presentation india short head box

7/22/2019 Presentation India Short Head Box

1/63

HIGH PERFORMANCEHYDRAULIC HEADBOX

SYSTEMwith Central Distributor Pulsation

dampener and CD basisweight

Dilution Control


2/63

What Does your Mill

Benefit from this

Presentation?


3/63

Cost Cutting

because95 % of Your

Papermaking ProblemsCost Money


4/63

Objective for this Presentation:

Analyze Economic Potential

of

Improvement forYour Paper Machine


5/63

This mill in Spain found that the grade changes were much easierwith the Automatic Consistency Profiling solution.

The dry weight profile variation was reduced by 71%.

Automatic Consistency ProfilingSystem


6/63

Hydraulic Headbox and

Distributor with Automatic

Consistency Profiling

System


7/63

Air-padded Central Distributor with Automated Dilution Control


8/63

Base System Layout

CD Control

QCS with CD Consistency

Control

FAST LAN

Existing

Scanner

CD Network

MappingPrinter

Central Distributor

with Dilution Injection


9/63

High Performance

Hydraulic Headbox:

Central Distributor, Automatic

BW Control.

Providing Superior Profiles inCD, MD, Residual & Total %


10/63


11/63


12/63

Central Distributor

Pulsation dampener withDilution water Injection


13/63

Diffuser Inlet Branch Tubes and Headbox


14/63

It Brings You Closer toPerfect Papermaking

Eliminate AnnoyingProblems!


15/63

The Cause?

Flocculation.Rotational Flows.Cross Flows.


16/63

The Result ?

Efficiency.Breaks + Rejects.

Moisture Profile.


17/63

The Culprit ?

The PE-Tank and

Tapered Header !


18/63

CD-Pressure

ProfileinManifo

ld.

Tapered Header:Typical Profile

BTF-143-0


19/63

Tapered Header-Limitations

Requires a high velocity ratio betweenthe header and the tube bank, which

limits the maximum turn down ratio of

the system.

Is designed for one flow range, and

requires adjustable recirculation to

achieve even pressure distribution.


20/63

Tapered HeaderTurndown Ratio

Effective Flow Range for Air Padded

Rectifier Roll Boxes is

approximately 2.0 / 2.5 to 1. Effective Flow Range for Hydraulic

Boxes is approximately 1.3 / 1.5 to 1.

The CDP Hydraulic Headbox System

is 4.0to 1.


21/63

Overview of CD-Slice Lip Control

Slice lip has limited bending capacity Restricts zone resolution

Constrains adjacent actuator control range

Slice lip is a continuous beam

Zone-to-zone response coupling degradescontrol accuracy

Slice lip bending changes local flow rates.

Cross flows cause

poor CD-fiber profiles.


22/63

Tapered Header :Whats wrong with it?


23/63

CD-Pressure

ProfileinManifo

ld

Tapered Headers have a Very Narrow Sweet Spot.

Without Slice Control, This is How the Profile

Normally Looks Like.

Result: High CD-Variation, Inferior Formation, Fiber

Orientation & Fiber Index, Long Grade Changes,

Edge, Curl and Printing Problems.


24/63

Grade Change from 40 to 70 #/3000 Initial CD-Profile

Coefficient of Variation : 5.3 # or 13.2 % - Fiber Orientation :

32 Degrees


25/63

Grade change from 40 to 70 #/3000 CD-Profile after 6 Minutes

Coefficient of Variation : 2.7 # or 6.7 % - Fiber Orientation : 19 Degrees


26/63


Coefficient of Variation : 0.95 # or 2.37 % - Fiber Orientation : 7.3 Degrees


27/63


Coefficient of Variation : 0.45 # or 1.12 % - Fiber Orientation :

6.1 Degrees

Typical CD-Profile with Tapered Header


28/63


29/63

CDP Hydraulic Headbox


30/63

CD-Pressure Profile across Inlet Branch Tube Bank

High Performance Hydraulic Headbox:Grade change from 40 to 70 #/3000


31/63

Grade change from 40 to 70 #/3000: Initial CD-Profile

Coefficient of Variation :

Fiber Orientation :

0.2 # or 0.5%

3.0 Degrees


32/63

Grade change from 40 to 70 #/3000: After 35 Minutes


Fiber Orientation :

0.12 # or 0.3%

3.0 Degrees


33/63

CD-Pressure

ProfileinBTF-DiffuserBank

Grade change from 40 to 70 #/3000: After 10 Minutes


Fiber Orientation :

0.09 # or 0.22%

3.0 Degrees


34/63

Dr. H.-J. Schultz, The Inventor and Founder:

Ph.D. in Fluid Mechanics. Worked for Escher Wyss and developed the

Escher Wyss Step-Diffuser Headbox.

Author of many headbox technical papers. Well known throughout the world.

Developed and patented the Central Distributor

Technology.

Started BTF in 1992 - Over 130 units sold

The Perfect Distributor for injection control.


35/63

How Does The

System Operate?


36/63

The more Changes, themore Micro-Turbulenceand Formation/DrainageImprovement.

Typical VelocityChanges.

Higher Efficiency of

Chemicals. Downturn

Ratio: 4 to 1

VelocityShown is four

times lower Except for #11,representing themachinespeed.

2

3

5

6

7

8

4

9 10 11

1

2

3

4

56

7

8

9

10

11

12

Flow

Spe

ed(m/s)

Speed Diagram At Maximum Throughput

119

6

8

1075

1

3

2

4


37/63

The Benefits from

Secondary Tube Bank:

High level of shear

forces.

Improvement in

Formation &Drainage.

2

3

4

5

6

7

8 9 10 11TB

1

2

3

4

56

7

8

9

10

11

12

Flow

Spe

ed(m/s)

1

3

4

Speed Diagram At Maximum Throughput

11

6

10

8

75

2

Secondary Tube BankImproving Formation

Accelerating Drainage

TB

9


38/63

Presenting:

High Performance HydraulicHeadbox-Retrofit

For Existing Headboxes.


39/63

Stock LevelEqual Hose Length

= Equal FlowEqual Hose Length= Equal Flow

Typical Installation of a Retrofit with Central Distributor


40/63

CD-Profile: Coefficient of Variation : 0.5 % and Lower

Typical CD-Profile with Central Distributor

Central

Distributor


41/63

FiberOrientation


42/63

Future.

Dilution Headbox

System will

Provide TSO of

3 degrees.

Stronger Strength

Properties will be

Obtained.Future

TSO: 3

degrees.


43/63

Provide Superior Strength Properties

in MD and CD (COV, TSO, TSI)

The Dilution Headbox System provides

High Micro-Turbulence LevelThrough the Entire System:

Preventing Flocculation

Eliminating Twist And Curl Resulting in Flat Sheet Surface

Superior Printability.


44/63

Consistency Profiling Control

Reduce profile recovery time. Reduce CD weight.

profile variability.

Improve CD caliper and

CD moisture profiles.

Reduce off-spec

production.

Reduce converting

losses.

Allow target shifting.


45/63

Automated CD-Profile Control

Scanner Signal

Traversing

Scanner

Actuators

Reel

Slice Lips: Always

Parallel

Vat#1TopLinerTopLinerFurnish Vat#2BackingLinerBackingLine rFurnishFillerFurnish

Vat#3Filler1Vat#4Filler2Vat#5Filler 3

Vat#5 withConsistencyAutom aticorManualBasisWeigh tControl

Vat#6Filler4Vat#7Filler5 Vat#8Filler6Vat#9Backliner

BacklinerFur nish


46/63

Smaller Approach Piping

Stepped Hole Diffuser

Block

Air Padded Chamber Uniform Flow in all

Hoses

Simple Injection Water

Feed

Perfect Mixing of Stock

and Dilution Water

BTF-154-0


47/63

Consistency ProfilingExcellent Injection Control Systems do this:

Obtain perfect mixing of two flows of

different consistencies.

Keep total flow constant in each zone, at

any given head.

Minimize the injection ratio to prevent local

variations in fines or filler content, and

changes in formation.BTF-040-1


48/63

Distributor with Automatic Injection Control on Voith W-Type Headbox


49/63

Injection water is fed into theeye of each hose inlet.

Equal pressure always

maintains equal flow in each

hose.Minimize the injection ratio to

prevents local variations in fines

or filler content, and changes in

formation.

By adding the injection water

back at the Central Distributor,

perfect mixing is achieved.

Point of Injection

C i t P fili


50/63

Consistency Profiling

1) Fiber Orientation Control

Fixed Slice Lip CD Weight can now be controlled

from Fiber Angle (TSO/TSI)

2) The Dilution Headbox System only uses a smallvolume of Injection Water .less than 5%

3) Competitors Tapered Header Systems require as much

as 20 and 30% of Dilution Water:

Streaks are a very common problem.CD Weight and Fiber Angle are not independent.


51/63

Headbox + Distributor with Automatic Injection ControlSystem including:

Central Distribution Tank with Stock Accelerating Tube Bank

Built-in Attenuator CD-Profile Control

Connector Hoses with Stock Accelerating Diffuser Bank

Headbox with One or Two Stock Accelerating Tube Banks


52/63

Results:

Printing and writing, coated base sheet, complete new headbox

system with injection control:

CD-Profile Improvement, 85 gsm

0

0.5

1

1.5

2

2-Sigma Coefficient of Variance

BeforeAfter


53/63

CD-Profile Improvement

0

0.20.4

0.6

0.8

1

1.2

1.4

B.W. 230 - 350 gsm B.W. 350 - 550 gsm

2-S

igma

Before

After

Results:

4-ply Board machine, injection control retrofitted to existing

headbox on filler ply:


54/63

More Results: Envelope, Printing & Writing36#/3000 at Clariana - Spain

1.48 1.27 1.39

2.39

0.52 0.34 0.60.86

0

0.5

1

1.5

22.5

CD [%] MD [%] Residual [%] Total [%]

Improvement of Coefficient o f Variation [%] with BTF-Headbox

Envelope, Printing & Writing - 36#/3000 - 1640 fpm

With BTF-Headbox: Reduction of CD-Profile: 65%

Before Replacement of Two Ro ll Rectifier Roll Headbox


55/63

Advantages:

1) Flexibility 4 to 1 flow turn-down ratio possible by eliminating

the high velocity gradient required for a tapered

header.

2) Stability Grade changes are made easily and quickly due to

fast response of dilution control compared to slice

bending.

3) Simplicity Operator friendly design

Readily adaptable to mill control systems


56/63

Presenting:

The IndividualComponents of the

BTF-System


57/63

Application: Recommended for all Types and Brandsof ExistingRectifier Roll-, Hydraulic- or Dilution Controlled Headboxes.

The Benefits

Improves CD-Profiletoapprox. 0.1 to 0.5%.

Gain in strength allowslower basis weight or lowcost furnish.

Extremely fast gradechanges (few minutes).

Uncomplicatedinstrumentation.

Substantial improvement inTSI, TSO, Fiber

Orientation, Streaks, LowFormation, Curl, Two-Sidedness, etc.


58/63

The Benefits

Flawless conceptual layoutand design.

Fiber Orientation is alwayswithin few degrees (no need

for slice actuator control). Grade changes and recovery

time after breaks withinminutes.

No cross flows inside box oron wire.

Downturn Ratio of 4 to 1. Best suitable headbox on the

market for multi-grademachines.


59/63

The Benefits Introduction of additionalenergy provides MOREMICRO-TURBULENCE.

Substantial reduction insheet sealing andstratification.

IMPROVED DRAINAGE.

Dandy Roll or Top Former

can penetrate deeper intosheet, resulting insubstantial FORMATIONIMPROVEMENT.


60/63

CDP Hydraulic Headbox with CD Basis weight Dilution Control


61/63

Inlet of Headbox with Branch Tubes


62/63

Side view of Headbox


63/63

CDP Hydraulic Headbox for Fine paper

presentation india short head box

Documents