Dryer Drainage System Design

Basics
Papelera de Chihuahua
No. 2 PM
Chihuahua, Mexico

Zod Zandi – Kadant Johnson Systems

Steam

An invisible gas
generated by adding
heat energy to water
during which water
changes to a gas.
Qualities of Steam

• High usable heat content

• Gives up its heat at constant temperature
• Produced from water
• Clean, odorless and tasteless
• Heat can be used over and over – flash
• Easily distributed and controlled
• Constant characteristics
– Pressure, temperature, volume
Energy States of Water

• High – Steam

• Medium – Water

• Low - Ice
British Thermal Unit (BTU)

The amount of heat

needed to raise one
pound of water one
degree Fahrenheit (°F)
Types of Steam

• Saturated Steam – steam in immediate

contact with the water from which it was
formed. It is also known as wet steam.

• Superheated Steam – steam to which

energy has been added to raise its
temperature above its boiling point. It is
also known as dry steam.
Steam Properties

Pressure Temp Heat of Latent Specific

Total Heat
(psig) (°F) Liquid Heat Volume

0 212 180 970 1150 26.8

50 298 267.5 911.6 1179 6.6

100 338 309 880 1189 3.9

Specific Volume

• Amount of space occupied by one pound of

steam at a given pressure
• Inverse relationship between steam
pressure and volume
• Increase in pressure, decrease in volume
• The higher the steam pressure, the less
space required
Specific Volume

Pressure Water Steam (ft3/lb) Steam/Water

(psig) (ft3/lb) (ft3/lb)
0 0.0167 26.8 1600
50 0.1750 6.70 380
100 0.0179 3.88 216
Specific Volume

• The relationship between pressure and

volume is important to reduce
– Pipe erosion due to high velocity
– High pressure drop
– Noise
Recommended Velocities

• Steam flow < 6000 fpm

• Condensate flow < 4000 fpm

Line Losses

1000 lb/hr steam flow at 100 psig

Pipe Size Velocity
MPH P/100ft
(Sch 40) (fpm)
¾” 17,580 190 87
1” 10,830 120 25
1 ¼” 6,250 70 6
1 ½” 4,600 50 3
2” 2,780 30 1
Purpose of the Steam System

• Control drying pressures over the entire operating

range

– Capable of turning down to low pressures so dryers never

need to be “valved” out.

– Maximize pressures on dryer limited grades

– Graduate wet end drying pressures for sensitive grades

• Very low pressures sometimes needed (-6 psig)

– Maintain control during upset conditions, e.g. grade changes,

breaks, etc.
Purpose of the Steam System

• Efficiently remove condensate

– Maximize heat transfer by keeping condensate
layer thin
– Provide uniform CD surface temperatures

• Minimize steam use

– Manage differential pressure and blow-through
flow rates
– Make efficient use of blow-through steam
Effects on Dryer Operation
• Dryer Operations • Sheet Quality
– Drying capacity – Moisture profile
– Range of operation – Cockle
– Runnability (picking, sheet – Wrinkles
flutter, dryer flooding) – Picking
– MD moisture control – Curl
– Tail threading
– Energy consumption
System Design Information

• Accurate projection of drying pressures and

speeds
– Low pressure design point as critical
– Low pressure conditions determine line sizing

• Accurate projection of dryer condensing loads is

essential
– Computer simulation must account for dryer
effectiveness, unorun dryers, pocket humidities, dryer
felting, etc.
Condensate Layer Behavior

Puddling Cascading Rimming

Low Speed 700 To 900 Fpm Above 1,000 Fpm
100 to 500 Fpm
Drying Mechanism
FABRIC
STEAM CONDENSES MINIMIZES
IN DRYER AND TRAPPED
TRANSFERS HEAT AIR LAYER
INTO SHEET

WATER
EVAPORATES IN
POCKETS

AIR TRAPPED
BETWEEN SHEET
AND DRYER
Drying Mechanism

Steam
Introduced at
Set Pressure
Heat is Transferred Thru Dryer Shell Into Cooler Sheet Surface

Steam
Inside Dryer
at Saturation
Temperature

Condensate and
Blowthrough
Steam Removed

Condensate Forms
on The Inside
Surface of the Dryer
Resistance to Heat Transfer

FABRIC

CONDENSATE DRYER
LAYER SHELL AIR LAYER
SCALE ON
TRAPPED SHEET
DRYER
BETWEEN
SURFACE
SHEET AND DRYER
Resistance to Heat Transfer

• Condensate Layer Inside Dryer

– Thin Layer Is Desirable
– Resistance Is Greater At Higher Speed

• Air Layer Between Sheet And Dryer Shell

– Dryer Fabric Tension Reduces This Layer

• Scale Or Fiber Build-Up On Dryer Surface

Resistance to Heat Transfer

• Non-Condensable In Steam Supply

– Occasional Purging Of The System Is Needed
– Proper Start-Up Procedures Needed

• Properties Of The Sheet

– Thickness, Roughness, Refining Level, Filler
Content, Fiber Type, Porosity

• Dryer Shell Metal Thickness

Syphon Design & Selection

• A primary function of the steam and condensate

system is to manage and make use of blow-
through steam

• Syphon type and flow characteristics dictate blow-

through flow amounts

• Selecting the syphon type and syphon size is the

most important step to designing the steam and
condensate system
Stationary Syphon

• Cantilever Stationary Syphon

• Rigid mounting
• High stiffness
• Low vibration
• Low deflection
Stationary Syphons
• Advantages
– Low Differential Pressure Requirement (2 to 4 Psi)
– Low Blowthrough Requirement (8% to 10%)
– Few Problems With Dryer Flooding
– Good For High Speed, Low Pressure Operation
– Ideal For Felt Driven Dryers
– Piping Sizes Smaller Due To Lower Blowthrough Flows
– Motive Steam Usage Is Lower

• Disadvantages
– Syphon Clearance Is Critical
– Rolls Can Induce Vibration & Failure
– Dryer Bars Required For Good Heat Transfer &
Uniform Cross Machine Temperature Profiles
 Turbulator Bars

Improved Heat Transfer

through greater turbulence
• The more turbulent the condensate inside a
dryer, the higher and more consistent its heat
transfer rate.
Under high speeds, condensate forms into a
laminar rim -- reducing heat transfer capacity.

Turbulator bars reintroduce turbulence inside

the cylinder improving heat transfer and
temperature profile.
Condensate Behavior
Puddling, Cascading, Rimming
When are the best results achieved?

• High condensing load

• High machine speed
 Turbulator Bars

Improved Heat Transfer

through greater turbulence
Syphon Blowthrough &
Differential Requirement
Blowthrough Flow Is Responsible For Condensate Removal -
Differential Pressure Produces Blowthrough Flow

Differential Pressure Required :

•To Overcome Steam Line And Joint Loss
•To Accelerate Condensate And Blowthrough Steam
Under Syphon Shoe And Into Syphon Pipe
•To Overcome Syphon Pipe Loss
•To Overcome Centrifugal Force (Rotary Syphons)
•To Overcome Condensate Line And Joint Loss
Stationary Syphon System

STEAM IN

BLOWTHRU STEAM
ENTRAINS
CONDENSATE
& CARRIES IT OUT
OF DRYER

CONDENSATE & BLOWTHRU

STEAM OUT OF DRYER
Stationary Syphon Operating Characteristics

Speed Normal Flood Good Design

(Fpm) Operating Recovery (% BT)
Delta P Delta P
(psi) (psi)
1,500 2 to 4 1 10% to 12%

2,000 2 to 4 0 8% to 10%

2,500 2 to 4 0 8% to 10%

3,000 2 to 4 0 8% to 10%

3,500 2 to 4 0 8% to 10%
 8
With 0.9” Orifice Plate In
Condensate Drop Pipe.
7
Differential Pressure (Psi)

6 4 Psi Differential Pressure

Gives 10% Blowthrough
With No Orifice Plate In
5
Condensate Drop Pipe
4

2 Curves Are Based On:

1.5” x 1.5” JOCO Stationary Syphon
1 50 Psig Dryer Pressure
1400 lbs/hr Condensing Load
0
0 5 10 15 20 25 30
Blowthrough (Percent Of Condensing Load)
Syphon Blowthrough &
Differential Pressure
Requirement
What is Differential Pressure?

80 psig 80 psig
Case 1
0 psig
Atmosphere
Valve 100%
Open
What is Differential Pressure?

80 psig 5 psig
Case 2

0 psig
Atmosphere

Valve 100%
Open
Blowthrough Flow Example

100 psig

20 psig
Dryer X
Set Point 20 psig = 259 Deg F
3 psid

17 psig

5 psig
Blowthrough Flow Example

1,100 #/hr Total Steam Additional 10%

1,000 #/hr Steam Required to
Load Required for This Blowthrough Steam
Dryer
= (100 #/hr) is Required + Maintain 20 psig While
Drying Sheet
to Entrain Condensate
100 psig

20 psig

Set Point 20 psig = 259 Deg F

3 psid

17 psig

5 psig
Mixture of 1,000 #/hr
Condensate & 100 #/hr
Steam
Simple Steam System
Steam Supply

Pressure
Control
Valve

Dryers

Differential
Pressure
Control Valve
Simple Steam System
Steam Supply

Pressure
Control
Valve

Dryers

Atmosphere
Differential
Pressure
Control Valve Level
Control
Valve

Condensate Return
Separator Stations

• Separation efficiency is determined by

– The vapor velocity through the tank, which is
affected by blow-through rates and tank size
– The design of the separator tanks
(internal baffles to improve separation)

• Efficient condensate separation

– Can potentially increase drying rates, especially in
cascade type steam and condensate systems
– Reduces risk of severe erosion in
thermocompressors
Separator Stations
Cascade Steam System

Steam Supply Steam Supply

Make-Up
Valve
50-100% 0-100%

Steam Group Steam Group

0-50%
Vent
Valve
Thermocompressor System
High Pressure Motive Steam

Make-Up Steam
Thermocompressors

Thermocompressors
recompress low-pressure
steam to a higher, usable
steam pressure.
Thermocompressor Section
High Pressure Make-Up
Motive Steam Steam

Steam Group
Blow-through
Steam

Vent
Valve Separator
Station

Condensate
Return
Thermocompressors
Motive steam
enters
Motive steam
discharge
Mixture
accelerated to
high velocity

Expands to
discharge at
dryer
Blow-through pressure
steam enters
Thermocompressor Section
Low Signal High Pressure Make-Up
Selector Motive Steam Steam

50-100%
Flow 0-50% A/O
A/O
Control

Steam Group

ORIFICE TO
MONITOR
BLOWTHROUGH
STEAM FLOW

Separator
Vent Station
50-100% Valve
A/O
Condensate
Return
No. 2 PM Dryer Study – Major Conclusions

• Drying capacity can be improved

– Drying capacity before the Clupak is the limit.
– Dryer mechanical reliability is poor.
– Dryer drainage reliability is poor.
• Low motive steam pressure.
• Inaccurate differential indication & control.
– Existing syphons produce poor heat transfer.
– Not all dryers have bars installed.
– Dryer pressures are not maximized.
No. 2 PM Dryer Study – Major Conclusions

• Steam pressure at the machine is low.

– Steam pressure is too low for efficient
thermocompressor operation.
– Dryer pressures often limited to prevent steam
venting or dryer flooding.
– Differential pressures are marginal.
– Maximum dryer pressures can not be achieved.
• The maximum dryer pressure rating of the dryers
needs to be determined.
No. 2 PM Dryer Study – Major Conclusions

• Stationary syphons & bars following the Clupak

will produce benefits.
– Improved moisture profile.
– Increased capacity by 4% on corrugating & linerboard.
– Reduced joint maintenance.
– No need to valve out dryers.
– Improved consistency of drainage.
– Higher speeds will make drainage more difficult with
rotary syphons.
• Increased risk of dryer flooding.
No. 2 PM Dryer Study – Major Conclusions

• 2,300 kg / hr of flash steam is wasted at the

boiler house.
– 1,925 kg / hr can be recovered for use in the
fourdrinier steam shower.
– 2.8 million pesos / year ($255,000 US per year)
No. 2 PM – What’s Changed?
• Stationary syphons & bars in dryers 1 to 32.
– Improved mechanical reliability
– Improved drainage reliability
– Improved CD profile
– Reduced maintenance

• Convert the dryers before the Clupak to a cascade

design.
– Elimination of thermocompressors allows highest
possible dryer pressures with low pressure steam from
boiler house.
No. 2 PM – What’s Changed?

• Install a flash steam recovery system.

– 1,925 kg/hr of flash steam recovered to
fourdrinier steam shower.

• Install stationary syphons & turbulator bars

for dryers 33 to 54.
System Changes
Existing System
System Changes – Before Clupak
• Install stationary syphons & dryer bars in all dryers prior to
Clupak.
• Convert the dryers before the Clupak into a cascade
design.
– Remove thermocompressors from 1st, 2nd, 3rd sections.
– Move dryers 7 to 10 from 1st section to 2nd section.
– Move dryers 15 to 20 from 2nd section to 3rd section.
– Cascade blowthrough steam from 3rd to 2nd and 2nd to 1st.
– Install pressure control valve for 1st section.
– Install differential control valve for 1st section to direct blowthrough
steam to fourdrinier steam shower.
– Revise controls.
• Add differential pressure control for Clupak dryer.
Before Clupak Changes
System Changes - After Clupack

• Install stationary syphons and turbulator

bars in all dryers after Clupak (dryers 33 to
54).
– Replace thermocompressors to match
stationary syphons.
– Install non-condensable bleeds for the 4 th & 5th
sections.
After Clupak Changes
 Range Of Operation With Proposed Changes
Current Dryer Future Dryers Design Design
Grouping Grouping Pressure Pressure
Maximum Minimum
(psig) (psig)
1st Section 1 to 10 1 to 6 70 8
2nd Section 11 to 20 7 to 14 75 15
3rd Section 21 to 32 15 to 32 80 20
Clupak
4th Section 33 to 38 33 to 38 70 10
5th & 6th 39 to 54 39 to 54 70 10
Sections
Flash Steam Recovery
• Install new condensate collection tank at the
machine.
• Pipe condensate from existing separators to new
collection tank.
• Pipe flash steam from collection tank to fourdrinier
steam shower.
– Control flash tank at the pressure required by the steam
shower.
• Install a moisture eliminator prior to the steam
shower in the flash steam line.
• Install an atmospheric vent line for pressure control.
Before Clupak Changes With
Flash Steam Recovery
Start-Up Procedure

The Mill cold start-up procedure should be

followed for warm-up. In an event that there are
no detailed procedures, the following procedures
should be followed when steam has been off long
enough for the dryers to cool.
Start-Up Procedure
• Open the drain valves on the separator tanks
• Make certain that the Pressure Control Valves for all steam sections
are closed.
• Rotate the dryers at low speed (under 2 ft/min).
• Set the pressure controllers for each dryer to “manual” and open the
Pressure Control Valve to 5% open
• Wait until pressure begins to build in each dryer (30 to 60 minutes),
and then set the pressure controllers to the “automatic” position
• Increase the pressure by 5 psig every 10 minutes.
• After about 30 minutes close off the separator tank drain valves.
• Check the condensate levels in the separator tanks
• Set the dryers to operating pressure before speeding up the dryers
• Bring the sheet across the dryers
 Dryer Drainage System Design
Basics
Papelera de Chihuahua
No. 2 PM
Chihuahua, Mexico

Zod Zandi – Kadant Johnson Systems