from “top of pile” to deeper in the chip pile Enable optimisation of liquor to chip ratio

Online Chip Fibre content correlates well with Lab MeasurementsFrequency of measurements from 4 times a day to continuous and real time measurementTool can now be used confidently in feed forward controls

2018 Valmet Chip ‘n’ Bark Moisture Analyzer - Enabler for better digester control

Visy’s vision on Industrial InternetFuture Applications

Visy views on Digitalization outcome Predictability of quality & equipment failures

Simulation & training tools

Cost & quality optimization

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Remote access to remote locations

INTERNAL

Valmet Industrial Internet – how we serve our customers

4 October, 2018 © Valmet | Valmet Customer Days 2018

Valmet training simulators• Process design verification• Operator training• Continuous competence development

Predictive applications• Equipment health indicators and

performance monitoring• Equipment failure prediction• Recovery boiler reduction degree and

scaling level prediction

Valmet Performance center• On-demand remote expert support• Remote monitoring and optimization• Big data analysis

Cost and quality optimization• Quality advisory solutions i.e. on-line

strength • Advanced process controls for stock

preparation• Cost monitoring and energy

optimization

Valmet Customer Portal

Thanks

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