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SYSTEM
with Central Distributor Pulsation dampener and CD basisweight Dilution Control
Cost Cutting
because 95 % of Your Papermaking Problems Cost Money
This mill in Spain found that the grade changes were much easier with the Automatic Consistency Profiling solution. The dry weight profile variation was reduced by 71%.
Mapping Printer
CD Network
CD Control
The Cause?
Cross Flows.
Rotational Flows. Flocculation.
The Result ?
Moisture Profile.
Breaks + Rejects. Efficiency.
BTF-143-0
Tapered Header-Limitations
Requires a high velocity ratio between the header and the tube bank, which limits the maximum turn down ratio of the system.
Restricts zone resolution Constrains adjacent actuator control range Slice lip is a continuous beam Zone-to-zone response coupling degrades control accuracy Slice lip bending changes local flow rates. Cross flows cause poor CD-fiber profiles.
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.
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
Grade change from 40 to 70 #/3000: Initial CD-Profile Coefficient of Variation : 0.2 # or 0.5%
Grade change from 40 to 70 #/3000: After 3 5 Minutes Coefficient of Variation : 0.12 # or 0.3%
Grade change from 40 to 70 #/3000: After 10 Minutes Coefficient of Variation : 0.09 # or 0.22%
10 11
The more Changes, the more Micro-Turbulence and Formation/Drainage Improvement. Typical Velocity Changes. Higher Efficiency of Chemicals. 12 Downturn 11 Ratio: 4 to 1 10 9 Velocity 8 Shown is four 7 times lower 6 1
Except for #11, representing the machine speed.
5 4 3 2 1
7 6
5 3 2 4
8
4
3
11
9
6
10
8 7
TB
10 11
The Benefits from Secondary Tube Bank: High level of shear forces. Improvement in Formation & Drainage. 12
11 10 9 8 7 6 5 4 3 2 1
6 5 3 4 2
8
4
TB
Secondary Tube Bank
Improving Formation Accelerating Drainage
2
1
3
11 6
7 9
10
Stock Level
CD-Profile:
Central Distributor
Fiber Orientation
3 degrees.
Stronger Strength Properties will be Obtained.
profile variability.
Improve CD caliper and CD moisture profiles.
Reduce off-spec
production. Reduce converting losses. Allow target shifting.
Actuators
Reel
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
Consistency Profiling
Excellent 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
Point of Injection
Injection water is fed into the eye 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.
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 small volume 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.
Results:
Printing and writing, coated base sheet, complete new headbox system with injection control:
Before After
Results:
4-ply Board machine, injection control retrofitted to existing headbox on filler ply:
2-Sigma
0.8 0.6 0.4 0.2 0 B.W. 230 - 350 gsm B.W. 350 - 550 gsm
With B TF-Headbo x: Reductio n o f CD-P ro file: 65% B efo re Replacement o f Two Ro ll Rectifier Ro ll Headbo x
2.39 1.48 0.52 CD [%] 1.27 0.34 MD [%] 1.39 0.6 Residual [%] 0.86 Total [%]
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
The Benefits
Improves CD-Profile to approx. 0.1 to 0.5%. Gain in strength allows lower basis weight or low cost furnish. Extremely fast grade changes (few minutes). Uncomplicated instrumentation. Substantial improvement in TSI, TSO, Fiber Orientation, Streaks, Low Formation, Curl, TwoSidedness, etc.
The Benefits
Flawless conceptual layout and design. Fiber Orientation is always within few degrees (no need for slice actuator control). Grade changes and recovery time after breaks within minutes. No cross flows inside box or on wire. Downturn Ratio of 4 to 1. Best suitable headbox on the market for multi-grade machines.
The Benefits
Introduction of additional energy provides MORE MICRO-TURBULENCE. Substantial reduction in sheet sealing and stratification. IMPROVED DRAINAGE. Dandy Roll or Top Former can penetrate deeper into sheet, resulting in substantial FORMATION IMPROVEMENT.