Paper Machine 5,100mm (4,700mm Trim), 600m/min, printing writing. 35-230gsm
- Speed 250 - 600M/min
- Maximum Trim 4,700mm
- Formation Width 5,100mm
- Basis Weight 35gsm - 230gsm
- PCW usage from 0 - 100%
- Advanced colour control
- FDA compliance
- Grease resistant
- Surface coatings (industrial, print, food)
- Super calender (split reels)
- Cognex defect detection systems
- Wet Strength Capabilities
- Roll size 1,000mm - 1,500mm diameter : 280mm-2,000mm width
- Process Historian
Current Machine Production
- The existing paper machine was manufactured by Beloit and installed in 1958/1959.
- It was rebuilt in 1997 and in 2011 with over US$50 million in rebuilds.
- It has a new 5,130mm BTF dilution headbox slice,
- runs a 5,232mm Fourdrinier wire,
- and trims to 4,724mm sheet at the reel.
- Balance speed of the machine is 610m/min.
The current production information is as follows:
- Paper grade: Free Sheet - Fine Printing Paper
- Furnish: 50-100% hardwood (aspen & maple)
- 0-60% softwood
- 10-20% PCW
- 30-60% broke
- • Sheet Weight: 35gsm - 230gsm
- • Production (Average): 325 TPD
- • Moistures: 1% headbox consistency
- 65-70% moisture into press
- 55-65% moisture into dryers
- 0.5-1.5% moisture into the size press
- 3-5% moisture at reel
BTF Headbox with Honeywell Automatic Dilution Control
New in 2011
- Basis Weight range & grade type: P&W 82gsm - 237gsm
- Other 32gsm - 46gsm
- Design headbox consistency: 0.2%-0.88%
- Retention (average): 86% - 92%
- Furnish: Swk, Hwk, Hpz
- Forming fabric width: 5,232mm
- Pond width: 5,130mm
- Trim width at reel: 4,597 - 4,813in.
- Distributor size: 1,100 mm
- Distributor max. Flow: Max. 50 Cubic Meters/min
- Headbox max. Flow: 42 Cubic Meters/min
- Slice vertical adjustment: 6.35mm - 76.2mm (Approx.)
- Slice horizontal movement: +/- 16mm (Approx.)
- Dilution control: By Honeywell, 66 zones
- Dilution water flow: 2.23 Cubic Meters/min
- Machine design speed: Max 610 m/min
- Hand of machine: Standing at the Headbox looking toward
- The reel, drive is left
HEADBOXES LEADING DIMENSIONS
BASE SHEET HEADBOX:
- Headbox overall height: 1,96mm.
- Headbox overall length (CD): 1,600,
- Headbox overall width (MD): 6,248mm
- Formation width: 5,130mm
- Distribution hoses diameter: 50mm
- Number of distribution hoses: 66
- Maximum temperature: 82 °C
- Maximum design speed: 609m/min
Fourdrinier
Beloit roll-out Fourdrinier with a 5,232mm wire. It includes a Beloit breast roll shake, a forming
board, (7) 4-blade foils, (3) low-vac boxes, a 1,524mm diameter dandy roll, and (3) high-vac flat boxes.
The centerline of breast roll to couch roll is 16.408mm.
Rebuilt in 2011
813mm" φ x 5,283 face width rubber covered (9.5mm) breast roll complete with steel shell, cast iron heads, stainless steel journals, balanced to 762 m/min, bearings, Inpro seals, bearing housings, mounting pads to the existing Fourdrinier framing and a new doctor.
(b) Seven (7) new 508mm φ rubber covered wire returning rolls, 5,283mm face, including the wire stretch and wire guide roll complete with steel shell, cast iron heads, stainless steel journals, balanced to 763m/min, bearings, Inpro seals bearing housings and mounting pads or brackets.
(c) Modifications to the existing wire guide, wire stretch and wire return roll doctors, with adapter places, lever arms, turnbuckles and mounting brackets, as required, to accommodate the wider face width wire return rolls
Press Section
Rebuilt & redesigned in 2011
Suction pick up roll, 660 mm diameter Beloit
1st press, 914mm suction & 914mm smooth Beloit. Configuration: double felted 200 PLI,
New 2ndpress nips with the Bi nip suction roll at 300 PLI and double doctored. The press is double felted with a bottom tandem felt extending through the 1st and 2nd press
The 3rd press consists of a Bi nip press roll is designed to nip with another fixed crown roller at 400 PLI (now removed due to proprietary design) The Bi-nip suction roll is 1,117mm diameter with 3 vacuum zones, 2 nipped and one holding zone. The press is top felted with the felt extending through the 2nd and 3rd press.
The press has the ability to run a 5,080mm (maximum) sheet width through the press section.
There is a steam box between the first and second press that has the ability to profile in 6 zones.
The press showers consist of 3 Albany 2000 series lubrication showers and 3 Albany 2000 series high pressure cleaning showers on 76.2mm centers. The electromechanical shower oscillators are Albany EMO-3 series.
Dryer Section
Uni-Run Dryer Section
The Uni-run consists of (3) Bottom felted dryers and (3) top felted dryers, each driven by a 100 HP AC electric drive. An Enerquin Synervac suction box id designed to keep the sheet drawn to the felt between the dryers.
Bottom felted dryers 1 & 3 are new 2011 GL&V 1,24mm diameter coded pressure is 10.3 bar and have a Plasma hard coat. Dryer 2 is a Beloit 1,524 dryer Coded for 4.13 bar.
The top felted dryers 4, 5 &6 are Beloit 1,524mm diameter dryers and coded for 5.1 bar.
Main Dryer Section
The main dryer section consists of (2) separate drive sections.
Dryers 7 - 22 are 1st section driven from the line shaft with electric variable speed inching drive. The dryers are Beloit 1,524 diameter 5,080mm face rated at 5.1 bar steam. The dryers are gear connected in an enclosed lubricated gear case.
Dryers 23 - 36 are 2nd section driven from the line shaft with electric fixed speed inching drive. The dryers are Beloit 1,524 diameter 5,080mm face rated at 5.1 bar steam. The dryers are gear connected in an enclosed lubricated gear case.
Dryer Section
Uni-Run Dryer Section
The Uni-run consists of (3) Bottom felted dryers and (3) top felted dryers, each driven by a 100 HP AC electric drive. An Enerquin Synervac suction box id designed to keep the sheet drawn to the felt between the dryers.
Bottom felted dryers 1 & 3 are new 2011 GL&V 1,524mm diameter coded pressure is 10.3 bar. and have a Plasma hard coat. Dryer 2 is a Beloit 1,524 dryer Coded for 5.1 bar.
The top felted dryers 4, 5 &6 are Beloit 1,524 diameter dryers and coded for 5.1 bar.
Main Dryer Section
The main dryer section consists of (2) separate drive sections.
Dryers 7 - 22 are 1st section driven from the line shaft with electric variable speed inching drive. The dryers are Beloit 1,524mm diameter 5,080mm face rated at 5.1 bar steam. The dryers are gear connected in an enclosed lubricated gear case.
Dryers 23 - 36 are 2nd section driven from the line shaft with electric fixed speed inching drive. The dryers are Beloit 1,524mm diameter 5,080mm face rated at 5.1 bar steam. The dryers are gear connected in an enclosed lubricated gear case.
Size Press
New in 2004
The size press is a Nekoosa inclined puddle press rated at 25-175 PLI with 1 soft 844 mm diameter roll and 1 hard 844 mm diameter roll x 5,258 mm roll face. Each roll driven by a 100 HP AC drive. The size press is followed by a TEC floatation air turn.
After Dryer Section
Dryers 37 - 51 are 3rd section, driven from the line shaft with electric fixed speed inching drive. The dryers are Beloit 1,524mm diameter 5,080mm face rated at 3.4 bar steam. Dryers 37-40 are controlled individually and dryers 41-51 are controlled top and bottom split for curl control. The dryers are gear connected in an enclosed lubricated gear case. The after section was upgraded to Dublin stationary siphons and controls in 2004.
Andritz / Kusters
Modernized in 2011
- PrimeCal hard 2 roll calender with deflection control roll and a Peritherm counter roll. Neither
- Roll has a synthetic coating, the rolls are hard nipped for pre glazing of coating or finish glazing.
- Paper web: 115-200gsm
- Web width: 4,674mm min., 4,852mm max,
- Paper tension: 0.70-1.08 N/mm, 4-6.2 PLI
- Roll face: 5232mm,
- Line force: 8-150 N/mm, 46-857 PLI
- Speed Construction & balance: 915m/min,
- Speed production: 400-900m/min,
- Peritherm surface temperature: 120oC,
Reel
Beloit reel with a 914mm diameter reel drum capable of 2,032mm paper rolls. A Valmet Reel spool storage/indexing system installed in 1995.
Winder
Valmet Wind Drum, two-drum winder designed for 2,430m/min. Unit includes (15) pairs of slitters with automatic positioning, a core loading system, and Reliance VFD drives with RGU drive upgrade in 2007. The winder was installed in 1995.
Machine Drives
The machine line shaft driven by a line shaft powered by a 1650 HP Worthington steam turbine. Individual drives are Beloit differentials and transfer cases with PIV's for draw control. There are AC electric drives on the Fourdrinier shake, the couch and wire turning rolls, the press section, The Uni-run and winder and DC electric drives on calendar.
Steam Turbine
Worthington non-condensing steam turbine1650 HP S/N 21503. R.P.M. 4656/1000 Rotation: clockwise Steam pressure: 39.6 bar Temperature 385 C
Note: 4656 is max rotor speed at 1000 RPM line shaft speed and 610m/min paper speed with P.I.V. units in the dryer section centered. The steam turbine now drives only the dryer section and the reel due to the addition of electric drives.
STOCK PREP
Refiners
(All 3 units) Remanufactured by SP Engineering in 2012
- 2 ea. Beloit - Jones 38"DD Series 4000 Double-D Refiner Hi-Flow refiner with floating splined 38" diameter rotor.
- 4.5% consistency 3000 GPM hydraulic capacity. Inlet outlet: Stainless steel, casing liner: Stainless steel, Disc rotor: Stainless steel, Sliding head: Stainless steel, Shaft sleeve: 304 with Nickel-Boron, Packing gland & nut: Stainless steel. Motor 2300V synchronous 1000 HP @514 rpm
- 1 ea. Beloit - Jones 38"DD Series 4000 Double-D Refiner Hi-Flow refiner with floating splined 34" Reduced diameter rotor.
- Disc rotor: Stainless steel, Sliding head: Stainless steel, Shaft sleeve: 304 with Nickel-Boron, Packing gland & nut: Stainless steel. Motor 2300V synchronous 800 HP @600 rpm
- Refiners have over US$118,000 worth of rebuilds in each refiner.
Cleaners
Celleco 350 series centrifugal cleaner system utilizing four stages with (96), (56), (20) and (6) cleaners respectively and a reject control unit as the final stage.
Screens
New in 1994
Fiberprep 0.010" slotted screening system utilizing two 1500sph screens for the primary stage; and a 1000spm, 600spm, 400spm, and a Celleco vibratory screen for the proceeding stages.
Beloit M24 Screen
Black Clawson 12P SS Screen & (2) 24P SS Screens
Fan Pump
New casing and rebuilt rotating element in 2010
Gould's double suction pump 24 x 20 -20 low pulse rotor, up to 79.5 cubic meters/min with a VFD 600 HP Motor.
Machine Pulpers
Press Pit Pulper: Model 3696 UTM shark pulper, continuous with 1,117mm IE impeller. Motor 400 HP 1170 rpm with belt drive.
Size Press Pulper: Bolton Emerson 914 mm Tornado pulper, 17-4 ph stainless steel rotor and stator, 316 SS outlet chamber. Motor 400 HP 1170 rpm motor and belt drive w/ jack shaft arrangement.
Reel Pulper: Bolton Emerson 914 mm Tornado pulper, 17-4 ph. stainless steel rotor and stator, 316 SS outlet chamber. Motor 400 HP 1170 rpm motor and belt drive w/ jack shaft arrangement.
Winder Pulper: Valmet twin agitator shark pulper. Motor 150 HP each
Vacuum System
- Fourdrinier low-vac boxes: Hartzell stainless steel Vacuum Exhauster
- Fourdrinier flat boxes: Nash CL-1501 and Nash K-6 vacuum pumps
- Press Section uhle boxes :( 2) Siemens Elmo-F vacuum pumps
- Couch and press suction rolls :( 5) Nash H-11A lineshaft vacuum pumps driven by an 1800hp Elliot steam turbine. A 900hp motor/generator either drives the line shaft or generates power determined by the demand of the turbine exhaust steam.
- The Bi-Nip suction press roll is supplied vacuum by a New Somarakis (2011) SV-4440-2 vacuum pump and driven by a 400 HP electric motor.
Dryer Drainage System
The steam and condensate system was completely replaced in 1995 and again upgraded in 2011 with a Fulton System Design and new Johnson joints sized for an approximate 40,000 lbs. /hr. evaporative load. The system has the following dryer groups to control dryer pressures separately:
- Dryer 1: 0 - 10.3 bar (individual dryer can pressure control)
- Dryer 2: 0 - 5.1 bar (individual dryer can pressure control)
- Dryer 3: 0 - 10.3 bar (individual dryer can pressure control)
- Dryer 4: 0 - 6.9 bar (individual dryer can pressure control)
- Dryer 5: 0 - 5.1 bar (individual dryer can pressure control)
- Dryer 6: 0 - 5.1 bar (individual dryer can pressure control)
- Dryers 7-12: 0 - 50psi
- Dryers 13-22: 0- 5.1 bar
- Dryers 23-36: 0- 5.1 bar
- New Deublin stationary siphons and joints were installed in 2004 for the 15 dryers in the after section.
- Dryers 35-39: -1.3 to 0.69 bar (individual/group dryer can pressure control)
- Dryers 40-50: 0-3.5 bar (top and bottom dryer can pressure control)
- There are (6) separators that transfer condensate to one collection tank, which then pumps through the building make-up air heat recovery coils to the boiler room.
Hood and Air System
The paper machine dryer hood and air supply/exhaust system was replaced in 1995 with a modern Valmet Enerdry System. It includes the following:
Modular high humidity hood designed for an excess of 1,100 grains humidity.
Pocket ventilation system with (30) pocket ventilators and (2) Northern Blowers designed for 2,095 cubic meters/min at 82 C.
Hood exhaust and heat recovery system consisting of (4) Northern Blowers designed for 3,851 total exhaust. Each exhaust plenum includes air to glycol plate coils to recovery heat for the building air glycol system, Fans and heat exchangers constructed from 316SS.
Building make-up air system with a glycol heating station and (6) Northern Blowers to supply 385,000 cubic meters/min of air to Building #43.
Paper Machine and Process Control
A Fisher Provox system controls and/or monitors all components of the paper machine. It utilizes three 500pt controllers and one 320pt controller. These controllers interface with the Measurex gauging system and Allen Bradley PLCs. Operator interface is done using two Fisher six user OWPs for Provox control and MSX entry windows. Archiving is done using a 5000pt PI system.
The Measurex system controls several machine functions, such as basis weight, machine speed, dryer pressures, etc. There are two Measurex cross-machine scanners, one before the size press and one before the reel.
The ABB colour scanning system also interfaces between the ABB work station and processing centre and the Fisher Provox. This uses an ABB SP-1200 (7) meter scanner "O" frame before the calender stack where top and bottom Mcbeth colour head sensors control the dye additive system.
The balance of the paper machine controls are either electric or pneumatic and are operated from standard bench boards or control boxes, as originally furnished with the equipment or updated based on machine modifications.
Additions:
Projet felt cleaner, Cognex camera system, ABB high speed cameras, Calcoil Profiler on The Andritz Prime Cal. And the NDC optical moisture sensors
We have an engineer on site to answer any of your questions.