You are here

Tough specification demands behind record-breaking valve

China is not only a huge and important market, it is also hold an industry requiring large components. Stafsjö were consulted with a challenge, which one solved and qualified Stafsjö into the group of suppliers to one of the world’s largest pulp and paper mills. “We are breaking new ground” says Stafsjö’s KAM Pulp and Paper in China Su Chuansheng.

The blow tank tower is 32 meters high and the pressure is obviously very high. The bottom valve should be able to hold this tight and to operate through highly concentrated pulp. The environment is aggressive and exposed. 

– This was a demanding project, explains Su Chuansheng.

– There was no knife gate valve in such a large dimension for a duty like this, as far as we know. We went through the whole process together with the end customer and machine supplier and made some detailed calculations. The outcome was a success, adds Su.

The end customer is a giant within the Chinese business world and one of the largest producers within the pulp and paper industry. Their catalogue of demands is clear. Growth and productivity are in focus, but not at the expense of economic, social and environmental sustainable values. It wants to be a model playing a leading role in the industry.

To achieve near-zero emission rates and minimize consumption of resources, the pulp producer carefully selects its technical solutions.  High quality at a reasonable price. To meet this challenge, Stafsjö was forced to make every effort. The result was one of the largest valves in the company’s history, tailored to meet requirements from the customer.

–The valves have gradually increased in size over the last years. It was not so long ago that we manufactured a couple of DN 1200 (48”) valves. Then we made some DN 1400 (56”) for Brazil and now we have built a DN 1600 (64”) valve. But then again, we have the competence and expertise amongst our design engineers and a strong team in the workshop, says Marcelo Alvarez, Product Manager for Stafsjö in China. 

So it was a ’real piece’ – a customized MV valve – that left Stafsjö’s factory for its eastward bound train journey. Back in China, work is now underway to deal with new enquiries and projects.  

Stafsjö is a strong and well-known knife gate brand in China. With an office in the country for over twenty years, it is easier to monitor market demands and there are still many sectors with a strong growth. With this reference, the company will be able to further strengthen its position within Pulp and Paper industry.

– We have the skills and experience which allows customers to consult with us to find the adaptations for various processes. Our strength is also that we keep delivery times, even if they are tight sometimes, says Su.

Further information
Please feel free to contact Stafsjö on sales@stafsjo.se or on +46 11 39 31 00 for any questions on valve solutions for the Pulp and Paper industry.

If you are you interested in the knife gate solutions for pulp related processes in China, please feel free to contact our sister company Ebro Armaturen:

Su Chuansheng, KAM Pulp and Paper, suchuansheng@ebro.cn 
Marcelo Alvarez, Stafsjö Product Manager in China, marcelo.alvarez@ebro.cn

Experience how we contribute to cleaner water

At the new Pålslund wastewater treatment plant in Värnamo municipality, Sweden, the knife gate valve WB14 are used to shut-off and to keep tight during long periods of time. No less than 230 pcs have been installed.

Now you can experience the shut-off performance online on http://stafsjo.com/products/knife-gate-valves-wb-wb11-wb12-wb14

Stafsjö valves provide cleaner water

Clean water. The production is full running at the new Pålslund waste water treatment plant in Värnamo municipality, Sweden. One of the most modern around the Baltic Sea. This is a unique project where suppliers are subject to the highest demands. No less than 230 of Stafsjö’s knife gate valves can be found in the facility. Each and every one from Stafsjö, that scores the highest rating for its flexibility.

Demands placed on sewage treatment plants continue to increase. But so too does the necessity of returning the water used by households and industry to nature.  A purity of the highest order must be attained, enabling our ecosystem of microorganisms residing in watercourses to continue working. This is a responsibility that we all share.

Quality in focus
 - We quickly realized that it is better and easier to build a new plant than to patch up our old installations, especially if should meet the demands required of us. Here we have a system that is designed with functions that we can easily control and manage. Pålslund is unique, says Ulf Nilsson, Water & Drainage engineer at Värnamo municipality.

This set high demands on all equipment. From a mechanical point of view, it is a large and complex project. The specification requirements are clear. The valves used must be fully up to the job. This is of particular importance because the sewage treatment plant in Värnamo is controlled and managed on-line.

Value for money
At every turn a Stafsjö valve can be seen, often several per section. Yet their implementation is a science in itself. A completely new pump station has been built down in the centre of Värnamo. With its impressive capacity, 1,600 cubic meters of waste water per hour pumped 40 vertical metres over a distance of 6 km up to the waste water treatment plant located just outside the town.

- Stafsjö is a natural choice for us, says Håkan Wennerhag at the construction company, Malmberg.

- In terms of quality, these are excellent products and I cannot find anything ‘comparable’. Stafsjö may not be the cheapest but they always meet the highest standards and have a support organisation that is fast and steps up to the mark. These are affordable, reasonably-priced valves for the money. 

Sizeable installations
Down in the pumping station, 10 metres below ground, a huge hall can be found. Here it is difficult to even embrace the tubes with open arms. The valves from Stafsjö are also sizeable.

- One might think that we have exaggerated. But the last plant lasted for 40 years. Here we have planned for a longer life span and the increasingly high demands placed on purification. This is why we have equipped the plant with components, control systems, piping, pumps and valves that meet these requirements, says Ulf Nilsson.

Those municipalities and operators which do not meet the increasingly stringent treatment requirements for nitrogen risk large fines and penalties. 

Smooth operator
Leachate from the Stomsjö landfill and waste dump is also transferred to the Pålslund wastewater treatment plant. Three additional municipalities in the region, which up until now have had their own treatment plants, will be connected to the plant in the near future.
In the planning phase the dialogue with suppliers, as well as establishment of parameters such as price, quality, deliverability and performance, are all crucial.

- For me, Stafsjö is synonymous with safe and secure delivery, says Håkan Wennerhag at Malmberg Water. We wanted and needed 230 units, fully lugged type, bolted from both sides, for the sewage treatment plant in Värnamo. Stafsjö was out in front. We got a really good service and they did not let us down at any time.

Serve as a model
A number of situations arose during the construction period. When changes were made on the pipe sizing, Stafsjö managed to squeeze in additional orders in the middle of their production schedule, just to ensure they fulfilled the supply obligations.

- We are very satisfied. Whenever we needed any customizations of any components they, in principle, came with the return delivery. They are as committed to the final delivery as we are. So this is not the last time we will contract Stafsjö, adds Håkan Wennerhag who also took valves from Stafsjö with him to the sewage treatment plants in St: Petersburg, Russia, and Klaipeda in Lithuania, both in need of upgrading.

Värnamo municipality with the Pålslund facility will serve as a model. This is a plant that represents a major step forward for the technology in waste water treatment.

Further information
Please feel free to contact Stafsjö on sales@stafsjo.se or on +46 11 39 31 00 for any questions on valve solutions for water and waste water.

Stafsjö steaming ahead in the energy sector

In Alabama, there are 24 power plants. One of them is James H. Miller, Jr. Electric Generating Plant outside Birmingham. It's a real big one that produces over 2800 MW with its four generators. Here plays Stafsjö a central role. With over 300 knife gate valves.

Sustainability is a key word for Alabama Power, Southern Company. Environmental responsibility permeates everything the company does. Working in the energy sector becomes then a challenge, especially if the power plant is fired with coal. Air emissions must be minimized to zero.

"The goal is to reduce fly ash release. It is an important health and safety factor to ensure  good air quality for the plant personnel” says Mason Romans, Stafsjö specialist on Ebro Armaturen USA and adds:

"With Stafsjö products we were able to present a solution that has worked like clockwork since installation. Our customized solution yielded reliability. We have not had any reports of malfunctions since installations began. 

Sustainability for the energy company is not just about managing strict emission requirements, but also to dispose of and to use the fly ash. With proper control of the process you also get a quality suitable for concrete production.

In all production there are residues and wastes. So also here. Fly ash is fine powder found in plant exhaust gases exiting the boiler and it is removed before the gas is discharged to atmosphere. The fly ash is generally collected in electrostatic precipitator hoppers and then fed into a conveying system. The isolating valve under a ash hopper is normally in open position and it have to close on a static column of ash, without using extreme force or any other unsafe practises. 

Handling of fly ash is difficult. It is very fine-grained and harmful. Before the installation of Stafsjö valves, the plant used conventional knife gate valves. Fine ash collecting in cavities of these valves, caused routine malfunctions. 

"The production line was pretty annoyed. They wanted to get a better solution. In Stafsjö’s portfolio we have the HG series which was the perfect solution. Now we have 77 HG valves in place in each unit. A total of four units becomes 308 valves. And both parties are quite satisfied, "says Bill Lollar, Territory Manager on Severe Service Specialist, Inc (Triple S).

“The HG series is an O ported knife gate with a through-going gate designed for static column applications. This valve series has excellent flow characteristic and no area in the bore where the ash can get packed preventing the valve from operating.  Any ash in the valve body is naturally cleared through normal operation.”, says Mason Romans.

Mason Romans also emphasizes that the Stafsjö HG enables operators to open and close the valves easily, without having to resort to some unsafe practices. Through simple maintenance and reliable performance they have achieved a higher level of safety and air quality at an affordable cost for the facility.

"Competition among manufacturers of knife gate valves is razor sharp. We have many domestic manufacturers, a lot from Asia and a few from Europe. But I would say they have started talking about Stafsjö in the US as a reliable quality brand with a flexible product range and the ability to customize solutions, emphasizes Bill Lollar. 

James H. Miller, Jr. Electric Generating Plant is outside of Birmingham, a city of nearly 225,000 inhabitants. Birmingham is a hub for business in the American South with everything from steel and telecoms to the financial sector and a number of universities. There is also the 18-story headquarters of Alabama Power.

“You know, with Stafsjö we have a track record back to 1666”, summarizes Mr. Lollar.

Further information
Please feel free to contact Stafsjö on sales@stafsjo.se or on +46 11 39 31 00 for any questions on valve solutions for ash handling.

If you are you interested in the knife gate solutions for ash handling in the USA, please feel free to contact Mason Romans on Ebro Armaturen USA on m.romans@ebro-usa.com

Stafsjö enabled the world record

The region west of Sao Paulo in Brazil has become the world’s largest producer of cellulose. With annual production of approximately 1.5 million tons of bleached eucalyptus market pulp, Eldorado Brazil’s new Três Lagoas mill is currently the largest single-line pulp mill in the world. And further expansions are planned.

The mill uses Best Available Technology and the mandate is clear: develop a large-scale, state-of-the art plant with high productivity and low conversion cost. Meeting al sustainability requirements. 

“For technical solutions and highly respected quality Stafsjö was a natural choice, say chief engineer Vesa Romppanen from Andritz, the key supplier for the new pulp line. He specified and purchased the Stafsjö valve type “MV DN 1400/56” for high density bleach stock and tower isolation. “We needed a tailor made valve says Vesa, and Andritz know from past experience that we can rely on the team at Stafsjö. Together we found the solution for this project, a customized 3,5 tonnes MV valve with purge ports close to the seat, capable to handle really high pulp concentrations. This is a huge project with many challenges, extreme pressures and large amounts of pulp and water per second”.

Eldorado started up on December 6, 2012. On time. Everything has worked as a clock works since. Vesa Romppanen has not heard any remarks or complaints. On the contrary. The first shipment of pulp left for its final destination to Mobile, Alabama in January 2013. The plant reached maximum capacity for first time in March 2013. A year after Eldorado set wold record three times in a week producing around 5,000 tons in a single day.

The output, from planted eucalyptus forests, a 100 per cent renewable source, is exported to paper producing markets in South America, North America, Europe and Asia, to produce everything from toilet paper to paper towels, napkins and wrapping paper.

The company plans a two-phase expansion that will create the largest pulp mill in the world. The 2017 phase will double the mill's capacity and the 2021 phase will increase total production capacity to 5 million tons. The facility is also contributing to the local population, providing jobs for about 25,000 people and is an important contribution to Brazilian exports.

Further information
Please feel free to contact Stafsjö on sales@stafsjo.se or on +46 11 39 31 00 for any questions on customized solutions for pulp and paper applications.

If you are you interested in the knife gate solutions for pulp and paper applications in Finland, please feel free to contact our sales partner Tecalemit Flow Oy and Marcus Finne on marcus.finne@tecaflow.fi or +358 29 006 280.