refining system optimization - j&l fiber services© 2007 j&l fiber services, inc. all rights...
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© 2007 J&L Fiber Services, Inc. All rights reserved.
Refining System OptimizationRefining System OptimizationA Six-Step Approach
© 2007 J&L Fiber Services, Inc. All rights reserved.
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
2. Consistency
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
HydraulicsHydraulicsWhy are Hydraulic Conditions Important to Refining?
Rotor is Stable & CenteredIncreases Probability of Fiber Mat FormationFiber Strength Development Potential is MaximizedPlate Life Potential is MaximizedVariation is Minimized
It’s just not a good thing to try to refine metal
Step 1: Hydraulics - Flow
© 2007 J&L Fiber Services, Inc. All rights reserved.
Hydraulic ChartHydraulic ChartDDOOUUBBLLEE DDIISSKK RREEFFIINNEERR CCAAPPAACCIITTYY CCHHAARRTT
RREECCOOMMMMEENNDDEEDD FFLLOOWW RRAANNGGEESS FFOORR VVAARRIIOOUUSS SSIIZZEE RREEFFIINNEERRSS ((6600 HHZZ SSPPEEEEDDSS))
DDiiaammeetteerr mmmm
((iinncchheess))
MMaaxx PPoowweerr kkWW ((HHpp))
NNoorrmmaall RRPPMM
NNoo LLooaadd kkWW ((HHpp))
FFLLOOWW RRAATTEESS –– GGPPMM
LLooww MMeeddiiuumm HHiigghh 550088 ((2200)) 222255 ((330000)) 990000 5555 ((7755)) 115500 225500 440000 661100 ((2244)) 333355 ((440000)) 772200 8855 ((6655)) 225500 335500 660000 666600 ((2266)) 337755 ((550000)) 772200 9900 ((112200)) 330000 445500 880000 776622 ((3300)) 445500 ((660000)) 660000 9955 ((112255)) 337755 660000 11110000 886644 ((3344)) 559955 ((880000)) 551144 110000 ((113355)) 447755 775500 11440000
775500 ((11000000)) 660000 116600 ((221155)) 555500 887755 11665500 996655 ((3388)) 993355 ((11225500)) 551144 116600 ((221155)) 665500 11007755 22002255
11006677 ((4422)) 11112200 ((11550000)) 445500 116655 ((222200)) 777755 11225500 22440000 11330055 ((11775500)) 551144 224455 ((333300)) 990000 11445500 22880000
11116688 ((4466)) 11449955 ((22000000)) 445500 224400 ((332255)) 11002255 11667755 33227755 11332211 ((5522)) 22224400 ((33000000)) 440000 228855 ((338855)) 11330000 22115500 44330000
22224400 ((33000000)) 445500 441100 ((555500)) 11447755 22442255 44885500 11337722 ((5544)) 22224400 ((33000000)) 440000 333355 ((445500)) 11447755 22442255 44885500
DDOOUUBBLLEE DDIISSKK RREEFFIINNEERR CCAAPPAACCIITTYY CCHHAARRTT RREECCOOMMMMEENNDDEEDD FFLLOOWW RRAANNGGEESS FFOORR VVAARRIIOOUUSS SSIIZZEE RREEFFIINNEERRSS
((6600 HHZZ SSPPEEEEDDSS)) DDiiaammeetteerr
mmmm ((iinncchheess))
MMaaxx PPoowweerr kkWW ((HHpp))
NNoorrmmaall RRPPMM
NNoo LLooaadd kkWW ((HHpp))
FFLLOOWW RRAATTEESS –– GGPPMM
LLooww MMeeddiiuumm HHiigghh 550088 ((2200)) 222255 ((330000)) 990000 5555 ((7755)) 115500 225500 440000 661100 ((2244)) 333355 ((440000)) 772200 8855 ((6655)) 225500 335500 660000 666600 ((2266)) 337755 ((550000)) 772200 9900 ((112200)) 330000 445500 880000 776622 ((3300)) 445500 ((660000)) 660000 9955 ((112255)) 337755 660000 11110000 886644 ((3344)) 559955 ((880000)) 551144 110000 ((113355)) 447755 775500 11440000
775500 ((11000000)) 660000 116600 ((221155)) 555500 887755 11665500 996655 ((3388)) 993355 ((11225500)) 551144 116600 ((221155)) 665500 11007755 22002255
11006677 ((4422)) 11112200 ((11550000)) 445500 116655 ((222200)) 777755 11225500 22440000 11330055 ((11775500)) 551144 224455 ((333300)) 990000 11445500 22880000
11116688 ((4466)) 11449955 ((22000000)) 445500 224400 ((332255)) 11002255 11667755 33227755 11332211 ((5522)) 22224400 ((33000000)) 440000 228855 ((338855)) 11330000 22115500 44330000
22224400 ((33000000)) 445500 441100 ((555500)) 11447755 22442255 44885500 11337722 ((5544)) 22224400 ((33000000)) 440000 333355 ((445500)) 11447755 22442255 44885500
Step 1: Hydraulics - Flow
© 2007 J&L Fiber Services, Inc. All rights reserved.
Negatives to Low FlowNegatives to Low FlowLittle or No Fiber Mat Between PlatesFiber ChannelingHigh Pressure Rise (25-50 psi)Plate ClashingShort Plate LifeInefficient Refining (power vs fiber development)Poor Strength DevelopmentIncreased Fines Generation
PowerPower
Step 1: Hydraulics - Flow
© 2007 J&L Fiber Services, Inc. All rights reserved.
Negatives to High FlowNegatives to High FlowInability to Optimize Plate Design For Maximum Strength Development (Compromise)Short Plate LifePressure DropMotors Maxed Out
Step 1: Hydraulics - Flow
PowerPower
© 2007 J&L Fiber Services, Inc. All rights reserved.
Possible SolutionsPossible SolutionsLow Flow
RecirculationParallel to SeriesPattern ChangeHoldbackSmaller Refiner
High FlowPump ChangeSeries to ParallelPattern ChangeAn Additional &/or Larger RefinerIncrease Consistency
Step 1: Hydraulics - Flow
© 2007 J&L Fiber Services, Inc. All rights reserved.
2. Consistency
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
Consistency GuidelinesConsistency GuidelinesConsistency Guidelines for Various Fiber Types
Fiber Type
Recommended Range of Refining Consistency
Unbleached Softwood Kraft 3.5 - 4.5%
Bleached Softwood Kraft 3.5 - 5%
Bleached Hardwood/Eucalyptus Kraft 4 - 6%
OCC 3.5 - 5%
Mechanical Pulps 4 - 6%
Unbleached Semi-Chem Hardwood 4.5 - 6%
Mixed Waste 4 - 6%
Step 2: Consistency
© 2007 J&L Fiber Services, Inc. All rights reserved.
ConsistencyConsistencyWhy is the Proper Consistency Important to Refining?
Increases the Probability of Fiber Mat FormationFiber Strength Potential MaximizedPlate Life Potential is MaximizedVariation is Minimized
Step 2: Consistency
© 2007 J&L Fiber Services, Inc. All rights reserved.
Effects of Operating Outside Recommended ConsistencyEffects of Operating Outside Recommended Consistency
High ConsistencyPlate PluggingPoor Fiber Development
Low ConsistencyLittle to No Fiber Mat Between PlatesInefficient RefiningPoor Fiber DevelopmentFiber CuttingPlate ClashingShort Plate Life
Step 2: Consistency
© 2007 J&L Fiber Services, Inc. All rights reserved.
2. Consistency
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
Specific EnergySpecific EnergyDefinition: The amount of Energy Transferred from the Refiner’s Motor to the Fiber.
S.E. = kWh/t =
S.E = HPD/T =
Motor Load (kW) – No Load (kW)Tons per Hour
Motor Load (HP) – No Load (HP)Tons Per Day
Step 3: Specific Energy
© 2007 J&L Fiber Services, Inc. All rights reserved.
No Load EnergyNo Load EnergyDefinition: The Energy Required to spin the rotor in a pulp slurry.
No Load (kW) = (2.299x10-13)(Diam4.249)(RPM3)
Diam = Plate diameter in InchesRPM = Refiner rotor speed
THE REFINER IS AN INEFFICIENT PUMP
Step 3: Specific Energy
© 2007 J&L Fiber Services, Inc. All rights reserved.
Energy Transfer to FiberEnergy Transfer to Fiber
42” RefinerMotor
1305 kW
No Load = 245 kW
Fiber = 1060 kW 81% Efficiency
Step 3: Specific Energy
© 2007 J&L Fiber Services, Inc. All rights reserved.
Specific Energy GuidelinesSpecific Energy GuidelinesNET REFINING REQUIREMENTS
FOR MAJOR GRADES
GRADE HPD/UST KWH/UST KWH/MT
Linerboard Base 5 - 7 89 - 125 99 - 138Top 10 - 12 179 - 215 197 - 237
Sack, Bag 12 - 14 215 - 250 237 - 276
Medium Virgin HWD 6 - 10 107 - 179 118 - 197Waste 2 - 3 36 - 54 39 - 59Tickler 1.0 - 1.5 18 - 27 20 - 30
Fine Papers Hardwood 4 - 6 72 - 107 79 - 118Softwood 6 - 8 107 - 143 118 - 158
Tickler 1.0 - 1.5 18 - 27 20 - 30
Foodboard, Hardwood 2 - 3 36 - 54 39 - 59Milk Carton Softwood 3 - 4 54 - 72 59 - 79
Tickler 1. 0 - 1.5 18 - 27 20 - 30
News SB Kraft 2 - 5 36 - 89 39 - 99Groundwood 2 - 3 36 - 54 39 - 59
Grades w/ OCC OCC 2.5 - 5.0 81 - 117 50 - 100
Step 3: Specific Energy
© 2007 J&L Fiber Services, Inc. All rights reserved.
2. Consistency
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
Freeness Drop / HPD/TFreeness Drop / HPD/TFreeness Drop / HPD/T is a Great Measure to Determine the Refiner(s) Efficiency and if it is Operating Correctly
Equation: Delta CSF / HPD/T = CSF In - CSF OutHPD/T
Step 4: ∆Specific Freeness
© 2007 J&L Fiber Services, Inc. All rights reserved.
Freeness Drop / HPD/T Guideline ChartFreeness Drop / HPD/T Guideline Chart
FREENESS DROP / NET HPD/TVarious Furnishes
UNBLEACHED SOFTWOOD KRAFTNORTHERN U.S. 15 - 25 CSF / Net HPD/TSOUTHERN U.S. 15 - 30 CSF / Net HPD/T
BLEACHED SOFTWOOD KRAFTNORTHERN U.S 25 - 50 CSF / Net HPD/TSOUTHERN U.S. 25 - 60 CSF / Net HPD/T
BLEACHED HARDWOOD KRAFTMOST SPECIES 60 - 100 CSF / Net HPD/TEUCALYPTUS 45 - 50 CSF / Net HPD/T
SECONDARY FIBEROCC 40 - 70 CSF / Net HPD/TMIXED 50 - 70 CSF / Net HPD/TNEWS 20 - 35 CSF / Net HPD/T
Step 4: ∆Specific Freeness
© 2007 J&L Fiber Services, Inc. All rights reserved.
Freeness Drop / HPD/TFreeness Drop / HPD/TPossible Causes for a Low Freeness Drop/HPD/T
“Tough” FiberLow or High Flow ConditionsLow ConsistencyImproper Pattern ApplicationWorn Out Plate - Bar edge Rounding, Bar WearMechanical Problem w/ Refiner - Out of Tram, a Rotor that will not FloatImproper Plate Installation
Step 4: ∆Specific Freeness
© 2007 J&L Fiber Services, Inc. All rights reserved.
2. Consistency
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
Refining Intensity (SEL) Refining Intensity (SEL) Definition: A Term used to Define “How” the Energy is Applied the the Pulp.
The Amount of Energy (watts) Applied Across One Meter of a Refiner Plate’s Bar Edge and Transferred to the Pulp in One Second; (Ws/m)
Pattern Design Plays Key Role
Equation: Int = WS/M = (KM Bar Edge Crossings/Rev) (RPM) (1min/60sec)
Motor Load (kW) - No Load (kW)
Step 5: Refining Intensity
© 2007 J&L Fiber Services, Inc. All rights reserved.
FIBER TYPE TYPICAL SEL RANGE WS/M Unbl. Northern SW Kraft 2.5 - 4.5
Unbl. Southern SW Kraft 2.5 - 4.5
Bl. Northern SW Kraft 1.5 - 3.5
Bl. Southern SW Kraft 1.5 - 3.5
Semi-Chem HWD 1.0 - 2.5
Bl. HW Kraft 0.5 - 1.0
Bl. Eucalyptus Kraft 0.5 - 1.0
TMP Post Refining less than 0.5
OCC .75 - 2.5 (As low as possible w/out Plugging)
Mixed Waste .75 – 1.5
Deinked News / Magazine (70 / 30 mix) less than 1.0
Typical SEL Ranges forVarious Fiber TypesTypical SEL Ranges forVarious Fiber Types
Step 5: Refining Intensity
© 2007 J&L Fiber Services, Inc. All rights reserved.
Impact of Intensity on the FiberImpact of Intensity on the Fiber
High IntensityRefining – Cutting
Low IntensityRefining - Fibrillation
Step 5: Refining Intensity
© 2007 J&L Fiber Services, Inc. All rights reserved.
Effects of RefiningOutside the Recommended Intensity RangeEffects of RefiningOutside the Recommended Intensity Range
Lower Than Recommended
Potentially Poor Fiber Development (All Fibers Require a Certain Intensity Level to Break Down Their WallsMaintain Fiber lengthInefficient Freeness drop
Higher Than Recommended
Severe Fiber CuttingPlate Clashing, Exceed Fiber Threshold Short Plate LifePoor Strength Development
Step 5: Refining Intensity
© 2007 J&L Fiber Services, Inc. All rights reserved.
2. Consistency
Six-Step ApproachSix-Step Approach1. Hydraulics - Flow
3. Specific Energy (kWh/t)
4. Specific Freeness Drop CSF/ kWh/t
5. Refining Intensity (Ws/m)
6. Plate Material
Process Optimization and/or Pattern and Alloy Recommendation
© 2007 J&L Fiber Services, Inc. All rights reserved.
Plate Material SelectionPlate Material SelectionFailure Modes of Refiner Plates
Bar WearSerrationBar Edge RoundingCorrosionBar BreakageSmearing
Alloy Selection is Based on Dominant Failure Mode - Maximize Plate Life
Step 6: Plate Material
© 2007 J&L Fiber Services, Inc. All rights reserved.
Questions?Questions?If you have any questions on J&L’s Six Step Approach on Refiner System Optimization, or if you would like additional information on our product line, call your J&L Representative. Together with J&L's Technical Support, he can assist you in applying this Six-Step Process to ensure optimal performance of your refining system.