The case for engineered solutions: Decreasing steam consumption while Increasing machine production, Jorge Trujillo - Product Manager, Paper Industry, Deublin Company Lisa Freed - Manager, Steam and Condensate Systems, Deublin Company - Paper Technology International 2025 FlipBook - Journal - Page 119

The case for engineered solutions: Decreasing steam consumption while Increasing machine production, Jorge Trujillo - Product Manager, Paper Industry, Deublin Company Lisa Freed - Manager, Steam and Condensate Systems, Deublin Company

PAPERTECHNOLOGYINTERNATIONAL
Figure 3: Lisa Freed, of Deublin Company, in front of a newly installed separator skid.
Case Study: A Southern U.S. Mill Transformed
Case Study: Driving efficiency and productivity at a southern
US paper mill with Deublin’s turn-key solution
Mill Overview
Location: Southern United States
Product: Solid Bleach Sulfate (SBS)
Paper Machines: 2 machines with consecutive installations
Project Type
Complete turn-key installation encompassing steam and
condensate systems and steam joints siphon systems, designed to
improve operational efficiencies in a mature and competitive market.
Project Scope
The project covered a full-scope solution tailored to address
the mill’s operational challenges, including:
•
Exclusive FSU Steam Joints and siphon systems rated
to 200 psi.
•
Comprehensive steam and condensate systems,
integrating Deublin’s proprietary Blow-Thru Control
technology.
•
Engineering Services: Complete system design to
optimize performance for current operating conditions.
•
Installation Services: Expert deployment to ensure
seamless system integration and performance.
Challenges Before the Rebuild
Prior to the project, the mill faced numerous operational
inefficiencies and cost burdens, including:
•
Steam and condensate losses led to energy
inefficiencies.
•
High maintenance costs due to frequent repairs of
outdated steam joints.
•
Excessive motive steam consumption from a poorly
designed steam and condensate system.
•
Equipment wear and erosion, including undersized
components that could not meet current demands.
Key Solution: Deublin Blow-Thru Control Technology
The Deublin Blow-Thru Control system was a cornerstone
of the project. Its innovative design automatically and continuously
adjusts differential pressures (DP) across the Dryer Section
based on operating conditions, eliminating the need for operator
intervention.
Benefits of the Blow-Thru Control System:
•
Automatically synchronizes DP with dryer pressure,
ensuring optimal performance at all pressure levels.
•
Prevents dryer flooding by automatically adjusting DP
based on operating conditions.
•
Significantly improves system reliability and efficiency.
•
Results After the Rebuild
•
The turn-key installation delivered remarkable
improvements:
•
Production Increase: A 10% boost in production
capacity.
•
Energy Savings: A 30% reduction in motive steam
consumption.
•
Enhanced Product Quality: Improved MD/CD moisture
profiles, contributing to better product uniformity and
quality.
•
Cost Savings: Reduced maintenance expenses and
longer equipment lifespans due to robust and properly
sized components.
Conclusion
Deublin’s comprehensive turn-key solution, featuring
proprietary Blow-Thru Control technology, transformed the Southern
U.S. paper mill’s operations. By addressing inefficiencies in steam
and condensate management and upgrading outdated systems,
the project not only increased production but also reduced energy
consumption and maintenance costs.
This case underscores Deublin’s commitment to delivering
innovative, high-value solutions that drive efficiency and productivity
for mills in even the most mature markets.
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