paper machine 2010 final
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Paper technology program for Taiwan TAPPI
CG Kiang2010 04 27 Taichung, Taiwan
2010 04/CGK
1
Paper mill
2010 04/CGK
2
Paper machine in the stone age
2010 04/CGK
3
2010 04/CGK
4
: 0.2-1.5% : ;2% : 20% : 60%-50% : 40%-50%90%-95% 2010 04/CGK 5
Paper machine in 1884
2010 04/CGK
6
Paper machine in 2000s
2010 04/CGK
7
Paper machine in 2000sDry End
2010 04/CGK
8
20% 40-50%
90%-95%
2010 04/CGK
9
Paper machineSections
Formation section
Press section
Dryer section Head box
2010 04/CGK
10
Paper machineDewatering wet end
Fo ilb ox
n um io cu ct u va h ts ig la H F
m
x bo
fo i
ilb fo
lb o
ox
x
va c
Couching cons. 8-10%
rm Fo
Lo w
g in
bo
uu
ar
d
Headbox cons. 0.30-0.50%
00
Headbox cons. 0.50-0.70%rm Fo00
lb o
Fo ilb ox
g in
va c
bo
uu
ar
m
d
fo i
Lo w
h ig H
c va
uu
m
fo
ilb
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Couching cons. 8-10% Couching cons. 8-10%uc n tio x bo sf
ox rb e Fl s at uc
an x oxtr bo bet ne l er F io h sf ct S an su tr t at ee Fl Sh s at
n tio
x box bo
Dryness 24-26%
at Fl
n io ct su
2010 04/CGK
11
Paper machineDewatering - press
up to 50 % consistency ~ 34-36% consistency ~ 38-40% consistency ~ 20-25% consistency ~ 30% consistency
2010 04/CGK
12
Paper machineDrying~ 50 % consistency 8 12% moisture content
2010 04/CGK
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Paper machineMain types The following main types of paper machines are significant today :- Fourdrinier machines - Combination machines - In vat machines ( cylinder machine ) - Tissue paper machines - Board machines - Twinwire machines2010 04/CGK 14
( Fourdriner Machine )
2010 04/CGK
15
Paper machineFourdrinier machine development
2010 04/CGK
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Paper machineCombination machine folding boxboard machine
2010 04/CGK
17
( Combination Machine )
2010 04/CGK
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Paper machineMG dryer Yankee dryer
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Paper machineMG dryer Yankee dryer
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Paper machineMG dryer Yankee dryer Purposes of useWrapping paper machines MG-gloss as a target for the sake of appearance Usually combined machines owing to capacity Multi-layer board machines The Yankee dryer is used not only to gain gloss, but also to gain smoothness without losing bulk (stiffness). It is difficult to perform a sufficient amount of drying using the Yankee dryer Crpe paper machines MG-gloss is not set as a target. The Yankee cylinder drying efficiency may become a bottleneck for the production2010 04/CGK 21
Paper machineMG dryer Yankee dryerEffect of the MG cylinder drying on board surface
Surface prior to MG cylinder2010 04/CGK 22
Surface after MG cylinder
In vat cylinder machine direct flowVACUUM BOXES
COUCH ROLL
SHOWER TO DRIERS
COUCH ROLL PRESS ROLLS WHITE WATER DISCHARGED THROUGH CENTER
2010 04/CGK
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In vat cylinder machine contra flowVACUUM BOXES COUCH ROLL
SHOWER
TO DRIERS
COUCH ROLL PRESS ROLLS WHITE WATER DISCHARGED THROUGH CENTER
2010 04/CGK
24
In vat cylinder machineMulti-layer board machine
Couch rollShower water
Suction box
Forming cylinder
2010 04/CGK
25
( Tissue Paper Machine )
2010 04/CGK
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( Board Machine )
2010 04/CGK
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( Twinwire Machine )
2010 04/CGK
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Paper machineTwinwire machine
2010 04/CGK
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Paper machineBoard machine
Fourdrinier and secondary gap forming unit
2010 04/CGK
30
Paper machineBoard machine
Primary gap forming unit and on-top fourdrinier
2010 04/CGK
31
Paper machineBoard machine
2-Ply gap forming section
2010 04/CGK
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Raw materials and their effect on final product Recycled fiber Less bulky Lower brightness Lower tensile High fines content => slow drainage
Virgin fiber bulky and high brightness good tensile fast drainage
2010 04/CGK
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Three-, Four- or Five ply forming section3-layer forming Scandinavian type Folding box board
4-layer forming high quality WLC
5-layer forming high quality and versatile concept
2010 04/CGK
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Linerboard structure Top ply: Undertop ply: Back ply: UKP, OCC OCC, Mixed waste, Broke OCC
2010 04/CGK
35
Two layer headbox producing containerboardEuropean OCC and mixed waste
2-layer forming
2010 04/CGK
36
Paper machineHeadbox The headbox has four main functions :1. 2. To spread the stock flow across the entire width of the wire To maintain a turbulence in the stock to prevent formation of fiber flock To remove temporal and spatial flow disturbances that may cause basis weight variations To produce a stock flow of desired consistency, speed and direction to the wire
3.
4.
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Paper machineHeadbox The traditional headbox is formed of the following components :- Inlet header - Headbox with rectifier rolls and air cushion - Slice with top slice and apron
2010 04/CGK
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Paper machineHeadbox
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HeadboxInlet header conic pipesThe shape of the inlet header is to optimized to distribute the stock evenly across the width of the machine, especially uniform distribution for all flow rates not only for headbox design flow rate Electropolished for all flow surfaces is must
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HeadboxInlet header tapered right angle ducts
2010 04/CGK
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HeadboxBox rectifier rolls
Tampella rectifier roll headbox2010 04/CGK 42
HeadboxBox rectifier rollsStock flows in headbox with rotating and stationary rolls
2010 04/CGK
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HeadboxBox rectifier rolls
Accumulation of fibers in a rectifier roll
2010 04/CGK
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HeadboxBox rectifier rolls The rectifier rolls has many disadvantages :1. 2. A great part of the flow passes in between the rectifier rolls and is therefore not mixed Influence of the inlet header on the flow on such a way that vortexes are formed inside and between the rolls. Since these vortexes are not identical across the entire width of the headbox, they cause severe disturbances in the flow The rectifier rolls is the occasional piling of fibers on the surfaces between the holes or on the edges, when flushed away, they end up as hard fiber lumps in the paper Paper quality can be decisively influenced by such factors as the openness of roll, hole size and location of the rectifier roll which located closest by the headbox outlet. As the machine speed increased, it is the roll that usually cause a problem
3. 4.
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HeadboxBox rectifier rolls The rectifier rolls are necessary in every headbox for the following reasons :1. The rectifier rolls even out the flow speed in the cross direction of headbox and stabilize the flow The rectifier rolls evoke turbulence in the entire headbox. It helps disperses fiber lumps so that in the outflowing mixture, the fibers are evenly distributed in the water
2.
2010 04/CGK
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HeadboxBox air cushion On open headbox, the ratio between surface level h ( cm ) and outflowing speed V ( m/min ) : h = V 2 / 700h V
V = 300 m/min ; h = 125 cm
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HeadboxBox air cushion
Valmet air cushion headbox2010 04/CGK 48
HeadboxBox air cushion
Air cushion headbox2010 04/CGK 49
HeadboxBox air cushion
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HeadboxBox air cushion
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HeadboxBox air cushion
Pulsation dampening located close to slice without a compromise Dampens both dilution and main flows Continuous flow from stilling chamber to overflow No back flow or build-ups to main flow
2010 04/CGK
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HeadboxBox air cushion
2010 04/CGK
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HeadboxBox air cushion
2010 04/CGK
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HeadboxBox attenuator
Attenuator which incorporates headbox for dampening of pressure pulsations
2010 04/CGK
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HeadboxBox attenuator dampen pressure pulsation
Prior to headbox
After headbox2010 04/CGK 56
HeadboxSlice
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HeadboxSlice
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HeadboxSlice.4 in .2 in 10 mm 5 mm max 150 mm [6 in]
0.79 in max -2 in min 0 in O of breast roll
20 mm max -50 mm min 0 mm
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HeadboxHigh turbulence headbox
2010 04/CGK
60
HeadboxHigh turbulence headbox
Pressure loss to : Create micro turbulence Uniform CD flow distribution (profiles and fiber orientation) Improve pulsation dampening for MD variation control
2010 04/CGK
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HeadboxHigh turbulence headbox
smooth flow geometry from round to rectangular
Low large scale turbulence low random basis weight variation good stability
Turbulence level fine tuning with turbulence sheets
Fluidization in circular enlargement
2010 04/CGK
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HeadboxHigh turbulence headboxm/s f/s
2010 04/CGK
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HeadboxHigh turbulence headbox - multilayer
2010 04/CGK
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HeadboxHigh turbulence headbox - multilayer
Multilayer separation by vanes
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Formation of sheetFlow monitoring in short circulationVariations in the flow speed, consistency or in the properties of the stock temporal or across the headbox - lead to grammage variations, poor sheet formation and many other difficulties. The problems can often be localized in the short circulation or drive unit and may often lead to change of headbox If the fiber form large flocks in the slice section, it is difficult to correct later in the process. If the flow is too turbulent on the other side, it tears the earlier formed sheet off and makes the paper cloudy although the fibers are relatively well distributed2010 04/CGK 66
Formation of sheetFlow monitoring in short circulationOne-sidedness means a difference in the formation, filler content or fiber orientation between the top and bottom sides of paper sheet One-sidedness is determined e.g. by the impingement angle of the stock jet and the wire. The angle is set by shifting the top slice in the horizontal direction.
2010 04/CGK
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Formation of sheetPaper formation measurement by small scale beta absorption
2010 04/CGK
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Formation of sheetFormation analyzer measuring principle
2010 04/CGK
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Formation of sheetFormation - what are variationsCD profile
ed hi n c ma
cti ir e
on
Paper sheet is a measure and an image of pressure and flow conditions
MD profile
c ma
on ct i ire ed hin
Residual variations
hi n ac m
cti ir e ed
on
2010 04/CGK
70
Machine direction
Formation of sheetFormation - typical variations in paperCD
ed hi n c ma
cti ir e
on
CD profile depends on performance of profiling actuators of headbox and other sections in PM. (usually 0,3 - 0,6 % from average) MD variations come from variations in raw material and chemical aid supplies, consistency and pressure controls. Fast (20..30 Hz) MD-variations come from pulsation for example piping, fan pump, machine screen. Note: pulsation can appear also at frequency-multipliers (0,1 - 1,5 % from average)
MD
c ma
on ct i ire ed hin
RES
hi n ac m
cti ir e ed
on
Unsystematical variations come from incomplete mixing in approach system and from unstable drainage process. (0,6 - 2,5 % from average)
2010 04/CGK
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Paper structure engineering
2010 04/CGK
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( Forming ) : (Fourdriner machine) (Cylinder machine)
2010 04/CGK
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( Fourdriner machine )
2010 04/CGK
74
BeloitBel-Bond I. (formation) II. III.
610m/min 150g/m2 45 ton/min/cm
2010 04/CGK
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BeloitBel-Bond
2010 04/CGK
76
CEDECOPond
I. II. III. IV. 700 m/min 20-90 g/m2
2010 04/CGK
77
Escher Wyss(Top Former)
I.MD/CD2151 II. III. : 400 m/min 25-60 g/m2
2010 04/CGK
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Escher Wyss(Short Top Former)
: 40-750 m/min 25-350 g/m2
2010 04/CGK
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KobayashiUltra
I. II. 500 m/min 40-100g/m2
2010 04/CGK
80
KobayashiSuccess
700 m/min 40-100g/m2
2010 04/CGK
81
Voith:(Compact Wire Former)
: : 700 m/min 30-220 g/m2
2010 04/CGK
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Voith:(Compact Wire Former)
80-600 m/min 80-400 g/m2
2010 04/CGK
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( Cylinder machine )
2010 04/CGK
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( Cylinder machine )
2010 04/CGK
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( Cylinder machine ):()
2010 04/CGK
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( Cylinder machine )
2010 04/CGK
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Escher Wyss(Pad Former)
I. II.21/51 III. IV.(2%) 150 m/min() 25-110 g/m2
2010 04/CGK
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Tampella
50-350 m/min 20-130 g/m2
2010 04/CGK
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Tampella Arch Former
70-600 m/min
2010 04/CGK
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Voith:
I.MD/CD II.
250-510 m/min 20-110 g/m2
2010 04/CGK
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( Hybrid former )
2010 04/CGK
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( Gap former ) :
2010 04/CGK
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( Gap former )
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( Gap former )
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( Gap former )
2010 04/CGK
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( Gap former )
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( Multi-ply former )
2010 04/CGK
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( Multi-ply former )
2010 04/CGK
99
Paper machineWire section drainage
Fo ilb ox
Couching cons. 8-10%fo if lb oi
n um io cu ct u va h ts ig la H F
m
x bo
fo i
ilb fo
lb o
ox
x
va c
rm Fo
lb o
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x
00
10
Lo w
g in
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ar
d
Headbox cons. 0.30-0.50%
2-3 0 0 0
Fo ilb ox
Headbox cons. 0.50-0.70%
rm Fo
00
2-3 0
10
Lo w
g in
va c
bo
uu
a
m
rd
h ig H
c va
uu
m
Couching Couching cons. 8-10% cons. 8-10%ox rb n fe tio ns x xtra uc t bo bo ts n ee la er F io h sf ct S an su tr t at ee Fl Sh x bo n tio uc s n io ct su x bo x bo
00
Dryness 24-26%
at Fl at Fl
KSD/BRD 499338_1 9/93
2010 04/CGK
100
Paper machineWire section - drainage
1% 7-8% 4-5% 11 % 32 % 4% 12 % 35 % 1,5 - 2 %10 0 %
2,5 % 15-18 % 0,5 %
2%
2010 04/CGK
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Paper machineTissue machine suction former
2010 04/CGK
102
Paper machineTissue machine drycrepe, Crescent former
2010 04/CGK
103
Paper machineTissue machine drycrepe, Crescent former
2010 04/CGK
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Paper machineTissue machine drycrepe, Crescent former
2010 04/CGK
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Paper machineTissue machine
2010 04/CGK
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Paper machineTissue paper
2010 04/CGK
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Paper machineTissue paper
2010 04/CGK
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Paper machineTissue paper
2010 04/CGK
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Paper machineTAD tissue machine
2010 04/CGK
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Paper machineTAD tissue machine - elements
2010 04/CGK
111
Paper machineTissue machine
2010 04/CGK
112
Paper machineTAD tissue machine moulding process
2010 04/CGK
113
Paper machineTAD tissue machine roll with through head exhaust
Air flow
Air flow2010 04/CGK 114
Paper machineTAD tissue machine through dryer process
Combustion fan
2010 04/CGK
115
2010 04/CGK
116
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