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UMKA cardboard factory saves energy costs after hood rebuild
Felix Schoeller saves energy costs with the help of Lang-Hafner
New Lang-Hafner hood for UMKA
LANG-HAFNER acting as emergency specialists
Only 1,15 kg Steam / kg paper after the rebuild with Lang-Hafner
LANG in new offices
New lift-gate hood and air technology for Melitta household products in Minden
LANG-HAFNER lowers energy consumption at Thai Union Paper Ltd.
Energieeinsparung mit neuer Haube bei Varel
More than 10 % steam saving thanks to overall concept
GRÜNPERGA Papier GmbH Modification of air technology on PM 6 - A real challenge
Energy-efficient testliner production at Papierfabrik Tillmann: Only 6 % primary energy

UMKA cardboard factory saves energy costs after hood rebuild
The UMKA cardboard factory in Beograd is a member of KappaStar Group manufacturing special cardboards with basis weights between 230 and 500 g/m2 on an operating width of 320 cm. Comprehensive refurbishment works on the board machine were completed last year, the largest element of which was the replacement of the 77m-long drying hood.
The objective was to improve the drying process of the board produced and, at the same time, to reduce thermal energy consumption considerably and thus save on the high energy costs. Against tough international competition, LANG-HAFNER won the order for the supply of a new lift-gate hood thanks to the decisive and convincing price-performance ratio it could offer. The new hood has been built using state-of-the-art technology. Special seals on the insulation cassettes, rivet-free cassettes inside the hood, sealed cassette joints as well as ventilated hood steel construction enable an operating dew point up to 64°C. The thermal radiation loss from the drying cylinders has been significantly reduced through higher air temperatures in the hood and the reduction of the leakage air rate, and this has enhanced the efficiency of the dryer section. It was possible to retain the existing machine-related air technology without changes, despite increased water evaporation. Simply by installing the new hood, the board machine’s steam consumption has been lowered by 6 %. The thermal heat radiation of the hood was significantly decreased while, simultaneously, the leakage of swaths of water into the paper machine hall was eliminated. With both factors combined, a real improvement in the climatic conditions in the machine hall has been achieved. A particular challenge was the short shutdown period of 10 days. There was no problem adhering to the shutdown schedule, thanks to a detailed and coherent erection plan as well as the perfectly coordinated cooperation between our customer UMKA, HAFNER and customer’s mounting company GrappS a.d.

LANG-HAFNER was the right partner for us, was the conclusion of technical director, Stanisa Lukic, after a successful, on-schedule startup.

Felix Schoeller saves energy costs with the help of Lang-Hafner
Felix Schoeller Group has been producing high-quality special papers for almost 120 years. Quite a number of different operational processes are required on PM 1 at Osnabrück to deal with the wide variety of products it manufactures for digital print, nonwoven and décor papers. To ensure flexible and energy-efficient operation it became necessary to modify the steam and condensate system as well as the related hood air technology in the dryer section. This is where the experience of Lang-Hafner was key. The main focus of the rebuild project was on saving energy. The end result is that the entire hall ventilation can now be operated, depending on the product, without the use of live steam. The hood’s nested air system was structured and clearly assigned, and subject to the actual production and steam requirements in the respective dryer groups, the fans are automatically controlled in terms of the number of rotations required to ensure a constantly high and efficient dew point in the hood. The steam and condensate system was also adapted considerably. In addition to the newly-arranged heating groups, it is now possible to heat up or switch off individual cylinders, and cooling water consumption during the paper making process has been reduced to “zero”. The waste and flow steam, which was condensed with cooling water prior to the rebuild, is now used to heat the paper machine. Ever since startup, on schedule, in June 2014, the machine has given problem-free service and continuous savings in primary energy.

Jörg Laing (project manager at Felix Schoeller) says: “We opted for Lang-Hafner as our supplier because it offered a logical overall concept from a single source. In my view, the success of this project is based on the cooperation and mutual trust between supplier and customer.”

New Lang-Hafner hood for UMKA
UMKA of Serbia, recognized as the most important board producer in the region, has awarded Bellmer’s subsidiary Lang-Hafner the order for a complete dryer hood for board machine # 1, featuring a dew point of 64°C. The scope of supply includes lighting as well as the fire safety system.

The new, closed and insulated hood will be approximately 77 m long, 7.50 m high and 6.50 m wide and will span the pre-dryer section, the Yankee dryer and the post dryer section. The hood has some special features: It is made from ventilated and heated hollow profiles, and the design of the entire hood structure prevents any condensation even at high operating dew points. The top and sides of the hood are constructed internally to be rivet free above 2.5 m. The hood roof with surrounding aluminium guard rails is accessible and loadable up to 130 kg/m2. Integrated passdoors enable the hood to be entered even in closed condition.
The top and side elements, connected firmly to the hood’s steel construction, are equipped with EPDM seals to keep operating costs low. Efficient drainage of water from the dryer section keeps steam consumption in check. The capacity increase of the existing heat recovery system brings thermal energy savings, while power consumption by the fans is reduced thanks to low circulating air flow. In addition, it has been possible to increase production without extending the existing air system. A notable advantage for production staff is the improvement in hall climate, with reduced heat and moisture. Sound levels have also been minimized.

Commissioning of the new hood is imminent.

LANG-HAFNER acting as emergency specialists
In early November a machine fire at Lenzing Papier GmbH, Austria, caused significant damage to the hood in the pre-dryer section and the associated hood exhaust air plant including the heat recovery system. Lang-Hafner was quick to respond to the emergency.

Within just 4 weeks, the crew succeeded in carrying out all necessary remedial works on the hood and channel elements in their workshop in Apfeltrach, Germany, and was thus able to deliver and mount custom-tailored parts with no problems. Thanks to mutual trust and unbureaucratic project procedures between Lenzing Papier and Lang-Hafner the machine was provisionally ready for production before Christmas. At the same time as the new parts were manufactured, the heavily damaged hood elements were repaired on site and professionally remounted by Lang-Hafner experts.

The customer thanked Lang-Hafner for its successful efforts and in the meantime has placed an order for the full restoration of the hood exhaust air unit for the pre-dryer section including a two-step air/air heat recovery plant.

Completion is expected early March.

Only 1,15 kg Steam / kg paper after the rebuild with Lang-Hafner
A successfully executed rebuild in the previous year was the basis, that the company Smurfit Kappa in Hoya entrusted our daughter Lang-Hafner with the modernisation of its PM 2 steam and condensate system. The extensive and challenging project included a redistribution of the heating groups including the piping from the main steam pipe up to the cylinders.

The necessary fittings were inserted, existing and new separators were displaced and the associated pumping stations were built up.

A new driving steam line including pressure reduction, steam cooling, volume measurement and safety valve, were moved from the boiler house to the PM. An outflow manifold including muffler now runs along the PM to above the roof. The condensed water pipe was moved from the condensate collecting tank up to the deaerator. Condensate quantity and conductivity measurements are integrated there.

Because of the new heating group division and the restructuring of the previous cascade system into a thermo compressor system Hoya now achieves more flexible conditions of production. The surface temperature of the cylinder has been enhanced.
By exploiting the secondary energy, the specific water evaporation, is now at 1.35kg steam/kg H2O or 1.15kg steam/kg of paper.

The plant was on schedule and fully functional in operation.

LANG in new offices
As a member of the Bellmer Group, Lang is a well-known, leading supplier of steam and condensate systems. Together with its sister company HAFNER of Apfeltrach, this flourishing enterprise located in Eschborn, near Frankfurt, offers complete, integrated consulting services and energy concepts for paper and board producers.

Just recently, Lang moved to new offices in Eschborn, with a better layout which is more conducive to efficient working practices and teamwork. The shipping and storage division has been modified and is now freely accessible to all other departments.

Managing director Jürgen Schubbert is delighted with the new office environment and thanked his colleagues
in Niefern for their support.

Erich Kollmar officially opened the new premises during a special reception.

Neue Hubtore für Rondo Ganahl in Frastanz, Vorarlberg
Im Rahmen von Modernisierungsmaßnahmen hat die Firma Rondo Ganahl die Bellmer-Tochter LANG-HAFNER mit der Lieferung und Montage einer neuen vollisolierten Hubtorhaube für die Vortrockenpartie der Papiermaschine beauftragt. Die Rondo Ganahl AG, eines der traditionsreichsten Unternehmen Österreichs, hat ihren Stammsitz in Frastanz/Vorarlberg. In der modernen Papierfabrik werden hochwertige Testlinersorten (weiß, geflammt, braun) auf der Basis von 100 % Altpapier produziert. Die zu liefernde Hubtorhaube mit einem Konstruktions-Taupunkt von 64°C wird nach modernstem Stand der Technik gebaut. Durch den automatisch geregelten Betriebstaupunkt von 60°C werden die erforderlichen Zu- und Abluftmengen auf ein Minimum reduziert und gleichzeitig die thermischen Abstrahlungsverluste der Trockenzylinder verringert. Dadurch kann der Wirkungsgrad der Trockenpartie gesteigert und der Einsatz von Primärenergie, sowohl in der Lufttechnik als auch in der Trockenpartie, reduziert werden. Zum Lieferumfang von LANG-HAFNER gehören auch die MCC-Steuerung der Zu- und Abluftventilatoren sowie die, durch den Einbau einer Taupunktregelung, erforderliche Neuprogrammierung des PLS.
Energieeffiziente Trockensysteme aus dem Hause Lang-Hafner

New lift-gate hood and air technology for Melitta household products in Minden
Bellmer subsidiary LANG-HAFNER has received an order for a new lift-gate hood and multi-step heat recovery plant and associated air technology, as part of an extensive modernisation of Melitta’s machine-related air systems. The customer’s key requirements were reliability and energy efficiency. The hood to be supplied represents state-of-the-art technology, which allows high dew points combined with minimal air throughput. The high dew point ensures reduced thermal heat radiation, while higher air temperatures in the hood allow a reduction in thermal radiation loss from the drying cylinders and enhanced efficiency in the dryer section. The result is minimum primary energy consumption. Access-doors enable quick entry to the hood.
Up-to-date measuring technology enables fully automatic air volume control, adapted to the actual volume of water evaporation within the dryer section. Waste heat is used in the first heat recovery stage (air / water) and the secondary heating water cycle is warmed up for room aeration. Additional machine air is pre-heated in the second heat recovery stage (air / air).

Energy savings with new housing in Varel
For its process air system, Varel has placed its faith in Bellmer technology: Bellmer’s daughter company Lang-Hafner received the order for the complete process air technology aspect of the project, including existing heat recovery systems. The stabilizers come under the remit of mechanical engineering, and were built by the paper machine suppliers.
They are supplied with the necessary air by the Lang-Hafner installation. On the recommendation of Lang-Hafner the customer opted to invest in a new hood, designed and constructed with the latest technology. This was absolutely the right decision – and one vindicated as the project ran its course. The new dew point controlled hood now guarantees significant energy savings.
Lang Hafner had already begun installation of indoor air facilities and stock preparation for PM 4 last year.
The existing pump hot water system has been completely redesigned to the latest technology standards.

Uwe Wollschläger, Managing Director of PK Varel, was very satisfied with the professional manner in which the project was undertaken, as well as with the quality of the lift-gate hood supplied by Lang-Hafner and its air-related components.
PM 4’s air system is now up to date

LANG-HAFNER lowers energy consumption at Thai Union Paper Ltd.
Thai Union Paper Ltd. is a subsidiary company of Siam Cement Group in Thailand and operates two paper machines at its site in Kanchanaburi. When the steam and condensate system started to cause considerable problems, the weak points were first detected through an ExpertCheck performed on site.

It showed that the specific steam consumption was much too high, and that hardly any secondary energy was being harnessed to warm up additional machine air. As a consequence, steam was permanently being lost through the roof or deposited on the auxiliary condenser. It proved impossible to adjust the temperature curve in the dryer section correctly and frequent breaks through sticking and picking occurred. The auxiliary condenser also became blocked with lime-scale.

The solution was a system modification based on LANG-HAFNER’s integrated energy use technology. The control of the steam and condensate system was revised, and new damper registers installed in the additional machine air system to exploit energy from exhaust vapours and hot condensate. The success of the project became obvious right after startup. The steam plume above the roof had disappeared, and the auxiliary condenser is only slightly loaded with steam. Steam consumption has been reduced by approximately 0.4 tons / per ton of paper, which means return on investment will be achieved comfortably within two years.

In addition to the energy savings, the heating of the drying cylinders can be adjusted more precisely, and effective dewatering assured.

More than 10 % steam saving thanks to overall concept
In August 2011, Lang-Hafner is set to install and commission a heat recovery system for packaging board manufacturer Delkeskamp Verpackungswerke GmbH. As a result, Delkeskamp will need considerably less steam for its testliner production. This is thanks to an integrated Lang-Hafner concept featuring an optimised steam and condensate system in combination with heat recovery from hood exhaust air. White water currently heated using exhaust vapour, will receive a boost from the new heat recovery plant to more than 50° C. Measurements taken in the steam and condensate system will enable targeted use of residual energy to heat machine supply air up to blowing-in temperature without the need for additional primary energy. A new hall ventilation system – also designed to operate without any additional primary energy consumption – will ensure a comfortable working temperature right from startup.
In winter, for example, when temperatures can plummet, live steam will be used for additional heating. An energy-efficient hot water heating system will ensure that heating energy is conveyed from the heat recovery to the individual hall supply air plants. Frequency controlled pumps will guarantee a maximum yield of heat output while, at the same time, minimising electrical energy consumption. The return on investment for the entire project is expected to be less than two years, so this rebuild makes absolute sense from all perspectives.

During the project tendering phase, Delkeskamp Verpackungswerke plant manager Christian Austermühle was adamant that “We will only specify the best concept – simple as that”, so for Lang-Hafner, the order was a great affirmation of its technology.
Lang-Hafner concepts guarantee use of available heat capacity is maximised

GRÜNPERGA Papier GmbH Modification of air technology on PM 6 - A real challenge
In August 2010, GRÜNPERGA Papier GmbH in the east of Germany took delivery of a fully insulated hood for PM 6, and the machine-related air technology system was completely modernised at the same time. PM 6 produces greaseproof papers of 30 – 80 g/m2 and crepe papers in the range 40 – 120 g/m2, used for coffee filters, for example. The project’s targets were to reduce the specific primary energy consumption and simultaneously to increase the machine’s production speed.

And this project included a real challenge: an efficient, custom-made hood had to be integrated within the confines of the existing building. In addition, the entire machine-related air technology had to be designed, manufactured and supplied in modular construction for installation outside the PM hall: the reason being that neither truck-mounted nor construction cranes were able to access the installation site. The Lang-Hafner team did an outstanding job in overcoming this challenge, and the result was a fully satisfied customer. Another hurdle was that GRÜNPERGA needed the new hood installed within a strict time window of just five days. Since there was no hall crane for mounting the hood, almost every element had to be lifted into place manually.
Ulf Ender, managing director of GRÜNPERGA Papier GmbH, praised Lang-Hafner’s skill, flexibility and effectiveness from initial installation through to startup. “With Lang-Hafner, we chose the right partner”, said Mr Ender. Operating personnel have also been very pleased with the significant improvement in working conditions in the production hall made possible by the modernised air system.
The new custom-made air technology system

Energy-efficient testliner production at Papierfabrik Tillmann: Only 6 % primary energy
Tillmann’s paper mill in Zülpich-Sinzenich belongs to Tillmann Wellpappe (Wellpappe is corrugated board) in Sundern-Stockum (both locations are in North Rhine-Westphalia). Tillmann Wellpappe has been producing packaging media from corrugated board for over 50 years. The comprehensive quality control system starts at Zülpich-Sinzenich where approximately 70 % of the papers to be converted into corrugated board are produced, based on a waste paper furnish.
At the end of last year, the paper machine on this site was comprehensively rebuilt and updated, with state-of-the-art production and drying technology. Wolfgang Bayer, plant manager at Hafner Air Technology, described the project in a paper he gave during Bellmer Paper Days. In addition to paper quality, great emphasis was placed on energy efficiency, particularly in the drying section. With this in mind Bellmer Group member LANG-HAFNER was given the order for supply and installation of the new steam and condensate system, as well as all relevant ventilation technology required for the machine and hall. The whole package, from the cleverly devised drying function within the steam and condensate system, to the energy-efficient layout of the machine and hall ventilation system, convinced the customer that LANG-HEFNER was the right choice. The main target was to minimize the use of primary energy. The newly installed hall ventilation system has to cope with a total volume of additional air of 310,000 m3/h, and it is designed to maintain this at a suitable temperature without the use of live steam, right down to outside temperatures of – 12°C. With the need for live steam in the machine’s supplementary air system reduced to a minimum, only 6 % of primary energy is required to fulfil the entire energy requirement of 6,000 kW/h – the input needed to heat the machine and hall air systems. Secondary energy can be exploited fully, thanks to optimisation of the steam and condensate system for machine air ventilation.
This is another project which demonstrates that the key to energy-efficient production is the combination of air technology with the appropriate steam and condensate system, such as that supplied by Bellmer subsidiary Lang-Hafner.
Energy-saving production thanks to Lang-Hafner know-how