UPM Wisaforest

Located 470 km northwest of Helsinki in Pietarsaari, Finland, the UPM Wisaforest pulp mill produces pulp for bags, sacks and various industrial operations. Slightly over 23 percent of the mill's pulp goes to its integrated partner, the UPM Wisapaper paper mill, while the majority goes to other UPM mills and the open market.

When a decision was made to raise pulping capacity by one-third as a means of increasing competitiveness, Wisaforest quickly realized that its pulping line was a lesser concern. Instead, it was the outdated recovery line that had to be renewed, as this was creating a bottleneck in the form of regular maintenance shutdowns.


A partner with added value

Besides replacing the evaporation plant, recovery boiler, causticizing line and lime kiln, Wisaforest decided to incorporate the latest automation into the recovery process. Optimization and reporting systems would be crucial, as the automation was to be an important tool in ensuring process reliability and availability.

The choice of supplier, however, came down to more than technology. Since Wisaforest's own engineers were well versed in technical administration, it was important to find a qualified supplier who could provide added value in the form of interaction.

Metso Automation, with its extensive expertise, nearby development facilities and a local service unit in Pietarsaari, seemed an ideal match. Moreover, since Metso solutions are built on industrial standards, the choice of Metso Automation as a partner would allow easy updates and renewal down the road.


Solutions built on trust

Wisaforest had already worked with Metso Automation on a number of previous projects, and was therefore familiar with its organization and staff. The existing trust and understanding between the joint team's members made it easy to cooperate in setting the system and process definitions.

The new recovery line was completely automated with Metso Automation's metsoDNA solution, including an extensive Information Management Activity application for managing the process automation. Also included were optimization controls for the evaporation plant, recovery boiler and lime kiln, as well as for the soot blowing, causticizing and steam load levelling processes. Metso also supplied the control system for the entire recovery line, the process-related alkali and kappa analyzers, and a substantial share of the recovery plant's instrumentation field equipment and control valves.





Looking to the long term

When it came on-stream as planned in 2004, the new recovery line hinted at its potential by reaching 85 percent of its capacity on the very first day. Since then it has demonstrated consistent production, without a single ton being lost due to automation problems.

Moreover, while pulp production has grown to 800,000 tons annually, the new recovery line has reduced Wisaforest emissions and increased energy generation. In fact, the line produces enough energy that the Pietarsaari mills are now self-sufficient in their energy needs.

As a result, Wisaforest's focus will now shift to the long-term challenges: maintaining full capacity at all times and optimizing the plant's production. Metso will continue to play a key role in this process, supplying guidance, service and automation expertise.