Toscotec TT DOES Solution An Efficient Package to Optimize the Drying Section of a Tissue Machine

Transcription

1 Toscotec TT DOES Solution An Efficient Package to Optimize the Drying Section of a Tissue Machine Tissue World Miami, March 014 TT DOES Solution A new integrated approach Tissue Machine Drying Energy Reduction and Recovery TT DOES Drying Optimization for Energy Saving Optimize Drying Efficiency Maximize Recovery of Unused Energy Engineered Solutions with Real World Results Tissue World Miami, March 014 1

2 TT DOES Solution Overview of the technologies Press section Yankee Hood Configuration Nip Width Nip Load Steel v Cast Iron Rib Design Head Insulation Hood Technology Hood Efficiency Balance 3 Tissue World Miami, March 014 Press Section Energy Savings vs Conventional Press Performance is critical for Maximizing Energy Saving Large Diameter Press 4 Post Press Dryness 0 Single press +10% +11% Large diameter press Double press +16% Shoe press Double Press Configuration Shoe Press NIP Pressure (MPa) 3, MPa Conventional press,8 MPa - SPR ,5 MPa Shoe Press NIP Length (mm) Post Press Dryness increase of 1% = Reduction of 4% Drying Energy 4 Tissue World Miami, March 014

3 Press Section Large Diameter Press configuration Larger Pressing Area Longer Dwell Time in Nip Increased Dryness at Given Pressure Higher same dryness (High Quality) Less bulk More bulk Less Installed Power Less Thermal Energy BULK Suction Press Higher same bulk (energy saving or more tonnes) Jumbo Press DRYNESS Up to 10% increase in Post Press Dryness from conventional press 5 Tissue World Miami, March 014 Press Section Double Press configuration Additional level of pressing water removal Decreases Bulk Less bulk More Installed Power Less Thermal Energy Up to 11% increase in Post Press Dryness from conventional press 6 Tissue World Miami, March 014 3

4 Press Section Shoe Press configuration Largest Pressing Area Highest Dwell Time in Nip Adjustable Pressure Profile Pressure Pressure Curve More bulk Less Installed Power Less Thermal Energy Nip Up to 16% increase in Post Press Dryness from conventional press 7 Tissue World Miami, March 014 Toscotec Steel Yankee Dryer Energy Saving Advantages 1. Reduced Shell Thickness - Up to 50 % vs Cast Iron. Increased Drying Capacity Minimum of 30% vs Cast Iron 3. Reduced Steam Energy Loss Up to 6% vs Uninsulated Heads Toscotec Patented Head Insulation 4. Reduced Weight - 35% less than Cast Iron Lower thermal inertia > faster warm up time > less wasted paper 5. Reduced Maintenance vs Bolted Head Design Toscotec Patented process for Welding Heads to Shell Uniform drying to edge of Yankee eliminates edge fiber build up No head mounting bolts 8 Tissue World Miami, March 014 4

5 Toscotec Steel Yankee Dryer Shell Thickness Savings Steel Construction nd Generation Rib Design Up to 50% Decrease in Shell Thickness More than 5% Increase in Drying Capacity TT SYD 13 years of success, 135 Steel Yankee Dryer Sold 9 Tissue World Miami, March 014 Toscotec Steel Yankee Dryer Patented head insulation Up to 6% reduction is Steam Energy Loss Waterproof Design Welded Head Design and Journal Attachment No Edge Over-drying No Edge Fiber Build Up Heat loss reduction (%) 7,0 6,0 5,0 4,0 3,0,0 1,0 0, Insulation thickness (mm) 10 Tissue World Miami, March 014 5

6 Milltech High Efficiency Hood Energy Saving Opportunities 1. Since 01 Milltech has been a division of Toscotec Close collaboration between Steel Yankee and Hood designers Comprehensive energy saving solution from ONE company. Hood Optimization Hood calibration Yankee vs Hood drying balance Low emission burner 3. Energy Recovery Equipment 4. Multigeneration dryness process 5. Customized solution based on fuel availability and operating costs 11 Tissue World Miami, March 014 Yankee hood & Air system ATACAMA Series MONO e MT STEREO e MT EXHAUST e MT HYBRID e MT SMART e MT MULTIGEN e MT Mono system gas YH Duo system gas/steam cascade/parallel YH Suction YH Hybrid steam YH High level of heat recovery YH Cogeneration Duo YH 1 Tissue World Miami, March 014 6

7 Milltech High Efficiency Hood Multigeneration and Energy Recovery Equipment Cogeneration Exhaust as well as Hood Exhaust Gases can be used for: Dryness by means of Hood Blowing Air (burners off) Steam self production (High and Low pressure) Machine Hall Heating Process Water Heating 13 Tissue World Miami, March 014 (4) Case Studies - Assumptions Conservative Assumptions used for Hypothetical Studies Steam Price = $6.00 / 1000lb (based on Gas Boiler at Specific Parameters) Industrial Gas Price = $6.50 / 1000ft3 (Monthly Average over period from 004 to 014) Source Energy Information Administration All 4 case studies are machine rebuilds Energy Savings Correlates Directly to Cost Savings Drying Rate Increases allow for Production Increases Collected Data Confirms Drying Rate Increase of Steel Yankee Drying Rate Increases allow for Production Increases 14 Tissue World Miami, March 014 7

8 Drying Rate of Toscotec Steel Yankee Dryer Cast Iron Yankee Replacement Drying Rate - FIELD DATA % % % % % Drying Rate [lb H 0/ft hr] Cast Iron TT SYD D=1 ft P= psig Width=149.6" D=1 ft P= 7.5 psig Width=108.3" D=1 ft P= 7.5 psig Width=145.7" D=15 ft P= psig Width=11." D=15 ft P= 79.7 psig Width=106.3" 15 Tissue World Miami, March 014 Drying Rate vs Pressure 15 FT Steel vs Cast Iron Yankee Drying Rate Capacity- FIELD DATA 5 0 Drying rate [lb/ft hr] Cast Iron Drying rate Steel Yankee Drying rate Pressure [psig] 16 Tissue World Miami, March 014 8

9 Case #1 Hood and Air System Replacement Tissue Machine features Paper Production: 60,000 tpy 16 ft Yankee Dryer Paper Width 13.4 (5.4 meters) Modifications Replaced Hood with Duosystem SMART e MT Gas < 0% Air System Electric Energy < 10% Steam < 4% 17 Tissue World Miami, March 014 Case # Ribbed Yankee replacement Drying Energy per Short Ton Produced Original Tissue Machine 1 Ribbed Cast Iron Yankee Modifications Replaced Yankee with TT SYD 1FT 46 fpm Speed Increase Energy Consumption [MMBTU] Steam Natural Gas 4.7 Paper Width Increase 0 Old TM TM With Modifications.3% More Production = 10,330 ton/year 5.3% Less Drying Energy = $ 93,951/year 18 Tissue World Miami, March 014 9

10 Case #3 Plain bore Yankee replacement Drying Energy per Short Ton Produced 7 Original Tissue Machine 1 Plain Bore Cast Iron Yankee Modifications Replaced Yankee with TT SYD fpm Yankee Speed Increase Energy Consumption [MMBTU] Old TM Steam Natural Gas TM With Modifications 17.3% More Production = 7,300 ton/year 5.4% Less Drying Energy = $114,53/year 19 Tissue World Miami, March 014 Case #4 Yankee and Press Roll Replacement Drying Energy per Short Ton Produced Original Tissue Machine 6 1 Ribbed Cast Iron Yankee Φ5.6 Blind Drilled Press Roll Modifications Replaced Yankee with TT SYD 1FT BDPR Diameter Increased to 31,7 Energy Consumption [MMBTU] Steam Natural Gas Post Press Dryness Increased by % Speed Increased by 1083 fpm 0 Old TM TM With Modifications 9.3% More Production = 9,16 Ston/year 17.4% Less Drying Energy = $70,783/year 0 Tissue World Miami, March

11 Toscotec TT DOES Solution An Efficient Package to Optimize the Drying Section of a Tissue Machine 1. Up to 16% Increase in Post Press Dryness. More Than 30% Increase in Drying Rate Capacity from Yankee 3. Up to 30% Increase in Production Capacity from Yankee Drying Rate Increase 4. Up to 30% Reduction in Gas Consumption 5. ROE from Energy Savings and Capacity Increase 6. Energy Recovery From Hood Exhaust Toscotec is at BOOTH N Tissue World Miami, March