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Nordic Pulp & Paper Research Journal 2021; 36(1): 33–41

Mechanical pulping

Jan-Erik Berg*, Börje Hellstadius, Mikael Lundfors and Per Engstrand

Low-consistency refining of CTMP targeting high


strength and bulk: effect of filling pattern and trial
scale
https://doi.org/10.1515/npprj-2020-0061
Received June 17, 2020; accepted September 21, 2020; previously
Introduction
published online December 1, 2020
Chemithermomechanical pulp (CTMP) is often used in
Abstract: Chemithermomechanical pulp (CTMP) is often
central layers, as a mixture together with broke and soft-
used in central layers of multiply paperboards due to its
wood kraft pulp, of multiply paperboards due to its high
high bulk and strength. Such a CTMP should consist of
bulk and strength. The present study emanated from a
well-separated undamaged fibres with sufficient bonding
project where the key research challenge was to find ways
capacity. The basic objective of this work is to optimize pro-
to produce paperboards with higher bulk and with as good
cess conditions in low-consistency (LC) refining, i. e. to se-
strength properties as the standard material. The aim of
lect or ultimately develop new optimal LC refiner filling
the project was to find synergetic effects by joint stud-
patterns, in order to produce fibrillar fines and improve
ies in three different technology areas: chip refining, low
the separation of fibres from each other while preserving
consistency (LC) refining and fibre surface chemistry. In
the natural fibre morphology as much as possible. Further-
chip refining, the fibres should be well separated with
more, the aim is to evaluate if this type of work can be done
preserved stiffness. This is achieved if conditions affect-
at laboratory-scale or if it is necessary to run trials in pilot-
ing wood chip softening are optimized and refiner fillings
or mill-scale in order to get relevant answers. First stage
giving a favourable processing are utilized (Persson et al.
CTMP made from Norway spruce (Picea abies) was LC re-
fined in mill-, pilot- and laboratory-scale trials and with 2019). The present study is based on results from the LC re-
different filling patterns. The results show that an LR1 lab- fining technology area and its objective is to produce fib-
oratory refiner can favourably be used instead of larger re- rillar fines, improve fibre surface area and improve separa-
finers in order to characterize CTMP with regard to tensile tion of fibres from one another while preserving the fibre
index and z-strength versus bulk. A fine filling pattern re- stiffness as much as possible. This would be achieved by
sulted in CTMP with higher tensile index, z-strength and gentle mechanical treatment, i. e. low intensity refining of
energy efficiency at maintained bulk compared to a stan- the fibre surface. The strength of CTMP can then be fur-
dard filling pattern. ther improved by introducing cationic and anionic func-
tional groups together with an organic catalyst, enhancing
Keywords: bulk; filling patterns; low consistency refining; fibre-to-fibre adhesion (Alimohammadzadeh et al. 2019).
mechanical pulping; pulp strengths. The impact of possible improvements in the three technol-
ogy areas is modelled in a fourth parallel synergetic project
both with regard to process modifications and with regard
to material properties as strength and bulk. These models
are then validated by means of mill scale trials.
In a previous study, Rusu et al. (2011) found that
*Corresponding author: Jan-Erik Berg, Mid Sweden University,
internal fibrillation, i. e. kinks and micro-compressions,
FSCN, Department of Chemical Engineering, SE-851 70 Sundsvall,
Sweden, e-mail: jan-erik.berg@miun.se was decisive for fibre stiffness, as assessed by FiberMas-
Börje Hellstadius, BillerudKorsnäs, SE-801 81 Gävle, Sweden, ter bendability measurements (Karlsson et al. 1999). Their
e-mail: borje.hellstadius@billerudkorsnas.com finding was supported by the fact that the pulp with the
Mikael Lundfors, Valmet, Refiner Segments, Vretenvägen 11,
lowest specific refining energy (SRE) also was found to be
SE-171 54 Solna, Sweden, e-mail: mikael.lundfors@valmet.com
Per Engstrand, Mid Sweden University, FSCN, Department of
the stiffest. Pettersson et al. (2015) pointed out that fibre
Chemical Engineering, SE-851 70 Sundsvall, Sweden, e-mail: stiffness is important in achieving a bulky paper with suf-
per.engstrand@miun.se ficiently high strength, and that fibre length is less impor-

Open Access. © 2021 Berg et al., published by De Gruyter. This work is licensed under the Creative Commons Attribution 4.0 International
License.
34 | J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk

tant. They performed laboratory refining trials with CTMP, LC refining trials
of different freeness and fibre length, reinforced by kraft
pulp. Klinga et al. (2008) reported similar results from tri- Pilot
als with CTMP in pilot-scale refiners. Moreover, they found In October 2016, first stage CTMP was taken from Billerud-
that stiff fibres formed stronger bonds if they were pressed Korsnäs’ Rockhammar mill. The sampling point, (posi-
together during drying in a Rapid Köthen sheet former tion 1) is marked with an x symbol in Figure 1a. Sub-
(100 kPa and 93 °C) compared to a standard sheet for- sequently, two pilot trials were performed on that pulp
mer (400 kPa and 23 °C). Elahimehr (2014) showed that at Valmet Technology Centre, Sundsvall in a low con-
bulk correlates to SRE and freeness for different rotational sistency JC00 conical pilot refiner (Valmet, Espoo, Fin-
speeds and filling patterns. He did not find any differ- land). Refining was performed with a filling pattern (type
ence in the relationship between tensile development and JC00RAD2/JC00SAD2) referred to as “standard fillings”
change in bulk in pilot trials where three different rota- and a filling with a fine pattern (type JC00RMM15Z/
tional speeds and a wide range of filling patterns were JC00SMM15Z). In each trial, the pulp was pumped through
used. This is to some extent contradictory to the find- the refiner from one chest to another, as shown in Figure 1b
ings reported by Klinga et al. (2008). However, Elahimehr and the refining gap was adjusted in order to achieve a
(2014) used a standard sheet former. In the present work certain refining energy and thereby a certain refining in-
testing of pulp strength and bulk is performed on Rapid tensity. Pulp samples were taken at six different refining
Köthen sheets, and that is assumed to shed light to these gaps.
contradictory results.
LC refining would make it possible to produce more
Mill
fibrillar fines also called secondary fines (Odabas et al.
In May 2017, a reference mill trial was performed at Rock-
2016) and thereby further increase the network strength
hammar mill. The refining gap in a RF5 conical LC refiner
at maintained bulk (Ljungqvist et al. 2014, Moberg et al.
(Valmet, Espoo, Finland), was adjusted in order to achieve
2014, Hafrén et al. 2014). Also Motamedian et al. (2019)
three different power loads, P (1.5, 1.96 and 2.34 MW)
found that an increased number of fibrillar fines increases
and thereby three different refining intensities. Normally,
the strength of paper. This was explained by the ability
the RF5 mill refiner operates close to 1.5 MW which cor-
of fibrillar fines to reinforce the bonds in the fibre net-
work. responds to 1.0 J/m in specific edge load. The standard
The basic idea in this work is to optimize process con- fillings in the RF5 were of the type RF5RPLF2SDD2/
ditions in LC refining, i. e. to select or ultimately develop RF5SLFSDD2P. All samples for the mill trial were taken
new optimal LC refiner filling patterns, in order to produce within one hour in order to avoid variations with vary-
fibrillar fines, improve fibre surface area and to improve ing fibre treatment on rejects; directly after the LC refiner
the separation of fibres from each other while preserving (position 3 in Figure 1a) and for the zero power load di-
the inherent stiffness as much as possible. Furthermore, rectly before the LC refiner (position 2). The mass reject
the aim is to evaluate if this type of work can be done at ratio was about 10 %. As the refiner functions as a com-
laboratory-scale or if it is necessary to run trials in pilot- or bined second stage and reject refiner it would have been
mill-scale in order to obtain meaningful results. One bene- more correct to evaluate the development of fibre and
fit of laboratory- and pilot-scale trials is that a wide variety pulp properties over the combined refining and screen-
of pulps and filling patterns can be tested at relatively low ing stage, i. e. from position 1 to position 4 (Sandberg
cost compared to mill-scale trials. Another benefit is not et al. 2017). However, this is unworkable due to the long
to jeopardize production losses for the entire mill if a trial time for the process to stabilise after a change in power
should fail. load.

Laboratory
Materials and methods In conjunction with the mill trial, first stage CTMP was
also taken from position 1 (Figure 1a) for two laboratory tri-
First stage CTMP from BillerudKorsnäs’ Rockhammar mill als in a laboratory refiner LR1 (Voith-Sulzer, Heidenheim,
made from Norway spruce (Picea abies) was used in all Germany) at BillerudKorsnäs’ Karlsborg mill. The refining
LC refining trials. Trials were performed at mill-, pilot- and with LR1 was performed with either a conical filling pat-
laboratory-scale. tern (type 3/0.5/30) or a flat filling pattern (type 3/0.84/30).
J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk | 35

The specific edge load, SEL (J/m) was calculated by:

P − P0
SEL = (2)
ω CEL

where ω = rotational speed (rev/s); CEL = cutting edge


length (m/rev); and cutting speed, Ls (m/s) was defined
as:

Ls = ω CEL (3)

Lumiainen (1995) showed that width of bars should


also be taken into consideration and introduced the spe-
cific surface load, SSL (J/m2 ), which is obtained by divid-
ing specific edge load, SEL by impact length, IL (m):

SEL
SSL = (4)
IL
Wr + Wst
IL = (5)
2 cos α
Figure 1: Refiner configurations. Sampling positions are marked
with x symbols. a) CTMP mill at BillerudKorsnäs’ Rockhammar mill. where Wr = width of rotor bar (m); Wst = width of stator
Two HC single disc chip refiners in parallel supply pulp to the RF5 LC bar (m); α = bar angle (intersecting angle of opposite bars
refiner. b) JC00 pilot refiner at Valmet Technology Centre, Sundsvall. is 2α)
The pulp is pumped through the refiner from one chest to another. The refining conditions for all trials are summarised in
c) Laboratory refiner LR1 at BillerudKorsnäs’ Karlsborg mill. The
Table 1.
pulp is recirculated through the refiner and a pulp chest. The refiner
symbol indicates a conical refiner, but LR1 may also be configured
as a disc refiner.
Analyses
After hot disintegration (ISO 5263-3), tensile index (ISO
In each trial, the laboratory refiner operated with a fixed 1924-2), z-strength (ISO 15754) and bulk (ISO 5270) were
power load, P. The pulp was recirculated through the re- measured on handsheets (grammage 140 g/m2 ) made with
finer, as shown in Figure 1c, and pulp samples were taken a Rapid Köthen sheet former (Rycobel, Deerlijk, Belgium,
at six different net specific refining energies (0, 40, 80, 120, ISO 5269-2).
160 and 200 kWh/ton). In order to get an indication of fibrillar fines content,
Net specific refining energy, SRE (J/kg) was calculated a method that uses light sources in the UV (peak sen-
by: sitivity wave-length around 0.25 µm) and IR wavelength
spectrum, the crill method was used. The crill value ac-
P − P0 counts for fines of about 0.25 µm in diameter (Lundberg
SRE = (1)
QC et al. 2018) while a typical diameter of fibrillar fines is
0.5 µm (Odabas et al. 2016).
where P0 = no-load power (W); Q = mass flow (kg pulp
Fibre properties of first stage CTMP that were used in
suspension/s); C = pulp consistency (kg fibre/kg pulp sus-
LC refiner trials are shown in Table 2.
pension).
There is no common definition of refining intensity.
Berg et al. (2015) found that specific edge load (Brecht and
Siewert 1966), refining gap (Mohlin 2006) and force on fi- Results and discussion
bres (Kerekes and Senger 2006) were adequate measures
for refining intensity as they all predicted fibre shorten- Different filling patterns were compared in a pilot-scale
ing with approximately equal sufficiency. However, refin- conical JC00 refiner and a laboratory-scale LR1 refiner with
ing gap was not measured with sufficiently high precision regard to tensile index, z-strength and energy efficiency.
in this study and therefore force on fibres could not be cal- A reference trial was also performed in a conical LC refiner
culated properly. RF5 at BillerudKorsnäs’ Rockhammar mill.
36 | J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk

Table 1: LC refining conditions.

Refiner JC00 JC00 LR1 LR1 RF5


Scale Pilot Pilot Lab. Lab. Mill
Filling Standard Fine Conical Flat Standard

Width of bar W , mm 4.0 1.3–1.4 3 3 2.0–4.0


Bar angle α, ° 18 33–15 30 30 18
Cutting edge length CEL, km/rev 1.8 10.1 0.020a 0.0336a 120
Specific edge load SEL, J/m 0.68–2.0 0.075–0.29 1.0 1.0 1.0–2.0
Impact length IL, mm 4.21 1.53–1.47 3.46 3.46 3.15
Specific surface load SSL, J/m2 160–480 50–190 290 290 330–620
Rotation speed ω, rpm 1200 1200 2000 2000 470
Temperature, °C 56 60 36–49 36–49 60
Pulp consistency C, % 4.3 4.1 4.0 4.0 3.9
Flow through the refiner, l/min 200 200 100 100 7000
Idle load, kWh/ton 20 30 – – 34b
Net refining energy SRE, kWh/t 48–142 29–118 40–200 40–200 66–120b
a
LR1 fillings are labelled with cutting speed, Ls (km/s) at 3000 rpm per refiner filling, see Eq. (3) for calculation of CEL.
b
Net refining energy and idle load is based on flow through the refiner minus recirculated flow, 550 l/min, i. e. Q = 6450 l/min. in Eq. (1).

Table 2: Fibre properties on first stage CTMP taken after latency


In the following, we use net SRE in order to calcu-
chest. Measured with a PulpEye pulp analyser (PulpEye, Örn-
sköldsvik, Sweden). Fibre length is expressed as a length-weighted late energy efficiency with regard to tensile index and
average, LWA. z-strength. The energy efficiency for tensile index was
(32.6 − 23.2)/0.092 = 102 (Nm/g)/(MWh/ton) and (30.2 −
1st stage CTMP October 2016 May 2017 23.2)/0.091 = 77 (Nm/g)/(MWh/ton) for fillings with a
Pilot trials Lab. and mill trials fine pattern and standard fillings respectively. The cor-
Freeness, ml 736 676 responding energy efficiencies for z-strength were (255 −
Fibre length (LWA), mm 1.82 1.60 179)/0.092 = 826 kPa/(MWh/ton) and (238 − 179)/0.091 =
Shives sum, no./g 547 403
648 kPa/(MWh/ton).
Crill value (unwashed) 200 278
Additional pulp measurements are shown in Figure 4.
The crill value (unwashed) was 206 for fillings with a fine
pattern and 198 for the standard fillings as shown in Fig-
Pilot trials with two different filling patterns ure 4d. There was no evident difference on different filling
pattern (at bulk 2.3 cm3 /kg) regarding freeness (600 ml), fi-
Figure 2a shows that tensile index was 32.6 Nm/g for fill- bre length (1.80 mm) or shives content (0.29 %), shown in
ings with a fine pattern and 30.2 Nm/g for the standard Figure 4a–c.
fillings, both evaluated at bulk 2.3 cm3 /g. Figure 2b shows In summary, the pilot trials showed that gentle LC
that the corresponding z-strength was 255 kPa for fillings refining in JC00 with a fine filling pattern result in a
with a fine pattern and 238 kPa for the standard fillings. pulp with higher tensile index (+2.6 Nm/g) and z-strength
The tensile index and z-strength before pilot refining in (+17 kPa) at bulk 2.3 cm3 /kg, compared to harsher refining
JC00 were 23.2 Nm/g and 179 kPa respectively. Mean val- with standard fillings. The increase in strengths can be ex-
ues of standard deviations for tensile index, z-strength and plained by a higher amount of fibrillar fibres which is in-
bulk in this study were 1.3 Nm/g, 9 kPa and 0.06 cm3 /g re- dicated by the higher crill value (+8). Another explanation
spectively and are indicated by solid lines placed at regres- can be that a gentle treatment of fibres preserves more of
sion lines at bulk 2.3 cm3 /g. their inherent stiffness. Both these explanations are sup-
As indicated in Figure 3, net SRE was 92 and ported by Hyll et al. (2016) who found increased tensile in-
91 kWh/ton at bulk 2.3 cm3 /g for fine-patterned and stan- dex and bulk by laboratory refining, though of bleached
dard fillings respectively, the corresponding specific edge kraft softwood pulp. They found that the generated fines
loads were 0.22 and 1.3 J/m. Energy efficiency for a re- were more fibrillar and that less fibre shortening and kinks
finer is defined as the increase in a pulp property over were introduced with a finer filling pattern compared to
the refiner divided by applied SRE (Sandberg et al. 2017). standard ones.
J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk | 37

Figure 2: Tensile index, z-strength and bulk measured on Rapid Köthen sheets. Fillings with different cutting edge length, CEL. Solid lines
(placed at regression lines at bulk 2.3 cm3 /g) indicate mean values of standard deviations for data points.

Figure 3: Tensile index and z-strength measured on Rapid Köthen sheets versus net specific refining energy. Fillings with different cutting
edge length, CEL. Solid lines placed at regression lines, at a strength that corresponds to bulk 2.3 cm3 /g, indicate mean values of standard
deviations for data points. Net SRE was 92 and 91 kWh/ton at bulk 2.3 cm3 /g for fine-patterned and standard fillings respectively, the corre-
sponding specific edge loads were 0.22 and 1.3 J/m.

The refining was also performed with higher energy ef- properties as those shown in Figure 4 are unfortunately
ficiency (+30 %), with regard to both tensile index and z- only available for the pilot trials.
strength. Net SRE was 90 and 74 kWh/ton at bulk 2.1 cm3 /g
for flat and conical filling types respectively as indicated
in Figure 6b. The energy efficiency can be calculated as
Laboratory trials with two different filling 38 (Nm/g)/(MWh/ton) or 780 kPa/MWh/ton for flat fillings
types and 51 (Nm/g)/(MWh/ton) or 680 kPa/MWh/ton for coni-
cal fillings.
Figure 5a shows that tensile index was about 36 Nm/g In summary, the laboratory trials showed that LC re-
at bulk 2.1 cm3 /g for both filling types in LR1 (actually fining in LR1 with flat fillings resulted in higher z-strength
36.2 Nm/g for flat and 35.8 Nm/g for conical fillings). The (+33 kPa) at bulk 2.1 cm3 /g compared to conical fillings.
tensile index at zero power load were 32.8 and 32.0 Nm/g The tensile index was about the same (Figure 6a). Refining
for flat and conical filling types respectively. Figure 5b with a flat filling resulted in opposite differences in energy
shows that z-strength was 345 kPa at bulk 2.1 cm3 /g for efficiency, with regard to tensile index (−25 %) and with re-
the flat type of fillings and 312 kPa for the conical ones. gard to z-strength (+15 %). These finding are somewhat in
The z-strength at zero power load were 275 and 262 kPa for contrast to those by Lumiainen (1997a, 1997b) who indi-
flat and conical filling types respectively. Additional pulp cated that refiners with conical fillings have lower energy
38 | J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk

Figure 4: Freeness (ISO 5267-2). Average length-weighted fibre length and shives content (PQM, Valmet, Espoo, Finland) and crill value (un-
washed) (PulpEye, Örnsköldsvik, Sweden) versus bulk. Fillings with different cutting edge length, CEL.

Figure 5: Tensile index, z-strength and bulk measured on Rapid Köthen sheets. Conical and flat fillings. Solid lines (placed at regression
lines at bulk 2.1 cm3 /g) indicate mean values of standard deviations for data points.

Figure 6: Tensile index and z-strength measured on Rapid Köthen sheets versus net specific refining energy. Conical and flat fillings. Dash-
dot lines indicate net SRE at z-strength that corresponds to bulk 2.1 cm3 /g.
J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk | 39

Figure 7: Tensile index, z-strength and bulk measured on Rapid Köthen sheets. RF5 Standard fillings, CEL 120 km/rev.

Figure 8: Tensile index and z-strength measured on Rapid Köthen sheets versus net specific refining energy. RF5 Standard fillings, CEL
120 km/rev. Dash-dot lines indicate net SRE at z-strength that corresponds to bulk 2.1 cm3 /g.

consumption and produce better fibre development than in filling pattern in a laboratory or pilot refiner also could
flat disc refiners due to geometric differences. However, Lu- be detected in larger refiners. Refining in a JC00 pilot re-
miainen performed the trials in larger-scale refiners. finer with fine-patterned fillings (bar width 1.3–1.4 mm) re-
sults in higher tensile index and z-strength at specified
bulk compared to standard fillings (bar width 4 mm). A dif-
Mill trial ference is also seen in an LR1 laboratory refiner where flat
fillings gives higher z-strength compared to conical fill-
Figure 7a–b shows that tensile index was 35.5 Nm/g and ings, both with 3 mm bar width. Pulp properties and refin-
z-strength was 318 kPa, both evaluated at bulk 2.1 cm3 /g. ing characteristics evaluated at specified bulk values are
Tensile index and z-strength versus net SRE are shown in put together in Table 3.
Figure 8a–b. Net SRE was 109 kWh/ton at bulk 2.1 cm3 /g
as indicated in Figure 7b, the corresponding specific edge
load was 1.8 J/m. The tensile index and z-strength before
refining were 30.5 Nm/g and 266 kPa respectively. The en- Conclusions
ergy efficiency can be calculated as 46 (Nm/g)/(MWh/ton)
or 480 kPa/MWh/ton. First stage chemithermomechanical pulp (CTMP) made
from Norway spruce were used in low consistency refining
trials performed at mill-, pilot- and laboratory-scale. Dif-
Summary of all trials ferent filling patterns were compared with regard to tensile
index, z-strength and energy efficiency.
Refining curves from laboratory-, pilot- and mill-scale re- – A fine-patterned filling in a pilot-scale conical refiner
fining follow a common trend as seen in Figure 9a–b. It is gave higher tensile index and z-strength at maintained
therefore plausible that refining effects due to differences bulk than did a standard filling.
40 | J.-E. Berg et al.: LC refining of CTMP targeting high strength and bulk

Figure 9: Tensile index, z-strength and bulk measured on Rapid Köthen sheets. Fillings with different cutting edge length, CEL.

Table 3: Pulp properties and refining characteristics evaluated at specified bulk values.

Refiner JC00 JC00 LR1 LR1 RF5


Scale Pilot Pilot Lab. Lab. Mill
Filling Standard Fine Conical Flat Standard

Tensile index, Nm/g 30.2 32.8 36 36 35.5


Z-strength, kPa 238 255 312 345 318
Energy efficiency, (Nm/g)/(MWh/t) 76 102 51 38 46
Energy efficiency, kPa/(MWh/t) 650 830 680 780 480
Net refining energy, kWh/t 84 90 74 90 109
Specific edge load, J/m 1.3 0.22 1.0 1.0 1.8
Specific surface load, J/m2 310 150 290 290 560
Bulk, cm3 /g 2.3 2.3 2.1 2.1 2.1

– Refining with a fine-patterned filling also resulted in References


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