WASTE HEAT RECOVERY BY ROTAMILL INTELLIGENT ENERGY RECOVERY AND USE OF PROCESS HEAT
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1 WASTE HEAT RECOVERY BY ROTAMILL INTELLIGENT ENERGY RECOVERY AND USE OF PROCESS HEAT
2 TABLE OF CONTENTS Page WASTE HEAT RECOVERY AT HIGH TEMPERATURES 4-5 Recuperators 6 Waste heat boilers 7 COST-EFFECTIVE UTILISATION OF WASTE HEAT. PROCESS HEAT TECHNOLOGY FOR THE PAPER INDUSTRY 8 Steam and condensate management 9 Heat recovery at medium temperatures 10 Ventilation systems 11 Drying systems Reject and fibre sludge drying 14 Paper machine hoods and hood systems 15 Pocket ventilation 16 Hall ventilation 17 ENERGY ANALYSIS SERVICE 18 PLANT SERVICE 19 ROTAMILL plans, designs, and builds thermodynamic products, complete waste heat systems and turn-key solutions in the high-, medium- and lowtemperature range. Our focus is mainly on the paper and glass industry, but other industries, like foundries and galvanizing plants, also benefit from our extensive experience. As a company with many years of experience, combined with the know-how of the former Langbein und Engelbracht and the former Schirm Wärmetechnik, we provide solutions that help to increase the efficiency of your plant. Exhaust gases from industrial combustion processes, as well as hot exhaust air or steam, have a high potential for waste heat utilisation. With a wide range of products, we provide solutions which enable costeffective utilisation of exhaust gases from industrial combustion processes and thus help our customers to save energy and to reduce costs. In the area of air, steam and condensate technology, we offer turnkey solutions for all aspects of the paper machine that are convincing in terms of economy, ecology and performance. That is why we deve- lop and build thermotechnical plants for an all-embracing, cost-efficient energy concept. Whether planning new plants or optimizing existing machines, we work closely at the side of our long-standing customers, accompany and advise them, while always keeping an eye on technological developments, in order to provide consistent production conditions and to increase the efficiency of the plant. 2 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 3
3 WASTE HEAT RECOVERY AT HIGH TEMPERATURES. With ROTAMILL systems, exhaust gas energy can be economically decoupled and used for other processes. Robust plant operation, low maintenance and low operating costs are typical advantages of our systems. Thanks to the know-how of the former Schirm Wärmetechnik, we look back on many years of experience in the field of waste heat utilisation in the high-temperature range and advise our customers on how to use process waste heat economically instead of literally throwing energy away up the chimney. Exhaust gases are produced in all combustion processes, such as in fired furnaces or in combustion plants. These exhaust gases are usually discharged from the process at high temperatures, although they have a very high residual energy content, depending on temperature and volume flow. With the help of a heat transfer process, a large part of this exhaust gas energy can be economically decoupled and used for other processes. The usable exhaust gas energy results from the exhaust gas temperature, the volume flow and the medium to be heated. High exhaust gas temperatures can be used to achieve high media temperatures, regardless of whether it is air, water, steam or thermal oil. The following applies: The more exhaust gas volume there is, the more medium can be heated. Waste heat can be used economically in many ways. The simplest form is by supporting the heating system: The return water of the heating circuit with a temperature of about 60 C is raised to 80 C in a controlled manner by means of an exhaust gas heat exchanger. The boiler requires less fuel and can often even be switched off completely. It is also possible to generate hot water according to a similar scheme. In this case, the water is raised to more than 110 C at a higher pressure and can also be used for heating purposes. It is also possible to operate adsorbers for cooling or compressors. Higher temperature exhaust gases can be used to produce steam. Due to its high temperature, the steam can be used in many different ways for heating processes. With high exhaust gas temperatures and simultaneously high exhaust gas quantities, the use of a turbine makes economic sense. With the help of a turbine, power can be generated and used in your own plant or sold. Robust plant operation Low operating costs Low maintenance Short payback periods (partly less than one year) Effective and efficient internal energy use Long service life of the plants 4 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 5
4 RECUPERATORS FOR AIR PREHEATING. WASTE HEAT BOILERS FOR LARGE VOLUMES OF EXHAUST GAS. Recuperators are often placed downstream of the furnaces. The exhaust gases are used to preheat the air required for combustion. The energy is efficiently reused directly in the process. Our sophisticated waste heat boilers achieve direct energy savings through optimum utilisation of process energy. ECONOMICAL AND EFFICIENT. Recuperators are efficient heat exchangers that transfer thermal energy directly. Recuperative air preheating uses exhaust gas energy to preheat the air required for combustion. The energy is efficiently reused directly in the process. Combustion requires up to 30 % less fuel, which directly contributes to a reduction in operating costs. Application areas: Combustion air preheating Air preheating for other heating processes Preheating of technical gases Drying processes (wood, pickling baths, etc.) Air preheating Exhaust gas cooling Our exhaust gas waste heat boiler plants, which are installed downstream of medium to large furnace and combustion plants, are technically advanced and proven concepts that are perfectly matched to the upstream primary process. They are suitable for large quantities of exhaust gas up to 150,000 Nm³/h. The large quantities of heat from waste heat boilers can be used in many ways. If, for example, exhaust gases from a filter are to be cooled or if the energy from large quantities of exhaust gases is to be used for other purposes, we will install correspondingly large waste heat boiler systems. By using our systems you achieve an optimal utilisation of the process energy and thus the highest possible energy savings. Effective reduction of operating and production costs Reduction of pollutant emissions Improvement of production and product quality possible 6 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 7
5 PROCESS HEAT TECHNOLOGY FOR THE PAPER INDUSTRY. STEAM AND CONDENSATE MANAGEMENT. OVERVIEW OF THE PRODUCTION RANGE For all aspects of the paper machine we offer turnkey solutions that help to increase the overall energy balance of your plant. The heating requirements of the specific product are taken into consideration for every type of paper machine. With many years of experience and the know-how of the former Langbein und Engelbracht (L&E), we offer our customers economical, ecological and high-performance solutions that help to save energy. Our innovative concepts for waste heat utilisation in the mediumand low-temperature range as well as for steam and condensate management improve your overall energy balance so efficiently that the implementation costs pay for themselves within just a few months. Our focus is mainly on the paper industry, but other industries also benefit from our extensive experience. We offer complete turnkey solutions for all aspects of paper machines and advise our customers. We are the right partner for the planning of new plants as well as for all questions concerning the optimisation of existing paper machines. With our energy analysis service we support you in using the energy contained in waste water and exhaust air econo- mically and thus in working resource-efficiently. Our range in the field of paper technology includes: Steam and condensate management Ventilation systems Drying technology Reject drying Paper machine hoods and hood systems Process and automation systems EFFICIENT ENERGY USE. Steam and condensate systems for paper, board, cardboard and tissue machines, specially tailored to the needs of the respective process, ensure excellent product quality and a high flow rate during the drying process. The heating requirements of the specific product are taken into consideration for every type of paper machine. Using steam boxes can increase the mechanical dewatering performance in the press section with little effort. Steam boxes can be used to increase production and/or correct the moisture profile. Efficient use of the complete steam energy Applicable for every grammage range Short payback times due to high operational reliability and runability 8 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 9
6 HEAT RECOVERY AT MEDIUM-TEMPERATURES. VENTILATION SYSTEMS FOR THE PAPER INDUSTRY. Our heat recovery systems use the waste heat from the dryer section, e.g. to heat the building. ROTAMILL ventilation systems contribute significantly to improving the overall energy balance of paper machines. VERSATILE APPLICATIONS. Heat recovery systems recover energy from the dryer section exhaust air via air/air and air/ water heat exchangers and return it to the process as warm air for paper machine and hall ventilation. Our heat recovery systems recycle the sensitive and latent heat. Glass tubes or stainless steel tubes mounted in special seals are used as heat exchanger surfaces. These guarantee a long service life and easy cleaning. Application areas: Ventilation and process systems for polluted and aggressive exhaust air Air/air for process air of the dryer section Air/water for hall heating Air/water for process water heating ROTAMILL plans, supplies and installs ventilation systems for an all-embracing, cost-efficient energy concept - as complete solutions in the construction of new plants or in the expansion and modernisation of existing machines. Saving expensive primary energy increases the efficiency of every production machine and pays off very quickly. The use of ventilation systems helps to create uniform production conditions and drying profiles for the paper web, thus improving paper quality. In addition, the climatic conditions for the staff and for the protection of the building fabric are sustainably improved. The heat recovery and sound insulation systems integrated in these plants also make an active contribution to protecting the environment. Because we know that sustainability counts as an important competitive factor. Our ventilation systems offer a high potential for improving the overall energy balance: Energetic optimisation of the dryer section Active protection of the building fabric Improvement of climatic conditions Extension or modernisation of existing plants 10 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 11
7 DRYERS FOR DRYING AFTER COATERS. ROTAMILL dryers are optimally adapted to the respective process and guarantee a consistently high quality and cost efficiency in the production of paper, cardboard, film and nonwoven. Dryer systems developed for a wide variety of processes are specially tailored to the situation in which they are fitted, allow paper web feeding and provide good access for inspection. SOPHISTICATED DRYING TECHNOLOGY. Our dryers are ideally suited for drying paper (tissue, LWC etc.), cardboard, film and nonwoven. They guarantee consistently high quality and cost efficiency in production and are optimally adapted to the respective process conditions. Thanks to consistent further development, they are ecologically and economically mature and are suitable for new plants or for increasing the output of existing plants. Patented CombiFoil nozzles ensure short heating times, high availability and minimal pressure losses. High and uniform heat transfer coefficient High availability and minimal pressure losses Optimum adaptation to the respective process conditions Optimum adaptation to spatial conditions Air-Turn dryer For contactless turning and drying. Our Air-Turn dryer is the optimal solution for contactless turning and drying of single and double-sided coated paper webs, e. g. downstream of size presses and coaters. A special feature is the contactless turning of the paper web during drying. An air cushion is built up between the nozzles and the paper web to prevent the coated paper from coming into contact with the nozzles. Trans-Air dryer For stable and contactless web guidance. This dryer type is the preferred choice for drying floatable paper webs coated on one or both sides. Characteristic of the Trans-Air dryer is stable, contactless web guidance, resulting from the patented Combi-Foil nozzle which is installed on both sides. Contac-Air dryer For board or paper webs coated on one side. This dryer type is ideal for drying cardboard or paper webs coated on one side. The Contac-Air dryer is distinguished by safe and flexible guide roller-supported web guidance. The Contac-Air dryer is fitted with slot- or hole-type nozzles that provide an even and high heat transfer coefficient. 12 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 13
8 REJECT AND FIBRE SLUDGE DRYING. PAPER MACHINE HOODS AND HOOD SYSTEMS. ROTAMILL reject drying systems can achieve dry contents of up to 90 %. Hood systems specially adapted to the production process allow reduced energy consumption and optimised heat recovery. HIGH DEGREE OF DRYING. Adequate reject handling is becoming an increasingly important topic in the paper industry. ROTAMILL offers a plant system that can easily and reliably increase the dry content from 50 % to 90 %. Disposal costs are reduced in line with the dry content leaving the compactor/press. The ROTAMILL reject dryer dries the rejected material easily and effectively in the low-temperature range. Using waste heat avoids the need for any additional primary energy. The reject dryer pays for itself within a very short time by reducing the high specific disposal costs and by eliminating transport costs. Dryness of up to90 % viable Robust and reliable design Short payback periods Resource-saving use of waste heat With over 45 years of experience in steam hoods for the paper industry, we develop the best and most efficient solutions for paper manufacturers, such as dryer section hood systems specially adapted to the production process. Special lifting, rolling or sectional gate systems provide quick and easy access to the machines during production and maintenance. Our hoods are equipped with an exhaust air system inside and outside the hood, which is optimally adapted to the respective requirements. The special configuration of hood top and side sections produces a very high dew point. This helps to reduce the amount of energy needed to heat up the carrier air and provides the possibility of optimising heat recovery systems. In addition, we offer the right equipment for stripping the basement area to the dryer section, with access ways suitable for maintenance work and reject clearance. Designed to fit any paper machine Effective heat recovery due to high dew point (up to 64 C of exhaust air) Low false air rates, even in the basement area Low primary energy use thanks to special insulation 14 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 15
9 POCKET VENTILATION WITH NOZZLE SYSTEMS. HALL VENTILATION AND AND AIR EXTRACTION. Specially adapted nozzle systems increase efficiency in paper production. Sophisticated hall ventilation and air extraction systems ensure optimum climatic conditions and protect both the building fabric and the health of the employees. ENERGETICALLY EFFECTIVE VENTILATION. ROTAMILL supplies pocket and machine ventilation nozzle systems matched specifically to needs in drying paper as a means of optimising energy efficiency in ventilating machines. Special nozzles for the transfer zone from press to dryer section, stabiliser systems for the slalom zone, stabiliser systems for fast-running machines and conditioning nozzles for stretching are all part of our product portfolio. FOR OPTIMAL CLIMATIC CONDITIONS. In paper production, hall ventilation and air extraction systems are indispensable for improving the climatic conditions in order to protect the building fabric in the production halls and the personnel. ROTAMILL supplies hall ventilation and air extraction systems geared to the specific conditions of the paper industry. Supplying air to and extracting air from production areas and ancillary spaces is an essential prerequisite for protecting the building fabric from moisture generated in the production process. Application areas: Wet-end section Press section Dryer section Electrical rooms Control rooms Staff rooms 16 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 17
10 ENERGY ANALYSIS SERVICE FOR EFFICIENT ENERGY USE. THE ROTAMILL SERVICE EVERYTHING FROM A SINGLE SOURCE. The competent energy analysis service helps to increase the resource efficiency continuously and sustainably. Preventive maintenance and repair help to reduce standstill to a minimum. ROTAMILL is your reliable and competent partner for planning and implementation of energy saving processes and for a continuous and sustainable increase in resource efficiency, taking into account the respective legal regulations. With our many years of international experience and a multitude of innovative solutions, we develop and implement heat and energy concepts in close cooperation with our customers and ensure that the energy escaping via waste wa- ter and exhaust air is used efficiently. Together with our customers, we develop an overall concept for a continuous and sustainable increase in efficiency and are responsible for its implementation. The starting point is a comprehensive analysis of the current situation, which forms the basis for the resulting optimisation approaches. Our energy analysis service includes: Determination of the actual situation on site Analysis and evaluation of energy efficiency as well as production and quality requirements Development of a detailed action plan Professional implementation Our service employees operate worldwide for you, even when things get really uncomfortable. With their many years of experience, they help to reduce downtimes and increase the efficiency of your plant. From our company locations in Siegen and Bochum we serve customers all over the world. In case of problems, an experienced technician is always at your side with help and advice - whether as a service deployment on site or cost-efficiently via remote maintenance. Preventive maintenance and repair considerably help shorten response times and downtimes and the regular replacement of spare and wear parts contributes to increasing the availability of your plant. Detailed maintenance reports with measured value analyses and optimisation suggestions also belong to the scope of services. Our trained service technicians and engineers have many years of experience, which they bring to bear in order to increase the efficiency of your plant. Our services: Assembly, maintenance and repair Maintenance contracts Consulting and training Teleservice and remote maintenance Measured value analyses Detailed reports Optimisation suggestions Update of the control and monitoring technology Worldwide deployment 18 ROTAMILL. WASTE HEAT RECOVERY CLEANING AIR. SAVING ENERGY. 19
11 _RM-WT_EN/FK Subject to change without notice ACT NOW! FIX YOUR APPOINTMENT FOR ENERGY ANALYSIS. CONTACT US: ROTAMILL GmbH Eisenhuettenstrasse Siegen, Germany Phone: Fax:
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