ECOPUMP TURBO SYSTEM - Runtech Systems

Paper machine vacuum system
ECOPUMP TURBO SYSTEM
- THE ADVANTAGES AND PRINCIPLES OF INSTALLING AND USING
SPEED CONTROLLED VACUUM SYSTEM

CONTENTS
1. GENERAL 4
2. ECOPUMP TURBO VACUUM SYSTEM FOR A
PAPER, BOARD OR PULP MACHINE 4
2.1. PRINCIPLE OF THE ECOPUMP TURBO 5
2.2. CHALLENGES IN PRODUCING VACUUM FOR
PAPER MACHINE 6
2.3. LIMITATIONS OF TRADITIONAL VACUUM
SYSTEMS 6
2.4. DIFFERENT PRACTISES AND TRADITIONS OF
VACUUM USAGE 7
3. ECOPUMP TURBO FEATURES 8–11
4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER
MACHINE INSTALLATIONS 12
4.1. POWER SAVING 12
4.2. WATER SAVING 13
4.3. IMPROVING SYSTEM RELIABILITY 14
4.4. SAVING IN BUILDING COST 15
4.5. REDUCING SHUTDOWN TIME IN REBUILDS 15
4.6. HEAT RECOVERY POTENTIAL 16
5. TECHNICAL DATA EP500-700-S(D1) & EP315-500-S(D1) 17
6. REFERENCE LIST 18
3

1. GENERAL
Ecopump energy saving group has been working since 1989,
with a clear target of reducing power consumption of paper
machine pumping systems. Four product lines have been developed
to realize the great saving potential in paper production
process:
This book describes the benefits and working principles of
ECOPUMP TURBO VACUUM SYSTEM for paper machines:
• Power savings 500..1000 kW compared with
traditional systems
• Ecopump Turbo vacuum systems
• Ecoflow dewatering measurements
• Ecosep water separators
• Vacuum system consulting
Based on the experiences on practical process optimization
work, and the fact that no vacuum pumps with good controllability
were available on the market, Ecopump started to develop
its own system. The development was done in close cooperation
with top technologists from technological universities,
aerospace engineering companies and electric drive suppliers.
After some years of intensive design, testing and production
scale piloting, the system has found its position as the most
efficient modern vacuum system for paper machines.
• Water savings up to 1000 000m3/a per
production line
• Improving system reliability
• Saving in installation cost
• Saving in building cost
• Saving in shutdown time
• Saving in maintenance cost
There are examples described. The technical scope and results
are based on real life projects.
2. ECOPUMP TURBO VACUUM SYSTEM FOR A PAPER, BOARD OR PULP MACHINE
During years of optimizing
existing paper machine vacuum
systems, and conducting
dewatering trials utilizing
Ecoflow dewatering measurements,
it became obvious that
there is a need for a VACU-
UM SYSTEM WITH ADJUST-
ABLE SPEED CONTROL. There
is a great potential for power
savings by eliminating excess
capacity due to over dimensioning
– the systems are often
over dimensioned due to
uncertainties concerning new
machine concept or when reserving
capacity for eventual
speed increase. There are also
variations in capacity need
because of different running
conditions new felts vs. old
felts, different felt types, high
grammage vs low grammage,
etc. With adjustable capacity
these savings can be realized
directly to the bottom line.
Other important features are:
water savings, savings in foundation
work due to compact
size and low weight, savings
directly in maintenance work
and parts as well as indirectly
in saving maintenance shutdown
time.
4

2.1. PRINCIPLE OF THE ECOPUMP TURBO
Ecopump turbo is based on
a combination of modern
high-speed electric drive and
high efficiency turbo blower.
The unit is driven with a frequency
converter, which enables
the speed control from
zero to maximum without
any limitations in operation
range. Even marginal savings
in vacuum capacity will
result to significant savings in
electric power. Speed control
is the most efficient way to
adjust capacity.
The turbo impellers are directly
mounted on the motor
shaft, which makes the
system very compact and mechanically
reliable. No gearbox
or couplings are needed.
The solid shaft AC motor is
robust and has no resonance
frequencies within the operating
range. Cast titanium impellers
are mechanically and
chemically very stable.
Oil lubricated ceramic ball
bearings and lightweight parts
make the system easy to handle
from maintenance point
of view. Scheduled maintenance
(bearing change) can
be done on minimum during
an 8-12 hours shutdown.
Picture 1: Ecopump Turbo. The electric drive is included in the scope.
5

2.2. CHALLENGES IN PRODUCING VACUUM FOR PAPER MACHINE
An efficient use of vacuum system for paper machine positions
face the following An efficient use of vacuum system for paper
machine positions face the following challenges:
• The vacuum system must handle today’s production, but
also possible speed increases in the future
• The vacuum need on felt conditioning is varying
depending on the felt types and age of them
• The grammage, grade and speed varies
• Seal water is becoming ever more costly due to not
only regulations but also to increasing need to
control temperatures, pH and bacteria (specially
with closed circulation)
• Availability requirements do not allow long
maintenance shutdowns
• The air to be pumped contains water, other
liquid media and solids.
• The rising cost of power means it is not economical
just to simply bleed off the extra capacity
2.3. LIMITATIONS OF TRADITIONAL VACUUM SYSTEMS
For a long time, water ring pumps have been the main way to
make vacuum for paper machines. In this kind of pump, you
need to rotate a water ring to get the air moving. In spite of
their seemingly robust structure, there are certain limitations
in use of this kind of pump.
a) Poor power efficiency; especially with low vacuums
b) Limited control range; the water ring will collapse
after certain point
c) Need for cooling; specially with closed circulation
and during summer time
d) Bacteria control; specially when circulating the
water => optimum circumstances for bacteria
Another widely used technology, multistage blower aggregate,
avoids many of the disadvantages of water ring pumps. But
there are other problems related to these:
a) Limited control ability; due to big size and few ag
gregate installed in one system
b) Complex startup procedure; risk for overloading the
electrical motor
c) Complex maintenance procedure; need for long
shutdown when serving
d) Risk of production shut down; normally no back
up system. If one unit fails it is not possible to run
the PM
e) Heavy investment on building and foundation;
heavy construction with low frequencies.
e) Heavy investment on foundation; heavy units,
which are critical for vibration.
6

2.4. DIFFERENT PRACTISES AND TRADITIONS OF VACUUM USAGE
There are some general principles in evaluating the need for
vacuum capacity. A good parameter to benchmark the vacuum
usage is the specific power consumption (kWh/ton) of the
vacuum system. Of course, one value is not comparable for all.
Typically, the following guidelines can be found.
A typical distribution of specific consumption is shown in the
graphic below.
2) Grammage: heavier grammage requires less power
per ton than lower grammage.
1) The specific consumption of vacuum system is
depending on the grade: typical benchmark values
can be given:
• Pulp drying machine
20..40 kWh/ton
• Board machine 40..80
• Linerboard machine 35..80
• Fine paper 40..80
• Magazine 70..120
• Newsprint 70..120
• Specialty papers 80..180
• Tissue 100..200
3) Speed: lower speed requires less power per ton
than higher speed.
4) Size: Large machine capacity requires some less
power per ton produced than a small machine
capacity.
Vacuum system specific consumption vs. Production, Magazine Papers
Specific energy consumption kWh/t
200
180
160
140
120
100
80
60
40
20
• specific
consumption
kWh/t
0
0 10 20 30 40 50
Production kWh/t
Picture 2: Specific power consumption of vacuum system, magazine paper grades.
7

Different working shifts can run the machines in different ways.
There are some traditions and some common beliefs that sometimes
are based on facts, which do not exist anymore.
By systematic optimization with dewatering measurement
system and benchmark information from other machines alike,
an energy efficient running practice can be developed. Also
Ecopump turbo blower can be easily automated to avoid different
running philosophy.
3. ECOPUMP TURBO FEATURES
During years of optimizing vacuum systems and dewatering,
it become obvious that the vacuum system should have the
following properties:
a) Flexible capacity adjustment: the system shall fulfill the
capacity requirements of the machine supplier’s specs. But
the capacity requirement of the actual running situation is
often different.
=> ENERGY SAVING POTENTIAL
b) Flexible in capacity adjustment: different grammages
require different vacuum. Old felt and new felt require
different vacuum capacity.
=> ENERGY SAVING POTENTIAL
c) Efficient pumping principle: The power should be
used to move the air, not to rotate the seal water.
=> ENERGY SAVING POTENTIAL
d) Good potential for recovering the power used in vacuum
system heat.
=> ENERGY SAVING POTENTIAL
e) Easy to adjust and flexibility.
=> optimum running condition for the production
Main benefits
Ecopump turbos are specially designed for paper machine
environment and for best operational economy.
a) Flexible capacity adjustment with ECOPUMP TURBO:
All turbos are speed controlled to enable economical
use from zero to max capacity. This gives
freedom to design an efficient system for different
and/or varying conditions.
b) Efficient pumping principle: 3-dimensional high speed
turbo impeller running variable speeds: all power is used
to move air from vacuum to atmosphere. No power used
to rotate water, no vacuum adjustment with speed.
c) Heat recovery potential: The pumping energy is transferred
to the air. The temperature reaches up to 160 °C,
which offers good potential to use it in different stages of
production.
80
70
Vacuum Levels and Flow Rates
60
50
40
30
20
10
0
0 1 2 3 4 5 6 7 8 9 10
Air flow under vacuum (m³/s)
Picture 3: Ecopump Turbo flow/vacuum range
Vacuum (kPa)
8

Principles in designing a vacuum system
Ecopump vacuum systems are the result of practical experience
for evaluating the system needs, realizing the project and
optimizing the running conditions. All our field engineers are
trained for process expertise.
Some general principles in designing and operating vacuum
systems can be stated.
• Capacity needed: capacity designed by the machine
builder, capacity to be optimized at real life run situation.
Ecoflow.
• Controllability: how to build a system where each
vacuum position can be optimized for best efficiency and
quality. Ecoflow.
• Backup connections.
• Optimising piping design. Separator features. Tested in
laboratory.
• Silencers to reduce the noise in the pump room, pipeline
silencers and silencers for exhaust air.
Picture 4: Ecopump EP315-series
9

Ecopump EP315-500-S
Ecopump EP315-500-S is designed for smaller capacity, especially
for retrofit installations for medium and small paper
machines, where the space is limited and where production is
versatile and maintenance conditions are limited. It is compact
to fit in small space available, the lightweight parts can easily
be handled by hand in short service shutdowns. No long
shutdowns are needed. The materials are corrosion resistant:
titanium impeller and stainless steel casing.
Ecopump Turbo EP500-700-S
Ecopump EP500-700-S is a heavy-duty turbo for high capacity
and highest efficiency, designed for large paper machines and
for both greenfield and retrofit installations. Its 3-dimensional
turbo design gives top efficiency together with good controllability
– as all Ecopump turbos. It is, although clearly larger
than EP315-500-series, still compact when compared with
other commercial technologies. The up-time availability and
cost efficient maintenance are valid for this series, too.
The series contains altogether the following models:
EP200-500-D1 low
200 kW, nominal 500mm impeller
EP250-500-S
250 kW, two nominal 500 mm impellers in series
EP315-500-S
315 kW, two nominal 500 mm impellers in series
EP400-700-D2
400 kW, nominal 700 mm impeller
EP400-700-D1
400 kW, nominal 700 mm large impeller
EP500-700-D1
500 kW, nominal 700 mm large impeller
EP500-700-S
500 kW, two nominal 700 mm impellers in series
Each unit is tested in Ecopump laboratory..
Picture 5: Electric drive
10

Lube unit
Picture 6: The lubrication system is extendable for multiple
turbo system and is equipped with double pumpfor reliability.
Reserve pump can be served during PM run, if needed.
Vacuum
breaker
valve
Blower
outlet
Cooling
air
Drop
separator
Lubrication
unit
M
M
Turbo
blower
PI
Suction
position
PI
Power
supply
Frequency
convertor
DCS
FI
SCOPE OF DELIVERY
Discharge to
seal pit tank or pump
Picture 7: The functional scheme of the system
11

4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER MACHINE INSTALLATIONS
The main benefit of choosing Ecopump Turbo system is power saving. But there are also other quite significant reasons to go
for Ecopump technology.
4.1. POWER SAVING
b) Investments in reducing energy consumption are often
backed by government programs. Innovative financing such
as ESCO (= Energy Saving Company) arrangements is often
available, too. Ecopump and its network will help in evaluating
the operation.
Turbo information and energy savings
BEFORE
AFTER
kW
12

4.2. WATER SAVING
In one of Ecopump Turbo customer mills, the water comes
from a distance with a pipeline. The supply is thus limited. At
the time of machine rebuild, there was a need of either
a) cut the fresh water consumption in the mill
b) build water circulation for seal water of the liquid
ring vacuum pump system.
After reviewing the power saving potential in vacuum system,
it was concluded that Ecopump Turbo system was the best
solution. The Nash pumps were removed and Ecopump Turbo
System was installed in a machine rebuild.
Results:
a) The water consumption was cut by some 1000 000 m³/a.
b) Power saving was cut down by some 500 kW, even
though the speed was increased and new vacuum
positions (top former) were installed on forming section.
Picture 8: No seal water is needed for Ecopump Turbo.
13

4.3. IMPROVING SYSTEM RELIABILITY
In this installation, there were
originally two large multistage
turbo blowers and
one liquid ring pump in the
vacuum system. Because of
this configuration, the system
was vulnerable: if any of the
two large turbos were down,
the production would have
to be stopped. At the same
time, the power consumption
was a bit high, despite
the system principle (in general,
turbo principle is power
efficient).
Optimizing the system, and
implementing a new configuration
shut one of the two
large blowers and the liquid
ring pump shut down. One
Ecopump turbo was installed
to serve suction press roll. By
running the multistage turbo
and Ecopump turbo only, the
machine now is not vulnerable.
The multi-stage blower
can be replaced with the other,
now obsolete one. Also,
the EP turbo can be replaced
by the multistage turbo. The
water ring pump can be kept
still.
As a side effect, the total power
was cut down by 900 kW.
Picture 9: The overall system reliability was improved by installing one Ecopump Turbo.
14

4.4. SAVING IN BUILDING COST
Space needed for Ecopump
turbo vs. traditional pump
system is far less than that
for liquid ring pump system
or that for multi-stage turbo
system. The compact construction
with motor and
turbo integrated, it makes
it possible to accommodate
in very limited space. In fact,
the vacuum system can be
decentralized, if needed – no
separate pump room necessary.
Relatively low weight reduces
the building cost further,
since no heavy foundations
are needed. An even concrete
floor is enough, if Ecopump
base plate is used. Another
option is to have concrete
foundation for the turbo.
In rebuild projects, the new
vacuum system can often be
installed before dismounting
the existing system. This
way, the system rebuild can
be realized practically without
production shutdown.
The old multistage blower
was getting too old to run
– no spares were available.
There was no room for a new
unit of the same kind. Dismounting
the one and building
in a new one would have
required a long shutdown.
Building a liquid ring pump
system would have required
an extensive and expensive
investment on seal water
system.
4.5. REDUCING SHUTDOWN TIME IN REBUILDS
By installing Ecopump system, the new system could be built
parallel with the old system. Switching from old to new system
was done in normal shutdown. The new system was installed
and tested during normal paper machine run. The valves in
connection pipes made this possible.
Picture 10. Ecopump Turbo can be installed during normal production without a long shutdown
15

4.6. HEAT RECOVERY POTENTIAL
Recovering the energy used for pumping air, makes the energy
balance superior. Practically all of the power used to generate
vacuum is transformed into process air heat. In water ring
pump, this heat is transferred to seal water, making it necessary
to cool the water – which is causing an additional cost. Ecopump
system principle enables recovering this heat: especially
in high vacuum positions this results to high temperature air,
which makes recovery very feasible. It can be taken into an
exchanger, to heat process water or to heat the hood supply
air. In some cases, it can be blown directly to the hood. Where
the heat is used, depends on the mill needs.
Picture 11: Recovering pumping power offers further energy effiency potential.
16

5. TECHNICAL DATA EP-500-S(D1) & EP 315-S(D1)
Power
400/500/690 V 500 kW
Production (air +20ºC/1, 01325 bar)
Serial connection (EP500-700-S) 68 kPa/7,0 m³/s
(EP315-500-S) 60 kPa/2,5 m³/s
Single impeller (EP500-700-D1) 46 kPa/8,0 m_/s
(EP315-500-D1) 40 kPa/2,2 m³/s
Cooling air
Flow
0,5 m³/s /+20ºC
Filtering
EU5
EP-500-S
Frequency converter
Type
VACON NX
Filter
LC
Voltage
400/500/690 V
Main dimensions EP500-700-S(D1) EP315-500-S(D1)
Width 1850 (1850) mm 1390 mm
Height 2210 (1430) mm 1395 mm
Lenght 2995 (1965) mm 2360 mm
Weight 5000 (3500) kg 1500/1200 kg
Process connections EP500-700-S(D1) EP315-500-S(D1)
inlet (vacuum) DN 600 PN10 DN 300 PN10
Outlet (pressure) DN 400 PN10 DN 250 PN10
Cooling air Ø 315 Ø 250
EP-500-D1
Materials EP500-700-S(D1) EP315-500-S(D1)
Blowers cast iron stainless steel
Impellers cast titanium cast titanium
Foundings Fe360 Fe360
Bearing units
Bearings
Lubrication
Hybrid ball
Oil
Automation
Bearing vibrations 2 x Transmitter
Bearing temp 2 x Transmitter
Coil temp 2 x Transmitter
Oil flow
2 x Transmitter
Oil level
1 x Switch
Oil filter pressure difference 2 x Switch
17

6. REFERENCE LIST
Arjo Wiggins SAS, Annonay PM7, France, 1 Turbo blower
• Drawing paper
M-real, Kangas PM 2, Finland, 1 Turbo blower
• Fine paper
Cartiere del Polesine, S.p.A., Italy, 7 Turbo blowers
• Test liner
M-real, Kirkniemi PM 1, Finland, 1 Turbo blower
• LWC
Daehan Paper, Cheongju PM 1, South Korea, 2 Turbo blowers
• Copy / News
Daehan Pulp, Cheongju PM 3, South Korea, 1 Turbo blowers
• Board
Georgia Pacific, Cuijk, Netherlands, 2 Turbo blowers
• Tissue converting process
Georgia Pacific, Nederland B.V., Netherlands, 1 Turbo blower
• Tissue
Georgia Pacific, Nokia PM 7, Finland, 1 Turbo blower
• Tissue
Hadera Paper Ltd, Israel, 5 Turbo blowers
• Test liner
International Paper, Papeteries Etienne, France, 1 Turbo blower
• Fluting
International Paper, Kenitra Mill, Marocco, 1 Turbo blower
• Test liner
Kimberly Clark, Rouen, France, 1 Turbo blower
• Tissue
Kimberly Clark, Enstra Mill, South-Africa, 3 Turbo blower
• Tissue
L.C. Paper 1881 S.A., Papelera La Confianza, Spain,
1 Turbo blower
• Tissue
Mayr-Melnhof Karton, Baiersbronn Frichfaserkarton BM 1,
Germany, 1 Turbo blower
• Board
M-real, Kyro BM 1, Finland, 1 Turbo blower
• Board
M-real, Kyro PM 1, Finland, 1 Turbo blower
• Wall paper base
M-real, Lielahti, Finland, 1 Turbo blower
• Pulp machine
M-real, Tako BM 1, Finland, 1 Turbo blower
• Board
M-real, Tako BM 3, Finland, 1 Turbo blower
• Board
M –real Simpele Board, Finland, 1 Turbo blower
• Board
M-real, Äänekoski Board, Finland, 1 Turbo blower
• Board
Metsä Tissue, Mänttä PM 1, 1 Turbo blower
• Tissue
Metsä Tissue, Mänttä PM 7, Finland, 1 Turbo blower
• Tissue
Mufindi Paper Mills Limited, Tanzania, 2 Turbo blowers
• Kraft liner and sack
Papeteries de Clairefontaine, France, 2 Turbo blowers
• Fine copy paper
Pulp Machine, Confidential PM 1, Finland, 1 Turbo blower
• Pulp
Pulp Machine, Confidential PM 2, Finland, 1 Turbo blower
• Pulp
18

Stora Enso, Anjala PM 1, Finland, 1 Turbo blower
• Book paper
Stora Enso, Enocell PM 2, Finland, 1 Turbo blower
• Pulp machine
Stora Enso, Kaukopää PM 8, Finland, 1 Turbo blower
• Fine paper
Stora Enso, Kotka PM 1, Finland, 5 Turbo blowers
• Laminating base paper
Stora Enso, Summa PM 3, Finland, 1 Turbo blower
• Newsprint
Stora Enso, Tainionkoski BM 5, Finland, 1 Turbo blower
• Board
Stora Enso, Sachsen PM 1, Germany, 3 Turbo blower
• News
Unipak, Halat PM 1, Lebanon, 1 Turbo blower
• Tissue
UPM-Kymmene, Kaukas PM 1, Finland, 3 Turbo blowers
• Pulp machine
UPM-Kymmene, Rauma PM 4, Finland, 3 Turbo blowers
• Lwc
UPM-Kymmene, Chapelle PM 3, France, 3 Turbo blowers
• News
19

RunEco
Minimized energy and water consumption in your process.
Maximized dewatering, fiber and filler economy.
• EcoPump
• EcoFlow
Runtech Systems Oy
Kastarintie 27
FI-35990 KOLHO
FINLAND
Tel: +358 3 471 1000
www.runtech.fi
runtech@runtech.fi
• EcoSep
More profitability - Less energy