Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and...
Transcript of Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and...
![Page 1: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/1.jpg)
New Technology for Increased FillerNew Technology for Increased Filler Use and Fiber Savings i G hi G din Graphic Grades
05/02/2011
W i Ch Ph DWeiguo Cheng, Ph.D
Nalco Company
1
Nalco and the logo are trademarks of Nalco Company
p y
PaperCon 2011 Page 621
![Page 2: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/2.jpg)
Outline
• Introduction– Impact of Fillers on Sheet Properties
– Challenges of Increasing Filler Contentg g
• Effects of Filler Preflocculation Technology on Sheet Properties p
– Pilot Machine Study
Commercial Application– Commercial Application
• Summary
2PaperCon2011, Covington, KY
PaperCon 2011 Page 622
![Page 3: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/3.jpg)
Fillers in Papermaking
• Fillers were introduced into papermaking for improving sheet propertiesfor improving sheet properties– Optical properties, print quality, smoothness
• Filler is much smaller than fiber Interference with fiber‐fib b difiber bonding
Interference with wet‐end chemicalsend chemicals Sizing agent Strength agent
3PaperCon2011, Covington, KY
PaperCon 2011 Page 623
![Page 4: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/4.jpg)
Why Is Higher Filler Content Desired?
• Fiber substitution1000
SBSKFiber substitution ‐> cost savings– Kraft 850$/ton; 800
900
/tonn
e)
SBSK
NBHK
Kraft 850$/ton;
– PCC 100$/ton700
800
ce in
US
($/
• Energy savings500
600Pu
lp P
ric
4001/3/2008 6/1/2008 10/29/2008 3/28/2009 8/25/2009 1/22/2010 6/21/2010
Ti
4
Time
PaperCon2011, Covington, KY
PaperCon 2011 Page 624
![Page 5: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/5.jpg)
Challenges in Higher Filler Usage
Sheet Strength d
Dusting and k
55
Reduction Picking
45
50
stre
ngth
ndex
Nm
/g)
35
40
She
et s
(ten
sile
in
3019 21 23 25 27 29 31
% Filler in sheet
5PaperCon2011, Covington, KY
PaperCon 2011 Page 625
![Page 6: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/6.jpg)
More Challenges in Higher Filler Usage
• Sheet Properties Loss Internal sheet strength reduction– Internal sheet strength reduction
– Surface strength reduction– Bulk loss
• Poor Machine RunnabilityWet web strength reduction– Wet web strength reduction
– Press picking
R t ti d Sh t F ti• Retention and Sheet Formation– Fillers are harder to retain– Increased retention chemicals leads to poor formation– Increased retention chemicals leads to poor formation
6PaperCon2011, Covington, KY
PaperCon 2011 Page 626
![Page 7: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/7.jpg)
Traditional Methods of Increasing Filler Content
• Furnish Optimization– Composition, Refining
• Filler Optimizationp– PCC vs. GCC
– Size and morphologyp gy
• Wet end chemical optimization– RDF program
– Size press formula
D t th dditi– Dry strength additives
7PaperCon2011, Covington, KY
PaperCon 2011 Page 627
![Page 8: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/8.jpg)
Filler Preflocculation Technology
Increase filler particle size and reduce the interference with fiber fiber bondingwith fiber‐fiber bonding
UntreatedFiller
Prefloc.Filler
8PaperCon2011, Covington, KY
PaperCon 2011 Page 628
![Page 9: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/9.jpg)
Why Not Use Larger Sized Filler Particle?
9PaperCon2011, Covington, KY
PaperCon 2011 Page 629
![Page 10: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/10.jpg)
Why not Use Larger Sized Filler Particle?
10PaperCon2011, Covington, KY
PaperCon 2011 Page 630
![Page 11: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/11.jpg)
Challenges of Filler Preflocculation
• Proper filler flocs size and size distribution
Fill fl t b h• Filler flocs to be shear resistant
L h i d
Hurting Sheet Strength
– Large shear in modern high speed paper‐machine
• Economical• Economical
11PaperCon2011, Covington, KY
PaperCon 2011 Page 631
![Page 12: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/12.jpg)
Controllable Preflocculationwith Improved Particle Size Distributionp
C i l M h d N M th dConventional Method New Method
12PaperCon2011, Covington, KY
PaperCon 2011 Page 632
![Page 13: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/13.jpg)
Controllable Preflocculationwith Improved Shear Stabilityp y
13PaperCon2011, Covington, KY
PaperCon 2011 Page 633
![Page 14: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/14.jpg)
Pilot Machine Trial Conditions
• EuroFEX gap‐former pilot machine at Innventia
• Machine speed: 1000 m/min
• Grade: 75 gsm sheet at 20%, 25% and 30% ash
• Furnish: 85/15 eucalyptus (26 SR) / pine (22 SR)
• Filler: Untreated or preflocculated dispersed PCC p p
• Chemical Additives 7 5 kg/ton starch 4 5 kg/ton OBA 6 kg/ton AKD 7.5 kg/ton starch, 4.5 kg/ton OBA, 6 kg/ton AKD,
cationic flocculant (dosage varied), 5 kg/ton microparticle
14PaperCon2011, Covington, KY
PaperCon 2011 Page 634
![Page 15: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/15.jpg)
Effect of Preflocculation on Strength
15PaperCon2011, Covington, KY
PaperCon 2011 Page 635
![Page 16: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/16.jpg)
Effect of Preflocculation on Opacity
16PaperCon2011, Covington, KY
PaperCon 2011 Page 636
![Page 17: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/17.jpg)
Case Study of Commercial Application
• Grade: Coated freesheet, off‐machine coater
i i h f b h 06• Basis weight of base sheet: 106 gsm
• Machine Speed: 1400 m/min
• Filler– Starting ash content: 17%
Fill 100% PCC– Filler: 100% PCC
• Wet end chemicals5 k /t d t th t– 5 kg/ton dry strength agent
– 9.5 kg/ton cationic starch
17PaperCon2011, Covington, KY
PaperCon 2011 Page 637
![Page 18: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/18.jpg)
Effects of Preflocculation on Sheet Properties
Highlights: fAsh content increased from 17% to 22%, or 5%
Critical sheet strength properties were maintained
Opacity increased
Bulk loss was 1.5%, which was recovered by furnish yoptimization
Tear and stiffness decreased slightly, but within specsg y, p
400% ROI
18PaperCon2011, Covington, KY
PaperCon 2011 Page 638
![Page 19: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/19.jpg)
Steam Reduction with Increased Filler Content
19PaperCon2011, Covington, KY
Treatment started
PaperCon 2011 Page 639
![Page 20: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/20.jpg)
Steam Reduction with Increased Filler Content
20PaperCon2011, Covington, KY
PaperCon 2011 Page 640
![Page 21: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/21.jpg)
Impact on First Draw
Treatment started
21PaperCon2011, Covington, KY
Treatment started
PaperCon 2011 Page 641
![Page 22: Use and Fiber Savings in GhiG raphic GdG rades ppt.pdfNew Technology for Increased Filler Use and Fiber Savings in GhiGraphic GdGrades 05/02/2011 WiWeiguo Cheng, Ph DPh.D Nalco Company](https://reader031.fdocuments.in/reader031/viewer/2022011815/5e644321e9ec687cb446c3e1/html5/thumbnails/22.jpg)
Summary
• With increasing fiber prices, increasing the ash content in graphic paper can significantly decreasecontent in graphic paper can significantly decrease the production costs of papermaking
• Filler preflocculation technology was proven capable of helping papermakers increase filler content by 3% to 5% while maintaining sheet propertiesto 5% while maintaining sheet properties
• Filler preflocculation technology has minimal impact hi bilion machine runnability
• Steam consumption reduced with increased ash.
22PaperCon2011, Covington, KY
PaperCon 2011 Page 642