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Refining of Recycled Fibers

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Refining of Recycled Fibers 磨漿技術及配料,填料的添加 Paper technology program 2010 08 26 Taichung, Taiwan 2010 10 / CGK 1 Refining of recycled fibers - A key to upgrading of fiber potential for papermaking 2010 10 / CGK 2 Once refined fibers should not be refined again 2010 10 / CGK 3 History of recycled fibers Dried or never dried virgin fibers Printing and converting processes have passed through the stock have produced various reading preparation and papermaking and packaging materials for processes everyday use Which have then been collected for a further use in the papermaking • Has often been the only papermaking fiber in some countries • Is today more and more used in all papermaking countries 2010 10 / CGK 4 Treatment of recycled fibers Collected recycled fiber pulp contains various harmful foreign materials Those are either removed or But the bonding ability of fibers made to non-visible particles is not always properly developed And the result very often is ? Clean fibers with a low bonding ability requiring a high amount of expensive chemical binders 2010 10 / CGK 5 Why refine recycle fibers Fibers are refined In the papermaking inorder to improve their process, fiber bonding bonding ability ability has weakened Recycled fibers are no longer optimal paper raw materials as such - Irreversible changes - Deinking has cleaned fibers - Bonding ability of recycled fibers can be improved through refining 2010 10 / CGK 6 Recycled fibers for papermaking Never dried pulps from own Dried market pulps from recycled fiber plant commercial plants In most cases these fibers are not always ready for papermaking as: • Previous severe pressing and drying in papermaking have created hornification and other irreversible changes in the fiber structure Some fines have been removed Hot dispersion has created curly and kinky fibers Flash drying has created strong fiber bundles 2010 10 / CGK 7 Stock preparation for recycled fibers Is needed as for all other papermaking fibers Never dried pulps from own Dried market pulps from recycled fiber plant commercial plants • Refining • Slushing • Deflaking • Refining Need of stock preparation stages and the amount of treatment in those stages depend on • The previous history of fibers • The targets in the papermaking • Recycled fiber can be used as a filler • Recycled fiber can give strength 2010 10 / CGK 8 Refining of recycled fibers Why to refine recycled fibers? Because once refined fiber has But once through the paper- been developed to give a good making process has reduced bonding ability that bonding ability and Once so nicely developed fibers are not any more in their best condition for the next use in papermaking • Severe drying and pressing forces have created irreversible changes (hornification and closed fibrils) • Recycled fiber treatment process has cleaned but not necessarily developed the fibers 2010 10 / CGK 9 Targets of the recycled fiber refining It is desirable It is not desirable Regenerate the swelling and • Shorten the fibers the bonding ability of fibers • Weaken the fibers • Increase the dewatering resistance • Reduce the bulk This can be reached These negative effects can with all refiners best be minimized by using but wrong refining has suitable refiners with correct so strong negative selection of fillings which enable effect that it can be to get the best out of recycled fiber best not to perform it 2010 10 / CGK 10 Development of market DIP 120 100 80 60 40 Unrefined = 135 CSF 27 kWh/t = 123 CSF 20 % Unrefined market as 100 % market Unrefined % 48 kWh/t = 114 CSF 77 kWh/t = 93 CSF 0 Tensile Tear Fibre length Bulk Porosity Unrefined 36.8 Nm/g 6.89 mNm2/g 1.18 mm 2.35 cm3/g 350 ml/min 2010 10 / CGK 11 Fiber development of DIP 160 140 120 100 80 60 40 Unrefined = 235 CSF 50 kWh/t = 170 CSF % Unrefined marked as 100 % marked Unrefined % 20 100 kWh/t = 125 CSF 150 kWh/t = 95 CSF 0 Tensile Burst Tear Fiber length Bulk Unrefined 26.2 Nm/g 1.30 kPam2/g 7.38 mNm2/g 1.23 mm 2.05 cm3/g 2010 10 / CGK 12 Fiber development of OCC 200 180 160 140 120 100 80 60 Unrefined = 620 CSF 50 kWh/t = 560 CSF 40 % Unrefined marked as 100 % marked Unrefined % 100 kWh/t = 460 CSF 150 kWh/t = 360 CSF 20 0 Tensile Burst Tear Fiber length Bulk Unrefined 24.1 Nm/g 1.36 kPam2/g 8.30 mNm2/g 1.35 mm 2.07 cm3/g 2010 10 / CGK 13 Fiber development of OCC 300 275 250 225 200 175 150 125 100 75 Unrefined = 620 CSF 50 kWh/t = 560 CSF 50 % Unrefined marked as 100 % marked Unrefined % 100 kWh/t = 460 CSF 150 kWh/t = 360 CSF 25 0 TEA Scott Bond CMT 30 RCT Unrefined 0.28 J/g 84 J/m2 82 N 1.19 kN/m 2010 10 / CGK 14 Development of white kraft waste 160 140 120 100 80 60 40 Unrefined = 440 CSF 25 kWh/t = 415 CSF 50 kWh/t = 375 CSF 75 kWh/t = 285 CSF % Unrefined marked as 100 % marked Unrefined % 20 0 Tensile Tear Burst Bulk Unrefined 25.0 Nm/g 10.0 mNm2/g 2.2 kPam2/g 1.8 cm3/g 2010 10 / CGK 15 Fiber development of AOCC 180 160 140 120 100 80 60 40 % Unrefined marked as 100 % marked Unrefined % 0 kWh/t = 540 CSF 43 kWh/t = 430 CSF 20 86 kWh/t = 355 CSF 0 Schopper Tensile Burst Tear Unrefined 23 SR 32.5 Nm/g 1.9 kPam2/g 13.2 mNm2/g 2010 10 / CGK 16 Fiber development of AOCC 220 200 180 160 140 120 100 80 60 0 kWh/t = 540 CSF 43 kWh/t = 430 CSF 40 86 kWh/t = 355 CSF % Unrefined% marked as 100 % 20 0 Fiber length Bulk TEA Scott Bond Unrefined 1.50 mm 2.28 cm3/g 0.49 J/g 90 J/m2 2010 10 / CGK 17 Change of recycled pulp beating degree (CSF) in refining 2010 10 / CGK 18 Change of recycled pulp beating degree (SR) in refining 2010 10 / CGK 19 How refining of recycled pulp affects paper tensile strength 2010 10 / CGK 20 How beating degree of recycled pulp affects paper tensile index 2010 10 / CGK 21 How refining of recycled pulp affects paper tear index 2010 10 / CGK 22 How refining affects the average fiber length of recycled pulp 2010 10 / CGK 23 How refining of recycled pulp affects paper bulk development 2010 10 / CGK 24 How refining of recycled pulp affects paper air permeability 2010 10 / CGK 25 How refining affects the shives content of recycled pulp 2010 10 / CGK 26 How refining of recycled pulp affects paper bursting index 2010 10 / CGK 27 Refining process 2010 10 / CGK 28 Stator Stator Stator Fiber bundle Rotor Rotor Rotor Fiber pick-up Edge to edge Edge to surface Stator Stator Stator Rotor Rotor Rotor Refined area Surface to surface Surface to surface End of refining 2010 10 / CGK 29 Fibers stapling on rotor bar edge Good stapling • Strong vortex • Strong centrifugal force • Weak force along groove 2010 10 / CGK 30 Refiner flow pattern Stator Rotor Grooves must be wide enough for fibers • they must be able to rotate in grooves • the longer the fibers the wider the grooves Vortex flows get fibers stapled on bar edges 2010 10 / CGK 31 The effect of refining • Strength properties generally, like tensile, burst and internal bonding strength are increased TENSILE STRENGTH Fibrillating Cutting kWh/t 2010 10 / CGK 32 The effect of refining • Tear strength is initially increased, but is then reduced after prolonged refining TEAR STRENGTH Fibrillating Cutting kWh/t 2010 10 / CGK 33 The effect of refining • Drainage resistance and water removal resistance are increased REFINING DEGREE, SR REFINING DEGREE, CSF Cutting Fibrillating Fibrillating Cutting kWh/t kWh/t 2010 10 / CGK 34 The effect of refining • Air permeability, bulk, absorbency, opacity, brightness and light scattering are reduced BULK LIGHT SCATTERING COEFFICIENT Cutting Cutting Fibrillating Fibrillating kWh/t kWh/t 2010 10 / CGK 35 The effect of refining • Fiber length are reduced FIBER LENGTH Fibrillating Cutting kWh/t 2010 10 / CGK 36 Refiners 2010 10 / CGK 37 Refiners - batchwise operated Hollander - Beater 2010 10 / CGK 38 Refiners Geometry Conical Refiners Disc Refiners Low cone Short cone Short cone Single Double Multidisc Shallow angle Shallow angle Wide angle Disc Disc “Jordan” “Conflo” “Claflin” 2010 10 / CGK 39 Conical refiner 2010 10 / CGK 40 Conical refiner 2010 10 / CGK 41 Conical refiner 2010 10 / CGK 42 Disc refiners • The disc refiner group comprises three types, namely single-disc, double-disc and Multi-disc type refiners 2010 10 / CGK 43 Rotor Centralizing Rotating Element TriConic® System System Main Body Adjustment Mechanism Construction 2010 10 / CGK 44 Andritz Papillon refiner 2010 10 / CGK 45 Andritz Papillon refiner Refining gap open Plates in refining position 2010 10 / CGK 46 The amount of refining Beating degree / Net refining energy 800 60 700 2*150 kWh/bdmt 50 4*75 kwh/bdmt 600 40 500 400 30 300 BEATING DEGREE, °SR 20 BEATING DEGREE, CSF Ml 200 2*150 kWh/bdmt 4*75 kWh/bdmt 100 10 0 50 100 150 200 250 300 0 50 100 150 200 250 300 NET REFINING ENERGY, kWh/bdmt NET REFINING ENERGY, SRE kWh/bdmt Short fiber 2010 10 / CGK 47 The amount of refining Tensile index / Refining energy input 90 90 80 80 70 70 60 60 50 50 40 40 TENSILE INDEX, Nm /g TENSILE INDEX, Nm/g 2*150 kWh/bdmt 2*150 kWh/bdmt 30 30 4*75 kWh/bdmt 4*75 kWh/bdmt 20 20 0 50 100 150 200 250 300 0 50 100 150 200 250 300 350 400 NET REFINING ENERGY, kWh/bdmt TOTAL REFINING ENERGY, kWh/bdmt Short fiber 2010 10 / CGK 48 The amount of refining Tensile index / Beating degree 90 90 80 80 70 70 60 60 50 50 40 40 TENSILE INDEX, Nm/g INDEX, TENSILE TENSILE INDEX, Nm/g INDEX, TENSILE 2*150 kWh/bdmt 30 30 2*150 kWh/bdmt 4*75 kWh/bdmt 4*75 kWh/bdmt 20 20 100 200 300 400 500 600 700 800 10 20 30 40 50 60 BEATING DEGREE, CSF Ml BEATING DEGREE, °SR Short fiber 2010 10 / CGK 49 The amount of refining Tensile index / Refining energy input 90 90 80 80 70 70 60 60 50 50 40 40 TENSILE INDEX, Nm /g TENSILE INDEX, Nm/g 2*150 kWh/bdmt
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