SuperWash Technologies Brown Stock Washing Discovery …/media/Ecolab/Ecolab...
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SuperWash ™ Technologies Brown Stock Washing Discovery Questions SuperWash Value Levers: Increased black liquor solids provide steam savings: 1-4 points Reduced bleaching costs due to less carryover to Bleaching System: As much as $3.00/ton Lower defoamer cost by 10-40% Increased production by 1-4% at same quality specs Improved pulp quality; reduced silicone carry over, less off-spec paper Improved washer control to reduce risks associated with vats overflowing 30,000 Foot View – Big Picture Questions • What are the Key Business Drivers for the pulp mill? • What are the pulp mill’s operational goals and why? a) Increased Production? b) Increased liquor solids? c) Lower Bleaching costs? d) Improved pulp quality/reduced silicone carryover? • What is preventing customer from reaching the opera- tional goals now? • Where are the bottlenecks in the process that keep them from reaching their goals? • Are there any restrictions to the type of wash aid used? a) EBS, silicone, silica, oil, FDA Approval, BfR Approval, etc. • What tonnage capacity is the pulp mill designed to produce? Peel the Onion- Drill Down Questions • How much over design-capacity is the mill running? – What is the specific loading of the customer’s washer? – On rotary drum/vacuum Brown Stock washer – The design parameter is defined as oven-dry (o.d.) tons per day of pulp per square foot of a single stage cylin- der surface. Typical design: specific loadings are in the range of 0.6 to 0.8 oven-dry tons/day/ft 2 . Some mills have converted from older, wire-wound drum design to a “Corru-Deck”. The Corru-Deck design was set up to handle 1 air dry ton/day/ft 2 . Many mills exceed this design parameter and are now operating in the 1.2-1.4 air dry ton range. • What are the current weak black liquor solids? – 1% increase in solids = ~$1,000,000 savings in steam and energy – What is the limiting factor? • Bleaching Costs: – What is current usage (and cost) of following bleaching chemistries: • Sulfuric Acid • Chlorine Dioxide • Hydrogen Peroxide •Caustic – Does mill measure the Chemical Oxygen Demand (COD) of the pulp entering bleaching? If so, how often and what are the normal values? • How do you measure soda loss? What is your target? – Does the mill ever target a higher soda loss target due to issues in the Evaporators or full Weak Black Liquor Tanks? (Continued on Reverse Side) ENERGY EARTH SAFETY
Transcript of SuperWash Technologies Brown Stock Washing Discovery …/media/Ecolab/Ecolab...
SuperWash™ Technologies Brown Stock Washing Discovery Questions
SuperWash Value Levers: Increased black liquor solids provide steam
savings: 1-4 points
Reduced bleaching costs due to less carryover to Bleaching System: As much as $3.00/ton
Lower defoamer cost by 10-40%
Increased production by 1-4% at same quality specs
Improved pulp quality; reduced silicone carry over, less off-spec paper
Improved washer control to reduce risks associated with vats overflowing
30,000 Foot View – Big Picture Questions• WhataretheKeyBusinessDriversforthepulpmill?
• Whatarethepulpmill’soperationalgoalsandwhy? a)IncreasedProduction? b)Increasedliquorsolids? c)LowerBleachingcosts? d)Improvedpulpquality/reducedsiliconecarryover?
• Whatispreventingcustomerfromreachingtheopera-tionalgoalsnow?
• Wherearethebottlenecksintheprocessthatkeepthemfromreachingtheirgoals?
• Arethereanyrestrictionstothetypeofwashaidused? a) EBS, silicone, silica, oil, FDA Approval, BfR Approval, etc.
• Whattonnagecapacityisthepulpmilldesignedto produce?
Peel the Onion- Drill Down Questions• Howmuchoverdesign-capacityisthemillrunning? –Whatisthespecificloadingofthecustomer’swasher? – On rotary drum/vacuum Brown Stock washer – The
design parameter is defined as oven-dry (o.d.) tons per day of pulp per square foot of a single stage cylin-der surface. Typical design: specific loadings are in the range of 0.6 to 0.8 oven-dry tons/day/ft2. Some mills have converted from older, wire-wound drum design to a “Corru-Deck”. The Corru-Deck design was set up to handle 1 air dry ton/day/ft2. Many mills exceed this design parameter and are now operating in the 1.2-1.4 air dry ton range.
• Whatarethecurrentweakblackliquorsolids? – 1% increase in solids = ~$1,000,000 savings in steam
and energy –Whatisthelimitingfactor?
• BleachingCosts: – What is current usage (and cost) of following bleaching
chemistries:
• SulfuricAcid
• ChlorineDioxide
• HydrogenPeroxide
•Caustic – Does mill measure the Chemical Oxygen Demand (COD)
ofthepulpenteringbleaching?Ifso,howoftenandwhatarethenormalvalues?
• Howdoyoumeasuresodaloss?Whatisyourtarget? – Does the mill ever target a higher soda loss target due
to issues in the Evaporators or full Weak Black LiquorTanks?
(Continued on Reverse Side)
ENERGY
EARTH
SAFETY
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• Doyouhavehistoricaldataforwasherefficienciesordisplacementratios?
– Washer Efficiency - The % efficiency at which a single washing stage displaces showers, dilutes and re-thickens the stock. A measure of the effectiveness of the washer.
– Displacement Ratio - The effectiveness of a single displacement washing stage in removing solids from the pulp. Defined as the ratio of the actual reduction in solids content in the stage compared to the maximum possible reduction.
– Running WE and DR are excellent ways to differentiate from the competition and show value!
• Isthereaspecificwasherthatisaproblemforyou?
• Doyouswitchbetweenspecies?HardwoodtoSoftwoodandback?
– Managing a Brown Stock washing system is the most difficultwhenswitchingfromSoftwoodtoHardwood.The Softwood liquor has a higher viscosity, the Hardwoodfiberisshorter.Thisscenarioisthemostdifficult to wash.
• DoyouhaveanybaselinedataonsiliconecarryoveronthecurrentBrownStockwashingprogram?
• Doyouhaveanypitchissuesinthepulpmilloronthepapermachine?Sheetdefectsordefoamer/pitch“balls”depositingincleaners?
• Whatistheresidualalkalilevelintheblownpulp? –Howoftenisitmeasured,andhowmuchdoesit
normallyvary? – If running softwood, any visual indications of soap
inthewashers?
Technical Assistance:The Pulp ITC team brings a wealth of knowledge to you and your customer. They can find the hidden value in many cases and ensure you are providing the best value proposi-tion to your customer possible. To get the most out of your integration with the ITC team please have the following basic system information available.
PROCESS INFOMATION DEFOAMER INFORMATION
Production Rate Supplier, Product, Type
Wood Species Usage lbs/ton
Washer Type Feed Points
Conductivity / Temp Profile Feed Controls
Conductivity Target Type of feed equipment
Weak Black Liquor Solids
