Foam Process Headbox Injection Mixing for Paper Manufacturing
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Solution Overview
Problem
Existing foam-based paper manufacturing processes require complex and costly equipment for foam production and regeneration, with high energy consumption and space requirements, and involve challenging foam transfer and pumping issues, making it difficult to maintain production capacity in conventional paper mills.
Innovation Solution
A method and arrangement for manufacturing fibrous webs using a foam process that simplifies equipment needs by injecting gas and surfactant directly into the furnish between the headbox screen and headbox of a fiber web machine, allowing for in-line production of foamed furnish without separate foam preparation or specialized pumps, and enabling simultaneous production of precipitated calcium carbonate using flue gas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foam is produced using separate foam generation apparatus and pumped through pipelines to the headbox, then foamed furnish can be delivered to the fiber web machine, but equipment complexity and energy consumption increase significantly
Solution Approach 1:
The patent combines the foam generation function directly into the headbox assembly, merging previously separate components (foam generator, pump, pipeline system) into a single integrated unit. This eliminates the need for external foam preparation equipment and reduces system complexity while maintaining reliable foam delivery to the wire.
Solution Approach 2:
The invention extracts the foam generation function from the conventional water-based furnish system and integrates it directly at the headbox location. By taking out the separate foam preparation step and combining it with the existing headbox structure, the patent eliminates complex foam transfer piping and pumping requirements.
2Quantity of substance
If separate foam preparation equipment is used, then foamed furnish can be produced, but space requirements and manufacturing costs increase
Solution Approach 1:
The headbox is designed to perform multiple functions simultaneously: it continues to distribute the fiber furnish while also generating the foam in-situ. This multi-functional design eliminates the need for dedicated foam preparation equipment, reducing space requirements and manufacturing costs while maintaining foamed furnish production capability.
Solution Approach 2:
The headbox serves itself by generating the foam required for furnish delivery within its own structure. The foam generation components are integrated into the headbox, allowing it to prepare its own foamed furnish without requiring external foam preparation systems, thereby simplifying the overall manufacturing process.
3Ease of operation
If foam is pumped through pipelines from separate generation apparatus, then furnish can be delivered to headbox, but energy consumption increases
Solution Approach 1:
The invention extracts the foam generation function from remote locations and places it directly at the point of use (the headbox). This eliminates the need to pump foam through long pipelines from separate generation apparatus, significantly reducing the energy required for foam transport while maintaining effective furnish delivery.
Solution Approach 2:
By merging the foam generation function with the headbox location, the patent eliminates the foam pumping and pipeline transfer step entirely. The foam is generated in-situ right where it is needed, eliminating energy-consuming foam transport operations while maintaining reliable furnish delivery to the wire.
4Stability of the object's composition
If conventional foam processes are used, then fiber suspension in foam is achieved, but separate foam preparation and transfer piping are required
Solution Approach 1:
The patent merges the foam generation capability directly into the headbox structure, combining previously separate functions (fiber suspension in foam and foam generation) into a single integrated system. This maintains stable fiber suspension while eliminating the need for separate foam preparation equipment and transfer piping infrastructure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces equipment costs and energy consumption, eliminates the need for separate foam preparation and transfer piping, allows for simultaneous addition of chemicals and fillers, and effectively binds carbon dioxide from flue gas, thereby simplifying the manufacturing process and reducing fresh CO2 usage.
Implementation Method 1
injecting gas by means of an injection liquid into the furnish for preparing a foamed furnish
Implementation Method 2
introducing and mixing gas by means of an injection liquid into the furnish for preparing a foamed furnish
Implementation Method 3
injection mixing station located between a headbox screen and the headbox for introducing and mixing gas by means of an injection liquid into the furnish
Implementation Method 4
producing precipitated calcium carbonate (PCC) in the paper or board making stock simultaneously, i.e. in-line, with the formation of fibrous foam, by using flue gas in the foam formation
Data Source
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AI summary
The present invention relates to an arrangement for and a method of manufacturing a fibrous web, i.e. paper or board. The present invention relates specifically to so-called foam formation of a fibrous web. A further feature of the present invention is to produce foamed furnish by injecting gas into the furnish by means of an injection mixer.