Objectives
- Eliminate emissions leaking into the plant to improve worker safety
- Replace end-of-life dryer while maintaining the original dryer’s footprint
- Integrate Westmill’s Patented Westvac™ seal technology on both dryer end walls for improved efficiency and emissions control
Project Overview
In early 2024, Westmill supplied a new steam-heated 4-deck jet veneer dryer to West Fraser’s Williams Lake Plywood mill to replace their existing Dryer #1, Coe M-72, that had been in service since the mid-1970s. The new dryer combines proven design elements with modern technologies, including improved insulation and enhanced emission controls, to deliver higher efficiency and increased production.
Existing Condition
By the time the replacement was greenlit, Dryer #1 had reached the end of its serviceable life. “Blue haze” VOC emissions released during wood drying were leaking from the old dryer into the plant area and presenting a potential safety hazard for workers. The aging housing and doors could no longer maintain adequate containment pressure, and manual exhaust control left the dryer prone to excessive heat loss and pressure buildup, compounding the leakage problem.
Design & Upgrade Strategy
Westmill delivered peak performance within two firm constraints: matching the existing footprint and retaining the original steam heating platform. Using modern cooling technology, Westmill eliminated one roller section to make room for WestVac™ seal sections at both ends, while engineering the new dryer to align seamlessly with the plants existing infeed and outfeed equipment.
Key Elements Included
- Dual WestVac™ Seal Sections
Westmill’s Patented WestVac™ systems were installed on both ends of the dryer, sealing in heat and locking out emissions at their two critical points. - Automated Exhaust Controls
Westmill’s Automated Exhaust control keeps conditions consistent, eliminating the inefficiency of manual adjustments. - Upgraded PLC Controls
Rather than replacing the existing PLC, it was upgraded – adding WestVac™ integration, humidity control, and automated pressure management. - Steel Finned Steam Coils
Existing steam coils were replaced with coils featuring steel fins on the coil face, eliminating fin damage and protecting the rest of the coil from wear.
Challenges & Solutions
Challenge: In-plant fugitive emissions
Solutions: Westmill’s Patented WestVac™ seal sections at both ends of the dryer capture emissions and maintain efficient dryer pressure, eliminating vapor leakage into the plant.
Challenge: Maintain existing dryer footprint
Solutions: Westmill’s Advanced Cooling Section Technology allowed us to reduce one roller section to accommodate the two new seal sections, preserving the original dryer footprint.
Challenge: Manual exhaust controls contributing to heat loss and leakage
Solutions: Automated a manual process helping keep conditions consistent.
Results & Feedback
- Steam usage decreased by 25%
- Overall production increased by 5%
“The new dryer has been a huge success since the installation”
Paul Bradley, Regional Manager – West Fraser
The Bottom Line
When West Fraser’s aging Dryer #1 became a liability, they turned to the people who know dryers best. Westmill engineered a solution that eliminated the emissions problem at its source, cut steam consumption, and increased production, all without touching the existing footprint or infrastructure while integrating with the existing infeed and outfeed equipment. This cost-effective replacement for the aging dryer has delivered outstanding results and has been a major success for the plant since installation.
