CompletPresentationA An

Main reg C" |
Glossary ^^
Gallery ^}
CEPATEC AB
Knut-Erik Persson
PAPER MAKING, GENERALLY 1. Paper machine, different types 2. Paper making, an introduction 3. Fibre selection for different paper grades 4. Interfibre bonding 5. Chemical and mechanical pulps 6. Stock composition, the furnish Page 1 5 8 10 12 15
1. Paper machine, different types
The design of a paper machine can vary, but there are always a forming section, a press sec
Fig. 1. Forming section, press section, drying section. (2-0
The sheet is formed in the forming section. The fibres in the stock are directed and spread, a
Fig. 2. Fourdrinier machine. (2-002.tif)
A formning section can have the original form

an ordinary headbox with perforated rolls
Fig. 3. Headbox with perforated rolls (KMV). (2-003
L:\2-2-e.doc
KEP 01-12-19
Main reg C^ |
Glossary
Gallery
a flat wire where the paper is formed.
D-
Fig. 4. Illustration. Fourdrinier machine. (2-004.
Genuine Fourdrinier machines are found mostly at old fine paper, kraft and at sack paper m
To increase the dewatering there is often a top wire on the Fourdrinier wire. This is particul
Fig. 5. Illustration. Hybrid machine. (2-005.tif)
This headbox, called hydraulic headbox, is of a different type.
Fig. 6. Hydraulic headbox. (2-006.bmp)
Paper can be produced also on twin wire machines with hydraulic headboxes. This one is for newsprint and a simplified sketch looks like this.
Fig. 7. Twin wire machine. (2-007.tif)
L:\2-2-e.doc
KEP 02-01-07
Main reg
Glossary
Gallery
Tissue is another grade, which in most cases is produced on double wire machines. The mac
Fig. 8. Illustration. Double wire machine produ (2-008.tif)
Some paper grades are produced both on double wire machines and on Fourdrinier machine
Fig. 9. Illustration. Fourdrinier wires on a board machine. (2-009.tif)
Paper board consists of several layers, so a board machine can have several Fourdrinier wir
In the press section the wet web is dewatered. The presses can be arranged in many ways. W
Fig. 10. Press section in a sack paper machine. (2
There may be two or more press nips, with one or two felts to each nip.
Fig. 11. Press section in a board machine. (2-011
L:\2-2-e.doc
KEP 02-01-08
Main reg Q" |
Glossary ^^
Gallery
A press roll can be engaged in more than one press nip.
Fig. 12. Press section in a fine paper machine. (2-0
The press rolls are sometimes very big. Bigger rolls mean a longer press nip and a higher dr
Fig. 13. Press section with press rolls in the first ni (2-013.tif)
There may also be special cylinders which have very long nips, known as Shoe Presses.
tfi VALMET Paper Machinery
Fig. 14. Shoe press, Valmet. (2-014.tif)
One of the opposing rolls in a nip may be a hot drying cylinder, as on a tissue machine. A w
Fig. 15. Tissue machine. (2-015.tif)
L:\2-2-e.doc
KEP 01-12-19
Main reg
Glossa
Gallery
An ordinary drying section for most types of paper and board is a multicylinder section. Suc
Fig. 16. Multicylinder section. (2-016.tif)
Sometimes the drying is a combination of a big drying cylinder and of blowing hot air from This method of drying paper is used preferably for soft tissue but also for drying some kraft
Fig. 17. Yankee cylinder, with a gas heated ho
Conclusion: Paper machines can have different designs. Each paper grade requires its spec
2. Paper making, an introduction
Paper is a multi-layer network of paper fibres bound to each other. The fibres are very smal
Fig. 18. Microscope photo. Newsprint. (STFI) (2-01
Actually, paper is produced in the same way in a paper machine as has been done manually
L:\2-2-e.doc
KEP 01-12-19
Main reg ^" |
Glossary ^^
Gallerv
Before the dewatering, the fibres must be treated in a way making it possible to create stron During the dewatering the fibres form an even network. Manually this is done with a mould
Fig. 19. Manual paper production at Grycksbo Paper Mill. (2-0
The wet sheet is laid down, is couched, on a felt. The sheets and the felts are piled and the w
The same steps still remain in the industrial process. In most cases different kinds of stock a In a fine paper mill for example a blend of chemical soft- and hardwood fibres.
Fig. 20. A simplified process line, fine paper mill. (2-020
After a mechanical treatment, refining, the stocks are mixed in the blend or mixing chest. N
Fig. 21. Simplified process line, fine paper mill. The refin (2-021.tif)
L:\2-2-e.doc
KEP 01-12-19
Mam reg
Glossary
ej
Gallery
After cleaning, screening and perhaps also deaeration of the stock, the sheet is formed.
Fig. 22. Process line. Cleaning, deaeration, screening. (2
During the forming process the stock is first uniformly spread on a wire and dewatered to m
Fig. 23. Headbox, wire section. (2-023.tif)
From the wire the wet paper web is brought to the presses, often with the help of a felt. The
Fig. 24. Paper web follows the top felt into the press sect
L:\2-2-e.doc
KEP 01-12-19
Main reg
<
Glossary
1^1 Gallery________|
In the press section the water is squeezed out of the web in a number of nips. Press felts sup
Fig. 25. Illustration. Single felted press roll nip. (2-02
After the press section the web enters the drying section. The web is led above drying cylin
Fig. 26. Multicylinder dryer. (2-026.tif)
3. Fibre selection for different paper grades At the production of paper it is important to utilise the specific properties of the fibres.
Long fibres from chemical softwood pulp are used for production of strong papers, e.g. sa
Fig. 27. Illustration. Long softwood fibres.
Short fibres from chemical hardwood pulp give the sheet a more even surface. Thus, they are suitable for finer printing paper or for the
Fig. 28. Illustration. Short hardwood fibres
L:\2-2-e.doc
KEP 01-12-19
Main reg
Glossary ^^
Gallery
4. Interfibre bonding
How is paper made? What makes the fibres in the wet web to keep together and what makes
On the fibre surface and inside the fibre wall there are chemical groups called hydroxyl or O
The OH groups are bound to the carbon in the cellulose and the hemicellulose of the fibre w
Fig. 32. Illustration. Enlarged fibre surface with ma (2-032.tif)
The OH groups are attracted to each other. However the groups are not only attracted to eac
Water is written with the chemical formula H2O.
/ \ H
Fig. 33. Structural formula, water. (2-033.tif)
Water can help the OH groups to bind by forming bridges between them. When the water evaporates the fibres draw closer. When they have come close enough brid H n ^A K 1,
M B
" ***
-__
- ^^^^"^^^* Fig. 34. Illustration. Water molecules forming b
L:\2-2-e.doc
KEP 01-12-19
10
Main reg ^m |
Glossary ^+
Gallery c^>
When the water has evaporated, the water bridges disappear as well. But now the fibres are The OH groups bind to each other by hydrogen bonds.
Fig. 35. OH groups bind directly to each other with (2-035.tif)
To develop the binding between the fibres as strong as possible, the fibres shall have a cont
Fig. 36. Illustration. Soft, formable fibres. (2-036.tif
The softer the fibres become and the easier they are to bend, the tighter they can fit to other
There must also be a great number of OH groups on the fibre surfaces which can bind to ea
Fig. 37. Illustration. Hydrogen bonding between two (2-037.tif)
L:\2-2-e.doc
KEP 01-12-19
11
The springwood fibre has a thinner fibre wall than the summerwood fibre and it collapse
Fig. 17. Illustration. Fibre collapse, springwood and sum (5-017.tif)
4. Refiner tackle, segments and fillings
The refiner tackle has bars and grooves. There are two parts. In most cases one of them is
Fig. 18. Illustration. Refiner filling: rotor and sta (5-018.tif)
The refiner tackles may have different patterns. The design depends on the pulp grades a
The refining bars may have different length and width. The grooves between the bars ma STATOR
ROTOR
Fig.19. Illustration. Refiner fillings. (5-019.tif)
5-2-e.doc
01-12-19
Main reg (^ Wide bars are used for refining of long fibre pulp.
J Gallery cz>
Fig. 20.1. Refiner fillings with wide bars. (5-020
Thin bars are used for refining of short fibre pulp.
Fig. 20.2 Refiner fillings with thin bars. (5-020.
5. Gap clearance
The distance between the rotor and the stator bars is called gap clearance.
The gap clearance is changed according to how hard the fibres should be treated.
Fig. 21. Illustration. Gap clearance. (5-021.tif)
The gap clearance should be a bit larger than the fibre thickness. During the refining the If the gap is too small the fibres may be cut off. Normally, this should be avoided.
Fig. 22. Illustration. Fibres in a refiner gap. (5-
5-2-e.doc
01-12-19
Gallei
6. Refining machines
The refining, or beating, machines may have different designs but there are two main typ
The conical refiner is the oldest type.
Fig. 23. Classical conical refiner. (5-023.tif)
The more modern conical refiners have a larger cone angle.
Fig. 24. Modern conical refiner: Conflo. (5-024.t
The disc refiner can have a single or a double disc gap. This one has double disc gaps a
Fig. 25. Double disc refiner. (5-025.tif)
5-2-e.doc
01-12-19
Main rt
-
7. Refining energy
The refining result depends on the applied energy as well as on how this is used within th
The refining quantity is shown in kWh by multiplying the motor power by time. The powe 7.1 Idling power (No load power) Not all applied power can be transferred into effective refining.
In all refining a certain amount of the applied power is consumed only to operate the roto
Idling power, kW
The idling power is measured with water flowing trough the refiner and the gap clearanc
The effective refining power, the net refining power, is estimated, if the applied power of
Total power, kW - Idling power, kW
= Net refining power, kW
7.2 Refining quantity
By refining quantity, kWh/ton, is understood the consumed net refining energy during on
Refining quantity: Net energy, kWh/ton
5-2-e.doc
01-12-19
Main 7.3 Refining quality
Gallei
The added net refining energy can be used in different ways.

The energy can be divided either into - a great number of small energy inputs or into
Refining quality:
Net energy divided into many small or few large
a few large energy inputs. The different methods to use the net refining energy will influence the beating result and
Distance between refining bars
Tightly placed refining bars means that each fibre is treated many times while it passes th - High number of low energy impacts gives a gentle refining.
Fig. 26. Illustration. Tightly placed refining bar (5-026.tif)
If the bars are thinly placed the effect will of course be the opposite one. The applied net
- Low number of high energy impacts gives a more severe refining.
Fig. 27. Illustration. Thinly placed refining bars (5-027.tif)
5-2-e doc
02-01-07
10
Main reg C^ Rotor speed
lossa
Gallery c^>
The rotor speed is a factor influencing how many times a fibre will pass a refiner gap in t
Fig. 28. Illustration. Refining bars. Marked roto (5-028.tif) - High number of low energy impacts gives a gentle refining.
Bar width
Also the bar width influences the refining result. If the bar width increases it will take a l
Fig. 29. Illustration. Wide refining bars. (5-029.
- If the energy of impacts is constant, the severity of impacts decreases as the length of th
Weak fibres, like e.g. hardwood pulp, require a gentle refining. By the same reason long f
The individual fibres are not treated but groups or networks of fibres are. The groups are
Fig. 30. Illustration. Fibre in a refiner gap. (5-0
5-2-e.doc
02-01-07
11
Main rt
-
7.4 Fibre consistency
Until now we have talked about how the fibres, passing a refiner gap, are influenced by d
Refining at a high fibre consistency means that there are many fibres in the refiner gap to
Fig. 31. Illustration. Many fibres in a refiner gap
If the consistency is decreased, the number of fibres being able to absorb the applied ene
Fig. 32. Illustration. Few fibres in a refiner gap.
8. What happens to the fibre during the refining?
When refining the fibre walls are treated. The primary wall, P, is more or less peeled off.
Fig. 33. Illustration. Refined chemical fibre. (5-033.tif)
5-2-e.doc
02-01-07
12
Main reg C^
Even the inner part of the fibre wall, S2, is influenced by the refining. The fibre wall start
When the outer fibre walls P and S1 are removed and the fibre wall S2 is delaminated, wa
Fig. 34. Illustration. A split up fibre wall. (5-034.
The water absorption increases the fibres softness and pliancy.
Fig. 35. Illustration. Soft, pliable fibres. (5-035.ti
Later, when the water between and inside the soft fibres evaporates in the drying section
Fig. 36. Microscope picture. Liner. (STFI) (5-036
Thus, the main reason to refine is to attain an outer and an inner fibrillation but some und
Fig. 37. Microscope picture. Inner and outer fibr
5-2-e.doc
01-12-19
13
Main reg C^
When the fibre wall is split up, parts of the wall are peeled off and a lot of fine material i
Fig. 38. Microscope picture. Fibre, surrounded by
The fibre is bent and wrinkled.
Fig. 39. Microscope picture. Fibre folds. (STFI) (5
The fibre may even be pressed together so hard that it will be cut off.
Fig. 40. Microscope picture. Fibres cut off during t
A too intensive refining may be detrimental: - The average fibre length decreases. - The fibre walls are weakened. - The fine material content becomes too high.
5-2-e.doc
01-12-19
14
=;
The fibre changes may lead to: A stock difficult to dewater. A lower paper strength.
During the refining some substances are released from the fibres. Small amounts of ligni 9. The influence of the refining on the paper strength
The classical valley beater is sometimes called a hollander. It existed before the conica
In the hollander the pulp circulates in a trough and at each turn it is treated by rotating kn
Fig. 41. Principle picture. Hollander. (5-041.tif)
When the properties of a paper produced from the stock is measured and related to the re
In the beginning the tensile strength increases sharply, but the more the fibre is refined th
Fig. 42. Diagram. Tensile strength after different refinin (5-042.tif)
5-2-e.doc
01-12-19
15
Main reg C^
Glossary ^^ | Gallery n^>
At first, the papers tearing resistance increases, but later it decreases.
Fig. 43. Diagram. Tearing resistance after different refi (5-043.tif)
The more the pulp is refined the more the opacity decreases.
Fig. 44. Diagram. The opacity after different refining ti
The density slowly increases to an even level.
Fig. 45. Diagram. The density after different refining ti
5-2-e.doc
01-12-19
16
Main
J Gallery cz> |
10. Measuring of the refining degree
It is desirable to be able to quickly check how much a pulp is refined. One well-tried met
Fig. 46. Principle sketch. Refining grade gauge. (5-
For a mechanical pulp another measuring method called Canadian Standard Freeness, C
The Freeness method measures the drainabil-ity. Thus, a high Freeness number means a The stocks dewatering capacity can continuously be measured with a gauge installed in
Fig. 47. Connection between SR and CSF. (5-047.tif)
5-2-e.doc
01-12-19
17
Main r
11. Examples of products with different refining
A greaseproof paper is an extremely tight paper.
Fig. 48. Printed paper partly covered with grease
The paper is made from high-refined fibres with aim on inner fibrillation. The papers op
Fig. 49. Microscope picture. Greaseproof paper (5-049.bmp)
The other extreme is a sack paper, which has to be very strong and resilient.
Fig. 50. Different types of paper sacks. (5-050.tif)
5-2-e.doc
01-12-19
18
Main rt
-
Gallery ^}
**
The sack paper stock is refined in two steps. In the first step the pulp is refined at a high c lossa
Soft wood fibres
n W **
i
Ww
Blend chest
Fig. 51. Flow diagram showing the refining of a sack paper. (5
At the high consistency the fibres are bent and lengthways compressed. At the same time
The outer and inner fibrillation of the fibres, necessary to make them bind strongly to eac
Fig. 52. Microscope picture. Fibres, refined at a
5-2-e.doc
01-12-19
19
li Main reg
^\
The freeness method measures the drain-ability. Thus, a high freeness number means an
Fig. 57. Connection between SR and CSF. (6-057.tif)
6.2 Different freeness, influence on the paper properties
The freeness is measured to get an approximate apprehension of which properties a pape Mechanical pulps always have a lower freeness than a normal, unrefined chemical pulp.
Fig. 58. Tambour with finished paper. (6-058.tif)
Because the chemical pulp is unrefined the amount of fine fraction is very low. The mechanical pulps contain much more fine fraction.
Fig. 59. Unrefined chemical fibres. (6-059.tif)
J:\pfib\texth\dok\6-2.doc
KEP 01-12-19
17
Main reg
lossary
Gallery ^^
Of course, the freeness values can vary within the different types of mechanical pulps.
However, SGW always has the lowest freeness and CTMP the highest. The TMP freenes
The difference depends on the amount of fine fraction, The greater it is, the lower the fre
6.2.1 Tensile strength and tearing resistance
A low freeness value gives a paper high tensileNm/g Tensile index strength, whereas the tearing resistance is
600 700 ml CSF
Fig. 62. Tensile index at different CSF. (6-062.tif)
6.2.2 Opacity
The opacity of a sheet depends on how the fibres are separated and on the applied energy
Fig. 63. Edge cross section, newsprint. (6-063.tif
KEP 01-12-19
18
Main reg
Glossary
iallery
The fine fraction has few hydroxyl groups and forms few hydrogen bonds.
Thus, the more fine fraction, the larger the area of unbound fibre surfaces being able to sp
Fig. 64. Illustration. The reflection and the refraction
It is the other way round with chemical pulp. If the refining is increased, the opacity decr
Fig. 65. Picture covered with a low-refined and a high
The more pliable the fibres becomes and the more OH groups that can be exposed, the m
Fig. 66. Extremely high-refined paper, grease-proof p (6-066.tif)
KEP 02-01-08
19
lain reg
^j
6.2.3 Brightness
The mechanical pulp contains almost all the wood lignin. When the lignin is exposed to u
Fig. 67. Part of a newspaper page, which has become y (6-067.tif)
6.2.4 The strength of the wet paper web The wet paper web must have such a strength that it resists breaking.
Fig. 68. Side view: modern newsprint machine. (6-068.tif)
If the strength is too low, it must be improved by addition of a chemical, long fibre, reinf
Fig. 69. Chemical fibres (reinforcement fibres) in a newsprint
KEP 02-01-08
20
, Main reg v^
.* m.m Glossary ^^ Gallery ^>
6.2.5 The paper density and stiffness The density is a measure of the fibre tightness in the sheet.
Fig. 70. Microscope picture. Newsprint. (6-070.tif)
The density is measured by weighing a sample sheet with a determined area.
Fig. 71. Thereafter, the thickness is measured and the volume is calculated. The density is calcula (6-071.tif)
Fig. 72. (6-072.tif) Fig. 71 and 72. Determination of the sheet density.
Chemical fibres are soft. The fibres collapse and come close to each other. The paper den
The high stiffness of mechanical fibres prevent the fibres to collapse. The paper thicknes
Fig. 73 and 74. Illustration. Comparison between sheet ma
KEP 01-12-19
21
Glossary ^^ |
iallery
-v
It is just because of the lower density that mechanical pulp is used, for example, in the m The board becomes stiff and the price per volume becomes lower.
Fig. 75. Example of products with mechanical fibres i
The lower the energy input during the grinding or refining, the lower the density will be.
Fig. 76. Edge cross-section. Board. (6-076.tif)
7. Examples of products containing mechanical pulp
Formerly SGW was often used, for example in newsprint. Nowadays TMP is the main ra
Fig. 77 and 78. Examples of products containing TMP.
KEP 01-12-19
22
Main reg
lossary
Gallery ^^
SGW was often used for the middle layer in board. Today CTMP is primarily used.
CTMP is also mixed into simple printing and writing paper. The main reason for this is th CTMP is an excellent fluff pulp for hygienic products and different tissue papers.
Fig. 79. Example of products produced from CTMP pulp. (6-0
8. Pulp for sale
Recirculated air SGW, TMP and CTMP are sold as market pulp in Sweden. To increase the possibilities to
pulp to press
Air<=$>
Fig. 80. Flash dryer. (6-080MJ)
KEP 01-12-19
23
II Main reg
Glossary ^^ Gallery E^>
9. Grade properties, summary
In mechanical pulp the majority of the original wood material remains. The wood yield is
In a chemical pulp most of the lignin and extractives are removed. A large part of the hem
Mechanical pulp fibre is shorter as well as thicker than the chemical. It has thicker fibre w
Fig. 81. Illustration. Weight difference between mech
The mechanical fibres do not collapse as easily as the chemical. Few hydrogen bonds are The original brightness of mechanical pulp is higher than that of the chemical one, but it
Mechanical pulp is less expensive to produce than chemical pulp.
KEP 01-12-19
24
Glossary
Gallery
CEPATEC AB Knut-Erik Per
FORMING 1, GENERALLY
1. Forming process..........................................................................................................2 l.lDewatering .............................................................................................................2 1.2 Wet web strength.....................................................................................................4 2. Forming and paper properties...................................................................................6 2.1 Formation................................................................................................................6 2.2 Fibre orientation....................................................................................................10 2.3 Distribution of the fine material in the Z direction...............................................15 |j 3. Factors influencing the forming process.................................................................16 [ 3.1 Forming of fibre floes...........................................................................................16 ' 3.2 Fibre orientation in the sheet.................................................................................27 3.3 Distribution of the fine material in the Z direction...............................................28 II
J:\Pfib\texth\dok\ll-2.doc
KEP 2001-11-20
Main reg
Glossary
Gallery
1. Forming process 1.1 Dewatering
During the forming process, the stock has to be dewatered in a way which an even fibr
Fig. 1. Forming section in a liner machine. (11-001.
What influences the dewatering and what makes the fibres in the network keep togethe
If there is a large amount of fine material in the stock 2. Microscope photo. TMP pulp.and so Fig. or if the fibres are swollen (STFI
Fig. 3. Microscope photo. Beaten chemical fibres. (Sunds Def.) (11-003.tif)
If a higher concentration in the head box is chosen, the amount of water leaving the sto
Fig. 4 and 5. Pictures illustrating how the stock volume
J\Pfib\texth\dok\11-2 doc
KEP 2001-11-21
Main re
Glossary
Gallery
The stock temperature is another factor, influencing the drainage.
Fig. 6. Dewatering on a Four-drinier machine. (ll-
The higher the temperature is, the lower the water viscosity will be and the faster the s
Fig. 7. Diagram showing the connection between t (11-007.tif)
Adding a retention chemical is another way to increase the drainage rate.
Fig. 8 and 9. Equipment for preparation and dosage of a rete
J:\Pfib\texth\dok\11-2.doc
KEP 2001-09-11
Main re
Glossary
Gallery
The dewatering does not depend on the stock conditions, only. The design of the wire
Fig. 10. Two-sided dewatering on a hybrid machine. (
1.2 Wet web strength
In the finished paper the fibres bind to each other with hydrogen bonds. To make these
Fig. 11. Illustration. Enlarged surface section showin
However, the wet web has a certain strength, too. The reason is the so called surface te
Fig. 12. Open transfer of the web from the wire to the (11-012.tif)
KEP 2001-09-11
Main re
Glossary
Gallery
Wet fibres are surrounded by a thin water layer.
Fig. 13. Illustration. Two fibres surrounded by a water (11-013.tif)
When two such fibres get into contact with each other, the water layers will overlap in
Fig. 14. Illustration. Two fibres in close contact. The w
Forces, trying to keep the water layers together, arise and the fibres will keep together,
Fig. 15. Illustration. Forces arising between two wet fib (11-015.tif)
KEP 2001-09-11
Main re
Glossary
Gallery
2. Forming and paper properties 2.1 Formation
The forming process means a lot for all paper properties. In this part of the presentati
The local distribution of the fibres in a paper is called paper formation.
Fig. 16. Microscope photo. Fine paper. (STFI) (11-016.ti
A simple, but not always correct, way to judge the formation is to view the paper in tra
Fig. 17. Visual judgement of the paper formation. (ll-017
KEP 2001-09-11
Main re
Glossary
Gallery
Of course, instruments in the mills can measure the formation more exactly.
Fig. 18. Sensor measuring the paper formation. (11-018.ti
A better formation makes the paper more even and improves its printability.
Fig. 19. Picture from a printing office. (Norra Skne) (11-
The formation influences the paper strength, but how much depends on how a certain
Fig. 20. Reeling up of a kraft liner. (ll-020.tif)
A good formation will not only be of importance for the properties of the finished pape
Fig. 21. Paper machine for liner production. (11-021.tif)
KEP 2001-09-11
Main re
Glossary
Gallery
Fig. 22. With good formation, it will become easier to dewater and press the web. Fourdrinier section. (11-022.tif)
However, above all, the formation means the most during the drying process.
Fig. 24. Drying cylinders in a multi cylinder dryer. (11-02
When the fibres dry, they shrink crosswise and become thinner. In the cross point the f
Fig. 25. Microscope picture showing how the overlying fib
If the formation is bad, the paper dries and shrinks unevenly. There will be tensions in
Fig. 26. An example of a paper with a cockled finish. (11-0
KEP 2001-09-11
Main re
Glossary
Gallery
A paper that should have a high gloss has to be calendered. At this operation the forma
If the paper sheet has a bad formation, the thicker parts of the sheet will be harder pres
Fig. 27. Calender. (Twin roll with a soft nip; soft calender.
If the paper has a very uneven formation the thick parts may still be moist when the pa
Fig. 28. Drying section in a fine paper machine. (11-028
Moist parts are easier compressed in the calender. The free surfaces in the paper sheet,
Fig. 29. Paper that has been calendered and made trans
KEP 2001-09-11
Main re
Glossary
Gallery
In another lighting the transparent parts appear as dark spots. This is called blackening
Fig. 30. Transparent parts appearing as dark spots. (11-0
2.2 Fibre orientation
During the forming, the fibres are not only to be distributed, but also directed or orien
Fig. 31. Forming of sack paper. (ll-031.tif)
In many paper grades it is desirable to have the properties the same as possible in alltyp Fig. 32. Different d
Fig. 32 and 33. Examples of grades where the properties hav
KEP 2001-09-11
10
Main re
Glossary
Gallery
In fine and sack papers, the fibres are to be equally orientated in all directions.
Fig. 34. Illustration. Sheet with the fibres equally orientate
However, sometimes it is desirable to have the fibres directed, as much as possible, in
Fig. 35. Illustration. Sheet where the fibres are more orien
Newsprint and tissue are examples of such grades.
Fig. 36. Newspapers. (11-036.tif)
Fig. 37. Tissue paper. (11-037.tif)
Fig. 36 and 37. Examples of grades where the strength has to
KEP 2001-11-02
11
Main re
Glossary
Gallery
The more the fibres are orientated in the machine direction, the higher the strength in t
Fig. 38. Paper web in a printing press. (11-038.tif)
With machine direction orientation the web becomes stronger and it will be easier to p
MFig. 39. (ll-039.t
Fig. 41. (11-041.tif) Fig. 39 - 41. Magazine paper machine: forming, pressing, drying.
KEP 2001-09-11
12
Main re
Glossary
Gallery
How the fibres are orientated in the sheet does not only influence the strength properti
Fig. 42. Paper web in the drying section. (11
The fibres always shrink more crosswise than lengthwise during the drying. If most fib
Fig. 43 and 44. Paper web during the drying. The main shri
Thus, if the fibre orientation is different in machine direction, a different shrinking is a
Fig. 45 and 46. Paper web during drying. The main shr
KEP 2001-11-02
13
Main re
Glossary
Gallery
The fibre orientation is often different in the edges. This is one reason, why the edge ro
Fig. 47. The edges of a paper web often have a differen
How the fibres are orientated in the paper can be estimated by measuring the tensile str
Fig. 48. Measure of the tensile strength. (11-048.tif)
With the help of new, modern instruments the fibre orientation can be defined safely an
Fig. 49. Apparatus for determination of the main fibre d
Sometimes, the fibre orientation is different on the two sides of the paper, that is one s
Fig. 50. Illustration. Paper with different fibre orientati
KEP 2001-09-11
14
Main re
Glossary
Gallery
If the humidity in the atmosphere surrounding the paper is changed, the paper will shri
Fig. 51. Sheet pile in a printing office. (11-051.tif)
The result will be a curly paper and the phenomenon is called curl.
Fig. 52. Illustration. Curl. (11-052.tif)
2.3 Distribution of the fine material in the Z direction It is not only the paper formation and the fibre direction in the sheet that have a direct
Fig. 53. Microscope picture. Cross-section of a paper s (11-053.tif)
KEP 2001-09-11
15
Main re
Glossary
Gallery
A usual problem, in one-sided dewatering, is that most of the fine material will be loca Such a paper may give curl.
Fig. 54. Microscope picture. Cross-section of a pape
The surface strength and the printing properties are also strongly influenced by an une
Fig. 55. Offset printing. (Norra Skne) (11-055.tif)
3. Factors influencing the forming process 3.1 Forming of fibre flocs
We have seen how some important paper properties are influenced by the forming pro
The quality of the supplied stock and the conditions during the forming are both of gre
KEP 2001-11-02
16
Main re
Glossary
Gallery
3.1.1 Stock fibre properties
Fig. 58. Photo. The fibres in a stock easily tangle and bind mechanically to each other, they create Fibr floc
Such fibre flocs can be quite stable, so rather great forces are needed to split them up.
During the forming, fibre flocs are always created.
Fig. 60. Forming section in a board machine. (11-060.tif)
If these flocs are not broken down, they will remain in the finished paper. The paper w
Fig. 61. Example of papers with better and worse f
KEP 2001-09-11
17
Main re
Glossary
Gallery
Thus, fibre flocs cause bad formation.

What determines how much fibre flocs there will be in the stock?
Fig. 62. Forming in a Fourdrinier machine. (ll-062.tif)
A stationary fibre will occupy a space equal to its own volume.
Fig. 63. Illustration. Fibre. (11-063.tif)
The fibres in water follow the water movements. If there are whirls, or turbulence, in The largest possible volume the fibre can sweep over, corresponds to a sphere with a
Fig. 64. Illustration. Fibre rotating in water. The sweep v
KEP 2001-09-11
18
Main re
Glossary
Gallery
The fibre in a softwood pulp is about three times as long as the fibre in a hardwood pu
Fig. 65. Microscope picture. Long soft
Fig. 66. Microscope picture. Short, hardwood chemical fibres
The sweep volume increases with the cube of the fibre length. So if the softwood fibre
Fig. 67. Illustration. Comparison between the sweep
However, the hardwood fibre is lighter than the softwood fibre. In order to get the sam
In spite of the number of hardwood fibres being four times higher, the short fibres swe
Fig. 68. Illustration. Four short hardwood fibres hav
KEP 2001-09-11
19
Main re
Glossary
Gallery
The ideal way to form a sheet would be to have enough space to let the fibre move free
Fig. 69. Illustration. Few fibres in water. Here, the fi
However, forming a paper under such conditions is not realistic from practical or econ Consequently, the fibres, not being able to move freely, will tangle and form flocs.
Fig. 70. Illustration. Many fibres in water. Here, the
The risk for such floc formation increases with the fibre length. Therefore, forming a s
Fig. 71 and 72. Illustrations. Many short and few long
KEP 2001-09-11
20
Main re
Glossary
Gallery
Fibres easily form flocs. However, what really happens when a floc is formed?
If there is not enough space for the fibres to move freely, the fibres penetrate into each
Fig. 73 and 74. Illustrations showing how the movement s
The turbulence force in the stock make the fibres move. As long as the moving force is
Fig. 75. Illustration. Turbulence whirls in the stock. (11
The fibres are elastic and therefore, they bend when they move.
However, if the turbulence decays, the fibres stop moving. An immobile fibre will take
Fig. 76. Illustration showing fibres straightening out w
KEP 2001-09-11
21
Main re
Glossary
Gallery
The fibres, however, prevent each other from straightening out completely. As a result
Fig. 77. Illustration showing how the fibres lock each o
Fig. 78. Chemical fibres. (STFI) Refined chemical fibres are softer and more elastic, than unrefined ones. These proper (11-078.tif)
Fig. 79. Conical refiner. (11-079.tif)
The fibres in mechanical pulps are short and stiff. Such fibres are not Fig.easily entangl so 80. Mechanica
KEP 2001-09-11
22
Main re
Glossary
Gallery
The choice of fibres depends on which paper that is to be produced. Thus, the furnish p Fig. 82. Magazine f
(11-082.tif)
Fig. 84. Kraft paper (sacks). (11-084.tif)
It is during the forming process in which the floc formation could be prevented.
Fig. 85. Flow diagram. The short circulation. (11-0
Before the web is formed, the stock is always highly diluted. This dilution is done in th
Fig. 86. Dilution of the stock in the short circulatio (11-086.tif)
KEP 2001-09-11
23
Main re
Glossary
Jallery
Diluting the stock is the ideal way to prevent fibres from forming flocs.
Fig. 87 and 88. Photos. Stock before and after diluting.
A paper produced of a highly diluted stock gets a good formation. The better the formation is, the stronger the paper will be.
Fig. 89. Liner is one example of a strong paper formed fro
However, the stock can not be diluted too much. The lower the fiber concentration is, t
Fig. 90. Diluting before the fan pump. (11-090.tif)
Thus, there is maximal limit beyond which the stock can not be diluted. The next step i
KEP 2001-09-11
24
Main re 3.1.2 Stock turbulence
Glossary
Gallery
The way to prevent the fibres from forming large flocs is to have enough stock turbulen
If the turbulence is strong, the shearing forces tearing up the flocs becomes greater tha
Whether the fibre floc is decreased only, or dispersed totally, depends on the character
Fig. 92. (11-092.tif)
Fig 91 and When the turbulence is estimated, the intensity92. Photossize of the whirls must be taken and the showing stocks before and after gen
The intensity is the velocity difference between two adjoining whirls.
Fig. 93. Illustration. The intensity of whirls. (11-0
The size is the area influenced by every single whirl.
Fig. 94. Illustration. The size of the wirls, the sca (11-094.tif)
KEP 2001-09-11
25
Main re
Glossary
Gallery
When the diameter of a simple whirl is approaching the fibre length, micro turbulence
Fig. 95. Illustration of micro turbulence. (ll-095.tif)
Fig. 96. (11-096.tif) If the turbulence is more coarse, the flocs are only partly broken down.
Fig. 97. (11-097.tif) Fig. 96 and 97. Illustrations showing a fibre floc being broken
The smaller the turbulence whirls are, the greater the probability to release single fibre
Fig. 98 and 99. Illustrations showing a fibre floc broken down b
KEP 2001-09-11
26
Main re
Glossary
Gallery
However, what will happen to the fibre flocs does not depend on the turbulence, only. If the fibres are long and elastic the number of points locking each fibre increases and
Fig. 100. Illustration. Long fibres lock each other in ma (11-100.tif)
Thus, long fibres do not only form flocs easily. The fibre length, too, makes the flocs di
The stock turbulence can never totally prevent the fibres from forming flocs, but it limi
However, the strength of the paper never becomes as high when the flocs are broken d
3.2 Fibre orientation in the sheet
During the forming process, the fibres tend to orientate in the flow direction of the stoc The longer and stiffer the fibres are, the more they tend to orientate.
Fig. 101. Illustration. Alignment of the fibres in a flo (11-101.tif)
KEP 2001-09-11
27
Main re
Glossary
Gallery
If a local cross flow is generated during the forming, the fibres will orientate in the sam
Fig. 102. Illustration. The orientation of the fibre in
The fact that the fibres tend to orientate in the flow direction depends on laws of physi
3.3 Distribution of the fine material in the Z direction Stock properties
The more fine material there is in a head box stock, the greater the risk becomes to get
Single-sided dewatering When the stock is dewatered, the fibres form a connected network. The fibre network
Fig. 103 and 104. Illustration. Single-sided dewatering.
KEP 2001-09-11
28
Main re
Glossary
Gallery
The large quantities of water, flowing through the initially formed fibre layers, wash off some of the fine Fig. 105. Dewatering over foils. (11-105.tif) material, too. This is another reason for the different amount of fine material in the Z direction.
A single dewatering causes the content of fine material in paper to be lower closest to
Two-sided dewatering
When dewatering between two wires, the same thing will happen.
Fig. 107. Twin wire former. (11-107.tif)
However, in this case the fine material becomes more symmetrically distributed. It wil
Fig. 108. Microscope photo. (STFI) (11-108.tif)
KEP 2001-09-11
29
Main re
Glossary
Gallery
When dewatering in two directions, the two fibre networks are only half as thick as wh
Fig. 110. (11-110.tif) Fig. 109 and 110. Illustrations. One- and two-sided
Retention chemicals (Retention aids) To help bind the fine material to the fibres, retention chemicals are often used.
The wire retention becomes higher. Besides, when the fine material forms flocs which
Fig. 111. Illustration showing how the fibre surfa (11-111.tif)
During the forming process, the more even distribution of the fine material is enhancin
Fig. 112. Dewatering over foils. (11-112.tif)
KEP 2001-11-02
30
Main re
Glossary
Gallery
Thus, the retention agent improves the retention and makes the stock to drain more qui
What could happen is that the fine material binds together and creates flocs, which can
Fig. 113 and 114 illustrate how the fine materi
Forming a paper means that the stock is to be dewatered and that the fibres are to be d
However, the quality demands on each paper grade is specific and the supplied furnish
Of course, the demands on the section forming the net work becomes specific as well.
KEP 2001-11-15
31
Main reg C^
Glossary ^
Gallery
CEPATEC AB Knut-Erik Perss
FORMING 2, SHORT AND LONG CIRCULATION

1. White water system ........................................................................................... 2 1.1 Short circulation .............................................................................................. 2 1.2 Long circulation .............................................................................................. 5 1.3 White water cleaning ....................................................................................... 6 2. Wet end system ................................................................................................. 8 2.1 Broke system ................................................................................................... 8
=>
3. Approach flow system ..................................................................................... 12 3.1 Grammage regulating valve .......................................................................... 12 3.2 Fan pump ....................................................................................................... 14 4. Cleaning and screening ................................................................................... 16 4.1 Hydrocyclone ................................................................................................ 16 4.2 Stock deaerator .............................................................................................. 22 5.1 Feeder pump .................................................................................................. 24 5.2 Screens .......................................................................................................... 25 5.3 Feeder pipe .................................................................................................... 28
L:12-3.doc
KEP 2001-11-21
Main reg C^
Glossary
Gallery
This chapter is about the stock and process water flows around the paper machine. Th
1. White water system 1.1 Short circulation
During the forming, the water in the stock suspension drains through the wire and the
Fig. 1. Dewatering on a Fourdrinier machine. (12-001.tif)
The water passing through the wire is called white water. Some parts of the stock solid
r^<]<-
*-
< ; u ,i >
Fig. 2. Illustration. One-sided dewatering. (12-002.tif
By wire retention it is meant how much of the solids in the stock from the headbox tha
Fig. 3. Fourdrinier section in a liner machine. (12-003.tif)
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
The wire retention depends on how much fine material the stock contains from the beg
Fig. 4. Microscope photo. Headbox stock in a fine paper m (12-004.tif)
An additional important factor is of course the mechanical conditions on the wire secti
Fig. 5. Fourdrinier section. (12-005.tif)
The short circulation is a term used describing the process flows around a paper mach
By the short circulation is meant the flow loop from the wire tank, through pumps and
T
^
Machine W chest <j
^^^v^^v
-;
i
iMaskirlHIKSZ "
Ikar IBEffl grc:1

ii i
Fig. 6. Process schedule. The short circulation. (12-006.tif
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
In the short circulation the stock from the machine chest is diluted. The dilution is done before the fan pump with water from the wire tank.
Fig. 7. Dilution of the machine chest stock, before the f (12-007.tif)
The wire tank is the chest where the white water is collected when the stock is dewater The constant level is obtained as some of the white water always spills over.
Fig. 8. Wire tank with flooding white water. (12-008.tif)
4 the short The reason why there is always a water surplus in 1 18-20% circulation is that the stock
When the paper web then leaves the wire it has a consistency of about 20%.
III
II kar 1
B9t 3 %
1 Vlra-E
II
9rop E
Fig.ch The short circulation. Marking of typical stock c 9. ^
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
1.2 Long circulation

The excess water from the short circulation goes to the long circulation.
Fig. 10. Process schedule. The short and the long circulation
In the long circulation the water is first collected in a white water tower. The white wa
Fig. 11. Process schedule. Water flood to the white water tow
The water in the white water tower is later used for regulation of the stock consistency
Fig. 12. Process schedule. The long circulation with marked (12-012.tif)
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
The water in the white water tower is also used to slush broke or dry pulp bales.
Fig. 13. Process schedule. A part of the long circulation w
1.3 White water cleaning

UJ___
The excess water from the white water tower is cleaned from fibres and fibre fragment -i fk-^v
Blond Machln* J chfffil chfffil 1
H Bak-
Xi'l
ivi
Fig. 14. Process schedule. The white water flood from the
To catch the fine material better, pulp from some of the stock chests is usually mixed i
Fig. 15. Disc filter for cleaning of the white water. (12-015
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
The cleaned white water is used for various shower water on the paper machine.
Fig. 16. Wire showers in a Fourdrinier section. (12-016.tif)
The remaining water leaves the process and goes to the exterior cleaning.
Fig. 17. Process schedule. The white water surplus from the
The separated fibres and the fine material are normally not led back to the paper mill. I
Fig. 18. The exterior cleaning of the white water. (12-018.ti
The energy content in the dewatered sludge is made use of when it is later mixed with
The cleaned water leaves the process.
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
You always try to minimise the amount of fresh water to a paper machine system. A sm
Normally, the system must not be too closed. Dissolved organic substances and dissolv
2. Wet end system 2.1 Broke system

The broke taken back may be wet and come from, for example the couch pit. Or the broke may be dry coming from broke pulpers.
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
The conditions in the pulpers vary and it is difficult to keep an even consistency in the
Consequently, the consistency in the broke tower where the different pulped broke is s
Fig. 21. Process schedule. Recovery of wet and dry br
To get an even consistency the pulp is pumped further and dewatered on a thickener.
The thickened pulp goes further to a second broke chest.
The water leaving the pulp at the dewatering on the thickener goes back to the white w
Fig. 24. Process schedule. The broke chest after the thickener is ma
L:12-3.doc
KEP 2001-09-11
Main reg C^
Glossary
Gallery
The pulp from the broke chest is diluted with white water to the correct consistency. It
Fig. 25. Process schedule. The blend chest after the thickener is
If the broke is difficult to slush, it may first pass through a deflaker before it lands in th
Fig. 26. Deflaker. (12-026.tif)
2.2. Stock preparation
The stock in the blend chest contains the correct balance of fibre chosen to give the pa
Fig. 27. Process schedule. The refiners are marked.
L:12-3.doc
KEP 2001-09-11
10
Main reg C^
Glossary
Gallery
Chemical fibres have always passed a number of refiners before they land up in the ble
Fig. 28. Conical refiner. (12-028.tif)
After the blend chest the stock is forwarded to the last stock chest: the machine chest. On the way to the machine chest there is a final regulation of the stock consistency.
Fig. 29. Proces
Fig. 30. Measuring of the consistency after the dilution with white wate
If dry strength agent is added it is often brought to the stock in the machine chest. If ro
Fig. 31. Process schedule. Ordinary addition points for alum and dry (12-031.tif)
L:12-3.doc
KEP 2001-09-11
11
Main reg C^
Glossary
Gallery
3. Approach flow system 3.1 Grammage regulating valve
When the stock leaves the machine chest, the consistency is constant. The flow from th
Fig. 32. Proc (12-032.tif)
Fig. 33. Machine chest pump. (12-033.tif)
By regulating the flow from the machine chest the disired amount of fibres is supplied
Fig. 34. The grammage regulating valve controls the s (12-034.tif)
L:12-3.doc
KEP 2001-09-11
12
Main reg C^
Glossary
Gallery
A computer informs about the correct fibre amount.
The computer receives information about the machine speed, the web width and the gr
Fig. 35. Measuring device, grammage. (12-035.tif)
The stock size is often added just when the stock leaves the machine chest.
Fig. 36. Machine chest pump. The addition point for size is mark
L:12-3.doc
KEP 2001-09-11
13
Main reg C^
Glossary
Gallery
If filler is added, it is in most cases done just before the fan pump.
Fig. 37. Fan pump. The addition point for filler is marked. (12-037
The stock is later cleaned in hydrocyclones and in screens. It is not possible to avoid th
3.2 Fan pump

The consistency in the machine chest is too high to make it possible to clean the stock
To get a good admixture it is important how the dilution of the stock with the white wa
Fig. 38. Process schedule. The short circulation.
L:12-3.doc
KEP 2001-09-25
14
Main reg C^
Glossary
Gallery
In most cases the stock pipe from the machine chest is led into the wire tank. Then, the
Fig. 39. Illustration. Arrangement for stock dilution. (12-
Sometimes the same thing is done with the pipe collecting and bringing back the flow
Fig. 40. Illustration. Arrangement for dilution of the retu
Previously the flow was in most cases controlled by throttling it after the pump.
Fig. 41. Controlling the flow by a throttle valve. (12-04
L:12-3.doc
KEP 2001-09-11
15
Main reg C^
Glossary
Gallery
Nowadays, the flow is controlled by regulating the rotation speed of the pump motor
Fig. 42. Controlling the flow by a pump motor with va
4. Cleaning and screening

4.1 Hydrocyclones
After the fan pump the stock is cleaned in small cyclones: hydrocyclones.
Fig. 43. Battery. (12-043.tif)
L:12-3.doc
KEP 2001-09-11
16
Main reg C^
Glossary
Gallery
The reason why the hydrocyclones are so small, is that the smaller the diameter, the be
Fig. 44. Cyclones in a cleaner battery. (12-044.tif)
A hydrocyclone is cone-shaped. The incoming stock, the inject, is fed into the thick en
Fig. 45. Exploded view of a hydro-cyclone. The injec (12-045.tif)
The stock, when it comes into the cyclone, starts rotating.
Fig. 46. Exploded view of a hydrocyclone. The rota (12-046.tif)
L:12-3.doc
KEP 2001-09-11
17
Main reg C^
Glossary
Gallery
The quicker the stock rotates, the more the centrifugal force will influence the stock.
The centrifugal force influences particles with a high density more, than particles with
Fig. 47 and 48. Exploded view of a hydrocyclone.
The fact that the centrifugal force influences heavy particles more than light ones and
Closest to the wall the stock streams in a downwards spiral. The heavy particles come dr
1
L:12-3.doc KEP 2001-09-11 18
r > Reject
Fig. 49. Exploded view of a hydro-cyclone. (12-049.ti
Main reg C^
Glossary
Gallery
However, in the centre of the cyclone the flow spiral is directed upwards and its conten
Fig. 50. Exploded view of a hydrocyclone. (12-050.t
Thus, heavy stock particles, for example grains of sand and very big filler particles, ca
Fig. 51. Microscope picture. Grains of sand. (12-051
The stock might contain other contamination, even lighter than the fibres. In spite of th
The reason why just this contamination is separated is that it is larger than the fibres. A
Fig. 52. Microscope picture. Bark particle in a stock reject. Note the size differe (12-052.tif)
L:12-3.doc
KEP 2001-09-11
19
Main reg C^
Glossary
Gallery
An important thing to remember is that the fibres easily form flocs, particularly when t
The flocs may surround the contamination making it more difficult for the contaminati
Fig. 53. Illustration. Fibre floc. (12-053.tif)
Because of this, the fibre concentration in the inject is seldom above 0.8% and often as
The accept from the first cleaning step is ready to go further into the process.
In most cases the reject volume is about 10% of the inject volume. The reject leaving t
Thus, the weight of reject leaving the cyclone may come up to 20% of the weight of th
Fig. 55. Exploded view of a hydrocyclone. The numbers deno (12-055.tif)
L:12-3.doc
KEP 2001-09-11
20
Main reg C^
Glossary
Gallery
First the reject is diluted with white water and then pumped to a recycling step, step 2,
Fig. 56. Step 2 is the first recycling step in a cleaning s
The amount of reject from step 2 is still too high to be allowed to leave the process. It
Fig. 57. Step 3 is the second recycling step in a cleaning s (12-057.tif)
The procedure is repeated and in most cases the reject passes from step 3 through ano
Fig. 58. Step 4 and 5 in a five step cleaning system. (12-05
L:12-3.doc
KEP 2001-09-11
21
Main reg C^
Glossary
Gallery
The reject from a recycling step is always led back to the inject of the previous step.
When the hydrocyclones are connected in this way they are said to be cascade connect
Fig. 59. Five cascade connected steps. (12-059.tif)
4.2 Stock deaerator
The stock leaving the hydro-cyclones contains air, which may disturb the forming proc
Fig. 60. Microscope picture. Air bubbles in a stock. (Cellc
The air bubbles may expand and disrupt the stock jet from the headbox.
The higher pressure in the box, the more the bubbles are pressed together and the more
Fig. 61. Stock jet in a twin wire former. (12-061.tif)
L:12-3.doc
KEP 2001-09-11
22
Main reg C^
Glossary
Gallery
A way to get rid of the air is to pump the stock to a deaerator. A deaerator is a closed v
Fig. 62. Exploded view. Horizontal deaerator tank. (12-06
The air bubbles in the stock are fixed to the fibres. To remove them, the stock is ejecte There is an underpressure in the deaerator making the stock boil. When it boils the air
Fig. 63. Exploded view. Enlarged part of a deaerator. (12-
The deaerator must be placed on a high level. The outgoing stock pipe should not only
Fig. 64. View showing the placing of the deaerator on an (12-064.tif)
L:12-3.doc
KEP 2001-09-11
23
Main reg C^
Glossary
Gallery
5.1 Feeder pump
The fibre concentration in the stock is now low enough to form a sheet. However, if the
The water from the wire tank used for dilution of the stock also contains air. If there is
Fig. 65. Flowsheet showing a system where there is
Normally the feeder pump has a variable rotary speed and the flow determines the con
Fig. 66. Feeder pump. (12-066.tif)
L:12-3.doc
KEP 2001-09-11
24
Main reg C^
Glossary
The feeder pump must give a flow free from pulsations. The pump is therefore designe
Fig. 67. Exploded view. Feeder pump. Note the doub
5.2 Screens
The stock is not ready for the paper machine. First it has to be cleaned a last time in a
The task of the screen is to remove remaining particles that may contaminate or damag
Fig. 68. Fourdrinier machine. The screened stock is (12-068.tif)
The screen drum in a machine screen can be single or double. Figure 69 shows an exp
Fig. 69. Exploded view. Machine screen with a scree
L:12-3.doc
KEP
2001-09-11
25
Main reg C^
Glossary
Gallery
The drum plates can have round holes or slots. The slot width is always much smaller
Fig. 70. Sketch. Screen plates with slots and holes. (12-070.tif)
The clean stock passes through the drums perforated plates. Coarse elements, such as
Fig. 71. Exploded view. Screen. The inject, accept
The screen is equipped with rotating wings.
Fig. 72. Exploded view. Screen, rotating wings. (12
L:12-3.doc
KEP 2001-09-11
26
Main reg C^
Glossary
Gallery
When a wing rotates it first creates a pressure pulse and later a suction pulse.
The pulses break up the fibre layer formed on the pressure side and prevent plugging o
Fig. 73 and 74. Illustrations showing the effect of the pres
Thus, the rotating wings simplify the screening. However, the pressure pulses generate
Fig. 75. Outgoing pipe after the screen; the feeder pipe. (1
One way to decrease the risk for harmfull pressure pulses is to twist the rotating wings
Fig. 76. Screen rotor with twisted wings. (Valmet) (1
L:12-3.doc
KEP 2001-11-08
27
Main reg C^
Glossary
Gallery
To make the screen work in a right way the reject must not be too small. A reject up to
Fig. 77. Exploded view. Screen. Normal amount of rej (12-077.tif)
The reject is rescreened in a secondary screen. The accept of the screen is brought bac
5.3 Feeder pipe
The inner surfaces of the screen are thoroughly polished. The pipe after the screen mu
Fig. 78. Exploded view. Screen. The inner surfaces ar
The polished surface is there to prevent deposits. If the surface is too coarse, the frictio
L:12-3.doc
KEP 2001-09-13
28
Main reg C^
Glossary
Gallery
Normally it is desirable to add the retention agent as close as possible to the headbox.
One problem with the selected addition point is that it is difficult to distribute such a sm
Fig. 79. A common arrangement for dosage
Before the headbox the flow should be as uniform or laminar as possible.
Pipe bends easily create whirls, which may follow the flow into the headbox. Actually,
Fig. 80. Feeder pipe to the headbox. (12-080.tif)
L:12-3.doc
KEP 2001-11-08
29
______^_
Main reg
Glossary
Gallery c^>
FORMING 3, HEADBOX
1. Headbox, generally...................................................................................................2 2. Flow spreader (cross direction distributor)...............................................................4 3. Middle chamber......................................................................................................10 4. Headbox nozzle......................................................................................................14
^>
5. Hydraulic headboxes..............................................................................................24 6. Hydraulic headboxes with air cushion....................................................................29 7. Hydraulic boxes with local stock dilution..............................................................31 |C
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
Gallery
1. Headbox, generally
The task of the headbox is to distribute the fibres evenly over the wire and give them a
At one time the headbox was really a box: an open box at the entrance of the paper ma
Fig. 1. Old type of an open headbox. (13-001.tif)
Even if the headboxes used today look differently, the task is the same, to distribute th
To make this possible the stock jet must have an even thickness and concentration and
Fig. 2. The outflow of the stock jet on a Fourdrinier wir (13-002.tif)
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
<
allery
The headbox, on this sack paper machine, can be seen as an example of a box type use
Fig. 3. The headbox on a sack paper machine. (13-003.tif)
The stock comes into the flow spreader. This part distributes the stock across the mach
Fig. 4. Headbox. Marking of the flow spreader. (13-0
The stock leaves the box through the headbox nozzle. In this part the jet is formed.
Fig. 5. Headbox. Marking of the outflow nozzle. (13
Between the flow spreader and the headbox nozzle there is an equalisation chamber.
It is, above all, the size of this chamber that separates the box type from the box mostly
Fig. 6. Headbox. Marking of the equalisation chamb
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
Gallery
2. Flow spreader
On old paper machines the stock was distributed to the box by branching off the feede
Fig. 7. Old type of flow spreader. (13-007.tif)
The flow spreaders used today look almost in the same way.
The stock is lead into the thick end of a tapered channel with rectangular, or sometime
Fig. 8. Modern type of a flow spreader. (13-008.tif)
The flow is then pressed through a thick plate with drilled holes or through a tube bank
Fig. 9. Tube parcel, a section cut out. (Seen obliq (13-009.tif)
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
<
allery
The reason for the tapered form of the entrance channel is that the static pressure shou
Fig. 10. Illustration. A tapered flow spreader. The static press
If the flow spreader does not taper, the pressure would be lower in the outlet end.
Fig. 11. Illustration showing what would happen to the static
The lower pressure in the outlet end would make the stock velocity slower.
Fig. 12. Illustration showing what would happen to the flow v
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
<
allery
It is not easy to get the same pressure over the whole width. If the flow to the flow spr
Fig. 13. Illustration showing what happens to the static pres
To avoid the undisirable pressure difference there must be an overflow from the outlet
Fig. 14. Illustration. The static pressure in the tapered flow
How much stock that has to pass through the outflow valve to even out the pressure di
Fig. 15. Illustration. Pressure check tube with a sight glass.
On modern machines the outflow valve is regulated by signals from pressure gauges m
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
Gallery
In spite of all the static pressure at the entrance of the tubes will not be exactly the sam
When the stock streams through the tubes a certain back-pressure will be formed. The
Earlier the tubes were totally straight, but they could be slightly conical, too. Fig. 16.
Illustration. Tube bank with totally st (13-016.tif)
Fig. 17. Illustration. I Tube bank with I conical tubes. I
I H H
(13-017.tif) ^H
The reason for making the tubes conical was to increase the pressure drop over the tub
The velocity of the stock streaming out of the tubes.
i g . 1 8 . I ll u s t r a t i o n . P r e s s u r d r o p o ve r s t r a i g h t a n d c o n i c
tubes. (13-018.tif) The distance between the mo
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
<
allery
Fig. 19. The lower the velocity is when the stock streams out, and the smaller the distance betw (13-019.tif)
Fig. 20. (13-020.tif)
Figure set. Illustrations. Flow streams after straight and after
The tubes must not be too conical. If they are, the stock may no longer follow the tube
t/\tMt
Fig. 21. Illustration. Flow streams after conical tub
In modern headboxes the tubes are longer and the risk for the stock to release the tube
Fig. 22. Illustration. Prolonged tubes. (13-022.tif)
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
<
allery
Another change is that the tube diameter in most cases is increasing step by step.
Fig. 23. Illustration. Tubes with a sudden increa (13-023.tif)
When the stock passes such a step zone, small whirls, micro turbulence, will be forme
Fig. 24. Illustration. Forming of micro turbulen (13-024.tif)
The micro turbulence is meant to disperse the fibre flocs in the stock.
Fig. 26. (13-026.tif) Figure set. Illustrations. Fibre flocs are broken
13-2.doc
-KEP 2001-09-12
Main reg
Glossary
Gallery
3. Equalisation chamber
The task of this chamber (sometimes called reception chamber, stilling pond, etc.) is to
However, the pressure levelling out in this chamber is always achieved at the price of u
The velocity of stock jet has to follow the wire speed. In the first totally open headbox
If the wire speed increases, it is not enough to increase the stock height in a direct prop
Already at a low machine speed, the limit is reached when the stock height is no longe
give the jet the desired velocity.
Figure set. Illustration of the connection betw
V = y ( 2 g h) * 60 V = m/min g = 9.81 m/sec2 h = m
13-2.doc
-KEP 2001-11-08
10
Main reg
Glossary
The next development step was to close the boxes and to make them work under press
Fig. 29. Illustration. Closed headbox. (13-029.tif)
It was not very easy to get a completely even stock flow to the headbox. Pressure pulse
A way to make this possible is to keep a constant stock height and to work with a press
The stock height in the chamber may be rather high, in most cases between 500 and 10
Fig. 30. Illustration. Air cushion head-box. Normal sto
13-2.doc
-KEP 2001-09-12
11
Main reg
Glossary
Gallery
The higher the stock height is, the more slowly the stock will stream through the cham The stock turbulence forces become weak and the fibres easily form flocs.
MM.
Fig. 31. Illustration. Building up of a fibre floc. (13-031
To break down the developed fibre flocs, perforated rolls, so-called rectifier rolls, are u
Fig. 32. Photo. Interior picture of a head-box with perfora
Fig. 33. The turbulence generated by the perforated rolls becomes coarse. Because of the coars (13-033.tif)
Fig. 34. (13-035.tif)
Figure set. Illustration. Fibre floc broken down by a coars
13-2.doc
-KEP 2001-09-12
12
Main reg
Glossary
<
allery
To prevent the fibres from getting stuck over the hole edges the rolls are slowly rotatin
Fig. 35. Illustration. Perforated rolls. (13-035.tif)
However, the primary reason for having rectifier rolls is not to break down flocs. When
mmmmmmm
rmmmmmmtt
Fig. 36. Illustration. The velocity of the stock flow in various
The hole area of the rolls is in most cases smaller than half the total area. In other word
Fig. 37. The surface of the rectifier roll. (13-037.tif)
13-2.doc
-KEP 2001-09-12
13
Main reg
Glossary
<
allery
When the stock streams through the holes, the velocity increases to more than the doub
The turbulence downstream the rectifier roll is coarse. If it is not eliminated, it is to be
Fig. 38. Illustration. Streams created when the stock pas
Thus, the perforated rectifier rolls may create streaks, local regions, where the basis w
4. Headbox nozzle
The nozzle is the converging channel forming the stock jet.
Fig. 39. The nozzle part of a headbox with perforated rec (13-039.tif)
13-2.doc
-KEP 2001-09-12
14
Main reg
Glossary
<
allery
The nozzle itself consists of a lower lip and an upper lip, sloping to create a convergin
Fig. 40. Illustration. Headbox nozzle. The top and the bott (13-040.tif)
The pressure in the headbox determines the velocity of the stock jet when it leaves the
V =/ (P) Q = / (P h)
Fig. 41. Headbox. (13-041.tif) P = pressure V = the stock jet velocity h = discharge opening Q= stock flow (b= lip width)
The discharge opening is not the factor that determines the amount of fibres streaming
13-2.doc
-KEP 2001-09-12
15
Main reg
Glossary
<
allery
When the discharge opening increases, the flow area increases, too, and more stock im
Figure set. Illustration. Increased discharge opening in
However, when the back-pressure in the nozzle drops, the pressure in the headbox dro
44.
Fig. 044.tif)
\(13-
7^_
Fig. 45. (13-045.tif)
EX.
Figure set. Illustration. Increased discharge opening lower back-pressure. Lower back-pressure lower P Lower P lower V.
Sometimes, instead of difference, you talk about the jet to wire speed ratio or the disch The speed difference is small and even a small change of the difference may influence
13-2.doc
-KEP 2001-09-12
16
Main reg
Glossary
<
allery
When the box pressure decreases a pressure gauge in the headbox sends a signal to the
Fig. 46. Short circulation. A signal from a pressure ga
When the flow increases, the flow resistance in the nozzle increases, too, and the press
Figure set. Illustration. Increased Qin increased P
When the rotation speed of the feeder pump increased, the stock from the machine che
If, on the other hand, the discharge opening was changed only locally? What would th
13-2.doc
-KEP 2001-11-14
17
Main reg
Glossary
Gallery
The outflow nozzle is equipped with a number of adjusting screws. With the help of th
Fig. 49. Adjusting screws for local adjustment of th (13-049.tif)
By locally changing the discharge opening it is possible to adjust how much stock that
Fig. 50. Illustration. The stock jet streaming out fro
On big paper machines the top lip is stiff and therefore impossible to bend. Instead the
Fig. 51. Illustration. Marking of the slice bar. (13-0
13-2.doc
-KEP 2001-09-12
18
Main reg
Glossary
Gallery
The discharge opening is regulated by bending the slice bar only.
Fig. 52. Illustration. A straight slice. (13-052.tif)
Adjustment of the discharge opening influences adjoining areas, too.
If the discharge opening is decreased, the stock streams towards the places where the d
Fig. 53. Illustration. A local adjustment of the regu (13-053.tif)
If these waves meet other similar waves, they may reinforce each other.
Fig. 54. Waves overlaying and reinforcing each oth
The cross streams make it difficult to adjust the correct basis weight profile. The cross
13-2.doc
-KEP 2001-09-12
19
Main reg
Glossary
<
allery
The top lip can not be adjusted to increase and decrease the discharge opening, only. T
Fig. 55. Outflow from a headbox nozzle. The top lip c
The longer it is moved forwards, the more steeply the stock jet will go down.
Figure set. The angle of the stock jet against the wire. I
However, it is not only the horizontal position of the top lip that determines the angle o
Figure set. Illustration. Influence on the angle of the stock jet aga
13-2.doc
-KEP 2001-09-12
20
Main reg
Glossary
Gallery
Fig. 60. The angle of the stock jet determines the location of the jet landing on the wire and by (13-060.tif)
Fig. 61. (13-061.tif) Figure set. Illustration. The yellow arrow describes the directio
Thus, the discharge opening determines the flow from the headbox. If the opening is lo
If the discharge opening then is horizontally adjusted, the angle of the jet landing on w The discharge opening influences the stock jet in another way, too.
When the discharge opening decreases, the stock flow will contract even more, on its w
The more the stock flow contracts, the more the stock velocity will increase. The flow
When the stock accelerates, it will be drawn out in the stream direction. The flow elon
Fig. 62. Illustration. The acceleration of the stock in a he (13-062.tif)
13-2.doc
-KEP 2001-11-07
21
Main reg
Glossary
<
allery
The flow elongation is always in the machine direction, which makes the fibres orienta
Fig. 63. Illustration. Elongational flow in a headbox n
If there are fibre flocs in the stock, they are stretched. As a result of the stretching, the
Figure set. Illustration. Fibre flocs are broken down when the s
When the stock flow elongates, the turbulence whirls are also extended. As they do so,
Fig. 66. Illustration. A turbulence whirl stretching out i
13-2.doc
-KEP 2001-09-12
22
Main reg
Glossary
Gallery
Thus, a small discharge opening is good, if it is desirable to orientate the fibres in the
However, it is not possible to reduce the discharge opening too much There is a limit f
A smaller discharge opening means that the pressure in the headbox will increase. The
Figure set. Illustration. A reduced discharge opening higher P higher V
The velocity of jet has to follow the wire speed and must not be changed. Therefore, th
Fig. 69. If the velocity of the stock jet becomes too hig (13-069.tif)
13-2.doc
-KEP 2001-11-08
23
Main reg
Glossary
<
allery
However, an increased stock concentration means an increased risk for creation of new Fig. 70.
(13-070.tif)
Figure set. Photos. A well dispersed stock and a floced sto
If the discharge opening is reduced, the fibre concentration will increase and the fibres
To find the optimal discharge opening is always a compromise between the risk of buil
5. Hydraulic headboxes
The development of headboxes has continued and today a new type of headbox is mos The equalisation chamber is much smaller and sometimes there is none. In most cases
Fig. 72. An example of modern hydraulic headboxes. (13-0
13-2.doc
-KEP 2001-09-12
24
Main reg
Glossary
Gallery
The hydraulic headbox is easier to place in small spaces and therefore it is suitable in s
Fig. 73. The placing of a hydraulic headbox in a modern twin w
In this type of box there is no air cushion that can reduce the pressure variations of the The space between the flow distributor and the outflow nozzle is small and the time it
Fig. 74. Exploded view. Hydraulic headbox. (13-074.tif)
13-2.doc
-KEP 2001-09-12
25
Main reg
Glossary
<
allery
The desired turbulence is achieved when the stock streams through narrow tubes.
Fig. 75. Exploded view of the inside of a hydraulic headbox
To create the desired fine-scale turbulence the tube diameter increases stepwise.
The small chamber levels out the pressure after the tubes and is therefore called equali
13-2.doc
-KEP 2001-09-12
26
Main reg
Glossary
Gallery
In some hydraulic headboxes there is no equalisation chamber.
Fig. 78. Example of a hydraulic headbox without any equalisation ch
A small equalisation chamber, or sometimes no such chamber at all, reduces the possi
After the chamber the flow must again be directed and the stock therefore passes throu
Fig. 79. Exploded view of the inner part of a hydraulic head (13-079.tif)
The inlet side of the tubes are round but later they become increasingly square. Square
13-2.doc
-KEP 2001-09-12
27
Main reg
Glossary
Gallery
When the stock streams out from the square holes, the jets come closer to each other a
Fig. 81. Illustration. Outflow from tube bank with
In a hydraulic headbox the stock streams rapidly through the tubes. The turbulence bec
Fig. 82. Illustration. Fine-scale turbulence. (13-0
Developing the right turbulence is very important. The contraction in the nozzle of a h
Fig. 83. Exploded view. The outflow nozzle in a h
The low contraction in the nozzle of the hydraulic headbox makes the stretching forces
13-2.doc
-KEP 2001-11-14
28
Main reg
Glossary
Gallery
A way to prevent the fine-scale i&VALMET turbulence from getting weaker is to install thin partitio
OptiFlo
Adjustable Turbulence Slice Section
Fig. 84. The outflow nozzle with thin partition walls. (13
However, the turbulence must not be too strong. If it is too strong it breaks up the stock
6. Hydraulic headboxes with air cushion
Working without air cushion is possible if the dewatering is done between two wires. O
One way of getting back the pulsation moderating effect was to place an airfilled vesse
Fig. 85. Exploded view. A hydraulic headbox with a pulsat (13-085.tif)
13-2.doc
-KEP 2001-09-12
29
Main reg
Glossary
<
allery
Another way is to place a tank before the headbox.
Fig. 86. Photo. Pressure levelling out tank before the flow
The aim of the perforated plate in the tank is to eliminate the coarse-scale turbulence.
Fig. 87. Exploded view. Pressure tank with a perforated pl
The hole diameter increases step by step to increase the fine-scale turbulence.
Fig. 88. Exploded view. Perforated plate in a pressure tan
13-2.doc
-KEP 2001-09-12
30
Main reg
Glossary
Gallery
7. Hydraulic headboxes with local stock dilution
Adjusting the basis weight profile with the help of the slice was not an easy operation.
A straight lip means that the stock flow can not be locally changed.
Fig. 89. Example of a headbox with a straight lip. (13-0
Instead of changing the stock flow the stock concentration is changed in a certain posi
Fig. 90. Photo. Dilution equipment for a local adjustme
The local stock concentration is changed by dilution with different quantities of white The flow out of the tubes has to remain constant in all positions.
A = incoming stock flow B = white water flow C = outgoing stock flow C= A+B = constant
Fig. 91. Exploded view. Dilution arrangement for local
13-2.doc
-KEP 2001-11-14
31
Main reg
Glossary
Gallery
The stock is now distributed over the dewatering wire or wires. Now it is necessary to
13-2.doc
-KEP 2001-09-12
32
Mam reg
Glossary
Gallery
FORMING 4, FOURDRINIER SECTION

1. One-sided dewatering .................................................................................................... 2
2. Table rolls ...................................................................................................................... 3

3. Forming board ............................................................................................................... 5 4. Landing of the stock jet on the wire .............................................................................. 7 5. Speed difference between stock jet and wire ................................................................ 9 6. Cross streams and their influence on fibre orientation ................................................ 12 7. Foils ............................................................................................................................. 15 7.1. Pressure and suction pulses ................................................................................. 16 7.2. Turbulence ........................................................................................................... 17 7.3. Pulse frequency .................................................................................................... 21 8. Wet suction boxes ....................................................................................................... 23 9. Dry suction boxes ........................................................................................................ 24 10. Couch roll .................................................................................................................. 26 11. Dandy roll .................................................................................................................. 26
^> ^>
12. Forming wire ............................................................................................................. 27
14-1.doc
01-09-12
Mam reg
Glossary
Gallery
The forming process is not finished until the water is drained from the stock and a wet we
The dewatering can be either one-sided or two-sided. On a Fourdrinier the sheet is alwa
1. One-sided dewatering
One-sided de-watering. This is how it once started in the manual paper mill.
Fig. 1. Manual paper production. (14-001.tif)
It was even from the beginning quite obvious that there had to be a certain movement in
Fig. 2. Paper machine with a Fourdrinier. (14-002.tif)
14-1.doc
01-11-08
Mam reg
Glossary
Gallery
When the stock is de-watered through a forming wire, a fibre3. Fig. network starts forming clos
(14-003.tif)
Figure set. Illustration. One-sided dewatering. The fibre conce
dewatered, the remaining dewatering takes place as a thickening process, which means a
2. Table rolls
From the beginning the driving force for the dewatering was the gravitation only. Howev
Fig. 5. Old Fourdrinier section with table rolls. (14-
When the wire entered a table roll, a pressure pulse was generated. Later, when leaving t
The pressure difference caused turbulence in the stock on the wire and to some degree im
Fig. 6. Illustration. Pressure and suction pulse over (14-006.tif)
14-1.doc
01-09-13
Mam reg
Glossary
Gallery
The machine speed increased and so the strength of the pressure pulses. Soon the machin
When these fragments of the broken up fibre net rejoined the net, they disturbed the form
Figure set. Illustration. Fibre network broken up by a p
Not only the formation became worse when the machine speed increased. The retention w
The fibre network is considerably more fine meshed than the wire. The tighter the net, th
Fig. 9. Illustration. Wire, covered by a fine-meshed fibre
If the pressure pulses break up the fibre net, the fine material could pass through more ea
Fig. 10. Illustration. A broken fibre network. (14-010.tif)
14-1.doc
01-11-08
Mam reg
Glossary
Gallery
The table rolls made it difficult to increase the speed of the paper machine, without destr
3. Forming board
The first element supporting the wire is called the forming board. The forming board is built up of a number of bars or blades.
Fig. 11. Illustration. Forming board. (14-011.tif)
One of the reasons for installing a forming board is to prevent the wire from bending dow
Fig. 12. Illustration. The stock jet lands on the wire. (14-0
14-1.doc
01-09-12
Mam reg
Glossary
Gallery
The wire, dewatering the stock, can have various mesh sizes. Even if the wire meshes are
Fig. 13. Illustration of the difference in size be (14-013.tif)
The other purpose of the forming board is to prevent too quick a dewatering. The dewatering speed on the forming board can be regulated by the blade length and the
Fig. 14. Forming board. (Huyck) (14-014.tif)
Normally a small part of the stock jet meets the wire just in front of the first blade. The re
Fig. 15. Illustration. A small part of the stock jet lands ju
14-1.doc
01-11-16
Mam reg
Glossary
Gallery
4. Landing of the stock jet on the wire
Not only the position of the forming board and its openness influence the dewatering. Th
The stock jet is ejected with a small angle towards the wire.
The oblique angle makes the stock jet move both forward and downward, both horizonta
Fig. 16. The velocity of the stock jet in horizontal and ve (14-016.tif)
The steeper the jet, the greater the velocity in the vertical direction will be. The force of t
Fig. 17. Calculation of the vertical force of the stock jet a
The vertical force of the jet must not be too high. Parts of the stock jet may then bounce o
14-1.doc
01-11-16
Mam reg
Glossary
Gallery
The wire is woven of round threads and the upside opening between the meshes almost h
Fig. 18. Illustration showing the narrowing form of (14-018.tif)
If the fibres are pushed too powerfully into the wire, they will penetrate and plug the funn
Fig. 19. Illustration. Fibres penetrating into and dec (14-019.tif)
If some fibres are pressed too hard into the narrowing channels, they may be difficult to pull out again. As a consequence, instead some fibres will be pulled out of the web when it is lifted on the coach roll.
Fig. 20. The web lifted from the wire over the couch (14-020.tif)
Even if that does not happen, an inprint of the wire pattern may sometimes be seen in the
The angle of the stock jet determines where on the wire it will land and how the velocity w Not only the velocity in the vertical direction is important. The velocity in the horizontal
14-1.doc
01-09-12
Mam reg
Glossary
Gallery
5. Speed difference between stock jet and wire
Normally the stock jet velocity differs from the wire speed. In most cases the jet velocity
Fig. 21. Illustration. The stock jet velocity related to the wire speed.
When the jet meets the wire, the stock closest to the wire will, quicker than the rest of the
Fig. 22. Illustration. Cross-section of a stock jet. The velocity in diffe
The shear forces are the same forces that are achieved when using pressure generating d
14-1.doc
01-09-12
Mam reg
Glossary
Gallery
One thing distinguishing the shear fields of the jet speed difference from those created by
Fig. 23. Illustration. The size of the shear forces and their capability
The greater the speed difference between the jet and the wire is, the greater the shear for
The fact that the shear fields have the same direction makes the fibres orientate in the she The closer to the wire, the greater the shear becomes, and the more the fibres orientate in the machine direction.
Figure set. Shear fields directed in the machine direction orientate th
14-1.doc
01-11-07
10
am reg
Glossary
iallery
Thus, one effect of various intensity of the shear fields is that the fibres on the two sides
Fig. 26. Illustration. Paper where the fibres of the papers tw
14-1.doc
01-09-12
11
Mam reg
Glossary
Gallery
6. Cross streams and their influence on the fibre orientation
The fact that the shear forces are directed only in the machine direction presumes that th
The speed differences between the jet and the wire make the fibres move in relation to th
If the stock jet velocity is greater than the wire speed the movement is forward along the
Fig. 27. Illustration. Stock on the Fourdrinier with a
If there are cross streams in the stock jet, the fibres will also move across the wire and th
Fig 28. Illustration. Cross streams make the stock m (14-028.tif)
14-1.doc
01-09-12
12
Mam reg
Glossary
Gallery
Thus, the fibres move at the same time both in the machine and in the cross directions. T
The direction of the shear forces follows the real movement and the fibres orientate in the
Fig. 29. Illustration. The white arrow marks the stock
If the jet velocity is instead lower than the wire speed, the fibres will move in the opposit
Fig. 30. Illustration. The stock moves backwards in re (14-030.tif)
The crosswise movement is the same as before.
Fig. 31. Cross streams make the stock move crosswise (14-031.tif)
14-1.doc
01-09-12
13
Mam reg
Glossary
Gallery
The white arrow shows the real movement, determining the fibre orientation. It now is po
Fig. 32. Illustration. The white arrow marks the stock
Thus, how the cross streams influence the fibre orientation does not depend only on the d
Dewatering the stock on the forming board is easy. The jet pressure is high. The fibre net
During the subsequent dewatering it is different. The shear forces decline and the gravity A way to strengthen the forces, which dewater and shear the stock, is to use foils.
14-1.doc
01-09-12
14
Mam reg
Glossary
Gallery
7. Foils
A foil is a bar or a strip, in most cases with a width between 45 and 75 mm. The bar has a The slope of the blade is in most cases between one and three degrees.
Fig. 33. Foil. (14-033.tif)
When the waterlogged wire runs over the sloping blade surface it is influenced by a force
Fig. 34. Illustration. The path of the wire over a foil. (14-0
The water sucked away follows the underside of the wire and is then scraped off towards
Fig. 35. Illustration. Dewatering over foils. (14-035.tif)
14-1.doc
01-09-12
15
Mam reg
Glossary
Gallery
7.1. Pressure and suction pulses

The strength of the suction pulse depends on the blade angle. The larger the angle is, the
Fig. 36. Illustration. Pressure and suction pulse formed when t
The distance the wire runs over the blade surface is also of importance. When the blade-l
Fig. 37. Illustration. The suction pulse increases by the increas
However, the foil blades do not only give suction pulses. When the wire enters the plane blade surface, short pressure pulses are generated.
The small pressure pulses loosens up the fibre layer and the subsequent dewatering will b
Fig. 38. Illustration. The pressure pulse over the front blade ed
14-1.doc
01-09-12
16
Mam reg
Glossary
Gallery
The pulse strength does not depend only on the design of the foils. It also depends on the
7.2. Turbulence
Sucking out the water of the stock might be done in different ways. Using foils is a way t
Fig. 39. Forming of turbulence over the foils. (14-039.t
When the wire runs over the sloping blade it has to move downwards. Before the next bl
The repeated down and up movements of the wire create shear forces breaking down the
Fig. 40. Illustration. Shear forces breaking down fibre f (14-040.tif)
When the wire runs over the sloping blade surfaces, turbulence is created in the undrain
The created shear forces break down the fibre flocs. It is obvious that the size of the shea
The importance of the machine speed is manifest, but how important is the influence of th
14-1.doc
01-09-12
17
Mam reg
Glossary
Gallery
In the first example the running distance, along the slope of the blade, is doubled.
Figure set. Foils with different blade lengths.
A doubling in the blade length means a doubling in the horizontal distance (S h). At a con
Fig. 43. Ex. 1. Doubling the blade length. Vertica (14-043.tif)
th The time (2tv) for the wire to move the vertical distance (2Sv) will, at the same time, be tw
a tv= th
| 2-tv
2-th a
Fig. 44. Ex. 1. Doubling the blade length. Time-c
14-1.doc
01-09-12
18
Mam reg
Glossary
Gallery
When the distance (Sv) and the time (tv) increase proportionally the vertical speed (Vv) re
Fig. 45. Ex.1. Doubling the blade length. The ve
o. In another example, instead the angle () increases from 1o to 2Sh Now, the wire moves v
Sv
Sh
2a
2-Sv
Fig. 46. Ex. 2. Doubling the blade angle. The len
The time (tv) of the motion (2Sv) will still be the same.
a
th
tv=th
th
2a
lth=tv
Fig. 47. Ex. 2. Doubling the blade angle. The tim (14-047.tif)
The exactness is enough at such small angles.
14-1.doc
01-09-12
19
Mam reg
Glossary
Gallery
The vertical velocity now becomes twice as high andVh shear forces increase. the
a
Vv
Vh
2a
2-Vv
Fig. 48. Ex. 2. Doubling the blade angle. The velocity (14-048.tif)
A large blade angle is to prefer if it is desirable to produce great shear forces, but attentio
Fig. 49. Illustration. Fibre net broken up by too strong (14-049.tif)
14-1.doc
01-09-12
20
Mam reg
Glossary
Gallery
Different foils give differently powerful turbulence and therefore the choice of the foil mu
7.3. Pulse frequency
The number of foils determines how many times the stock is influenced by the vertical w
Instead of selecting a large blade angle it might be suitable to decrease the angle and incr
Fig. 50. Foils battery. (14-050.tif)
A smaller blade angle and a greater number of blades decrease the vertical movement ov Turbulence energy = f (pulse strength pulse freq.)
A high pulse frequency means that the stock turbulence will mainly remain in the areas b
The reduced energy input in each pulse decreases the risk of breaking up the fibre networ
That risk is also connected to the type of fibres, and the number of fibres in the created n
14-1.doc
01-09-12
21
Mam reg
Glossary
Gallery
When describing what is happening in the stock on the wire the word used is activity. A
Fig. 51. Stock turbulence: activity. (14-051.tif)
Normally, small, short waves in the free stock are desirable.
Fig. 52. Example of a suitable grade of acitvity. (1
If the activity instead grows to a degree causing free drops to leave the stock it is most pr
Fig. 53. An activity that, most probably, is too high
Thus, by studying the activity the degree of turbulence in the undrained fibre suspension
14-1.doc
01-09-12
22
Mam reg
Glossary
Gallery
8. Wet suction boxes

The more the fibre network grows, the more difficult it will be to drain the stock.
Fig. 54. Illustration. Fibre network. Now, the larger part of th
A way to overcome the increasing drainage resistance is to gather the foils in closed boxe
Fig. 55. Illustration. Wet suction box. (14-055.tif)
The underpressure between the foils makes the suction pulses longer and more water is s
Fig. 56. Suction pulses over wet suction boxes. (14-056.tif)
14-1.doc
01-09-12
23
Mam reg
Glossary
Gallery
The vaccum in the suction boxes is increased keeping step with the growth of the fibre ne
Fig. 57. Normal vaccum in wet suction boxes (metre columns
When the wire has passed the last suction box, the free stock is in most cases gone and th
Fig. 58. The last wet suction box. The wet line is visible. (14-
9. Dry suction boxes
The vacuum level in the dry suction boxes is higher than in the wet ones. In most cases th
Fig. 59. Illustration. Dry suction boxes. (14-059.tif)
14-1.doc
01-09-12
24
Mam reg
Glossary
Gallery
The water can be removed only at a limited rate.
If the suction increases too much, the wire is pressed harder against the blades of the suc
Fig. 60. Illustration. The counter force F strongly incre
The increased friction causes the wire and the blades of the suction box to get unnecessar
Fig. 61. Fourdrinier section with wet and dry suction b
The blades of the suction boxes are quite plane. Now the fibres are totally fixed and it is
Fig. 62. Dry suction boxes with quite plane blades. (14
14-1.doc
01-09-12
25
Mam reg
Glossary
Gallery
10. Couch roll

The last dewatering on the wire section takes place when the web runs over a perforated
In the couch roll there is a suction box, its suction force is greater than in the former suct
Fig. 63. Couch roll on a liner machine. (14-063.tif)
11. Dandy roll

The importance of shear forces in the undrained fibre suspension to avoid harmfull fibre
In the wire section on a Fourdrinier machine producing fine paper a dandy roll was used
The dandy roll is a wire covered drum placed on the wire with a carefully adjusted pressu
Fig. 64. The dandy roll on a fine paper machine. (14-
The reason for having the dandy roll is not only to disperse un-desired fibre flocs. It also
At high machine speed, it is difficult to avoid splash from the drum. Consequently, on the
14-1.doc
01-09-12
26
Mam reg
Glossary
Gallery
12. Forming wire

The wire has to be as plane as possible on the paper side and the mesh openings small.
Fig. 65. Illustration. The top side of a forming wire.
As most of the fibres are orientated in the machine direction it is an advantage that the su
The fibres then more easily bridge the wire openings without penetrating and blocking th
Fig. 66. Illustration. Fibres drawn against the top si
The backside shall give the wire the mechanical stability and the durability.
Fig. 67. Illustration. The underside of a forming wir
14-1.doc
01-09-12
27
Mam reg
Glossary
Gallery
A way to meet the various demands on the wire is to use different thread layers. A wire of several layers has a fine paper side and coarse backside.
Fig. 68. Illustration. Cross-section of a forming wire w
On the Fourdrinier section the dewatering always takes place in one direction, only. The
A way to avoid these weaknesses is to dewater between two wires. The next part is about
14-1.doc
01-09-12
28
Mam reg
Gallery
CEPATEC AB Knut-Erik Persson
FORMING 5, TWIN WIRE FORMER

1. Two-sided dewatering ..................................................................................................... 2 2. Hybrid former .................................................................................................................. 6 2.1. Generally .............................................................................................................. 6 2.2. Sym-Former from Valmet .................................................................................... 8 2.3. Duoformer D from Voith .................................................................................... 13 2.4. SymFormer MB from Valmet ............................................................................ 16 3. Twin wire formers ......................................................................................................... 17 3.1. Roll former ................................................................................................................. 18 3.1.1. Speed-Former from Valmet ............................................................................. 18 3.1.2. Roll formers for tissue paper ........................................................................... 23 4. Blade formers ................................................................................................................ 24 4.1. Bel Baie 2 from Beloit ........................................................................................ 24 5. Blade-roll formers and roll-blade formers ..................................................................... 27 5.1. Blade-roll former ................................................................................................ 28 5.1.1. Bel Baie 4 from Beloit ..................................................................................... 28 5.1.2. Bel Baie 3 from Beloit ..................................................................................... 30 6. Roll-blade formers ......................................................................................................... 32 6.1. Speed-Former HS from Valmet .......................................................................... 32 6.2. Speed-Former SC from Valmet .......................................................................... 34 6.3. Speed-Former HHS from Valmet ....................................................................... 35 6.4. OptiFormer with forming shoe from Valmet ..................................................... 36 6.5. Duoformer CFD from Voith ............................................................................... 38 6.6. OptiFormer with loadable blades from Valmet .................................................. 40
PFIB15/FILM15-4
2001-09-12
Mam reg
Gallery
1. Two-sided dewatering
The Fourdrinier machine works well if the speed is not too high. However, when the spee
Fig. 1. Dewatering on a Four-drinier section. (15-
Besides, at a one-sided dewatering, the fine material is unevenly distributed in the Z dire
The difficulties increasing the machine speed and the constantly increasing demand on p
Fig. 2. Dewatering in a twin wire former. (15-002.
Dewatering in two directions means that the fibre net, which the water has to cross, is jus
When dewatering through a fibre net half as thick the flow resistance, becomes only half
Figure set. Illustration. The thickness of the fibre net at o
PFIB15/FILM15-4
2001-09-12
Mam reg
The flow penetrating a single fibre net will also change. When the stock is dewatered in two directions, the amount of water streaming in each direction becomes half as much as when dewatering in only one direction. This, too, means that the flow resistance is halved.
Gallery
Figure set. Illustration. Flow amounts in each direction at on
Thus, if the flow resistance is halved twice, it is decreased to one fourth compared with d But how fast, depends not only on the flow resistance.
When dewatering on a Fourdrinier machine only gravity and suction forces are at work.
Fig. 7. Suction of water on a Fourdrinier section. (1
If the dewatering is instead done between two wires the water can also be pressed out of
Fig. 8. A combined pressure and suction dewatering
PFIB15/FILM15-4
2001-09-12
Mam reg
The pressure in the dewatering zone can be constant.
Gallery
Figure set. Illustration. Dewatering at a constant pressure.
It could also be divided into a number of single pressure pulses.
Figure set. Illustration. Dewatering at pulsating pressures.
The pressure pulses make the undrained fibre suspension alternately slow down and spee
Figure set. Illustration. Stretch and shear forces in the undrained st
PFIB15/FILM15-4
2001-09-12
Main reg <^
The pressure pulses must not be too strong. Pulses that are too strong make the shear forc
Fig. 15. Illustration. Too strong a pressure pulse bre (15-015.tif)
Dewatering the stock between two wires goes quickly and the time it takes to form the sh
However, the time is in most cases not so short that the fibres do not manage to form any
How strong the pressure pulses have to be is always a balance between the wish to achie
PFIB15/FILM15-4
2001-09-12
Mam reg
Gallery
2. Hybrid former 2.1. Generally
The stock is not always dewatered in the two-sided manner from the very beginning. Som
Fig. 16. Hybrid former in a sack paper machine. (15-0
The fact that the initial dewatering is more slow when dewatering on a Fourdrinier wire c In the paper the small channels are then to be seen like small holes, pinholes.
Fig. 17. Twin wire former in a newsprint machine. (15-017.tif)
The risk of forming pinholes increases the tighter the fibre net is. It becomes particularly
PFIB15/FILM15-4
2001-09-12
Mam reg
Glossary
Gallery
In the hybrid former the first dewatering to about 2% dryness takes place on a convention
Fig. 18. The dewatering on a Four-drinier wire bef (15-018.tif)
Besides, in a hybrid former a rather stable fibre net has been formed before it enters the n
Fig. 19. Illustration. Forming of fibre net at a one(15-019.tif)
PFIB15/FILM15-21
2001-11-17
Main reg
Gallery
2.2. Sym-Former from Valmet

A Fourdrinier machine can, rather easily, be rebuilt to a hybrid former. The headbox and the main part of the wire section can be the same.
Fig. 20. Sym-Former R. (15-020.tif)
The picture shows a Fourdrinier machine being rebuilt to a hybrid former.
Fig. 21. Sym-Former R is a concept suitable particularly when rebui
A new model of machine is similar to the rebuilt machine.
Fig. 22. Sym-Former. (15-022.tif)
PFIB15/FILM15-4
2001-09-12
Mam reg
Gallery
The dewatering over the top wire normally corresponds to between 20 and 40% of the to
Fig. 23. The top wire section in a Sym-Former. (15-023.tif)
The velocity of the stock entering the nip between the wires is the same as the speed of th
Fig. 24. Illustration. The retarding of the "free" s (15-024.tif)
The fact that the undrained stock and the fibre net get different velocities creates shear fo
Figure set. Illustration. Shear forces break down the fibre fl
PFIB15/FILM15-4
2001-09-12
Mam reg
Gallery
The forming roll is open and covered with a wire cloth.
Fig. 27. Forming roll, covered with a wire cloth.
The dewatering over the forming roll takes place at a constant pressure. How high the pre
P = dewatering pressure T = wire tension, bottom wire R = the radius of the forming roll P = f (T/R)
Fig. 28. Components determining the dewatering pres
Fig, 29. The stock will mainly be dewatered upwards, towards the forming roll. During the one-s (15-29.tif)
tttttt
Fig. 30. (15-030.tif)
Figure set. Illustration. The fibre net, built on the bottom w
PFIB15/FILM15-4
2001-09-12
10
The water, pressed out, mainly enters the cavities in the forming roll. After the nip this w
Fig. 31. Illustration. The water leaving the forming roll enters (15-031.tif)
After the forming roll there is a slightly curved zone, with parallel blades, the forming sh
The reason why the forming shoe is curved is to increase the dewatering pressure betwee
However, in this case, the curvature is small and as a consequence the constant pressure b
Between the blades the forming shoe has a certain amount of vaccum. The reason for this
Fig. 32. Illustration. Dewatering over the forming shoe. (15-03
Fig. 33. (15-033.tif)
Figure set. Illustration. The vaccum between the blades dete
PFIB15/FILM15-4
2001-09-26
11
Mam reg
Gallery
The higher the vaccum is, the more the wire bends over the blade edges and the stronger
Fig. 35. Illustration. (15-036.tif)
When the web enters the blade zone, the dryness is already so high that the majority of th
Fig. 36. Illustration. The majority of the fibres are alread
This machine concept is very suitable for production of printing paper containing mecha
PFIB15/FILM15-4
2001-09-12
12
Main reg 2.3. Duoformer D from Voith
Gallery
In Duoformer D there is no longer any predewatering over the forming roll.
Fig. 37. Duoformer D. Note the distance h between the fo
The forming roll is now quite smooth and it is placed a bit above the bottom wire.
Fig. 38. The bottom wire before the formin
In this concept the driving force dewatering the stock and creating the necessary shear fo
Fig. 39. The blade part in a Duoformer. The blade pressure can (15-039.tif)
PFIB15/FILM15-4
2001-09-12
13
Mam reg
Gallery
The blades in the lower row are mobile and can be adjusted in the way making the stock
Fig. 40. Illustration. The blade pressure controls the p
How much the web bends over the blade edges determines how strong the pressure pulse
Fig. 41. The size of the pressure pulses depends on ho (15-041.tif)
Under each blade in the lower row there is a small rubber tube filled with air.
Figure set. Illustration. When the pressure over the bl
PFIB15/FILM15-4
2001-09-12
14
Mam reg
Gallery
If the dewatering resistance increases, the tubes are pressed together and the distance bet
The path, the web has to follow through the blade zone, remains the same and as a conse
Figure set. Illustration. The path the web has to follow is indepe
Between the blades on the over side row a vaccum is applied.
That the fibre net is thinner on the upper side increases the possibility of influencing the d
Fig. 46. The underpressure between the blades in the upper blad
PFIB15/FILM15-4
2001-09-12
15
Mam reg
Gallery
The dewatering of the stock made before the blade zone is now lower than Withoutearlier d Fig. 47. Illustration. in the pre-dew
(15-047.tif)
Thus, the amount of fibre remaining in the un-drained fibre suspension is higher than bef
Fig. 48. Illustration. With predewatering over the forming roll. (15-048.tif)
Figure set. Comparison between the amounts of still undrained s
fibre flocs before they are of improving the formation
2.4. SymFormer MB from Valmet

SymFormer MB is a former with a construction similar to the one described above.
The former is in the first place used at the production of paper with high basis weight or w
Fig. 49. SymFormer MB. (15-049.tif)
Generating pulses over straight blade units brings the advantage that the strength of the
The ability of creating controllable dewatering pulses make the formers particularly suit
PFIB15/FILM15-4
2001-09-12
16
Main reg
Gallery
3. Twin wire formers
The hybrid formers often run somewhat more than 1100 metres per minute. However, wh
Pure twin wire formers were used already in the beginning of the sixties. The main purpo
From the beginning two main types were developed. One of them can be regarded as a p
The difference between the two models was the way of pressing the water out of the stoc
PFIB15/FILM15-4
2001-09-12
17
Main reg
Gallery
3.1. Roll former

3.1.1. Speed-Former from Valmet
Speed-Former is an example of a pure roll former being mainly used at the production of
Fig. 52. Speed-Former. (15-052.tif)
The roll former has two wires surrounding a large, open forming roll.
Fig. 53. Principle sketch. Roll former. (15-053.tif)
The wrap angle of the surrounding wires is high, up to 120 o.
Fig. 54. Illustration. Forming roll. (15-054.tif)
PFIB15/FILM15-4
2001-09-12
18
Mam reg
Gallery
The centrifugal force drives the water towards the outer wire.
Fig. 55. Photo. Dewatering over the forming roll. (15-055.ti
In the forming roll there is a broad suction box.
The vaccum in the suction box has to create a suction force as strong as the centrifugal fo Normally, it is desirable to get as much water leaving the web in the both directions.
Fig. 56. Illustration. Dewatering over the forming roll. (15-
It is neither the centrifugal nor the suction force that determines how fast the dewatering
P = dewatering pressure R = the radius of the forming roll T = the tensile tension of the wire P = f (T/R)
Fig. 57. Illustration. Factors determining the dewatering pr
PFIB15/FILM15-4
2001-09-12
19
Mam reg
Gallery
In a roll former the pressure in the dewatering zone is almost constant during the dewater
The shorter the radius of the forming roll is, and the higher the wire tension is, the higher
Fig. 58. Illustration. Dewatering over a forming roll. The
Looking back on a Fourdrinier machine, it is the angle between stock jet and the wire tha The shear forces developt in the stock depend on the speed difference between the stock
Fig. 59. Illustration. The direction and the speed of the s
When dewatering in a nip between two wires results become the same. However, before
Fig. 60. Illustration. The direction of the stock jet agains
PFIB15/FILM15-4
2001-09-12
20
Mam reg
Gallery
In a roll former the dewatering zone is short. To compensate for that, the nip pressure mu
The higher the nip pressure is, the higher the pressure in the stock jet must be. The veloci
Fig. 62. Photo. The high dewatering pressure requires a
When the stock jet comes into the nip between the wires it is retarded by the hydraulic pr
Fig. 63. Illustration. Dewatering over a forming roll. (15-063.tif) V1 = The original velocity of the stock jet. V2 = The velocity of the stock jet after retardation.
PFIB15/FILM15-4
2001-09-12
21
Main reg <^
When dewatering on a twin wire former it is the speed difference between the retarded st
Shear forces break down the fibre flocs in the fibre suspension.
Here, the shear forces are directed only in the machine direction. Consequently, they orie
Fig. 65. Illustration. Dewatering over a forming roll. She
The shear forces created in the dewatering zone in the roll former influence the stock onl
The loss of pressure pulses during the continued dewatering decreases the stress on the f
Roll formers have been used on some of the fastest newsprint machines. They give a high
Pure roll formers are not very common today, but there is one important exception; pape
PFIB15/FILM15-4
2001-09-12
22
Main reg
Gallery
3.1.2. Roll formers for tissue paper

Roll formers are frequently used at the production of tissue paper.
Fig. 66. Tissue paper machine. (Photo Valmet) (15-066.tif)
The forming roll, used on the tissue paper machine, is in most cases quite smooth and the
The low basis weight gives a low dewatering resistance and therefore the dewatering is v
Fig. 67. Illustration. Dewatering over the forming roll o
The former on the picture differs from other types as the press felt is a part Fig. 68. Tissue paper machine. Crescent former. (15-068.tif) of the forming unit. The sheet is formed between the forming wire and the forming felt. The felt transfers the sheet to a press nip between a roll and the hot yankee cylinder.
PFIB15/FILM15-4
2001-09-12
23
Main reg
Gallery
4. Blade formers
A way to avoid flocs, thus improving the formation, is to create pressure pulses during th
Fig. 69. Twin wire former. Bel Baie 2. (15-069.tif)
4.1. Bel Baie 2 from Beloit

Bel Baie 2 can be seen as an example of a pure blade former. In the blade former there is no dewatering at all over the forming roll.
Fig. 70. Principle sketch, Bel Baie 2. (15-070.tif)
PFIB15/FILM15-4
2001-09-12
24
Mam reg
Gallery
In the drainage zone there is a slightly curved forming shoe. The curvature of the forming shoe creates a small constant pressure between the wires.
Fig. 71. Illustration. Forming shoe. (15-071.tif)
The pressure pulses are then formed when the wires bend over the blade edges in the form
Fig. 72. Illustration. Pressure pulse over blade bar (15-072.tif)
The stretch and shear forces over the forming shoe in a blade former influence the fibres
Even now, the angle between the stock jet and the forming wire at the point of impact de
Just as is the case on the forming board of the Fourdrinier machine, it is desirable to have
Fig. 73. Illustration. The angle between the stock a
PFIB15/FILM15-4
2001-09-12
25
Mam reg
Gallery
The curvature of the wire over the forming shoe is much smaller than over the forming ro
Fig. 75. (15-075.tif) Figure set. Illustration. The bending of the wires in the
That the pressure in the nip is lower means that the pressure from the stock jet does not h Consequently, the velocity of the jet in a blade former can be lower than in a roll former.
Fig. 76. (15-076.tif)
X
Fig. 77. (15-077.tif)
PFIB15/FILM15-4 2001-09-12
Figure set. Illustration. Comparison between the pressure in
26
Main reg
Gallery
5. Blade-roll formers and roll-blade formers

A blade former made it possible to produce a well formed paper, but the pressure pulses
In the machines of today the dewatering is done over both blades and a roll, but the order
PFIB15/FILM15-4
2001-09-12
27
Main reg
Gallery
5.1. Blade-roll former

5.1.1. Bel Baie 4 from Beloit
Bel Baie 4 is the latest design in the row of pure twin wire formers from Beloit and is an e
In the blade-roll former the dewatering is done first over blades and then over a roll.
Fig. 80. Principle sketch. Bel Baie 4. (15-080.tif)
Compared with the older models Bel Baie 2 and 3, the first forming shoe is now placed c
Another advantage is that the length of the free stock jet gets shorter. The shorter it is, the
Fig. 81. Principle sketch. Bel Baie 4. The forming roll
PFIB15/FILM15-4
2001-09-12
28
Mam reg
Gallery
The stock jet meets the inner wire just in front of the first blade.
Fig. 82. Illustration. The stock jet angle and the po (15-082.tif)
The other forming shoe is now placed on the opposite side. Here, in contrast to the earlie The fact that the blades are oppositely placed makes the pressure pulses to influence the How strong the pressure pulses will be, depends on how high the blade load is.
The increasing number of pressure pulses may make it possible to lower the strength in e
Fig. 83. Principle sketch. The second forming shoe in a Bel B
Figure set. Blade load determines the size of the pressure pulses.
PFIB15/FILM15-4
2001-09-12
29
Mam reg
Gallery
Another advantage with oppositely directed pulses is that it is easier to distribute the fine
Fig. 86. Illustration. The pressure pulse over the
The subsequent dewatering over the suction roll takes place under constant pressure. How
Fig. 87. Principle sketch. Dewatering over the su
The length of the wires surrounding the couch roll is higher than in the precurser, Bel Baie 2. Thus, in this former the dewatering over the suction roll is higher and the need to dewater over the forming shoe becomes lower. The pressure pulses may be softer and the risk of breaking up the formed fibre net is decreased. The formation and the retention develops better. 5.1.2. Bel Baie 3 from Beloit
Bel Baie 3 was a precursor to Bel Baie 4, and the first former using the combination of bl
Fig. 88. Photo. Bel Baie 3. (15-088.tif)
PFIB15/FILM15-4
2001-09-12
30
Main reg <^ Comparison between Bel Baie 3 and the earlier described Bel Baie 4
On Bel Baie 3 the distance between the forming roll and the forming shoe is longer.
On Bel Baie 3 there are (15-089.tif) no opposite blades being able to generate directed pressure pulses.
Fig. 89. Principle sketch Bel Baie 3.
The main difference from the pure blade former is that on the blade-roll former there is m
If counter-directed pressure pulses then are formed, it is easier to distribute the fine mate
PFIB15/FILM15-4
2001-09-12
31
Main reg
Gallery
6. Roll-blade formers
The aim of the roll-blade former is the same as the blade-roll former; to decrease the am
In the roll-blade former it is the pre-dewatering over the forming roll that makes it possib
6.1. Speed-Former HS from Valmet
Speed-Former HS can be regarded as an example of a roll-blade former.
Fig. 90. Speed-Former HS. (15-090.tif)
The stock jet is injected tangentially towards the forming roll and meets the outer wire ju
The length of a wire wrapping the forming roll is much smaller than on the earlier descri
Fig. 91. Dewatering over the forming roll. (15-091.tif)
Now the dewatering over the forming roll is going so quickly that the fibres do not have
PFIB15/FILM15-4
2001-09-12
32
Mam reg
Gallery
On the old roll former the stock was dewatered and the fibre firmly fixed already after th
The forming shoe is slightly curved. The reason for that is to increase the constant dewat
Fig. 92. The dewatering shoe on a Speed-Former HS. (15-092.ti
The size of the pressure pulses is even now regulated by using vaccum between the blade
Figure set. Illustration. Regulation of the pressure pulses by adjustm
PFIB15/FILM15-4
2001-09-12
33
Mam reg
Gallery
The pressure pulses must not be too strong. Strong pulses can break up the fibre net form
Fig. 95. Illustration. Too strong a pressure pulse bre
6.2. Speed-Former SC from Valmet The former type, Speed Former HS, is generally used at the production of newsprint.
However, when magazine paper is produced there has to be a larger amount of filler in th
SPEED-FORMER HS
(FOR SC GRADES)
Outer wire
Hi VALMET Paper Machinery
Fig. 96. Speed-Former SC. (15-096.tif)
In order to meet that specific quality demand better the former has got a somewhat differe
PFIB15/FILM15-4
2001-09-12
34
Mam reg
Gallery
In contrast to the earlier described former, the forming roll is now placed in the outer wire
Fig. 97. Speed-Former SC (15-097.tif)
The dewatering over the forming roll makes the top side well closed and the filler will be
Fig. 98. Speed-Former HS (15-098.tif)
Compared to Speed-Former HS the wire wrapping on the couch roll is longer and more w
Figure set. Comparison between Speed-Former HS an
The increased dewatering over the couch roll decreases the demand of dewatering over th
6.3. Speed-Former HHS from Valmet

When rebuilding of a paper machine with a Fourdrinier wire it may be both difficult and
The picture describes a pure Fourdrinier machine rebuilt to a twin wire former.
Fig. 99. Example of rebuilding of a Four-drinier former to a (15-099.tif)
PFIB15/FILM15-4
2001-09-12
35
Mam reg
Gallery
The rebuilding shown on the picture, the starting-point was instead a hybrid former from
Fig. 100. Example of the rebuilding of a hybrid former to a ro (15-100.tif)
6.4. OptiFormer with forming shoe from Valmet
The machine speed at the production of printing paper is today almost 2000 metres per m
Fig. 101. OptiFormer is an example of a modern roll-blade former.
PFIB15/FILM15-4
2001-09-12
36
Mam reg
Gallery
Forming Section for earlier described Speed-Former An importent difference between OptiFormer and theSC and LWC Paper OptiFormer with OptiFlo con
j^valmet
Fig. 102. OptiFormer. (15-102.tif)
An OptiFormer with a forming shoe is used primarily in production of magazine paper.

The length of the wire wrapping the couch roll is high, just like in Speed-Former SC.
Another difference between the concepts is that the forming shoe in OptiFormer is closer
PFIB15/FILM15-4
2001-09-12
37
Main reg
Gallery
6.5. Duoformer CFD from Voith
Duoformer CFD is another example of a modern roll-blade former. This former is disting
Fig. 105. Principle sketch. Duoformer CFD. (15-105.tif)
The initial dewatering is done over the forming roll.
Fig. 106. Photo. The forming roll and parts of the blade secti (15-106.tif)
The fact that the radius of the forming roll is smaller than in the earlier described roll form
Fig. 107. Illustration. The forming roll and parts of the b (15-107.tif)
PFIB15/FILM15-4
2001-09-12
38
Mam reg
In the same way as in the hybrid former, Duoformer D, the wires then run between two ro Thus, pulses influence the stock alternately from both sides.
Fig. 108. Illustration. Dewatering over the blade section part. (15
The frequent pulses give enough stretch and shear forces in the stock, in spite of the low
Fig. 109. Illustration. The path of the web through the blade zone
The continued dewatering then takes place over the firm suction boxes and the final couc
Fig. 110. Illustration. Dewatering over firm bars and over the cou
PFIB15/FILM15-4
2001-09-12
39
Main reg
Gallery
6.6. OptiFormer with loadable blades from Valmet
Stock containing high amounts of long fibres demands high turbulence to prevent the fib
In machines mainly producing fine paper, but also newsprint, the forming shoe may be re
Fig. 111. OptiFormer with loadable blades. (15-111.tif)
The short dewatering time over the forming roll and the decreased distance between the forming roll and the blade section reduces the time when the stock is not influenced by shear forces. The following
Fig. 112. (15-112.tif) pressure pulses come more frequently than in earlier designs. The concept allows the necessary turbulence in the stock to be kept up during the whole dewatering process and the risk of the fibres forming flocs is minimised.
PFIB15/FILM15-4
2001-09-12
40
Main reg <^
When producing fine paper it is desirable that the fibres are orientated as much as possib
A way to prevent the fibres from orientating too much in the machine direction is to crea
Fig. 113. Headbox with special blades in the out flow nozzle is used
Formers should give a good formation without decreasing the retention. Besides, it is nec
It is important to select the right strength of the pressure pulses during the whole dewate
PFIB15/FILM15-4
2001-09-12
41
Main reg C^
Glossary ^
Gallery
CEPATEC AB Knut-Erik Perss
WET PRESSING
1. Wet Pressing, Introduction ....................................................................... 2 2. Counter-forces in a press nip ................................................................... 6 3. Wet pressing and paper properties ........................................................ 11 4. Single or double felted press nip ........................................................... 16 5. Press rolls and press felts ...................................................................... 21 6. Various ways to extend the press nip .................................................... 25
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
1. Wet Pressing, Introduction

It is always cheaper to press the water out than to dry it out. Another advantage is that
The design of the press section is a question of the type of rolls that are used, how they a
The following pages will mainly inform about the fibre properties, their influence on the
When the paper web enters the presses it has a dry solids content of about 20%.
In the press section, the web is then pressed between one or two felts in a number of pre
Fig. 1. Press section in a liner machine. (16-00
The function of a the press felt is to support the sheet and maximise the water removal.
Fig. 2. Double felted press nip. (16-002.tif)
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
When the web is pressed together the water between the fibres and in the lumen is sque
Fig. 3. Illustration. Fibres in the wet web. (16-0
There is water in the fibre wall, too.
Fig. 4. Illustration. Enlarged cut of a fibre wall.
Particularly much water is to be found in a chemical fibre, beaten so that the fibre wall i
The water in the fine pores is more difficult to squeeze out than the water between the f
Fig. 5. Illustration. Enlarged cut of a swollen fib (16-005.tif)
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
With rising temperature, the viscosity of the water drops. The higher the web temperatu
Fig. 6. The viscosity of water at different temper
Sometimes the web is heated by steam boxes located ahead of the press section.
Fig. 7. Steam box, placed at the end of the wire
Normally, the steam boxes are placed in the press section. By placing the steam box ove
Fig. 8 and 9. Press section with steam box in a newsprint m
The water in the fibre wall is not only difficult to squeeze out. The water also makes the
L:\16-2.doc
KEP 2001-11-09
Main reg C^
Glossary
Gallery
Thus, what happens in the wet pressing process depends on the web properties, but of course also on how the pressing is done. The press nip in a paper machine can be designed in many different ways.
The result of the pressing depends on the pressure in the press nip and on the nip length
Fig. 10. Press nip. (16-010.tif)
The pressure in the nip is not the same all along through the nip length. The amount of w
Fig. 11. The division of the nip pressure in a (16-011.tif)
If the average nip pressure is multiplied with the time it takes for the web to pass the pre
Fig. 12. The press impulse = P t. (16-012.tif)
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
The press impulse can never be so large that enough water can be pressed out in a singl
Fig. 13. Press section in a fine paper machine
2. Counter-forces in a press nip

When the pressing is done in several nips, the sum of the press impulses in the single ni However, the web solids content after the presses does not depend on the press impulse
If the web is pressed between a smooth roll and a felt it is called single-felted pressing.
Fig. 14. Illustration. Single-felted pressing. (1
The water squeezed out streams from the web and into the felt.
Fig. 15. Illustration. The flow direction of the (16-015.tif)
L:\16-2.doc
KEP 2001-11-15
Main reg C^
Glossary
Gallery
When pressing the water out of the wet paper web there are two counter forces to overc
The first force is the mechanical counter-force arising when the fibres as such are comp
Fig. 16. Illustration. Cross-section of fibres in (16-016.tif)
The second counter-force is the force arising when the water is forced to stream out of t
Fig. 17. Illustration. Fibres in a wet web press (16-017.tif)
That the flow meets a resistance creates an internal fluid pressure in the paper web. The
Fig. 18. Illustration. A pressure increasing (P) (16-018.tif)
L:\16-2.doc
KEP 2001-11-09
Main reg C^
Glossary
Gallery
The mechanical counter-forces in the fibre network can be compared with the counter-f
Fig. 19. Illustration. The mechanical counter-forc
The hydraulic pressure corresponds in the same way to the counter-force in a shock abs
Fig. 20. Illustration. The hydraulic counter-force
Thus, the press force added when pressing together and driving out the water of the wet
- The mechanical spring force. - The hydraulic force originationg from the resistance when the water is forced to strea
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
If the fibres are stiff and hard, the spring force is in most cases the dominating counter-f
Fig. 21.Illustration. Cross-section of fibres in (16-021.tif)
Thus, if the mechanical counter-force dominates, it is just to increase the press load in o
If the fibres instead have more water in the fibre wall, making them soft and pliable, the
Fig. 22. Illustration. Cross-section of soft and
It is not only the properties of the fibres that determines which of the two counter-force
Fig. 23. Illustration. Single-felted press nip. Th (16-023.tif)
L:\16-2.doc
KEP 2001-09-13
Main reg C^
Glossary
Gallery
The longer the distance the water has to flow through a fibre network, the higher the flo
Fig. 24. Illustration. The pressure P is highest in th (16-024.tif)
The flow resistance arising when the water streams out of the paper web does not only d
The velocity of the water streaming in the channels is connected to how quickly the pap
If the press load gets too high, the hydraulic pressure in the web increases so much that
If the flow resistance limits how fast the water can be pressed out, it is not as simple as
Fig. 25. Illustration of the idea of sheet crushing. (
L:\16-2.doc
KEP 2001-09-13
10
Main reg C^
Glossary
Gallery
Thus, how much water feasible to press out depends on the applied average nip pressur
In most cases, it is not feasible just to increase the press load without running the risk of Fig. 26.
(16-026.tif)
Fig. 26 and 27. Press nip curves illustrating the increase
3. Wet pressing and paper properties
Which of the two counter-forces is dominating, the spring force or the force originating The counter-forces do not only influence the web in the press nip. The properties of the
If the mechanical force dominates, the web will re-expand immediately after the press n Fig. 28.
(16-029.tif)
Fig. 29. (16-029.tif)
Fig. 30. (16-030.tif) Fig. 28, 29 and 30. Illustrations showing what happens in a
L:\16-2.doc KEP 2001-09-13 11
Main reg C^
Glossary
Gallery
That the fibres take back their original form means that the conditions in the press nip o
Fig. 31. Reeling up of finished paper. (16-031.tif)
Fig. 32. Microscope photo. TMP Mechanical fibres or unbeaten chemical fibres are examples of fibres giving the web the (16-032.tif)
Fig. 33. Microscope photo, unbeaten softwood sulphate fibres. (16-033.tif)
Well beaten chemical fibres, on the other hand, swell a lot and are therefore soft and for
Fig. 34. Microscope photo, well beaten chemical lo (16-034.tif)
L:\16-2.doc
KEP 2001-09-13
12
Main reg C^
Glossary
Gallery
If a paper web consisting of such chemical fibres is too quickly compressed, the flow re
Fig. 35. Illustration. The hydraulic pressure P is s
To avoid crushing the fibre net the press load must be low. However, a low pressure in t
Fig. 36. Press nip curve. (16-036.tif)
A way to get around this, and still be able to increase the compression of the paper web,
Fig. 37. Press nip curve. (16-037.tif)
L:\16-2.doc
KEP 2001-11-19
13
Main reg <^
Glossary
Gallery
Because of the reduced hydraulic pressure the web will be more compressed. The area o
The fact that beating increases the swelling makes the fibre wall soft and pliable. The fi
Fig. 38. Illustration. Soft strongly compressed fib
When such a web is dried, many hydrogen bonds can be formed between the fibres.
Fig. 39. Illustration. OH groups on the fibre surfa (16-039.tif)
Thus, compressing the wet paper web in a press nip is a way to get a paper with a high s
Fig. 40. Measuring of tensile strength. (16-040.ti
L:\16-2 doc
KEP 2001-11-19
14
Main reg C^
Glossary
Gallery
However, pressing together fibres in the web does not give only advantages. The high p
Fig. 41. Measuring of the bending stiffness. (16-041.tif)
The optical paper properties are influenced as well. The low amount of free, non bound
Fig. 42. Low capacity of reflecting light means that print
L:\16-2.doc
KEP 2001-11-01
15
Main reg C^
Glossary
Gallery
4. Single or double felted press nip
The longer distance the water pressed out has to stream through the web, the stronger t
The press felts are manufactured in two steps.
In the first step a basic fabric is produced, the base weave. In the second the batt fibre is
Fig. 43. Press felt. Batt layer fastened by needling. (N
The felt has a much more open structure than the web has.
Fig. 44. Illustration. Web pressed between a roll and a (16-044.tif)
L:\16-2.doc
KEP 2001-09-13
16
Main reg
Glossary
Gallery
The flow channels in the felt are coarser than in the web, thus the hydraulic pressure be
Fig. 45. Illustration. The water streams out from the w
A press nip without felts means that the water squeezed out must stream along the web.
Fig. 46. Illustration. Flow directions in an unfelted pr (16-046.tif)
Thus, in an unfelted press nip the water has to stream a long distance and the hydraulic
Fig. 47. Illustration. Web burst into pieces. Too high h (16-047.tif)
The fact that the applied press load is balanced by the sum of the mechanical force coun
L:\16-2.doc
KEP 2001-11-15
17
Main reg C^
Glossary
Gallery
If the dewatering is done in a singled felted press nip the flow resistance will diminish a
Fig. 48. Illustration. The pressure P is high in the beg
As the hydraulic pressure on the felt side is lower than on the roll side the compression
As a result, the fibres on the side of the web running against the felt bind stronger to eac
Fig. 49. Illustration. Fibres in a web more pressed tog (16-049.tif)
The roll surface is smoother than the felt surface and the surface of paper running again
Thus, when dewatering in a single felted press nip the web will always get different prop
In most cases you prefer to have the two sides of the paper as equal as possible: the pap
There are different ways to avoid getting unequal-sided paper.
L:\16-2.doc
KEP 2001-11-09
18
Main reg C^
Glossary
Gallery Fig. 50.
One way to avoid unequal sided paper is to change between(16-050.tif) pressing on the felt and roll
Fig. 50 and 51. Illustrations. Change between felt and
Another way is to press the web between two felts by using a double felted press nip.
Fig. 52. Double felted press nip. (16-052.tif)
In a double felted press nip the water will stream from the web into the two felts.
Fig. 53. The flow of the water in a double felted press
L:\16-2.doc
KEP 2001-09-13
19
Main reg C^
Glossary
Gallery
When the water streams from the middle of the sheet and outwards the pressure conditi
Fig. 54. Illustration. Fibres in a double felted press
However, the main reason to use a double felted press nip is not to achieve a more symm
Fig. 55. Press section in a board machine. (16-055
If the dewatering is done in two directions, the distance the water has to flow through th
The amount of water flowing through the fibre network and the felts is halved andfelted h this Fig. 56. Illustration. Water flow in a double
(16-056.tif)
L:\16-2.doc
KEP 2001-09-13
20
A twice halved flow resistance makes a higher nip load possible without risk of crushin
Fig. 57. Illustration. An increased press load is possib
5. Press rolls and press felts
The conditions in the press nip are not only influenced by running one or two felts in the
If the amount of water streaming out of the paper web increases excessivly, the flow res
Fig. 58. (16-058.tif)
Fig. 059. (16-059.tif)
Fig. 58 and 59. Illustrations. The hydraulic pressure crus
L:\16-2.doc
KEP 2001-09-13
21
Main reg C^
Glossary
Gallery
If the water runs a shorter distance through the felt in the press nip, the flow resistance d
A way to make this possible is to use a press roll having a surface with channels or hole
Fig. 60. Illustration. The flow of the water in a single (16-060.tif)
After the press nip the water might return from the felt and stream back into the web, th
To minimise this rewetting it is important to separate felt and web directly after the pres
Fig. 61. Illustration. Rewetting of the web after the pr
The type of felt used is important. The felt surface is much coarser than the paper surfac
Fig. 62. Picture. Enlarged part of the felt surface. (16
L:\16-2.doc
KEP 2001-09-13
22
Main reg C^
Glossary
Gallery
In the press nip all the voids in the felt are filled with water.
Fig. 63. Illustration. Water filled felt in a press nip
After the press nip, when the press felt is separated from the web a great deal of the wat
Fig. 64. Illustration. Separation between web and p (16-064.tif)
Thus, using a felt with a surface as smooth as possible is important if it is desirable to p
If the flow resistance in the web is low the nip pressure can be high and the nip residenc
In such a case the dewatering of the web proceeds rapidly and the flow velocity in the f
Fig. 65. Illustration. A rapid dewatering makes the (16-065.tif)
L:\16-2.doc
KEP 2001-11-19
23
Main reg
Glossary
Gallery
When the water spurts out of the nip, the press felt needs not absorb all the squeezed wa
Fig. 66. Cross-section of a thin compact felt. (16
If the web is difficult to dewater the nip pressure must be lower and the nip residence tim
Fig. 67. Illustration. Press nip with a long press
The felt in such a press nip must be able to carry all the water streaming out of the web.
To be able to do this the felt must have voids large enough even when the felt is compre
The base weave in the press felt must be heavier and coarser than in the felts mentioned
Fig. 68. Cross-section of a heavy and coarse pr (16-068.tif)
L:\16-2.doc
KEP 2001-11-19
24
Main reg C^
Glossary
Gallery
The water in the press felt is then sucked away when the felt passes suction boxes.
Fig. 69. Felt suction box. (16-069.tif)
Press felts must always be designed to the web and to the press roll types.
Advances in felt technology have been directed toward improved uniformity and reduce
6. Various ways to extend the press nip
The facts that the nip pressure must not be too high and the nip residence time must be l
The nip residence time is often short; in most cases not more than a few milliseconds.
Fig. 70. The press impulse. (t = 1-2 m sec.) (16-070.tif)
L:\16-2.doc
KEP 2001-09-13
25
Main reg C^
Glossary
Gallery
Usually the rolls are covered with rubber or other elastomers having varying elasticity
Fig. 71. Single felted press nip with rubber covered (16-071.tif)
If there are two felts in the nip, the residence time is prolonged even more.
Fig. 72. Double felted press nip with rubber covere (16-072.tif)
Another way to prolong the nip residence time is to use rolls with very large diameters.
During recent years a totally new type of press has been used, a so called shoe press.
Fig. 73. Shoe press. (16-073.tif)
L:\16-2.doc
KEP 2001-09-13
26
Main reg C^
Glossary
Gallery
SYM-BELT SHOE The reason why the press is called shoe press is that one ofS,the UNIT ^*i^ rolls is replaced by press
z?Z^'*^fflm
ju
rv^4^/ .!p\
^1
Fig. 74. Exploded view. Shoe press. (16-074.tif)
With this technique the nip length can be increased up to about 25 cm.
Such a nip length makes it possible to increase the press impulse considerably without i
Fig. 75. Exploded view. Shoe press. (16-075.tif)
The graph, showing the nip pressure, becomes different. A quickly decreasing nip press
Fig. 76. Typical press nip curve in a shoe press. (16-
L:\16-2.doc
KEP 2001-09-13
27
Main reg C^
Glossary
The design of the press section in a paper machine can vary. In each machine there is an
Fig. 77. A modern press section in a sack paper machin
What determines the design of a press section is how much water there is to squeeze ou
However, there is one important thing to remember. How the water is pressed out alway
L:\16-2.doc
KEP 2001-09-13
28
DRYING
1. Introduction..............................................................................................................- ^^S 2. The capability of the fibre wall to absorb water.......................................................3
\^^M 3. Forces affecting external and internal fibre surfaces................................................9 \^^M \^^M 6. Drying and fibre properties.....................................................................................15 \^^M
7. Shrinkage and drying section conditions................................................................17 KM 8. Shrinkage and fibre orientation in the web.............................................................18 j 9. Shrinkage and internal sheet tension......................................................................19 ^^M 10. Drying and additives.............................................................................................22 MJ 11. Evaporation process..............................................................................................24 ^^B 12. Multicylinder machines........................................................................................30 ^S 13. Drying in a multicylinder machine.......................................................................33] 14. Final paper drying.................................................................................................38 ^^B 5. Shrinkage of the paper web....................................................................................14
4. Fibre shrinkage.......................................................................................................12 1
KEP 01-09-13
Main reg C^
Glossary
Gallery
1. Introduction
Paper drying is an expensive method to remove water. The energy consumption is high
Fig. 1. In the wire section and later in the press section, large amounts of water are mechanica (17-001.tif)
Fig. 2. (17-002.tif)
Fig. 1 and 2. Wire and press sections in a sack paper machine
The dry solids content in the finished paper is in most cases between 90 and 96%.
Fig. 3. Measuring instrument for basis weight an
Water, impossible to remove mechanically, must be thermally removed; evaporated.
Fig. 4. Drying cylinders in a multicylinder drying (17-004.tif)
KEP 01-09-13
Main reg C^
Glossary
Gallery
Even if the amount of water to be evaporated is less than 1% of the amount removed d
Fig. 5. Dried sack paper. (17-005.tif)
Drying a paper web means that the water leaves the paper machines drying section as
Fig. 6. The vapour leaving the drying section. (17-0
2. The capability of the fibre wall to absorb water
Most of the water between the fibres in the web is removed in the previous press sectio But there is water inside the fibre wall, too, and most of that water is still there.
Fig. 7. Illustration. Cross-section of two partly colla (17-007.tif)
KEP 01-09-13
Main reg C^
Glossary
Gallery
Most water is to be found in the fibre wall from a well beaten chemical fibre. The split
Fig. 8. Illustration. Enlarged cut of a fibre wall. (17-
There is another factor facilitating water penetration into the fibre wall; the pores form
Fig. 9 and 10. Illustrations. Strongly enlarged cut of a fibre wa
The cellulose in the fibre wall is built up of a large number of cellulose molecules bind
Fig. 11 and 12. Illustrations. Enlarged cut of the fibre wall. It can be
KEP 01-09-13
Main reg C^
Glossary
Gallery
A number of cellulose chains form a micro-fibril.
Fig. 13. Illustration. A number of cellulose molecule (17-013.tif)
A number of micro-fibrils joining form fibrils.
Normally the distance between the cellulose molecules is so small that a water drop ca
Fig. 14. Illustration. Cellulose fibrils: orientated an
However, in some zones the cellulose molecules are not so strictly arranged.
Fig. 15. Illustration. A part in the fibre wall with dis (17-015.tif)
KEP 01-09-13
Main reg C^
Glossary
Gallery
In disordered areas the distance between the cellulose chains is larger than the size of a
Fig. 16. Illustration. Water has penetrated between t
When the water penetrates the cellulose chains, the hydrogen bonds are partly split up.
0---H H--- O
H 0 O---H H o
nH
H O 0- H H 0 H
Fig. 17. Water molecules break up the hydrogen bon
The hemicellulose in the fibre wall is located between the cellulose fibrils; partly in th
Fig. 18. Illustration. Enlarged cut of the fibre wall s (17-018.tif)
The hemicellulose consists of branched molecule chains.
Fig. 19. Illustration. Branched hemicellulose chain.
KEP 01-09-13
Main reg C^
Glossary
Gallery
The molecule chains in the hemicellulose are not as strongly orientated in the fibre wa
Fig. 20. Illustration. Loosely packed hemicellulose m (17-020.tif)
Water can penetrate between the molecule chains and the hemicellulose layer will swe
Fig. 21. Illustration. Water has penetrated between t
The lignin in the fibre wall is naturally hydrophobic. Even if that property can be modi
Fig. 22. Illustration. The location of the lignin in a f
KEP 01-09-13
Main reg C^
Glossary
Gallery
Water localised in the fibre wall is always difficult to remove. One reason is the very n
Fig. 23. Illustration. Enlarged cut of a fibre wall. (1
But it is not only by reason of physics the water is difficult to remove. There is also a c
The OH groups on the cellulose and the hemicellulose chains attract adjacent water mo
Fig. 24. Illustration. Water molecules attracted by th (17-024.tif)
Not only OH groups attract water molecules. If there are also charged chemical groups
Fig. 25. Illustration. The carboxyl acid groups on th
KEP 01-09-13
Main reg C^
Glossary
Gallery
The water molecules are not only attracted by the internal chemical groups, localised o
Fig. 26. Illustration. Enlarged cut of a fibre surface w
3. Forces affecting external and internal fibre surfaces
The fact that the water disappears is not the only thing happening to the web in the dry
When the web enters the drying section, forces of the surface tension, keep the fibres t
Fig. 27. Illustration. Two fibres kept together by the c
KEP 01-09-13
Main reg C^
Glossary
Gallery
When the water in the lumen disappears the same forces will affect the inside of the fi
Fig. 28. Illustration. A fibre is drawn together when th
How close the fibre surfaces come depends on how formable the fibres are.
The more water the fibre wall absorbs, the softer and the more pliable it will be. The a Well beaten chemical fibres are examples of fibres that are particularly formable.
Fig. 29. Illustration. Collapsed fibres with large area
In liquid water there are forces attracting all molecules to each other; hydrogen bonds.
When this happens, the kinetic energy of the water molecules is high enough to enable
Fig. 30.1. Illustration. Attraction forces between the w
KEP 01-09-13
10
Main reg
Glossary
Gallery
The closer to the fibre surfaces the water molecules are located, the greater the attracti
The water molecules are attracted to the OH groups on the fibre surfaces with a force g
Fig. 30.2. Illustration of the concept bound water. Th
When the bound water gradually disappears hydrogen bonds are formed, direct betwe
It is only when such direct bonds are formed that the hydrogen bonds reach their maxi
Fig. 31. Illustration. OH-groups binding direct to each (17-031.tif)
The more the paper web dries, the more hydrogen bonds can be formed and the strong
Fig. 32. Paper web in a multi-cylinder dryer. (17-032.ti
Naturally, there is a direct connection between the amount of hydrogen bonds that can
KEP 01-11-19
11
Mam reg
Gallery
The number of OH groups on the outer fibre surface depends on the type of chemical p
Fig. 33. Illustration. Beaten chemical fibre with many (17-033.tif)
On a mechanical fibre partly covered with lignin the OH groups are considerably fewe
Fig. 34. Illustration. Mechanical fibre with few OH gr (17-034.tif)
4. Fibre shrinkage
When the water on the fibre surfaces is removed the water in the pores inside the fibre
Fig. 35 and 36. Illustrations showing that fibre walls shrin
KEP 01-11-19
12
Main reg ^
Glossary
Gallery
The more water there is in the fibre wall, the more the fibre will always shrink. As a co
Well beaten fibres always shrink more than unbeaten ones.
Fig. 37 and 38. Microscope photos. Beaten and unbeaten ch
Mechanical pulps always shrink less than well beaten chemical pulps.
Fig. 39. Microscope photo. Fibres in a TMP (17-039.tif)
KEP 01-11-19
13
am reg
Glossary
Gallery
5. Shrinkage of the paper web
The fibres shrink almost only crosswise, but when the paper web is dried the shrinkage
When the fibres shrink crosswise, in the cross points they will compress the fibres leng
Fig. 40. Microscope photo showing how an overl
As a result the whole fibre network diminish; the web will shrink.
Fig. 41. Illustration. Fibres in a paper sheet. (17-
On a paper machine, the shrinkage could be seen as a narrowing of the web.
Fig. 42. Paper web in a multi-cylinder dryer. (17-
KEP 01-09-13
14
Main reg C^
Glossary
Gallery
The shrinkage is especially high at 65 to 80% dryness, the shrinkage zone. The shrinka
Fig. 43. The paper shrinkage at dryness increase (17-043.tif)
6. Drying and fibre properties
When the water disappears the lamellae in the fibre wall draw closer to each other. The
Fig. 44. Illustration. Enlarged cut of the fibre wa (17-044.tif)
When the lamellae come in contact with each other hydrogen bonds are, as said before
Fig. 45. Illustration. OH groups on the fibre lame
KEP 01-09-13
15
Main reg C^
Glossary
Gallery
The fibre wall develops more compact and the fibre gets harder and stiffer.
Fig. 46. Illustration. Beaten chemical fibre. (17-04
The changes taking place when the fibres dry make it more difficult for water to penet
Fig. 47. Broke rolls before slushing. (17-047.tif)
Actually, that a fibre swells less if it formerly has been dried means that the fibres in a
Fig. 48. Dried paper pulp. (17-048.tif)
Recycled fibres can be dried several times. The more times, the less the fibres will swe
Fig. 49. Corrugated board bales. (17-049.tif)
KEP 01-09-13
16
Main reg ^
The less a fibre can swell, the less it can shrink, too. Thus, if it is desirable to get a pap
7. Shrinkage and drying section conditions

When the fibres shrink during drying, the whole web will shrink. But how much it will
If the shrinkage of the paper web is prevented by supporting dryer fabrics and a high w
When loading the paper sheet all the fibres are sharing the load evenly. The paper deve
Fig. 50. Illustration. Straightened fibres in a paper s
The opposite way of drying is to let it shrink freely within that part of the drying sectio
Fig. 51. Illustration. Unstretched fibres in a paper a (17-051.tif)
KEP 01-11-19
17
Main reg C^
Glossary
Gallery
The tensile strength and the elongation of a paper sheet is to a great extent connected
8. Shrinkage and fibre orientation in the web

The fibre orientation in the web strongly influences the paper web during the drying.
If most fibres are orientated in the machine direction the paper will shrink mainly in th
Fig. 52. Illustration. Paper with most of the fibres orient
The drying tension is not equal all across the web. It is always lower close to the web e That the tension is lower at the edges makes the paper edges shrink more than the rest
Fig. 53. Paper web in a multicylinder dryer. (17-053.tif)
KEP 01-09-13
18
Main reg C^
Glossary
Gallery
To compensate for the increased basis weight the head box nozzle opening has to be sm
But if the opening is unequal cross streams are generated. Such cross streams always i
Fig. 54. Headbox with locally adjustable nozzle openin (17-054.tif)
_^>1__
Different fibre orientation at the edges of the paper web is rather usual. The different f
At the modern headboxes with local stock dilution, the nozzle opening is constant acro
Fig. 55. Headbox with a fixed nozzle and locally variab (17-055.tif)
9. Shrinkage and internal sheet tension
Drying paper is a complicated and delicate operation. The dryness must be equal both
It is important to dry uniformly in the Z direction, too. The two web sides must normal
KEP 01-09-13
19
Main reg
Glossary
Gallery
If a paper with a high basis weight is produced, the sheet may have different dryness o
Fig. 56. Board. Microscope photo. (17-056.tif)
When the difference in dryness is later levelled out such a paper will shrink or expand
Fig. 57. Edge cut of a sheet of paper. Illustration of cu (17-057.tif)
Thus, if a paper curls or not does not only depend on the fact that the fibres are unequ
But not only the dryness in the Z direction of the finished paper creates curl. That the p
KEP 01-09-13
20
Main reg C^
Glossary
Gallery
If the web dries at the same rate on the two sides, the fibres in the sheet shrink uniform
Fig. 58. Illustration. Edge cut of a sheet of pape (17-058.tif)
On the other hand, if one side dries faster than the other, that side also shrinks earlier.
Fig. 59. Illustration showing what happens whe (17-059.tif)
When the other side then shrinks the fibres on the dry side are not as soft as when they
Fig. 60. Illustration. The picture shows what ha (17-060.tif)
KEP 01-09-13
21
Main reg C^
Glossary
Gallery
10. Drying and additives

How the paper is dried does not influence only the fibres in the paper, but some of the
The heat during the drying makes the size particle soften, spread and cover the surface
Fig. 61. (17-061.tif)
Fig. 62. (17-062.tif)
Fig 61 and 62. Illustrations. Size particles spread and cover t
A rosin size particle becomes fully hydrophobic only when the resin acid has reacted w
Fig. 63. Aluminium resinate molecules after the heat tre
KEP 01-09-13
22
Main reg
Gallery
Even the AKD and ASA sizes need a certain temperature before being active.
However, the two sizes, as here AKD, react chemically with the OH groups of the cell
Fig. 64 and 65. Illustrations. AKD molecules reacting wi
The necessary reactions can not take place until in the drying section.
Fig. 66. Sack paper machine. (17-066.tif)
High temperature in the drying section is a must not only for sizing chemicals. If for ex
KEP 01-11-19
23
Main reg C^
Glossary
Gallery
11. Evaporation process
The previous part of this lesson was about how the drying process affects the propertie
All molecules in water are attracting each other.
The water molecules, like molecules in all substances, are constantly moving. The hig
Fig. 67. Illustration. Attraction forces between w (17-067.tif)
When the temperature in a water drop gets high enough the kinetic energy of some wa
Fig. 68 and 69. Illustrations. Free water molecules leave the d
KEP 01-11-02
24
Mam reg
Glossary
Gallery
The energy needed to release the water molecules from the drop equals the added ener
Fig. 70. Illustration. Free water molecules leavi
When free water molecules leave the drop the water is said to evaporate. The released
It is not only the amount of added energy that determines how fast the water evaporate
The air receiving the vapour molecules has a determined pressure, the air pressure P
Fig. 71. Illustration. The air above the water su (17-071.tif)
KEP 01-11-19
25
Main reg C^
Glossary
Gallery
Dry air is a gas containing molecules, mainly nitrogen and oxygen. Molecules in motio
Fig. 72. Illustration. (Blue) nitrogen and (red) oxyge
Each molecule in the air contributes to the total air pressure. The more molecules of a
air =
nitrogen + P oxygen
Vapour is also a gas and
butes to the total pressure.

wet air = N2+ P O2 + P H20
Fig. 73. Illustration. Thefc nitrogen and oxygen molec
Fig. 74. Illustration. The vapour-molecules part of th
KEP 01-11-02
26
Main reg C^
Glossary
Gallery
With more vapour molecules in the air, a larger part of the total pressure originates fro
Fig. 75. Illustration. When the number of vapour mole
The lower the vapour pressure is from the beginning, the more vapour molecules the s
Fig. 76 and 77. Illustrations. Vapour molecules leave a wate
When enough water molecules have left the drop the vapour pressure in the air has fin
Fig. 78. Illustration. The maximal amount of vapour mo (17-078.tif)
KEP 01-11-02
27
Main reg C^
Glossary
Gallery
Now, the added energy is instead used to increase the temperature in the water drop.
Fig. 79. When the air is saturated with vapour the te
The evaporation stops because the air can not receive more vapour molecules. The air
M~H The higher the air temperature is, the quicker the vapour molecules move and the close
AA
AT A
Fig. 80. Illustration. Vapour molecules. (17-080.tif)
KEP 01-11-02
28
Main reg C^
Glossary
Gallery
If the air temperature falls the kinetic energy decreases and the vapour molecules rebin
Fig. 81. Illustration. The temperature falls. The vapou (17-081.tif)
When the vapour molecules are caught up by the hydrogen bonds their kinetic energy
Fig. 82. Illustration. The water drop temperature incr (17-082.tif)
Thus, how many vapour molecules there are in the air surrounding a water drop depen
KEP 01-11-02
29
Main reg C^
Glossary
Gallery
12. Multicylinder machines
In the manual paper mill the paper was hanged up and dried in the air. How fast the pa
Fig. 83. Manual manufacture of paper. (17-083.tif)
For a paper machine the same rules apply, but here the drying must be done very fast.
How the drying is done can be seen by following the course on the most common type
Heat is added alternately to the webs two sides and the web temperature starts to incre
Fig. 84. Multicylinder dryer. (17-084.tif)
KEP 01-11-02
30
Main reg
Glossary
Gallery
On the first cylinder there is almost no evaporation of water. Evaporation starts when
The temperature on the first cylinders is low. Otherwise there is a risk to burn the web.
(The web on the previous picture runs outside the wire in the bottom cylinder row. Thi
Fig. 85. The first drying cylinder in a multicylinder d
On later dryers the cylinder surface can be higher than 100C. The web temperature always stays below 100C. The water is not boiled away.
Fig. 86. Paper web on a multi-cylinder dryer. (17-08
What determines how much water that can be evaporated is the difference between the
P H2 0 Fig. 87. Paper web. Marking of the vapour pressure in the
KEP 01-11-19
31
Main reg C^
Glossary
Gallery
Another way is to keep the vapour pressure in the surrounding air as low as possible.
Fig. 88. Paper web. Marking of the vapour pressure in
If the vapour pressure in the surrounding air is too high, the air becomes saturated an
To avoid saturation the moist air must be exhausted and new, drier and preferably war
By special blow boxes the hot, dry air is added at the right place and with the correct f
The wires between the dryers also help to ventilate the dryer pockets.
Fig. 89. Cylinder dryer. The blow box is marked.
KEP 01-11-02
32
Main reg C^
Glossary
Gallery
To be able to exchange the moist air a lot of hot, dry air must be added.
The weight of the air leaving the drying section is in fact in most cases ten times highe
Fig. 90. (17-090.tif)
It is important to arrange the ventilation in the very best way. If the ventilation is not h
If the ventilation is uneven the paper dryness becomes uneven, too. The paper quality g
13. Drying in a multicylinder machine
To get the contact as good as possible the dryer fabrics press the paper against the cyl
However, the high heat transfer can not be explained only by heat conduction. There m
KEP 01-11-02
33
Main reg C^
Glossary
Gallery
The paper web is a complicated element where both water and vapour can move in the
Fig. 91. Cross-section of the paper web. (17-091.tif)
When the paper surface next to the drying cylinder has reached a certain temperature t
Fig. 93. (17-093.tif)
Fig. 92 and 93. Illustrations. Cross-section of the paper
As the vapour penetrates the inner part of the web it cools down and condenses.
Fig. 94. Illustration. Cross-section of the outer part of a (17-094.tif)
KEP 01-11-02
34
Main reg C^
Glossary
Gallery
When the vapour condenses, the vaporization heat is set free. This heat is now taken u
Fig. 95. Illustration. Cross-section of the outer part o
In the open draw between the drying cylinders the vapour on the web surface and in th
(17-097.tif)
Fig. 96, 97 and 98. Illustrations. Cross-sections of the outer part of a pa
KEP 01-11-02
35
Main reg C^
Glossary
Gallery
Capillary suction brings the condensate back towards the warm paper surface again.
Fig. 99. Illustration. Paper web in the free draw b
As long as the vapour pressure at the web surface is higher than in the surrounding air,
Fig. 100. Illustration. Paper web in the free draw
The heat needed to evaporate the water is taken from the web itself. As a result the we
Fig. 101. Illustration. Paper web in the free draw
When the paper web enters the following drying cylinder the process will repeat itself.
KEP 01-11-02
36
Main reg C^
Glossary
Gallery
The water between the fibres vaporises. This time the vapour will penetrate a bit longe
Fig. 102 and 103. Illustrations. Paper web and drying
In the following draw the free vapour leaves the web and the condensate flows back to
Fig. 104. Illustration. Paper web in the f
This is repeated as long as there is water left in the channels to be vaporised.
Fig. 105. Multicylinder dryers. (17-105.tif)
KEP 01-11-02
37
Mam reg
&j
Glossary
Gallery
The web temperature falls slightly in the open draws between the cylinders. However,
14. Final paper drying
The lower the amount of water remaining in the web, the more difficult it will be to tra
The declining heat transfer is one of the reasons why the evaporation rate always decr
When the water in the channels between the fibres is removed the vapour pressure insi
(17-107.tif)
Fig. 106 and 107. Illustrations. Cross-section of t
KEP 01-11-20
38
Main reg C^
Glossary
Gallery
It is the difference in vapour pressure that makes the water in the fibre walls evaporate
P H20 in the fibre wall > P H20 in the channels between the fibres.
Fig. 108. Illustration. Fibre walls with intermediate (17-108.tif)
The pores in the fibre wall itself are much smaller than the channels between the fibres
Fig. 109. Illustration. Lamellae in the fibre wall. (17
The fact that the pores are that narrow makes the water stream more slowly to the evap
Fig. 110. Illustration. Vapour penetration through th (17-110.tif)
KEP 01-11-02
39
Main reg C^
Glossary
Gallery
The amount of heat necessary to evaporate the water now becomes lower than the amo
Fig. 111. Paper web on a multi-cylinder dryer. (17-
The last water molecules bind chemically on the cellulose and hemicellulose. These st
Fig. 112. Illustration. Water molecules attracted by
To remove the chemically bound water it is not enough with the vaporisation heat. Wh
All water can not be removed from a paper web. Some water molecules bind so strong
A filler in the paper does not bind the water molecules in the same way. Consequently,
KEP 01-11-02
40
Main reg C^
Glossary
Gallery
When producing thick paper, i.e. board, it is very important that the web does not dry t
Fig. 113. Microscope photo. (STFI). Sheet of b
If the evaporation becomes too strong the fibre surfaces next to the paper surfaces can
As a result the sheet centre, in the Z-direction, becomes too moist and the layers close
Fig. 114. Illustration. A paper web that has dried too quickly. (17-114.tif)
The dryness in the finished paper must not only be the same straight through the sheet
How high the dryness must be depends on how easily the moisture can penetrate into t
The amount of water absorbed in the fibre wall is a question of the chemical compositi
If the air is very moist the bonds between the fibres are influenced, too. The hydrogen b
KEP 01-11-20
41
Main reg C^
Glossary
Gallery
The filler does not bind water to the same extent as the fibres do. The more filler there
KEP 01-11-02
42
<^
Main reg
>allery
FORMING 6, MULTI-LAYER
1. Forming of layers - separately or simultaneously .......................................................... 2
2. Layer adhesion ............................................................................................................... 3

3. Separate forming ........................................................................................................... 6
3.1. Conventional cylinder (vat) machines ................................................................. 6 3.2. Modified cylinder machines ................................................................................ 8 3.3. Fourdrinier machine with a separate top wire; top former .................................. 9 3.4. Fourdrinier machine with a separate former of a Fourdrinier type ................... 12 3.5. Fourdrinier machine with separate top formers of the roll former type ............ 16 3.6. Modified Fourdrinier machine with separate top formers of the roll- blade former type ............ 3.7. Headboxes ......................................................................................................... 19 4. Simultaneous multi-layer forming ............................................................................... 21
Headbox with stratified jet .............................................................................................. 21
Flersk4
01-11-14
Main reg
>allery
1. Forming of layers - separately or simultaneously
Board is an example of a product built up from several layers. At the production of board
One reason of forming separate layers at board production is the difficulty to form a sing
The fact that each layer usually has its own furnish is another reason to form separate lay
Fig. 1. Board machine with separate forming units. (FS-001.tif)
Giving the paper the desired properties at the lowest cost has led to a development of pro
Instead of forming each stock layer separately, a multi-channel headbox is used. Each sto
Fig. 2. Stratified stock jet from a sectioned headbox, kno
Flersk4
01-09-13
Mam reg
Glossary
Gallery
2. Layer adhesion
Developing a sheet in several layers gives a good possibility to optimise the sheet proper
An important board property, being direct related to the forming process, is how strongly
How strongly the layers will bind to each other in the finished board is called layer adhes
Fig. 3. Laboratory method for measuring of the streng
It is the number of hydrogen bonds formed between adjoining fibre surfaces which determ
Fig. 4. Microscope picture. Corner cut of a board she
Flersk4
01-09-13
Main reg
>allery
The number of hydrogen bonds depends on the number of OH groups available on the fib
Fig. 5. Illustration. Hydrogen bonds between two ad (FS-005.tif)
In a multi-layer construction, the direct contact area between the fibre surfaces in the adj
Fig. 6. Illustration. Board produced from three sepa (FS-006.tif)
One thing that determines the strength of the bonds between the layers is the dry substan
The lower the dry substance content is, the better the chance of getting a water film cove
Fig. 7. Illustration. Two fibres with a joint water lay (FS-007.tif)
Flersk4
01-09-13
Main reg
>allery
When the water on the fibre surfaces gradually evaporates in the dryer section, the forces
Figure set. Illustration. Drying progression. Water mole
The softness and formability of the fibre wall are of course important. The more the fibre
Fig. 10. Illustration. Soft fibres with a large direct cont
Fig. each other than mech Well beaten chemical fibres therefore always bind more strongly to 11. Well beaten chemical (FS-011.tif)
A more pliable fibre does not only mean that the fibres bind more strongly to each other w
Flersk4
01-09-13
Main reg
>allery
A soft and formable fibre develops a high layer adhesion. However, it also makes the she
Another way to strengthen the forces keeping the layers together is to have as high an am
The fine material fills up the cavities between the fibre layers and thus helps to increase t
Bwb^-^ I __~ "" ^^^wr^
Fig. 13. Illustration. Fine material fills out and create
3. Separate forming 3.1. Conventional cylinder (vat) machines

The cylinder machine, is a former used since a long time to produce board.
Fig. 14. Old cylinder mould and vat. (FS-014.tif)
Flersk4
01-09-13
Main reg
>allery
The stock comes into a trough and is dewatered through a wire covered drum rotating in The fibre layer formed on the drum can be rather thick, up to 100 grams per m2. Over the drum a felt is running.
Fig. 15. Principle sketch. Cylinder mould and vat. (FS-01
The strong capillary forces between the felt and the fibre net make the fibre net follow th
Fig. 16. Illustration. Couching of a fibre layer (FS-016.tif)
The number of forming units in a board machine depends on the basis weight of the prod If a heavy board grade is produced, there may be up to five formers.
The cylinder machine had a simple construction but it was not easy to get an even basis w
Flersk4
01-09-13
Main reg
Glossary
aiiery
3.2. Modified cylinder machines
The next step in the development of the cylinder machine was to distribute the stock dire
Fig. 17. Modified Cylinder former. (FS-017.tif)
Now it was possible to regulate the stock flow across the machine, which gave a more ev
Fig. 18. Sketch. Head box (BRDA-former). (F
Flersk4
01-09-13
Main reg
>allery
3.3. Fourdrinier machine with a separate top wire; top former
The machine speed on the fastest cylinder machines could come up to about 250 metres p
In this new construction a base layer is often formed on a conventional Fourdrinier mach
Fig. 19. Fourdrinier with four separate headboxes
One way to form the added layers was to inject the stock in the already formed Fourdrini
Fig. 20. Fourdrinier with a separate headbox and a follo (FS-020.tif)
The forming board is curved to let the constant pressure in the dewatering zone to increa
Fig. 21. Top former, Bel-Bond. (Beloit) (FS-021.tif)
Flersk4
01-09-27
Main reg
>allery
When the wire bends over the blade edges, pressure pulses are formed. The aim of pressu
Fig. 22. Illustration. Pressure pulse before (FS-022.tif)
The stock is mainly dewatered up towards the forming board. The one-sided dewatering
Fig. 23. Illustration. Fibre net formed durin (FS-023.tif)
Between the blades in the forming board there is a vaccum enhancing the dewatering thro
Fig. 24. Bel-Bond, Suction chamber over th
The vaccum also helps to adjust the size of the pressure pulses. The higher the vaccum is
Fig. 25. Illustration. The bending of the wir (FS-025.tif)
Flersk4
01-09-13
10
Main reg
>allery
The task of the suction box in the bottom wire is to prevent the new layer from following
Fig. 26. Bel-Bond. The suction box in the bottom wire i
One thing that distinguishes the described former from the conventional cylinder type is
A problem with this type of former is the risk for destroying the already formed fibre net w
An advantage is that the machine speed may be considerably higher than in the previous
However, the speed of such a board machine will not be as high as when producing pape
Flersk4
01-09-13
11
Main reg
>allery
3.4. Fourdrinier machine with a separate former of a Fourdrinier type
The stock in the surface layer often contains chemical fibres, only. As the surface of the b
One way to decrease the production cost is to keep the grammage of the surface layer as
A good formation is achieved by working with a low concentration in the stock jet and by
The high opacity is achieved by adding a filler. To develop the desired effect the wire rete
A former giving both a good formation and a high retention is the Fourdrinier former. Bu
The upper critical speed limit for a Fourdrinier former is soon above 1 000 metres per mi
Fig. 27. Fourdrinier machine. (FS-027.tif)
An increasingly common way is therefore to form the individual layers on separate Fourd
Fig. 28. Board machine with separate Fourdrinier formers. (Esch
Flersk4
01-09-13
12
Main reg
>allery
If it is desirable to increase the dewatering over the Fourdrinier wire and at the same time
Fig. 29. Fourdrinier former with a top wire. (Duoformer Voith). (F
On the overlying Fourdrinier unit in a board machine the outer wire sometimes wraps the
(The lower machine height is a practical advantage facilitating when rebuilding an old b
Fig. 30. Fourdrinier wire with a top wire. (Duoformer D/K Vo
The strength of the formation improving pressure pulses can be controlled by adjustment
Fig. 31. Illustration. Blade section in a Duformer D, D/K.
Flersk4
01-09-13
13
Main reg
>allery
How much of the fine material that will be localised in the contact surfaces between the l
Fig. 32. The fibre net formed on a Fourdrinier wire is tighter than the wire itself, so the fibre net c (FS-032.tif)
Figure set. The growth of the fibre net at one-side
2 Thus, to get as strong bonds as possible between the layers it is desirable to couch two to
rv o
ps"Sffi affii
w *%
/T
\l^"*"
7T
nQQQQJH!
Fig. 34. Principle sketch. Part of a board mac
When there are more than two layers, one wire side and one top side will always meet.
Fig. 35. Principle sketch. In the 2:nd and 3:rd couch nip a top and a wire side wi
Flersk4
01-09-13
14
Main reg
A way to increase the fine material content in the contact
>allery
Fig. 36. Principle sketch. A complete board machine. A highly refined chemical pu zone between the layers is to refine a small amount of stock to a very high degree, and add it on the base web just before the nip where the webs are couched together. An alternative to a highly refined stock could be to spray an uncooked starch slurry on the stock.
If the different layers are formed on separate Fourdrinier wires, large amounts of water c
If there are top wires with blades they also give pressure pulses which improve the forma
Flersk4
01-09-13
15
Main reg
Gl ossary
>allery
3.5. Fourdrinier machine with separate top formers of the roll former type
Fourdrinier formers make it possible to form a sheet with a good formation. The disadva
A way to increase the dewatering and further improve the formation on a Fourdrinier wi Another way becoming more and more common is to use two-sided dewatering from the Nowadays, the same development can be seen on a board machine.
A way of producing board in several layers is to complete the Fourdrinier machine with a
Fig. 37. TWINTOP former N. (Escher Wyss) (FS-037.tif)
A weak point with a pure roll former is that the shear forces, formed when the stock jet m
The lack of pressure pulses during the dewatering in a roll fomer means that the fibres ea
Fig. 38. Illustration. Dewatering in a roll former. (
Flersk4
01-09-13
16
Main reg
>allery
One disadvantage with a roll former is that the formation is not the very best.
Another disadvantage related to the two-sided dewatering in the top former is the fact th As long as there is only one top former the layer formed on the top wire will be couched
However, as soon as there are more top formers it will no longer be possible to couch tog
3.6. Modified Fourdrinier machine with separate top formers of the roll-blade form
A technique used in ordinary paper production was to combine roll and blade dewatering
This technique to improve the formation on the top wire was previously used also in a bo
The stock is dewatered in the two-sided manner from the very beginning in a roll-blade f After the two-sided de-watering the wire runs as in a conventional Fourdrinier machine.
Fig. 39. Board machine with two-sided dewatering of a base layer (FS-039.tif)
Flersk4
01-09-13
17
Main reg
>allery
The stock is ejected into the nip between two wires. The initial dewatering takes place at
The continued dewatering then takes place over the slightly curved blade section. The str
Fig. 40. The dewatering zone in a roll blade former of the type
In the following top formers the stock is in principle dewatered in the same way as in the
Fig. 41. Top former with two-sided dewatering. (DUOFORME
Flersk4
01-09-13
18
Mam reg
Glossary
allery
The dewatering pulses over the forming blades do not only help to improve the formation
3.7. Headboxes
Hydraulic headbox or perforated roll box
The headboxes used in a board machine are of the same type as those on a Fourdrinier m
Fig. 42. Hydraulic headbox. (Escher Wyss) (FS-042.tif)
The effect of the turbulence generator is connected to the flow through the pipe tubes. If the flow becomes too low, the effect becomes low and the fibres easily floc.
Fig. 43. Illustration. Turbulence generating pipe tubes
Flersk4
01-09-13
19
Main reg
>allery
If the flow, on the other hand, becomes too high, large scale whirls could be generated in
t MtM t
CO
Fig. 44. Illustration. If the flow becomes too high the st (FS-044.tif)
The fact that the flow through the headboxes often varies at the production of multi-layer
Fig. 45. Modern hydraulic headbox. (Valmet) (FS-045.tif)
Flersk4
01-09-13
20
Main reg
>allery
4. Simultaneous multi-layer forming

Headbox with stratified jet
When producing board the different layers are normally formed separately and then they
But there is also another way making it possible to use separate furnishes without formin
The process is to use a multi-channel headbox. From a single head box, a stratified jet is
Fig. 46. Modern sectioned hydraulic headbox with a stock jet in three layers
Pipe tubes are not always used. There are concepts where the stocks are separated by thin
Fig. 47. Hydraulic headbox with a three layers stratified jet.
Flersk4
01-09-13
21
Main reg
>allery
A disadvantage is that the stock layers can not be kept totally separated from each other i
The stronger the stock turbulence is during the forming, the higher becomes the risk to m
Fig. 48. Illustration. High turbulence in the stock j
Of course, the greatest risk for mixing the stock is in the zone closest to the borderline be
The turbulence during the dewatering serves to prevent the fibres from forming flocs, det
Figure set. Small whirls, micro turbulence, break down the fib
Flersk4
01-09-13
22
Main reg
>allery
In a roll-former the turbulence is low during the forming and the dewatering takes place s
Fig. 51. Illustration. Dewatering over the forming roll in a ro
Roll formers are mainly used when producing tissue paper. The low basis weight and the
Fig. 52. Illustration. Dewatering over the forming roll in a tis (FS-052.tif)
The low risk of mixing the stocks is one reason for using head-boxes with stratified stock
Fig. 53. Headbox with three separate stock jets. (Valmet) (FS
Flersk4
01-09-13
23
Main reg
>allery
The extremely fast dewatering and the low turbulence in a roll former producing tissue p
An example of another grade produced in two, or sometimes three, layers and where hea In the machine shown on the picture there is a headbox with
Fig. 54. Paper machine with a headbox with two layers. (Escher W two separate stock jets. If a third layer is desired you can choose to increase the number of separate stock jets from the headbox or to prolong the Fourdrinier wire and form the third layer in a separate forming unit.
An advantage of simultaneous multi-layer forming is that the investment cost for the form
A disadvantage, however, is that it is more difficult to keep the stocks separated, than wh
Another weakness is that the white water is mixed in the wire pit, making it impossible to
To provide a multi-layer box with different stock there must be a separate line for each st
Flersk4
01-09-13
24
Main reg
>allery
A way to avoid the high cost for the extra stock lines, still making it possible to utilise th
Fig. 55. Headbox fed with the same grade of fibre but with differ
When producing a paper or board with a high basis weight it is necessary to form separa
The other reason to form a sheet with several layers is that the desired properties for the
The technique to form simultaneously (and not separately) is a way to decrease the inves
The method to form several layers simultaneously is however most interesting and in the
Flersk4
01-09-13
25

CompletPresentationA An

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

CompletPresentationA An

Caricato da

Copyright:

Formati disponibili

Main reg C" |

1. Paper machine, different types

Fig. 1. Forming section, press section, drying section. (2-0

Fig. 2. Fourdrinier machine. (2-002.tif)

A formning section can have the original form

Fig. 3. Headbox with perforated rolls (KMV). (2-003

a flat wire where the paper is formed.

Fig. 4. Illustration. Fourdrinier machine. (2-004.

Fig. 5. Illustration. Hybrid machine. (2-005.tif)

This headbox, called hydraulic headbox, is of a different type.

Fig. 6. Hydraulic headbox. (2-006.bmp)

Fig. 7. Twin wire machine. (2-007.tif)

Fig. 8. Illustration. Double wire machine produ (2-008.tif)

Fig. 9. Illustration. Fourdrinier wires on a board machine. (2-009.tif)

Fig. 10. Press section in a sack paper machine. (2

Fig. 11. Press section in a board machine. (2-011

Main reg Q" |

A press roll can be engaged in more than one press nip.

Fig. 12. Press section in a fine paper machine. (2-0

tfi VALMET Paper Machinery

Fig. 14. Shoe press, Valmet. (2-014.tif)

Fig. 15. Tissue machine. (2-015.tif)

Fig. 16. Multicylinder section. (2-016.tif)

Fig. 17. Yankee cylinder, with a gas heated ho

2. Paper making, an introduction

Fig. 18. Microscope photo. Newsprint. (STFI) (2-01

Main reg ^" |

Fig. 19. Manual paper production at Grycksbo Paper Mill. (2-0

Fig. 20. A simplified process line, fine paper mill. (2-020

Fig. 22. Process line. Cleaning, deaeration, screening. (2

Fig. 23. Headbox, wire section. (2-023.tif)

Fig. 25. Illustration. Single felted press roll nip. (2-02

Fig. 26. Multicylinder dryer. (2-026.tif)

Fig. 27. Illustration. Long softwood fibres.

Fig. 28. Illustration. Short hardwood fibres

Fig. 32. Illustration. Enlarged fibre surface with ma (2-032.tif)

Water is written with the chemical formula H2O.

Fig. 33. Structural formula, water. (2-033.tif)

- ^^^^"^^^* Fig. 34. Illustration. Water molecules forming b

Fig. 35. OH groups bind directly to each other with (2-035.tif)

Fig. 36. Illustration. Soft, formable fibres. (2-036.tif

Fig. 37. Illustration. Hydrogen bonding between two (2-037.tif)

Fig. 17. Illustration. Fibre collapse, springwood and sum (5-017.tif)

4. Refiner tackle, segments and fillings

Fig. 18. Illustration. Refiner filling: rotor and sta (5-018.tif)

Fig.19. Illustration. Refiner fillings. (5-019.tif)

Fig. 20.1. Refiner fillings with wide bars. (5-020

Thin bars are used for refining of short fibre pulp.

Fig. 20.2 Refiner fillings with thin bars. (5-020.

Fig. 21. Illustration. Gap clearance. (5-021.tif)

Fig. 22. Illustration. Fibres in a refiner gap. (5-

The conical refiner is the oldest type.

Fig. 23. Classical conical refiner. (5-023.tif)

The more modern conical refiners have a larger cone angle.

Fig. 24. Modern conical refiner: Conflo. (5-024.t

Fig. 25. Double disc refiner. (5-025.tif)

= Net refining power, kW

7.2 Refining quantity

Main 7.3 Refining quality

The added net refining energy can be used in different ways.

Distance between refining bars

Fig. 26. Illustration. Tightly placed refining bar (5-026.tif)

Fig. 27. Illustration. Thinly placed refining bars (5-027.tif)