Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.
-
Upload
phoebe-dawson -
Category
Documents
-
view
219 -
download
0
description
Transcript of Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.
![Page 1: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/1.jpg)
Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study
![Page 2: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/2.jpg)
Yash Papers Ltd.• Yash Papers established in the year 1981 and is located in Faizabad,
Uttar Pradesh• We are agro based and use bagasse, wheat straw, gunny bags and a
portion of softwood as a raw material. The production capacity of the plant is 39,100 MT per annum
• We have three MG paper machine with capacity of PM 1- 30 MT/day PM 2- 30 MT/day PM 3- 70 MT/day• We have a Recovery Boiler of 140 MT Dry Solids/day capacity and
Power Plant of 6 MW capacity.• We make specialty and packaging grades of paper.
![Page 3: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/3.jpg)
Objective
To optimize the fiber propertiesTo produce a paper with enhanced fiber
properties and hence value addition to existing product basket
To reduce energy consumption and long fiber consumption & hence reduction in cost of production
![Page 4: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/4.jpg)
Approach
• To achieve better fiber strength properties we modified & optimized our refiner operations
• Installation of online measurement & control systems and automation
• Consistency optimization• Flow Optimization• Different grades of Long Fiber Optimization
![Page 5: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/5.jpg)
TDR Overview
![Page 6: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/6.jpg)
TDR Control Panel
![Page 7: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/7.jpg)
Recirculation0SR 15 20 25 48
Recirculation Time
3.30 hrs. 4 hrs. 5 hrs. 8 hrs.
Cy% 4.2 4.2 4.2 4.2
Burst Factor 16.89 18.38 35.01 40.41
Tear Factor 103.70 137.03 140.86 104.22
Load 21”/17” (Amp)
180/160 180/160 180/160 180/160
![Page 8: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/8.jpg)
Consistency Optimization
![Page 9: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/9.jpg)
Consistency TrialConsistency% 4.5 4.2 3.9 3.5 3.3
Burst Factor 29.4 26 24.4 22.9 35.8
Tear Factor 196.9 185 187.5 191.5 190.4
![Page 10: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/10.jpg)
Observation
• The Burst Factor increased by reducing the consistency of the pulp without affecting other properties
![Page 11: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/11.jpg)
FLOW OPTIMIZATION
![Page 12: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/12.jpg)
Flow@ 3.3% Consistency
• Flow @ 3.3% ConsistencyFlow Initial 20 m3/hr
After 21” Refiner
30 m3/hr After 21” Refiner
40 m3/hr After 21” Refiner
50 m3/hr After 21” Refiner
MT/hr 0.66 0.9 1.3 1.6
0SR 21 20 20 19
Burst Factor 11.8 42.9 39.6 37 35.8
Tear Factor 150.4 173.7 200 168.6 168.1
Refiner load 21”/17” (Amp)
180/160 90/91 120/100 160/155 180/163
Pressure (kg/cm2)
1.1 2.8 2.4 2.1 1.9
![Page 13: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/13.jpg)
Flow@ 3.7% ConsistencyFlow Initial 20 m3/hr
After 21” refiner
30 m3/hr After 21”
refiner
40 m3/hr After 21”
refiner
50 m3/hr After 21”
refiner
MT/hr 0.7 1.1 1.5 1.9
0SR 20 18 17 15
Burst Factor 9.2 36.3 33.8 31 22.9
Tear Factor 101.4 204.7 206.3 191.9 173.2
Refiner load 21”/17” (Amp)
180/160 85/92 120/126 165/136 170/164
Pressure (kg/cm2)
1.2 2.5 2.3 1.9 1.8
![Page 14: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/14.jpg)
Flow @ 3.9% ConsistencyFlow Initial 20 m3/hr
After 21” Refiner
30 m3/hr After 21” Refiner
40 m3/hr After 21” Refiner
50 m3/hr After 21” Refiner
MT/hr 0.8 1.2 1.6 2.0
0SR 18 16 16 15
Burst Factor 9.9 33.1 28.6 27.6 24.4
Tear Factor 91.2 239.4 202.8 187.3 178.5
Refiner load 21”/17” (Amp)
180/160 82/90 107/100 133/125 150/160
Pressure (kg/cm2)
1.1 2.8 2.4 2.1 1.9
![Page 15: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/15.jpg)
Flow @ 4.1% consistencyFlow Initial 20 m3/hr
After 21” Refiner
30 m3/hr After 21” Refiner
40 m3/hr After 21” Refiner
50 m3/hr After 21” Refiner
MT/hr 0.8 1.2 1.6 2.1
0SR 19 18 17 15
Burst Factor 10.7 35.3 34.6 32 26
Tear Factor 105.4 200 192.6 176.2 157.5
Refiner Load 21”/17” (Amp)
180/160 100/104 120/126 130/132 140/137
Pressure (kg/cm2)
1.2 2.4 1.9 1.8 1.5
![Page 16: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/16.jpg)
Flow @ 4.5% ConsistencyFlow Initial 20 m3/hr
After 21” Refiner
30 m3/hr After 21” Refiner
40 m3/hr After 21” Refiner
50 m3/hr After 21” Refiner
MT/hr 0.9 1.4 1.8 2.3
0SR 17 17 16 15
Burst Factor 9.7 31.7 30.3 29.4 25.6
Tear Factor 106.2 191.5 213.3 196.9 154.3
Refiner Load 21”/17” (Amp)
180/160 180/100 120/124 135/137 140/136
Pressure (kg/cm2)
1.1 2.5 2.1 1.8 1.5
![Page 17: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/17.jpg)
Trends
3.3 3.7 3.9 4.1 4.505
101520253035404550
@ 20 m3/hr
3.3 3.7 3.9 4.1 4.505
1015202530354045
@ 30 m3/hr
3.3 3.7 3.9 4.1 4.505
10152025303540
@ 40 m3/hr
3.3 3.7 3.9 4.1 4.505
10152025303540
@ 50 m3/hr
BF
Cy%
BF
Cy%
BF
Cy%
BF
Cy%
![Page 18: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/18.jpg)
Observation
• At any particular consistency, strength property is increasing with reduced flow rate level
• At any particular flow rate, it is observed that with decreasing stock consistency strength properties are better
![Page 19: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/19.jpg)
Grades Selection & optimization of Long Fiber
![Page 20: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/20.jpg)
Burst Factor @ 3.3% ConsistencyFlow (m3/hr) Grade 1 Grade 2 Grade 3
20 44.7 35.2 70.5
30 41.2 33.4 54.8
40 39.0 32.1 53.1
![Page 21: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/21.jpg)
Burst Factor @ 3.9% ConsistencyFlow (m3/hr) Grade 1 Grade 2 Grade 3
20 36.3 32.1 68.4
30 33.9 30.6 50.7
40 32.2 29.6 39.2
![Page 22: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/22.jpg)
Burst Factor @ 4.2% ConsistencyFlow (m3/hr) Grade 1 Grade 2 Grade 3
20 34.0 35.0 66.1
30 36.6 30.6 50.8
40 37.7 28.4 42.5
![Page 23: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/23.jpg)
Trends
20 m3/hr 30m3/hr 40 m3/hr0
10
20
30
40
50
60
70
80
44.6941.23 3936.21 33.41 32.1
70.53
54.76 53.06
At Consistency 3.3%
20 m3/hr 30m3/hr 40 m3/hr0
10
20
30
40
50
60
70
34 36.65 37.7535.0230.56 28.41
66.12
50.8
42.46 Grade 1Grade 2Grade 3
At consistency 4.2%
BFBF
BF
20 m3/hr 30m3/hr 40 m3/hr0
10
20
30
40
50
60
70
80
36.3 33.9 32.232.1 30.6 29.6
68.36
50.74
39.21
At consistency 3.9 %
![Page 24: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/24.jpg)
Observation
• Grade 3 of long fiber shows better strength properties as compared with other two grades
![Page 25: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/25.jpg)
COST BENEFIT
![Page 26: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/26.jpg)
Cost Benefit
• By using Single pass refining we achieved a reduction of 1% long fiber in the papermaking resulting in a saving of Rs. 1.18 crore
• The energy consumption observed decreased in single pass refining as compared to recirculation
• The paper produced through single pass refining shows better strength properties as compared to recirculation
• The paper thus produced added value by increased NSR
![Page 27: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/27.jpg)
Cost Benefit by Softwood ReductionSerial No. Parameters September October
With Circulation Single Pass
1 Softwood 15% 14%
2 Bagasse Tear 42.0 41.6
3 Bagasse Burst Factor
16.07 15.82
4 Savings 15.0-14.0 = 1%
5 Softwood Saving/Month
18 Tons/Month
6 Saving/Year 216 Tons/Year
7 Cost 216*55000 = 1.18 Crore
![Page 28: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/28.jpg)
Running Load Refiner running Load Data
Refiner Current (Amp) Power (Kwhr)
21” 180 109.73
17” 160 97.54
![Page 29: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/29.jpg)
Power SavingSerial No. Particulars Recirculation Single Pass
1 Running Hours 13.25 6.97
2 Batch Size 50 m3 @ 4.2cy%= 2.10 MT
30 m3/hr. @ 3.3 cy%= 0.99 MT
3 Recirculation Time 4 hrs.
4 Net Output 2.14*(13.25/4)= 6.95 MT
0.99*6.97= 6.9 MT
5 Power Consumption/Day (Kw/Day)
2746.32 1444.71
6 Power Consumption/year (Kw/Year)
906285.6 476754.3
7 Power Consumption Saving/Year (Kw)
429531.3
8 Cost Saving (Per Unit Cost-Rs.3)
Rs. 12,88,593
![Page 30: Optimization of Fiber Properties Using Single Pass Refining v/s Recirculation- A Case Study.](https://reader035.fdocuments.net/reader035/viewer/2022062401/5a4d1b5d7f8b9ab0599abc5e/html5/thumbnails/30.jpg)
THANK YOU