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MITSUBISHI – BELOIT 2,540 MM PAPER PRODUCTION LINE (PAPER MILL)

2,540 MM PAPER PRODUCTION LINE (PAPER MILL)

1  Specfications
Maker : Mitsubishi – Beloit
Year : 1987
Capacity : 27,000 ton / y ear
Products : Quality Paper / Information Paper / Special Paper
This line has glossy features.
Paper Width : 2,540 mm

2.  Specific Specifications

1)  Mtisubishi – Beloit S type winder
2)  Slitter : Bottom Knife (Solely Driven)
Above Knife : Dienes type
3) Unwinder Brake : Wate – Cooled Block Brake (Air Dia Type)
Drum No. 1 – 378 Ø x 3010  / Drum No. 2- 378 Ø x 3010

4) Wire Part roll

Specification :

Bread Roll   :  510 Roll Dia (MM
Cough Roll  :  660 Roll Dia (MM) – 3260 Roll Length - 3728 Bearing Center
Turning Roll :  510 Roll Dia (MM) – 3120 Roll Length - 3670 Bearing Center
Wire Roll  : 336 Roll Dia (MM) – 3020 Roll Length -  3420 Bearing Centre

5)  Power : 3,300 V, 60Hz, Drive : AC inverter type
6) Space of line : 14 m (W) x 120 m (L) x 4 m (H) (bottom 4 m)
7) type of machine : foured linear
8) Line of flow : from left to right.
9) Basic Paper Weight : 50 g ~ 205 g/m2
10) Wire Width : 2,920 mm
11) Max Sheet width : 2,605 mm
12) Design Speed : 450 m / min
13) Operation Speed : 450 m / min
14) Wire Length : P/W 30, 410 mm
15) Wire Length : B/W 30, 530 mm
16) Dandy Roll
Roll Dia : 800 mm/ Roll Length : 3190 mm / Made  Year : 1997

Specification :

Roll Dia : 460 mm Bottom Swimmig Roll, 460 mm Middle Swimming, 410 mm Heated Water Roll, 915 mm Reel Drum, 165 mm Paper Roll, 240 mm Reel Spool.

Circumference : 1445 mm Bottom Swimmig Roll, 1445 mm mm Middle Swimming, 1288 mm Heated Water Roll, 2870 mm Reel Drum, 680 mm Paper Roll, 750 mm Reel Spool.
 
Length : 2800 mm Bottom Swimmig Roll, 2800 mm Middle Swimming, 2800 mm Heated Water Roll, 2810 mm Reel Drum, 2800 mm Paper Roll, 3050 mm Reel Spool.

Center : 3816 mm Bottom Swimmig Roll, 3816 mm Middle Swimming, 3816 mm Heated Water Roll, 3650 mm Reel Drum, 3270 mm Paper Roll, 3650 mm Reel Spool.

Ref. 101265

ABB DCS 800 xA BOARD MACHINE

The machine is all on one level with partial basement. The machine has a sectional drive on the right from the wet end. The machine has two overhead cranes for maintenance. The machine is well maintained and this can be seen during inspection.
DCS system by ABB installed in 2010/11. Type xA

DCS system by ABB installed in 2010/11. Type xA

The paper machine and stock preparation systems are integrated.
Machine drive ABB, year approximately 2008/9. All HT panels etc. are of recent manufacture by ABB.

Production volume 2011: 62,000 ton. Installed production capacity: 70,000 ton
Reel up width 2650 mm.
Total paperboard length 76 m.
Bearing center width: 3360 mm except two dryer sections: 3500 mm.

Normal paperboard machine operating speed:
160 gsm brown board 420 m/min 10.7 t/h
190 gsm plasterboard liner 350 m/min 10.6 t/h
240 gsm brown board 260 m/min 10.0 t/h
300 gsm brown board 180 m/min 8.8 t/h
Paperboard grade produced;
 Plasterboard liner 160 – 300 gsm
 Core board 200 – 250 gsm

STOCK PREPARATION
The stock preparation system has an ABB DCS 800 xA system and is also covered by camera control.

PULP LINES
OCC LINE

Single conveyor with truck loading. Inline metal wire de wiring unit with compactor for wire removed. Conveyor on load cells.
Voith HD C32 High consistency pulper with gearbox drive

Useful pulper: volume 32 m3. Capacity 252 ton BD/24 h, batch time 10 + 10 min
Power requirement 455 kW. Installed power capacity 560 kW.
Rejects to trommel drum with perforated plate.
Stock preparation reject handled by conveyor with metal detector.

Fiberizer F4-P. BP. 2 Finckh ICHO Screen II HS 8 t/h
Secondary LC pulper: Grubbens 12 SR
Maule GR-III/L. Power requirement 450Kw

Voith VS 20 low consistency pulper.
Pulper volume: 20 m3
Power requirement: 160 Kw
Coarse screen Turbo 2 ATS 10, Fine screen Moduscreen F1F, Secondary Moduscreen F0.
Cellwood disperger

Krima KSR 550 SL/ 55kW screw press/ Krima KD 450 450 kW 3t/h
Twin waste discharge points externally.
Screw compactor for de watering rejects prior to external discharge.

In line rotary screen for removal of plastic waste in water system: model Roto Sieve
Finckh Fractionator:

Refiner OCC.
2 Jyhlavara JC 01. Power requirement 250 kW
Refiner Top surface line
ÖMV KK1 Power requirement 315 kW
Storage tank OCC 500 m3
White water screen Moduscreen 1F1
Colour kitchen with addition pumps
WET END FORMING SECTION

5 Black Clawson Newport underfelt formers. 2950mm face, Frames are stainless steel and each former can be cantilevered to make changing of felts. Two spare forming rolls for the formers.

Individual stock approach to each former comprising stainless Valmet pressure screens and a Valmet

reject pressure screen.

Formers have fan assistance. Each former 25to75gsm range. Centre formers 85to 100gsm
Dilution control by an Octopus unit located in the basement for two formers.
Machine screen Moduscreen HB2, Secondary Moduscreen F0.
Forming width 2850 mm, Reel up width 2650 mm.
Unloaded suction press UMV. Steambox Devronizer D5A/10F
Under machine pulper with single side mounted rotor, taking edge trim from machine and breaks.
Wet End pulper: Grubbens pulper for rewinder trim and machine broke complete with Voith 1 E deflaker.
PRESS SECTION

1st suction press: Voith Linear pressure 60 kN/m
2nd and 3rd press: plain Presses. Linear pressure 60 kN/m
4th press: hot press, Tamsec UMV Linear pressure 110 kN/m
5th press: hot press, Tamsec UMV Linear pressure 110 kN/m

DRYING SECTION

4 Cylinders: face width 2955 mm, diameter 1250 mm, operating 2.5 bar.
9 Cylinders: face width 2955mm, diameter 1500 mm ,operating 4.5bar.
First and second section dryers have open gear drives with a mixture of Polypemco and cast iron gears.
15 Cylinders: face width 2930 mm, diameter 1500 mm. Overmechanica manufacture with silent drives, operating at 10 bar.
8 Cylinders: face width 2900 mm, diameter 1500 mm, operating at 5 bar.
Pocket ventilation hood and heat recovery: Langbein & Engelbracht.
All dryers on A/F bearings, some sections are with oil auto lub systems. Felt rolls with remote greasing.
Dryers have auto guide units and manual felt tensioning by pneumatic operation.
Fully enclosed dryer hood with front opening panels.
IR-dryer: Compac
Kuster soft calender. Normal 90 kN/m

Located at wet end of the machine is the broke pulper: LC operation with a stand to take rolls to be repulped. This unit has in line a Voith model 1E deflaker to assist with pulp disintegration.
Roll truck for moving rolls from paper machine to rewinder.

REWINDER

Bruderhaus RS553/23. 2700. Number RS 576, year 1974, drive on left from the unwind. Hydraulic brake water cooled and including a brake generator.
5 slitters: manual set.
Unwind diameter 2200mm and rewind diameter up to 2000mm.
Shaftless rewind with roll ejector and lowering table.
Power controlled double drum drive: ABB.
Rider roll control: ABB
Maximal operating speed: 1,000 m/min
Tambour reel oscillation.
Floor mounted reel stop.
Winder has its own crane frame for loading rolls onto unwind stand.
Rewinder trim is blown to pulper located opposite the formers.
At front side of machine in recess is a vacuum cleaner and high pressure washer.
FINISHING
Core link semi automatic core cutter
Dust collection unit with bag for core cutter
Paper wrap roll frame with paper roll wrapping station complete with crane for loading paper wrapping rolls.
Work bench with vice for knife changing etc.
Floor mounted scale LED for weighing finished rolls.
In the area are spare paper machine rolls and a stand with reel shells.

BASEMENT
Vacuum pumps: Nash and Katachi
Hydraulic unit for press sections. Hydraulic unit for Nipco calendar
Oil tanks for cylinder lubrication systems.
Condensate collection tanks
Eight vacuum pumps with V belt drive complete with silencers.
Multi stage high pressure pumps for showers
Sump pump for water removal.
Various stock and water pumps
Black Clawson screen
Two water filters painted green: Broderna manufacture
Four small stainless in - line filters
Two manual hydraulic cranes: pull type, painted blue
Waste container painted blue
Two Voith model 2E deflakers
Pulpers Grubbens two off for former/press section broke and dry end broke.
LABORATORY
Auto Lab installed 2009. Sample strip cutter.
Air porosity Gurley, surface smoothness Bendtsen, moisture, tensile strength L/T, substance.
Printer, PC and spare.
Shopper Reigler freeness tester
Sheet maker
Sheet press
Oven
Pan balance
Quadrant gsm scales

Tear tester
Thickness tester
Tensile tester
Gurley
Pan balance
Fold tester
Scott plybond tester
Venticell unit
Tear tester
Electric burst tester
Hydraulic press
Smoothness and porosity tester
VACUUM PUMPS SPARE
1 Nash CL 2002.
1 Nash CL 1002
1 Kakati KVM 300 ( like Nash 2002)
Spare silencer for vacuum pumps, stainless steel on pallet
In store a Stainless Finch screen model Type Finckh HICHO Screen II HS
Fitted basket 1,4 mm, basket, rotor and mechanical sealing in spare.
ELECTRICAL WORKSHOP AND OTHER SMALL WORKSHOPS
Hydraulic lift table
Work benches with small tools drills, vices etc.
Overhead mono rail crane
Hydraulic testing unit
Sump pump
Hydraulic lift table

Blue portable bins
Instrumentation store
New flowmeters
New consistency transmitters: ABB manufacture
Inventory forthcoming.
Range of small motors approx 1 to 3 kw capacity
Rear of paper machine
Transformer located at rear of paper machine .
Three oil filled units, ABB 1600KVA 400v, ASEA 1600 KVA 400v and ASEA 1250 KVA 400v.
One resin encased unit.
Tanks external
EXTERNAL
Spare rolls in crates: PMC
Mould for former on support frame
Screw for Maule dispersor
Old boiler house chimney
Located next to office: Two blue insulated tanks: one for Bentonite and other for starch.
OLD BOILER HOUSE
Electric boiler: make K.V. Myhre AS, 8000 KW, 10,000 volts, 21 bar pressure, volume 16.2 m³ and year 1985.
Boiler no longer in use: Eckrohr manufacture with twin burners.
Steam accumulator tanks. Four inline water filters.
Individual Favallesa floor pick up shaftless unwind stand width 2000mm and diameter 2000mm. Brakes are Witchata, disc air cooled and with tension control. Year 1993, type PBF 183/6 number 1125.

BOILER HOUSE IN USE

Dynaflow sand filter in stainless self cleaning
Two stainless self cleaning filters
VEA boiler with twin burners type SAKKE burning gas. Oil option. Specification is 19,660 kw, year 2005, operating 17 bar pressure and test pressure 25 bar.
Oil storage tank external.
Transformers in stock prep
ASEA 1000KVA , 400v two off
Transformer Effluent plant
GBE 630 KVA 420 v

SMALL MACHINE SHOP AND METAL STORAGE
40 foot container with end door for storage of stainless steel
Rack for carbon steel storage
Boxes for AFT screen baskets
Three Marko waste buckets blue
URSVIKEN metal guillotine type C-SD-5 4/368
Spare rotor and perforated bedplate for pulper
Bench vice in welding shop
Two electric welding sets
Anvil
Electric hacksaw
Chain block sets
Three bench vices
Sets of skates
Sheet bender
Two disc grinder
Vertical metal cutter
Maza lathe (green) with bed approx 1.5 mtrs
Vertical drill
Planner
Horizontal metal table with light
FSA surface grinder
MECA vertical hydraulic press
Twin disc grinder
Pipe threading unit
Industrial cleaner

Small belt grinder
EFFLUENT PLANT AT BASE OF MILL
The effluent plant is a concrete construction with tanks made from sectional concrete.
The culture is attached to floating plastic membranes. Settler tank followed by an aeration tank.
In line PH alarm tester with auto shut down.
Three blowers Delta screw units in cabinets. Recent manufacture .
Polymer make up unit.
Effluent plant next to stock prep area.

CONCRETE BUILDING WITH BASEMENT
Pre flocculation tanks for chemical dosing with Bentonite. The system has an SDA tank by HMM.

Floatation in concrete rectangular tank with surface sludge scrappers.
Belt press: 1m width, discharging to bay below.
The mill has a spare belt press, 1m width. Not in use. This unit has a pre flocculation tank with mixer.
Sludge collected and loaded by shovel truck onto trailers.

COMPRESSORS

Two air dryers model make Hamrin
Atlas Copco screw type compressor model ZR160 -10-50 YEAR 2001
Atlas Copco compressor item 914 run 46955 hrs
INTERNAL STORE AREA
Two new AFT baskets for pressure screens
Various spare rolls
Sets of skates
Spare body for Finckh screen
New fillings for the JCO-1 refiners
OTHER EXTERNAL TANKS
Large blue tank insulated in front of boiler house.
Lorry base unit with small rear wheels for site transportation of paper machine rolls
The mill has a sophisticated fire alarm system about four years old Type Siemens Sinteso. About 90 sensors. Investment Ca £ 150k
The below listed specifications is more general and suitable for the specification;

Production data.

T/h

Minimum grammage  : 25  Gr/M2 ,  125  Total BM , 450 Operating Speed M/min,
8.5  Capacity

Maximum grammage : 80   Gr/M2 ,  400  Total BM , 160 Operating Speed M/min,
9  Capacity

Average grammage : 38  Gr/M2 ,  190  Total BM , 350 Operating Speed M/min,
10.5  Capacity

The above capacities are based on four ply OCC furnish and one ply Office waste.
Capacities OCC pulp 11 T/h
Capacities office waste 3 T/h can easily be increase if higher demand is needed.
1. Thermal energy consumption 1,2 MWh/ton.
2. Electrical energy consumption 0,5 MWh/ton.
Energy requirements Thermic energy 1,2 MW/ton Boile

Ref.1012201

 

CORE BOARD MACHINE AND RECYCLING PLANT

Core board machine & RecyCore Recycling plant
The recycling plant is from 1997 and the board machine basicly 1989 with major reconstruction
in 2004

Recycling plant
Basics of design
Recycling plant has been design to handle multi material packages like liquid
packages (e.g. TetraPak) and wrappings (kraft fiber). The idea was to utilize all
components as further material or energy (see fig 1). Therefore the line has some
extra benifits compared to conventinal OCC line liike
‐ Large scale of raw material grades (liquid packages,wrappings,OCC,
mixed waste etc)
‐ High separation rate of fiber and reject (plastick/aluminium , impurities)
Cl d hi h d t t( 70%) j tf f th ‐ Clean and high dry content (over reject for futher processng(gasifying,
inceneration)
‐ Because of modern fine screening the sticky removal rate is high
The capacity of the line
Infeed raw material : 440 t/d
Fiber screening : 300 t/d
Annual raw material flow, fig2

Feeding and Pulping
Feeding Conveyor
The raw material 440 t/d
Width 1,5 m
Length 36,6m

Fiberlow drum FF350 ext
Diameter 3,5m
Length 30m
Capactiy
Fiber min. 70%
Reject max. 30%
A Ahstrom OY, 1995

CLEANING AND MC SCREENING
Screening
Fiber Capacity 300 t/d
Consistency 2,5%
Flakes 3-6%

Coarse Screening:
Cyclone
DR 400 / 15, 2 pc
Voith Sulzer, Year 1995
1 A Omniscreen OS4-LR
Hole Screening 1.4mm
Voith Sulzer
1B Fibersorter FS1B
Hole screening 2,6mm
Escher Wyss, Year 1995
Fine Screening:-
2 A Moduscreen F 50
Slot Screening, 0 18mm / 3.25m3
Andritz OY, Year 2009

2B Omniscreen OS8-BR
Slot Screening, 0.25 mm / 1.42m3
Voith Sulzer, Year 1995

Disc filter Akse F300 / 05-04
Disc 8kpl
Speed 11.8 rpm
Andreas Kufferath, Year 1995

Reject capacity 150 t/ work
Pulper STRC-A
Diameter 3,5m
Vat 16 m3
Voith Sulzer, year 1997

Drum Screen STR9R
Diameter 2,5m
Length 4,9m
Screening 12 mm /3.73m3
Max. Capacity 260 t/vrk
Voith Sulzer, Year 1997

Flas drum (Junko-mat)
Diameter 2,4m
Feed hopper volume 5m3
Voith Sulzer, Year 1997

Screw Screenex SX60
Feed hopper volume 3m3
Length 6m
Spiral d = 0,53 x 5,8m angle 250
Voith Sulzer, Year 1997

OTHER EQUIPMENT

Pumps   22 pce
Blowers 11 pce
Hydraulic plant units 2 pce
Tank 12 pce
Conveyors 12 pce
Sort and cleaner 10 pce
Press 2 pce
Gears 1 pce
Mixers 8 pce
Other equipments 6 pce

CORE BOARD MACHINE CM1
Machine Width 2900 mm
Min. accepted trim 2650 mm
Substances 200- 600 g/m2
Speed (max.) 100 …300 m/min
Main reconstruction 2004
Capacity 2008 : 100,000 t

CM1, HEADBOX
Alflow – R
Slice Width : 3150 mm
Slice 35-65 mm
Flow rate on wire : 363 I/S
Temp. Max 50C0
By pass flow 10%
Press 0.6 mvp
Consistency 1-5%
Slice control

CM1, WIRE SECTION
Constructed 1989
Wire Width 3300 mm
Dryness 20%
Rag Roll
Last reconstruction 2008
5 Ceramic list vacubox
11 Ceramic list vacubox
Suction roll : Modernization 2006

3 roll press
1st Press Section (Double Felt)
F=70 kN/m
3.th press section (Since felt)
F = 120 kN/m

CM1, PAPER THREADING
1 pce blow pipe
1 pce Metso tailshooter
6 pce plates

CM1, DRYING SECTION
46 Steam Heated Drying Cylinders (diam. 1500 mm)
1.st drying group
5 cylinders (10.5 bar)
2.ndt drying group.
9 Cylinders (10.5 bar)
3rd drying group
32 cylinders (10.5 bar)

CM1, PULPER AND CALENDER
Pulper : Tampella SD 331/B  (1989)
Consistency 4%
Net Volume 14m3
Calender (1970)
Kuesters roll
Osc. +/- 10 mm

CM1, QCS SCANNER
Measurement box SM1200 (1994)
Basis Weight
Caliber measurement
QCS Video Screens
Modernization 2008

CM1, MACHINE REEL HANDLING
Reeling Section (Ahlstrom Karhula 1970)
Witter roll
Machine reel transport
System (Qualtroll 2004)
Diameter max 3000 mm
Reel Storage 4 pce
Automatic reel return

CM1, WINDER
Quatroll QDW T2960
Constructed 2004
Max. speed 1500 m/min
58 pcs Blades
Min.roll width 50 mm
Automatic wep width (Dieness werke)
Automatic core feeding
Hot melt glue

CM1, CORE SYSTEM
Cutler : Corelink CL3090 (1996)
4 pce conveyors
(kuljetinrauma Oy)
Automatic core feeding

CM1, ROLLHANDLING AND PACKING
Jetting heads for hotmelt (2004)
Broke Roll Splitter JRS (1996)
Label Report Motoman UP 130
XRC (2004)
Strapping machine
(Swingmaster 2004)
Stretch film wrapping machine
(Swing master 2004)
Roll Conveyors (2004)

CM1, STOCK SECTION
2 pce refinere (Sunds Defibrator JC-03)
Starch System
Silos, mixers, screws, pumps and classifiers

CM1, OTHER EQUIPMENT
Pumps – 65 pce
Blowers – 13 pce
Rolls – 120 pce
Gears – 49 pce
Hydraullic Plant Units 4 pce
Tank 20 pce
Mixers 13 pce
Conveyors 25 pce
Classifiers 9 pce
Refiners 2 pce
Central Creasing 1 pce
Missing process machines
Stock preparation plant :
Dewing equipment (Voith Sulzer)
Raw material shredder (Roxon)
Refiner (JC03, Jylhavaara), one exists
DCS (Alcont, Honeywell)
(Reject balling and wrapping system)

Board Machine
2 refiners (JC03)
Machine Screen (Tampella)

2 Stock pump (Ahstom)
Web cross cutting device, dry end (xx)

Ref. 1012200