[Case Study] Contributing to Cost Reduction and Environmental Conservation through Efficiency Improvements in Steam Management
Improve efficiency through steam management, contributing to cost reduction and environmental conservation!
At the paper manufacturing company, in the dry part of the paper machine (the machine used to produce paper), there was a high usage of steam, leading to significant costs, and frequent maintenance was causing issues in terms of time, effort, and expenses. Issues: 1. The amount of steam supplied to the cylinder dryers is high. 2. To increase production, there is a desire to increase machine speed. 3. The wear of the seal rings (carbon) in the rotary joints currently in use is rapid, leading to significant losses due to steam leakage, and maintenance requires a lot of time and effort. 4. There are temperature inconsistencies on the surface of the cylinder dryers, resulting in poor product yield. In the process of manufacturing thick paper at the paper mill, a large amount of steam is introduced into the interiors of several large cylinder dryers (approximately φ2000) to heat the surfaces and dry the paper.
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We identified the problematic areas and made proposals that lead to cost reduction, increased production volume, and reduced maintenance. Points: 1. To significantly reduce steam volume, we used a fixed siphon to lower the pressure of the injected steam, improving the discharge of blow-through steam, non-condensable gases, and drains, while reusing the remaining thermal energy. 2. We incorporated a drainage system (cascade method) to maximize the thermal efficiency of the steam and reduce usage. 3. By changing the rotary joint and using a long-life sealing ring, we greatly reduced maintenance frequency. 4. We installed a turbulator bar, which allows for increased production speed with the same steam volume, reduces surface temperature variations in the cylinder dryer, and improves quality. Replacement of the rotary joint.
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