PM3 Hydra Pulper’s Junk-Trap

Jams
 Junk-Trap Jamming Reasons(5 whys)
• Number of Junk-Trap jamming since 17/12/2016 till 26/4/2017 are 14 jams in
4 months period
• Reason(main) behind Junk-Trap’s jamming (90% of the time): is due to poor
OCC quality (containing metal parts, gas cylinders, small pumps, hard plastic,
oil cans, wheels, radiator, etc.…). (why)?
• 2nd reason: due to poor bad OCC quality from our supplier, sending OCC bales
filled with mixed waste (as mentioned above), as they arrange the bale they
do not check for any mixed waste.
• 3rd reason: lack of thoroughly checking in our warehouses and sending as it is,
warehouse’s in charge blame it on the bales quality checkers for not checking
thoroughly .
• Continue to next slide
• 4th reason: in the bales conveyor loading area we have multiple reasons:
a) Lack of proper of equipment to check the big metal parts.
b) Sometimes forklift drivers accidently drag with them junk into the loading
conveyor (10% chance of happening).
c) Availability of bales quality checkers in all times, we have one operator who is
responsible of bale’s wires cutting (idle automated wire cutter) can check
from time to time what is inside the bales, but can’t check thoroughly
because the bale is very well stacked(except in the case of manual stacked
OCC bales).
• 5th reason: the type of furnish we load in PM3’s conveyor different from PM2’s
conveyor ( 90% OCC: 10% NCC >> 6 OCC: 1 NCC) and sometimes 100% OCC
(why)
Because management said that PM3’s has more screening system(coarse & slot
screening),therefore can handle a large quantity contaminants from bales.
PM.3 Available data on Junk-Trap jams
# Junk-Trap jamming dates FPP production loss Reason
1 17th & 18th December 2016 3 hours total operation loss Hard plastic, gas cylinders, oil drums

2 22th December 2016 removed for hr and half – no fpp production loss Automobile driving shaft

3 8th January 2017 Removed for 1 hr no production loss Heavy metals, food cans, automobile parts

4 10th January 2017 Removed for 1 hr 30 mins, production loss Mixed waste parts within the OCC bales

5 5th February 2017 Removed for 1 hr – fpp production loss Wheel, metal junks

6 7th February 2017 Removed for 1 hr – fpp production loss Mixed waste

7 12th March 2017 No fpp production loss Availability of qc checkers

8 22th March 2017 2 or 3 times jams – fpp production loss Bad/Poor OCC bales quality

9 27th March 2017 Removed for 1 hr -fpp production loss Big metal part

10 31th March 2017 Removed for 1 hr – fpp production loss Round plate, pump

11 2nd April 2017 No fpp production loss Mixed waste

12 17th April 2017 3 jams on 1 day – production loss – speed reduced Metal pieces in OCC bales from supplier
by 90 mpm
13 18th April 2017 Removed for 1 hr- no fpp production loss NA

14 26th April 2017 Removed for 1 hr 30 mins, fpp production loss Poor OCC quality (metal junks)
Effects of Junk-Trap Jamming
• Deteriorating of (by time):
a) junk-trap’s body due to frequent jams inside.
b) Knife gate valves will also be affected (valve gates get damaged specially the
blade) from frequent entrapment of big material.
c) Junk-trap is connected to pulper in order to reduce the wear inside from the
slushing process by taking heavy coarse material, therefore jamming of big
material(metal) will reduce lifetime of the pulper.

• Fibre production plan (FPP) production loss specially when taking a long period
of time to clean the junk-trap, if so will also affect the paper machine
production when pulper is being stopped for many hours (paper production
loss)
PM3 vs. PM2 Process Layout
20% or 30%
accepts to pulper
UniPulper PM3

Fiberizer.1 Fiberizer.2 HydraPulper PM2

junktrap Dil’N Water (70-75 %

valve opening)
Junktrap

Hydrapurger
Elutriation
Knife gate
water(treated) White Water valve (
Water pressure
Valve single acting
( 3.5-5.5 bar)
cylinder)
Knife gate valve
(double acting
cylinder) Clear Filtrate
(sealing watet)
Water pressure
(3 bar)
Technical Data
Capacity[𝑴𝟑 ]
Type of Valves at junk-trap end
Type of cylinders controlling the valve
PM3 Unipulper’s Junko-Mat
2900
Knife gate valve
We have two upper & lower;
Upper(single acting cylinder)
Lower(double acting cylinder)
PM2 Hydrapulper’s Junk-Trap
1000
Knife gate valve
We have two upper & lower;
Upper(single acting cylinder)
Lower(single acting cylinder)

Distance between valves Approx. 100 cm 90 cm

Valve Diameter[mm] 400 400
Inlet Diameter[mm] 400 (?) 400
Sequence Time[discharge time] (18-20) seconds 40 seconds
Operation Time 2.9 minutes = 174 seconds 240 seconds = 4 minutes
Modifications - Operation time was 10 minutes before
Easy to reach when cleaning No Yes
Control Type Automatic, ability to switch to manual Automatic, ability to switch to manual
control control
PM.2 Junk-Trap Operation Sequence
0 : Begin 10 : HS107 Opening & Closing
> Wait time : 10 seconds till the closing of the lower valve Operation time: 240 seconds > 4 minutes
HS107 from previous cycle
After that, there will be 10 seconds delay before the valve
closing.
Then white water valve will close immediately and the upper
valve needs 6 seconds to close

1 : Initial Step 15 : Dumping(Discharge/Purge) Time

Wait time(delay): 10 seconds delay till the start of the Wait time(delay): 10 seconds till the start of the
operation time purging(dumping) operation.

After that, two valves will open at the same time:

a) Lower Valve(HS108) connected to Clear Filtrate pipe.
b) 2nd Junk-trap output slot valve

5 : Operation Time 20 : HS108 Opening & Closing

Wait time(delay): 10 seconds till the start of the
operation.
After that, two valves will open at the same time:
a) Upper Valve(HS107) connected to Clear Filtrate pipe
b) White Water Valve.
Control time(discharge): 40 seconds
After that, 2nd Slot will close immediately and the lower
valve needs 10 seconds to close
Then the sequence will start again from the 0: Begin
Sequence : (0: Begin & 1:Initial step)
10 sn till the closing of the lower valve
10 sn delay till the start of operation time
Sequence : (5: Operation Time &
10:HS107 opening & closing)
10 sn delay till the start of operation->
Upper valve & white water valve open
4 minutes interval for the cycle
Then white water valve will close & 6 sn
for upper valve closing
Sequence : (15: Dumping Time &
20:HS108 opening & closing)
10 sn delay till the dumping time ->
Lower valve & 2nd junk-trap slot open
40 sn for discharge time (purging), then
2nd slot will close before the lower valve
by 5 sn
PM.3 Operation Sequence (approx.)
Begin Upper Valve opening & closing
Wait time: 10 seconds till the closing of the lower valve Control time: 2.9 minutes

Then, elutriation water valve closes immediately and upper

valves needs 5 seconds to close

Initial Step Dumping(discharge) Time

Wait time(delay): 10 seconds till the start of operation Wait time(delay): 6 seconds till the start of discharge
time operation

Elutriation valve opens immediately

Operation Time Lower Valve opening & closing

Wait time: 5 seconds till the opening of the upper valve control time: (18-20 ) seconds

Then back to the begin sequence

Single Acting
Cylinder

Single Acting
Cylinder[knife
gate valve]

Double Acting
cylinder[ knife
gate valve]

PM3 PM2
• Information about Knife Gate Valve.
a) Utilization of blade to cut through clogging of heavy liquids.
b) Designed orinially for the use in pulp & paper industry.
c) Knife gate valve is easily diminished when used dry bulk application( sand,
etc,,,)
d) Frequent jamming of the junk-trap will affect blade of the valve(it will not
close tightly).
Possible solutions
• Records(reports) writing on the day of the jams. Report should include(jams dates, type of
furnish, cause, if any production loss, duration of the jam). Reports will be for future
reference.
• Costly solution >> providing a big metal scanner, which will take a lot of time & efforts.
• Providing a metal scanner in the warehouses (costly solution).
• Thorough checking of bales in warehouses(because they time to open and check the bale).
• Providing a bale stacking device.(costly)
• Availability of Bales QC checkers (more manpower is recommended).
• Checking the weight of the truck(RM weight) if possible to check for any abnormalities in the
weight (for ex heavy metal parts).
• Preventive maintenance(specially the valves, inlet).
• PM3 Junk-trap is hard to reach than PM2,therefore we should try to make reaching to it easy,
so they can clean fast.
•THANK YOU