VER3645 - 3710 mm Coated Board Mill

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Board machine
Supplier: ERWEPA, 1981
Shut down: 1990
Width: 4100 mm
Working width: 3710 mm
PM length: 197 m
Speed: 250 m/min max
Maximum of layers: 5 (without coating)
Capacity: 150–200 Tpd (45.000 Tons/year at 300 working days)
Products:
Testliner 140 – 160 gr/m²;
Fluting from 140 gr/m²;
Duplex/triplex 240 – 550 gr/m²;
High gloss board;
Chromoboard;
Tetrapack carton (liquid packaging board);
Grey board 160-600 gr/m²
Furnish:
Bleached/unbleached pulp (short/long fibre);
Semichemical pulp;
Groundwood pulp;
All grades of waste paper;
Overall status: paper machine is complete, packed in about 130 containers

Stock preparation
Number of lines: 3
Brands: ERWEPA, Voith, Finck, Sprout-Waldron, Sulzer, KSB, Siemens, etc.

First line
Capacity: 160 Tpd
Waste paper pulper, 2-stage sorting-cyclocleaners, centricleaners, vertical sorters, steam agitators with presses, vibrating screens, disc refiners, conical refiners, chests
Second line
Capacity: 130 Tpd
Top layer – pulp pulper, disc refiners, conical refiners, machine chests
Third line
Capacity: 60 Tpd
Bottom layer- waste paper pulper, cyclo-screen, vertical sorters, disc refiners, conical refiners, machine chests, etc.

Formation part
There are totally four formers and one long wire
Formers have configuration F1, F2, F1, F2 and long wire
Two formers are secondary former - F1. This former is with dewatering on the suction roll. From this former paper layer goes on to transporter felt I., which is under all formers
Two formers are type duplex former - F2. This former has headbox with short wire and dewatering elements. Burst roll is non suction roll. On the driving roll of wire is top former wire. Layer goes on the transport felt I

Secondary former:
Position: F1 and F4
Function: creating of cover layer
Supplier: ERWEPA
Measures of wire: 4100 mm
Main parts:
Burst suction roll Ø 1100 x 4300 mm
2 guiding rolls Ø 300 x 4300 mm
Wire couch roll Ø 800 x 4300 mm
Wire tensioning system
Wire guiding system
High pressure spray nozzle
Low pressure spray nozzle
Drive on the wire couch roll; 26,5 Kw motor, 50 – 1760 rpm, 1760 – 2450 rpm
Drive on the headbox opening; 0,55 Kw motor, 1420 rpm

Duplex former
Position: F2 and F3
Function: creating of middle layer
Supplier: ERWEPA
Bottom wire 15000 x 4100 mm
Burst roll Ø 500 x 4300 mm
Forming suction roll Ø 1100 x 4300 mm
2 guiding rolls Ø 300 x 4300 mm
Wire couch roll Ø 800 x 4300 mm
Wire tensioning system
Wire guiding system
High pressure spray nozzle
Low pressure spray nozzle
Drive on the wire couch roll; DC motor 1,8-58 Kw, 50-1950 rpm, 1950-3000 rpm
Drive on the headbox opening; 0,55 Kw motor, 1420 rpm
Drive for lifting; 0,37 Kw motor, 1500 rpm
Top wire 9500 x 4100 mm
Drive roll Ø 520 x 4300 mm
4 guiding rolls Ø 300 x 4300 mm
Wire tensioning system
Wire guiding system
High pressure spray nozzles
Low pressure spray nozlles
Drive on the wire drive roll; DC motor, 0,48-20 Kw, 50–2150 rpm; 2150-3000 rpm

Long wire
Function: creating of top layer of board
Type: cantilvered
Supplier: ERWEPA
Measures of wire: 28000 x 4100 mm
Burst roll Ø 700 x 4300 mm
11 registration rolls Ø 220 x 4300 mm
Eguter roll Ø 800 x 4200 mm
Wire suction roll Ø 1000 x 4260 mm
Wire back roll Ø 720 x 4300 mm
4 guiding rolls Ø 300 x 4300 mm
Wire tensioning system
Wire guiding system
High pressure spray nozzles
Low pressure spray nozzles
Oscillation of doctor blades on burst and guiding rolls
Drive on the wire suction roll; DC motor, 1,8-58 Kw, 50–1950 rpm, 1950-3000 rpm
Drive on the wire back roll; DC motor, 1,8-58 KW, 50–1950 rpm, 1950-3000 rpm

Transport felt I
Name: Ablage filc
Function: carrying of layers from formers F1, F2, F3, F4 to the press rolls
Supplier: ERWEPA
Measures of felt: about 68–70000 x 4100 mm
Couch rubber roll Ø 520 x 4300 mm
Drive felt roll Ø 520 x 4300 mm
Vacuum prepress
Vacuum prepress bottom roll Ø 850 x 4360 mm
Top roll of vacuum prepress Ø 750 x 4220 mm
Couch press
Couch suction bottom roll, rubber; Ø 850 x 4200 mm
Suction pre-press-pressure 50 kN/m
Top roll of couch press Ø 750 x 4220 mm
Crown: 1,8 mm
16 guiding rolls Ø 300 x 4300 mm
Wire tensioning system
Electro motors
Combined wire guiding and tensioning system
Manual felt guiding system
Felt conditioning
High pressure spray nozzles
Low pressure spray nozzles
Suction boxes
Oscillation of doctor blades on the rolls
Drive on the drive felt roll, DC motor, 1-37 Kw, 50–2000 rpm
Drive on the vacuum prepress bottom roll, DC motor, 1-37 Kw, 50–2000 rpm
Drive on the couch suction bottom roll, DC motor, 1-37 Kw, 50–2000 rpm

Transport felt II
Function: transport of board from former part on the long wire
Supplier: ERWEPA
9 guiding rolls Ø 300 x 4300 mm
Guiding drive roll Ø 450 x 4300 mm, DC motor 0,48-20 Kw, 50–2150 rpm

Total installed power of the formation part:
Long wire 116 Kw
Duplex former 40 Kw
Bottom wire 116 Kw
Secondary former F1 53 Kw
Transport felt I 37 Kw
Suction prepress 37 Kw
Couch press 37 Kw
Transport felt II 20 Kw
Total forming section installed power: 456 Kw

Press part
Press part: 3 wet presses
Suction pre-press-pressure 50 kN/m; bottom roll Ø 860 x 4200 mm, rubber; crown 3,2 mm; top roll Ø 750 x 4220 mm; crown 1,8 mm
1^st vacuum press 70 kN/m; bottom roll Ø 850 x 4360 mm, rubber; crown 3,3 mm; top roll Ø 750 x 4200 mm; crown 1,8 mm
2^nd straight press 80 kN/m; bottom roll Ø 850 x 4200 mm, rubber; crown 2 mm; top roll Ø 750 x 4220 mm; crown 1,8 mm
3^rd inverted press 100 kN/m; bottom roll Ø 590 x 4200 mm; top roll Ø 850 x 4200 mm
Press felts
1^st and 2^nd bottom 16000 mm (18400 stretched)
1^st top 13000 mm (15000)
3^rd top 13400 mm(15400)
Felt width 4000 mm
Installed power
1^st press 58 Kw; 2^nd press 58 Kw; 3^rd press 58 Kw

Drying part
Numer of dryers: 52 + 2 after MG cylinder
Ø: 1500 mm
Width: 4060 mm
Pressure: 4 bar max
Drying unit
1^st section 4 cylinders, 37 Kw
2^nd section 10 cylinders, 37 Kw
3^rd section 10 cylinders, 37 Kw
4^th section 10 cylinders, 37 Kw
MG cylinder Ø 5000 mm, 118 Kw
5^th section 8 cylinders, 37 Kw
6 section 8 cylinders, 37 Kw
Correction section 4 cylinders
Each cylinder equiped with Johnson steam joint
Total installed power: 340 Kw

Coating unit
Coater I
Name: Flexibar
Function: precoating
Type: Model 55
Supplier: Jagenberg
Working width: 3680 mm
Main parts: unit with construction, coating roll, registration roll for coating color, Flexibar racle, Flexibar roll, box for color, control desk

Drying I
Function: drying of precoting layer
Supplier: Jagenberg
Type: air drying boxes
Number: 2 pcs
Length: 3 m

Coater II
Function: main coating layer
Coater: air knife
Name: LBA model 45-30
Working width: 3680 mm
Main parts: unit with construction, coating roll, registration roll for coating color, blade, color box, color roll, turning roll, air knife with injector

Drying II
Function: drying of precoting layer
Supplier: Jagenberg
1 piece type air drying boxes closed, length 3 m
3 pieces type air drying boxes opened, length 3 m

Coater III
Name: Flexibar
Function: cover coating layer
Type: Model 55
Supplier: Jagenberg
Working width: 3680 mm
Main parts: unit with construction, coating roll, registration roll for coating color, Flexibar racle, Flexibar roll, box for color, control desk
Installed power
1^st coater - Precoater Flexibar
Ink roller 10,2 Kw, pressure roller 26,5 Kw, 2 guiding rolls 10,2 Kw
2^nd coater - Main coater – Air knife
Ink roller 10,2 Kw, pressure roller 35 Kw, guiding rolls 20 Kw
3^rd coater - Flexibar
Ink roller 10,2 Kw, pressure roller 26,5 Kw, guiding roll 20 Kw
Drying of coating layer
12 fans x 18,5 Kw, 4 fans x 22 Kw, 1 fan x 7,8 Kw, 1 fan x 9 Kw
Total installed power for the coat drying: 537,8 Kw

Drying III
Function: drying of cover coating layer
Supplier: Jagenberg
1 piece type air drying boxes closed, length 3 m
1 piece type air drying boxes opened, length 3 m

Calender
Supplier: ERWEPA
Main parts:
Top roll Ø 480 x 4060 mm
Middle roll driven, Ø 450 x 4060 mm
Bottom roll swimming, Ø 460 x 4060 mm
Hydraulic unit for the swimming roll, regulations valves, filter, cooling, electrical motor
Motor: DC - Installed power 2,2 – 79 Kw, 2000 rpm

Pope reeler
Supplier: ERWEPA
Diameter of pope roll: 1000 mm
Length: 4075 mm
Number of tambours: 15
Installed power: 37 Kw

Off-line coater
Brand: Jagenberg, high gloss
Width: 1050 mm
Speed: 100 m/min
Substance: 150 – 450 gr/m²
Capacity: 6000 Tons/Year

Sheet cutter
2 identical units:
Supplier: Jagenberg
Width: 2400 mm
Speed: 250 m/min
Format: 650 – 2030 mm

Heat-chamber pallet packing
Pallet width: 650 - 1220 mm
Pallet length: 650 - 1440 mm
Pallet height: 1800 mm
Capacity: 30 pallets/h

Boiler house
Boiler capacity: 45 Tpd
Boiler pressure: 85 bar
Outlet presure: 73 bar
Outlet temperature: 500 C°
Water temperature: 140 C°
Fuel: heavy oil 9600 kcal/kg

Turbogenerator
Max output: 5800 Kw
Outlet steam pressure: 74 bar
Steam temperature: 500 C°
Back-pressure: 4 bar
Turbine: 12500 rpm
Generator: 1500 rpm
Frequence: 50 Hz
Specific steam consumption: 6,85 kp/kWh

Waste water treatment plant
Brand: Babcock
Capacity: 270 m³/hour
Technology: 3-stages ( mechanical, chemical, biological treatment)