Paper Machine Dewatering and Cleaning Solutions

• Increase in dryness post-press section by 1-3%
• Reduction in dryer section steam usage by 4-10% and/or a considerable uptick in production
• Ensures efficient water discharge and prevents rewetting perfectly
• Investment payback period of less than one year

Enhancing sheet dryness and cleanliness from the wire section to the dryer results in measurable cost reductions. This includes marked improvements in paper machine efficiency and decreased energy consumption in the dryer section. 

Refined dewatering and cleaning technologies can significantly diminish numerous production issues, such as inadequate moisture profiles, contamination, corrosion, cleaning time, and poor fabric permeability. This leads to fewer breaks and potentially reduced wet draws, making the working environment safer and more healthful.

European Fluting & Testliner Machine: Before the save-all and doctoring project, the production manager compared the mill's overhaul to installing cruise control in a car: it may not increase speed, but it guarantees a more stable, dependable, and cost-effective operation. Immediately after the project, the mill experienced a speed boost of +10 m/min, with an additional +10 m/min increase following thereafter. This speed enhancement was consistent across all paper grades, and the maximum speed also saw an increase. One liquid ring pump was turned off at the start, and another was later deactivated, which was an unforeseen but welcome change, saving the mill an extra 100,000 euros each year. Operations also returned to normal more quickly after felt changes, with the bottom felt reaching its target in 24 hours instead of the previous three days, and the need for felt washing was either reduced or no longer necessary.

The delivery included a Save-All with an upper catch pan and two integrated blades for the press suction roll, a Double Doctor for the first press bottom roll, a splash wall following the first press bottom roll, and a comprehensive EcoFlow system for the wire and press sections. The primary advantage for the paper mill has been a more controlled operation regarding dewatering and process stability, which is more precise and faster. EcoFlow enhances process transparency and enables operators to set key parameters in a more effective manner. Issues such as problems with sheet edges are now either avoided altogether or resolved much more swiftly than in the past.

European Fine Paper Machine: The greatest benefits can often be achieved by combining improvements in dewatering with a rebuild of the vacuum system, particularly for mills still using traditional vacuum pumps. Runtech carried out such an upgrade at a fine paper machine in Europe, implementing a single-stage EP500 Turbo Blower, EcoDrop water separator, and EcoFlow Multi dewatering measurement system. The overhaul also included a Combi press save-all with an RSE AirBlade and a third press bottom roll doctor equipped with an RSP AirBlade.

The enhancement of the press section dewatering and the fine-tuning of vacuum levels with the EcoFlow system allowed the mill to operate exclusively with one EP500 Turbo Blower. This change resulted in the cessation of seven liquid ring pumps, leading to energy savings of 700 kW and water savings of 60,000 m^3 annually. The specific energy consumption was dramatically reduced from 93 kWh/t to just 21 kWh/t. Despite achieving maximum nip dewatering, the system experienced minimal rewetting. Additionally, the specific steam consumption was cut by 10%, and the frequency of sheet breaks was notably reduced, further contributing to the efficiency and productivity of the mill.