UPM Nordland Papier is expanding the use of John Crane‘s Smartflow IG technology across its paper mill in Dörpen, Germany, following initial installations aimed at reducing freshwater consumption from pump sealing systems.
The technology can save up to 180 litres of freshwater per hour on each pump, depending on the application. UPM Nordland Papier said seal-water consumption on pumps fitted during the initial phase was reduced to almost zero without compromising reliable operation.
Paper mill targets overlooked source of water consumption
UPM Nordland Papier manufactures fine and graphic papers at the Dörpen site and operates at approximately four cubic metres of freshwater per tonne of paper. As part of efforts to improve water efficiency further, the company reviewed the barrier water consumed by pumps fitted with double mechanical seals.
Barrier water is used to support the operation of mechanical seals, including providing cooling. Across an industrial facility containing numerous pumps, the cumulative freshwater requirement can become significant even when consumption from an individual asset appears relatively small.
John Crane recommended its Smartflow IG system as a way of controlling this water demand. The system regulates freshwater supply so that water is used when the mechanical seal requires cooling rather than maintaining a continuous flow.
Smartflow IG responds automatically to seal temperature
Smartflow IG uses a heat-activated shape-memory alloy device to respond to changing operating conditions. According to John Crane, the system requires no external energy supply or additional automation and can be installed without extensive modifications to existing equipment.
Depending on the application, John Crane says each unit can save up to 180 litres of freshwater per hour. Reducing the amount of water entering the process can also lower the volume that subsequently requires treatment and discharge.
The initial installations at Dörpen reduced seal-water consumption on the fitted pumps to almost zero while maintaining pump operation, according to UPM Nordland Papier.
“Reducing freshwater consumption is an important part of our approach to operating the Dörpen mill responsibly. Smartflow IG has enabled us to reduce seal water consumption on the pumps fitted so far to almost zero, without compromising reliable operation,” said Peter Reisige, Director Technical Services at UPM Nordland Papier.
“The results have given us the confidence to purchase additional units and begin introducing the technology more widely across the plant.”
UPM begins wider rollout across Dörpen mill
Following the results of the first installations, UPM Nordland Papier has purchased additional Smartflow IG units for progressive deployment across the mill. The overall water-saving potential will therefore increase as more pumps are fitted with the technology.
The project illustrates how industrial water-efficiency programmes can extend beyond major production processes to supporting equipment. Where the same equipment is used across multiple assets, relatively small reductions at individual points can translate into larger site-wide savings.
“With water scarcity affecting a significant proportion of Europe each year, industrial water efficiency is becoming an increasingly important operational and environmental priority. This project shows how addressing a routinely overlooked source of consumption can deliver a meaningful benefit,” said Christian Naldini of John Crane.
“Smartflow IG can save up to 180 litres of freshwater per hour on each pump, so the cumulative opportunity becomes significant when the technology is applied across multiple assets.”
Industrial water efficiency gains importance in Europe
The rollout comes as water efficiency receives greater attention across European industry. Around 30% of EU land experiences seasonal water scarcity each year, according to figures cited by the companies, with pressure typically increasing between April and September.
The European Commission’s Water Resilience Strategy includes an ambition to improve water efficiency across the EU by at least 10% by 2030. Industrial operators are therefore under increasing pressure to identify opportunities to reduce freshwater demand while maintaining production and asset reliability.
For UPM Nordland Papier, the Smartflow rollout forms part of its longer-term approach to protecting local water resources. The Dörpen project demonstrates how targeted changes to supporting equipment can contribute to broader industrial water-efficiency programmes without requiring changes to the main production process.
John Crane says Smartflow IG can save up to 180 litres of freshwater per hour on each pump, depending on the application.
UPM Nordland Papier is installing Smartflow IG on pumps with double mechanical seals at its Dörpen paper mill in Germany to reduce the freshwater used as barrier water.
Smartflow IG uses a heat-activated shape-memory alloy device to regulate freshwater supply according to the cooling requirements of a mechanical seal. It does not require an external energy supply.
UPM Nordland Papier says its initial Smartflow IG installations reduced seal-water consumption on the fitted pumps to almost zero while maintaining reliable pump operation.
