TWMilan Yankee Operations and Energy Optimisation Abstract (v6)

Conference Abstracts

YANKEE OPERATIONS AND ENERGY OPTIMISATION SESSION - 11 APRIL 2017 Yankee Operations and Energy Optimisation Session

Jean Desharnais, Director Applications, Sales & Marketing, ENERQUIN AIR, Canada 08:50 - 09:10 Is Your Tissue Machine a Gas-Guzzler? The first step toward optimizing the Yankee cylinder, hood and process air system is to determine all key performance indicators and compare them to industry standards for similar equipment and process. After this baseline testing is complete, the process can be optimized by means of on-the-run adjustment of dampers, temperatures and flows toward the end goal of minimizing the amount of gas usage per kilogram of water evaporated.

This is achieved by means of a comprehensive air systems audit. The methodology for a typical such audit will be described as well as detailed results for select case studies. A summary of data gathered from 30 recent studies will be presented and will demonstrate that simply fine-tuning the process normally results in a significant reduction in gas consumption

Calibrated press load

Sjaak Melkert, Managing Director, msquared GmbH, Germany Mark Penton, Service Manager, msquared GmbH, Germany 09:10 – 09:30 Applying the right load force to the pressure rolls to obtain the correct line load is foremost a safety requirement. However, uniform mechanical dewatering requires also a known and balanced load to the press (es). This directly impacts safety and strongly affects machine efficiency.

Safety and efficiency: CPL – or Calibrated Press Load is an msquared re-developed and renewed system for measuring the real and effective pressure roll loading force in relation to a hydraulic or pneumatic pressure. The system uses calibrated force and pressure sensing components to establish calibration curves for the Front Side and Back Side press loading mechanisms.

In addition, comparisons to the DCS calculated/indicated load and actual loads, indicated pressure and actual pressures are established. Loading/Unloading hysteresis curves are established. This indicates the effectiveness and condition of the loading mechanism. Case studies are presented.

Conference Abstracts

YANKEE OPERATIONS AND ENERGY OPTIMISATION SESSION - 11 APRIL 2017 Seamed tissue press development enhances performance and installation safety Clemens Stortelder, Paper Grade Manager Tissue, Albany International, Netherlands 09:50 – 10:10 Tissue paper manufacturing cost and safety are main “key drivers” for the papermaker. With this reality it is imperative that suppliers of paper machine clothing must provide innovative solutions in order to reduce these paper manufacturing cost and have safer press fabric installations. Albany International has invested many years of development to improve seamed press fabrics to a quality level where they can be used now on high-speed tissue machines. Sheet marking from the seam area was the limitation for a long time but not anymore.

This paper describes the technical advancements made in the seam and the base construction, and how these advances have led to success on all kind of Tissue machines. Machine speed over 1800 meter per minute, sheet weights down to 14 gsm, machine width up to 7 m wide and press fabric life up to 80 days. Besides the presentation of the new technical developments, case histories of the new seamed press fabric technology will highlight increase paper machine efficiency, reduce dry energy cost and fast, safe press fabric installations.

Advanced Yankee data management for quality, productivity, and asset protection Ian Padley, Marketing Manager, BTG Eclépens, UK 09:30 – 09:50 Role of advanced data management in a Yankee Care program for quality, productivity and asset protection.

Yankee management is a complex and dynamic subject; there are many process inputs from wet end, pressing, furnish and chemicals to steam, hood drying and creping. To master this is to produce the best quality at the highest productivity with superior asset protection. But how to do this?

It is often said in process industries ‘if you don’t measure it, how can you control it?’ Smart vibration measurement not only gives the tissue marker a window on Yankee operations for asset protection, but by linking this to other data, quality and productivity improvements may also be driven forward.

BTG has identified a discrete set of process measurements which can help to define the ideal operating window for maximum Yankee performance. The accepted methodology for determining the best operation window is using centerline tool for mining the historical, grade-based data to define the best combination of process settings & variables. The defined operating windows are then presented through centerlining displays in a real-time and grade-based manner.

The introduction of advanced data collection and management tools, allowing visualisation of key performance indicators, is the solution to making sense of a large data set. A good data management platform will help the tissue maker to define good centerlines from disparate data and deliver a solution to maximise Yankee performance.

Conference Abstracts

YANKEE OPERATIONS AND ENERGY OPTIMISATION SESSION - 11 APRIL 2017 Yankee service - the icing on the cake

Erwin Walcher, Sales and Services Manager Yankees, Andritz AG, Austria 10:10 – 10:30 ANDRITZ has a high level of overall competence for Yankee dryers: It starts with the manufacture of new Yankees in the company’s own workshops and extends to cover services and quality assurance. With the Yankee service, the focus is put on the overall added value of the Yankee: from the calculation to manufacturing, grinding and coating, operation, and optimization. It starts by being near the customer, ready to act, listening carefully and fast responding to customers’ needs – which are always different, and then defining fields of action together. It also includes customized solutions for new Yankees and for rebuilds, and accompanies the customer throughout the entire Yankee lifecycle.

The Yankee service succeeds with lasting effect in improving the machine’s efficiency as well as the Yankee’s performance. The service range is suitable for all types of Yankee, for tissue or paper machines, MG paper or tobacco, steel or cast Yankees, old or new, regardless of the OEM. The service package includes solutions and support for upgrades and replacements, safety issues, production, and analysis (e.g. on the run measurements).

The speech describes the main principles of a successful Yankee service, highlights technical solutions and shows Yankee service in practice, like for example at the Slovenian tissue producer Paloma Hygienic Paper.

Yankee coating development for structured sheets Gary Furman, Corporate Scientist, Nalco, USA 11:00 – 11:20 High energy costs have restricted the growth of products in Europe based on the structured sheet (TAD) manufacturing process. However, this situation is now changing with the introduction of new manufacturing processes such as ATMOS and NTT. These ‘hybrid TAD’ processes provide most of the TAD benefits of improved sheet properties (bulk, absorbency and softness) while still using less fiber, but with the important additional benefit of doing so with reduced energy costs.

Structured sheet processes present their own unique challenges with regard to demands on the Yankee coating, first in transferring the sheet to the Yankee dryer and, secondly, in creping the sheet effectively.

Some considerations include moisture content of the incoming sheet, transfer and dry crepe adhesion, film durability, coating uniformity and the responsiveness of the Yankee coating package to changing conditions. This presentation discusses experiences gained through laboratory, pilot and commercial scale work in developing improved coating packages for structured sheets.

Conference Abstracts

YANKEE OPERATIONS AND ENERGY OPTIMISATION SESSION - 11 APRIL 2017 New Yankee Metallizing Technology

Laslo Monte, Director Sales Tissue EMEA (Europe, Middle East & Africa), Voith Paper Rolls GmbH & Co. KG 11:20 – 11:40 The critical area of dewatering via evaporation on the Yankee is energy intensive and small improvements in this area can have significant benefits. All metal coatings act as Yankee insulators and by improving the heat transfer coefficient of the applied metallization more of the available thermal energy can reach the paper web.

It is possible to reduce the amount of thermal energy consumed for a given production rate, alternatively realize higher production rates. The benefits are particularly interesting for machines that are dryer limited.

TerraDry HHT is the name of this latest innovation from Voith Paper using a refined, proven procedure for applying a metal coating onto a cast-iron or steel Yankee surface.

Currently metal coatings are applied with arc spray methods and using a wire consumable. Voith has refined the HVOF (high velocity oxygen fuel) procedure for applying a powdered metal alloy to the Y ankee surface. The use of this procedure allows the metallizing to be applied with higher kinetic energy and the built-up surface of higher density thus reducing the insulating effect. Higher particle bond strength ensures increased crack resistance and more security against surface de-bonding.

The procedure carries additional health and safety benefits as the exposure to Cr6+ airborne particles is significantly less than the arc spray method.