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New Ways to Manage Drainability, Fiber Properties and Shive Content of Pulp

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New Ways to Manage Drainability, Fiber Properties and Shive Content of Pulp NEW WAYS TO MANAGE DRAINABILITY, FIBER PROPERTIES AND SHIVE CONTENT OF PULP Authors Pasi Keinänen, Esa Piirainen, Janne Määttä, and Emerson Armani New Ways to Manage Drainability, Fiber Properties and Shive Content of Pulp Metso Automation Oy, Pasi Keinänen, Esa Piirainen and Janne Määttä Kajaani, Finland Metso Automation do Brasil Ltda. Emerson Armani, Sorocaba, Brazil 1. ABSTRACT Pulp and paper producers are increasingly developing their processes and pulp qualities in order to achieve certain specific, optimum paper properties. This trend, together with the need for more stable final product quality and decreased production costs, has increased the demands for high capacity, accurate, reliable pulp quality measurements. Traditional laboratory measurements cannot determine pulp properties frequently enough for accurate control, and the use of older quality analyzers in process management has been limited by unreliability problems. Recent advances in computer and camera technology have enabled the development of a new revolutionary method to measure fiber properties and shive content from pulp. These new meas- urements, together with Canadian Standard Freeness (CSF) measurement, are now included in the kajaaniMAP on-line analyzer. The analyzer is suited for all pulp and paper making processes and has been designed to exceed the present quality, capacity and functional expectations of pulp and paper producers. This paper presents experiences from several pulp and paper mills where the new on-line pulp quality analyzer was utilized in process management. Keywords: Freeness, Schopper Riegler, Fiber, Shive, on-line analyzer, Refining, Screening, Dewatering, Drain- age. 1. Resumo Os produtores de papel e celulose estão desenvolvendo sempre mais seus processos e a qualidade em celulose, a fim de conseguirem algumas ótimas propriedades específicas de papel. Essa tendência, juntamente com a necessidade de uma qualidade final de produto mais estável e custos de produção reduzidos, aumentou as demandas para medições confiáveis, precisas e de alta capacidade da qualidade da celulose. As medições tradicionais de laboratório não podem determinar as propriedades da celulose freqüentemente suficientes para um controle preciso, e o uso de analisadores de qualidade antigos na gestão do processo foi limitado por problemas de falta de confiabilidade. Avanços recentes em tecnologia da computação e câmera possibilitaram o desenvolvimento de um novo método revolucionário para medir as propriedades da fibra e fragmentar o conteúdo da celulose. Essas novas medições, juntamente com a medição pelo método Canadian Standard Freeness (CSF), estão agora incluídas no analisador online kajaaniMAP. O analisador é adaptado para todos os processos de fabricação de papel e celulose e foi projetado para superar a qualidade atual, a capacidade e as expectativas funcionais dos produtores de papel e celulose. Este documento apresenta experiências realizadas em fábricas de papel e celulose, onde o novo analisador online da qualidade de celulose foi utilizado na gestão do processo. Palavras-chave: Coeficiente de refino; Método de teste Schopper Riegler; Analisador online; Refinação; Filtragem; Esgotamento, Drenagem. 2. INTRODUCTION Globalization is one of the driving forces behind the recent changes in forest industry: the real prices of certain paper grades have gone down while at the same time competition has increased. Success in the international competition requires strict control of production costs in order to ensure high pro- ductivity. Many companies have decided to increase their competitiveness by specializing in certain products to achieve optimum paper properties. As productivity and quality targets are getting more crucial, the need for fast, accurate and reliable on-line pulp quality analyzers is increasing. Paper quality control often relies on measurements from the dry end of the machine: basis weight, moisture, ash content, thickness, etc. In many cases the level of instrumentation in the wet end is far less sophisticated, even though paper quality is determined primarily in the stock preparation and wet end processes [1, Leiviskä]. Freeness is one of the most frequently measured pulp quality variables in mill laboratories. Freeness gives an estimate of what kind of fibers the pulp contains and what kind of paper can be made from it [2, Riippa]. It affects paper machine runnability and several paper proper- ties, for instance tensile, burst and tear strength, bulk, stiffness, gloss and formation. Freeness control can also be used to fix certain quality defects in the finished product. However, identical drainability values do not always translate into identical paper properties, especially when comparing different pulp grades. Other measurements of fiber properties are therefore needed. Fiber measurements, especially fiber length, are often used e.g. for monitoring raw material variations and for refining and blending optimization. Shive content, especially with mechanical pulps, has also been a very important measurement when evaluating pulp quality. Discontinuities like shives, holes, or dirt specks affect paper machine runnability and local strength of the wet web and can cause web breaks and production losses. [1, Leiviskä]. Shive measurement is therefore utilized in the quality control of refining and screening and when determining finished pulp quality. Manual freeness, fiber and shive measurements in a laboratory are often unable to meet the require- ments of modern pulp production, and substitutive measurements must be found. Traditional meas- urements are also plagued by accuracy problems when measuring the very low shive levels that we have today. In the past few years, fiber measurements have evolved toward more accurate determi- nation of fiber size and shape [3, Tiikkaja]. New computer and camera technology gives an opportunity to develop multifunctional, fast measurements of fibers and shives. These modern fiber and shive measurements are now combined with a reliable standard freeness measurement in one analyzer, which improves the control possibilities in different pulping processes and opens a new window into paper machine operation. 3. ONLINE QUALITY ANALYZER kajaaniMAP (Modular Analyzer Platform), the analyzer discussed in this paper, was first introduced in 2005. The analyzer is able to measure crucial pulp quality parameters from mechanical pulping, chemical pulping, recycled pulping processes and from paper machine stock preparation. The ana- lyzer is specially designed for on-line control purposes, and a lot of attention has been paid to ensure reliable, accurate and fast operation. The analyzer consists of separate Freeness, Fiber and Shive content measurement modules that can be freely selected according to each mill's needs (Fig.1). The expandable construction allows new measurement modules to be easily added later on. The analyzer provides shive content measurements that are 15 times faster and fiber measurements that are up to 500 times faster than previous-generation devices. The total measurement time is 4–6 minutes per sample, and about 300–350 freeness, fiber and shive analyses are performed daily. 3.1 Process sampling and automated analysis In many cases the most error-prone stage of measurement is sampling from pulp slurry, and therefore representative, reliable sampling is an essential part of a reliable analysis [4, Ämmälä]. It also requires deep knowledge of the materials and techniques used to transport and condition the sample. The 2 analyzer's measurements are available from 100 meters' distance, from up to ten sampling points and up to 15% consistency. The sample is first delivered to the sample handling unit, where sample consistency is adjusted to 0.3% as in Tappi standard Freeness measurement. Consistency-controlled samples are then fed to the modules for freeness, fiber and shive analyses. If required, a 0.3% consistency sample from the same batch is also available for laboratory validation. The analyzer utilizes the 30-year experience ac- cumulated in Metso Automation’s Kajaani product line in taking and processing samples from various locations in the pulp and paper process. Examples of sampling points in mechanical pulping and stock preparation processes are shown in Figures 2 and 3. Figure 1. The analyzer consists of sample handling unit (left), freeness module (middle) and fiber/shive module. kajaaniMAP Figure 2.Typical sampling points of the analyzer in TMP process. 3 W G P M T T AF KR KE O BR Figure 3. Typical sampling points of the analyzer in stock preparation. 3.2 Standard Freeness measurement kajaaniKSF was the first on-line analyzer to measure freeness according to Canadian Standard method, and nowadays nearly 100 units are in operation [2, Riippa]. The kajaaniMAP freeness meas- urement is an improved version of the kajaaniKSF, and it uses the consistency, chamber dimensions, screen plate and measurement sequence of the Tappi T227 standard. After consistency calibration the analyzer performs freeness analysis in standard 0.3% consistency, and thus the freeness measurement itself requires no time-consuming calibration. During freeness measurement the volume and temperature of the pulp suspension are recorded and freeness or Schopper-Riegler value is calculated. Freeness measurement accuracy is according to Tappi stan- dard. Repeatability is excellent over a wide freeness range and even at very low freeness levels (~20 ml) due to the completely automatic system that prevents any systematic
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