Tag: Pulp and Paper Industry

  • Chesterton® Mechanical Seals: Game Changer for Profitability in Pulp and Paper Plants

    Chesterton® Mechanical Seals: Game Changer for Profitability in Pulp and Paper Plants

    Chesterton is a full-solutions provider for pulp and paper mills and understands energy, efficiency, reduced water consumption and downtime are key cost differentiators in the industry.

    The pulp and paper industry faces several significant challenges today. These challenges span environmental, economic, technological, and regulatory aspects. Some of the main challenges are the aging infrastructure, cost of energy and maintenance as well as water scarcity and environmental regulations.

    Mechanical seal technology plays a vital role to combat challenges in Today’s environment for the manufacturers in Pulp and Paper Industry.

    Keep your Machinery Running 24/7 – Achieve More Reliable Sealing of your rotating equipment

    Chesterton’s advanced mechanical seal technology utilizes high-quality materials that provide long-term resistance to corrosion from chemicals such as caustic soda and chlorine compounds, as well as erosion and wear from abrasive particles in the pulp slurry.

    Our mechanical seal designs are ideal in applications with varying pressures, temperatures and speeds / flow rates and are easy to install, inspect and replace. Maintenance times and costs can be significantly reduced, resulting in optimum operating efficiency.

    Chesterton cartridge seals reliably minimize leaks and maximize pump performance

    Chesterton Mechanical Seal 1510

    Chesterton offers a wide range of suitable mechanical seals for the demanding paper industry. In this article, we like to highlight our AXIUS™ Platform 1510 Single Cartridge Seal. With this pre-assembled cartridge seal, you can achieve maximum pump performance with simple installation:

    • Reliable through temperature cycling and intermittent process with monolithic seal faces
    • In service impeller adjustment is possible with the unique centering strap
    • Mounts easily on various types of rotating equipment using Chesterton T.A.B.S.™ technology
    • Prevents damage to your equipment and internal components via true non-fretting design

    The Chesterton T.A.B.S. (Tapered Adjustable Bolting System) is an innovative fastening system that helps ensure even stress dispersion and optimum sealing due to its tapered design and adjustability. It offers numerous benefits, including improved sealing performance, longer component life, ease of installation and maintenance, increased operational reliability and cost efficiency. Due to these features, the T.A.B.S. system is successfully used in various industries, including the pulp and paper, chemical, power plant, and food and beverage industries.

    Key Benefits of Chesterton Mechanical Seals

    1. Plant wide standardizations with AXIUS Platform seals 1510 and 2510: Equipment standardization in industrial plants, including those in the pulp and paper industry, can significantly impact cost reductions in several ways.

    Here are the primary benefits:

    • Improved Reliability and Performance
    • Lower Maintenance and Repair Costs
    • Training and Workforce Efficiency
    • Innovation and Upgrades
    Chesterton Mechanical Seal 2510

    By adopting equipment standardization, plants can achieve significant cost savings across various areas, enhancing overall operational efficiency and financial performance.

    2. AXIUS Seal product line with 5 Key Seal features to “safety-belt” off conditions: These design elements help ensure that the seals can withstand challenging operational environments, reduce maintenance costs, and enhance overall equipment performance.

    • Protected springs
    • Balanced design
    • Non fretting
    • Monolithic seal faces
    • Stationary design

    By focusing on the five key features of mechanical seal design, Chesterton mechanical seals aim to provide high reliability, ease of use, and longevity in a wide range of industrial applications.

    3. Improved Efficiency reduces overall cost: High-quality sealing technologies are crucial for the efficiency of pulp and paper systems. Water and energy savings are critical for reducing environmental impact and operational costs. Here is how they contribute to these savings:

    • Energy savings through reduced friction losses compared to gland packing technology.
    • Water savings by eliminating or reducing seal leakage and flush requirements.

    Decades of presence in the paper sector bring plant operators forward

    Chesterton has been a leading supplier of sealing solutions in the paper industry for many years. Our advanced mechanical seal technology effectively contributes to a longer service life of mechanical equipment, significantly extending MTBR. Chesterton also has systems that achieve considerable savings in flushing water.

    With the Chesterton Connect™ system, we also offer an IIOT-based monitoring solution for mechanical seals and rotating machinery that monitors the performance of your equipment and alerts you to anomalies that could lead to downtime or malfunctions.

    For more information about our mechanical seals, visit our “Reliability Matters” blog, which covers essential topics such as the “5 Key Features for Good Mechanical Seal Design.”

    Here you can gain an insight into our decades of experience in the water and wastewater sector:

    Case Study #1:
    Chesterton 1510 Seal and Connect Monitoring Increase MTBR

    Case Study #2:

    Chesterton 442C Cartridge Split Seal & SpiralTrac Saves Plant 3 Million Gallons of Water

    Pulp and Paper Brochure:

     Pulp and Paper Brochure – Industry Solutions and Services

    Conclusion

    Addressing the challenges the pulp and paper industry is challenged with multiple requirements a multifaceted approach, including adopting sustainable practices, investing in new technologies, improving operational efficiency, and engaging with stakeholders to align on environmental and economic goals.

    A thorough review of equipment and their sealing solutions in terms of water and energy efficiency is required and Chesterton solutions are available to increase plant profitability in many ways.

    Do you have any questions about our Mechanical Seal Technology? Our Expert Desk is here to help. We are happy to assist you!

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.

  • Roll on, Roll on, Roll on – with Chesterton® Advanced Bearing Reliability Programs

    Roll on, Roll on, Roll on – with Chesterton® Advanced Bearing Reliability Programs

    Modern paper machines are up to 150 meters long, 10 meters wide and run at speeds of up to 2000 meters per minute. Huge giants, 24/7 in operation, programmed for smooth production without downtime. Outside of the paper machine itself there is a complex process including the wood yard, stock preparation, pulping and paper conversion.


    The operational challenges of the pulp and paper industry are complex. The production process is demanding, and equipment is constantly exposed to a humid and chemical-laden atmosphere. Without suitable lubricants, damage occurs to rotating machinery, which in the worst case can bring the entire plant to a shutdown and result in extremely high maintenance costs. Maximizing the Mean Time Between Failures (MTBF) is essential to optimize the production process and profitability.

    Defying all challenges – Chesterton® Advanced bearing lubrication

    Lubricants are required to deliver top performance in the pulp and paper industry, as they have to perform reliably under harsh environmental conditions such as moisture, dust, contamination, chemicals, temperature, pressure or vibration. In these aggressive conditions, high performance lubricants and maintenance products help to keep machines running reliably and trouble-free, prevent premature equipment failure and thus increase plant productivity.

    For these demanding applications, Chesterton provides lubrication products for chains, bearings, wire ropes, cables, open gears, pneumatics and sliding lubrication.

    In this article, we focus on bearing lubrication, which plays a crucial role in the pulp and paper industry.

    Chesterton Industrial Lubricants prevent from corrosion

    As a lubricant manufacturer, what special factors do we consider when developing bearing lubricants? What special benefits do our products offer paper mills?

    • “Water and moisture” factor in paper mills – risk of bearing corrosion and wear
      Conventional elastomer lip seals for equipment bearings are designed to prevent the ingress of water and moisture. However, their service life is limited, and reliable sealing diminishes after approx. 3000 operating hours. If these simple lip seals fail, water from the environment ingresses into the bearing housing and the grease can be washed away. Grease being washed away is a concern, but even more concerning is, with what it is replaced with, water!!!
      Constant lubrication is now interrupted and bearing wear is accelerated by friction and corrosion. This reduces the service life of the bearing and leads to premature failure. Chesterton’s advanced sulfonate complex technology shows best in class water washout resistance and corrosion protection. This high performance can be seen in tests according to ASTM, ISO and DIN standards. You can find the test results on our product data sheets – feel free to compare them with those of our competitors.
    • “Load and vibration” factor – risk of bearing damage
      Bearings are among the most important components of rotating equipment and electric motors. High speeds, heavy loads, high operating temperatures, start/stop function, high vibrations in rotating equipment – all these factors push bearings to their limits. Many customers replace the bearings on their equipment due to damage caused by wear and vibration. Chesterton lubricant technology contains advanced lubricity and extreme pressure additives that enhance grease performance in these challenging conditions for both, equipment and electric motor bearings. As with the “water/moisture factor”, there are standard ASTM, ISO and DIN tests to measure the performance of greases to help customers select the best product for their application.
    • The “human” factor in paper mills
      Another factor that has not been addressed yet is the “human factor”. Timely manual lubrication often is not carried out consistently or regularly during the operational process. This can lead to over- or under-lubrication. Over-lubrication means excessive consumption of lubricants, is therefore uneconomical and can cause temperature build up, which reduces the lifetime of the grease and can lead to premature failure of the bearing. Under-lubrication can lead to system failure in the long term. Automatic programmable lubrication systems for grease and oil, such as the Chesterton Lubri-Cup™ dispenser, help ensure a regular and timely supply of lubricants.  
    Chesterton Industrial Lubricants prevent from corrosion
    Chesterton Industrial Lubricants for Paper machines
    Chesterton Industrial Lubricants prevent from bearing failure

    Continuous lubrication with Chesterton Lubri-Cup™ Lubricant Dispenser means optimum bearing performance and increased work safety

    Our Chesterton Grease Lubri-Cup automatic lubricator provides the right amount of lubricant when required. It helps extend bearing lifetime and reduces bearing maintenance. As the name suggests, lubrication runs automatically with the right grease, at a constant interval with the correct amount of lubricant. Our “Stories of Success” result in longer service life of the bearings and an immense extension of the MTBF.

    Here is one of our success stories:

    “Our Lubri-Cups were used in a plant with over 7000 electric motors. The customer had a vibration monitoring program in place but found that some critical motors were experiencing excessive vibration causing premature bearing failure. The customer decided to run a test using Chesterton 638 Electric Motor Grease. Immediately after applying 638 EMG into the bearing housing, a reduction in vibration was visible. As a result of the test, the customer decided to use Chesterton 638 EMG as the standard grease for all electric motors. Other benefits for the customer included reducedgrease consumption and an increase in bearing lifetime. One of the reasons for the success of the 638 EMG was due to its additive plating technology called QBT (Quiet Bearing Technology). This helps fill any surfaceirregularities or damage on the bearing surface and allows the bearing to run more smoothly and quietly.“

    Chesterton® High-Performance-Grease for bearing lubrication under extreme conditions

    From our extensive portfolio of industrial lubricants, we focus on our high-performance greases 615, 617(E) and 638 EMG for the pulp and paper industry. These greases are specifically designed for heavy loads and high temperature applications in wet, corrosive environments. They are used in various equipment in many industries and offer outstanding performance for the lubrication of machine bearings.

    Benefits include:

    • Less grease washout, therefore lower grease consumption and lower acquisition costs. Elimination of bearing failures due to corrosion.
    • High lubricity, extreme pressure performance – resulting in longer bearing lifetime and reduced downtime.
    • Thermal and shear stability – elimination of oil bleed from grease and hardening in the bearing.  

    Bearing protection at its best – our lubricants and polymer seals

    Chesterton also offers advanced bearing sealing solutions in the form of our Polymer Labyrinth Seal (PLS), which provides protection for the bearing and offers customers a significant advantage over conventional lip seals in terms of service life. In addition, this solution is available in a split design, which allows for easy installation.

    Conclusion

    The pulp and paper industry has very special requirements for machine bearings. The advanced lubricants from Chesterton help against “bearing killer” conditions such as corrosion, grease washout, load and vibration and make a considerable contribution to a long bearing life.

    If you would like more information about our bearing reliability program, please contact our Expert Desk.

    You can also make a preliminary product selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.

  • Chesterton® High-Performance Industrial Coating Solutions for Corrosion and Abrasion Challenges in the Pulp and Paper Industry

    Chesterton® High-Performance Industrial Coating Solutions for Corrosion and Abrasion Challenges in the Pulp and Paper Industry

    The pulp and paper sector is a demanding industry. From debarking and wood processing to the chemical processing of paper pulp and the manufacture of finished products – the work steps in this field are complex. The production of paper, cardboard and pulp requires many machines, a lot of water and certain chemicals. Plant operators have major challenges with corrosion and abrasion, which can affect the plants’ operation and performance. Increasing equipment performance, occupational and environmental safety and energy saving are extremely important for manufacturers to be able to reduce costs and increase profitability.

    How can Chesterton help to improve efficiency in pulp and paper production with high-performance industrial coatings?

    The processes used in the production of pulp and paper from wood chips, recycled paper and fibers are associated with high temperatures, high pressures, wear, abrasion, impacts or corrosion, all of which can affect the operation of mechanical equipment in various parts of the plant. High costs are incurred due to the wear of metal and concrete surfaces, erosion or cavitation of pumps, or corrosion caused by contact with chemicals. With Chesterton coatings, not only can new equipment be protected to increase the meantime between repair or failure, but also the repair and reconstruction of already damaged components is possible to increase operating lifetime, reduce spare part inventories and can therefore be extremely cost-efficient.

    wood storage for paper industry

    As in any other industry, the pulp and paper sector has several main targets:

    • Increasing profitability and reliability
      Chesterton offers a comprehensive portfolio of ARC and Ceramic-Polymer Coatings specifically designed for areas where severe abrasion resistance, long-term corrosion protection even in wet chemical applications or high temperature corrosion resistance are required. Whether concrete or steel substrates, the use of Chesterton coatings – also for surface repairs – can help extendthe service life of mechanical equipment.
    • Worker safety and environmental protection
      The long-term performance of Chesterton industrial coatings significantly reduces the need for repair and maintenance work. This not only saves labor costs, but also increases the safety of personnel. The environment benefits, for example, from properly coated secondary containment basins that prevent chemical-containing production water from entering the surrounding area. Repair and protection of operating equipment with Chesterton coatings also contributes to improved environmental performance by reducing the number of new parts that must be kept in inventory.
    • Energy saving
      The application of smooth high performance ceramic coatings to fluid flow equipment such as agitator propellers, cyclones, pipes, and many types of pumps can increase the flow speed of the fluids being handled, reduce power consumption, increase machine efficiency, and thus contribute to energy savings.

    Benefit from our experience in the pulp and paper industry

    Debarking Drums, Log Conveyors and Chippers, Agitators, Cyclones, Fan and Vacuum Pumps, Screws, Pulp Tanks, Press Rolls as well as Wastewater Tanks and Barrier Tanks – all these types of equipment can benefit from increased abrasion and corrosion protection. Chesterton industrial coatings of the ARC and Ceramic-Polymer product lines contribute to a considerably increased service life of the machines and the profitability of the entire plant is significantly improved. Furthermore, unscheduled machine downtimes due to unexpected failure or damage can be effectively prevented.

    Lime kiln in a pulp production plant
    Agitator for Pulp and Paper Mill
    Paper Mill - Pulping department

    The high-performance Chesterton coatings provide long-term protection for metal and concrete surfaces with the following properties:

    • 100% solids
      No evaporating solvents, enhances the safe use
      Resists corrosion and permeation.
    • Maximum Adhesive Strength to Substrate
      Resists disbondment, provide long-term performance.
    • Resists Underfilm Corrosion
      Enables localized repair on small areas.
    • Manufactured Under Vacuum
      Resists permeation through coating – critical for immersion applications.
    • Ceramic and Special Particle Reinforcements
      Resists abrasion, extends equipment life, reduces spare parts, reduces downtime.
    • Abrasion, Erosion/Corrosion, Chemical, Temperature Resistance
      Provides long-term protection of metal or concrete surfaces.
    • Cost effective
      Versus traditional repair methods.
    • Ease of application
      1-layer application by hand tools or airless spraying, saves working time and can often be applied on-site without removal of equipment.
    • Cold curing Technology
      No hot work or welding is required.

    From wood to paper – requirements for coatings to protect the mechanical equipment

    First, the bark is removed from the logs, and they are processed into wood chips. Debarking Drums and Screws Conveyors or Chutes require coatings that are highly resistant to impact and abrasion. 
    Our ARC I BX1(E), for example, is designed precisely for such demanding operating conditions. High impact resistance, hardness, and resistance to sliding wear characterize this product, hence it is also used in the mining sector.

    The ARC BX2(E) is equipped with finer particles and is applied for areas in pulp processing, such as screw presses and agitators, which require moderate abrasion resistance but increased temperature resistance and chemical resistance.

    The thick film coating ARC 858(E) is ideally suited for rebuilding heavily corroded or eroded metal surfaces in pumps or pulp tanks. ARC 855(E) and ARC SD4i(E) are often used as a topcoat for these repaired surfaces. With a thin layer, this system protects metal substrates against abrasion, erosion corrosion and chemical attack.

    Of course, the Chesterton portfolio also includes coatings for the protection of concrete structures, such as wastewater basins, stock, pulp and whitewater chests or secondary containment areas with chemical tanks.

    Talk to us! We will be happy to offer you the optimum coating solution. Please ask our Expert Desk for further information.

    You can also make a preliminary selection using our product selector. Our product consultants will gladly assist you in selecting the ideal product for your application.