Success Story ABB helps Sappi Saiccor’s cellulose mill expand smoothly with System 800xA.

Sappi Saiccor recently upgraded to the Extended Automation System 800xA, ABB’s new automation platform – an improvement that fits into the mill’s continuing, successful growth.

When the Sappi Saiccor chemical cellulose mill located Reducing the environmental footprint near , , was extended and modernized In 1994, Sappi Saiccor invested more than USD 250 million in 1994, the company invested in ABB's Advant OCS to expand and upgrade the mill’s facilities, increasing pulp control system, a decision made after detailed analysis production capacity from 450,000 to 585,000 t/y and and planning. enhancing product quality. The upgrade significantly reduced the mill’s environmental footprint. Five years later the installed control system was modern- ized, paving the way for later expansion. In 2001, ABB supplied engineering and delivered a millwide control system. Largest chemical cellulose producer Located at on the KwaZulu- south coast Improved availability and profitability just 50 km south of the of Durban, Sappi Saiccor is the In 2006 the Sappi Group invested in a USD 46.5 million world’s largest producer of chemical cellulose. expansion that will increase Sappi Saiccor’s pulp capacity from about 600,000 tons per year to 800,000. Founded 50 years ago, Saiccor was the first mill to produce chemical cellulose from eucalyptus – an important milestone In combination with this project, ABB won a USD 32 million that has revolutionized the industry. Sappi, the international order from Sappi to be a single-solution provider. ABB’s saw paper giant, bought the company in 1988. control system will have five redundant AC800M controllers for 2,500 S800 I/O channels and 10 Process Portal operator Today Sappi Saiccor produces approximately 600,000 tons workplaces along with extensive Profibus communications. of elemental chlorine free chemical cellulose per year. The order includes 2,700 smart instruments and 600 smart any disruptions. several generationsare runningatthesametime–without smooth. Theplant’s systemsare operatinginparalleland Sappi Saiccor’s systemchangeoverhasbeenremarkably upgraded instages,operatingbreakdowns are minimized. a majoradvantage.Andbecausethesystemisbeing integrate newsystems,whichSappiSaiccoralsoregards as the mill’s future expansion.Openstandards makeiteasyto The newapplicationsolutionshavethecapacitytohandle Future capacity r if everaproblem occurs.Theservicetechniciansare always as ateam,”hesays.“We alwaysknowtowhomwecanturn cians from ABBdonottrytocontrol us,andwereally work “We have beenworkingtogethersince1994,butthetechni- to themenonfactoryfloor”–hasrunverysmoothly. T for future documentationandtraceability. parts oftheprocess inreal time,andallthedataare stored makes itpossibletomaintaincontinuouscontactwithall r He isalsohighlypositiveaboutstoring,displayingand tion platformas“outstanding.” control systems,”saysToward, whodescribestheautoma- seen animprovement intheavailabilityandreliability ofour “Since wehavebeenusingABB’s control systems,wehave obtained alotforitsmoney. ease toconfigure andrun.HebelievesthatSappiSaiccor Saiccor, praisesthesystem’s flexibility, software designand Ken Toward, DivisionalEngineer-InstrumentsatSappi ality. Fivecontrol rooms received newoperatorsystems. Management andDTM(DeviceType Management)function- motor controllers aswellInformationManagement,Asset eally professional.” etrieving process andhistoricaldata.ABB’s System800xA oward says hiscooperationwithABB–“from management www.abb.com/pulpandpaper Fax: +16148186571 T W 579 ExecutiveCampusDrive Inc. ABB Fax: +862161298499 T Shanghai, 201319,P. R.ofChina Kangqiao Town, PudongDistrict S.P. Building,No.5,Lane369,ChuangyeRoad ABB EngineeringLtd. Fax: +353429385124 T Dundalk, Co.Louth,Ireland Finnabair IndustrialPark ABB Ltd. For more information,pleasecontact: © 2011byABBInc. el: +16148186300 el: +862161056777 el: +353429385100 esterville, Ohio43082,USA

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