OVERMADE: where energy saving experience belongs to DNA

The latest dramatical increase of the costs of energy, also due to international frictions, are pushing all paper mills to develop and urgently implement new road maps to improve the energy efficiency in the production lines.
If in the last years we could have observed energy prices volatility, lately the energy bills in the mills became the main headache. Parallelly, the “ecological driven” requirements to reach the target of zero emissions are pushing towards solutions of lower and lower NOX and CO emissions in the production lines.
Both targets have been pursed since long by OVERMADE and POWERMADE so that we can simply state that energy saving belongs to our Dna. In particular we implemented in our latest installations notable solutions to reduce the electrical energy consumption in the forming area and the thermal energy consumption in the drying area.

The energy saving in the forming area is mainly passing through the formation performances of the headbox and former, while some design optimizations are possible in the approach flow system. The OVER experience in the tissue forming has been the base of the latest developments of the new DYNAFLO-C headbox in connection to the OVER CR former. The obtained improvement of the fibers distribution permitted higher consistency operations with a consequent amazing reduction (up to 25%) of the energy consumption in the approach flow area.

We put at your disposal our know-how in all phases of your project

From the thermal energy point of view, we devote resources to energy saving and energy recovery projects implementing air flows control tools and energy recovery systems.

Managing and using all the available energy content of the air, the savings has been really attractive.

The drying of tissue is performed by using steam in the Yankee and high volumes of hot air (400/500 °C) in the hood. While air volumes are directly connected to air temperature, the evaporated water, that increase the humidity of exhaust air, is cooling the blown air to values of 250-300 °C. Flow, temperature and humidity of the impingement air are the key factors used in the POWERMADE drying systems to reduce the energy consumption, avoid over-ventilation and improve cross direction drying performances.

The generated exhaust fumes in any case contain huge amount of energy, NOx and CO: energy and pollution can be drastically reduced through a recovery system plant and the implementation of new generation of hot air gas generators. In this way we reduce the specific thermal energy consumption and the so called “carbon taxes” implemented for a more ecological production.
The available package consists in the supply of the new generation LOW-NOx burners in connection with a system to generate steam from the hot fumes coming from the hood exhaust.

We develop taylor-made systems for tissue production and its specificities

The recovery steam generator can produce free of cost up to 25-30% of the total Yankee steam consumption. The POWERMADE Recovery Steam Generator System (RSG1) can be applied organically on all new machine but also on existing machine where the hood air system has to be rearranged to operate with the new recovery configuration while a steam plant integration will be necessary to let the use of steam supply coming from the new generator. On top of that a condensate recovery system can be updated to increase even more the energy efficiency. Where gas turbine is installed, the energy can be completely recovered from the exhaust of turbine.

A further increase in energy recovery can be implemented with additional cycles of recovery plants for hall ventilation heating and for water heating. At the end the final exhaust air temperature will be reduced to 50 °C – 70 °C.
The projects are developed to satisfy the highest flexibility requests. From concept design to installation engineering, the compact and modular systems fit all layout and maintenance space requirement. With passion for paper and tissue manufacturing, we keep our promises for ECO and LOGIC Solution.