Refining System Optimization - J&L Fiber Services

1 2007 J&L Fiber Services , Inc. All rights System OptimizationRefining System OptimizationA Six-Step Approach 2007 J&L Fiber Services , Inc. All rights ApproachSix-Step Approach1. Hydraulics - Flow2. Consistency3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights Why are Hydraulic Conditions Important to Refining ?9 Rotor is Stable & Centered9 Increases Probability of Fiber Mat Formation9 Fiber Strength Development Potential is Maximized9 Plate Life Potential is Maximized9 Variation is Minimized It s just not a good thing to try to refine metalStep 1: Hydraulics - Flow 2007 J&L Fiber Services , Inc. All rights ChartHydraulic ChartDDOOUUBBLLEE DDIISSKK RREEFFIINNEERR CCAAPPAACCIITTYY CCHHAARRTT RREECCOOMMMMEENNDDEEDD FFLLOOWW RRAANNGGEESS FFOORR VVAARRIIOOUUSS SSIIZZEE RREEFFIINNEERRSS ((6600 HHZZ SSPPEEEEDDSS)) DDiiaammeetteerr mmmm ((iinncchheess)) MMaaxx PPoowweerr kkWW ((HHpp)) NNoorrmmaall RRPPMM NNoo LLooaadd kkWW ((HHpp)) FFLLOOWW RRAATTEESS GGPPMM LLooww MMeeddiiuumm HHiigghh 550088 ((2200)) 222255 ((330000)) 990000 5555 ((7755)) 115500 225500 440000 661100 ((2244)) 333355 ((440000)) 772200 8855 ((6655)) 225500 335500 660000 666600 ((2266)) 337755 ((550000)) 772200 9900 ((112200)) 330000 445500 880000 776622 ((3300)) 445500 ((660000)) 660000 9955 ((112255)) 337755 660000 11110000 886644 ((3344)) 559955 ((880000)) 551144 110000 ((113355)) 447755 775500 11440000 775500 ((11000000))

2 660000 116600 ((221155)) 555500 887755 11665500 996655 ((3388)) 993355 ((11225500)) 551144 116600 ((221155)) 665500 11007755 22002255 11006677 ((4422)) 11112200 ((11550000)) 445500 116655 ((222200)) 777755 11225500 22440000 11330055 ((11775500)) 551144 224455 ((333300)) 990000 11445500 22880000 11116688 ((4466)) 11449955 ((22000000)) 445500 224400 ((332255)) 11002255 11667755 33227755 11332211 ((5522)) 22224400 ((33000000)) 440000 228855 ((338855)) 11330000 22115500 44330000 22224400 ((33000000)) 445500 441100 ((555500)) 11447755 22442255 44885500 11337722 ((5544)) 22224400 ((33000000)) 440000 333355 ((445500)) 11447755 22442255 44885500 DDOOUUBBLLEE DDIISSKK RREEFFIINNEERR CCAAPPAACCIITTYY CCHHAARRTT RREECCOOMMMMEENNDDEEDD FFLLOOWW RRAANNGGEESS FFOORR VVAARRIIOOUUSS SSIIZZEE RREEFFIINNEERRSS ((6600 HHZZ SSPPEEEEDDSS)) DDiiaammeetteerr mmmm ((iinncchheess)) MMaaxx PPoowweerr kkWW ((HHpp)) NNoorrmmaall RRPPMM NNoo LLooaadd kkWW ((HHpp)) FFLLOOWW RRAATTEESS GGPPMM LLooww MMeeddiiuumm HHiigghh 550088 ((2200)) 222255 ((330000)) 990000 5555 ((7755)) 115500 225500 440000 661100 ((2244)) 333355 ((440000)) 772200 8855 ((6655)) 225500 335500 660000 666600 ((2266)) 337755 ((550000)) 772200 9900 ((112200)) 330000 445500 880000 776622 ((3300)) 445500 ((660000)) 660000 9955 ((112255)) 337755 660000 11110000 886644 ((3344)) 559955 ((880000)) 551144 110000 ((113355)) 447755 775500 11440000 775500 ((11000000)) 660000 116600 ((221155)) 555500 887755 11665500 996655 ((3388)) 993355 ((11225500)) 551144 116600 ((221155)) 665500 11007755 22002255 11006677 ((4422)) 11112200 ((11550000)) 445500 116655 ((222200))

3 777755 11225500 22440000 11330055 ((11775500)) 551144 224455 ((333300)) 990000 11445500 22880000 11116688 ((4466)) 11449955 ((22000000)) 445500 224400 ((332255)) 11002255 11667755 33227755 11332211 ((5522)) 22224400 ((33000000)) 440000 228855 ((338855)) 11330000 22115500 44330000 22224400 ((33000000)) 445500 441100 ((555500)) 11447755 22442255 44885500 11337722 ((5544)) 22224400 ((33000000)) 440000 333355 ((445500)) 11447755 22442255 44885500 Step 1: Hydraulics - Flow 2007 J&L Fiber Services , Inc. All rights to Low FlowNegatives to Low Flow Little or No Fiber Mat Between Plates Fiber Channeling High Pressure Rise (25-50 psi) Plate Clashing Short Plate Life Inefficient Refining (power vs Fiber development) Poor Strength Development Increased Fines GenerationPowerPowerStep 1: Hydraulics - Flow 2007 J&L Fiber Services , Inc. All rights to High FlowNegatives to High Flow Inability to Optimize Plate Design For Maximum Strength Development (Compromise) Short Plate Life Pressure Drop Motors Maxed OutStep 1: Hydraulics - FlowPowerPower 2007 J&L Fiber Services , Inc.

4 All rights SolutionsPossible Solutions Low Flow9 Recirculation9 Parallel to Series9 Pattern Change9 Holdback9 Smaller Refiner High Flow9 Pump Change9 Series to Parallel9 Pattern Change9An Additional &/or Larger Refiner9 Increase ConsistencyStep 1: Hydraulics - Flow 2007 J&L Fiber Services , Inc. All rights ConsistencySix-Step ApproachSix-Step Approach1. Hydraulics - Flow3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights GuidelinesConsistency GuidelinesConsistency Guidelines for Various Fiber Types Fiber Type Recommended Range of Refining Consistency Unbleached Softwood Kraft - Bleached Softwood Kraft - 5% Bleached Hardwood/Eucalyptus Kraft4 - 6% OCC - 5% Mechanical Pulps 4 - 6% Unbleached Semi-Chem Hardwood - 6% Mixed Waste 4 - 6% Step 2: Consistency 2007 J&L Fiber Services , Inc.

5 All rights Why is the Proper Consistency Important to Refining ?9 Increases the Probability of Fiber Mat Formation9 Fiber Strength Potential Maximized9 Plate Life Potential is Maximized9 Variation is MinimizedStep 2: Consistency 2007 J&L Fiber Services , Inc. All rights of Operating Outside Recommended ConsistencyEffects of Operating Outside Recommended Consistency High Consistency9 Plate Plugging9 Poor Fiber Development Low Consistency9 Little to No Fiber Mat Between Plates9 Inefficient Refining9 Poor Fiber Development9 Fiber Cutting9 Plate Clashing9 Short Plate LifeStep 2: Consistency 2007 J&L Fiber Services , Inc. All rights ConsistencySix-Step ApproachSix-Step Approach1. Hydraulics - Flow3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights EnergySpecific Energy Definition: The amount of Energy Transferred from the Refiner s Motor to the = kWh/t = = HPD/T =Motor Load (kW) No Load (kW)Tons per HourMotor Load (HP) No Load (HP)Tons Per DayStep 3: Specific Energy 2007 J&L Fiber Services , Inc.

6 All rights Load EnergyNo Load Energy Definition: The Energy Required to spin the rotor in a pulp Load (kW) = ( )( )(RPM3) Diam = Plate diameter in Inches RPM = Refiner rotor speed THE REFINER IS AN INEFFICIENT PUMP Step 3: Specific Energy 2007 J&L Fiber Services , Inc. All rights Transfer to FiberEnergy Transfer to Fiber42 RefinerMotor1305 kWNo Load = 245 kWFiber = 1060 kW81% EfficiencyStep 3: Specific Energy 2007 J&L Fiber Services , Inc. All rights Energy GuidelinesSpecific Energy GuidelinesNET Refining REQUIREMENTSFOR MAJOR GRADESGRADEHPD/USTKWH/USTKWH/MTLinerboar dBase5 - 789 - 12599 - 138 Top10 - 12179 - 215197 - 237 Sack, Bag12 - 14215 - 250237 - 276 MediumVirgin HWD6 - 10107 - 179118 - 197 Waste2 - 336 - 5439 - - - 2720 - 30 Fine PapersHardwood4 - 672 - 10779 - 118 Softwood6 - 8107 - 143118 - - - 2720 - 30 Foodboard,Hardwood2 - 336 - 5439 - 59 Milk CartonSoftwood3 - 454 - 7259 - 79 Tickler1. 0 - - 2720 - 30 NewsSB Kraft2 - 536 - 8939 - 99 Groundwood2 - 336 - 5439 - 59 Grades w/ - - 11750 - 100 Step 3: Specific Energy 2007 J&L Fiber Services , Inc.

7 All rights ConsistencySix-Step ApproachSix-Step Approach1. Hydraulics - Flow3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights Drop / HPD/TFreeness Drop / HPD/T Freeness Drop / HPD/T is a Great Measure to Determine the Refiner(s) Efficiency and if it is Operating Correctly9 Equation: Delta CSF / HPD/T = CSF In - CSF OutHPD/TStep 4: Specific Freeness 2007 J&L Fiber Services , Inc. All rights Drop / HPD/T Guideline ChartFreeness Drop / HPD/T Guideline ChartFREENESS DROP / NET HPD/TVarious Furnishes UNBLEACHED SOFT WOOD KRAFTNORTHERN - 25 CSF / Net HPD/TSOUTHERN - 30 CSF / Net HPD/T BLEACHED SOFTWOOD KRAFTNORTHERN - 50 CSF / Net HPD/TSOUTHERN - 60 CSF / Net HPD/T BLEACHED HARDWOOD KRAFTMOST SPECIES60 - 100 CSF / Net HPD/TEUCALYPTUS45 - 50 CSF / Net HPD/T SECONDARY FIBEROCC40 - 70 CSF / Net HPD/TMIXED50 - 70 CSF / Net HPD/TNEWS20 - 35 CSF / Net HPD/TStep 4: Specific Freeness 2007 J&L Fiber Services , Inc.

8 All rights Drop / HPD/TFreeness Drop / HPD/T Possible Causes for a Low Freeness Drop/HPD/T9 Tough Fiber9 Low or High Flow Conditions9 Low Consistency9 Improper Pattern Application9 Worn Out Plate - Bar edge Rounding, Bar Wear9 Mechanical Problem w/ Refiner - Out of Tram, a Rotor that will not Float9 Improper Plate InstallationStep 4: Specific Freeness 2007 J&L Fiber Services , Inc. All rights ConsistencySix-Step ApproachSix-Step Approach1. Hydraulics - Flow3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights Intensity (SEL) Refining Intensity (SEL) Definition: A Term used to Define How the Energy is Applied the the Amount of Energy (watts) Applied Across One Meter of a Refiner Plate s Bar Edge and Transferred to the Pulp in One Second; (Ws/m) Pattern Design Plays Key Role9 Equation: Int = WS/M= (KM Bar Edge Crossings/Rev)(RPM) (1min/60sec)Motor Load (kW) - No Load (kW)Step 5: Refining Intensity 2007 J&L Fiber Services , Inc.

9 All rights TYPE TYPICAL SEL RANGE WS/M Unbl. Northern SW Kraft - Unbl. Southern SW Kraft - Bl. Northern SW Kraft - Bl. Southern SW Kraft - Semi-Chem HWD - Bl. HW Kraft - Bl. Eucalyptus Kraft - TMP Post Refining less than OCC .75 - (As low as possible w/out Plugging) Mixed Waste .75 Deinked News / Magazine (70 / 30 mix) less than Typical SEL Ranges forVarious Fiber TypesTypical SEL Ranges forVarious Fiber TypesStep 5: Refining Intensity 2007 J&L Fiber Services , Inc. All rights of Intensity on the FiberImpact of Intensity on the Fiber High IntensityRefining Cutting Low IntensityRefining - FibrillationStep 5: Refining Intensity 2007 J&L Fiber Services , Inc. All rights of RefiningOutside the Recommended Intensity RangeEffects of RefiningOutside the Recommended Intensity Range Lower Than Recommended9 Potentially Poor Fiber Development (All Fibers Require a Certain Intensity Level to Break Down Their Walls9 Maintain Fiber length9 Inefficient Freeness drop Higher Than Recommended9 Severe Fiber Cutting9 Plate Clashing, Exceed Fiber Threshold 9 Short Plate Life9 Poor Strength DevelopmentStep 5: Refining Intensity 2007 J&L Fiber Services , Inc.)

10 All rights ConsistencySix-Step ApproachSix-Step Approach1. Hydraulics - Flow3. Specific Energy (kWh/t)4. Specific Freeness Drop CSF/ kWh/t5. Refining Intensity (Ws/m)6. Plate MaterialProcess Optimization and/or Pattern and Alloy Recommendation 2007 J&L Fiber Services , Inc. All rights Material SelectionPlate Material Selection Failure Modes of Refiner Plates9 Bar Wear9 Serration9 Bar Edge Rounding9 Corrosion9 Bar Breakage9 Smearing Alloy Selection is Based on Dominant Failure Mode - Maximize Plate LifeStep 6: Plate Material 2007 J&L Fiber Services , Inc. All rights If you have any questions on J&L s Six Step Approach on Refiner System Optimization , or if you would like additional information on our product line, call your J&L Representative. Together with J&L's Technical Support, he can assist you in applying this Six-Step Process to ensure optimal performance of your Refining System .