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DIY guidelines for optimization of wire vacuumDevesh Singhal
This presentation indicates how paper mills can collect data from their own machines and do the optimization to reduce energy consumption and get more dryness after the wire part.
For recycling of paper we have decided to design and develop the paper recycling machine. This machine enables the conversion of waste paper to reusable new paper. The designed machine consists of five major components that are the hydropulper, the head box, the felt conveyor, the driers and the rollers.
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In the papermaking process, paper is dried on rotating, steam-heated, cast iron drying cylinders. Steam is supplied to each of these drying cylinders through a rotary joint and the steam that has condensed inside the dryers is removed by a syphon system that extends out through either the same rotary joint or a rotary joint on the other dryer journal.
Dryer doctors have a number of purposes in a paper machine dryer section: sheet shedding, dryer surface cleaning, threading, and air handling and control. Paper dryer doctors are often overlooked in the papermaking process, but they need proper attention to maintain efficient dryer operation.
Paper dryers are occasionally shut down for periods of time ranging from a few hours to many months. It important that proper procedures be followed when shutting down dryers to be sure that the process is complete and appropriate for the duration of the shutdown.
Single-felt dryer sections are used to enhance the runnability of high-speed paper machines. In single-felt dryer sections, the web is supported by the dryer felt (i.e., fabric) in the draws between dryers. Fabric style, air handling equipment, and runnability devices are critical to efficient operation. Steam control in bottom single-felt dryers is also important.
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This paper reviews data on thermal response of a dryer cylinder to changes in heat load (sheet break simulation) and to changes in dryer steam pressures. It also shows the improvements that are possible with the application of Turbulator® bars and advanced dryer section control.
Flex-Valve, is a brand under General Rubber Corp. representing a state of the art line of pinch valves, pressure isolation rings and duck bill check valves. Flex-Valve has become a worldwide recognized brand and leading manufacturer in the industry
Understanding Paper Dryer Rotary Joint ReliabilityKadant Inc.
In the papermaking process, paper is dried on rotating, steam-heated, cast iron drying cylinders. Steam is supplied to each of these drying cylinders through a rotary joint and the steam that has condensed inside the dryers is removed by a syphon system that extends out through either the same rotary joint or a rotary joint on the other dryer journal.
Dryer doctors have a number of purposes in a paper machine dryer section: sheet shedding, dryer surface cleaning, threading, and air handling and control. Paper dryer doctors are often overlooked in the papermaking process, but they need proper attention to maintain efficient dryer operation.
Paper dryers are occasionally shut down for periods of time ranging from a few hours to many months. It important that proper procedures be followed when shutting down dryers to be sure that the process is complete and appropriate for the duration of the shutdown.
Single-felt dryer sections are used to enhance the runnability of high-speed paper machines. In single-felt dryer sections, the web is supported by the dryer felt (i.e., fabric) in the draws between dryers. Fabric style, air handling equipment, and runnability devices are critical to efficient operation. Steam control in bottom single-felt dryers is also important.
Dryer Surface Temperature Response CharacteristicsKadant Inc.
This paper reviews data on thermal response of a dryer cylinder to changes in heat load (sheet break simulation) and to changes in dryer steam pressures. It also shows the improvements that are possible with the application of Turbulator® bars and advanced dryer section control.
Flex-Valve, is a brand under General Rubber Corp. representing a state of the art line of pinch valves, pressure isolation rings and duck bill check valves. Flex-Valve has become a worldwide recognized brand and leading manufacturer in the industry
Design and analysis of control valve with a multi stage anti cavitation trimnaz4u
Valves are the components in a fluid flow or pressure system that regulate
either the flow or the pressure of the fluid. This duty may involve stopping
and starting flow, controlling flow rate, diverting flow, preventing back
flow, controlling pressure, or relieving pressure.
Embark on a journey of precision control with DCB Accumulators. Our cutting-edge DCB (Diaphragm, Composite, and Bladder) Accumulators are engineered to deliver unparalleled precision in hydraulic systems. Reel Power ME patented innovative depth compensated accumulators reduce subsea equipment weights, lowers maintenance requirements and improves equipment access. Subsea Accumulators are used to deliver hydraulic fluids to a wellhead blowout preventer, subsea control systems and subsea trees.
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Introduction:
Gas Absorption is one of the very first Mass Transfer Unit Operations studied in early process engineering. It is very important in several Separation Processes, as it is used extensively in the Chemical industry.
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7 basic valve questions to specify the correct valveDesign World
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CFD is being used nowadays extensively in many areas. We had an opportunity to optmise the duct system using CFD. The case stuy is presented in this paper.
Stack height often surprises me. Can we consider cutting short stacks of factories to reduce pollution, as the polluter would be faced to get into self compliance, willingly or unwillingly. Think.
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Transcript: Selling digital books in 2024: Insights from industry leaders - T...BookNet Canada
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Rise in volumes of AI-powered cyberattacks
Major cyber events in 2024
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Attacks on counties – USA
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Cyber risk predictions
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Monitoring and observability aren’t traditionally found in software curriculums and many of us cobble this knowledge together from whatever vendor or ecosystem we were first introduced to and whatever is a part of your current company’s observability stack.
While the dev and ops silo continues to crumble….many organizations still relegate monitoring & observability as the purview of ops, infra and SRE teams. This is a mistake - achieving a highly observable system requires collaboration up and down the stack.
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2. Barometric Legs
Barometric legs are long neglected
specially for paper machine wet end
vacuum systems.
There are many mills using these since
long, still, improper designs have led to
poor functioning, and hence, operational
problems.
2Rethinking Barometric Legs by D K Singhal
3. What Papermakers Want?
Essentially, a papermaker wishes to get
maximum web dryness with minimum
vacuum, least drag load and good control
over the entire operation.
Yet, paper machine operators adjusting
vacuum levels, valves to reach the desired
level; are common for many machines.
3Rethinking Barometric Legs by D K Singhal
4. WireVacuum Control
Wire vacuum control is a complex,
difficult and annoying process.
When you alter gauge vacuum level in a
suction box, this results in changes in
outlet web dryness and hence airflow in
all subsequent suction boxes.
4Rethinking Barometric Legs by D K Singhal
5. Airflow
The sum of airflow through the individual
suction boxes is what the vacuum pump is
supposed to handle.
But, with change in airflow, the gauge
vacuum reading changes again.
Thus, we need to make different
alterations.
5Rethinking Barometric Legs by D K Singhal
6. Vacuum Pump
Vacuum level depends upon the total
amount of air flow through the vacuum
pump.
Any alteration in a particular suction box
alters the total airflow and hence vacuum
level in other suction boxes.
6Rethinking Barometric Legs by D K Singhal
7. Machines in Developing World
Most of the paper machines in developing
world are assigned for many different
grades, raw materials, and basis weight
range.
Vacuum level settings for one grade may
or may not work for other grades.
7Rethinking Barometric Legs by D K Singhal
8. Designing Barometric Legs
The trouble with barometric leg design is
its simplicity.
Barometric legs allow a significant
flexibility from the design parameters.
Often, it is considered a too simple job,
and the barometric leg dimensions are
just copied from other installations rather
than proper designing.
8Rethinking Barometric Legs by D K Singhal
9. Thinking Outside the Box
This shows the need to think beyond the
conventional barometric legs, and explore
possibilities to have a better vacuum
control with these.
Let’s have a quick look with the problems
encountered.
9Rethinking Barometric Legs by D K Singhal
10. Non-LinearVacuum
Quite often we face a problem that the
dewatering rate is too high from a
particular box even if the vacuum valve
opening is slightly increased.
If you close the valve slightly again, the
drainage (almost) ceases.
This finally results in more vacuum in a
particular suction box than actually
desired.
10Rethinking Barometric Legs by D K Singhal
11. Larger Seal Pits
Seal pits are designed on the basis of
barometric leg volume.The more is the
volume of seal pit, the more will be the
retention time in this and hence the
possibility for slime generation.
11Rethinking Barometric Legs by D K Singhal
12. Ideas to Improve Design
The first major problem is related to
control.
If you evaluate on the basis of operational
data you will find that the initial suction
box handles much more water compared
to the last one.
For air, the situation is reversed.
12Rethinking Barometric Legs by D K Singhal
13. Conventional Barometric Legs
Conventionally, many mills have installed
barometric legs of almost the same design
and size.
This generally results in too overdesigned
barometric legs, particularly in the last
section.
The concept indicates we MUST use two
or three different designs for better
control.
13Rethinking Barometric Legs by D K Singhal
14. New Design?
There is nothing new. Only, we must
design each leg separately.
The idea is to use three/four different
barometric leg types; with larger, medium
and smaller leg water line size.
Each leg must be adequate and fully
capable of handling the desired flow.
14Rethinking Barometric Legs by D K Singhal
15. Dewatering Control
We can use flow control valves to restrict
flow rate.
But, the problem is that if drainage is
more at a particular vacuum, and we
restrict water flow, after some time, the
water level will reach nearly at same level
as the box, and hammering will start.
That is why, good airflow control valve is
a must to get desired vacuum.
15Rethinking Barometric Legs by D K Singhal
16. Dewatering Control
In the initial suction boxes, even a minor
change in gauge vacuum level results in
significant variations in dewatering rates.
This means we need better vacuum
control in these boxes.
16Rethinking Barometric Legs by D K Singhal
17. Vacuum => Dewatering
In the initial suction boxes, web is less dry,
hence, airflow will be less. Furthermore,
we need lesser vacuum level.Thus the
airflow would be very low.
As the dewatering is too sensitive to
applied vacuum in the initial sections,
oversized valves are the main reason of
problems.
17Rethinking Barometric Legs by D K Singhal
18. SmallerValves!
Yes! In the initial suction boxes, the size of
valve should be very small. Furthermore,
as these boxes are too sensitive, we need
fine control valves likeV-notch ball valves
or even the needle valves.
But, in the later sections, air valves are of
higher sizes, while the water pipe (bottom
side) is of much smaller diameter.
18Rethinking Barometric Legs by D K Singhal
19. Valve Size
A simple technique to check if the valve
size is higher than the desired one is to
check if the valve opening is too little.
If this is the case, replace the valve with a
lower size one.
Typically, if the valve opening is between
25%-75%, the valve is suitable.
Refer to sample calculations on the next
slide for an insight of designing process in
brief.
19Rethinking Barometric Legs by D K Singhal
20. Typical figures
Water removed is nearly 30 times more
in first box compared to sixth.
Airflow is 50 times more in last box
compared to first.
20Rethinking Barometric Legs by D K Singhal
21. Initial Suction Boxes
A minor change in initial suction box
vacuum level can result in a significant
change in dewatering rate in these boxes.
For a better control on dewatering, one
needs to give more attention to vacuum
levels.
Valves like needle valves, or even betterV-
notch valves can be considered for such
applications.
21Rethinking Barometric Legs by D K Singhal
22. Finishing Suction Boxes
Here, an excess vacuum level does not
yield in proportionate savings in
dewatering.
Thus after a limit, benefits of additional
vacuum diminish. However, the drag load
on wire keeps on increasing with applied
vacuum.
That means- more drive power, more
wire wear (poor wire life), and more wear
of suction box tops.
22Rethinking Barometric Legs by D K Singhal
23. Finishing Suction Boxes
That is why a good vacuum control of
these is important.
A good control should include a set point
based methodology, where the valve
opening is automatically adjusted to
ensure desired vacuum level.
23Rethinking Barometric Legs by D K Singhal
24. Future Scope
After having an individual barometric leg
vacuum control, a future modification of
having a “TOTAL WET ENDVACUUM
CONTROL” system.
This system would be a PLC based
system to control the followings-
◦ Vacuum level in individual boxes
◦ Header vacuum level
◦ Vacuum pump speed through aVFD
24Rethinking Barometric Legs by D K Singhal