Varaoke International Oy

http://varaoke.eu/products/paper-machines/paper-machine-producing-200-tpd-deckle-of-2500mm/

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Varaoke International Oy
Business ID: 0925191-4
Kullervonkatu 20 B 112
33500 TAMPERE
Tel: +358 10 292 2090

2. Contact person in matters relating to the register
Harri Aikio
Kullervonkatu 20 B 112
33500 TAMPERE

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Sulje [x]

Paper Machine. Producing 200 tpd, Deckle of 2500mm

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  • Product ID: VAK10586
  • Name: Paper Machine. Producing 200 tpd, Deckle of 2500mm

Machine was in operation until the end of 2008.


STOCK PREPARATION

Continuous Pulper (No.2)


  • 14’ Black Clawson, rated at 240 BD tonnes / day @ 3.5%

  • Junk trap, light rejects removed with overhead grab.

  • 2nd Hand unit , Installed in 1995

  • Stainless steel construction

  • 1.5 m wide feed conveyor




Ultrascreen

  • Black Clawson Ultra V400, installed 2000



  • 1st stage screen following 16’ pulper

  • 400 m3 / hour @ 3.5% = 14.0 tonnes / hour

  • 2mm holed extraction plate

  • 110 KW drive motor running at 600 RPM




Turbo Separator (No.1)


  • Voith ATS 021

  • 2nd stage screen on 16’ line, treating rejects from Ultrascreen

  • 70 m3 / hour @ 5.0% = 3.5 tonnes / hour (85 BD tonnes / day)

  • 205 KW drive motor




Screw Compactor


  • Beltec screw thickener supplied 2004



Elephant Filter


  • Meri - Model 3-10 (Now Voith)

  • 10-Disc unit, arranged in 5-banks of 2

  • Maximum flow rate = 24.0 m3/hour, 3.2 tonnes / day



Trommel Screen


  • Rotating drum design

  • 10 BD tonnes / day @ 1.4%



Vibrating Screen


  • 20 BD tonnes / day @ 5.0%



Thickstock Chest


  • 200 m3 stainless steel chest, installed 2000

  • 9.0 BD tonnes maximum stock holding at 4.5%

  • Side mounted agitator

  • 2 x Thickstock feed pumps, Scanpump BA 200/150 – 40, rated at 330 m3/hour



  • Consistency control




PM1 STOCK APPROACH – BOTTOM WIRE

Refining


  • Jylhavaara JCO2 conical refiner

  • 5000 litres / min @ 6% = 18.0 tonnes / hour



Fan Pump


  • Scanpump BA 350/350 – 45

  • 17,200 litres / min @ 19.0m head



Primary Cleaners


  • 48 x Voith HC5 – TB36 Cleaners

  • 400 litres / min per unit = 19,200 litres / min total



Secondary Cleaners


  • 19 x Voith HC5 Cleaners

  • 400 litres / min per unit = 7,600 litres / min total



Tertiary Cleaners


  • 8 x Voith HC5 – TB1B Cleaners

  • 400 litres / min per unit = 3,200 litres / min total



Quaternary Cleaners


  • 4 x Voith Elutricone EBOB Cleaners

  • 400 litres / min per unit = 1,600 litres / min total

  • Continuous rejects



Final Stage Cleaners


  • 2 x Palmac P200 RFD Cleaners

  • 1,000 litres / min per unit = 2,000 litres / min total

  • Intermittent rejects



Primary Screen


  • Voith vertical screen Size 25

  • 0.25 mm slotted basket

  • 300 tonnes / day



Secondary Screen


  • Voith vertical screen Size 12

  • 0.20 mm slotted basket

  • 20 tonnes / day @ 1.0%

  • Common to top wire screening system



Rejects compactor


  • Fan press, size 4

  • Installed in 2004,

  • Maximum flow rate = 1,500 litres / min @ 5.0%

  • Maximum discharge solids content = 45.0%



PM1 STOCK APPROACH – TOP WIRE

Refining


  • 2 x Metso JCO-1

  • 100 tonnes / day output (combined max)



Fan Pump


  • Scanpump BA 300 / 300 – 40

  • 15,300 litres / min @ 0.6%, 38.0m head



Primary Cleaners


  • 9 x Celleco TW 1500 combi cleaners

  • 1,540 litres / min per unit @ 1.1% = 13,860 litres / min total





Secondary Cleaners

  • 2 x Celleco TW 1500 cleaners

  • 1,400 litres / min per unit @ 0.9% = 2,800 litres / min total



Fibermizer


  • 528 litres / min @ 0.6%




Stage 1R Cleaners


  • 7 x LWR CLP 250 cleaners

  • 250 litres / min per unit @ 0.6% = 1,750 litres / min total



Stage 2R Cleaners


  • 1 x LWR CLP 250 cleaner

  • 225 litres / min @ 0.5%




Primary Screen


  • Voith vertical screen Size 20

  • 0.20 mm slotted basket

  • 15,000 litres / min @ 1.0% = 9.0 tonnes / hour



No.1 MACHINE

General Description


  • Twin ply Fourdrinier machine with nominal deckle of 2,500mm

  • Built in 1986, with a maximum design speed of 600 m/min

  • SSD digital drive suite installed March 2005, L/hand drive.

  • Current maximum operating speed – 600 m/min (at reel)

  • Grammage range 90 GSM – 170 GSM. Production at 170 gsm = 10.5 t/hr.

  • Testliner and Un-Dyed Chip

  • ABB 1190 Advant DCS control system, with Smart Platform QCS dry-end scanner




Flowbox (Bottom Wire)


  • Simon Holder, rectifier roll flowbox

  • 18 x manually controlled slice positioners

  • Slice width – 2750mm

  • Consistency range – 0.65% - 0.85%

  • Flow rate – 11,000 litres / min (min) – 14,000 litres / min (max)



Wire Table (Bottom Wire)


  • Simon Holder, bottom wire Fourdrinier

  • Cantilever design

  • Part ceramic, part plastic drainage elements

  • Wire width – 2,900mm

  • Wire length – 45.5m, couch to breast roll centres 27 mtrs.

  • Single zone, suction couch roll with double doctor

  • Variable position forward drive roll

  • Steam profiling shower fitted over final tri-vac suction box

  • Exit moisture circa 22%



Flowbox (Top Wire)


  • Simon Holder, rectifier roll flowbox

  • 18 x manually controlled slice positioners

  • Slice width – 2,750mm

  • Consistency range – 0.45% - 0.55%

  • Flow rate – 5,000 litres / min (min) – 10,500 litres / min (max)



Wire Table (Top Wire)


  • Simon Holder, top wire Fourdrinier

  • Cantilever design

  • Plastic drainage elements

  • Wire width – 2,950mm

  • Wire length – 20.6m



First Press


  • Single felted, suction pick-up roll with 3 vacuum zones

  • 2 x UHLE Box’s, with herring bone design plastic tops

  • PU covered, with blind drillings and grooves

  • Vacuum assisted save-all tray

  • 450 PLi line load

  • Synthetic covered plain pressing roll with double doctor

  • Couch pit, with side entry agitator

  • Open draw transfer to 2nd press, via William Kenyons tail transfer system, installed 2005

  • Exit moisture circa 40%



Second Press


  • Large diameter jumbo press, 1.030 m diameter rolls

  • Rubber covered with blind drill pattern

  • Automated internal cooling system

  • 1750 PLi line load

  • Double felted

  • 3 x UHLE Box’s, with herring bone design plastic tops

  • Exit moisture circa 50%



Vacuum


  • 2 x Nash 901, installed 2000

  • 5 x Nash CL2001

  • 1 x Nash CL1001

  • 2 x 2-stage vacufoil fans for wire table low vacuum requirements

  • Pre-separators and pumps

  • Albany filter for recirculating seal water

  • Seal water temperature control




Dryiers


  • 3 x mechanical groupings arranged in 5 x steam sections: -

    • 1st Section – 3 x 1.2m diameter cylinders @ 1.8 barg

    • 2nd Section – 7 x 1.2m diameter cylinders @ 1.8 barg

    • 3rd Section – 10 x 1.5m diameter cylinders @ 5.3 barg

    • 4th Section – 5 x 1.5m diameter cylinders @ 10.0 barg

    • 5th Section – 11 x 1.5m diameter cylinders @ 5.3 barg



  • Potential to uprate 5.3 barg cyclinders to 7.5 barg, subject to re-cerification and insurance checks

  • Johnson Systems International, thermo-compressor based steam system

  • Steam groupings 1,2, 3 & 5 fitted with rotating siphons

  • Steam group 4 fitted with stationary siphons

  • Steam groupings 4 & 5 fitted with spoiler bars

  • Drier group 1 configured with unirun drier fabric

  • Drier groupings 2 & 3 configured with standard top & bottom drier fabrics

  • Open gear drive train with part plastic, part metal gear wheels

  • Partially enclosed hood with 2-fan PV System. Incorporates heat recovery from flash steam and condensate sources

  • Automatic fabric tensioning (E & L)

  • Automatic rope stretching (William Kenyons)

  • SSD touch screen HMI control stations, installed 2005




Calender


  • 2 x roll hard nip calendar

  • Top roll diameter – 295mm

  • Bottom roll diameter – 390mm

  • Design nip load – 100PLi



Reel-Up


  • Simon Holder drum reel

  • Capable of producing single set parent reels, maximum diameter 1.6m

  • Future upgrade potential to allow production of 4-set jumbo reels

  • 5-tonne overhead crane

  • UTM pulper with consistency control

  • IBS automatic sheet turn-up system

  • 30-reel spoils

  • Belt driven, reel spool speed up system

  • ABB Smartplatform scanner

  • Maximum gross deckle – 2,580mm



General


  • Anti-friction roller bearings throughout

  • Automatic grease lubrication system

  • Condition monitoring sensors installed on all major rolls, cylinders etc.

  • HP showers on wet-end and press clothing, fitted with ruby nozzles

  • Thermo compressors on dryers

  • DCS control on stock prep

  • Computer on machine ABB Advant 1190



Spares


  • All major rolls

  • Motors & gear-boxes for all drive positions

  • Full set of machine clothing



Finishing


Rewinder


  • Masson Scott Autotorque, twin-drum winder



  • Maximum operating speed – 1,800 metres / min

  • 2 x unwind stations for tambours,

  • Unwind and rewind 1500mm diameter

  • Shaftless rewind

  • Brake driven tension control

  • Rider roll

  • Hydraulic reel lowering table

  • PLC controlled, Eurotherm drive system

  • Trim handling and conveying system

  • Trim bale compactor, circa 3 tonnes / day

  • Twin motor drive R/hand from unwinds



Backwater / Ancilliaries

Dissolved Air Floatation Unit


  • Meri Deltafloat – Model 23, installed 1990

  • Floatation surface area = 23m2

  • Maximum flow rate = 185 m3/hour

  • Operating in partial pressurization mode



Drum thickener (No.2)


  • Hedomora drum thickener

  • Drum dimension – 0.75m diameter x 5.0m face length

  • Thickens from 0.8% to 4.5%

  • Spare drum



Heat & Power Generation

Package boilers (Sold)


  • 3 x Maxicon package boilers installed 1971

  • Shell boiler design, each unit rated at 11.0 tonnes steam / hour @ 13.8 Bar

  • Co-fuel capability – gas and LFO Sold



Gas turbine CHP (Sold)


  • Ruston (Now Siemens) TB5000 gas turbine, rated at 3.5 MWe (Sold)

  • Purchased as an unused, second hand unit in 1986 from Shell. Originally constructed in 1981 (Sold)

  • Co-fuel capability – gas and LFO

  • Gas compressor designed to raise incoming gas pressure from 3.0 to 11.0 Bar

  • 33m Chimney

  • Waste heat economiser installed in 1993

  • Gas fired supplementary burner installed in 1993



Waste Heat Boiler


  • Natural circulation water cooled boiler, rated at 26.0 tonnes steam / hour @ 13.8 barg, installed 1993



Steam turbine


  • KKK steam turbine rated at 0.5 MWe @ 18tph steam flow

  • Installed in 1987

  • Steam pressure reduction from 13.8 barg to 2.8 barg



Gas engine CHP ( Sold)


  • Caterpillar, 16-cylinder gas engine, installed 1991, Hrs 92,500. Sold

  • Gas only

  • Rated at 1.0 MWe and 1.5 tonnes / hour steam at 1.0 barg

  • Hot water supply – 19m3/hour @ 40oC



Water Treatment


  • Twin stream de-min plant (1986), rated at 12m3/hour

  • Reverse osmosis plant (2001), rated at 12 m3/hour



General


  • Steam accumulator (1993)

  • Thermal de-areator (1993)

  • Air compressors – various

  • 5 x Oil-cooled transformers, stepping down from 11KV to 415V. Ratings: -

    • 2 x 1,000 kVA

    • 1 x 1,500 kVA

    • 2 x 2,000 kVA

    • 1 x 2,500 kVA






  • HT & LT distribution equipment for PM1

  • Power factor correction equipment



DVD AVAILABLE OF THE PLANT IN OPERATION


All equipment was run on a 6 week maintenance cycle.

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