ECOPUMP TURBO SYSTEM

- THE ADVANTAGES AND PRINCIPLES OF INSTALLING AND USING

SPEED CONTROLLED VACUUM SYSTEM

Paper machine 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

During years of optimizing

existing paper machine vac-

uum systems, and conduct-

ing dewatering trials utilizing

Ecoflow dewatering measure-

ments, it became obvious that

there is a need for a VACU-

UM SYSTEM WITH ADJUST-

ABLE SPEED CONTROL. There

2. ECOPUMP TURBO VACUUM SYSTEM FOR A PAPER, BOARD OR PULP MACHINE

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.

is a great potential for power

savings by eliminating excess

capacity due to over dimen-

sioning – the systems are of-

ten over dimensioned due to

uncertainties concerning new

machine concept or when re-

serving capacity for eventual

speed increase. There are also

Other important features are:

water savings, savings in foun-

dation work due to compact

size and low weight, savings

directly in maintenance work

and parts as well as indirectly

in saving maintenance shut-

down time.

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 de-

veloped to realize the great saving potential in paper produc-

tion process:

• 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 controlla-

bility were available on the market, Ecopump started to develop

its own system. The development was done in close coop-

eration 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.

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

• 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.

4

Ecopump turbo is based on

a combination of modern

high-speed electric drive and

high efficiency turbo blower.

The unit is driven with a fre-

quency converter, which ena-

bles the speed control from

zero to maximum without

any limitations in operation

range. Even marginal sav-

ings 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 di-

rectly mounted on the mo-

tor shaft, which makes the

Picture 1: Ecopump Turbo. The electric drive is included in the scope.

2.1. PRINCIPLE OF THE ECOPUMP TURBO

system very compact and me-

chanically reliable. No gear-

box or couplings are needed.

The solid shaft AC motor is

robust and has no resonance

frequencies within the oper-

ating range. Cast titanium im-

pellers are mechanically and

chemically very stable.

Oil lubricated ceramic ball

bearings and lightweight parts

make the system easy to han-

dle from maintenance point

of view. Scheduled mainte-

nance (bearing change) can

be done on minimum during

an 8-12 hours shutdown.

5

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

• The rising cost of power means it is not economical

just to simply bleed off the extra capacity

2.2. CHALLENGES IN PRODUCING VACUUM FOR PAPER MACHINE

• 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.

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

e) Heavy investment on building and foundation;

heavy construction with low frequencies.

2.3. LIMITATIONS OF TRADITIONAL VACUUM SYSTEMS

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 foundation; heavy units,

which are critical for vibration.

6

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.

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

2.4. DIFFERENT PRACTISES AND TRADITIONS OF VACUUM USAGE

A typical distribution of specific consumption is shown in the

graphic below.

2) Grammage: heavier grammage requires less power

per ton than lower grammage.

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

Production kWh/t

• specific

consumption

kWh/t

Spec

ific

ener

gy

con

sum

pti

on

kW

h/t

200

180

160

140

120

100

80

60

40

20

0

0 10 20 30 40 50

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 some-

times are based on facts, which do not exist anymore.

By systematic optimization with dewatering measurement

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 economi-

cal 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 transfer-

red to the air. The temperature reaches up to 160 °C,

which offers good potential to use it in different stages of

production.

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 dif-

ferent running philosophy.

0 1 2 3 4 5 6 7 8 9 10

Picture 3: Ecopump Turbo flow/vacuum range

Vac

uu

m (

kPa)

80

70

60

50

40

30

20

10

0

Vacuum Levels and Flow Rates

Air flow under vacuum (m³/s)

8

Principles in designing a vacuum system

Ecopump vacuum systems are the result of practical experi-

ence 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, es-

pecially 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 ea-

sily 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 controll-

ability – 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.

Picture 7: The functional scheme of the system

PI

FI

PI

DCS

M M

Cooling air

Blower outlet

Turboblower

Powersupply

Vacuumbreakervalve

Dropseparator

Suctionposition

Discharge toseal pit tank or pump

Frequencyconvertor

SCOPE OF DELIVERY

Lubrication unit

11

4. MAIN BENEFITS OF ECOPUMP TURBO IN PAPER MACHINE INSTALLATIONS

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 evaluat-

ing the operation.

kW

Turbo information and energy savings

AFTER

BEFORE

The main benefit of choosing Ecopump Turbo system is power saving. But there are also other quite significant reasons to go

for Ecopump technology.

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 multi-

stage 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 consump-

tion was a bit high, despite

the system principle (in gen-

eral, turbo principle is power

efficient).

Optimizing the system, and

implementing a new config-

uration 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 vulner-

able. The multi-stage blower

can be replaced with the oth-

er, 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

4.5. REDUCING SHUTDOWN TIME IN REBUILDS

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 con-

struction 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 neces-

sary.

Relatively low weight reduc-

es 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

Picture 10. Ecopump Turbo can be installed during normal production without a long shutdown

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.

4.4. SAVING IN BUILDING COST

vacuum system can often be

installed before dismount-

ing 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. Dis-

mounting the one and build-

ing 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.

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. Eco-

pump 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

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

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 Hybrid ball

Lubrication 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

EP-500-S

EP-500-D1

17

6. REFERENCE LIST

Arjo Wiggins SAS, Annonay PM7, France, 1 Turbo blower

• Drawingpaper

Cartiere del Polesine, S.p.A., Italy, 7 Turbo blowers

• Testliner

Daehan Paper, Cheongju PM 1, South Korea, 2 Turbo blow-

ers

• Copy/News

Daehan Pulp, Cheongju PM 3, South Korea, 1 Turbo blowers

• Board

Georgia Pacific, Cuijk, Netherlands, 2 Turbo blowers

• Tissueconvertingprocess

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

• Testliner

International Paper, Papeteries Etienne, France, 1 Turbo blower

• Fluting

International Paper, Kenitra Mill, Marocco, 1 Turbo blower

• Testliner

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, Kangas PM 2, Finland, 1 Turbo blower

• Finepaper

M-real, Kirkniemi PM 1, Finland, 1 Turbo blower

• LWC

M-real, Kyro BM 1, Finland, 1 Turbo blower

• Board

M-real, Kyro PM 1, Finland, 1 Turbo blower

• Wallpaperbase

M-real, Lielahti, Finland, 1 Turbo blower

• Pulpmachine

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

• Kraftlinerandsack

Papeteries de Clairefontaine, France, 2 Turbo blowers

• Finecopypaper

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

• Bookpaper

Stora Enso, Enocell PM 2, Finland, 1 Turbo blower

• Pulpmachine

Stora Enso, Kaukopää PM 8, Finland, 1 Turbo blower

• Finepaper

Stora Enso, Kotka PM 1, Finland, 5 Turbo blowers

• Laminatingbasepaper

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

• Pulpmachine

UPM-Kymmene, Rauma PM 4, Finland, 3 Turbo blowers

• Lwc

UPM-Kymmene, Chapelle PM 3, France, 3 Turbo blowers

• News

19

Runtech Systems OyKastarintie 27

FI-35990 KOLHOFINLAND

Tel: +358 3 471 1000

www.runtech.firuntech@runtech.fi

More profitability - Less energy

RunEco™

Minimized energy and water consumption in your process.

Maximized dewatering, fiber and filler economy.

• EcoPump™

• EcoFlow™

• EcoSep™