Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21D—TREATMENT OF THE MATERIALS BEFORE PASSING TO THE PAPER-MAKING MACHINE
  • D21D1/00—Methods of beating or refining; Beaters of the Hollander type
  • D21D1/20—Methods of refining
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21D—TREATMENT OF THE MATERIALS BEFORE PASSING TO THE PAPER-MAKING MACHINE
  • D21D5/00—Purification of the pulp suspension by mechanical means; Apparatus therefor
  • D21D5/18—Purification of the pulp suspension by mechanical means; Apparatus therefor with the aid of centrifugal force
  • D21D5/24—Purification of the pulp suspension by mechanical means; Apparatus therefor with the aid of centrifugal force in cyclones

Definitions

• the present invention refer to a fiber development process and a fiber development device to treat wood fibers.
• One of the aims with the present invention is to manufacture wood containing printing grades of paper, news ⁇ print paper qualities and finer paper qualities (value added grades of paper) such as SC/LWC, from preferably TMP (thermo mechanical pulp), CTMP or CMP. This is performed with a significant energy saving, bleaching chemicals saving and lower investment costs in washing and dewatering equipment,
• Another aim with the invention is to manufacture TMP, CTMP, CMP or other mechanical pulp with lower energy input, yet holding an acceptable quality of the pulp.
• Another aim is to by using a modified process and a modified device according to the invention to treat fiber from any pulping process for example DIP, Kraft pulp or any other pulp and thereby saving energy and improving pulp quality among other things.
• Another aim is to improve drainability and dewatering of a cellulose pulp.
• the technology that is used today to manufacture mechanical pulp such as TMP, CTMP, CMP and improved qualities of these, is with help of one or multi ⁇ stage refining in the main line where the energy consumption is a known problem. Thereafter a separation is done with help of screening in multiple stages where a long fiber fraction is separated. This fraction is treated with simple or multi-stage HC (high consistency) refining followed by screening stages or with screening stages in between. Possibly the refined rejects from the HC-refining can be treated with LC (low consistency) refining.
• the known art doesn't show how one should do to get a paper with good surface properties, at the same time as one saves energy and still gets a paper with good strength properties.
• Mechanical pulp such as TMP
• TMP can untreated be used for finer paper qualities, but the yield is lowered and a higher energy input is required.
• To make finer paper qualities today one can use more expensive chemical pulp fiber, such as, sulfate pulp, sulfite pulp or similar, that is mixed with mechanical pulp to achieve desired properties.
• the reinforcement chemical pulp has high strength and long fibers.
• a device that comprises some sort of milling machine (5, 5a) such as a refiner, ball mill or similar.
• cellulose pulps in which defibered cellulose is screened to remove shives, and said pulp is then fractionated, and that the fractionation is done according to specific surface, preferably with a device (1) comprising hydrocylones, characterized by that the process comprises process stages(7) that fractionates out fibers with high specific surface, preferably thin walled fibers, and that the process comprises process stages (2) that fractionates out fibers having lower specific surface, preferably fibers with thicker fiber wall, and said pulp is fractionated into at least three fractions (10, 3, (3a) 12), which fractions are treated each by itself and then are brought together completely or partly, and that one or several fiber fractions (3, 3a) are treated, to be split, fibrillated and permanently collapsed preferably by a device that comprises a comminution device (5, 5a) such as a grinder, a refiner, a ball mill or similar.
• a comminution device such as a grinder, a refiner, a ball mill or similar.
• fractions (3,3a) that are treated in comminution device (5, 5a comprise fibers with a z-value between 0,3 and 0,8.
• the comminution device (5, 5a) be run so that the fibers in the fraction at hand are collapsed permanently through cracks in the fiber wall created by the comminution device.
• the effect of this is that the fibers in need of treatment are less sensitive to fiber sprinback and the surface stability of the end product is improved, especially when considering rewetting.
• the comminution device (5, 5a) comprise refining at a pulp consistency in the interval 0,8-14%, preferably in the interval 1-5%.
• the comminution device (5,5a) comprise regfining at a pulp consistency of either of 0,8 %, 0,9 %, 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11 %, 12%, 13%, 14%.
• the comminution device (5,5a) comprise regfining at a pulp consistency of 3%-8%.
• the comminution device (5, 5a) comprise a refiner run at a energy input of 10-800 kWh/t preferably 100-600 kWh/t even more preferred 200-500 kWh/t.
• hydrocyclones The effect of using hydrocyclones is that the fibers are separated on specific surface, and fibers of different lengths can be obtained in the same fraction.
• a fraction with lower specific surface (3, 3a) and more thick walled fibers that have been treated leaves from the base of a hydrocyclone stage.
• the fraction (10) enriched in fines material and comprising fibers with high specific surface is bleached in non alkaline environment.
• Non alkaline bleaching environment is less sensitive to be affected by impurities in the fraction (10), said impurities can comprise metall ions for example. Also non-alkaline bleaching can be performed at a lower cost.
• the fraction (10) is bleached at a pH which is less than 9.
• the fraction (10) is bleached with a reducing bleaching agent.
• the fraction (10) is bleached with a bleaching agent comprising dithionite.
• dithionite The effect of using dithionite is that the bleaching is performed at a lower cost and that the dithionite is less sensitive to break down before it can bleach the fibers.
• the fraction (3,3a) with fibers with lower specific surface is bleached with oxidative bleaching.
• Oxidative bleaching agents are more effective and therefore the bleaching of this fraction (3,3a) with these types of bleaching agents are better with regard to brightness, of the pulp.
• the fraction (3, 3a) is bleached with a bleaching agent comprising hydrogen peroxide.
• the fraction (3, 3a) is bleached with a bleaching agent comprising ozone.
• the fraction (12) that remains after previous process stages and which has the lowest specific surface is cleaned from sand, bark and other heavy impurities and treated, preferably with a device (15), to peel of fiber wall of the fibers in this fraction (12) and that the device comprises some sort of comminution device such as a refiner, or similar and that the fraction after treatment completely or partly is returned back to, preferably back ways, in the process.
• a device to peel of fiber wall of the fibers in this fraction (12) and that the device comprises some sort of comminution device such as a refiner, or similar and that the fraction after treatment completely or partly is returned back to, preferably back ways, in the process.
• the device (15) refines at > 15 % more preferably > 14 % consistency.
• the fiber stream with lower specific surface (3, 3a), preferably with fibers with thicker fiber wall, after treatment is completely or partly mixed with the stream (10) of fibers and fines material with high specific surface to improve the dewatering properties.
• the effect of mixing part of or completely the fraction (3, 3a) with the fraction 10 is that it will be easier to extract water.
• the fraction 10 is enriched in fibers and fines with low specific surface, this fraction is difficult to dewater since it tend to plug filters and other dewatering equipment and even if not plugging equipment dewatering is slow.
• the fiber stream with lower specific surface (3, 3a), preferably with fibers with thicker fiber wall, is dewatered alone to a higher consistency than the finally wanted consistency of the mix of fractions, so that the fraction with fibers with high specific surface (10), preferably thin walled fibers and fines material only needs to be dewatered partly or not at all.
• the fraction (3, 3a) is easier to dewater. This is due to less fines content in this fraction as well as different properties of the fibers with lower specific surface comprised in this fraction.
• concentration dewatering to this fraction (3,3a) instead of trying to dewater the fines enriched fraction (10), a more optimized use of the dewatering equipment can be obtained, this is among other things due to the lower tendency to plug the dewatering equipment. This altogether makes it possible to lower investments in this type of equipment.
• fractions (10, 11 , 11a) comprising fibers with high and lower specific surface, after treatment is brought together to a pulp stream (32) with pulp that has been produced with lower input of energy and bleaching agents than in a conventional factory for wood containing printing grades of pulp, news-print pulp, SC, LWC, SC A++ pulp and other pulps.
• Device to treat cellulose pulps to give improved properties with regard to properties such as, light scattering, tensile index, tear index, surface roughness, bleaching chemicals consumption, energy consumption comprising a first hydrocylone device (7), a second hydrocyclone device (2), a refiner (5) and transfer devices between these, characterized by that cellulose pulp is led to a first hydrocyclone devise (7) dividing out a base fraction (10) and an apex fraction (14) that via another hydrocyclone devise (2) dividing out a base fraction (3) that after dewatering continues to further treatment with a device (5) comprising refiner and treatment is done at a consistency between 1-14%.
• the effect of using hydrocyclones in the dividing in a device for treating pulp is that fibermorphology is the important factor determining what fibers will be separated from others. This means that fiber length is not the factor on which fractionation is based as when using screens. This means that the device can divide out the fibers in need for treatment.
• a base fraction (10) is bleached with a non alkaline reducing bleaching agent.
• Non alkaline bleaching environment is less sensitive to be affected by impurities in the fraction (10), said impurities can comprise metall ions for example. Also non-alkaline bleaching can be performed at a lower cost.
• a second base fraction (11) is bleached with an oxidizing bleaching agent.
• an apex fraction (33) continues to a hydrocyclone unit and is divided into a base fraction (3a) and an apex fraction (33a) in which said base fraction (3a) after dewatering is treated with a refiner (5a) at a consistency between 1-14%.
• a base fraction (3a, 11a) is bleached with an oxidizing bleaching agent.
• treated base fractions (10, 11 and/or 11 a) are brought together to a common pulp stream (32) with improved properties.
• An effect of the treatment in the device is that fiber development performed makes the stream 32 easier to dewater on the paper machine.
• an apex fraction (33, 33a) continues to cleaning with hydrocyclones (8) that removes heavy impurities such as sand, bark, and other heavy impurities which leaves in an apex fraction (12).
• a base fraction continues to treatment comprising refining (15) at a consistency > 5% and this fraction is then returned in an advancing pulp stream that are led to the inlet of the device.
• Another embodiment is disclosed as a process to produce and dewater cellulose pulps in which defibered cellulose is screened to remove shives, fractionated into at least three fractions (10, 3,(3a) 12), that the fractionation is done according to specific surface, preferably with a device (1) comprising hydrocylones, characterized by that said pulp is fractionated into at least three fractions (10, 3, 12), and that the process comprises process stages(7) that fractionates out fibers with high specific surface, preferably thin walled fibers, and that the process comprises process stages (2) that fractionates out fibers having lower specific surface, preferably fibers with thicker fiber wall that the fraction having lower specific surface (3, 3a) is dewatered in a device (5) to a given consistency, and that this fraction (3, 3a) is then mixed at least partly with at least one other fraction (10) before the mixed stream are led to the next process step.
• defibering is done through refining in one or several stages.
• the pulp is screened to remove larger particles.
• the advancing pulp stream is then led to fractionation based on specific surface, which in the case of fibers means by fiber wall thickness.
• the particles that have the highest specific surface are sorted out first.
• This fraction there are thin walled fibers and fines particles, so called fines.
• This fraction doesn't need further treatment for fiber springback (surface stability), increased strength, better surface roughness properties (better smothness) and so on, but can continue in the process.
• This fraction is bleached with a non alkaline bleaching agent, such as dithionite.
• Remaining pulp stream is fractionated once more on specific surface and here fibers with lower specific surface are sorted out from fibers that have the thickest walls and having the lowest specific surface. This fraction then continues to treatment with LC (Low Consistency) or MC (Medium Consistency) refining to create cracks in the fiber wall, fibrillate the fiber and collapse the fiber without affecting the fiber length to much, i.e. there will be no significant reduction of the fiberlenght. This prevents among other things fiber springback in the final product. Then this fraction is bleached in an own bleaching stage with oxidative bleaching.
• LC Low Consistency
• MC Medium Consistency
• the remaining fraction with the lowest specific surface is cleaned, in hydrocyclones, for example in a hydrocyclone cascade, to remove impurities such as sand, bark and other heavy impurities.
• Remaining fibers with thick fiber walls continues to treatment with for example HC refining and are returned back or backwards to the process.
• a w Fiber wall cross-section area
• P Fiber circumference Table 1
• Figure 1 Discloses the different types of fibers which are fractionated out and treated in a process according to the invention.
• Figure 2 Discloses the core of a system according to the invention
• Figure 3 Discloses an embodiment of the core of a system according to the invention
• Figure 4 Discloses an embodiment of the core of a system according to the invention
• Figure 5 Discloses an embodiment of the core of a system according to the invention
• Figure 6 Discloses an embodiment of the core of a system according to the invention
• Figure 7 Discloses an embodiment of a complete process according to the invention
• Figure 8 Discloses the experimental disposition according to example 1
• Figure 9 Discloses the experimental disposition according to example 2.
• Figure 16 Discloses an embodiment of the invention according to claim 28
• pulp follows the stream 13 to a hydrocyclone stage 7 with fractionating hydrocyclones, where the incoming stream are divided up into two streams 10 and 14.
• the stream 10 comprises fibers with a z-value between 0 and 0,3 (EEW) and fines material.
• the stream 14 comprises fibers with a z-value larger than 0,3 (LEW, ELW, LLW).
• This stream continues to a hydrocyclone stage 2 with fractionating hydrocyclones that divides the stream 14 into two streams 3 and 33.
• the stream 3 comprises fibers with a z-value between 0,3 and 0,8 (LEW, ELW).
• the stream 3 continues to dewatering 4 and to treatment in a refiner 5 with LC or alternatively MC-refining.
• the stream 11 that leaves the refining 5 there are fibrillated, splitted and collapsed fibers.
• the stream 33 comprises fibers with a z-value larger than 0,8 (LLW) and impurities of heavier kind, the stream 33 continues to cleaning in a cyclone cascade 8 optimized for cleaning away sand, bark and other heavy impurities.
• the impurities leave the process and the stream 12 continues to other treatment.
• the streams 10, and 11 continues to suitable treatment such as dewatering, complex binding of metals, bleaching etc.
• the base fraction 3 from hydrocyclone stage 2 it is possible to process the fibers that gives the largest problem with the surface properties in the final paper product and by concentrating on the stream it is possible to save energy compared with refining of the complete incoming fiber stream 13. Furthermore the streams 10, 11 and 12 can be treated separately in a suitable way so that an optimized final product can be obtained.
• the incoming pulp 13 is divided into the streams 10, 11 , 11a and 12.
• the stream 10 comprises fibers with a z-value which is less than 0,3 (EEW) and fines material.
• the stream 11 comprises fibers with a z-value between 0,3-0,6 (LEW) that have been treated in a refiner (MC or LC consistency) and the stream 11a comprises fibers with a z-value between 0,6-0,8 (ELW) and which have been treated in a refiner (MC or LC consistency).
• the stream 12 comprises fibers with a z-value larger than 0,8 (LLW).
• preheated chips are washed and defibered in two refiner stages (each stage can comprise several refiners in parallel and fewer or more than two stages).
• the pulp is diluted with water to a consistency of 3-4 % and is led to latency chest, where the fibers are allowed to rest to make them resume their shape after the refining process.
• the pulp is then pumped through screens at a consistency of 1-3%, these being of slot or hole type, this is done to remove shives and larger impurities.
• the reject stream from the screens are fed to the reject refining system, for example via a transfer device (not shown) to stream 12, or directly to a device (23, 24,15, 25, 26) in the reject refining system. If there are chemicals or other substances such as complex binders, that needs to be washed out, the pulp is washed in a washer 22 and the pulp 13 that has finished defibering continues to a process 1 according to the invention.
• a stream 10 is separated out comprising fibers with a z-value less than 0,3 (EEW) according to figure 1 , with help from hydrocyclones of conventional type, for example Noss AM 8OF, or other hydrocyclones of suitable type. It's possible to imagine some other type of equipment separating on specific surface. Fibers with a z-value less than 0,3 together with fines material are comprised in the pulp stream 10. In this arrangement a two stage cascade is shown (6 second stage in cascade) and recirculation, but here one can imagine several variants. Fibers with a z-value less than 0,3 and fines leaves in the base of the hydrocyclones 6,7.
• fibers are comprised with a z-value larger than 0,3 (LEW, ELW, LLW).
• the base fraction 3 from this comprises fibers with a z-value between 0,3 and 0,8 (LEW, WLW).
• These fiber types are the ones which particularly causes fiber springback in the finished product, which in turn creates problems with for example roughness.
• the stream 3 continues to treatment, preferably LC- refining (1-5%), alternative ways of treatment can be ball-mill, other refining MC (5%-14%) or mills of different kind, the treatment is done to induce (create) cracks in the fiber wall, fibrillate the fiber and collapse the fiber permanently, without affecting fiber length to much.
• the apex fraction from the hydrocyclone stage 2 continues to a hydrocyclone cascade 8 to clean it from heavy impurities such as sand, bark and other heavy impurities, these leaves in the apex of the hydrocyclones and leaves the process.
• the stream 12 from the base of these hyrdocyclones comprises fibers with a z-value larger than 0,8 (LLW) with very thick fiber wall. These fibers' wall can not be broken easily by LC-refining 5, so they continues to have the fiber wall pealed off, preferably by HC-refining or other pealing treatment and in that way the fiber wall is made thinner, then these treated fibers are returned to the process to once again continue through a system 1 according to the invention.
• the stream 10 continues to a bleaching stage 17 where one bleaches with a bleaching agent that tolerates fines material and small particles, preferably a bleaching agent that is used at non alkaline conditions (pH below 9), such as dithionite, for example sodium dithionite, zinc dithionite, or similar.
• a bleaching agent that is used at non alkaline conditions such as dithionite, for example sodium dithionite, zinc dithionite, or similar.
• the stream 11 that comprises fibers with a z-value between 0,3-0,8 (LEW, ELW) continues after adding of complex binders to washing 27 and bleaching 16 preferably with hydrogen peroxide, ozone or other suitable oxidative bleaching agent.
• the oxidative bleaching agents are sensitive to for example heavy metals (e.g.
• the fines material that comes with the fines material, but in a process according to the invention the mayor part of the fines material are comprised in the stream 10 and never continues in large amounts into the bleaching stage where the oxidative bleaching agents are used.
• the fibers After a further washing 28 and 29 the fibers continues to dewatering in a disc filter 30. After that these fibers are returned and mixed with the fibers in the stream 10.
• the disc filter 30 dewater this fraction 11 to a higher consistency than necessary, the fraction 10 can be more diluted and in doing so an easier dewatering of the pulp seen as a whole is obtained.
• the fraction 10 is difficult to dewater due to larger contents of fines material.
• the system according to the invention can on detail level be arranged in several ways.
• the core of the invention is the fractionating arrangement that preferably constitutes of hydrocyclones, but can be made from other equipment that can fractionate on specific surface.
• Figure 2, 3, 4, 5 and 6 one can see different variants of arrangements.
• Figure 2 discloses a magnification of a system where one can see that it's possible to have a cascade in both the first hydrocyclone stage and/or in the second. The dashed line shows that one can have a cascade if that is desired.
• Figure 4-6 develops part what is comprised in figure 2, for clarity.
• Figure 4 discloses a single stage in both first 7 and second stage 2.
• Figure 5 discloses how one has a system with a single stage in first stage 7 and a cascade in the second stage 2.
• Figure 6 discloses how one has hydrocyclone cascades in both first stage 7 and in second stage 2.
• Softwood TMP was sampled from a factory which produces paper of news-print quality. The sample was taken at the second stage refiner. After that the pulp was latency treated at 90 °C for 3 hours and was then processed in the new system. Mass flow and different fiber fractions can be seen in table 3 and figure 8.
• Base 1 (m4) accept from first stage cascade enriched in fibers with a z-value less than 0,3 (EEW) and fines material.
• Base 2 accept from second fractionation stage enriched in fibers with a z- value between 0,3 and 0,8 (LEW and ELW).
• Base 2 (m ⁇ ) was further refined in the LC-refiner (12" Andritz) at three different energy levels 215, 417, 504 kWh/t. The total energies for the different pulps correspond to 73, 142, and 171 kWh/t for the pulp seen as a whole. The obtained unrefined and refined pulps were tested separately. Also, pulp blends were made from Base 1 and Base 2 according to the pulp mass flow split in the system - 47:53% (bl1 , bl2, bl3). Handsheets from different pulp fractions and blends were made and tested. Dynamic de-watering tests, as well as surface roughening tests were conducted on some pulp samples. Base 1 (m4) and Base 2(m8) and their blends, were bleached using dithionite and alkaline peroxide (lye and hydrogen peroxide) in different sequences.
• the LC-refining improved the bonding ablility of the Base 2 long fibers to similar level as Base 1 , as measured by tensile strength of the P16/R50 Bauer McNett fraction. This resulted in relatively high long fiber bonding ability of the blend 2 and 3.
• Base 2 was bleached with hydrogen peroxide and blended with unbleached Base 1 and the blend was then bleached with dithionite.
• Latency treated second refiner stage pulp from a factory producing TMP of news-print quality was screened at a predetermined reject rate to remove shives and was fractionated in a two stage cascade hydrocyclone system.
• the reject rate was chosen so that 25% of the fibrous material, (25 % of the R100 Bauer-McNett fiber fraction of the feed pulp), ended up in the base fraction, Base 1 (s6).
• the Apex 1 fraction (s4) was further fractionated in the hydrocyclone system resulting in the Base 2 (s7) fraction containing 25 % of the fibrous material (in per cent of the initial hydrocyclone feed) and Apex 2 (s5).
• Base 2 (s7) fraction containing 25 % of the fibrous material (in per cent of the initial hydrocyclone feed)
• Apex 2 (s5) was fractionated, which resulted in Base 3 (s8) containing 25% of the fiber material and Apex 3 (s9) containing at least 25 % of the fiber material according to the above.
• Bas 1 , 2 and 3 were used for further experiments.
• Base 2 and 3 were refined at 300 kWh/t in a LC-refiner and the pulps where processed in a similar way as the unrefined samples.
• Base 2, 3 where split into two parts from which one part continued to LC- refining at 300 kWh/t and one part which was not refined.
• the unrefined part which comprised Base 1 and the unrefined part was decrilled (i.e. the P100 fines fraction was removed using a Bauer-McNett fractionator).
• the fiber fraction was mixed with 40 % fines (by weight) obtained from the second stage refiner at the TMP pulp factory.
• Two sets of handsheets at 60 g/m 2 surface weight were made. The first set of hand sheets where tested according to SCAN standards.
• the second set of hand sheets was cut into strips, calendered and used for roughening experiments. After calendering, the strips were randomly split into two groups.
• the first group was tested on tensile strength, density, porosity, surface roughness and scattering.
• the second group of calendered strips was subjected to 100 % humidity at 25 °C for 3 hours and after that was subjected to the same tests as the first group.
• LC refining of the base fraction Base 2 (s7) and the base fraction Base 3 (s ⁇ ) increases the strength of these.
• LC refining reduces freeness of the pulp to some extent, but the amount of fines material that are produced do not correspond to the slope of the regression of the freeness-fines material relationship.
• the LC-refining has treated the fibers without a corresponding fines material production.
• Base 3 long fiber fraction (P16/R50 ml/min) was significantly reduced after LC-refining, while the bonding ability was increased to the same level as the long fiber fraction from Base 2 (s7) see Figure 12.
• Long fiber fraction of Base 2 increased the bonding ability to the same level as Base 1 (s6) after LC-refining without significantly changing roughness.
• Base 2 and Base 3 fractions exhibited higher tendency to get increased surface roughness compared with Base 1 , reflected in larger relative change of the sheet caliper and surface roughness after re-wetting ( Figure 14-15).
• cyclone stages according to the invention are 1 modified according the fiber at hand to be treated. It should for example be understood that the person skilled in the art can put so called broken or open cascades at all or places of choice in the system 1. Especially it should be noted that what's given in Figures only are variants of what the thought of the invention is representing and the number of cyclones that are used and their physical data are a question of adaptation of the construction of the system to the fibers it is constructed to treat. The same goes for the concentration conditions that are at hand in the refiners according to the invention and pressure drop over hydrocyclone stages.

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