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ABSTRACT
The headbox as the link from the approach flow system to the forming section is one of the
most important tools for reaching best paper sheet properties. To fulfill best sheet quality
criteria such as CD basis weight profile, fiber orientation, homogeneous sheet structure,
and so on, largely depends on the headbox concept.
The hydraulic concept, geometric dimensions and the accuracy of the headbox are the key
factors for optimum uniformity of the sheet structure.
The C-clamp design of the headbox ensures that the slice opening remains parallel
irrespective of the pressure inside the nozzle and the jet velocity.
The Voith Paper dilution control system ModuleJetTM and the control system ProfilmaticTM M
on the headbox ensures the independent optimization of the paper sheet properties CD
basis weight profile and fiber orientation.
To deflocculate fiber flocs, the optimum intensity of the microturbulence is the key
parameter. Therefore the headbox is equipped with replaceable inserts in the turbulence
generator to optimize the hydraulic conditions for any operating conditions for board and
packaging paper machines.
The lamella technology, available for all Voith Paper headbox types, further improves the jet
quality and influences the MD/CD ratio. By installing lamellas in the headbox nozzle, the
microturbulence in the jet will be optimized and the macroturbulence in the jet will be
eliminated in the same time. In this way, "Tigerstripes" on board and packaging papers can
get rid of.
The two-layer headbox technology, mainly used on packaging paper machines, additional
demands like layer purity and the structured sheet formation are very important. To
separate the both layers inside the headbox nozzle, a rigid separating element is used.
Thus this rigid element, different jet velocities in the layers can be realized. This additional
feature, running the headbox in "differential speed operation", allows further improvements
in paper sheet properties.
INTRODUCTION
The headbox, as the link between the approach flow system and the forming section, is one
of the most important tools for reaching a homogeneous sheet structure. Its main tasks are
to distribute the stock uniformly in cross direction and to create a homogeneous jet for
achieving an optimum sheet structure in terms of physical properties. Even stock
distribution with regard to uniform volume flow and stock consistency in cross direction is
one of the important criteria for an optimized headbox. Another important criterion for good
headbox performance is the carefully optimized intensity of the jet turbulence.
To satisfy the high demands on product quality, optimum flow guidance of the stock within
the headbox is a fundamental requirement. The main key factors and the basis for
achieving a uniform jet, and thus a uniform sheet structure, are the hydraulic concept and
the geometric dimensions and stability.
Another important task of a modern headbox is the possibility to adjust the CD basis weight
and fibre orientation profiles independently, thus further improving the product quality.
MECHANICAL DESIGN ASPECTS
The quality and stability of the CD profiles, especially the fibre orientation profile, depend
largely on the precision and stability of parallelism of the slice opening. To achieve a parallel
and stable slice opening under operating conditions, all Voith Paper headboxes are designed
according to the C-clamp principle (Figure 1).
Parabolic header with constant pressure from tending side to drive side, for uniform
stock distribution across the headbox width. On fourdriniers and hybrid formers, a
pulsation dampening tank is installed in front of the headbox.
ModuleJet...dilution control system with dilution header, valves with stepper motor,
mixing chambers, throttles and distributor blocks.
The ModuleJetTM unit adds dilution water locally across the full headbox width. The dilution
water white water 1 is metered by an optimally designed valve. This design avoids dead
water areas inside the valve, and thus no solids can deposit even in the closed position of
the valve, because the valve is always opened a minimum and flushed.
The stock flow from the main header and the dilution water flow from the dilution water
header are joined locally in the mixing chamber. A throttle at the mixing chamber outlet
ensures optimum mixing of the two flows, resulting in a homogeneous average local stock
consistency (Figure 5).
The flow configuration inside the headbox nozzle without lamellas is shown in Figure 10,
and Figure 11 shows the effect of eddies on the free jet.
cause the end of the lamella to vibrate, thus resulting in disturbances in the free jet and
also in the sheet structure. There are two kinds of vibrations on long lamellas without
serrated tip:
1) Vibrations along the width with steady nodes on the lamella tip result in steady streaks
in the free jet (Figure 16).
2) Vibrations, as described under 1, are superimposed by vibrations of the lamella across
the whole lamella width. These combined vibrations cause a rhomb structure in the free jet
(Figure 17).
Figure 16 Effects on the free jet structure by using non-optimized lamella tip on
long lamellas
Figure 17 Effects on the free jet structure by using non-optimized lamella tip on
long lamellas
To prevent such effects as shown in Figure 16 and Figure 17, Voith Paper has developed a
specially designed lamella tip. The tip of the lamella has a very fine saw tooth structure on
the last few millimetres at the end of the lamella. This special tip allows to install long
lamellas ending just a few centimetres before the slice lip.
Combining long lamellas with a length of nearly 99% of the nozzle length and short
lamellas with approximately 60% of the nozzle length arranged in a certain pattern gives
the optimum jet quality and, as a result, optimum sheet quality without macroturbulence
and with an optimized intensity of microturbulence. The free jet quality improvements are
shown in Figure 18.
Figure 22 Differential speed operation and operation with identical jet velocities
If the headbox is operated with identical jet velocities in both layers, a difference in the jetto-wire ratio between the outer and inner layers will occur, resulting in a higher z
-orientation in the outer layer and thus a higher plybond.
The possibility of differential speed operation neutralizes the effect of different jet-to-wire
ratios, thus achieving almost the same z-orientation in the inner and outer layers and a
lower plybond compared to operation with identical jet velocities.
With differential speed operation, however, several improvements in strength properties can
be achieved and are confirmed in trials on the pilot paper machine.
Operating the two-layer headbox with a higher speed on the outer layer will improve the
strength properties as follows:
Higher RCTCD
Higher SCTCD
geom. mean
The two-layer technology using a rigid separating element and the possibility of differential
speed operation, in combination with the lamella technology, is a big step forward in
papermaking and gives the maximum flexibility and potential for optimizing the
papermaking process.
SUMMARY
The demands on sheet uniformity and sheet properties are mainly based on the quality of
the headbox. The geometric dimensions and stability as well as the hydraulic concept
determine the quality of the headbox.
To reach all state-of-the-art sheet strength properties as well as surface properties, the free
jet quality is one of the most important criteria.
The volume flow rate and the stock consistency distribution in cross direction, combined
with a uniform and optimum microturbulence generated in the stock, result in an optimum
free jet quality.
Due to the well-tuned system of turbulence generator, nozzle geometry and lamella
technology, a distinct improvement in free jet quality and also in sheet quality is achieved.
The multi-layer technology, in combination with the optimized hydraulic concept with
lamella technology, allows to produce a specific stratified sheet on one forming unit only.
Due to this optimized hydraulic concept with lamella technology in combination with the
optimum mechanical design, slogans like optimum free jet quality or optimum sheet quality
are no longer slogans, but will become reality now and in the future.