Toscotec’s technical and R&D departments continuously upgrade their technology with the aim to achieve sustainable production capacity increase; final paper quality improvement; reduction of maintenance or grade-change downtime; reduction of energy demand for the same output.
Primary water recovery system and Headbox Stock approach line
Toscotec’s deaerator unit on the primary water recovery line is designed to reduce the air entrained in the water recovered from the forming roll’s save-all water pan. Internally the deaerator is designed without any movable parts, which guarantees consistent performance and virtually maintenance-free operations. The flume, which is installed immediately after the deaerator unit, is designed to extend the effect of air removal before the water is fed back to the fan pump. The total air content measured at the fan pump suction point can be as low as 0,2%. The flume is connected to the fan pump through a stand pipe which replaces the traditional large-dimension silo.
Toscotec introduced the TT Mix unit on the stock line in order to deliver efficient hydraulic mixing of fibers with low pressure losses and entirely eliminate the installation of an intermediate mixing chest with its agitator and discharge pump. The key advantages of TT Mix include: important reduction of energy per ton (compared to previous solutions with a mixing chest – this solution saves up to 10% of the total energy required for the approach flow system); reduction of space required in the mill layout; reduction of buffer volumes on the line for easier and faster cleaning and grade and/or color changes; reduction of chemicals usage.
The design solution complete with TT Mix, TT De-aerator, TT Flume and TT Stand Pipe determines an overall 35%-40% reduction in required space if compared with previous solutions. The elimination of the mixing tank and the silo has also led to a reduction of approximately 50% in excavation activities for a single floor machine installation.
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In addition Toscotec’s complete solution for stock mixing and primary water recovery has led to an overall reduction of storage volumes in the approach system of up to 75%, which corresponds to faster and more flexible cleaning and grade-change operations. Toscotec has also recently included a Double Dilution System as a standard feature on its approach lines to the headbox. The idea underling the new double dilution system is that any contaminant that might enter the system comes from the stock preparation line. The double dilution is designed so initially the dense stock flow is only diluted to only approximately 1% consistency before passing through the pressure screen, then it is diluted to desired consistency for the fan pump and headbox. This solution reduces energy consumptions due to the reduction of the flow passing through the screen. In particular the system achieves a flow reduction of 85-90% at the screen, which leads to substantial energy savings, up to 15 kWhr/ton.