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HIGH PERFORMANCE HYDRAULIC HEADBOX

SYSTEM
with Central Distributor Pulsation dampener and CD basisweight Dilution Control

What Does your Mill Benefit from this Presentation?

Cost Cutting
because 95 % of Your Papermaking Problems Cost Money

Objective for this Presentation:

Analyze Economic Potential of Improvement for Your Paper Machine

Automatic Consistency Profiling System

This mill in Spain found that the grade changes were much easier with the Automatic Consistency Profiling solution. The dry weight profile variation was reduced by 71%.

Hydraulic Headbox and Distributor with Automatic Consistency Profiling System

Air-padded Central Distributor with Automated Dilution Control

Base System Layout

Mapping Printer

QCS with CD Consistency Control Existing Scanner FAST LAN

CD Network

CD Control

Central Distributor with Dilution Injection

High Performance Hydraulic Headbox:


Central Distributor, Automatic BW Control. Providing Superior Profiles in CD, MD, Residual & Total %

Central Distributor Pulsation dampener with Dilution water Injection

Diffuser Inlet Branch Tubes and Headbox

It Brings You Closer to Perfect Papermaking


Eliminate Annoying Problems!

The Cause?
Cross Flows.
Rotational Flows. Flocculation.

The Result ?
Moisture Profile.
Breaks + Rejects. Efficiency.

The Culprit ? The PE-Tank and Tapered Header !

CD-Pressure Profile in Manifold.

Tapered Header: Typical Profile

BTF-143-0

Tapered Header-Limitations
Requires a high velocity ratio between the 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.

Tapered Header Turndown 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 4.0 to 1.

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 degrades control accuracy Slice lip bending changes local flow rates. Cross flows cause poor CD-fiber profiles.

Tapered Header : Whats wrong with it?

Tapered Headers have a Very Narrow Sweet Spot.


CD-Pressure Profile in Manifold

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.

Grade Change from 40 to 70 #/3000 Coefficient of Variation : 5.3 # or 13.2 %

Initial CD-Profile - Fiber Orientation : 32 Degrees

Grade change from 40 to 70 #/3000 Coefficient of Variation : 2.7 # or 6.7 %

CD-Profile after 6 Minutes

- Fiber Orientation : 19 Degrees

Grade change from 40 to 70 #/3000

CD-Profile after 20 Minutes

Coefficient of Variation : 0.95 # or 2.37 %

- Fiber Orientation : 7.3 Degrees

Grade change from 40 to 70 #/3000 CD-Profile after 40 Minutes Coefficient of Variation : 0.45 # or 1.12 % - Fiber Orientation : 6.1 Degrees

Typical CD-Profile with Tapered Header

CDP Hydraulic Headbox

CD-Pressure Profile across Inlet Branch Tube Bank

High Performance Hydraulic Headbox:


Grade change from 40 to 70 #/3000

Grade change from 40 to 70 #/3000: Initial CD-Profile Coefficient of Variation : 0.2 # or 0.5%

Fiber Orientation : 3.0 Degrees

Grade change from 40 to 70 #/3000: After 3 5 Minutes Coefficient of Variation : 0.12 # or 0.3%

Fiber Orientation : 3.0 Degrees

CD-Pressure Profile in BTF-Diffuser Bank

Grade change from 40 to 70 #/3000: After 10 Minutes Coefficient of Variation : 0.09 # or 0.22%

Fiber Orientation : 3.0 Degrees

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.

How Does The System Operate?

10 11

Flow Speed (m/s)

The more Changes, the more Micro-Turbulence and Formation/Drainage Improvement. Typical Velocity Changes. Higher Efficiency of Chemicals. 12 Downturn 11 Ratio: 4 to 1 10 9 Velocity 8 Shown is four 7 times lower 6 1
Except for #11, representing the machine speed.
5 4 3 2 1

7 6

5 3 2 4

8
4
3
11

9
6

10

Speed Diagram At Maximum Throughput

8 7

TB

10 11

The Benefits from Secondary Tube Bank: High level of shear forces. Improvement in Formation & Drainage. 12
11 10 9 8 7 6 5 4 3 2 1

6 5 3 4 2

8
4

TB
Secondary Tube Bank
Improving Formation Accelerating Drainage

Flow Speed (m/s)

2
1

3
11 6

7 9

10

Speed Diagram At Maximum Throughput

Presenting: High Performance Hydraulic Headbox-Retrofit For Existing Headboxes.

Typical Installation of a Retrofit with Central Distributor

Equal Hose Length = Equal Flow

Stock Level

Equal Hose Length = Equal Flow

CD-Profile:

Coefficient of Variation : 0.5 % and Lower

Typical CD-Profile with Central Distributor

Central Distributor

Fiber Orientation

Future. Dilution Headbox System will Provide TSO of

3 degrees.
Stronger Strength Properties will be Obtained.

Future TSO: 3 degrees.

Provide Superior Strength Properties in MD and CD (COV, TSO, TSI)


The Dilution Headbox System provides High Micro-Turbulence Level Through the Entire System: Preventing Flocculation Eliminating Twist And Curl Resulting in Flat Sheet Surface Superior Printability.

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.

Automated CD-Profile Control


Scanner Signal Slice Lips: Always Parallel
Traversing Scanner
Backliner Furnish Fil er Furnish Backing Liner Furnish Top Liner Vat #1 Vat #2 Vat #3 Vat #4 Vat #5 Furnish Top Liner Backing Liner Fil er 1 Fil er 2 Fil er 3 Vat #6 Vat #7 Vat #8 Vat #9 Fil er 4 Fil er 5 Fil er 6 Backliner Vat #5 with Consistency Automatic or Manual Basis Weig ht Control

Actuators

Reel

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

Consistency Profiling
Excellent 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

Distributor with Automatic Injection Control on Voith W-Type Headbox

Point of Injection
Injection water is fed into the eye 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.

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 small volume 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.

Headbox + Distributor with Automatic Injection Control


System 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

Results:
Printing and writing, coated base sheet, complete new headbox system with injection control:

CD-Profile Improvement, 85 gsm 2 1.5 1 0.5 0


2-Sigma Coefficient of Variance

Before After

Results:
4-ply Board machine, injection control retrofitted to existing headbox on filler ply:

CD-Profile Improvement 1.4 1.2 1 Before After

2-Sigma

0.8 0.6 0.4 0.2 0 B.W. 230 - 350 gsm B.W. 350 - 550 gsm

More Results: Envelope, Printing & Writing 36


#/3000 at Clariana - Spain
Impro vement o f Co efficient o f Variatio n [%] with B TF-Headbo x Envelo pe, P rinting & Writing - 36# /3000 - 1 640 fpm

2.5 2 1.5 1 0.5 0

With B TF-Headbo x: Reductio n o f CD-P ro file: 65% B efo re Replacement o f Two Ro ll Rectifier Ro ll Headbo x

2.39 1.48 0.52 CD [%] 1.27 0.34 MD [%] 1.39 0.6 Residual [%] 0.86 Total [%]

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

Presenting: The Individual Components of the BTF -System

The Benefits
Improves CD-Profile to approx. 0.1 to 0.5%. Gain in strength allows lower basis weight or low cost furnish. Extremely fast grade changes (few minutes). Uncomplicated instrumentation. Substantial improvement in TSI, TSO, Fiber Orientation, Streaks, Low Formation, Curl, TwoSidedness, etc.

Application: Recommended for all Types and Brands of Existing


Rectifier Roll-, Hydraulic- or Dilution Controlled Headboxes.

The Benefits
Flawless conceptual layout and design. Fiber Orientation is always within few degrees (no need for slice actuator control). Grade changes and recovery time after breaks within minutes. No cross flows inside box or on wire. Downturn Ratio of 4 to 1. Best suitable headbox on the market for multi-grade machines.

The Benefits
Introduction of additional energy provides MORE MICRO-TURBULENCE. Substantial reduction in sheet sealing and stratification. IMPROVED DRAINAGE. Dandy Roll or Top Former can penetrate deeper into sheet, resulting in substantial FORMATION IMPROVEMENT.

CDP Hydraulic Headbox with CD Basis weight Dilution Control

Inlet of Headbox with Branch Tubes

Side view of Headbox

CDP Hydraulic Headbox for Fine paper

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