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89 A Formingfabricsdrainageratesandpaperproperties
89 A Formingfabricsdrainageratesandpaperproperties
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Figure 2: Paper forming described as Boundary Layer BWt , mean3 basis weight (gsm).
Filtration process [7].
Equation 1 was derived from studies where the vacuum
Hence, the final position of the fibres is significantly application was held constant and only one type of forming
influenced by the boundary layer shear at the wire [7]. fabric was used. It is anticipated that this model might be
Thus the drainage rate and wire structure, including expanded to include a characterisation of the de-watering
permeability and smoothness, are expected to be important process, a “drainage number”, Dr such that:
factors in determining the extent to which the boundary NFI = k NFI Cr e1 Fr e2 Fa e3 Dr e4 Eq. 3
layer acts on fibres. where,
Dr, Drainage number,
The key process variables of paper forming that have been kNFI, constant, (gsm0.5),
identified to date are shown in Figure 3. e1-4, exponents for each dimensionless group.
MD The Dr might be expected to be a function of the forming
P1 fibre l
air fabrics mesh design (e.g. hole size, number) and process
z
c suspension d conditions (e.g. DP).
v h
DP = P2 - P1 The fibre orientation of the sheets formed on the UoM
laboratory former have not been correlated with process
wire conditions due to various problems associated with the
P2
testing and measurement of different basis weight sheets as
discussed in [8].
Figure 3. Flow Field Characterisation of Forming:
Time dependent point analysis in the MD-CD plane
viewed in the z-MD plane, (the point of interest is APPARATUS & PROCEDURE
represented by the dashed vertical line) [11].
UoM Sheet Former.
It has been possible to develop an empirical model for The principal components of the UoM former are shown in
predicting formation from combining these key process Figure 4.
variables into dimensionless groups [11]. The formation
(NFI) of the sheets formed on the model Fourdrinier from
three different pulps (one long fibre and two short fibre)
Head
were found to correlate well (R2= 0.94) with these groups Tank
according to Equation 1:
GV1 V1 Distributor
Self Supporting
Headbox
0.6 -0.18 -0.13 Flow Receiver
NFI = k ´ Cr Fr Fa Eq. 1 (with wall ext.)
V3
V4
for 10 < Cr < 60, 1 < Fr < 5, 3 < Fa < 15, and k~ 0.2
Receiver
gsm0.5, with, Tank
p cl 2 v2 h Vacuum
V2
Cr = , Fr = , Fa = , Pump
Reservoir
Vacuum Vessel
6d gh l (with falling plate)
where,
Cr, crowding number,
Fr, Froude number, Figure 4. Schematic diagram of the basic components
Fa, aspect ratio of flow depth to fibre length, and the configuration of the laboratory former.
c, consistency (g/l),
l, characteristic mean fibre length (mm),
d, fibre coarseness, (mg/m). 2
g, gravitational acceleration, (m/s2). I.e. jet to wire difference
3
Over bar denotes mean.
4
The fibre properties (l =1 mm, d = 10 mg/100m) were
assumed to calculate the Cr and Fa for Eq 4. The fibres
were not modified during the experiment and so this
5
assumption does not affect the trend shown in Figure13. Also referred to as the standard formation number [7].
12
10
Depth (mm)
8
4
h(h54) = -0.0003t2 - 0.1099t - 0.0199
2 R2 = 1
0
-250 -200 -150 -100 -50 0
Figure 6: Typical FOI images a). topside, and b). wire Tim e (m s)
side, (sheet 11092001-04).
Figure 8: Drainage curves for fabric 540
12
RESULTS & DISCUSSION
The initial stock velocity was maintained well into the 10
forming process and then decreased rapidly during the final
Depth (mm)
6
I.e. the fabric often drainage very quickly for the first
sheet formed due to its extreme cleanliness and dryness.
Vz late (m/s)
0.08
wire (i.e. 0.52 m/s).
The fines retention of the fabrics was different due to the 0.07
different porous structures of the fabrics7 and the average
white water consistency8 is shown in Figure 10.
0.06
The properties of the sheets was affected by the fabrics h34 h54 hO3 h28 h12 h61 All
drainage behaviour and the properties of the sheets formed 1.10
for each fabric are summarised in Table A1 (Appendix A).
The de-watering process was separated into an early (h > 1.05
9mm) and late (8mm > h > 0mm) drainage velocity to
investigate the effect of de-watering rate on the two 1.00
sidedness and formation of sheets. The interaction between
NFI (gsm 0.5)
0.95
the structural characteristics of the forming fabric and the
de-watering behaviour it exhibited was complex, see 0.90
Figure 11. Simple measures of permeability (e.g. surface
open area) are potentially misleading as for example the 0.85
geometry, size, and number of holes (per area) in the fabric
are all important in determining the drainage rate. Hence, 0.80
the effect of fabric design on sheet structure has first been
considered in terms of the drainage rates observed. 0.75
0.05 0.06 0.07 0.08 0.09 0.1 0.11
Vz late (m /s)
The importance of the late drainage velocity was more It was initially thought the wire side anisotropy would be
evident when the modified formation was used, as shown affected by the early drainage rate however this didn’t
in Figure 13. appear to be so, see Figure 15. The most probable
explanation for this observation is the de-watering rate
being slow enough to allow most fibres to align in the MD.
h34 h54 hO3 h28 h12 h61 All
1.10
h34 h54 hO3 h28 h12 h61 All
1.05 0.80
1.00
0.75
Wireside Anisotropy
0.95
NFI*
y = 5.5714x + 0.4848
R2 = 0.8178 0.70
0.90
0.85 0.65
0.80
0.60
0.75
0.05 0.06 0.07 0.08 0.09 0.1 0.11
0.55
Vz late (m /s)
0.01 0.02 0.03 0.04 0.05
Figure 13: The effect of late drainage velocity on Vz early (m /s)
modified formation, NFI* (Eq 4) to allow for the small
variations in other key process variables. Figure 15: The effect of early drainage on wire side
anisotropy.
The late drainage rate also had a significant effect on the
anisotropy of the top side of the sheet with a higher vz late It appeared that the wire side was more greatly affected by
leading to lower MD fibre alignment, see Figure 14. the structure of the fabric. In particular the amount of CD
surface mesh, see Figure 16. It should be noted that the h54
fabric yielded anisotropy results which were somewhat
h34 h54 hO3 h28 h12 h61 All anomalous and are not understood9.
0.60
0.50 0.75
Wireside Anisotropy
0.45 0.70
0.40 0.65
0.35 0.60
0.05 0.06 0.07 0.08 0.09 0.1 0.11
Vz late (m /s) 0.55
50 60 70 80 90 100 110
Figure 14: The effect of late drainage on Topside
anisotropy. CD Surface Mesh
CONCLUSION
The late drainage rate during paper forming process
significantly affected the formation and anisotropy of
sheets formed on the UoM former.
Acknowledgements
The authors wish to thank:
· Huyck Australia Ltd. for supplying forming fabric
samples and useful discussions.
· Australian Paper for supplying the pulp.
· Amcor Limited for use of testing equipment, loan of
experimental equipment from its Research and
Technology (R&T) Centre.
Â.
REFERENCES
1. Trepanier, R. J., “The G/W drainage-retention tester”,
Tappi J., 75(5) : 139,(1992).
2. Britt, K. W., and Unbehend, J. E., “Water removal
during paper formation”, Tappi J., 68(4) : 103, (1985).
3. Sampson, W. W., “The interdependence of sheet
structure and drainage”, Paper Tech., 38(8) : 45,
(1997).
4. Räisänen, K. O., Paulapuro, H., and Karrila, S. J., “The
efects of retention aids, drainage conditions, and
pretreatment of slurry on high vacuum de-watering: a
laboratory study”, Tappi J., 78(4): 140, (1995).
5. Siven, S., and Manner, M., “Multicomponent retention
systems in twin wire forming”, Proc. 54th Appita
Annual Conf., Vol. II, 215, (2000).
6. CPPA Standard Method C.1; TAPPI Test Methods T
227 om-85 and T 221 om-88.
7. Helmer, R. J. N., Covey, G. H., Raverty, W. R., and
Vanderhoek, N., “Flow phenomena and paper forming”
Proc. 54th Appita Annual Conf., (1999).
8. Helmer , R. J. N., “Laboratory simulation of paper
forming”, PhD thesis, The University of Melbourne,
Melbourne, Australia, (2000).
9. Helmer, R. J. N., Covey, G. H., Raverty, W. R., and
Vanderhoek, N., “Preliminary development of a
laboratory former for oriented sheets”, Proc. 53rd
Appita Annual Conf., Vol. I., 79 (1999).
10. Helmer, R. J. N., Covey, G. H., Raverty, W. D., and
Vanderhoek, N., “Optimising simulated commercial
paper for pulp quality analysis”, 54th Appita Gen. Conf.
Proc., p 663, (2000).
11. Helmer, R. J. N., Covey, G. H., Raverty, W. D., and
Vanderhoek, N., Dimensionless characterisation of a
air
stock
fabric
a). b). c). d).
Table A1
Summary of selected fabric characteristics, drainage rates, and sheet properties.
Fabric h34 h54 hO3 h28 h12 h61
0.5
Formation NFI gsm 0.979 1.016 0.886 0.941 0.871 0.926
NFI* 1.03 1.015 0.868 0.934 0.923 0.997
?The size and shape (and alignment) of the holes in forming fabrics are quite varied and depend on the structure and yarn. An
average hole size was calculated for the purposes of this paper assuming a characteristic dimension for square holes according
to:
Surface Open Area
Ave Hole Size =
No. Holes
12 12
10 10
Depth (mm)
Depth (mm)
8 8
6 6
4 4
2 2
0 0
-250 -200 -150 -100 -50 0 -250 -200 -150 -100 -50 0
Tim e (m s) Time (ms)
Figure B1: h34 fabric drainage curves. Figure B4: h12 fabric drainage curves.
12 12
10 10
Depth (mm)
Depth (mm)
8 8
6 6
4 4
2 2
0 0
-250 -200 -150 -100 -50 0 -250 -200 -150 -100 -50 0
Time (ms) Time (ms)
Figure B2: h03 fabric drainage curves. Figure B5: h61 fabric drainage curves.
h28-01 h28-02
h28-03 (fail) h28-04
14
12
10
Depth (mm)
0
-250 -200 -150 -100 -50 0
Time (ms)