7LVVXH:RUOG$VLD

Applying Control Systems to the

New Air Dried Tissue (ADT)
Machine Concept
Darren Honaker
TMEIC-GE
Paper Industry Application Engineer
Naomoto Akiyama
TMEIC
Paper Industry Application Engineer
Jin Cheng
TMIB Shanghai Branch
Paper Industry Application Engineer
Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

Air Dried Tissue (ADT) offers advantages over

traditional Crepe or TAD Tissue Machines.
1. Present Size limitations exceeded {400 inch
(10.2 m) CD width possible}
2. Present Speed limitations are surpassed
3. Energy consumption reduced by more than 14%
4. Steam Heated Yankee Dryer not necessary
5. Reduction of ceiling height of machine room

Ref: Ed Graf, TADs latest challenger, Tissue World Dec/Jan 2007: 15.

Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

Energy Consumption Values

ADT

Conventional TAD

Greater than 25%

reduction

Gas Consumption
KWH/ Ton:

3840

Steam Consumption
KWH/Ton:

942

Drive Energy Consumption

KWH/ Ton:

1987

Total Energy (KWH/Ton) Use:

Shanghai, China November 20, 2008

6769

Same as conventional
Greater than 14% reduction

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

ADT Tissue Machines

(Air Dried Tissue)
Outer Fabric

Transfer Fabric

Dryer Section
Reel

Dryer Fabric

Inner Fabric
Headbox

0
0

Fan
Pump

Dryer Fabric #1
112 kW

Forming Roll
186 kW

Wire Turning
186 kW
Shanghai, China November 20, 2008

Wire Return
11 kW

Transfer Fabric
112 kW

Control Systems Air Dried Tissue

Machine

0
Dryer Fabric #2
112 kW

Reel
Drum
37 Kw

Spool Starter
11 kW

Booth 1K01

7LVVXH:RUOG$VLD

Power Calculations Results

1580 m/min and 2800 mm
HP Requirements

kW Requirements

Forming Roll

250 HP

186 kW

Wire Turning

250 HP

186 kW

Transfer Roll

150 HP

112 kW

Dryer Fabric #1

150 HP

112 kW

Dryer Fabric #2

150 HP

112 kW

Wire Return

15 HP

11 kW

Reel Drum

50 HP

37 kW

Spool Starter

15 HP

11 kW

1030 HP

768 kW

Total Power

Power Calculations are based on Tappi constants.

Tappi Technical Association of the Pulp and Paper Industry.
Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

Tissue Machine Speed Control

Forming
Section

Transfer
Section

Draw
Ratio

Reel
Drum

Dryer Fabric

Draw
Ratio

Draw
Ratio

Machine Speed Setpoint

Speed Setpoint = 1000 m/min

Speed Setpoint = 2000 m/min

Draw
Ratio

Speed m/min

Draw

Forming Section

0.98

980 m/min

10 m/min

Transfer Section

0.99

990 m/min

10 m/min

1000 m/min

0.9

900 m/min

100 m/min

Section

Dryer Fabric
Reel Drum

Shanghai, China November 20, 2008

Draw
Ratio

Speed m/min

Draw

Forming Section

0.98

1960 m/min

20 m/min

Transfer Section

0.99

1980 m/min

20 m/min

2000 m/min

0.9

1800 m/min

200 m/min

Section

Dryer Fabric
Reel Drum

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD
Forming Sections
Outer Fabric

Transfer Fabric

Inner Fabric

Forming Roll will follow the

torque reference of the Wire
Turning.

Gearbox

Wire Turning will be a speed

regulated motor with operator
draw adjustment.

Speed

Torque

Dryer
Section

2000 m/min

50%

Wire Turning

1960 m/min

60%

Forming Roll

1960 m/min

48%

80%

Forming
Roll

Transfer
Roll

TQ

TQ

TQ

SPD

SPD

SPD

Torque Ratio

Draw
Ratio

80% Setpoint would be a 80% of

Wire Turning Torque
Shanghai, China November 20, 2008

Gearbox

Wire Turning
Roll
M

M
Torque
Ratio

Gearbox

Control Systems Air Dried Tissue

Machine

Draw
Ratio

Line Speed

Booth 1K01

7LVVXH:RUOG$VLD
Transfer Section Biggest Challenge
Transfer Fabric

Dryer Section

Dryer Fabric

Inner Fabric

The Transfer Section will be the

biggest challenge for controlling the
ADT machine.

Gearbox

Forming
Section

The Transfer Roll will be controlled

as a speed regulator but with
droop. Droop will allow the speed
of the Transfer Fabric to fluctuate as
needed due to the process.

Draw
Ratio

Gearbox

Wire
Return
Roll M

TQ

TQ

TQ

SPD

SPD

Transfer
Roll
M

The Transfer Roll will bridge the

Inner Fabric to the Dryer Fabric.
Optionally, operator draw
adjustment will be available for
Forming Section.

Gearbox

Dryer
Fabric #1

Draw
Ratio

Torque
Ratio SPD

Gearbox

Dryer
Fabric #2
M

TQ
SPD

Line Speed

Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD
Transfer Section Speed Regulator Droop Control
Drive Regulation

Speed
Ref

Ki
Droop

+
Speed
Feedback

Kp

+
+

+
+

Torque
Cmd

Kp - Proportional Gain
Ki - Integral Gain

Predicted
Torque

The above droop regulator is excellent for an application where low nip
pressure Soft Nip exists between felts.

Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

Tissue Machine - Reel

2 methods exist for the Tissue Reel
1.

Standard method Reel Drum with Spool Starter.

The Spool Starter is accelerated to running speed,
the sheet is cut and attaches to a new spool.

2.

Centerwind method The Jumbo Roll has 2 motors

that clutch into the spool to assist the Reel Drum in
reeling the sheet.

Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01

7LVVXH:RUOG$VLD

ADT Air Dried Tissue - Summary

The advanatges of ADT include:

Reduction of Energy Consumption.

Reduction of height of production area.
Increase of Tissue Machine speeds.
Increase of Tissue Machine width.

The power requirements of the drive system

for an ADT machine will be similar to TAD or Yankee

Machine.

The Dryer Fabric will be the master section.

The transfer fabric will be speed regulated with droop.

Shanghai, China November 20, 2008

Control Systems Air Dried Tissue

Machine

Booth 1K01