Disc filter rebuild The Voith product range to optimize the dewatering process 1
1 The new generation of dewatering from Voith The new BaglessPlus fi lter discs, V-sectors and V-bags from Voith enhance the capacity and quality of the dewatering process. All Voith and conventional disc fi lters can be upgraded to these new high-quality products. Broken filter bags result in high costs The technology used in conventional disc fi lters is often obsolete and no longer meets requirements for effi cient and resource-saving production. As a result, maintenance and operating costs tend to rise constantly. Conventional disc fi lters are fi tted with fi lter discs that generally only have short service lives. As the fi lter bags tear after a short time, fi lter quality deteriorates rapidly, fi ber loss increases and in consequence, the desired capacities cannot be maintained. This leads to reduced dewatering effi ciency. In addition, the spray water becomes contaminated because of the fi lter bags tearing and the spray nozzles of the disc fi lter and paper machine get blocked. These consequences reduce the availability of the paper machine and due to the damage the fi lter bags must be replaced, causing high maintenance and downtime costs. Efficient and low-cost dewatering To ensure effi cient dewatering capacity, Voith has developed a new generation of products combining long service life, excellent fi ltration qualities, high capacities and low energy consumption. As a result of these benefi ts, operating costs, fresh water consumption and fi ber loss can be reduced. Upgrading your existing disc fi lters to BaglessPlus sectors or V-bags with Voith spray nozzles and fi ltrate valves, achieves excellent dewatering performance and availability of your disc fi lter and paper machine. 2
All benefits of the Voith product portfolio 2 + + BaglessPlus filter discs offer a service life of more than 10 years + + High cost savings due to low maintenance demand + + Capacity increase of up to 20% + + Reliable filtrate quality over the entire operating life - Saving of fibers and fillers - Reduction of fresh water consumption + + Optimized dewatering thanks to a high and stable vacuum + + Higher availability of the paper machine + + All machines from Voith and conventional disc filters can be upgraded 1 InfiltraDiscfilter IDF570 2 BaglessPlus sector Comparison of Voith filter discs Investment costs Maintenance / Operational costs Lifetime Constant vacuum and filtrate quality V-bag P V-bag C with Protector sheet V-bag S on V-sector BaglessPlus 3
3 4 BaglessPlus filter discs Outstanding running times due to an efficient dewatering without filter bag Slash your maintenance costs Thanks to the development of the BaglessPlus filter discs, previously unrivaled running times and maintenance costs are achieved. BaglessPlus sectors are made from corrugated stainless steel and are the only filter discs on the market which operate without filter bags. Upgrading disc filters to BaglessPlus completely eliminates expensive and timeconsuming replacement of damaged filter bags as well as high maintenance costs. In addition, the low maintenance and cleaning requirement for the BaglessPlus sectors ensures high availability of the disc filters. Operating costs are reduced enormously, as the filter discs have a service life of more than 10 years, the longest in the industry. The improved knock-off performance, combined with the larger available filter disc surface due to the corrugated design of the segments, increases capacity by up to 20%. The consistently high filtrate quality over the entire service life of the BaglessPlus filter discs leads to a significant reduction of fiber loss and fresh water consumption. There are no restrictions on using the super-clear filtrate on the spray nozzles of the paper machine. Your benefits BaglessPlus + + Maintenance and running costs are reduced to a minimum + + Filter disc service life of more than 10 years + + Reliable filtrate quality over the entire operating life - Saving of fibers and fillers - Reduction of fresh water consumption + + Increase in capacity of up to 20% + + Saves on fibers and fillers within the paper machine circuit + + Reduction of fresh water consumption + + Higher availability of the paper machine Upgrades to BaglessPlus are possible for all Voith disc filters and all Hedemora (GL&V), Andritz, Impco and Wenrui disc filters. Area of application BaglessPlus filter discs are used in stock preparation and as Save-all within the paper machine circuit. 4
3 Detailed view BaglessPlus 4 Example of available sizes of BaglessPlus fi lter discs*: Left: IDF370 / DF370 Center: IDF570 Right: IDF520 *comparable sizes are available for machines from other manufacturers 5 Detailed view BaglessPlus 5 Comparison of operational and investment costs Disc filter with 12 filter discs Normal wear Application example Stock preparation Application example White water cleaning PM Upgrade with BaglessPlus Spare parts: sectors 34,00 28,00 Spare parts: fi lter bags 4,00 18,60 Necessary maintenance time for replacing sectors and fi lter bags 260 h/year 380 h/year Costs for service staff (4/h) 10,40 15,00 Fiber losses - 95,00 Fresh water consumption - 33,00 Complete costs for maintenance and operation per year 48,40 189,60 With BaglessPlus technology, you save 50,00/year for servicing and operation of a disc fi lter with 12 fi lter discs in stock preparation applications and 200,00/year for save-all applications! 5
6 7 V-sectors, V-bags and nozzles Innovative products for a reliable dewatering process The right filter bag for any requirement V-sectors impress thanks to their stable, durable operation compared with conventional sectors. The high quality of the V-sectors also enhances the service life of the V-bags. Various filter bags are available for V-sectors from Voith and non-voith sectors. If required, Voith offers filter bags tailored to customer needs: Voith V-bag P: Polypropylene bag Voith V-bag C: Corrugated polypropylene bag Voith V-bag S: Stainless steel disc Protector sheet: Can be combined with V-bag C and V-bag P The new generation of V-bags from Voith achieves longer service lives and therefore more reliable and stable operation of the disc filter. The integration of the Protector sheet in the filter bags offers the bags additional protection against damages caused by sharp sector edges. This substantially extends the service life and as a result the maintenance intervals of the disc filter. In addition, capacities can also be adjusted by means of special blind strips on the filter bags. The right filter bag for any requirement An upgrade of your disc filter can consist of replacing the complete sectors or the individual filter bags. The corrugated filter bags (V-bag C) can be customized for special applications. The other V-bags and V-sectors can be installed in all available disc filters from Voith and other manufacturers. The patented nozzles optimize disc filter operation Fast and clean removal of the fiber mat and cleaning of the filter discs are necessary for constant disc filter operation. The Voith nozzles achieve reliable knock-off of the fiber mats over the entire life cycle of the disc filter. This means that the pulp can be removed via the transport shafts quickly and without leaving residues. Continuous and thorough cleaning of the filter discs is achieved by the knock-off and cleaning nozzles. Any blockages can be removed during operation by turning the lever. 6
6 V-sectors with V-bags Left: V-bag C Center: V-bag Right: V-bag P 7 Knock-off and cleaning nozzle 8 Filtrate valve 8 Filtrate valves Stable vacuum creation increases disc filter capacities Consistently good filtrate qualities A constant vacuum in the range 0.4-0.5 bar is the basis for reliable and constant operation of the disc filter. Because a low fines burden and high dry content at rated capacity can only be achieved with optimum vacuum, for which the filtrate valve is largely responsible. The Voith filtrate valve distinguishes between two filtrate qualities during dewatering: cloudy and clear filtrate. When used in the paper machine circuit, super clear filtrate is also produced. This distinct separation into the different filtrate qualities is made possible by the innovative design of the filtrate valve. As a result, accumulation of air is avoided and a high, stable vacuum is therefore generated. Wear plate Holey bridge increases capacity by up to 30% The vacuum is formed more gently through the additional use of the holey bridge in the filtrate valve. The fiber layer occurs more slowly which leads to improved filtration. This optimization produces a capacity increase of up to 30% and at the same time an improvement of quality. The holey bridge can be installed in new machines or upgrades. 7
9 10 HiCon disc fi lters High production capacity and operational safety Long service lives thanks to better stability Voith HiCon disc fi lters were specially developed to dewater suspensions with high stock consistencies and for stocks that dewater quickly and therefore need mechanically stable fi lter discs. Compared with conventional disc fi lters, the sectors in HiCon disc fi lters are additionally supported and guided by integrated rails and the position of the inlet box is adjusted to achieve stronger circulation in the disc fi lter. Because in case of high stock consistencies, the suspension has to be mixed to avoid deposits in the lower section of the machine. The combination of HiCon disc fi lters, BaglessPlus fi lter discs and Voith fi ltrate valves achieves high production capacities, excellent fi ltrate quality and the longest service lives available in the industry. This reduces the high costs for maintenance and investment and cuts the fresh water requirement. Benefits of upgrading to HiCon technology + High capacities in combination with BaglessPlus fi lter discs and fi ltrate valves + Long service life with high stock consistencies + Maintenance requirements reduced to a minimum + Signifi cant cost savings for maintenance and investment + Minimal fresh water requirement due to high fi ltrate quality Increase in production capacity due to HiCon technology Capacity [metric tons/m 2 ] Infi ltradiscfi lter with HiCon technology 4.0 3.0 2.0 1.0 Standard disc fi lter 0 0 0.5 1.0 1.5 2.0 2.5 Feed consistency [%] 8
9 Infi ltradiscfi lter 10 BaglessPlus fi lter discs with HiCon technology 11 Bagless Plus fi lter discs with HiCon guide rails 11 Field report #1 High Reliability thanks to upgrade to HiCon technology Low costs due to intelligent technology Before upgrading the disc fi lter the maintenance requirements were high due to tearing of the fi lter bags or broken sectors. The frequent replacement of sectors and associated shutdown times for the disc fi lter resulted in high costs. Thanks to the Voith HiCon technology, the fi lter discs can be operated reliably even at high stock consistencies without breaking. BaglessPlus fi lter discs are also guided and therefore further stabilized through the use of rails. In addition, the time-consuming and costly replacement of fi lter bags is eliminated. Successful results of the upgrade + Reliable operation at constant stock conistencies of 1.6% + Signifi cant reduction in fresh water consumption + No maintenance costs thanks to BaglessPlus fi lter discs and HiCon technology + Increase in production capacity by 30% + Maintenance requirements reduced to a minimum + Reduction in heating and chemical requirements Comparison of technical data Filter bag type Delivery rate [lpm] Stock consistency [%] Operation Production [bdmtpd] Capacity increase [%] Before upgrade Standard polypropylene surface 18,000 Design: 0.9, in operation: 1.6-1.9 Critical 415 After upgrade BaglessPlus fi lter discs HiCon technology 24,000 In operation: 1.6 Safe operation 480 30 9
12 Field report #2 Upgrade to BaglessPlus increases capacity and improves filtrate quality ROI in just four months Upgrading the Save-all disc filter to BaglessPlus filter discs achieved a significant improvement in the quality of the cloudy, clear and super-clear filtrate. In addition, production capacity could be increased by 56%. This successfully implemented all of customer s goals and also reduced the fresh water requirement to a minimum thanks to the new filter discs. Successful results of the upgrade + + Higher availability of the paper machine + + Reduction of the stock consistency of the super-clear filtrate by 95% + + Fresh water savings of 2,657,315 m 3 per year + + ROI in four months + + Capacity increase from 960 to 1500 m 3 /h + + Maintenance requirements reduced to a minimum + + Reduction in heating and chemical requirements Comparison of filtrate quality Cloudy filtrate [ppm] Clear filtrate [ppm] Super-clear filtrate [ppm] Fresh water consumption [m³/year] Before upgrade 500 400 1,100-1,300 2,657,315 After upgrade 270 90 25-35 0 10
12 BaglessPlus filter dics 13 BaglessPlus filter disc 570 13 Field report #3 Upgrade to BaglessPlus and new filtrate valve reduces costs Improved filtrate quality reduces water requirement Due to the customer s high filtrate stock consistencies, large volumes of fresh water had to be added. This resulted in high costs for the fresh water resource. After the upgrade of the disc filter to Voith BaglessPlus filter discs, the stock consistency of the super-clear filtrate was reduced by up to 80%. By now, the fresh water is replaced by the super-clear filtrate. In addition, the capacities of the disc filter were increased by up to 25%. Successful results of the upgrade + + Reduction of stock consistency of super-clear filtrate to 80% + + Significant reduction in fresh water consumption + + ROI in 8 to 12 months + + Capacity increase of up to 25% + + Maintenance requirements reduced to a minimum + + Reduction in heating and chemical requirements Comparison of super clear filtrate Paper machine 1 [ppm] Paper machine 2 [ppm] Paper machine 3 [ppm] Paper machine 4 [ppm] Before upgrade 160-370 200 150 150 After upgrade 25-35 40 25-35 21-29 11
vpz 1114 En Design: sos I Content: dennera 2015-06-02 Technical data and illustrations subject to change! Headquarters Voith Paper Holding GmbH & Co. KG St. Poeltener Str. 43 89522 Heidenheim, Germany Further Information paper@voith.com www.voith.com/paper Regional Contacts Asia Voith Paper in Kunshan, China Tel: +86 512 5799 3600 Europe Voith Paper in Heidenheim, Germany Tel: +49 7321 37 2487 North America Voith Paper in Wilson (NC), USA Tel: +1 252 265 4405 South America Voith Paper in São Paulo, Braszil Tel: +55 11 3944 4966