Press Felt Optimization
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1 Press Felt Optimization Chemical Strategies and Trends in Recycled Board September 26, 2013 Mike Carroll CC Applications Project Mgr
2 Application Strategies Passivation Agenda Batch-on-the-Fly/Batch Down Continuous/Semi-continuous Chemistry Strategies Alkaline Acid Solvent Enzyme Trends in Recycled Paperboard Treatments
3 Felt Chemical Application Strategies
4 Why Do We Chemical Treat Felts Uniform water removal Uniform CD moisture profiles Reduced press section deposition Reduced press related defects/breaks Increased felt life Increased paper/board production Improved machine efficiency
5 Felt Passivation Felt Fiber Felt Fibers Are Surrounded With A Layer Of Polymer and Surfactant Molecules Which Block Contaminants From Contacting And Adhering To The Felt Structure
6 Wet Felt Chemical Passivation 1 -High Pressure Shower 2 - Uhle Box Lubrication Shower 3 - Passivation Application Shower Angled degrees PSO\WETFELT.CDR
7 Chemical Passivation Application Most common on forming fabrics and sheet side felt rolls Chemistry Options Straight Cationic Polymers Cationic Polymer/Surfactant Blend Non-ionic polymer Allows for Recycled WW Use in Application
8 Batch Felt Cleaning Options Batch On The Fly Cleaning Pros Clean felts on the run (no downtime needed) Cleaning on regular basis keeps felts more open Cons Proper Control Needed to Avoid Operational Issues Batch Down Cleaning Pros Higher Concentration Most thorough way to clean felts Cons Downtime required
9 Press Felt Conditioning Showering (Chemical Application Shower) Best possible location Reasonable location HP shower acceptable for some conditioning applications but not for batch cleaning Lube shower and fan shower worst performance
10 Fingerprinting a Batch on the Fly Wash Recommended Conditions - Alkaline ph shower (to low end on mechanical grades) uhle box discharge ph change chemical feed concentration accordingly immediate increase and taper-off of turbidity in effluent Optimize timeof chemical feed maintain shower flow after chemical for rinse monitor ph, conductivity back to pre -BOTF levels
11 Batch on the Fly Fingerprint #8PM Batch on the fly Uhle box turbidity ph Turbidity ph :05 8:10 8:13 8:16 8:19 8:22 8:25 8:28 8:31 8:34 8:37 8:40 8:43 8:46 8:49 Time 0.00
12 FELT CONDITIONING PROGRAM MONITORING Uhle Box Vacuum Indicates Degree of Felt Openness Increasing Vacuum May Mean Felt Filling, Compaction or a Wetter Felt Loss of Vacuum May Indicate batt loss or uhle box cover issues
13 Batch Wash Uhle Box Trends Impact of Washing No Wash Batch Down Only Uhle Box Va acuum Batch Down & BOTF BOTF Only Time (days)
14 FELT CONDITIONING PROGRAM MONITORING Felt Perms Indicates Porosity by Jet Water Flow Can do Cross Directional Scans to Identify Problem Areas Relative Measurement Based on Felt Design Correlation to Vacuums May be Beneficial in Determining Felt Wash Need or Cleaning Results
15 Permeability (ml/min) FELT CONDITIONING PROGRAM MONITORING 0 #3 PM 1st Bottom Felt Cross Direction Scan Front Middle Back 9/25/ /6/ /12/ /21/2009
16 FELT CONDITIONING PROGRAM MONITORING 850 Felt Life VS Permeability (ml/min) Permeability ( Felt 1 Felt Felt Life (Days)
17 FELT CONDITIONING PROGRAM MONITORING Uhle Box or Nip Weir Flow A Direct Indicator Of Water Handling Capacity Affected By: Compaction Wear Porosity Permeability Uhle Vacuum With Felt Conditioning Flow gpm 0 Time Without Treatment
18 Felt Conditioning Equipment DCS Controlled BOTF/BD System
19 Parameters That Impact Felt Cleaning Performance Shower ph ( for alkaline in uhle ) Shower Temperature (Sheet Temperature or Greater) HP Shower Pressure ( psi) Shower Coverage and oscillation stroke length/rates Shower Water Solids Uhle Box Vacuum pump capacity -CFM Wet End Chemistry Chemical Feed System Shower Position
20 Felt wash Chemistry Options
21 What Are the Contaminants Your Dealing With Solvent Extracts Stickies Amide Grease Oil Latex Wax Alkaline Extracts Fatty Acid FattyEster Rosin Size Alkaline Size Acid Extracts Biological Slime Cellulosic Derivatives Starch Lignin Dry Strength Aluminum Hydroxide Calcium Carbonate Wet Strength Resin
22 Felt Analysis History -Recycled Paperboard Percen nt 6 4 High Medium Low 2 0 2:1 CH2Cl2:EtOH Extracts Alkaline Extracts Ash
23 Building Blocks Solubilizers Felt Conditioning Chemistries alkali acid solvent Surfactants cationic anionic non-ionic Polymers cationic anionic non-ionic Metal ion complexing agents sequestrants chelants
24 Trends in Recycled Paperboard
25 Felt Conditioning Trends Recycled Paperboard Batch-On-The-Fly Most common approach with or/ without Batch Down Alkaline/surfactant chemistry Alkaline/Solvent Blends less common Continuous or Semi-Continuous Less common as a felt cleaning practice Mild Acid semi-continuous for nozzle cleanliness
26 Felt Conditioning Trends Recycled Paperboard Surface Passivation Treatment Common practice on Forming Fabrics Common practice on Sheet Side Roll Surfaces Traditional Cationic Polymers - NEW Nonionic Chemistries Press Fabrics currently not common Environmental Constraints Desire for Green Chemistry NPE Free Surfactants across entire North America Petro based Solvents (High VOC and Flash Point) Agricultural based solvent chemistries Enzyme blends
27 THANK YOU! Questions?
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