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Yankee Dryers

The Yankee dryer is the heart of a tissue machine. It needs to retain a stable surface for creping, withstand high loads of creping and cleaning blades, and cope with occasional dry running situations. Optimized thermal sprayed coatings, often referred to as Yankee metallization, are compatible with the organic Yankee coating and resistant to chatter. These coatings provide creping stability with ceramic-tipped blades and allow trouble free operation that is demanded by tissue producers. State-of-the-art electric arc wire spray equipment allows our customers to operate with reliability and achieve top-notch results for time-critical, on-site coating projects.

No Chatter is What Matters

High-quality thermal spray coatings on a Yankee dryer protects the tissue mill’s assets by prolonging the cast iron Yankee life significantly. A coating lifetime of over 10 years in operation is achievable, while a Yankee without a coating would need a regrind every couple of years. A thermal spray coating can also be reapplied, when required, with almost no loss of material thickness on the Yankee shell. This makes thermal spray a perfect solution for steel Yankees as well.

Oerlikon Metco’s spray equipment and a full range of materials for consistent on-site spraying is the ideal solution for high-performance Yankee dryer coatings. Our proven SmartArc™ arc spray technology provides the quality, stability and consistency needed for coatings in these challenging on-site environments.

With the Oerlikon Metco solutions, you can achieve

• Highly wear-resistant coatings that are compatible with the organic chemistry
• High application rates and good application economics
• Economical coating solutions with reliable, high-throughput spray technology
• Cleaner on-site operation with new low-dust materials with excellent cohesive and adhesive strength
• Excellent reproducibility and consistent microstructure for optimal Yankee performance, long life and low chatter

Oerlikon Metco delivers materials ranging from economical standard feedstock wire products to high-end materials engineered using our proprietary Scoperta™ rapid alloy development methodology. The wires are designed to work reliably and repeatably with Oerlikon Metco’s electric arc wire spray equipment.

Our extensive process, material, and application knowledge allows us to find the optimum solution for our customers’ needs — through standard materials and processes or unique solutions developed using our Coating Solution Centers and/or through joint R&D collaboration.

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Steel Yankee dryer: Advantages, development and rapid acceptance

This section will mainly cover the Steel Yankee Dryer , which has been rapidly adopted by the industry over the past 15 years. This text also briefly covers some basic principles of sheet drying on a tissue machine. However, these principles will be covered in much more detail in a separate section entitled Drying: Yankee dryer & Air hood .

Basic principles of the Yankee After pressing, on a conventional wet press machine, the tissue sheet is approximately 40-45% solids and the remaining water must be removed by using thermal energy to evaporate it. This is most often accomplished on a single large metal cylinder, the Yankee dryer, which  can be up to 22 feet (6.7 m) in diameter and serves to both carry the sheet as well as drying it until it has reached the dryness and strength required to get the final paper quality.

The Yankee is partially enclosed by a high-velocity impingement hood and, in modern conventional tissue machines, at least 50 to 60 % of drying effect typically comes from the cylinder side, while 40 to 50% comes from the hood side.

The heart of the machine For several reasons, the Yankee dryer is often considered the heart of a tissue machine . This is due not only to the size of the cylinder, which can be enormous, but also the critical role it plays for:

• Supplying the energy needed for drying the wet web • Transporting and supporting the sheet during the drying process • Functioning as a roll in the hot-pressing operation • Providing the base for the creping process , in conjunction with the doctor blade.

By the way, the origin of the name “Yankee” for this drying cylinder is a bit of a mystery. There are several theories about where it comes from but no definitive reason for this name has been firmly established, as far as we know.

Cast-iron was the standard for a century For almost 200 years cast iron has been the material used for Yankee cylinders. Over the years, advances have been made in cast iron Yankees, such as improving material properties, strength, and heat conductivity, as well as enhancing the design by changing from a smooth inside shell to one with grooves and ribs.

Starting around 2000, Steel Yankee Dryers began to be introduced as a Tissue drying concept. Improvements in manufacturing methods, and especially in welding technology, made steel Yankee cylinders feasible. This offered new opportunities to papermakers which will be covered below.

Toscotec pioneered steel Yankee dryer, based on 40 years’ experience Toscotec, the paper machine producer in Lucca, Italy, is widely seen as the pioneer and driving force for development of the steel Yankee dryer (SYD) concept. Already in the 1960s, the company was producing steel drying cylinders for standard paper machines. In 1999, Toscotec started to design the first SYD based on emerging methods of engineering analysis and in 2000 the first steel Yankee, 2.5 m (8 feet) in diameter, was officially started in commercial operation on a tissue machine.

In 2013 the company launched its second-generation design, with a diameter of 22 feet, a width of 5.6 m and an operating speed of 2000 m/min. This is the largest diameter steel Yankee ever made so far and, it is claimed, the fastest ever using steam only as the heating source in the drying process.

Steel has many advantages Steel offers the tissue maker numerous advantages in terms of safety, energy consumption, flexibility, investment costs, and weight.

Safety is of course a very important consideration for companies. Explosions on cast iron Yankee dryers unfortunately have sometimes occurred due to the material properties of cast iron. Thus the cylinder can explode if it is over pressurized, loaded with excessive load, or in case of an accident for other reasons. Steel, on the other hand, will have a better performance in the event that internal stresses exceed the allowable limits.

Since steel is a stronger material and has a modulus of elasticity which is considerably higher than cast iron, the pressure vessel safety codes allow for better design parameters on steel. The much higher allowable stresses for steel mean that the shell wall can be thinner , which gives the positive benefit of higher heat transfer . The shell root thickness on a SYD can be approximately 30% lower than a cast-iron shell.

Lower shell root thickness for steel means the resulting heat flow is higher through the cylinder. This gives a higher evaporation rate which can flexibly either be used: to increase the production rate at constant energy input or, when the machine speed is kept constant, to reduce the drying energy.

Higher heat transfer and lower energy costs Cast iron and steel have essentially comparable thermal conductivities, so if the shell is 30% thinner, heat transfer increases accordingly with steel, giving greater drying efficiency. Since drying is accomplished by a combination of the Yankee and the hood, the increased heat exchange efficiency translates to over 15% increase in production capacity at constant energy input.

Another benefit of the reduced shell thickness and higher heat transfer is that lower steam pressure can be used for drying. In such a case, the same production rate can be reached using lower steam pressure.

Alternatively, the tissue machine can utilize more steam, and less hood contribution and electricity , to produce the same amount of paper. The result is lower total energy consumption. Depending on the cost ratio between the different energy sources, energy cost savings of up to 20% are possible in tissue machines with a SYD. The investment cost for steel Yankees are normally somewhat lower than for the cast iron variety, and the physical weight is 25 to 30% less as well.

Metalizing benefits It should be mentioned that steel Yankee dryers are metalized prior to delivery because the steel itself is too soft for creping and the wear rates would be unacceptable. Metallization eliminates the need for re-grinding of the shell wall base metal, which on cast iron can eventually result in de-rating. Metallization is also a key reason that steel Yankees are far less prone to developing chatter problems.

Summary In summary, steel Yankees have major advantages compared with cast iron in safety matters, and also in energy costs due to higher drying capability in the Yankee-to-Hood drying balance. Steel Yankees therefore offer potential energy cost savings, while also having a lower capital investment cost than cast iron. Although the SYD technology was pioneered by Toscotec, essentially all the major tissue machine suppliers have begun making steel Yankee dryers and offer them to the market today.

Internal view, Toscotec SYD

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Toscotec to supply a TT SYD Steel Yankee Dryer to Mirae Paper

Toscotec’s TT SYD Steel Yankee Dryer

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Toscotec will supply a  third-generation design  TT SYD  Steel Yankee Dryer  to the South Korean tissue manufacturer Mirae Paper at their Jeonju paper mill. This is a repeat order from Mirae Paper who installed their first TT SYD on PM3 in 2013.

The new steel Yankee will replace PM2’s existing cast-iron cylinder and it is scheduled for start-up in the second half of 2022. 

The third-generation design of TT SYD Steel Yankee Dryer benefits from an ideal ratio of the weight, width and pitch of the internal ribs and the optimization of the shell thickness. The scope of supply includes the condensate removal system and Toscotec’s patented heads insulation for  maximum thermal energy efficiency . The associated services include the complete project management, erection supervision, operation and maintenance training, commissioning and start-up assistance. 

The TT SYD will be manufactured at Toscotec’s fully integrated  TT SYD Technology Center  in Massa (Italy), situated just 3 kilometers away from seaport to ensure fast and safe shipping operations.

Toscotec is continuously upgrading the design of TT SYD, benefiting from the vast experience of  over 200 TT SYD  running across 5 continents worldwide under the most diverse operational and environmental conditions. This year, Toscotec has launched  TT Defender ® , a breakthrough patented innovation that equips TT SYD with an internal protection coating against corrosive steam.

Yeong Rok Lee, Mirae Paper’s Production Manager , says, “The steel Yankee on PM3 has been operating efficiently for over 8 years, allowing us to reduce our thermal energy consumption by a significant amount. We expect the new Yankee on PM2 to be as reliable and to deliver even higher performances, considered the design upgrades that Toscotec has implemented on their TT SYD since our first installation. We consider the Yankee dryer to be the core component of our tissue machine’s drying capacity. We chose the best technology available in the market, with all the technical support we need from an expert supplier.”

Gabriele Martinelli, Toscotec’s Sales Manager , says, “It is very rewarding that Mirae Paper has chosen Toscotec for the second time on their Yankee replacement. Toscotec strengthens its position in South Korea, where it is the only supplier of steel Yankee dryers, with 12 TT SYD sold in 9 years, including two installed on Toscotec’s AHEAD tissue lines.” 

This order was obtained with the support of CleanTech Corporation, Yongin, South Korea. 

About Mirae Paper Co., Ltd. Established in 2000, Mirae Paper operates one paper mill in Jeonju, South Korea. The company manufactures approximately 65,000 tpy of high quality tissue, including toilet tissue, handkerchiefs, and towels, using recycled fibers. It distributes its products mainly to the Korean market.

Source: Toscotec

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Mirae paper boosts high-quality capacity with steel yankee.

South Korea’s Mirae Paper has invested in a Toscotec-supplied TT SYD Steel Yankee Dryer to be delivered to its Jeonju paper mill. 

It will replace PM2’s existing cast-iron cylinder and is scheduled for start-up in the second half of 2022. 

Yeong Rok Lee, Mirae Paper’s Production Manager, said: “The Steel Yankee on PM3 has been operating efficiently for over eight years, allowing us to reduce our thermal energy consumption by a significant amount.  

“We expect the new Yankee on PM2 to be as reliable and to deliver even higher performances.

“We consider the Yankee dryer to be the core component of our tissue machine’s drying capacity.” 

Toscotec said the third-generation design “benefits from an ideal ratio of the weight, width and pitch of the internal ribs and the optimisation of the shell thickness”.  

The scope of supply includes the condensate removal system and Toscotec’s patented heads insulation for maximum thermal energy efficiency.  

Established in 2000, Mirae Paper operates one paper mill in Jeonju, South Korea.  

It manufactures 65,000tpy of high-quality tissue including toilet tissue, handkerchiefs, and towels, using recycled fibres, which are distributed primarily in the Korean market.  

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Toscotec launches breakthrough in steel yankee dryers for sustainable papermaking.

Toscotec, the global market leader of Steel Yankee Dryers, introduces  TT Induction SYD , a  carbon-reduction breakthrough  that redefines Yankee dryer technology entirely. TT Induction SYD uses  electrical induction  instead of steam energy to dry the paper web, thereby  cutting direct greenhouse gas emissions to zero . 

In 2000, Toscotec pioneered a major technological innovation,  TT SYD , the first Yankee dryer entirely made of steel. Steel Yankees have since surpassed their cast-iron equivalent to become the benchmark for drying efficiency and safety in the paper industry. TT Induction SYD is now set to be the new game changer in tissue for its capability to use clean energy and slash direct carbon emissions associated with the drying process. 

A disruptive innovation for dry crepe and TAD tissue machines With TT Induction SYD, the internal steam distribution and steam/condensate removal systems are entirely replaced by an induction system composed of static coils installed inside the shell and electrical controls and instrumentation located outside for easy maintenance and monitoring. As a result of precise coil geometry, the induction system delivers a very fast and accurate heating effect exactly on the areas of the shell where it is required, while preventing residual circulating currents in other areas.   Steam-heated Yankees use steam energy typically generated by burning fossil fuels. TT Induction SYD uses electrical energy that can be derived from  renewable energy  sources while delivering the same result, i.e. uniformly heating up the Yankee’s shell in contact with the paper web to achieve dryness. TT Induction SYD is suitable for installation on dry crepe as well as Through-Air-Drying (TAD) tissue lines. 

Luca Ghelli, Toscotec R&D Director , says, “Sustainability is the guiding idea of TT Induction SYD’s design. As a proven industrial technology, an induction system offers multiple advantages when applied to the most energy-intensive section of the tissue machine. The efficiency of this cutting-edge technology will dramatically reduce the carbon footprint of papermaking. Based on our expertise in steam-heated TT SYD and induction systems, we succeeded in developing a more efficient and sustainable steel Yankee dryer.”

Substantial carbon reduction with unchanged productivity and paper quality Normally, approximately half of the carbon dioxide emissions produced by a tissue machine originate from the operation of the Yankee dryer. By using clean energy, TT Induction SYD achieves zero direct emissions, while maintaining productivity unchanged and  reducing energy consumptions because of the higher efficiency of the induction system . Due to the precise heating of the shell, it also eliminates possible moisture profile issues related to uneven condensate removal, thereby ensuring an improvement in moisture uniformity in both cross direction (CD) and machine direction (MD).  

Maximum safety, easier operation, and maintenance  TT Induction SYD was designed without any electrical, mechanical, and radiation risk to ensure maximum safety. Besides offering  safe operations , it also clears all issues related to the maintenance of steam-heated Yankees, including pressure vessel’s mandatory and planned controls, maintenance of condensate straw pipes against potential plugging and of special heads for steam and condensate inlet and outlet. The entire Yankee system is simplified in the absence of steam: the heads, the internal surface which is groove-less, and the steam and condensate auxiliary system disappears entirely, including the steam generator with related maintenance and controls and delicate controls for steam quality. TT Induction SYD simply requires relatively easy maintenance on the electromagnetic induction system. 

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An Investigation of a Dryer Can Failure in a Paper Mill

• Technical Article---Peer-Reviewed
• Published: 21 January 2015
• Volume 15 , pages 251–257, ( 2015 )

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• M. Ananda Rao 1 &
• M. V. Pavan Kumar 2  

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The failure of a rotary dryer in a paper manufacturing facility is reported and analyzed. The primary cause of failure is identified as a weakened structure and as a consequence, inlet pressure of the steam into the dryer reaching a critical limit. Post failure, the shell, and the two heads of the dryer were analyzed using characterization techniques such as stereomicroscopy and scanning electron microscopy with energy dispersive analysis. The threads of the shell were found completely chipped off. In the microchemical analysis, silicon in the form of quartz was found inside the shell at the threads. Silica in the form of quartz is theorized as having entered through the steam and becoming entrapped in the gaps of the threaded connections. Although wear between brittle shell and the connecting bolts can potentially develop torsion and lead to the chipping off of the crest regions of the threads over the time, the deposition of silica might have instigated and aggravated the same.

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The authors thank the Director, the National Metallurgical Laboratories Jamshedpur for his encouragement in publishing this article.

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Ananda Rao, M., Pavan Kumar, M.V. An Investigation of a Dryer Can Failure in a Paper Mill. J Fail. Anal. and Preven. 15 , 251–257 (2015). https://doi.org/10.1007/s11668-015-9922-y

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Revised : 19 December 2014

Published : 21 January 2015

Issue Date : April 2015

DOI : https://doi.org/10.1007/s11668-015-9922-y

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New York Times Statement About 1932 Pulitzer Prize Awarded to Walter Duranty

Duranty, one of the most famous correspondents of his day, won the prize for 13 articles written in 1931 analyzing the Soviet Union under Stalin. Times correspondents and others have since largely discredited his coverage.

Duranty’s cabled dispatches had to pass Soviet censorship, and Stalin’s propaganda machine was powerful and omnipresent. Duranty’s analyses relied on official sources as his primary source of information, accounting for the most significant flaw in his coverage – his consistent underestimation of Stalin’s brutality.

Describing the Communist plan to “liquidate” the five million kulaks, relatively well-off farmers opposed to the Soviet collectivization of agriculture, Duranty wrote in 1931, for example: “Must all of them and their families be physically abolished? Of course not – they must be ‘liquidated’ or melted in the hot fire of exile and labor into the proletarian mass.”

Taking Soviet propaganda at face value this way was completely misleading, as talking with ordinary Russians might have revealed even at the time. Duranty’s prize-winning articles quoted not a single one – only Stalin, who forced farmers all over the Soviet Union into collective farms and sent those who resisted to concentration camps. Collectivization was the main cause of a famine that killed millions of people in Ukraine, the Soviet breadbasket, in 1932 and 1933 – two years after Duranty won his prize.

Even then, Duranty dismissed more diligent writers’ reports that people were starving. “Conditions are bad, but there is no famine,” he wrote in a dispatch from Moscow in March of 1933 describing the “mess” of collectivization. “But – to put it brutally – you can’t make an omelet without breaking eggs.”

Some of Duranty’s editors criticized his reporting as tendentious, but The Times kept him as a correspondent until 1941. Since the 1980’s, the paper has been publicly acknowledging his failures. Ukrainian-American and other organizations have repeatedly called on the Pulitzer Prize Board to cancel Duranty’s prize and The Times to return it, mainly on the ground of his later failure to report the famine.

The Pulitzer board has twice declined to withdraw the award, most recently in November 2003, finding “no clear and convincing evidence of deliberate deception” in the 1931 reporting that won the prize, and The Times does not have the award in its possession.

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