HEE Chip Quality Chipper design and operation for optimum chip quality Nils Hartler For the conventional disc chipper with the main force parallel o the fiber axis, the _feeding of the log through the chipper is critical not only to uniformity but also 10 ‘splitting and compression damage. Chip quality Chip quality can be assessed by measuring a suitable combination of chip properties. Taking into account the different processes and machinery used in pulp production Tines, it is not easy to reach a well-balanced and complete combination. The properties listed in Table I represent a compromise. Our ideal chips are as uniform as possible in length (standard deviation 5 mm or less) with an average length of 20-25 mm. Few chips are thinner than 2 mm or thicker than 8 mm, The lower limit is critical because of its relationship to mechanical instability; the upper is related jpregnation difficulties, particularly in alkaline cook- ing. The limit is less critical if there are more cracks in the wood. Tdeal chips also have a small oversized fraction and few fines and pins. They pack well and have a chip density that rarely varies with a frequency of less than 1 h. They also have a minimum of chip damage, particularly when they are intended for use in acidie cooking processes. Disc chipper with the main force parallel to the fiber axis General ‘The most commonly used chipper has a plain dise (or a slightly helical one in the case of the Norman chipper) with ‘a number of radially positioned knives. Here, for simplic- the projection of the log on the disc is taken to be either vertical or horizontal. The knife position is shown in relation to the log as a vertical seetion in Fig. 1, where we see the three most important angles—the spout, the clear- ance, and the sharpness angles. Indrop feed, the spout is practically always positioned on the dise as indicated at Point A in Fig. 2, whereas with a horizontal feed there are two possible positions, either above the shaft at Point B or below theshaft at Point. The knives are sometimes positioned with some deviation from the radius, also called “sweep back,” as shown in Fig. 3. Nils Harter is a professor, Royal Institute of Technology, $-100 44 Stockholm, Sweden. 62 october 1986 Tappi journal Feeding to the machine With the horizontal spout, a more well-defined approach can bearranged. Thatis, the log axis ean be kept parallel to the spout axis, and the log speed can be kept equal to the feeding speed through the chipper. A correct angle is obviously an advantage, and Fig. 4 indicates that a correct speed is also advantageous. ‘Thenext question is whether the logs should be introduced one by one or in bundles. The advantages of chipping a bundle of logs instead of single logs are that (a) the logs fill through the machine and (b) the machine capacity is ‘consequently more fully utilized. The drawbacks are that (a)amore complicated arrangements needed on the input side for the grouping and (b) ahigher electrical motor load is needed for chipping bundles of logs. The upshot is that with current design, single log chipping is the best strategy. But, provided that the modifications for controlling for correct angle and speed are made, chipping bundle by bundle would be advisable. ‘An uncontrolled situation with several logs entering ‘together is not recommended, because the logs often disturb each other and prohibit ideal feeding. Feeding through the machine ‘The force that pulls the log through the chipper is exerted by the front surface of the knife. Counteracting forces are the friction force (mainly from the spout) and the reaction force from the back of the knife (small if there is enough clearance) or from the wear plates of the dise. Let us consider three cases. In the first case (Fig. 5), the clearance angle is not large enough, and this leads to too short a movement and consequently to chips that are too short. A high reaction force from the back surface of the knife (exerting a ‘compression action on the wood) results in chip damage even in the “undamaged” half of the chip. The reaction force can occasionally effect bouncing of the log. ‘The next case (Fig. 6) represents an “ideal” case, when the movement of the log between two adjacent knives is just sufficient to bring the log up to the dise in the correct position prior tothe next cut. The movement is continuous, as shown in the upper part of the figure. The clearance— ———— 44. Relationships between undersize fractions and distance be- tween knife and becknife edges using normal and controlled Chip properties Property ‘Measure by: Target) tion (i). Length Hand-sorting Unitormity Thickness Slot screening Notailintheis- Ee tribution above | | 8mm : ‘Oversized chips Hole screening Low 5 Undersized chips 5 ot (bins and fines) Special nole sereening Low 3 Density Volume after standard Low variation & filing conditions and s dry weight 8 Mechanical Increase in small-sized High & | normal teeding stability fractions 3 Chip damage Sulfite cooking and Low for acid 5 evaluation through sulfite, ess im- t paper strength portant for alkaline pro- DISTANCE, mm cesses, Pin chips. Controlled feeding 3emm undersize traction feeding, where controlled feeding means correct speed and diroo- « Vertical section through the log in @ ‘drop feed spout with the 4 most important angles. The complementary angle is equal to 90° minus the sum of the other three. 2. Alternative spout locations in relation to € clockwise rotating disc. Drop feed occurs. at A, and horizontal feed occurs above the shaft at B or below the shatt at C. —_——_______L 3. Chipper discwith kniveshavinga"sweep back” deviation from the radius. 4, Complementary angle, Sharpness angle, 8 'S. Toosmallaclearance angle resulting in insufficient feeding. The dotted curve repre- sents occasionally observed bouncing, 6. “Ideal” clearance angle resulting 1h “idea!” feeding. ing. 7. Normal clearance angle resulting inac- ccelerations, retardations, and stepwise feed fength + Time between knives Nominat Sin iengin 1 Time between knives Nominal chip. fength LOG MOVEMENT IN LENGTH DIRECTION TIME LOG MOVEMENT IN LENGTH DIRECTION LOG MOVEMENT IN LENGTH DIRECTION TIME October 1986 Tappijounal 63angle is somewhat larger, and the compressive action from the back surface of the knife is smaller, so small that the surface region of the undamaged half normally stays undamaged. In the third case (Fig. 7), the inward movement is quicker: the log hits the wear plate of the disc, where it is retarded until the next cut. This means a larger clearance angle and consequently an even smaller compressive action from the back of the knife on the wood. In fact, when the log is pressed against the disc, there will be no compressive action at all from the back of the knife. Instead, a reaction force from the dise will act on part of the newly cut surface of the log. The movement will be discontinuous, as shown in the upper part of the figure. Case 3 represents the common arrangement in a dise chipper. ‘The distance between adjacent knives increases toward the dise periphery, so the clearance angle should also decrease toward the periphery. The dise design that incorporates this principle is the Norman design, with twisted knives and with wear plates between the knives, ‘The wear plates support the whole cut surface as it slides from one knife to the next. The compressive force is distributed over a larger surface, and the stress is lower. ‘This design represents the most ideal case. To achieve the necessary pulling force, a large enough clearance angle (often called the “pulling angle”) is essen- tial, but the knives must also be sharpened well. ‘Tanget settings of some of the more important angles The first targetsetting is the protruding of the knives from the dise, found by multiplying the nominal chip length by the sine of the spout angle. A correct setting of all the kknives in combination with correct position and angle for the log prior to the next cut will result in the best possible uniformity of chip length. The “ideal” clearance angle (Pig. 6) can be calculated in two ways, It is found by dividing the inverse tangent of the distance that 2 knife protrudes from the dise by the circumferential distance between adjacent knives at a radius corresponding to the center of the location on the dise of a “typical” log cross section. Alternatively, it ean be calculated by considering the vectors for the log and the knife edge speeds. By ‘compounding these and also considering the dynamic 'B. Solving for ne clearance angie by Con sideration ofthe vectors for the speedof the knife and for the speed of the log. 'B. Relationships between the undersize fraction (S-mm openings) and the ratio of chip length to thickness and the angle A. ‘10. Relationships betwoon the chip density land the chip damage and the spout angle @ Data from (1.2 _ 2 Fo 240)- Zz ees 3 Zz a 5 S = — 2 p Clearance 8 780 3 | E sao 3 E {20 | nate. Aa eae = a =e z 2 ™~ pee | 8 & os| 3 a 3 [6 * 2 3 5 so 10} 10 Speed 1 L 1 1 n of tog 10 20° 30 2 30 40 50 ‘COMPLEMENTARY ANGLE, ‘SPOUT ANGLE, degrees 11. Relationship between the undersize fractions for spruce logs and sawmill cuttings and the cutting speed (1). 12. Relationships between undersize chip fractions (3 mm) and cutting speed in mill scale trials (6) ‘CUTTING SPEED, mvs Pn 1 = 1 5 ef 5 St | E sol Logs oat amm s = 903 Sets ae z fe 885, 2 ie Am* Li 1 1 1 Z ee REVOLUTIONS, rpm \ 1 1 f 1 7 2 3 AVERAGE CUTTING SPEED, m/s 64 ocsober 1986 Tapp journalsituation, theclearance angle can be obtained, as shown in Fig.8. The other twoangles of importanceare the spout anglee and thesharpness angle of the knife 8. The chip quality as todimensions and chip density is mainly governed by the A angle, which is complementary to the sum of ¢, the clearance angle a, and 6. Thus if either « or 6 is changed, the effect on chip quality will be governed by A, provided that a is kept constant. Increasing 4 will change the load situation in chip formation from strictly shear at =Otoan increasing portion of cleavage. Furthermore, an increase in d results in thinner chips and a lower content of small- sized chips (Fig. 9). A decrease in the spout angle is consequently favorable for thin chips and the small-sized fraction but undesirable when it comes to chip density (Fig. 10), chip damage (Fig. 10), and the maximum diameter that can be processed; the smaller the spout angle, the larger the cut surface at the same diameter. The optimum spout angle therefore de- pends strongly on which chip property is of the greatest interest. Similarly, a decrease in sharpness angle is favorable, but the durability of sharpness is impaired as the angle gets smaller. A compromise is usually chosen somewhere between 30° and 35°; the larger the angle is, the more durable itis, Inthe last few years, new designs incorporating replace- able knife edges have appeared, like the Iggesund turn xnives for instance. Besides improved durability, such a design also promises a more precise positioning of the knife. A target cutting speed of 20-25 m/s is advisable. Higher speed gives higher production, but it also yields a “¥3, The reaction force Nom the Tom surface of the knife is resolved into com- Ponents. The component in the shearing plane is Ns. This vector forms an angle ¢ with aplane perpendicular to the fiber axis. Ta. Thenew designusing aplain disc and spout locatedat approximately one o'clock In relation to the clockwise rotating disc. high fraction of undersized chips. The effect of a decrease in speed is shown in Fig. 11, which emphasizes the* importance of setting the cutting speed low. Speeds that are too low can result in a tendency for the wood only to crack and not to split up fully in distinct pieces, which results in cakes of wood containing cracks. To counteract this, a special design on the frontside of the knives has been developed that helps to split up the chips. This is used in conjunction with a more gentle handling of the chips through so-called “side discharge” (3). ‘The effect of a decrease in speed as experienced in a temporary test arrangement as presented in Fig. 11 has been verified in an installation with variable motor speed in a full-scale chipper using a slip-ringed asynchronous motor (4). The results are presented in Fig. 12. In addition to these target settings, the parameter in question must be adjusted to its set value with precision. This has already been pointed out for chip length with regard to the distance that the knife protrudes. In addition, the wear plates have to be renewed in time because of their gradual wear. Furthermore, each knife edge must be adjusted to a distance of 1 mm from the bed knife with the greatest possible precision. The effect of too large a distance is demonstrated in Fig. 4. New chipping concepts Chippers with the main force perpendicular to the fiber axis A new chipping principle was introduced some 20 years ‘ago (6) based on the following considerations: TE. Rolationship betwoon chip damage. (decrease in paper strength in relation to laboratory chips for corresponding un- bleached acid bisulfite pulps) and spout angle for a pilot plant chipper having the main force largely perpendicular to the fiber axis, Data from (6) " SCRE CHIP DAMAGE, T tee L 102030 40 SPOUT ANGLE, degrees October 1996 Tappijournst 65,‘+ Wood shows approximately 65% lower shear strength when the force is applied perpendicular than when it, is applied parallel to the fiber axis. From a pulp quality viewpoint, wood is much less sensitive to compressive plastic deformations when the force is applied perpendicular rather than paral- Tel to the fiber axis, Forces strong enough to feed the log through the chipper ought to be achieved by having only asmall component of the pulling force ofthe knife parallel to the fiber axis, This led me to a design with the knife cutting in such a way that the component in the shearing plane of the reaction force (Nj in Fig. 18) forms an angle of about 20° with a plane perpendicular to the fiber axis. The pilot machine was designed using a plain dise with radially oriented knives. The log was fed through a drop feed (without side angle) and with a location in relation to the dise corresponding to approximately one o'clock (clock- wise rotation of the dise), as shown in Fig. 14. The chip forms rhombi, while the form is rectangular for conven- tional chips. The new chips are some 40% thinner than conventional chips, and their bulk density is lower. The chip damage was lower, as seen in Fig. 15. With a spout angle of 25-30", the chip damage is reduced by about 50%. ‘A ull-seale version based on this principle wasmanufac- tured by the Soderhamn company having conventional knives on the envelope of a double cone as seen in Fig. 16. ‘The logs were fed horizontally somewhat below the apex of the cones and with the log axis perpendicular to the cone axis, Operational experience with this chipper has been favorable. First, the time between knife sharpenings was prolonged, indicating less wear on the knives, In keeping with this observation, a much lower temperature of a knife inoperation was also noticed. Second, although the pulling force was by design much lower, the feeding of the logs was excellent even with frozen hardwood logs. Third, high- density hardwoods that show rapid wear and feeding problems in conventional chippers can be chipped in this 16. A full-scale chipper according to the ‘new principle with knives on the envelope ff a double cone and horizontal feeding perpendicular to the cone axis somewhat below the cone apex (7). i 9 machine with much less difficulty. ‘Testing of thenew chipper within the Weyerhaeuser Co. revealed a 1-2% higher yield in sulfite pulping (8). Separate knife edges for length and for thickness a To(a) control the length and the thickness separately and (b) achieve chip formation mainly through cleavage with much less stresses involved, some different new designs have been tried, like the drum chipper (9), the HP-chipper (10), and the axial waferizer from Domtar. One knife edge cleaves parallel to but moves perpen- dicular to the fiber axis, and another knife edge moves and cuts perpendicular to the fiber axis (Fig. 17). The first knife edge determines the thickness, and the second determines the chip length. ‘None of these designs has been commercially successful, although they showed much promise from a chip-quality pointof view. The HP-chipper produced chips with practi- cally nochips thicker than the set point 8 mm. Thisis what weare ideally looking for, to have homogeneous delignifica- tion in kraft cooking. Unfortunately the HP-chipper pro- duced large quantities of pins and undersized chips, which isa major drawback for this type of chipper. Literature cited |. Hartler, N.and Stade, Y., Svensk Papperstid. 80: 447(1977). . Hartler, N., Svensk Papperstid. 65: 851(1962). . Ake Svensson, KMW, Sweden, private communication. Karl Aberg, ASEA, Sweden, private communication. Sture Backhind, SCA, Sweden, private communication . Harte, N., Svensk Papperstid. 66: 650(1963). Hartler, N., Svensk Papperstid. 68: 618(1965), Filler, WS, Weyerhaeuser, Tacoma, Wash. privatecommuni- cation. . Logan, K.G., Sepal, O..K.,Chollet, J.C. and Liltle, TB, Pulp Paper Mag. Can, 61: T515(1960), 10. Svensk Papperstid. 68: 5(1965) ‘Received for review Feb. 14,1986. Accepted May 1, 1988 17. One knife edge cleaves parallel to the fiber axis and defines the chip thickness, and ‘another edge cuts perpendicular to the fiber axis and defines the chip length.