Andritz energy saving pump ACP (single stage centrifugal pump) and MC (medium consistency pump) 安德羅茨節能 ACP 泵 ( 單級離心泵 ) 和 MC 泵 ( 中濃泵 )

Transcription

1 Andritz energy saving pump ACP (single stage centrifugal pump) and MC (medium consistency pump) 安德羅茨節能 ACP 泵 ( 單級離心泵 ) 和 MC 泵 ( 中濃泵 ) 主講者 : 祝妙楠小姐吳忠先生友瑜有限公司

2 Field of application Andritz Energy Saving Centrifugal Pump ACP Series Presentation Tried and tested: In the pulp and paper industry Chemical pulp Mechanical pulp Recycled fibres Caustic lye Fibrous sludge White water In sewage water treatment Flue gas desulphurization Chemical industry The food industry Pulp and paper stock up to 6% atro Capacity up to 7500 m³/h Head up to 150 m Operating pressure up to 25 bar Operation temperature up to 200 C Center-line design available Flange drilling for DIN, ASTM, JIS 4 Field of application Our supply programme for centrifugal pumps covers 62 different sizes Successfully used all over the world Characteristic Curves 1500rpm and 1000rpm Characteristic Curves 3000rpm Hydraulic competence with tradition The first centrifugal pump was built by ANDRITZ more than 130 years ago. The systematic advancement of our pumps is founded on our comprehensive experience in pulp and paper engineering. ANDRITZ pumping systems are operating successfully all over the world, and their outstanding advantages are rugged design, wear resistance and highest efficiency. The small flow area are covered by ACP-ISO types, with semi-open or closed impellers 2 5 Content Field of application Design and function of the pump Research and Development Quality Management Why choosing a ANDRITZ ACP-Pump? Assembly Sketch Impeller Sealing system Bearing unit Material combination Centreline pump ACP ready to ship for APP (Indonesia)

3 Assembly Sketch Section Drawings Rigid design All bores on bearing housing are machined from one side, perfect accuracy. Easy assembly and disassembly for maintenance work. Front Liner Casing Cover PN25 design Different sealing types, same casing cover 7 10 Design of the process pump Assembly Sketch Removable of Pull out Unit Easy dismantling without moving pipes and motors Pull out unit Sealing system Andritz Single Mechanical seal, 2 components (type A1) Andritz Double Mechanical seal, 2 components (type A2) Andritz Cartridge Single Mechanical seal, (type B1) Andritz Cartridge Double Mechanical seal, (type B2) Standard Sealing System For ACP pumps All Andritz standard sealing system are with dry shaft design, Single mechanical seal can have flushing water in critical application (Option) Mechanical seal suppliers (Standard): Johncrane, Burgmann; 8 11 Impeller Semi open impeller or Sealing system Stuffing Box Packing Dynamic Seal (In developing) Fully open Impeller for non-clog application Special Spline connection with shaft, easy to dismantle Except Dynamic seal, All seal types use same casing cover, minimize the spare parts variety and Easy to change among different seals

4 Bearing unit Only 5 bearing units for 27 pump sizes Compact, rigid design Oil or grease lubrication PN25 bar pump, with Centreline design ACP ACP ACP ACP Temperature up to 200 C Pressure up to 25 bar or higher Sand blasting / prime coating (Epoxy paint) Bearings type (SKF Explorer C3) Standard base frame Special centreline support Material combination PN25 bar pump, with Centreline design Except ACP ACP ACP ACP Designation ENG JL Material combinations C-Steel Temperature up to 200 C Pressure up to 25 bar or higher Volute casing Casing cover Impeller Front liner Bearing house Shaft Base frame Standard base frame Special centreline support PN10/16 bar pump Motor Alignment

5 Research and development Latest technology in simulation Numerical simulation for high efficiency Why choosing a ANDRITZ process pump? Technical & economy Delivery process 27 pumps sizes with only 5 different bearing units Shortest delivery time High efficiency based on computer-aided development Low life cycle costs Open impeller with wear linings Up to 25 bar operating pressure Temperatures up to 200 C New ANDRITZ Standard Mechanical Seal system Suitability for conveying chemicals according to industry standards Operation process Long life time cycles After sales service Excellent after sales service Ease of maintenance due to process design All pump components available from our warehouse Research and development Impeller development Product home ANDRITZ Graz Business Area Hydraulic Machines, HM Department: Centrifugal Pumps Stattegger Strasse 18 A-8045 Graz, Austria Tel.: FAX.: Quality Management Quality Standard Worldwide the same high quality standard within the ANDRITZ Group ISO Certification European Management staff at the China workshop Fabrication according to the applicable DIN standards and as per drawings provided by ANDRITZ Graz Material inspection certificate Dimensional inspection incl. report of each part by CMM machines Hydraulic test on a selected number of units 21 43

6 Advantages UNIVERSAL SIMPLE RELIABLE ANDRITZ Energy Saving Medium Consistency Pump MC Series Innovative and smart products Efficiency over 70% Consistency 0-14% Flow from l/s Head from m Direct mounting of the control valve to the pressure flange SMARTSEP Sufficient degassing for all stages in a pulp mill fiber loss in any operating situation Only one shaft A minimum of instrumentation vacuum pump in most applications pressure difference control needed Simple programming of the control logics Very simple operation control Reduced number of components Only one mechanical seal Flushing water prevents long-term plugging Easy to maintain Service friendly 4 Innovative and smart products ANDRITZ MC-pump series Content Main Components / Standpipe Introduction Development Advantages Cross section Functions & Features of the components Capacity Ranges Reference Projects Control box (optional) Bearing unit Base frame Compensator (optional) Stand pipe (Cone design) Dilution water connection Level measurement mounting position Volute with horizontal (left/right) and vertical pressure pipe 2 Innovative and smart products ANDRITZ MC-pump series 5 Content Menu Innovative and smart products ANDRITZ MC-pump series Introduction Cross section The ANDRITZ MC-pump series, a already well proved pumping system used in pulp mills all over the world, is now equipped with the patented air separator system SMARTSEP, making the usage of the ANDRITZ MC-pump even more Volute Impeller Bearing housing Shaft UNIVERSAL SIMPLE SMARTSEP RELIABLE JUST EASY! Degassing Valve Fluidizer Suction pipe / Front liner Degassing line 3 Innovative and smart products ANDRITZ MC-pump series 6 Innovative and smart products ANDRITZ MC-pump series 44

7 Design Features A very remarkable feature is the possibility of choosing between either horizontal or vertical delivery. Very good chemical mixing is another attractive possibility. Chemicals feed SMARTSEP Separator system: A special designed apparatus Unique development MC-applications A revolution for the control: Fixed in-line with impeller and fluidizer Controls the air/fiber flow resistance for air to flow out fiber loss in any operating situation Operated by a very simple on/off logic Open to run with/without vacuum pump MC-Test loop with MC , driven by a 1,2 MW double drive motor 7 Content Menu Innovative and smart products ANDRITZ MC-pump series 10 Innovative and smart products ANDRITZ MC-pump series Fluidizer / Suction pipe fluidizes the pulp (non-newtonian fluid) roughly separates air from pulp creates sufficient pre pressure feeds the pump with pulp optimized shape improves the degassing Due to hydraulically optimized fluidizer no vacuum-pump is needed! SMARTSEP Separator system For normal MC-pump design, the control of the pump (degassing system) was difficult especially for low Production (low flow and low consistency fiber loss / plugging of degassing) Pressure degassing line [mbar] With the SMARTSEP system, no control of the degassing (PDIC) is needed! Pump is running deg. valve is opened 100% Pump stops valve closes to 0% Pressure in the degassing line indicates the amount of fibre loss Without Smartsep With Smartsep Ambient pressure Q [m³/h] 8 Innovative and smart products ANDRITZ MC-pump series MC , 10% consistency, longfibre sulfat pulp, 1400rpm 11 Innovative and smart products ANDRITZ MC-pump series Impeller / Degassing: Impeller pumps pulp into the pressure pipe while the air/gas is forwarded through the degassing holes to the back of the impeller New SMARTSEP separator impeller prevents fiber loss SMARTSEP Separator system Without separator it was crucial to find a balance between pressure created by the fluidizer (high pressure high, but high fibre loss) and stability of the pump (low pressure low, but also low fibre loss) Due to SMARTSEP this compromise is not needed anymore high and no fibre loss 1,0 0,9 0, With SMARTSEP Q [l/s] Separator and degassing chamber are flushed with water to prevent long-term plugging Air/Gas is discharged through degassing line, water separator, efficiency 0,7 0,6 0,5 0,4 0,3 Without SMARTSEP 0,2 0,1 Q [m³/h] 0, MC , 10% consistency, longfibre sulfat pulp, 1400rpm 9 Innovative and smart products ANDRITZ MC-pump series 12 Innovative and smart products ANDRITZ MC-pump series 45

8 SMARTSEP Separator system SMARTSEP made higher heads at a given pull out diameter possible! sheet-title: Head + Temp DELIVERY HEAD [m] Q [l/s] Additional features: In most applications, no need for a vacuum pump Direct mounting of control valve to the pressure flange possible Degassed pulp Delivery Head [m] With SMARTSEP Without SMARTSEP Possibility of feeding chemicals (ph 0-14) Air/Gas 4-feet volute casing out Service friendly due to separate fluidizer, impeller and separator Free selectable degassing line orientation Pulp in 10 Q [m³/h] MC , 10% consistency, longfibre sulfat pulp, 1400rpm, pull out diameter 550mm Water separator optional 13 Innovative and smart products ANDRITZ MC-pump series 16 Innovative and smart products ANDRITZ MC-pump series SMARTSEP Separator system SMARTSEP lets the gas/air pass through the degassing system sheet-title: AIR Content Air content [%] Capacity Ranges 1,0 0,8 Air content [%] 0,6 0,4 Without SMARTSEP 0,2 With SMARTSEP Q [m³/h] 0, MC , 10% consistency, longfibre sulfat pulp, 1400rpm 14 Innovative and smart products ANDRITZ MC-pump series 17 Innovative and smart products ANDRITZ MC-pump series Material Combinations Flow sheet With SMARTSEP technology: pressure measurement needed Minimum number of flowmeters Reduced water consumption Simple control of the pump 15 Innovative and smart products ANDRITZ MC-pump series 18 Innovative and smart products ANDRITZ MC-pump series 46

9 mill type installed started no. of pumps pulp type unbleached U bleached B vacuum pump cons. [%] Position Zellstoff Pöls, Austria Zellstoff Pöls, Austria Tiger Paper, Huaihua, China Sep 2007 Sep % SW U Oct 2008 Oct Jul 2007 July % SW U/B 3 x 6 x Yes Feed to wash press O2 booster pump 3 with high suct. head (no vacuum p.) 6 with low suct. head (w. Vacc. Pump) Application: VCP Jacarei Mill, Brazil Jul 2007 Aug % HW U To storage tower Syktyvkar, Russia Dec 2009 April CTMP U/B 9-12 Storage tower feed Reactor feed Feb 2010 Syktyvkar, Russia Dec SW/HW U/B 9-12 Whole fibre line (2pcs) From disc filter to storage tower Propapier, Gemany Aug 2009 Feb 2010 Recycled U To reactor Nantong, China Oct 2009 June %SW U 9-11 Feed to DD-washer 40%HW UPM Fray Bentos, Uruguay Oct v HW (Euc.) U Storage tower feed, equipped with new separator technology Fajar Indonesia Aug 2010 v HW (Euc.) B 8-12 Storage tower feed, Refiner stage Pulpaca, Venezuela v TMP U/B 8-12 Whole mill Twin Rivers Paper, Canada Aug Recycled U/B Yes 9-13 HD feed / Wash press discharge Shoguang Meilun OCC 10 Billerud Skärblacka Aug Kraft 12 After Disc Filter Medium: softwood Kraft, unbleached Consistency: 10-12% Production: 1400 ADmt/d + 10% safety margin Flow: 530 m³/h at 10% 442 m³/h at 12% Head: ~80m Temperature: C Position: O2 stage reactor feed pump Since smooth run without ANY problem Customer is very pleased 19 Innovative and smart products ANDRITZ MC-pump series 22 Innovative and smart products ANDRITZ MC-pump series no. of pulp unbleached U vacuum cons. mill type installed started Position pumps type bleached B pump [%] Boise Paper, Wallula, USA July NSSC 12 Screw Press Rigesa Brasil Yes 12 HD-Tower feed SAPPI Kirkniemi 2011 Dec GW+RMP 10 B U/B 4 x Yes Montes del Plata HW 9-12 Whole fibre line 4000 t/d x x Yes JK Paper HW U 9-12 Bleaching line x Stora Enso Narew Recycled Screw Press / Disc Filter Ostroleka LF/SF SCA Ortmann Waterwalk Recycled Yes 8-10 Twin wire press 2x Yes Moorim Paper Bleaching Line U/B 1x SW IP Svetogorsk Yes 8-14 Sulphate Waste Schoenfelder DIP With Andritz steam feeding system paper Storage tower CMPC Maule Chile CTMP B Disc Filter Tiger Paper, Huaihua, China Application: Medium: softwood ~55% chinese red pine, ~15% fir, ~15%alder, 15%eucalyptus Consistency: 10 to 12% Production: 1500 ADmt/d Flow: 135 to 190 l/s Head: 65 to 140m Temperature: 60 to 85 C Position: 9 pcs in the whole fiber line Klabin Monto Alegre, Brasil CTMP B DHT stage tower Started up in , the Pumps are running smoothly; In 2012, they buy 1 more MC-pumps for a rebuild projects 20 Innovative and smart products ANDRITZ MC-pump series 23 Innovative and smart products ANDRITZ MC-pump series Zellstoff Pöls, Austria Application: VCP Jacarei mill, Brazil Application: Medium: softwood Kraft pulp, unbleached (70% spruce, 25%pine, 5% larch) Consistency: 7-8%, up to 10-12% Production: 1400 ADmt/d + 10% safety margin Flow: 832 m³/h at 7% ; 583 m³/h at 10% Head: 70-75m Temperature: C Position: Wash press feed pump Since smooth run without ANY problem Vacuum pump free run tested for 7 to 11,5% consistency fibre loss through degassing line, easy handling We forgot, that we installed a new pump! Summary: Medium: hardwood, sulfate (100% eucalyptus) Consistency: ~11% Production: 1350 BDmt/d Flow: ~142 l/s Head: ~90m Temperature: ~80 C Position: storage tower Started up in vacuum pump needed, stable run up to 16%! Pump is running according to contract values 21 Innovative and smart products ANDRITZ MC-pump series 24 Innovative and smart products ANDRITZ MC-pump series 47

10 Plot / 6/ :46: 04,915 5,00 day s 26/6/ :46: 04,915 CorrenteEl 彋 rica1038 VelocidadeBomba1038 Produ 誽 oest 墔 io 繁 idolfb Corrente minal Bba I C. MV 323 A S I MV rp m F I D.MV Adt /d NOMINAL.Value 344 Plot /9/ :45:1 4, ,00 day s 9/9/ : 45:14,469 CorrenteEl 彋 rica1038 VelocidadeBomba1038 Produ 誽 oest 墔 io 繁 idolfb Corrente minal Bba I C. MV 283 A S I MV rp m F I D.MV Adt /d NOMINAL.Value 344 VCP Jacarei mill, Brazil - Reference from customer: VCP Jacarei mill, Brazil - Reference from customer: POWER CONSUMPTION Previous Situation Actual Situation MPC 25/15 Kvaerner MC pump with internal vacuum pump in operation since The nominal capacity for this MC was 792 adt/d, but the actual production of the fiber line B is 1250adt/d, in others words, the pump was running with over load. The Frequency Converter was working with 95Hz (nominal = 60Hz), and the Motor was running with 2834 rpm (nominal = 1800 rpm). With that there were several problems with the Pump and Motor, and consequently production losses. Replaced the old MPC 25/15 Kvaerner for the New ANDRITZ MC Pump (MC ) without vacuum pump, internal neither external, with capacity up to 1500 adt/d. We are using the same Electric Motor and the same Frequency Converter in 60Hz. We also have got the following spare parts: Bearing Unit, Impeller + Fluidizer and Mechanical Seal. BLUE Motor Current (A) WHITE Production rate (Adt/d) Kvaerner pump Current in average (8 hours): 437,33 A Production in average: 1205,24 adt/d Power Consumption: ,5 kwh / m BLUE Motor Current (A) WHITE Production rate (Adt/d) ANDRITZ MC pump Current in average (8 hours): 279,12 A Production in average: 1193,25 adt/d Power Consumption: kwh / m Energy Costs: R$ ,32 / y Energy Costs: R$ ,97 / y Energy Economy: R$ ,35 / year Energy Costs: R$ 145,00 MWh (april/2009) Premissa: Tensão de alimentação 440V Fator de potência do motor: 0,85 - Fórmula: 3 x 440V x Corrente (A) x cos (0,85) 25 Innovative and smart products ANDRITZ MC-pump series 28 Innovative and smart products ANDRITZ MC-pump series VCP Jacarei mill, Brazil - Reference from customer: Plot Kvaerner Pump Andritz Pump I C. MV 266 A S I MV rp m F I D.MV Adt /d NOMINAL.Value 344 VCP Jacarei mill, Brazil - Reference from customer: EQUIPMENTS DATA COMPARATION Kvaerner MC New ANDRITZ MC Speed: 2834 rpm 1500 rpm (47% reduction) (minal: 1800 rpm) FC Current: 474 A 290 A (39% reduction) (minal of the Motor: 344 A) Frequency Converter: 95 Hz 50 Hz (47% reduction) 200 Startup Production Rate (FLB): 1250 Adt/d 1250 Adt/d POINT A 11/ 7/ :48: 00,516 60,00 days 9/9/ : 48:00,516 CorrenteEl 彋 rica1038 VelocidadeBomba1038 Produ 誽 oest 墔 io 繁 idolfb Corrente minal Bba 1038 POINT B By Luiz Augusto Rodrigues Senior Maintenance Engineer luiz.rodrigues@vcp.com.br Jacareí, 23/04/2009 Integration into ANDRITZ sheets by Stefan Hödl, Engineering MC pump Stefan.Hoedl@andritz.com Graz, 07/12/ Innovative and smart products ANDRITZ MC-pump series 29 Innovative and smart products ANDRITZ MC-pump series VCP Jacarei mill, Brazil - Reference from customer: Capacity upgrade UPM pulp mill, Fray Bentos, Uruguay Application: POINT A Kvaerner pump POINT B ANDRITZ MC pump Medium: hardwood Kraft, unbleached (100% Eucalyptus) Consistency: 10-12%, up to 13%, Production: increased to 4000 ADt/d Flow: 400 l/s at 10% 320 l/s at 13% Head: 100m Position: after screening & 2 DD washers, feeding into unbleached storage tower Remarks: sulphuric acid feed (ph 2-4) BLUE Motor Current (A) RED Pump speed (rpm) YELLOW Production rate (Adt/d) WHITE minal Motor Current (A) 27 Innovative and smart products ANDRITZ MC-pump series 30 Innovative and smart products ANDRITZ MC-pump series 48

11 Capacity upgrade UPM pulp mill, Fray Bentos, Uruguay UPM wanted to increase the production to 4000 ADt/d Existing Sulzer MC pump at Screening had to be replaced Sulzer offered a bigger MC-pump to UPM But asked UPM to buy a bigger motor for their pump Andritz offered a MC-pump fulfilling the requirements with the existing 800kW motor UPM decided to use Andritz MC-pump, start-up in vember 2010 Pump is running without problems, but full production not reached yet (problems with screening) fiber loss during the whole start up Less motor power is used, the control valve opening is reduced to 55% 31 Innovative and smart products ANDRITZ MC-pump series Questions? Questions? Thanks for your attention! For further information please contact: Ludwig.Michal@andritz.com Stefan.Hoedl@andritz.com 32 Innovative and smart products ANDRITZ MC-pump series 49