Continuous kilns Continuous kilns combine high capacity and economy of operation with the right drying quality.
2 “ By helping you, as a customer, to be profitable, we are earning our place in the supply chain.”
3 Valutec is Europe’s biggest supplier of lumber kilns. And the reason for its success? Photo: Martinsons. Jonas Westling CONTINUOUS KILN TC 4, CONTINUOUS KILN 2-ZONE FB 6, CONTINUOUS KILN OTC 8, CONTINUOUS KILN 3-ZONE FB 10, A SUSTAINABLE CHOICE 12, TECHNICAL SOLUTIONS 14, FACT GUIDE 15 CONTENTS There are, of course, many different explanations for Valutec’s market successes. Factors such as our offering high quality timber kilns and control systems tailored to our customers’ needs may be one reason. Another may be that we have both the expertise and the desire to drive development forwards. However, I feel that the most important reason for our success is really something more basic. We believe in our continuous improvement and optimisation of the drying process. We are also absolutely convinced that it enables us to contribute to better timber products and the increased competitiveness of wood. In turn, this leads to increased use of wood. This is the foundation of our long-term right to exist. By helping you, as a customer, to be profitable, we are earning our place in the supply chain. It also constantly inspires us to develop new, innovative concepts. With the above attitude as our base and with a mind that is open to customer processes and challenges, we jointly continue to take the technology to new levels. Our timber kilns and our industry-unique control systems enable you to work from the factors that are most important for each individual end product and control the drying process to achieve the desired properties. In other words, they enable you to optimise quality, capacity and energy consumption – all at the same time. This was long the ultimate goal of our development department. It is now one of the basic functions in our control systems. In the following pages, you can read about our continuous kilns and the various possibilities they offer. We hope that this brief brochure can serve as a basic aid when you are choosing a timber kiln. Nonetheless, I would still recommend getting directly in touch with us at Valutec. Together, we can find the drying solution that is exactly right for your operations. Robert Larsson, MD
4 TC Continuous kiln Start-up: 2020 Capacity: Approx. 295,000 m3/year 125 MMBF/year JDI, GRAND LAKE TIMBER
5 PRINCIPLE The timber is dried as it indexes through a number of zones that have separate climates. Once loaded lengthways on trolleys, the timber is fed into the channel from a buffer track at the kiln’s input end. A fully automatic feed system carries the wood through the stainless steel kiln and out through its output end. Via heat coils, laterally located axial fans blow circulation air across the channel’s longitudinal direction and through the wood. The system is also equipped with automated doors at entrance and exit. Flexibility and high capacity. The TC principal has created conditions for high-capacity continuous kilns with great flexibility when it comes to mixing lumber dimensions. The advantages include minimum moisture content variation and a reduced risk of checking. The TC kiln is also well suited for efficient heat recovery. Multiple unique solutions. The latest models in Valutec’s TC program were developed to take full advantage of the capabilities of the TC principle. All of the designs, components and control systems are based on advanced technology, and in many cases solutions that are unique in lumber drying (see Technical Solutions on page 14–15). Lumber types and capacity. Valutec’s TC kilns were specially developed for the production of boards and planks and have an annual capacity of up to 200,000 m3 (85 MMBF) and a target moisture content down to approx 12–18%. The TC kiln combines the capacity advantages of continuous kilns with the flexibility of batch kilns. The TC principle is based on feeding lumber packages length-wise through zones in which the air circulates laterally across that drying zone. Hence the name, the Swedish abbreviation for cross circulation. This enables the separate regulation of the climate in different zones in a schedule that comes very close to an ideal batch kiln schedule.
6 2-zone (FB) Continuous kiln Start-up: 2018 Capacity: Approx. 46,000 m3/year 19 MMBF/year SETRA, NYBY
7 Photo: Christina Brandin Englund, Svenskt Trä PRINCIPLE The timber is dried during transport through the various climates in a drying channel that has 2 separate zones. Once loaded on trolleys, the timber is fed into the channel from a buffer track at the kiln’s input end. A fully automatic feed system carries the wood through the stainless steel kiln and out through its output end. Via heat coils, axial fans in each zone blow circulation air through the timber. In the first zone, the air is blown in the opposite direction to timber travel. In the second zone, it is blown in the same direction as timber travel. Advantages of this kiln type 2-zone kilns offer both improved quality and greater capacity. In principal, the first zone acts like a short 1-zone continuous kiln where the air is humidified more quickly. This reduces surface drying and thus the risk of checks at the input end. The second zone acts as a balancing zone to reduce moisture content variation. Capacity and drying economy By collaborating closely with researchers and customers, we have developed 2-zone models that ensure the optimum use of capacity and the very best drying economy. To their advantage, the kilns can also be equipped with a heat recovery system. Everything from the building's structure to technical solutions and the control system is based on a combination of expertise, experience and advanced international research (see Technical Solutions on page 14-15). Lumber types and capacity Valutec’s 2-zone kilns were especially developed for small- dimension lumber and center lumber and have an annual capacity of up to 100,000 m3 (42.5 MMBF) and a target moisture content down to approx 8–18%. Drying takes place in two separate zones in the 2-zone continuous kiln. This type of kiln is also known as FB (Feedback), as the climate in zone 2 is fed back to zone 1, where general ventilation takes place.
8 OTC Continuous kiln Start-up: 2016 Capacity: Approx. 80,000 m3/year 34 MMBF/year HASSLACHER, SACHSENBURG
9 Photo: Christina Brandin Englund, Svenskt Trä PRINCIPLE The timber is dried during transport through the various climates in a drying channel that has 2 separate zones. Once loaded on trolleys, the timber is fed into the channel from a buffer track at the kiln’s input end. A fully automatic feed system carries the wood through the stainless steel kiln and out through its output end. Via heat coils, axial fans in each zone blow circulation air through the timber. In the first zone, the air is blown in the direction of timber travel. In the second zone, it is blown in the opposite direction to timber travel. The OTC model (optimized two-stage continuous) is a patented solution developed to create a climate profile that resembles a batch kiln’s drying schedule. The blowing direction is opposite to that of the conventional 2-zone FB model. Larger dimensions. The solution has enabled the development of a continuous kiln that minimizes the risk of checking in larger dimensions. The combination of the continuous kiln’s high capacity and the batch kiln’s high quality provides a kiln that also manages rapid drying to a low final moisture content. The kilns can advantageously be equipped with a heat recovery system. Unique in the market. OTC continuous kilns are a good example of Valutec’s ambition and long-term investments aimed at putting new ideas and opportunities from the cutting edge of research to good use. Valutec introduced the OTC principle to the market, which combined with smart technical detail solutions, has resulted in a unique product concept that meets all of the high standards we demand of our products (see Technical Solutions on page 14–15). Lumber types and capacity. Valutec’s OTC kilns were developed for boards and planks and have an annual capacity of up to 100,000 m3 (42.5 MMBF) and a target moisture content down to approx 8–18%.
10 3-zone Continuous kiln Start-up: 2014 Capacity: Approx. 85,000 m3/year 36 MMBF/year SCA, RUNDVIK
11 Photo: Johannes Rousseau PRINCIPLE After standard drying, the timber arrives at a conditioning zone. Here, the climate is set to reduce the stresses in the timber. Via heat coils, axial fans blow circulation air through the timber. To achieve the best equalisation of moisture content, the air direction is reversed. Valutec has a long list of high-class references. Scan the QR code to take a closer look! You can also visit www.valutec.ca. Advantages of this kiln type. A third zone opens the possibility of using continuous kilns for drying to low moisture contents. Previously, this was something usually reserved for batch kilns. The conditioning zone is equipped with fans, heat coils, pressure frames, spraying/steaming equipment and its own ventilation. A door is installed between the conditioning zone and zone 2. Consequently, the conditioning zone’s climate can be regulated separately from that in the rest of the stainless steel kiln. Normally, the zone has two stations. Depending on loading intervals, this gives a conditioning time of 4 – 8 hours (see Technical solutions, pages 14 – 15). Timber types and capacity. As both FB and OTC models can be equipped with a conditioning zone, capacity can be up to 100,000 m3 (43 MMBF). All dimensions can suitably be handled and target moisture content can be down to around 8 – 18%. Our 3-zone continuous kilns add a further zone to the two found in our FB and OTC models. This zone has its own climate and is operated purely as a conditioning zone. This makes it possible to achieve better quality, even at really high capacities. Valutec has a long list of high-class references. Click to see more. You can also visit www.valutec.ca.
12 A sustainable choice. From design to operation. Energy efficiency Energy efficient lumber drying solutions are under constant development at Valutec. This includes e.g. well-insulated kilns, heat recovery and many energy-saving functions in the company’s Valmatics 4.0 control system. Sustainable materials and components Valutec kilns are built in stainless steel to maximize lifetime and minimize CO2 emissions. Thanks to our well-designed kilns, heat recovery and smart control systems, Valutec offers a more sustainable drying process with minimal energy consumption and maximum value yields. One of the best ways of supporting sustainable development is to use more wood. Valutec enables the increased use of wood, as its lumber kilns and control system fully exploit the raw material’s value. The design of the system is planned to achieve the smart, sustainable use of resources.
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14 Solutions at the cutting edge of technology. In every detail. Valmatics 4.0 is the only control system on the market that provides sawmills around the world with tools to automate and optimize drying in every type of lumber kiln. The system, which was developed for Industry 4.0, has a modern, intuitive user interface and is constantly being developed using the latest lumber drying technology. The high quality of the process is ensured by simulators programmed with data from hundreds of thousands of measurements to enable the calculation of drying processes with unbeatable accuracy from beginning to end. Valmatics 4.0 is also the only control system on the market to combine simulator technology with adaptive control, enabling the optimization of capacity, quality and energy consumption. Simultaneously. Stainless steel unit construction • All kilns are built using Valutec’s stainless steel construction system, an FEM calculated design in 2–10 mm steel. • Prefabricated modules with minimal welding. • Static joints with screw joints and silicone seals. • Resistant to heat expansion and fatigue. • No need for assembly welding. • Great protection against instability and fractures. Efficient motors Valutec’s continuous kilns are built with synchronous reluctance motors as an option. The motors have an efficiency standard of IE5, three levels above IE2, which is the current EU standard. This ensures energy efficiency and minimizes CO2 emissions. Energy savings can reach up to 25 percent, and because the bearings are permanently lubricated, they maintain a 10-20°C lower temperature, resulting in motors with service lives up to four times longer than motors with an IE2 rating. Doors • Robust doors made of aluminum or stainless steel. • Same elements and joints as the building system. • Mineral wool insulation and profiled. covers with good insulation against heat and noise. • The elements are held together by an outer frame with a sealing strip. • Bearing pins provide effective locking to the door frame’s sealing surface. • Door lift with electric vertical wire winch. Fans • Axial fans optimized based on operating conditions for maximum efficiency. • Adjustable or fixed blades. • For operating temperatures above 90 °C (195 °F), we supply motors with air cooling. • An external cooling fan provides cooling air for each motor. Baffles • F or sealing around the lumber load to prevent energy leakage and unnecessary moisture content variation. • Fixed side and roof baffles with EPDM rubber or polyamide wire cloth. • Adjustable side baffles with manual operation. • Roof baffles integrated with pressure frames. Lumber feed • Package feeder system with stable lumber trolleys and hooked bar feeder function with motor external to kiln. • Fully automatic feeder system at the input and output buffers. Pressure frames • For minimal deformation of top layers. • Stable, stainless steel guided load frames allows permanently mounted cylinders and fully tiltable frames with no risk of jamming. • Holds up to one metric ton per cylinder. • Stainless steel piston rods with Viton seals, stainless steel pipes and connections. • Also available in a scissors design for integration into existing kilns. Security solutions • Light beams at input and output of buffer and loading zone. • Safety switches at all wicket doors. • Hatch doors, operable from inside and outside.
15 A complete range of continuous kilns. Brief specifications. • •passes recommendation CHARACTERISTICS TC 2-ZONE OTC 3-ZONE Boards Planks Online dimension changes Mixed dimensions (mm) 16–50 16–63 16–75 16–75 Low final moisture content Minimal checking (planks) Minimal moisture content variation TECHNICAL DATA Max kiln temperature 90 °C (194 °F) Annual capacity (m3) Annual capacity MMBF 40,000–200,000 17–85 25,000–100,000 10.5–42 25,000–100,000 10.5–42 25,000–100,000 10.5–42 Building Material Stainless steel Heat transmit. coeff. (W/m2 °C) < 0.30 Door system Vertical doors Air seal/flaps Fixed wall and roof flaps integrated in pressure frames Feeding system Fully automatic Fans 2–4 axial fans/zone Air velocity (m/s) 2–4 3–6 3–6 3–6 Supply/exhaust air Mechanical evacuation Evacuation flow (m3/h) 10,000–50,000 Heat recovery Air/air or air/fluid Control system Valmatics 4.0 Heating coil Lamella heating coils, Valutec special Spraying/steaming system High-pressure hot water or steam
16 www.henson.nu SWEDEN Valutec AB Box 709 SE-931 27 Skellefteå SWEDEN Phone +46 (0)910 879 50 Fax +46 (0)910 879 59 valutec@valutec.se www.valutec.se FINLAND Valutec Oy Tehdaskylänkatu 11 A FI-11710 Riihimäki FINLAND Phone +358 75 756 1401 Fax +358 (0)19 760 4440 valutec@valutec.fi www.valutec.fi NORTH AMERICA Valutec AB PO Box 447 East Longmeadow MA 01028 USA Phone +1 413-246-2881 robert.weithofer@valutec.se www.valutec.ca With nearly 100 years in the industry Valutec has developed drying equipment for the sawmill industry. Over the years we have delivered more than 4 000 wood dryers to customers all around the world. Valutec is Europe’s largest supplier of wood dryers. Valutec has established an extensive program for research and development. Close collaboration with leading researchers has resulted in continuous kiln dryers and batch kiln dryers which today are market leaders in terms of both quality and total economy. Additionally, Valutec’s development of control system and simulator technology has resulted in value-adding solutions, making it possible to seize the full value of the raw material. The Valutec Group AB includes Valutec AB, Skellefteå and Valutec Oy in Riihimäki, Finland. Collectively, the Group has a complete range of products based on Swedish and Finnish expertise in wood drying.
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