A modern paper mill factory based at the west of the country has been fighting for a long time with the reliability of a Sulzer-Escher E2K. These decomposers, or called De-inkers, get ink pulp from paper pulp and are essential for paper making. Fault, or failure, causes major problems. However, these occurred frequently caused by large water leakage from the stuffing box room. A lot of flush water was needed to flush and cool the packing. On average 1x per 3 month, the decoder was removed from the system and revised. This resulted in high maintenance costs and therefore a very low return. Sellon was asked to think and came up with an improvement proposal. This was found in replacing the packing with a S10 cassette seal + spiraltrac.
In November 2009, the solution was converted and returned. Since then, it has been working smoothly. No leakage, no bearing damage and additional benefit, only a fraction of water consumption is required to keep the seal environment clean. It is expected that the investment will be returned within 6 months.
The customer has so much confidence in this solution that has now been placed in order to build the 2nd de-inker
A paper mill in the middle of the country has high costs on refiner seals.
1st; A lot of flush water
2nd; A lot of leakage paper stock and cleaning costs.
3e; High maintenance costs due to wear
4th; Packing chamber shifts to the shaft by setting
the refiner plates causing accelerated packing leakage.
The Sellon solution
We have locked up the Chesterton CMS 2000 in the stuffing box by means of a top and bottom ring of Chesterton gasket 1730 millpack.
There is no need for a flush here.
The CMS can handle the axial displacement of 20-30mm.
A large calcium carbonate producer uses monopumps to transport this product. The pumps are fitted with a new stopper box each month. This is labor intensive, but does not solve the leakage of the stopper box. There is a lot of cost of cleaning the pumps and much of the product is lost, which in itself is already a significant loss item.
The Sellon solution
The solution found was replacing the stopper sealing rings by Chesterton CMS 2000 in combination with Chesterton style 1727 top and bottom gasket ring.
Chesterton CMS 2000 forms an endless composite ring between the bottom and top ring in the gasket and shaft or shaft bus. The leakage is eliminated and no water purge is required. CMS 2000 does not provide visual leakage and save on maintenance costs.
Accumulated shafts or shaft buses belong to the past and contribute to cost savings. Also, the CMS 2000 is easy to maintain even with rotating equipment. By means of a supplied injection pump, the CMS 2000 is introduced via a ball valve which is in communication with the packing chamber.
A large producer of high-quality deep-frozen potato products and appetizers with plants in Zeeland, Brabant and Friesland has a lot of leaks on the Cornellpumps, which are set up in the production areas. Leakage is caused by the sealing of the pumps with a stuffing box which results in a lot of wear on the shaft. The pumps are overheated twice per year. Shaft bearings and packing rings are then replaced.
The Sellon solution
Sellon has conducted a survey of the 60 pumps and the costs are registered. A proposal has been submitted to convert the pumps to mechanical seals. Investment costs to convert the pumps to mechanical seals come to 1 time € 90,000, maintenance costs of the pumps with stuffing box packing amounts to € 120,000 per year.
In 2007, the conversion of the pumps to mechanical seals started, since then about 50 pumps have been converted. None of these pumps have fallen out since then. This directly results in a saving. Currently the lifetime is over 5 years. The goal was to convert all pumps to mechanical seals by the end of 2009. The bearing rings are also replaced by labyrinth seals to increase the bearing life.
Cost savings when all pumps have been converted € 120,000 per year.