Post on 09-Feb-2018
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HIGH PERFORMANCEHYDRAULIC HEADBOX
SYSTEMwith Central Distributor Pulsation
dampener and CD basisweight
Dilution Control
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What Does your Mill
Benefit from this
Presentation?
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Cost Cutting
because95 % of Your
Papermaking ProblemsCost Money
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Objective for this Presentation:
Analyze Economic Potential
of
Improvement forYour Paper Machine
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This mill in Spain found that the grade changes were much easierwith the Automatic Consistency Profiling solution.
The dry weight profile variation was reduced by 71%.
Automatic Consistency ProfilingSystem
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Hydraulic Headbox and
Distributor with Automatic
Consistency Profiling
System
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Air-padded Central Distributor with Automated Dilution Control
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Base System Layout
CD Control
QCS with CD Consistency
Control
FAST LAN
Existing
Scanner
CD Network
MappingPrinter
Central Distributor
with Dilution Injection
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High Performance
Hydraulic Headbox:
Central Distributor, Automatic
BW Control.
Providing Superior Profiles inCD, MD, Residual & Total %
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Central Distributor
Pulsation dampener withDilution water Injection
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Diffuser Inlet Branch Tubes and Headbox
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It Brings You Closer toPerfect Papermaking
Eliminate AnnoyingProblems!
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The Cause?
Flocculation.Rotational Flows.Cross Flows.
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The Result ?
Efficiency.Breaks + Rejects.
Moisture Profile.
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The Culprit ?
The PE-Tank and
Tapered Header !
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CD-Pressure
ProfileinManifo
ld.
Tapered Header:Typical Profile
BTF-143-0
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Tapered Header-Limitations
Requires a high velocity ratio betweenthe header and the tube bank, which
limits the maximum turn down ratio of
the system.
Is designed for one flow range, and
requires adjustable recirculation to
achieve even pressure distribution.
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Tapered HeaderTurndown Ratio
Effective Flow Range for Air Padded
Rectifier Roll Boxes is
approximately 2.0 / 2.5 to 1. Effective Flow Range for Hydraulic
Boxes is approximately 1.3 / 1.5 to 1.
The CDP Hydraulic Headbox System
is 4.0to 1.
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Overview of CD-Slice Lip Control
Slice lip has limited bending capacity Restricts zone resolution
Constrains adjacent actuator control range
Slice lip is a continuous beam
Zone-to-zone response coupling degradescontrol accuracy
Slice lip bending changes local flow rates.
Cross flows cause
poor CD-fiber profiles.
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Tapered Header :Whats wrong with it?
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CD-Pressure
ProfileinManifo
ld
Tapered Headers have a Very Narrow Sweet Spot.
Without Slice Control, This is How the Profile
Normally Looks Like.
Result: High CD-Variation, Inferior Formation, Fiber
Orientation & Fiber Index, Long Grade Changes,
Edge, Curl and Printing Problems.
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Grade Change from 40 to 70 #/3000 Initial CD-Profile
Coefficient of Variation : 5.3 # or 13.2 % - Fiber Orientation :
32 Degrees
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Grade change from 40 to 70 #/3000 CD-Profile after 6 Minutes
Coefficient of Variation : 2.7 # or 6.7 % - Fiber Orientation : 19 Degrees
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Grade change from 40 to 70 #/3000 CD-Profile after 20 Minutes
Coefficient of Variation : 0.95 # or 2.37 % - Fiber Orientation : 7.3 Degrees
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Grade change from 40 to 70 #/3000 CD-Profile after 40 Minutes
Coefficient of Variation : 0.45 # or 1.12 % - Fiber Orientation :
6.1 Degrees
Typical CD-Profile with Tapered Header
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CDP Hydraulic Headbox
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CD-Pressure Profile across Inlet Branch Tube Bank
High Performance Hydraulic Headbox:Grade change from 40 to 70 #/3000
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Grade change from 40 to 70 #/3000: Initial CD-Profile
Coefficient of Variation :
Fiber Orientation :
0.2 # or 0.5%
3.0 Degrees
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Grade change from 40 to 70 #/3000: After 35 Minutes
Coefficient of Variation :
Fiber Orientation :
0.12 # or 0.3%
3.0 Degrees
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CD-Pressure
ProfileinBTF-DiffuserBank
Grade change from 40 to 70 #/3000: After 10 Minutes
Coefficient of Variation :
Fiber Orientation :
0.09 # or 0.22%
3.0 Degrees
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Dr. H.-J. Schultz, The Inventor and Founder:
Ph.D. in Fluid Mechanics. Worked for Escher Wyss and developed the
Escher Wyss Step-Diffuser Headbox.
Author of many headbox technical papers. Well known throughout the world.
Developed and patented the Central Distributor
Technology.
Started BTF in 1992 - Over 130 units sold
The Perfect Distributor for injection control.
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How Does The
System Operate?
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The more Changes, themore Micro-Turbulenceand Formation/DrainageImprovement.
Typical VelocityChanges.
Higher Efficiency of
Chemicals. Downturn
Ratio: 4 to 1
VelocityShown is four
times lower Except for #11,representing themachinespeed.
2
3
5
6
7
8
4
9 10 11
1
2
3
4
56
7
8
9
10
11
12
Flow
Spe
ed(m/s)
Speed Diagram At Maximum Throughput
119
6
8
1075
1
3
2
4
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The Benefits from
Secondary Tube Bank:
High level of shear
forces.
Improvement in
Formation &Drainage.
2
3
4
5
6
7
8 9 10 11TB
1
2
3
4
56
7
8
9
10
11
12
Flow
Spe
ed(m/s)
1
3
4
Speed Diagram At Maximum Throughput
11
6
10
8
75
2
Secondary Tube BankImproving Formation
Accelerating Drainage
TB
9
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Presenting:
High Performance HydraulicHeadbox-Retrofit
For Existing Headboxes.
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Stock LevelEqual Hose Length
= Equal FlowEqual Hose Length= Equal Flow
Typical Installation of a Retrofit with Central Distributor
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CD-Profile: Coefficient of Variation : 0.5 % and Lower
Typical CD-Profile with Central Distributor
Central
Distributor
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FiberOrientation
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Future.
Dilution Headbox
System will
Provide TSO of
3 degrees.
Stronger Strength
Properties will be
Obtained.Future
TSO: 3
degrees.
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Provide Superior Strength Properties
in MD and CD (COV, TSO, TSI)
The Dilution Headbox System provides
High Micro-Turbulence LevelThrough the Entire System:
Preventing Flocculation
Eliminating Twist And Curl Resulting in Flat Sheet Surface
Superior Printability.
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Consistency Profiling Control
Reduce profile recovery time. Reduce CD weight.
profile variability.
Improve CD caliper and
CD moisture profiles.
Reduce off-spec
production.
Reduce converting
losses.
Allow target shifting.
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Automated CD-Profile Control
Scanner Signal
Traversing
Scanner
Actuators
Reel
Slice Lips: Always
Parallel
Vat#1TopLinerTopLinerFurnish Vat#2BackingLinerBackingLine rFurnishFillerFurnish
Vat#3Filler1Vat#4Filler2Vat#5Filler 3
Vat#5 withConsistencyAutom aticorManualBasisWeigh tControl
Vat#6Filler4Vat#7Filler5 Vat#8Filler6Vat#9Backliner
BacklinerFur nish
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Smaller Approach Piping
Stepped Hole Diffuser
Block
Air Padded Chamber Uniform Flow in all
Hoses
Simple Injection Water
Feed
Perfect Mixing of Stock
and Dilution Water
BTF-154-0
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Consistency ProfilingExcellent Injection Control Systems do this:
Obtain perfect mixing of two flows of
different consistencies.
Keep total flow constant in each zone, at
any given head.
Minimize the injection ratio to prevent local
variations in fines or filler content, and
changes in formation.BTF-040-1
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Distributor with Automatic Injection Control on Voith W-Type Headbox
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Injection water is fed into theeye of each hose inlet.
Equal pressure always
maintains equal flow in each
hose.Minimize the injection ratio to
prevents local variations in fines
or filler content, and changes in
formation.
By adding the injection water
back at the Central Distributor,
perfect mixing is achieved.
Point of Injection
C i t P fili
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Consistency Profiling
1) Fiber Orientation Control
Fixed Slice Lip CD Weight can now be controlled
from Fiber Angle (TSO/TSI)
2) The Dilution Headbox System only uses a smallvolume of Injection Water .less than 5%
3) Competitors Tapered Header Systems require as much
as 20 and 30% of Dilution Water:
Streaks are a very common problem.CD Weight and Fiber Angle are not independent.
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Headbox + Distributor with Automatic Injection ControlSystem including:
Central Distribution Tank with Stock Accelerating Tube Bank
Built-in Attenuator CD-Profile Control
Connector Hoses with Stock Accelerating Diffuser Bank
Headbox with One or Two Stock Accelerating Tube Banks
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Results:
Printing and writing, coated base sheet, complete new headbox
system with injection control:
CD-Profile Improvement, 85 gsm
0
0.5
1
1.5
2
2-Sigma Coefficient of Variance
BeforeAfter
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CD-Profile Improvement
0
0.20.4
0.6
0.8
1
1.2
1.4
B.W. 230 - 350 gsm B.W. 350 - 550 gsm
2-S
igma
Before
After
Results:
4-ply Board machine, injection control retrofitted to existing
headbox on filler ply:
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More Results: Envelope, Printing & Writing36#/3000 at Clariana - Spain
1.48 1.27 1.39
2.39
0.52 0.34 0.60.86
0
0.5
1
1.5
22.5
CD [%] MD [%] Residual [%] Total [%]
Improvement of Coefficient o f Variation [%] with BTF-Headbox
Envelope, Printing & Writing - 36#/3000 - 1640 fpm
With BTF-Headbox: Reduction of CD-Profile: 65%
Before Replacement of Two Ro ll Rectifier Roll Headbox
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Advantages:
1) Flexibility 4 to 1 flow turn-down ratio possible by eliminating
the high velocity gradient required for a tapered
header.
2) Stability Grade changes are made easily and quickly due to
fast response of dilution control compared to slice
bending.
3) Simplicity Operator friendly design
Readily adaptable to mill control systems
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Presenting:
The IndividualComponents of the
BTF-System
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Application: Recommended for all Types and Brandsof ExistingRectifier Roll-, Hydraulic- or Dilution Controlled Headboxes.
The Benefits
Improves CD-Profiletoapprox. 0.1 to 0.5%.
Gain in strength allowslower basis weight or lowcost furnish.
Extremely fast gradechanges (few minutes).
Uncomplicatedinstrumentation.
Substantial improvement inTSI, TSO, Fiber
Orientation, Streaks, LowFormation, Curl, Two-Sidedness, etc.
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The Benefits
Flawless conceptual layoutand design.
Fiber Orientation is alwayswithin few degrees (no need
for slice actuator control). Grade changes and recovery
time after breaks withinminutes.
No cross flows inside box oron wire.
Downturn Ratio of 4 to 1. Best suitable headbox on the
market for multi-grademachines.
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The Benefits Introduction of additionalenergy provides MOREMICRO-TURBULENCE.
Substantial reduction insheet sealing andstratification.
IMPROVED DRAINAGE.
Dandy Roll or Top Former
can penetrate deeper intosheet, resulting insubstantial FORMATIONIMPROVEMENT.
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CDP Hydraulic Headbox with CD Basis weight Dilution Control
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Inlet of Headbox with Branch Tubes
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Side view of Headbox
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CDP Hydraulic Headbox for Fine paper