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
title, author short name | 2007-08-xx | 4
1. How can energy be saved?
- Avoid flow losses!
Excentricity instead of flow resistant directional baffles
Conventiona IntensaPulper IP
l
title, author short name | 2007-08-xx | 5
1. How can energy be saved?
- Avoid flow losses!- Color test
Conventionel
Intensa
5 sec
Pulper
10 sec
15 sec
Mixing by excentricity, instead of
baffles title, author short name | 2007-08-xx | 6
Investigate your savings! title, author short name | 2007-08-xx | 7
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 ②**
Bale Breaker 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
title, author short name | 2007-08-xx | 10
Projects at a Glance
Customer in Thailand
Pulper type UP10 Scope of supply:
Furnish AOCC and LOCC
Intensa Deflector
Rotor Modification
Tonnage 404 bdmt/day
Rotor cap with Eddy
Operation Continuous Cross
Operation volume 38 m3 Installation on site
Installed power 710 kW Startup supervision
Power
590 kW in average Measurement before
consumption and after rebuild
Consistency 3,5%
title, author short name | 2007-08-xx | 11
Results of rebuild-ROI calculation
Customer in Thailand
Before After
Power consumption 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
Cost saving per year
(with 350 days per year) 42.350 €/year ROI ≈ 13 months
title, author short name | 2007-08-xx | 12
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 Eclipse Rotor
12.5 mm Gap 5 mm Gap
title, author short name | 2007-08-xx | 15
Eclipse Rotor: Energy saver for DIP applications
Head to head trials: Current Step Rotor vs. Eclipse Rotor
Development of Power Consumption vs. Rotor Tip Speed
Power consumption [kW]
up to minus 30% power
consumption (kW)
at 20% higher
throughput level for
Eclipse Rotor
Rotor tip speed [m/s]
title, author short name | 2007-08-xx | 16
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%
specific energy
Spec. energy [kWh/t]
at 20% higher
throughput level for
Eclipse Rotor
Rotor tip speed [m/s]
title, author short name | 2007-08-xx | 17
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
title, author short name | 2007-08-xx | 18
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 Screen Basket old
higher open area
title, author short name | 2007-08-xx | 22
Reduction ofPower Consumption in First Stage:
Situation before upgrade: Installed power: 2 x 132 kW
rotor speed: 550 rpm
power consumption: 2 x 110 kW
Situation after upgrade: Installed power: 2 x 132 kW
rotor speed: 440 rpm
power consumption: 2 x 80 kW
Annual savings in energy at 350 running days a year:
504.000 kWH / year @ 0,07 €/kWh = 35.280,-- €/year
title, author short name | 2007-08-xx | 23
Sticky removal efficiency before upgrade:
1st Stage:
ηSticky 60%
title, author short name | 2007-08-xx | 24
Sticky removal efficiency after upgrade:
1st Stage:
ηSticky 74%
title, author short name | 2007-08-xx | 25
C-bar™ Q
The High Capacity Screen Basket
for Stock Preparation
C-barTM Q
Profile Relative
width open
[mm] area
[%]
length unit length unit C-barTM S 3.3 100
Standard bar Narrow bar
C-barTM S C-barTM Q
(previous SQ) C-barTM Q 2.7 ~120
More bars at given length higher number of slots higher open area
title, author short name | 2007-08-xx | 27
C-barTM Q – Results of mill tests:
Influence on sticky removal
10
09 C-barTM S Sticky efficiency at
0
8 C-barTM Q same slot velocity
Sticky efficiency
0
7 seems to be same
0
6
B&P with
0
5
DIP C-barTM S and Q
0
4
[%]
0
3
0
2 Sticky efficiency is
0
1 better with lower
00
1 1, 1, 1, 1, 2
slot velocity
2 4 velocity6
Slot 8
[m/s]
title, author short name | 2007-08-xx | 28
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“
title, author short name | 2007-08-xx | 29
C-bar™ / MF Rotor Combination
Best screening efficiency / sticky and dirt removal
title, author short name | 2007-08-xx | 30
C-bar™ / MF Rotor Combination
title, author short name | 2007-08-xx | 31
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
title, author short name | 2007-08-xx | 34
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.
title, author short name | 2007-08-xx | 35
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
title, author short name | 2007-08-xx | 36
EcoMizer™ Technology
Influence on sand separation
100
Sand removal [%]
98
96
conventional cleaner
94 (without back-flushing water)
cleaner with tangential
92 water injection
EcoMizer™ Cleaner
90
0 5 10 15 20 25 30 35
Fiber losses [%]
title, author short name | 2007-08-xx | 37
Rebuild to EcoMizer technology
Example: Stock prep Newsprint – A500T -1-
Inlet 246 Accept
Before 68 1st step
After
26 17e fibre loss reduction
Energy 8 4e Energy
1.040 kW 1e 945 kW
rebuild to EcoMizer™
Fibre losses not needed anymore Fibre losses
existing cleaner
3,67 t/d 1,2 t/d
Reject Reject
6,6 t @ 45% ash • Energy 40.000 € 4,3 t @ 72% ash
7-stage
• Fibre losses 343.000 € 5-stage
cascade
cascade
• Savings 383.000 € /year
title, author short name | 2007-08-xx | 38
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
title, author short name | 2007-08-xx | 41
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
title, author short name | 2007-08-xx | 43
PLURALIS – Advantages of a new concept
• Small bars & optimized grooves = more bars @ same diameter
• More bars = more cutting edge length (CEL)
Refining intensity
Net refining power [kW]
Specific edge load [J/m] =
Cutting edge length [km/s]
• More CEL = lower SEL = lower refining intensity possible
• Energy savings against standard designs = 10 – 20 % possible
title, author short name | 2007-08-xx | 44
PLURALIS design =
reduction of specific edge load SEL by increase of CEL
b
b
g
b = bar width
g = groove width more CEL
g
lower Energy @ same Technology
title, author short name | 2007-08-xx | 45
Advantages by using Pluralis fillings
save Energy = COST SAVINGS boost Quality = TECHNOLOGY
80
Tensile index [Nm/g]
50
Freeness [SR]
40 60
30 40
20 20
10 0
0 100 200 300 0 100 200 300
Total spec. energy [kWh/t] Total spec. energy [kWh/t]
Fillings type Spec. edge load
Pluralis
1 J/m
Common
Bleached Brazil Eucalypt pulp
title, author short name | 2007-08-xx | 46
title, author short name | 2007-08-xx | 47
