50 years

Refining Optimization
Maximizing Energy Efficiency
Presented at Heinbach/PaperRun Seminar Paris, June 2005

Sergio Zalewska
Application Manager Pilo S/A - Brazil

50 years

50 years of expertise in pulp and

paper business

Focus on refining systems

More than 2000 installed refiners

Present in 54 countries

Thousands of processes
optimizations

Partnership with Paper Research
Institutes/Universities

50 years

Refining process
Mechanical treatment of the fibers to reach the desired
paper characteristics and strenght.

Not refined fiber mat

Refined fiber mat

50 years

Celullose fiber structure

Cell Walls

Cell walls

Plant cells

Celullose
chains

Fibrills
Microfibrills

Celullose
monomer

50 years

Refining effects
Primary
Primary wall scratch
Secondary wall opening
Water absortion
Fiber cutting
Secondary
Allow hydrogen bridge connection between
fibers
Flexibility through hydratation
Better sheet formation

50 years

How it works





Fibers are collected by the bars

Fiber mat is compressed between rotor and stator
Fibers are relaexed again after have passed through the
bars

50 years

Affecting factors

Refiner

Type
Mechanical conditions
Speed

Installation

Series/Parallel

Process Conditions

Fiber type
Consistency
pH
Flow
Aditives

In order to optimize
the refining process
all these aspects must
be analised

Applied energy

Number of impacts (intensity)

Fillings characteristics :

Bar height/width/space
Cut length
Crossing angle
Dams (flow restrictors)
Fillings material
No Load (pumping action and hydraulic losses)

50 years

Energy applied
8

6
5
km

Breaking Length

Unbleached Pine
Pulp
Bleached
Eucalyptus Pulp

3
2
1
0
100

200
Total Energy
kWh/t

300

50 years

Energy Intensity
Measures the intensity with wich the
energy is applied to the stock
Has big influence on the paper
properties
Each type of fiber has its better
energy intensity to give the better
paper results





Breaking length (km)

7
6
5

0,7 ws/m
1,4 ws/m
3,9 ws/m

4
3
2

mx. recommended intensity

Ws/m

3,5
3

Bleached Sulfate
Pinus
Unbleached
Sulfate Pinus
Bleach Sulfide
Pulp
Unbleached
Sulfide Pulp
Bleached
Eucalyptus

2,5
2
1,5
1
0,5

1
0

0
0

50

100

150

Total energy
kWh/t

200

250

300

20

40

60

SR

80

100

50 years

Energy Intensity
Is affected by:
 Total applied energy
 Size of discs (conical fillings)
 Bar pattern
 Motor speed
 Number of refiners

50 years

Optimized operation conditions

Consistency




Pine (3,0 - 4,0 %)

Eucalyptus (4,0 - 5,0 %)
Low consistency promotes more cutting effect
Higher consistency promotes the fiber/fiber
contacting causing more fibrillation than cutting

4%

60
Nm/g

40
20
0
50

80

kWh/t

pH

Tensile index (Nm/g)

3%

80
70
60
50
40
30
20

pH 5
pH 7
pH 9

20 40 60 80 100 120

Applied energy (kWh/t)

5%

50 years

Optimized operation conditions

Flow and Pressure
 Effect the

process stability
 Keep the fiber mat and centers the rotor between the two stators
 Are dependent on pump and instalation (series/parallel)
 Low flow must be correct using recirculation or parallel
instalation
 Low pressures cause instability of the rotor. Too high pressures
causes uneven wearing.

50 years

Pilo Solutions
For Refiner Improvement

50 years

Bar Pattern Optimization

Paper properties
Better sheet formation
Improve fillings life

Welded Construction

HIGHER BARS

BETTER BREAK RESISTANCE

CONSTANT BAR PATTERN

POSSIBILITY TO MAKE
THINNER BARS

50 years

TriDisc Conversions for DD Refiners

Original Double
Disc System

Pilo TriDisc
System

50 years

TriDisc Conversions for DD Refiners

Features:

Lighter Rotor

Lower No-load

Easier Shaft Movement

Lower Bearing Loads

Less Bolts

More Refining Area

Lower Intensity

Larger Openings

Better Flow Distribution

Balanced Gaps

Advantages

5 - 10% Less Applied HP Required For
Identical Refining Level

Longer Life

Improved Fiber Quality Due To More
Even Stock Distribution

More Uniform Plate Wear

Faster, Easier And Less Frequent
Plate Changes

Resistance To Damage

Will Not Shatter

50 years

TriConic Refiners

50 years

TriConic Refiners
TRIPLE CONE CONCEPT
DUO FLOW

STOCK
OUTLET

STOCK
INLET

SHAFT

STATOR # 1

STATOR # 4
ROTOR # 2 and # 3

BARS

50 years

TriConic Refiners
Application 1 TMP Post-Refiner
CHILE

SECONDARY REFINERS
OLD INSTALLATION

DDR INSTALLATION
1 x DDR 30 - 600HP

CURRENT INSTALLATION

TRICONIC INSTALLATION
1 x Triconic RTC 2000 600 HP

Annual Saving : US$ 425.000

50 years

TriConic Refiners
16,8 g/m 2

Application 2 Tissue (Italy)

Reel
Target
1
2
3
4
5
6
7

Long
kN/m
3,53
4,15
3,60
4,00
3,85
4,08
4,02
4,10

Trans
2,06
2,30
2,20
2,45
2,40
2,19
2,25
2,25

15,5 g/m 2
Reel

Long

Trans

Electrical Savings: 15,3%

Amp
CSF
650
640
640
640
640
600
600
550

525
425
425
425
425
500
500
550

Electrical Savings: 33,3 %

Amp
CSF

kN/m
TARGET

1
2
3
4
5
6
7
8

2,34
3,10
3,75
3,50
3,37
3,45
3,70
3,09
3,57

0,78
1,65
1,90
1,95
1,68
1,47
1,54
1,03
1,46

600
500
500
500
450
450
450
400
400

525
540
540
540
550
550
550
575
575

50 years

TriConic Refiners
Application 3 P&W - Short Fiber Line
Cartiera Della Valtellina (Italy)
3 x DD20 200kW (590kW used)
65 TPD 19 38SR

1 x RTC-1000 315kW (300kW used)

65 TPD 19 35SR