Toschi Continuous crescent former 2.760 mm 13.5~40 gsm 18.000 TPY/ 50 TPD

Continuous crescent former paper machine
Year: 1999 – Startup: 2000
Toschi hyper modulo
New Yankee installed in 2007, steel construction, 2500mm diameter
Nominal paper width: 2760mm
Max diameter of parent rolls: 2500mm
Range of grams of paper from 13.5 g/m2 to 40 g/m2
-----------------------------------------------------

- This machine is a complete production line including following scope
The pulper (High consistency)
The stock preparation
The approach flow
The paper machine
The pope-reeler at the end of the machine
The vacuum system
The lubrication system,
The dosing station
The electrical control systems
an inventory of dedicated spares
- There is no Rewinder with this machine as the mill uses one rewinder for their three machines and are not selling it.
- There is also an available Hot dispersion system offered as an option
--------------------------------------------------
Operating speed: 900 mts/min (Yankee)
Design Speed: up to 1200 mts/min (Yankee)
Annual production: 18.000 tons per year
Energy consumption: 0,68 MWh/ton (including stock preparation)
Steam consumption: 1,36 ton of steam/ton of paper
Hood gas consumption: 64 m3/ton
------------------------------------------------------
Drying system with dual hot air developed by Aerothermic, Fomat Spa. Max temperature of hood (Wet side) 650 C – Max temperature of hood (dry side) 450 C
Technical diagrams of the Yankee and complete machine are available as well layouts and civil engineering.
Suction roll of 740mm diameter
Forming roll of 1200mm diameter

Headbox brand ST Machine, consistency of 0,2%, electromechanics opening
Refiner with double disc, RDM 26”/N supplied by AGA Machine
Water management system by Berica, Model CF2005, diameter of the bucket 5600mm
Fiber selector ECT2 of conic opening from 1.8mm to 2.4mm
Thermocompressor Steam module by Körting
Filtering system of multiple stages, Superscreen (diameter of opening 2mm), Vortiscreen (diameter of opening 1.75mm) and vibrating screen
Fan pump brand AHLSTROM (Sulzer) model ZPP 21-300
Vacuum generating system composed by 4 pumps NASH CL3001
Low consistency cleaner of three stages, brand Alfa Laval Celleco Clean Pack 700

III) Process Description (all components indicated are included)
-----------------------------
A) Dissolving system:

Steel-plate conveyor: Length 14400 mm, height: 3800 mm. Powered by xxx AC motor
High density pulper: Volume: 8 m3. Stainless steel rotor. ABB level and water flow control. Powered by 160 kw AC motor controlled by ABB driver, V belts transmission. Motor RPM : 992--- Max rotor RPM: 260
Stainless steel pulper coarse selector: Plate diameter : 1180 mm, hole diameter. 8 mm, rotor diameter: 1100 mm. Powered by AC motor 30 Kw – 1475 rpm
Discharge pump ( Pump 4): Robuschi RKC 200-3, Q= 4500 lpm. H=14 mts, powered by AC motor 30 kw, 985 rpm.
Pulper stainless steel tank. Volume: 60 m3. Agitator manufactured by ST Macchine, type AST 1000, powered by Ac motor 18.5 kw, 985 rpm. ABB level control.
High density cleaner: Manufactured by ST Macchine, model DPD 12/A-1200 lts. infeeded by Robuschi pump, model RKC 65-36, AC motor 22 kw-1465 rpm ( Pump 6)
Screening module: Manufactured by Toschi. cby Robuschi pump RKC 80-27(Pump 7), 11 kw- 1450 rpm AC motor. BTG Consistency transmitter, model MBT 2300.

Screening module composed of:

Superscreen SS1: Drilled basket and rotor filtering system, hole diameter: 2mm, open area: 15%. Basket dimension: 400 mm diameter, 400 mm length. Powered by AC motor, 30 Kw- 1475 rpm
Vortiscreen VS3.1 : Drilled plate and rotor filtering system, hole diameter : 2mm.Powered by AC motor, 15 Kw- 1475 rpm
Vibrating screen : Powered by AC motor 1.1 Kw- 930 rpm
Deflaker: Manufactured by Toschi, model : T1/D6. Powered by AC motor, 90 Kw- 2970 rpm
Stainless steel machine tank: Volume. 30 m3. Agitator manufactured by ST Macchine, type AST 800, powered by Ac motor 15 kw, 985 rpm. ABB level control.
Refiner feed pump: Robuschi RKC 65-36 ( Pump 14), AC motor 18,5 kw-1465 rpm.
AGA Macchine refiner: Diameter plate 26”. Double disc. Gap distance control by refiner main motor current control. Main motor: 250 Kw, 8 poles, AC motor.

--------------------------------------
B) Approaching system:
Stainless steel level box, two stages
Basis weigh valve, manufactured by Fomat, model FRG. Controlled from control room.
Cleaner Alfa laval Celleco.

First stage low density: CleanPac 700 S-8. Infeed by Robuschi pump RCN 200-36, Ac motor 45 kw- 1500 rpm
Second stage low density. CleanPac 700 L-2. Infeed by Robuschi pump RCN 80-36/SB, Ac motor 18,5 kw- 1500 rpm
Single Fiber mizer

Fan pump (Pump 19): Manufactured by AHLSROM (Sulzer) model ZPP 21-300. Q=32000 lts/min, H=36mts. Operation consistency: 0.2%. Powered by DC motor ABB 260 KW, 1550 rpm controlled by driver

Machine pressure screen: Manufactured by Toschi, model ECT2. Drilled basked, dimension: 595 mm diameter, height 1096 mm, width: 4mm, conical hole: 1.8 mm (internal diameter). Powered by AC motor 30 Kw, 900 rpm.

-----------------------------------------------------
C) Paper machine: 1- Forming section
Headbox: Manufactured by ST Macchine. Stainless steel Pressure headbox. Width: 2850 mm. Automatic lip opening range: 8 – 25 mm. Stock consistency 0,17 to 0,35 %
Wire forming roll: Diameter: 1200 mm, width: 3260 mm. Powered by ABB DC motor 104 kw, 1710 rpm, controlled by ABB DCS500 driver technology
Four roll wire loop : One breast roll, diameter: 340 mm and 3 Guide rolls, Diameter :290 mm
Shower system: High pressure oscillating shower, nozzle diameter 1 mm, nozzles amount. 20 units controlled by Fomat.
Wire fan spray shower, nozzles amount. 19 units Wire roll fan spray shower, nozzles amount. 15 units

2- Press section

Suction press roll: Manufactured by Toschi, diameter: 770 mm. Widht: 3200 mm. Suction width: 2780mm, hole diameter: 3.75 mm. Powered by ABB DC motor 104 kw, 1710 rpm, controlled by ABB DCS500 driver technology
Seven felt roll loop: Seven guide felt roll, diameter 290 mm
Shower system: High pressure oscillating shower, nozzle diameter 1 mm, nozzles amount. 21 units controlled by Fomat.
Felt fan spray shower, nozzles amount. 19 units Felt fan spray shower, nozzles amount. 19 units Three felt roll fan spray shower
Felt edge shower
Suction box: Two suction box for felt cleaning, wide slot : 18.5 mm

3-Drying & Creeping Section:

Steel yankee dryer: Manufactured by Toscotec, production year: 2007. Yankee diameter: 2500 mm, face length: 3110 mm. Paper width on yankee dryer: 2850 mm. Total shell thickness: 40mm, nominal Thickness: 14mm, depth inner groove: 25 mm, metallization thickness: 1 mm, number of grooves: 94.

Maximum working pressure: 10 bar Maximum temperature design: 184 C. Capacity: 14.000 lts. Design speed: 1200 m/min. Metal coating: Varihard-HE.

Powered by DC motor ABB 260 KW, 1550 rpm controlled by driver DCS 500 ABB.

Yankee hood air system: Machine type: Duo system, manufactured by AeroThermic –Fomat group. Last upgrade: 2006. Fluid max inside: 650 C (wet end) and 450 C (drive end)

Composed of:

Recirculating air fan wet (V1): Manufactured by CBI, model MB/100. Powered by Ac motor 110 kw, 1500 rpm controlled by GE driver.
Burner and combustion chamber wet (G1): Manufactured by Icotec, model BVA 2000. Power Max/Min: 2350/120 Kw. Fuel: natural gas
Combustion air fan for G1 burner (V4): Manufactured by Ferrari, type: VCM 631 N12. . Powered by Ac motor 30 kw, 3000 rpm
Recirculating air fan wet (V2): Manufactured by Ferrari, model 1121N12S. Powered by Ac motor 110 kw, 1500 rom controlled by GE driver.
Burner and combustion chamber wet (G2): Manufactured by Icotec, model BVA 1250.
Doctoring system:
Power: 1500Kw. Fuel: natural gas
Combustion air fan for G2 burner (V5): Manufactured by Ferrari, type: FG561N12A. Powered by Ac motor 15 kw, 2930 rpm
Exhaust air fan (V3): Manufactured by Ferrari, type FQ711N12. Powered by Ac motor 30kw, 1500 rpm
Heat recovery system (R1): Air to air exchanger, manufactured by AeroThermic, total surface:187 m2
Wet end hood: Manufactured by AeroThermic, sweep angle: 135 degrees, wet blowing velocity: 140 m/seg, blowing temperature: 650oC. Moisture profile control done by 12 damper, manually controlled.
Dry end hood: Manufactured by AeroThermic, sweep angle: 110 degrees, dry blowing velocity: 100 m/seg , blowing temperature: 450oC
Cut off blade: Manufactured by Oradoc, blade holder replaced in 2015, stainless steel blade holder, model: ORADOC LBH PLUS full oscillating
Creeping blade: Manufactured by Oradoc, blade holder replaced in 2015, stainless steel blade holder, model : ORACREPE/VARICREPE full oscillating
Cleaning blade: : Manufactured by Oradoc.

4-Reel section: System composed by:

Primary arms, driven for AC motor.
Pneumatic secondary arm: Manual control pressure
Reel drum: Diameter. 1000 mm, face length: 2940 mm. Crepe control from: local panel and control room
Max reel diameter: 2200 mm. Powered by DC motor ABB 37 KW, 1485 rpm controlled by driver DCS 500 ABB.
Expansible core shaft: manufactured by Svecom, core diameter: 12 “, amount : 5 pieces.
Shaft puller

-------------------------------------------------
D) MACHINE AUXILIARY FACILITIES:
Water treatment system:
Fresh water tank : Stainless steel tank, volume 6m3. ABB level control
Clarified water tank: Stainless steel tank, volume 30m3. ABB level control
White water tank: Stainless steel tank, volume 6m3. ABB level control
Flotation plant: Manufactured by Berica Engineering, model CF2005. Diameter. 5600 mm, Q max 156m3/h
Infeed pump: Robuschi RCN135-32 .Q=3200 lts/min H=14 mts, powered by Ac motor :15 kw- 1445 rpm
Pressurizer feed pump: RCN65-27 .Q=700 lts/min H=65 mts, powered by Ac motor: 18.5kw- 2920 rpmVacuum system

1. Vacuum pump: four vacuum pumps manufactured by Nash, model CL3001
Powered by AC motor 132 kw -1485 rpm
General manifold for pumps exchanging without stopping.
Sealing fresh water tank: stainless steel tank, volume: 6 m3
Uhle box vacuum separator
Press suction roll separator

6. Exhaust air separator
Steam and condensate system:
Condensate removal system: Four steam collector located inside the yankee, 50 stainless steel soda straw each one.
Condensate tank: volume 500 lts. Level control
High pressure condensate pump: KSB HTN40/9. Powered by AC motor . 7.5 kw- 3000 rpm
Pressure system loop: rousemont pressure meter, korting thermocompresor and help valve.
Blow through spread loop control: composed by Rousemont Vortex flow meter and proportional relief valve.

Power and control system
1) Power system: Power cabinet manufactured by SEEI SPA
a) Main power cabinet : ABB Main switch and sectional swtiches.
b) DCS 500 ABB cabinet: Fan pump,forming roll, suction press roll, yankee dryer and pope reel
c) AC cabinet motor: General process pumps, process auxiliaries equipment and AC pulper driver
d) AC cabinet hood system: V1 y V2 fan drivers.

2) Control system:
a) Main PLC: Siemens CPU 416-2DP.
b) Pulper ET200 station and HMI for operator interface
c) Screening ET200 station and HMI for operator interface.
d) Control room ET200 station and HMI for operator interface.
e) Flotation plant ET200 station.
f) Power control room ET200 station.
g) PCs control room: Two Pcs dedicated to control the process via MPI. h) Hood and steam plant PLC and HMI, located in control room.
i) HP shower control.
j) Suction press roll control cabinet and pneumatic auxiliaries.


IV) SPARE PARTS (Included in the Price)
Complete suction press roll, ready to operate.
Pulper: Plate and rotor refurbished.
Coarse Selector: Drilled plate and rotor
Superscreen: Basket and rotor.
Vibrating screen: drilled plate.
Set Refiner disc.
Yankee rotary joint: 1 PCs- refurbished with original spare parts.
Wire screw jack: 2 pcs
Wire breast roll- refurbished.
Wire and felt guide roll: 3 Pcs refurbish
Pulley for hood fans system: V1,V2, V3, V4 and V5
V1 bearing housing.
FIP shower oscillator fomat: 2 Pcs- refurbished
Berica flotation unit: Helical-Bevel geared motors with variable block, manufactured by SEW
Pressure selector: refurbished shaft unit
Wire and felt positioner: JUD, model SR 694, refurbished complete unit and spare parts.
Refurbished DC motor: Yankee position, pope position, forming position and suction press roll
DCS 500 ABB driver yankee o fan pump position.
DCS 500 ABB driver former
DCS 500 ABB driver suction press roll
DCS 500 ABB driver pope reel
HMI for hood and steam system
PLC power supply PLC PS-407
Analog input 6ES7431-0HH00-0AB0
Digital ouput 6ES7422-1BL00-0AA0
Digital input 6ES7421-1BL00-0AA0