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E-LineEnergy Saving Forming Fabrics 21.-22.11.2012

presented by Bernd O. StöfflerProduct ManagerFormWeave

DITP 39th Int. Symposium, Bled – E-Line 11.20122

Contents

� Energy Consumption

� Development Focus

� E-Line

� Case Study

� Benefits

DITP 39th Int. Symposium, Bled – E-Line 11.20123

Share on energy consumptionEnergy Consumption

Pressing

Drying

15% Forming

Drives

Vacuum

45%35%

DITP 39th Int. Symposium, Bled – E-Line 11.20124

Share on energy consumption at formingEnergy Consumption

70-80 % of power consumption

DITP 39th Int. Symposium, Bled – E-Line 11.20125

Drive load as a cause of friction and vacuumEnergy consumption

Vacuum

FN = f(∆p)

Friction

Fµ = µFabric x FN

Drive load

FD = Fµ

DITP 39th Int. Symposium, Bled – E-Line 11.20126

Contents

� Energy Consumption

� Development Focus

� E-Line

� Case Study

� Benefits

DITP 39th Int. Symposium, Bled – E-Line 11.20127

Development Focus

� Main application- Paper production at high energy cost

� Paper machines- Fourdrinier, Hybrid-Former and Gap-Former

� Operational targets- Decrease of energy consumption- Speed increase, but max drive load is reached

DITP 39th Int. Symposium, Bled – E-Line 11.20128

Contents

� Energy Consumption

� Development Focus

� E-Line

� Case Study

� Benefits

DITP 39th Int. Symposium, Bled – E-Line 11.20129

A new yarn technology providing

� decrease of power consumption- by reduced coefficient of friction

� standard wear resistance- by harmonized polymer specifications

Innovative yarn technologyE-Line

DITP 39th Int. Symposium, Bled – E-Line 11.201210

New polymer combining only advantages of standard yarnsE-Line

DITP 39th Int. Symposium, Bled – E-Line 11.201211

Drive load decrease – Friction coefficientE-Line

� Drive load at different yarn materials based on PA / PET

E-L

ine

PA

/ P

ET

PE

T

25 %20 %

E-Line has comparable energy saving like PET

DITP 39th Int. Symposium, Bled – E-Line 11.201212

� Life time with yarn materials compared to PA / PET

E-L

ine

PA

/ P

ET

PE

T

Life time expectation - AbrasionE-Line

- 50 %

+/- 0 %

E-Line has equal life time expectation as PA / PET mix

DITP 39th Int. Symposium, Bled – E-Line 11.201213

Contents

� Energy Consumption

� Development Focus

� E-Line

� Case Study

� Benefits

DITP 39th Int. Symposium, Bled – E-Line 11.201214

Application1. Case study

PM Type: 2 ply FourdrinierWidth: 5.45 mSpeed: 700 m/minGrades: Cardboard, TestlinerGrammage: 120-210 gr/sqmPosition: Bottom fabricFabric: Standard SSB

DITP 39th Int. Symposium, Bled – E-Line 11.201215

Energy saving on Testliner1. Case study

E-Line saves 36% energy compared to std. SSB

36%

19%16%

� Energy savings with E-line vs. mill's standard SSB

E-L

ine

Low

Fric

tion

PE

T

E-Line = 160,000 EUR annual savings

DITP 39th Int. Symposium, Bled – E-Line 11.201216

Energy saving on Cardboard1. Case study

E-Line saves 45% energy compared to std. SSB

45%

34%

23%

� Energy savings with E-line vs. mill's standard SSB

E-L

ine

Low

Fric

tion

PE

T

E-Line = 220,000 EUR annual savings

DITP 39th Int. Symposium, Bled – E-Line 11.201217

Application2. Case study

PM Type: Hybridformer: BelBond + 2nd HeadboxWidth: 5.42 mSpeed: 700 m/minGrades: Corrugated Medium, Liner, White Top LinerGrammage: 125-240 gr/sqmPosition: Bottom fabricFabric: Standard SSBFurnish: 100% Waste

DITP 39th Int. Symposium, Bled – E-Line 11.201218

Drive load with E-Line2. Case study

400

500

600

700

800

900

1000

1 8 15 22 29 36 43 50 57 64

Power consumption [kW]

Lifetime [d]

∆∆∆∆P = -150 kW

HEGOFLEX L 328-4 49/32(#40449, Std. SSB)

HEGOFLEX EL 328-4 49/32(#40450, E-Line SSB)

DITP 39th Int. Symposium, Bled – E-Line 11.201219

Trial PET/PA and E-Line 2. Case study

Customer focus: Maximum production outputLimitation: Close to maximum drive load

PM setup�Consistency increase�Vacuum decrease

PM setup�Normal Consistency�Maximum vacuum

Added Value:�Good paper quality�Less chemicals(mainly starch) demand

�Good runability�Drive load decrease of 150 kW

Undesirable effects:�Decrease on paper quality�High chemicals(mainly starch) demand

�Worse runability

1. PA/PET SSB 2. E-Line SSB

DITP 39th Int. Symposium, Bled – E-Line 11.201220

Energy saving2. Case study

E-Line = 112,500 EUR annual savings

� Energy savings with E-line vs. standard SSB

E-L

ine

PA

/ P

ET

E-Line saves 15-20% energy compared to std. SSB

DITP 39th Int. Symposium, Bled – E-Line 11.201221

Contents

� Energy Consumption

� Development Focus

� E-Line

� Case Study

� Benefits

DITP 39th Int. Symposium, Bled – E-Line 11.201222

Benefits

E-Line products offer

• Reduction of energy cost

• Improved paper machine runability

• Increase of total paper production

• No readjustment of paper machine operation

• Unchanged easy handling of fabric

DITP 39th Int. Symposium, Bled – E-Line 11.201223

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