Method and device for producing a multi-layered fibrous web
The invention relates to a method and a device for producing a multi-layered fibrous web.
Methods of this type are known. Thus, patent document WO12041392A1 describes the production of an at least three-layer fibrous web in the forming section of a paper machine. The forming section comprises a plurality of fourdrinier wire units each for forming a single layer of the fibrous web. The individual plies are couch-pressed or pressed together to form a multi-layered fibrous web. As a raw material for the intermediate layer, waste cardboard (OCC, old corrugated cardboard pulp) mixed with used paper, newspaper, waste paper, and the like are generally used. Deinked material, cellulosic material, CTMP as well as OCC and waste paper were used for the back layer.
With increasing use of old paper and increasing recovery rates, the proportion of fillers and fines in the raw material resulting from the recycling of fibre-containing products is increasing. This results in a reduction in the strength of the paper product produced, particularly in paperboard and wrapping paper. This disadvantage is eliminated by a higher weight per unit area or by increasing the use of higher quality raw materials, such as pulp. This leads to increased production costs, especially in the production of paperboard and packaging.
The object of the present invention is therefore to provide a method and a device for producing a multi-layered fiber web, with which it is possible to achieve, on the one hand, a reduction in the production costs and, on the other hand, a strength potential of the fiber web.
This object is achieved by a method for producing a multi-layered fibrous web, comprising at least a stock preparation section, two headboxes and a forming section of a paper machine for producing a multi-layered fibrous web, wherein a fibrous raw material, which at least partially contains old paper with filler and fines, in particular OCC, and/or waste paper produced in the method for producing a multi-layered fibrous web, is fed to a disintegration device of the stock preparation section and there is formed at least one suspension flow, and the at least one suspension flow is fed to a washing stage for separating filler and fines in order to form a filler fines flow and a fibrous suspension flow, wherein the fibrous suspension flow is fed to the at least one headbox and the filler fines flow is separated in the separation stage into a filler flow and a fines flow, and the filler flow is fed in the forming section between two plies of the multi-layered fibrous web being formed.
The filler contained in the old paper-based raw material reduces the potential for mechanical properties, in particular the strength potential, for example the breaking length, of the produced fibrous web. By separating the filler from the suspension flow, the filler content of the layers of the fibrous web, which are produced at least partially from the remaining fibrous suspension flow, is reduced, thus increasing the strength of the fibrous web. Thus, in practice, the negative consequences associated with an increase in the filler content of old paper can be compensated. Depending on how much filler is separated from the fibre-containing stock, a higher strength can also be achieved than with the current conventional methods. This also enables a reduction in the use of high-quality fibrous material or a reduction in the weight per unit area of the individual plies or of each ply of the multi-layered fibrous web. The cost per ton of paper web can be significantly reduced. On the other hand, the method also enables the production of a multi-layered fibrous web for the purpose of use with high demands on mechanical stress without reducing the weight per unit area. A further advantage is that the separated filler does not need to be disposed of expensively, but can be used for producing a fibrous web without adversely affecting the quality of the multilayered fibrous web. This is achieved in that the wadding is arranged in a suitable manner between two adjacent plies of the multi-ply fibrous web in the region of the forming section.
The filler is a mineral material, such as kaolin, titanium dioxide, calcium carbonate. In contrast, fines include organic materials, such as organic materials formed from organic fibrous materials.
To determine the mass fraction of fines and fillers of the fiber suspension, a sample of the fiber suspension is fractionated in a Bao Er macnit fiber sieve apparatus (standard: TAPPI T233) and the D100 cut (sieve plate ASTM 100) is used for the determination. The quality of the filler in the D100 fraction is determined by treating the D100 fraction in a burning furnace and determining the quality of the so-called burning residue in accordance with DIN ISO 1762. The mass of the ignition residue is referred to the total mass of solids in the sample of the fiber suspension to give the mass fraction of filler in the fiber suspension. The fine fraction is determined by the difference between the total mass of solids in the D100 fraction and the mass of the burned residue of the D100 fraction, with reference to the total mass of solids in a sample of the fiber suspension.
The method can be used not only for the filler-containing raw materials that are put into use, but also for the recycling of filler-containing waste paper produced in the manufacturing method. For example, waste paper may be produced in the case of a paper web tear in the paper machine during production, or also by edge cutting of the fibrous web. Since the filler separated according to the method of the invention is fed into the multi-layered fibrous web, this waste paper also inevitably contains filler and fines and can therefore be reused in an advantageous manner.
Waste paper, which is produced in particular when producing pigment-coated multi-layer fiber webs, can be treated particularly advantageously by the method according to the invention. The filler added with the pigmented coating is substantially separated from the fibre-containing part of the waste paper after disintegration in the washing stage.
In an advantageous embodiment, the waste paper and the fiber-containing raw material can be shredded in a common shredding device.
It is also conceivable to disintegrate the waste paper in a separate disintegration device.
Furthermore, it is possible to use a common washing stage and/or a common separation stage for the treatment of waste paper and fiber-containing raw materials.
In a possible embodiment, separate washing stages and/or separate separation stages are used in order to dispose of waste paper and fiber-containing raw material.
Furthermore, waste paper can also be treated according to the method according to the invention in a separate stock preparation. This separate slurry preparation section may also be part of the sizing system of the slurry preparation section.
The separation in the washing stage is preferably carried out such that in the filler fines stream the filler mass fraction is greater than 50%, preferably from 50% to 70%, and the fines mass fraction is less than 50%, preferably from 30% to 50%. The filler mass fraction is calculated from the filler mass with reference to the total mass of solids in the filler fines stream. This also applies correspondingly to the fines mass fraction.
In practical terms, the separation in the separation stage is carried out such that in the filler stream the filler mass fraction is greater than 50%, preferably greater than 60%, particularly preferably greater than 70%, in particular greater than 80%, and in the fines stream the filler mass fraction is less than 50%.
The fines stream can be fed again into the disintegrating device or into the fibre suspension stream. The advantage of feeding the fibre suspension flow is that especially when the amount of fines is higher, the enrichment of fines in the breaker device is thus suppressed, so that operational malfunctions can be avoided. The input to the comminution device can be a cost-effective solution when the amount of fines is low.
In some cases, it may be advantageous to concentrate the filler stream. This can be advantageous when a filler flow is introduced in the forming section between two plies of the multi-ply fibrous web to be formed.
The filler flow is preferably applied along the entire width of the plies of the multi-layered fibrous web to be built up.
However, it is also conceivable to apply the filler flow in the multilayered fibrous web to be formed in regions along the width of the material layer. In this case, it may be advantageous to be able to control or regulate the application quantity in different regions.
In a possible embodiment, the filler flow is applied directly to the already formed layers of the multi-layer fibrous web to be formed. This can be carried out by spraying or by means of a Curtain Coater (Curtain Coater) by means of a feed device, for example a secondary flow headbox or a spray bar with nozzles arranged along the width of the layer. The average consistency of the structured bed at the feed point is preferably in the range from 2.0% to 6%, in particular between 3% and 5%, advantageously greater than 4%.
It is also possible for at least one headbox to be constructed with a plurality of flow layers in layers and for a layer to be pressed against a further layer of material by at least one of the flow layers to be produced and for the filler flow to be directed into the flow layer adjacent to the at least one flow layer and facing the further layer of material. In this solution, no additional feeding device is required, since the feeding device is formed by an existing headbox which is only of a multi-layer type. This embodiment is therefore characterized by lower costs and an increased interlaminar strength of the produced multi-layered fibrous web.
In a possible embodiment, at least one strength-increasing additive can be added to the filler flow in order to increase the interlaminar strength of the finished multi-layered fibrous web.
For example, at least one strength-enhancing additive can be added to the filler flow before it is applied between the two layers of the multi-layered fibrous web to be formed.
It is also conceivable to add at least one strength-enhancing additive to the filler flow after it has been applied between the two layers of the multi-layered fibrous web to be formed.
The at least one strength-enhancing additive may be selected from the group consisting of starch, synthetic polymers, nanocellulose, highly fibrillated cellulose, fibrous materials, especially highly ground fibrous materials, such as Pulp, TMP (thermo mechanical Pulp), CTMP (chemical thermo mechanical Pulp).
It is conceivable that at least one strength-increasing additive is added to the feed stream by means of a secondary headbox or a spraying device.
In an expanded possibility, a substream is branched off from the fiber suspension stream and this fiber suspension substream is ground and added to the filler stream.
In order to meet the special requirements for a multi-layered fibrous web, in addition to raw material and/or waste paper, pulp can be mixed into the disintegrating device.
The invention further relates to a device for carrying out the method for producing a multi-layered fibrous web, wherein the device for producing a multi-layered fibrous web comprises at least a stock preparation section, two headboxes and a forming section of a paper machine for producing a multi-layered fibrous web, wherein the device further comprises a disintegration device in the stock preparation section for feeding fibrous raw material at least partially containing old paper with filler and fines, in particular OCC, and/or for feeding waste paper produced in the production of the multi-layered fibrous web and for forming at least one suspension flow, wherein the device further comprises a washing stage for separating filler and fines from the suspension flow for forming a filler fines flow and a fiber suspension flow, wherein the fiber suspension flow is guided into a line connected to the at least one headbox, wherein the device further comprises a separation stage for separating the filler fines flow into a filler flow and a fines flow, wherein the device further comprises a feeding device for applying the filler flow in the forming section between two multi-layered webs of fibers being formed.
The forming section may comprise, for example, a fourdrinier wire former with a supporting wire and a fourdrinier wire unit with a dewatering wire for constituting, respectively, the plies of the multi-layered fibrous web, such as the backing layer and the cover layer. A support wire headbox or headbox for applying the fibre suspension flows respectively in order to form the respective stock layer is assigned to the support wire and fourdrinier unit. The two material layers are pressed together by a couch roll at the position of the couch roll. The two-layered fibrous web thus formed is transported further to a discharge point (Abnahmestelle) via a supporting wire.
In other practical cases, the forming section may comprise, in addition to the fourdrinier former, fourdrinier unit, an additional fourdrinier unit with an additional headbox. They are arranged relative to one another in such a way that the further material layers formed on the further fourdrinier wire unit form a lining-in layer and are pressed against one another at the couch roll in each case at the couch roll position, first with the material layer formed on the fourdrinier wire unit and then with the material layer formed on the supporting wire.
The cover layer and/or backing layer and/or the liner layer may itself be of a multi-layer construction. In this case, each respective headbox is designed in a multi-layer manner for forming at least one further flow layer.
The support wire may be assigned an upper wire unit for improved dewatering. The upper wire unit dewaters a part of the fibre suspension in the opposite direction to the support wire. The layer thus structured is pressed by the couch roll at the couch roll position with the layer constituted by the fourdrinier wire units in a further process seen in the production direction.
The feed device can be assigned to the layer built up by the fourdrinier wire unit and be arranged before the couch roll position.
However, it is also conceivable for the feed device to be assigned to the material layer formed by the fourdrinier wire former and to be arranged before the couch roll position.
The feeding device for applying the filler flow can be assigned to the material layer built up by the further fourdrinier wire unit and be arranged before the couch roll position.
The feeding device for applying the filler flow can be configured as a support-wire headbox of a multi-layer construction and/or as a headbox of a further multi-layer construction.
It is basically conceivable to provide several feed devices at different feed points for applying a filler flow between two layers of the multilayered fibrous web being formed in the forming section.
The feeding device is preferably designed as a multi-layer headbox and/or as a secondary headbox and/or as a spray bar with nozzles and/or as a curtain coater. The use of curtain coaters, which are also known in the paper industry as curtain coating devices in coating technology, is particularly advantageous for applying thin layers of filler flow between the layers of a multi-layered fibrous web.
In practical terms, the weight per unit area of the filler flow applied to the material layer by the feed device is in the range of 3% to 25%, in particular between 5% and 20%, of the weight per unit area of the multilayer fibrous web, depending on the filler input of the raw material or waste paper.
Furthermore, the layer thickness of the applied filler flow lies in the range from 1% to 12%, preferably in the range from 1.5% to 10%, of the thickness of the multilayer fibrous web.
Further embodiments are described in the examples according to the invention.
The invention also extends explicitly to embodiments which are not given by the combination of features which is formed by explicit reference of the claims, and the features disclosed in the invention can be combined with one another as desired in this embodiment, as long as the technical justification is achieved.
Further features and advantages of the invention will appear from the following description of a preferred embodiment, with reference to the accompanying drawings. In the drawings:
fig. 1 shows in a schematic view an exemplary embodiment of a slurry preparation section for carrying out the method according to the invention;
fig. 2 shows a further exemplary embodiment of a slurry preparation section for carrying out the method according to the invention in a schematic view;
fig. 3 shows an exemplary embodiment of a forming section for carrying out the method according to the invention in a simplified view; and
fig. 4 shows a further exemplary embodiment of a forming section for carrying out the method according to the invention in a simplified view.
Fig. 1 shows in a schematic view an exemplary embodiment of a stock preparation for carrying out the method according to the invention for manufacturing paperboard and packaging paper. The fibre-containing
stock 2, which contains at least partially filler-containing OCC (old corrugated containers), is fed into a disintegrating
device 11, for example a pulper. The
suspension flow 12 formed after comminution and impurity separation is fed to the
treatment stage 5. The treatment stage may comprise a plurality of cleaning stages known per se, for example a high consistency cleaning stage, a HW cleaning stage (heavy fraction cleaning stage) or a slot sorting stage. The suspension is then fed to a
washing stage 13 for separating off the filler and fines, to form a filler fines stream 14 and a
fibre suspension stream 15. The separation in the washing stage is carried out such that in the filler fines stream 14 the filler mass fraction is greater than 50%, preferably from 50% to 70%, and the fines mass fraction is less than 50%, in particular from 30% to 50%.
Cleaning stage 13 may be by known product name
Or alternatively
The scrubber of (1). The
fibre suspension flow 15 is led to a
further treatment stage 6, in which
treatment stage 6 the fibre suspension flow is concentrated and dewatered and, if necessary, dispersed and re-diluted, and ground in the grinding stage 9. The
fibre suspension flow 15 is then fed, preferably via a sizing system 8', to the
respective headbox 24, 29, 34 of the forming
section 20 in order to form in each case a layer of a
multi-layered fibre web 38.
The stream of packing fines 14 formed in the washing stage 13 is separated in a separation stage 17 into a stream of packing 18 and a stream of fines 19. The separation process of the separation stage 17 is carried out such that in the filler stream 18 the filler mass fraction is greater than 80%, preferably greater than 85%, and in the fines stream 19 the fines mass fraction is less than 50%. The fines stream 19 is then preferably fed into the fibre suspension stream 15 after the washing stage 13. The fines stream 19 can also be fed back into the comminution apparatus 11, in particular when the feedstock 2 has a low filler content. It is however also possible to lead a part of the fines stream 19 to the destructuring unit 11 and the remaining part to the fibre suspension flow 15. The filler flow 18 is concentrated in the concentration stage 7 and optionally fed via the sizing system 8 into the forming section 20 for forming the multi-layered fibrous web 38 and is applied there between the two layers 25, 30, 35 of the multi-layered fibrous web 38 being formed at the feed point. In order to further improve the mechanical strength, in particular the interlaminar strength, of the multi-layered fibrous web 38, at least one strength-enhancing additive 39 can be added to the concentrated filler stream 18, said additive being selected in particular from the group of materials: starch, synthetic polymers, nanocellulose, microfibrillated cellulose, fibre materials, in particular highly ground fibre materials, such as Pulp, TMP (Thermomechanical Pulp), CTMP (Chemithermomechanical Pulp). Additives are preferably added to the sizing system 8.
The stock preparation 4 described here for the use of a fibrous stock 2 which at least partially contains a filler-containing OCC (old coated paper) is also suitable for the case in which filler-containing waste paper 3 produced by the production of a multi-layered fibrous web 38 is incorporated into the stock 2 in the shredding device 11. The filler content in the waste paper 3 can be significant, in particular, when the multi-layered fibrous web 38 is coated with a pigmented coating color during production, for example, when white-coated linerboard. It can therefore also be advantageous to provide a separate stock preparation for carrying out the method according to the invention in order to dispose of the waste paper 3. The separate pulp preparation section may also be part of the sizing system 8, 8' of the pulp preparation section 4.
The only difference in the embodiment of the stock preparation 4 shown in fig. 2 from the embodiment shown in fig. 1 is that after the grinding stage 9, a substream of the fibre suspension 16 is branched off from the fibre suspension stream 15 and fed to a further grinding stage 10. In this further grinding stage 10, the fibers are intensively ground to a highly fibrillated fiber fraction and fed as an additive to the filler stream 18 before or preferably in the sizing system 8.
Fig. 3 shows an exemplary embodiment of a forming section 20 for producing a two-layer fibrous web 38 for carrying out the method according to the invention in a simplified view. The forming section 20 comprises a fourdrinier former 21 with a support wire 22 and comprises a support wire headbox 24 and a fourdrinier unit 26 with a dewatering wire 27 and a headbox 29, which fourdrinier former 21 and fourdrinier unit 26 are used to construct layers 25, 30, respectively, a backing layer 25 and a cover layer 30, for example a two-layered fibrous web 38. The fibre suspension flow 15 is fed into the headbox and applied to the respective dewatering wire 22, 27. Additionally, the fourdrinier wire former 21 is assigned an upper wire unit 23 for improved dewatering. The upper wire unit 23 dewaters a part of the fibre suspension in the opposite direction to the support wire 22. In the further course of the process, viewed in the production direction 37, at a couch position 36, the bed 30 built up by the fourdrinier wire unit 26 is couch-pressed onto the bed 25 thus built up. The two-layered fibrous web thus formed is transported further to a discharge point via a supporting wire 22. A feed device 41 for applying the filling flow 18 at a feed point 40 is associated with the material layer 30 formed by the fourdrinier wire unit 26 in the region of the dewatering section 28 and is arranged before the couch roll position 36. It is also conceivable, however, for the feed device 41 and the feed point 40 to be associated with the material layer 25 formed by the fourdrinier former 21 and to be arranged before the couch roll position 36. It is also possible to provide two feed devices 41 correspondingly. The feed device 41 for applying the filler flow 18 can also be configured as a flow layer of the multiply designed support-wire headbox 24 and/or as a flow layer of the multiply designed headbox 29. In this case, the fibre suspension flow 15 is introduced into the lower flow layer, i.e. into the flow layer of the respective multi-layer headbox 24, 29, which is directed toward the respective dewatering wire, in order to form the backing layer 25 or cover layer 30. The filler flow 18 is introduced into the upper stock layer, i.e. into the stock layer of the multi-layered headbox 24, 29 facing the stock layer to be couch-pressed, and is applied to the correspondingly configured stock layer 25, 30. Thus, better interlayer strength can be achieved.
Fig. 4 shows a further exemplary embodiment of a forming section 20 for carrying out the method according to the invention in a simplified view. This embodiment is an extension of the embodiment shown in fig. 3, which is used to produce a three-layer fibrous web 38. The description of the technical features provided with the same reference numbers refers to fig. 3. Instead of the upper wire unit 23, a further fourdrinier wire unit 31 with a further dewatering wire 32 is arranged, and a further headbox 34 assigned to the further dewatering wire 32 is arranged, which further dewatering wire 32 forms the dewatering section 33. Additional layers are built on the additional fourdrinier wire units 31: lining layer 35. The liner-in layer 35 is couch-rolled together with the cover layer 30 at a couch roll position 36 and transported flat with the cover layer 30 over the dewatering wire 27 to the next couch roll position 36, where it is pressed against the backing layer 25. The three-layer fibrous web 38 thus constructed is transported via the support wire 22 to a discharge point and is discharged for further processing. In addition to the feed point 41 for the filling flow 18 described in the embodiment according to fig. 3, further possible feed points 41 are provided in this variant. The filler flow 18 can be applied directly to the already built material layer, the lining layer 35, only at the feed point 41 or additionally at a further feed point 41 in the region of a further dewatering section 33 before the next couch roll position 36. The filler is in this case located between the cap layer 30 and the liner layer 35. This further embodiment provides a further feed device 41 for applying the filler flow 18. The feed device 41 can also be configured as an additional layer of the multi-layer design of the headbox 34. In this case, the fibre suspension flow 15 is introduced into the lower flow layer, i.e. into the flow layer of the multi-layer headbox 34 facing the further dewatering wire 32, for the formation of the liner layer 35. The filler flow 18 is introduced into the upper stock layer, i.e. into the stock layer of the additional headbox 34 facing the cover layer 30 to be couch-pressed, and applied to the structured stock layer 35. Better interlayer strength can also be achieved.
In the embodiment depicted in fig. 3 and 4, the material layers can be constructed in layers as fiber layers. The headbox used for producing the multi-layer fiber layer is constructed in multiple layers. In this case, the respective associated headbox 24, 29, 34 is designed in a multi-layer manner for forming at least one further layer, that is to say a further fibre layer. It is basically conceivable to provide several feed devices 41 at different feed points 40 for applying a filler flow between two layers of the multilayered fibrous web 38 being formed in the forming section 20. The feed device 41 for applying the filler flow 18 can be designed as a multi-layer headbox 24, 29, 34 and/or as a secondary headbox and/or as a spray bar with nozzles and/or as a curtain coater.
Corresponding elements of the embodiments are provided with the same reference numerals in the figures. The functions of the described elements are equivalent to each other in each figure, unless otherwise described and contradicted. And thus the detailed description is omitted. It is also pointed out that different features of the embodiments shown can be interchanged and combined with one another. The invention is therefore not limited to the combinations of the features shown in the exemplary embodiments.
List of reference numerals
1. Device for measuring the position of a moving object
2. Raw materials
3. Waste paper
4. Slurry preparation section
5. Treatment stage
6. Additional processing stages
7. Thickener
8. Sizing system
8' sizing system
9. Grinding stage
10. Additional grinding stages
11. Disintegrating device
12. Suspension flow
13. Cleaning stage
14. Flow of filler fines
15. Fibre suspension flow
16. Fiber suspension substream
17. Separation stage
18. Flow of filler
19. Fines stream
20. Forming section
21. Long net forming device
22. Supporting net
23. Upper net unit
24. Supporting wire stock discharge box
25. Backing layer
26. Long net unit
27. Dewatering net
28. Dewatering section
29. Head box
30. Cover layer
31. Additional fourdrinier wire units
32. Additional dewatering nets
33. Additional dewatering stages
34. Additional headbox
35. Liner layer
36. Couch roll position
37. Direction of production
38. Multi-layered fibrous web
39. Additive agent
40. Feeding point
41. Feeding device