New instrument provide multiply

board property enhancements

Page 4835 PaperCon 2014

 Multiply board machine formation

•Formation of single ply has a direct impact on the formation of the entire board
•Dewatering can be optimized in order to achieve the best sheet properties
•Water distribution is a key-factor as far as water removal and energy consumption
•On-line monitoring of the ply consistency allows to optimize dewatering and obtain
specific setting by grade.

Page 4836 PaperCon 2014

Why measuring consistency in the forming
section ?
•For a precise evaluation of the dryness in the
forming section, to improve the energy
efficiency

•An accurate optimization of the vacuum in

the suction boxes, ensuring that it is not used
more vacuum than necessary

•A system to control immediately the effects of

the stock quality and slice setup

•To improve board quality and reduce energy

conumption

Page 4837 PaperCon 2014

 Monitoring process safely with
on-line diagnostic systems
The safety issue pushed Cristini Diagnostic Systems to develop not only portable devices,
but also on-line systems.

The logic of our planar microwave array sensors technology is typically oriented to the
easy integration into other elaborate systems (DCS-MCS-QCS)

DCS

Page 4838 PaperCon 2014

Planar sensor microwave consistency reading
 er ’ +er ’’
MUT
 Mass
 Others

Forming Fabric
MW - IN MW - OUT

 Resonance (Fris) Foil

 Reflections/Losses Sensor
 Others

Page 4839 PaperCon 2014

 On-Line Microwave Consistency Meter

Control hub, sensors network

ethernet connection
• Up to 8 sensors connected
• 8 outputs 4 – 20 mA to DCS
• 1 ethernet T-base 100 to DCS/PC
• Easy navigation menu

Microwave sensor
• 5 – 50.000 gsm reading range
 (0,005 – 50 mm water thickness)
• 3 – 1024 samples per sec
• 0,01 % accuracy
• Stainelss steel AISI 316
• Ceramic foil cover

Page 4840 PaperCon 2014 -6-

 Instrument advantages
• Patented principle to automatically compensate the water charge changes,
insensitivity to chemicals, best accuracy on any application.
• Harmless microwaves instead of radioactive sources to obtain the
measurements. No radioactive hazard to the operator.
• Improved reading reliability and repeatability.
• Reading range up to 50.000gr/m2 of water (50mm); the sensors can be applied
from tissue paper to pulp.
• Software package for the detection of stock pulsation ( FFT analysis)

Page 4841 PaperCon 2014

 Board formation vs consistency at bonding
Dewatering distribution on each single ply has a direct impact on board quality properties.
Water distribution through the board has a direct impact on quality properties and specific
energy consumption.
Ideal condition at bonding leads to better fibre cohesion and distribution.
Dryness %
11,0%

16,8%
2,8%
12,5%

16,4% 14,1% 8,9%

Page 4842 PaperCon 2014

 Dewatering optimization
It is quite familiar the unnecessary use of the vacuum at low consistemcy range ( from 1,5%
to 5%) which leads in many case to the phenomenon of “sheet sealing”.
A fast dewatering in the low vaccum area result in many cases in poor dewatering
efficiency at the suction boxes.

Reference condition Optimized conditions

Poor dewatering High dewatering Regular dewatering

Page 4843 PaperCon 2014

 Case studies summary
1st: energy saving on a multi-ply coated board machine

2nd : energy saving and formation improvements on a kraft-liner machine

3rd : ply-bonding property enanchments on a test-liner machine

4rd : compressive strength improvement and energy saving on a test liner machine

5th : compressive strength improvement and energy saving on a test-liner machine

Page 4844 PaperCon 2014

 Energy saving on a multi-ply coated board
machine
• Test focused on the dewatering of the middle ply
• Reference sensors: after the top former and before wire suction roll on back ply

Trial: Vacuum reduction of 40% on the top former

Results:
• Stable dryness before couch roll
• Reduced consistency on filler ply of 2%
• Reduced steam consumption (4%)
• Total drive load saving :157 A
8

1
1 f
1
0
9

6 5 4 3 2 1
7

Page 4845 PaperCon 2014

 Energy saving ( drives)

Motors spec.

Top former (9): 132 KWh 240 A

06: 45 Kwh 80 A
07: 200 KWh 340 A
08: 200 KWh 340 A

Page 4846 PaperCon 2014

 Payback period less than 6 months
• Thanks to the sensor on the filler ply ,operators can set the proper vacuum on the
top former, defining a range of consistency that are suitable for each single board
production
• Sensor at couch roll control the global dewatering performance of the forming section.
ensuring that the board enters the press section with the best dryness possible

reduced steam consumption

best dryness on forming
Reduced drive consumption

Lower specific energy

consumption

Page 4847 PaperCon 2014

 Energy saving and formation improvements on a
kraft-liner machine
Test focused on the dewatering of the back ply
Reference sensors: before bonding and before wire suction roll

• Consistency at III sector of the Top former from 10%

to 4%!!
•Lower dewatering on the II and III top sector .
•Decreased consistency at Ply bond ( about 2%)
•Increased dewatering on high vacuum area
•Constant dryness at couch roll
•Stable steam consumption

Page 4848 PaperCon 2014

 Energy saving thanks to an optimal vacuum
setting
• One blower ( Low vac. Bottom wire) turned off( 55 KW)
•Reduced torque of drive roll from 65% to 50% ( 110 KW saving)
•Reduced torque of Couch roll from 72% to 56% ( 115 KW saving)
•Reduced torque of Top former from 50% to 39% ( 35 KW saving)
•Reduced torque on vacuum Pump ( top former II and III sector) from 60% to 40%

Page 4849 PaperCon 2014

Quality enhancement ( formation and
compressive strength)

Page 4850 PaperCon 2014

Ply-bonding property enhancements on a test-
liner machine

Page 4851 PaperCon 2014

 Ply-bonding property enhancements on a test-
liner machine
Test focused on the dewatering of all ply
Reference sensors: before bonding on each ply and before wire suction roll

• Vacuum reduction in Trial

all ply except low
vacuum of filler ply
• Stable consistency
before couch roll
• Stable steam
consumption
• Reduced consistency
at bonding on filler
and bottom ply

Page 4852 PaperCon 2014

 Quality enhancement and energy saving
• Thanks to the sensor on the filler ply ,operators can set the proper vacuum on the
top former, in order to achieve the best board quality
• Sensor at couch roll control the global dewatering performance of the forming section.

Improved
bonding
Dewatering
optimization
Reduced drive
consumption
c c

Page 4853 PaperCon 2014

Compressive strength improvement and energy
saving on a test liner machine
Test focused on the dewatering of the back ply
Reference sensors: before bonding and before wire suction roll

A lower consistency before the top former

result in a better distribution of the fibres and
fines in the z-direction.

Page 4854 PaperCon 2014

 Dewatering opmization

Consistency at
CR % Steam presure
bar

Cons. Before
top %

VF vacuum reduction SB vacuum reduction

Page 4855 PaperCon 2014

 Quality enhancement and energy saving
• Thanks to the sensor on the back ply ,operators can set the proper vacuum on the
vacuum foils and top former, in order to achieve the best board quality
• Sensor at couch roll control the global dewatering performance of the forming section.

Dewatering Improved
optimization strength +10%

Page 4856 PaperCon 2014

Compressive strength improvement and energy
saving on a gap former

A lower consistency before the bonding, as

result of important vacuum reduction in the
gap former, result in a better distribution of
the fibres and fines in the z-direction.

Page 4857 PaperCon 2014

 Vacuum reduction
Vacuum reduction of 50% on the gap former (from 190 mbar to 80 mbar)

Page 4858 PaperCon 2014

 Quality enhancement and energy saving
• Thanks to the sensor on the filler ply ,operators can set the proper vacuum on the
top former, in order to achieve the best board quality
• Sensor at couch roll control the global dewatering performance of the forming section.

+5% burst index

Improved +10% SCT index
strenght +10% TSI index
Dewatering
optimization
Reduced drive
consumption
c c

Page 4859 PaperCon 2014

 Energy saving
On-line FiberScanFix
measurement

Dewatering optimization through specific setting

Drive and pumps Steam consumption Property enhancement

consumption reduction reduction

Reduction of greenhouse
gas emission

Page 4860 PaperCon 2014

Thank you for your attention

Page 4861 PaperCon 2014