Vacuum System Case Studies For Board And Paper

Papelera de la Alqueria, Spain
VACUUM SYSTEM REBUILD

RESULTS:


  • Energy savings 663 kW
  • 2% dryness and average 11% more production
  • 90 000 m3/a water savings

Europac Viana PM4, Portugal
VACUUM SYSTEM REBUILD

RESULTS:

  • Power consumption is at the moment 45% of the original situation.
  • Water saving 330 000 m3/a. Cooling tower stopped.
  • One Turbo stopped because vacuum levels has been optimized based on Ecoflows

Stora Enso Skoghall BM8, Sweden
VACUUM SYSTEM REBUILD (LIQUID BOARD, 450-700 M/MIN, >60 t/h)

RESULTS:

  • Energy savings over 16.6 GWh/a
  • Very accurate vacuum control
  • Reduced maintenance costs
  • Significant water savings

Confidential BMx, China
VACUUM SYSTEM REBUILD (BOX BOARD, 185-400 gsm, 4.6 m)

RESULTS:

  • Vacuum system energy saving 1000 kW
  • Reduced maintenance costs
  • Cooling tower stopped
  • 70 000 m3/a water savings

Savon Sellu PM1, Finland
VACUUM SYSTEM REBUILD (3-NIP PRESS, SC-FLUTING, 800 M/MIN)

RESULTS:

  • Energy savings 1100 kW (35 - 40% less than original situation)
  • Dryness after press +1,5%
  • Production increase +8 %
  • Steam savings 7%
  • Significant water savings

Hadera Paper PM8, Israel
GREENFIELD VOITH TESTLINER MACHINE

KEY TARGETS:

  • Top energy efficiency
  • No water consumption
  • Backup process connections
  • Savings in building cost

Stora Enso Ostroleka PM5, Poland
GREENFIELD VOITH LINERBOARD MACHINE

KEY TARGETS:

  • Top energy efficiency
  • No water consumption
  • Backup process connections
  • Savings in building cost
  • Savings in piping cost

RESULTS:

  • Energy efficiency targets reached
  • No seal water, no cooling water
  • Backup connections and capacity available

RESULTS:

  • Energy efficiency targets reached
  • No seal water, no cooling water
  • Compact design: Turbos on top of concrete separators
  • Simplified, inexpensive piping
  • Backup connections and capacity available

DS Smith Kemsley PM6, UK
MULTISTAGE BLOWER SYSTEM REBUILD

RESULTS:

  • Project main target was to improve system reliability.
  • System adjustability is much better than before.
  • Power consumption is at the moment 45% of the original situation

Oyka Paper Caycuma PM1, Turkey
VACUUM SYSTEM REBUILD (3-NIP PRESS WITH SHOE, SACK AND KRAFTLINER, 650 M/MIN)

RESULTS:

  • Energy savings 1150 kW
  • 10 000 m3/a water savings

Smurfit Kappa Coronel Suarez PM1, Argentina
VACUUM SYSTEM REBUILD (TANDEM NIP PRESS,TEST LINER 100 – 200 g/m2)

RESULTS:

  • Energy savings 225 kW (52% less than the original situation)
  • Improved profiles and ~2 % lower steam usage
  • 32 000 m3/a water savings

Confidential Mill PMx
VACUUM SYSTEM REBUILD (BELOIT 3-NIP WITH SHOE, LINERBOARD, 600-800 M/MIN)

RESULTS:

  • Energy savings 555 kW (40% less than the original situation)
  • Significant water savings

Confidential PMx, USA
VACUUM SYSTEM REBUILD AND DOCTORING IMPROVEMENT (BELOIT 3-NIP PRESS), SACK & KRAFTLINER, 3150 FPM)

Vacuum system was studied in April 2012 and calculations showed significant energy saving potential. Vacuum system includes three (3) single stage blowers

  • Vacuum system was rebuild and automatic throttle valves were added to all vacuum positions
  • Ecoflow system for the press section
  • 1st, 2nd and 3rd press doctor were rebuild and new save-all pan was added for 2nd press roll
  • RSP Air Blades were installed for 1st and 2nd press rolls
  • Energy saving > 750 Hp

KRPA Hostinne PM6, Czech Republic
VACUUM SYSTEM REBUILD (Greaseproof paper)

RESULTS:

  • Energy savings 370 kW
  • Savings in seal water
  • Improved vacuum control
  • Flexible use in different grammages

Reno De Medici Santa Guistina BM1, Italy
MACHINE REBUILD WITH ONE TURBO BLOWER (BOARD)

  • New forming section from Andritz
  • Additional vacuum capacity needed
  • Limited space for installation
  • ROI compared to similar size LRP was less than 1 year


RESULTS:

  • Very easy to handle
  • Very low energy consumption
  • No problems with the start up
  • Turbo runs always in automatic mode

Confidential PM1, USA
VACUUM SYSTEM REBUILD

RESULTS:

  • Project main target was to improve system reliability
  • System adjustability is much better than before
  • Power consumption is at the moment 50% of the original situation
  • Production increase 8-12%

Confidential Mill PM3, China
GREENFIELD VOITH FINE PAPER MACHINE

KEY TARGETS:

  • Top energy efficiency
  • Water free system
  • Compact design: Turbo blowers on top of concrete separators
  • Simplified, inexpensive piping
  • Backup process connections
  • Savings in building cost
  • Savings in piping cost

RESULTS:

  • Energy efficiency targets reached immediately after the start-up
  • Very easy to operate and optimize
  • Backup connections and capacity available

Vege PM1, Turkey
VACUUM SYSTEM REBUILD WITH EP TURBO BLOWERS (3-NIP PRESS FINE PAPER, 370-650 M/MIN)

RESULTS:

  • Energy savings 700 kW
  • Specific steam consumption reduced -10%.
  • 60 000 m3/a water savings

Confidential, Slovakia
VACUUM SYSTEM REBUILD (SINGLE SHOE PRESS, FINE PAPER, 1550 M/MIN)

RESULTS:

  • Energy savings 1000 kW (46% less than original situation)
  • Specific energy consumption 24 kwh/ton.
  • Cooling tower stopped
  • Exhaust air savings 1 ton/h of steam

Sappi Stockstadt PM1, Germany
SULZER TURBO SYSTEM REBUILT WITH RUNECO VACUUM SYSTEM

RESULTS:

  • Power consumption is 55 % of the original, ie. 18 kWh/ton
  • No seal water and no need for civil work

Confidential, Slovakia
VACUUM SYSTEM REBUILD WITH TURBO BLOWER (FINE PAPER)

RESULTS:

  • Energy savings 310 kW (43% less than original situation)
  • Improved vacuum control

Stora Enso Kaukopää PM8, Finland
SULZER TURBO SYSTEM REBUILT WITH RUNECO VACUUM SYSTEM

RESULTS:

  • Energy savings 945 kW (46% less than original situation)
  • Water savings 140 000 m3/a

UPM Chapelle PM3, France
SULZER TURBO SYSTEM REBUILT WITH RUNECO VACUUM SYSTEM

Chapelle PM3 vacuum system was fully rebuilt 2012 together with wire and press section dewatering optimization. Chapelle PM3 is newsprint machine (wire width 6,0 meters) with conventional tri-nip press and machine speed up to 1250 m/min.

  • Three (3) EP Turbo blowers from RUNTECH replaced all old blowers and water ring vacuum pumps.
  • Project included also new double doctor for suction couch roll, new doctor for 1st press grooved roll and press suction roll save-all modification.
  • EP Turbo compact design minimized civil work, piping and installation time.

RESULTS:

“New vacuum system allows a more reliable and smoother runnability than the old system. Possibility to install it on existing foundation and the flexibility of the Turbos thanks to variable speed allows the system to adapt in lots of situation and a wide functioning area. Energy saving already made is quite significant and future optimization is still planned.

Doctor optimization has been a key to improve press section dewatering and improve dryness after press section for speed development. Being as well a vacuum system expert and a doctoring expert is really a runtech strength. This has allowed to see the project as a whole package and to really optimize the system.”

Sebastien Finel, Production Manager PM3.


Leipa Schwedt PM4, Germany
TURN-KEY VACUUM SYSTEM REBUILD (LWC, 1600 m/min)

Original (since 2004) vacuum system was oversized but it was not possible to just stop any of the existing blowers.

One EP500 Turbo replaced 1,3 MW multistage unit.

RESULTS:

  • Energy saving 900 kW (30% less than original situation)

Sachsen Papier PM1, Germany
NASH PUMP SYSTEM REBUILT PARTIALLY WITH EP TURBO TO HYBRID SYSTEM

RESULTS:

  • Energy saving 655 kW