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A VIRTUAL TOUR of SSK BIRMINGHAM

A VIRTUAL TOUR of SSK BIRMINGHAM. Wednesday, 21st March 2012. THE MILL. THE MILL. THE MILL. Founded by 3 Victorian Gents (Smith, Stone and Knight) in 1862 22 Acre site 110 employees Single machine (PM4) Output = 200,000 t.p.a. Saleable width (deckle) = 4.7m

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A VIRTUAL TOUR of SSK BIRMINGHAM

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  1. A VIRTUAL TOUR of SSK BIRMINGHAM Wednesday, 21st March 2012

  2. THE MILL

  3. THE MILL

  4. THE MILL • Founded by 3 Victorian Gents (Smith, Stone and Knight) in 1862 • 22 Acre site • 110 employees • Single machine (PM4) Output = 200,000 t.p.a. • Saleable width (deckle) = 4.7m • Machine Speed = 850m/min max. • Products manufactured: T2, T3 & Recycled Fluting • Grammage range = 100 – 220 gsm • 2 Bore holes providing process water requirements • 2 CHP’s generating 8MW of electricity & 40t/hr of steam at 12bar • 3 Package boilers generating 60t/hr of steam at 12bar • An Anaerobic Waste Water Treatment Plant

  5. STORAGE YARD – (The Front End) • 14.9Kt stock capacity (up to 3 weeks supply) / 4Kt per week input • 14.5Kt baled • 400tonnes loose

  6. THE PAPER MAKING PROCESS • Pulping: add water (96%) to recovered fibre (4%) = “thickstock” • Cleaning: the “thickstock” by sieving, screening and centrifuge • Spraying: Spray a jet of thinstock (99% water) onto a wire (a woven synthetic fabric – the forming sheet - moving at 720 mtrs/min). • Drying: remove water from the forming sheet • Sizing: – add chemicals (starch etc) to achieve physical strength properties by squeezing into the paper. • Reeling up, slit, and wind to required customer width and diameter. • Finishing/Transporting: - to finished reel warehouse.

  7. PULPING and CLEANING • ‘Stock’ preparation on twin stream pulping lines • 17.5 Kt rejects p.a. (80% landfilled, 20% land spread)

  8. PM4

  9. SPRAYING – (The ‘Wet’ End)

  10. DRYING • This is achieved in 4 stages: • Draining – by gravity 1% fibre:99% water • Drawing – by vacuum 20% fibre:80% water • Squeezing – by rollers 54% fibre: 46% water • Heating – by hot air 93% fibre: 7% water

  11. SQUEEZING (PRESS SECTION) • Two presses working at 5 bar reduce water content to about 60% • A third, extended nip press (ENP) reduces water content further to about 47% • The ENP operates at 68 bar using hydraulic pressure.

  12. HEATING and SIZING (The ‘Dry’ End) • Steam heated cylinders in the Pre-Dryer section are now used to bring moisture content down to about 12%. • Starched / sized products have to be rewetted in a size press as the chemical additives are absorbed. • More steam heated cylinders in the After-Dryer section are now used to bring moisture content down to the finished product specification of 7-8%.

  13. WINDING • Jumbo reels c.18 Tonnes

  14. FINISHING • The Valmet slitter is fully automatic and capable of being run by 1 man • Jumbo reels are slit to customers orders • 6 to 15 finished reels per jumbo are produced • Each weighs between 0.78 and 3.2 tonnes

  15. WAREHOUSING – The Rear End • Fully automated unmanned forklifts (self guided vehicles – SGV’s)

  16. ENERGY FROM WASTE PLANT • Energy • 2 Gas fired CHP’s • CHP1 Centrax KB5 built in 1985, generating 3.5 MW &20 tonnes/hour of Steam • CHP2 Centrax KB7 built in 1997 installed at SSK in 2000, generating 4.5 MW & 20 tonnes/hour Steam • 3 dual-fuel, package boilers • installed 1989, generating 20 tonnes/hour each of Steam • Import and Export electricity dependant on product mix • Typical specific electricity usage 315 KWh/gross tonne

  17. WATER TREATMENT PLANT

  18. THE LOCAL ENVIRONMENT • Water is drawn from the aquafer under the city • Input from 2 boreholes at 3.5 m3/tonne • Input from city’s water main at 1.1 m3/tonne • Output 3.1 m3/tonne to Severn Trent Minworth sewage works • Used water is treated on site before returning to Severn-Trent

  19. THE ACTUAL TOUR • Health and Safety – • Do • Stay with your guide / supervisor • Follow all marked foot paths • Be alert • PPE • Wear High Visibility Vests • Use hearing protection in all production area as designated • Clothing • Wear stout footwear & preferably safety shoes • It’s loud, it’s hot, it’s humid, it’s wet – do you still want to see it?

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