Long-term collaboration yields improved optimization for Visy Tumut mill

The Visy Tumut integrated pulp and paper mill in Australia operates with the highest environmental standards and is run efficiently by a small team of experts. The staff understands that efficient operations in all aspects of the mill require a foundation of reliable data – data gathered with the help of Valmet solutions.

To ensure high-frequency, reliable data and allow for efficient decision-making and process optimization, which are crucial with a small team, the mill uses a range of Valmet analyzers and automation tools in cooking, recausticizing, fiber refining and the wet end.

"Valmet's advanced analyzers, which provide real-time data, accurately monitor our equipment and processes, allowing our team to make informed decisions fast," says Fonnie Botha, Technical Manager, Visy Tumut. "With this data, we're better able to automate our processes and optimize each step of the production process."

Meeting Visy Tumut's customers' demands for specific grades and production volumes is critical. And, by applying Valmet's advanced process controls (APC) together with Valmet’s analyzers and measurements, Visy Tumut is reaping optimization benefits in real-time. The result is a more streamlined operation and reduced wood, energy, and chemical consumption.

Fonnie Botha, Technical Manager at Visy Tumut.

Accurate and reliable data as standard

The mill is dedicated to continuously improving and refining its processes to achieve the highest standards of operational excellence. For years, the mill has collaborated closely with Valmet for analyzers, service and support – both onsite and remotely.

This collaboration has helped the mill maintain and improve analyzer performance, ensuring that laboratory and analyzer results align closely.

Valmet's onsite and remote services have helped to maintain and improve analyzer performance. 

"We've always found that if and when we experience any problems or issues, our contacts at Valmet have been there to support us quickly," says Botha. "They're able to log into our systems remotely, which has allowed us to significantly improve our processes with their help over the years. Plus, it's helped to ensure the results from our laboratory and our analyzers match almost every time."

Automating the online analyzer process

One of the challenges that Visy Tumut faces is wide variability in raw material input. To address this, staff rely on online analyzers that help optimize controls and maintain stability in key areas.

Visy Tumut utilizes a range of consistency measurements, such as Valmet Rotary.

On the pulp mill side, the Valmet Kappa Analyzer (Valmet Kappa QC), Valmet Cooking Liquor Analyzer (Valmet Alkali C) Valmet Recovery Liquor Analyzer (Valmet Alkali R), and Valmet Chip 'n' Bark Moisture Analyzer (Valmet CBA) are the basis for automatic controls. 

"I'm very happy with the performance of the Valmet analyzers and optimizers. For example, in causticizing, the system helps to maximize efficiency and green liquor strength by controlling the green liquor quality and the slaker lime addition. Those are the two main inputs, which are continuously controlled and monitored by the optimizer. This helps to reduce the dead load in the recovery cycle, save energy, and brings many other benefits, like preventing over-liming and reducing acid cleaning," says Uday Bhagwat, Pulp Mill Manager, Visy Tumut.

Uday Bhagwat, Pulp Mill Manager at Visy Tumut, is very happy with the performance of Valmet analyzers.

Multiple Valmet Wet End Analyzers

The mill uses two Valmet Wet End Analyzers (Valmet WEM), which feature several measurement modules and functionalities. The team initially brought these onsite for the measurement possibilities they offered for their paper machine ply and layers.

“We continue to optimize the wet end analyzers’ performance and have started relying on them to measure and monitor pH, as well as connectivity temperature in all streams,” says Botha.

Optimizing the refining process

A Valmet Pulp Analyzer (Valmet MAP) measures pulp refining, and the mill also installed freeness analyzers to ensure optimal refining conditions. These provide high-frequency information, indicating any drift or other movement.

"Operators can manage these analyzers with minimal input and regular attention," says Botha. "We experience almost no issues as long as we perform regular maintenance."

They have also implemented weekly calibration checks for the freeness analyzers, where the team regularly checks samples to ensure the analyzer's calibration matches laboratory results. From there, they're able to make adjustments as needed.

Navigating wood supply challenges

In recent years, one of the more challenging realities for Visy Tumut has been a reduced wood supply due to the record bushfires of 2019-20, which destroyed over 24 million hectares, including large areas of local forestry in and around New South Wales.

"We were quite affected by the bushfires, which heavily reduced our nearby wood supply," says Botha. "That, combined with the continual increases in energy costs, are among our biggest challenges. Valmet's offering is helping to alleviate these challenges by ensuring we have information that allows us to control our processes more efficiently."

The long-term collaboration between Visy Tumut and Valmet has yielded in improved optimization.