Evaluating Energy And Economics Of Paper Machine Clothing

RAY A.K.

ABSTRACT

In this present investigation a brief outline description of all the three types of fabrics employed for formation ,
pressing and drying of paper is given. Further the available models developed for operations related to paper
machine clothing are reviewed for industrial practice with special reference to evaluation of energy
consumption,improved performance and economics related to press and dryer fabrics. Some case studies for press
and dryer clothings are especially discussed through already developed model based on C++ programming
parameter studies and economic evaluation.

Introduction both. It can be shown by simple requirements of change in some

Average relative cost per ton of paper calculation that 1% change in sheet properties e.g basis weight, porosity
to dewater the sheet can be of the dryness in press section with 40% ,flow rate etc.
following order(1). B.D.will give 4.2 % reduction in
· Forming Section 10% 1.0 evaporative drying.All the above will The dryer fabrics have significant
· Press Section 12 % 1.2 depend on the syngergistic efforts of influence on drying efficiency. This is
paper machine , machine clothing and shown in the following table.
· Dryer Section 78% 7.8 fiber stock characteristics. It is evident
In terms of energy consumption it has therefore, paper machine clothing is an Effect of drying variables on drying
been estimated that the distribution of integral part of paper machine. It is efficiency(1):
energy consumption of paper machine
is in the order : forming: pressing:
drying =15:20:65( 2 ). Variables Assume %
the dryer influence
It has also been reported that high Condensate Removal geometry 30
dryness after the press is very
advantageous because steam Furnish , Grade and Sheet Properties is fixed 25
consumption for drying of paper is Dryer Fabric Design,Permeability and and the 20
reduced. Removal of water in dryer Tension steam
section by evaporation is 7-10 times pressure is
costlier than on presses and 60-70 times Pocket Ventilation 15
costlier than the wire part. It depends to Hood and Dryer Air System constant 5
a great deal on power and steam cost Others 5
and felt conditioning.
classed based on its application in the
In forming section itself, the operation such as Formation Fabrics
distribution of energy is in accordance · Forming Fabrics ( Fourdrinier Important properties required are:
with the following in percentages(2) wire,Twin Wire, Hybrid wire, or Dewatering,Retention, Stability-
:Hydraulic 1, pressurized air 1,drives multi cylinder machines etc.) elasticity under tension( 12-15 kN/m)
47,vacuum,35,broke collection,6, in gap formers),stiffness, diagonal
shower water ,11 and ventilation,4.
· Press Fabrics( Wet Felts) stability, good tension profile(P=T/R),
· Dryer Fabrics( Felts / Screens) wear Resistance(6,8,9,10,11)
It is wellknown(1,3-7) that increased
hydrostatic, and mechanical loadings Felt/ Screen are designed fabrics used Material of Construction
either on wires in forming section or in synergistically with machine( pressing
press section improves water removal. or drying) in order to do the variety of The following materials are used to
Hydrostatic load and vacuum are functions. The properties of the manufacture synthetic wires in mono
employed in forming section whereas Forming Fabrics, Press Felts and or multifilament threads.
vacuum and external mechanical Dryer Felts or Dryer Screens must be
loadings are used in press section. characteristically different because of Polyethylene,Trevira,terelene,Polyeth
Dryer section uses thermal energy in their specific functions in each section ylene terephthalate(PET), Elana /
form of steam. However electrical and therefore these fabrics must be polyamide fibers, kapron, Nylon,
power is required compulsorily in compositionally and structurally ( Parlon, Dacron, Orlon, Acrilan, Dynol,
drives of the machine /felt/ screen or c h e m i c a l l y, m e c h a n i c a l l y o r Nylon 6,6 etc.
metallurgical point of view)different.
IIT-Roorkee,Saharanpur Campus, Even for different sections of Press part Details of mechanical properties are
Department of Paper Technology ; pick-up press, transfer press and the given ( 9 ). Comparison of other
Saharanpur-247 001 presses in position there are
IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 137
properties are also qualitatively dealt must be kept in mind. K=3/k1S02(1-t)2
with( 9 ). Generally MD or Warp yarns Stiffness and tensile strength ;good Permeability is related to the filtration
are made from Poly ester(PET) because runnability; high resistance to wear; equation as
of its good tensile strength, and low good pick-up property; high adhesion dV/dt=AK∆P/μ
elongation under load but CD must be between web and felt;texture L=A[ε3/{k(1-ε)2 S02}(∆P/μ L)
prepared from combination of possessing little clogging v0=(P0-PL) (DP2/150 μ) (ε3/(1-ε)2)
polyester and polyamide(PA)/ other tendency;withstand the high pressure
polymers. PA improves wear resistance showering; good durability; required
but absorp water and possesses high compression and springback For cellulose fibres Kozeni's constant is
elongation under load. Wear resistance properties; resiliency, compaction 5.55
can be improved by adding other pressure resistance; tension tolerance; For higher porosity ( > 0.80), the
polymers or additives into polyester resistance to puncture , tear and edge equation can be modeled according to
polymer before extrusion of filament. cracks; and uniformity of pressure Davies( 13 ) as
distribution K=[k1S02(1-t)3/2 {1 +k2(1-t)3}]-1
Classification:SL,DL-LWD,-HWD,-
EWD,TL,2.5 L,TW,SSB Modeling Of Some Parameters For cellulosic fibres, the values of the
For Wires And Press Fabrics constants are found of the order of 3.5
( Refpaulalapuro) and 57 respectively as reported by
Some of the specifications are shown Ingmanson( 14).
below: Permeability refers to the ease with
Formation Fabric Specifications(6): which water (or air) can flow through a The equation can be related to basis
weight weight of the fibrous mat.
Type/Specification DL 2873 TL 3565 ML 5168 The specific resistance of wires or felts
Yarn 72.6 x 51.6 31.9 x 26.8 67.2 x 79.2 can be used for comparison purposes,
Density,yarns/cm The permeability constant of 6
different felts are compared in the
Yarn code 15, 16, 19, 19 16 18 16 13 22 22 15 17 15 19 25 25 following table.
MD CD CD CD MD MD CD B CD CD MD CD CD CD CD CD

Air 5700 5700 6100 * Batts are made with

Permeability,m3/m2/h extraordinary thin fibres; Base is
very light and batt is
Air 360 360 390
permeability,CFM
exceptionally heavy
** Batts are made with
Thickness,mm 0.62 0.76 0.96 extraordinary thin fibres, placed
on a coarse mesh
Void Volume,% 49.4 51.5 57.5 + Fibres in the batt were very
thick.and the felt was the
Max. Water 260 348 503
Content,gsm roughest one as it was made from
of thick fibes needled to a coarse
Press Fabrics Permeability coefficients of felts (6)
Composition: Polyamide( Felt ype Compressing Pressure, MPa
Nylon) 2.5 5.0 10
High permeability, even under the Permeability Coefficient,10-2 m2
pressure prevailing in the press F.1( Commercial) 6.9 4.9 2.7
nip;physical and good dimensional F.2(com.)Old,60day 4.1 2.8 1.8
stability even with exposure of different Felt3* 1.6 0.9 0.4
chemicals Felt4** 4.5 2.8 1.4
Felt 5+ 18.8 15.5 7.2
Felt 6++ 19.4 10.0 3.5
Felt Parameters ( 1,3-6,11-12)
material ; it is an expression of the mesh.
Basis weight=1000-1800 openness of the material to ++ Fibres in the batt were very thick
gsm;thickness:20-100 μm;base flow.Scanpro FeltPerm is currently and made by using fine mesh a
textile:200-400 μm;Batt/ Base ratio( being used to measure water special batt formation technique
mass of batt/ mass of base). Other permeability during the machine run.
parameters are : to develop macroscale
Felt construction; suction pipe nonuniformities.
The permeability constant ,K is related
cover;felt water content( moisture to specific cake resistance which can be
ratio);driving force/ vacuum level(mm Compression parameters are important
written in terms of wellknown Kozeny
Hg.);felt basis weight; felt permeability Carmann or Blake Kozeny constant. for taking decision when felt could be
Specific cake resistance changed.. The following table depicts
During designing and manufacturing ,α=k(1- ε)S02/ ε3ρs =1/K((1-ε) ρs some value.
of felts the following requirements It can also be written as

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 138

Compression Parameters of A typical set of values put forward by imprint dia( 1.9 mm@ 150 mm)
new and used felt ( 6) huyck is shown below(11 huyck). More R=3.4 cm/min
specific data are also available( 6 ).
Felt CFM also depends on the type of
Properties New Felt Old Felt paper to be manufacture as shown in
Nip width,mm 43.0 36.6 the following table.
Max. pressure,MPa 7.00 9.41
Caliper in mid-nip,mm 1.91 1.60 Felt CFM ranges(12)
Moisture Ratio 0.41 0.20 Alternatively Traversing
speed,inches/minute=FPM x 0.04/F.T
A felt has adequate void volume to Simple models for Fabric
absorb water expressed from the sheet FPM =Machine speed ,ft/minute(say
Cleaning and Conditioning:
in the press nip. Type of paper CFM
Tissue 10-25
Void Volume(E) is defined as a Fine Paper 25-80
material's internal void volume divided Newsprint 25-80
by its total volume. Void volume Liner/ Corrugating 60-120
needed in a press felt differs from Cylinder 70-150
grooved suction or blind drilled roll to
plain roll shoe press, increases with the 2000 FPM)
above order( 6). Details of fabric cleaning and F.T.=Fabric speed ,(65 ft.)
conditioning are detailed 0.40= water jet width(inches)
For a felt made of one material , void elsewhere(8,11 ). Oscillation speed=2000/65x 0.40=1.23
fraction can be expressed(3)as: inch/min.
ε== 1-(mf/ρf)/ (mfab/ρfab) Oscillator speed VB (mm/min)
If the mass of air is neglected, then must be matched to fabric speed and Running void volume: C x W x S
ε≈ 1- ( fabric density)/ ( fiber density)= can be calculated as follows: xV
1-ρfab/ρf VB= VS x eb/2 x SL=VS x p/ SL Where C = caliper of fabric,mm
Where VS= Fabric speed ,MPM W= fabric width,m;S ,the speed of felt
Where mf ,mfab, ρf ,ρfab represent mass SL=Fabric length,M ,m/min ;V,the Void volume
and density of fibres and fabrics e b =Width of cleaned strip, mm
respectively(11) (approximately 1.9 x nozzle diameter) It is very important to use a correct
% Felt Void Volume, ε=100-(0.1 x Felt p=nozzle pitch oscillating speed in relation to fabric
gsm)/t x SG
Where t, is the felt caliper,mm and S.G. Specifications Typical Values
, the specific gravity Nozzle diameter,mm 0.7-1.2
Distance between nozzles,mm 50-100
The specific gravity of Nylon is 1.14 Water pressure in shower type,bar 20-30
and that of polyester=1.30 Distance from Fabric,mm 150-300
ε1/ε2= (t2 x SG2)[100 x t1 xSG1-0.1 x gsm1 Oscillating Width,mm 150-300
]/[ 100 x t2 xSG2-0.1 x gsm2]( t1 x SG1) The cleaning time, tR=SL x k/Vs eb speed and nozzle diameter( 6)
SGav=100/[(x/SGA) +(1-x)/SGB]
,min
Flooding shower/ Lubricating
Where SGA and SGB represent the shower(1,3-6, 8)
k=Nozzle Spacing,mm=100 mm
specific gravities of the two
g=nozzle distance to fabric(90-100
components of the felt.,x1 and x2 are the Water flow rate=GPM=S x W x C
mm)
mass fracrion
α =Approximately 6 bar fan angle x %RVV x 7.48/144
be=2g x Tan(α/2)=2g x Tan(60o/2)
Felt Applications - Cleaning Nozzle quantity=z=b/be Where S= machine speed,FPM
And Conditioning Nozzle Spacing k=b/z W=Machine width,in
Shower volume =110% of fabric C=caliper of clothing,% RVV running
Effective Uhle box dewatering volume(fabric caliper/speed/free void volume
operation depends on the following volume)
important factors:
Power Calculations of power
Oscillating Rate:2 R=S x 1.9/L x 10 due to various components
Driving force/ Vacuum Level(mm Hg.) R= Oscillating Rate,cm/min,
Air flow(m3/min) including vacuum pump
S=Speed ,m/min(say 900 mpm)
Dwell time( milliseconds) L=Loop Size,m(25.4 m) Vacuum Pump Drives(1,15,15,)
t= Nozzle aperature diameter/ jet

Power required by vacuum pump of

various types( liquid ring ) needs data
MPM Min. Air Flow,m3/min/m2 Min. Vacuum,mm of volumetric capacity,SCFM
< 450 270 250
(standard cubic flow per minute )at
450-900 350-440 300
15.55 oC and at 1 atm pressure and
>900 440-660 380
IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 139
acfm( actual volume in cubic feet per equation has been proposed machine direction width of the box in
minute) at the location.This can be μ = (0.004) x (P & J)1.22+ .022 inches, and the vacuum is inches of Hg.
easily calculated by using Boyle's law Considering wrap only, the basic The cover on this machine was all made
and Charle's law. The pressure must relationship for maximum tension of alumium oxide. Coefficient of
consider the losses due to skin friction, difference across a roll without friction for this material is 0.12.
enlargement, contraction, and fittings. slippages is given the following
equation. The relationship between fabric life
P1V1/T1=P2V2/T2 or using PV=WRT Δ T = Tt-Ts = Ts (eμα -1) and running horsepower (NRL) may be
expressed by the following proposed
This calculation can be used for felt The corresponding power can be equation where NRL is in hp/inch/ 100
suction tube at the press felt,couch roll, estimated from the following equation fpm.
This volumetric flow is then used to
calculate power. HP = Ts (eμα -1)Wl S/33000= Km Ts Fabric life (days) = 0.465 (NRL) -2.55
(eμα-1) /330
The theoretical work Wad,J/kg for a where Wl =machine width Press and Dryer section power
vacuum pump can be calculated using If a nip roll is used e.g. lumpbreaker, the requirement
thermodynamic formula ( adiabatic nip also adds to the drive ability. With
/isoentropic compression) as follows: the corresponding power Power Drives for Press and dryer
HP = PnKM/ 330 section are based on NRL ( normal
m-1)/m
Wad={m/(m-1)}P1V1 [( P2/P1)( 1) The maximum amount of additional running load)or RDC( recommended
=={m/(m-1)}RT1 [( P2/P1)(m-1)/m 1) =H2- tension a suction roll can transmit drive capacity) estimation. Each
H1 without slippage is dependent upon the element of these sections has different
T2/T1=( P2/P1) (m-1)/m minimum operating vacuum and the value of NRL power constant and
P= G Wad/3600* 1000 machine dimensions machine drive constant . When all the
Where G, the mass of a gas ,kg ; , the Tv== (0.4912 μ v W2 NRL constants are added followed by
overall efficiency,m is the polytropic Where v is the amount of vacuum,W2, multiplying machine drive
coefficient which needs to be estimated. the size of vacuum box, and μ ,is the constant,km=, one can estimate the total
The equation can be modified on coefficient of friction between the roll NRL HP. A multiplying factor of 1.15-
volume basis also. and fabric. . The power is then 1,35 gives the RDC or RDC HP values.
calculated as These are well documented in various
How to select the vacuum dewatering HP =0.4912μ v Wl W2 (0.4912μ v texts( 1,3,5,7 ) and publications(16-18
profiles? w KM )/330 ).
Two empirical models relating the As an example, the application of
parameters , namely solid content , The maximum hp the various rolls can multinip and multiple felt presses
vacuum level , residence time are supply may be estimated as requires the development of
available. These are due to Caufield HPmax= (Tt-Ts)(Wl)S/33000 component value system based on
based on viscoelastic properties and the an actual nip load in the form of:
other due to Neun (10,15, ) ; the later Tension-Power Input Relation HP = Km (K1 Pn + a)
being transcendental in nature.. ship(5) and friction leads losses for each roll
Pnet=(Tmax-Tmin)v which are not proportional to nip load,
Estimating Driving Power For Tmax= Tension before couch, but are dependent upon roll type. The
Forming Fabrics (1,12,16-17) Tmin=Tension in return part load associated with each felt or fabric
v=velocity,m/s in the form:
Model For Power Transmitted Pnet=kW/m width(30-110kW/m)
Due To Wrap Average tension , T av. : (0.75 HP = KM (K2Pn + K3 (No. of rolls)
Tmin)+(0.25 Tmax) Felt Load=[(0.000003)(pli+(0.0007)
The power transmitting ability of (No. of felt rolls)]
Fourdrinier rolls can be estimated as Models for Power consumption Adjustable Crown=[(0.000004)(plix
follows: in suction box due to Derrick ( ft/min)0.5+(0.0060)]
17-18 ) Similar calculations can be made for
The ratio of tensions on each side of belt various elements of presses and dryers.
(fabric) driven by a roll is given by Typically over a half of the power
Tt/Ts = eμα needed to drive a foudrinier is caused by \Power Drive requirements of
where Tt and Ts are the tight and slack flat box drag. This drag also has large the Suction Box due to Neun
side of felt tensions μ , the coefficient of implicatios for fabric life. The vacuum (15)
friction between roll and wire( usually and air flow used by flat boxes require
taken as 0.25 for metal to metal),α, the substantial energy and large, and costly F=0.020U0.517N0.622 l0.325P0.239mp10.139T-0.054
angle of wrap. equipment. For just flat boxes,the
follwing equation can be used : HP=(6.06 *10 - 7 )U 1 . 5 1 7 N 0 . 6 2 2 l 0 . 3 2 5
The coefficient of friction (μ) between a P0.239mp10.139 T-0.054
rubber covered roll and a monofilament NRL = 0.0015ì (box width) (vacuum HPT=HP * x
fabric is largely determined by the level) Where F =the reaction force, lbf /in.
hardness (P & J value) of the rubber NRL is horsepower/inchwidth/100 width,
covering on the roll. The following fpm. ì is the box cover, box width is the U, felt speed,ft/min,N=number of slots
in suctionbox,

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 140

L=MD dimension of slots,in Where asp represents open area , in Mp,1= Felt moisture content
P=,box vacuum,in hg square inch. approaching suction tube, lb water/ lb of
MP1= water content of felt before the The dwell time of the particle of the felt
suction box, kg water/kg of felt fabric as it passes over suction box slot( Mp,2= Felt moisture content leaving
T, single layer felt tension,pli milli second) suction tube , lb water/ lb of felt
HP=hp /in.width ( td)=n.WB*60*1000/12*S n= number of slots in suction box
HP T = hp,x=suction box slot CD WB=Width of each slot
dimension For the drainage rate of the suction box S=Machine speed
one can use the following equation N=Number of slots in suction box
Neun(15 ) also reported experimental
data of lube shower flow volume as R=(mp1-mp2) x S x B/198 The permeability will decrease through
function of felt speed. the life of the felt to about 20% of the
original value of a new felt. With that
Felt Speed,ft/min Lube Shower volume,gal/min-in.-width
information , one can calculate the new
1000 0.03
and the old felt vacuum requirements.
2250 0.04
Typical inlet moisture values are 0.8 lb
3500 0.05
water /lb felt for the first press , 0.7 for
Where B is the basis weight of felt or the second and 0.6 for the third.
Press Felt Conditioning: fabric The following is a case study of an
Indian mill for laboratory assessment of
The conditions for felt cleaning are Shower Water addition Rate(1): felt conditions:
discussed in great depth( 1,3-6,8)
Air flow required for felt dewatering The shower water addition rate can be Felt Specification Running Period=155
can also be calculated using the calculated as days , effective period =124 days:
DeCrosta equation(1,15-21) based on G=(Wp /16) Up xsp (∆mp/8.35)
the variables affecting felt dewaterimg(
TIS 0404-27) is reproduced below: Felt type Specifications
Using a series of equations it is Triathlon Caliper:
New felt ,mm=2.50;Used felt,mm=1.96;Remaining felt caliper=78.4%
possible to relate specific air flow Loss of caliper,%=21.6%;Loss of caliper per day=4.3548387 *10-
through the felt at the suction pipe to the 3
=1.58 mm/year
resultant felt moisture content. The Basis weight New felt,gsm=1135.0;Used felt,gsm=920.52;Remaining
equation can be used to estimate air weight,%=81.1;Loss of weight %=18.9 Loss of subs.,gsm=214.48
flows in felt dewatering. Air flow Loss of subs. gsm/day=1.7296774
through a slot on a suction box can also Compression,% 2.7
be expressed as, Blinding Analysis Wear %=18.0;Wear,gsm=214.48
Air Permeability New Felt,l/dm2,min.=170.0;Used felt,l/dm2,min.=207.44;Remaining
Air Flow requirement for air permeability% =122;Loss of air permeability,l/dm2,min.=+22.0;
Loss of air permability,l/dm2.min.=+37.44;Loss of air
conditioning of press felts at permeability,l/dm2.min.per day=0.302
suction pipes: Void Volume,ml/m2 New Felt,ml/m2=1504;Used felt ml/m2=1153;Loss of open void
volume,ml/m2=351;Loss of open void volume ml/m2/day=2.8306451
Multivariable multiplicative nonlinear Open void volume of new felt %=58.7;Loss of open void
regression models: volume,%=1.3

For specific airflow at the suction box Suction box dewatering

cover Where G= Total shower water flow rate
W= Felt basis weight(Oz/ft2) For good operation in general the
V/= ao(∆ Psp)a1 ( td)a2 ( V*)a4 /(Mp,1)a U= machine speed,ft/min hydraulic capacity has been
ln V/= ao + a1 ln(∆ Psp) +a2( td)+a4 lnV* -a3 x= Felt width,ft recommended by DeCrosta(19-21).
ln(Mp,1) ∆mp=Water removed from felt at Typical Felt moisture contents and
suction pipe,kg of water per kg of fabric recommended shower water addition
V/= 0.069(∆ Psp)0.476( td)0.110( rate
V*)0.916/(Mp,1)0.628 Where V/= Specific air flow through the
Press Position Hydraulic load,kg water/kg Fabric Recommended shower water
For resultant felt moisture content
,mp2 rates,kg water/kg of felt
First 0.6-0.8 0.1
lnmp2=b0+ b1ln(V/)+b2ln(∆ Psp) +b3ln(td) Second 0.5-0.7 0.08
+a4 ln(mp1) Third 0.4-0.6 0.06
M p , 2 = 1.23( M p , 1 ) 0 . 8 1 9 /(V / ) 0 . 0 2 4 (∆ felt/ fabric at the suction tube, scfm/ in2
Psp)0.124(td)0.096 ∆ Psp = Pressure drop across the felt at Case A and B:
the suction tube, in.Hg.
Vacuum Pump Capacity: Td = Dwell time of a particle of felt at Assumed Values for press
V /
the suction tube , milliseconds( ms) position-second/First bottom
total new Vvp=V x asp x 30/(30 -∆ Psp+1) V* = Felt permeability , cfm/ sq ft. at
0.5 inch water

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 141

 Up, machine 5000/3000 V*, felt 45/50
speed, ft/min permeability,ft3/min/ft2
At 0.5 in. of water
L, slot width,in 2 x 1/0.75 Wp, felt basis 4.5/3.5
weight,oz/ft2
td dwell 2/1.25 Assume mp1 0.70/0.9
time,milliseconds Fig.2. Relation between vacuum
level and total air
xsp ,slot 300/300 Desired mp2 0.62/0.8
length,in
asp , open 600/225 ? mp 0.08/0.1
area,in2
Calculation for new felt felt will be replaced. It has also been
how to use the curve to estimate the air
∆? P,in 2 5 10 15 20 25 30
Hg Fig. 3 Relationship between Vacuum
V/ 4.2/3.8 6.6/5.9 9.1/8.1 11.1/9.9 12.7/11.3 14.1/12.5 - /13.7 level and water holding capacity
Mp2 0.76/0.98 0.67/0.87 0.61/0.79 0.58/0.75 0.56/0.72 0.54/0.70 -/0.68
VTotal 2800/- 4950/- 8621/- 14271/- 25400/- 63450/- -/- Figures 2 and 3 are also drawn to find
the relation between vacuum level and
Calculation for old felt flow requirement. total air and between vacuum level and
From the data which has been water holding capacity.
∆? P,in 2 5 10 15 20 25 30
The values obtained from the graphs
Hg
are now added in the programs to solve
V/ 0.97/0.87 1.5/1.34 2.1/1.86 2.5/2.26 2.9/2.59 3.2/2.89 -/3.14
Mp2 0.77/1.02 0.70/0.90 0.63/0.82 0.60/0.77 0.58/0.74 0.56/0.71 -/0.70
the objective function for optimization.
VTotal 647/- 1125/- 1989/- 3214/- 5800/- 14520/- -/-
Dryer Felts / Screens (1, 2-7,11)
Case Study B (23):
The dryer fabrics must work
Parameters: synergistically with the machine part to
provide desired machine production
Shower water addition rate: 0.1 kg with reasonable heat transfer efficiency
water/kg of felt;Felt=1000gsm; and maintains the requisite paper
speed=300 m/min;fabric width=3.5 quality. Dryer fabrics has dramatic
m;permeability of new felt=45 effects on the overall performance of
ft3/min/ft2 at 0.5 inch W.G.; machine.
Old felt permeability= 0.2 new felt
permeability;dwell time=5.08 Material of construction:
milliseconds;slot width =1inch; Natural:Cotton,Wool and Asbestos
machine speed=1000 ft/min;open area, Synthetic includes Acrylics, Polyamide
a sp=600 ft2 (Nylon), Nomex,Polypropylene ,Poly-
Assume mp1=0.5 and mp2=0.4 phenylene sulfides (PPS), Aramid,
Kevlar, Fiberglass etc.
Calculation for new felt
Degradation from moisture and
Calculation for old felt Fig. 1 Sizing a suction pipe felt conditioner heat
∆? P,in 2 5 10 15 20 25 The order of strength retained with the
Hg days exposed is
V/ 5.876 8.949 12.447 15.897 17.313 19.253
Fibre glass> PPS> Polyamide>
Mp2 0.524 0.477 0.429 0.4012 0.385 0.360
Aramid> Acryalic> Polyester
VTotal 15641 17446.15 21600 28350 41236 75600 Cotton> Wool
calculated we can get the air flow
through pump of the order of 26,000 The polyester,cotton and wool can
retain almost 30%( on 10 days
∆
? P,in 2 5 10 15 20 25 exposure) and 0.0 ( 6 days exposure)
Hg and 0.0 for nearly 3 days exposure
V/ 1.327 2.053 2.855 3.629 3.971 4.416 respectively.
Mp2 0.543 0.498 0.437 0.413 0.398 0.386 The dry heat degradation ( after
VTotal 3128.27 4361.53 5400 7057.50 10309.1 18900 exposure to elevated temperatures in a
forced draft ,hot air oven) polyester
The results are plotted in Fig.1 ft3/min/inch and vacuum requirement is retains nearly 70% of their original
DeCrostra has demonstrated how to use 15 inch. strength.
this curve and at what conditions the

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 142

Monofilament polyester type, Acrylics, object of felt or fabric tension is to
Fiber Glass can not stand 1500C squeeze air out from the space between
MD multifilament ( Combination of the paper and dryer. This is shown in
multifilament and spin) Fig. 4.
Polyester , Nylon, Nomex or It is established that dryer felts are
Homoacrylic can make-up yarns used on paper machines to force the
paper into close contact with the dryers
Relative degradation in order to increase the rate of heat Fig. 4 Influence of dryer felt tension
resistance of yarn to heat and transfer with certain amount of tension. on contact surface between cylinder
moisture(12,16) However, it increases heat transfer rate and paper and heat transfer.
Type of Low temp./low High temp/high Low temp/high High film is directly proportional to machine
materials moisture moisture moisture temp/moisture speed and varies with roll size to the 1.5
Nylon E P VG F power. Thus a 1.52 m roll should need
Polyester E VG G F about 40% more tension than a 1.22 m
Nomex E E E E roll, and a 1.83-m roll needs about 31%
Fiberglass E E E E more than a 1.52 m roll.
Acrylic E VG VG G
Kevlar E F Vg P Most machines were used to run
PPS E E E E between 3 to 8 PLI( 0.5 to 1.5 kg/cm)
up to a certain value beyond which the earlier with 6 pli being the average. This
E = Excellent, VG = Very good, G = gains are reduced. The condensing is shown in Fig.5
Good, F = Fair and P = Poor rates, a direct measure of heat transfer
Air Permeability values are shown in increases with felt tension to a certain However, newer machines now a days
the following table. level beyond which very little or no run at 10 to 15 PLI( 1.8 to 2.7 kg/cm).
further gains could be measured. Reports are also available that
Comparison of Air Permeability Tension is falling within a range of application of synthetic fabrics and use
values of different fabrics( 1) about 10% of the recommended tension of larger diameter lead rolls in a single
felted design have allowed an increase
Type Cfm/sq.ft at 0.5 in. water m/h in fabric tension on new machines to
pressure approximately 4 kN/m( 7).
Cotton or woolen felt 0-2 0-33
Needled fabrics(100% 40-100 650-1630
synthetic),batt-on-base or
batt-on-mesh
Open-mesh dryer fabrics 30-400 490-6500
Monofilament dryer fabrics 30-1000 490-16300
which should provide optimum heat
With monofilament and multi-filament transfer without being wasteful. Higher
dryer clothing ,it is possible to achieve felt tensions have certain limitations.
much higher permeabilities than with Use of higher tensions needlessly
cotton felts . shortens felt life, increases bearing
Overall, polyester has the best balance loads and drive loads, and causes
of characteristics for modern dryer excessive deflection of felt rolls
clothing though it is susceptable to
moist heat degradation which decreases The boundary film conditions in the
running time under extreme conditions. ingoing wedge shaped space between a
Materials more resistant to hydrolysis , smooth roll and a smooth impermeable Fig.5 Recommended static tensions for
such as acrylic, polyamide, and aramid web under tension have been described the dryer felts
are being used in such cases. The by Riddiford( 16 ).
monofilament fabrics must be heat set The residual thickness of the air film
and may be chemically treated to add between roll and web beyond the wedge Effect of Felt Tension on Drying
stability.The fabrics are made of flat area is Rates:
instead of round monofilaments.
H=1.51 R[(μU/T)(3/4 π √2/4)]2/3 According to Belanger, there is little
From the repairability point of Where R, the roll diameter,μ, the increase in drying rate above 6 pli felt
viscosity of air, U , the machine speed, tension whereas according to Anderson
view Aramid multi-filament
and T , the tension. The theoretical there is a significant increase in drying
thread must be there. rates up to 10pli( obtained by repeated
tension required to reduce the air film to
a given value can be obtained by experiments). Suppliers today are
Dryer Felt Tension designing dryer sections for felt
rearranging equation as under:
tensions of 10 to 17 pli. The best
Tappi has given guidelines for recommendation would be to run the
predicting in an approximating manner T=6.2 μU(R/H)1.5
design allowed felt tension and not limit
the most efficient static tension for to 6 pli . Dryer felt tensions should also
dryer felts and fabrics(TIS 0404- This relationship shows that the
tension needed to produce a fixed air be designed for a minimum of 15 pli
04,1989). It is well known that the tension.
IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 143
Steam Consumption with various dryer The time utilization factor,KP=tP/tW press=0.73;K3, constant depending on
fabric tension(7) condition of press=17 ;SP,dryness of
1.5 kN/m 2.2 kN/m web before press(17%);Spf ,the dryness
Shift 1 40.1 t/h Shift 7 36.3 t/h of felt after press(69 %);SR, degrees
Shift 2 38.2 t/h Shift 8 34.7 t/h SR( say 45);α,β,γ,δ,ν,φ ,the factors
Shift 3 40.2 t/h Shift 9 34.2 t/h obtained from experiments (
Shift 4 37.6 t/h Shift 10 34.9 t/h 0.123,0.07,0.127,0.026,0.145,0.06
Shift 5 40.1 t/h Shift 11 35.4 t/h respectively).
Shift 6 39.0 t/h Shift 12 35.4 t/h Using the above values of the constants
Average 39.2 t/h Average 35.1 t/h one can determine the value of
F2=31.2%
Now the gross production,Pb= Pth KV KR
Mathematical Model For KP= Bmax Vmax GSM*(60/1000)*24* KV In this particular case D was found of
Optimization Of Press And KR KP the order of 121 TPD and taking 20,000
Dryers per tonne of kraft paper , D was found
2. Estimation of B M a x , the to be 151200 Rs and K f =55.55
To evaluate the performance of press trimmed deckle of Pope Reel : Rs/tonne.
section and dryers in terms of The width of the wire is calculated from Further calculation shows that
economics Tappi (TIS 0404-22) the final trimmed width of the paper, Bp Km=Rs.15/tonne of paper.
documented the following procedure in taking into consideration of the
order to provide uniform results from shrinkage in press and dryer part, Water cost has been calculated with the
mill-to-mill comparisons. The trimming at the couch,a (0.025-0.05 m) data from table for pick up felt=0.1* kg
procedure lay emphasis on the and cutters and distance of deckle of felt
evaluation of machine clothing. strap,e,(0.005-0.05) , and free portion =0.1 * 1000 x 10-3 x 300 x 60 *3.5=6300
In view of the high capital investment in of wire required to move in lateral m3/h
the paper industry, production rate on a direction for guiding the wire,f,(0.02- Water cost is taken as Kw=Rs.10/tonne
given paper machine is of prime 0.05 m) of paper produced.
concern. It is therefore important in any Cost of lost production=121 x 2
economic evaluation to tie the result as Bs=Bn x 100/(100- %shrinkage) + 2 x20,000/24=201600
closely as possible to the production (a+e+f) = (Bp +22)x 100/(100- % Klp=74.0 Rs./tonne
rate.In view of the fact that production shrinkage) +2(a+e+f) The total cost still requires many other
rate often varies with the grades being costs including the cost of dewatering in
produced , it is desirable to determine an Where Bs,Bn,Bp= width of the web at
Uhle box and cost due to shower water
average daily production rate , Pd, the wire , of the paper at pope reel, at the
addition .
normalized over a suitable period of cross cutter. Approx. a=0.03
These are evaluated from DeCrosta
time , say one month or the life of a press m,e=0.01m,f=0.035 m, total a+e+f=75
equation. The shower water can also be
(Lfp,days) or drier fabric(Lfd) in days. mm and % shrinkage ≈6% are assumed
found out from respective equation. All
The average daily theoretical from practical considerations.
terms must be calculated at different
production rate can be computed as: production capacities.
3. Estimation of Wire length,
Based on the computer program in
Case study : Production Rate C++,the total costs per tonne basis as
L=A/B=(Pth /Kx B)(2.1 to 2.3), A being
Calculations of mill A(5,23) objective function all the cost
cross sectional area and K ,the loading
factor; depends on the type of paper contributing equations have been
Pth = 60 Bmax Vmax GSM *24/1000 evaluated for various production
TPD=60 x 3.5 x 300x 80/1000 x produced and many other factors such
as gsm and speed of machine.. capacities. These are tabulated below:
24/1000=120.96 tonnes/day=121 TPD Production vs Press section
Deckle of paper machine can not be Production Rate,tones /day Press section cost, Rs./tonne
utilized completely and machine does 100 646.0
not operate at maximum speed,rather it 150 475.0
works at average speed of machine,V If 200 389.5
the machine utilization factor for design 250 338.3
speed of machine ,KV=V/Vmax, varying 300 304.0
KV=0.9-0.95 3.Empirical model for cost:
estimation of dryness of paper
Machine does not run without stoppage leaving press/ dryer The cost of press section , Rs/tonne as a
. If to, be the total stoppage time and tw, function of production rate have been
theworking time=tP + tunprod. , the factor Fiber content at the exit plotted in Fig.6
for machine runnability, defined as . The data are fitted to a polynomial
KR=(24-to)/24 F2=K1K2K3(P/100)α (SP )β equation as
(Spf)γ(gsm)δ/(ν/60)ν(SR)φ
During working machine does not Y=0.0149 X2-8.7412 X +1715
produce paper always. If tP, production Where K1,a constant depends on
period per day, tunprod.,tW=24-to= tP + tunprod designing of press=B 0.047 * H 0.023 Y =cost of press section
;B=width of suction box=120 X=production rate
mm;K2,constant depending on type of

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 144

Cost of press section vs. Life of Items Press Fabrics Dryer Fabrics
felt(23):
A. Clothing Costs
Fabric cost calculated from the
respective equation is plotted as a 1. Fabric cost Kf=Cf/Pd Lf Kf=Cf/Pd Lf
function of production rate and fabric
2. Fabric Installation cost Kfi=D ti/Pd Lf Kfi=D ti/Pd Lf
life(Fig.7).The data for fabric life have
been collected from mill ( for 100-121 3. Cleaning cost Kfc=Cc/Pd + D tcN/Pd Lf Kfc=Cc/Pd + D tcN/Pd Lf
tonnes per day). The operating cost of
press section is a function of life of felt. 4.Fabric maintenance cost Certain percentage of Certain percentage of
If life of felt decreases the overall cost Fabric cost Fabric cost
of the press section decreases according
to the linear regression equation as Mill specific, depends on Mill specific, depends on
5. Conditioning cost type of felts and type of felts and
under:
contaminants contaminants
Y=-0.0162-4.591 X +0.885 B. Equipment Maintenance Km=D tm/Pd t + CLtm/Pd Km=D tm/Pd t + CLtm/Pd
Where Y= cost of press section cost t,Rupees/tonne t,Rupees/tonne
X= Production rate.
C. Water cost Kw=CfcUfw/Pd
+CwwUww/Pd

D. Cost of loss of production Klp=D td/Pd t Klp=D td/Pd t

Downtime cost D=Pd ti/24 Cost( D=Pd ti/24 Cost(

Rupees/tonne) Rupees/tonne)

Operating Cost, Cop=Kf+Kfi+Kfc+Km+Kw+Kip

Fig. 6 Relation between production III. Energy Costs
rates and cost of press section
A. Drive System of Kdc=? Edc 24 Cc/1000 Pd Edc=VI
machine/Electrical Power
Kdc=? Edc 24 Cc/1000 Pd

B. Vacuum Pump Drives/Fan Eac=VI Cosφ Eac=VI Cosφ

drives(DS)
Ev=0.334 Qf[1- Kve==? Ev 24 Cc/Pd
(P2/P1)0.287]Ws

Fig.7 Relation between cost of Kve==? Ev 24 Cc/Pd

press section and life of felt
C. Water Pump drives/ Kpc==? Ep24 Cc/ Pd Kpc==? Ep24 Cc/ Pd
Condensate pump(DC)
Economic Evaluation
D. Heat input to Ktc=Et-Es.24.Ct /Pd Ktc=Et 24 Ct/Pd
(Nomenclature are given in
Sheet/Thermal Energy costs
Tappi Information sheet ,16,23-
24) Total Energy Costs= Kdc+Kvc+Kpc+Ktc

I.Primary Paper Related Variables IV. Potential Savings/ Cost reduction

A.Production Rate: Pd=P/Lf =P/T A. Saving in steam costs Ks=2 ds ? M*Cs* e A.Reduce evaporation load

B.Sheet Dryness B. Savings due to increased Kp=24 D ? M e f/Pd B.Tune the dryer section
production( dryer limited
C.Downtime including any loss machines)
production time
Saving due to quality Kf=(Cca)(Fa ) C.Cost reduction through
improvement +(Ccb)(Fb)+……… increased productivity
II Operating Costs
D.Recover Waste Heat

The calculations considered here for Total potential savings=Ks+Kr+Kf

both pressing and drying operations in Sample Calculation For Econo-mic Evaluation (based on the cost basis assumed in
this sample calculation is a general TIS 0404-22)
technique. The costs of various Wire, cost/m2=4075- Press Fabrics Dryer Fabrics
components given in Tappi information 4200For single- double wire
sheets revised in 1984 have just 100% synthetic: Depends 100% synthetic
converted at the rate of 43 rupees per 2.5 layer= upon gsm; 1100gsm,
USD. No time value of money , Approx.Rs.6000/m2 Rs.2587 /kg Mono up to Rs.2400/m2

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 145

escalation of costs, inflation , and scale efficiency design an investment min each were required in 45 days;cost
ratio are considered. The costs may be analysis is made considering time value of maintenance, km=Rs 9.03/ton; cost of
thus hypothetical in Indian of money and escalating costs of Shower water, Kw=9.89/ ton;total
conditions.In actual practice,the materials, energy etc. Standard method downtime at press section=2.75 h
following procedure available in all for evaluating an investment in high
standard texts of plant design must be efficiency equipment at a price Operating costs
used. For example, premium can be used as follows:
A. Press clothing costs
Power of Pumps:P=QρgH/1000η, Q, NPV, Net present value, a discounted
the volumetric flow rate, m3/s; ρ, the cash flow methods determines the net 1. Press Fabric costs, Kf=Cf/ (Pd*Lf) =
density , kg/m3,H, the total equivalent present value of all cash flows by 258000/282*45= Rs.20.33 /ton
height of transport of fluids,m, η,the discounting them by the required rate of
overall efficiency which can be defined return ( known as the hurdle rate or 2. Fabric Installation costs= Kfi=D ti/Pd
as η = ηp ηt ηm where ,p,t, and m indicate cutoff rate and similar terms Lf=86000*1/282*45=Rs.6.77698
for pump, transmission as well as
motor. The efficiency of motor can be NPV= A 0 +∑nt=1 ( ACF)t/(1+r+pt)t 3.Fabric Cleaning Costs=Kfc=Cc/Pd + D
assumed of the order of 93-95%. Ηp can tcN/Pd Lf=2580/282 + 86000 *8*
be estimated from curve plotted for Where ACF , the net cash flow in period (15/60)/282*45=9.14893617+13.5539
efficiency vs. volumetric flow rate. In t, r, the required rate of return,A0 ,the 795=Rs. 22.703/ton
absence of the data the following intial cash investment (because this is
equation can be used: an outflow, it will be negative),pt, the Total Fabric related costs=20.33
predicted rate of inflation or deflation +6.77698+22.703=Rs. 49.80998/ton
ηp=-0.01(lnQ)2+0.15lnQ+0.3 during the period t.
4. Maintenance costs, Km=D tm/Pd t +
For motor Curve for efficiency of motor The project will successful and thus CLtm/Pd t=86000*…..= Rs.9.03/ton
as a function of Brake Power,kW can be acceptable if the sum of the net present
used . In absence of data , the following values of all estimated cash flows over 5. Cost of Shower water,Kw = Rs.9.89/
table can be used the life of the project is positive. The ton
concept must be used for
Approximate efficiencies of electric allminvestment decisions. 6.Cost of lost production= Klp=D td/Pd
motors t=86000*2.75/282*45=Rs.18.63672
/ton
Economic Evaluation Of Press
Cost, CA=CB(S2/ S1)M x ( Ip/Iold) x fmxfTx Section
fP x ftype index at present/Index value at D=(Pd ti/24 )Cost( Rupees /tonne) =
282*1 /24
Size,kW Efficiency,% Size,kW Efficiency,%
Total Operating Costs = 20.00 +
5 80 200 92 6.77698 +22.703 + 9.03 + 9.89 +
18.63672 = Rs. 87.0367/ton
15 85 750 95
B. Energy Costs:
75 90 >4000 97
1. Drive costs= Kdc=∑Edc 24 Cc/1000
thetime original cost was obtained) Case 1: First considering a Pd=89.5 kW x 24 x 1.29/282 = Rs.
hypothetical third press 9.82595/ton
Cost exponent of the equipment, M,
must be considered from the designer's Fabric cost= Rs.258000; Fabric 2. Vacuum Costs= Eac=VI Cosφ
handbook. For example the exponent M Life=45 days and average daily
for centrifugal pump with motor, is production rate=282 TPD(O.D. Ev=0.334 Qf[1-(P2/P1)0.287]Ws
0.55, vacuum pump including Basis);fabric Installation time , Ti= 1
motor,0.44 and electric motor h; hourly cost of downtime, D=Rs Kve==∑Ev 24 Cc/Pd=78 kW * 24 * 1.29/
alone,0.85. The exponent values 86000/h 282 = Rs.8.5634/ton
however changes from designer to
designer. The base cost also varies. The Typical sheet dryness during run: Out Total cost = 87.0367 + 9.82595 +
multiplying factors fi represent for of press section=42%( moisture 8.5634 = 18.38935=Rs.105.42605/ton
material of construction, temperature, ratio=1.38) and at reel=6%( moisture
pressure and types. To calculate present ratio=0.064). Potential Savings
cost of the equipment or item like felts
or screens , the chemical engineering Cost of steam, Cs=Rs. 107.5 /1000 lb Drying Costs( steam): Specific steam
plant cost index may be considered. steam;Dryer efficiency=1.5 lb steam/ib demand=, ds =1.5 kg of steam/kg water
Alternately the cost due to inflation at water evaporated; production evaporated(1.38-0.064)=1.974 kg
an appropriate rate ( averaged over efficiency factor, e = 0.04;cost of fabric steam/kg of paper
certain period) in any country may be cleaning chemicals , Cc=Rs
employed. 2580/day;power input to drive, B. Cost Steam = (1.974*107.5/1000) *
Edc=89.5 kW; power input to vacuum 2000 = Rs. 424.41/ton
For economic comparison among pump , Ev=78 kW;Cost of electricity,
several alternatives for higher Ce=Rs 1.29/ kWh; eight wash ups of 15

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 146

Case 2 : Installation of a new 6.Cost of lost productivity(efficiency 7. Markku karlsson-Papermaking
fabric loss):24(1-0.9)=2.4 h/day; 2.4 * D/Pd = Science and Technology, Book 9,
Rs. 731.915/ton papermaking Part 2, Drying,
New Style of Press Fabric of higher Papet Oy,Finish Paper Engineers'
costs, 1.5 times the former is installed. 7. Thermal Energy costs = Kte= 45 * 24 * Association and Tappi ,2000
As a result production capacity is 4/282=Rs.15.319/ton
increased by 5% to 210 tonnes but the 8. Mukherjee Ashish and Naveen
fabric life,2/3 rd of the earlier one, is Ktc(water)=15.319/{(94/42)-1} * D = Srivastava, IPPTA Workshop, 18-
reduced to 30 days. The new fabric Rs. 0.000144/lb of water 19 Dec, Rajahmundry
installation increased the dryness by 1.5
% more. All other costs are assumed to Conclusions 9. Rao N.J. & Ray A.K., IPPTA,
remain the same on a cost per ton basis. Vol.20(4), 1983,1-15
The lost time was reduced to 2 hours. In this present investigation various 10. P a n d e y R a v i , D i s s e r t a t i o n
Should we go ahead with the new mathematical models are attempted to submitted to DPT,IITR,2004
fabric installation? apply in practical calculation of energy 11. Phamplets of Felt manufacturing
estimation , specifically electrical company of India and Abroad(
Simple calculations show the following energy in relation to paper machine Voith fabrics, Wire and Fabrieks ,
changes without going for more clothing. Detailed calculations are Shalimar Wire, Shri Dinesh mills,
accurate estimation using NPV based made for vacuum pump , suction roll huyck, Nippon ,heimbach Ippolito
on discounted cash flow and inflation and drive power requirements. & Pisani S.p.A etc
rate. DeCrosta equations have been used for 12. Practical Aspects of Pressing and
various case studies of Indian mill. Drying Short Course-Ta[ppi
The net savings compring of steam Economic evaluations of both press Press,1995
savings ,increased production down and dryer fabrics are made with some 13. Davies C.N.,1952, Proc. Inst
time saving,increased pressing cost and assumed data used abroad. Case studies Mech.Engrs(London),1B,pp. 185.
less longevity of the order of Rs. 315.6 for press and dryer clothings are 14. Ingmanson W.L., Andrews B.D.
per tonne will be anticipated. especially discussed through already and Johnson R.L., 1959, Tappi, 42
developed model based on C++ (10) , pp.840-849.
Economic Evaluation Of Dryer programming for parameter studies and 15. John A. Neun J.A.-Tappi Sept.
Section economic evaluation as a function of 1981, Vol.64(9), pp 123-127
production rates. More extensive work
Dryer Fabric cost=Rs.2580000;fabric should be carried out with more 16. Technical Information Sheets TIS
life , Lf=180 days; average daily authentic economic data from paper 0404-17,-21,-22 ,-26,-27and 0404-
production rate=282 TPD; fabric mill. 30
Installation time , Ti=18h;hourly cost of
downtime, D=Rs.86000/h References 17. Derrick, R.P., Tappi J., Vol.60,1977

Typical sheet dryness during the run: 18. Derrick R.P., P.T. McNulty, and
1. Pulp and Paper Manufacture, Vol. 7,
W.F. Robertson, Tappi, Vol.64(9),
Paper Machine Operations,edited
Entering dryer section=42%(moisture 117119
b y B . A . T h o r p a n d
ratio=1.38); at reel=6%(M.R.=0.064) M.J.Kocurek,The joint textbook 19. DeCrosta E.F., Tappi, Vol. 56
committee of the paper Industry, (11),1973,100-106
Cost of steam,Cs=Rs.172/1000 lb
TAPPI and CPPA,1991, Third
steam;production Efficiency=90%;cost
Edition,pp 563-593 20. DeCrosta E.F., Pulp & Paper
maintenance=Rs.10.75/tonne;down
2. Leigh Ged,,ipw 6/2009 Canada (1),1980,pp.97-102
time for dryer section=3h/month;steam
3. Pulp and Paper- Chemistry and
energy,Et=45000 lb/hr
chemical Technology, Edited by 21. DeCrosta E.F., Tappi, Vol. 63
J . P. C a s e y , Vo l . I I , T h i r d (5),1980,93-95, 97-101
Operating costs
Edition,1960,pp 1076-1090, 1096-
Dryer Fabric costs 1099. 22. Ravi Pandey ,Paper Machine drive
4. Pulp and Paper Manufacture,Vol.3, load calculations,Project Report,
1.Press fabric costs= Kf = Cf/(Pd*Lf) = edited by Macdonald R.C. and DPT,IITR,2003
2580000/282 * 180 = Rs. 50.827 /ton J.N.Franklin,399-401,,380-
382,428-436 23. Puri M.K.,Optimization of press
2. Fabric Installation Costs :Kfi=D ti/Pd 5. Kikiewicz,Z and R.S.D.Pandey, section,Project report submitted to
Lf=86,0000*18/282*180=30.4964539 Theory and Design of Paper DPT, IITR,,2005
Machines, Vol.1 and II,Tara Book
3.Fabric Cleaning Costs: = 0.0 = Kf c= Agency, 1983 and 1990 24. Hemant Kishore, Nikhil Kumar and
Cc/Pd + D tcN/Pd Lf 6. Hannu Paulapuro-Papermaking S.Amit, Project report , submitted
Science and Technology, Book 8, in IPT, University of Roorkee,2000
4. Maintenance costs: Km= D tm/Pd t + papermaking Part 1, Stock
CLtm/Pd t = 86000/282 preparation and Wet End, Finish
Paper Engineers' Association and
5.Cost of lost production dryer section= Tappi ,2000
Klp=D td/Pd t=Rs.30.496/ton

IPPTA J. Vol.21, No. 4, Oct.-Dec., 2009 147