Power Utility Voith - datasheet-522

8/12/2019 Power Utility Voith - datasheet-522

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POWER UTILITY

The power and utility area consists of equipments, their potential outputs and general condition.

Boilers (8): All boiler supply steam to a common 875 psi header at 825

!o." #ower: $esign ma%imum steam flow 2&&,&&& '(hr

uel: )ludge, *ar+, T$ and natural gas

eneral condition of this boiler is good. The primary super heater sectionis an e%ception and was scheduled for partial replacement in year 2&&".

The -$ fan rotor was replaced in 2&&&.

!o.2 #ower: This boiler was dry fired and seerely damaged. -t is not consideredrepairable.

!o.2A #ac+age: $esign steam flow "/5,&&& '(hr

uel: !atural as eneral 0ondition: airThis boiler is need of super heater repairs. 5&1 of super heater tubes were

scheduled for replacement in 2&&&. The generator wall tubes in this boilerdo not hae ibration bars and stress related crac+ing is suspected to be

present no failures in this area to date3

!o.2* #ac+age: $esign steam flow "/5,&&& '(hruel: !atural as eneral 0ondition: 4ery ood

This boiler receied a maor oerhaul in "666 which included generator

wall tube replacement and ibration bars to preent stress related crac+ing.This boiler, li+e its twin 2A, is difficult to properly warm up and bring into

serice due to the lac+ of a startup burner and an oersied main burner

for starting purposes.

!o.20 #ac+age: $esign steam flow "/5,&&& '(hr

uel: !atural as eneral 0ondition: %cellentThis is a new boiler that went into operation in "666 to replace the !o.2

power boiler.

!o." 9aste eat: $esign steam flow /5,&&& '(hr

eat )ource: '2 as Turbine enerator %haust

This unit is not operational and requires a maor oerhaul before returningto serice. -t will also require retrofit of steam inection for !;% control

!o.2 9aste eat: $esign steam flow /5,&&& '(hr

eat )ource: '< as Turbine enerator %haustThis boiler was found to be in good condition following the inspection (

oerhaul of the gas turbine generator ( waste heat boiler unit in "666.


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=ecoery *oiler: $esigned to process 2." >> ' dry solids(day and generate 25&,&&& '(hrsteam

#rimary uel: *lac+ ?iquor )econdary uel: !atural as

This boiler is in poor condition oerall. The integrity of the furnace and

other pressure parts are in fair condition. The duct wor+, cascade

eaporators and precipitator are in e%tremely poor condition. ie of thetwenty two pendants in the intermediate super heater section hae been

remoed following tube failures in the past seeral years. A** conducteda study of the boiler capabilities considering the super heater issue and

concluded that the ma%imum steam output be limited to 2&&,&&& '(hr. This

equates to a ".8 >> dry solids(day firing rate. The recoery boiler waslast fired in 2&&& and is no longer considered an operational unit.

*lac+ ?iquor aporators: $esign is "2&& gpm, howeer they are limited to 6&& gpm due to

all internal body heaters being bypassed. eneral condition is fair.These units were last operated in 2&&&.

Turbine Generators (4)

!o." )team Turbine eneral lectric3: =ated 25,&&& @9, will operate at 9

)ingle /5' e%traction with condensing e%haust.

eneral condition: ood. $ue for maor oerhaul in2&&". >ar+ -- 0 is obsolete.

!o. )team Turbine 9estinghouse3: =ated 9

)ingle /5' e%traction with condensing e%haust.eneral condition: air. )cheduled for maor

oerhaul in 2&&&.

!o.2 as Turbine: =ated "/,&&& @9, not operational

!o.< as Turbine: =ated "/,&&& @9, limited to appro%imately

".5 >9 due to !;% emissions. This unit is not

equipped with steam inection for !;% control. This

unit was oerhauled in "666 and is in goodcondition.

15 K Ele!tri!al "istribution #$ste%

This system consists of original main bus and feeders, plus addBons that hae ta+en place in pastseeral years during e%pansion proects. The system is in fair condition but is not user friendly

and presents ris+ when bring the public utility on and off the >ill system. >aintaining designed

system oltages across the four buses could not be accomplished primarily due to transformer


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taps being froen in place. A study of entire electrical systems needs to be done in order to

proide for a reliable and efficient operation.

Boiler &ee' Water #$ste%

$emineraliers: 0onsists of three cation and three anion units. The units are rated in /&&

gpm each. The system is in good condition with new resin in all units. Allessel rubber liners were inspected and repaired in "666.

$eaerator: 0onsists of two heaters with one storage essel. The system is rated at ".2

million pounds per hour. The system is in good condition.

eed 9ater #umps: 0onsists of four 75& gpm pumps. Three pumps are steam turbine drien

and one electric. All four are in ery good condition.

Water #ul$

)een wells at site are capable of proiding 2& million gallons(day but are limited to "&1 of thetotal mill usage by goernmental regulation. All are in good condition. The surface water

treatment plant is capable of proiding 2& mgd. The city proides la+e water to surface water

treatment plant. quipment consists of a lift station, two clarifiers, eight multimedia filters,associated pumps and a three million gallon storage tan+. The filter media was replaced in 2&&&.

There are two sludge ponds.

Wasteater Treat%ent

ydraulic capacity appro%imately "8 mgd. 0onsists of two primary clarifiers, three aeration

basins, two secondary clarifiers, and a lift station to moe effluent water through pipe todischarge at a long distance. The system is in good condition.

#lu'*e "eaterin* Plant

0apable of dewatering up to 225 bone dry tons *$T3 per day of fuel to '" power boiler. The

system was upgraded to


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"EI-K PL,-T .,/OR PRO+E## E0UIP.E-T

Wareouse

*ale $ewiring: ;ne "3 ?amb >ar+ 5 ( "5&B&8B$ *ale $ewiring >achines.

=ated at 6& bales(hr each. -nstalled in 2&&&.

*ale $ewiring 0oneyor: !ielson C iebert 7DB"&D % "82EB2D=ated at , 2562 ;$)T#$. -nstalled in 2&&&.

#ulper eeder: !ewsprint 0oneyor: race >etal )lat 0oneyor =ated at ""65&;$)T#$. -nstalled in "662

>againe 0oneyor: race >etal )lat 0oneyor =ated at 2"" ;$)T#$.

-nstalled in "662

$rum #ulper eeder 0oneyor: !ielson C iebert 6/D % ""/.""E=ated at , "&/ ;$)T#$. -nstalled in 2&&&.

"ein2in* Plant

#ulping: Ahlstrom $rum #ulper F iberflow 25 e%tended

=ated at "7&& A$)T#$. -nstalled in 2&&&.

$ 0leaners: Three ill abricated "2D 0leaners=ated at "&76 #> G feed G feed G 2.671 cons. -nstalled in "662.

;ne "3 Thermo *lac+ 0lawson $iablo < )creen

-nstalled in "662.


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loatation: Two 23 lotation >i%ing 0ells F 4oith )uler ".5 >eter 0ells=ated at G "."81 cons. -nstalled in "662

ourteen "3 #rimary lotation 0ells F 4oith )uler < >eter 0ells

=ated at 2// #> G "."81 cons. -nstalled in "662

our 3 )econdary lotation 0ells F 4oith )uler 2 >eter 0ells

=ated at 2/5& #> -nstalled in "662

;ne "3 lotation >i%ing 0ell F 4oith )uler 00/(

=ated at 2&&&& #> -nstalled in 2&&&

)i% /3 #rimary lotation 0ells F 4oith )uler 00/(

=ated at "27&& #> -nstalled in 2&&&

Two 23 )econdary lotation 0ells F 4oith )uler 00/(

=ated at 52&& #> -nstalled in 2&&&

orward 0leaners: ie 53 *an+s of Alshtrom 0leaners ", =ows, =*5, )#H

=ated at /268 #> G &.6"5"1 cons each. -nstalled in 2&&&

our 3 *an+s of *eloit #*5& 0leaners F 8 0leaners per *an+

=ated at 2&"7 #> G &.81 cons per ban+. -nstalled in "662

Two 23 *an+s of *eloit #*2& 0leaners F 2& 0leaners per *an+

=ated at 58/ #> G &./1 cons per ban+. -nstalled in "662

;ne "3 *an+s of *eloit #*"& 0leaner F "& 0leaners per *an+=ated at "6< #> G &.B"5&&

=ated at 278& #> G &.751 cons. -nstalled in "662

;ne "3 Thermo *lac+ 0lawson )creens F iberprep )#>B8&&=ated at "?9B"8=ated at 8 G &.771 cons. -nstalled in "662

;ne "3 @aerner $is+ iltersF $B52&I28(?9B"8=ated at 6& ;$)T#$ -nstalled in 2&&&


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)crew #resses: Three -nstalled in 2&&&

;ne "3 Transfer 0oneyor F !ielson C eibert 2D % 77EB2D

?;A =ated at "7& T(hr G 2&& #> -nstalled in 2&&&

;ne "3 )toc+ 0oneyor F 0ontinental 0oneyor 0ured *elt2D % "6&&E =ated at "7& T(hr G -nstalled in 2&&&

-dled quipment Aailable for )ale: Two 23 igh 0onsistency ydra #ulpers

4oith F $& with ansen =4@2) 6.6) otors, eating

)crews, etc. *uilt in "66"

.,/OR E0UIP.E-T ,##ET#

Woo' 3an'lin* Prearation

>aor 0omponents hae been out of serice for appro%imately 5 years

". ?og andling: 0hain 0oneyors

2. 0hip(*ar+ andling: *elt 0oneyors


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5. 9ood 0hipping: ;ne "3 "&D F "5 @nife >urray 0hipper

/. =echipper: ;ne "3 &D F / @nife Arcowood7. 0hip )creens: ;ne "3 ' 8"2 *lac+ 0lawson F Two 23 =ote% 0hip

)creens

Pul .ill


". @raft Ag. $aily #roduction 0apabilityK *leached )9$K 575 Tons Hn *leached and

)emi *leached2. 0ontinuous $igester: @amyr

aor 0omponents hae been out of serice for appro%imately 2 years>a%imum production capacity is "7&& Tons per day

Blea! Plant

)equence, @raftK 0BB, TowersK " Hplow, 2 $ownlowK 5&& Tons per day


Pul Pro!essin*

$rainers: @raft >ill:


". )creens: < #rimary, 2 )econdary, " =eect ymac

2. 0leaners: " B 2&E >agna 0leanersill F 2 ymac, 2 Thune #resses

/. )creens: 6 F -mpco 4ibratory, "" F ymac

7. 0leaners: 5 F agna 0leaners, "B Two )tage , Twenty *ody *auer)team


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PRO+E## "E#+RIPTIO- &LOW "I,GR,.

$-!@ #=;0))

The dein+ mill was initially installed and run in "66< at a production rate of appro% any e%pansion proects occurred between "665 until 2&&" to replace the pulp productioncapacity after the shutdown of @raft, roundwood and T># mills. Total production of the plant

at full operation by design is "7&& T#$. >odifications to the $ein+ mill from to e%pansion

proects included changing from the batch pulpers and trash screens to a continuous drum pulperand trash screens. ;ther changes included modifications to the highBdensity cleaners and coarse

screens before the floatation cells, and remoal of the reerse screens after the floatation cells.

The pulping chemistry was changed to neutral p, and the screw presses were located after thedisc filters in the process.

The paper arries at dein+ plant by truc+ and rail. -t comes in bales and loose shipments. ;ld

newspapers +nown as ;!#, and old magaines +nown as ;> are shipped and are storedseparately so that they may be metered for the dein+ process. ;perators place the paper for the

pulpers on the proper coneyor. As the paper goes to the top its respectie coneyor, it passes

through a weighing deice, which determines how much paper is being fed to the pulper.


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$uring pulping, water, chemicals, ;!# and ;> are all added to the pulper. These wor+ to

hydrolye the fiber and also separate in+ and filler from the mi%ture. The system continuouslyfeeds into the drum pulper the desired quantities of hydrogen pero%ide, sodium silicate, $T#A

chelant3 and surfactant along with hot water and paper. As the paper traels through the drum,

the mechanical rubbing brought about by the rotation brea+s down the paper into pulp. The

chemicals and water help the paper to disintegrate for remoal of in+ from the fibers. The end

section of the pulper has a screen and shower noles and wash the pulp from the drum. As thepulp is flushed from the drum, the contaminants roll to the end and are discharged to the ground.

The pulp is pumped from the pulper to coarse screen feed chest. rom the chest, pulp is fed tohigh density cleaners in to ban+s. The high density cleaners remoe large material that is heaier

than water. These contaminants include roc+s, glass, nuts, bolts, etc. rom the high density

cleaners the stoc+ passes through two ban+s of centrifugal coarse screens with holes that remoeadditional reects from the stoc+. =eects from the quaternary screen are discharged to a sand

separator and are subsequently land filled.

After remoal of large contaminants, the pulp enters the floatation system for in+ remoal. Thestoc+ is diluted to a ".251 consistency after the floatation feed chest before it enters the

floatation mi%ing cell chamber. There are three lines of floatation with two stages each, theprimary stage and the secondary stage. -n each cell, air is drawn in and thoroughly mi%ed withthe pulp. The in+ attaches to the air bubbles and is turned into in+y foam which is s+immed off.

The accepted pulp e%its the bottom of first cell and moes to the second cell to repeat the process

through all seen cells on A and * line and si% cells on 0 line. The accepted pulp from theprimary floatation stage is discharged into a deareation chest to be further processed. The in+y

foam discharges into a weir and onto the secondary system. The secondary floatation stage

which operate li+e the primary stage, recoers acceptable fiber from the in+y foam. The in+yfoam reected from the secondary stage goes into the sludge tan+. The accepted pulp returns into

the floatation cells for additional cleaning.

The accepted pulp after being dein+ed in the floatation system must now be cleaned. The stoc+ ispumped to the forward cleaners. The forward cleaners perform under the same principles as the

high density cleaners, only at much lower consistency. There are four stages in forward cleaners

to remoe additional contaminants and in+ heaier than water. The accepted pulp enters the finescreen feed chest and the reects go to the sludge tan+. The fine screen also contains four stages

and remoes all but the smallest of particles. The accepted pulp from the fine screens is sent to

the disc filters and the reects are sent to the sludge tan+. The pulp sent to disc filters isdewatered to a "21 to "51 consistency using acuum. rom the disc filters the pulp is coneyed

and pumped to the screw press feed chest. )crew presses remoe the water from the stoc+ by

squeeing it at high pressure. The stoc+ e%its the press at appro%imately


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#A#= #=;0))


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The process for the paper machines begins with stoc+ preparation. The stoc+ preparation processis to bleach the mechanical and dein+ pulps with sodium hydrosulfite to improe brightness, and

meter these pulps together with bleached @raft. The pulps are mi%ed together in blend chests that

are agitated, and then diluted with recycled water to slurry of 661 water and "1 fiber. After

blending the stoc+ is deBaerated, screened to remoe contaminants not remoed in the pulpingprocess, dyed, p controlled, and heated. At this time, the pulp is ready for paper machines.

The paper machine comple% consists of three twin wire paper machines. All three papermachines ma+e a newspaper grade made from pulp manufactured in the mills for pulping

processes. The pulp furnishes ary with the grade of paper that is being manufactured. -n the wet

end of the paper machine, the mi%ed pulp is sprayed from the head bo% between two moingwire screens. 9ater is remoed from the pulp with acuum pumps which create a pressure

differential between the stoc+ and the screen. After passing between the wire screens, the stoc+

begins to form a paper sheet which passes through the press section of the machines. 9ater issqueeed out of the sheet while moing between seeral rollers. The sheet then enters the dryer

section where the water is remoed by eaporation. -n the dryer section, the sheet moes along aseries of rolls called the calendar stac+. The calendar stac+ is designed to remoe the wrin+les

and smooth the sheet. The sheet is then collected on a reel and then cut to customerspecifications. Through the paper machine process, the pulp is dewatered and dried from a 661

consistency to about a 1 consistency as finished paper. A large portion of the water that is

dewatered from the pulp is recycled and reused in the paper ma+ing process.


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#;9= )L)T>

The power and utilities department plays a +ey role in the manufacturing of newsprint. -t

supplies four serices to the mill: electricity, steam, air and water. The water is supplied to themill as surface water from a nearby la+e and from seen wells located on the mill site. 0hlorine

gas, used as *iocide, Alum and #olymer are added to the raw water as it enters the surface water

treatment plant. The water used to ma+e steam in the boilers at the mill must be treated before itsuse. $emineraliing is the process which remoes minerals in order to preent scaling on boiler

tubes. This is a critical concern on any boiler operation. There are si% boilers in the power and

utilities area that produce 875 psi steam. The !o." power boiler is a negatie draft type boilerwith a fluidied sand bed. This boiler is fueled form the bar+ from the woodyard, sludge from the

waste water treatment plant, and tire deried fuel or scrap tire chips3 which can be supplemented

with natural gas. -t produces 2&&,&&& pounds of steam per hour. There are also 2A, 2* and 20

pac+age boilers which are fired by natural gas and can each produce "/5,&&& pounds of steam

per hour. The last two boilers are the !o." and !o.2 waste heat boilers. The e%haust heatproduced in !o." and !o.2 gas turbines can be used to generate steam in the waste heat boilers.

These boilers can each produce 7&,&&& pounds of steam per hour which is an efficient use of millresources.


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9A)T9AT= T=AT>!T

The purpose of the wastewater treatment plant is to eliminate pollutants from the water so it can

be safely discharged. The mill uses an actiated sludge process to remoe these pollutants. The

main sewer carries wastewater generated at the mill into the diision structure. The processsewer at the dein+ plant also oins at this point. The influent is diided into two primary

clarifiers. )ludge is remoed from the bottom of the clarifiers and pumped to the surge tan+.

rom the clarifiers, the oerflow goes onto the chemical feed bo% where nutrients in the form ofammonia and phosphoric acid are supplemented. $efoamer is also fed on as needed basis. rom

the bo%, the effluent goes through the aeration basins which are equipped with mechanical

surface aerators. The effluent enters two secondary clarifiers for final clarification before it isdischarged to the outfall. A portion of the biological sludge that settles at the secondary clarifiers

is recycled bac+ to the aeration basins to maintain the microbial population.

rom the surge tan+, sludge is pumped to the sludge plant for dewatering. A portion of the dein+sludge is directly pumped from the dein+ plant to the sludge plant. )ludge is combined +ept

agitated in the mi% tan+s. #olymer and Alum are added to the sludge for conditioning. )ludge is


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pumped to floc+ tan+s which feed the graity belt thic+eners *TEs3. rom the *TEs the

sludge goes into the screw presses where any remaining water is e%tracted to achieeappro%imately 5&1 dryness. )ludge emerging from the screw presses is transported to the !o."

power boiler by a coneyor. The deried fuel is also deposited on this coneyor to be burned in

the boiler as supplemental fuel.

-!-)-! A!$ )-##-!

;nce the paper sheet has been manufactured, the rolls are processed and stored in the finishing

area prior to be shipped out to the customer. After the rolls are cut to the sie on the winder, theyare coneyed by a series of automatic eleators, coneyors, ramps, +ic+ers, cushion stops and

turntables, to the roll wrap area. After the rolls are inspected, a protectie wrap is placed onthem, inside protectie heads are inserted, and the roll ends are crimped. The roll ends are thenglued in preparation of protectie outside head application, using heat, the heads are sealed to the

ends of the roll.

After the rolls leae finishing, they enter the shipping area on one of the two coneyor belts. The

rolls are chec+ed for proper identification numbers, sie and weight and mar+ed for rail, truc+ or

warehouse storage for later shipments. The storage for paper at the mill is for 5,&&& tons of


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paper. At the time of loading, the rolls are secured with air bags, wood supports or metal

banding. ;nce a load is completed, the shipment is chec+ed for correct roll and weight count.

Documents

Power Utility Voith - datasheet-522