How industrial sealing impacts paper and cellulose production

Seals are systems designed to prevent the escape of liquids or gases from pressurized systems and to prevent the entry of contaminants, maintaining the integrity and others performance of machinery and equipment.

Like this, It is understood that sealing is an essential component for the proper and efficient functioning of any industrial process and, no paper and cellulose sector, it's no different.

Still, This specific segment faces a number of challenges regarding seals due to extreme operating conditions. High temperatures and pressures during the process, presence of aggressive chemicals such as sulfuric acid, hydroxides and peroxides and even mechanical wear due to the abrasiveness of the materials, demand high performance and resistance seals.

When seals fail, impacts can be severe, compromising operational efficiency and resulting in high corrective maintenance costs, unexpected stops and production losses. This not only reduces productivity, but also affects safety and sustainability of the industrial process.

Sector-specific challenges

The pulp and paper sector presents unique challenges for seals, demanding solutions that withstand extreme conditions and guarantee operational continuity. Among the main obstacles, stand out:

➜ Aggressive environment

The cellulose sector is characterized by the highest level of environmental variability, covering the entire production process, from the transport of raw materials, which generates dust with the chips, until the cellulose dries, in machines that operate with very high humidity due to the evaporation of fiber dilution water.

In the same way, o extraction process involves rotating systems, pumping, unloaders and mixers, all generating trepidation, which adds challenges.

In the boiler area, pressures that reach 120 bar and superheated steam make the environment even more hostile, with equipment that reaches up to 100 meters high, significantly complicating any type of management.

➜ Wear and corrosion

Corrosion in the chemical cellulose extraction system is a constant concern. The process, that occurs in an alkaline environment, with high concentration of sodium hydroxide, injections of gaseous oxygen via mixers and temperatures that reach 160 gray Celsius, results in high levels of oxidation.

➜ Maintenance cost

Each routine of the cellulose production process is highly specialized, and an inadequate material specification can result in serious impacts, such as unexpected downtime or chronic problems that are difficult to solve. Although, the true cost of a maintenance stop is not just about the value of the parts, necessary labor or equipment, as cranes for lifting. The biggest impact comes from lost production.

Types of sealing in the pulp and paper sector

In a complex system such as a pulp and paper mill, sealing requirements are diverse and essential for the proper functioning of operations. Among the most critical, stand out gaskets for pumps and compressors, in addition to gaskets and sealing rings for flanged applications.

The most used materials, as teflon e graphite, are chosen for their low reactivity and high resistance to temperature conditions typical of the process. Another important point is the pre-specified sealing gaskets, that meet the specific needs of each client, considering the measurements and conditions of pressure and temperature, what is the case with boiler balloon gaskets.

Regardless of the point of application, the main function of gaskets, gaskets or sealing rings is to guarantee the continuous operation until the next scheduled stop.

To the apply the correct material and monitor the system within pre-established conditions, the seal will be efficient, the system will continue to operate without failure and the operating condition will be maintained at ideal levels, resulting in greater plant availability. This increase in availability directly translates into greater profitability.

Application of the correct sealing material ➜ System monitoring under pre-established conditions ➜ Failure-free system operation and operating conditions maintained at ideal levels ➜ Greater plant availability ➜ Increased profitability.

Waste reduction for the environment

Although the purpose of sealing is minimize any type of leak as much as possible, especially when it comes to harmful chemicals or fluids, It is practically impossible to completely eliminate the possibility of leaks due to several factors, as natural wear of materials, unforeseen failures or extreme operating conditions.

Or focus, then, is in effective prevention strategies, continuous monitoring and containment of leaks, ensuring that, if they occur, the environmental and operational impact is as small as possible. This includes choosing suitable sealing materials, the implementation of containment systems and efficient treatment of effluents.

By reducing leaks, sealing reduces the amount of biochemical particles in the environment, which facilitates the work of microorganisms responsible for treating effluents. These organisms, powered by oxygen, degrade waste, making them suitable for safe disposal. With fewer leaks, the volume of substances to be treated decreases, reducing chemical consumption and optimizing the process.

In the operational scope, efficient sealing contributes to fewer losses and fewer stops, ensuring greater continuity and safety in operations. E, regarding disposal, Proper use of seals minimizes waste generation, mainly non-recyclable materials, favoring a more sustainable management and prolonged resources.

KLINGER solutions for the pulp and paper market

To maintain the efficiency e security of industrial processes, It is necessary to use appropriate materials for each system. The use of appropriate components contributes to the performance and durability of the equipment.

Below, We list the suitable materials for each system and application. Check it out:

A) Cooking:

Graphite laminate – PSM or RKFLEX CRIR
• Steam lines

KL1080
• Black liquor and white liquor supply lines/valves
• Black liquor and white liquor circulation lines/valves
• Batch digesters – liquor displacement system

KLINGER GFO
• High pressure feeders
• Low pressure feeders
• Black liquor and white liquor supply pumps
• Black liquor and white liquor circulation pumps
• Top tabs
• Bottom dischargers

B) Washing and Bleaching:

KSIL C-4553 (ca.. 120°C)
• Liquor lines for purification dilution
• Steam heating lines for washing and bleaching
• Washing hot water/condensate pumps

KL1080
• Mass lines (pulp) main purification and washing
• Sulfuric acid injection lines for bleaching
• Chlorine dioxide injection lines for bleaching

KLINGER GFO
• Bottom agitator unloaders and separators of all bleaching and washing towers

KLINGER GFO
• Blowtank agitator
• Sealing of purifiers
• Slurry Pumps with low consistency

KLINGER KL-46
• High consistency dough pump (washing)
• Hot water/condensate pumps (washing)
• Washers and washing presses (washing and bleaching)

C) Evaporation:

PSM / RKFLEX CRIR
• For steam lines, condensates and weak liquor at temperatures above 260 degrees

KL1080
• For lines with concentrated liquor up to 260 degrees

KLINGER PSM ou RKFLEX CRIR
• Lines with concentrated liquor above 260 degrees
• Tall oil lines (for softwood factories)

KLINGER GFO:
• Concentrated liquor pumps up to 260 degrees

BLADES KL8202
• Weak liquor pumps
• Vacuum pumps
• Tall oil pumping system

D) Recovery Boiler:

Graphite Laminate PSM ou RKFLEX CRIR
• For all existing lines and systems, both fuel combustion injection and condensate injection for steam

RINGS AT SFGG/SFTG
• SFGG-GRAPHITE SOOT BLOWER AND GASKET
• SFTG-TEFLON SOOT BLOWER AND GASKET
• Blower system seal

BLADES KL8202
• Recirculation pumps
• Liquor injection pumps

E) Caustification:

KSIL C-4500
• For all lines involving green and white liquor

BLADES KL8202
• For all green and white liquor pumping systems