ThermoMax Steam System Efficient. Reliable. Consistent.

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1 ThermoMax Steam System Efficient. Reliable. Consistent. Modern steam systems for modern corrugators. Maximize energy efficiency, reliability, and corrugator productivity.

2 Maximize Heat Transfer Temperature and pressure control A trapped system can provide high energy efficiency, but may not optimize heat transfer and production. The objective of a trap is to eliminate steam losses and only remove condensate. However, in a high speed condensate removal system, blow-through steam is required to efficiently evacuate condensate and produce high heat transfer rates. The Kadant Johnson ThermoMax steam system optimizes heat transfer, production, quality, and energy efficiency. The first priority of a corrugator steam system is to provide maximum temperature at the liner and medium interface for glue bonding. The ThermoMax system provides maximum steam pressure to the corrugator rolls and two preheater rolls that immediately precede them. Pressure control is incorporated for corrugators making light weight flutes requiring lower temperatures. A PLC provides visibility into the system leading to greater control and reduced maintenance requirements.

3 Steam System Optimization The two basic functions of a corrugator steam system are to: u Distribute steam efficiently to each steam-heated roll and section of the corrugator u Remove condensate rapidly so it does not inhibit the heat transfer capability of the system In doing so, a proper steam system: u Delivers dry steam at the desired pressure to every vessel u Continuously removes condensate as it forms u Delivers low-pressure wet shower steam to precondition the medium u Provides a means to purge non-condensable gases (primarily air) from the system during startup u Automatically handles large heat load variations ranging from a stopped corrugator to one producing heavy weight double- or triple-wall at high speed u Accomplishes these functions reliably and efficiently with minimum maintenance requirements The Kadant Johnson difference Unlike conventional corrugator steam systems, the ThermoMax steam system controls the differential steam pressure and blow-through steam across each roll to achieve the highest possible heat transfer and temperature uniformity, with higher efficiency and less maintenance than any conventional steam trap system. Unique features include: u The ThermoMax steam system is designed specifically for the application to increase machine responsiveness and system visibility. Decades of experience and research on the heat transfer from steam-heated rolls uniquely positions Kadant Johnson to address the problems other steam systems encounter when varying heat loads and operating at various speeds. u System design is linked to the performance of all the system components including rotary joints, syphons, heat transfer Turbulator bars, and thermocompressors u Kadant Johnson technicians provide regular on-site support for process evaluations, upgrades, installations, and optimization Features u Tight integration of steam system with steam joints, syphons, and related components u Blow-through differential control u Thermocompressor steam booster u Elimination of steam traps u Simplified control Benefits u Maximum heat delivered to the liner and medium u Maximum steam efficiency and control u Fast heat-up of system u Reduced maintenance requirements u Optimized energy use

4 High-speed corrugating using peripherally drilled rolls Testing at Kadant Johnson s W.R. Monroe Research Center has shown that the velocity through the drilled passages is critical for drilled corrugator rolls operating at high speeds. Too little blow-through steam will cause poor heat transfer and mechanical instability in the rolls. This condition is termed condensate stall. Using too much blow-through steam increases the pressure drop and reduces the heat transfer capacity of the drilled roll as well as down-stream heating components. Heat transfer maximization High heat transfer is needed from the liner and preheater and medium preconditioner rolls for high speed production of heavy weight board combinations. Kadant Johnson CorrPro rotary joints, Turbulator bars, and advanced stationary syphons are used to produce the highest possible roll temperatures. Optimized syphon clearance, differential pressure, and blow-through steam flow are needed to maximize heat transfer and provide uniform cross-directional temperature profiles. Blow-through steam Blow-through from the rolls with stationary syphons and steam system balance are maintained by matching the system design to the flow characteristics of the syphons. Kadant Johnson supplies both the hardware and the system components to achieve the required blow-through steam flow and condensate drainage. Kadant Johnson CorrPro rotary joints installed on corrugating rolls. It is important to provide proper separation of the blow-through steam and condensate that is removed from the rolls. Condensate tanks are used to provide efficient separation. These tanks are designed to achieve over 98% steam quality leaving the tank. The condensate level in the tanks is actively controlled by a level-control valve. Conventional traps cannot provide reliable control of the condensate levels in the separator tanks. Blow-through steam from the separator is recirculated and recompressed using a high-efficiency Kadant Johnson thermocompressor. The thermocompressor allows for the reuse of blow-through steam and provides high energy efficiency. Computational fluid dynamic (CFD) modeling of the thermocompressor provides the highest possible efficiency. High-pressure steam inlet Low-pressure steam inlet Kadant Johnson high-efficiency thermocompressor.

5 Maximize Performance Kadant Johnson research center Extensive testing at Kadant Johnson s W.R. Monroe Research Center has allowed Kadant Johnson to study the behavior of condensate in steam-heated rolls to evaluate: u Critical performance parameters for drilled corrugator rolls u Critical performance parameters for plain-shell rolls u Amount of blow-through steam required u Effects of corrugator speed on heat transfer rates and temperature profile uniformity u Effects of syphon design and syphon clearance u Transient performance following splices, breaks, and grade changes u Rapid start-ups and grade changes JOCO 2000 u 500 mm (20 ) diameter x 2.6 m (104 ) face roll u Rated for 14 bar (200 psig) u Operating speed 730 mpm (2400 fpm) u Adjustable condensing rates up to 60 kg/m 2 -hr (12 lb/ft 2 -hr) u Real-time measurement of roll temperature, differential pressure, steam and condensate flow rates u Real-time observation of condensate behavior inside the roll using digital CCTV Rotary steam joints Testing at the Kadant Johnson research center includes evaluation of all elements of rotary steam joints to provide high reliability. This allows the corrugator to run longer with less maintenance and fewer unplanned shut downs. Kadant Johnson s corrugator test stand is capable of running a wide range of conditions to allow direct simulation of the operating performance of corrugating rolls for both existing and future speeds.

6 Related Services Corrugator steam system audit The Kadant Johnson corrugator steam system audit focuses on all of the essential steam system components of the corrugating machine. Faulty components can result not only in low energy efficiency, but also in low production, poor product quality, high waste, and high operating costs. A Kadant Johnson steam system audit will uncover multiple deficiencies that either risk or are causing poor steam system performance. Corrugator steam system training Kadant Johnson provides steam system training for your operating personnel for proper and efficient operation of steam systems. It is important your personnel are properly trained and able to identify and promptly address problems that could affect production or efficiency. Trained people recognize when a system is working well, what to do when something goes wrong, and how to restore the systems to their maximum potential. Boiler operational audit The Kadant Johnson boiler operational audit picks up where the boiler inspections leave off. A Kadant Johnson audit is conducted while the boiler is in operation and includes the auxiliary systems as well. It identifies areas for operational improvement, efficiency improvement, and productivity. Engineering services Kadant Johnson believes that to get the most out of your corrugator you must have well-trained operators and reliable machinery. To help achieve this, Kadant Johnson provides control engineering services including a qualified system and control engineer on-site for five days, PLC configuration, development of graphics for operator screens, check out of instrumentation and PLC logic, and review of logic operation and fine tuning of logic. Pre-piping design Kadant Johnson provides recommendations for optimal piping configuration with detailed piping design services. Piping design services include required system tie-ins, suggested hanger and support drawings, drawings depicting necessary sectional, elevations, and plan views, line lists, and recommended transmitter installation arrangement. Kadant is a global supplier of high-value, critical components and engineered systems used in process industries worldwide. Contact us: KADANT JOHNSON INC. 805 Wood Street Three Rivers, MI USA Tel: Fax: info@kadant.com ThermoMax Steam System-3002 US 03/2015 Replaces: ThermoMax Steam Systems Kadant Inc.