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We accept the challenge!www.andritz.com
Diseno y aplicacion de las technologias del secado de tissue y su
impacto en medio ambienteAcotepac , Cali , Febrero 2016
George Nowakowski , Andritz Paper Machinery Ltd. , Montreal , Canada
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2 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Factores del impacto sobre medio ambiente
Consumo de la energia
Emisiones del proceso de combustion
Emisiones del polvo y de la niebla
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3 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Fossil fuels consumption
Diesel Oil, Natural Gas , LPG , Carbon
21%
55%
24%Drives
Vacuum SystemDrying
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4 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Energy Cost
Cost of Natural Gas
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5 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Energy Consumption in Tissue Drying Process
Typical Drying Energy Costs
200” (5.5m)
18 ft. (5.5m)
200 – 230 t/day
Large
140” (3.6m)
15 ft. (4.5m)
110 – 130 t/day
Medium
110” (2.8m)
12 ft. (3.6m)
US$1,680,000US$1,100,000US$670,000
US$2,800,000US$1,650,000US$1,145,000
US$480,000US$320,000US$230,000
70 – 90 t/day
Small
Sheet width
Machine diameter
Typical steam cost per
year ( gas heated boiler)
Typical natural gas cost
per year
Typical electrical energy
cost per year
Production
Machine size
Natural gas: US$7.9/MBTU; electricity: US$0.065/kW; steam : US$ 20/ton
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6 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Energy Consumption in Tissue Drying
Machine Size
Small2.8m; 12ft dia. Medium3.6m; 15ft dia. Large5.5m; 18ft dia.
Typical Production 70-90 T/day 110-130 T/day 200-230 T/day
Typical Steam
Consumption,
approx.
4,000 Kg/hr 6,500 Kg/hr 10,000 Kg/hr
Typical Steam Consumption Yankee Cylinders
Note: TAPPI Rw drying contribution split ,Yankee Dryer / Yankee Hood : 50/50
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7 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Hood Fuel Energy Consumption
Yankee
web
hood
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8 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Hood Fuel Energy Reduction
STATIC DYNAMIC
IMPINGEMENT DISTANCE (mm)
JET EFFICIENCY vs IMPINGEMENT DISTANCE
0
0.2
0.4
0.6
0.8
1
1.2
0 5 10 15 20 25 30 35 40
1
2
3
5
4
6
Typical : 3/4” hood to dryer gap
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9 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
0.3 0.4 0.5
30
35
40
45
25
0.1 0.2
Yankee Hood Fuel Energy Reduction
T SUPPLY = 875°F
V NOZZLE = 28,000 fpm
Basis W = 12.9 lb/3000 ft2
Pstm = 110 psi
Air Humidity (lb H2O/lb DA)
H e a t t o
H o o
d
( B t u / h r x 1 0 6 )
33-28= 5MMBTU/hrSavings: 600,600 US$/hr
Nat.Gas:US$14.3/MMBTU
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10 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Hood System Energy Reduction - Heat Recovery
Options
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11 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Hood System Energy Reduction - Cascading & Heat Recovery
s u p pl y
ai r
WE Hood DE Hood
s u p pl y
ai r
exhaust airmake up air
combustion air
recirculation air
fuel fuel
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12 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
s u p pl y
ai r
WE Hood DE Hood
s u p pl y
ai r
make up air
combustion air
recirculation air
steam toYankee
condensatefrom Yankee
exhaust airfuel fuel
Steam Saving approx.
30 %
Re Evaporation - Steam generation for the Yankee dryer
Yankee Steam Energy Reduction in Tissue Drying
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13 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Steam Energy Reduction in Tissue Drying
Re Evaporation - Steam generation for the Yankee dryer
Live Steam
Condensate
S3
CondensateHeat Exchanger
Steam and Condensate System YankeeReEvaporation System
ExhaustAir from
Hood
Existing S&C-System
New parts air system
New parts ReEvap
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14 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Condensate in
Condensate out
Exhaust air in
Exhaust air out
Heat exchanger - arrangement
Yankee Steam Energy Reduction in Tissue Drying
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15
Steam Consumption reduction
Process water preheating
Water flow :20m3/hr
Water temp. in : 24 CWater temp. out :65 C
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We accept the challenge!www.andritz.com
Andritz Steel Yankee
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17 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Advantages Steel vs. Cast Iron
Higher performance (up to 20 % more evaporation
by the Yankee depending on
diameter) due to lower wall thickness and higher possible
pressure (allowed by the properties
of steel)
Example : Cast Iron 15ft ( shell 38mm; rib 42mm)
Steel 15ft (shell 28mm; rib 33mm)
Full performance of the Yankee from the
first day on, no increase or decrease of the performance
during lifespan
Higher performance can be used for
more production or for energy savings
50
45
55
H e a t F l u x [ k W / m 2 ]
Lifetime
Steel Yankee
Cast Yankee
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18 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Energy Reduction in Tissue Drying
Energy Cost Savings with Steel Yankee vs. Cast Iron Yankee
Steam Gas Electricity Energy
Energy
Savings
Energy
Cost
Cost
Savingskg/h kg/h kWh/h kWh/h kWh/h €/h €/year
Conventional
Yankee4 806 425 427 8 588 0 334 0
PrimeDry
Steel Yankee5 975 361 328 8 316 271 319 121 500
(Values shown are indicative only)
Prices typical for Western Europe today,(changes from country to country and from millto mill possible)
Steam 20 € /t
Gas 0,5 € /kgElectric 0,06 € /kWh
Annual Energy Cost Savings up to
€120.000.- ( 5 %)
or 8 % production increasedue to higher Yankee performance
2,8 m working width | 17,5 gsm (toilet paper) | 15 ft Yankee | 1 press roll | 1800 m/min
Rw TAPPI value for Steel Yankee 15%
higher than for Cast Iron Yankee
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19 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Yankee Steam Energy Reduction in Tissue Drying
Energy Savings – Yankee Head Insulation
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20 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Fossil fuels – combustion emission & consumption reduction
Aplicacion del control automatica de la mezcla aire/combustible
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Fossil fuels combustion emission reduction
Ultra Low NOx , Low CO burners
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22 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Hood Burner System Emissions – Ultra Low NOx Burner
NOx0. 036 lbs/MBTU
CO
0. 184 lbsCO/MBTU
NOx
0. 06 lbs/MBTU
CO0. 30 lbs/MBTU
Typical Emission Requiremnts in North America
US Confidential
US Confidential
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23 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Dust Emissions in Tissue Production
Paper grade (supersoft, TAD) very high
Raw material (waste paper, short / long fiber) very high
Final dry content (< 5%) very high
Refining (freeness) high Coating high
Use of chemicals high
Creping (doctor operation) high
Dust generation : 0.5 – 1.5% of the gross production
(70% approx.captured by dust extraction system)
Dust generation : 0.5 – 1.5% of the gross production
(70% approx.captured by dust extraction system)
Risk of FiresRisk of ExplosionsRespiratory Health RiskPaper Breaks
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24 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Dust Control in Tissue Production - Regulations
ACGIH TLV’s : 10 mg/m³
(American Conference of Governmental Industrial
Hygienists)
OSHA PEL’s : 15 mg/m³ Total, 5 mg/m³ Respirable fraction
(Occupational Safety & Health Administration)
NIOSH REL’s : 10 mg/m³ Total, 5 mg/m³ Respirable
fraction
(National Institute for Occupational Safety & Health)
Occupational Exposure Values
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25 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Dust Collector
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26 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Dust Extraction System – Typical Header Location
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27 Paper Machines / March 2010
Wet dust extraction system- typical arrangement
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28 Paper Machines / March 2010
Dust Extraction System – Headers Location
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29 Paper Machines / March 2010
Dust Extraction – Typical Dust & Mist Separation Equipment
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30 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Tending Side Tissue Machine Dust Concentration - following system installation
Guarantee
0.5
0.86
1.29
0.810.69
0.95
0.57
0.92
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
mg/m3
1 2 3 4 5 6 7 8 9
Test samples
front side, outside machine frame
Samples 1 and 2: Reel
Samples 3 and 4: Doctor
Samples 5, 6, 7 and 8 between
reel and doctor
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Wet End Tissue Machine – Mist Generation
31 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
Typical Areas of Mist Generation
• Head Box• Former• Wire• Felt• Pressure Roll
Typical Impact on Environment
• Corrosion of building structure• Corrosion of equipment• Increased cost to maintain clean operation
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Wet End Mist Generation – Corrosion of building structure
32 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes
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Typical Arrangement of Mist Extraction System
33 Andritz Paper Machinery – Energy Reduction in Tissue Drying Processes