Paper technology program for Taiwan TAPPI

CG Kiang
2010 04 27 Taichung, Taiwan

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Paper mill

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Paper machine in the stone age

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: 0.2-1.5% : ;2% : 20% : 60%-50% : 40%-50%90%-95%

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Paper machine in 1884

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Paper machine in 2000s

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Paper machine in 2000s

Dry End

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20%
40-50%

90%-95%

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Paper machine
Sections

Formation section

Press section

Dryer section Head box

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Paper machine
Dewatering wet end

Fo ilb ox

n um io cu ct u va h ts ig la H F

x bo

fo i

ilb fo

lb o

ox

va c

Couching cons. 8-10%

rm Fo

Lo w

g in

bo

uu

ar

Headbox cons. 0.30-0.50%

00

Headbox cons. 0.50-0.70%

rm Fo
00

lb o

Fo ilb ox

g in

va c

bo

uu

ar

fo i

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c va

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fo

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ox

Couching cons. 8-10% Couching cons. 8-10%

uc n tio x bo sf

ox rb e Fl s at uc

an x oxtr bo bet ne l er F io h sf ct S an su tr t at ee Fl Sh s at

n tio

x bo
x bo

Dryness 24-26%

at Fl

n io ct su

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Paper machine
Dewatering - press

up to 50 % consistency ~ 34-36% consistency ~ 38-40% consistency ~ 20-25% consistency ~ 30% consistency

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Paper machine
Drying
~ 50 % consistency 8 12% moisture content

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Paper machine
Main types The following main types of paper machines are significant today :
- Fourdrinier machines - Combination machines - In vat machines ( cylinder machine ) - Tissue paper machines - Board machines - Twinwire machines
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 ( Fourdriner Machine )

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Paper machine
Fourdrinier machine development

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Paper machine
Combination machine folding boxboard machine

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 ( Combination Machine )

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Paper machine
MG dryer Yankee dryer

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Paper machine
MG dryer Yankee dryer

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Paper machine
MG dryer Yankee dryer
Purposes of use
Wrapping paper machines MG-gloss as a target for the sake of appearance Usually combined machines owing to capacity Multi-layer board machines The Yankee dryer is used not only to gain gloss, but also to gain smoothness without losing bulk (stiffness). It is difficult to perform a sufficient amount of drying using the Yankee dryer Crpe paper machines MG-gloss is not set as a target. The Yankee cylinder drying efficiency may become a bottleneck for the production
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Paper machine
MG dryer Yankee dryer
Effect of the MG cylinder drying on board surface

Surface prior to MG cylinder

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Surface after MG cylinder

In vat cylinder machine direct flow

VACUUM BOXES

COUCH ROLL

SHOWER TO DRIERS

COUCH ROLL PRESS ROLLS WHITE WATER DISCHARGED THROUGH CENTER

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In vat cylinder machine contra flow

VACUUM BOXES COUCH ROLL

SHOWER

TO DRIERS

COUCH ROLL PRESS ROLLS WHITE WATER DISCHARGED THROUGH CENTER

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 In vat cylinder machine

Multi-layer board machine

Couch roll
Shower water

Suction box

Forming cylinder

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 ( Tissue Paper Machine )

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 ( Board Machine )

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 ( Twinwire Machine )

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Paper machine
Twinwire machine

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Paper machine
Board machine

Fourdrinier and secondary gap forming unit

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Paper machine
Board machine

Primary gap forming unit and on-top fourdrinier

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Paper machine
Board machine

2-Ply gap forming section

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Raw materials and their effect on final product

Recycled fiber
Less bulky Lower brightness Lower tensile High fines content => slow drainage

Virgin fiber
bulky and high brightness good tensile fast drainage

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Three-, Four- or Five ply forming section

3-layer forming Scandinavian type Folding box board

4-layer forming high quality WLC

5-layer forming high quality and versatile concept

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Linerboard structure
Top ply: Undertop ply: Back ply: UKP, OCC OCC, Mixed waste, Broke OCC

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Two layer headbox producing containerboard

European OCC and mixed waste

2-layer forming

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Paper machine
Headbox The headbox has four main functions :
1. 2. To spread the stock flow across the entire width of the wire To maintain a turbulence in the stock to prevent formation of fiber flock To remove temporal and spatial flow disturbances that may cause basis weight variations To produce a stock flow of desired consistency, speed and direction to the wire

3.

4.

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Paper machine
Headbox The traditional headbox is formed of the following components :
- Inlet header - Headbox with rectifier rolls and air cushion - Slice with top slice and apron

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Paper machine
Headbox

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Headbox
Inlet header conic pipes
The shape of the inlet header is to optimized to distribute the stock evenly across the width of the machine, especially uniform distribution for all flow rates not only for headbox design flow rate Electropolished for all flow surfaces is must

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Headbox
Inlet header tapered right angle ducts

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Headbox
Box rectifier rolls

Tampella rectifier roll headbox

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Headbox
Box rectifier rolls
Stock flows in headbox with rotating and stationary rolls

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Headbox
Box rectifier rolls

Accumulation of fibers in a rectifier roll

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Headbox
Box rectifier rolls The rectifier rolls has many disadvantages :
1. 2. A great part of the flow passes in between the rectifier rolls and is therefore not mixed Influence of the inlet header on the flow on such a way that vortexes are formed inside and between the rolls. Since these vortexes are not identical across the entire width of the headbox, they cause severe disturbances in the flow The rectifier rolls is the occasional piling of fibers on the surfaces between the holes or on the edges, when flushed away, they end up as hard fiber lumps in the paper Paper quality can be decisively influenced by such factors as the openness of roll, hole size and location of the rectifier roll which located closest by the headbox outlet. As the machine speed increased, it is the roll that usually cause a problem

3. 4.

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Headbox
Box rectifier rolls The rectifier rolls are necessary in every headbox for the following reasons :
1. The rectifier rolls even out the flow speed in the cross direction of headbox and stabilize the flow The rectifier rolls evoke turbulence in the entire headbox. It helps disperses fiber lumps so that in the outflowing mixture, the fibers are evenly distributed in the water

2.

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Headbox
Box air cushion On open headbox, the ratio between surface level h ( cm ) and outflowing speed V ( m/min ) : h = V 2 / 700
h V

V = 300 m/min ; h = 125 cm

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Headbox
Box air cushion

Valmet air cushion headbox

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Headbox
Box air cushion

Air cushion headbox

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Headbox
Box air cushion

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Headbox
Box air cushion

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Headbox
Box air cushion

Pulsation dampening located close to slice without a compromise Dampens both dilution and main flows Continuous flow from stilling chamber to overflow No back flow or build-ups to main flow

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Headbox
Box air cushion

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Headbox
Box air cushion

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Headbox
Box attenuator

Attenuator which incorporates headbox for dampening of pressure pulsations

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Headbox
Box attenuator dampen pressure pulsation

Prior to headbox

After headbox
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Headbox
Slice

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Headbox
Slice

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Headbox
Slice
.4 in .2 in 10 mm 5 mm max 150 mm [6 in]

0.79 in max -2 in min 0 in O of breast roll

20 mm max -50 mm min 0 mm

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Headbox
High turbulence headbox

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Headbox
High turbulence headbox

Pressure loss to :
Create micro turbulence Uniform CD flow distribution (profiles and fiber orientation) Improve pulsation dampening for MD variation control

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Headbox
High turbulence headbox

smooth flow geometry from round to rectangular

Low large scale turbulence low random basis weight variation good stability

Turbulence level fine tuning with turbulence sheets

Fluidization in circular enlargement

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Headbox
High turbulence headbox
m/s f/s

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Headbox
High turbulence headbox - multilayer

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Headbox
High turbulence headbox - multilayer

Multilayer separation by vanes

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Formation of sheet
Flow monitoring in short circulation
Variations in the flow speed, consistency or in the properties of the stock temporal or across the headbox - lead to grammage variations, poor sheet formation and many other difficulties. The problems can often be localized in the short circulation or drive unit and may often lead to change of headbox If the fiber form large flocks in the slice section, it is difficult to correct later in the process. If the flow is too turbulent on the other side, it tears the earlier formed sheet off and makes the paper cloudy although the fibers are relatively well distributed
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Formation of sheet
Flow monitoring in short circulation
One-sidedness means a difference in the formation, filler content or fiber orientation between the top and bottom sides of paper sheet One-sidedness is determined e.g. by the impingement angle of the stock jet and the wire. The angle is set by shifting the top slice in the horizontal direction.

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Formation of sheet
Paper formation measurement by small scale beta absorption

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Formation of sheet
Formation analyzer measuring principle

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Formation of sheet
Formation - what are variations
CD profile

ed hi n c ma

cti ir e

on

Paper sheet is a measure and an image of pressure and flow conditions

MD profile

c ma

on ct i ire ed hin

Residual variations

hi n ac m

cti ir e ed

on

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Machine direction

Formation of sheet
Formation - typical variations in paper
CD

ed hi n c ma

cti ir e

on

CD profile depends on performance of profiling actuators of headbox and other sections in PM. (usually 0,3 - 0,6 % from average) MD variations come from variations in raw material and chemical aid supplies, consistency and pressure controls. Fast (20..30 Hz) MD-variations come from pulsation for example piping, fan pump, machine screen. Note: pulsation can appear also at frequency-multipliers (0,1 - 1,5 % from average)

MD

c ma

on ct i ire ed hin

RES

hi n ac m

cti ir e ed

on

Unsystematical variations come from incomplete mixing in approach system and from unstable drainage process. (0,6 - 2,5 % from average)

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Paper structure engineering

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 ( Forming )
:
(Fourdriner machine) (Cylinder machine)

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 ( Fourdriner machine )

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BeloitBel-Bond
I. (formation) II. III.

610m/min 150g/m2 45 ton/min/cm

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BeloitBel-Bond

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CEDECOPond

I. II. III. IV. 700 m/min 20-90 g/m2

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Escher Wyss(Top Former)

I.MD/CD2151 II. III. : 400 m/min 25-60 g/m2

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Escher Wyss(Short Top Former)

: 40-750 m/min 25-350 g/m2

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KobayashiUltra

I. II. 500 m/min 40-100g/m2

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KobayashiSuccess

700 m/min 40-100g/m2

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Voith:(Compact Wire Former)

: : 700 m/min 30-220 g/m2

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Voith:(Compact Wire Former)

80-600 m/min 80-400 g/m2

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 ( Cylinder machine )

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 ( Cylinder machine )

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 ( Cylinder machine )
:
()

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 ( Cylinder machine )

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Escher Wyss(Pad Former)

I. II.21/51 III. IV.(2%) 150 m/min() 25-110 g/m2

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Tampella

50-350 m/min 20-130 g/m2

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Tampella Arch Former

70-600 m/min

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Voith:

I.MD/CD II.

250-510 m/min 20-110 g/m2

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 ( Hybrid former )

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 ( Gap former )
:

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 ( Gap former )

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 ( Gap former )

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 ( Gap former )

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 ( Gap former )

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 ( Multi-ply former )

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 ( Multi-ply former )

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Paper machine
Wire section drainage

Fo ilb ox

Couching cons. 8-10%

fo i
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fo i

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10

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Headbox cons. 0.30-0.50%

2-3 0 0 0

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Headbox cons. 0.50-0.70%

rm Fo

00

2-3 0

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Couching Couching cons. 8-10% cons. 8-10%

ox rb n fe tio ns x xtra uc t bo bo ts n ee la er F io h sf ct S an su tr t at ee Fl Sh x bo n tio uc s n io ct su x bo x bo

00

Dryness 24-26%

at Fl at Fl

KSD/BRD 499338_1 9/93

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Paper machine
Wire section - drainage

1% 7-8% 4-5% 11 % 32 % 4% 12 % 35 % 1,5 - 2 %

10 0 %

2,5 % 15-18 % 0,5 %

2%

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Paper machine
Tissue machine suction former

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Paper machine
Tissue machine drycrepe, Crescent former

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Paper machine
Tissue machine drycrepe, Crescent former

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Paper machine
Tissue machine drycrepe, Crescent former

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Paper machine
Tissue machine

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Paper machine
Tissue paper

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Paper machine
Tissue paper

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Paper machine
Tissue paper

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Paper machine
TAD tissue machine

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Paper machine
TAD tissue machine - elements

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Paper machine
Tissue machine

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Paper machine
TAD tissue machine moulding process

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Paper machine
TAD tissue machine roll with through head exhaust

Air flow

Air flow
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Paper machine
TAD tissue machine through dryer process

Combustion fan

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