Transcript SAPPI

Saving Energy
Improving Technology
Voith Paper
Fiber & Environmental Solutions
Ravensburg / Germany
Eugen Loderer
TAPPSA Conference Cape Town
23rd Sept. 2010
Voith Paper
Fiber & Environmental Solutions
Ravensburg / Germany
Contacts South Africa:
Hennie Alberts
Tel:
+27 11 418-4016
Cell:
+27 824550049
e-mail: [email protected]
Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
IntensaPulper IP-V (Virgin)
Pulper for Virgin Fiber
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1. How can energy be saved?
- Avoid flow losses!
 Excentricity instead of flow resistant directional baffles
Conventional
IntensaPulper IP
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1. How can energy be saved?
- Avoid flow losses!Color test
Conventionel
5 sec
Intensa
Pulper
10 sec
15 sec
Mixing by excentricity, instead of baffles
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Investigate your savings!
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Intensa Technology
- A Chance for any Pulper
Intensa Technology
- Rebuild
Low Energy
Consumption in Pulping
Intensa Pulper Rebuild
- Deflector and other
components create a
very good vortex and
the suspension is
guided to the center
Modifications by INTENSA components
for existing pulpers
③
Bale Breaker
②**
Intensa Deflector
④
Double Cone
Bottom
(option only)
①
Rotor Modification
**2 = to guide suspension and to improve vertical movement of suspension down to rotor
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Projects at a Glance
Customer in Thailand
Pulper type
Furnish
UP10
AOCC and LOCC
Tonnage
404 bdmt/day
Operation
Continuous
Scope of supply:
Intensa Deflector
Rotor Modification
Rotor cap with Eddy
Cross
Operation volume 38 m3
Installation on site
Installed power
710 kW
Startup supervision
Power
consumption
590 kW in average
Consistency
3,5%
Measurement before
and after rebuild
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Results of rebuild-ROI calculation
Customer in Thailand
Before
After
590 kW
590 kW
No change
Consistency
3,5%
4,6%
31% increased
Capacity
404 t
548 t
34% increased
Net volume
38 m3
38 m3
No change
Specific energy input
15,5 kW/m3
15,5 kW/m3
No change
Specific energy consumption
35,1 kWh/t
25,9 kWh/t
26% of savings
Power consumption
Cost saving per year
(with 350 days per year)
42.350 €/year
ROI ≈ 13 months
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Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
Outlook in
Screening
Energy savings with
Eclipse
...replaces step rotor
Eclipse Rotor: Energy saver for DIP applications
Head to head trials: Current Step Rotor vs. Eclipse Rotor
 Low energy Rotor to keep the current
performance of Step Rotor
Step Rotor
12.5 mm Gap
Eclipse Rotor
5 mm Gap
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Eclipse Rotor: Energy saver for DIP applications
Head to head trials: Current Step Rotor vs. Eclipse Rotor
Power consumption [kW]
Development of Power Consumption vs. Rotor Tip Speed
 up to minus 30% power
consumption (kW)
 at 20% higher
throughput level for
Eclipse Rotor
Rotor tip speed [m/s]
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Eclipse Rotor: Energy saver for DIP applications
Head to head trials: Current Step Rotor vs. Eclipse Rotor
Development of Spec. Energy vs. Rotor Tip Speed
 up to minus 45%
Spec. energy [kWh/t]
specific energy
 at 20% higher
throughput level for
Eclipse Rotor
Rotor tip speed [m/s]
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Eclipse Rotor: Energy saver for DIP applications
Eclipse Performance
 Higher throughput performance up to 20%
 Specific energy reduced up to 45%
 Similar thickening factor for both Rotor types
 Up to 30% higher screening efficency
Operational recommendation
 For rebuild and new installation instead Step Rotor
 Rotor tip speed 18 to 20 m/s
 Stock consistency 2,0 to 4.5 %
 Rotor-Screen Basket gap 5 mm
 Basket combination: All hole types
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Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
Guangzhou DIP 2 retrofit in
2005
 rotor and screen basket situation
before and afterwards
 reduction of power consumption
 increasing of sticky removal efficiency
Rotor Situation Ahlström Screen F4 before and after
upgrade
Rotor Situation before upgrade
Rotor Situation after upgrade
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Old Screen Basket and New C-bar Screen Basket
New C-bar Screen Basket with much
higher open area
Screen Basket old
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Reduction ofPower Consumption in First Stage:
 Situation before upgrade:
Installed power:
rotor speed:
power consumption:
2 x 132 kW
550 rpm
2 x 110 kW
 Situation after upgrade:
Installed power:
rotor speed:
power consumption:
2 x 132 kW
440 rpm
2 x 80 kW
 Annual savings in energy at 350 running days a year:
504.000 kWH / year @ 0,07 €/kWh = 35.280,-- €/year
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Sticky removal efficiency before upgrade:
1st Stage:
ηSticky 60%
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Sticky removal efficiency after upgrade:
1st Stage:
ηSticky 74%
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C-bar™ Q
The High Capacity Screen Basket
for Stock Preparation
C-barTM Q
length unit
Standard bar
C-barTM S
length unit
Profile
width
[mm]
Relative
open
area
[%]
C-barTM S
3.3
100
C-barTM Q
2.7
~120
Narrow bar
C-barTM Q
(previous SQ)
More bars at given length
 higher number of slots  higher open area
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Sticky efficiency [%]
C-barTM Q – Results of mill tests:
Influence on sticky removal
100
90
80
70
60
50
40
30
20
10
0
 Sticky efficiency at
C-barTM S
C-barTM Q
same slot velocity
seems to be same
with
C-barTM S and Q
B&P
DIP
 Sticky efficiency is
1
1,2
1,4
1,6
Slot velocity [m/s]
1,8
2
better with lower
slot velocity
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C-bar™ Q Baskets - Summary
 Increased Production with same slot size – C-bar™ Q provides up to
20% more capacity than C-bar S basket
 Improved Quality – Higher screening efficiency at low slot velocities
 NDura material assures basket strength and lifetime (add. we offer
chromium layser)
 Basket Wear Measurement Tool – repeatable method for measuring
basket wear over time – developed by Voith – value added
 “C-bar™ Q just one part of Voith‘s “ screening toolbox“
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C-bar™ / MF Rotor Combination
Best screening efficiency / sticky and dirt removal
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C-bar™ / MF Rotor Combination
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Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
HW-Cleaner HCL5 – I
and
EcoMizer Technology
Technical Data HCL5-I:
Size
HCL5-I
Max admissible operation pressure
4 bar
Max admissible operation temperature
70°C
Pressure drop: Inlet  Outlet
1.5 – 2.0 bar
Inlet flow range
380 – 470 l/min
Min required accept pressure
0.1 bar
Dilution water flow
30 – 60 l/min
Max Inlet stock consistency
≤3%
Schematic of the HCL5-I
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HW cleaner HCL5-I with EcoMizer Technology
Customer’s benefits
EcoMizer feature for the HCL5 allows:
Minimum number of cleaners.
Minimum number of stages.
Hydraulically optimized head design for maximum production and
efficiency.
High concentration of contaminants in the reject
Minimum fiber losses.
Fine cleaning at consistencies up to 3 % without reduced operational
reliability.
Transparent reject chamber
easy inspection of reject flow.
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EcoMizer™ Technology
Principle
 Back-flushing of fibers to the accept
 Specific adjustment of reject consistency
possible
 Flow on cone wall remains unchanged
 So reduction of reject without affecting
separation efficiency
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EcoMizer™ Technology
Sand removal [%]
Influence on sand separation
100
98
96
94
conventional cleaner
(without back-flushing water)
92
cleaner with tangential
water injection
EcoMizer™ Cleaner
90
0
5
10
15
20
25
30
35
Fiber losses [%]
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Rebuild to EcoMizer technology
Example: Stock prep Newsprint – A500T -1Before
Inlet
246
Accept
68
26
Energy
1.040 kW
Fibre losses
3,67 t/d
Reject
6,6 t @ 45% ash
7-stage
cascade
1st step
fibre loss reduction
17e
8
Energy
945 kW
4e
1e
rebuild to EcoMizer™
not needed anymore
existing cleaner
• Energy
• Fibre losses
• Savings
After
Fibre losses
1,2 t/d
Reject
4,3 t @ 72% ash
40.000 €
343.000 €
383.000 €
/year
5-stage
cascade
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Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
EcoCell
LowEnergyFlotation
50% Energy Savings
LowEnergyFlotation
The most efficient flotation concept, which saves up to 50% of energy
Target:
Reduction on energy consumption compared to
standard applications by up to 50% at same quality
demands.
How:
 Modification of injector technology
 Optimized injector hydrodynamics
 Optimized EcoCell hydrodynamics
 High efficiency pumps
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Products for Saving Energy and
Improving Technology:
1.
Pulper
2.
Coarse Screening
3.
Slot Screening
4.
Cleaning
5.
Flotation
6.
Refining
Refining with
PLURALIS – optimize your CEL
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PLURALIS – Advantages of a new concept
• Small bars & optimized grooves = more bars @ same diameter
• More bars = more cutting edge length (CEL)
Refining intensity
Specific edge load
[J/m] =
Net refining power [kW]
Cutting edge length [km/s]
• More CEL = lower SEL = lower refining intensity possible
• Energy savings against standard designs = 10 – 20 % possible
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PLURALIS design =
reduction of specific edge load SEL by increase of CEL
b
b
b = bar width
g = groove width
g
lower
more
CEL
g
Energy @ same Technology
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Advantages by using Pluralis fillings
boost Quality = TECHNOLOGY
50
Tensile index [Nm/g]
Freeness [SR]
save Energy = COST SAVINGS
40
30
20
80
60
40
20
0
10
0
100
200
300
Total spec. energy [kWh/t]
Fillings type
0
100
200
300
Total spec. energy [kWh/t]
Spec. edge load
Pluralis
1 J/m
Common
Bleached Brazil Eucalypt pulp
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