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Cooking and Fiberline

Possibilities forImprovementsPlata Region SeminarJune 13th, 2016Buenos Aires

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Contact information

Richard BarrosManager, Mill ImprovementsPaper and Fiber TechnologiesServices Business Line

Valmet Celulose Papel e Energia LtdaRua Pedro de Alcântara Meira, 130183704-530 Araucária, Paraná StateBrazil

Mobile phone:+55 41 9269 8482Tel: +55 41 3358 4823Fax: +55 41 3358 4728

e-mail: richard.barros@valmet.com

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Agenda

Batch Cooking

Date Author Title INTERNAL3

Brown Stock Screening

MC Machinery

Washing

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Batch Cooking

4

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CHIP SILO(OPTIONAL)

DIGESTERS LIQUOR TANKS

NCG ANDTURPENTINESYSTEM

HEAT EXCHANGERS

DISCHARGE TANK

LIQUORACCUMULATORS

CHIP FEEDING TODIGESTERS WITHSCREW CONVEYORS

LIQUOR PIPES TOAND FROMDIGESTERS

Equipment Introduction

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Equipment Introduction

SCREEN

DIRECT STEAM

SCREEN

CHIP SCREWCONVEYOR

DEGASSING SCREEN CHIP STEAM PACKER

CIRCULATION PUMP

DISCHARGE PUMP

NOZZLES FORDISCHARGE DILUTION

CIRCULATION

CIRCULATION

LIQUORS INTODIGESTER

LIQUORS OUTFROM DIGESTER

CAPPING VALVE

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Single digestor - benefits

ü An extra or new digestor canbring more flexibility forcurrent production

ü Capacity increaseü New designes can attend

higher capacities comparedto existing ones(replacement cases)

ü In normal applications, a newdigestor (in parallel withexisting ones) can increasethe production about 10-20%

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Chip packing system

ü Chip packing system withair evacuation and dustseparation.

ü Air evacuation either fromtop or from suctionscreen.

ü Packing degree 15-20%depending on rawmaterial.

ü Composed of steampacker, cyclone, dust boxand exhaust fan.

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Chip packing systemBenefits and principal arrangements

ü Cycle time saving fromsimultaneous packingand chip filling

ü Preheating of chips withLP-steam

ü More chips per digestermeans also higherproduction

ü Normal applications achip packing system canincrease the productionabout 10-15%

Lowpressuresteam lineand valveto controleachdigestor

Shut-offvalve for airevacuationfor eachdigestor

Evacuation airfan andcyclone. Oneunit per chipfeeding line.Even if 2 fillingsare occurringsimultaneously,2 lines areapplied

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Hot and White Black Liquor AccumulatorsHot Liquor Fill for Softwoods

ü Hot black liquor treatment– Hot black liquor impregnation– Heating of digester with liquor

displacement– Residual alkali control and profile in

order to ensure optimum conditions– Spent soluble calcium rich

impregnation liquor is taken into K-tankfor futher processing

ü Hot white liquor fill– Fresh alkali charging

Date Author Title10

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Black Liquor AccumulatorProduction increase and more stable steam consumption

ü Higher temperatureduring cooking circulationheating, for instance,120°C instead of 80°C –brings up to 40 min timesaving during the chipfilling and impregnation

ü Continuos heating –stability of steamconsumption

ü In normal applications, aHBL accumulator canincrease the productionabout 20-25%

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Chip screws and chip feeding systemsFor batch digesters with and without capping valve

ü Electric motor and gearbox-driven screw conveyor forchip feeding

ü High safety; no dusting,closed design

ü Possible to run in bothdirections

ü Single machine length up to12 meters

ü Capacity up to 1500 loose m3

of chips / hourü Compared to belt Chip screw

offers even capacity (nooverflows), less dust etc.

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Knot pumpingBenefits

ü Direct pumping of knots tothe digester(s).

ü Pumping consistency 4%to prevent plugging oflines.

ü Trouble-free operation andlow energy consumptiondue to simple and provendesign.

ü No presses or blowersneeded.

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SuperHeaterDirect heating system for the liquor circulations

ü Direct steam heating systemdesigned for trouble-freeoperation

ü Designed and used to replaceheat exchangers and to removethe problems caused by indirectheat transfer (scaling, poor heateconomy)

ü Steam condensate improvesdigester washing

ü As most of the equipment isinstalled inside the existingpipeline, very little space isrequired

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Brown Stock Screening

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Valmet’s screening philosophyToday’s development Improvements Area

ü New designs targeting capacityover 5000 adt/d for single lines

ü Focus on reject handlingsystem

ü Product PortfolioCompetitiveness analyses in aregular bases– What is our customer requirements

and how can we reach theirexpectations?

ü Is it your screening roomoperating over designedcapacity?– How does your reject handling looks

like?– Does a process audit/study is

performed in a regular basis?

ü Factors that might affect theefficiency resulting in fiberlosses:– Reject rates– Dilution rates in the screens and over

the stages/system– Pressure balance over the screens– Instruments, calibration– Screen baskets technology and slot

width / hole diameter

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Costs mapping in a brown stock screening room

ü There are several factors to be considered when looking for savingsin the screening room

31%

16%13%

9%3%

13%

9% 6%

Cost of good fiber losses

Cost of energy in screening

Cost of energy in pumping

Cost of wear and spare partsin warehouseCost of baskets

Availability loss due tounplannded shutdownPerformance loss due to lowperforming screeningQuality loss due to brokemade

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Costs mapping in a brown stock screening room

ü Example study shows that over 30% of the cost on screening room isrelated to fiber losses

ü Case example, reference mill study;– Laboratory samples showed a fiber content of 60% (good fibers) on final reject to be

send to landfill– Mill has as an average around 18m3 per day of reject

ü What’s the situation with your screening room?

WHERE ARE MY GOOD FIBERS GOING TO ?

Total estimated waste to the landfill ≥ 4 adt/day

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Identifying points of possible losses in yourscreening room

ü When a shive washer and areject press is installed as laststage;– Shive washer equipment should

have ≥ 80% efficiency in fiberrecoveryü Shive washer shall operate with

low inlet consistency ≤1,2% andoutlet consistency ≥ 15%

– Reject pressü Reject press equipment must

dewatering the reject slurry to aconsistency ≥ 30%

ü Recovered filtrate back to rejecttank

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Identifying points of possible losses in yourscreening room

ü When a reject press isinstalled as last stage;– Reject pressü Reject press equipment must

dewatering the reject slurry toa consistency ≥ 30%

ü Recovered filtrate back toreject tank

– Last pressurized stage screenü If equipment is not overloaded,

the reject going to reject pressshall contain an amount ofshives much higher than fibers(70/30)

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Screening

Excessive wear areaPlugged Screen=No Screening

Reject Thickening - Typical Phenomena

Feed

Rejects

Typical wear pattern

INTERNALNimax db provides two stages in one basket

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Nimax db™ with Belt DilutionMajor Benefits

• An additional screening stage is addedwithout adding a new screen. Noadditional piping, motors, etc.

• Increased capacity and screeningefficiency

• Reduced fiber losses at maintainedscreening efficiency because of theaddition of another screening stage

• Reduced and controlled rejectthickening

Nimax db™

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Screen Basket Products

© Valmet | Screen products24

For low and high consistency pulpapplications except machinescreening

For all applicationsDrilledbaskets

Nimax LD

NimLuc

For machine screening applicationsFor machine screening applications

ScreenBoost Recoatings, NimCat, agreements,screening studiesRecoatings, NimCat, agreements,screening studies

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NimLuc screen basket familyFocus on lower cost for targeted pulp quality

ü Designed for low and highconsistency screeningapplicationsü NimLuc has more simple

structure with less stages inmanufacturing compared toNimaxü Seamless support rings of

NimLuc will provide theprecision of the dimensions

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Nimax

NimLuc

© Valmet | Screen products

Laser cut grooves in support ringsWires welded directly to support ring

Grooves are milled to support ringWires laser welded to support ring

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Rotation direction of foils

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Nimax LD Screen Basket FamilyNew generation Laminar Design wire

ü The laminar flow pattern after the slotensures outstanding operation withoutfiber blockage or stringingü Increases capacity by minimizing

pressure drop and reducing flowresistance through the slots

0

10

20

30

40

50

60

70

0 0.5 1 1.5 2 2.5 3

PR

ES

SU

RE

DR

OP

[kP

a]

PASSING SPEED THROUGH SLOTS, M/S

Conventional basket

35% lowerpressure drop

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ü Smooth and NWP drilled baskets,open area and drill pattern to meetcustomer demands

ü NimClear screen basket equippedwith tiny holes for fiber recovery andwater cleaning applications

© Valmet | Screen products27

Drilled and Perforated Screen Baskets

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MC Machinery

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MC-pumps and chemical mixers

Internalvacuum pump

Thick stock pumpto MC-pump

InducerEnergy savingSMB

SMF-MixerCW-Pump CM-Pump

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FlowHeater™Process Machinery

SMF-Mixer

CM-PumpCW-PumpRFB

SA-D SA-U TMC TSB-T/V

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Where to look for energy savingsPump and mixer system

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• Optimized pump dimensioning

• Optimized mixing technology

• Pressure losses

• Correct dimensioning of Piping

• Correct dimensioning of Valves

• Degassing

• Inlet levels

• Drive

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Identify pressure lossesExample, 300-500 adt/d

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• 20-25% valves• 10-15% mixer• 25-30% Piping• 25-30% Static height

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Medium consistency pump CM/CW

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Consistency 6-8%

CMCW

Consistency 9-14%

27 different sizes

CMD

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Efficient pumping – Valmet MC Pump

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Low energy consumption

MC pump T2 (E-stage) MC pump T3 (P-stage) MC pump T4 (Storage)

VALMET EXIST. VALMET EXIST. VALMET EXIST.

Pump type CM 2015-440 MCA 42-200 CM 2015-440 MCA 42-200 CM 2015-440 MPP-15-P1

Production 720 adt/d 720 adt/d 720 adt/d 720 adt/d 720 adt/d 720 adt/d

Head(Pressure)

90 mwc 90 mwc 90 mwc 90 mwc 65 mwc 65 mwc

Consistency 12 % 12 % 12 % 12 % 12 % 12 %

Drive VFD Direct VFD Direct VFD Direct

Cons.energy

120 kW 315 kW 120 kW 315 kW 83 kW 115 kW

Install. Motor 160 kW 300 kW 160 kW 400 kW 110/132 kW 200 kW

Pump speed 1805 rpm 1500 rpm 1805 rpm 1500 rpm 1555 rpm 1868 rpm

TotalConsumption

today

730kW

TotalConsumption

Valmet

323 kW

Reduction– 407 kW

CASE Study

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Valmet SMF MixerModern mixing technology

ü “All-in-One” solutionü Applicable on whole fiberlineü Low chemical consumptionü Low energy consumptionü Low installation costü Low maintenance cost

– Few spare and wear parts– Easy maintenance– Low wear and tear

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Considered to be the best on the market!

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ALL-IN-ONEIS OUR CONCEPT

ü We add everything directlyinto the mixer

ü Highly effective mixingzone

ü Perfect control of mixingü Can be used as heater up

to 20°Cü Covers production levels

up to 6400 admt/dü Low impact on fiber quality

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Valmet SMF Mixer

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Low energy consumption

CASE STUDYHardwood - Existing mixers Hardwood - New installationsPosition Cons.in

[%]Production

[adt/d]Consumedpower [kW]

Mixer type Installedpower [kW]

Consumedpower [kW]

EnergyReduction

[%]D0 5 600 74 SMF-3040 45 30 59%D1 A 10 600 77 SMF-1525 30 21 72%D1 B 10 600 98 SMF-1525 30 21 79%

Mill case shows up to 70% energy savingscompared to conventional mixers.

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Washing

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Washing Technology – Upgrades & RebuildsChallenges through the years...

ü Production increaseü Energy consumption decreaseü Improve washing efficiency

– Reduce chemical consumption

ü Improve availabilityü Press conditions:

– Mechanical problems?– Outlet consistency?– Feeding consistency?ü Plugging problems? ü Mechanical Improvements

ü Capacity & ProcessImprovements

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ProDry Description

ü Insert cassettes for the TwinRollpress filtrate channels

ü Minimizes the pulp re-wettingü ProDry makes your washing

more efficient and reduces thewash loss carry over.

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Standard With ProDry

Mantle section(Circumferential rings)

Longitudinal filtratechannel

Perforated plate

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ProDry™ Benefits & Mill resultsMill in Chile, DPA-1555

ü DPA-1555 pre-bleach plantü ProDry was recommended due to poor outlet consistency caused by

high production levels– The outlet pulp consistency has increased by from 25,3% up to 31,2%.– The outlet COD (kg/adt) has been reduced in 2,5 kgCOD/adt.– The mill reduced consumption of sulphuric acid, ClO2 and sodium hydroxid with

the Prodry.

41 2012.09.21 Richard Barros - MIL41

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ProStream™

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ProStream™

ü Automatic system for highpressure cleaning of the pressrolls– Control via DCS system– Cleaning interval can be set to match

extent of scaling problems

ü Manual cleaning not needed– Personnel safety– Reduced labor cost– Reduced production downtime

ü Improved press performance– Optimized filtrate evacuation– Less fiber accumulation– Secure washing efficiency and press

capacity

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Wash Filter ImprovementsTypical areas for improvement

• Pulp Inlet- Piping- Dilution- Distribution profile

• Washing zone- Shower arrangement- Nozzle type

• Take off and wire cleaning- Several doctor options- Several cleaning system options

• Conveying and shredding- Feed system- Rotor design

• Filtrate system- Drop leg and tank design- Ventilation and degassing

• Washer ventilation system- Closed filter hoods- Internal circulation system to reduce

scrubber load

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Valmet nozzle is designedto facilitate an evendistribution of washingcleaning fluid.

Valmet nozzles

CSDU_H_2018_618-02

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BackgroundWashing distribution

CSDU_H_2018_618-02

• Old SS steel standard nozzles

• Valmet nozzles

Valmet nozzles

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Benefits

ü More even distribution ofcleaning fluid

ü Strong and reliableconstruction due to PVDF”Kynar” material

ü Reduced risk of blockageü Reduced wash water

consumptionü Reduced chemical

consumption

CSDU_H_2018_618-02

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Wire cleaning device

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Advantages• Hand- or automatically

operated brush device• Filtrate to flush away fiber

accumulations• More efficient wire cleaning

increases filter runnability.

Available for All filter-types:as CCA, VFA/B and MFA etc.

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Wire cleaning deviceAutomatic spray pipe type

1. Motor2. Housing3. Ball valves4. Actuator device

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