9/26/2013

Glen A Harvey
Director Rolls Engineering Technology NA

Agenda

• Roll Covers
– Overview of different roll cover materials,
– Construction
– Factors considered for cover selection
• Press Optimization
– TIPS
– Effective Void Volume
– Innovations and cases studies
• SMART ROLL

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Why do we cover a roll?

• Protect the roll core

• Vibration dampening
• Traction (slippage of sheet)
• Release properties
• Pressure Intensity of a nip
– Clothing wear
– Sheet Characteristics
• Quality of sheet
• Improved drainage (open area of roll)

Roll Cover Materials

Rubber

Polyurethane

Composite

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Rubber Cover Technology

Typical Rubber Cover Construction

TOP STOCK
TIE-IN
BASE
CORE

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Effects of Press Loading

A rubber cover does not compress

It is displaced and assumes a different shape

Nip width is dependant upon modulus, thickness and load

Nip loading exerts both compressive and shear stresses on
the cover

Bonding system must
be able to withstand
the shear stress force
found at the bond line
Unloaded Loaded

Typical Press Roll Cover Base Construction

Rubber Cover Rubber Cover Rubber Cover

0-450 PLI 450- 800PLI & Suction > 800 PLI

Topstock Topstock
Topstock thks as thks as
thks as required required
required .125” Tie in
.125” Tie in
.125” Tie in .250” Base
.1875” Base
.125” Base

=
Cement Layer

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Bases

• Three Primary Functions

– Provides a high modulus material for
optimum mechanical bonding
strength.
• High hoop strength
• Minimize shear stress at core / base
interface
– Creates a modulus (psi) transition
between the lower modulus top
stock / tie-in and the high modulus
core
– Retards moisture permeation to the
core

Base Options

• Standard Bases
– Co-cured or pre-cured/pre-ground (majority co-cured)
• Chemical bonding with co-cured system
– 150°F bond line temperature limit
– Bond strength degrades as temperature increases
– Heat Transfer calculations are run for water cooling
requirements

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Base Options

• Lifegard I
– Composite base, very high hoop strength
– °
185 F bond line temperature capability
– Minimize or eliminate water cooling
– Specific water cooling temperature requirements

• Lifegard II
– °
240 F bond line temperature capability
– High bond strength at elevated temperatures
– Eliminate water cooling
– Top Stock may now be the limiting factor for temperature

Tie-in – Rubber Covers

• Intermediate layer between base

and top-stock
– Typically a mix of base stock and top Top Stock
stock material to provide a good
Tie-in
chemical bond. Base
– Provides an intermediate modulus Core

layer between the top stock and base

decreasing possibility of sheer stress
failure at high modulus/low modulus
interface.

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Compounding and Mixing

2-roll mills used to blend rubber components

Accurate cover specifications are essential to ensure the proper “recipe” for
the desired cover properties

Core Preparation

Blasting Cementing
Increases core surface Promotes adhesion
area for improved of base to core
bond

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Rubber Covering

Extruding Wrapping

Curing

Vulcanization
Reverse inside steam – steam flowing through core. Note that roll
heads must have vent holes and those holes must be plugged prior to
shipping roll.

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Grinding, Drilling, Grooving, Balancing

Reassembly, Paint, Wrap, Ship

Accurate bearing, grease and

paint specifications are essential.

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Polyurethane Technology

Polyurethane Working Rolls

Incline Cast JetCast Rotational Cast

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Typical Press Roll Cover Base Construction

Rubber Cover Rubber Cover Rubber Cover

0-450 PLI 450- 800PLI & Suction > 800 PLI

Topstock Topstock
Topstock thks as thks as
thks as required required
required .125” Tie in
.125” Tie in
.125” Tie in .250” Base
.1875” Base
.125” Base

Polyurethane Cover Polyurethane Cover

Non-suction Suction

=
Cement Layer
Topstock Topstock
thks as thks as
required required

.250” Epoxy Base

.1875” Epoxy Base

Rotational Cast

• Developed by SW Sweden
• Single pass application
• Many advantages
– Fast manufacturing process
– Elimination of molds
– Elimination of oversize waste
– Elimination of mold release
– Superior physical properties
equal to or better than mold
cast
– Possible reduction in rejects
and warranties

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Polyurethane Machine

Composite Roll Covers

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Composite Cover Construction

Top stock: Fiber reinforced epoxy

with various filler systems. .300” thick. Topstock
Generally 88-93 Shore D Hardness

Base Layer
Base Layer: Fiber reinforced epoxy.
.200” thick Steel Core

Side Total Thickness = .500” per side

Manufacturing: Wrap / Lamination Process

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Factors considered for cover selection

Critical Roll Cover Performance Properties

1. Hardness – static modulus 11. Coefficient of Friction
2. Dynamic modulus 12. Temperature capabilities
3. Hysteresis 13. Hardening properties
4. Moisture diffusion 14. Effect of thickness
5. Chemical resistance 15. Vibration dampening
6. Release properties properties
7. Abrasion resistance 16. Residual stress
8. Mark Resistance 17. Machining capabilities
9. Crack Resistance

Water Diffusion in Roll Covers

Concentration Gradient: Immersed cover sample will absorb water until

the concentration gradient disappears and the cover reaches saturation

Cover
Sample

Concentration
Gradient

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Water Diffusion in Roll Covers

Temperature Gradient forces water to the cooler
side and can result in Supersaturation - water in
excess of saturation.
°
Surface 115 F
Topstock
Base
Steel Core
Temperature
Gradient
Internal

°
Water Cooling
75 F

Water Diffusion Failure

Moisture Diffusion / Channeling Failure

Small “fingernail shaped” surface cracks

As the cover is tooled away, the cracks are found to open up into channels
that spiral around the cover

Many additional channeling areas are revealed at base

Cover Removal Process in Steps

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Press Optimization

TIPS - Total Innovative Press Solutions

1. Establish performance and quality objectives

2. Analyze current operating conditions and capabilities
3. Establish appropriate dewatering theory for specific grade and
machine design
4. Design roll covers to create optimum nip
intensity and width Total nip pressure

5. Design felts to handle water, transfer

Paper structure pressure
sheet and for pressing uniformity and
Pressure

sheet smoothness Hydraulic pressure

6. Design cover venting to compliment felt

design and dewatering theory
Press / Nip length
1 2 3 4

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TIPS - Objective

Optimizing machine conditions and performance to achieve a predetermined set of

goals

Press Studies have to be “Objective” driven

Production Goals Cost Reductions Sheet Qualities (Tests)

Increase moisture removal Fiber reduction Bulk / Smoothness / Caliper
Speed Increase Increased felt life Strength properties
Run-ability Energy savings Internal bond
Holes reduction Water savings Shadow marking
Blowing Maintenance cost Picking and linting
Moisture profile Felt Installation time “De-fiberization” energy
Basis weight Chemical cleaner Softness
Faster start up Seam mark
Breaks Batt felt mark
Drop offs Base fabric mark
Edge flipping
Vibration

TIPS - Total Innovative Press Solutions

Determine recommended pressure range from application guidelines
based on:

40 years of practical experience

Paper grade / Desired sheet properties

Press configuration

Incoming solids

Max load – normal load = Lost Impulse

Sheet densification

Crushing

Poor felt performance

Poor run-ability

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TIPS - Philosophy

Impulse is the driving force in sheet dewatering

Load (Kn/m, PLI)
Impulse =
Speed (mpm, fpm)

Develop ideal nip conditions at

the optimal press Impulse. Sheet

Maximize moisture removal Felt

Protect sheet qualities

Nip Curve

Sustain performance of rolls and
felts 1 2 3 4
Hydraulic
Pressure

TIPS - Optimize All Press Nips

Design press nips to compliment other nips for the best dewatering
efficiency and sheet quality

Engineer covers to
Nip Peak Pressure and Cumulative Nip Width
produce incremental 157.5 Kn/m

pressure increases 900 PLI

2nd Press
Original Arrangement

between presses at 3rd Press 4th Press 4th Press

full load 105 Kn/m

600 PLI 3rd Press

Maintain nip peak 1st Press 2nd Press

pressures at proper 52.5 Kn/m Optimized Design
levels to maximize nip 300 PLI
1st Press

width and dwell time

Example of existing machine
0

0 51 mm 2 102 mm 4 152 mm
inches inches 6 inches

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Benefits / Deliverables

Improved sheet qualities

Caliper / bulk
Strength tests
Smoothness
Improved paper machine performance
Increased sheet solids
Reduce steam usage
Incremental speed
Fiber Savings
Sustained performance of press felts
Less wear to roll covers

Effective Void Volume

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Venting Options

Grooved

Dri-Press - Engineered Blind Drilling

Dri-Press and Grooved

Suction

Suction Double Drilled

Suction Grooved

Suction Dri-Press / Suction Blind Drilled

Suction Dri-Press Grooved

Engineering Nip Venting

• Dri-Press patterns have been designed to provide the most uniform
open area

Typical Dri-Press Patterns

Hole Land Distance Land Distance Land Distance
Pattern # Open Area
Diameter A B C

14 25% .093” .0833 .0838 .0840

15 21% .085” .0913 .0918 .0920
16 28% .098 .0771 .0782 .0789
3 21% .098” .1169 .0870 .1170
4 21% .078” .0681 .0786 .1287

• New patterns: No. 32 and No. 50 with 0.140” and 0.109” hole
diameters and approx. 25% open area
• All patterns have a grooving option and all patterns can be
engineered with all holes intersecting a groove

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Engineered Nip Venting

Pattern 32 Pattern 68 Pattern 50

0.140” Hole Diameter 0.109” Hole Diameter 0.109” Hole Diameter
25% Open Area 32% Open Area 25% Open Area

Engineered Suction Venting Patterns

Suction Suction Dri-Press® Suction Suction Dri-Press®

14 – 18% OA 25 - 31% OA Grooved Grooved
(23 - 27% Up to 35% OA Up to 44% OA
double drilled)

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Suction Roll Evaluation – Board and Pulp

Cover softness not suitable for grooving

Changed suction roll from straight
drilling to double drilling

Suction open area opened from 17% to
32%

Vacuum system, pans and doctors were
evaluated first for water handling capability

Felt was evaluated for flow rate tolerance

Application Benefits

1% increase in press solids into dryer

Engineering Value

Coordination

Cover design sets nip conditions
1000 PLI

Felt design controls sheet smoothness and
influences press performance

Engineered venting compliments felt design
Grooved

Recent example Bottom

Reengineered cover for appropriate nip

pressure

Evaluation kept existing felt design

Redesigned grooving pattern to reduce flow
restriction and increase void volume Now: 8 GPI 0.035” Wide x 0.125” Deep

Value

Improved sheet quality

Higher press solids / 5% speed increase

$3 million Value Results Was: 10 GPI 0.020” Wide x 0.100” Deep

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1st Press Builds 2nd Press Performance

Engineered venting improved tandem

felt performance

Traditionally blind drilled bottom rolls

Redesigned 1st press bottom venting to
improve 2nd press performance.

1st press bottom changed to partial nip
dewatering

More felt void volume entering 2nd Nip

Less hydraulic forces in 2nd press Now: Blind Drilled Grooved 35% Open

Application Benefits

Customer A : 1.5 - 3 ton/hour increase

Customer B : 15 FPM increase on all grades
Was: Blind Drilled 21% Open

Hydrophobic Cover Material

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Development of Surface Properties

Super-hydrophobic surface
properties

Non-plugging, clean
running

Support for water
handling concepts

Doctor elimination
potential

Primary Press Innovations

Soft Covers Over Grooved Rolls

Superior soft cover materials in top
positions generate proper nip
intensities while hard grooved bottom
roll that allows the moisture to escape
the nip. The open area reduces the
hydraulic forces and allows optimal
loading.

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Soft Covers Over Grooved Rolls

Install 70 P&J top primary roll covers

Grooved 3 bottom primary rolls

Increased press load on 1st primary 190 PLI

Increase dwell time: 116% 1st, 30% 2nd, 22% 3rd , 17% main

Install 24 P&J, 1” thick cover with LGII base in main

Increase main press load 100 PLI

Opened primary felts for better water removal
2% Reduction WEM = 6% production Increase
Maintain sheet bulk / density
$198,000 / year value

Polyurethane and Rubber Advancements

– Super low hysteresis - cooler under pressure

– Long run life with superior abrasion resistance
– Superior ability to withstand wad impacts
– High performance bonding system

– Drier performance with greater stability

– Runs clean with less wax build-up and hole plugging

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Polyurethane and Rubber Advancements

Unique high performance

polyurethane and rubber
elastomers run cooler

Increased bond strength from
lower operating temperature

More tolerant of biased loads

Extractor to Main Press

Covers are old, thin and harder than original covers

Generates higher nip intensity and less dwell time

Re-establish original condition – begin w/ extractor

4% increase in speed
Improved efficiency
Improved ply bond
$268.416

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New Concepts for

Maximum Performance,
Reliability, Life

Aquarius Armor

Soft rubber base produces low nip

intensity and wide nip width

Harder thin poly top offers hardness

and chemical stability, superior
abrasion resistance, and release

Harder Shell Poly
Consistent operation – minimal

Top Coat change in hardness, thickness or CD
uniformity

Soft Rubber
Minimal maintenance – 1 to 2 long

Substrate runs reduces handling, grinding, and
freight costs

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Nip width and

nip pressure CD history

Standard deviation

Shoe Press Application

First ever real time impulse curve from a shoe press nip

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Roll Technology

Customer : East Coast NA

Position : Suction Drum Rider Roll (SMART® Roll)
Speed : 700 fpm, 215 mpm
Grade : Packaging
Press load : 150-250 pli
Cover : Aquarius with
Hardness : 110 P&J

Performance
• SMART® Roll technology allowed the mill to have consistent nip profiles
• Improved sheet caliper profile
• Felt usage reduced from 10 felts annually to 4 felts annually
• ValueResults signed off for $60,000 per year!

Mid-West Board Machine

Value Results
$980,196 /Year
Incremental Tons
Steam Savings
Record Year 2011
2012 Record Pace

Proper Nip Intensity at Optimal Impulse
29% Increase - Total Nip Width

Additional 960 PLI
Engineered Venting

Incremental Increase Between Presses

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White Pigeon Paper Company

Forming Section

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PRIMARY PRESS

• 150 PLI
• TOP FELTED
• TOP & BOTT ROLLS
26
BLIND DRILLED SUCTION

26 25%
SOLIDS
OLD
TOP ROLL 70 P & J
BOTT ROLL 35 P & J

NEW
TOP ROLL 120 P & J
BOTT ROLL 60 P & J

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VR PRESS

• 250 PLI
• TOP FELTED
• TOP ROLL BLIND DRILLED
• BOTTOM ROLL BLIND
DRILLED WITH SUCTION
• SIDE ROLL SMOOTH
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OLD
TOP ROLL SUCTION
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26 35% TOP ROLL 35 P & J
SOLIDS BOTT ROLL 45 P & J
SIDE ROLL 1 P & J

NEW
NO SUCTION TOP ROLL
TOP ROLL 50 P & J
BOTT ROLL 55 P & J
SIDE ROLL 1 P & J

SECOND PRESS

• 1000 PLI
• TOP & BOTT FELTED
• TOP & BOTT ROLLS
BLIND DRILLED

26 46%
SOLIDS
26 TOP AND BOTT 20 P & J

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THIRD PRESS

• 2000 PLI
• BOTT FELTED
42 • TOP ROLL SMOOTH
48% • BOTT ROLL BLIND DRILLED
• 42” FINISHED O.D.
SOLIDS
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TOP AND BOTT 20 P & J

Summary

• Softer Nips in 1st Primary and VR Press

• Removed suction from VR Press top roll
• Overall improved machine runnability
• Increased production of 8%

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Press Optimization Summary

Define operating objectives and limitations

Select recommended pressure range

Choose the proper cover material – Top stock and base

Cover thickness to develop proper nip intensity at optimal press
impulse

Develop incremental increase in nip intensity

Utilize most effective void volume

Press Optimization Summary

“Soft over Grooved”

Low hysteretic material

Begin at extractors

Keep roll covers in like new condition

Smart Technology for additional operating insight and improved
qualities

Design felts to compliment conditions –

Handle the water

Transfer the sheet,

Pressing uniformity

Improve sheet smoothness

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