Академический Документы
Профессиональный Документы
Культура Документы
1. GENERAL 4
6. REFERENCE LIST 18
3
1. GENERAL
Ecopump energy saving group has been working since 1989, This book describes the benefits and working principles of
with a clear target of reducing power consumption of paper ECOPUMP TURBO VACUUM SYSTEM for paper machines:
machine pumping systems. Four product lines have been de-
veloped to realize the great saving potential in paper produc- Power savings 500..1000 kW compared with
tion process: traditional systems
During years of optimizing is a great potential for power variations in capacity need Other important features are:
existing paper machine vac- savings by eliminating excess because of different running water savings, savings in foun-
uum systems, and conduct- capacity due to over dimen- conditions new felts vs. old dation work due to compact
ing dewatering trials utilizing sioning the systems are of- felts, different felt types, high size and low weight, savings
Ecoflow dewatering measure- ten over dimensioned due to grammage vs low grammage, directly in maintenance work
ments, it became obvious that uncertainties concerning new etc. With adjustable capacity and parts as well as indirectly
there is a need for a VACU- machine concept or when re- these savings can be realized in saving maintenance shut-
UM SYSTEM WITH ADJUST- serving capacity for eventual directly to the bottom line. down time.
ABLE SPEED CONTROL. There speed increase. There are also
4
2.1. PRINCIPLE OF THE ECOPUMP TURBO
5
2.2. CHALLENGES IN PRODUCING VACUUM FOR PAPER MACHINE
An efficient use of vacuum system for paper machine positions Seal water is becoming ever more costly due to not
face the following An efficient use of vacuum system for paper only regulations but also to increasing need to
machine positions face the following challenges: control temperatures, pH and bacteria (specially
with closed circulation)
The vacuum system must handle todays production, but
also possible speed increases in the future Availability requirements do not allow long
maintenance shutdowns
The vacuum need on felt conditioning is varying
depending on the felt types and age of them The air to be pumped contains water, other
liquid media and solids.
The grammage, grade and speed varies
For a long time, water ring pumps have been the main way to Another widely used technology, multistage blower aggregate,
make vacuum for paper machines. In this kind of pump, you avoids many of the disadvantages of water ring pumps. But
need to rotate a water ring to get the air moving. In spite of there are other problems related to these:
their seemingly robust structure, there are certain limitations
in use of this kind of pump. a) Limited control ability; due to big size and few ag
gregate installed in one system
a) Poor power efficiency; especially with low vacuums
b) Complex startup procedure; risk for overloading the
b) Limited control range; the water ring will collapse electrical motor
after certain point
c) Complex maintenance procedure; need for long
c) Need for cooling; specially with closed circulation shutdown when serving
and during summer time
d) Risk of production shut down; normally no back
d) Bacteria control; specially when circulating the up system. If one unit fails it is not possible to run
water => optimum circumstances for bacteria the PM
e) Heavy investment on building and foundation; e) Heavy investment on foundation; heavy units,
heavy construction with low frequencies. which are critical for vibration.
6
2.4. DIFFERENT PRACTISES AND TRADITIONS OF VACUUM USAGE
There are some general principles in evaluating the need for A typical distribution of specific consumption is shown in the
vacuum capacity. A good parameter to benchmark the vacuum graphic below.
usage is the specific power consumption (kWh/ton) of the
vacuum system. Of course, one value is not comparable for all. 2) Grammage: heavier grammage requires less power
Typically, the following guidelines can be found. per ton than lower grammage.
1) The specific consumption of vacuum system is 3) Speed: lower speed requires less power per ton
depending on the grade: typical benchmark values than higher speed.
can be given:
4) Size: Large machine capacity requires some less
Pulp drying machine 20..40 kWh/ton power per ton produced than a small machine
Board machine 40..80 capacity.
Linerboard machine 35..80
Fine paper 40..80
Magazine 70..120
Newsprint 70..120
Specialty papers 80..180
Tissue 100..200
200
180
Specific energy consumption kWh/t
160
140
120
100
specific
80 consumption
kWh/t
60
40
20
0
0 10 20 30 40 50
Production kWh/t
7
Different working shifts can run the machines in different ways. system and benchmark information from other machines alike,
There are some traditions and some common beliefs that some- an energy efficient running practice can be developed. Also
times are based on facts, which do not exist anymore. Ecopump turbo blower can be easily automated to avoid dif-
By systematic optimization with dewatering measurement ferent running philosophy.
During years of optimizing vacuum systems and dewatering, e) Easy to adjust and flexibility.
it become obvious that the vacuum system should have the => optimum running condition for the production
following properties:
Main benefits
a) Flexible capacity adjustment: the system shall fulfill the Ecopump turbos are specially designed for paper machine
capacity requirements of the machine suppliers specs. But environment and for best operational economy.
the capacity requirement of the actual running situation is
often different. a) Flexible capacity adjustment with ECOPUMP TURBO:
=> ENERGY SAVING POTENTIAL All turbos are speed controlled to enable economi-
cal use from zero to max capacity. This gives
b) Flexible in capacity adjustment: different grammages freedom to design an efficient system for different
require different vacuum. Old felt and new felt require and/or varying conditions.
different vacuum capacity.
=> ENERGY SAVING POTENTIAL b) Efficient pumping principle: 3-dimensional high speed
turbo impeller running variable speeds: all power is used
c) Efficient pumping principle: The power should be to move air from vacuum to atmosphere. No power used
used to move the air, not to rotate the seal water. to rotate water, no vacuum adjustment with speed.
=> ENERGY SAVING POTENTIAL
c) Heat recovery potential: The pumping energy is transfer-
d) Good potential for recovering the power used in vacuum red to the air. The temperature reaches up to 160 C,
system heat. which offers good potential to use it in different stages of
=> ENERGY SAVING POTENTIAL production.
80
Vacuum Levels and Flow Rates
70
60
50
40
30
Vacuum (kPa)
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Air flow under vacuum (m/s)
Picture 3: Ecopump Turbo flow/vacuum range
8
Principles in designing a vacuum system
Ecopump vacuum systems are the result of practical experi-
ence for evaluating the system needs, realizing the project and
optimizing the running conditions. All our field engineers are
trained for process expertise.
9
Ecopump EP315-500-S Ecopump Turbo EP500-700-S
Ecopump EP315-500-S is designed for smaller capacity, es- Ecopump EP500-700-S is a heavy-duty turbo for high capacity
pecially for retrofit installations for medium and small paper and highest efficiency, designed for large paper machines and
machines, where the space is limited and where production is for both greenfield and retrofit installations. Its 3-dimensional
versatile and maintenance conditions are limited. It is compact turbo design gives top efficiency together with good controll-
to fit in small space available, the lightweight parts can ea- ability as all Ecopump turbos. It is, although clearly larger
sily be handled by hand in short service shutdowns. No long than EP315-500-series, still compact when compared with
shutdowns are needed. The materials are corrosion resistant: other commercial technologies. The up-time availability and
titanium impeller and stainless steel casing. cost efficient maintenance are valid for this series, too.
EP250-500-S
250 kW, two nominal 500 mm impellers in series
EP315-500-S
315 kW, two nominal 500 mm impellers in series
EP400-700-D2
400 kW, nominal 700 mm impeller
EP400-700-D1
400 kW, nominal 700 mm large impeller
EP500-700-D1
500 kW, nominal 700 mm large impeller
EP500-700-S
500 kW, two nominal 700 mm impellers in series
10
Lube unit
Vacuum
breaker
valve
Cooling
air
Lubrication
unit
Blower
outlet Drop
separator
M M
Suction
position
Turbo PI
blower
PI
Power FI
supply
Frequency
convertor DCS
Discharge to
seal pit tank or pump
SCOPE OF DELIVERY
11
4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER MACHINE INSTALLATIONS
The main benefit of choosing Ecopump Turbo system is power saving. But there are also other quite significant reasons to go
for Ecopump technology.
b) Investments in reducing energy consumption are often as ESCO (= Energy Saving Company) arrangements is often
backed by government programs. Innovative financing such available, too. Ecopump and its network will help in evaluat-
ing the operation.
kW
BEFORE
AFTER
12
4.2. WATER SAVING
In one of Ecopump Turbo customer mills, the water comes After reviewing the power saving potential in vacuum system,
from a distance with a pipeline. The supply is thus limited. At it was concluded that Ecopump Turbo system was the best
the time of machine rebuild, there was a need of either solution. The Nash pumps were removed and Ecopump Turbo
System was installed in a machine rebuild.
a) cut the fresh water consumption in the mill
Results:
b) build water circulation for seal water of the liquid a) The water consumption was cut by some 1000 000 m/a.
ring vacuum pump system.
b) Power saving was cut down by some 500 kW, even
though the speed was increased and new vacuum
positions (top former) were installed on forming section.
13
4.3. IMPROVING SYSTEM RELIABILITY
In this installation, there were time, the power consump- ring pump shut down. One by the multistage turbo. The
originally two large multi- tion was a bit high, despite Ecopump turbo was installed water ring pump can be kept
stage turbo blowers and the system principle (in gen- to serve suction press roll. By still.
one liquid ring pump in the eral, turbo principle is power running the multistage turbo As a side effect, the total power
vacuum system. Because of efficient). and Ecopump turbo only, the was cut down by 900 kW.
this configuration, the system machine now is not vulner-
was vulnerable: if any of the Optimizing the system, and able. The multi-stage blower
two large turbos were down, implementing a new config- can be replaced with the oth-
the production would have uration shut one of the two er, now obsolete one. Also,
to be stopped. At the same large blowers and the liquid the EP turbo can be replaced
Picture 9: The overall system reliability was improved by installing one Ecopump Turbo.
14
4.4. SAVING IN BUILDING COST
Space needed for Ecopump separate pump room neces- vacuum system can often be mounting the one and build-
turbo vs. traditional pump sary. installed before dismount- ing in a new one would have
system is far less than that ing the existing system. This required a long shutdown.
for liquid ring pump system Relatively low weight reduc- way, the system rebuild can Building a liquid ring pump
or that for multi-stage turbo es the building cost further, be realized practically without system would have required
system. The compact con- since no heavy foundations production shutdown. an extensive and expensive
struction with motor and are needed. An even concrete investment on seal water
turbo integrated, it makes floor is enough, if Ecopump The old multistage blower system.
it possible to accommodate base plate is used. Another was getting too old to run
in very limited space. In fact, option is to have concrete no spares were available.
the vacuum system can be foundation for the turbo. There was no room for a new
decentralized, if needed no In rebuild projects, the new unit of the same kind. Dis-
Picture 10. Ecopump Turbo can be installed during normal production without a long shutdown
15
4.6. HEAT RECOVERY POTENTIAL
Recovering the energy used for pumping air, makes the energy in high vacuum positions this results to high temperature air,
balance superior. Practically all of the power used to generate which makes recovery very feasible. It can be taken into an
vacuum is transformed into process air heat. In water ring exchanger, to heat process water or to heat the hood supply
pump, this heat is transferred to seal water, making it necessary air. In some cases, it can be blown directly to the hood. Where
to cool the water which is causing an additional cost. Eco- the heat is used, depends on the mill needs.
pump system principle enables recovering this heat: especially
Picture 11: Recovering pumping power offers further energy effiency potential.
16
5. TECHNICAL DATA EP-500-S(D1) & EP 315-S(D1)
Power
400/500/690 V 500 kW
EP-500-S
Production (air +20C/1, 01325 bar)
Serial connection (EP500-700-S) 68 kPa/7,0 m/s
(EP315-500-S) 60 kPa/2,5 m/s
Single impeller (EP500-700-D1) 46 kPa/8,0 m_/s
(EP315-500-D1) 40 kPa/2,2 m/s
Cooling air
Flow 0,5 m/s /+20C
Filtering EU5
Frequency converter
Type VACON NX
Filter LC
Voltage 400/500/690 V
Bearing units
Bearings Hybrid ball
Lubrication Oil
Automation
Bearing vibrations 2 x Transmitter
Bearing temp 2 x Transmitter
Coil temp 2 x Transmitter
Oil flow 2 x Transmitter
Oil level 1 x Switch
Oil filter pressure difference 2 x Switch
17
6. REFERENCE LIST
Arjo Wiggins SAS, Annonay PM7, France, 1 Turbo blower M-real, Kangas PM 2, Finland, 1 Turbo blower
Drawing paper Fine paper
Cartiere del Polesine, S.p.A., Italy, 7 Turbo blowers M-real, Kirkniemi PM 1, Finland, 1 Turbo blower
Test liner LWC
Daehan Paper, Cheongju PM 1, South Korea, 2 Turbo blow- M-real, Kyro BM 1, Finland, 1 Turbo blower
ers Board
Copy / News
M-real, Kyro PM 1, Finland, 1 Turbo blower
Daehan Pulp, Cheongju PM 3, South Korea, 1 Turbo blowers Wall paper base
Board
M-real, Lielahti, Finland, 1 Turbo blower
Georgia Pacific, Cuijk, Netherlands, 2 Turbo blowers Pulp machine
Tissue converting process
M-real, Tako BM 1, Finland, 1 Turbo blower
Georgia Pacific, Nederland B.V., Netherlands, 1 Turbo blower Board
Tissue
M-real, Tako BM 3, Finland, 1 Turbo blower
Georgia Pacific, Nokia PM 7, Finland, 1 Turbo blower Board
Tissue
M real Simpele Board, Finland, 1 Turbo blower
Hadera Paper Ltd, Israel, 5 Turbo blowers Board
Test liner
M-real, nekoski Board, Finland, 1 Turbo blower
International Paper, Papeteries Etienne, France, 1 Turbo blower Board
Fluting
Mets Tissue, Mntt PM 1, 1 Turbo blower
International Paper, Kenitra Mill, Marocco, 1 Turbo blower Tissue
Test liner
Mets Tissue, Mntt PM 7, Finland, 1 Turbo blower
Kimberly Clark, Rouen, France, 1 Turbo blower Tissue
Tissue
Mufindi Paper Mills Limited, Tanzania, 2 Turbo blowers
Kimberly Clark, Enstra Mill, South-Africa, 3 Turbo blower Kraft liner and sack
Tissue
Papeteries de Clairefontaine, France, 2 Turbo blowers
L.C. Paper 1881 S.A., Papelera La Confianza, Spain, Fine copy paper
1 Turbo blower
Tissue Pulp Machine, Confidential PM 1, Finland, 1 Turbo blower
Pulp
Mayr-Melnhof Karton, Baiersbronn Frichfaserkarton BM 1,
Germany, 1 Turbo blower Pulp Machine, Confidential PM 2, Finland, 1 Turbo blower
Board Pulp
18
Stora Enso, Anjala PM 1, Finland, 1 Turbo blower
Book paper
19
RunEco
EcoSep