WO2000029667A1 - Method for maximizing water removal in a press nip - Google Patents
Method for maximizing water removal in a press nip Download PDFInfo
- Publication number
- WO2000029667A1 WO2000029667A1 PCT/US1999/027097 US9927097W WO0029667A1 WO 2000029667 A1 WO2000029667 A1 WO 2000029667A1 US 9927097 W US9927097 W US 9927097W WO 0029667 A1 WO0029667 A1 WO 0029667A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nip
- pressing unit
- web
- pressure
- less
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 109
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title abstract description 50
- 238000003825 pressing Methods 0.000 claims abstract description 215
- 230000002745 absorbent Effects 0.000 claims abstract description 80
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- 229920002472 Starch Polymers 0.000 description 1
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- ZNNLBTZKUZBEKO-UHFFFAOYSA-N glyburide Chemical compound COC1=CC=C(Cl)C=C1C(=O)NCCC1=CC=C(S(=O)(=O)NC(=O)NC2CCCCC2)C=C1 ZNNLBTZKUZBEKO-UHFFFAOYSA-N 0.000 description 1
- 239000000665 guar gum Substances 0.000 description 1
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- MTNDZQHUAFNZQY-UHFFFAOYSA-N imidazoline Chemical compound C1CN=CN1 MTNDZQHUAFNZQY-UHFFFAOYSA-N 0.000 description 1
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- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
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- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
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- GCLGEJMYGQKIIW-UHFFFAOYSA-H sodium hexametaphosphate Chemical compound [Na]OP1(=O)OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])OP(=O)(O[Na])O1 GCLGEJMYGQKIIW-UHFFFAOYSA-H 0.000 description 1
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Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F3/00—Press section of machines for making continuous webs of paper
- D21F3/02—Wet presses
- D21F3/0209—Wet presses with extended press nip
- D21F3/0218—Shoe presses
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
- D21F11/14—Making cellulose wadding, filter or blotting paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
- D21F11/14—Making cellulose wadding, filter or blotting paper
- D21F11/145—Making cellulose wadding, filter or blotting paper including a through-drying process
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F3/00—Press section of machines for making continuous webs of paper
- D21F3/02—Wet presses
- D21F3/0209—Wet presses with extended press nip
- D21F3/0218—Shoe presses
- D21F3/0227—Belts or sleeves therefor
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F3/00—Press section of machines for making continuous webs of paper
- D21F3/02—Wet presses
- D21F3/0281—Wet presses in combination with a dryer roll
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
- D21F3/00—Press section of machines for making continuous webs of paper
- D21F3/02—Wet presses
- D21F3/029—Wet presses using special water-receiving belts
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H25/00—After-treatment of paper not provided for in groups D21H17/00 - D21H23/00
- D21H25/08—Rearranging applied substances, e.g. metering, smoothing; Removing excess material
- D21H25/12—Rearranging applied substances, e.g. metering, smoothing; Removing excess material with an essentially cylindrical body, e.g. roll or rod
- D21H25/14—Rearranging applied substances, e.g. metering, smoothing; Removing excess material with an essentially cylindrical body, e.g. roll or rod the body being a casting drum, a heated roll or a calender
Definitions
- the invention relates to a method for maximizing water removal from an absorbent paper web in a press nip. More particularly, the present invention relates to the use of a shoe press on the Yankee dryer with a pressure profile that maximizes water removal. Still more particularly, the present invention relates to a method for utilizing a very steep pressure drop at and/or following the exit of a nip curve in order to maximize water removal by minimizing rewet. Finally, the present invention relates to a method for increasing paper machine speed by utilizing a press section that maximizes water removal.
- packaged paper products In modern society, bath tissue, paper towels, facial tissue, and paper napkins (hereinafter referred to as packaged paper products) have been remarkably successfully consumer products. The success of these paper products stems from the ability of manufacturers to consistently enhance product attributes at lower cost and to meet volume demands on a timely basis.
- Packaged paper products offer consumers an array of attributes necessary to such jobs as performing the daily tasks of wiping up spills, personal cleansing, and cleaning household goods.
- paper towels are engineered to be absorbent and strong while wet whereas bath tissue products are expected to be soft to the touch yet strong while in use. Absorbency and softness are inversely related to strength, often making it difficult to obtain the right balance of attributes.
- This patent describes a papermaking scheme for enhancing product quality by avoiding overall web compression and by using a pattern array of densified regions in the xy plane of the sheet to enhance product strength.
- Thicker more absorbent structures can be made using a low batting papermaking felt as described in U.S. Patent No. 4,533,457 by Curran et al., assigned to Scott Paper Company, and incorporated herein by reference in its entirety.
- a more recent method for improving the quality of a through-air-dried sheet is described in U.S. Patent No. 4,440,597 by Wells and Hensler, assigned to Procter and Gamble Company, and incorporated herein by reference in its entirety.
- This patent describes a method for increasing the stretch of a paper web by operating the forming section of a paper machine faster than the through air dryer section of the paper machine. As a result of the speed differential, the paper web is inundated into the through air-dryer- fabric leading to enhanced stretch and absorbency properties in the base sheet and resulting product.
- Fibers and chemicals can be used to enhance the quality of packaged paper products.
- U.S. Patent No. 5,320,710 by Reeves et al., assigned to Fort James Corporation, and incorporated herein by reference in its entirety describes a new furnish combination extracted from the species Funifera of the genus Hesporaloe in the Agavaceae family. This furnish has fibers which are very long and which have very fine-geometrical attributes known to enhance tissue and towei performance.
- U.S. Patent No. 3,755,220 by Freimark and Schaftlein, assigned to Scott Paper Company, and incorporated herein by reference in its entirety describes a debonding scheme for maintaining wet strength while reducing product dry strength-a method known to enhance the handfeel of towel products.
- U.S. Patent No. 5,348,620 by Hermans et al., assigned to Kimberly- Clark Worldwide Inc., and incorporated herein by reference discusses a high consistency/high temperature fiber-treatment-process using a disperser to improve product attributes.
- a disperser to improve product attributes.
- several approaches are available to the papermaker such as using certain species of hardwood like eucalyptus in stratified webs as disclosed in U.S. Patent No. 4,300,981 by Carstens and U.S. Patent No. 3,994,771 by Morgan et al.
- the last two patents are incorporated herein by reference in their entirety. These aforementioned patents describe just a few of the many methods developed over the last thirty years to enhance the quality of packaged paper products.
- gap formers have been developed to enhance sheet drainage ultimately leading to increased machine speed.
- New developments in Yankee hood design and Yankee cylinder design have allowed improvements in heat transfer coefficients and mass transfer coefficients, ultimately leading to enhanced machine speeds.
- New developments in forming fabrics, e.g., multi-layer and triple-layer forming fabrics have resulted in improved drainage, better fabric life, and enhanced fiber support. These factors translate into enhanced machine speed and productivity. Improvements in press felts, e.g.
- the present invention improves the efficiency of known water removal methods by adding one or more pressing units to the production paper machine, in place of or in conjunction with a suction pressure roll.
- Pressure units include those units that physically engage a belt or pressing blanket, which contacts the impression fabric or felt upon which the web travels.
- Formaminous endless fabric as defined in accordance with the present invention includes either an impression fabric or felt.
- Pressing unit as defined in accordance with the present invention includes any press members allowing deformation of the pressing blanket/impression fabric and/or felt/web sandwich to result in asymmetric pressure profiles.
- Pressing units including pressing blankets are generally discussed in the literature as “shoe presses.”
- Pressing units according to the present invention do not include suction pressure rolls since they lead to symmetrical pressure distributions frequently mathematically described by sine or haversine functions.
- Shoe presses have been used to increase water removal at wet presses, ultimately leading to increased machine speed for linerboard grades and more recently, newsprint and fine paper grades.
- the idea of extending the time in a press nip as a means to enhance water removal is not a new idea.
- Nissan in 1954 published a paper in Tappi, Vol. 37, No.12, p.597 (1954) suggesting that the use of extended time in a press nip would enhance the water removal performance of a press.
- a wide shoe press as described in the literature is essentially a controlled crown roll with a flexible shell and a concave shoe hydrodynamically loaded against each other.
- the belt or blanket is usually a fabric reinforced polyurethane-coated structure that can be grooved or blind drilled for more efficient water removal.
- the inside of the belt is generally lubricated with oil, which develops a hydrodynamic film as it passes over the shoe and reduces wear/friction in both surfaces.
- Wide shoe press nips are on average 5 to 10 times longer than conventional roll press nips (generally, 5" - 10" versus 1" - 2"). Water deflectors (not shown) on the outside surface will dewater the blanket.
- Yankee dryers are loaded with suction pressure rolls to remove water from the tissue web and attach the web to the dryer for further processing by the creping operation.
- the pressure distribution in the suction pressure roll nip is symmetrical in shape and is described mathematically by a sine or a haversine curve.
- Suction pressure rolls loaded to a Yankee dryer are
- the loading cylinders are located at each end of the pressure roll, profiling
- the typical peak pressure is on the order of 1700 kN/m as Figure 3 demonstrates. Since the press nip for low weight tissue and towel grades is pressure controlled, the very low peak pressure could cause a decrease in
- Ampulski et al. achieves this extended nip length through the use of a shoe press. Ampulski et al., like all previous users of shoe presses, fails to consider the use of increased peak pressure.
- dwell times in an extended nip press serve to density the sheet beyond that experienced by conventional tissue wet pressing methods.
- Friedbaurer overcome the increased density due to extended nip pressing by incorporating modified resilient fibers (e.g., chemically cross-linked cellulosic fibers) in the web and by wet micro-shaping the web. They also disclose shoe lengths typically in the range of 5 to 10 inches. Like Ampulski et al., Hermans and Friedbaurer do not consider critical peak pressures or line loads
- the '384 patent describes the use of a shoe press preceding or contacting a Yankee drying cylinder.
- the shoe press is used in conjunction with an impermeable belt to reduce remoistening of the sheet by the felt.
- presses are suited essentially for drying thick, heavy webs, since they
- the second nip is a shoe press nip.
- the criticality of pressure distribution shape and peak pressure/line load magnitudes are not disclosed in the '092 patent. In the September 1997 article W. Schuwerk, "Shoe Presses and
- Steiner et al. also discloses that the joint path of travel of the paper web, felt, and blanket can be made substantially shorter than prior art.
- the joint travel of the felt, web, and blanket can be made equal to zero, i.e., the web can detach itself from the felt directly at the emergence from the press nip.
- Steiner et al. does not address low line loads and high peak pressures needed for optimum shoe press
- Escher Wyss and incorporated herein by reference describes a process for
- the heated pressing arrangement can be a shoe press.
- Crouse et al. found that by application of pressure for an increased period of time, the
- WO 97/16593 by Wedel and Worcester discloses an impulse drying method for tissue structures using a
- the present inventors unexpectedly discovered that good sheet dewatering and appropriate bulk/strength properties for low weight absorbent products could be attained with this pressure optimized shoe press.
- the optimized pressure conditions can be achieved according to the present
- the pressing unit being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of less than about 240 kN/m.
- An apparatus for forming an absorbent paper sheet product comprising: a moving foraminous endless fabric;
- a pressing unit engaging the pressing blanket adapted to urge the nascent web for the absorbent paper sheet on the foraminous endless fabric into engagement with the Yankee drying cylinder thereby forming a nip
- the pressing unit being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of less than about 240 kN/m, the pressing unit being configured to disengage the web from the foraminous endless fabric such that rewet of the nascent web by the foraminous endless fabric is less than about 50% of the rewet predicted by the Sweet equations based upon the properties of the foraminous endless
- a pressing unit engaging the pressing blanket adapted to urge the
- pressing unit being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of less than about 240 kN/m,
- the pressing unit being configured to both disengage the web from the foraminous endless fabric and disengage the foraminous endless fabric from the pressing blanket at a nip length of less than about one inch from the point the nip pressure reaches zero.
- a pressing unit engaging the pressing blanket adapted to urge the nascent web for the absorbent paper sheet on the foraminous endless fabric into engagement with the transfer cylinder thereby forming a nip, the pressing unit being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of less than about 240 kN/m.
- a moving endless pressing blanket adapted to urge the nascent web for the absorbent paper sheet on the foraminous endless fabric into engagement with the transfer cylinder thereby forming a nip, the pressing unit being configured to create a peak engagement pressure of at least about
- a nascent web for the absorbent paper sheet on the foraminous endless fabric means for depositing a nascent web for the absorbent paper sheet on the foraminous endless fabric; a moving endless pressing blanket; a backing roll; and a pressing unit engaging the pressing blanket adapted to urge the nascent web for the absorbent paper sheet on the foraminous endless fabric
- the pressing unit being configured to create a peak engagement pressure of at least about
- a method of making an absorbent paper sheet product comprising:
- the moving foraminous endless fabric and contacting the moving foraminous endless fabric bearing the deposited nascent web with a moving endless pressing blanket engaged with a pressing unit thereby forming a nip, the pressing unit being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of
- a method of making an absorbent paper sheet product comprising:
- a method of making an absorbent paper sheet product comprising:
- nascent web with a shoe press thereby forming a nip between the shoe press and a Yankee drying cylinder, the shoe press being configured to create a peak engagement pressure of at least about 2000 kN/m 2 at an overall line load of less than about 240 kN/m; disengaging the web from the foraminous endless fabric in the nip onto
- Figure 1 illustrates a side view of a typical stand alone shoe press.
- Figure 2 illustrates the relationship between peak pressure and line load for a variety of shoe press arrangements found in the literature, as well as for Yankee suction pressure rolls.
- Figure 3 illustrates nip pressure profiles for a suction pressure roll
- FIG 4 illustrates one conventional wet press processing apparatus.
- FIG. 5 illustrates one conventional through-air-drying processing
- Figure 6 illustrates a typical pressure profile in the nip of a suction
- Figure 7 illustrates a pressure profile in the nip of a shoe press.
- Figure 8 illustrates a preferred pressure profile in the nip of a shoe press where the negative pressure corresponds to the vacuum level in the
- Figure 9 illustrates a shoe press with a large diameter transfer cylinder
- Figure 10 illustrates a tapered shoe in a shoe press with a large diameter transfer cylinder where the felt is rapidly separated from the web but
- Figure 11 illustrates a tapered shoe in a shoe press with a large diameter transfer cylinder where the felt is simultaneously stripped from the sheet and from the pressing blanket on the exit side of the nip.
- Figure 12 shows a plot of cold Yankee press solids versus line loading for a conventional 120 mm shoe, for a 50 mm shoe made according to the present invention, and for a suction pressure roll.
- Figure 13 illustrates a side view of a typical stand alone shoe press
- Figure 14 illustrates a blind drilled blanket or belt.
- Figure 15 illustrates a grooved blanket or belt.
- the present invention improves paper web moisture removal through the controlled use of a pressing unit in conjunction with a backing roll and/or a transfer cylinder or Yankee drying cylinder.
- An absorbent paper web as defined herein includes bath tissue, paper towels, paper napkins, wipers, and facial tissue. The basis weight of such products and their base sheets
- absorbent paper may be produced
- papermaking methods are (I) conventional wet pressing (CWP) and (II)
- TAD through-air-drying
- a furnish is fed by means not shown through conduits (40, 41 ) to headbox chambers (20, 20').
- a web (W) is formed on a conventional wire former on fabric (12), supported by rolls (18, 19), from a
- conduit (24) The web is then transferred to a moving felt (14), supported by roll (11 ) for pressing and drying. Materials removed from
- Liquid adhesive may be applied to the surface of the
- web is then usually passed between calender rollers (not shown) and rolled up on reel (28) prior to further converting operations, for example, embossing.
- a web may alternatively be subjected to vacuum deformation on an
- impression fabric alone or in conjunction with other physical deformation
- TAD process through- air-drying process
- the web is carried along forming fabric (30) until it is transferred to a TAD fabric (70) at junction (80) by means of a vacuum pickup shoe (90).
- the web is further dewatered at dewatering box (100) to increase web solids. Besides removing water from the web, vacuum pickup shoe (90) and
- dewatering box (100) inundate the web into TAD fabric (70) causing bulk and absorbency improvements.
- the web is then carried on TAD fabric (70) to drying unit (110) where heated air is passed through both the web and the fabric to increase the solids content of the web.
- drying unit (110) where heated air is passed through both the web and the fabric to increase the solids content of the web.
- the web is 30 to 95% dry after exiting drying unit (110).
- the web may be removed directly from TAD fabric (70) in an uncreped state.
- creped web is then usually passed between calender rollers (160) and rolled
- an absorbent paper web can be made by dispersing fibers into aqueous slurry and depositing the aqueous
- any art recognized forming scheme might be used.
- an extensive but non- exhaustive list includes a crescent former, a C-wrap twin wire former, an S- wrap twin wire former, a suction breast roll former, a fourdrinier former, or any
- the forming fabric can be any material that is critical to the success of the present invention.
- the forming fabric can be any material that is not critical to the success of the present invention.
- the forming fabric can be any material that is not critical to the success of the present invention.
- One forming fabric found particularly
- present invention include cellulosic fibers commonly referred to as wood pulp
- Fibers liberated in the pulping process from softwood (gymnosperms or coniferous trees) and hardwoods (angiosperms or deciduous trees).
- Cellulosic fibers from diverse material origins may be used to form the web of
- These fibers include non-woody fibers liberated from
- sugar cane bagasse, sabai grass, rice straw, banana leaves, paper mulberry (i.e., bast fiber), abaca leaves, pineapple leaves, esparto grass leaves, and fibers from the genus Hesperaloe in the family Agavaceae. Also recycled
- Suitable fibers are
- Papermaking fibers can be liberated from their source material by any one of the number of chemical pulping processes familiar to one experienced in the art including sulfate, sulfite, polysulfide, soda pulping, etc.
- the pulp can be bleached if desired by chemical means including the use of chlorine,
- papermaking fibers can be liberated from source material by any one of a number of
- thermomechanical pulping These mechanical pulps can be bleached, if
- the suspension of fibers or furnish may contain chemical additives to alter the physical properties of the paper produced. These chemistries are well understood by the skilled artisan and may be used in any known
- the pulp can be mixed with strength adjusting agents such as wet
- urea-formaldehyde resins melamine formaldehyde resins, glyoxylated polyacrylamide resins, polyamide-epichlorhydrin resins and the like.
- Thermosetting polyacrylamides are produced by reacting acrylamide with
- DMAC diallyl dimethyl ammonium chloride
- dialdehydes can be substituted for glyoxal to produce thermosetting wet
- polyamide-epichlorhydrin resins an example of which is sold under the tradenames Kymene 557LX and Kymene 557H by Hercules Incorporated of Wilmington, Delaware and CASCAMID® from Borden Chemical Inc. These resins and the process for
- the pulp when making towel grades according to the present invention, preferably contains up to about 30 lbs/ton, more preferably from 10 to 20 lbs/ton of wet strength aids. Wet strength resins are not normally added
- carboxymethyl cellulose includes starch, guar gum, polyacrylamides, carboxymethyl cellulose and the like. Of particular utility is carboxymethyl cellulose, an example of which is
- the pulp preferably contains from 0 to10 lbs/ton, more preferably from 1 to 5 lbs/ton of dry strength aid.
- debonders will be readily apparent to the skilled artisan. Debonders or softeners may also be incorporated into the pulp or sprayed
- the pulp preferably contains from 0 to 10 lbs/ton, more preferably from 1 to 5 lbs/ton of debonder/softener.
- the present invention may be used with a particular class of softener materials - amido amine salts derived from partially acid neutralized amines.
- Quasoft 202-JR is a suitable softener material, which may be derived by alkylating a condensation product of oleic acid and diethylenetriamine.
- non-ethylated species result in a mixture consisting of cationic ethyiated and cationic non-ethylated species.
- a minor proportion (e.g., about 10%) of the resulting amido amine cyclize to imidazoline compounds. Since only the imidazoline portions of these material are quaternary ammonium compounds,
- compositions as a whole are pH-sensitive. Therefore, in the practice of the present invention with this class of chemicals, the pH in the headbox
- Quaternary ammonium compounds such as dialkyl dimethyl quaternary ammonium salts are also suitable particularly when the alkyl
- Biodegradable softeners can be utilized. Representative biodegradable cationic softeners/debonders are disclosed in U.S. Patent Nos.
- the fibrous web is then either deposited on an impression drying
- impression fabrics would include plain weave fabrics described in U.S. Patent No. 3,301 ,746; semitwill fabrics described in U.S. Patent Nos. 3,974,025 and 3,905,863; bilateraily- staggered-wicker-basket-cavity type fabrics described in U.S. Patent Nos.
- felts can have double- layer base weaves, triple-layer base weaves, or laminated base weaves.
- Preferred felts according to the present invention are those having the laminated base weave design.
- a wet-press-felt found particularly useful with the present invention is AMFIex 3 made by Appleton Mills Corporation.
- Non- exhaustive background art in the press felt area includes U.S. Patent Nos. 5,657,797; 5,368,696; 4,973,512; 5,023,132; 5,225,269; 5,182,164;
- web/foraminous fabric sandwich is contacted with a pressing blanket engaged with a pressing unit, one embodiment in the art referred to as a shoe press.
- the web/foraminous fabric sandwich is preferably contacted with the pressing blanket engaged with a pressing unit after the web has reached a solids content of at least about
- the pressing unit including a pressing blanket according to the present invention can have any art-recognized configuration.
- the nip can be created
- backing roil refers to a roll that contacts the web but does not remove the fibrous web from the carrier fabric or felt.
- Backing rolls for use according to the present invention may be
- the backing roll can be made of hard rubber or metal.
- the rolls are heated with an induction heater
- the roll is preferably constructed or coated with high diffusivity material, such as copper, to aid in increasing
- transfer cylinder refers to a roll that
- cylinders according to the present invention can include a steel roll, a metal coated roll, a granite roll, a Yankee drying cylinder, and a gas fired drying cylinder.
- Transfer cylinders for use according to the present method may be heated or cold.
- the transfer cylinder is heated with an induction heater the cylinder is preferably constructed or coated with high diffusivity material, such as copper, to aid in increasing heat transfer.
- high diffusivity material such as copper
- Heat is preferably applied to the transfer cylinder and/or backing roll.
- Heat can be applied by any art-known scheme including induction heating, oil heating and steam heating. Commercial available induction heaters can be used to heat any art-known scheme including induction heating, oil heating and steam heating. Commercial available induction heaters can be used to heat any art-known scheme. Commercial available induction heaters can be used to heat any art-known scheme. Commercial available induction heaters can be used to heat any art-known scheme. Commercial available induction heaters can be used to heat any art-known scheme including induction heating, oil heating and steam heating. Commercial available induction heaters can be used to any art-known scheme. Commercial available induction heaters can be used to heat.
- Backing roll or transfer cylinder temperature can be anywhere from ambient to 700 ° F but are more preferably from 180 ° F to
- Preferred heating schemes according to the present invention are induction heating and steam-heating. Increased temperature in the backing roll or transfer cylinder
- the pressing unit including a pressing blanket according to the
- a shoe press includes a shoe element(s), which is pressed against the backing roll or transfer cylinder.
- the shoe element is loaded hydrodynamically against the backing roll or transfer
- a pressing belt or blanket traverses the shoe press nip with the fibrous web in contact with the foraminous fabric. Pressing blankets can be smooth, or to enhance water removal at the press they can be grooved or blind drilled. Conventional pressing blanket designs contain a fabric coated with polyurethane where the fabric is used as reinforcement. Other pressing blanket designs use yarns embedded in the polyurethane to provide reinforcement.
- One preferred pressing blanket according to the present invention is a yarn reinforced blanket design under the tradename QualiFlex B, which is supplied by Voith Sulzer Corporation.
- the shoe element length can be less than about 7 inches but is more preferably less than about 3 inches for the present invention. According to the present invention the shoe element will also be referred to as a hydraulic
- Shoe designs can be hydrodynamic, hydrodynamic
- the hydrodynamic pocket design incorporates a machined full width pocket in the shoe used for emptying the oil in the pressurized zone of the shoe.
- the final design is the hydrostatic design where oil is fed into the center region of the shoe.
- the preferred shoe design according to the present invention is hydrodynamic.
- Shoe presses for use according to the present invention can be open
- the peak pressure in the shoe press is preferably greater than about 2000 kN/m 2 , with a line load of preferably less than about 240 kN/m.
- the peak pressure is preferably greater than about 2000 kN/m 2 , while the line load is
- kN/m is an abbreviation for
- kilonewtons per meter and kN/m 2 is an abbreviation for kilonewtons per
- the sheet can be creped from the transfer cylinder by any art- recognized methods using any art recognized creping aid.
- the maximum line load a current standard Yankee can sustain is on the order of 100kN/m.
- the Yankee needs to be precisely crowned at the prevailing load to obtain a uniform nip. This procedure is necessary due to the inflexibility of
- Figure 6 shows a schematic sketch of a typical pressure distribution curve for a suction pressure roll described by symmetrical mathematical functions like the sine and haversine curves. Since the nip pressure is
- Figure 7 shows a schematic sketch of a pressure distribution curve for a shoe press with a steep drop off where the felt is stripped from the sheet and
- Figure 8 shows a schematic sketch of a pressure distribution curve for a shoe press with a steeper drop off and where suction occurs in the felt at the point of simultaneous separation of the felt, sheet, and blanket when the nip pressure reaches about zero.
- the negative pressure in the felt, when the blanket and felt are stripped apart, is caused by capillary forces and should aid in holding water in the felt and should help further
- Figure 9 is a schematic sketch of a shoe press nip showing sheet, felt, and blanket. Point A in Figure 9 is the point of zero pressure on
- K p K 0 + R/W
- K p is the moisture ratio of the paper after the wet press in grams
- R is the magnitude of the rewet of paper in g/m 2 and corresponds to the slope of the straight line used to fit moisture ratio versus
- Sweet plot frequently referred to in the literature as a Sweet plot.
- the original work can be found in Sweet, J.S., Pulp and Paper Mag. Can., 62, No. 7: T267 (1961 ) and a review article can be found in Heller, H., MacGregor, M., and Bliesner,
- Rewet has been estimated to be from 5 to 50 g/m 2 of water, depending on the
- Rewet for a conventional shoe press can be determined from the above equation.
- the amount of rewet for the optimum shoe press is preferably less than about 50 % of the amount determined from Sweet's
- Rewet is preferably from 0 to
- a pressing felt wraps the blanket and, therefore, pulls away quickly from the sheet reducing the time for possible rewetting.
- This design can be achieved by altering the take-away angle of the felt from the nip and tapering the exit side of the shoe.
- the blanket diameter can be reduced; the blanket can be eccentrically arranged with respects to the press plane; or a roll (not shown in Figure 10) positioned against the blanket can deflect the belt
- FIG. 11 shows another embodiment according to the present
- FIG 11 a schematic sketch of a shoe press showing a sheet, felt, and blanket is displayed. This shoe press utilizes a very steep pressure
- the press can control the tension level on the felt.
- the objective of this embodiment according to the present invention is to affect the transfer of the sheet from the felt at the same time that the negative pulse caused by the separation of the felt and blanket occurs. This design not only minimizes the
- Point A in Figure 11 is the point of zero pressure on the pressure
- the web is preferably either adhered to the Yankee dryer by nip
- the web is dried by steam and hot air
- any suitable art recognized adhesive might be used on the Yankee dryer.
- Preferred adhesives include poiyvinyl alcohol with suitable plasticizers, glyoxylated polyacrylamide with or without poiyvinyl alcohol, and polyamide epichlorohydrin resins such as Quacoat A-252 (QA252),
- Betzcreplus 97 (Betz+97) and Calgon 675 B.
- Suitable adhesives are widely described in the patent literature. A comprehensive but non-exhaustive list
- the final product may be calendered or uncalendered and is usually
- the products according to the present invention may be subjected to any art recognized converting operations, including embossing, printing, etc.
- a nascent web was formed on a Crescent-forming machine using a
- the basis weight of the sheet on the Yankee dryer was 8.5 lbs/3000 ft 2 .
- the sheet was pressed onto a Yankee dryer with a suction
- the vacuum in the suction roll was nominally 0.22 bar.
- the suction pressure roll was replaced by a
- the sheet was conditioned before the shoe press with a suction turning roll having the same size and open area as the suction pressure roll.
- the suction turning roll vacuum was nominally equivalent to the level used during the suction pressure roll experiments.
- the web was pressed onto the Yankee with a shoe press.
- a shoe press In order to obtain precise sheet solids data after the shoe press or the suction
- Figure 12 depicts a plot of sheet solids versus line loading.
- the typical 120 mm shoe shows no solids benefit versus the suction pressure roll at present operating iine load limits of current Yankee dryers (i.e., approximately, 87.5 kN/m), while the 50 mm pressure optimized shoe press shows an advantage of several
- Figures 13-15 illustrate a method for maximizing water removal in a press nip in accordance with another embodiment of the present invention.
- the present embodiment involves a conventional wet pressing (CWP)
- the present embodiment uses a shoe press, preferably a controlled crown roll with a flexible shell and a concave shoe
- the present embodiment further includes a belt or blanket (100) having a void volume that enhances
- void volume can be achieved by a number of blanket configurations, including, but not limited to, those made by grooving, blind drilling and the like.
- the total void volume of the belt or blanket for use according to the present invention is preferably about 50 to about 3000 cm 3 /m 2 , more preferably about 100 to about 1000 cm 3 /m 2 , most preferably from about 200 to about 500 cm 3 /m 3 .
- Blankets for use according to the present invention can include any art
- blankets disclosed by E.J. Justus and D. Cronin in Tappi disclose blankets disclosed by E.J. Justus and D. Cronin in Tappi.
- the groove width is about 0.01 to about 0.03 in.
- the land width is about 2 to about 20 times the groove width and the groove depth is about 2 to about
- the belts include groove widths of about 0.5 to about 1 mm and a void volume of about 100 cc/m 2 to about 500 cc/m 2 .
- blankets disclosed by P. Slater and K. Fitzpatrick in the 84 th Annual Meeting of the Technical Section, CPPA, January 1998 which is incorporated herein by reference, include grooved belts that provide a press dryness about 1 % to about 3% greater than the press dryness obtained with a similar smooth belt.
- the belts have groove widths of about 0.58 to about 0.79 mm and a void volume of about 200 cc/m 2
- grooved belts that provide a press dryness about 1 % greater than the dryness obtained with a blind drilled belt.
- the grooved belt has an open area of about a 20.3% and a void volume of about 260 cc/m 2 ,
- the blind drilled belt has an open area of about 21 % and a void volume of
- blind drilling involves drilling holes into a smooth blanket, as will be understood by one of skill in the art.
- the blind drilled blanket preferably has a plurality of holes sequentially
- the blind drilled blanket can take a variety of configurations.
- the hole depth, hole diameter, hole spacing, hole angle, hole geometry, row spacing and/or row pattern can be varied.
- the hole depth can range from about 0.2 to about 10 mm, more preferably about 0.5 to about 5 mm, most preferably from about 0.5 to
- the hole depth can extend partially or completely through
- the hole diameter can range from about 0.2 to about 10 mm, more preferably about 0.5 to about 5 mm, most preferably from about 1 to about 3
- the hole spacing can range from about 1 to about 20 mm between
- the hole angle (i.e., the angle measured from the surface of the belt material counterclockwise to the side of the hole) can range from about 45 to about 135 degrees along any wall in either the machine or cross-machine, more preferably about 70 to about 110 degrees, most preferably from about
- the row spacing can range from about 1 to about 20 mm, more
- the hole geometry can be curved, linear or curvilinear, e.g. round,
- square, elliptical, polygonal, and the row pattern can be such that the holes in each row are aligned in the cross-machine direction, offset in the cross- machine direction, aligned in the machine direction, offset in the machine
- each of the holes can have a different configuration, or one or more individual or set of holes can have the same configuration as one or more
- hole pattern form any type of geometric or other pattern, for example, the pattern can be random.
- Nip compression of the grooved blanket and the press felt causes a hydraulic pressure gradient in the machine direction, which improves water flow and removal.
- the grooved blanket preferably has a plurality of grooved sections sequentially arranged in the cross-machine direction that circumscribe the blanket to cause machine direction water movement.
- the grooved blanket can take a variety of configurations. For example, the groove depth, groove
- the groove depth can range from about 0.1 to about 8 mm, more preferably about 0.2 to about 5 mm, most preferably from about
- the groove width can range from about 0.1 to about 6 mm, more preferably about 0.2 to about 4 mm, most preferably from about 0.4 to about 3
- the groove bevel (i.e., the angle measured from the surface of the belt material counterclockwise to the side of the groove minus 90°) can range from about 0 to about 45°, more preferably about 0 to about 30°, most preferably from about 0 to about 20°.
- the groove angle can range from about 45 to about 135 degrees (with 90 degrees being orthogonal to the cross-machine direction), more preferably
- the land width can range from about 0.2 to about 25 mm, more
- the open area can range up to 80% of the total blanket area, more preferably about 15 to about 50%, most preferably from about 20 to about
- the groove pattern can be such that the grooves in each row are
- grooves need not have the same configuration, rather, all the grooves can have a different configuration
- one or more individual or set of grooves can have the same configuration as one or more other individual or set of grooves. Further, there is no
- the groove pattern form any type of geometric or other pattern, for example, the groove placement can also be random.
- Blankets having the disclosed void volume will be readily apparent to the skilled artisan. Such blankets can include any physical arrangement as long as the void space requirements are satisfied. Blankets for use in the
- present invention may be manufactured by any art recognized process, including but not limited to, casting molding, laser engraving, etc.
- EXAMPLE 2 A punch press was used to perform dewatering experiments with different belt structures. An AMFIex 3S felt manufactured by Appleton Mills Corporation was used to dewater the paper web. The web basis weight was
- Web moisture was controlled to 19.3% dryness by rewetting moist webs using a water spray. The webs were
- a smooth belt, a blind drilled belt and a grooved belt were used in the
- the blind drilled belt had a bore area of 3.82 mm 2 ,
- the grooved belt had a groove width of 0.66 mm, a groove depth of
- the punch press was operated such that the average nip pressure was
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
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EP99960375A EP1047830A1 (en) | 1998-11-13 | 1999-11-12 | Method for maximizing water removal in a press nip |
CA002317438A CA2317438C (en) | 1998-11-13 | 1999-11-12 | Method for maximizing water removal in a press nip |
US10/376,319 US7300552B2 (en) | 1998-11-13 | 2003-03-03 | Method for maximizing water removal in a press nip |
US11/874,251 US7754049B2 (en) | 1998-11-13 | 2007-10-18 | Method for maximizing water removal in a press nip |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/191,376 US6248210B1 (en) | 1998-11-13 | 1998-11-13 | Method for maximizing water removal in a press nip |
US09/191,376 | 1998-11-13 |
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US09/191,376 Continuation-In-Part US6248210B1 (en) | 1998-11-13 | 1998-11-13 | Method for maximizing water removal in a press nip |
US09/439,610 Continuation-In-Part US6387217B1 (en) | 1998-11-13 | 1999-11-12 | Apparatus for maximizing water removal in a press nip |
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WO2000029667A1 true WO2000029667A1 (en) | 2000-05-25 |
WO2000029667A9 WO2000029667A9 (en) | 2000-11-02 |
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PCT/US1999/027097 WO2000029667A1 (en) | 1998-11-13 | 1999-11-12 | Method for maximizing water removal in a press nip |
Country Status (5)
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US (7) | US6248210B1 (en) |
EP (1) | EP1047830A1 (en) |
CA (1) | CA2317438C (en) |
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WO (1) | WO2000029667A1 (en) |
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US6413363B1 (en) * | 2000-06-30 | 2002-07-02 | Kimberly-Clark Worldwide, Inc. | Method of making absorbent tissue from recycled waste paper |
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DE10129613A1 (en) * | 2001-06-20 | 2003-01-02 | Voith Paper Patent Gmbh | Method and device for producing a fibrous web provided with a three-dimensional surface structure |
DE10130038A1 (en) * | 2001-06-21 | 2003-01-02 | Voith Paper Patent Gmbh | Method and machine for producing a fibrous web |
US6797114B2 (en) * | 2001-12-19 | 2004-09-28 | Kimberly-Clark Worldwide, Inc. | Tissue products |
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Also Published As
Publication number | Publication date |
---|---|
US20020088595A1 (en) | 2002-07-11 |
US20020088594A1 (en) | 2002-07-11 |
US6387217B1 (en) | 2002-05-14 |
US7754049B2 (en) | 2010-07-13 |
CA2317438A1 (en) | 2000-05-25 |
TR200002032T1 (en) | 2001-01-22 |
US6458248B1 (en) | 2002-10-01 |
WO2000029667A9 (en) | 2000-11-02 |
US6517672B2 (en) | 2003-02-11 |
US20030226650A1 (en) | 2003-12-11 |
US6248210B1 (en) | 2001-06-19 |
US20080035289A1 (en) | 2008-02-14 |
CA2317438C (en) | 2008-10-28 |
EP1047830A1 (en) | 2000-11-02 |
US7300552B2 (en) | 2007-11-27 |
US6669821B2 (en) | 2003-12-30 |
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