Case study Lower energy consumption and high fiber quality ANDRITZ MDF Spiral refiner plates www.andritz.com We accept the challenge! The challenge: Reduce energy costs and increase fiber quality Current situation MDF producers are facing a situation with That is why there is no alternative but to considerably more competitive pressure make more efficient use of existing refiner globally, while being confronted at the plants. same time with a drop in raw material With these requirements, ANDRITZ refin- quality and higher demands on the qual- er plate technology is also breaking new ity of the final product. Rising energy costs ground and presenting important innova- always account for a large part of the tions for energy-efficient operation of ex- manufacturing costs in MDF production. isting refiner units. Fiber samples from refining with standard plates Parallel design Ro ion tat 70° Rota tion The ANDRITZ solution: MDF Spiral refiner plate technology Before the innovative ANDRITZ MDF Spi- constant breaks in the fiber pad. In addi- ral design was developed, all models had tion, the following was noted: the smaller parallel bars with varying cutting angles the cutting angle, the higher the number depending on the current position of the of fiber cuts. And the larger the cutting fibers on the refiner plate. Parallel bars angle, the higher the fines content. This do have an average cutting angle of 30° means that the fibers are treated differ- between rotor and stator, however the ently depending on their position on the range can fluctuate between 17° and 38°. refiner plate. The parallel refiner plate design is accompanied by erratic raw material feed and Crossing angle in course of sweeping process 76° 55° 34° 38° 17° Bar angle Ro n tatio 58° Rotat ion Analysis and evaluation The challenge: Reduce energy costs and increase fiber quality ANDRITZ innovation The diagram shows how the cutting angle the outer sector it is produced more by thus tapers from the inner diameter out- crushing in the refiner gap. This is why wards as the rotor rotates against the sta- short, broad fibers are produced in the in- tor. This reduction in cutting angle has a ner sector and long, thin fibers in the outer negative impact on the fiber quality and sector. Due to the varying cutting angles on energy consumption. In the inner sec- in parallel bar refiner plates, the load on tor of the refining zone the fiber is pro- the cutting edges varies, which can lead duced more by the cutting effect, while in to higher energy consumption. Fiber samples from refining with ANDRITZ MDF Spiral plates ANDRITZ Spiral design ta Ro tion 58° Rotat ion The ANDRITZ solution: MDF Spiral refiner plate technology Unlike the parallel bar refiner plates, the The cutting angle zones can also be il- Spiral refiner plate has a constant cutting lustrated in a graph of the cutting angle angle formed by the logarithmic shape of spectrum. This shows the angle of the re- the bars, and fiberizing takes place with finer plate and the cutting angle applied the same angle over the entire refining as the rotor rotates. The constant angle of zone. Due to the constant cutting angle, the refiner bars on the Spiral refiner plate a homogenous fiber spectrum is created. and the constant cutting angle are illus- The energy consumption can be reduced trated as one single point in the diagram. by up to 20% compared to conventional By contrast, the parallel bar refiner plate designs due to the high fiberizing intensity with its refiner bars at varying angles and of this design. A further positive aspect of changes in cutting angle as the rotor ro- the Spiral refiner plates is the reduction in tates is displayed as a wider spectrum in vibrations achieved by even fiber trans- the diagram. port in the refining zone 50° Crossing angle in course of sweeping process 40° 30° 20° 10° 0° 10° 15° 20° 25°30°35° 40° 45° 50° Bar angle R io otat n 58° R o tati on ANDRITZ innovation The challenge: Reduce energy costs and increase fiber quality ANDRITZ innovation Spiral (top) vs. standard pattern (bottom) In the meantime, the new Spiral refiner MDF producers are also facing a situa- plate technology is available for all types tion with considerably more competitive and sizes of refiner. It has been tested pressure globally, while being confronted successfully on all continents and has at the same time with a drop in raw ma- already become established as standard terial quality and higher demands on the plate equipment in many mills. Depending quality of the final product. Rising energy on the process requirements and charac- costs always account for a large part of teristic production data (throughput, re- the manufacturing costs in MDF produc- quired fiber quality, specific energy con- tion. That is why there is no alternative but sumption, quality of raw material, etc.), to make more efficient use of existing re- ANDRITZ develops a refiner disc design finer plants. to suit a specific customer’s needs and With these requirements, ANDRITZ refin- then assesses the result. If necessary, the er plate technology is also breaking new refiner disc design is then adapted to suit ground and presenting important innova- specific customer requirements. tions for energy-efficient operation of existing refiner units. The ANDRITZ solution: MDF Spiral refiner plate technology Customer references SEC (kWh/t) Energy savings: 4% ANDRITZ MDF Spiral 58" plate Ø 105 kWh/t ANDRITZ 58" Parallel plate Ø 109 kWh/t PLT (Days) In one test series the 58” MDF Spiral re- In this case, the specific refining energy finer plate design was compared with was 4% less, whereas the fiber quality the 58” ANDRITZ parallel bar design. showed an improvement. SEC (kWh/t) Energy savings: 7% ANDRITZ MDF Spiral 48" plate Ø 135 kWh/t Competitor 48" plate Ø 145 kWh/t PLT (Days) The second example shows a 48” Spiral The comparison of refiner plate lifetimes refiner plate (48SD801/811) in a compari- (PLT) shows that there are no differences son with a plate from a different manufac- when using MDF Spiral refiner plates. The turer. Here, too, 7% of the specific energy service lifetime of the refiner plate is de- could be saved, while maintaining the pending on its design and intensity. same fiber quality. In both of the examples shown above there was a positive increase in the PLT. If savings of 10 kWh/t at an output of 20 t/hr are assumed and the energy costs are calculated at 0.07 €/kWh, the annual savings potential is as follows: 10 kWh/t x 20 t/hr x 24 hrs/day x 365 days/year x 90% availability x 0.07 €/kWh ≈ 110,000 € per year Benefit & savings Expert support for the MDF industry Production reliability, reduced energy Our process experts can help you opti- costs, consistent quality, and maintenance mize your refining process to keep pro- efficiency are the key challenges facing ductivity and quality at a high level. Fol- MDF manufacturers. To ensure that you lowing a thorough analysis of your refining meet these challenges, ANDRITZ offers process, we offer advice on how you can a portfolio of technologies, services, and reduce the amount of energy required to process experts who can help you extract manufacture your fiberboard product and the maximum productivity from your refin- increase refining quality. ing system. Technology and service are the highest priorities at ANDRITZ. We provide the world’s best plate designs to meet your demands for lower energy consumption Kastamonu Entegre Agaç San.Tic.A.S. and improved fiber quality (or lower resin in Turkey is already using the MDF Spiral usage) due to longer average fiber length. refiner plate technology successfully in its Adaptations to general plate designs can 48” and 66” lines. be tailored to your individual application. Andritz Inc. Tualatin, OR, USA Phone +1 (503) 691-5106 Andritz AG Vienna, Austria Phone +43 (1) 81195 6288 www.andritz.com MDF_Plates@andritz.com All data, information, statements, photographs and graphic illustrations made in this leaflet are without any obligation and raise no liabilities to or from part of any sales contracts of Andritz AG or any affiliates for equipment and/or systems referred to herein. © Andritz AG 2011. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of Andritz AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. Andritz AG, Stattegger Strasse 18, A-8045 Graz, Austria PW.MDFcs1.02.eng.03.12 Case study Lower energy consumption and high fiber quality ANDRITZ MDF Spiral refiner plates www.andritz.com We accept the challenge!
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