Method and machine for manufacturing paper products using fourdrinier forming
09677224 ยท 2017-06-13
Assignee
Inventors
Cpc classification
International classification
D21F11/00
TEXTILES; PAPER
Abstract
An improved method for producing paper from pulp includes a plurality of subassemblies arranged in the forming or wet section of a Fourdrinier. The Fourdrinier includes a dewatering table having a plurality of blades that are static and on-the run adjustable in height and/or angle to control orientation of paper fibers in the stock to create a superior quality of paper and improved paper strength characteristics. Gravity and vacuum assisted drainage elements are equipped with on-the-run adjustable angle and height dewatering foil blades starting from a paper dryness of 0.1% and extending all the way to 5% dryness. The result of this process and machine is to improve the paper quality, save fibers and chemicals and fulfill the required paper properties.
Claims
1. A paper making process comprising: operating a forming fabric of a Fourdrinier machine in a rush mode or a drag mode to promote an initial machine direction alignment of paper fibers within a paper web deposited onto the forming fabric, the Fourdrinier machine including: 1. a forming board section having a plurality of height adjustable blades; and 2. a hydrofoil section having a plurality of height adjustable blades and a control subassembly that controls a height of a respective blade relative to an underside of the forming fabric, wherein the hydrofoil section is a gravity drainage section; adjusting heights of the plurality of height adjustable blades in the forming board section on to produce a drainage rate so that the paper web has a consistency in the forming board section within a range of 0.1% to 2% to immediately freeze the machine direction alignment of paper fibers and to produce turbulence so that the paper fibers are kept mobile and entanglement of the paper fibers is prevented; and, adjusting heights of the plurality of height adjustable blades and vacuum levels in the hydrofoil section to gradually achieve a consistency of 5%.
2. The paper making process of claim 1, wherein the papermachine includes a low-vacuum section and the method includes a step of adjusting a level of vacuum in the low-vacuum section.
3. The paper making process of claim 2, wherein the low-vacuum section includes a plurality of vacuum assisted foil units and a fixed blade at each end of each of the plurality of vacuum assisted foil units.
4. The paper making process of claim 1, wherein during the step of adjusting the height of the plurality of height adjustable foil blades the plurality of height adjustable blades are set at a setting of 0 mm so that the height adjustable blades are in the same plane as the forming fabric and the height of the height adjustable foil blades are lowered from the fabric so that the amount of drainage increases.
5. The papermaking process of claim 1, wherein the hydrofoil section includes a plurality of angle adjustable blades and the process includes a step of adjusting an angle of the plurality of angle adjustable blades.
6. The papermaking process of claim 5, wherein each of said angle adjustable blades comprise an angle adjustment mechanism arranged therein, an underside of the angle adjustment mechanism being secured to a frame and said angle adjustment mechanism includes an adjustable T-bar that extends across the frame of the Fourdrinier machine, and the method includes a step of rotating a drive so that a leading edge of the angle adjustable blade over a range of angles.
7. The paper making process of claim 5, wherein the foil blades that are height adjustable and the foil blades that are angle adjustable are alternatingly arranged.
8. The paper making process of claim 5, wherein the foil blades that are angle adjustable can be varied between an angle of +2 degrees and 4 degrees.
9. The paper making process of claim 1, wherein the process includes a step of adjusting vacuum levels.
10. The paper making process of claim 1, wherein the papermachine includes a high-vacuum section located between the low-vacuum section and a couch roll and the low-vacuum section does not include angle adjustable blades or height adjustable blades.
11. A papermaking process comprising: operating a forming fabric of a Fourdrinier machine in a rush mode or a drag mode to promote an initial machine direction alignment of paper fibers within a paper web deposited onto the forming fabric, the Fourdrinier machine including: 1. a forming board section having a plurality of angle adjustable blades; and 2. a hydrofoil section having a plurality of angle adjustable blades and a control subassembly that controls an angle of a respective blade relative to an underside of the forming fabric, wherein the hydrofoil section is a gravity drainage section; adjusting angles of the plurality of angle adjustable blades in the forming board section to produce a drainage rate so that the paper web has a consistency in the forming board section within a range of 0.1% to 2% to immediately freeze the machine direction alignment of paper fibers and to produce turbulence so that the paper fibers are kept mobile and entanglement of the paper fibers is prevented; and, adjusting angles of the plurality of angle adjustable blades and vacuum levels in the hydrofoil section to gradually achieve a consistency of 5%.
12. The paper making process of claim 11, wherein the papermachine includes a low-vacuum section that includes a plurality of vacuum assisted foil units and a fixed blade at each end of each of the plurality of vacuum assisted foil units, and the method includes a step of adjusting a level of vacuum in the low-vacuum section.
13. The papermaking process of claim 12, wherein each of said angle adjustable blades comprise an angle adjustment mechanism arranged therein, an underside of the angle adjustment mechanism being secured to a frame and said angle adjustment mechanism includes an adjustable T-bar that extends across the frame of the Fourdrinier machine, and the method includes a step of rotating a drive so that a leading edge of the angle adjustable blade over a range of angles.
14. The paper making process of claim 12, wherein hydrofoil section includes a plurality of height adjustable blades and the height adjustable blades and the angle adjustable blades are alternatingly arranged, and the angle adjustable blades can be varied between an angle of +2 degrees and 4 degrees.
15. The paper making process of claim 11, wherein the process includes a step of adjusting vacuum levels, and the papermachine includes a high-vacuum section located between the low-vacuum section and a couch roll and the low-vacuum section does not include angle adjustable blades or height adjustable blades.
16. A paper making process comprising: operating a forming fabric of a Fourdrinier machine in a square mode to promote an initial cross-machine direction alignment of paper fibers, the Fourdrinier machine including: 1. a forming board section having: a. a lead blade and b. a plurality of trailing blades that are height adjustable blades; 2. a gravity assisted hydrofoil section comprising: a. a plurality of angle adjustable blades that generate a vacuum pulse that dewaters ta stock slurry; b. a plurality of adjustable T-bars that extend from a first side of the Fourdrinier machine to a second side of the Fourdrinier machine; 3. a low-vacuum section comprising: a. a vacuum assisted drainage elements; and b. a plurality of height adjustable blades; adjusting a height of the plurality of height adjustable blades in the low-vacuum section to create turbulence and water drainage of the paper fibers; adjusting a height of the height adjustable blades in the forming board section; and adjusting an angle of the angle adjustable blades in the gravity assisted hydrofoil section to control an amount of drainage.
17. The paper forming process of claim 16, wherein the forming board section includes a plurality of angle adjustable blades and the process includes a step of adjusting an angle of the plurality of angle adjustable blades.
18. The paper forming process of claim 16, wherein the forming board section includes a lead blade that is fixed.
19. The paper forming process of claim 16, wherein the Fourdrinier machine includes a high vacuum system and the process includes a step adjusting vacuum of the high vacuum system.
20. The paper forming process of claim 19, wherein the high vacuum system is located downstream of the low-vacuum system and upstream of a couch roll, and wherein the high vacuum system is free of angle adjustable blades and height adjustable blades.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
(1) Other objects and purposes of this invention will be apparent to person acquainted with apparatus of this general type upon reading the following specification and inspecting the accompanying drawings, in which:
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DETAILED DESCRIPTION OF THE INVENTION
(11) The embodiments of the invention and the various features and advantageous details thereof are more fully explained with reference to the non-limiting embodiments and examples that are described and/or illustrated in the accompanying drawings and set forth in the following description. It should be noted that the features illustrated in the drawings are not necessarily drawn to scale, and the features of one embodiment may be employed with the other embodiments as the skilled artisan recognizes, even if not explicitly stated herein. Descriptions of well-known components and techniques may be omitted to avoid obscuring the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those skilled in the art to practice the invention. Accordingly, the examples and embodiments set forth herein should not be construed as limiting the scope of the invention, which is defined by the appended claims. Moreover, it is noted that like reference numerals represent similar parts throughout the several views of the drawings.
(12) For illustrative purposes only, the invention will be described in conjunction with a Fourdrinier papermaking machine although the invention and concept could also be applied to hybrid and gap formers. The invention is implemented in the wet section of the Fourdrinier and includes a forming board section 10, a hydrofoil section 20, and a low-vacuum section 30. High-vacuum section 40 does not include automatically adjustable height blades or automatically angle adjustable blades. It should be noted that a headbox is known and is therefore not shown in
(13) As shown in
(14) During this stage, some water is drained from the stock and a very thin wet sheet is carried over to various other dewatering devices such as foil blades in hydrofoil section 20, until a sheet paper dryness of around 1% to 1.5% is achieved. Following this, the paper dryness is increased by the foil blades in the Varioline and Vaculine in the low vacuum section 20 to a dryness level of 5%. Next, a paper dryness of 8% to 10% is achieved in the elements of the low-vacuum section 30 and the sheet is transferred to the high-vacuum section 40 to achieve a paper dryness of 18% or greater. Finally, the sheet is transferred over the couch roll where additional dryness level is achieved.
(15) A Fourdrinier composed of the previously described equipment is fitted with a plurality of adjustable angle and height foil blades starting from the forming board section 10 and partially through the low-vacuum section 30. As the stock travels with the forming fabric 105, it encounters the adjustable angle and height foil blades at various points along the dewatering table to manipulate the paper web and orient more fibers in a desired direction. On the forming board section 10 and the hydrofoil or gravity section 20, the adjustable angle foil blades generate a vacuum pulse that dewaters the stock slurry. The amount of drainage produced along each adjustable angle foil blade is determined by the angle setting of the foil blade which can be typically varied between +2 and 4 degrees. A higher angle will produce more drainage.
(16) Also within the forming board section and hydrofoil or gravity section of the papermaking process, the stock encounters adjustable height foil blades. These blades also drain water from the stock slurry. The amount of water drained by the adjustable height foil blades is determined by their height setting in relation to the forming fabric. At a setting of 5 mm, they do not touch the fabric and do not drain any water. At a setting of 0 mm, they are in the same plane as the forming fabric and will drain water. As the adjustable height foil blades are lowered from the fabric, the amount of drainage increases up until a point at which the static and dynamic vacuum forces generated by the adjustable height foil blade are overcome by the tension forces of the forming fabric. When this occurs, the fabric breaks its seal with the adjustable height foil blade and no dewatering, occurs. The setting at which this occurs will vary based on the drainage characteristics of the stock, the stock consistency, and the speed of the forming fabric. As can be understood, changing the height settings will directly influence the fiber orientation.
(17) The wet slurry will leave the hydrofoil section 20 at a consistency of around 1.5% depending on the paper grade and speed. From here, it travels to the initial vacuum assisted foil units in the low-vacuum section 30 which are referred to as the Varioline elements. In addition to natural gravity drainage, these Varioline elements also use a dynamic and an external vacuum source to create a vacuum which is drawn onto the lower side of the forming fabric 105. This further increases drainage within these units. The Varioline elements are equipped with a plurality of stationary and adjustable height foil blades. Similar to the previous section, as the foil blades are lowered from the forming fabric, the drainage rate increases as discussed above.
(18) Following the Varioline table elements, another set of vacuum assisted units is encountered by the underside of the forming fabric 105. These table elements are the Vaculine elements which are equipped with adjustable angle foil blades. Again, as the angle of the foil blades is increased, the drainage rate will increase until a consistency of 5% is achieved.
(19) In addition to controlling drainage, the adjustable angle and height foil blades in the previously described drainage units also control turbulence within the wet slurry. This is accomplished through deflection of the forming fabric from its original plane as it travels along the top surface of the adjustable angle foil blades and adjustable height foil blades. This deflection creates a series of accelerations within the stock slurry that results in turbulence and shear within the stock slurry. This turbulence keeps the fibers fluidized and mobile within the wet slurry so that they can be orientated in the cross-machine or machine direction, depending on what the finish paper property strength requirements are.
(20) For example, if machine direction fiber orientation is desired, the headbox jet speed is operated in a rush or drag mode to promote an initial strong machine direction alignment of the paper fibers. From here, the foil blade angles and height, along with the vacuum levels on the vacuum assisted dewatering units are adjusted to produce a high early drainage rate in the initial sheet dewatering zone (0.1% to 2% paper dryness) to immediately freeze the machine direction fiber orientation produced by the headbox.
(21) In addition to this, the foil blade angles, heights and vacuum levels are adjusted to produce a high amount of turbulence in this paper dryness zone (0.1% to 2%). This keeps the fibers from entangling with each other and allows the headbox shear to become more effective in orientating fibers in the machine direction. After 2% paper dryness, the angle and height and vacuum levels are adjusted to gradually achieve a paper dryness of 5% However, the foil angle and height are adjusted to achieve only moderate turbulence levels to prevent disruption of the machine direction fiber orientation achieved earlier in the sheet dewatering and forming process.
(22) For cross-machine direction fiber alignment, the process is completely reversed. The headbox stock jet is adjusted to produce a speed difference close to zero (square mode) to promote the highest possible cross-machine direction fiber orientation. However, due to friction created within the headbox nozzle, a certain unavoidable degree of machine direction fiber alignment is still always present in the fiber slurry when it lands on the dewatering fabric that cannot be reversed through normal fourdrinier dewatering equipment.
(23) To break this natural machine direction fiber orientation up and produce the most random fiber orientation and highest amount of cross-machine direction fiber orientation, the claimed invention is operated as follows. First, the foil blade angles and heights along with the vacuum levels of the vacuum assisted dewatering elements are adjusted to significantly retard drainage in the early sheet forming zone (0.1% to 2% dryness). This is completely opposite of the previously described process. In addition to this, the angle height of the foil blades are adjusted to produce a very high degree of turbulence to prevent fiber entanglement and generate the most random fiber orientation possible for the highest level of cross-machine direction fiber alignment. After a dryness of 2% is achieved, the foil angle and height is adjusted to maintain this high level of turbulence all the way until a paper dryness of 5% is achieved. A very gentle early drainage along with high turbulence all the way until a dryness of 5% is achieved will create the most random fiber network resulting in the highest amount of cross-machine direction fiber alignment.
(24) After passing through the forming board section, the paper stock is moved along to pass through a hydrofoil or gravity section 20 equipped with Hydroline elements 21. Each Hydroline element 21 comprises height adjustable blades 13 and angle adjustable blades 22 which are alternately arranged as shown in
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(33) Tables 1 and 2 show blade angle and height settings for a paper grade with machine direction fiber alignment and a grade with cross-machine direction fiber alignment. The tables show a variety of angle adjustable and height adjustable blades which may be utilized in the respective regions of the wet end of the Fourdrinier to achieve synergistic results. It should be noted that in this instance seven blades are shown in each section with the abbreviations H or A indicating that the blade is either height or angle adjustable respectively. Moreover, the gravity units 1-3 correspond to the hydrofoil sections and are three Hydroline elements. Low vacuum units 1-3 correspond to Varioline elements. Low vacuum units 4, 5 correspond to Vaculine elements.
(34) TABLE-US-00001 TABLE 1 Machine Direction Fiber Alignment Low Low Low Low Low Vac- Vac- Vac- Vac- Vac- Forming Gravity Gravity Gravity uum uum uum uum uum Blade Board Unit 1 Unit 2 Unit 3 Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 1 H 0.25 mm A 1.5 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 2 A 0.25 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 3 H 0.25 mm A 1.5 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 4 A 0.25 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 5 H 0.25 mm A 1.5 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 6 A 0.25 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0 7 H 0.25 mm A 1.5 H 0.5 mm A 1.5 H 0.5 mm H 0.5 mm H 0.5 mm A 0.75 A 0.0
(35) TABLE-US-00002 TABLE 2 Cross-machine Direction Fiber Alignment Low Low Low Low Low Form- Grav- Grav- Grav- Vac- Vac- Vac- Vac- Vac- ing ity ity ity uum uum uum uum uum Blade Board Unit 1 Unit 2 Unit 3 Unit 1 Unit 2 Unit 3 Unit 4 Unit 5 1 H 0.0 mm A 0.0 H 0.0 mm A 0.5 H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 2 A 0.0 H 0.0 mm A 0.25 H 0.0 mm H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 3 H 0.0 mm A 0.0 H 0.0 mm A 0.5 H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 4 A 0.0 H 0.0 mm A 0.25 H 0.0 mm H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 5 H 0.0 mm A 0.0 H 0.0 mm A 0.5 H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 6 A 0.0 H 0.0 mm A 0.25 H 0.0 mm H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0 7 H 0.0 mm A 0.0 H 0.0 mm A 0.5 H 1.0 mm H 1.25 mm H 1.5 mm A 1.5 A 2.0
(36) It is to be understood that the invention is not limited to the exact construction illustrated and described above, but that various changes and modifications may be made without departing from the spirit and the scope of the invention as defined in the following claims. While the invention has been described with respect to preferred embodiments, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in limiting sense. From the above disclosure of the general principles of the present invention and the preceding detailed description, those skilled in the art will readily comprehend the various modifications to which the present invention is susceptible. Therefore, the scope of the invention should be limited only by the following claims and equivalents thereof.