New dryer design
This first 6-deck jet veneer dryer in the southern pine industry was commissioned late in 2012 ; it is the 4th 6-deck dryer built by USNR . The Chopin dryer includes 18 drying sections ( 144 ’) long and is heated with thermal oil . Unique USNR-designed pressurized fan shaft seals effectively keep the plant environment exceptionally clean .
The Chopin plant also invested in the proprietary Automatic Dryer Exhaust Control ( ADEC ) system . ADEC allows automatic control of the total dryer exhaust volume , and ensures efficient production and maximum veneer quality . Cooler Pressure Balance and Veneer Temperature Control work together at the end of the process to ensure uniform temperature is maintained as the veneer exits the dryer , minimize pitch build up and maximize thermal efficiency . ( For more information on these features , please see http :// www . usnr . com / about / news / newsletters / MI _ 6- 12-E . pdf .)
Maintaining market momentum
Jonathan Martin was determined to take every advantage of the profitable market conditions , and looked for inspiration to achieve his goal to maintain the company ’ s momentum in the market place . Often the largest cost a producer bears when investing in a new veneer dryer is the outage ( production down time ) required to demolish the old dryer , erect and commission the new dryer in its place . Jonathan
“ I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks .”
found his inspiration and took his idea to Alan Knokey , VP of USNR ’ s plywood and panel products . Jonathan explained . “ We ’ ve experienced a very good plywood market for the past 18 months , so one of the major costs is taking that much production ( about 1 / 3 of our dry veneer production ) out for an extended period of time . I told Alan we had to come up with a way to tear the dryer out and put the new one in in 3 weeks .” He went on , “ I ’ ve seen this done with major pieces of equipment in chemical plants . We build it off line , we roll it into place , we hook up the hot oil and electrical , and away we go .” Alan and the USNR engineering team were very excited about this new concept and the challenge it presented .
A new challenge
Clint Spangler , engineering manager for USNR ’ s plywood and panel division , was charged with directing engineering efforts for the project . His initial reaction when presented with the idea was , “ That ’ s a pretty big piece of machinery but there ’ s
no reason that would prohibit us from doing it .” The opportunity was enticing , and he commented , “ Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position . Dryers are typically erected in place , so this project involved designing a means of supporting the dryer for the initial assembly , for rolling it into position and for the final positioning .”
Randy Bullion , mechanical engineering manager , designed the rail system the dryer was assembled and transported on . “ The rail system needed to be free of abrupt changes in elevation and width . It was designed using various sizes of beams to account for changes in floor elevation . Structural steel can have variances not only between sizes , but within the same size and weight depending on where and when the beams were produced .”
Game-changing process
A typical new dryer installation can require 18 weeks of downtime ; with this new concept the Chopin plant
“ Our biggest challenge was designing the dryer in such a way that we would not pull it apart when we moved it into position .”
In making preparations for the big move , a large winch was mounted to the mill floor to provide the moving force required for the 1 million pound dryer .
4 Millwide INSIDER | ISSUE 3 - 2013