Calculation of the stock preparation department of the paper machine, which produces paper for corrugation. Calculation of thickeners Calculation of thickener performance for the production of paper pulp

Ministry of Education of the Russian Federation

Perm State Technical University

Department of TCBP

Group TCBPz-04

COURSE PROJECT

Topic: “Calculation of the stock preparation department of a paper machine producing paper for corrugation”

Akulov B.V.

Perm, 2009

Introduction

1. Characteristics of raw materials and finished products

Introduction

Paper is of great economic importance and its production. Paper production technology is complex, as it is often associated with the simultaneous use of fibrous semi-finished products with different properties, large quantity water, thermal and electrical energy, auxiliary chemical substances and other resources and is accompanied by the formation of a large amount of industrial waste and wastewater, which has a harmful effect on the environment.

Evaluating general state problems, it should be noted that according to the European Confederation of Paper Producers (CEPI), since the beginning of the 90s, the volume of waste paper recycling in the world has increased by more than 69%, in Europe - by 55%. With total reserves of waste paper estimated at 230-260 million tons, approximately 150 million tons were collected in 2000, and by 2005 the collection is projected to increase to 190 million tons. At the same time, the average world consumption level will be 48%. Against this background, the indicators for Russia are more than modest. Total resources waste paper amounts to about 2 million tons. The volume of its procurement has been reduced compared to 1980 from 1.6 to 1.2 million tons.

Against the background of these negative trends in Russia, the developed countries of the world over these 10 years, on the contrary, have increased the degree of state regulation in this area. In order to reduce the cost of production using waste, tax benefits. To attract investors to this area, a system of preferential loans has been created; in a number of countries, restrictions are imposed on the consumption of products manufactured without the use of waste, and so on. The European Parliament has adopted a 5-year program to improve the use of secondary resources: in particular paper and cardboard up to 55%.

According to some experts, industrial developed countries, currently, from an economic point of view, it is advisable to recycle up to 56% of waste paper raw materials from total number waste paper. About 35% of this raw material can be collected in Russia, while the rest of the waste paper is mainly in the form household waste ends up in a landfill, which is why it is necessary to improve the system of its collection and storage.

Modern technologies and equipment for processing waste paper allow it to be used not only for the production of low-quality, but also high-quality products. Obtaining high-quality products requires the availability additional equipment and the introduction of chemical auxiliaries to refine the mass. This trend is clearly visible in descriptions of foreign technological lines.

The corrugated cardboard industry is the largest consumer of waste paper and its main component is old cardboard boxes and boxes.

One of decisive conditions improving the quality of finished products, including strength indicators, is improving the quality of raw materials: sorting waste paper by grade and improving its cleaning from various contaminants. The increasing degree of contamination of secondary raw materials negatively affects the quality of products. To increase the efficiency of using waste paper, it is necessary to match its quality to the type of product being manufactured. Thus, container board and corrugating paper should be produced using waste paper mainly of MS-4A, MS-5B and MS-6B grades in accordance with GOST 10700, which ensures the achievement of high product performance.

In general fast growth The use of waste paper is determined by the following factors:

The competitiveness of the production of paper and cardboard from waste paper raw materials;

The relatively high cost of wood raw materials, especially taking into account transportation;

The relatively low capital intensity of projects for new enterprises operating on waste paper compared to enterprises using primary fiber raw materials;

Ease of creating new small businesses;

Increased demand for recycled fiber paper and board due to lower cost;

Governmental legislative acts(futures).

Another trend worth noting in the field of waste paper recycling is the slow decline in its quality. For example, the quality of Austrian containerboard is continuously declining. Between 1980 and 1995, the flexural stiffness of its core layer decreased by an average of 13%. The systematic repeated return of fiber to production makes this process almost inevitable.

1. Characteristics of raw materials and finished products

Characteristics of the feedstock are shown in Table 1.1.

Table 1.1. Brand, type and composition of waste paper used for the production of corrugated paper

Waste paper brand
	Unbleached kraft paper	Waste from paper production: packaging twine, electrical insulation, cartridge, bag, abrasive base, base for adhesive tape, as well as punched cards.
	Non-moisture-resistant paper bags	Used bags without bitumen impregnation, interlayer, reinforced layers, as well as residues of abrasive and chemically active substances.
	Corrugated cardboard and containers	Waste from the production of paper and cardboard used in the production of corrugated cardboard, without printing, adhesive tape and metal inclusions, without impregnation, coating with polyethylene and other water-repellent materials.
	Corrugated cardboard and containers	Waste from the production and consumption of paper and cardboard, used in the production of corrugated cardboard with printing without adhesive tape and metal inclusions, without impregnation, coating with polyethylene and other water-repellent materials.
	Corrugated cardboard and containers	Waste from the consumption of paper and cardboard, as well as used corrugated containers with printing without impregnation, coating with polyethylene and other water-repellent materials.

2. Selection and justification of the production flow diagram

Forming of the paper web takes place on the mesh table of the paper machine. The quality of paper largely depends on both the conditions of entry onto the grid and the conditions of its dewatering.

Characteristics of paper machine, composition.

In this course project, a mass preparation department will be designed for a paper machine producing corrugated paper weighing 1 m 2 100 - 125 g, speed - 600 m/min, cutting width - 4200 mm, composition - 100% waste paper.

Main design solutions:

Installation of fire protection equipment

Advantages: due to repeated sequential passage of waste from the first stage of purification through other stages, the amount of usable fiber in the waste is reduced and the number of heavy inclusions at the last stage of purification increases. Waste from the last stage is removed from the installation.

Installation of SVP-2.5

Advantages:

· supply of the sorted suspension to the lower part of the housing prevents heavy inclusions from entering the sorting zone, which prevents mechanical damage to the rotor and sieve;

· heavy inclusions are collected in a heavy waste collection and removed as they accumulate during operating sorting;

· in the sorting, a semi-closed rotor with special blades is used, which allows the sorting process to be carried out without supplying water to dilute the waste;

· mechanical seals made of siliconized graphite are used in the sorting, which ensures high reliability and durability of both the seal itself and the bearing supports.

Parts of the screens that come into contact with the suspension being processed are made of corrosion-resistant steel type 12Х18Н10Т.

Installation of a hydrodynamic headbox with regulation of the transverse profile by local changes in mass concentration

Advantages:

· the range of regulation of the weight of 1 m 2 of paper is greater than in conventional boxes;

· the weight of 1 m 2 of paper can be changed in sections by dividing 50 mm, which improves the uniformity of the transverse profile of the paper;

· the zones of influence of regulation are clearly limited.

The method of producing paper on flat mesh paper machines, despite the widespread and significant improvement of the equipment and technology used, is not without drawbacks. They noticeably manifested themselves when the machine was operating at high speed, and these were due to increased requirements for the quality of the paper being produced. A special feature of paper produced on flat mesh paper machines is some difference in the properties of its surfaces (versatility). The mesh side of the paper has a more pronounced mesh imprint on its surface and a more pronounced orientation of the fibers in the machine direction.

The main disadvantage of conventional molding on one mesh is that the water moves only in one direction and therefore there is an uneven distribution of fillers and fine fibers throughout the thickness of the paper. The part of the sheet that comes into contact with the mesh always contains less filler and fine fiber fractions than the opposite side. In addition, when the machine speed is over 750 m/min, due to the action of the built-in air flow and the operation of the dewatering elements at the beginning of the mesh table, waves and splashes appear on the mass filling mirror, which reduce the quality of the product.

The use of two-mesh forming devices is associated not only with the desire to eliminate the versatility of the paper produced. When using such devices, prospects have opened up for a significant increase in paper machine speed and productivity, because in this case, the speed of the filtered water and the filtration path are significantly reduced.

When using double-mesh forming devices, these are characterized by improved printing properties, a reduction in the dimensions of the mesh part and power consumption, simplified maintenance during operation and greater uniformity of the mass profile of 1 m 2 papers at high speed paper machine work. The Sim-Former forming device commonly used in practice is a combination of a flat and double-mesh machine. At the beginning of the formation of the paper web occurs due to the smooth removal of water on the forming board and subsequent single adjustable hydroplanes and wet suction boxes. Its further molding occurs between two meshes, where first, above the arcuate surface of the waterproof forming shoe, water is removed through the upper mesh, and then into suction boxes installed below. This ensures a symmetrical distribution of fine fiber and filler in the cross section of the paper web and its surface properties on both sides are approximately the same.

In this course project, a flat mesh machine was adopted, consisting of: a console table, a chest, rotating mesh and mesh drive shafts, a suction couch roll, a forming box, dewatering elements (hydroplane, wet and dry suction boxes), scrapers, mesh straighteners, mesh tensioners, spray systems, walkways service.

Also in paper production great importance has a selection of cleaning and sorting equipment. Fiber contaminants have different origins, shapes and sizes. Depending on the density, inclusions found in the mass are divided into three groups: with a density greater than the density of the fiber (metal particles, sand, etc.); with a density less than the density of the fiber (resin, air bubbles, oils, etc.); with a density close to or equal density fibers (chips, bark, firewood, etc.). Removal of the first two types of contaminants is the task of the cleaning process and is carried out at the waste treatment facility, etc. Separation of the third type of inclusions is usually a task of the sorting process, carried out in sortings of various types.

The purification of the mass at the waste treatment plant is carried out according to a three-stage scheme. Modern designs of waste treatment plants have a completely closed system, operate with back pressure at the waste outlet, and when used in front of a paper machine, are also equipped with devices for deaerating the mass or work together.

Pressure screens are screens closed type with hydrodynamic blades, used for such and coarse sorting of fibrous mass. Distinctive feature This type of screening is the presence of special profile blades designed for cleaning sieves.

Screens of the UZ type are single screens with hydrodynamic blades, located in the zone of the sorted mass. These sorters are used mainly for fine screening of pulp cleaned at the UVK, immediately before the paper machine. SCN type sortings are installed to sort waste from the knotter.

3. Calculation of the material balance of water and fiber on the paper machine

Initial data for calculation

Composition of corrugated paper:

Waste paper 100%

Starch 8 kg/t

The initial data for the calculation are presented in Table 3.1

Table 3.1. Initial data for calculating the water and fiber balance

Data name	Magnitude
1. Composition of corrugated paper, %
Waste paper
2. Dryness of the paper web and mass concentration during the technological process, %
waste paper coming from a high concentration pool
in the waste paper receiving pool
in the machine pool
in the pressure overflow tank
at the third stage of centric cleaners
at the second stage of centricliners
waste after the third stage of centric cleaners
waste after the second stage of centric cleaners
waste after the first stage of centric cleaners
waste from the knotter
waste from vibration sorting
for vibration sorting
sorted mass from vibratory sorting into the recycling water collector
in the headbox
after the preliminary dehydration section
after suction boxes
after the cauch shaft
cutoffs and rejects from the couch shaft
after the press part
defects in the press section
after the drying part
defects in the drying section
defects in finishing
after coasting
after slitting machine
in a couch mixer
in pulpers
return defect after thickener

from the concentration regulator of the waste pool
3. Amount of paper waste from paper production, net, %

in finishing (from machine calender and rolling)
in the drying section
in the press area
cut-offs and wet marriage with gouch - shaft
4. Amount of sorting waste from incoming mass, %
from the knotter
from the third stage of centric cleaners
from the second stage of centric cleaners
5. Concentration of circulating water %
from the couch shaft
pressed water from the press part into the drain
from the press part, water from washing the cloth into the drain
from suction boxes
from the pre-dewatering area to the sub-grid water collection
from the pre-dewatering area to the recycled water collection
from the thickener to the collection of excess recycled water
6. Mass overflow,%
from the headbox
from the pressure overflow tank
7. Cellulose consumption per sublayer, kg
8. Degree of fiber collection on the disk filter, %
9. Fresh water consumption, kg
for defoaming in the headbox


for washing the mesh
for washing cloth
for cutoffs
for thickener

Longitudinal cutting machine

From rolling forward

dry waste in pulper

The amount of dry waste is 1.8% of net production, i.e.

Check substance water mass

consumption: to warehouse 930.00 70.00 1000.00

marriage 16.74 1.26 18.00

Total 946.74 71.26 1018.00

arrival: from roll 946.74 71.26 1018.00

Machine calender and rolling (finishing)

dry waste in pulper

The amount of dry scrap from calender and reeling is 1.50% of net production, i.e.

Check substance water mass

Total 960.69 72.31 1033.00

Drying part

from the press part

The amount of dry waste is 1.50% of net production, i.e.

Check substance water mass

consumption: for calender 960.69 72.31 1033.00

Total 974.64 1329.47 2304.11

We assume that the dryness of the cloth does not change after washing, then if the waste contains 0.01% fiber, total weight their amount will be 4000.40 kg. Fiber losses with these waters are 4000.40-4000 = 0.4 kg.

Wet scrap from the couch shaft is 1.00% of net production,

those. at humidity 7.00%

The cutoffs are 1.00% of net production, i.e.

at humidity 7.00%

on the couch shaft

on suction boxes

The overflow of sub-grid water into the collector is 10.00% of the incoming mass,

The amount of waste from the knotter is 3.50% of the incoming mass, i.e.

Waste dilution unit for vibration sorting

The amount of waste from vibration sorting is 3.00% of the incoming mass, i.e.

We accept the amount of waste from the III stage of waste treatment - 2.00 kg. Waste from the III stage of FTP constitutes 5.00% of the incoming fiber

Concentration of circulating water in the collection tank

Waste from the second stage of FRP constitutes 5.00% of the incoming fiber, i.e.

to the 2nd stage of labor protection

to the knotter

at the first stage

Check substance water mass

The overflow is 10.00% of the incoming mass, i.e.

to pulse mill

in the marriage thickener

in the pool of wet marriage

because then

The degree of fiber collection on the disk filter is 90%, i.e.

for the concentration regulator of the waste pool

into the composition pool

into the pressure overflow tank

machine pool

We calculate starch with a concentration of 10 g / l

B 4 =800 - 8=792kg

In table 3.2 shows the consumption of clarified water.

Table 3.2. Consumption of clarified water (kg/t)

The excess of clarified water is

The loss of fiber with clarified water is

The summary balance of water and fiber is presented in table. 3.3.

Table 3.3. Summary table of water and fiber balance

Income and expense items

Fiber + chemical ingredients (absolutely dry matter):
Waste paper
Cellulose on sublayer

Finished paper
Fiber with water from presses
Vibratory sorting waste
Waste from the third stage of centric cleaners
Fiber with clarified water


with waste paper
with cellulose on the sublayer
with starch glue
for washing cloth
for cutoffs
for sealing the vacuum chambers of the couch shaft
for sealing suction boxes
for cleaning the mesh
for defoaming
for thickener
in finished paper
evaporates when dried
from presses
with waste from vibratory sorting
with waste from the third stage of centric cleaners
clarified water

The irretrievable fiber loss is

The fiber wash is equal to

The consumption of fresh fiber per 1 ton of net paper is 933.29 kg of absolutely dry (waste paper + cellulose on the sublayer) or air-dried fiber, including cellulose.

4. Calculation of the mass preparation department and machine productivity

Calculations for the stock preparation department of a papermaking machine producing corrugated paper:

Weight 1m 2 100-125g

B/m speed 600 m/min

Cutting width 4200 mm

Composition:

Waste paper - 100%

The maximum calculated hourly productivity of the machine during continuous operation.

Вн - width of the paper web at reeling, m;

V - maximum working speed, m/min;

q - maximum weight of 1m2 of paper, g/m2;

0.06 is the multiplier for converting minute speed to hourly speed and paper weight.

Maximum estimated output of the machine (gross output) during continuous operation per day

Average daily machine productivity (net output)

Keff - efficiency factor of machine use

K EF =K 1 K 2 K 3 =0.76 where

K 1 - coefficient of utilization of machine working time; at V<750 = 0,937

K 2 - coefficient taking into account defects on the car and idling of the car, = 0.92

K 3 - technological coefficient of use of the maximum speed of the machine, taking into account its fluctuations associated with the quality of semi-finished products and other technological factors, for mass types of paper = 0.9

Annual machine output

thousand tons/year

We calculate the capacity of pools based on the maximum amount of mass to be stored and the required storage time of the mass in the pool.

where M is the maximum amount of mass;

P H - hourly productivity;

t - mass storage time, h;

K - coefficient taking into account incomplete filling of the pool = 1.2.

High concentration pool volume

Volume of the composite pool

Reception basin volume

Machine basin volume

Wet scrap pool volume

Dry scrap pool volume

Recycling pool volume

The characteristics of the pools are shown in Table 4.1.

Table 4.1. Characteristics of swimming pools

To correctly select the type and type of grinding equipment, it is necessary to take into account the influence of factors: the place of the grinding apparatus in the technological scheme, the type and nature of the grinding material, the concentration and temperature of the mass.

To process dry waste, a pulper with the required maximum productivity is installed (80% of the net output of the machine)

349.27 H 0.8= 279.42 t

We accept GRVn-32

For finishing defects, a hydraulic pulper GRVn-6 is installed

Technical characteristics are shown in table 4.2.

Table 4.2. Technical characteristics of pulpers

Cleaning type installations

We accept UOT 25 at the first stage

Technical characteristics are shown in table 4.3

Table 4.3. Technical characteristics of UOT

Knotter

We accept SVP-2.5, productivity 480-600 t/day, technical characteristics are indicated in table 4.4

Table 4.4. Technical specifications

Parameter
Mass productivity w.d.w. sorted suspension, t/day, at the mass concentration of the incoming suspension:



Side surface area of the sieve drum, m 2
Electric motor power, kW
Nominal diameter of pipes DN, mm:
Suspension feed
Suspension removal
Removal of light inclusions

Vibration sorting

We accept VS-1.2 productivity 12-24 t/day

Technical characteristics are shown in table 4.5.

Table 4.5. Technical specifications

Parameter
Mass productivity w.d.w. sorted suspension (waste from sorting paper pulp with a sieve hole diameter of 2 mm), t/day
Mass concentration of incoming suspension, g/l
Sieve area, m 2
Electric motors: - quantity - power, kW
Nominal diameter of pipes DN, mm: - supply of suspension - discharge of sorted suspension
Overall dimensions, mm



Weight, kg

Calculation of centrifugal pumps

High Concentration Pool Pump:

reception basin pump:

composite pool pump:

machine pool pump:

wet scrap pool pump:

dry scrap pool pump:

mixing pump No. 1:

mixing pump No. 2:

mixing pump No. 3:

Sub-network water collection pump:

return water collection pump:

Couch mixer pump:

Main technical and economic indicators of the workshop

Electricity consumption kW/h………................................................... .......275

Steam consumption for drying, t……………………………………………3.15

Fresh water consumption, m 3 /t……………………………………………………23

water fiber paper making machine

List of information sources used

1. Paper technology: lecture notes / Perm. state tech. univ. Perm, 2003. 80 p. R.H. Khakimov, S.G. Ermakov

2. Calculation of water and fiber balance for a paper machine / Perm. state tech. univ. Perm, 1982. 44 p.

3. Calculations for the pulp preparation department of a paper mill / Perm. state tech. univ. Perm, 1997

4. Paper technology: guidelines for course and diploma design / Perm. state tech. univ. Perm, 51s., B.V. Akulov

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Introduction

1. Technological schemes for the production of paper and cardboard and their individual sections

1.2 General technological scheme for recycling waste paper

2. Equipment used. Classification, diagrams, principle of operation, main parameters and technological purpose of machines and equipment

2.1 Pulpers

2.2 Vortex cleaners type OM

2.3 Devices for magnetic separation of AMS

2.4 Pulse mill

2.5 Turbo separators

2.6 Sorting

2.7 Vortex cleaners

2.8 Fractionators

2.9 Thermal dispersion units - TDU

3. Technological calculations

3.1 Calculation of paper machine and mill productivity

3.2 Basic calculations for the mass preparation department

Conclusion

List of used literature

Introduction

Currently, paper and cardboard have become firmly established in the everyday life of modern civilized society. These materials are used in the production of sanitary and hygienic and household items, books, magazines, newspapers, notebooks, etc. Paper and cardboard are increasingly used in such industries as electric power, radio electronics, mechanical and instrument engineering, computer technology, astronautics, etc.

An important place in the economy of modern production is occupied by the produced range of paper and cardboard for packaging and packaging of various food products, as well as for the manufacture of cultural and household items. Currently, the global paper industry produces over 600 types of paper and cardboard, which have diverse, and in some cases completely opposite properties: highly transparent and almost completely opaque; electrically conductive and electrically insulating; 4-5 microns thick (i.e. 10-15 times thinner than a human hair) and thick types of cardboard that absorb moisture well and are waterproof (paper tarpaulin); strong and weak, smooth and rough; steam-, gas-, grease-proof, etc.

The production of paper and cardboard is a rather complex, multi-operational process that consumes a large number of different types of scarce fiber semi-finished products, natural raw materials and chemical products. It is also associated with high consumption of thermal and electrical energy, fresh water and other resources and is accompanied by the formation of industrial waste and wastewater, which has a detrimental effect on the environment.

The purpose of this work is to study the technology of paper and cardboard production.

To achieve the goal, a number of tasks will be solved:

Technological production schemes are considered;

It was found out what equipment is used, its structure, principle of operation;

The procedure for technological calculations of the main equipment has been determined

1. Technological schemes for the production of paper and cardboard and their individual sections

1.1 General technological scheme of paper production

The technological process of manufacturing paper (cardboard) includes the following main operations: accumulation of fibrous semi-finished products and paper pulp, grinding of fibrous semi-finished products, composition of paper pulp (with the addition of chemical auxiliaries), diluting it with circulating water to the required concentration, cleaning from foreign inclusions and deaeration, pouring the mass onto the mesh, forming the paper web on the mesh table of the machine, pressing the wet web and removing excess water (formed when the web is dehydrated on the mesh and in the press parts), drying, machine finishing and winding the paper (cardboard) into a roll. Also, the technological process of manufacturing paper (cardboard) involves the processing of recycled waste and the use of waste water.

The general technological scheme of paper production is shown in Fig. 1.

Fibrous materials are ground in the presence of water in batch or continuous grinders. If the paper has a complex composition, the ground fibrous materials are mixed in a certain proportion. Filling, adhesive and coloring substances are introduced into the fibrous mass. The paper pulp prepared in this way is adjusted in concentration and accumulated in a mixing basin. The finished paper pulp is then greatly diluted with recycled water and passed through cleaning equipment to remove foreign contaminants. The mass enters the endless moving mesh of the papermaking machine in a continuous flow through special control devices. On the mesh of the machine, fibers are deposited from a dilute fibrous suspension and a paper web is formed, which is then pressed, dried, cooled, moistened, machine-finished on a calender and, finally, supplied to reeling. After special moistening, machine-finished paper (depending on requirements) is calendered on a supercalender.

Figure 1 - General technological scheme of paper production

The finished paper is cut into rolls, which are sent either to packaging or to the sheet paper workshop. Roll paper is packaged in the form of rolls and sent to the warehouse.

Some types of paper (telegraph and cash register paper, mouthpiece paper, etc.) are cut into narrow strips and wound in the form of narrow spools of bobbins.

To produce cut paper (in the form of sheets), paper in rolls is sent to a paper cutting line, where it is cut into sheets of a given format (for example A4), and packaged into bundles. The waste water from the paper machine, containing fiber, fillers and glue, is used for technological needs. Before being discharged, excess waste water is sent to collection equipment to separate fibers and fillers, which are then used in production.

Paper waste in the form of tears or scraps is turned back into paper. The finished paper can be subjected to further special processing: embossing, creping, corrugation, surface painting, impregnation with various substances and solutions; Various coatings, emulsions, etc. can be applied to paper. This treatment allows you to significantly expand the range of paper products and give different types of paper different properties.

Paper often also serves as a raw material for producing products in which the fibers themselves undergo significant physical and chemical changes. Such processing methods include, for example, the production of vegetable parchment and fiber. Special processing and processing of paper is sometimes carried out in a paper mill, but most often these operations are carried out in separate specialized mills.

1.2 General technological scheme for recycling waste paper

Schemes for recycling waste paper at different enterprises may be different. They depend on the type of equipment used, the quality and quantity of waste paper processed and the type of product produced. Waste paper can be processed at low (1.5 - 2.0%) and at higher (3.5-4.5%) mass concentrations. The latter method makes it possible to obtain higher quality waste paper pulp with fewer units of installed equipment and lower energy consumption for its preparation.

In general, the scheme for preparing paper pulp from waste paper for the most common types of paper and cardboard is shown in Fig. 2.

Figure 2 - General technological scheme for recycling waste paper

The main operations of this scheme are: waste paper dissolution, coarse cleaning, additional dissolution, fine cleaning and sorting, thickening, dispersing, fractionation, grinding.

In the process of dissolving waste paper, carried out in pulpers of various types, waste paper in an aqueous environment under the influence of mechanical and hydromechanical forces is broken and dissolved into small bundles of fibers and individual fibers. Simultaneously with dissolution, the largest foreign inclusions in the form of wire, ropes, stones, etc. are removed from the waste paper mass.

Coarse cleaning is carried out with the aim of removing particles with a high specific gravity from the waste paper pulp, such as metal clips, sand, etc. For this, various equipment is used, generally operating according to a single principle, which makes it possible to most effectively remove heavier particles from the paper pulp than fiber. In our country, for this purpose, we use vortex cleaners of the OK type, operating at a low mass concentration (no more than 1%), as well as high concentration mass purifiers (up to 5%) of the OM type.

Sometimes magnetic separators are used to remove ferromagnetic inclusions.

Additional dissolution of the waste paper mass is carried out for the final breakdown of fiber bundles, of which quite a lot are contained in the mass leaving the pulper through the holes of the ring sieves located around the rotor in the lower part of the bath. For additional dispensing, turboseparators, pulsation mills, enstippers and cavitators are used. Turbo separators, unlike other mentioned devices, allow, simultaneously with the final dissolution of the waste paper mass, to carry out its further cleaning from the remnants of waste paper that has blossomed on the fiber, as well as small pieces of plastic, films, foil and other foreign inclusions.

Fine cleaning and sorting of the waste paper mass is carried out to separate from it the remaining lumps, petals, bundles of fibers and contaminants in the form of dispersions. For this purpose, we use screens operating under pressure, such as SNS, SCN, as well as installations of vortex conical cleaners such as UVK-02, etc.

To thicken the waste paper mass, depending on the concentration obtained, various equipment is used. For example, V in the low concentration range from 0.5-1 to 6.0-9.0%, drum thickeners are used, which are installed before subsequent grinding and mass accumulation .

If the waste paper pulp is to be bleached or stored wet, it is thickened to an average concentration of 12-17% using vacuum filters or screw presses.

Thickening of waste paper to higher concentrations (30-35%) is carried out if it is subjected to thermal dispersion treatment. To obtain a mass of high concentrations, devices are used that work on the principle of pressing the mass in screws, disks or drums with a pressure cloth.

Recycled water leaving thickeners or associated filters and presses is reused in the waste paper recycling system instead of fresh water.

Fractionation of waste paper during its preparation makes it possible to separate fibers into long- and short-fiber fractions. By carrying out subsequent grinding of only the long-fiber fraction, it is possible to significantly reduce energy consumption for grinding, as well as increase the mechanical properties of paper and cardboard produced using waste paper.

For the process of fractionating waste paper pulp, the same equipment is used as for its sorting, operating under pressure and equipped with sieves of appropriate perforation (sorting type SCN and SNS.

In the case where the waste paper pulp is intended to produce a white covering layer of cardboard or for the production of such types of paper as newspaper, writing or printing, it can be subjected to refining, i.e., removal of printing inks from it by washing or flotation, followed by bleaching with using hydrogen peroxide or other reagents that do not cause fiber destruction.

2. Equipment used. Classification, diagrams, principle of operation, main parameters and technological purpose of machines and equipment

2.1 Pulpers

Pulpers- these are devices that are used at the first stage of waste paper processing, as well as for the dissolution of dry recycled waste, which is returned back to the technological flow.

By design they are divided into two types:

With vertical (GDV)

With a horizontal shaft position (GRG), which, in turn, can be in various designs - for dissolving uncontaminated and contaminated materials (for waste paper).

In the latter case, the pulpers are equipped with the following additional devices: a harness catcher for removing wire, ropes, twine, rags, cellophane, etc.; a dirt collector for removing large heavy waste and a tow cutting mechanism.

The principle of operation of pulpers is based on the fact that a rotating rotor sets the contents of the bath into intense turbulent motion and throws it to the periphery, where the fibrous material, hitting stationary knives installed at the transition between the bottom and the body of the pulper, is broken into pieces and bundles of individual fibers.

Water with material, passing along the walls of the pulper bath, gradually loses speed and is again sucked into the center of the hydraulic funnel formed around the rotor. Thanks to such intensive circulation, the material is dissolved into fibers. To intensify this process, special strips are installed on the inner wall of the bath, against which the mass, when hitting, is subjected to additional high-frequency vibrations, which also contributes to its dissolution into fibers. The resulting fibrous suspension is removed through an annular sieve located around the rotor; the concentration of the fibrous suspension is 2.5...5.0% for continuous operation of the pulper and 3.5....5% for periodic operation.

Figure 3 - Diagram of a hydraulic pulper type GRG-40:

1 -- tow cutting mechanism; 2 -- winch; 3 -- tourniquet; 4 -- cover drive;

5 -- bath; 6 -- rotor; 7 -- sorting sieve; 8 -- sorted mass chamber;

9 -- dirt collector valve drive

The bath of this pulper has a diameter of 4.3 m. It is of a welded structure and consists of several parts connected to each other using flange connections. The bath has guide devices for better circulation of the mass in it. To load the dissolving material and comply with safety requirements, the bath is equipped with a closing loading hatch. Using a belt conveyor, waste paper is fed into the bath in bales weighing up to 500 kg with pre-cut packaging wire.

A rotor with an impeller (1.7 m in diameter) is attached to one of the vertical walls of the bath, which has a rotation speed of no more than 187 min.

Around the rotor there is a ring sieve with hole diameters of 16, 20, 24 mm and a chamber for removing the mass from the pulper.

At the bottom of the bath there is a dirt collector designed to catch large and heavy inclusions, which are removed from it periodically (every 1 - 4 hours).

The dirt trap has shut-off valves and a water supply line to flush out the good fiber waste.

Using a harness remover located on the second floor of the building, foreign inclusions (ropes, rags, wire, packaging tape, large polymer films, etc.) that are capable of being twisted into a bundle due to their size and properties are continuously removed from the bath of a working pulper. To form a bundle in a special pipeline connected to the pulper bath on the opposite side of the rotor, you first need to lower a piece of barbed wire or rope so that one end is immersed 150-200 mm below the matsa level in the pulper bath, and the other is clamped between the pulling drum and the pressure roller of the harness puller. For ease of transportation of the resulting bundle, it is cut by a special disk mechanism installed directly behind the bundle puller.

The productivity of pulpers depends on the type of fibrous material, the volume of the bath, the concentration of the fibrous suspension and its temperature, as well as the degree of its dissolution.

2.2 Vortex cleaners type OM

Vortex cleaners of the OM type (Fig. 4) are used for rough cleaning of waste paper in the process stream after the pulper.

The cleaner consists of a head with inlet and outlet pipes, a conical body, an inspection cylinder, a pneumatically driven mud pan and a support structure.

The waste paper mass to be cleaned is fed under excess pressure into the cleaner through a tangentially located pipe with a slight inclination to the horizontal.

Under the influence of centrifugal forces that arise when the mass moves in a vortex flow from top to bottom through the conical body of the purifier, heavy foreign inclusions are thrown to the periphery and collected in the mud pan.

The purified mass is concentrated in the central zone of the housing and along the upward flow, rising upward, leaves the purifier.

During the operation of the purifier, the upper valve of the sump must be open, through which water flows to wash the waste and partially dilute the purified mass. Waste from the mud pit is removed periodically as it accumulates due to the water entering it. To do this, alternately close the upper valve and open the lower one. The valves are controlled automatically at predetermined intervals depending on the degree of contamination of the waste paper mass.

OM type cleaners work well at a mass concentration of 2 to 5%. In this case, the optimal mass pressure at the inlet should be at least 0.25 MPa, at the outlet about 0.10 MPa, and the dilution water pressure 0.40 MPa. With an increase in mass concentration of more than 5%, the cleaning efficiency sharply decreases.

The vortex cleaner type OK-08 has a similar design to the OM cleaner. It differs from the first type in that it operates at a lower mass concentration (up to 1%) and without the addition of diluting water.

2.3 Devices for magnetic separation of AMS

Devices for magnetic separation are designed to capture ferromagnetic inclusions from waste paper.

Figure 5 - Apparatus for magnetic separation

1 - frame; 2 - magnetic drum; 3, 4, 10 - pipes for supplying, removing mass and removing contaminants, respectively; 5 - valves with pneumatic actuator; 6 - sump; 7 - pipe with valve; 8 - scraper; 9 - shaft

They are usually installed for additional purification of the mass after pulpers before OM type purifiers and thereby create more favorable operating conditions for them and other cleaning equipment. Devices for magnetic separation in our country are produced in three standard sizes.

They consist of a cylindrical body, inside of which there is a magnetic drum, magnetized using blocks of flat ceramic magnets mounted on five faces located inside the drum and connecting its end covers. Magnetic stripes of the same polarity are installed on one face, and opposite ones on adjacent faces.

The device also has a scraper, a mud pan, pipes with valves and an electric drive. The device body is built directly into the mass pipeline. ferromagnetic inclusions contained in the mass are retained on the outer surface of the magnetic drum, from which, as they accumulate, they are periodically removed using a scraper into the mud trap, and from the latter with a stream of water, as in OM-type devices. The drum is cleaned and the mud tray is emptied automatically by turning it every 1-8 hours, depending on the degree of contamination of the waste paper.

2.4 Pulse Mill

The pulsation mill is used for the final dissolution into individual fibers of pieces of waste paper that have passed through the holes of the annular sieve of the pulper.

Figure 6 - Pulsation mill

1 -- stator with headset; 2 -- rotor headset; 3 -- stuffing box; 4 -- camera;

5 -- foundation slab; 6 -- gap setting mechanism; 7 -- coupling; 8 -- fencing

The use of pulsation mills makes it possible to increase the productivity of pulpers and reduce the energy consumption, since in this case the role of pulpers can be reduced mainly to breaking down waste paper to a state where it can be pumped using centrifugal pumps. For this reason, pulse mills are often installed after pulping in pulpers, as well as dry waste from paper and board machines.

A pulsation mill consists of a stator and a rotor and in appearance resembles a steep conical grinding mill, but is not intended for this purpose.

The working set of stator and rotor pulsation mills differs from the set of conical and disk mills. It has a cone-shaped shape and three rows of alternating grooves and protrusions, the number of which in each row increases as the diameter of the cone increases. Unlike grinding devices in pulsation mills, the gap between the rotor and stator fittings is from 0.2 to 2 mm, i.e. tens of times greater than the average thickness of the fibers, so the latter, passing through the mill, are not mechanically damaged, and the degree the grinding mass practically does not increase (an increase of no more than 1 - 2°SR is possible). The gap between the rotor and stator fittings is adjusted using a special additive mechanism.

The operating principle of pulsation mills is based on the fact that a mass with a concentration of 2.5 - 5.0%, passing through the mill, is subjected to intense pulsation of hydrodynamic pressures (up to several megapascals) and velocity gradients (up to 31 m/s), resulting in good separation of lumps, tufts and petals into individual fibers without shortening them. This happens because when the rotor rotates, its grooves are periodically blocked by the stator protrusions, while the open cross-section for the passage of the mass is sharply reduced and it experiences strong hydrodynamic shocks, the frequency of which depends on the rotor rotation speed and the number of grooves on each row of the rotor and stator headset and can reach up to 2000 vibrations per second. Thanks to this, the degree of dissolution of waste paper and other materials into individual fibers reaches up to 98% in one pass through the mill.

A distinctive feature of pulsation mills is that they are reliable in operation and consume relatively little energy (3 to 4 times less than conical mills). Pulse mills come in a variety of brands, the most common ones are listed below.

2.5 Turbo separators

Turbo separators are designed for the simultaneous re-dispersion of waste paper after pulpers and its further separate sorting from light and heavy inclusions that were not separated at the previous stages of its preparation.

The use of turbo separators makes it possible to switch to two-stage schemes for dissolving waste paper. Such schemes are especially effective for recycling mixed contaminated waste paper. In this case, the primary dissolution is carried out in hydraulic pulpers that have large sorting sieve openings (up to 24 mm), and are also equipped with a rope puller and a dirt collector for large, heavy waste. After the primary dissolution, the suspension is sent to high-concentration mass purifiers to separate small heavy particles, and then to secondary dissolution in turbo separators.

Turbo separators come in various types, they can have a body shape in the form of a cylinder or a truncated cone, they can have different names (turbo separator, fibrizer, sorting pulper), but the principle of their operation is approximately the same and is as follows. The waste paper mass enters the turboseparator under an excess pressure of up to 0.3 MPa through a tangentially located pipe and, thanks to the rotation of the rotor with blades, acquires intense turbulent rotation and circulation inside the apparatus to the center of the rotor. Due to this, further dissolution of waste paper occurs, which is not fully carried out in the pulper at the first stage of dissolution.

Additionally, the waste paper mass, dissolved into individual fibers, due to excess pressure, passes through relatively small holes (3-6 mm) in the annular sieve located around the rotor and enters the receiving chamber of good mass. Heavy inclusions are thrown to the periphery of the apparatus body and, moving along its wall, reach the end cover located opposite the rotor, fall into the dirt collector, in which they are washed with circulating water and periodically removed. To remove them, the corresponding valves are automatically opened alternately. The frequency of removing heavy inclusions depends on the degree of contamination of the waste paper and ranges from 10 minutes to 5 hours.

Light small inclusions in the form of bark, pieces of wood, corks, cellophane, polyethylene, etc., which cannot be separated in a conventional pulper, but can be crushed in pulsation and other similar types of devices, are collected in the central part of the vortex flow of the mass and from there through a special The nozzle located in the central part of the end cover of the device is periodically removed. For efficient operation of turboseparators, it is necessary to remove at least 10% of the total mass received for processing with light waste. The use of turbo separators makes it possible to create more favorable conditions for the operation of subsequent cleaning equipment, improve the quality of waste paper pulp and reduce energy consumption for its preparation by up to 30...40%.

Figure 7 - Scheme of operation of the sorting type pulper GRS:

1 -- frame; 2 -- rotor; 3 -- sorting sieve;

4 -- chamber of sorted mass.

2.6 Sorting

Sorting SCN are intended for fine sorting of fibrous semi-finished products of all types, including waste paper. These sorters are available in three standard sizes, and differ mainly in size and performance.

Figure 8 - Single-screen pressure screening with a cylindrical rotor SCN-0.9

1 -- electric drive; 2 -- rotor support; 3 -- sieve; 4 -- rotor; 5 -- clamp;

6 -- frame; 7, 8, 9, 10 -- pipes for the input of mass, heavy waste, sorted mass and light waste, respectively

The sorting body is cylindrical in shape, located vertically, divided in the horizontal plane by disk partitions into three zones, of which the upper one is used for receiving the mass and separating heavy inclusions from it, the middle one is for the main sorting and removal of good mass, and the lower one is for collecting and removing sorting waste.

Each zone has corresponding pipes. The sorting cover is mounted on a rotating bracket, which facilitates repair work.

To remove the gas that collects in the center of the upper part of the sorter, there is a fitting with a tap in the lid.

The housing contains a sieve drum and a cylindrical glass-shaped rotor with spherical protrusions on the outer surface arranged in a spiral. This rotor design creates a high-frequency pulsation in the mass sorting zone, which eliminates mechanical grinding of foreign inclusions and ensures self-cleaning of the sorting screen during the sorting process.

The screening mass with a concentration of 1-3% is supplied under an excess pressure of 0.07-0.4 MPa to the upper zone through a tangentially located pipe. Heavy inclusions, under the influence of centrifugal force, are thrown towards the wall, fall to the bottom of this zone and, through the heavy waste pipe, enter the mud pit, from which they are periodically removed.

The mass, cleared of heavy inclusions, is poured through an annular partition into the sorting zone - into the gap between the sieve and the rotor.

The fibers that have passed through the sieve opening are discharged through the sorted mass nozzle.

Coarse fiber fractions, bundles and petals of fibers and other waste that do not pass through the sieve are dropped into the lower sorting zone and from there are continuously discharged through the light waste pipe for further sorting. If it is necessary to sort a mass of high concentration, water may enter the sorting zone; water is also used to dilute the waste.

To ensure efficient operation of sorting facilities, it is necessary to ensure a pressure drop at the input and output of the mass of up to 0.04 MPa and maintain the amount of sorting waste at a level of at least 10-15% of the incoming mass. If necessary, SCN type sorters can be used as waste paper fractionators.

A dual pressure sorter, type SNS-0.5-50, was created relatively recently and is intended for preliminary sorting of waste paper that has undergone additional screening and removal of coarse inclusions. It has a fundamentally new design that allows for the most efficient use of the sorting surface of the sieves, increasing the productivity and efficiency of sorting, and also reducing energy costs. The automation system used in sorting makes it an easy-to-maintain device. It can be used for sorting not only waste paper but also other fibrous semi-finished products.

The sorting body is a horizontally located hollow cylinder; inside which there is a sieve drum and a rotor coaxial with it. Two rings are attached to the inner surface of the housing, which are the annular support of the sieve drum and form three annular cavities. The outermost ones are receiving for the sorted suspension; they have pipes for supplying mass and mud collectors for collecting and removing heavy inclusions. The central cavity is designed to drain the sorted suspension and remove waste.

The sorting rotor is a cylindrical drum pressed onto a shaft, on the outer surface of which stamped bosses are welded, the number of which and their location on the surface of the drum are made in such a way that during one rotation of the rotor, two hydraulic pulses act on each point of the drum sieve, promoting sorting and self-cleaning of the sieve . The suspension to be cleaned with a concentration of 2.5-4.5% under an excess pressure of 0.05-0.4 MPa enters tangentially in two streams into the cavities between the end caps, on the one hand, and the peripheral rings and the rotor end, on the other hand. Under the action of centrifugal forces, heavy inclusions contained in the suspension are thrown towards the housing wall and fall into the mud traps, and the fibrous suspension into the annular gap formed by the inner surface of the screens and the outer surface of the rotor. Here the suspension is exposed to a rotating rotor with disturbing elements on its outer surface. Under the pressure difference inside and outside the sieve drum and the difference in mass velocity gradient, the purified suspension passes through the sieve holes and enters the receiving annular chamber between the sieve drum and the housing.

Sorting waste in the form of fires, petals and other large inclusions that did not pass through the sieve holes, under the influence of the rotor and the pressure difference, moves in counter flows to the center of the sieve drum and leaves the sorting through a special pipe in it. The amount of sorting waste is regulated using a valve with a tracking pneumatic drive depending on its concentration. If it is necessary to dilute the waste and regulate the amount of usable fiber in it, recycled water can be supplied to the waste chamber through a special pipe.

2.7 Vortex cleaners

They are widely used at the final stage of cleaning waste paper, as they allow you to remove from it the smallest particles of various origins, even those that slightly differ in specific gravity from the specific gravity of good fiber. They operate at a mass concentration of 0.8-1.0% and effectively remove various contaminants up to 8 mm in size. The design and operation of these installations are described in detail below.

2.8 Fractionators

Fractionators are devices designed to separate fiber into various fractions that differ in linear dimensions. The waste paper pulp, especially when processing mixed waste paper, contains a large number of small and destructed fibers, the presence of which leads to increased fiber washouts, slows down the dewatering of the pulp and worsens the strength properties of the finished product.

In order to bring these indicators to some extent closer to those, as in the case of using original fibrous materials that have not been used, the waste paper mass has to be additionally ground to restore its paper-forming properties. However, during the grinding process, further grinding of the fiber inevitably occurs and the accumulation of even smaller fractions, which further reduces the ability of the mass to dehydrate, and in addition, leads to a completely useless additional expenditure of a significant amount of energy for grinding.

Therefore, the most reactive scheme for preparing waste paper is one in which, during the process of sorting, the fiber is fractionated, and either only the long-fiber fraction is subjected to further grinding, or they are ground separately, but according to different modes that are optimal for each fraction.

This makes it possible to reduce energy consumption for grinding by approximately 25% and increase the strength characteristics of paper and cardboard obtained from waste paper by up to 20%.

As a fraction, SCN type sorters with a sieve opening diameter of 1.6 mm can be used, but they must operate in such a way that waste in the form of a long-fiber fraction constitutes at least 50...60% of the total amount of mass entering the sorting. When fractionating waste paper pulp from the process flow, it is possible to exclude the stages of thermal dispersion processing and additional fine cleaning of the pulp in sortings such as SZ-12, STs-1.0, etc.

The diagram of a fractionator, called an installation for sorting waste paper pulp, type USM and the principle of its operation are shown in Fig. 9.

The installation has a vertical cylindrical body, inside the upper part of which there is a sorting element in the form of a horizontally located disk, and under it, in the lower part of the body, there are concentric chambers for selecting various fiber fractions.

The sorted fibrous suspension under an excess pressure of 0.15 -0.30 MPa through a nozzle nozzle is directed perpendicularly to the surface of the sorting element through a nozzle nozzle at a speed of up to 25 m/s and, hitting it, due to the energy of the hydraulic shock, it is broken into individual tiny particles, which in the form the splashes scatter radially in the direction from the center of the impact and, depending on the size of the suspension particles, fall into the corresponding concentric chambers located at the bottom of the sorting. The smallest components of the suspension are collected in the central chamber, and the largest of them are collected at the periphery. The amount of fiber fractions obtained depends on the number of receiving chambers installed for them.

2.9 Thermal dispersion units - TDU

Designed for uniform dispersion of inclusions contained in the waste paper mass and not separated during its fine cleaning and sorting: printing inks, softened and fusible bitumen, paraffin, various moisture-resistant contaminants, fiber petals, etc. During the dispersion of the mass, these inclusions are evenly distributed throughout the entire volume suspension, which makes it monochromatic, more uniform and prevents the formation of various kinds of stains in finished paper or cardboard obtained from waste paper.

In addition, dispersion helps reduce bitumen and other deposits on drying cylinders and clothes of paper and board machines, which increases their productivity.

The thermal dispersion process is as follows. The waste paper mass, after additional dissolution and preliminary coarse cleaning, is thickened to a concentration of 30-35%, subjected to heat treatment to soften and melt the non-fibrous inclusions contained in it, and then sent to the dispersant for uniform dispersion of the components contained in the mass.

The technological diagram of the TDU is shown in Fig. 10. The TDU includes a thickener, a screw ripper and a screw lift, a steaming chamber, a disperser and a mixer. The working body of the thickener is two completely identical perforated drums, partially immersed in a bath with the thickened mass. The drum consists of a shell, into which disks with trunnions are pressed at the ends, and a filter sieve. The discs have cutouts to drain the filtrate. On the outer surface of the shells there are many annular grooves, at the base of which holes are drilled to drain the filtrate from the sieve into the drum.

The thickener body consists of three compartments. The middle one is the thickener bath, and the two outer ones are used to collect the filtrate draining from the internal cavity of the drums. The mass for thickening is supplied through a special pipe to the lower part of the middle compartment.

The thickener operates at a slight excess pressure of the mass in the bath, for which all working parts of the bath have seals made of high molecular weight polyethylene. Under the influence of a pressure difference, water is filtered from the mass and a layer of fiber is deposited on the surface of the drums, which, when they rotate towards one another, falls into the gap between them and is additionally dehydrated due to the clamping pressure, which can be adjusted by horizontal movement of one of the drums. The resulting layer of condensed fiber is removed from the surface of the drums using textolite scrapers, hinged and allowing the clamping force to be adjusted. For washing drum screens, there are special sprays that allow the use of recycled water containing up to 60 mg/l of suspended solids.

The productivity of the thickener and the degree of thickening of the mass can be adjusted by changing the rotation speed of the drums, the filtration pressure and the pressure of the drums. The fibrous layer of the mass, removed by scrapers from the thickener drums, enters the receiving bath of the ripper screw, in which it is loosened into separate pieces using a screw and transported to an inclined screw that feeds the mass into the steaming chamber, which is a hollow cylinder with a screw inside.

Steaming of the mass in the chambers of domestic installations is carried out at atmospheric pressure at a temperature of no more than 95 °C by supplying live steam with a pressure of 0.2-0.4 MPa to the lower part of the steaming chamber through 12 nozzles evenly spaced in one row.

The length of time the mass remains in the steaming chamber can be adjusted by changing the screw speed; it usually ranges from 2 to 4 minutes. The steaming temperature is adjusted by changing the amount of steam supplied.

In the area of the unloading pipe, there are 8 pins on the screw of the steaming chamber, which serve to mix the mass in the unloading zone and eliminate its hanging on the walls of the pipe through which it enters the screw feeder of the dispersant. The mass disperser in appearance resembles a disk mill with a rotor speed of 1000 min-1. The working dispersant set on the rotor and stator consists of concentric rings with awl-shaped protrusions, and the protrusions of the rotor rings fit into the spaces between the stator rings without coming into contact with them. Dispersion of the waste paper mass and the inclusions contained in it occurs as a result of the impact of the protrusions of the headset with the mass, as well as due to the friction of the fibers against the working surfaces of the headset and among themselves when the mass passes through the working area. If necessary, dispersants can be used as grinding devices. In this case, it is necessary to change the dispersant set to the disk mill set and create the appropriate gap between the rotor and stator by adding them.

After dispersion, the mass enters the mixer, where it is diluted with recycled water from the thickener and enters the dispersed mass pool. There are thermal dispersion plants operating under excess pressure with a waste paper processing temperature of 150-160 °C. In this case, it is possible to disperse all types of bitumen, including those with a high content of resins and asphalt, but the physical and mechanical characteristics of the waste paper mass are reduced by 25-40%.

3. Technological calculations

Before carrying out calculations, it is necessary to select the type of paper machine (CBM).

Selecting a Paper Machine Type

The choice of paper machine type (CBM) is determined by the type of paper produced (its quantity and quality), as well as the prospects for switching to other types of paper, i.e. Possibility of producing a varied assortment. When choosing a machine type, the following issues should be considered:

Quality indicators of paper in accordance with GOST requirements;

Justification of the type of molding and operating speed of the machine;

Drawing up a technological map of machines for producing this type of paper;

Speed, cutting width, drive and its control range, the presence of a built-in size press or coating device, etc.;

Mass concentration and dryness of the web by machine parts, concentration of circulating water and the amount of wet and dry machine defects;

Drying temperature schedule and methods of its intensification;

degree of paper finishing on the machine (number of machine calenders).

Characteristics of machines by type of paper are given in Section 5 of this manual.

3.1 Calculation of paper machine and mill productivity

As an example, the necessary calculations were made for a factory consisting of two paper machines with a non-cut width of 8.5 m (cut width 8.4 m), producing newsprint 45 g/m2 at a speed of 800 m/min. The general technological scheme of paper production is shown in Fig. 90. The calculation uses data from the given balance of water and fiber.

When determining the productivity of a paper machine (BDM), the following are calculated:

maximum calculated hourly productivity of the machine during continuous operation QCHAS.BR. (performance can also be denoted by the letter P, for example RFAS.BR.);

maximum design output of the machine during continuous operation for 24 hours - QSUT.BR.;

average daily productivity of the machine and factory QSUT.N., QSUT.NF.;

annual productivity of the machine and factory QYEAR, QYEAR.F.;

thousand tons/year,

where BH is the width of the paper web at reel, m; n - maximum speed of the machine, m/min; q - weight of paper, g/m2; 0.06 - coefficient for converting grams into kilograms and minutes into hours; KEF - the overall efficiency factor of paper machine use; 345 is the estimated number of days the paper machine operates per year.

where KV is the coefficient of utilization of machine working time; at nSR< 750 м/мин КВ =22,5/24=0,937; при нСР >750 m/min CV =22/24=0.917; KX is a coefficient that takes into account defects on the machine and idling of the KO machine, breakdowns on the slitting machine KR and failures on the supercalender KS (KX = KO·KR·KS); CT is the technological coefficient of utilization of the paper machine speed, taking into account its possible fluctuations associated with the quality of semi-finished products and other technological factors, CT = 0.9.

For the example in question:

thousand tons/year.

Daily and annual productivity of the factory with the installation of two paper machines:

thousand tons/year.

3.2 Basic calculations for the mass preparation department

Calculation of fresh semi-finished products

As an example, a calculation was made of the stock preparation department of a factory producing newsprint in accordance with the composition specified in the calculation of the balance of water and fiber, i.e. semi-bleached kraft pulp 10%, thermomechanical pulp 50%, defibrated wood pulp 40%.

The consumption of air-dried fiber for the production of 1 ton of net paper is calculated based on the balance of water and fiber, i.e. fresh fiber consumption per 1 ton of net newsprint is 883.71 kg of absolutely dry (cellulose + DDM + TMM) or 1004.22 kg of air-dried fiber, including cellulose - 182.20 kg, DDM - 365.36 kg, TMM - 456.66 kg.

To ensure maximum daily productivity of one paper machine, the consumption of semi-finished products is:

cellulose 0.1822 · 440.6 = 80.3 t;

DDM 0.3654 · 440.6 = 161.0 t;

TMM 0.4567 · 440.6 = 201.2 t.

To ensure the daily net productivity of one paper machine, the consumption of semi-finished products is:

cellulose 0.1822 · 334.9 = 61 t;

DDM 0.3654 · 334.9 = 122.4 t;

TMM 0.4567 · 334.9 = 153.0 t.

To ensure the annual productivity of the paper machine, the consumption of semi-finished products is accordingly:

cellulose 0.1822 · 115.5 = 21.0 thousand tons

DDM 0.3654 · 115.5 = 42.2 thousand tons;

TMM 0.4567 · 115.5 = 52.7 thousand tons.

To ensure the annual productivity of the factory, the consumption of semi-finished products is accordingly:

cellulose 0.1822 231 = 42.0 thousand tons

DDM 0.3654 · 231 = 84.4 thousand tons;

TMM 0.4567 · 231 = 105.5 thousand tons.

In the absence of calculating the balance of water and fiber, the consumption of fresh air-dried semi-finished product for the production of 1 ton of paper is calculated using the formula: 1000 - B 1000 - B - 100 · W - 0.75 · K

RS = + P+ OM, kg/t, 0.88

where B is the moisture contained in 1 ton of paper, kg; Z - ash content of paper, %; K - rosin consumption per 1 ton of paper, kg; P - irreversible losses (washing) of fiber with 12% moisture content per 1 ton of paper, kg; 0.88 - conversion factor from absolutely dry to air-dry state; 0.75 - coefficient taking into account the retention of rosin in paper; RH - loss of rosin with circulating water, kg.

Calculation and selection of grinding equipment

The calculation of the amount of grinding equipment is based on the maximum consumption of semi-finished products and taking into account the 24-hour operating time of the equipment per day. In the example under consideration, the maximum consumption of air-dry cellulose to be ground is 80.3 tons/day.

Calculation method No. 1.

1) Calculation of disk mills of the first grinding stage.

For grinding cellulose at high concentration according to the tables presented in“Pulp and paper production equipment” (Reference manual for students. Special. 260300 “Technology of chemical wood processing” Part 1 / Compiled by F.Kh. Khakimov; Perm State Technical University Perm, 2000. 44 p. .)Mills of the MD-31 brand are accepted. Specific load on the knife edge INs= 1.5 J/m. In this case, the second cutting length Ls, m/s, is 208 m/s (section 4).

Effective grinding power Ne, kW, is equal to:

N e = 103 Vs Ls · j = 103 1.5 . 0.208 1 = 312 kW,

where j is the number of grinding surfaces (for a single-disk mill j = 1, for a double-disc mill j = 2).

Mill performance MD-4Sh6 Qp, t/day, for the accepted grinding conditions will be:

Where qe=75 kW . h/t specific useful energy consumption for grinding sulfate unbleached cellulose from 14 to 20 °SR (Fig. 3).

Then the required number of mills for installation will be equal to:

Mill productivity varies from 20 to 350 t/day, we accept 150 t/day.

We accept two mills for installation (one in reserve). Nxx = 175 kW (section 4).

Nn = Ne +Nxx= 312 + 175 = 487 kW.

TONn > Ne+Nxx;

0,9. 630 > 312 + 175; 567 > 487,

performed.

2) Calculation of mills of the second grinding stage.

To grind cellulose at a concentration of 4.5%, mills of the MDS-31 brand are used. Specific load on the knife edge INs=1.5 J/m. The second cutting length is taken according to the table. 15: Ls= 208 m/s=0.208 km/s.

Effective grinding power Ne, kW will be equal to:

Ne = Bs Ls= 103 ·1.5 . 0.208·1 = 312 kW.

Specific energy consumption qe, kW . h/t, for grinding cellulose from 20 to 28°ShR according to the schedule will be (see Fig. 3);

qe =q28 - q20 = 140 - 75 = 65 kW . h/t

Mill performance Qp, t/day, for the accepted operating conditions will be equal to:

Then the required number of mills will be:

Nxx = 175 kW (section 4).

Mill power consumption Nn, kW, for the accepted grinding conditions will be equal to:

Nn = Ne +Nxx= 312 + 175 = 487 kW.

Checking the power of the drive motor is carried out according to the equation:

TONn > Ne+Nxx;

0,9. 630 > 312 + 175;

Therefore, the condition for checking the electric motor is fulfilled.

Two mills are accepted for installation (one in reserve).

Calculation method No. 2.

It is advisable to calculate the grinding equipment according to the above calculation, however, in some cases (due to the lack of data on the selected mills), the calculation can be carried out using the formulas given below.

When calculating the number of mills, it is assumed that the grinding effect is approximately proportional to the energy consumption. Electricity consumption for grinding cellulose is calculated using the formula:

E= e· PC·(b- a), kWh/day,

Where e? specific electricity consumption, kWh/day; PC? quantity of air-dry semi-finished product to be ground, t; A? degree of grinding of the semi-finished product before grinding, oShR; b? degree of grinding of the semi-finished product after grinding, oShR.

The total power of electric motors of grinding mills is calculated by the formula:

Where h? load factor of electric motors (0.80?0.90); z? number of mill operating hours per day (24 hours).

The power of mill electric motors for grinding stages is calculated as follows:

For the 1st grinding stage;

For the 2nd grinding stage,

Where X1 And X2 ? distribution of electricity to the 1st and 2nd grinding stages, respectively, %.

The required number of mills for the 1st and 2nd stages of grinding will be: technological paper machine pump

Where N1 M And N2 M ? power of the electric motors of the mills intended for installation at the 1st and 2nd stages of grinding, kW.

In accordance with the accepted technological scheme, the grinding process is carried out at a concentration of 4% up to 32 oSR in disk mills in two stages. The initial degree of grinding of semi-bleached sulfate softwood pulp is 13 oShR.

According to practical data, the specific energy consumption for grinding 1 ton of bleached sulphate softwood pulp in conical mills will be 18 kWh/(t oSR). In the calculation, a specific energy consumption of 14 kWh/(t·shr) was taken; Since the grinding is designed in disc mills, are energy savings taken into account? 25%.