Oscillating Needle Shower for Press Felt Cleaning
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Solution Overview
Problem
Current papermaking processes face challenges in effectively cleaning press felts due to residual chlorine damage and contamination, leading to premature wear and sheet defects, as traditional high-pressure oscillating needle showers struggle to achieve sufficient soil removal without disrupting the manufacturing process.
Innovation Solution
Implementing a pulsed application of cleaning agents through high-pressure oscillating needle showers, with specific wash durations and alternating chemical cleaners to ensure thorough coverage and optimal cleaning efficacy, managed by a PLC for cost-effective and continuous press felt cleaning during paper production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional high-pressure oscillating needle showers are used for continuous cleaning, then press felt contamination is reduced, but residual chlorine damage accelerates felt degradation and causes premature wear
Solution Approach 1:
The patent implements periodic pulsed cleaning cycles where cleaning agents are applied intermittently rather than continuously. The PLC controller activates the cleaning system for specific durations (e.g., 5-15 minutes) at scheduled intervals, allowing the press felt to be cleaned effectively while minimizing cumulative chlorine exposure and damage to the nylon fabric.
Solution Approach 2:
The patent changes the operational parameters of the cleaning system by controlling the duration, frequency, and timing of cleaning agent application. The PLC adjusts these parameters dynamically based on production conditions, optimizing the balance between cleaning efficacy and felt preservation, thereby extending service life while maintaining paper quality.
2Reliability
If cleaning agents are applied continuously through high-pressure showers, then soil removal effectiveness is improved, but production downtime increases and paper quality may deteriorate
Solution Approach 1:
The system employs periodic pulsed cleaning cycles controlled by a PLC, where cleaning agents are applied for specific durations at scheduled intervals during production. This intermittent approach maintains effective soil removal while minimizing disruption to paper manufacturing, thereby preserving productivity.
Solution Approach 2:
The cleaning system operates continuously in the sense that the PLC manages ongoing periodic cleaning cycles throughout production without requiring shutdowns. The useful action of cleaning is maintained continuously through automated interval-based application, ensuring press felt performance is sustained without interrupting paper production.
3Reliability
If high-pressure oscillating needle showers operate at full capacity, then cleaning thoroughness is improved, but press felt permeability degradation accelerates due to mechanical stress
Solution Approach 1:
By implementing periodic pulsed cleaning cycles with controlled durations, the system achieves thorough cleaning over time without subjecting the press felt to continuous high-pressure mechanical stress. The intermittent operation allows permeability to stabilize between cycles while maintaining cleaning effectiveness.
Solution Approach 2:
The system applies cleaning agents at high concentration during brief pulsed intervals, using partial action in time to achieve complete cleaning效果. This concentrated intermittent application provides sufficient cleaning thoroughness while reducing cumulative mechanical stress on the felt structure, preserving permeability.
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 method significantly improves press felt permeability, reduces sheet defects, and extends the service life of press felts, while maintaining paper quality and minimizing production downtime, resulting in enhanced paper machine runnability and yield.
Implementation Method 1
high-pressure oscillating needle showers
Implementation Method 2
oscillating needle showers
Implementation Method 3
application of a cleaning composition to the oscillating needle shower
Implementation Method 4
pulsed application of cleaning agents through high-pressure oscillating needle showers, with specific wash durations
Data Source
AI summary
An apparatus is described for cleaning papermaking felt by applying a low concentration of a cleaning solution through the oscillating needle nozzles. The detergent is applied intermittently while paper is being manufactured. Each cleaning period lasts for at least the length of time required for the nozzles to cover the entire surface of the felt, and preferably twice that period of time. The application of cleaning solution is then discontinued for a period of time. This cycle is repeated continuously as the paper is being manufactured. The apparatus includes a first cleaning chemical reservoir, a second cleaning chemical reservoir, a high pressure pump coupled to the first and second reservoirs, and a control unit having programming for selectively injecting the chemicals.