Objective
A calender is arranged at the end of a paper production line. It has the task to provide paper thickness compensation in the um range over the entire paper width and to give the paper the required surface finish. With conventional technology this involves high energy losses due to the process. Because of a new process technology (paper thickness compensation of fine profiling not with thermoelectric heating elements but with hydraulic control elements) and a new technology (substitution of the solid grey cast iron roll tube of lOOmm(!) by a thin-walled chemical fibre-reinforced plastic composite tube) losses due to the process are extremely minimised. The demonstration plant of a calender in the paper industry is to provide verification so that compared with conventional technologies about 85% energy (normally mainly electrical energy) for so-called fine profiling can be saved.
The innovation of the process innovation of today' s thermal control process is the paper thickness compensation in the calender. The paper thickness compensation in the um area today is handled by a great number of electrical heating elements on the massive steel roll in the distance of a couple of millimeters. These heating elements are creating an expansion of the steel roll diameter so that the paper thickness compensation is possible in the area of some micromes. This type of possible fine profiling should be reached in the demonstration unit with the help of many hydraulic pressure elements in the mating roll where the roll shell will be manufactured out of FRC material. So the full flexibility for the fine profiling could be realized over the entire roll face width. The innovation of the process technology lies in the change of the fine profiling process technology away from external energy-intensive fine profiling systems to a flexible, internally pressurised fibre-reinforced tube. Because of the high flexibility of the fibre-reinforced roll tube, transverse profiling of the product (paper or board) can be compared with and is possibly even better than the current technology using the external, energy intensive profiling system, because:
a) extremely narrow wave profile deviations can be corrected, whereby the correctable wave lengths can even be below the wave lengths of all so far known internal and external profiling systems
b) the pressure settings can be adjusted to the profile corrections more effectively, more accurately and more quickly than with conventional, thick steel or grey cast iron tubes of high rigidity.
By means of both effects, the broke quota can be reduced, particulary when restarting the production after a paper web breakage.
Second the innovation of the hydraulical working principle is the product innovation. Today, the mating roll has loading elements for the long wave profiling in a massive grey cast ironroll shell with a thickness of 100 mm (!). In this configuration there are big flow losses of the hydraulic oil in the gap between the roll shell and the roll shaft. In the demonstration unit, the inner part of the roll will nearly be oil-free, so that here no flow losses are to be expected. The demonstration unit is expected to prove an energy saving (electrical energy) of more than 85% compared with today's profiling technology in a paper machine line at same the productivity and paper quality. Today one calender, average sized, requires at a 24-hour-day electrical energy of about 7,400 MWhel/year for the thermal control of the so-called caliper correction. This new procedure makes it possible to save approx. 6,300 MWhel/year for one single calender. With reference to the European potential for calenders for this new technology (about 600) you can save within Europe 3,780,000 MWhel,/year (3,780 GWhel/year) of secondary current and about 11,000 GWh/year (!) primary current.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques. See: The European Science Vocabulary.
- social sciences economics and business economics production economics productivity
- engineering and technology materials engineering woodworking
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Coordinator
47805 KREFELD
Germany
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