Papermaking

STOCK PREPARATION LC REFINING

A special thanks to FineBar for the excerpted notes from their
Introduction to Stock Prep Refining Manual available at:
www.finebar.com

1. Structure of Paper & The Role of Refining

Paper is a tangled web of fibers. The fibers are more or less lying in a
flat plane, and they are attached to one another at the many points of
contact that occur wherever one fiber lies across another fiber. The
strength of paper is largely determined by the strength of the
attachments at these fiber crossing points. While it is true that
strength of the individual fibers can also be a factor in determining the
strength of the resulting paper, it is often the case that paper fails
when the fiber-fiber bonds fail.

The linkage that occurs at the fiber crossing points of paper is

made up of hydrogen bonds which are formed between
corresponding points on two cellulose or hemicellulose molecules
when an interconnecting water molecule is removed by drying. A
representation of this type of bond in cellulose is shown below.

LC Refining Page 1
Anything that can increase the number of hydrogen bonds engaged
at a crossing point will increase the strength of the linkage and, thus,
the strength of the paper.

For simplicity, consider just two fibers and a single crossing of one
over the other. If the cell wall of these fibers is very rigid, as with a
glass tube for example, the area of contact at the crossing point will
be small. On the other hand, if the fiber walls are very flexible, as with
a bicycle inner tube, the contact area at the crossing point will be
much larger. It is important to recognize that as fibers become mo re
flexible and collapse to ribbon-like structures, the contact area
increases dramatically as does the potential number of hydrogen
bonds that can be formed. The thickness of the cell wall has a
dominant influence on the collapsibility of the fiber. For this reason,
the type of wood used largely determines the potential for achieving
critical paper properties. However, for any given fiber source and
pulping process, it is the process of refining which essentially
determines the extent to which the fibers collapse.

The degree of fiber collapse and the resulting increase in contact

area are important in determining how many bonds can potentially be
formed. It is also necessary that the surfaces in contact have a
relatively large number of exposed bonding sites. This can be
accomplished by ensuring that all the surface lignin has been
removed together with the primary cell wall, and that many of the
fibrils near the exterior of the S2 layer are teased out so as to create
the effect of a frayed rope. The removal of lignin and primary wall
material is largely accomplished in the pulping process. The teasing
out of fibrils, referred to as fibrillation, is accomplished in refining.

The principal objectives of stock preparation refining are thus: 1) to

LC Refining Page 2
increase the flexibility of the cell wall to promote increased contact
area, and 2) to fibrillate the external surface of the fiber to further
promote the formation of hydrogen bonds and increase the total
surface area available for bonding. From the figure below, we see
that the cell wall is weakened through delamination of the cell wall
and the outer wall of the fibre is fibrillated.

Now that we have examined what happens at a single fiber

crossing point, we can consider what the aggregate effects are on
the structure of the paper sheet.

The function of the paper machine is to convert a suspension of fiber

and water into a relatively moisture-free web with specific
characteristics. If you visualize a layered structure of fibers piled one
on top of the other, the thickness of the resulting paper may be
equivalent to anywhere from five individual fiber thicknesses up to
several tens of fiber thicknesses. If the fibers act like rigid cylinders,
the paper sheet will be very thick and full of void spaces (i.e. it will be
bulky); whereas if all the fibers collapse to ribbons, the sheet will be
much thinner and denser. Indeed, the most evident result of refining
is an increase in the density of the paper that is formed. Along with
this increase in density comes a reduction in air permeability (or

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porosity), an increase in tensile strength, and often a reduction in tear
strength. Whether or not a reduction in tear strength occurs, refining
almost always increases the fracture toughness of the sheet. It is
easy to imagine that surface smoothness will be better when ribbons
are used in place of rigid cylinders, so long as the ribbons lie flat in
the plane of the sheet. Figure below shows a typical cross section of
paper, illustrating quite clearly how fiber collapse might affect several
paper properties.

Another effect of increasing bonding and paper density is to make the

resultant sheet less opaque (i.e. more transparent). For printing
papers, this is an undesirable side effect because sheet opacity is
important in preventing the printing on one side of the paper from
showing through on the other side.

It is important to remember that there are other steps in the forming

process that substantially affect paper properties. After the sheet is
formed on the machine, water is removed in the press section where
the nature and extent of press loading can have considerable effects

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on paper properties. Pressing increases the density of the wet mat
and of the finished paper as well. In the drying section of the
machine, conditions will again affect final sheet properties. Hydrogen
bonds form when intervening water is removed, after which a
significant amount of shrinkage takes place both in the individual
fibers and in the paper sheet. Fibers shrink mostly in the cross-wise
direction rather than along their length. However, the cross-wise
shrinking of one fiber can cause a length-wise compression of a fiber
that is bonded to it in a perpendicular orientation. The resulting
internal stresses can dramatically affect paper properties (e.g.
dimensional stability, curl). The extent to which the sheet is restrained
during drying can play a large role in determining paper performance.

Clearly, while refining is a very important step in engineering the

structure of paper, is only one of several critical process steps. It is
impossible to optimize any one of the critical steps without due
consideration of the others.

So far, we have discussed the refining process and how it affects

paper structure in a mostly qualitative way. In later sections, we will
try to quantify the process and learn how to use refiners and refiner
fillings to assist the paper maker in achieving economic and product
quality benefits.

2. Refining Equipment

Laboratory refiners

PFI Mill

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 Bedplate Roll

Figure: PFI laboratory refiner

To evaluate pulp in the laboratory, it must be first beaten or refined,

as is the case in industrial papermaking. Several types of laboratory
refiners exist for this purpose. The most common is the PFI mill. The
PFI mill, shown schematically, is by far the most common laboratory
refiner in use today. However, its action differs substantially from
industrial refiners. It operates at 10% consistency as opposed to the
normal 3-4% in industrial refiners. It is in essence a very high energy,
very low intensity refiner. It gives strength increases often well
beyond those obtained in mill refiners

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 DRIVE
STOCK
SLURRY
BOLT
ELEVATING BEATER
TOWERING
MECHANISM
TUB

BEARING
ROTOR
BEATER BLADE BEATER
WOOD
MIDFEATHER

BACK FALL

BEDPLATE
DUMP VALVE

PATH OF
STOCK FLOW

STATOR BLADES
AND WOODS

TO DUMP PUMP

Hollander Beater

The Hollander Beater was invented in Holland in the late 17th

century.

This is one of the first refiners used. It uses a bar and groove rotor to
impose cyclic compression into the fibres as they flow through an
open trough. These are not used commercially but are used in some
laboratories and used in making hand-made papers.

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Modern refining equipment

Refiners can be either disc refiners or conical refiners. Conical

refiners are shown in the following figures. The pulp enters through a
feed port, travels between a conical rotor and stator and then leaves
through the discharge port. The rotor and stator will have a bar and
groove pattern. Only one of the elements will rotate (the rotor). The
gap between the refiners can be controlled by pushing the rotor and
stator together.

SHELL SPHERICA
FILLIN L
PACKING OUT LE PLUG INLE ROLLER
ASSEMBL FILLIN

T APERED
ROLLER

PLUG
ADJUST MEN

CLEANOU
T
1-PIECE
SHELL

A disc refiner is very similar to the conical refiner. The pulp travels
between two discs with bars and grooves. There are essentially
three categories of disc refiner:
1. Single disc refiners, where the pulp goes between a rotating rotor
and a stationary stator.
2. Twin refiner where the rotor and stator both rotate.
3. Double disc refiner where the pulp moves between a rotating rotor
that has bars and grooves on both sides and it moves against two
stationary stators.

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 INLET INLET
(PARALLEL FLOW)

DRIVE
OUTLET
(SERIES FLOW)

OUTLET
(PARALLEL FLOW)

THRUST MECHANISM

ROTOR
(OUTBOARD SIDE) BAR

SLIDING COUPLING DISC PLATE

STATOR (OUTBOARD)

ROTOR
(INBOARD SIDE)

STATOR
(INBOARD)
STOCK FLOW

SEAL

BEARINGS

The refiner plates come in a large number of patterns to control the

intensity of treatment and capacity, although, these are often
competing. Refiners can have a fine bar pattern that gives high
intensity but lower throughput or can have a coarse bar pattern that
gives a high intensity treatment (even cut the fibres) and a larger flow
rate through the refiner. The sampling of the different types of
patterns can be seen below.

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4. Theory of Refining

i) Qualitative Analysis

In this section, the details of stock preparation refining process will be

examined more closely. It will be shown that fiber and pulp properties
can be manipulated by altering the refiner plate configuration and the
operating conditions of a refiner in order to achieve an optimal
combination of paper properties.

Pulp refining is a process in which fiber flocs collect on refiner bar

edges and are subsequently deformed by compressive and shear
forces such that the cell wall of at least some of the fibers is
permanently modified.

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The nature of the cell wall modification is dependent on the
magnitude of the compressive stresses (or strains) that occur during
the deformation of the fiber flocs. The extent of the cell wall
modification depends on how frequently fiber flocs are collected and
subsequently deformed for a given mass of fiber. In pulp refining, we
are interested in both the magnitude and the frequency of these
deformations.

Within each fiber floc, the average cell wall deformation of individual
fibers is directly related to the deformation of the floc itself: e.g. if the
floc is only slightly deformed, then the average fiber cell wall
deformation will also be slight. On the other hand, if the floc is greatly
deformed, then the stresses and subsequent deformation of
individual cell walls will be much greater. If the deformation of the
fiber floc is so extreme as to cut it into two, a portion of the fibers
within the floc are also likely to be cut.

Recognizing that the deformation of the cell wall of an individual fiber

during refining can only be accomplished by deforming the fiber floc
in which it lies is a very important concept. First, it makes it quite
obvious that the nature of deformations is highly varied. Even if it
were possible to precisely control the degree of deformation of the
floc, the randomly distributed fibers within the floc would be subjected
to a wide range of deformations. Therefore, it is only possible to
speak of average degrees of deformation and average subsequent

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effects on fibers. Second, it underscores the importance fiber flocs.
How many and how large are the flocs that support the refining load
at any instant? What effect does a change in the refiner filling design
have on the size and number of fiber flocs?

In the earlier section on paper structure, the two-fold objective of

stock preparation refining was described as follows:

1. Increase the flexibility of the cell wall in order to promote

increased contact area, and
2. Fibrillate the external surface to further promote the formation
of hydrogen bonds as well as increase the total surface area of fiber
available for bonding.

The more refining that is done, the greater the increase in both fiber
flexibility and surface fibrillation. Yet for a given amount of refining,
there is no direct evidence linking the nature of the cell wall
deformation with the resulting fiber characteristics. This would require
a mechanism for precisely deforming a large number of individual
fibers and then applying some sort of quantitative inspection criteria
on those fibers after deformation. Nonetheless, there is some indirect
evidence from measured pulp and paper properties which suggests
that high magnitudes of cell wall deformation tend to cause surface
fibrillation and internal swelling and, in the extreme, fiber cutting.
Lower magnitudes of cell wall deformation tend to promote surface
fibrillation without much cell wall swelling, along with a greatly
reduced likelihood of fiber cutting. Recognizing the probabilistic
nature of the refining process, it is quite certain that all of these
effects take place to some degree under any given refining condition.
However, it is possible to control the emphasis of one effect relative
to the others by controlling the intensity of refining.

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In the following section, the idea of refining intensity and its
relationship to cell wall deformation will be discussed. Quantitative
methods for calculating intensity will be described, and the practical
application of these analytical methods to papermaking problems will
be reviewed. Before discussing the effects of refining intensity, it is
worthwhile looking at the general behavior of paper properties as the
amount of refining is increased. Figures below illustrate typical
refining trends for mill refined softwood and hardwood kraft pulps.

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ii) Quantitative Analysis

Specific Energy

The main parameter to characterize the refining effect is the amount

of energy that is delivered to the pulp. This is called the Specific
Energy, E, and it is calculated as,

P PNo Load
E=
QC

Where Q is the volumetric flow rate through the refiner and C is the
consistency. It is usually given in kW hr/tonne. The table below
gives the typical specific energy input for the major grades (ref:
FineBar)

Table: Specific Energy input for the major pulp grades (ref: FineBar)
Grade Pulp hpd/t kWh/t

Fine Papers Hardwood 1.5-6.0 30-120

Softwood 2.0-6.0 40-120

News SW Kraft 1.0-3.0 20-60

Groundwood 1.0-3.0 20-60
Linerboard OCC 1.5-3.0 30-60

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 Table: Typical Freeness drop for a given Specific Energy (ref: FineBar)

Furnish CSF Drop per 20 kWh/t

Bleached SWD Kraft 20-40 ml

Bleached HWD Kraft 60-100 ml
GWD / TMP 3-7 ml
OCC 40-70 ml
Mixed Office Waste 50-70 ml
News 10-25 ml

Specific Edge Load Theory At the microscopic level of fibers and fiber
flocs, refining effects are dependent on the magnitude and frequency
of deformations. In the macroscopic world of commercial
papermaking, we cannot directly control these factors. However, we
can control them indirectly by making two broad assumptions.

We can first assume that the greater the number of bar edges
available in the refining zone, the greater will be the number of fibers
able to absorb a given refining load because fiber flocs are collected
on bar edges. The average number of crossing points where flocs
can be caught between opposing edges of the rotor and stator plates
can be calculated based on the inner and outer diameter of the
plates, bar and groove widths, and the average radial angle of the
rotor and stator bars. While the term bar edge length is generally
used to describe this factor, it is mathematically proportional to the
average number of crossing points.

Second, we can assume that the torque applied by a refiner motor

is directly proportional to the normal force acting to push a refiner
rotor against a stator. This means that, with a fixed motor speed,
the motor power is proportional to the normal force.

LC Refining Page 15
With these two assumptions, it is possible to conclude that the
average magnitude of fiber deformation is directly related to the
applied power divided by the product of rotating speed and edge
length. This is the basis of the Specific Edge Load Theory which
was first introduced back in the 1960s. The calculated variable is
referred to as refining intensity or specific edge load (SEL), and is
typically expressed in units of watt-seconds per meter (Ws/m).

In order to calculate the refining intensity, it is necessary to first

determine the true load applied to the fibers. In a commercial
refiner, there is significant power consumption resulting from
hydraulic losses. The bars and grooves of the refiner filling
accelerate and decelerate the fluid as it passes through the refiner,
causing a heating of the fluid but no net refining effect on the fiber
in the process. This is called the no-load power and it must be
subtracted from the total motor load in order to accurately define
the net power actually applied to the fibers.

Given these relationships, the intensity, I, (Specific Edge Load, SEL)

of refining may be calculated according to the following equation:

P PNo Load
I=
RPM
( BarEdgeLength )
60

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R2
N n n
nr ns
BarEdgeLength = dr i i r
r s

R1
cos i =1 cos

(Note: Bar edge length is sometimes called the cutting edge length)

Where is the angle the bar makes with the radial direction and n is
the number of bars at the radius, r.

Bar edge length is the total length of bar edges that the fibres will see
in one revolution. Note that for a double

Table: Typical intensities used for different pulp types

SEL (Ws/m)
Unbleached SWK 2.0-3.0
Bleached SWK 1.0-2.0
Bleached HWK 0.2-0.6
Bleached Eucalyptus 0.2-0.6
Recycled Fiber* 0.2-0.8
TMP/GWD post-refining 0.2-0.5

*depends on fiber type

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To define the refining process, it is not enough to know the magnitude
or intensity of deformations. It is also necessary to know the
frequency or, more accurately, the average number of deformations
per unit mass. Computing the average number of deformations
requires the assumptions that the deformation at any crossing point
occurs over a finite time interval, and that the number of deformations
per unit time is directly proportional to the rotating speed. Thus, the
number of deformations per unit mass (N) is calculated according to
the following equation:

RPM
( BarEdgeLength )
N=
60
QC
Note: TPD is the mass flow rate of pulp through the refiner

Since the amount of refining (P) is by definition equal to the product

of the magnitude and the number of deformations, it can be
calculated according to the following equation:

P= I N

Note that I is Power divided by a constant and N is equal to the same

constant divided by F.

P K
E=
K F

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 High Intensity
EA

I
Low Intensity
EB

The traditional application of refining theory usually refers to the

specification of two parameters: Specific Energy (equal to P above)
and Intensity (equal to I above). There is seldom any specific
reference to N. However, a useful insight is gained by knowing that
applied power determines the magnitude of deformations while
throughput determines the number of deformations.

C-Factor Analysis. In recent years, the introduction and application of

the C-Factor analysis by R.J. Kerekes et al. has lent substantial
credibility to the notion of I and N. The C-Factor analysis takes the
refining theory a step further by incorporating values for average fiber
length and fiber coarseness in order to calculate I and N on a per
fiber basis.

C-Factor analysis also takes into account certain factors relating to

bar and groove geometry which provide for a more accurate
description of refining intensity.

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It is appropriate to use both Specific Edge Load and C-Factor
methods when analyzing a refiner filling application. It is important
to recognize that SEL does not take into account fiber
characteristics but does provide a benchmark value for which there
exists a great deal of historical information.

The actual equation for the C-Factor calculation is too complex to

include here. In fact, it is somewhat tedious to perform the
calculation in the absence of a computer program. Virtually all C-
Factor analyses are performed using a spreadsheet program that
requires input information regarding refiner size, speed, no-load
power and motor load. It also requires input on refiner filling
configuration (including bar and groove widths, depths and radial
angles), as well as input regarding pulp consistency, throughput, fiber
length and coarseness. The output of the spreadsheet program
includes a value called the C-Factor which of itself is not physically
meaningful, and the two values I and N on a per fiber basis.

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8. Refiner Plate Selection: i) The Correct Amount of Refining
(Specific Energy Input)

The net specific energy consumption of a refiner or refining system

determines the amount of refining that is applied to a pulp. Common
North American units are horsepower per short ton per day, or hpd/t.
The common metric units are kWh/metric ton.

Example calculations:

a) With a flow rate of 500 gpm and a consistency

of 4.5%, the throughput is: t/d = 500 x 6.0 x
0.045 = 135 st/d

b) With a flow rate of 1200 lpm and a

consistency of 5.3%: t/h = 1200 x 0.06 x 0.053 =
3.8 mt/h

c) If the motor load is 575 hp and the no-load power is 115 hp, then
the net applied power is: 575 115 = 460 hp
and the specific energy input is: 460 hp / 135 t/d = 3.4 hpd/t

To convert from hp to kW, multiply hp by a factor of 0.746. The

equivalent specific energy calculation for the flow rate of 1200 lpm
would then be: (575 hp x 0.746) (115 hp x 0.746) = 342 net kW 342
kW / (1200 * 0.06 * 0.053) = 90 kWh/t

According to these equations, if the applied motor load is

increased or if the throughput is decreased, then the net

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specific energy will increase.

The specific energy required for a given installation is usually

determined based on historical experience at a given mill. Even for
the same or similar grades, and the same fiber source and pulping
process, two paper mills may apply significantly different specific
energy levels in the stock preparation refining system. Table 4
shows some typical energy ranges for different paper and
paperboard grades.

Table 4

Grade Net hpd/t

Fine Paper HWD Kraft SWD 2-5 3-7 1-1.5
Kraft Tickler
Linerboard Base Top 5-7 10-12
News SWD Kraft 2-5 1-5
TMP/GWD
GWD Printing Paper SWD Kraft 3-7 3-6
TMP/GWD

An estimate of the specific energy requirement can be made for a

given type of pulp if the unrefined pulp freeness and the target
freeness level are known. By subtracting the target freeness from the
unrefined freeness, the total amount of freeness change is calculated.
Values in Table 5 can then be used to predict approximately how
much energy should be required to achieve the desired freeness
drop.

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 Table 5

Furnish Freeness Drop / Net

hpd/t
Bleached SWD Kraft 20-40 ml
Bleached HWD Kraft 60-100 ml
GWD 3-7 ml
OCC 40-70 ml
Mixed Office Waste 50-70 ml
News 20-35 ml

Note that this represents a rough guideline only. It is often the case
that specific energy requirements are best determined based on
paper quality checks during mill processing. It is therefore advisable
that the available power for refining be around 25% greater than the
expected nominal level.

5. Refiner Plate Selection:ii) The Correct Intensity of Refining

(Specific Edge Load)

Determining the best refining intensity for a particular refining

application can be considerably more difficult than specifying the
required specific energy input. Even with a substantial background of
mill operating data, designing a refining system to operate at optimal
intensity involves several economic trade-offs. Hence, it requires a
clear understanding of the economic impact of paper quality
improvements.

If a pulp is only lightly refined, the refining intensity is usually not so

important because there is not enough fiber modification taking

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place to make the difference discernable. An exception to this is the
refining of unbleached kraft for sack paper applications for which the
initial increase in tear with refining can only be assured if the
intensity is sufficiently low (i.e. 1.5-2.0 Ws/m).

The benefits of low intensity refining for hardwood pulps and for
mechanical pulp post-refining are quite widely acknowledged by
papermakers. In the past, the lower limit of intensity had been
established at 0.6-0.8 Ws/m due to the limitations of plate
manufacturing technology. However, recent developments in this
area have enabled intensities of 0.2-0.6 Ws/m to be achieved while
maintaining efficiency and hydraulic capacity.

Low refining intensity has long been considered unnecessary for

softwood pulps and deemed too costly in terms of potential
increases in specific energy requirements. This view is changing as
many mills are seeking gains in tear strength and toughness that
lower refining intensity can provide. Many mill refiners currently
operate in the range of 2.0 4.0 Ws/m. Any easily achieved
reduction in intensity will almost always be beneficial to quality.
For hardwood pulps, low refining intensity results in greater bulk and
opacity at a given level of most strength properties. There is no
substantial evidence to demonstrate that refining intensity can be too
low in the case of hardwood pulps. Most mill refiners currently
operate in the range of 0.6-1.0 Ws/m, and nearly all applications
could benefit from any reduction achieved by changing plate patterns.
Another key benefit of low intensity refining for hardwood is the
reduction in energy required to achieve a given pulp quality or
drainage level. Figure 8 shows a compilation of pilot plant and mill
data illustrating the impact of intensity on freeness drop for various
bleached hardwood pulps.

LC Refining Page 24
Figure 8

The data points clearly show a trend of increased freeness drop per
net hpd/t applied as the refining intensity is reduced from 2.0 to 0.2
Ws/m. In other words, less energy is needed to achieve a given
freeness. This can be taken as an operating cost reduction, or as an
increase in power available for quality enhancement or to
accommodate a higher throughput.

For mechanical pulp post-refining, low refining intensity will yield

higher freeness, increased fiber length and improved tear strength
at a given debris level and energy input. At an equivalent freeness
(with higher specific energy input), reduced debris levels can be
obtained.

Table 6 lists recommended ranges of refining intensity for various

types of fiber. For most applications, refining intensity should be as
low as is practically achievable in order to maximize pulp quality
potential.

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 Table 6

Refining Intensity
Fiber Type
(Ws/m)
SWD Kraft 1.0-2.5
HWD Kraft 0.3-0.8
Recycle 0.2-0.8
TMP/GWD 0.2-0.5

In certain softwood refining applications, reducing the total power

consumption or increasing the power available for refining can be
more beneficial than achieving the lowest possible intensity level. In
these instances, it is often possible to reduce the active diameter of
the refiner by using reduced periphery plates. The reduced active
diameter will have a lower no load power demand. The relationship
between plate diameter and no load is as follows:
4.3 3
No load power = k * diameter * rpm

Note: Diameter is in inches, power is in HP

Table 7 demonstrates the potential energy savings that would result

from a reduction in the active diameter of refiner plates operating at
typical speeds.

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 Table 7

Reduced Estimated Annualized

Active Active Power Savings at
Plate Plate Savings $0.045/kWh
Diameter Diameter hp $
in In
46 43 83 $24,400
46 40 150 $43,800
42 39 90 $26,460
38 35 65 $19,100
34 31 75 $22,020
30 27 45 $13,275
26 23 45 $13,275

Depending on the specific circumstances, a mill may choose to take

the economic benefit of the no load power savings, or they may use
the additional available energy to achieve quality benefits.

Whether full diameter or reduced periphery plates are used, it is

nearly always beneficial to use the narrowest practical bar width
and groove width in any refiner. The practical limits of bar and
groove width depend on the specifics of the application. The
following guidelines apply:

Bar Width. In the absence of potential metal contamination and no-

load power concerns, the width of bars would be only as great as
required to rigidly hold the flocs of pulp that are being deformed. In
real situations, the bar width is dictated mostly by the metal
contamination potential of the application. Metal contamination
introduces bending loads on the bars that far exceed the normal
refining load. As a result, the minimum practical bar width is usually in
excess of 0.050. Experience has shown that in a refiner where baling
wire contamination is likely, the minimum bar width should be in the

LC Refining Page 27
order of 0.075.
Groove Width. The minimum practical groove width is usually
determined by the tendency for plugging of the groove, either by fiber
or by a common contaminant. For post-refining of groundwood in a
contaminant free system, a groove width of 0.050 would be possible.
For hardwood pulps the groove width should be at least 0.075. For
softwood pulps the groove width should be at least 0.090 or 0.125,
depending on the average fiber length of the species being refined.
Another factor to consider is that no-load power varies directly with
the hydraulic section or open area of the cross section of the pattern.
A plate with 1/8 grooves and 1/4 bars will have a higher no-load
power than a plate with 1/4 grooves and 1/8 bars.

Minimum bar and groove widths create the lower limit of refining
intensity for any given refiner size operating at a fixed speed. If there
is a strong quality incentive to reduce intensity further, it can only be
done be adding additional equipment.

6. Flow Considerations in a Stock Preparation Refiner

All stock preparation refiners are hydraulic machines with high speed
rotating elements. That means that they operate in an
incompressible medium (no appreciable air or other vapor present)
and are subject to the considerable influence of fluid friction and
centrifugal forces. They act much like centrifugal pumps, albeit with
very leaky wear plates.

As discussed previously, the capacity of a refiner may be limited by

the available net power which will limit the amount of refining that can
be done. It is very important to recognize that the capacity of a refiner

LC Refining Page 28
is also limited by its ability to pass a volumetric flow. The flow
capacity of a refiner is determined by its disk diameter, its operating
speed, and the hydraulic section and pumping angle of the installed
refiner plates. Table 8 contains the recommended flow ranges for
different sizes of double disk refiners. In most instances, the high end
of these ranges is very optimistic and will result in poor refining with
very short useful plate life. High flows are primarily encountered with
tickler refiners where the entire flow of the paper machine stock must
pass through the refiner.

LC Refining Page 29
 Table 8

DOUBLE DISK REFINER CAPACITY CHART RECOMMENDED FLOW RANGES

FOR VARIOUS SIZE REFINERS

PLATE
DIAM. MAX POWER HP MOTOR RPM FLOW RATES -GPM LOW MED HIGH
INCHES NOMINAL NO LOAD HP

20 300 900 75 150 250 400

24 450 720 85 250 350 600

26 500 720 120 300 450 800

30 600 600 125 375 600 1100

34 800 514 135 1000 600 215 475 750 1400 550 875 1650

38 1250 514 215 650 1075 2025

42 1500 450 220 1750 514 330 775 1250 2400 900 1450 2800

46 2000 450 325 1025 1675 3275

52 3000 400 385 3000 450 550 1300 2150 4300 1475 2425 4850

54 3000 400 450 1475 2425 4850

General Bibliography

For additional information on this topic, a list of literature references

can be found in the Resource Center at the FineBar website
www.finebar.com. Also on the web site is a Stock Prep Calculator
that can be used to calculate refining energy, intensity, and many
1. Isenberg, I.H.; Pulpwoods of the United States and Canada
(1981)

LC Refining Page 30
2. Paulapuro, H.; Papermaking Science and Technology Book 8:
Papermaking Part 1, Stock Preparation and Wet End; Finnish Paper
Engineers Association and Tappi Press (2000)
3. Scott, W.E. and Abbott, J.C.; Properties of Paper: An
nd
Introduction, 2 edition; Tappi Press (1995)
4. Smook, G.A.; Handbook for Pulp & Paper Technologists; Tappi
Press (1988)

LC Refining Page 31
 Appendix A

No-Load Power in a Stock Preparation Refiner

In all pump-through refiner applications, a certain amount of applied power is consumed

by the hydraulic pumping effect and the energy loss associated with viscous shearing of
the fluid. This is called the no-load or circulating power. This energy produces no
measurable change in the properties of the pulp being refined, except in the case of very
sensitive pulps and/or very low relative throughput rates.

No-load power is mostly dependent on the diameter and rotational speed of the rotor, but
it can also be significantly affected by the bar and groove configuration of the refiner
plates. Factors such as flow rate, stock consistency and plate gap have a relatively minor
influence. Contrary to frequent supplier claims, no-load is not dependent on the weight or
mass of the rotating elements. The inertial mass of the rotating elements affects only the
acceleration time for the motor-refiner system at motor start, and the resulting torsional
loads on the rotating system.

Since all changes in pulp properties are determined by the effective power applied
(i.e. total motor power minus no-load power), it is important to know what is the actual
no-load power for any given refiner, installed plate pattern, and relative plate wear.
No-load can be determined by careful measurement or it may be calculated in accordance
with theoretical formulas. A precise measurement of no-load power requires that the rotor
be firmly held so as to prevent contact with the stators on either side. Because of the
radial variability in the static pressure profile acting on each side of the rotor, it is often
the case that instability exists which causes the rotor to lean against one or the other of
the stators. If only water is present, it will result in noisy contact and a slight increase in

LC Refining Page 32
the measured load. The absence of a fiber mat will also result in a slight scarring of the
bar surfaces of the refiner plates. If fiber is present, this instability can result in a
significant increase in measured load and is usually the cause of incorrect no-load
measurements. It is important to recognize that, for any given refiner with a given plate
pattern, the no-load power will vary considerably from a maximum value when the plates
are new to some much lower value (as much as 60-80% lower) when the plates are fully
worn.

Since it is somewhat difficult to obtain an accurate measurement of refiner no load, it is

often easier to rely on the calculated value. With an extensive collection of historical
data, refiner and refiner filling manufacturers have developed quite reliable predictive
models for this purpose.

Most formulas used for calculating no-load power are based loosely on the affinity laws
used in pump design. Indeed, a refiner does behave much like a pump, albeit a very
inefficient one. Every plate pattern will exhibit a characteristic curve that describes how
the total head (pressure rise) varies with capacity (flow rate). The pressure rise will be
at a maximum at zero flow, and will decrease as flow is increased, and actually become
a pressure drop at a sufficiently high flow rate.

As with a pump impeller, pumping power (or no-load) in a refiner is proportional to the
third power of rotational speed. However, unlike a homologous series in pump
impellers, the no-load power for the refiner is proportional to the active plate diameter
raised to the power of 4.3.

In addition to the effect of diameter and speed, the groove depth and hydraulic section
ratio have a dramatic effect on no-load for a particular refiner plate configuration and
wear condition. The hydraulic section ratio is the ratio of groove width to the sum of bar
and groove width, accounting for any effect of tapered groove walls. Based on these

LC Refining Page 33
relationships, a formula for the calculation of no-load power is:

3 4.3
NL = 102 x (RPM/100) x (Da/100) x Hs/0.45 x Gd/0.25

where, NL = no-load (measured in horsepower)

RPM = rotational speed of the motor (revolutions/minute)
Da = diameter of the active surface of the refiner plate (inches)
Hg = section ratio (dimensionless)
Gd= groove depth (inches)

Note: have to multiply by 2 if it is a double disc refiner

Note: that most published no-load data for refiners is based on brand new cast refiner
plate fillings with a typical section ratio of about 0.45 and an available groove depth of
about 0.25.

LC Refining Page 34
 Case Study and Sample Calculations

A fine paper mill is refining bleached hardwood kraft under the following operating
conditions:

One 34 DD refiner with a 1000 hp/600 rpm motor

700 hp applied motor load
900 gpm flow with no recirculation
4% consistency
500 ml freeness target
34 cast plates with a 2.0, 2.0, 4.5 pattern
30 km/rev bar edge length

Use this information to calculate the no load power, net hpd/t, refining intensity and
freeness change per hpd/t applied.

STEP 1 -Calculate no load power

3 4.3

NL = (102*(RPM/100) *(Diam/100) )*(2*Groove Width/(Bar+Groove Width))*(Groove Depth/4)

Motor speed 600 rpm Plate diameter 34 inches

Bar width 2.0 1/16 in Groove width 2.0 1/16 in
Groove depth 4.0 1/16 in

No Load = 213 hp

STEP 2 Calculate applied power

Net Power = Applied Motor Load No Load Power

Applied power 700 hp No load power 213

hp

Net Power = 487 hp

STEP 3 Convert from hp to kW Net kW = 0.7457 * net hp = 363 kW STEP 4

Calculate throughput

Short Tons/Day = Gallons per Minute * % Consistency * 6

Flow 900 gpm Consistency 0.04 Throughput = 216 t/d STEP 5 Calculate net

LC Refining Page 35
 specific energy

Specific Energy = Net Power / Tons per Day

Net power 487 hp

Tons per day 216 t/d

Specific Energy = 2.3 net hpd/t

STEP 6 Calculate Specific Edge Load (refining intensity)

Specific Edge Load (SEL) = Net kW /(Bar Edge Length*Motor Speed* 1 min / 60 s)

Net kW 363 kW Bar edge length 30 km/rev

Speed 600 rpm

SEL = 1.2 Ws/m

STEP 7 Calculate the freeness drop achieved per hpd/t applied

CSF/ hpd/t = (Inlet CSF Outlet CSF) / net Specific Energy

Inlet CSF 625 ml Outlet CSF 500 ml Specific

energy 2.3 hpd/t

CSF/ hpd/t = 55 ml / hpd/t (60-100 ml is typical for HWD kraft)

STEP 8 Assess potential benefits of reduced periphery Finebar plates with equal
groove volume and twice the edge length.

Reduced plate diameter 31 in

Bar width 1.0 1/16 in
Groove width 1.5 1/16 in
Groove depth 3.5 1/16 in
Bar edge length 59 km/rev
Motor speed 600 rpm

New No Load = 150 hp -a savings of 63 hp based on plates as new

New SEL = 0.6 Ws/m - in recommended SEL range for HWD of 0.3-0.8 Ws/m

Annualized energy cost savings @$0.045/kWh = (63 hp*0.7457

kW/hp)*($0.045/kWh)*(24 h/day)*(365 days/yr) = $ 18,400

Note that additional energy savings would likely be realized from the improved
efficiency achieved when refining hardwood kraft at low intensity.

LC Refining Page 36
Appendix: Sample calculation for bar edge length of a double disc refiner where the
stator and rotor have the same pattern

LC Refining Page 37