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News Release from: Flocare | Subject: Scalewatch electronic scale control system
Edited by the Manufacturingtalk Editorial
Team on 08 January 2001
Scalewatcher oversees de-inking line
Flocare, manufacturers and distributors of the patented Scalewatcher? electronic scale control system has won an order from the Bridgewater Paper Mill, Ellesmere Port.
Flocare Ltd., the exclusive manufacturers and distributors of the patented Scalewatcher? electronic scale control system has won an order from the Bridgewater Paper Mill, Ellesmere Port, following the successful treatment of the pipework, control valves, and in-line equipment on the company's No 3 De-inking Line by the Scalewatcher system The Brigewater Paper Mill has been the site for the revival of the British newsprint industry
This article was originally published on Manufacturingtalk on 14 Oct 2004 at 8.00am (UK)
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Using the latest production technology the Mill has created newsprint from 100% recycled fibre that is far superior to traditional paper.
Recent advances in de-inking technology have made it possible to produce recycled fibre which improves many of the properties of the final product.
The De-Inking Plant is one of the largest and most modern in the world.
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Computers control the progress of the fibre through seven stages of cleaning and screening.
The water recycling system minimises wastage and makes water consumption, per tonne of fibre, extremely low.
Bridgewater Paper operates three de-inking lines with a combined capacity of 800 tonnes per day.
The newest de-inking line, De-ink 3, uses a mixture of newspapers and magazines, typically with an 85/15 ratio.
Process equipment removes contaminants (plastics, staples, inks, adhesives, etc) and controls carry-over of materials (ash, hydrophobics, colloids, etc.) which reduce paper quality.
De-ink 3 incorporates alkaline flotation followed by acid washing.
The process water contains large amounts of salts (carbonates, oxalates and silicates of calcium/magnesium/aluminum) and other soluble materials and chemicals.
These salts caused severe scaling within the pipework, control valves, and pressure screens with one of the most problematical areas being the disc filter where the build-up of scale resulted in a lack of hydraulic pull-through.
The pipes and in-line equipment needed acid descaling and high pressure cleaning periodically during plant shutdowns.
In addition, the disc filter segments had to be removed and sent away for chemical descaling regularly.
Blockages occurred in screen baskets, showers and pipes causing a substantial loss of production.
The Scalewatcher Electronic Scale Control System was discussed as a possible solution during talks with Phil Claydon, Operations Manager, Pulping and John Pearson, De-inking Superintendent.
The plant management agreed to a trial period to test the efficiency of the Scalewatcher system.
Following a full site survey by Flocare engineers, five units were installed at various points throughout the process line.
Commenting on the results achieved, John Pearson said, "We are now able to maintain production at the same quality, with reduced maintenance costs, and a significant reduction in chemical descaling on the disc filter.
After the Scalewatcher application, the rate of reduction in hydraulic pull-through was reduced, and in some cases reversed".
At the end of the trial period, Bridgewater Paper purchased all five units.
Scalewatcher's patented technology works by producing a complex frequency -modulated waveform, which is applied to signal coils wrapped around the pipework.
An induced field inside the pipe promotes crystal growth of the scaling minerals in the water.
As the crystals remain within the flow of the water, they no longer contribute to the build-up of hard pipewall deposits.
Existing scale layers are softened, and loosened scale is removed from the system by the water flow.
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