Pulp and Paper

A Guide to Steam
Conditioning

CHP Pulp and Paper Process

CHP in Pulp and Paper

Introduction, What is CHP in Pulp and Paper Industry

Requirement of Steam

Steam Conditioning Applications

CHP (Combined Heat and Power) is an efficient technology for

generating electricity and heat together.

Pulp and Paper, Recovery Cycle

Paper Making

Key Products for Severe Service Applications:

VST-SE

VLB

DRAG

Desuperheaters

A CHP plant is an installation where there is simultaneous generation

of usable heat and power in a single process. Figure 1 shows a possible
configuration for a CHP plant. The heat source can be established from many
different sources. Waste heat from process (e.g. black liquor recovery) and
waste heat from gas turbine (also electricity generator) by a heat recovery
steam generator (HRSG). This heat is used to provide process steam which
is required for the production of pulp and the paper machine. Availability of
steam is of the utmost importance, electricity can be bought via the grid, but
non availability of steam means that production (revenue) will stop.
CHP provides a secure and highly efficient method of generating electricity
and steam at the point of use. Due to the utilization of heat from electricity
generation and the avoidance of transmission losses because electricity
is generated on site, CHP typically achieves a 35% increase in efficiency
compared with power stations and heat only boilers. This can allow
economic savings where there is a suitable balance between the heat and
power loads.

Pulp and Paper A Guide to Steam Conditioning

Why is Steam Required and at What Degree of Superheat?

Steam is required for the paper machine and evaporators at a condition close
to saturation owing to the excellent heat transfer properties of saturated
steam. Paper making, typically requires steam at 3.5 bar a at 145 C. If there is
too much superheat in the steam, then there the heat transfer at the process
will be inefficient and the paper run can be ruined.
Steam is therefore normally available from the steam turbine or its bypass
valve or a combination of both. It should be noted, the requirement of
the power plant is primarily to provide steam for the process (industry)
and generating electricity is merely a benefit as the electrical needs can be
imported if necessary. Steam supply at the correct pressure and temperature
and not electricity is of the utmost importance.

Figure 1: Typical simple CHP scheme with black liquor recovery boiler and
steam turbine.

CHP Pulp and Paper Process

Steam Provided by Steam Turbine

Steam from the (boiler or HRSG), normally high pressure and superheated,
will pass through the steam turbine. For example, steam to the relevant
process can be taken from extraction or the exhaust of a steam turbine of the
backpressure design (refer to Figure 1).
Turbine Extraction/Exhaust
The outlet steam temperature from extraction or exhaust varies depending on
the steam going through the steam turbine(refer to Figure 2). For example,
considering exhaust steam, as the steam flow through the turbine decreases,
the outlet temperature increases. Depending on the exhaust flow in general
as the extraction flow reduces, the extraction steam temperature increases.
Figure 2: Turbine extraction/exhaust
desuperheating

This means to obtain a constant set temperature downstream, the proportion

of spraywater required at low flow is higher than compared to at full flow
where the requirement will be small if any at all.
The exhaust steam supply pipe to paper mill will be large in diameter and
combined with the conditions as detailed above and potentially low flow,
providing good temperature control to the process close to saturation will
need special consideration.
Steam Provided by the Bypass Valve

Figure 3: HP turbine bypass to process

Steam Turbine Bypass to Extraction/Exhaust for Back Pressure

Turbines
The steam turbine bypass reduces the pressure and temperature of the steam
to match the appropriate extraction/exhaust conditions. They are used during
startup, in the event of a turbine trip, non availability of the steam turbine
or supplementing steam to process that may not be available from the steam
turbine.
The bypass valve should:

Be suitable for severe thermal

shock (up to 300 C)

Have high rangeability to

maximize turndown

Modulate in 2-3 seconds or less.

Snap action in this time is not

Provide repeatable tight shutoff

Inline repairability

Be of low noise design

acceptable as the boiler will trip.

Figure 4: VST-SE bypass valve for fine

control of steam to paper machine

Reliability of this equipment is of the utmost importance. Non availability

means loss of production. The valve illustrated in Figure 4 (VST-SE) meets all
the above criteria. CCI with extensive experience and knowledge can provide
installation guidelines in conjunction with the correct product selection for
the optimum system solution.

Pulp and Paper A Guide to Steam Conditioning

If the steam turbine is not available, then the bypass valves are utilized to
condition the steam to the exact conditions required for the process (refer
to Figure 3). When the steam flow through the turbine does not meet the
process demand the bypass valve must make up the difference between the
process demand and that being supplied by the steam turbine. Availability of
turbine bypass valve is therefore critical to production.

CHP Pulp and Paper Process

Figure 5: Manufacture of pulp and

the recovery cycle

Pulp Manufacture and Recovery Cycle

Pulp and Paper A Guide to Steam Conditioning

The details below are typical for a large pulp and paper mill.

Figure 6: Pulp and paper mill incorporating

recovery cycle

Received wood is cleaned, processed and made into small chips. The bark
that is stripped will be used to burn in the bark boiler that produces steam
at the same pressure as he black liquor recovery boiler described later.

Wood chips are cooked in the digesters. White liquor, hydroxide sulfide
is used in the boiling process to separate fibres from the chemicals in the
wood that bond the fibres together. The remaining water and chemical
mixture is known as white or feed liquor. The mixture is 15% white
liquor and 85% water.

The pulp is refined in the respective fibreline and includes screening,

washing and possibly bleaching (for production of white paper)
Unbleached pulp will be in its natural color and produces cardboard and
brown paper bags etc. The pulp can be packed ready for export or used
for the paper mills on site.

The white liquor goes to the evaporators where water is evaporated and
the chemicals become concentrated until it constitutes over 70% of the
mixture which is known as black liquor and is used in the recovery boiler
for combustion. The ash created is called smelt and is fluid at about 1100 C.

Water is added to the smelt which is known as green liquor and is then
mixed with chalk and becomes white liquor and can be used again at the
beginning of the process with treatment (addition of chemicals.)

The recovery boiler produces 350 T/hr steam at 60 bar and 485 C. There
is also a bark burning boiler which at the same pressure and temperature
produce about 70-80T/hr. There can be 4 headers, 60 bar, 35 bar, 10 bar
and 3 bar. Some of the 60 bar steam is used for the breaking of wood at
full temperature. The evaporators will take steam from the 10 bar header
(approx 70 T/hr) which will be let down to 3 5 bar for evaporating the
water from the white liquor to produce black liquor. 60 bar superheated
steam is used in the flash dryers in the fibreline process, to remove moisture
from the damp pulp. The 3 bar header is used to supply the paper mills and
the 10 bar header may also be used in some of the paper machines.

CHP Pulp and Paper Process

Figure 7: Typical paper machine, showing

heating cylinders

It is important that steam for the paper mill is provided at a condition close
to saturation. Steam that has too high a degree of superheat will result in
possible damaged product, but also reduced output owing to the fact that
superheated steam has poor heat transfer capabilities compared to saturated
and steam and therefore throughput of paper is reduced.
The pulp is blended with water and other chemicals, separated and fed to
the headbox at the right consistency. The raw materials (pulp) material fibres
(99% water) are pumped into head box. The stock is fed evenly onto wire
mesh. As the paper stock flows from the head box onto the wire the water
drains away leaving the tiny fibres as a mat on the mesh. When the mat has
reached the end of the wire section, it has become a sheet of paper, although
very moist and of little strength. It then passes over the press section.
The press consists of a number of cylinders which squeezes moisture from
the paper and the water is drawn away by suction. The Paper then passes to
the drier section, which consist of a large number of steam heated drying
cylinders. The cylinders temperature is normally slightly over
100 C. Synthetic drier fabric carrys the web of paper round the cylinders
until the paper is completely dry. Part of the way through the cylinders, is a
size press, where a solution of water and starch can be added to improve the
surface for printing. For tissue machines, a yankee drum can be used which
is a rely large diameter and relies on the large surface area to dry the tissue
paper. Steam quality at this stage is paramount to the quality and speed the
machine can operate at.
At the end of the process, the paper is smoothed using an, ironing method,
which consist of polished iron rollers. This helps to consolidate, polish and
glaze the surface of the paper. The paper is then reeled and ready for
uss/distribution.
High quality papers can be additionally coated by using clay and other
pigments. These coated papers are usually done on a separate machine, ut in
some cases may also have an on-machine coater for precoating before
being reeled.
The board machine is a similar process, but has several wet ends (headboxes
and wires) producing multiply sheet.

Pulp and Paper A Guide to Steam Conditioning

Figure 8: Paper machine using low pressure

steam close to saturation

Paper Making

CHP Pulp and Paper Products

VST-SE
The VST-SE was designed as a steam turbine bypass to process conditioning
valve. The requirements are to open and close very quickly in response to a
turbine trip, startup or to provide additional steam flow to the process.
The bypass to process with VST-SE will benefit from:

Reliable operation: suitable for up to 300 C thermal shock. Fully

machined circular section valve body.

More revenue owing to higher electrical production: this is achieved by

providing high turndown capability with regard to steam flow by means
of steam atomization.

High performance and stable control: solved by integral water

proportioning.

Reduced maintenance cost & downtime: provide repeatable tight

shutoff despite exposure to thermal shock having unique two piece seat
providing flexibility.

Maximize plant flexibility: the VST-SE provides modulating steam

atomization. Generally standard systems provide on/off atomization

Figure 9: VST-SE steam atomizing and

water proportioning

VLB
The VLB was designed as a steam turbine bypass valve and is widely used for
bypass or dump to condenser.

Pulp and Paper A Guide to Steam Conditioning

The bypass system with VLB will benefit from:

Reliable operation: suitable for up to 300 C thermal shock. Fully

machined circular section valve body.

High performance and stable control: system stability despite

pressure, flow and temperature transients with CCI total system
understanding implemented.

Reduced maintenance cost & downtime: provide repeatable tight

shutoff despite exposure to thermal shock having unique two piece seat
providing flexibility.

Excellent evaporation of water: ensuring trouble free operation when

bypassing to condenser owing to special multiple nozzle configuration
around valve outlet.

Pressure sealed bonnet: maintains tightness regardless of temperature

transients and allows quick and easy access to valve internals.

Accurate control of final steam conditions to condenser: preventing

condenser damage owing to overspray and vibration.

Low noise (DRAG dump tube used if noise requirements are onerous.)

Custom design of bypass valve: inlet/outlet connections to suit

application.

Figure 10: Typical VLB

Figure 11: Bypass to water cooled

condenser

CHP Pulp and Paper Process

CCI will provide the correct total

system solution for the application.

DRAG Velocity Control Technology

High velocity fluid or steam as a result of high pressure drop or large change
in pressure ratio creates velocity, which if to high causes cavitation and or
erosion resulting in valve failure.
CCI DRAG solution is unique in solving this, utilizing multi flow paths and
introducing the required number of pressure reducing stages. Refer to CCI
DRAG brochure.
CCI DRAG Benefits
Low noise: depending on application, noise levels of >85 dBA at 1 m are
possible. Working with CCI can provide reduced total system noise.

Reliable operation: by controlling velocity.

Longer valve life: controlling velocity and pressure head

More revenue owing to higher electrical production: will reduce or

eliminate maintenance activity or process shut down owing to
equipment failure.

High performance and stable control: disk stack can be custom

characterized to suit particular application, such as boiler level control
valve (feedwater control valve.)

Reduced maintenance cost & downtime: provide repeatable tight shutoff

utilizing MSS-SP61 shutoff by pressurized seat design.

Reduced installation cost: valve custom designed including connections

to suit application.

Figure 12: Uncontrolled velocity a

control valves worst enemy

Desuperheating of Process Steam

Controlling desuperheating of extraction and exhaust steam is challenging
owing to the following:
Figure 13: DRAG disk multi-trim/flow path

Low velocity at startup

Insufficient coverage

Large piping diameters dont encourage mixing

Set temperature close to saturation

Desuperheaters subject to transient conditions

Key components for successful desuperheating:

Figure 14: Multi nozzle DAM desuperheater

Small Diameter + High Velocity = Good Mixing

Hotter water (up to 120-130 C) smaller water droplet dia.

Higher

Smaller water droplet diameter = quicker evaporation

Even distribution (across the area of the steam) of the spraywater

Control of downstream temperature

Installation considerations CCI have several innovative styles of

desuperheaters, review and advice of the system is necessary. Aspects
such as liners, enthalpy control, reduced sections of piping, installation
are all aspects necessary to meet performance requirements.

P means better atomization of water (smaller water drop dia.)

Pulp and Paper A Guide to Steam Conditioning

Throughout the world, companies rely

on CCI to solve their severe service
control valve problems. CCI has provided
custom solutions for these and other
industry applications for more than
80 years.

Sales and service locations worldwide.

CCI World Headquarters
California
Telephone: (949) 858-1877
Fax: (949) 858-1878
22591 Avenida Empresa
Rancho Santa Margarita,
California 92688
USA

CCI FK
(Fluid Kinetics)
Telephone: 805 644 5587
Fax: 805 644 1080
2368 Eastman Avenue, Suite 8
Ventura
California 93003
USA

CCI Austria
(Spectris Components GmbH)
Telephone: 43 1 869 27 40
Fax: 43 1 865 36 03
Carlbergergasse 38/Pf.19
AT-1233 Vienna
Austria

CCI Italy
(STI)
Telephone: 39 035 29282
Fax: 39 035 2928247
Via G. Pascoli 10 A-B
24020 Gorle, Bergamo
Italy

CCI China
Telephone: 86 10 6501 0350
Fax: 86 10 6501 0286
Room 567/569
Office Tower, Poly Plaza
14 Dongzhimen South Avenue
Beijing 100027
China

CCI Japan
Telephone: 81 726 41 7197
Fax: 81 726 41 7198
194-2, Shukunosho
Ibaraki-City, Osaka 567-0051
Japan

CCI Korea
Telephone: 82 31 980 9800
Fax: 82 31 985 0552
26-17, Pungmu-Dong
Gimpo City
Kyunggi-Do 415-070
Republic of Korea
CCI Sweden
(BTG Valves)
Telephone: 46 533 689 600
Fax: 46 533 689 601
Box 603
SE-661 29 Sffle
Sweden

CCI Switzerland
(Sulzer Valves)
Telephone: 41 52 262 11 66
Fax: 41 52 262 01 65
Hegifeldstrasse 10
CH-8404 Winterthur
Switzerland

Contact us at:
info@ccivalve.com
Visit us online at:
www.ccivalve.com
DRAG is a registered trademark of CCI.
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