Stock Flow Equalizer for Chemical Mixing in Paper Machines

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Solution Overview

Problem

The existing methods for mixing chemicals and additives in paper production lead to uneven distribution due to consistency variations in the stock flow, resulting in suboptimal retention of solids and increased chemical usage, which affects the quality and cost of the final product, as well as environmental impact.

Innovation Solution

A stock flow equalizer is introduced in the headbox feed pipe to create a chaotic turbulence zone that equalizes consistency differences, followed by an injection mixing station to ensure even distribution of chemicals across the entire cross-section of the stock flow pipe, using a mixer like the TrumpJet™ to mix additional stock components efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If chemicals are added to the stock flow without equalizing consistency differences, then the mixing process is simpler and faster, but the distribution of chemicals becomes uneven and chemical usage efficiency decreases

Engineering Contradiction:

Improveevenness of chemical distributionVSAvoidcomplexity of mixing arrangement

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The stock flow equalizer equalizes consistency differences in the stock flow before the chemical mixer introduces chemicals. This preliminary action ensures that when chemicals are added, they are distributed evenly throughout the stock, resolving the technical contradiction by improving chemical distribution evenness without requiring complex control systems during the mixing process itself.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mixing arrangement is segmented into two distinct functional components: a stock flow equalizer section that addresses consistency variations, and a chemical mixer section that introduces and distributes chemicals. This segmentation allows each component to perform its specific function optimally, achieving even chemical distribution while maintaining overall system simplicity.

Inventive Principle:

Principle #1Segmentation

2Reliability

If more chemicals are used to compensate for uneven distribution, then adequate retention of solids is achieved in all parts of the stock, but chemical costs increase and environmental impact worsens

Engineering Contradiction:

Improveretention of solidsVSAvoidamount of chemicals used

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

By equalizing consistency differences before chemical addition, the system ensures that chemicals are distributed evenly across all parts of the stock flow. This prevents the need to over-dose chemicals to compensate for poor distribution, thereby maintaining reliable solid retention while minimizing chemical consumption and environmental impact.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system changes the physical state of the stock flow by equalizing consistency parameters before chemical introduction. This parameter optimization ensures that chemicals interact uniformly with the stock, achieving reliable retention effects with minimal chemical quantities.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If chemicals are added before the headbox screen, then retention chemicals can bind solids effectively, but the screen turbulence may break the formed agglomerations and reduce retention efficiency

Engineering Contradiction:

Improveretention of solidsVSAvoidoperational conditions at headbox

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The stock flow equalizer prepares the stock flow by equalizing consistency differences before chemicals are added and before the stock reaches the headbox screen. This preliminary preparation ensures that when chemicals bind solids to form agglomerations, the reduced turbulence conditions are maintained, preventing screen-induced breakdown and ensuring reliable retention without compromising operational ease.

Inventive Principle:

Principle #10Preliminary action

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 minimizes chemical usage, reduces waste, and enhances the evenness of chemical distribution, leading to improved paper quality and reduced costs by ensuring that all parts of the stock receive an optimal amount of chemicals, thereby improving the consistency and quality of the end product.

Implementation Method 1

A stock flow equalizer is introduced in the headbox feed pipe to create a chaotic turbulence zone that equalizes consistency differences

Methodology Applied

Scientific EffectTurbulence: Turbulence

Implementation Method 2

followed by an injection mixing station to ensure even distribution of chemicals across the entire cross-section of the stock flow pipe

Methodology Applied

Scientific EffectInjection: Injector

Data Source

PatentUS11459700B2Method of and an arrangement for adding at least one additional stock component to an approach flow system of a fiber web machine

Publication Date: 2022.10.04 VALMET TECH OY

AI summary

A method of and an arrangement for adding at least one additional stock component to an approach flow system (30) of a fiber web machine by mixing the at least one additional stock component to a fibrous stock such that the stock flow is equalized (50) and the at least one additional stock component is introduced to the stock flow by injection mixing (80).