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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
Celullose fiber structure
Microfibrills
FibrillsCelullosechains
Cell wallsCell Walls
Plant cells
Celullose
monomer
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
Energy Intensity
Is affected by:
Total applied energy Size of discs (conical fillings)
Bar pattern
Motor speed
Number of refiners
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
Pilo Solutions
For Refiner Improvement
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
TriDisc Conversions for DD Refiners
Pilo TriDiscSystem
Original Double
Disc System
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
17/21
50 years
TriConic Refiners
8/10/2019 Refining Efficiency Seminar
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50 years
BARS
SHAFT
STOCKINLET
STATOR # 1
ROTOR # 2 and # 3
STATOR # 4
TRIPLE CONE CONCEPT
DUO FLOWSTOCKOUTLET
TriConic Refiners
8/10/2019 Refining Efficiency Seminar
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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
8/10/2019 Refining Efficiency Seminar
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50 years
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
8/10/2019 Refining Efficiency Seminar
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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
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