Pulping is the first step in the papermaking process, with the purpose of producing a clean fiber suspension that can be pumped forward in the process. Fibers from virgin pulp, recovered paper or paper machine broke are mixed, i.e., pulped, with water to form a suspension inside the pulper. The optimal pulping technology is selected depending on the type of furnish, production output and the contaminants in the furnish. Pulping systems for recovered paper not only disintegrate the paper and board into single fibers but also remove large non-fiber components (rejects), such as plastics or glass.
In order to avoid breaking the rejects into too small pieces, it is important for the pulping process to find a balance between the main parameters, such as pulping consistency, temperature, retention time and chemical additives. A low amount of rejects in the pulp makes the downstream process easier and more efficient to operate.
With a total length of 78 m and a pulping capacity of almost 3000 tons of recovered paper per day, the IntensaDrum Duo is the largest unit ever built for a stock preparation plant. It consists of a 48 m pulping drum and a 23 m screening drum. In addition to the engineering advantages, the dual-part design offers decisive advantages in terms of operating efficiency and is thus more resource-saving than comparable one-part pulping drums.
Since the specific operating costs decrease significantly with increasing size of pulping units, the IntensaDrum Duo is particularly efficient. Due to their special design, the drums also work in a particularly resource-saving fashion. Just as important as the drum itself is the overall concept of the pulping area. Voith is also breaking new ground here, for example in the discharge of the pre-cleaned pulp from the screening section out of a special flow and thus energy-optimized collecting chest.
The IntensaDrum Duo is based on the same drum design as the IntensaDrum ID45XL. Many customers have used these successfully for smaller production quantities. When developing the IntensaDrum Duo, we were therefore able to utilize the experience from this size. Standard machine components also ensure high engineering quality in the design of the IntensaDrum Duo. Compared to a one-piece design, the two-piece IntensaDrum Duo offers significant advantages with these dimensions in terms of transport and installation.
Pierre-Haakon Berger, product manager for drum pulpers at Voith Paper
The installation of the IntensaDrum Duo at Progroup's Taurus PM 3 project in Germany shows how well it works in practice. With a diameter of 4.5 m each, the 48 m long pulper drum and the 23 m long sorter drum have been processing 3,000 tonnes of recovered paper every day since then. The total length of the IntensaDrum Duo, which weighs over 300 tonnes, is 78 metres. The Taurus pulping plant is thus the largest of its kind in the world.
Discover the IntensaDrum and IntensaDrum Duo via Augmented Reality
To discover the proven IntensaDrum and Voith’s latest innovation IntensaDrum Duo via Augmented Reality, download the IntensaDrum app to your tablet or smartphone. Enjoy the interactive functions by activating the AR mode in the lower right corner and follow the on-screen instructions.
The BlueLine product range from Voith comprises modern machines and products for stock preparation that are characterized above all through the efficient use of energy and other raw materials and by gentle treatment of the fibers.
Thanks to a wear-free design and few wear parts due to small or no relative movement between pulp and machine components, the IntensaDrum Duo reduces the need for maintenance stop. Especially the labyrinth sealing makes sure the inlet doesn´t need any sealing rope and saves operating costs.
Due to optimum design of shower pipes and carfully chosen water flow, the pulp is quickly diluted and the fibers are separated from the reject. By efficient washing of the reject, the fiber loss is kept to a minimum.
Access to the inside of IntensaDrum Duo is secured by to safety doors with interlock the main drives. Open reject outlet and well designed entry equipment makes the access easy.
IntensaDrum is a machine for efficient pulping of stock consistencies up to 18% and for gentle and effective separation of fibers and contaminants.
Voith's IntensaDrum drum pulper consists of one pulping section and one screening section. In the pulping zone, special lifting bars lift the pulp suspension from the bottom and almost to the top. From there, the suspension falls back onto the drum shell. This process is very gentle since there is no rotor to crush or cut the contaminants.
In the sorting zone of IntensaDrum, the suspension is lifted in the same way, and water is added via spray pipes to wash out the fibers through the perforated drum shell. In this way, an efficient separation of fibers and contaminants already takes place inside the pulping process, without damaging the contaminants.
The simple and basic principle of IntensaDrum leads to low maintenance and increased runtimes. Due to its high consistency range, IntensaDrum has a low specific energy consumption, and the lack of wear parts gives a constant accept quality.
Discover the IntensaDrum and IntensaDrum Duo via Augmented Reality
To discover the proven IntensaDrum and Voith’s latest innovation IntensaDrum Duo via Augmented Reality, download the IntensaDrum app to your tablet or smartphone. Enjoy the interactive functions by activating the AR mode in the lower right corner and follow the on-screen instructions.
The BlueLine product range from Voith comprises modern machines and products for stock preparation that are characterized above all through the efficient use of energy and other raw materials and by gentle treatment of the fibers.
Conventional drum pulping systems generate maintenance costs up to 20,000 €. Due to the non-contact labyrinth sealing, the machine offers a wear-free inlet chute. As a result, IntensaDrum is nearly maintenance-free.
Efficient pulping of recovered paper and pulp bales in stock preparation
IntensaPulper facilitates efficient pulping of fibers from virgin pulp, recovered paper or paper machine broke in stock preparation.
The Intensa technology from Voith offers quick and intensive mixing of the suspension in the pulper. The flow-optimized pulper vat, in combination with the eccentrically arranged rotor, generates a perfect turbulence. As a result, quicker mixing of the suspension and accelerated bale intake are achieved. The double-coned bottom of IntensaPulper creates a flow-optimized transition from the pulper bottom to the cylindrical trough wall.
IntensaPulper IP-R is specifically designed for the pulping of recovered paper at a high pulping consistency. The rotor configuration ensures a reliable ragger operation, and the number of ragger breaks can be reduced to once a month. The double-coned bottom combined with the baffle urges the coarse heavy contaminants towards the reject discharge allowing a reliable removal in the Junkomat.
IntensaPulper IP-V enables efficient pulping of virgin fibers, clean recovered paper or broke in batch or continuous mode. A bale breaker divides the bales and thus contributes to an increase in production capacity. A trap for heavy parts ensures the separation of wires.
IntensaPulper from Voith achieves a significant increase in production capacity, while keeping the pulping quality consistently high. Significant energy savings of up to 25% are obtained in comparison to conventional low consistency pulpers, thus high cost savings can be achieved.
Environment. Quality. Reliability.
IntensaPulper is a BlueLine product
The BlueLine product range from Voith comprises modern machines and products for stock preparation that are characterized above all through the efficient use of energy and other raw materials and by gentle treatment of the fibers.
The flow-optimized vat design, in combination with the eccentrically arranged rotor, produces intensive turbulence. This results in improved mixing at a lower energy input.
Highly contaminated stock flows in the pulping system for recovered paper can only be pumped reliably and largely free of blockages using a special pump. Whether in LC or HC system, Contaminex pumps the critical contaminants to the next machine very reliably in both systems, TwinPulp and PreClean.
Featuring large nozzle diameters and a free-flow impeller, Contaminex is designed for plug-free pumping of stock flows with a high proportion of contaminants. The impeller has a long service life thanks to its hard facing. A frequency converter offers the possibility for optimized pump speed and reduced energy consumption for intermittent pumping operation.
Your benefits with Contaminex
High capacity and maximum efficiency due to frequency converter and variable rotor speed
Robust operation and high reliability thanks to low sensitivity for air and reject contents
Easy maintenance thanks to simple design and long service-life due to wear resistant rotor
The particular orientation of the rotor-screen unit on the top of the asymmetrically shaped tank ensures that no vortices can form inside IntensaMaXX. Development of spinnings is thus successfully counteracted, and even maximum contaminant contents are not a problem. Reject discharge in a downward direction ensures reliable removal of contaminants. IntensaMaXX with rotor type B is available for high levels of contaminants; rotor type S is available for hard-to-pulp raw materials.
IntensaMaXX can be used in continuous low consistency (LC) pulping with recovered paper grades containing contaminants or in high consistency (HC) pulping as a dumping machine after the batch HC pulper.
ENVIRONMENT. QUALITY. RELIABILITY.
IntensaMaxx is a BlueLine product
The BlueLine product range from Voith comprises modern machines and products for stock preparation that are characterized above all through the efficient use of energy and other raw materials and by gentle treatment of the fibers.
IntensaScreenDrum is a new development based on many years of rich pulping system experiences. The internal spray pipe with newly developed water nozzles keeps the reject almost fiber free and reduces the water and power consumption at the same time. Using lower water pressure than conventional spray pipes makes a significant improvement for the water pumps.
The hood of the IntensaScreenDrum has been redesigned to minimize water vapor and droplets forming on pipes and handrails, keeping the surrounding area clean and safer for the operators.
The reject is purged by intermittent flushing from IntensaMaXX to the IntesaScreenDrum, where it is washed to recover all useable fibers. The internal 3D water spray ensures that all the plastic reject is washed efficiently. By adjusting the water jet, one can optimize the retention time for reject washing, depending on specific conditions for each raw material, system and customer.
ENVIRONMENT. QUALITY. RELIABILITY.
IntensaScreenDrum is a BlueLine product
The BlueLine product range from Voith comprises modern machines and products for stock preparation that are characterized above all through the efficient use of energy and other raw materials and by gentle treatment of the fibers.
Thanks to a closed hood there is almost zero water spray and deposits in the surrounding equipment, thereby improving the cleanliness of the pulper area.
The CompactPulper ensures reliable pulping of broke through improved rotor contact and a higher circulation rate. Thanks to its narrow and compact design, the CompactPulper requires minimal space and is used with couch and press broke and with dry broke at a pulping consistency between 3% and 6%.
An effective agitation with low vat height, together with an intensive rotor contact results in a higher circulation rate providing a more intensive pulping with simultaneous low energy consumption. The CompactPulper is available with one to four pulping units per pulper vat and with a width of up to 12 meters. Each pulping unit provides an electrical power of between 55 and 900 kW.
Your benefits
Low space requirement thanks to slim and compact design
Low energy consumption
Up to 40% more pulper working width for the same installed power
The Ragger from Voith offers high efficiency to remove the wires and spinning contaminants from the pulping process. The ragger is mainly used for brown packaging paper grades from recovered paper, but it can occasionally be used for white paper grades too. For virgin fibers there is no need for a ragger since there is no large spinning rejects in the raw material.
The wires are necessary for the transportation of paper bales, but expensive to remove before the pulper itself, especially for production lines with high production. The Ragger is a simple tool to remove the wires during pulping in order to make sure no steel wires are broken down by the rotor and cause excessive wear on valves and pumps.
Combined with the rotor from the IntensaPulper the number of broken ragger ropes can be reduced to a minimum. Strong ribs on the pulling wheel prevent slippage. The direct drive equipped with an electrical brake in combination with fixed wheel positions guarantee maximum contact.
Equipped with a 1.1 kW motor, it has 1.6 tons of tractive force. Forward and backward transportation of the ragger is possible with push-buttons. The high gear-ratio allows an intermittent speed control from 10 to 300 m/h.
Your benefits
Improved safety for personnel and machines thanks to automatic operation and easy adjustment
Robust and reliable removal of spinning material from pulper thanks to maximum profile contact
Forward and reverse transport possibilities for perfect positioning
Since recovered paper, bales and many contaminants make the pulping process in stock preparation more difficult, a robust process and resistant machines are essential in pulping. An investment in the Intensa family from Voith is particularly worthwhile, as Voith combines robustness with low energy consumption and fiber loss.
Wolfgang Mueller, Global Product Manager
Profit from proven Voith quality
With the innovative BlueLine product line, customers profit from proven Voith quality in stock preparation and at the same time lower costs for the resources used.
At Voith, the success of the customer takes center stage. Service means delivering customized service solutions and utilizing our full expertise to help our customers reach their goals.
Higher Runability
Reduced Fiber Loss
Enhanced Safety
Lower Maintenance Cost
Lower Energy Consumption
