Refining Efficiency Seminar

8/10/2019 Refining Efficiency Seminar

1/21

50 years

Refining Optimization

Maximizing Energy EfficiencyPresented at Heinbach/PaperRunSeminar Paris, June 2005

Sergio ZalewskaApplication Manager Pilo S/A - Brazil


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50 years

50 years of expertise in pulp andpaper business

Focus on refining systems

More than 2000 installed refinersPresent in 54 countries

Thousands of processes

optimizationsPartnership with Paper ResearchInstitutes/Universities


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50 years

Refining process

Mechanical treatment of the fibers to reach the desired

paper characteristics and strenght.

Not refined fiber mat Refined fiber mat


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Celullose fiber structure

Microfibrills

FibrillsCelullosechains

Cell wallsCell Walls

Plant cells

Celullose

monomer


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50 years

Refining effects

Primary

Primary wall scratch

Secondary wall opening

Water absortion

Fiber cutting

Secondary

Allow hydrogen bridge connection betweenfibers

Flexibility through hydratation

Better sheet formation


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50 years

How it works

Fibers are collected by the bars

Fiber mat is compressed between rotor and stator

Fibers are relaexed again after have passed through the

bars


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Affecting factors Refiner

Type Mechanical conditions Speed

Installation Series/Parallel

Process Conditions Fiber type Consistency

pH Flow Aditives

Applied energy

Number of impacts (intensity)

Fillings characteristics : Bar height/width/space Cut length Crossing angle Dams (flow restrictors) Fillings material No Load (pumping action and hydraulic losses)

In order to optimize

the refining processall these aspects must

be analised


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50 years

Energy applied

0

1

2

3

4

5

6

7

8

Breaking

Length

km

100 200 300

Total EnergykWh/t

Unbleached PinePulp

BleachedEucalyptus Pulp


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50 years

Energy Intensity

Measures the intensity with wich theenergy is applied to the stock

Has big influence on the paperproperties

Each type of fiber has its betterenergy intensity to give the better

paper results

0

0,5

1

1,5

2

2,5

3

3,5

0 20 40 60 80 100

SR

mx.recommendedintensity

Ws/m

Bleached SulfatePinus

UnbleachedSulfate Pinus

Bleach SulfidePulp

UnbleachedSulfide Pulp

BleachedEucalyptus

0

1

2

3

4

5

6

7

0 50 100 150 200 250 300Total energy

kWh/t

Breakinglength(km)

0,7 ws/m

1,4 ws/m

3,9 ws/m


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Energy Intensity

Is affected by:

Total applied energy Size of discs (conical fillings)

Bar pattern

Motor speed

Number of refiners


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50 years

Consistency Pine (3,0 - 4,0 %)

Eucalyptus (4,0 - 5,0 %)

Low consistency promotes more cutting effect Higher consistency promotes the fiber/fiber

contacting causing more fibrillation than cutting0

20

40

60

Nm/g

50 80

kWh/t

3% 4% 5%

Optimized operation conditions

20

30

40

5060

70

80

0 20 40 60 80 100 120

Applied energy (kWh/t)

Tensileindex(Nm

/g)

pH 5

pH 7

pH 9pH


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50 years

Flow and Pressure

Effect the process stabilityKeep the fiber mat and centers the rotor between the two stators

Are dependent on pump and instalation (series/parallel)

Low flow must be correct using recirculation or parallelinstalation

Low pressures cause instability of the rotor. Too high pressures

causes uneven wearing.

Optimized operation conditions


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Pilo Solutions

For Refiner Improvement


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50 years

Bar Pattern Optimization

Paper properties

Better sheet formation

Improve fillings life

Welded Construction

HIGHER BARS CONSTANT BAR PATTERN

BETTER BREAK RESISTANCE

POSSIBILITY TO MAKE

THINNER BARS


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50 years

TriDisc Conversions for DD Refiners

Pilo TriDiscSystem

Original Double

Disc System


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50 years

Advantages 5 - 10% Less Applied HP Required For

Identical Refining Level Longer Life

Improved Fiber Quality Due To MoreEven Stock Distribution

More Uniform Plate Wear Faster, Easier And Less Frequent

Plate Changes Resistance To Damage

Will Not Shatter

Features: Lighter Rotor

Lower No-load Easier Shaft Movement

Lower Bearing Loads Less Bolts

More Refining Area Lower Intensity

Larger Openings Better Flow Distribution

Balanced Gaps

TriDisc Conversions for DD Refiners


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50 years

TriConic Refiners


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50 years

BARS

SHAFT

STOCKINLET

STATOR # 1

ROTOR # 2 and # 3

STATOR # 4

TRIPLE CONE CONCEPT

DUO FLOWSTOCKOUTLET

TriConic Refiners


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50 years

SECONDARY REFINERS

DDR INSTALLATION1 x DDR 30 - 600HP

TRICONIC INSTALLATION1 x Triconic RTC 2000 600 HP

OLD INSTALLATION

CURRENT INSTALLATION

Application 1 TMP Post-RefinerCHILE

Annual Saving : US$ 425.000

TriConic Refiners


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Application 2 Tissue (Italy)Reel Long Trans Amp CSF

kN/m

Target 3,53 2,06 650 525

1 4,15 2,30 640 4252 3,60 2,20 640 4253 4,00 2,45 640 4254 3,85 2,40 640 4255 4,08 2,19 600 5006 4,02 2,25 600 5007 4,10 2,25 550 550

Reel Long Trans Amp CSF

kN/mTARGET 2,34 0,78 600 5251 3,10 1,65 500 540

2 3,75 1,90 500 5403 3,50 1,95 500 5404 3,37 1,68 450 5505 3,45 1,47 450 5506 3,70 1,54 450 5507 3,09 1,03 400 5758 3,57 1,46 400 575

16,8 g/m2 Electrical Savings: 15,3%

Electrical Savings: 33,3 %15,5 g/m2

TriConic Refiners

50


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50 years

Application 3 P&W - Short Fiber LineCartiera Della Valtellina (Italy)

3 x DD20 200kW (590kW used)

65 TPD 19 38SR

1 x RTC-1000 315kW (300kW used)

65 TPD 19 35SR

TriConic Refiners

Refining Efficiency Seminar

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