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Klingele Papierwerk: New water treatment for the energy center
Manufacturer of corrugated board paper and packaging solutions opts for EnviroFALK boiler feed water treatment
The paper mill, which has been based in Weener for over 50 years, produces around 250,000 tons of corrugated base paper every year. The power plant belonging to the Klingele Group, which is operated on the basis of substitute fuels, provides the energy requirements. This is because the RDF power plant replaces around 32 million cubic meters of natural gas and primary energy. This will make a significant contribution to climate and environmental protection, as fossil CO2 emissions will be reduced by up to 55,000 tons per year.
The substitute fuels thermally utilized in the power plant on a grate firing system generate heat and steam. The thermal firing capacity in the steam room is 84 megawatts, while the steam boiler system produces 102 tons of steam per hour. Around 50% of this steam is transported to the paper mill via a 1.8 km long, underground steam pipeline. The remaining 50 % is used in the power plant to generate electricity. The resulting condensate returned from the paper mill to the power plant in a parallel line. It was used as boiler feed water to operate boilers and turbines to generate heat and electricity.
Magnus Häbel
Boiler feed water treatment system consisting of pre-treatment, water demineralisation and fine water demineralisation.
Challenge for the customer
Integration of the fully automatic water treatment system into the power plant’s process control system.
As part of various process optimizations, the power plant was to be equipped with its own boiler feed water treatment system. This is because high-quality boiler water makes a decisive contribution to extending the life cycle of pipes, boilers and heat exchangers, thereby ensuring continuous performance and operational reliability. The requirement was to treat drinking water into a deionized water – i.e. salt-free make-up water – with a capacity of 10 m³/h. In addition, the fully automatic water treatment system was to be integrated into the power plant’s process control system.
No two boiler feed water treatment systems are the same. This is because the requirements for the feed and boiler water, the steam quality, the boiler output including the operating pressure, the water quantities, water costs, the condensate return and, of course, the composition of the raw water depend on the respective conditions on site. Decisive factors that have a significant impact on component selection and system design.
After extensive consultations, the deionized water treatment system was designed to produce high-quality boiler feed water, taking all relevant factors into account. The professional process concept comprising pre-treatment, water desalination and fine water desalination convinced not only those responsible at the energy center, but also the contacts at the paper mill. The experts also developed a solution to integrate deionized water treatment into the power plant’s control system and thus ensure the complete process sequence in the power plant’s own automation system. Two condensing turbines are now used to generate electricity for the power plant’s own operations as well as for the paper mill.
The power plant’s own deionized water treatment system now continuously supplies the energy center with deionized water, thus also maximizing the paper mill’s production reliability. In addition, the entire boiler feed water treatment process was integrated into the power plant’s own automation system.
The professional advice and confidence in the EnviroFALK process water technology won the contract. EnviroFALK also impressed the local contacts with its reliable and professional project management. Frank Schulz, deputy power plant manager: “The water treatment plant went into operation with the agreed performance and pure water quality from day one. We made exactly the right decision with EnviroFALK”.
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