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New Age Vacuum System Concepts for Tissue Machines
New Technology
Presented by:Troy MillerNational Sales Manager
Quick points• High vacuum ≠ high productivity
• In many cases nip dewatering, not vacuum level, improves production
• Need to measure water removal accurately and effectively
How to build efficient vacuum system
RuntechTurbo
EcoFlowOnline Measuring Device
Save-All & Doctoring System
SPR’s & Shoe Presses
How to build efficient vacuum system
RuntechTurbo Blower
Runtech TurboTM• Variable speed/capacity controlled turbo blower saves energy and eliminates water
consumption in vacuum system• Wide capacity range thanks to frequency
converter• Impeller fitted on motor shaft > no gearbox• Air cooled, no water needed• Easy to install • Excellent option for new or rebuild vacuum system
and optimization• Fast and uncomplicated maintenance• Turbo energy recoverable
Product comparison
Typical scope of supply
ECODROP WATER SEPARATORDIA 2000 mm
OIL LUBRICATION UNIT
EP600 WITH MOTOREXHAUST (SILENCER)
EXTRACTION PUMP
COOLING FAN
Heat recovery1. Air / Air2. Air / Water
• Part of hood heat recovery• Process water heating• Building heating• Roof heating• Etc.
How to build efficient vacuum system
RuntechTurbo Blower
Save-All & Doctoring System
SPR’s & Shoe Presses
Save-All: Typical problemsWATER JET MISSES THE SAVE-ALL
POOR DOCTORING > REWETTING
Optimized suction roll doctoring
EcoFlowSave-all DoctoringAir
How to build efficient vacuum system
RuntechTurbo Blower
EcoFlowOnline Measuring Device
Save-All & Doctoring System
SPR’s & Shoe Presses
EcoFlowTM Dewatering Measurement• Continous Online measuring device for
Suction Press Roll and Uhle box flow• Optimize dewatering and vacuum levels• Minimize vacuum energy consumption• Felt Optimization
– Minimize start up time of new felts– Maximize felt life– Reduce felt chemical usage/need– Optimize HP shower pressure
based on felt condition.
Felt cycle example
How to save energy?
RuntechTurbo
EcoFlowOnline Measuring Device
Save-All & Doctoring System
SPR’s & Shoe Presses
RuntechTurbo
Ecoflowdewatering
measurement
Doctoring and save-all
optimization
Exhaust heat recovery
Energy savings
30 - 60 %
Dryness after press increase
Steam saving
BEST DEWATERING CONTROL
IMPROVE RUNNABILITY
DIRECT BLOW TO HOOD OR VIA HEAT
EXCHANGER
MAXIMIZED DEWATERING
OPTIMAL VACUUMS
Best Dewatering vacuum
1% DRYNESS > 4% SAVINGS
HOT EXHAUST AIR
OPTIMAL VACUUMS
How to save energy?
Benchmarking – Tissue Papers
Turbos vs LRP
Doctoring improvement
Felt and vacuum level optimization
EcofIow
Ecoflow
Vacuum
PIC
Save-All
Uhle Boxes
Fine tuning uhle box vacuum
429 GPM
388 GPM
11.8
Vacuum inches of Hg
11.2 10.6 10 9.8 8.8 8.2
530 GPM 41 GPM Increase
Ecoflow
Vacuum
PICPress
waterUHLE Save all Total
Pickup 45.1 GPM 189.9 GPM 235 GPM
% 19.2 80.8 .47 ratio
1st press 148.8 GPM 32.2 GPM 181 GPM
% 82.2 17.8 .37 ratio
3rd press 3.4 GPM 76.6 GPM 80 GPM
% 4.3 95.7 .16 ratio
Press water removal rate 1877 l/m 496 GPM
Ecoflow
Optmized Save-All & Doctoring System
Uhle Boxes
Before/After Results: 67 GPM more water removed
Uhle box vacuum vs air flow
450 HP
210 HP
SAVING $115,000/YEAR
17.7” 16.2” 14.7” 13.2 11.8” 10.3” inches of Hg
8476 CFM
7416 CFM
6357 CFM
5297 CFM
4238 CFM
3178 CFM
2119 CFM
1059 CFM
RESULTS• Two EP500-D1 units to fulfill the vacuum requirements• Only one turbo is used• Vacuum levels optimized based on Ecoflows• Energy efficiency targets reached• Turbo exhaust air heat recovery system• No seal water, no cooling water
New system kWInstalled capacity 1000
- 2 Turbo’s
Operating power 300-350
Tissue PM9, 10, 11, 12NEW TISSUE MACHINE VACUUM SYSTEM (217 inches)
Confidential TAD Tissue PM1VACUUM SYSTEM REBUILD (220 inches, 3641 fpm)
Old system kWLRP x 6
Total 2607
Old system vs. Turbo blower
Pow
er k
W
Old system
Turbo blower
2800
0
New system kW2 x EP Turbo’s:
- EP500-700-D1
- EP500-700-S
Total 1020
Summary• High vacuum ≠ high productivity
• In many cases nip dewatering, not vacuum level, improves production
• Need to measure water removal accurately and effectively
