Refining Efficiency Seminar

50 years
Refining Optimization
Maximizing Energy Efficiency
Presented at Heinbach/PaperRun Seminar Paris, June 2005
Sergio Zalewska
Application Manager Pilo S/A - Brazil
50 years
50 years of expertise in pulp and

paper business
Focus on refining systems
More than 2000 installed refiners
Present in 54 countries
Thousands of processes
optimizations
Partnership with Paper Research
Institutes/Universities
50 years
Refining process
Mechanical treatment of the fibers to reach the desired
paper characteristics and strenght.
Not refined fiber mat
Refined fiber mat
50 years
Celullose fiber structure
Cell Walls
Cell walls
Plant cells
Celullose
chains
Fibrills
Microfibrills
Celullose
monomer
50 years
Refining effects
Primary
Primary wall scratch
Secondary wall opening
Water absortion
Fiber cutting
Secondary
Allow hydrogen bridge connection between
fibers
Flexibility through hydratation
Better sheet formation
50 years
How it works

Fibers are collected by the bars

Fiber mat is compressed between rotor and stator
Fibers are relaexed again after have passed through the
bars
50 years
Affecting factors
Refiner
Type
Mechanical conditions
Speed
Installation
Series/Parallel
Process Conditions

Fiber type
Consistency
pH
Flow
Aditives
In order to optimize
the refining process
all these aspects must
be analised
Applied energy
Number of impacts (intensity)
Fillings characteristics :
Bar height/width/space
Cut length
Crossing angle
Dams (flow restrictors)
Fillings material
No Load (pumping action and hydraulic losses)
50 years
Energy applied
8
6
5
km
Breaking Length
Unbleached Pine
Pulp
Bleached
Eucalyptus Pulp
3
2
1
0
100
200
Total Energy
kWh/t
300
50 years
Energy Intensity
Measures the intensity with wich the
energy is applied to the stock
Has big influence on the paper
properties
Each type of fiber has its better
energy intensity to give the better
paper results

Breaking length (km)
7
6
5
0,7 ws/m
1,4 ws/m
3,9 ws/m
4
3
2
mx. recommended intensity

Ws/m
3,5
3
Bleached Sulfate
Pinus
Unbleached
Sulfate Pinus
Bleach Sulfide
Pulp
Unbleached
Sulfide Pulp
Bleached
Eucalyptus
2,5
2
1,5
1
0,5
1
0
0
0
50
100
150
Total energy
kWh/t
200
250
300
20
40
60
SR
80
100
50 years
Energy Intensity
Is affected by:
Total applied energy
Size of discs (conical fillings)
Bar pattern
Motor speed
Number of refiners
50 years
Optimized operation conditions

Consistency

Pine (3,0 - 4,0 %)

Eucalyptus (4,0 - 5,0 %)
Low consistency promotes more cutting effect
Higher consistency promotes the fiber/fiber
contacting causing more fibrillation than cutting
4%
60
Nm/g
40
20
0
50
80
kWh/t
pH
Tensile index (Nm/g)
3%
80
70
60
50
40
30
20
pH 5
pH 7
pH 9
20 40 60 80 100 120
Applied energy (kWh/t)
5%
50 years
Optimized operation conditions

Flow and Pressure
Effect the
process stability
Keep the fiber mat and centers the rotor between the two stators
Are dependent on pump and instalation (series/parallel)
Low flow must be correct using recirculation or parallel
instalation
Low pressures cause instability of the rotor. Too high pressures
causes uneven wearing.
50 years
Pilo Solutions
For Refiner Improvement
50 years
Bar Pattern Optimization

Paper properties
Better sheet formation
Improve fillings life
Welded Construction
HIGHER BARS
BETTER BREAK RESISTANCE
CONSTANT BAR PATTERN
POSSIBILITY TO MAKE
THINNER BARS
50 years
TriDisc Conversions for DD Refiners

Original Double
Disc System
Pilo TriDisc
System
50 years
TriDisc Conversions for DD Refiners

Features:
Lighter Rotor
Lower No-load
Easier Shaft Movement
Lower Bearing Loads
Less Bolts
More Refining Area
Lower Intensity
Larger Openings
Better Flow Distribution
Balanced Gaps
Advantages
5 - 10% Less Applied HP Required For
Identical Refining Level
Longer Life
Improved Fiber Quality Due To More
Even Stock Distribution
More Uniform Plate Wear
Faster, Easier And Less Frequent
Plate Changes
Resistance To Damage
Will Not Shatter
50 years
TriConic Refiners
50 years
TriConic Refiners
TRIPLE CONE CONCEPT
DUO FLOW
STOCK
OUTLET
STOCK
INLET
SHAFT
STATOR # 1
STATOR # 4
ROTOR # 2 and # 3
BARS
50 years
TriConic Refiners
Application 1 TMP Post-Refiner
CHILE
SECONDARY REFINERS
OLD INSTALLATION
DDR INSTALLATION
1 x DDR 30 - 600HP
CURRENT INSTALLATION
TRICONIC INSTALLATION
1 x Triconic RTC 2000 600 HP
Annual Saving : US$ 425.000
50 years
TriConic Refiners
16,8 g/m 2
Application 2 Tissue (Italy)
Reel
Target
1
2
3
4
5
6
7
Long
kN/m
3,53
4,15
3,60
4,00
3,85
4,08
4,02
4,10
Trans
2,06
2,30
2,20
2,45
2,40
2,19
2,25
2,25
15,5 g/m 2
Reel
Long
Trans
Electrical Savings: 15,3%

Amp
CSF
650
640
640
640
640
600
600
550
525
425
425
425
425
500
500
550
Electrical Savings: 33,3 %

Amp
CSF
kN/m
TARGET
1
2
3
4
5
6
7
8
2,34
3,10
3,75
3,50
3,37
3,45
3,70
3,09
3,57
0,78
1,65
1,90
1,95
1,68
1,47
1,54
1,03
1,46
600
500
500
500
450
450
450
400
400
525
540
540
540
550
550
550
575
575
50 years
TriConic Refiners
Application 3 P&W - Short Fiber Line
Cartiera Della Valtellina (Italy)
3 x DD20 200kW (590kW used)
65 TPD 19 38SR
1 x RTC-1000 315kW (300kW used)

65 TPD 19 35SR

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50 years

50 years of expertise in pulp and

Not refined fiber mat

Refined fiber mat

Celullose fiber structure

Fibers are collected by the bars

Breaking length (km)

mx. recommended intensity

Optimized operation conditions

Pine (3,0 - 4,0 %)

Tensile index (Nm/g)

Applied energy (kWh/t)

Optimized operation conditions

Bar Pattern Optimization

BETTER BREAK RESISTANCE

CONSTANT BAR PATTERN

TriDisc Conversions for DD Refiners

TriDisc Conversions for DD Refiners

Annual Saving : US$ 425.000

Application 2 Tissue (Italy)

Electrical Savings: 15,3%

Electrical Savings: 33,3 %

1 x RTC-1000 315kW (300kW used)

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