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KGU AppStore

Apps and Downloads

Downloadable apps for benchmarking and estimation of energy consumption and energy saving potential of PM process systems, and OCC balance calculations

Pay-out time of energy saving improvement is also estimated at most of the apps.

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Calculation files can be downloaded in MS Office (.xls) format


Shortcut to applications by area

1. General purpose applications!
2. PM wet end vacuum system applications!
3. Centrifugal pumping applications!
4. Calculate OCC plant mass and water balance!
5. Heat recovery!
6. End of the page!



1. General purpose applications
1. Paper machine line electric energy consumption
FREE
Vacuum system energy consumption

This application is used to compare electric energy consumption of PM line to other machines.
Benchmarking is not the right tool to estimate saving potential, because machine and process concepts vary a lot. Energy saving possibilities, please see other applications



Load Excel file
KGU_App_PM_SEC.xls

 

2. Benchmark vacuum system energy consumption
FREE
Vacuum system energy consumption

Vacuum system is the palce, where often exists hidden energy saving potential.
It can be recommended to run this application, and benchmark the energy consumption of vacuum system.
Pay-out times if improvements can be short.

Tutorial at Youtube


Load Excel file
KGU_App_Vac_SEC.xls

  Compare blog Oct 2012

3. HB slice flow and fan pump capacity
FREE
PM headbox and fan pump capacity requirements

PM headbox slice flow is estimated based on PM production and HB operation conditions. Required fan pump head is also estimated and load is compared to the motor size.
If PM speed is increased,remember to check your fan pump.

Tutorial at Youtube

Load Excel file
KGU_App_HB_Flow.xls


4. Couch dryness
FREE
Dryness after couch roll

Rough estimatation of web dryness after couch roll based on vacuum level and retention time over soul of the roll.
Often couch dryness is maximized, but it is important to remember, that air flow increases exponentially, when the vacuum level is increased.

Tutorial at Youtube

Load Excel file
KGU_App_Couch_Dryness.xlsx


5. Couch air flow
FREE
Air flow from the couch roll

Air flow and required energy consumption of vacuum pumps/blowers are estimatd based on the roll geometry and vacuum level.
This application is typically used together with the estimation of dry content after the couch to find the optimum operation conditions for the roll.

Load Excel file
KGU_App_Couch air flow.xlsx




2. PM vacuum system applications
1. Effect of seal water temperature to vacuum pump capacity
FREE
Effect of seal water temperature to vacuum pump capacity

Capacity change of a vacuum pump is estimated at given air and seal water temperatures.
Change of the pump capacity is displayed as function of vacuum level.

Tutorial at Youtube

Load Excel file
KGU_App_Vac_Sealwater_Temp.xls

  Compare blog Jan 2014

2. Vacuum equipment efficiency ( vacuum pumps )
FREE
Benchmark vacuum pump efficiency

Vacuum pump ( or blower) energy consumption is compared to the best available level that could be achieved.
Energy saving potential ( kW and /a) is estimated for all pumps operating at a poor efficiency level.
In all PM rebuilds or grade change projects, remember to check also the vacuum system.

Load Excel file
KGU_App_Vac_Equipment_SEC.xls

Compare blog Mar 2013

3. Efficiency loss (bleed air) at vacuum level control
FREE
PM vacuum system energy losses because of bleed air flow

At LRP ( Liquid Ring Pump) systems the vacuum level is traditionally controlled with bleed air. Bleed is also used at the blower systems to avoid surge ( minimum load control).

Energy saving potential is estimated in kW and /a.

Tutorial at Youtube

Load Excel file
KGU_App_Vac_Bleed_Loss.xls

Compare blog Sep 2014

4. Efficiency loss because of throttle at PM vacuum system
FREE
PM vacuum system efficiency losses because of throttle at vacuum level control

Vacuum level at PM can also be controlled by throttling the suction lines between PM and vacuum pumps or blowers.

This throttle causes pressure drop and expansion of the air.

Vacuum system efficiency loss ( kW and /a) is estimated based on the pressure drop and air flow

Load Excel file
KGU_App_Vac_Throttle_Loss.xls

Compare blog Oct 2014

5. Efficiency of felt conditioning
FREE
Benchmarking of press section felt dryness and felt conditioning

PM production and felt measurement data are needed for benchmarking the efficiency of the uhlebox.
Felt water balance is displayed
Benchmarking is done by plotting dewatering at the uhlebox as function of felt moisture

Tutorial at Youtube

Load Excel file
KGU_App_Vac_Felt_Conditioning.xls

  Compare blogs Feb 2014
  and Oct 2014

6. Feasibility of variable speed drive at vacuum pump
FREE
Feasibility of variable speed drive at vacuum pumps

The efficiency losses of PM vacuum system ( bleed of throttle) can be eliminated with variable speed drive.

Energy saving potential and feasibility (=pay-out time) of installation of VSD to a vacuum pump is estimated with this application.

Load Excel file
KGU_App_Vac_Pump_VSD.xls

Compare blog Nov 2014

All in one - Vacuum system
Desktop study of PM vacuum system - Estimation of energy saving potential

Vacuum system desktop study, including execution of all applications based on the data given by the mill.

Results of the study (efficiency losses, equipment efficiency etc..) are estimated and explained on a separate report.

Costs are minimized, if all the work is done at KGU home-office, ( = no travel costs)

Brochure
Vacuum_Desktop_Model_Description

KGU Services
www.kgu.fi/services.html

  Compare blogs, 2014



3. Centrifugal pumping applications
1. PM wet end high pressure showers, VSD and water consumption
FREE
Variable speed drive at the pumps of PM wet end high pressure showers

High pressure pumps are needed at PM wet end high pressure needle showers. Often operation pressure is lower compared to the design, and pressure level is throttled with a valve.
Feasibility (pay-out time) of installation of variable speed drive (VSD) can be estimated with this application.

Tutorial at Youtube

Load Excel file
KGU_App_HP_Pump_VSD.xls

  Compare blog, Nov 2014
2. Feasibility of pressurized dosing compared to stuff box
FREE
Feasibility of variable speed drive at basis weight control of paper machine

Basis weight of the paper is traditionally controlled with a valve, and incoming thick stock pressure is stabilized with the stuff box.

Energy saving potential and feasibility (=pay-out time) of installation of VSD to the thick stock pump is estimated with this application.

Load Excel file
KGU_App_Thick_Stock_Dosing.xls

Compare blog Dec 2014

3. Circulation loss of pressure control
FREE
Feasibility of variable speed drive at pressure control instead of circulation

Especially at older machines, pressure is at some positions clontrolled with circulation back to the pump feeding tank.

Energy saving potential and of installation of VSD to the the pressure control is estimated with this application.

Load Excel file
KGU_App_Pump Circulation.xlsx




4. OCC plant mass and water balances
1. OCC line pulping
FREE
Material balance of OCC line pulping

Estimate the material, water and dirt flows at OCC line Pulping area.

Rejects flows are estimated based on the dirt content of the raw material.

Load Excel file
KGU_App_1_OCC_Pulping.xls


2. OCC line coarse screening
FREE
Material balance of OCC line pulping

Estimate the material, water and dirt flows at OCC line coarse screening.

Calculation needs feed consistency and reject rates of screens. Mass flow, water flows and dirt contents are estimated.

Load Excel file
KGU_App_2_OCC_Coarse_scrn_CAS.xls


3. OCC line cleaning
FREE
Material balance of OCC cleaning

Estimate the material, water and dirt flows at OCC line centrifugal cleaning.

Calculation needs feed consistency and reject rate of cleaners. Mass flow, water flows and dirt contents are estimated.

Load Excel file
KGU_App_3_OCC_Cleaning.xls


4. OCC line fine screening
FREE
Material balance of OCC cleaning

Estimate the material, water and dirt flows at OCC line fine screening.

Calculation needs feed consistency and reject rate of screens. Mass flow, water flows and dirt contents are esimated.

Load Excel file
KGU_App_4_OCC_Fine_scrn_CAS.xls


5. OCC line thickening
FREE
Material balance of OCC cleaning

Estimate the material and water flows at OCC line thickening, and effluent amout

Calculation needs feed consistencies and water flows from the paper machine. Mass and water flows are esimated.

Load Excel file
KGU_App_5_OCC_Thickening.xls


6. OCC line reject handling
FREE
Material balance of OCC cleaning

Calculation needs rejects amounts and water flow from the OCC. Mass flows, water flows and effluent COD and TSS are esimated.

Note! Reject amounts can be given manually, or the file can be linked to the other files to get these values automatically.

Load Excel file
KGU_App_6_OCC_Balance and Rejects handlng.xls




5. Heat recovery applications
1. Water heating with condensate
FREE
Water heating with conensate

Estimation of fresh water heating with the condensate from the dryer section

Note! Additional heating is often required from the hood exhaust.

Tutorial at Youtube

Load Excel file
Utilize conensate temperature.xlsx


2. Heat recovey and supply air heating
FREE
Water heating with conensate

Estimation of hood exhaust air heat recovery and use of condensate at supply air heating.

Note! Additional heating with steam coil is always needed, but the consumption of steam can be decreased

Tutorial at Youtube

Load Excel file
Supply air heating.xlsx



Phone:    +358 45 168 2404
Email:      kari.u.kokkonen@gmail.com
Adress:     Pikkukonka 6. 40520 JKL, Finland



Note !
The energy saving calculations in these pages and calculation apps are estimates, and should be considered to give rough guidelines only.
Final decisions of improvement projects should be done only based on more detail engineering work ( for example the pump curves should always be checked).