KWS Manufacturing

Tubular Inclined Screw Conveyors Feeding Boilers for Lumber Mill Power Generation

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Plant Name and Location

Georgia Pacific Lumber Mill
Camden, TX

General Description of the Application

Lumber Mills utilize the waste from processing wood to fuel boilers that ultimately generate electricity to power plant operations. Georgia Pacific (GP) was using an existing open-top drag conveyor to move sawdust and shavings from ground level up to the boilers. The primary problem with the existing system was the loss of product using the open-top drag conveyor. Product was either blown out of the drag conveyor or spilled on the ground prior to delivery. GP was losing approximately 50-percent of the product prior to reaching the boilers. GP needed a new system that would eliminate spillage and provide consistent product delivery to the boilers. Working together, KWS and Motion Industries provided a solution that has provided continuous cost-savings to GP.

Design Parameters of Application

  1. Product Type: Wood Sawdust and Shavings
  2. Material Density: 10 to 30 Lbs. per Cubic Foot
  3. Capacity: 1,100 Cubic Feet per Hour
  4. Duty: 24 Hours per Day, 7 Days per Week

Advantages Provided by KWS

GP contacted Motion Industries to discuss a material handling problem at the Camden plant. After review of the existing wood waste handling system, Motion Industries contacted KWS and asked for an experienced field engineer to help solve the problem. The KWS field engineer assigned to the application has over 35-years’ experience in the industry and easily identified the problems and offered a long-term, cost-effective solution. Motion Industries and KWS have partnered on hundreds of successful bulk material handling applications. GP was impressed with the solution offered by Motion Industries and KWS. When a project requires highly engineered bulk material handling equipment, KWS has the knowledge and experience.

KWS is at the forefront for designing unique solutions for bulk material handling. The project at the Camden plant utilized a unique screw conveyor design to eliminate losses and provide for efficient, uninterrupted delivery of waste fuel to the boilers. Motion Industries and KWS were in constant contact with GP’s project management team throughout the design and production phase of the project and communications continued until the system was up and running successfully. Since KWS has a large group of Professional Engineers on staff, we were able to provide answers every step of the way.

Special Features of KWS Design

KWS designed an inclined screw conveyor system to move the waste wood product from the hopper to the boiler infeed. 14-inch diameter formed flange split tubular screw conveyors were chosen for the application. The tubular housing enclosed the product and increased throughput by over 50-percent. To improve throughput, close tolerance screws were designed with Abrasion Resistant (AR235) flight material for extended life. The system was designed to start and operate under upset conditions. Additionally, integral unit drives were selected to reduce maintenance. The complete screw conveyor system was sealed to prevent any leakage of product.

The new screw conveyor system was installed during the Fourth of July holiday shut down and the anticipated performance was realized immediately. With the former system, GP was forced to purchase additional waste material for fuel to satisfy the necessary feed stock for the boiler. After installing the new system, GP has excess material that can be sold to other mills.

Testimonial

"The screw conveyors are working well, even better than expected! We have saved over $150,000.00 so far since we have installed the new screw conveyor system. Thank you Motion Industries and KWS!!"

Myrton Thompson, Project Engineer – Georgia Pacific

Sawdust

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