ContiRoll – Generation 8

Transcription

VIII Seminario
Latest Development for
the Wood Panel Industry
TEKNO MADERA
Conception, Chile – 15.11.2012 -
Abt. MOP (MDF), Concepcion 15.11.2012
Content
- ContiRoll Generation 8
- ECO RESINATOR
powered by Schlick
It is all about :
Pressure Distribution
Pressure Distribution Plates :
• What are they ?
• How do they work ?
• What are they good for ?
Additional Cylinder Row :
• low pressure oscillation across
• supreme thickness stability
Pressure Distribution – a History
1995 – Siempelkamp sold first ultra thin board ContiRoll
Target Thickness : less than 1,8 mm
Target Speed
: up to 1800 mm/sec.
-> Development
- of a high precision matforming
- of a high precision press gap
- safety features and press control (SPC)
1997 – first ultra thin board ContiRoll to produce
Thickness : continuously 1,5 mm
Speed
: continuously > 1600 mm/sec.
Pressure Distribution – a History
Speed
: continuously 2000 mm/sec.
1998 – 2012
Start-up of another 8 ultra thin board ContiRoll
All over the world (China / Indonesia / etc.)
Pressure Distribution Plates – How they work
Pressure Distribution Plates – How they work
ContiRoll 7 th. generation
Hot-platen field deformation
Hot-platen field deformation
≠
≠
=
=
Pressure Distribution Plates – Benefit
ContiRoll 8 th. Generation
Hot-platen
field pressure distribution
Hot-platen
field pressure distribution
Pressure Distribution – Additional Cylinder Row
Pressure Distribution – Additional Cylinder Row
Hot-platen field deformation: 0.2 mm
Hot-platen field deformation: 0.02 mm
with 830mm frame distance
with 830mm frame distance
Additional Cylinder Row - Benefit
THICKNESS Tolerance
- SPF - Ultra Thinboard Line
1,0 mm Board
Thickness [mm]
1,10
1,05
1,00
0,95
Tickness Tolerance :
+/- 0,025 mm
0,90
0,85
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Position : Left to Right
15
16
17
18
19
20
21
22
23
Supreme Pressure Distribution - length & across =
•
•
•
•
•
•
•
•
•
Your Savings Potential (Individually and/or in combination)
improved feasibility to produce thin boards
improvement of thickness tolerance
reduction of sanding or omission of sanding
improvement of internal bond
increased performance (heating time factor)
reduction of emissions (utilising E0,5 Resins)
higher productivity of your line
resin savings
wood savings
Glue-Saving
Potentials in MDF Plants
ECO RESINATOR
powered by Schlick
Glue Saving - Potentials in MDF Plants
• the 3 major cost driver in MDF making
Other Utility
costs
5%
Depreciation
0%
Labour
0%
variable costs of
MDF production
Therm al Energy
6%
Wood
31%
• Resin Cost per m³:
ca. 36 %
• Wood Cost per m³:
ca. 31 %
Electricity
20%
Resin
36%
Additives
2%
• Energy Cost per m³:
ca. 26 %
WHAT
WHERE
- causes resin losses ?
- are potential savings hidden ?
Losses in the board press :
• high pressure oscillation
Losses in blow-line blending :
• Low Velocity / turbulence in the blowline
• Resin Droplet : size and spectrum
3 major influences in Blow-Line-Blending
35
30
1. Steam Flow
higher resin coverage [%]
25
2. Spray Pressure
20
3. Flow Rate / Nozzle Position
15
10
5
0
nozzle type
emulsion
place of nozzle
production rate
changes in process
nozzle pressure
steam flow
Resin Loss Potential : BL Turbulence / Steam Flow
Low Blowline Steam Flow : Losses of 10 - 15 %
Resin Saving Potential : BL Turbulence / Steam Flow
High Blow Line Steam Flow : Saving of 10 - 15 %
Resin Saving Potential : Droplet Size / Spectrum
ECO RESINATOR :
20 - 80 µm
(Dual media injector nozzle powered by Schlick)
Standard Nozzle
(Single media injector nozzle)
:
40 - 750 µm
Blow Line Optimisation : ECORESINATOR
powered by Schlick
Blow Line Optimisation: - ECORESINATOR • Resin – Pressure
Automatic Control
and Adjustment
• Steam - Pressure
Automatic Control
and Adjustment
• Resin Mix - Viscosity
Automatic Control
and Adjustment
• Resin - Flow Rate
Automatic Control
and Adjustment
• Steam - Flow Rate
Automatic Control
and Adjustment
• Dual-Media-Injector
Automatic Control
and Adjustment
• PROD-IQ Optimising
Automatic Data sampling by Prod-IQ - Analyse of all Process Parameters
By data mining and probabilistic evaluation of the relevant influences
the system will support further optimising of Blow Line Blending
ECO RESINATOR
- System Benefits -
- shows typical resin reduction
for some board thickness
5 - 15 %
up to 20 %
- is a investment as low as about 1/10 of the Fibre Blending
- for e.g. 48 to/h plant needs less than 4 to/h of steam
- can be fitted into all existing blow line plants
- works integrated with any existing glue dosing system
- works stable and with low maintenance, no extra personal needed
- improves the overall board quality and the surface appearance
- is pre installed and tested in the Siempelkamp workshop
- is installed in the plant and ready to work within days
ECO RESINATOR
- cost saving potential -
(e.g. plant with 48 to/h fibre throughput, 7525 h production time)
• Resin :
-
(from 12,0 % down to 10,8%)
(5760 – 5184 kg/h solid)
-
(to replace resin, incl. refining energy)
(dual media injector)
+
+
(Price : 12 US$/to)
• Production Savings :
• Financing Costs :
+
(1.100.000 US$ / 10 years)
576 kg/h
495.800 US$/y
3.8 to/h
334.400 US$/y
- 1.640.500 US$/y
(resin / wood / steam)
• TOTAL COST SAVING :
+
+
(Price : 100 US$/to solid)
• Steam Energy :
576 kg/h
- 2.470.700 US$/y
(Price : 570 US$/to solid)
• Wood :
10 %
-
110.000 US$/y
1.530.500 US$/y
Siempelkamp :
we can help YOU to cut your cost
Thank you very much
for your interest

ContiRoll – Generation 8

Transcription

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