Professional Documents
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Process detail
2010 04 / CGK 1
REFINING
2010 04 / CGK 2
Targets & principles of refining
2010 04 / CGK 3
Targets of refining
Pine Eucalyptus
Pinus silvestris
27 μm 16 μm 16 μm 10 μm
2010 04 / CGK 5
Effect of refining
A B C
Stator
Rotor
2010 04 / CGK 7
Fiber properties of hardwood
2010 04 / CGK 9
REFINING
2010 04 / CGK 10
The effect of refining
TENSILE STRENGTH
Fibrillating
Cutting
kWh/t
2010 04 / CGK 11
The effect of refining
Fibrillating
Cutting
kWh/t
2010 04 / CGK 12
The effect of refining
Cutting
Fibrillating Fibrillating
Cutting
kWh/t kWh/t
2010 04 / CGK 13
The effect of refining
Cutting
Cutting
Fibrillating
Fibrillating
kWh/t kWh/t
2010 04 / CGK 14
The effect of refining
• Fiber length are reduced
FIBER LENGTH
Fibrillating
Cutting
kWh/t
2010 04 / CGK 15
Introduction to refining theories
Power
• Pmax = Mt × 2π × n
– Mt max moment
– n speed
Efficiency
• Pidling= k × n2,3 × d4,5
– k constant
– n speed
– d diameter
Rotation speed
2010 04 / CGK 17
Refining
Power distribution
kW
Refiner load NT Refiner load NT
Effective refining
power NE
2010 04 / CGK 19
Amount of refining
N
NEE (kW)
(kW) == N
NTT (kW)
(kW) -- N
NHH (kW)
(kW)
SRE
SRE (kWh/t)
(kWh/t) == —————————————
—————————————
mm (t/h)
(t/h)
2010 04 / CGK 20
Amount of refining
SRE
SRE (kWh/t)
(kWh/t) == IN
IN (km/kg)
(km/kg) xx IE
IE (Ws/m)
(Ws/m)
2010 04 / CGK 21
Specific edge load theory
Ptotal − Pno − load
SRE, kWh/t =
Production
2010 04 / CGK 22
Specific edge load theory
P total - P no − load
SEL, J/m =
CEL × n
2010 04 / CGK 23
Refining intensity
Specific Edge Load
N
NEE (kW)
(kW) == N
NTT (kW)
(kW) -- N
NHH (kW)
(kW)
SEL
SEL (J/m)
(J/m) == —————————————
—————————————
Ls
Ls (km/s)
(km/s) == Cl
Cl (km)
(km) xx nn (r/s)
(r/s)
2010 04 / CGK 24
Amount of refining
Energy of refining impacts
N
NEE (kW)
(kW) == N
NTT (kW)
(kW) -- N
NHH (kW)
(kW)
IE
IE (Ws/m)
(Ws/m) == ——————————————
——————————————
Ls
Ls (km/s)
(km/s) == Cl
Cl (km)
(km) xx nn (r/s)
(r/s)
2010 04 / CGK 25
Specific surface load theory
SEL
SSL, J/m 2
=
IL
2010 04 / CGK 26
Intensity of refining
Specific Surface Load
SEL
SEL (J/m)
(J/m)
SSL
SSL (J/m²)
(J/m²) =——————
=——————
IL
IL (m)
(m)
2010 04 / CGK 27
Refining intensity
Specific Surface Load
Wrotor
Wrotor(mm)
(mm)++Wstator
Wstator(mm)
(mm) 11
IL
IL(mm)
(mm)==——————————————
——————————————xx———— ————
22 cosα/2
cos α/2
Rotor bars α
Stator width
Impact Length
Stator bars Rotor width
2010 04 / CGK 28
Specific edge load vs. Specific surface load
BL Pine sulphate
80 3,7 J/m
70
440 J/m²
Tensile Index, Nm/g
60
3,7 J/m
50 704 J/m²
40
30
3,7 J/m
1210 J/m²
20
10 20 30 40
Refining Degree, SR
• The specific surface load theory is valid when the fiber floc cover the whole
width of bar surface
2010 04 / CGK 29
Refining system
2010 04 / CGK 30
Refining system
Combined system
Broke
To Machine
SW Chest
Blending
Chest
HW
2010 04 / CGK 31
Refining system
Energy input / split per stage
35 SR
15 SR
2010 04 / CGK 32
Refiner fillings
Geometry
2010 04 / CGK 33
Refiner fillings
Geometry
2010 04 / CGK 35
Cutting edge length calculation
• CEL = Zr × Zst × l
α=18°
• 12 segments in both rotor and stator
four 315mm long bar
l1
Z1 two 210mm long bar
two 105mm long bar
l2 Z2
2010 04 / CGK 36
Amount of refining
Typical specific refining energy
• NBKP 10 … 15 kWh/t/oSR
• LBKP 7 … 10 kWh/t/oSR
• NUKP 15 … 17 kWh/t/oSR
2010 04 / CGK 37
Refining intensity
Specific Edge Load, typical figures
• LBKP 40 … 80 kWh/t
• Post refining of
mechanical pulps 30 … 80 kWh/t
2010 04 / CGK 41
Refiners
Sizing – excises
5 ) Motor sizing :
Case 1 : 3 stage refining
NE = 168 kW ; speed 900 rpm
Supplier A : NH = 40 kW : NT = 168 + 40 = 208 kW
Motor : 225 kW ; 900 rpm
Supplier B : NH = 52 kW : NT = 168 + 52 = 220 kW
Motor : 250 kW ; 900 rpm
5 ) Motor sizing :
Case 2 : 2 stage refining
NE = 250 kW ; speed 720 rpm
Supplier A : NH = 90 kW : NT = 250 + 90 = 340 kW
Motor : 400 kW ; 720 rpm
Supplier B : NH = 115 kW : NT = 250 +115 = 365 kW
Motor : 400 kW ; 720 rpm
2010 04 / CGK 44
The amount of refining
Beating degree / Net refining energy
800 60
40
500
400
30
300
20
200 2*150 kWh/bdmt
4*75 kWh/bdmt
100 10
0 50 100 150 200 250 300 0 50 100 150 200 250 300
NET REFINING ENERGY, kWh/bdmt NET REFINING ENERGY, SRE kWh/bdmt
Short fiber
2010 04 / CGK 45
The amount of refining
Tensile index / Refining energy input
90 90
80
80
T E NS IL E IND E X , N m /g
70
60
60
50 50
40 40
2*150 kWh/bdmt 2*150 kWh/bdmt
30 30
4*75 kWh/bdmt 4*75 kWh/bdmt
20 20
0 50 100 150 200 250 300 0 50 100 150 200 250 300 350 400
NET REFINING ENERGY, kWh/bdmt TOTAL REFINING ENERGY, kWh/bdmt
Short fiber
2010 04 / CGK 46
The amount of refining
Tensile index / Beating degree
90 90
80 80
T E N S IL E IN D E X , N m /g
70
T E N S IL E IN D E X , N m /g
70
60 60
50 50
40 40
Short fiber
2010 04 / CGK 47
The amount of refining
Tensile index / Tear index
Short fiber
2010 04 / CGK 48
The amount of refining
Tensile index / Fiber length
Short fiber
2010 04 / CGK 49
The amount of refining
Beating degree / Net refining energy
Long fiber
2010 04 / CGK 50
The amount of refining
Beating degree / Net refining energy
Long fiber
2010 04 / CGK 51
The amount of refining
Tensile index / Total refining energy input
Long fiber
2010 04 / CGK 52
The amount of refining
Tensile index / Total refining energy input
Long fiber
2010 04 / CGK 53
The amount of refining
Tensile index / Fiber length
Long fiber
2010 04 / CGK 54
The amount of refining
Max. Specific Surface Load / Beating degree
2010 04 / CGK 55
No-load power & total power
2010 04 / CGK 56
Refining process
2010 04 / CGK 57
Refining result
HC vs LC refining
2010 04 / CGK 58
Refining result
HC vs LC refining
2010 04 / CGK 59
HC+LC Refining system
2010 04 / CGK 60
Refiners
Sizing - comparison
• Installed power
• Hydraulic flow rate
• No load power
• Control system
2010 04 / CGK 61
Refiners
Gap clearance and stability
LOADING FORCE LF
GC 1 GC 2
LOADING
GC FORCE LF
α AXIAL LOADING
MOVEMENT = ALM
AXIAL LOADING
MOVEMENT = ALM SF 1 SF 2
AXIAL AXIAL
LOADING FLOATING
FORCE MOVEMENT AFM
ALF
∆ GC = SINα x AM
ALF = SINα x LF
∆ GC = 0,5 X ALM
AFM = 0,5 X ALM
∆ GC = AFM
2010 04 / CGK 62
Refiner
Rotation direction
PRESSURE DIFFERENCE
+
OVER THE REFINER
FLOW
pumping
- not pumping
2010 04 / CGK 63
Pumping
2010 04 / CGK 64
Non Pumping
2010 04 / CGK 65
REFINING
2010 04 / CGK 66
Refiners - batchwise operated
Hollander - Beater
2010 04 / CGK 67
Refiners
Geometry
2010 04 / CGK 69
Disc refiners
2010 04 / CGK 70
Refining system
Control Strategy
PIC
LIC
FIC
PI
PIS
NIC EIC
Cs SEC
white water
2010 04 / CGK 71
Control of refining
• Manual control
– control with gap clearance
• Power control
– gap clearance controlled according motor power
• Specific refining energy control
– motor power controlled according production
• Freeness control
– refining energy controlled according freeness
– temperature and couch vacuum ie. can be used in a same way
2010 04 / CGK 72
Refining control
Power Control vs SEC Control
Specific Energy,
kWh/t
Fiber Flow,
t/h
Motor Power,
kW
2010 04 / CGK 73
Stock preparation & approach system
Process detail
2010 04 / CGK 74
Stock preparation
• Broke
Handling
• Stock
Preparation
• Approach
System
• White Water
Handling
2010 04 / CGK 75
Approach flow system
purpose of the system
2010 04 / CGK 76
Approach flow system
Requirement
• Stability
• Flexibility
• Simplicity
• Reduced costs
2010 04 / CGK 77
Approach flow system
Requirement
Stability
Agility
• Large volumes
• Plenty of recirculation
• Long stabilization time Modern approach flow
• Smaller process
• Accurate system
• Direct feed to the machine
• Smaller equipment can be
utilized
• Lower energy consumption
2010 04 / CGK 80
Approach flow system
Typical approach system for modern paper machine
DILUTION LINE
DEAERATION
OVERFLOW
DEAERATION ACCEPT
SYSTEM
S F R 1 R 1
VACUUM PUMP SEAL WATER
SEAL PIT
WIRE SILO
M ACHINE STOCK
PIGMENT RECOVERY
SYSTEM
2010 04 / CGK 81 STOCK INFEED
W HITE W ATER HEADER
Approach flow system
Typical approach system for modern board machine
DILUTION LINE
W IR E W A T E R
R 1
W IR E P IT
WIRE SILO
(passive deaeration)
MACHINE
SCREENING
ROOM
W H IT E W A T E R H E A D E R
2010 04 / CGK 82
Approach flow system
Approach system effect on quality
Properties Approach
of pulp System
Formation +++ ++
Bulk +++
Roughness +++
Porosity +++ ++
Pin holes +++ +++
Absorbency ++ +
Filler/Fines distribution ++ +++
Tensile strength ++
Tear ++
Internal bond strength +++ ++
Fiber orientation +
Curl ++
Stiffness ++
Brightness ++ +
Blackening
Opacity ++ +
Basis weight CD ++
MD ++ +++
RE ++
Big Influence +++ Caliper CD +
Moderate Influence ++ MD +++
Light Influence + RE ++
No Influence Moisture CD +
2010 04 / CGK 83 MD ++
RE +
Approach flow system
Proportioning control
2010 04 / CGK 84
Approach flow system
Fast and accurate consistency control
Conventional
2010 04 / CGK 85
Approach flow system
Fast and accurate consistency control
Modern
2010 04 / CGK 86
Approach flow system
Fast and accurate consistency control
Conventional Modern
- Difficult tuning + No need for re-tuning
- Sensitive for production changes + Independent from production changes
- Needs more mixing volume in the + Smaller mixing volumes can be used
chests after + Stable consistency
- Control is slow87
2010 04 / CGK
+ Fast control
- 1 flow meter more
White water system
2010 04 / CGK 88
White water system
Short circulation / Long circulation
2010 04 / CGK 89
Short circulation
General requirements
1. The short circulation should feed the headbox with a flow that
is :
- Free from pressure / flow variations ( pulsations )
- Free from consistency variations
To avoid basis weight variations
2. The approach flow should be as free from air as possible to
increase the de-watering speed and reduce bio activity
3. The headbox, wires and product should be protected from
debris, spinning and fiber bundles by appropriate machine
screening
2010 04 / CGK 90
White water system
Open system
Fresh water
- PM showers
- chemicals Evaporation
- sealing water
Pulp from stock prep
Paper
Headbox
5% 3% 1%
wire section
White water
Dilution for
headbox
2010 04 / CGK 91
White water system
Short circulation
Head box
1%
wire section
White water
Dilution for
headbox
Wire Pit
2010 04 / CGK 93
White water system
Short circulation – approach flow
2010 04 / CGK 94
White water system
PM Short circulation
2010 04 / CGK 95
White water system
Long circulation
Head box
5% 3% 1%
wire section
Recovered fibers
Dilution for
White water
Fiber recovery
headbox
Wire Pit
Clear filtrate
Suction box
water tank
2010 04 / CGK 97
White water system
Long circulation – stock preparation system
2010 04 / CGK 98