Drying Technology

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Drying of paper: A review 2000–2018

Stig Stenström

To cite this article: Stig Stenström (2020) Drying of paper: A review 2000–2018, Drying
Technology, 38:7, 825-845, DOI: 10.1080/07373937.2019.1596949

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DRYING TECHNOLOGY
2020, VOL. 38, NO. 7, 825–845
https://doi.org/10.1080/07373937.2019.1596949

Drying of paper: A review 2000–2018

€m
Stig Stenstro
Department of Chemical Engineering, Lund University, Lund, Sweden

ABSTRACT ARTICLE HISTORY

Drying of paper during 2000–2018 is reviewed. The review includes new drying processes, Received 11 February 2019
multi-cylinder dryers, tissue and impingement drying, TAD-drying, infrared drying and Revised 14 March 2019
energy use for drying of paper. It includes general aspects of infrared dryers but not drying Accepted 14 March 2019
of coated papers. Paper quality aspects, paper shrinkage and paper isotherms are not
KEYWORDS
included. Impingement drying has been the most successful new technology with several Review; drying; paper
applications while others such as impulse drying has not been commercialized mainly due
to problems with paper quality parameters. One promising development is the introduction
of steel instead of cast iron cylinders with increased heat transfer reducing the number of
cylinders. Future research should focus on modeling the internal transport phenomena and
to couple these phenomena to paper shrinkage and quality parameters. The influence of
the fabric for the drying process needs more attention, understanding the drying process
for new components such as microfibrillar cellulose in the stock and reducing energy use
and increasing the amount of renewable energies for drying of paper.

Introduction number of different designs have been proposed. Convac

Worldwide about 410 million tons of paper were pro-
duced 2016[1] and notwithstanding the internet era is still
increasing year by year. Drying of the paper (printing
paper, board, and tissue) is a major step on the paper
producing machine requiring large amounts of energy
and setting high demands on the quality for the produced
paper grades. In small countries such as Sweden and
Finland, the pulp and paper processes have a large share
of the national economy and new developments are sup-
ported by national research funds. The multi-cylinder
dryer is a large body of cast iron cylinders typically over
100 m long, and there are many incentives for reducing
the length, increasing the speed and controlling all the
different paper quality parameters. This review will cover
the developments that have taken place in different paper
drying technologies during 2000–2018.
Mujumdar published an early review about develop-
ments in the paper drying area.[2] The review mentioned
through drying, impingement drying and combinations of
mechanical and thermal dewatering-drying of the paper
web such as the Convac process as possible future indus-
trial applications. Impingement drying has been a topic of
considerable research during the years and a quite large
drying, later called the Condebelt process, has resulted in
two industrial installations. Wedel[3] discussed different
process configurations of the traditional multi-cylinder
dryer as well as the possibilities with hot air impingement.
Cross-directional shrinkage was mentioned as one chal-
lenge to achieve an even quality of the paper produced.
Pikulik and Poirier[4] in their review mainly focused on
the high intensity dryer concept which is based on
impingement drying on large diameter Yankee cylinders.
The series Papermaking Science and Technology devotes
book number 9[5] to different paper drying aspects such as
the multi-cylinder and other paper drying processes,
steam and condensate systems, paper quality, and automa-
tion aspects for the dryers and should be consulted for
information. A good chapter about drying of pulp and
paper is also given by Polat and Mujumdar.[6]
This review will cover published papers related to
paper drying technologies from scientific journals and
conferences during 2000 and 2018. The review
includes new drying processes, multi-cylinder dryers,
tissue, and impingement drying, TAD-drying, infrared
drying and energy use for drying of paper. It will not
include mechanical dewatering in the press section

CONTACT Stig Stenstr€ om stig.stenstrom@chemeng.lth.se

Color versions of one or more of the figures in the article can be found online at www.tandfonline.com/ldrt.
ß 2019 The Author(s). Published with license by Taylor & Francis Group, LLC
This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives License (http://creativecommons.org/licenses/by-
nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is properly cited, and is not altered, transformed,
or built upon in any way.
826 €
S. STENSTROM
Figure 1. Tending side of a gas heated drying cylinder in the
US [14] (courtesy of Andritz Canada).
even if some processes such as impulse drying
includes such phenomena as well. It will include gen-
eral aspects of infrared dryers but not include drying
of coated papers, paper quality aspects and paper iso-
therms. The reason for this is to limit the number of
papers reviewed.
The technology for drying of pulp has not changed
drastically during this period. The main development
has been the introduction of two shoe presses to
increase the dry matter content to around 50% before
the pulp dryer. For this reason only a few publications
related to the drying of pulp has been published dur-
ing this period. Strømmen et al.[7] studied heat pump
drying in a fluidized bed dryer and Vieira et al.[8]
studied drying kinetics for recycled paper pulp. The
best summary for drying of pulp is given by Larsson
and Karlsson in Papermaking Science and
Technology.[9]
New drying processes
Condebelt
The Condebelt process was developed by Prof. Jukka
Lehtinen and the first patent was issued already in
1975.[10,11] The idea is based on a heat pipe mechan-
ism to achieve high drying rates and at the same
improve several paper quality parameters such as
surface smoothness, density, and Scott Bond values.
The first industrial plant was started at the
Pankakoski mill in Finland during 1996 and the
second plant at the Dong Il mil in South Korea dur-
ing 1999. The machines produce cardboard, liner-
board, and fluting paper qualities. The machine in
Finland is still in operation but due to change in own-
ership the machine in Korea will be taken out of pro-
duction during 2019. Timofeev et al.[12] used an
experimental set-up to investigate different process
parameters for the process. Temperatures inside a
multi-layered sheet ranged between 100 and up to
160
C for a hot plate temperature of 170
C. Drying
rates were 6–8 times higher compared to the multi-
cylinder dryer. Clearly the motivation for this process
is the large improvements in different paper strength
parameters as well as the increased drying rates. The
drawbacks are a rather complicated and expensive
design involving moving steel bands at high velocities.
A review of Condebelt, impingement, and impulse
drying was presented by Talja et al.[13] from the
Metso company, presently the Valmet company.
Gas heated cylinder
Internally gas-heated cylinder dryers were developed
during the 1980s by ABB in Canada and later the tech-
nology was sold to the Andritz company. There were 13
units installed in the US, Canada and Australia and
today at least 4 of the US dryers are in operation,[14]
one installation is shown in Figure 1. The idea is to
increase the surface temperature by firing natural gas
inside the cylinder either using an impingement design
or an infrared design. In this way, the heat flux to the
paper web increased resulting in drying rates 2–4 times
higher compared with steam-heated cylinders. Lang
et al.[15] performed lab-scale experiments to study drying
rates and changes in paper quality parameters. Using a
surface temperature of 290
C, the drying rate for a
newsprint paper could be increased by 3 times com-
pared to a surface temperature of 100
C. The gas com-
bustion and flue gases circulating unit is rather complex
and exiting flue gases at high temperatures could result
in lower energy efficiencies.
Impulse drying
The idea of impulse drying was initially developed
during the 1980s at IPC in Appleton and the develop-
ments then moved to IPST in Atlanta, Georgia. It was
said by one of the inventors that the idea came up
when a heated hammer head was hit against a wet

Figure 2. Delamination of the paper web (reprinted from[20], by permission from Tappi J.).
paper surface and it was found out that the paper
area hit by the head had dried very significantly.
Thus, the idea was to use temperatures in the range
250–450
C, pressures 2–10 MPa and a very short resi-
dence times such as could be achieved in an extended
press nip. Significant resources were spent on develop-
ing this technology among universities,[16,17] research
institutes in Atlanta and Stockholm[18,19] and machine
building companies. One main challenge has been to
avoid delamination of the paper sheets, see Figure 2.
Two heated extended nips were built at the
EuroFEX pilot machine at Innventia in Stockholm
which could operate at industrial machine speeds on a
300 mm wide paper web. Nilsson and Stenstr€ om[21,22]
developed a model for the unsteady heat transfer in
the press nip and compared the results with lab-scale
experiments from an MTS-press[23] as well as the
EuroFEX pilot machine. The model only considered
conductive heat transfer in the web and did not
include compression of the web. Generally, the predic-
tions from the model were too low, for both the
MTS-press and the EuroFEX experiments, one result
from the MTS-press operating at a dwell time of
50 ms and a peak pressure of 8 MPa is shown in
Figure 3. The main explanation for the differences
was that no compression of the web was included.
Larsson and Orloff[24,25] performed experiments
with an MTS laboratory platen press with longer press
pulses in the range 32–64 ms. The moisture ratio
change increased from 0.6 to 0.8 kgwater/kgdry matter
when the press impulse was tripled. Also pilot-scale
experiments were performed by Larsson and
Stenstr€om[26,27] at STFI in Stockholm. The length of
industrial shoe-presses is limited to around 0.3 m so
this technology needs further development if residence
times longer than 30 ms are to be achieved for a web
moving at 10 m/s. Martinez et al.[28,29] studied dryness
and physical properties for a range of hot pressing
DRYING TECHNOLOGY 827
parameters in a laboratory platen press. The platen
press temperatures were in the range 23–380
C, resi-
dence times between 25 and 500 ms and peak pres-
sures 1–5 MPa. Either a positive or negative pressure
profile was studied in order to avoid delamination
phenomena and most of the experiments were per-
formed with a TMP furnish. As expected, the tem-
perature and the press impulse had a strong influence
on the amount of water removed, but no differences
were noted for different the shapes of the press pulse.
Riepen[30] developed a model for hot pressing proc-
esses and validated the model at a pilot paper machine
with press roll temperatures between 50
C and 235
C.
The agreement with the experimental data was good,
but the variation in the outgoing dryness of the web
was not large in the experiments. Aguilar Ribeiro and
Costa developed an extensive model that included densi-
fication of both the felt and the paper.[17,31–33] The pre-
diction for the felt compression was compared with
experimental data with fair agreement. Martin et al.[34]
evaluated data obtained from the EuroFEX machine in
Stockholm from an energy cost perspective and found
that the energy costs will increase by 5–20% due to the
use of more expensive electricity. However, the higher
energy costs were expected to be balanced by savings in
pulp costs and increased productivity.
Nilsson and Norman used a slightly different
approach with a thin metal band for transferring the
energy to the paper in the press nip.[35–37] The experi-
ments were performed in laboratory set-up where the
band was heated in a specially designed oven.
Dewatering was highest for the steel bands and below
a band thickness of 0.2 mm for steel and copper and
0.3 mm for aluminum the dewatering was reduced.
The idea with using bands is to limit the energy trans-
fer to the paper and thus reduce the problems with
flashing of steam at the nip exit causing delamination.
A 0.5 mm thick steel band could be heated to as high
828 €
S. STENSTROM
Figure 3. Comparison of experimental[23] and calculated data for an MTS-press.[21]
as 275
C without any detectable decrease in the z-dir-
ection strength of the paper as measured by the Scott-
Bond value. The backside of the band would need
some insulation to reduce heat losses and increase
energy efficiency for the process. The design using
bands for the energy transfer is similar to the
Condebelt approach and has been developed by
Valmet in the so-called soft calendering concept, see
Figure 4. The purpose here is not dewatering but to
improve the surface properties of the paper.
So far no industrial impulse drying processes have
been installed due to paper quality issues and using
electricity for heating to high temperatures which is
more expensive than the traditional low-pressure
steam in the multi-cylinder design.
Other new technologies
Drying using superheated steam is common for dry-
ing of beet pulp, wood particles, and bark.[38]
Research using this technology also for paper has
been performed by McCall and Douglas who studied
quality changes for the paper.[39] No industrial units
have been installed and one main challenge is to enter
the web in the superheated steam atmosphere without
entraining too much air. Also superheating the steam
requires rather high steam pressures which will reduce
the amount of backpressure power production at the
mill increasing the cost for the process.
Microwave drying is an attractive technology where
the energy is absorbed in the material where the water
is. The technology has also been tested for drying of
paper, Ahrens and Habeger[40,41] developed a model
for the applicator so that it can be designed for web
preheating and increased dewatering and drying.
Challenges to be addressed are the energy efficiency
of the microwave generator, high power levels are
required, electricity is normally more expensive than
steam and even distribution of the energy over the
machine width. To authors knowledge, there are no
industrial installations so far.
Pulsed combustion can be used to increase the heat
and mass transfer rates during impingement drying. Wu
et al.[42] performed both experiments and CFD calcula-
tions to study the technology. Two of the main conclu-
sions were that efficient drying extended up to three
diameters of the tail pipe and that near the stagnation
point heat transfer is governed by the impingement jet
flow while outside this region the impingement vortex is
of major importance. Patterson and Ahrens[43] and
Ahrens et al.[44] studied the process both experimentally
and by performing CFD calculations. The experiments
were performed with three different prototype combus-
tors; aerodynamic valve, pressurized combustion cham-
ber and a multifunctional system. The results showed
that the heat flux could be increased by 2.4 times com-
pared to a standard impingement system.
Multi-cylinder dryer
The multi-cylinder dryer is the standard dryer for dry-
ing of all kinds of paper, newsprint, printing papers,
linerboard, cardboard, and for the final drying of
coated paper qualities. It is estimated that about 90%
of the tonnage of papers produced are dried using the
multi-cylinder design. This cast iron design was
invented in the UK at the beginning of the 19th cen-
tury when it was running very slow and heated by
shoveling in coal on the one side and scraping out the
ash on the other side. Typical data today are a cylin-
der 1.5–2.1 m in diameter (5, 6, and 7 feet), up to
10 m wide and rotating with speeds up to 2000 m/
min. The number of steam-heated cylinders ranges
between 20 and 170 arranged in different configura-
tions. A modern machine which is to be started dur-
ing 2019 at the Gruv€ on Billerud mill in Sweden is

Figure 4. Metal belt calender (courtesy of Valmet).
Figure 5. First part of multi-cylinder dryer at the Gruv€on mill (courtesy of Voith GmbH & KGaA).
shown in Figure 5. The machine is producing board
and kraftliner and the dryer consists of 87 EvoDry
steel drying cylinders.
The main advantages are the robust design resulting in
small numbers of paper web breakages and thus a high
productivity, flexibility for different paper qualities and that
it is heated with low-pressure steam from the back-pressure
turbine at the mill. Some disadvantages being relatively low
drying rates resulting in a very long dryer section, large
amounts of metal to be heated and cooled resulting in slow
capacity or quality changes and that the secondary heat is
produced at a dew point of only 50–60
C. Despite this the
design is still the favored technology for new machines,
and it is not surprising that the majority of scientific papers
from this period deals with this design.
Cylinder design
The steam condenses on the inside of the cast iron
cylinder and at machine speeds of 2000 m/min the
DRYING TECHNOLOGY 829
centrifugal force on the condensate will be up 150 times
gravity resulting in a very stable and laminar condensate
layer. This laminar layer will drastically reduce the heat
flux to the paper and in spite of this importance, the
number of papers dealing with this problem is not large.
Stenstr€om et al.[45] studied the behavior of the conden-
sate film in a laboratory cylinder with a diameter of
0.283 m that could be equipped with spoiler bars, a tech-
nology used to favor condensate movement and
increased heat transfer coefficients. The water flow for a
centrifugal force of 60 times gravity and a water depth
of 2 mm is shown in Figure 6.
One conclusion from the project was to equip the
cylinders with axial flanges that can conduct the heat
through the condensate layer. Shin et al.[47] developed
a multi-port design essentially a double-walled cylin-
der with several flow channels and presented a heat
transfer coefficient of 16 kW/m2
C for the condensate
layer. This figure is around 10 times higher than for a
traditional design using spoiler bars.
830 €
S. STENSTROM
Figure 6. Water flow with for a water depth of 2 mm and a centrifugal force of 60 times gravity.[46]
Heat conduction through the cylinder shell with a
thickness of 25–32 mm is straightforward while the
energy transfer from the outer side of the cylinder to
the paper is more complex and depends on a number
of variables such as the contact pressure, the moisture
content and the composition of the paper and the sur-
face characteristics. This resistance is normally mod-
eled with a contact heat transfer coefficient often
being a function of the paper moisture content.
Milosavljevic et al.[46] performed measurements in a
pilot test rig and at a surface temperature of 120
C
the contact heat transfer coefficient was 1600 W/m2
C
at a moisture content of 50%. Timofeev et al.[48] per-
formed computer simulations of a paper dryer using
the contact heat transfer coefficient as the fitting par-
ameter and found good agreement with the experi-
mental data.[46] Increasing the fabric tension from 2
to 6 kN/m increased the contact coefficient by 12%.
Cameron and Tripathi[49] also performed measure-
ments in a laboratory dryer giving a contact heat
transfer coefficient of around 800 W/m2
C in the con-
stant rate period while for a dry paper it was only
around 100 W/m2
C. Noboa and Seyed-Yagoobi[50]
performed measurements for uncoated and coated
paper qualities. The increased contact conductance for
a coated paper was explained by the improved con-
formation to the heated surface. Berg and Berg[51]
performed detailed calculations of the heat transfer
between the heated surface and the paper and came to
the conclusion that control of the boundary layer
close to the cylinder is of importance for the contact
coefficient.
The tasks for the fabric is to support the paper dur-
ing the transport on and between the cylinders, achieve
a good contact between the paper and the cylinder sur-
face, aid ventilation in the pockets and drive the
cylinders. The felt covers the paper during a large part
of the drying process and acts as a resistance to mass
transfer from the paper to the ventilation air. Smrtnik
et al.[52] measured this resistance using the cup method
for eight different commercial felts resulting in mass
transfer coefficients between 0.004 and 0.011 m/s. Felts
are normally characterized with a permeability param-
eter and a good correlation was found between the
mass transfer coefficients and the permeabilities. The
measured data were used in a simulation program by
Smrtnik et al.[53–56] and showed that for a constant
machine capacity the energy recovery could be increased
from 43% to 73% for a fabric with a higher mass trans-
port coefficient. The temperature of the fabric also influ-
ences the drying process, a parameter which can have
potential for capacity increase in the paper dryer.
Milosavljevic et al.[57,58] investigated the drying behavior
of three felts with different of contact points and contact
area in a laboratory simulator. The results showed that
the number of contact points is more important than
the contact area.
One recent development during the last years has
been the introduction of steel instead of cast iron cyl-
inders in the dryer, the EvoDry design from Voith is
shown in Figure 7.
The advantage with steel is the higher tensile
strength resulting in a reduction of wall thickness,
typically from 31 to 20 mm for a 1.8 m cylinder. Also
the material has a higher thermal conductivity, both
of these things resulting in an improved heat transfer
reducing the number of drying cylinders.
Heat and mass transfer in the paper
Understanding the internal heat and mass transport
phenomena are of course of utmost importance for

Figure 7. EvoDry steel drying cylinder (courtesy of Voith GmbH & KGaA).
calculations of the drying rate, the paper shrinkage
and the development of paper quality parameters.
Large efforts are thus spent on research in this area.
Ramarao et al. presented a very extensive summary of
moisture diffusion in paper materials.[59]
Permeabilities are important for pressure-driven trans-
port during high intensity processes in paper,
Lavrykov et al.[60] used X-ray microtomography to
determine permeabilities in the plane and in the
thickness direction. Thermal conductivities and spe-
cific heats were measured for a large range of copy
papers with different densities and ash contents by
Lavrykov and Ramarao.[61]
Baggerud developed a model for the heat and mass
transfer phenomena during drying of paper which
included both diffusive and convective fluxes and
shrinkage of the paper.[62–64] The calculations were
compared with good agreement with experimental
data, see Figure 8.
One interesting result was the description of the
paper shrinkage during the drying process using tri-
angular diagrams[65–67] which has been applied also to
other drying areas. The real drying process can be
compared with no and ideal shrinkage represented by
solid lines, one example is shown in Figure 9.
The analogy between heat and mass transfer is
needed to couple the external convective phenomena.
Nilsson[68] and Berg[69] compared models at different
dew points. Lu and Shen[70] developed a model
including convective and capillary transport of both
liquid and gas in the paper with good agreement to
experimental data. A similar model was developed by
Hoshi et al.[71] but did not include a comparison with
experimental data.
Askfelt et al.,[72] Alexandersson et al.[73] and
Alexandersson and Ristinmaa[74] developed a very
extensive model based on mixture theory for transport
DRYING TECHNOLOGY 831
in cellulose networks. The model was used to study
temperature and moisture changes during heating of
wet paperboard as well as moisture and temperature
dynamics for paperboard rolls. It is expected that
more results will appear in the near future for differ-
ent transport processes in paper.
Experimental data for the moisture distribution
during drying of paper are of high importance for
model development and fitting of adequate trans-
port parameters. Magnetic resonance imaging (MRI)
offers one possibility to acquire such data.[75–79]
Harding et al.[76] achieved a resolution of 15 lm
which was sufficient to follow the moisture gra-
dients in a cardboard during drying. Leisen
et al.[78,79] studied in moisture transport during dry-
ing of handsheets and paperboard using a 2 D MRI
set-up. Both in-plane and through plane moisture
transport were studied.
Dryer simulation models
Simulation models for the dryers are important
tools in order to design and optimize the multi-
cylinder dryer. Nissan and Hansen[80] were among
the first and they divided the cylinder into four
phases which were repeated for each cylinder in the
dryer. Today detailed calculations can be performed
as the paper moves through the dryer and several
computing tools have been developed. Karlsson
et al.[81–87] developed a dynamic model which could
simulate processes such as capacity and paper qual-
ity changes and incorporated in the control algo-
rithm for the dryer section. In this way, the time
required for a quality change can be significantly
reduced and the productivity on the machine
increased. Nilsson studied data for four industrial
paper dryers and developed a model for the drying
832 €
S. STENSTROM

Figure 8. Comparison of modelled and experimental paper temperatures.[64]

Figure 9. Volume fractions during paper drying and shrinkage shown in triangular diagrams[68]

process.[88,89] One interesting result was the intro-
duction of two dimensionless Nilsson numbers:
U Coumans and Ramakers[94] calculated the internal
NiE ¼
kconv qCPF
k
NiI ¼
De qCPF
which compare the heat to the mass diffusivities
for the external and internal processes.
Motta Lima et al.[90–92] performed both experimen-
tal and modeling work using the concept of general-
ized drying rate curves. Initially, the paper[90,91] was
not supported on the heated surface but later a dryer
felt was also added.[92] Good agreement was found
between the experimental and modeled data. Motta
Lima et al.[93] used Nissan and Hansen’s model[80]an
industrial paper dryer, some deviations were noticed
such as that the average paper temperature reached
above 120
C in the model.
(1) temperature, moisture, and pressure gradients in a
drying paper sheet. The calculated internal gas pres-
(2) sure reached 26 kPa over atmospheric pressure which
could lead to delamination of the sheet. Gardner[95]
developed a model without taking internal transport
phenomena into account which showed good agree-
ment between measured and calculated sheet average
moisture content. Ghodbanan et al.[96] developed a
model for a dryer on a corrugating paper machine.
No internal transport was included and the model
estimated the TAPPI drying rate with about an error
of 2%. Reardon et al.[97] presented the outlines of a
model which was used to study two newsprint dryers.
Sadeghi and Douglas[98] included internal transport in

Figure 10. Impingement dryer OptiDry vertical (courtesy of Valmet).
a model that was validated against 12 industrial
machines ranging from tissue to linerboard. The aver-
age error between the measured and calculated sheet
temperatures was only þ1
C. However, no details
were given about how the experimental average sheet
temperature was measured. More details about the
model are given by Sadeghi.[99]
Perre et al.[100] developed an extensive model for
the multi-cylinder dryer including infrared dryers but
no comparison with industrial data was presented.
Paltakari[101] studied internal temperature and mois-
ture profiles in an experimental set-up for both single-
and double-sided configurations. More details can be
found in[102]. Kong et al.[103] developed a model for
multi-cylinder dryer which included also the complex
condensate system and heat recovery from the humid
air. Good predictions were presented for both drying
rate and the energy use for the dryer.
Tissue and impingement drying
Tissue
Tissue is dried on one single large drying cylinder,
5–7 m in diameter, often called a Yankee cylinder.
The origin of the name Yankee is said to come from
a Dutchman called Yonke who was working with the
technology and when this technology was transferred
to the US the name became Yankee.[104] Energy for
the drying process is transferred from the inside by
condensing steam and on the outside by blowing
heated air or combustion gases at high velocities
against the paper surface. This completes the drying
DRYING TECHNOLOGY 833
process during transport 2/3 of a revolution on the
cylinder. Apart from developing higher temperatures
and impingement velocities, this technology has not
changed drastically. Nilsson et al.[105] studied the con-
sequences of a higher dew point in the hood and thus
improved possibilities for energy recovery and
Ottosson et al.[106] developed a mathematical model
for the process with good agreement between experi-
mental and calculated final moisture contents.
Impingement drying
Impingement drying is used in very many different
paper drying process; tissue drying, drying of coated
paper qualities, and in multi-cylinder dryers for
increased drying capacity. One recent vertical design
from Valmet is shown in Figure 10.
The local Nusselt number and thus the local heat
transfer coefficient are of high importance for the
impingement design and several authors have studied
these phenomena[107–111]. Shi et al.[107] and
Milosavljevic and Heikkil€a[108] obtained the Nusselt
numbers and the heat transfer coefficients by compu-
tational fluid dynamic calculations while Heikkil€a
et al.[109–111] used experimental techniques to obtain
their data. One advantage with the impingement dryer
over the multi-cylinder dryer is the possibility of rela-
tively rapid machine changes provided that the con-
trol loops are adequately equipped and properly
tuned. Kokko et al.[112] studied a multivariable control
and found faster response for the moisture content of
the paper especially if feedforward control from the
press section was used. Duran-Olivencia et al.[113]
834 €
S. STENSTROM
Figure 11. TAD Advantage Thru-AirVtechnology unit from Valmet with two TAD cylinders followed by one Yankee cylinder (photo
R
courtesy of Valmet).
developed a multifluid model for drying applications,
essentially based on the previous work by Asencio.[114]
The model was tested with good agreement against
impingement drying data.
Several advantages using the impingement dryer
are mentioned by the industry[115–118] such as that the
vertical design increases the capacity for a fixed floor
area, quick response enables faster grade changes and
possibility to balance evaporation from both sides of
the paper for a single-felted design.
Ker€anen[119] studied impingement drying for a
paper in contact with a hot surface and covered by a
fabric. Both drying results and paper quality parame-
ters were evaluated. Large increases in drying rates
were recorded for the combined impingement and
cylinder drying case. Hashemi et al.[120,121] studied
combinations of impingement and multi-cylinder dry-
ing and one important conclusion from the study was
that a good validated dryer simulator is important for
the future development of the processes. Paprican in
Canada has developed a new drying technique based
on using large diameter cylinders covered with a high
capacity impingement hood. The process is similar to
a Yankee design and was called the PapridryTM pro-
cess.[122–124] Clearly, the capacity could be increased
by replacing a number of multi-cylinders with this
design and especially for low-basis weights such as
newsprint the design would be attractive but to the
authors knowledge no industrial machines have been
installed. Liewkongsataporn et al.[125] studied impinge-
ment drying in combination with a pulsating jet and
achieved interesting results with up to doubled drying
rates compared without the jet. The main drawback
for the design is that the confinement plate has to be
located a few centimeters from the paper. Vieira and
Rocha[126] and Motta Lima et al.[127] performed con-
vective drying experiments for recycled paper and fil-
ter paper.
TAD—through air drying
The principle for the TAD-process is to draw heated
air through the sheet resulting in high heat and mass
transfer coefficients and also high drying rates. This
results in a product that has improved softness and a
higher water absorbency. The drying process starts
from a high moisture content of around 70% resulting
in the use of large amounts of energy for evaporation.
Also at high moisture content the pressure drop
through the paper and the fabric is significant result-
ing in high electrical energy costs for the fans. The
process is operated on one or two large diameter cyl-
inders with a perforated honeycomb structure, the
design from Valmet is shown in Figures 11 and 12. In
most cases, it is followed by a Yankee cylinder for
creping the product.
Most of the TAD plants have been installed in the
US and Canada and today about 10 plants are in
operation in Europe. Because of the high energy costs

Figure 12. TAD Tri-CellVHoneycombV roll from Valmet (photo courtesy of Valmet).
R R
for the process a hybrid technology is developed
where a structure is created using the traditional
Yankee process producing a paper with some of the
advantageous properties of the TAD-paper.
Weineisen et al.[128–134] performed both experimen-
tal and modeling work related to the TAD process.
Experimental work at industrial conditions for a tissue
paper of 20 g/m2 with a drying time less than one
second is challenging.[132] One result from the study
was that the exiting air was saturated at the adiabatic
saturation temperature for the basis weights 30 and
40 g/m2 but not for the lowest basis weight studied
20 g/m2 which was explained by-pass effects for the
lowest basis weight. A model based on a distribution
of pore sizes showed good agreement with these
experimental data.[133] The energy use was evaluated
for different process alternatives showing a thermal
energy demand of around 4800 kJ/kg of
water evaporated.
Ramaswamy et al.[135–141] also studied the TAD
process by performing experiments and developing
models for the flow and the heat and mass transfer.
The experiments were performed at air temperatures
below 35
C but the overall drying behavior was com-
parable with the results presented by Weineisen
et al..[132] One interesting result from the experiments
was the acquisition of data for the local variation of
temperature and velocity resulting in local non-uni-
formity of moisture.[138] Modeling work used a char-
acteristic dimension for the Forchheimer equation to
describe the flow through the paper dur-
ing drying.[141]
Tysen et al.[142–144] studied TAD in an equipment
where sheets 9  9 cm were dried using air at room
temperature. The drying process and the temperatures
were followed using an infrared camera and thermo-
couples. Variation in local grammage has a large
influence on the local air velocities and the surface
DRYING TECHNOLOGY 835
temperature was used as an indicator for the non-uni-
formity in drying.[143] The process was also studied by
adding infrared radiation to the sheet resulting in
reductions in drying time between 10% and 45%
depending on the sheet basis weight and radi-
ation power.
McGill University has also been active in develop-
ing the TAD technology.[145–150] Several studies were
focused on the variation in grammage and formation
that will lead to uneven flow through the sheet,
uneven drying and poor quality parameters. To quan-
tify this a drying nonuniformity index was developed
and measured for different parameters.[147,149] The
moisture content for TAD drying of a 6-ply 180 g/m2
sheet was studied by interrupting the drying and sepa-
rating the sheets.[148] Sack paper with a basis weight
of 100 g/m2 was dried in a TAD experimental rig but
with a high pressure drop of 8 kPa.[150] One conclu-
sion from these studies was that in order to imple-
ment the TAD process and avoid high-pressure drops
for drying of heavier grades would be to use the cylin-
der dryer for the first part of the drying and the
TAD-process for the final stages of drying.[145,146]
Etemoglu et al.[151] developed a model for drying of
paper with good agreement for TAD and impinge-
ment drying.
Infrared drying
Electrically and gas-heated infrared dryers are used
for drying of coated papers, profiling of the paper
web and for increased capacity in limited dryers. The
advantages compared to the multi-cylinder design are
high heat fluxes, absorption of radiation inside the
wet web and profiling possibility, while disadvantages
are the use of more expensive energy sources (electri-
city and gas) and a lower energy efficiency for the
units. One gas-heated design is shown in Figure 13.
836 €
S. STENSTROM
Figure 13. Gas-heated IR-dryer (photo by author).
Seyed-Yagoobi and Wirtz[152,153] and Seyed-
Yagoobi et al.[154,155] performed experiments and
developed a drying model for a gas heated unit. Pilot
machine data were well predicted using the theoretical
model. Seyed-Yagoobi and Husain[156] further studied
the absorption of radiation from a gas-heated unit
and came to the conclusion that more data are needed
for the optical properties of different papers. Seyed-
Yagoobi and Noboa[157] used a model to investigate
the optimum location of two opposing gas-heated
emitters, the conclusion was that for this specific case
the best location for maximum speed increase was at
the end of the multi-cylinder dryer. The electrical and
gas-heated emitters have different spectral characteris-
tics which will influence absorption and transport
phenomena, Seyed-Yagoobi and Noboa.[158] In this
case, the heat flux from the electrical emitter was sig-
nificantly higher making a comparison difficult.
Energy use
Energy use for drying of paper is a very important
issue due to the large amounts used, increasing energy
costs and the drive to change from fossil to renewable
resources. In a country like Sweden with a large pulp
and paper sector, the energy used for drying of these
products is estimated to be about 20% of the total
industrial energy use. The multi-cylinder design domi-
nates for drying of paper and the main part of the
supplied energy comes from low-pressure steam. The
low-pressure steam is produced by burning lignin and
hemicelluloses in the recovery boiler followed by elec-
tricity production in the back-pressure turbine. The
specific energy use for a modern energy optimized
design is around 3000 kJ/kg evaporated water and this
figure cannot be lowered very much with existing
technology. Instead improved energy efficiency should
be aiming at increased mechanical dewatering in the
press section and increased waste heat recovery from
the exhaust moist air. As was mentioned earlier,
heated shoe presses such as impulse drying, has how-
ever not been a way forward for increased dewatering
due to paper quality issues. For a modern machine
60–70% percent of the supplied energy is recovered
from the wet exhaust air and potential exist for fur-
ther recovery, however at low temperatures below
50
C. Possibly part of it can be delivered to nearby
district heating networks. Increasing the solid content
in sizing solutions will also contribute to a lower
energy use for the total paper machine.
Heat recovery from the humid exhaust air to heat
the ingoing air, the process water and the circulation
water system was studied by Sivill et al.[159] using a
simulation program. The results were compared with
three industrial machines. By increasing the exhaust
air humidity the heat recovery could be increased by
300–1000 kW. Pettersson and S€ oderman[160] also used
mathematical methods to study how variations in the
parameters could be accounted for to arrive at an
optimal heat recovery system. Roonprasang[161] devel-
oped a model for the multi-cylinder dryer with the
goal to reduce the energy use but no direct industrial
results were presented.
The energy use for the drying section in Chinese
paper machine has been studied in a number of
papers.[162–167] Exergy analysis was use to increase
waste heat recovery reducing the energy use by
4.6%,[162] optimizing the process parameters for a
newsprint machine reduced steam consumption by
8%,[163] a detailed static model of the paper dryer
showed that the air supply temperature could be
reduced from 112 to 100
C resulting in a specific
heat reduction by 3.3%.[164] Chen et al.[165–167] per-
formed a similar detailed analysis of the dryer section

Figure 14. Number of publications reviewed per year 2000–2018.
showing that the total steam consumption for one
machine could be reduced from 1.82 to 1.50 ton of
steam per ton of water evaporated. One reason for
this rather large reduction is the high initial steam
consumption indicating a nonenergy optimized paper
dryer operation. By modifying a hood from semi-
closed to closed, Yin et al.[167] showed that the steam
consumption could be reduced by 12.9% and the
power consumption by 14.2% for a specific dryer.
Energy integration between different inlet and out-
let air streams in the dryer and other streams at the
mill is important and Lindell developed a modeling
tool in order to study this with wet exhaust air from
the hood, gas-fired hoods used for drying of tissue
and impingement drying.[168–171] Syngas from a gasifi-
cation plant can be connected directly to the hood of
a Yankee dryer or first used for electricity production
in a gas turbine and then the flue gases fed to the
Yankee dryer.[170] A system using gas-heated impinge-
ment drying in combination with the traditional mul-
ticylinder dryer has higher energy costs compared
with only using a traditional multicylinder design due
to the higher cost for the natural gas compared with
bark for the steam boilers.[171]
Exhaust from impingement dryers offers good
opportunities for energy integration and energy saving
measures. Hyt€ onen and Puumalainen[172] proposed
using an energy balance simulator for such studies
and Di Marco et al.[173] used detailed mass- and
energy balances showing that energy savings of 4.5%
DRYING TECHNOLOGY 837
should be possible. Laurijssen et al.[174] showed that
by increasing the dew point, increasing the process
water temperature to 55
C and increasing the starch
solid content from 8% to 30%, energy savings of 32%
could be accomplished. Efficient control is also very
important for a good energy efficiency, startup times
and quality changes should be minimized and process
changes controlled. Bhutani et al.[175] developed an
energy fingerprint solution indicating that steam sav-
ings of 10–15% should be possible.
Thermodynamic analysis has also been used to ana-
lyze and optimize the paper drying processes with sev-
eral advantages over traditional mass- and energy
balances. Dincer and Sahin[176] suggested using exergy
efficiency to analyze drying processes. Zvolinschi
et al.[177] and Koper et al.[178] used entropy produc-
tion for optimizing the paper dryer and one conclu-
sion was that the inlet air humidity should be
increased to reduce entropy production[177].
Conclusions and future work
The multicylinder design has not undergone drastic
changes during these 20 years, perhaps use of
impingement dryers for increased capacity and control
of paper quality and the new steel cylinders are two of
the most important developments. The scientific activ-
ity in this area was much higher during the first half
of this period, the number of papers reviewed here
per year is shown in Figure 14.
838 €
S. STENSTROM
One explanation for this decline can be that several
research groups in Sweden, Canada, and the US are not
active any more, another that the introduction of new
technological developments has been limited reducing
the industrial interest for research in this area.
However, several topics should need attention. The
fabric is often neglected from a drying point of view.
The temperature of the fabric also influences the dry-
ing process and impingement of the fabric has a sig-
nificant effect on the drying behavior. Transfer of heat
between the cylinder and the paper is normally mod-
eled using a contact coefficient, a concept that should
be replaced by a more physically based description.
Despite numerous attempts to model the internal
transport phenomena, more work is needed to couple
these phenomena to paper shrinkage and quality
parameters. Magnetic resonance imaging offers one
possibility to measure moisture gradients at high reso-
lution in time and space at realistic drying rates.
The biggest issue for the paper producing companies
is to achieve the right quality and an even quality across
the width and the length of the paper roll. Overdrying
on the edges tends and shrinkage in the free draws are
difficult to avoid. Machine-glazed paper (MG-paper) is
produced using a multicylinder dryer in combination
with a large Yankee-cylinder in the middle of the dryer.
Previously, the development was towards replacing the
Yankee-cylinder with a calendar design after the dryer
but during the last years several new MG-machines
have been built in Europe. Incorporating new materials
such as microfibrillar cellulose in the stock could be a
challenge for the existing paper dryer.
For an integrated mill, the multicylinder dryer is
mainly based on renewable energy from the recovery
boiler but impingement and Yankee dryers sometimes
use large amounts of natural gas or liquefied petroleum
gas. In this case, the companies are looking for biogas
as a replacement. Old machines are not designed for the
same energy efficiency and large improvements can
often be achieved when analyzing these units.
An interesting collaboration between industry and
academia has recently been established by Yagoobi in
the US,[179] Center for Advanced Research in Drying
(CARD). The center is coordinated from Worcester
Polytechnic Institute and University of Illinois and it
is expected that interesting results will emerge from
this collaboration.
Acknowledgments
The companies Andritz, Voith and Valmet are greatly
acknowledged for providing the pictures of the indus-
trial units.
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