In pulp and paper applications, operational efficiency is crucial, especially when it comes to handling black liquor, a byproduct of the pulp-making process.
In addition, the chemicals required to break down trees and turn them into pulp make proper sealing solutions essential. Using the wrong sealing product not only leads to safety concerns but can also result in costly repairs and operational downtime. The following is a real-world case study that demonstrates how proper sealing can produce substantial monetary savings in a typical paper mill application.
A Southeastern-based paper mill faced persistent challenges with two black liquor circulation pumps (A and B), which were experiencing frequent mechanical seal failures. Over a period spanning from 2012 to 2023, these issues led to high maintenance costs and significant operational downtime.
Pump A, with an average mechanical seal life of just 74 days, required 27 replacements, while Pump B, with a slightly better performance, still needed 11 replacements over the same period. The misalignment issues inherent to the spring base mounts exacerbated the problem, causing catastrophic mechanical failures, leading to substantial black liquor dilution. For Pump A, this amounted to more than 1 million gallons of additional evaporation costs. For Pump B, the evaporation costs exceeded 5 million gallons.
To address these costly challenges, SEPCO proposed converting the pumps from mechanical seals to braided packing, a more reliable and cost-effective sealing solution. This conversion proved to be highly successful. The braided packing sets required only annual replacement during scheduled outages, ensuring consistent performance and eliminating production downtime.
The financial benefits of this conversion were substantial. For Pump A, the annual cost of maintaining mechanical seals was approximately $1,814,140, compared to just $196.12 for braided packing. Similarly, for Pump B, the cost dropped from $732,966 to $196.12. This dramatic reduction in maintenance costs, coupled with the improved reliability of the pumps, underscores the effectiveness of SEPCO’s solution. SEPCO’s expertise in sealing technology allowed this mill to achieve significant cost savings, improved pump reliability, and enhanced operational efficiency. The switch to braided packing not only addressed the recurring issues but also contributed to the mill’s long-term success in the industry.
“At SEPCO we don’t simply sell products. We are a customer-centric company that offers the best sealing solutions,” says SEPCO Business Development Manager Cody Kaufmann. “We will come to your plant, assess your problem and needs, and provide you with the best long-term solution at the lowest possible cost. That’s the SEPCO promise and the reason we stand out from our competitors.”
SEPCO’s fluid sealing products are used daily in a wide range of applications in the pulp and paper industry. Their team of experts provides customized solutions that meet the unique needs of their customers, ensuring that they receive the right product for their specific requirements.
To learn more about SEPCO’s expertise in sealing solutions for the pulp and paper industry, please follow this link.
