MACHINE AND METHOD FOR MANUFACTURING TISSUE PAPER

Abstract

The machine (10) comprises a Yankee cylinder (35), having a cylindrical side surface (35S), rotating around an axis (35A) thereof, and a continuous flexible member (17) comprising a first surface (17A) suitable to receive a layer of cellulose pulp (S), comprising cellulose fibers and water, and a second surface (17B), opposite to the first surface (17A). A guide roller (31) is also provided, around which the continuous flexible member (17) is driven. The second surface (17B) of the continuous flexible member (17) is in contact with the first guide roller (31). The machine further comprises a first pressure roller (33) around which the continuous flexible member (17) is driven, arranged downstream of the guide roller (31) with respect to a feeding direction of the layer of cellulose pulp (S). The first pressure roller (33) and the Yankee cylinder (35) define a first pressure nip (34), inside which the continuous flexible member (17) is pressed by means of the first pressure roller (33) against the cylindrical surface (35S) of the Yankee cylinder (35) in order to remove water from the layer of cellulose pulp (S) through the continuous flexible member (17).

Claims

1. A machine (10) for wet manufacturing of tissue paper, comprising in combination: a Yankee cylinder (35) comprising a cylindrical side surface (35S), rotating around an axis (35A) thereof; a continuous flexible member (17) comprising a first surface (17A) suitable to receive a layer of cellulose pulp (S), comprising cellulose fibers and water, and a second surface (17B), opposite to the first surface (17A); a guide roller (31), around which the continuous flexible member (17) is driven; wherein the second surface (17B) of the continuous flexible member (17) is in contact with the first guide roller (31); wherein, in the area guided around the guide roller (31), the first surface (17A) of the continuous flexible member (17) is spaced from the Yankee cylinder (35); and wherein the guide roller (31) is suitable to remove water from the layer of cellulose pulp (S) through the continuous flexible member (17); a first pressure roller (33) around which the continuous flexible member (17) is driven, arranged downstream of the guide roller (31) with respect to a feeding direction of the layer of cellulose pulp (S); wherein the first pressure roller (33) and the Yankee cylinder (35) define a first pressure nip (34), inside which the continuous flexible member (17) is pressed by means of the first pressure roller (33) against the cylindrical surface (35S) of the Yankee cylinder (35); and wherein the first pressure roller (33) is suitable to remove water from the layer of cellulose pulp (S) through the continuous flexible member (17).

2. The machine (10) of claim 1, wherein the guide roller (31) is a suction roller.

3. The machine (10) of claim 2, wherein the guide roller (31) comprises an outer cylindrical skirt (39) provided with a plurality of through holes (51) connecting an outer surface of the guide roller and an inner suction chamber (43.2) of the guide roller (31).

4. The machine (10) of claim 3, wherein the suction chamber (43.2) extends for a portion of the circumferential extension of the suction roller (31) and is arranged in a stationary position with respect to the rotation axis (31A) of the guide roller (31), so as to generate a suction area through the through holes (51) of the cylindrical skirt (39), the suction area being fixed with respect to the path of the continuous flexible member.

5. The machine (10) of claim 4, wherein the suction chamber (43.2) is arranged in an area of the guide roller (31) that is in contact with the continuous flexible member (17), so as to generate suction of water contained in the layer of cellulose pulp (S), through the flexible member (17) in the through holes.

6. The machine (10) of claim 5, wherein inside the cylindrical skirt (39) an annular volume (43) is arranged, fluidly connected to the through holes (51), the annular volume (43) being subdivided into said suction chamber (43.2) and a non-suction area (43.1), so that water is temporarily sucked in the through holes (51) when they pass in front of the suction chamber (43.2) and is removed from the through holes (51) due to the centrifugal effect when the through holes pass along the non-suction area (43.1) of the annular volume (43).

7. The machine (10) of one or more of the previous claims, wherein the first pressure roller (33) is a pressure roller with dead holes (57).

8. The machine (10) of one or more of the claims 1 to 6, wherein the first pressure roller comprises an outer cylindrical skirt provided with a plurality of through holes connecting an outer surface of the first pressure roller and an inner suction chamber of the first pressure roller; wherein preferably the suction chamber extends for a portion of the circumferential extension of the first pressure roller and is arranged in stationary position with respect to the axis of the first pressure roller, so as to generate a suction area through the through holes of the cylindrical skirt, the suction area being fixed with respect to the path of the continuous flexible member (17); and wherein preferably the suction chamber is arranged in an area of the first pressure roller that is in contact with the continuous flexible member (17), so as to generate suction of water contained in the layer of cellulose pulp (S), through the flexible member (17) in the through holes; and wherein preferably inside the cylindrical skirt an annular volume is arranged, fluidly connected to the through holes, the annular volume being subdivided into said suction chamber and a non-suction area, so that water is temporarily sucked in the through holes when they pass in front of the suction chamber and is removed from the through holes due to the centrifugal effect when the through holes pass along the non-suction area of the annular volume.

9. The machine (10) of one or more of the previous claims, further comprising a second pressure roller (61), around which the continuous flexible member (17) is driven, arranged downstream of the first pressure roller (33) with respect to the feeding direction of the layer of cellulose pulp (S); wherein the second pressure roller (61) and the Yankee cylinder (35) define a second pressure nip (63), inside which the continuous flexible member (17) is pressed by means of the second pressure roller (61) against the cylindrical surface (35S) of the Yankee cylinder (35); and wherein the second pressure roller (61) is adapted to remove water from the layer of cellulose pulp (S) through the continuous flexible member (17).

10. The machine (10) of claim 9, wherein the second pressure roller (61) has the same structure as the first pressure roller.

11. The machine (10) of claim 9, wherein the second pressure roller has a different structure than the first pressure roller, and in particular one of the two pressure rollers has a dead holes configuration whilst the other of the two pressure rollers has a through holes configuration.

12. The machine (10) of one or more of the previous claims, comprising a heating device adapted to act on said continuous flexible member (17) and arranged between said guide roller (31) and said first pressure roller (33).

13. The machine (10) of claim 12, wherein said heating device faces said first surface (17A) carrying the layer of cellulose pulp (S).

14. The machine (10) of claim 12 or 13, wherein said heating device is a steam heating device and/or an infrared heating device and/or a microwave heating device and/or and electrical heating device, for instance a device for heating through resistance and/or electrical induction.

15. The machine (10) of one or more of claims 12 to 14, wherein said heating device comprises a steam box adapted to blow steam directly onto said continuous flexible member (17) carrying the layer of cellulose pulp (S).

16. The machine (10) of one or more of claims 12 to 15, wherein said heating device comprises a thermal radiation plate facing said continuous flexible member (17) carrying the layer of cellulose pulp (S).

17. The machine (10) of one or more of the previous claims, further comprising a forming wire (15), adapted to receive the layer of cellulose pulp (S) from a headbox (11), and configured to transfer, directly or indirectly, the layer of cellulose pulp (S) to the continuous flexible member (17).

18. The machine (10) of one or more of the claims 1 to 11, comprising a forming wire (15), driven around a forming drum (19), around which also said continuous flexible member (17) is driven, to form, between the continuous flexible member (17) and the forming wire (15), a volume for receiving cellulose pulp from a headbox.

19. The machine (10) of one or more of claims 12 to 15 and one of claims 16 and 17, wherein said guide roller (31) and said heating device are arranged downstream of the area where said forming wire (15) is separated from said continuous flexible member (17).

20. The machine (10) of one or more of the previous claims, wherein said heating device comprises an air suction module arranged preferably at opposite side from the continuous flexible member and facing it.

21. The machine (10) according to one or more of the previous claims, comprising a further heating device arranged immediately upstream of the guide roller.

22. A method for removing water from a layer of cellulose pulp (S) comprising water and cellulose fibers, the method comprising the following steps: forming a layer of cellulose pulp (S) comprising water and cellulose fibers on a first surface (17A) of a continuous flexible member (17); feeding the layer of cellulose pulp (S) towards a Yankee cylinder (35); driving the continuous flexible member (17) around a guide roller (31), the continuous flexible member (17) having a second surface (17B) in contact with the guide roller (31), and removing water from the layer of cellulose pulp (S) through the continuous flexible member (17) by means of the guide roller (31), with no contact between the layer of cellulose pulp (S) and the Yankee cylinder (35); downstream of the guide roller (31), feeding the layer of cellulose pulp (S) in a first pressure nip (34) defined by the Yankee cylinder (35) and by a first pressure roller (33), around which the continuous flexible member (17) is driven with the second surface (17B) in contact with the first pressure roller (33), and removing water from the layer of cellulose pulp (S) through the continuous flexible member (17) by means of the first pressure roller (33).

23. The method of claim 22, further comprising the following step: downstream of the first pressure roller (33), feeding the layer of cellulose pulp (S) in a second pressure nip (63) defined by the Yankee cylinder (35) and by a second pressure roller (61), around which the continuous flexible member (17) is driven with the second surface (17B) in contact with the second pressure roller (61), and removing water from the layer of cellulose pulp (S) through the continuous flexible member (17) by means of the second pressure roller (61).

24. The method of claim 22 or 23, further comprising a drying step through heating of said layer of cellulose pulp (S) between the are where the continuous flexible member (17) is driven around the guide roller (31) and said first pressure nip (34).

25. The method of claim 24, wherein said drying step occurs through heating generated by means of steam emitted onto said layer of cellulose pulp (S), or through thermal radiation.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The invention will be better understood by following the description and the accompanying drawing, which shows a non-limiting example of embodiment of the invention. More in particular, in the drawing:

[0044] FIG. 1 is a diagram of a first embodiment of a machine according to the invention;

[0045] FIG. 2 is a schematic enlargement of the action area of the suction guide roller;

[0046] FIG. 3 is a schematic enlargement of the first pressure nip of the machine of FIG. 1;

[0047] FIG. 4 is a diagram of a further embodiment of a machine according to the invention;

[0048] FIG. 5 is a diagram of a portion of the machine according to the invention, different than the cases of FIGS. 1 and 4, wherein the difference consists in a heating device inserted between the guide roller and the first pressure roller.

DETAILED DESCRIPTION OF AN EMBODIMENT

[0049] The detailed description below of example embodiments is made with reference to the attached drawing. The same reference numbers in different figures identify equal or similar elements. Moreover, the drawings are not necessarily to scale. The detailed description below does not limit the invention. The protective scope of the present invention is defined by the attached claims.

[0050] In the description, the reference to an embodiment, the embodiment or some embodiments means that a particular feature, structure or element described with reference to an embodiment is comprised in at least one embodiment of the described object. The sentences in an embodiment or in the embodiment or in some embodiments in the description do not therefore necessarily refer to the same embodiment or embodiments. The particular features, structures or elements can be furthermore combined in any adequate way in one or more embodiments.

[0051] With initial reference to FIG. 1, in an embodiment the machine for tissue paper wet manufacturing, indicated as a whole with number 10, comprises a headbox 11 arranged in front of a forming area defined between a forming wire 15 and a continuous flexible member 17, for example a felt. The continuous flexible member 17, herein simply called felt, is driven around a forming roller 19, around which also the forming wire 15 is driven.

[0052] The forming wire 15 follows a closed path defined by means of guide rollers 21, 22, 23, 24, as well as by means of the forming roller 19. The felt 17 follows a closed path defined by means of guide rollers 25, 26, 27, 28, the forming roller 19, a guide roller 31 and a first pressure roller 33, described below in greater detail.

[0053] The machine 10 further comprises a Yankee cylinder 35, around which air hoods 37 are arranged. The Yankee cylinder 35 rotates around a rotation axis 35A thereof, and has an outer cylindrical surface 35S. The path of the felt 17 passes through a pressure nip 34 defined between the outer cylindrical surface 35S of the Yankee cylinder 35 and the pressure roller 33, which is pressed against the cylindrical surface 35S.

[0054] With the Yankee cylinder 35 a scraping blade or doctor blade 38 co-acts, which detaches a tissue paper ply V at the exit of the Yankee cylinder 35, after it has been dried.

[0055] The headbox 11 feeds a pulp or water suspension of cellulose fibers to the nip or forming space between the felt 17 and the wire 15. The cellulose suspension or pulp comprises, for example, approximately 99.8% of water and 0.2% of solid matter, in particular cellulose fibers. Part of the water is removed, i.e. drained, through the forming wire 15, so that at the exit of the area in which the forming wire 15 and the felt 17 are in mutual contact, i.e. in the area of the guide roller 24, on the felt 17 there is a layer of cellulose pulp having approximately 6% of solid content. This layer of cellulose fibers remains adhering to the outer surface 17A of the felt 17 and is conveyed by the felt 17 towards the Yankee cylinder 35.

[0056] The layer of cellulose pulp, indicated by the letter S, is transported by the felt 17 along the path defined by it, driven around the guide roller 31 and the pressure roller 33, with which the felt 17 is in contact by means of the inner surface 17B thereof, opposite to the outer surface 17A, to which the layer of cellulose pulp S adheres. As it will be described below, the guide roller 31 and the pressure roller 33 are configured to remove water from the layer of cellulose pulp S before it is transferred from the felt 17 to the outer cylindrical surface 35S of the Yankee cylinder 35.

[0057] In a known manner, during the contact with the Yankee cylinder 35, the layer of cellulose pulp S is dried thanks to the heat provided by the Yankee cylinder 35 through the cylindrical wall thereof, and to the hot air supplied by the air hoods 37. Consequently, the layer of cellulose pulp S, which arrives to the Yankee cylinder 35 with a water percentage of more than 50%, is dried forming the ply or web V; the web V, after having been detached from the Yankee cylinder 35 through a scraping blade or a doctor blade 38, is fed to a winder, not shown, to form a reel.

[0058] The guide roller 31 can have a structure adapted to remove a fraction of the water contained in the layer of cellulose pulp S which adheres to the felt 17, driven around the guide roller 31 and in contact with said roller through the inner surface 17B.

[0059] An embodiment of the guide roller 31 is schematically illustrated in the enlargement of FIG. 2. In this embodiment, the guide roller 31 comprises a rotating outer cylindrical skirt 39 and a stationary inner core 41. An annular volume 43 is defined between the cylindrical skirt 39, rotating around a rotation axis 31A, and the stationary core 41. The annular volume 43 can be subdivided into two portions 43.1 and 43.2. The two portions 43.1 and 43.2 can be defined by stationary separating walls 45, mounted on the inner core 41. The portion 43.2 can be connected to a suction line, schematically indicated with number 49. The suction duct can be arranged at any one or both the ends of the guide roller 31. In this way, a suction chamber is defined between the separating walls 45.

[0060] The cylindrical skirt 39 can be provided with a plurality of through holes 51, which can be uniformly distributed over the entire extension of the cylindrical skirt 39. In this way, the through holes 51 connect the outer cylindrical surface of the guide roller 31 to the suction chamber 43.2 in the area comprised between the walls 45. A suction effect is thus generated in this area through the through holes 51 and through the felt 17. Due to this suction, the water contained in the layer of cellulose pulp S is sucked inside the through holes 51. When, following the rotation of the guide roller 31, the through holes 51 pass beyond the suction area defined between the walls 45, there is no more suction and, therefore, the centrifugal force causes the removal of the water accumulated in the through holes 51. The separating walls 45 are positioned relative to the path of the felt 17 such that the suction effect ends at the point, or downstream of the point, where the felt 17 moves away from the outer cylindrical surface of the guide roller 31, so that the water in the through holes 51 is removed from the roller 31 due to the centrifugal force, and does not return in the felt 17.

[0061] By means of this mechanism, a part of the water contained in the layer of cellulose pulp S is removed before the layer reaches the pressure nip 34 defined between the pressure roller 33 and the Yankee cylinder 35.

[0062] In the nip 34, the layer of cellulose pulp S is pressed between the outer surface 35S of the Yankee cylinder 35 and the felt 17 due to the pressure exerted by the pressure roller 33 against the Yankee cylinder 35. The structure of the pressure roller 33 can be the same as the structure of the guide roller 31, so that the water contained in the layer of cellulose pulp S is collected in the through holes of the rotating cylindrical skirt and then removed due to centrifugal effect.

[0063] In other preferred embodiments, the pressure roller 33 may have the structure shown in greater detail in the enlargement of FIG. 3. This structure is typical of a so-called blind-drilled press. It consists of a roller with heads, cylindrical skirt and support pins (not shown). On the cylindrical skirt 33.1, a layer of an elastic material 33.2 is applied, for example rubber or polyurethane. The layer of elastic material 33.2 is provided with a plurality of dead holes 57. In the area where the inner surface 17B of the felt 17 is in contact with the outer cylindrical surface of the pressure roller 33, the layer of cellulose pulp S and the felt 17 are pressed so that a part of the water contained in the layer of cellulose pulp S passes through the felt 17 and penetrates, through pressure, into the dead holes 57. In the area downstream of where the felt 17 is detached from the cylindrical surface of the pressure roller 33, the water collected in the dead holes 57 is removed through centrifugal force. In this way a part of water is removed from the layer of cellulose pulp S.

[0064] In some embodiments the combined effect of the suction guide roller 31 and the pressure roller 33 decreases the wet content in the layer of cellulose pulp S to about 42-43%, applying linear pressures in the pressure nip 34 in the order of 90-100 kN/m. The thickness of the cellulose web V that can obtained is in the order of 95-100 m for ten sheets, according to the standard TAPPI-T 580 Thickness (caliper) of towel, tissue, napkin and facial products. It should be understood that the numerical values of the applied linear pressures and the thicknesses are given just by way of non-limiting example. This applies, in general, to all the numerical values mentioned in the present description, unless otherwise specified.

[0065] Thanks to the combination of the pressure roller 33 and the suction guide roller 31, where the water is removed without compression and without pressing the layer of cellulose pulp S, an effective dewatering is achieved, i.e. a substantial reduction of wet in the layer of cellulose pulp S before starting drying by thermal effect around the Yankee cylinder 35. Dewatering occurs without excessive reduction in the thickness of the resulting layer of cellulose fibers, thanks to the fact that part of the water is removed without compression and without pressing the layer of cellulose pulp S.

[0066] FIG. 4 shows a second embodiment of a machine according to the invention. The same numbers indicate the same or equivalent parts to those of FIG. 1, which will be not described again. The main difference between the embodiment of FIG. 1 and that of FIG. 4 is that the latter has a second pressure roller 61 downstream of the pressure roller 33. The felt 17 is driven around an intermediate roller 64 provided along the closed path defined by the felt 17, between the first pressure roller 33 and the second pressure roller 61. The second pressure roller 61 defines a second pressure nip 63 between the pressure roller 61 and the outer cylindrical surface 35S of the Yankee cylinder 35.

[0067] In some embodiments, the second pressure roller can be provided with the suction structure as described with reference to the guide roller 31. In preferred embodiments, the second pressure roller 61 has a structure with dead holes, like the structure of the first pressure roller 33 described above (FIG. 3).

[0068] In the embodiment of FIG. 4, the water content of the layer of cellulose pulp S is reduced in three subsequent steps: due to the suction through the guide roller 31, due to the pressing in the first pressure nip 34 through the first pressure roller 33, and due to the pressing in the second pressure nip 63 through the second pressure roller 61.

[0069] With the configuration of FIG. 4 it is possible to have, before the drying step on the Yankee cylinder, a wet content inside the layer of cellulose pulp S lower than the content that can be obtained in the embodiment of FIG. 1, even if with a slightly greater pressing of the layer of cellulose pulp S and therefore with a slight reduction in the final thickness thereof. For example, with linear pressures in the order of 90-100 kN/m in the pressure nips 34 and 63, it is possible to obtain a solid content in the order of 44-45% in the layer of cellulose pulp S at the exit of the second pressure nip 63, and a paper thickness in the order of 93-95 m for ten sheets, according to the standard TAPPI-T 580 Thickness (caliper) of towel, tissue, napkin and facial products. As indicated above, the numerical values are given just by way of non-limiting example.

[0070] Conveniently, in FIG. 5 a further machine according to the invention is shown, which is a variant of the examples of FIGS. 1 and 4 and comprises a heating device 40 adapted to act on the continuous flexible member 17 (the felt) in order to increase the temperature of the layer of cellulose pulp and, consequently, to reduce the viscosity of the water contained in the cellulose pulp. This allows increasing the efficiency of the step of pressing the cellulose pulp between the pressure roller and the Yankee cylinder, and consequently to increase the dry content after the pressure nip defined between the pressure roller and the Yankee cylinder.

[0071] In particular, the heating device 40 is arranged between the guide roller 31 and the first pressure roller 33, and faces the first surface 17A of the felt 17, i.e. the surface carrying the layer of cellulose pulp S.

[0072] From an operative point of view, it is important that the heating device 40 is not too close to (and never overlapping) the guide roller 31 or the first pressure roller 33, i.e. that it is not arranged on the circumference of these rollers. In fact, the rotation of the two rollers 31 and 33 causes the dispersion in air of fragments of a cellulose pulp. If the heating device 40 overlaps one of the two rollers 31 or 33, or is arranged on the circumference thereof, the fragments of cellulose pulp tend to deposit on the heating device, forming thereon a pulp layer which would reduce the heating capacity thereof.

[0073] According to a preferred embodiment, the device 40 heats through steam. In this example, the device is a known steambox, which emits saturated, preferably dry or superheated steam on the cellulose pulp S present on the felt 17, thus contributing to the drying thereof.

[0074] The steam used to supply the steambox can arrive, through a duct 40A, from a heat recovery unit (not shown in the figures) generating steam, using for example the fumes of the hood 37. In practice, this recovery unit generates high pressure steam to feed the Yankee cylinder, and, with a reduction in pressure, supplies the steambox of the device 40 through the duct 40A. In a further embodiment, the heat recovery unit can generate low pressure steam just for the steambox.

[0075] According to other embodiments, the heating device 40 can be of the type exploiting electricity (joule effect), for example an electrical resistance or an induction plate, or generating infrared rays, such as infrared lamps or panels, or of the microwave type.

[0076] In this example, the heating device 40 also comprises a suction module 40B, arranged opposite to the steambox with respect to the felt 17 and close to this latter, so as to suck humid air in the area. The sucked air is removed through a duct, not shown in the figures.

[0077] It is clearly apparent that the use of the heating device 40, between the guide roller 31 and the first pressure roller 33, is particularly effective for increasing the drying of the cellulose pulp. The guide roller 33 allows removing the water contained in the cellulose pulp, which is not absorbed by the felt. Consequently, the heating device 40 is able to transmit more energy to the layer of cellulose pulp, and therefore to perform an optimal drying.

[0078] Thanks to the combined effect of the suction roller 31 and the first pressure roller 33, thanks to the heating device 40, the dry content in the cellulose pulp S is increased by a value comprised least between 2.8% and 3.5% compared to the embodiments described above.

[0079] In order to further increase the temperature of the layer of cellulose pulp S, in this example a further heating device 40 is provided, similar to the heating device 40 described above and arranged immediately upstream of the guide roller. In this case again, it can be of the steam type or of the type exploiting electricity, such as an electrical resistance or an induction plate, or generating infrared rays, such as infrared lamps or panels, or of the microwave type. It can also comprise a further suction module 40. In this case again, it is important that the further heating device 40 is not too close to (and never overlapping) the guide roller 31, i.e. that it is not arranged on the circumference of the roller.

[0080] While the particular embodiments of the invention described above have been shown in the drawing and described integrally in the description above with features and characteristics relating to different exemplary embodiments, those skilled in the art will understand the modifications, changes and omissions are possible without however departing from the innovative learning, the principles and the concepts described above and the advantages of the object described in the attached claims.

[0081] For example, at least one or both of the rollers 33, 61 can be without perforations and have a smooth cylindrical surface.

[0082] Therefore, the scope of the described improvements shall be determined only based upon the widest interpretation of the attached claims, so as to include all the modifications, changes and omissions. Furthermore, the order or sequence of any step of method or process may be changed according to alternative embodiments.