VIII Seminario Latest Development for the Wood Panel Industry TEKNO MADERA Conception, Chile 15.11.2012 -
Content - ContiRoll Generation 8 - ECO RESINATOR powered by Schlick
ContiRoll Generation 8 It is all about : Pressure Distribution Pressure Distribution Plates : What are they? How do they work? What are they good for? Additional Cylinder Row : low pressure oscillation across supreme thickness stability
ContiRoll Generation 8 Pressure Distribution a History 1995 Siempelkamp sold first ultra thin board ContiRoll Target Thickness : less than 1,8 mm Target Speed : up to 1800 mm/sec. -> Development - of a high precision matforming - of a high precision press gap - safety features and press control (SPC) 1997 first ultra thin board ContiRoll to produce Thickness : continuously 1,5 mm Speed : continuously > 1600 mm/sec.
ContiRoll Generation 8 Pressure Distribution a History 1998 first ultra thin board ContiRoll to produce Thickness : continuously 1,5 mm Speed : continuously 2000 mm/sec. 1998 2012 Start-up of another 8 ultra thin board ContiRoll All over the world (China / Indonesia / etc.) 2012 first ultra thin board ContiRoll to produce Thickness : continuously 1,0 mm
ContiRoll Generation 8 Pressure Distribution Plates How they work
ContiRoll Generation 8 Pressure Distribution Plates How they work ContiRoll 7 th. generation Hot-platen field deformation ContiRoll 8 th. generation Hot-platen field deformation = =
ContiRoll Generation 8 Pressure Distribution Plates Benefit ContiRoll 7 th. generation Hot-platen field pressure distribution ContiRoll 8 th. Generation Hot-platen field pressure distribution
ContiRoll Generation 8 Pressure Distribution Additional Cylinder Row
ContiRoll Generation 8 Pressure Distribution Additional Cylinder Row ContiRoll 7 th. generation Hot-platen field deformation: 0.2 mm with 830mm frame distance ContiRoll 8 th. generation Hot-platen field deformation: 0.02 mm with 830mm frame distance
ContiRoll Generation 8 Additional Cylinder Row - Benefit THICKNESS Tolerance - SPF - Ultra Thinboard Line 1,0 mm Board Thickness [mm] 1,10 1,05 1,00 0,95 0,90 0,85 Tickness Tolerance : +/- 0,025 mm 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Position : Left to Right
ContiRoll Generation 8 Supreme Pressure Distribution - length & across - = Your Savings Potential (Individually and/or in combination) improved feasibility to produce thin boards improvement of thickness tolerance reduction of sanding or omission of sanding improvement of internal bond increased performance (heating time factor) reduction of emissions (utilising E0,5 Resins) higher productivity of your line resin savings wood savings
Glue-Saving Potentials in MDF Plants ECO RESINATOR powered by Schlick
Glue Saving - Potentials in MDF Plants Thermal Energy 6% Other Utility costs 5% the 3 major cost driver in MDF making Depreciation 0% Labour 0% Wood 31% variable costs of MDF production Resin Cost per m³: ca. 36 % Electricity 20% Wood Cost per m³: ca. 31 % Resin 36% Additives 2% Energy Cost per m³: ca. 26 %
Glue Saving - Potentials in MDF Plants WHAT - causes resin losses? WHERE - are potential savings hidden? Losses in the board press : high pressure oscillation Losses in blow-line blending : Low Velocity / turbulence in the blowline Resin Droplet : size and spectrum
Glue Saving - Potentials in MDF Plants 3 major influences in Blow-Line-Blending 35 higher resin coverage [%] 30 25 20 15 10 1. Steam Flow 2. Spray Pressure 3. Flow Rate / Nozzle Position 5 0 nozzle type emulsion place of nozzle production rate nozzle pressure steam flow changes in process
Glue Saving - Potentials in MDF Plants Resin Loss Potential : BL Turbulence / Steam Flow Low Blowline Steam Flow : Losses of 10-15 %
Glue Saving - Potentials in MDF Plants Resin Saving Potential : BL Turbulence / Steam Flow High Blow Line Steam Flow : Saving of 10-15 %
Glue Saving - Potentials in MDF Plants Resin Saving Potential : Droplet Size / Spectrum ECO RESINATOR : 20-80 µm (Dual media injector nozzle powered by Schlick) Standard Nozzle : 40-750 µm (Single media injector nozzle)
Glue Saving - Potentials in MDF Plants Blow Line Optimisation : ECORESINATOR powered by Schlick
Glue Saving - Potentials in MDF Plants Blow Line Optimisation: - ECORESINATOR - Resin Pressure Automatic Control and Adjustment Steam - Pressure Automatic Control and Adjustment Resin Mix - Viscosity Automatic Control and Adjustment Resin - Flow Rate Automatic Control and Adjustment Steam - Flow Rate Automatic Control and Adjustment Dual-Media-Injector Automatic Control and Adjustment PROD-IQ Optimising Automatic Data sampling by Prod-IQ - Analyse of all Process Parameters By data mining and probabilistic evaluation of the relevant influences the system will support further optimising of Blow Line Blending
ECO RESINATOR - System Benefits - - shows typical resin reduction 5-15 % for some board thickness up to 20 % - is a investment as low as about 1/10 of the Fibre Blending - for e.g. 48 to/h plant needs less than 4 to/h of steam - can be fitted into all existing blow line plants - works integrated with any existing glue dosing system - works stable and with low maintenance, no extra personal needed - improves the overall board quality and the surface appearance - is pre installed and tested in the Siempelkamp workshop - is installed in the plant and ready to work within days
ECO RESINATOR - cost saving potential - (e.g. plant with 48 to/h fibre throughput, 7525 h production time) Resin : (from 12,0 % down to 10,8%) - 10 % Wood : (5760 5184 kg/h solid) - 576 kg/h (Price : 570 US$/to solid) - 2.470.700 US$/y Steam Energy : (dual media injector) + 3.8 to/h (Price : 12 US$/to) + 334.400 US$/y Production Savings : (resin / wood / steam) Financing Costs : (1.100.000 US$ / 10 years) (to replace resin, incl. refining energy) + 576 kg/h (Price : 100 US$/to solid) + 495.800 US$/y - 1.640.500 US$/y + 110.000 US$/y TOTAL COST SAVING : - 1.530.500 US$/y
Siempelkamp : we can help YOU to cut your cost Thank you very much for your interest