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F I R S T I N F I B E R

Portucel Setúbal Integration Project Andritz Stock Cleaning and


Portucel –Empresa Produtora de Pasta e Papel, SA Deaeration System
2901 – 861 Setúbal Codex
Portugal Technical Specification - FINAL

Project No: C-02-802989-009

Contract: 45195992

Date: October 30, 2008

Confidential document. All rights reserved. No duplication or disclosure to third parties


permitted without the written consent of Andritz AG.
FIBER PREPARATION SYSTEMS

TABLE OF CONTENT

1. Technical proposal................................................................................................................... 3
1.1 Technical summary ............................................................................................................ 3
1.1.1 Basic Design data...................................................................................................... 3
1.2 Technical specifications...................................................................................................... 5
1.2.1 One (1) Flying Wing Deculator® Ø2500x8500 Dual.................................................. 5
1.2.2 Deculator Cleaner Bauer 608 .................................................................................... 7
1.2.3 One (1) Andritz TwinCleaner TC133 Plant ............................................................... 8
1.2.4 One (1) Vacuum System Pre-Condenser ................................................................ 10
1.2.5 One (1) Primary Vacuum Pump and Interstage Water Separator ........................... 11
1.2.6 One (1) Secondary Vacuum Pump and Final Water Separator and Silencer.......... 12
1.3 Spare parts ....................................................................................................................... 13
FIBER PREPARATION SYSTEMS

1. TECHNICAL PROPOSAL

1.1 Technical summary

1.1.1 Basic Design data

The following design data is only for information.

Paper grades Uncoated surface sized printing and writing paper


- grammage g/m2 60 – 100
Most common g/m2 80

Paper furnish, average


- Bleached long fibre kraft pulp % 0 – 30
- Bleached short fibre kraft pulp
(eucalyptus) % 70 – 100
- Filler (PCC) % 13 – 25
- Starch to be added on the surface
sizing g/m2 3–4

Design production on at pope reel


with 100 % efficiency, 80 g/m2 t/d 1940

Moisture at reel % 4.0

Design data for Cleaner and Deaeration System

The requirements by the PM alternative suppliers impose 2 basic dimensioning


alternatives. The basis for the quotation shall be a dilution type headbox with following
design data in all alternatives.
Filler+
Fibre cons. flow
kg/s % l/s

Dimensioning flow through PM slice (1800 m/min, 60 g/m2)

30.59 1.17 2 615


Slice consists of:-
- stock 29.32 1.25 2 354
- white water 1.23 0.47 261

Recirculation from headbox manifolds to deaeration tanks:


- stock % 9
- white water % 10

Reject rate from the screens:


- stock primary screen (% of weight) % 7
- white water screen (% of volume) % 10

Stock temperature in headbox °C 45


pH 7–8

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

Air in stock (by volume) in


infeed to deaeration % 2.5

Wire pit consistency % 0.25 – 0.47


White water tank consistency % 0.25 – 0.47
(for possible dilution of a cleaning stage)

White water header consistency % 0.016


(for possible dilution of last cleaning
stages and for stock saver’s action water)

Equipment elevations
- basement floor +0.000
- headbox slice +10.000
- wire pit +10.000
- cleaner plant +8.000
- deaeration tanks +21.500
- vacuum system +16.000

Fresh water temperature °C 30

Flow rate to headbox can vary between 1 551 – 2 615 l/s. The headbox consistency varies
for different basis weights from 1.17 – 1.40 %.

Vacuum system
- flow to be deaerated l/s 3346
- air content % 2.5
- stock temperature °C 45
- condensing water temperature °C 30
- seal water temperature °C 30

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2 Technical specifications

1.2.1 One (1) Flying Wing Deculator® Ø2500x8500 Dual

Technical data:
Deculator® receiver diameter: Ø2500 mm
Deculator® receiver shell length: 8500 mm
Wing diameter (cleaner accept header): Ø900 mm

Main stock outlet connection: DN1500


Overflow outlet connection: DN1300
Vacuum outlet connection: DN700
Headbox recirculation inlet connection (thin stock): DN300
Dilution water inlet connection: DN400
Dilution water outlet connection: DN600
Headbox recirculation inlet connection (dilution water): DN125
Roof spray manifold inlet connection: DN50
Primary cleaner feed manifold inlet connection: DN350
Primary cleaner reject manifold outlet connection: DN250
Secondary cleaner feed manifold inlet connection: DN350
Secondary cleaner reject manifold outlet connection: DN250
Tertiary cleaner feed manifold inlet connection: DN200
Tertiary cleaner reject manifold outlet connection: DN250

Number dilution water Spinjet nozzles: 4 pcs


Number of cleaner stages on the Deculator: 3 pcs
Number of wings: 7 pcs

Number of primary cleaner connections: 250 pcs


Number of secondary cleaner connections: 48 pcs
Number of tertiary cleaner connections: 20 pcs

Number of primary wings: 5 pcs


Number of secondary wings: 1 pc
Number of tertiary wings: 1 pc

Scope of supply:
Main receiver tank:
Made of stainless steel material EN1.4404 (or equal) including: shell; dished ends, all outlet and
inlet connections listed above; overflow weirs; wing baffles on main section, reinforcing rings;
dilution water nozzles; sight glass frames, connections for level, temperature and pressure
measurement; local temperature gauge; interior surface finish Ra 0.8 µm;

Vortex Breakers:
For main stock outlet, overflow outlet and dilution water outlet made of stainless steel material
EN1.4404 (or equal);

Sight glasses;
Made of borosilicate; O-ring seals (EDPM);

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

Manhole DN600;
Made of stainless steel material EN1.4404 (or equal); EDPM seal;

Receiver support saddles:


Upper saddles made of stainless steel material EN1.4301 (or equal).
Lower saddles made of mild steel; surface treatment according to SFS-EN ISO 12944-5/S4.13
(EPPUR 240/3-FeSa 2 1/2); final colour RAL 7012 (dark grey).

Wing assembly:
Made of stainless steel material EN1.4404 (or equal) including: Feed, accept and reject manifolds
(2 of each/wing); Threaded 1” female connection for flushing on the end of reject manifold; cleaner
feed elbows; reinforcing rings; connections for electronic pressure transmitters (1 pc/stage);
Threaded ½” female connections for local pressure gauges (1 pc/wing); Threaded 1” female
connection with cap on top of the wing for pressure testing; interior surface finish Ra 0.8 µm;

Wing supports:
Support steelwork including cleaner support clamps made of stainless steel material EN1.4301 (or
equal); foundation bolts made of mild steel;

Spray nozzles:
For roof washing Spraying Systems Deflectojet 8686 – 3/8 – 316SS 5 – 180; for vacuum
connection Delavan ¾” AFF100 316SS;

Exclusions:
Local instrumentation:
One (1) single capillary level transmitter in main receiver and one (1) in dilution water section; one
(1) absolute pressure transmitter; three (3) feed pressure transmitters (1/stage); one (1)
temperature sensor and transmitter;

Piping; main outlet reducer; overflow outlet reducer; service platforms and stairs; outputs from
transmitters to DCS; foundations and foundation plates; isolation valves;

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2.2 Deculator Cleaner Bauer 608

Technical data:
Maximum feed pressure: 4.5 bar
Maximum operating temperature: 88 °C
Nominal pressure drop: 1.5 bar
Nominal capacity per cleaner: 11.67 l/s
Weight, empty: 21 kg
Weight, operating: 49 kg

Scope of supply:
Cleaner unit:
Cleaner body and middle cone made of fiber glass reinforced nylon; lower cone (reject tip) made of
ceramic; threaded sight glass made of Grilamid TR-55 Nylon (PA);

Feed and accept connections:


Connections with 3” Victaulic couplings style 75 FEZN/EDPM made of mild steel hot dipped
galvanised;

Gaskets:
Profile gaskets for reject manifolds; deflecting grommets for sight glasses – material EDPM;

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2.3 One (1) Andritz Twin Cleaner TC133 Plant

Technical data:
feed flow per twin cleaner 12,4 l/s
pressure drop: 1,3 bar
max. feed pressure: 3 bar
Number of cleaner stages: 5

Stage Type of Type of Cleaners Cleaners Empty


cleaner cone installed in banks spaces

4. Stage TC133 ribbed 8 8 0


5. Stage SC133VC ribbed 5 6 1

Scope of supply:

Feed Head
with accept pipe, made of Polypropylene

Classifier pipe
made of Polypropylene

Separating cone
made of ceramic

O-ring seals
made of nitrile rubber

Sight glasses
made of Polyamide

Vortex Control nozzles


instead of Sight Glasses, only supplied if Type of Cleaner is TC/SC133VC

Headers
Feed, accept, and reject manifolds, made of stainless steel acc. to mat. EN 1.4404
pipe connections DIN flanged
connections for air-relief with shut-off valves, R½" female thread
connections for pressure transmitters (type PMC or equal), 3 pcs / stage, made of stainless steel
acc. to mat. EN 1.4404

Reject Pipes
with reject hoses, made of nitrile rubber

Support frames
Made of stainless steel acc. to mat. EN 1.4301

Foundation bolts

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

Base plates and anchors

Special tools
One (1) key for the cone
One (1) unplugging device

Available options: Andritz Customer

Three (3) electronic pressure transmitters for each stage


x
Electric instrumentation case
local field box; Pressure manometers fitted on the box door; internal wiring
of manometer box to the terminals; manometer box's fitting and layout x
drawing

Installation; installation material and cabling outside the manometer box


X
Damped pressure gauges
x

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2.4 One (1) Vacuum System Pre-Condenser

Technical data:
Type Shell & Tube Heat Exchanger
Dimensional drawing later

Design pressure, inner channel (air/vapour) 3.0/-1.0 bar


Design pressure, outer channel (water) 3.0 bar
Design temperature 100 °C
Cooling water flow 2315 l/min
Diameter 640 mm
Total height 3000 mm
Orientation horizontal
Air/vapour inlet connection DN500
Air/vapour outlet connection DN300
Cooling water inlet connection DN200
Cooling water outlet connection DN200
Condensate outlet connection DN50
Vent connection DN25

Scope of supply:

Shell:
Made of stainless steel material EN1.4404 (or equal) including: Un-flanged vacuum inlet and outlet
connections; flanged water and condensate drain connections

Tube bundle:
Heat transfer pipes made of stainless steel material EN1.4404 (or equal)

End plates:
Made of mild steel with stainless steel lining according to material EN1.4404 (or equal); surface
treatment according to SFS-EN ISO 12944-5/S4.13 (EPPUR 240/3-FeSa 2 1/2); final colour RAL
7035 (light grey).

Supports:
Made of mild steel, surface treatment according to SFS-EN ISO 12944-5/S4.13 (EPPUR 240/3-
FeSa 2 1/2); final colour RAL 7035 (light grey).

Exclusions:
Vacuum piping made of stainless steel material EN1.4404 (or equal); seal pit made of stainless
steel material EN1.4404 (or equal)

Instrumentation

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2.5 One (1) Primary Vacuum Pump and Inter-stage Water Separator

Technical data:
Type Nash 2BE3
Dimensional drawing 778495-1-A001-1

Seal water flow 555 l/min

Scope of supply:
Liquid ring vacuum pump ASTM A283 Grade C + Polyisoprene lining
Foundation blocks with bolts (only for pump) DIN799
V-belt guard Mild steel with surface treatment
V-belt drive (belts, pulleys and bushings)
Seal water orifices EN1.4404 (or equal)
Start-up screens EN1.4404 (or equal)
Inter-stage water separator EN1.4404 (or equal)
Seal water piping EN1.4404 (or equal)
Inlet and discharge manifolds EN1.4404 (or equal)

Exclusions:
Vacuum and seal water piping other than specified above made of stainless steel material
EN1.4404 (or equal); Strainer, adjusting and shut-off valves made of stainless steel material
EN1.4404 (or equal); Base for motor and motor sliding rails made of mild steel
Motor: 315/1500 kW/rpm
Instrumentation

Note:
Seal water piping with orifice plate(s) included in the scope comprises only piping at the vacuum
pump no longer than half meter from the vacuum pump with connection to a water supply line.

A minimum water separator drop leg is 10.4 m from the seal pit level to the drain outlet of the
separator.

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.2.6 One (1) Secondary Vacuum Pump and Final Water Separator and Silencer

Technical data:
Type Nash XL250
Dimensional drawing later

Seal water flow 114 l/min

Scope of supply:
Liquid ring vacuum pump Ductile iron/ASTM A536
Common base for pump and motor including Mild steel with surface treatment
Motor slide rails
Foundation bolts Mild steel
V-belt guard Mild steel with surface treatment
V-belt drive (belts, pulleys and bushings)
Spray nozzle EN1.4404 (or equal)
Seal water orifices EN1.4404 (or equal)
Start-up screens EN1.4404 (or equal)
Final water separator EN1.4404 (or equal)
Seal water piping EN1.4404 (or equal)
Silencer DN200 EN1.4404 (or equal)

Exclusions:
Vacuum and seal water piping other than specified above made of stainless steel according to
material EN1.4404 (or equal); strainer, adjusting and shut-off valves made of stainless steel
according to material EN1.4404 (or equal);
Motor: 75/1500 kW/rpm
Instrumentation

Note:
Seal water piping with orifice plate(s) included in the scope comprises only piping at the vacuum
pump no longer than half meter from the vacuum pump with connection to a water supply line.

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007


FIBER PREPARATION SYSTEMS

1.3 Spare parts

Spare parts for FWD-system

FWD
2 pc Sight glass
2 pc O-ring for sight glass
2 pc Spray nozzle for washing roof
1 pc Rubber seal for the manhole (NS600)

Bauer608
20 pc Upper Nut
10 pc Middle Cone
20 pc Seal Ring
20 pc Lower Nut
10 pc Threaded Ceramic Cone 2-1/2" x 1" orifice
20 pc Threaded Sightglass
20 pc O-Ring

2BE3
1 set Repair kit

XL250
1 set Repair kit

Customer Portucel Setúbal Integration Project Quotation No.: 1125982,4716-2

Date:: November 30, 2007