[Case Study] Contributing to Cost Reduction and Environmental Conservation through Efficiency 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 increased 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 excessive. 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, resulting in significant losses due to steam leaks, and maintenance requires a considerable amount of time and effort. 4. There are temperature inconsistencies on the surface of the cylinder dryers, leading to poor product yield. In the process of manufacturing thick paper at the paper mill, a large amount of steam is introduced into several large cylinder dryers (approximately φ2000) to heat the surface and facilitate drying.
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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. By incorporating a drainage system (cascade method), we maximized the thermal efficiency of the steam and reduced usage. 3. We changed the rotary joint, which significantly decreased maintenance frequency due to the long-life sealing ring. 4. We installed a turbulator bar. This allows for increased machine speed with the same steam volume, enabling higher production, and reduces surface temperature variations in the cylinder dryer, thereby improving quality. Replacement of the rotary joint.
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