Andritz energy saving pump ACP (single stage centrifugal pump

Transcription

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
Centrifugal Pumps – “ACP-Series ”
Field of application
 Tried and tested:
 In the pulp and paper industry
 Chemical pulp
 Mechanical pulp
 Recycled fibres
 Caustic lye
 Fibrous sludge
 White water
 In sewage water treatment
 Flue gas desulphurization
 Chemical industry
 The food industry
Andritz Energy Saving Centrifugal Pump
–ACP Series
 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
Presentation
Andritz China _ Pump division
4
Field of application
 Our supply programme for centrifugal pumps covers 62 different sizes
Successfully used all over the world
Characteristic Curves 1500rpm and 1000rpm
Characteristic Curves 3000rpm
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.
The small flow area are covered by ACP-ISO types, with semi-open or closed impellers
2
5
Content
Design and function of the process pump
 Assembly Sketch
 Field of application
 Impeller
 Design and function of the pump
 Sealing system
 Research and Development
 Bearing unit
 Quality Management
 Material combination
 Why choosing a ANDRITZ
ACP-Pump?
 Centreline pump
ACP400-700 ready to ship for APP (Indonesia)
3
6
４０
Assembly Sketch
Front Liner
 Section Drawings
Casing Cover
 Rigid design
PN25 design
 All bores on bearing housing
are machined from one side,
perfect accuracy.
Different sealing types,
same casing cover
 Easy assembly and
disassembly for maintenance
work.
7
10
Design of the process pump
Sealing system
Assembly Sketch
Andritz Single Mechanical seal, 2 components
(type A1)
Andritz Double Mechanical seal, 2 components
(type A2)
Pull out unit
 Removable of Pull out Unit
Easy dismantling without
moving pipes and motors
Andritz Cartridge Single Mechanical seal,
(type B1)
Andritz Cartridge Double Mechanical seal,
(type B2)
Standard Sealing System
For ACP pumps
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;
8
11
Sealing system
Impeller
 Semi open impeller or
Stuffing Box Packing
Dynamic Seal
(In developing)
 Fully open Impeller for
non-clog application
 Special Spline connection with shaft,
easy to dismantle
Except Dynamic seal, All seal types use same casing cover, minimize the spare parts
variety and Easy to change among different seals
9
12
４１
ACP65-315
ACP100-315
ACP100-250
ACP125-250
PN25 bar pump, with Centreline design
Bearing unit
 Temperature up to 200°C
 Only 5 bearing units for 27 pump sizes
 Pressure up to 25 bar or higher
 Compact, rigid design
 Oil or grease lubrication
 Sand blasting / prime coating (Epoxy paint)
Standard base frame
 Bearings type (SKF Explorer C3)
13
16
Special centreline support
PN25 bar pump, with Centreline design
Material combination
Material combinations
Designation
ENG JL
250
Except
ACP65-315
ACP100-315
ACP100-250
ACP125-250
1.4460
1.4408
1.4517
1.4588
 Temperature up to 200°C
1.4404
1.4462
C-Steel
 Pressure up to 25 bar or higher
Volute casing
Casing cover
Impeller
Front liner
Bearing house
Shaft
Base frame
Standard base frame
14
PN10/16 bar pump
15
Special centreline support
17
Motor Alignment
18
４２
Research and development
Why choosing a ANDRITZ process pump ?
Latest technology in simulation
 Delivery process
 Technical & economy
 27 pumps sizes with only 5 different bearing units
Numerical simulation for high efficiency
 Operation process
development
 Long life time cycles
 Low life cycle costs
 Open impeller with wear linings
 After sales service
 Up to 25 bar operating pressure
 Excellent after sales service
 Temperatures up to 200°C
 New ANDRITZ Standard Mechanical Seal system
 Suitability for conveying chemicals according to
industry standards
19
 Shortest delivery time
 High efficiency based on computer-aided
22
 Ease of maintenance due to
process design
 All pump components available
from our warehouse
Research and development
Impeller development
Product home
ANDRITZ Graz
Business Area Hydraulic Machines, HM
Department: Centrifugal Pumps
Stattegger Strasse 18
A-8045 Graz, Austria
Tel.: +43 316 6902-2327
FAX.: +43 316 6902-413
www.andritz.com/pumps
www.stockpumps.com
20
23
Quality Management
Quality Standard
 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
21
４３
ANDRITZ MC pump series
Advantages
UNIVERSAL




SIMPLE
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
ANDRITZ Energy Saving Medium Consistency Pump
–MC Series
 Sufficient degassing
for all stages in a
pulp mill
 No fiber loss in any
operating situation
Innovative and smart products
4
RELIABLE
 Only one shaft
 Reduced number of
components
 A minimum of
instrumentation
 Only one
mechanical seal
 No vacuum pump in
most applications
 Flushing water
prevents long-term
plugging
 No pressure difference
control needed
 Easy to maintain
 Simple programming
of the control logics
 Service friendly
 Very simple operation
control
Innovative and smart products – ANDRITZ MC-pump series
Main Components / Standpipe
Content
Compensator (optional)
Control box (optional)
 Introduction
Stand pipe (Cone design)
 Development
Bearing unit
 Advantages
Dilution water connection
 Cross section
Level measurement
mounting position
 Functions & Features of the components
 Capacity Ranges
 Reference Projects
Base frame
2
5
Content
Menu
Volute with horizontal (left/right)
and vertical pressure pipe
Cross section
Introduction
Volute
The ANDRITZ MC-pump series, a already well proved pumping
system used in pulp mills all over the world, is now equipped with
the patented air separator system SMARTSEP, making the usage of the
ANDRITZ MC-pump even more…
Impeller
Bearing housing
Shaft
 UNIVERSAL
SMARTSEP
 SIMPLE
 RELIABLE
Degassing Valve
… JUST EASY!
Fluidizer
3
6
４４
Suction pipe / Front liner
Degassing line
Function & features of the components
Design Features
 A very remarkable feature is the possibility of choosing between either horizontal or vertical
delivery.
 Very good chemical mixing is another attractive possibility.
SMARTSEP Separator system:
A special designed apparatus
Unique development MC-applications
Chemicals feed
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






7
Content
Menu
10
MC-Test loop with MC250-600, driven by a
1,2 MW double drive motor
SMARTSEP Separator system
Fluidizer / Suction pipe
 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)
 fluidizes the pulp (non-Newtonian fluid)
 roughly separates air from pulp
 creates sufficient pre pressure
 feeds the pump with pulp
 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%
2400
 optimized shape improves the degassing
2300
Pressure in the degassing line
indicates the amount of fibre loss
2200
2100
Pressure degassing line [mBar]
2000
Due to hydraulically
optimized fluidizer
no vacuum-pump is needed!
1900
1800
Without
„Smartsep“
1700
1600
1500
1400
With
„Smartsep“
1300
1200
1100
1000
900
800
700
600
0
8
11
90
180
270
360
450
540
630
720
Ambient
pressure
810
900
990
Q [m³/h]
1080
1170
1260
1350
1440
1530
MC 200-550, 10% consistency, longfibre sulfat pulp, 1400rpm
Impeller / Degassing:
 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
 Impeller pumps pulp into the pressure pipe
while the air/gas is forwarded through the
degassing holes to the back of the impeller
0
25
50
75
100
125
150
175
200
225
250
275
300
325
350
375
1,0
 New SMARTSEP separator impeller prevents
fiber loss
400
425
Q [l/s]
With SMARTSEP
0,9
0,8
0,7
 Separator and degassing chamber are flushed
with water to prevent long-term plugging
efficiency
0,6
 Air/Gas is discharged through degassing line,
water separator, …
0,5
Without SMARTSEP
0,4
0,3
0,2
0,1
Q [m³/h]
0,0
0
90
180
270
360
450
540
630
720
810
900
990
1080
1170
1260
9
12
４５
1350
1440
1530
Additional features:
 SMARTSEP made higher heads at a given pull out diameter possible!
sheet-title: Head + Temp
0
25
 In most applications, no need for a vacuum
pump
DELIVERY HEAD [m]
50
75
100
125
150
175
200
225
250
275
300
325
350
375
400
425
200
450
Q [l/s]
190
Degassed
pulp
 Direct mounting of control valve to the
pressure flange possible
180
170
160
150
Delivery Head [m]
140
 Possibility of feeding chemicals (pH 0-14)
With SMARTSEP
130
120
 4-feet volute casing
110
100
Air/Gas
out
90
 Service friendly due to separate fluidizer,
impeller and separator
80
70
60
50
Without SMARTSEP
40
 Free selectable degassing line orientation
30
20
10
Q [m³/h]
0
0
90
180
270
360
13
450
540
630
720
810
900
990
1080
1170
1260
1350
1440
1530
 Water separator optional
1620
MC 200-550, 10% consistency, longfibre sulfat pulp, 1400rpm, pull out diameter 550mm
16
Capacity Ranges
 SMARTSEP lets the gas/air pass through the degassing system
sheet-title: AIR Content
Air content [%]
1,0
Air content [%]
0,8
Without SMARTSEP
0,6
0,4
With SMARTSEP
0,2
Q [m³/h]
0,0
0
90
180
270
360
450
540
630
720
810
900
990
1080
1170
1260
1350
1440
1530
14
17
Material Combinations
Flow sheet With SMARTSEP technology:
 No pressure measurement needed
 Minimum number of flowmeters
 Reduced water consumption
 Simple control of the pump
15
18
４６
Pulp in
Reference projects
Reference projects
mill
type
installed
started
no. of
pumps
pulp
type
unbleached U
bleached B
vacuum
pump
cons.
[%]
Zellstoff Pöls, Austria
150-470
150-470
Sep 2007
Oct 2008
Sep 2007
Oct 2008
2
95% SW
U
No
No
7-11.5
Feed to wash press
O2 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 feed
Reactor feed
Syktyvkar, Russia
150-470
125-450
Dec 2009
Feb 2010
(2pcs)
10
SW/HW
U/B
No
No
9-12
Whole fibre line
Propapier, Gemany
125-450
150-470
Aug 2009
Feb 2010
1
1
Recycled
U
No
No
10-12
From disc filter to storage tower
To reactor
Nantong, China
150-470
Oct 2009
June 2010
1
60%SW
40%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
19
Position
Application:
Medium:
Consistency:
Production:
Flow:
Head:
Temperature:
Position:
Since 10.2008 smooth run without ANY problem
“Customer is very pleased”
After Disc Filter
22
pulp
type
July 2011
1
NSSC
2012
1
2011
Dec. 2011
3
GW+RMP
200-550
250-600
2012
2012
11
HW
100-330
125-450
2012
2012
10
HW
installed
started
Boise Paper, Wallula, USA
80-350
2011
Rigesa Brasil
80-350
2011
SAPPI Kirkniemi
80-350
100-330
Montes del Plata
JK Paper
Stora Enso Narew
Ostroleka
Reference projects
no. of
pumps
type
125-450
150-470
4
Recycled
LF/SF
SCA Ortmann Waterwalk
100-330
2012
2012
1
Recycled
Moorim Paper
100-330
2012
2012
3
2012
2012
Reference projects
mill
softwood Kraft, unbleached
10-12%
1400 ADmt/d + 10% safety margin
530 m³/h at 10%
442 m³/h at 12%
~80m
85-92°C
O2 stage reactor feed pump
unbleached U
bleached B
B
U/B
vacuum
pump
cons.
[%]
No
12
Screw Press
Yes
12
HD-Tower feed
No
10
4 x Yes
7 x No
9-12
Whole fibre line 4000 t/d
U
5 x Yes
5 x No
9-12
Bleaching line
10-12
Screw Press / Disc Filter
Yes
8-10
Twin wire press
U/B
2x Yes
1x No
10-11
Bleaching Line
No
Tiger Paper, Huaihua, China
Position
IP Svetogorsk
100-330
2012
2012
2
SW
Sulphate
Yes
8-14
Schoenfelder DIP
100-330
2012
2012
2
Waste
paper
No
8-12
CMPC Maule Chile
80-350
150-470
2012
2012
2
CTMP
B
No
No
10
Storage tower
Disc Filter
Klabin Monto Alegre,
Brasil
125-450
2012
2012
1
CTMP
B
No
11-13
DHT stage tower
Application:
Medium:
Consistency:
Production:
Flow:
Head:
Temperature:
Position:
With Andritz steam feeding system
softwood
~55% chinese red pine,
~15% fir, ~15%alder, 15%eucalyptus
10 to 12%
1500 ADmt/d
135 to 190 l/s
65 to 140m
60 to 85°C
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
20
23
Reference projects
Reference projects
VCP Jacarei mill, Brazil
Application:
Medium:
Consistency:
Production:
Flow:
Head:
Temperature:
Position:
Application:
Medium:
softwood Kraft pulp, unbleached
(70% spruce, 25%pine, 5% larch)
7- 8%, up to 10-12%
1400 ADmt/d + 10% safety margin
832 m³/h at 7% ; 583 m³/h at 10%
70-75m
85-92°C
Wash press feed pump
Summary:
Consistency:
Production:
Flow:
Head:
Temperature:
Position:
hardwood, sulfate
(100% eucalyptus)
~11%
1350 BDmt/d
~142 l/s
~90m
~80°C
storage tower
Since 09.2007 smooth run without ANY problem
Started up in 07.2008
Vacuum pump free run tested for 7 to 11,5% consistency
No vacuum pump needed, stable run up to 16%!
No fibre loss through degassing line, easy handling
Pump is running according to contract values
“We forgot, that we installed a new pump!”
21
24
４７
Reference projects
Reference projects
VCP Jacarei mill, Brazil - Reference from customer:
POWER CONSUMPTION
• 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 consequently
production losses.
Previous
Situation
BLUE – Motor Current (A)
WHITE– Production rate (Adt/d)
• 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
WHITE– Production rate (Adt/d)
Kvaerner pump
ANDRITZ MC pump
• Current in average (8 hours): 437,33 A
• Current in average (8 hours): 279,12 A
• Production in average: 1205,24 adt/d
• Production in average: 1193,25 adt/d
• Power Consumption: 158.375,5 kWh / m
• Power Consumption: 101.081 kWh / m
• Energy Costs: R$ 175.880,97 / y
• Energy Costs: R$ 275.573,32 / y
Energy Economy: R$ 99.692,35 / year
Energy 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)
25
28
Reference projects
Reference projects
Plot-0
Kvaerner Pump
510 3000 1500 510
Andritz Pump
EQUIPMENTS DATA COMPARATION
4-20-42 -1038 -I C. MV
266
Kvaerner MC
New ANDRITZ MC
Speed:
2834 rpm
1500 rpm
(47% reduction)
FC Current:
474 A
290 A
(39% reduction)
Frequency Converter:
95 Hz
50 Hz
(47% reduction)
Production Rate (FLB):
1250 Adt/d
1250 Adt/d
A
4-20-42-SI-14462.MV
1365
rpm
400
4-20-42-F I-15708D.MV
1194
(Nominal: 1800 rpm)
Adt /d
NOMINAL. Va lu e
344
300
(Nominal of the Motor: 344 A)
200
Startup
100
POINT A
0
0
0
By Luiz Augusto Rodrigues
Senior Maintenance Engineer
luiz.rodrigues@vcp.com.br
Jacareí, 23/04/2009
POINT B
0
11/ 7/ 2008 15:48: 00,5 16
Co rrenteEl彋rica1038
60,00 day s
VelocidadeBomba1038
26
Produ誽oEst墔io繁 idoLFB
9/9/2008 1 5: 48:00,516
Corrente Nominal Bba 1038
29
Reference projects
Capacity upgrade UPM pulp mill, Fray Bentos, Uruguay
POINT A – Kvaerner pump
Application:
Medium:
POINT B – ANDRITZ MC pump
Plot-0
4-20- 42 -1 038 -I C. MV
510 3000 1500 510
283
A
A
4-20- 42 -S I- 14 462 .MV
4-20- 42 -S I- 14 462 .MV
265 0
139 2
rp m
4-20- 42 -F I- 15 708 D.MV
rp m
400
4-20- 42 -F I- 15 708 D.MV
123 5
119 4
Adt /d
Adt /d
NOMINAL. Va lu e
NOMINAL. Va lu e
344
344
300
300
200
200
100
100
0
0
0
0
21/ 6/ 20 08 15:46: 04 ,9 15
Co rren te El彋rica1038
5,00 day s
VelocidadeBomba1038
Produ誽 oEst墔 io繁 idoLFB
26/6/2008 15:46: 04 ,9 15
Consistency:
Production:
Flow:
4-20- 42 -1 038 -I C. MV
510 3000 1500 510
323
400
0
Reference projects
Plot-0
Integration into ANDRITZ sheets by
Stefan Hödl, Engineering MC pump
Stefan.Hoedl@andritz.com
Graz, 07/12/2010
Head:
Position:
0
0
Remarks:
0
4/9/200 8 15:45:1 4, 46 9
Co rren te El彋rica1038
5,00 day s
VelocidadeBomba1038
Produ誽 oEst墔 io繁 idoLFB
9 /9 /2 008 1 5: 45:14,469
hardwood Kraft, unbleached
(100% Eucalyptus)
10-12%, up to 13%,
increased to 4000 ADt/d
400 l/s at 10%
320 l/s at 13%
100m
after screening & 2 DD washers,
feeding into unbleached storage tower
sulphuric acid feed (pH 2-4)
RED – Pump speed (rpm)
YELLOW – Production rate (Adt/d)
WHITE – Nominal Motor Current (A)
27
30
４８
Reference projects
Capacity upgrade UPM pulp mill, Fray Bentos, Uruguay
 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%
31
Questions?
Questions?
Thanks for your attention !
For further information please contact:
Ludwig.Michal@andritz.com
Stefan.Hoedl@andritz.com
32
４９

Andritz energy saving pump ACP (single stage centrifugal pump

Transcription

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