Stock Prep Refining

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EFFECT ON FIBRES ON REFINING

1. Fibre delamination
Forces on the fibre in the refiner cause fibrils to move relative to
each other, breaking internal bonds and thus causing fibre
delamination. This has been clearly observed with the scanning
electron microscope. Fibre delamination contributes to other
changes in the fibre such as swelling and increased flexibility.
2. Fibre swelling
.2
Delamination of the fibres allows the entry of water into the fibre
walls, causing the fibres to swell. This water breaks additional
hydrogen bonds creating further swelling. Water Retention Value
has been shown to increase with refining, proving that there is an
increasing amount of water bound to the fibre as the level of
refining increases.

Increased fibre flexibility
.3
Breaking of internal bonds allows fibrils to move relative to each

other, making the fibres less resistant to deformation i.e. more
flexible. This increased flexibility enables surface tension forces to
bring more fibres into close proximity during consolidation of the
web. This, in turn, increases the level of fibre / fibre bonding and
thus influences paper strength, optical properties and other paper
characteristics.
Removal of outer layers .4

The thin primary wall (or what remains of it following pulping and
bleaching ) and part of the S1 layer can be removed by refining,
exposing a new surface and allowing an increase in fibre swelling.
The removed layers increase the fines level in the pulp and thus
affect paper properties.

5. Microcreping of fibres and the introduction of other defects
.5
These both affect the mechanical properties of the fibres. Micro creping
such as kinks and local produces a more extensible fibre and defects
reduction in the local fibre strength. ballooning of the fibre can cause a
6. Curling and Twisting of fibres

paper and thus Fibre twisting and curling influence the network structure of
affect its properties.
7. Increased specific surface

layers increases the The production of fine material with the removal of outer
by fibrillation i.e. loosening of specific surface. This is further increased
the surface fibrils.
8. Fiber length reduction

reduce the flocculating This occurs with harsher beating. It has been used to
at the expense of tearing strength. tendencies of long fibre pulp
GENERAL EFFECTS ON SHEET PROPERTIES

ON REFINING
1) Drainage resistance (water removal resistance ) increases
2) Tensile strength, burst strength, and internal bonding strength
increases
3) Tear strength of softwood fibers might slightly improve at first,
but then decreases, whereas that of hardwood fibers at first
significantly increases but then decreases after prolonged refining
4) Air permeability, bulk, absorbency, opacity and light scattering
decreases
5) Brightness slightly decreases
6) Fibre strength is little affected in refining
(( P
) (I
) (N
P= I N

P= IN
P= (Applied motor load-No load)/ (RPM Bar
edge length) : (RPM Bar edge length) / Tons
per day =
KW : Tons per day
= KWH/Ton
The Correct Amount of Refining

(Specific Energy Input)
The net specific energy consumption of a
refiner or refining system determines the
amount of refining that is applied to a pulp.
Net Specific Energy = (Total Applied Power No Load)/ t/d
Common North American units are

horsepower per short ton per day, or hpd/t.
The common metric units are kWh/metric ton.
The throughput in t/d or t/h

Throughput is based on moisture free
fiber (also referred to as oven dry or bone
dry basis), and can be calculated if both
the flow rate (in gallons per minute or
liters per minute) and the consistency are
known:
short t/d = Flow (gpm) x 6 x % Consistency
metric t/h = Flow (lpm) x 0.06 x %Consistency
Example calculations
a) With a flow rate of 500 gpm and a consistency of
4.5%, the throughput is:
t/d = 500 x 6.0 x 0.045 = 135 st/d
b) With a flow rate of 1200 lpm and a consistency of
5.3%:
t/h = 1200 x 0.06 x 0.053 = 3.8 mt/h
c) If the motor load is 575 hp and the no- load power

is 115 hp, then the net applied
power is: 575 115 = 460 hp
d) the specific energy input is:
460 hp / 135 t/d = 3.4 hpd/t
To convert from hp to kW
multiply hp by a factor of 0.746
The equivalent specific energy calculation for the
flow rate of 1200 lpm and consistency of 5.3 %
would then be:
(575 hp x 0.746) (115 hp x 0.746) = 342 net KW
342 kW / (1200 * 0.06 * 0.053) = 90 kWh/t
An estimate of the specific energy

An estimate of the specific energy requirement
can be made for a given type of pulp if the
unrefined pulp freeness and the target freeness
level are known.
By subtracting the target freeness from the
unrefined freeness, the total amount of freeness
change is calculated.
Values in Table 5 can then be used to predict
approximately how much energy should be
required to achieve the desired freeness drop.
The Correct Intensity of Refining

(Specific Edge Load)
If a pulp is only lightly refined, the refining
intensity is usually not so important because
there is not enough fiber modification taking
place to make the difference discernable.
An exception to this is the refining of
unbleached kraft for sack paper applications
for which the initial increase in tear with
refining can only be assured if the intensity is
sufficiently low (i.e. 1.5-2.0 Ws/m).
Benefits of low refining intensity for

softwood pulps
Low refining intensity has long been considered
unnecessary for softwood pulps and deemed too costly
in terms of potential increases in specific energy
requirements.
This view is changing as many mills are seeking gains
in tear strength and toughness that lower refining
intensity can provide.
Many mill refiners currently operate in the range of 2.0
4.0 Ws/m. Any easily achieved reduction in intensity
will almost always be beneficial to quality.

hardwood pulps
In the past, the lower limit of intensity had

been established at 0.6-0.8 Ws/m due to the
limitations of plate manufacturing technology.
However, recent developments in this area
have enabled intensities of 0.2-0.6 Ws/m to
be achieved while maintaining efficiency and
hydraulic capacity.

hardwood pulps
For hardwood pulps, low refining intensity results in
greater bulk and opacity at a given level of most
strength properties.
Most mill refiners currently operate in the range of 0.61.0 Ws/m, and nearly all applications could benefit from
any reduction achieved by changing plate patterns.
Another key benefit of low intensity refining for
hardwood is the reduction in energy required to
achieve a given pulp quality or drainage level.

mechanical pulp
For mechanical pulp post-refining, low refining

intensity will yield higher freeness, increased
fiber length and improved tear strength at a
given debris level and energy input.
RECOMMENDED VALUES OF SPECIFIC EDGE LOAD FOR VARIOUS PULPS
Pulp type
Recommended specific edge load
Unbleached softwood kraft
2.5 to 4.2
Bleached softwood kraft
2.0 to 3.2
Unbleached softwood sulphite
0.8 to 1.8
Bleached softwood sulphite
0.9 to 2.2
Hardwood kraft and sulphite
0.6 to 1.9
Recycled pulp (wood)
1.0 to 2.7
High yield kraft
1.1 to 3.0
High yield sulphite
0.9 to 1.4
NSSC
0.8 to 1.3
Chemi-mechanical pulp
0.2 to 1.2
Mechanical pulp
0.2 to 1.0
Bamboo
2.0 to 2.5
Straws
0.5
The reduced active diameter will have a lower no load power demand
The relationship between plate diameter and no load:

No load power = k * diameter4.3 * rpm3
Benefits of using the narrower bar width and

groove width
Whether full diameter or reduced periphery

plates are used, it is nearly always beneficial to
use the narrowest practical bar width and
groove width in any refiner.
The practical limits of bar and groove width
depend on the specifics of the application. The
following guidelines apply:
Flow Considerations in a Refiner

The flow capacity of a refiner is determined by its
disk diameter, its operating speed, and the
hydraulic section and pumping angle of the
installed refiner plates.
High flows are primarily encountered with tickler
refiners where the entire flow of the paper
machine stock must pass through the refiner.
Case Study and Sample Calculations

A fine paper mill is refining bleached hardwood kraft under the
following operating conditions:
One 34 DD refiner with a 1000 hp/600 rpm motor
700 hp applied motor load
900 gpm flow with no recirculation
4% consistency
500 ml freeness target
34 cast plates with a 2.0,2.0,4.5 pattern
30 km/rev bar edge length
Use this information to calculate the no load power,

net hpd/t, refining intensity and freeness change per
hpd/t applied.
STEP 1 - Calculate no load power

NL =
(102*(RPM/100)3*(Diam/100)4.3)*(2*Groove
Width/(Bar+Groove Width))*(Groove Depth/4)
Motor speed 600 rpm
Plate diameter 34 inches
Bar width 2.0 1/16 in
Groove width 2.0 1/16 in
Groove depth 4.0 1/16 in
No Load = 213 hp
STEP 2 Calculate applied power
Net Power = Applied Motor Load

No Load Power
Applied power 700 hp
No load power 213 hp
Net Power = 487 hp
STEP 3 Convert from hp to kW
Net kW = 0.7457 * net hp = 363 kW
STEP 4 Calculate throughput

Short Tons/Day = Gallons per Minute * %
Consistency * 6
Flow 900 gpm
Consistency 0.04
Throughput = 216 t/d
STEP 5 Calculate net specific energy

Specific Energy = Net Power / Tons per
Day
Net power 487 hp
Tons per day 216 t/d
Specific Energy = 2.3 net hpd/t
STEP 6 Calculate Specific Edge Load

(refining intensity)
Specific Edge Load (SEL) = Net kW /(Bar

Edge Length*Motor Speed* 1 min / 60 s)
Net kW 363 kW
Bar edge length 30 km/rev
Speed 600 rpm
SEL = 1.2 Ws/m
STEP 7 Calculate the freeness drop

achieved per hpd/t applied
D CSF/ hpd/t = (Inlet CSF Outlet CSF) / net
Specific Energy
Inlet CSF 625 ml
Outlet CSF 500 ml
Specific energy 2.3 hpd/t
D CSF/ hpd/t = 55 ml / hpd/t
(60-100 ml is typical for HWD kraft)
STEP 8 Assess potential benefits of reduced periphery

Finebar plates with equal groove volume and twice the
edge length.
Reduced plate diameter 31 in
( 34)
Bar width 1.0 1/16 in
( 2.0)
Groove width 1.5 1/16 in
( 2.0)
Groove depth 3.5 1/16 in
( 4.5)
Bar edge length 59 km/rev
(30)
Motor speed 600 rpm
(600)
New No Load = 150 hp - a savings of 63 hp based on plates as
new
( 213)
New SEL = 0.6 Ws/m - in recommended SEL range for HWD
of 0.3-0.8 Ws/m
( 1.2)
Annualized energy cost savings @$0.045/kWh
= (63 hp*0.7457 kW/hp)*($0.045/kWh)*(24 h/day)*(365
days/yr) = $ 18,400
( 216 t/d)
Effects of refining intensity on

paper properties
Control systems in refiners

Stock Prep Refining

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1393

EFFECT ON FIBRES ON REFINING

EFFECT ON FIBRES ON REFINING

Breaking of internal bonds allows fibrils to move relative to each

Removal of outer layers .4

EFFECT ON FIBRES ON REFINING

6. Curling and Twisting of fibres

7. Increased specific surface

8. Fiber length reduction

GENERAL EFFECTS ON SHEET PROPERTIES

2) Tensile strength, burst strength, and internal bonding strength

6) Fibre strength is little affected in refining

The Correct Amount of Refining

Common North American units are

The throughput in t/d or t/h

c) If the motor load is 575 hp and the no- load power

An estimate of the specific energy

The Correct Intensity of Refining

Benefits of low refining intensity for

Benefits of low refining intensity for

In the past, the lower limit of intensity had

Benefits of low refining intensity for

Benefits of low refining intensity for

For mechanical pulp post-refining, low refining

RECOMMENDED VALUES OF SPECIFIC EDGE LOAD FOR VARIOUS PULPS

Recommended specific edge load

Unbleached softwood kraft

Bleached softwood kraft

Unbleached softwood sulphite

Bleached softwood sulphite

Hardwood kraft and sulphite

Recycled pulp (wood)

High yield kraft

High yield sulphite

The relationship between plate diameter and no load:

Benefits of using the narrower bar width and

Whether full diameter or reduced periphery

Flow Considerations in a Refiner

Case Study and Sample Calculations

Use this information to calculate the no load power,

STEP 1 - Calculate no load power

STEP 2 Calculate applied power

Net Power = Applied Motor Load

STEP 4 Calculate throughput

STEP 5 Calculate net specific energy

STEP 6 Calculate Specific Edge Load

Specific Edge Load (SEL) = Net kW /(Bar

STEP 7 Calculate the freeness drop

STEP 8 Assess potential benefits of reduced periphery

Effects of refining intensity on

Control systems in refiners

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