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Our client decided to rebuild the Machine installing new presses and high-pressure dryer cylinders. Kappa Srl designed the complete aerothermic systems (Closed Hoods, Pocket Ventilation system, Heat Recovery Units), the Steam and Condensate system and two High Efficiency Hoods for coating heated by natural gas.
Pocket Ventilation system has been designed to blow air in each lower and upper pocket. Air is preheated in Heat Recovery units and then raised to 110÷120°C with steam coils and blowed on the felts.
After Start up, customer increased its range of products, including coating papers, from lower to higher grammage, with Top quality.
Closed Hood was equipped with three axial exhaust fans, not enough for the updated Paper Machine production, with wet air leaking in the room and damaging of the building. The request was to improve wet air exhaust replacing exhaust fans.
Our project was focalized, besides replacing axial fans, to improve Heat Recovery, to increase wet air section with new units and to obtain better heat exchange and higher inlet temperature.
Customer has increased the wet air exhaust, obtaining also an increase of Energetic efficiency by an increase of Heat Recovered in the Exchangers for Pocket Ventilation System.
The Paper Mill had only one exhaust chimney from Open Hood, without any Heat Recovery. The request was to increase the efficiency of Paper Machine installing one Heat Recovery Unit for Pocket Ventilation Unit for Pocket Ventilation system, one for winter Room ventilation and one for Process Water heating.
Even though an Open Hood with Low Dew Temperature, we succeeded in installing in first stage a Heat Recovery for Pocket Ventilation system, in second stage for Winter Room Ventilation and in third stage a unit for Process Water.
The system has given excellent results; Customer has achieved a thermal breakthrough of 52°C for Pocket Ventilation, 31°C for Winter Room Ventilation and 25°C for Process Water.
Paper Machine Room had a very bad situation: humidity from paper machine condensed on the ceiling and walls. The plant needed a complete cure of the whole area.
The project considered the whole room, analysing in detail the problem during summer and winter period. We solved the problem exhausting wet air from wire and from room. The air intake was guaranteed through two groups which blowed air on Operator Side.
The combination wet air exhaust and external inlet dry air has completely improved the room, with a complete satisfaction of the Customer.
The customer, after the installation of new Paper machine PM6, faced dripping problems on the ceiling of the building above wire area. These drippings caused damages to product creating holes and paper breaks.
We focused all our efforts on the project, shortening all phases, from production to erection, giving also consideration to energy savings: we used condensate water for air heating, without any saturated steam consumption.
Customer had to rebuild an old coating tunnel with a new one, with an easy access and that could guarantee the drying of “Release” coat.
In two years installation, we replaced the existing tunnel (50 m length) with nine drying hoods, six by steam and three by gas, separately heated. The alternate steam/gas arrangement is due to the need of guarantee the drying profile to the “Release” coating. We supplied also painted steel support structure, rolls with supports and machine electrical drive.
Customer obtained a better performance of the Hoods, increasing the speed of 16%; operators had compete access to the paper, therefore easy cleaning and maintenance.
