GW FASERTECHNIK GmbH Delivery program 2014
Contents The Company:... 3 Pulping line manufactured and supplied by GW Fasertechnik GmbH... 4 1. Pulper... 5 GW Pulper SP 800... 6 2. GW Ragger with measurement device... 9 3. Pulper Cleaning Systems:... 12 GW Reject Pump RE 400/400... 14 GW Junkscreen 19... 17 GW Dewatering Drum... 20 4. Coarse Screening:... 23 GW Vortexdrive... 24 GW Centrifugal heavy rejects cleaner SSL 1500... 30 GW Lastvortex LVS... 32 GW Lastvortex LVZ... 35 General Information:... 38 Contact Information:... 39 2
The Company: GW Fasertechnik GmbH was founded in 2001, in Erkrath, Germany. The company developed out of the SHS GmbH which had been founded in 1994. With the second half of 2013 the ownership was handed over to the Hellenbrand GmbH. Consequently, the company s headquarters were relocated to Lambrecht, Germany, into the buildings of the Hellenbrand GmbH on 01.09.2013. GW Fasertechnik supplies individual and foreward-looking technology for the pulp preparation. Improvement of pulper cleaning systems is one of GW Fasertechnik`s priorities. A large number of papermills from all over the world trust in the know how of GW Fasertechnik in order to optimize their stock preparation and to save energy. Up to now nearly 100 papermills in Europe and overseas took the chance to modernize their pulping lines with the technology of GW Fasertechnik. Increases of capacity of up to 70 % were the results after pulper upgrades. We analyse and optimise existing plants in the paper industry based upon the combination of our longtime experience in stock preparations and continuous feedback from paper makers and technologists. Our staff includes motivated and qualified personnel with many years of experience in the paper industry. 3
Pulping line manufactured and supplied by GW Fasertechnik GmbH Processing conditions: Furnish consisting of 30% mixed waste paper and 70 % OCC. Machinery: Pulper*, pulper detrashing equipment and ragger Guaranteed values: Capacity at the Pope reeler: 32 52 t/h Stock consistency in the pulper: 6% Energy consumption of the pulper drive with 52 tph: 12 kwh/t Fibre loss in the rejects: 10 % Share of flakes in the pulper s accept stock: 8 % Soon after its initial start-up, the pulping line well reaches all the guaranteed values. During a start up test, the plant has easily yielded a capacity of 63 tph. Machines installed: 1 x GW pulper SP 800 with a useful volume of 80 m³. Installed pulper motor of 800 kw 1 x GW Ragger with electronic rope control (rope too long, too short, torn off) 2 x GW Pulper cleaning system each with GW Reject pump, GW Junkscreen and GW Dewatering drum. The GW Pulper Upgrade Package is always tailor-made to suit your individual needs and requirements. Only minor investment is required to yield major effects and increase the capacity of the pulping machinery successfully. * Patent No. 102006031904 International patent application PCT/DE2007/001069 4
1. Pulper SP 100 SP 800 8 60 m³: GW Pulpers with level control are used in continuous and discontinuous operation with stock consistencies of 4 to 7 %. Raw materials vary from fresh virgin fiber, paper machine broke in rolls or bales to highly contaminated waste paper. Important Advantages: Low specific energy consumption Creation of a strong vortex Ragger operation possible for 20 m³ or more with corresponding raw material Contaminated Raw Material and Reject Removal: Heavy reject cannot pass the screen and is collected in the heavy reject trap which is cyclically emptied. Light rejects are removed with the GW pulper cleaning system. The discontinuous operation occurs without trap and possibly without sorting screen. Sizes: SP 100, SP 230, SP 320, SP 550, SP 800. GW pulper rotors stand out with their low specific energy consumption, strong vortex and high circulation rate. Rotors are available for all common pulper types with medium stock consistency. 5
Technical Description GW Pulper SP 800 6
1. Application and Function GW Pulpers with level control are used in continuous and discontinuous operation with stock consistencies of 4 to 7 %. Raw materials vary from fresh virgin fiber, paper machine broke in rolls or bales to highly contaminated waste paper. The GW Pulper has a low specific energy consumption, a strong vortex and ragger operation is possible with corresponding raw material Heavy reject cannot pass the screen and is collected in the heavy reject trap which is cyclically emptied. Light rejects are removed with the GW pulper cleaning system. The discontinuous operation occurs without trap and possibly without sorting screen. 2. Dechnical Data: Pulper Size (usable 80 m³ capacity) Inlet stock consistency Up to 7% Vat dimensions I-Ø 6350 mm; h= 4400 mm; H= ~7000 mm Rotor diameter Ø 2350 mm Packing Type Stuffing Box Rings or liquid packing Required Power 600 kw Rotor Speed 166,8 rpm Motor power rating 800 kw (Motor customer provision) Nominal Speed 1500 rpm Motor-type IM B3 Drive Material Helical bevel gear unit All parts in contact with stock made of chromenickel molybdenum steel (AISI 316) and welded. Coupling protection and motor foundation made of normal steel (varnished) 3. Machine Components: welded vat screening box (accept outlet 2x DN600) screen with support frame adjustable rotor with wear-resistant coating rotor hub with protective sleeve heavy reject trap DN400 motor foundation 7
coupling protection gear unit with coupling 4. Scope of Delivery: complete machine (without motor and without valves) gear unit with coupling coupling protection motor foundation anchor bolts 5. Not included: Motor Gate and trap valves pulper cover instrumentation 6. Foundation Plan: Nr. : F00819_Rev.1 Dated: 14.03.2007 (subject to technical modification ) 8
2. GW Ragger with measurement device Ragger operation is an important part of the pulping process in the stock preparation. Interruptions can lead to production failure. The causes for disruptions are the flows and forces and in the pulper which are difficult to predict. The result is a breaking tail causing production stops. To prevent such interruptions due to tail breaks the modern GW raggers have two new standards: the powered pressure wheel with additional drive 3000 kn force on the tail for better traction and the GW measurement device to detect and measure forces affecting the tail inside the pulper below the surface. GW Ragger Advantages: more traction on the tail measurable stress on the tail continuous ragger operation more control for on-time reaction automated operation lowers the risk of accidents 9
Technical Description GW Ragger with powered pressure wheel 10
1. Application and Function: The GW Ragger is used for collecting and removing spinning impurities (such as plastic sheets and films, tapes, wires and the hardly soluble raw material left in the pulper). In the core of the vortex that is generated in the pulper, these impurities are caught by a rope with entwined primary wires and form the so-called debris rope or tail. The rope is then withdrawn from the pulper by the GW Ragger with rope wheel and pressure roll (the load applied by the roll may be additionally increased using a compressed air-cylinder). To facilitate rope handling, the drive of the two-stage ripped rope wheel has been designed for right and left-handed operation and may operate at two pre-selectable speeds. In addition, the GW Ragger has a rope deflection pulley at the ingoing and discharge side each. 2. Technical Data: Bevel Gear Ragger Speed SEW KA 107B R77 DT 90S4/2/BMG/TF 1-10 m/h Main Power Unit: - motor rating 0,7/0,85 kw (50 Hz; 400 V) - RPM 0,97/2 1/min - motor weight 300 kg - bevel helical gear SK 9016.1 AZ-71 L/6 Power Unit Pressure Wheel: - motor rating 0,3 kw (50 Hz; 230-400V) - motor weight 30 kg Ragger Weight 2730 kg 3. Delivery Scope: Complete mounted aggregate, motors and force transmitter with signal amplifier. 4. Optional: Steel foundation 11
3. Pulper Cleaning Systems: Extreme importance in the area of pulper cleaning is given to uninterrupted operation. The new system increases pulping performance by up to 50 % compared to conventional cleaning systems with Contaminex and drum or Fiberizer/Hydrapurge and drum. The system consists of a non-clogging pump, a reject collector and a dewatering drum. All three parts of the system are available in different sizes. The choice of size depends on the total desired production capacity: Reject Pump RE 400/400 Junkscreen 0, 10, 17, 19, 25, 27 Dewatering Drum CON 2 or 3 A single cleaning line operates easily with 600 tpd with waste paper of average contamination. For higher capacities two cleaning lines are preferably installed. GW Fasertechnik delivered a single pulper cleaning line to Smurfit Kappa Bad Nieuweschans in order to relieve the stock preparation equipment after the pulper cleaning. In addition, optimised pulping technology was supplied to improve the existing pulper s performance. 12
According to the customer, the couple of GW Reject Pump and GW Junkscreen prove to prevent unwanted interruption in the operation which is usually caused by clogging. With modifications for a better pulping result and the pulper cleaning line, the customer has a smoothly running stock preparation. Since April 2011 the Papier- und Kartonfabrik Varel, Germany, started the operation of 2 GW pulper cleaning lines as part of its revamped PM4. According to the customer the 2 lines work so well that the first phase of the subsequent coarse screening only has to remove about 13 % of reject. Already in 2008 GW delivered a single line pulper cleaning system to Klingele Weener in Weener, Germany. Also the main pulper was optimised and its capacity increased from 28 to 36 tph. The pulper s energy conusumption was reduced by 20 % meaning a specific comsumption of 7 kwh/t. Due to these positive results the second existing pulper was modified. The latter is, however, solely in operation when the main pulper is not working for maintenance reasons. Smurfit Kappa Roermond Papier also has an energy efficient pulper cleaning system engineered by GW. The GW pulper SP800 with a production capacity of 1400 tpd has a specific energy consumption of less than 10 10 kwh/t. In combination, the GW pulper, two GW Reject Pumps, two GW Junkscreens and two GW Dewatering Drums require less than 12 kwh/t. 13
GW Reject Pump RE 400/400 The GW Reject Pump is usually the first machine operating in the GW pulper cleaning system. Since the stock to be processed has not yet passed through a screen the Reject Pump is one of the most important aggregates for providing an excellent pulper cleaning system. Today GW has obtained a very high efficiency with the constant optimisation and development of the Reject Pump. Today s efficiency is summarised by these results: High pumping capacity of more than 20 m³/min. No plugging affinity due to rope forming. Low electrical power consumption: under favourable conditions less than 20 kw. Low wear and tear of turning and stationary parts of the machine. Low investment. The avoidance of plugging affinity is reached by two means: 1. The housing has an ideal hydro-dynamic form. 2. The rotor and its rotational speed are matched so that parts causing rope forming have no chance to settle. All GW Reject Pumps that are currently in operation show similar results. 14
Technical Description GW Reject Pump RE 400/400 15
1. Application and function The GW reject pump is used in the waste paper processing as pulper cleaning equipment and removes in connection with the GW Junk Screen and GW Dewatering drum the lightweight rejects from the GW Pulper. 2. Technical data: Rotor speed: 200-420 rpm (FU operation) Required power: 15-35 kw Motor power 30 or 45 kw depending on the rating: particular situation and local terms Rated speed: 1483 rpm Motor mounting position / type: B3 225SM V-belts: 1 set ( matched set of 6 pieces ) Material: All parts which have contact with stock are made of chrome nickel molybdenum steel. V-belt guard made of normal steel (varnished) 3. Scope of supply: Complete machine, V-belt drive, V-belt guard, Motor tension rails 4. Not included: Motor 16
Technical Description GW Junkscreen 19 17
1. Application The GW Junk Screen is used in waste paper processing as pulper cleaning equipment and removes in connection with the upstream GW reject pump the lightweight rejects from the pulper. 2. Technische Daten: Inlet stock consistency: approx. 4-6 % Throughput: max. 14000 l/min Rotor speed: 330 rpm Perforation: 22 mm Ø Required power: approx. 48 kw 55 kw (Motor to be supplied by the Motor power rating: customer) Rated speed: 1475 rpm Motor mounting position / type: 280 B3 Drive: V-belt drive Pulleys: SPB or SPC 6 grooves V-belts: Heavy reject trap valves: DN 350 Materials: 1 set (matched set of 6 pieces) All parts in contact with stock are of stainless steel. V-belt guard and motor mounting plate made of normal steel (varnished) 3. Scope of supply: Complete machine, V-belt drive, V-belt guard, heavy junk trap, device for disassembly of screen plate and rotor 4. Not included: Motor, motor-frame, heavy duty valve 18
19
Technical Description GW Dewatering Drum CON Size 2 20
1. Application and function The GW dewatering drum separates the impurities that accumulate in waste paper or washing water from the fibre suspension or the process water. The remnants of plastic sheets and paper are discharged from the drum to a reject press. A filtrate container (glassfiber reinforced plastic) for fibres and water is located under the drum. The drum can run continuously or discontinuously depending on the operation of the Junkscreen. For continuous operation, a spray tube may be required. The drum consists of a screening body made of stainless steel, with large-dimensioned antifriction bearings, exchangeable driving journal. Protecting covers and screening drum are mounted on a steel frame (normal steel, varnished). 2. Technical data: Outer drum diameter from 1800 mm to 1200 mm Drum length (perforated part) 2500 mm Perforation 16 mm / pitch of 32 Drum speed approx. 12 rpm Empty weight 3000 kg + 1000 kg filtrate container Motor power raiting 7,5 kw Helical-bevel geared motor SEW KA107 DV132 M4 Overall length approx. 5440 mm Overall height approx. 3000 mm Overall width approx. 2400 mm All parts in contact with stock are of stainless steel, frame/protecting covers of normal steel Material (varnished) 3. Scope of supply: Drum body, splash guard, filtrate container, drive with helical-bevel geared motor, feeding pipe DN 350 with bracing - all parts are mounted on a common frame 4. Not included: Funnel and/ or chute for drum overflow. 21
22
4. Coarse Screening: The advantages: Even with a three stage system only one pump required Higher specific screen load due to improved cleaning of each single aggregate higher concentration of rejects toward the final stage increased life-time of rotors and screens reduced power consumption of aggregates improved removal of heavy reject Aggregates: Vortexdrive Sizes 2 to 4 Heave Reject Cleaner Sizes 400 / 1000 / 1500 / 2000 Lastvortex Disc Sizes 1 to 4 Lastvortex Cylinder Sizes 2 to 3 Capacity of one single line: 120 600 tpd 23
Functional Principle of the GW Vortexdrive GW Fasertechnik employs sorting aggregates with screen plates in its coarse screening lines for waste paper plants: the GW Vortexdrive. Advantages of the GW Vortexdrives: - Inlet stock consistency 6 % - Inlet pressure 1 bar - Specific energy consumption max: 6 kwh/t - Life-time of rotors and screens approximately 15,000 hours - Simple maintenance of rotors and screens The low energy requirements and long life-times of wear parts are owed to the hydrodynamic laws which operate in the GW aggregates. The Vortexdrive has a central inlet, a tangential accept outlet and only one reject outlet. The reject contains most of the remaining light and heavy reject. The name Vortexdrive is derived from vortex. The Vortexdrive operates with a highly developed vortex. This vortex concentrates the light reject at the centre of the machine while pushing the heavy reject to the periphery. Due to the vortex neither reject type touches the screen plate significantly. The light reject moves inside the vortex toward the machine cover and, hence, toward the inlet. The heavy reject moves from the outer diameter of the rotor along the machine s wall also towards the cover. The pressure near the machine s wall is much higher than the inlet pressure. Near the cover, light and heavy reject are combined, as the light reject moves outwards. That allows for the combined reject removal through one outlet. The GW system is based on the flow characteristics of a single jet. Such a jet always has a main jet with decreasing angle and a turbulent area with increasing angle. With real liquids such as water vortex calculations are easy. With waste paper stock it is more difficult and additional variables have to be taken into account, which distort the laws. GW has identified relations and variables and developed a usable model. 24
25
Technical Description GW Vortexdrive Size 2 26
1. Application and Function The GW Vortexdrive is used in waste paper stock preparation in the area of coarse screening. It is an highly effective cleaning and screening equipment. The machine can be fed directly with the accepted stock leaving the pulper. It separates light and heavy rejects from pure fibre material. The rejects are conveyed directly to the next cleaning step. The accepted stock is then collected in a chest. 2. Technical data Incoming Stock Consistency Up to 6 % Rotor Speed 565 min -1 Screen Plate Perforation 2.4 mm (GW Standard) Required power Depends upon surrounding engineering Motor Power Rating/Rated Speed Depends on required power Type of Motor B3 280 M Drive Materials V-Belt Drive Stock-contacting parts made of stainless steel Non-stock-contacting parts made of painted steel Inside of Machine coated with wearresistant aluminum-oxide ceramics. 3. Scope of supply Complete machine, v-belt drive, drive protection, motor tension rails 4. Optional Motor 5. Foundation plan GW VD18EL-F-953 Subject to technical modification 27
GW Heavy Reject Cleaner: Cleaning Equipment A Short Description GW differentiates in terminology between sorting and cleaning. Both terms deal with separation. In the case of sorting the separation happens with a barrier, mostly a screen. In the case of cleaning the separation usually happens along hydraulic-physical rules. The GW SSLs (Heavy Reject Cleaners) are cleaning equipment. An SSL separates heavy reject according to the hydraulic-physical process. This heavy reject is removed and discharged. The cleaner s degree of efficiency depends on many factors. Among these are the centrifugal force, discharge time and the point of too much thickening of the reject when separation stops being possible. The centrifugal force and the discharge time depend on the design of the equipment. GW has achieved the optimum with its design of the SSL. Regarding the high thickening of reject GW has invented and developed the backwashing insert with a Dralldüse. This translates literally into spinnozzle and operated correctly the high thickening in the cleaning process. The GW backwashing insert: This insert is placed at the end of the conical discharge part of the SSL. The main item is the Dralldüse made of specially hardened glass. This glass insert has tangential perforations towards the inner area. Outside of the glass the water is moved in tangentially. This process induces a great vortex which reaches inside the conical part of the SSL. Since the reject is being thinned out here, another vortex is created and based upon physical rules a negative pressure is created inside the vortex. This negative pressure increases the separation by thinning the solution and causes the transport of fibres towards the top. That way the proportion of small heavy reject is increased in the collection area and fibres are washed back into the stock preparation system. In other plants the back washing happens between the two valves of the reject trap. This causes higher wearing especially of the lower valve. This GW system and design exists for over ten years and has been steadily improved. All new experiences are used to improve our equipment quickly for the benefit of our customers. 28
29
Technical Description GW Centrifugal heavy rejects cleaner SSL 1500 and reject trap with gate valves 30
1. Application and function The GW centrifugal cleaner SSL 1500 is a hydrocyclone. It is used for removing heavy contaminants and operates continuously in a stock consistency range from approximately 2 to 4 %. The GW SSL 1500 is preferably installed at the GW Vortexdrive and is suitable for the separation of impurities such as sand, cullets, stones, bits of sheet metal and wires that are smaller in size than the perforation diameter of the pulper screen. 2. Technical data: Pressure difference approx. 1 bar Volumetric throughput 1200 1700 l/min Inlet stock consistency 2 4 % Outlet pressure min. 0,6 bar Admissible operating pressure 6 bar Amount of backwashing water at the trap 5-10 l/min Water quality Clarified water Water pressure 1 bar above inlet pressure SSL Amount of backwashing water from the vortex nozzle 50 80 l/min Water quality Clarified water Water pressure 1 bar above inlet pressure SSL Material: Cleaner head and separation cone made of plastic material. All stock-contacting parts made of VA. 3. Scope of supply: Cleaner head, Separation cone, Holder for inspection glass with inspection glass, Backwashing insert with nozzle, Reject trap with valves, Holders 4. Optional: Frame 31
Technical Description GW Lastvortex LVS 32
1. Application and function: In the stock preparation the GW Lastvortex Plate Part is mostly used for the separation of light reject. Even with a high stock consistency of up to 4 % the machine aims to separate light reject from fibres. That way the light reject is concentrated and the subsequent equipment can more effectively separate the light reject. GW reduces the built-up pressure in the pipe with the concentrated reject usually with a small cleaner. 2. Technical data: Stock consistency till 4 % Feed amount till 45 t/d Rotor speed 435 rpm Perforation 3 mm Ø Requuired power approx. 22 kw Motor power rating 30 kw Rated speed 1.475 rpm Motor mounting position / type B3 Drive V-belt drive Material All parts which have contact with stock are made of stainless steel. The other parts are made of normal steel (varnished) 3. Accomplishment: Compact welded housing Screen plate screwed to housing for easy exchange Ample bearing dimensions with easy-to-reach lubrication service points Distance rotor/screen plate externally adjustable with bearing Dimensions: see overview. 4. Scope of supply: Complete machine, V-belt drive, belt guard 5. Option: Motor 33
34
Technical Description GW Lastvortex LVZ 35
1. Application and function: The GW Lastvortex LVZ separates and removes the light reject in the coarse screening system. It is especially valuable for saving long fibres which otherwise are lost with the light reject. It returns the long fibres into the process without reducing the qualities of the long and strong fibres. 2. Technical data: Stock consistency 1,8 % Feed amount 400 l/min Rotor speed 360 rpm Perforation 2,4 mm Ø Requuired power approx. 13 kw Motor power rating see data sheet Rated speed see data sheet Motor mounting position / type V6 Drive V-belt drive Material All parts which have contact with stock are made of stainless steel. The other parts are made of normal steel (varnished) 3. Scope of supply: Cleaner head, Separation cone, Holder for inspection glass with inspection glass, Backwashing insert with nozzle, Reject trap with valves, Holders 4. Optional: Frame 36
37
General Information: All parts and all aggregates are designed, manufactured and mounted by the Hellenbrand Maschinenbau GmbH in Lambrecht. The systems and machines are designed to allow for automation in almost all areas. We have modified numerous plants for waste paper stock preparation with our know-how and our customers feedback. Manageable investments result in higher production capacities and cost-efficient operation. Considering the future challenges of waste, the quality of removed reject is of great importance. With our technology we offer you reject with extremely low fibre content - perfectly suitable for combustion. Our products have caught your attention and interest? We are happy to provide you detailed information. Or ask for a personal discussion. Please contact us for a list of references. 38
Contact Information: Engineering and Manufacturing: Michael Hellenbrand Mobile +49-170-9355211 E-Mail: hellenbrand@gw-fasertechnik.de Commercial Management and PR: Katharina Gopanok Tel: +49-6325-980998 Fax: +49-6325-980898 E-Mail: gopanok@gw-fasertechnik.de Manufacturing Site / Office: Beerentalstr. 3 DE-67466 Lambrecht (Pfalz) Germany 39