INTERNAL
Cooking and Fiberline
Possibilities for
Improvements
Plata Region Seminar
June 13th, 2016
Buenos Aires
INTERNAL
Contact information
Richard Barros
Manager, Mill Improvements
Paper and Fiber Technologies
Services Business Line...
INTERNAL
Agenda
Batch Cooking
Date Author Title INTERNAL3
Brown Stock Screening
MC Machinery
Washing
INTERNAL
Batch Cooking
4
INTERNAL
CHIP SILO
(OPTIONAL)
DIGESTERS
LIQUOR TANKS
NCG AND
TURPENTINE
SYSTEM
HEAT EXCHANGERS
DISCHARGE TANK
LIQUOR
ACCUM...
INTERNAL
Equipment Introduction
SCREEN
DIRECT STEAM
SCREEN
CHIP SCREW
CONVEYOR
DEGASSING SCREEN CHIP STEAM PACKER
CIRCULAT...
INTERNAL
Single digestor - benefits
Ÿ An extra or new digestor can
bring more flexibility for
current production
Ÿ Capacit...
INTERNAL
Chip packing system
Ÿ Chip packing system with
air evacuation and dust
separation.
Ÿ Air evacuation either from
t...
INTERNAL
Chip packing system
Benefits and principal arrangements
Ÿ Cycle time saving from
simultaneous packing
and chip fi...
INTERNAL
Hot and White Black Liquor Accumulators
Hot Liquor Fill for Softwoods
Ÿ Hot black liquor treatment
– Hot black li...
INTERNAL
Black Liquor Accumulator
Production increase and more stable steam consumption
Ÿ Higher temperature
during cookin...
INTERNAL
Chip screws and chip feeding systems
For batch digesters with and without capping valve
Ÿ Electric motor and gear...
INTERNAL
Knot pumping
Benefits
Ÿ Direct pumping of knots to
the digester(s).
Ÿ Pumping consistency 4%
to prevent plugging ...
INTERNAL
SuperHeater
Direct heating system for the liquor circulations
Ÿ Direct steam heating system
designed for trouble-...
INTERNAL
Brown Stock Screening
15
INTERNAL
Valmet’s screening philosophy
Today’s development Improvements Area
Ÿ New designs targeting capacity
over 5000 ad...
INTERNAL
Costs mapping in a brown stock screening room
Ÿ There are several factors to be considered when looking for savin...
INTERNAL
Costs mapping in a brown stock screening room
Ÿ Example study shows that over 30% of the cost on screening room i...
INTERNAL
Identifying points of possible losses in your
screening room
Ÿ When a shive washer and a
reject press is installe...
INTERNAL
Identifying points of possible losses in your
screening room
Ÿ When a reject press is
installed as last stage;
– ...
INTERNAL
Screening
Excessive wear area
Plugged Screen=
No Screening
Reject Thickening - Typical Phenomena
Feed
Rejects
Typ...
INTERNAL
Nimax db provides two stages in one basket
INTERNAL
Nimax db™ with Belt Dilution
Major Benefits
• An additional screening stage is added
without adding a new screen....
INTERNAL
Screen Basket Products
© Valmet | Screen products24
For low and high consistency pulp
applications except machine...
INTERNAL
NimLuc screen basket family
Focus on lower cost for targeted pulp quality
Ÿ Designed for low and high
consistency...
INTERNAL
Rotation direction of foils
26
Nimax LD Screen Basket Family
New generation Laminar Design wire
Ÿ The laminar flo...
INTERNAL
Ÿ Smooth and NWP drilled baskets,
open area and drill pattern to meet
customer demands
Ÿ NimClear screen basket e...
INTERNAL
MC Machinery
28
INTERNAL
MC-pumps and chemical mixers
Internal
vacuum pump
Thick stock pump
to MC-pump
InducerEnergy saving
SMB
SMF-Mixer
...
INTERNAL
FlowHeater™
Process Machinery
SMF-Mixer
CM-PumpCW-Pump
RFB
SA-D SA-U
TMC
TSB-T/V
INTERNAL
Where to look for energy savings
Pump and mixer system
31
• Optimized pump dimensioning
• Optimized mixing techno...
INTERNAL
Identify pressure losses
Example, 300-500 adt/d
32
• 20-25% valves
• 10-15% mixer
• 25-30% Piping
• 25-30% Static...
INTERNAL
Medium consistency pump CM/CW
33
Consistency 6-8%
CMCW
Consistency 9-14%
27 different sizes
CMD
INTERNAL
Efficient pumping – Valmet MC Pump
34
Low energy consumption
MC pump T2 (E-stage) MC pump T3 (P-stage) MC pump T4...
INTERNAL
Valmet SMF Mixer
Modern mixing technology
Ÿ “All-in-One” solution
Ÿ Applicable on whole fiberline
Ÿ Low chemical ...
INTERNAL
ALL-IN-ONE
IS OUR CONCEPT
Ÿ We add everything directly
into the mixer
Ÿ Highly effective mixing
zone
Ÿ Perfect co...
INTERNAL
Valmet SMF Mixer
37
Low energy consumption
CASE STUDY
Hardwood - Existing mixers Hardwood - New installations
Pos...
INTERNAL
Washing
38
INTERNAL
Washing Technology – Upgrades & Rebuilds
Challenges through the years...
Ÿ Production increase
Ÿ Energy consumpti...
INTERNAL
ProDry Description
Ÿ Insert cassettes for the TwinRoll
press filtrate channels
Ÿ Minimizes the pulp re-wetting
Ÿ ...
INTERNAL
ProDry™ Benefits & Mill results
Mill in Chile, DPA-1555
Ÿ DPA-1555 pre-bleach plant
Ÿ ProDry was recommended due ...
INTERNAL
ProStream™
42
INTERNAL
ProStream™
Ÿ Automatic system for high
pressure cleaning of the press
rolls
– Control via DCS system
– Cleaning i...
INTERNAL
44
44
Wash Filter Improvements
Typical areas for improvement
• Pulp Inlet
- Piping
- Dilution
- Distribution prof...
INTERNAL
Valmet nozzle is designed
to facilitate an even
distribution of washing
cleaning fluid.
Valmet nozzles
CSDU_H_201...
INTERNAL
Background
Washing distribution
CSDU_H_2018_618-02
• Old SS steel standard nozzles
• Valmet nozzles
Valmet nozzles
INTERNAL
Benefits
Ÿ More even distribution of
cleaning fluid
Ÿ Strong and reliable
construction due to PVDF
”Kynar” materi...
INTERNAL
Wire cleaning device
48
Advantages
• Hand- or automatically
operated brush device
• Filtrate to flush away fiber
...
INTERNAL
Wire cleaning device
Automatic spray pipe type
1. Motor
2. Housing
3. Ball valves
4. Actuator device
49
INTERNAL
Nächste SlideShare
Wird geladen in …5
×

Richard plata region seminar cooking & fiberline improvements_handout

223 Aufrufe

Veröffentlicht am

1° Seminário Latino Americano de Tecnologia Valmet
Buenos Aires

Veröffentlicht in: Serviceleistungen
0 Kommentare
0 Gefällt mir
Statistik
Notizen
  • Als Erste(r) kommentieren

  • Gehören Sie zu den Ersten, denen das gefällt!

Keine Downloads
Aufrufe
Aufrufe insgesamt
223
Auf SlideShare
0
Aus Einbettungen
0
Anzahl an Einbettungen
1
Aktionen
Geteilt
0
Downloads
29
Kommentare
0
Gefällt mir
0
Einbettungen 0
Keine Einbettungen

Keine Notizen für die Folie

Richard plata region seminar cooking & fiberline improvements_handout

  1. 1. INTERNAL Cooking and Fiberline Possibilities for Improvements Plata Region Seminar June 13th, 2016 Buenos Aires
  2. 2. INTERNAL Contact information Richard Barros Manager, Mill Improvements Paper and Fiber Technologies Services Business Line Valmet Celulose Papel e Energia Ltda Rua Pedro de Alcântara Meira, 1301 83704-530 Araucária, Paraná State Brazil Mobile phone:+55 41 9269 8482 Tel: +55 41 3358 4823 Fax: +55 41 3358 4728 e-mail: richard.barros@valmet.com
  3. 3. INTERNAL Agenda Batch Cooking Date Author Title INTERNAL3 Brown Stock Screening MC Machinery Washing
  4. 4. INTERNAL Batch Cooking 4
  5. 5. INTERNAL CHIP SILO (OPTIONAL) DIGESTERS LIQUOR TANKS NCG AND TURPENTINE SYSTEM HEAT EXCHANGERS DISCHARGE TANK LIQUOR ACCUMULATORS CHIP FEEDING TO DIGESTERS WITH SCREW CONVEYORS LIQUOR PIPES TO AND FROM DIGESTERS Equipment Introduction
  6. 6. INTERNAL Equipment Introduction SCREEN DIRECT STEAM SCREEN CHIP SCREW CONVEYOR DEGASSING SCREEN CHIP STEAM PACKER CIRCULATION PUMP DISCHARGE PUMP NOZZLES FOR DISCHARGE DILUTION CIRCULATION CIRCULATION LIQUORS INTO DIGESTER LIQUORS OUT FROM DIGESTER CAPPING VALVE
  7. 7. INTERNAL Single digestor - benefits Ÿ An extra or new digestor can bring more flexibility for current production Ÿ Capacity increase Ÿ New designes can attend higher capacities compared to existing ones (replacement cases) Ÿ In normal applications, a new digestor (in parallel with existing ones) can increase the production about 10-20%
  8. 8. INTERNAL Chip packing system Ÿ Chip packing system with air evacuation and dust separation. Ÿ Air evacuation either from top or from suction screen. Ÿ Packing degree 15-20% depending on raw material. Ÿ Composed of steam packer, cyclone, dust box and exhaust fan.
  9. 9. INTERNAL Chip packing system Benefits and principal arrangements Ÿ Cycle time saving from simultaneous packing and chip filling Ÿ Preheating of chips with LP-steam Ÿ More chips per digester means also higher production Ÿ Normal applications a chip packing system can increase the production about 10-15% Low pressure steam line and valve to control each digestor Shut-off valve for air evacuation for each digestor Evacuation air fan and cyclone. One unit per chip feeding line. Even if 2 fillings are occurring simultaneously, 2 lines are applied
  10. 10. INTERNAL Hot and White Black Liquor Accumulators Hot Liquor Fill for Softwoods Ÿ Hot black liquor treatment – Hot black liquor impregnation – Heating of digester with liquor displacement – Residual alkali control and profile in order to ensure optimum conditions – Spent soluble calcium rich impregnation liquor is taken into K-tank for futher processing Ÿ Hot white liquor fill – Fresh alkali charging Date Author Title10
  11. 11. INTERNAL Black Liquor Accumulator Production increase and more stable steam consumption Ÿ Higher temperature during cooking circulation heating, for instance, 120°C instead of 80°C – brings up to 40 min time saving during the chip filling and impregnation Ÿ Continuos heating – stability of steam consumption Ÿ In normal applications, a HBL accumulator can increase the production about 20-25%
  12. 12. INTERNAL Chip screws and chip feeding systems For batch digesters with and without capping valve Ÿ Electric motor and gearbox- driven screw conveyor for chip feeding Ÿ High safety; no dusting, closed design Ÿ Possible to run in both directions Ÿ Single machine length up to 12 meters Ÿ Capacity up to 1500 loose m3 of chips / hour Ÿ Compared to belt Chip screw offers even capacity (no overflows), less dust etc.
  13. 13. INTERNAL Knot pumping Benefits Ÿ Direct pumping of knots to the digester(s). Ÿ Pumping consistency 4% to prevent plugging of lines. Ÿ Trouble-free operation and low energy consumption due to simple and proven design. Ÿ No presses or blowers needed.
  14. 14. INTERNAL SuperHeater Direct heating system for the liquor circulations Ÿ Direct steam heating system designed for trouble-free operation Ÿ Designed and used to replace heat exchangers and to remove the problems caused by indirect heat transfer (scaling, poor heat economy) Ÿ Steam condensate improves digester washing Ÿ As most of the equipment is installed inside the existing pipeline, very little space is required
  15. 15. INTERNAL Brown Stock Screening 15
  16. 16. INTERNAL Valmet’s screening philosophy Today’s development Improvements Area Ÿ New designs targeting capacity over 5000 adt/d for single lines Ÿ Focus on reject handling system Ÿ Product Portfolio Competitiveness analyses in a regular bases – What is our customer requirements and how can we reach their expectations? Ÿ Is it your screening room operating over designed capacity? – How does your reject handling looks like? – Does a process audit/study is performed in a regular basis? Ÿ Factors that might affect the efficiency resulting in fiber losses: – Reject rates – Dilution rates in the screens and over the stages/system – Pressure balance over the screens – Instruments, calibration – Screen baskets technology and slot width / hole diameter
  17. 17. INTERNAL Costs mapping in a brown stock screening room Ÿ There are several factors to be considered when looking for savings in the screening room 31% 16% 13% 9% 3% 13% 9% 6% Cost of good fiber losses Cost of energy in screening Cost of energy in pumping Cost of wear and spare parts in warehouse Cost of baskets Availability loss due to unplannded shutdown Performance loss due to low performing screening Quality loss due to broke made
  18. 18. INTERNAL Costs mapping in a brown stock screening room Ÿ Example study shows that over 30% of the cost on screening room is related to fiber losses Ÿ Case example, reference mill study; – Laboratory samples showed a fiber content of 60% (good fibers) on final reject to be send to landfill – Mill has as an average around 18m3 per day of reject Ÿ What’s the situation with your screening room? WHERE ARE MY GOOD FIBERS GOING TO ? Total estimated waste to the landfill ≥ 4 adt/day
  19. 19. INTERNAL Identifying points of possible losses in your screening room Ÿ When a shive washer and a reject press is installed as last stage; – Shive washer equipment should have ≥ 80% efficiency in fiber recovery Ÿ Shive washer shall operate with low inlet consistency ≤1,2% and outlet consistency ≥ 15% – Reject press Ÿ Reject press equipment must dewatering the reject slurry to a consistency ≥ 30% Ÿ Recovered filtrate back to reject tank
  20. 20. INTERNAL Identifying points of possible losses in your screening room Ÿ When a reject press is installed as last stage; – Reject press Ÿ Reject press equipment must dewatering the reject slurry to a consistency ≥ 30% Ÿ Recovered filtrate back to reject tank – Last pressurized stage screen Ÿ If equipment is not overloaded, the reject going to reject press shall contain an amount of shives much higher than fibers (70/30)
  21. 21. INTERNAL Screening Excessive wear area Plugged Screen= No Screening Reject Thickening - Typical Phenomena Feed Rejects Typical wear pattern
  22. 22. INTERNAL Nimax db provides two stages in one basket
  23. 23. INTERNAL Nimax db™ with Belt Dilution Major Benefits • An additional screening stage is added without adding a new screen. No additional piping, motors, etc. • Increased capacity and screening efficiency • Reduced fiber losses at maintained screening efficiency because of the addition of another screening stage • Reduced and controlled reject thickening Nimax db ™
  24. 24. INTERNAL Screen Basket Products © Valmet | Screen products24 For low and high consistency pulp applications except machine screening For all applicationsDrilled baskets Nimax LD NimLuc For machine screening applicationsFor machine screening applications ScreenBoost Recoatings, NimCat, agreements, screening studies Recoatings, NimCat, agreements, screening studies
  25. 25. INTERNAL NimLuc screen basket family Focus on lower cost for targeted pulp quality Ÿ Designed for low and high consistency screening applications Ÿ NimLuc has more simple structure with less stages in manufacturing compared to Nimax Ÿ Seamless support rings of NimLuc will provide the precision of the dimensions 25 Nimax NimLuc © Valmet | Screen products Laser cut grooves in support rings Wires welded directly to support ring Grooves are milled to support ring Wires laser welded to support ring
  26. 26. INTERNAL Rotation direction of foils 26 Nimax LD Screen Basket Family New generation Laminar Design wire Ÿ The laminar flow pattern after the slot ensures outstanding operation without fiber blockage or stringing Ÿ Increases capacity by minimizing pressure drop and reducing flow resistance through the slots 0 10 20 30 40 50 60 70 0 0.5 1 1.5 2 2.5 3 PRESSUREDROP [kPa] PASSING SPEED THROUGH SLOTS, M/S Conventional basket 35% lower pressure drop
  27. 27. INTERNAL Ÿ Smooth and NWP drilled baskets, open area and drill pattern to meet customer demands Ÿ NimClear screen basket equipped with tiny holes for fiber recovery and water cleaning applications © Valmet | Screen products27 Drilled and Perforated Screen Baskets
  28. 28. INTERNAL MC Machinery 28
  29. 29. INTERNAL MC-pumps and chemical mixers Internal vacuum pump Thick stock pump to MC-pump InducerEnergy saving SMB SMF-Mixer CW-Pump CM-Pump
  30. 30. INTERNAL FlowHeater™ Process Machinery SMF-Mixer CM-PumpCW-Pump RFB SA-D SA-U TMC TSB-T/V
  31. 31. INTERNAL Where to look for energy savings Pump and mixer system 31 • Optimized pump dimensioning • Optimized mixing technology • Pressure losses • Correct dimensioning of Piping • Correct dimensioning of Valves • Degassing • Inlet levels • Drive
  32. 32. INTERNAL Identify pressure losses Example, 300-500 adt/d 32 • 20-25% valves • 10-15% mixer • 25-30% Piping • 25-30% Static height
  33. 33. INTERNAL Medium consistency pump CM/CW 33 Consistency 6-8% CMCW Consistency 9-14% 27 different sizes CMD
  34. 34. INTERNAL Efficient pumping – Valmet MC Pump 34 Low energy consumption MC pump T2 (E-stage) MC pump T3 (P-stage) MC pump T4 (Storage) VALMET EXIST. VALMET EXIST. VALMET EXIST. Pump type CM 2015-440 MCA 42-200 CM 2015-440 MCA 42-200 CM 2015-440 MPP-15-P1 Production 720 adt/d 720 adt/d 720 adt/d 720 adt/d 720 adt/d 720 adt/d Head (Pressure) 90 mwc 90 mwc 90 mwc 90 mwc 65 mwc 65 mwc Consistency 12 % 12 % 12 % 12 % 12 % 12 % Drive VFD Direct VFD Direct VFD Direct Cons. energy 120 kW 315 kW 120 kW 315 kW 83 kW 115 kW Install. Motor 160 kW 300 kW 160 kW 400 kW 110/132 kW 200 kW Pump speed 1805 rpm 1500 rpm 1805 rpm 1500 rpm 1555 rpm 1868 rpm Total Consumption today 730kW Total Consumption Valmet 323 kW Reduction – 407 kW CASE Study
  35. 35. INTERNAL Valmet SMF Mixer Modern mixing technology Ÿ “All-in-One” solution Ÿ Applicable on whole fiberline Ÿ Low chemical consumption Ÿ Low energy consumption Ÿ Low installation cost Ÿ Low maintenance cost – Few spare and wear parts – Easy maintenance – Low wear and tear 35 Considered to be the best on the market!
  36. 36. INTERNAL ALL-IN-ONE IS OUR CONCEPT Ÿ We add everything directly into the mixer Ÿ Highly effective mixing zone Ÿ Perfect control of mixing Ÿ Can be used as heater up to 20°C Ÿ Covers production levels up to 6400 admt/d Ÿ Low impact on fiber quality 36
  37. 37. INTERNAL Valmet SMF Mixer 37 Low energy consumption CASE STUDY Hardwood - Existing mixers Hardwood - New installations Position Cons.in [%] Production [adt/d] Consumed power [kW] Mixer type Installed power [kW] Consumed power [kW] Energy Reduction [%] D0 5 600 74 SMF-3040 45 30 59% D1 A 10 600 77 SMF-1525 30 21 72% D1 B 10 600 98 SMF-1525 30 21 79% Mill case shows up to 70% energy savings compared to conventional mixers.
  38. 38. INTERNAL Washing 38
  39. 39. INTERNAL Washing Technology – Upgrades & Rebuilds Challenges through the years... Ÿ Production increase Ÿ Energy consumption decrease Ÿ Improve washing efficiency – Reduce chemical consumption Ÿ Improve availability Ÿ Press conditions: – Mechanical problems? – Outlet consistency? – Feeding consistency? Ÿ Plugging problems? Ÿ Mechanical Improvements Ÿ Capacity & Process Improvements
  40. 40. INTERNAL ProDry Description Ÿ Insert cassettes for the TwinRoll press filtrate channels Ÿ Minimizes the pulp re-wetting Ÿ ProDry makes your washing more efficient and reduces the wash loss carry over. 40 Standard With ProDry Mantle section (Circumferential rings) Longitudinal filtrate channel Perforated plate
  41. 41. INTERNAL ProDry™ Benefits & Mill results Mill in Chile, DPA-1555 Ÿ DPA-1555 pre-bleach plant Ÿ ProDry was recommended due to poor outlet consistency caused by high production levels – The outlet pulp consistency has increased by from 25,3% up to 31,2%. – The outlet COD (kg/adt) has been reduced in 2,5 kgCOD/adt. – The mill reduced consumption of sulphuric acid, ClO2 and sodium hydroxid with the Prodry. 41 2012.09.21 Richard Barros - MIL41
  42. 42. INTERNAL ProStream™ 42
  43. 43. INTERNAL ProStream™ Ÿ Automatic system for high pressure cleaning of the press rolls – Control via DCS system – Cleaning interval can be set to match extent of scaling problems Ÿ Manual cleaning not needed – Personnel safety – Reduced labor cost – Reduced production downtime Ÿ Improved press performance – Optimized filtrate evacuation – Less fiber accumulation – Secure washing efficiency and press capacity 43
  44. 44. INTERNAL 44 44 Wash Filter Improvements Typical areas for improvement • Pulp Inlet - Piping - Dilution - Distribution profile • Washing zone - Shower arrangement - Nozzle type • Take off and wire cleaning - Several doctor options - Several cleaning system options • Conveying and shredding - Feed system - Rotor design • Filtrate system - Drop leg and tank design - Ventilation and degassing • Washer ventilation system - Closed filter hoods - Internal circulation system to reduce scrubber load
  45. 45. INTERNAL Valmet nozzle is designed to facilitate an even distribution of washing cleaning fluid. Valmet nozzles CSDU_H_2018_618-02
  46. 46. INTERNAL Background Washing distribution CSDU_H_2018_618-02 • Old SS steel standard nozzles • Valmet nozzles Valmet nozzles
  47. 47. INTERNAL Benefits Ÿ More even distribution of cleaning fluid Ÿ Strong and reliable construction due to PVDF ”Kynar” material Ÿ Reduced risk of blockage Ÿ Reduced wash water consumption Ÿ Reduced chemical consumption CSDU_H_2018_618-02
  48. 48. INTERNAL Wire cleaning device 48 Advantages • Hand- or automatically operated brush device • Filtrate to flush away fiber accumulations • More efficient wire cleaning increases filter runnability. Available for All filter-types: as CCA, VFA/B and MFA etc.
  49. 49. INTERNAL Wire cleaning device Automatic spray pipe type 1. Motor 2. Housing 3. Ball valves 4. Actuator device 49
  50. 50. INTERNAL

×