Recycling Residual Fluid from Paper Coating Machines
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Solution Overview
Problem
The paper manufacturing process generates significant amounts of contaminated and diluted coating color residues, leading to feedstock losses and disposal costs, as existing methods for recycling these residues are inefficient and resource-intensive.
Innovation Solution
A method and device for recycling residual fluid from paper manufacturing processes that concentrate the residues to a solids content of over 25%, preferably 50%, using a combination of concentration and comminution devices, allowing for efficient separation and reuse of the residues and separation liquid, optimizing energy and resource usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If residual fluid is strongly concentrated with large amounts of separation liquid separated before comminution, then energy efficiency of the overall process is improved, but device complexity increases due to the functional separation of concentration device upstream of comminution device
Solution Approach 1:
The recycling system is divided into distinct functional modules: a concentration device (upstream) that separates separation liquid from residual fluid to produce concentrated residue fluid, and a comminution device (downstream) that processes the concentrated material. This segmentation allows each device to be optimized for its specific function, improving overall energy efficiency while managing complexity through modular design.
Solution Approach 2:
The concentration device performs preliminary concentration of the residual fluid before it enters the comminution device. By pre-concentrating the residue fluid to high solids content (above 25%, preferably above 50%), the subsequent comminution process requires less energy and processes smaller volumes, thereby improving overall energy efficiency of the recycling system.
2Loss of substance
If residual fluid is concentrated to high solids content before comminution, then material savings are improved through efficient separation and reuse, but loss of time increases due to the additional concentration step
Solution Approach 1:
The concentration device changes the physical parameter of solids content in the residual fluid, concentrating it from low initial levels to high levels (above 25%, preferably above 50%). This parameter change enables efficient material separation and reuse, maximizing material savings by allowing the concentrated residue fluid to be effectively recycled back into the papermaking process.
Solution Approach 2:
The system maintains continuous operation by seamlessly integrating the concentration device and comminution device in series. The concentrated residue fluid flows continuously from the concentration device to the comminution device and then back to the papermaking process, ensuring that the recycling operation proceeds without interruption and minimizing time losses.
3Productivity
If concentration device is positioned upstream of comminution device, then productivity is improved through efficient separation and reduced comminution workload, but device complexity increases due to the sequential arrangement
Solution Approach 1:
The recycling system is segmented into a concentration device positioned upstream and a comminution device positioned downstream. This segmentation allows the concentration device to perform liquid-solid separation first, producing concentrated residue fluid that requires less comminution processing, thereby improving overall productivity while managing system complexity through functional modularity.
Solution Approach 2:
The upstream concentration device performs preliminary separation of separation liquid from residual fluid before the material reaches the comminution device. This preliminary action reduces the volume and changes the consistency of the material entering the comminution device, decreasing the comminution workload and improving overall system productivity.
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 enables efficient recycling of coating color residues, reducing disposal costs and feedstock losses by achieving high energy efficiency and material savings, with a significant increase in solids content and optimized resource utilization, allowing for the reuse of the residues and separation liquid in the papermaking process.
Implementation Method 1
the residual fluid is concentrated with a concentration device, in particular dewatered
Implementation Method 2
the residual fluid is comminuted with the comminution device, in particular a ball mill, is crushed
Data Source
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AI summary
The invention relates to a method for recycling (1) residual fluid (2), such as coating residues, from a papermaking process, in particular from a paper coating machine, wherein the residual fluid (2) is collected, concentrated (in particular dewatered) by a concentration device (4), and comminuted by a comminution device (7), in particular a ball mill. To optimize recycling, it is provided that the residual fluid (2) is concentrated by the concentration device (4) to a solids content of more than 25%, preferably more than 50%, after which the residual fluid (2) is comminuted by the comminution device (7), after which at least one fraction of the residual fluid (2) is reintroduced into a papermaking process.The invention further relates to a device for the recycling of residual fluid (2), such as coating residues, from a paper manufacturing process.