Improving Paper Machine Efficiency/Productivity through On-line Control

摘要

This project involves implementing a new technology, microforming, in a headbox to produce an isotropic sheet with significant reductions in the MD/CD stiffness ratio (increasing CD specific STFI) and improved sheet uniformity. Microforming involves generating axial vorticity (i.e., swirl) prior to the converging nozzle of the headbox by retrofitting an existing tube block with swirl generation devices referred to as Vortigen system. The Vortigen system developed in this project is a retrofit technology to a hydraulic headbox tube block. The tubes in the tube block are re-designed to generate axial vorticity (or swirl) in the tubes. This type of flow results in higher intensity small-scale turbulence in the forming jet at the slice. The net effect, as demonstrated in pilot and commercial trials, is improvement in formation and surface smoothness, lower MD/CD tensile ratio, and consequently, higher CD strength properties such as CD STFI, Ring Crush and tensile or breaking length. The objective of this project is to implement microforming by developing the retrofit technology for generation and on-line control of axial vorticity in the tubes to optimize turbulent scale and intensity, and consequently, fiber network structure properties in the sheet. This technology results in significant improvements in the performance and capital effectiveness of the paper machine (PM) for a fraction of the cost to replace a headbox.