Andritz energy saving pump ACP (single stage centrifugal ...

Andritz energy saving pump ACP (single stage centrifugal pump) and

MC (medium consistency pump) 安德羅茨節能 ACP 泵(單級離心泵)

和 MC 泵(中濃泵)

主講者：祝妙楠小姐吳忠先生

友瑜有限公司

４０

Centrifugal Pumps – “ACP-Series ”

Andritz China _ Pump division2

Successfully used all over the world

Hydraulic competence with tradition

The first centrifugal pump was built by ANDRITZ more than 130 years ago.

The systematic advancement of our pumps is founded on our comprehensive experience in pulp and paper engineering.

ANDRITZ pumping systems are operating successfully all over the world, and their outstanding advantages are rugged design, wear resistance and highest efficiency.

Andritz Energy Saving Centrifugal Pump –ACP SeriesPresentation



Field of application

Pulp and paper stock up to 6% atro

Capacity up to 7500 m³/h

Head up to 150 m

Operating pressure up to 25 bar

Operation temperature up to 200°C

Center-line design available

Flange drilling for DIN, ASTM, JIS

Tried and tested:

In the pulp and paper industry Chemical pulp Mechanical pulp Recycled fibres Caustic lye Fibrous sludgeWhite water

In sewage water treatment Flue gas desulphurization Chemical industry The food industry




Our supply programme for centrifugal pumps covers 62 different sizes

Characteristic Curves 1500rpm and 1000rpm Characteristic Curves 3000rpm

The small flow area are covered by ACP-ISO types, with semi-open or closed impellers



Content

Design and function of the pump


Quality Management

Why choosing a ANDRITZ ACP-Pump?

Research and Development



Design and function of the process pump

Impeller

Bearing unit

Sealing system

Material combination

Centreline pump

ACP400-700 ready to ship for APP (Indonesia)

Assembly Sketch

４１



Design of the process pump

Assembly Sketch

Removable of Pull out Unit

Easy dismantling without

moving pipes and motors

Pull out unit



Section Drawings

Assembly Sketch


Rigid design

All bores on bearing housing are machined from one side, perfect accuracy.

Easy assembly and disassembly for maintenance work.



Front Liner


Casing Cover

PN25 design

Different sealing types, same casing cover




Sealing systemAndritz Single Mechanical seal, 2 components (type A1)Andritz Double Mechanical seal, 2 components (type A2)

Andritz Cartridge Single Mechanical seal, (type B1)Andritz Cartridge Double Mechanical seal,(type B2)

All Andritz standard sealing system are with dry shaft design, Single mechanical seal can have flushing water in critical application (Option)Mechanical seal suppliers (Standard): Johncrane, Burgmann;

Standard Sealing SystemFor ACP pumps



Impeller


Semi open impeller or

Special Spline connection with shaft, easy to dismantle

Fully open Impeller for non-clog application




Sealing system

Stuffing Box PackingDynamic Seal(In developing)

Except Dynamic seal, All seal types use same casing cover, minimize the spare parts variety and Easy to change among different seals

４２



Base frame

Shaft

Bearing house

Front liner

Impeller

Casing cover

Volute casing

C-Steel1.44621.44041.45881.45171.44081.4460ENG JL

250Designation

Material combinations

Material combination





Bearing unit

Only 5 bearing units for 27 pump sizes

Compact, rigid design

Oil or grease lubrication

Sand blasting / prime coating (Epoxy paint)

Bearings type (SKF Explorer C3)



PN25 bar pump, with Centreline design


Special centreline supportStandard base frame

Temperature up to 200°C

Pressure up to 25 bar or higher

ACP65-315ACP100-315ACP100-250ACP125-250



PN25 bar pump, with Centreline design


Special centreline supportStandard base frame

Temperature up to 200°C

Pressure up to 25 bar or higher

ExceptACP65-315ACP100-315ACP100-250ACP125-250



PN10/16 bar pump




Motor Alignment


４３



Research and development

Impeller development



Research and development

Latest technology in simulation

Numerical simulation for high efficiency



Why choosing a ANDRITZ process pump ?

Technical & economy 27 pumps sizes with only 5 different bearing units

High efficiency based on computer-aided

development

Low life cycle costs

Open impeller with wear linings

Up to 25 bar operating pressure

Temperatures up to 200°C

New ANDRITZ Standard Mechanical Seal system

Suitability for conveying chemicals according to

industry standards

Excellent after sales service After sales service

Delivery process Shortest delivery time

Operation process Long life time cycles

Ease of maintenance due toprocess design

All pump components availablefrom our warehouse



Product homeANDRITZ GrazBusiness Area Hydraulic Machines, HMDepartment: Centrifugal Pumps

Stattegger Strasse 18A-8045 Graz, Austria

Tel.: +43 316 6902-2327FAX.: +43 316 6902-413

www.andritz.com/pumps www.stockpumps.com



Quality Management

Worldwide the same high quality standard within the ANDRITZ Group

ISO Certification

European Management staff at the China workshop

Fabrication according to the applicable DIN standards and as per drawings provided by ANDRITZ Graz

Material inspection certificate

Dimensional inspection incl. report of each part by CMM machines

Hydraulic test on a selected number of units

Quality Standard

４４

2 Innovative and smart products – ANDRITZ MC-pump series

Content

Introduction

Development

Advantages

Cross section

Functions & Features of the components

Capacity Ranges

Reference Projects

ANDRITZ MC pump series

Innovative and smart products

ANDRITZ Energy Saving Medium Consistency Pump–MC Series


Only one shaft

A minimum of instrumentation

No vacuum pump in most applications

No pressure difference control needed

Simple programming of the control logics

Very simple operation control

Efficiency over 70% Consistency 0-14% Flow from 0-750 l/s Head from 30-190m

Direct mounting of the control valve to the pressure flange

SMARTSEP

Sufficient degassing for all stages in a pulp mill No fiber loss in any

operating situation

UNIVERSAL Reduced number of

components

Only one mechanical seal

Flushing water prevents long-term plugging

Easy to maintain

Service friendly

SIMPLE RELIABLE

AdvantagesANDRITZ MC pump series


Main Components / Standpipe

Dilution water connection

Level measurementmounting position

Compensator (optional)

Control box (optional)

Bearing unit

Content Menu

Volute with horizontal (left/right)and vertical pressure pipe

Base frame

Stand pipe (Cone design)



The ANDRITZ MC-pump series, a already well proved pumping system used in pulp mills all over the world, is now equipped withthe patented air separator system SMARTSEP, making the usage of the ANDRITZ MC-pump even more…

UNIVERSAL

SIMPLE

RELIABLE

… JUST EASY!

IntroductionANDRITZ MC pump series


Cross section

Fluidizer Suction pipe / Front liner

Volute

Degassing line

Degassing Valve

Bearing housing ShaftImpeller

SMARTSEP


４５


Function & features of the components

Due to hydraulically optimized fluidizerno vacuum-pump is needed!

Fluidizer / Suction pipe

fluidizes the pulp (non-Newtonian fluid) roughly separates air from pulp creates sufficient pre pressure feeds the pump with pulp

optimized shape improves the degassing



A very remarkable feature is the possibility of choosing between either horizontal or vertical delivery. Very good chemical mixing is another attractive possibility.

Chemicals feed

Design Features

Content Menu




SMARTSEP Separator system:

A special designed apparatus

Unique development MC-applications

A revolution for the control:

Fixed in-line with impeller and fluidizer Controls the air/fiber flow No resistance for air to flow out No fiber loss in any operating situation Operated by a very simple on/off logic Open to run with/without vacuum pump

MC-Test loop with MC250-600, driven by a 1,2 MW double drive motor




600

700

800

900

1000

1100

1200

1300

1400

1500

1600

1700

1800

1900

2000

2100

2200

2300

2400

0 90 180 270 360 450 540 630 720 810 900 990 1080 1170 1260 1350 1440 1530

Q [m³/h]

Pres

sure

deg

assi

ng li

ne [m

Bar

]

Pressure in the degassing line indicates the amount of fibre loss

Without „Smartsep“

With „Smartsep“

Ambient pressure

For normal MC-pump design, the control of the pump (degassing system) was difficult especially for low Production (low flow and low consistency fiber loss / plugging of degassing)

With the SMARTSEP system, no control of the degassing (PDIC) is needed! Pump is running – deg. valve is opened 100% Pump stops – valve closes to 0%

MC 200-550, 10% consistency, longfibre sulfat pulp, 1400rpm

SMARTSEP Separator system




Impeller / Degassing:

Impeller pumps pulp into the pressure pipe while the air/gas is forwarded through the degassing holes to the back of the impeller

New SMARTSEP separator impeller prevents fiber loss

Separator and degassing chamber are flushed with water to prevent long-term plugging

Air/Gas is discharged through degassing line, water separator, …




Without separator it was crucial to find a balance between pressure created by the fluidizer (high pressure high , but high fibre loss) and stability of the pump (low pressure low , but also low fibre loss)

Due to SMARTSEP this compromise is not needed anymore high and no fibre loss

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

0,8

0,9

1,0

0 90 180 270 360 450 540 630 720 810 900 990 1080 1170 1260 1350 1440 1530

Q [m³/h]

effic

ienc

y

0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425

Q [l/s]

Without SMARTSEP

With SMARTSEP




４６



SMARTSEP lets the gas/air pass through the degassing system Air content [%]

0,0

0,2

0,4

0,6

0,8

1,0

0 90 180 270 360 450 540 630 720 810 900 990 1080 1170 1260 1350 1440 1530

Q [m³/h]

Air

cont

ent [

%]

sheet-title: AIR Content

Without SMARTSEP

With SMARTSEP






SMARTSEP made higher heads at a given pull out diameter possible! DELIVERY HEAD [m]

0

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

0 90 180 270 360 450 540 630 720 810 900 990 1080 1170 1260 1350 1440 1530 1620

Q [m³/h]

Del

iver

y H

ead

[m]

0 25 50 75 100 125 150 175 200 225 250 275 300 325 350 375 400 425 450

Q [l/s]

sheet-title: Head + Temp

Without SMARTSEP

With SMARTSEP

MC 200-550, 10% consistency, longfibre sulfat pulp, 1400rpm, pull out diameter 550mm




In most applications, no need for a vacuum pump

Direct mounting of control valve to the pressure flange possible

Possibility of feeding chemicals (pH 0-14)

4-feet volute casing

Service friendly due to separate fluidizer, impeller and separator

Free selectable degassing line orientation

Water separator optional

Air/Gas out

Pulp in

Degassed pulp


Additional features:



Capacity RangesANDRITZ MC pump series


Material CombinationsANDRITZ MC pump series



No pressure measurement needed

Minimum number of flowmeters

Reduced water consumption

Simple control of the pump

Flow sheet With SMARTSEP technology:


４７


Reference projectsmill type installed started no. of

pumpspulptype

unbleached U bleached B

vacuum pump

cons. [%] Position

Boise Paper, Wallula, USA 80-350 2011 July 2011 1 NSSC No 12 Screw Press

Rigesa Brasil 80-350 2011 2012 1 Yes 12 HD-Tower feed

SAPPI Kirkniemi 80-350100-330 2011 Dec. 2011 3 GW+RMP B No 10

Montes del Plata 200-550 250-600 2012 2012 11 HW U/B 4 x Yes

7 x No 9-12 Whole fibre line 4000 t/d

JK Paper 100-330 125-450 2012 2012 10 HW U 5 x Yes

5 x No 9-12 Bleaching line

Stora Enso Narew Ostroleka

125-450150-470 2012 2012 4 Recycled

LF/SF No 10-12 Screw Press / Disc Filter

SCA Ortmann Waterwalk 100-330 2012 2012 1 Recycled Yes 8-10 Twin wire press

Moorim Paper 100-330 2012 2012 3 U/B 2x Yes1x No 10-11 Bleaching Line

IP Svetogorsk 100-330 2012 2012 2 SW Sulphate Yes 8-14

Schoenfelder DIP 100-330 2012 2012 2 Waste paper No 8-12 With Andritz steam feeding system

CMPC Maule Chile 80-350150-470 2012 2012 2 CTMP B No

No 10 Storage towerDisc Filter

Klabin Monto Alegre, Brasil 125-450 2012 2012 1 CTMP B No 11-13 DHT stage tower



Reference projectsmill type installed started no. of

pumpspulptype

unbleached U bleached B

vacuum pump

cons. [%] Position

Zellstoff Pöls, Austria 150-470150-470

Sep 2007Oct 2008

Sep 2007Oct 2008 2 95% SW U No

No 7-11.5 Feed to wash pressO2 booster pump

Tiger Paper, Huaihua, China 150-470 Jul 2007 July 2008 9 70% SW U/B 3 x No

6 x Yes 10-12 3 with high suct. head (no vacuum p.)6 with low suct. head (w. Vacc. Pump)

VCP Jacarei Mill, Brazil 150-470 Jul 2007 Aug 2008 1 100% HW U No 10-16 To storage tower

Syktyvkar, Russia 80-350 Dec 2009 April 2010 2 CTMP U/B No 9-12 Storage tower feedReactor feed

Syktyvkar, Russia 150-470125-450 Dec 2009 Feb 2010

(2pcs) 10 SW/HW U/B NoNo 9-12 Whole fibre line

Propapier, Gemany 125-450 150-470 Aug 2009 Feb 2010 1

1 Recycled U NoNo 10-12 From disc filter to storage tower

To reactor

Nantong, China 150-470 Oct 2009 June 2010 1 60%SW40%HW U No 9-11 Feed to DD-washer

UPM Fray Bentos, Uruguay 250-600 Oct. 2010 Nov. 2010 1 HW (Euc.) U No 11-13 Storage tower feed, equipped with new separator technology

Fajar Indonesia 150-470 Aug 2010 Nov 2010 1 HW (Euc.) B No 8-12 Storage tower feed, Refiner stage

Pulpaca, Venezuela 125-450 Nov 2010 2012 6 TMP U/B No 8-12 Whole mill

Twin Rivers Paper, Canada 125-450 2011 Aug. 2011 2 Recycled U/B Yes 9-13 HD feed / Wash press discharge

Shoguang Meilun 150-470 2011 2011 1 OCC No 10

Billerud Skärblacka 100-300 2011 Aug. 2011 1 Kraft No 12 After Disc Filter



Application:

Medium: softwood Kraft, unbleachedConsistency: 10-12%Production: 1400 ADmt/d + 10% safety marginFlow: 530 m³/h at 10%

442 m³/h at 12%Head: ~80mTemperature: 85-92°CPosition: O2 stage reactor feed pump

Since 10.2008 smooth run without ANY problem“Customer is very pleased”

Zellstoff Pöls, Austria

Reference projectsANDRITZ MC pump series


Application:

Medium: softwood~55% chinese red pine, ~15% fir, ~15%alder, 15%eucalyptus

Consistency: 10 to 12%Production: 1500 ADmt/dFlow: 135 to 190 l/sHead: 65 to 140mTemperature: 60 to 85°CPosition: 9 pcs in the whole fiber line

Started up in 07.2008, the Pumps are running smoothly;In 2012, they buy 1 more MC-pumps for a rebuild projects

Tiger Paper, Huaihua, China



Application:

Medium: softwood Kraft pulp, unbleached (70% spruce, 25%pine, 5% larch)

Consistency: 7- 8%, up to 10-12% Production: 1400 ADmt/d + 10% safety marginFlow: 832 m³/h at 7% ; 583 m³/h at 10%Head: 70-75mTemperature: 85-92°CPosition: Wash press feed pump

Since 09.2007 smooth run without ANY problemVacuum pump free run tested for 7 to 11,5% consistencyNo fibre loss through degassing line, easy handling“We forgot, that we installed a new pump!”

Zellstoff Pöls, Austria



Application:

Medium: hardwood, sulfate(100% eucalyptus)

Consistency: ~11%Production: 1350 BDmt/dFlow: ~142 l/sHead: ~90mTemperature: ~80°CPosition: storage tower

Started up in 07.2008No vacuum pump needed, stable run up to 16%!Pump is running according to contract values

Summary:

VCP Jacarei mill, Brazil


４８


VCP Jacarei mill, Brazil - Reference from customer:

CorrenteEl彋rica1038 VelocidadeBomba1038 Produ誽oEst墔 io繁 idoLFB Corrente Nominal Bba 1038

4-20-42-1038-I C. MV

A4-20-42-SI-14462.MV

rpm4-20-42-F I-15708D.MV

Adt /dNOMINAL. Value

Plot-0

11/ 7/ 2008 15:48: 00,516 9/9/2008 15: 48:00,51660,00 day s

100

200

300

400

0

510

0

3000

0

1500

0

510

344

1194

1365

266

POINT A

Kvaerner Pump

POINT B

Andritz Pump

Start-up




• MPC 25/15 Kvaerner MC pump with internal vacuum pump in operation since 1995.• The nominal capacity for this MC was 792 adt/d, but the actual production of the

fiber line B is 1250adt/d, in others words, the pump was running with over load.• The Frequency Converter was working with 95Hz (nominal = 60Hz), and the Motor was

running with 2834 rpm (nominal = 1800 rpm).• With that there were several problems with the Pump and Motor, and consequentlyproduction losses.

Previous Situation

• Replaced the old MPC 25/15 Kvaerner for the New ANDRITZ MC Pump (MC150-470) without vacuum pump, internal neither external, with capacity up to 1500 adt/d.

• We are using the same Electric Motor and the same Frequency Converter in 60Hz.• We also have got the following spare parts: Bearing Unit, Impeller + Fluidizer and Mechanical Seal.

Actual Situation



VCP Jacarei mill, Brazil - Reference from customer:POWER CONSUMPTION

Energy Economy: R$ 99.692,35 / yearEnergy Costs: R$ 145,00 MWh (april/2009)

Premissa: Tensão de alimentação 440V – Fator de potência do motor: 0,85 - Fórmula: √3 x 440V x Corrente (A) x cos (0,85)

Kvaerner pump

• Current in average (8 hours): 437,33 A

• Production in average: 1205,24 adt/d

• Power Consumption: 158.375,5 kWh / m

• Energy Costs: R$ 275.573,32 / y

ANDRITZ MC pump

• Current in average (8 hours): 279,12 A

• Production in average: 1193,25 adt/d

• Power Consumption: 101.081 kWh / m

• Energy Costs: R$ 175.880,97 / y

BLUE – Motor Current (A)WHITE– Production rate (Adt/d)

BLUE – Motor Current (A)WHITE– Production rate (Adt/d)



VCP Jacarei mill, Brazil - Reference from customer:EQUIPMENTS DATA COMPARATION

Kvaerner MC New ANDRITZ MC

Speed: 2834 rpm 1500 rpm (47% reduction)(Nominal: 1800 rpm)

FC Current: 474 A 290 A (39% reduction)(Nominal of the Motor: 344 A)

Frequency Converter: 95 Hz 50 Hz (47% reduction)

Production Rate (FLB): 1250 Adt/d 1250 Adt/d

By Luiz Augusto RodriguesSenior Maintenance [email protected]í, 23/04/2009

Integration into ANDRITZ sheets byStefan Hödl, Engineering MC [email protected], 07/12/2010





4-20-42-1038-I C. MV

A4-20-42-SI-14462.MV

rpm4-20-42-F I-15708D.MV

Adt /dNOMINAL. Va lue

Plot-0

4/9/2008 15:45:14, 469 9/9 /2008 15: 45:14,4695,00 day s

100

200

300

400

0

510

0

3000

0

1500

0

510

344

1194

1392

283


4-20-42-1038-I C. MV

A4-20-42-SI-14462.MV

rpm4-20-42-F I-15708D.MV

Adt /dNOMINAL. Va lue

Plot-0

21/ 6/ 2008 15:46: 04,915 26/6/2008 15:46: 04,9155,00 day s

100

200

300

400

0

510

0

3000

0

1500

0

510

344

1235

2650

323

POINT A – Kvaerner pump POINT B – ANDRITZ MC pump

BLUE – Motor Current (A)RED – Pump speed (rpm)YELLOW – Production rate (Adt/d)WHITE – Nominal Motor Current (A)



Capacity upgrade UPM pulp mill, Fray Bentos, UruguayApplication:

Medium: hardwood Kraft, unbleached(100% Eucalyptus)

Consistency: 10-12%, up to 13%, Production: increased to 4000 ADt/dFlow: 400 l/s at 10%

320 l/s at 13%Head: 100mPosition: after screening & 2 DD washers,

feeding into unbleached storage towerRemarks: sulphuric acid feed (pH 2-4)


４９


Questions?

Thanks for your attention !

For further information please contact:[email protected]@andritz.com

Questions?ANDRITZ MC pump series


UPM wanted to increase the production to 4000 ADt/d Existing Sulzer MC pump at Screening had to be replaced

Sulzer offered a bigger MC-pump to UPM But asked UPM to buy a bigger motor for their pump

Andritz offered a MC-pump fulfilling the requirements with the existing 800kW motor

UPM decided to use Andritz MC-pump, start-up in November 2010

Pump is running without problems, but full production not reached yet (problems with screening)

No fiber loss during the whole start up

Less motor power is used, the control valve opening is reduced to 55%

Capacity upgrade UPM pulp mill, Fray Bentos, Uruguay


Andritz energy saving pump ACP (single stage centrifugal ...

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