Concept of the most efficient molding net

2022-07-28
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The concept of efficient molding

energy consumption is a focus of growing concern in the paper industry. Oil prices have reached record highs, forcing the costs of energy, raw materials and additives to rise in turn. At the same time, the price of paper and paperboard had to fall. Undoubtedly, rising costs and falling prices mean lower profitability. This article briefly talks about some aspects of forming (especially SSB forming *) that can help reduce the cost of papermaking

* concept of SSB forming

ssb stands for 'sheet support binder' - this is the latest forming and manufacturing technology. Different from the traditional three-layer forming, it no longer needs a separate binding line to integrate the layers

forming

forming is a technical consumable in the production of paper and paperboard. Its role is to help paper mills achieve the required paper/paperboard quality and obtain the highest paper machine performance. The continuous innovation in forming design has been promoting the development of the paper machine to a wider and faster direction while improving the quality and operating performance

ssb forming manufacturing

cost comparison of forming

the contribution of forming to cost reduction can be seen from two aspects. Forming itself certainly has a price - usually depending on the type, size and options that may be used. Secondly, some costs can be reduced by using special forms of forming. Forming is a kind of technical product that has a great impact on the operating performance and the cost of energy, raw materials and additives

a good way to judge the forming price is to use the concept of forming unit cost (euro/1000 tons of paper). The unit cost is easy to calculate: multiply the unit consumption of forming (m2/1000 tons of paper produced) by the price of forming per m2 (EUR/m2). For many people who often make hasty conclusions only based on the formed price, the use of the concept of formed unit price really surprises them

unit consumption of forming

the modern SSB concept has greatly reduced the unit consumption of forming. From 2001 to 2005, the share of SSB concept has risen from less than 10% to more than 50%. At the same time, in general, the unit consumption of all types of forming has decreased from 14.3 square meters/1000 tons to 13.0 square meters/1000 tons, a decrease of nearly 10%**

* * source: PCA, Statistical Bulletin No. 12 - September 2006 - cost saving potential of forming in Western Europe only

in addition to the unit price of forming, the savings that can be obtained by using the most appropriate forming type are much more interesting. The best realization of the two main functions of forming (paper quality consistency and paper machine efficiency) will not only bring considerable savings (because the paper machine efficiency is improved), but also reduce the consumption of energy, raw materials and additives

SSB forming should be innovated in industry, technology and products - the best solution

conflicting needs and hopes related to the wet end of the paper machine often mean a compromise. At present, SSB has the least compromise and the greatest possibility to help the paper mill achieve the required paper/paperboard quality, the highest paper machine performance and the lowest production cost. SSB forming can provide the best support for our customers with its special advantages - meet their requirements and bring the greatest cost savings to the wet end. Main technical parameters: maximum experimental force: 50kN; Range: 0n (5) 0kn; Accuracy of experimental force; Better than ± 1%; Displacement resolution: 0.01mm; Displacement measurement accuracy: better than ± 1%; Stretching stroke: 650mm (can be increased); Tightening stroke: 650mm (can be increased); Test stroke: 650mm (can be increased); Displacement speed control range: 1mm/min ~ 300mm/min; Displacement speed control accuracy: better than ± 1%; Level of testing machine: better than level 1; Deformation indication error: ≤± (50+0.15l); Size of testing machine: 660*420*1780 mm potential

the adoption of SSB concept has improved the quality of paper and paperboard and the operation performance of the paper machine. In terms of printing paper (the percentage of waste paper raw materials is very high), the traditional three-layer structure has caused quality problems (marks, roughness) and sometimes poor performance in strict compliance with the food safety law (because of delamination and limited life potential). Therefore, this aspect of the industry is more or less forced to adhere to the double-layer structure. Now, SSB structure can eliminate these negative effects while improving uniformity, Z-direction fine fiber/filler distribution and operation performance

other cost parameters

ssb structure has made it possible to improve the paper machine performance and reduce the use of expensive raw materials and additives. The efficiency of the paper machine is improved because of cleaner operation and better water treatment. Uniformity improvement is due to the ability to use fewer retention aids, to run at higher speeds without the risk of scarring, and to ensure better water treatment in controlled conditions. The smoother paper and paperboard surface and the more consistent Z-direction filler/fine fiber distribution have reduced the consumption of paint/starch and reduced the waste caused by the emergence of Mafia

consumption of working media

in addition to raw materials and additives, the paper machine also needs energy and other working media. The different kinds of energy consumed by the Ministry and its surroundings are electricity, vacuum, hydraulic pressure, air, water, and sometimes steam. The main impact of the forming type used is the consumption of electricity, vacuum and water: electricity is required to drive the forming, and vacuum is required to dehydrate and transfer. This is not only due to the uninterrupted support of the Korean government for paper delivery in recent years, but water is used to clean the forming or strip the paper

correct selection of forming can greatly reduce power consumption. A forming form with an open face structure receives less resistance from the dewatering elements, thus consuming less operating power. According to experience, the percentage of weft reduction on the wearing surface is consistent with the saving of electric energy. At this point, the best energy saving is achieved through the use of modern SSB design (paper/machine weft ratio greater than 1)

vacuum is used for dehydration and paper transfer, and most of the energy is consumed by components with high vacuum degree. Forming that promotes uniform sheet forming during dewatering - due to its surface texture and pulse transmission - may require a lower vacuum. During sheet forming, the open structure of the sheet is kept in the forming part, thus facilitating dehydration through the vacuum couch roll. Forming with a thin paper surface and a high open surface area (with a suitable permeability range) will help in this regard. Another advantage of this configuration is that the power required for drag forming is reduced

among other uses, water is used to keep the formed clean and stripped paper sheets. If the forming is designed in a way that makes it run cleaner, the cleaning workload will naturally be reduced. Therefore, high-pressure spray pipes with smaller orifice can be used - in many cases, these spray pipes can even be replaced by a voithduocleaner on a regular basis (for example). Less water is required for thin formed stripping sheets with small internal capacity. In both cases, the consumption of clean water is reduced, so there is a great cost saving potential. As mentioned, excellent shaping with high paper support and open wear surfaces provides the best savings potential

a weft binding method for SSB forming

mature products

Voith fabrics have a new SSB product series with considerable advantages, called PrintForm h and multiform H. We have two unique products in this series: printform/multiform HQ and HR. PrintForm HQ can be classified as SSB type "slim" products. The typical use of this type is to produce high-quality printing paper

multiform HR is a 'slightly stronger' form, especially designed for the production of high-quality packaging paper (corrugated board). Both models provide the best support for our customers' needs and offer high cost saving potential due to their fabric structure

printform HQ, multiform hq

Voith PrintForm HQ and multiformhq are characterized by low warp density and high weft density, thus forming an excellent paper support. HQ type has a coarser surface (with high shear and lateral stability), which helps to obtain the potential for long life. The adopted multi shuttle knitting technology (see page 58 of the 21st issue of twother and later) forms a traceless structure. By selecting the best model, cost savings can be achieved in clean operation, additive use, and vacuum, water, and power consumption

printform hq

printform HR, multiform hr

multiform HR and PrintForm HR have the same advantages as HQ forming because of their low density. Another advantage of this type is that the weft span of the wear surface is large, which makes the forming have the potential of long life. The weft spans eight longitudes instead of the more common six or five. Once again, choosing the best model will save costs in terms of clean operation, use of additives and consumption of vacuum, water and electricity

printform hr

summary

ssb forming brings great saving potential for wet end. The slightly higher SSB forming price will be quickly offset by the savings brought to the forming department and its surroundings. These savings are not only due to the improved performance of the paper machine, but also due to the reduction of raw material use, additives and power consumption. (end)

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