Wet End Control for strength optimization Roland Berger...
Transcript of Wet End Control for strength optimization Roland Berger...
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Wet End Control for strength optimization
Roland Berger, BTG Instruments GmbH
The 2nd International Conference
„The issues in mechanics of pulp-and-paper materials“
September 10-12
Arkhangelsk, Russia
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Content
1. Introduction BTG
2. Wet End related production and quality issues
3. Impact on functional and process chemicals
4. Charge - a window to the pulp suspension
2© BTG 2010
5. Mill examples showing various control strategies
1. Fine paper
2. Liner and corrugated Medium
6. Conclusions
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BTG is part of a financially strong parent: Spectris plc
Beta LaserMike
Brüel & Kjær Vibro
In-line instrumentationTest and measurement
HBM
Brüel & Kjær S & V
Materials analysis
Malvern
PANalytical
Spectris plc
Industrial controls
Microscan
Red Lion Controls
© BTG 2013
Each unit serves its own distinct customer base
� $1billion public company� Made up of 13 companies� Focused on improving productivity of industrial
processes
Brüel & Kjær Vibro
BTG
NDC Infrared Engineering
Servomex
HBM
Particle Measuring Systems
PANalytical Red Lion Controls
OmegaEngineering
FCW1001/15-3
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Our value proposition
� Instruments
� Broad and unique portfolio of consistency transmitters
� Broad portfolio of In-line analyzers
� Industry-leading laboratory instruments
� In-depth, on-site application expertise
Designed to
provide high ROI
solutions in pulping
and paper
production
© BTG 2013
� In-depth, on-site application expertise
� Duroblade
� Best-in-class high-performance meteringand doctoring blades
� Industry-standard, metering rods, beds and accessories
� In-depth, on-site application expertise
production
Product technology
combined with
application know-
how = improved
productivity and
surface quality
FCW1001/15-4
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Complex Wet End
5© BTG 2010
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Wet End Related Production Issues
Low FillerRetention
Deposits WhitePitch
6© BTG 2010
Poor DrainageLow Dry Content
Web breaks
Web BreaksHigh AOX, COD
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Wet End Related Quality Issues
Formation, Web Strength
7© BTG 2010
SCT, BurstAsh content
SizingElastic limit
Tensile StrenthBasis Weight
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Origin of charge
� A mixture of fibers, fines and papermaking additives
8© BTG 2010
Pigment
Retention aid
Fiber
Anionic trash
Fixative
Fine
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Colloidal system
� Papermaking components have colloidal dimensions
� Colloidally
dissolved� Fine
dispersed
� Coarse
dispersed
Lignin FibersCaCO3
� Ions in
solution
2-SO
4
9© BTG 2010
Size1 nm 1 µm 100 µm 1 mm
Lignin
PolyelectrolytesFines
FibersCaCO32+
2-
Ca
CO
Na
3
+
500 nm
Electrokinetic effects / electrokinetic phenomena
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Interactions in the wet end
Flocculant
Starch
Fixative
Fixative
Fixative
10© BTG 2010
Size
WSA
Fiber
Fixative
Fixative
Anionic Trash
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Charge detection
• A window to the pulp suspension
11© BTG 2010
Fibers, fines, Particles
Zeta potential (mV)Colloidally dissolved matter
Charge demand (ml)
PCD-04SZP-10
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Why 2x charge measurements?
Zeta PotentialDissolved Charge
12© BTG 2010
� What is the adsorption capacityof the fiber?
� Did the additive adsorb?
� How much dissolved charge in the system?
� What is the charge of additives?� How much fixing agent is
required?
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Optimum dosage of cationic starch
SZP: -25 mV PCD: -5 ml PCD: -2 mlSZP: -25 mV
Ineffective dosage
Strength Additive
+
13© BTG 2010
SZP: -25 mV PCD: -5 ml PCD: -2 mlSZP: -25 mVStrength Additive
SZP: -25 mV PCD: -1 ml PCD: -1 mlSZP: -15 mV
Effective dosage
Strength Additive
+
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Impacts on strength properties in relation to the wet end
� Furnish type, TMP, Kraft, recycled, broke,
fillers, etcG
� Shear forces from pump, cleaner, screen, etc
� Transport media pH, conductivity, solid
14© BTG 2010
� Transport media pH, conductivity, solid
content, temperature, etc
� Residence time, chest sizes
� Fiber treatment
� Residual chemicals
� Fines in back water
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Survey from stock prep to head box
15© BTG 2010
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Wet End Survey
� Understand interaction in pulp suspension
� selection and performance assessment of fixing agents, strength additives and retention chemicals
� Selecting of the ideal addition sequence
� Selection of optimum dosage points and dosage
16© BTG 201016
� Selection of optimum dosage points and dosage amount
� identification and quantification of carry over impacting strength properties
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Strength improvement Mill case I – Fine paper
Machine description
� Fine Paper machine
� Production 120.000 tpy
� Width 3.6 m� Width 3.6 m
Problem description
� High costs for retention chemicals
� High number of web breaks
� High costs due to unwanted down time
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Wet End Survey revealed problem
18© BTG 2010
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Sources of anionic disturbances
19© BTG 2007
� Optical brightener and dispersant are major reason for disturbance
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Charge control in fine paper
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Reduced retention aid
-200
-150
-100
-50
0
Coated broke charge
0,63
0,73
0,83
0,93
1,03
Retention aid dosage
Broke charge
© BTG 200721
-450
-400
-350
-300
-250
before charge control 6 month after charge control
Coated broke charge
0,23
0,33
0,43
0,53
0,63
Retention aid dosage
Charge set point
Ret.aid dosage
average dosageretention aid
� Increased initial web strength due to controlled flocculation
� Reduced retention aid consumption by 60%
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Reduced web breaks
8
10
12
14
number of wet breaks
Wet breaks
Average
� Increased initial web strength due to controlled flocculation
� Web breaks reduced by 60% after charge control loop
0
2
4
6
before charge control 6 month after charge control
number of wet breaks
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Strength improvement Mill case II – Liner & Fluting
Machine description
� Kraft Liner and Corrugated Medium
� Production 200.000 tpy
� Width 3.8 m� Width 3.8 m
Problem description
� Need to reduce basis weight
� Limited due to strength issues
� High costs due to unwanted down time
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Liner requirements
� BW, thickness
� Burst
� SCT
� Resistance to perforation
EASIER, SMALLER, SMARTER, LIGHTER 24© BTG 2013
� Resistance to perforation
� Tensile strength
� Water barrier
� Printability, brightness (white-top)
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Liner and corrugated medium production requirements
� Raw materials
� Waste papers ���� Cost / Strength properties
� Unbleached kraft pulp ���� Strength properties
� Refining (for some grades) ���� to increase strength
� Retention ���� to keep strength
� Drainage ���� to increase productivity
���� To decrease energy consumption
25© BTG 2013
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Strength optimization (Solution 1)
� Refining control with DRT-5500
� Refining waste paper requires a different
strategy than kraft pulp
� Goal : increase strength with no decrease of
drainage = ideally fibrillation without fines
EASIER, SMALLER, SMARTER, LIGHTER 26© BTG 2011
drainage = ideally fibrillation without fines
� Energy savings - FOC
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Case: refining control presented in Kadant Presentation
EASIER, SMALLER, SMARTER, LIGHTER 27© BTG 2011
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Case: Kadant PresentationCustomer savings 190 000$ / year
EASIER, SMALLER, SMARTER, LIGHTER 28© BTG 2011
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Strength optimization (Solution 2)
� Fines / ash management
� With RET-2512 and RET-5503
� To stabilize sheet homogeneity
� = to stabilize strength homogeneity
EASIER, SMALLER, SMARTER, LIGHTER 29© BTG 2011
� Fines / ash management by
� Right choice of raw materials
� Retention aid control
� Approach also valid for
porosity management
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� Basis weight and thickness control
� Accurate basis weight control
� With VBW-1100
Strength optimization (Solution 3)
EASIER, SMALLER, SMARTER, LIGHTER 30© BTG 2011
� Consistency management from pulper to
headbox
� With MEK-3000, TCR-2511
� Consistency survey of stock preparation
� Proactive maintenance and calibration service of
valuable consistency control tools
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Conclusions
In most paper processes, wet end chemicals are added in fixed dosages, usually optimized for a single process condition
Variations of the incoming raw materials and broke lines often not considered
31© BTG 2010
often not considered
Sustainable improvement through a solid approach with first lab measurements and later process
Quick ROI due to sustainable efficiency gain and impoved paper quality can be achieved with relatively low investment
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32© BTG 2010
Thank you very much for your
attention !