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Published byRandy Poulter
Modified over 2 years ago
Energy-saving solutions for the paper machine Mikko Osara Vice President, Sales Paper business line, Metso TAPPSA
© Metso Board production costs, by main grades Global average cost, FOB mill site 2 Source: Fisher International, Inc. (2007) LinerboardCorrugating MediumKraft BoardRecycled Board Euro per metric tonne Fiber Pulp Chemicals/ minerals Energy Labor Other Energy cost varies between 15 – 30%
© Metso Energy consumption Modern newsprint machine 3 Metso data Short circulation 12% Headbox 0% Forming section 19% Press section 31% Dryer section 17% Calender 15% Reel 4% Winder 2% Short circulation 11% Headbox 1% Press section 13% Dryer section 69% Ventilation (hall) 6% Electricity Steam
© Metso Electricity usage, forming and press sections Drives, vacuum and hydraulics, modern newsprint machine Metso data 4 Sectional drives 42% Vacuum system 35% Shower water system 11% Broke collection 6% Ventilation 4% Hydraulic system 1% Pressurized air system 1% Sectional drives 60% Vacuum system 20% Hydraulic system 15% Broke collection 3% Shower water system 2% Pressurized air system Forming section Press section
© Metso * Modern machines are more efficient 5 Efficient drying and heat recovery Film size press High dryness after press with shoe pressing Fast tail threading and break recovery High time efficiency
© Metso Run with less energy – Levels of improvement 6 1. Parhaat ajotavat nykyisillä laitteilla 2. Nykyisen laitekannan huolto 3. Korjaukset 4. Laiteuusinnat Extent of investment 1.Best operational parameters with the present equipment 2. Maintenence and preventive service 3. Repairs 4. Rebuilds 5. New technologies
Stock preparation - refining
© Metso One OptiFiner Pro can replace two traditional refiners and even deliver 20% electrical energy savings
Energy efficiency and vacuum system analyses
© Metso Energy efficiency analysis Results example: short-term actions 10 Grade: Fluting Grammage: g/m 2 Reel width: 6,680 mm Machine speed: 700 m/min Grade: Fluting Grammage: g/m 2 Reel width: 6,680 mm Machine speed: 700 m/min
© Metso Vacuum system upgrades Press section Vacuum system design - Typically all systems are designed at low cost energy time and based on very traditional engineering. -> System efficiency loss is high Felt types and operation conditions - Many fast running paper machines are today targeting dewatering at the nip instead of at the Uhle box. - Vacuum levels of Uhle boxes are often also lower than earlier. 11
© Metso Vacuum system rebuild - energy saving 770 kW European mill, LWC, project start-up Sept 2010 Preceded by a vacuum system study - total theoretical electric energy saving potential over 1 MW - About 70 % of savings with relatively small investment Rebuild results - Rebuild in a two day shut-down in September - Two vacuum pumps were stopped and total energy consumption decreased by 770 kW Metso scope: - Process engineering, automation field equipment, DCS system software modifications, pick-up logic update Customer scope: - Piping materials and installation 12 Patent pending
© Metso Optimization of dewatering in the forming section 14 Its all about maximizing the dewatering and minimizing the rewetting ! Friction
© Metso New perforated suction box cover Inclined drilling and new cover material for lower flow resistance 15 Traditional cover
© Metso New perforated suction box cover gives high consistency with low vacuum 16
© Metso Solutions to reduce energy usage Press section 18 Runnability improvements and cost savings with shoe pressing and belt doctoring (BeltDoc) From Uhlebox dewatering to nip dewatering Perforated uhlebox cover
© Metso Energy savings due to shift from Uhle box to nip dewatering Estimated normal running loads (kW) 20 Assuming, that blowers/pumps are selected to operate at optimum conditions (no bleed air, no throttling of valves) Open felt 55 kPa Uhle vacuum Press section drive NRL, kW Blower/Pump NRL, kW Load (kW) Open felt 45 kPa Uhle vacuum Dense felt 45 kPa Uhle vacuum Dense felt 25 kPa Uhle vacuum
Perforated Uhle box cover, shoe pressing & BeltDoc doctoring
© Metso Perforated Uhle box cover Longer felt lifetime – lower energy load Dewatering capacity is based on a large open area of the perforation - Long dwell time in the suction area Increases felt dewatering at a lower energy load and vacuum level than a conventional slotted cover Decreases friction between the cover and the felt - No slots for the felt to dive into anymore - Gives a longer felt lifetime Felt well supported over the entire suction area Quick and easy assembly to existing Uhle boxes 22 Pilot machine trial data; comparison to conventional slotted cover Perforated Uhle box cover *): 25 kPa lower vacuum level 13 kW lower friction effect 65 % lower air flow Perforated Uhle box cover *): 25 kPa lower vacuum level 13 kW lower friction effect 65 % lower air flow
© Metso Felt behaviour in the suction area 23 Pilot machine trial data Liner / fluting production machine Conventional slotted cover Pilot PM 2
© Metso SymBelt shoe press rebuild 24
© Metso BeltDoc improves dryness and moisture profile Minimizes misting around the shoe press Increases dryness and improves moisture profile after press Close to 100 references 25 Support bar Integrated BeltDoc doctor Saveall
© Metso Higher web dry content and speed BeltDoc doctoring solution – WFU line, 80 gsm copy Target - Increase web dry content & improve runnability after the SymPress B press section Actions - Installation of BeltDoc with saveall - Saveall close to felt possible to increase linear linear load from 700 kN/m to 850kN/m ActionResults Higher linear load1.5 % web dry content increase after press BeltDoc & saveall0.5 % web dry content increase after press Machine speedFrom 1,450 m/min to 1,505 m/min Dry contentFrom to 51 – 52 % BulkNo difference 26
Other energy saving solutions
© Metso Energy savings through optimized doctoring at the dryer section 28 Relative power consumption of doctor blade materials Based on laboratory tests in simulated paper machine environment
© Metso 7 m wide paper machine running at 900 m/min, using either glass fiber or carbon doctor blade on cast iron cylinders (dryer can) Assumptions Results Width 7 m Power consumption to overcome friction generated by a single blade on a dryer can Machine speed 900 m/min Load 300 N/mGlass fiber blade15,75 kW Dryer cylinder radius 0,915 m Carbon blade6,3 kW µ Glass fiber 0.5Difference per blade:9,45 kW µ Carbon fiber 0.2 x 50 blades472,5 kW Number of blades 50 Annual difference in Running days/year 300 energy consumption 3402 MWh Energy savings through optimized doctoring at the dryer section Results: Energy savings, a cleaner cylinder will improve cylinder drying capacity and runnability, reduced total doctoring costs. 29 Example calculation Potential annual savings 136,080 0,04 /kWh Energy price
© Metso High intensity air dryer to replace IR dryers PowerDry Plus High drying rate with effective nozzle technology Significant energy savings (50%) compared with infrared drying Environmentally friendly, 50% less fuel burned and CO2 formed Low moisture and heat loads to machine room Low maintenance costs 30
© Metso Summary Energy costs are the second biggest cost Improving efficiency reduces specific energy cost Metso offers many services, new innovations and technologies that directly reduce energy and production costs Most of these small investments have short payback times and can be installed as retrofits 31
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