Paper Machine 2500mm, 200 tpd, Fluting
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- Product ID: VAK10505
- Name: Paper Machine 2500mm, 200 tpd, Fluting
Paper Machine 2500mm
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:
o 1st Section – 3 x 1.2m diameter cylinders @ 1.8 barg
o 2nd Section – 7 x 1.2m diameter cylinders @ 1.8 barg o 3rd Section– 10 x 1.5m diameter cylinders @ 5.3 barg
o 4th Section– 5 x 1.5m diameter cylinders @ 10.0 barg
o 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
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 pressurisation 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
• 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 Gas turbine CHP
• Ruston (Now Siemens) TB5000 gas turbine, rated at 3.5 MWe
• Purchased as an unused, second hand unit in 1986 from Shell. Originally constructed in 1981
• 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
• 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:
o 2 x 1,000 kVA
o 1 x 1,500 kVA
o 2 x 2,000 kVA
o 1 x 2,500 kVA
• HT & LT distribution equipment for PM1
• Power factor correction equipment
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:
o 1st Section – 3 x 1.2m diameter cylinders @ 1.8 barg
o 2nd Section – 7 x 1.2m diameter cylinders @ 1.8 barg o 3rd Section– 10 x 1.5m diameter cylinders @ 5.3 barg
o 4th Section– 5 x 1.5m diameter cylinders @ 10.0 barg
o 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
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 pressurisation 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
• 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 Gas turbine CHP
• Ruston (Now Siemens) TB5000 gas turbine, rated at 3.5 MWe
• Purchased as an unused, second hand unit in 1986 from Shell. Originally constructed in 1981
• 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
• 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:
o 2 x 1,000 kVA
o 1 x 1,500 kVA
o 2 x 2,000 kVA
o 1 x 2,500 kVA
• HT & LT distribution equipment for PM1
• Power factor correction equipment
