EVAPS High-Performance Evaporation Systems
Fibria Celulose Très Lagoas, Brazil New XXL size, 6-effect EVAPS plant with a capacity of 1250 tons/h, producing heavy liquor of 80 % dry solids. TUBEL Concentrator and patented LP boosting for highest availability and flexibility. Best EPC supplier Eldorado Celulose e Papel awarded Valmet Best EPC supplier for the delivery to the mill in Três Lagoas, Brazil. Continued success Thanks to their high availability and economical operation, our fiberline and chemical recovery installations are key contributors to the success of a great number of the world s largest and most profitable pulp mills. Eldorado Celulose e Papel, Brazil Your Partner for Trouble-Free Evaporation New XXL size, 6-effect EVAPS plant with TUBEL Concentrator and patented LP boosting for highest availability and flexibility. Evaporation capacity is 1600 tons/h, with heavy liquor dry solids at 80 %. Pre-Study for New Evaporation Plant Service Visits & Studies Valmet is a leading supplier of evaporation plants and boilers for the pulp & paper and power industries worldwide. Thanks to their high availability and economical operation, our fiberline and chemical recovery installations are key contributors to the success of Efficiency a Energy Upgrade great number of the world s largest and most profitable pulp mills. Experience Full range of solutions Our specialists have accumulated experience from more than 400 major evaporation and condensate treatment projects around the world. We have long and extensive experience in building new evaporation and condensate treatment plants and in upgrading existing ones. Many upgrades incur very little downtime and provide increased capacity, higher dry solids content, better energy efficiency, improved condensate quality and more efficient operation. We also provide a full range of customized support services such as process analysis, studies, troubleshooting, and operator training. Mill-wide capability All our engineering and service specialists in fiberlines, evaporators, recovery boilers, recausticizing, power boilers and other product lines can be engaged to solve your mill problems. As one of the world s largest construction technology companies, we have the internal expertise to provide the necessary engineering services for your project. Performance test Pre-Study for New Evaporation Plant Service Visits & Studies Effective project execution Energy Efficiency Upgrade Performance test Simulator training Simulator training Plant inspections Effective project execution Plant inspections Global operations local presence Our global network of sales and service companies provides a wide range of products and services. These are backed by our comprehensive team of specialists and our own workshops for the manufacture of core equipment. Replacement of Evaporators Plant station Plant station Valmet office station Valmet office station Remote Service Remote Service Replacement of Evaporators Boosting of Capacity Optimization and Information System Boosting of Capacity Computer Based Training Computer Based Training Lifetime Remote Remote Service Service Environmental Upgrades Optimization and Information System Environmental Upgrades We build new installations, and provide products and services that support and enhance the performance of your mill throughout its lifetime. We call it Lifetime. 2 3
Cutting-Edge Evaporation Technology Stora Enso Skoghall, Sweden Complete new falling film evaporation train with excellent 9+-effect steam economy, integrated CTMP liquor evaporation and efficient condensate handling. Capacity: 580 tons of black liquor and 173 tons of CTMP liquor per hour, 80% DS product. We have a lot to offer when you want to improve your evaporators. Our innovative solutions have been used in more than 400 evaporation and condensate treatment plant projects around the world. Suzano Papel e Celulose, Maranhão, Brazil New cutting-edge XXL size, 6-effect EVAPS plant. Concentrator and effect 2 are of TUBEL technology, producing heavy liquor of 80% dry solids using only low pressure steam. Capacity 1600 tons/h. Reliable An evaporator must mechanically withstand the design pressure and temperature over many years of service. To maintain evaporator capacity, the risk of plugging must be minimized. In the TUBEL Concentrator, liquor is evaporated on the outside of the tubes, eliminating the risk of plugging. Moreover, the tubular design used in all our evaporators provides superior strength and longer life. Our evaporators are known for their outstanding reliability. High dry solids We pioneered Super Concentration and high dry solids firing in the mid- 1980s. Since then, we have installed most of the world s concentrators that produce liquor in the 80 85% concentration range. Increasing dry solids concentration improves recovery boiler capacity and performance, and increases steam production. Consequently, when the bottleneck of a mill is its recovery boiler, our Super Concentration concept boosts mill capacity. Energy efficient Evaporation of black liquor is the largest single consumer of process steam in a pulp mill. Valmet has solutions ready to take energy efficiency one step further. Our High Efficiency EVAPS concept includes optimized mill energy solutions, for an optimized life-cycle cost of the evaporation plant. Environmentally friendly Our technology enables effective removal of organic contaminants, and maximum reuse of condensates as process water in the pulping process. Arauco Nueva Aldea, Chile Complete evaporation plant with TUBEL Concentrator and TUBEL Super Concentrator. Total evaporation capacity: 1300 tons/h, 80% DS product. Mondi Packaging Dynäs, Sweden Valmet built a uniquely configured 6-effect evaporation train in the very limited space within the walls of an old chemical recovery boiler building. TUBEL Concentrator. Evaporation capacity: 330 tons/h, 75% DS product. 4 5
ASIA SYMBOL Rizhao, China Sappi Cloquet, MN., USA TUBEL Super Concentrator and TUBEL Concentrator for higher final dry solids and improved availability. Burgo Ardennes, Belgium View of the new TUBEL Super Concentrator. Two-train evaporation plant, Super Concentrator systems, 6+-effect heat economy, capacity: 2x1000 tons/h, 80% DS. Concentrator and Super Concentrator are of TUBEL technology, excellent condensate segregation and treatment. TUBEL for Excellent Availability Excellent availability in high dry solids/scaling applications Our well-proven TUBEL design has been shown to provide greater availability. The open design eliminates tube plugging. Falling film liquor is evaporated on the outside surface of the tubes by the steam/vapor on the inside. If scaling occurs, the convex shape of the tube surface makes on-line washing easy. There is normally no need for off-line washing with hydroblasting in kraft liquor applications. Mechanically reliable Proven, automated manufacturing methods in our own workshops ensure consistent TUBEL quality. Steam of high temperature and pressure Steam of high temperature and pressure can easily be used to achieve higher capacity, or to reduce viscosity at very high dry solids contents. 6 Compact concentrator Applications When available space is limited, a TUBEL Concentrator is normally designed with one shell divided into two or more sections. In order to achieve the best operating characteristics, steam and liquor circuits in the concentrator sections are controlled separately. TUBEL is the ideal solution for applications where scaling problems may arise and is therefore very suitable for concentrators. Moreover, the mechanical reliability of old plate-type units can be improved by replacing their heating surfaces with TUBEL elements. Key benefits Very high dry solids content without scaling problems Suzano Papel e Celulose, Mucuri, Brazil CMPC Celulose Riograndense, Guaíba, Brazil New cutting-edge XXL size, 6-effect EVAPS plant. Concentrator and effect 2 are of TUBEL technology, producing heavy liquor of 80% dry solids using only low pressure steam. Capacity 1100 tons/h. New XXL size, 6-effect EVAPS plant, capacity 1740 tons/h, 80 % DS. TUBEL concentrator for highest availability and easy washing. Very high availability Can always be washed clean during operation High mechanical reliability Low life-cycle cost Low electrical costs Avoid hydroblast costs 7
REVAP Concentrator Falling Film Tube Evaporator High dry solids possible using only LP steam Excellent condensate segregation, small footprint REVAP is a proven solution for high dry solids operation, without the need for MP steam. Recycled vapor flowing over the surface of the liquor film creates turbulence in the film. This results in improved heat transfer, which is well suited for high viscosity liquor. Vapor recycling increases turbulence of the liquor film. It substantially improves heat transfer at high dry solids concentrations. Key benefits Proven solution for high dry solids operation Well suited for high viscosity liquor High dry solids possible using only LP steam High availability High mechanical reliability Our tubular falling film evaporator is well proven and mechanically reliable. An innovative arrangement with more efficient horizontal flow droplet separators provides a smaller footprint than other falling film designs. This is especially advantageous when adding additional units in an existing evaporation train. Excellent condensate segregation and high evaporation capacity in a single vessel are two of the other major benefits of our falling film evaporator design. Key benefits Excellent condensate segregation Mechanically reliable design High evaporation capacity in single vessel Simple, stable operation Small footprint 1C 1B 1A CMPC Celulose Riograndense, Brazil Bahia Specialty Cellulose, Brazil Complete new 6-effect train with patented LP boosting, designed for dissolving pulp liquor. Recently upgraded to 810 tons/h, 80 % DS. Complete new train with on-demand washing and REVAP Concentrator. Evaporation capacity: 430 tons/h, 75% DS product. Suzano Papel e Celulose, Limeira, Brazil Falling film evaporation plant with 6-effect heat economy, REVAP Concentrator. Evaporation capacity: 370 tons/h, 75% DS product. Greatly improved condensate quality. 8 Celbi, Portugal Valmet built a complete 7-effect evaporation plant including TUBEL Concentrator. Evaporation capacity: 590 tons/h, 74% DS product. 9
Klabin Paraná Papéis, Monte Alegre, Brazil Evaporation upgrade including REVAP Super Concentrator. Capacity: 770 tons/h, 80% DS. Improved condensate handling: all condensates are successfully recycled in the mill. High-Performance Condensate Handling BillerudKorsnäs Gävle, Sweden New evaporation plant, capacity: 750 tons/h, 75% DS product, replacing four existing evaporation plants. Optimized energy handling, very low steam consumption; mill oil consumption 50% lower. Efficient condensate segregation and treatment. District heating integrated in the evaporation plant. Condensate segregation Evaporators heated with contaminated vapor are equipped with our well-proven design for internal vapor segregation. With this design, 80 90% of the malodorous contaminants in the vapor may be segregated into a small foul condensate fraction. This small stream of foul condensate is normally cleaned in the condensate treatment plant. Larger streams of clean and intermediate condensates are usually reused as wash and/or dilution water in the fiberline and recausticizing plant. This substantially reduces consumption of fresh water and bleaching chemicals. Condensate treatment Our condensate treatment plant is designed for optimal cleaning of contaminated condensates from the cooking and evaporation plants. It can be operated independently or be integrated with the evaporation train for improved overall heat economy. Internal condensate treatment In an evaporation plant with internal condensate treatment (ICT), condensates are recycled and treated inside Valmet Tube Evaporators. Intermediate B-condensates are converted into clean A-condensates that can be re-used in the mill. NCG treatment We are a leading designer and supplier of NCG treatment systems for the Vapor Large flow of cleaner condensate Small flow of foul condensate Efficient internal vapor segregation in a Tube Evaporator collection, handling and incineration of both weak and strong non-condensable gases formed in pulp mills. Methanol distillation Condensate treatment plants may also be equipped with a methanol plant. Liquid methanol product may be combusted in the recovery boiler, the lime kiln, or in a separate incinerator. Enriched volatile compound venting Volatile compound enriched vapor Segregation plate Customized systems Modern evaporation plants are designed not only for concentrating black liquor for combustion in the recovery boiler, but also for removing malodorous substances, and reducing pollution to air and water. Condensate segregation in evaporators Condensate treatement plant Stripper gas, to incineration Each new Valmet evaporation plant is designed with an optimized condensate segregation system for effective removal of malodorous compounds. Our experience shows that it is possible to attain an overall methanol removal efficiency of more than 97%. Our evaporation plant can produce clean condensates that can be reused 100% in the pulp mill, which minimizes overall water consumption. Clean condensate Intermediate condensate Foul condensate from external sources Foul condensate Treated condensate In order to obtain clean condensates that can be reused in the pulp mill, we combine customized condensate segregation in the evaporators with an efficient condensate treatment plant. Valmet is the world s leading supplier of condensate treatment and methanol plants, with more than 200 successful installations in operation worldwide. BillerudKorsnäs Gruvön, Sweden Gruvön s evaporation train features internal condensate segregation and an XL stripper. Up to 500 tons of contaminated condensate per hour is processed into super clean condensate. 10 11
Mercer Celgar, Canada Five-effect train with REVAP Concentrator. Evaporation capacity 582 tons/h, 75% DS product. SCA Obbola, Sweden Seven-effect plant with TUBEL concentrator. Evaporation capacity 270 tons/h, 75% DS product. Improved steam economy and condensate segregation. Cenibra - Celulose Nipo-Brasileira, Brazil Installation of two MVR pre-evaporators for significantly improved overall steam economy and condensate segregation. Capacity 235 tons/h. Iggesund Paperboard, Sweden Existing train replaced with a new one: increased capacity and dry solids content. Improved condensate segregation, steam economy and availability. Advanced and Effective Evaporation Features Super Concentration high dry solids content Our Super Concentration systems have a proven capability to produce black liquor of 85% dry solids content. This allows Super Combustion in the recovery boiler.we installed the first Super Concentration system in 1986 and it immediately went into full-scale operation, with excellent results. A large number of similar installations have since been commissioned. A few of the benefits of the Super Concentration system are: Increased liquor processing capacity Higher steam production Positive effect on steam balance Reduced soot blowing steam consumption Easy and stable recovery boiler operation Good sulfur balance control Low emissions Evaporation of secondary sludge Biosludge from the effluent treatment plant can be mixed with the black liquor and evaporated to high dry solids content for subsequent combustion in the recovery boiler. Evaporation, and combustion in the recovery boiler, is a cost-effective and environmentally acceptable way to dispose of biosludge. Viscosity control When operating on liquors with high dry solids content, viscosity is the limiting factor, not scaling. Our mechanically reliable tubular design allows you to use medium pressure steam to control the liquor temperature and viscosity. On-demand washing Evaporator washing is fully automated. The washing need is evaluated over time for each of the concentrator units. The washing of one individual unit of the concentrator is started on demand (washing only when needed). The product liquor dry solids content of the concentrator is maintained also during the washing of one unit. This ensures operational stability in both the recovery boiler and evaporation processes. Boosting of LP steam Valmet s patented boosting of low pressure steam provides the evaporation plant with extra flexibility and reliability. Capacity or final dry solids content may easily be increased by adding only a small amount of medium pressure steam. Valmet s advanced process control system stabilizes operation of the evaporation plant and improves recovery boiler performance. The result is lower emissions and improved operation of the recovery boiler. Black Liquor Evaporation Optimization A stable dry solids content of the product liquor makes it possible to keep the recovery boiler cleaner, and operate it with lower emissions and longer time between shutdowns. Our advanced process control system for evaporators stabilizes evaporation operation and manages external variations, such as level changes in storage tanks, variations in incoming weak liquor flow, dry solids changes, etc. MVR Evaporator MVR (Mechanical Vapor Recompression) evaporators are suitable for concentrating liquors with a low boiling point rise. MVR is used for BillerudKorsnäs Skärblacka, Sweden New evaporation plant, capacity 500 tons/h, 75% DS product, replacing existing evaporators to significantly improve energy efficiency of the mill. Efficient condensate segregation and treatment in order to produce clean condensates that can be reused in the mill. black liquor pre-evaporation, sulfite spent-liquor evaporation and evaporation of mill effluents. MVR is a very good way to improve condensate segregation and has outstanding overall steam economy. Evaporation of bleach plant and CTMP effluents Minimizing bleach plant or CTMP effluents is an important step in achieving environmentally-friendly pulp mills. Our solution to this is integrated pre-evaporation in falling film Tube Evaporators specially equipped with systems that minimize scaling problems. Metsä Fibre Äänekoski, Finland Upgrade of existing evaporation train with TUBEL Super Concentrator system, increased capacity and 80% DS product. 12 13
Quick Rebuilds & Upgrades Services to Improve Your Performance Improved performance and minimum downtime When it comes to rebuilds, factors like capacity increases, environmental considerations, safety, outage periods, investment and operational costs must be taken into consideration. We always develop our rebuild concept in cooperation with the pulp mill. This ensures the right results, with the right effort, at the right time. From rising film to falling film A falling film evaporator always provides the same high performance, while a rising film evaporator has poor performance at low loads. A falling film conversion can be a very efficient way to increase evaporation capacity and final dry solids content. We have successfully upgraded more than 50 evaporators from rising film to falling film technology. All mills have different requirements and our evaporation specialists will work with you to find the right solution for your mill. Step-wise renewal In many plants, new evaporation effects are added until there is no more space available. Additionally, upgrading an evaporation train has to be done with minimum impact on evaporation uptime. Step-wise renewal is the Valmet solution. Our comprehensive knowhow in evaporation processes and demanding, high-speed erection work enables us to remove an old effect and put a new one in its place, while keeping the evaporation plant fully operational. Moreover, thanks to the small footprint of our Tube Evaporator, the heating surface area may often be doubled when replacing an old rising film evaporator. Step-wise renewal gives you a staged upgrade of your plant in a cost-effective way, with minimum outage. This means minimum impact on production, increased evaporation capacity and maximum profitability. Södra Cell Mönsterås, Sweden Installation of a new TUBEL interior in the shell of what originally was a platetype concentrator. Cenibra, Brazil Upgraded with REVAP Concentrators and step-wise capacity increase. Inspections Our inspectors give you a precise picture of the operating status of your equipment. Our inspections provide the basis for preventive maintenance and process improvement work. Process optimization & troubleshooting Our service engineers work on assignments all over the globe, optimizing plant processes. Environmental studies Our studies provide a comprehensive and reliable condensate quality evaluation. They also show how consumption of fresh water and chemicals, as well as air and water pollution, can be reduced. Service Agreements A Service Agreement with us puts the focus on the measures required to keep your mill or plant fit and profitable. Our customers report results like achievement of production targets, increased availability and higher quality. Inspection and troubleshooting become an inherent part of a strategic, long-term program for keeping your plant competitive. The benefits: Activities are geared towards common targets We focus on the real problems Our reports constitute very useful documentation; results, suggestions and recommendations A long-term relationship establishes mutual commitment. Sharing our expertise is a sure way of attaining full plant potential Your advantages: increased evaporation capacity increased dry solids capability improved operation optimized steam economy improved condensate quality Most rebuilds can be carried out with minimum outage Smurfit Kappa Kraftliner, Sweden Plate-type concentrators upgraded with TUBEL heating surface area in order to increase availability and decrease steam consumption. Stora Enso, Veitsiluoto, Kemi, Finland Step-wise renewal over several years time. Munksjö, Aspa, Sweden Step-wise renewal over several years time. Training A state-of-the-art plant is nothing without state-of-the-art people. Our training programs and simulators make it easy for your people to understand your plant, and improve its operation. Capacity evaluation A capacity evaluation shows you how your capacity can be increased. This provides invaluable input when it comes to keeping your competitive edge. Evaporation Research Center Valmet and Chalmers University of Technology operate an evaporation research center in Gothenburg, Sweden. A fully equipped and very well instrumented research evaporator based on TUBEL technology delivers accurate and detailed information on evaporation characteristics for various black liquors and pulp and paper mill effluents. This unit is an excellent tool when studying new evaporation concepts that use less energy, produce higher dry solids content, offer improved scaling control and produce cleaner condensates. Our evaporation research center has been used to develop several full-scale evaporation projects, and it is available for testing your liquor. 14 15
Valmet s professionals around the world work close to our customers and are committed to moving your performance forward every day. LinkedIn.com/company/valmet Twitter.com/valmetglobal Youtube.com/valmetglobal Facebook.com/valmetcorporation www.valmet.com For more information, contact your local Valmet office. www.valmet.com Specifications in this document are subject to change without notice. Product names in this publication are all trademarks of Valmet Corporation. Valmet Corporation, HPGB_B_2300_084-02 02/2016.