Abstract
The study explores how changes in process variables, residence time and pulp consistency in refining influence the pulp properties. The equipment utilized in this study was a conical disc chip refiner (RGP82CD) producing thermomechanical pulp (TMP). The focus was on the ratio between tensile index and specific energy consumption. Pulp properties were measured for composite pulp samples taken from the refiner blow line. Residence times and pulp consistencies were estimated by use of the extended entropy model. This showed that the CD-refiner, with the flat and conical refining zone, has a process performance similar to that of a two-stage refiner set-up, and that the consistency in both refining zones is of high importance. Comparing different periods revealed that even if the values of measured blow line consistency are similar, significant differences in the estimated consistency in the flat zone can prevail. Therefore, only monitoring blow line consistency is not enough. Specifically, it was found that the pulp consistency after the flat zone could be very high, considerably higher than in the blow line, and this could have negative effects on tensile index and fibre length.
Funding statement: This publication is a part of the Energy Efficient Mechanical Pulping (e2mp) program at Mid Sweden University funded by the Knowledge Foundation, Stora Enso, SCA, Holmen, and Valmet. Special thanks to all who gave support to these trials and testing of the pulps.
Conflict of interest: The authors do not have any conflicts of interest to declare.
Appendix
Data from TEST2.
| Composite Pulp Sample | 21 | 22 | 23 | 24 | 25 | 26 | 27 | 28 | 29 |
| Load, MW | 23.7 | 24.6 | 24.9 | 23.3 | 21.9 | 23.1 | 24.2 | 24.2 | 21.4 |
| Gap FZ, mm | 1.35 | 1.20 | 1.05 | 1.21 | 1.37 | 1.35 | 1.36 | 1.35 | 1.36 |
| Gap CD, mm | 0.78 | 0.79 | 0.78 | 0.77 | 0.77 | 0.79 | 0.78 | 0.75 | 0.78 |
| Dil. water FZ, l/s | 3.42 | 3.43 | 3.43 | 3.43 | 3.43 | 3.36 | 3.26 | 3.17 | 3.43 |
| Dil. water CD, l/s | 5.23 | 5.24 | 5.24 | 5.23 | 5.23 | 5.23 | 5.23 | 5.24 | 5.23 |
| Prod., admt/h | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 |
| SE., kWh/admt | 1493 | 1552 | 1569 | 1473 | 1381 | 1457 | 1525 | 1527 | 1353 |
| Calc. conc. FZ, % | 76.7 | 84.3 | 89.8 | 77.9 | 69.3 | 75.9 | 81.0 | 82.0 | 68.2 |
| Calc. conc. CD, % | 60.0 | 64.1 | 65.4 | 58.9 | 53.7 | 58.6 | 64.0 | 65.3 | 52.3 |
| Tot. res. time, s | 1.23 | 1.28 | 1.30 | 1.23 | 1.17 | 1.22 | 1.28 | 1.30 | 1.15 |
| Res. time ratio FZ/CD | 1.03 | 0.98 | 0.97 | 1.04 | 1.11 | 1.05 | 1.00 | 0.99 | 1.13 |
| Force FZ 3, N | 1.11 | 1.20 | 1.26 | 1.19 | 1.21 | 1.15 | 1.11 | 1.13 | 1.26 |
| Pulp conc., % | 57.6 | 61.0 | 62.6 | 57.0 | 53.5 | 58.9 | 62.5 | 64.2 | 53.8 |
| Freeness, ml CSF | 198 | 192 | 182 | 197 | 225 | 202 | 192 | 193 | 230 |
| Fiber length (ww), mm | 2.11 | 1.96 | 1.92 | 2.15 | 2.29 | 2.20 | 2.03 | 2.01 | 2.31 |
| CWT, μm | 7.8 | 8.0 | 7.8 | 7.9 | 7.8 | 8.0 | 7.9 | 7.9 | 8.0 |
| Fibrillation, % | 5.43 | 5.64 | 5.62 | 5.39 | 5.56 | 5.82 | 6.06 | 5.67 | 5.62 |
| Curl, % | 14.1 | 13.6 | 13.5 | 13.6 | 13.6 | 13.9 | 13.8 | 13.4 | 13.6 |
| Somerville, % | 1.61 | 1.15 | 1.04 | 1.46 | 1.78 | 1.44 | 1.32 | 1.34 | 1.79 |
| Density, kg/m3 | 329 | 352 | 362 | 343 | 330 | 343 | 348 | 358 | 326 |
| Tensile index, Nm/g | 27.7 | 27.2 | 28.0 | 30.1 | 29.7 | 29.6 | 27.3 | 27.1 | 29.1 |
| Elongation, % | 1.78 | 1.71 | 1.73 | 1.82 | 1.73 | 1.79 | 1.78 | 1.73 | 1.83 |
| Tear index, mNm2/g | 6.37 | 5.72 | 5.86 | 6.72 | 7.21 | 6.88 | 5.95 | 6.11 | 7.27 |
| Light scatt. coeff. m2/kg | 45.3 | 47.7 | 48.1 | 45.9 | 43.2 | 45.5 | 47.0 | 47.8 | 43.5 |
Data from TEST3.
| Composite Pulp Sample | 31 | 32 | 33 | 34 |
| Load, MW | 22.4 | 22.1 | 22.1 | 21.9 |
| Gap FZ, mm | 1.23 | 1.24 | 1.22 | 1.23 |
| Gap CD, mm | 0.63 | 0.57 | 0.63 | 0.64 |
| Dil. water FZ, l/s | 3.78 | 3.79 | 3.78 | 3.79 |
| Dil. water CD, l/s | 5.12 | 5.11 | 5.12 | 5.06 |
| Prod., admt/h | 15.0 | 15.0 | 15.0 | 15.0 |
| SE., kWh/admt | 1496 | 1476 | 1470 | 1463 |
| Calc. conc. FZ, % | 60.7 | 58.0 | 59.8 | 59.5 |
| Calc. conc. CD, % | 50.6 | 49.6 | 49.4 | 49.5 |
| Tot. res. time, s | 1.03 | 1.15 | 1.15 | 1.15 |
| Res. time ratio FZ/CD | 1.13 | 0.99 | 0.99 | 0.99 |
| Force FZ 3, N | 1.23 | 1.28 | 1.27 | 1.25 |
| Pulp conc., % | 51.4 | 51.4 | 50.8 | 50.8 |
| Freeness, ml CSF | 214 | 212 | 213 | 220 |
| Fiber length (ww), mm | 2.22 | 2.21 | 2.28 | 2.20 |
| CWT, μm | 7.9 | 7.9 | 7.8 | 7.9 |
| Fibrillation, % | 5.48 | 5.31 | 5.72 | 5.72 |
| Curl, % | 14.5 | 13.7 | 14.8 | 14.0 |
| Somerville, % | 1.78 | 1.88 | 1.75 | 1.86 |
| Density, kg/m3 | 316 | 328 | 337 | 340 |
| Tensile index, Nm/g | 26.8 | 26.3 | 27.8 | 27.9 |
| Elongation, % | 1.78 | 1.71 | 1.77 | 1.78 |
| Tear index, mNm2/g | 6.42 | 6.36 | 6.82 | 6.79 |
| Light scatt. coeff. m2/kg | 44.0 | 44.2 | 43.8 | 43.9 |
Data from TEST4.
| Composite Pulp Sample | 35 | 36 | 37 | 38 | 39 | 40 | 41 | 42 | 43 | 44 | 45 | 46 | 47 | 48 | 49 |
| Load, MW | 19.7 | 19.6 | 19.7 | 19.5 | 19.6 | 21.5 | 21.5 | 21.6 | 21.3 | 21.3 | 22.5 | 22.5 | 22.3 | 22.4 | 22.5 |
| Gap FZ, mm | 1.48 | 1.48 | 1.48 | 1.49 | 1.48 | 1.48 | 1.47 | 1.47 | 1.48 | 1.48 | 1.49 | 1.48 | 1.48 | 1.48 | 1.48 |
| Gap CD, mm | 1.14 | 1.14 | 1.13 | 1.13 | 1.14 | 1.15 | 1.15 | 1.15 | 1.15 | 1.14 | 1.11 | 1.12 | 1.14 | 1.14 | 1.13 |
| Dil. water FZ, l/s | 3.39 | 3.39 | 3.39 | 3.39 | 3.40 | 3.41 | 3.40 | 3.40 | 3.39 | 3.39 | 3.38 | 3.41 | 3.40 | 3.43 | 3.38 |
| Dil. water CD, l/s | 3.89 | 3.88 | 3.88 | 3.88 | 3.88 | 3.88 | 3.88 | 3.88 | 3.88 | 3.89 | 3.88 | 3.89 | 3.88 | 3.89 | 3.88 |
| Prod., admt/h | 12.5 | 12.5 | 12.5 | 12.5 | 12.5 | 14.4 | 14.4 | 14.4 | 14.4 | 14.4 | 15.9 | 15.9 | 15.9 | 15.9 | 15.9 |
| SE., kWh/admt | 1580 | 1566 | 1578 | 1564 | 1568 | 1490 | 1494 | 1497 | 1478 | 1482 | 1418 | 1415 | 1403 | 1410 | 1418 |
| Calc. conc. FZ, % | 75.5 | 75.0 | 75.0 | 74.1 | 74.2 | 76.0 | 76.4 | 76.5 | 75.2 | 75.6 | 76.6 | 76.2 | 75.8 | 75.6 | 77.6 |
| Calc. conc. CD, % | – | 58.6 | 58.6 | 57.6 | 57.7 | 64.5 | 64.9 | 65.2 | 63.9 | 64.2 | 65.9 | 65.4 | 65.0 | 65.3 | 66.1 |
| Tot. res. time, s | 1.59 | 1.58 | 1.58 | 1.57 | 1.57 | 1.47 | 1.48 | 1.48 | 1.46 | 1.47 | 1.36 | 1.35 | 1.35 | 1.35 | 1.36 |
| Res. time ratio FZ/CD | 0.85 | 0.85 | 0.85 | 0.86 | 0.86 | 0.80 | 0.80 | 0.80 | 0.81 | 0.81 | 0.80 | 0.80 | 0.80 | 0.80 | 0.80 |
| Force FZ 3, N | 0.56 | 0.55 | 0.56 | 0.58 | 0.58 | 0.79 | 0.78 | 0.80 | 0.78 | 0.79 | 0.99 | 1.02 | 1.00 | 0.99 | 0.99 |
| Pulp conc., % | 56.7 | 63.2 | 60.3 | 58.9 | 58.8 | 67.7 | 68.5 | 70.4 | 64.0 | 65.8 | 70.8 | 73.2 | 70.9 | 69.5 | 75.8 |
| Freeness, ml CSF | 183 | 198 | 190 | 191 | 194 | 235 | 235 | 260 | 226 | 253 | 303 | 327 | 295 | 280 | 307 |
| Fiber length (ww), mm | 2.34 | 2.33 | 2.32 | 2.33 | 2.32 | 2.31 | 2.31 | 2.28 | 2.30 | 2.31 | 2.33 | 2.34 | 2.34 | 2.36 | 2.28 |
| CWT, μm | 7.6 | 7.7 | 7.8 | 7.7 | 7.7 | 7.9 | 7.9 | 8.0 | 7.9 | 7.9 | 8.1 | 8.2 | 8.0 | 8.0 | 8.3 |
| Fibrillation, % | 6.7 | 6.47 | 6.42 | 6.38 | 6.6 | 6.13 | 6.24 | 6.18 | 6.09 | 6.19 | 6.15 | 6.12 | 6.28 | 6.15 | 5.97 |
| Curl, % | 15.3 | 15.1 | 15.1 | 14.9 | 15.4 | 14.4 | 14.6 | 14.5 | 14.6 | 14.6 | 14.6 | 14.6 | 15.0 | 14.8 | 14.2 |
| Somerville, % | 0.88 | 0.92 | 0.85 | 0.78 | 0.95 | 1.26 | 1.27 | 1.22 | 1.32 | 1.28 | 1.40 | 1.54 | 1.43 | 1.39 | 1.34 |
| Density, kg/m3 | 362 | 355 | 360 | 360 | 364 | 341 | 352 | 350 | 356 | 346 | 336 | 337 | 339 | 350 | 339 |
| Tensile index, Nm/g | 34.4 | 31.6 | 33.1 | 32.9 | 32.9 | 28.1 | 28.6 | 28.0 | 30.5 | 28.4 | 25.5 | 24.5 | 27.2 | 28.1 | 24.9 |
| Elongation, % | 1.92 | 1.83 | 1.86 | 1.91 | 1.88 | 1.75 | 1.66 | 1.67 | 1.71 | 1.69 | 1.53 | 1.56 | 1.63 | 1.68 | 1.56 |
| Tear index, mNm2/g | 7.47 | 7.22 | 7.59 | 7.31 | 7.37 | 7.16 | 6.95 | 6.48 | 6.93 | 6.61 | 6.19 | 6.23 | 6.55 | 6.83 | 6.06 |
| Light scatt. coeff. m2/kg | 47.5 | 47.4 | 47.3 | 47.1 | 47.3 | 46.0 | 47.1 | 47.4 | 47.3 | 46.4 | 45.2 | 44.6 | 45.2 | 45.4 | 44.9 |
Data from TEST5.
| Composite Pulp Sample | 50 | 51 | 52 | 53 | 54 | 55 | 56 | 57 | 58 | 59 | 60 | 61 | 62 | 63 | 64 |
| Load, MW | 21.9 | 22.3 | 22.1 | 22.1 | 22.6 | 18.4 | 18.1 | 18.5 | 18.9 | 18.7 | 20.0 | 19.0 | 18.8 | 17.6 | 17.4 |
| Gap FZ, mm | 0.87 | 0.87 | 0.86 | 0.86 | 0.87 | 0.85 | 0.85 | 0.86 | 0.86 | 0.86 | 0.85 | 0.86 | 0.85 | 0.85 | 0.86 |
| Gap CD, mm | 0.67 | 0.67 | 0.67 | 0.67 | 0.65 | 0.65 | 0.64 | 0.65 | 0.65 | 0.65 | 0.67 | 0.66 | 0.66 | 0.65 | 0.65 |
| Dil. water FZ, l/s | 3.29 | 3.28 | 3.28 | 3.28 | 3.28 | 3.51 | 3.51 | 3.51 | 3.51 | 3.51 | 3.51 | 3.51 | 3.51 | 3.51 | 3.52 |
| Dil. water CD, l/s | 4.69 | 4.70 | 4.70 | 4.69 | 4.70 | 4.69 | 4.69 | 4.69 | 4.69 | 4.69 | 4.45 | 4.44 | 4.45 | 4.44 | 4.44 |
| Prod., admt/h | 14.2 | 14.2 | 14.2 | 14.2 | 14.2 | 14.3 | 14.3 | 14.3 | 14.3 | 14.3 | 14.2 | 14.2 | 14.2 | 14.2 | 14.2 |
| SE., kWh/admt | 1540 | 1568 | 1555 | 1555 | 1588 | 1285 | 1264 | 1297 | 1321 | 1306 | 1407 | 1339 | 1322 | 1243 | 1223 |
| Calc. conc. FZ, % | 61.2 | 62.5 | 62.1 | 62.2 | 62.5 | 53.4 | 52.9 | 53.6 | 54.3 | 53.9 | 56.4 | 54.6 | 54.2 | 52.4 | 51.9 |
| Calc. conc. CD, % | 57.7 | 59.2 | 58.4 | 58.5 | 60.4 | 45.4 | 44.7 | 45.7 | 46.8 | 46.2 | 51.5 | 48.8 | 48.1 | 45.2 | 44.5 |
| Tot. res. time, s | 1.16 | 1.17 | 1.17 | 1.17 | 1.18 | 1.04 | 1.03 | 1.04 | 1.05 | 1.05 | 1.10 | 1.07 | 1.06 | 1.04 | 1.03 |
| Res. time ratio FZ/CD | 0.94 | 0.92 | 0.93 | 0.93 | 0.90 | 1.11 | 1.13 | 1.11 | 1.09 | 1.10 | 1.01 | 1.05 | 1.06 | 1.11 | 1.12 |
| Force FZ 3, N | 1.56 | 1.64 | 1.62 | 1.63 | 1.68 | 1.28 | 1.27 | 1.30 | 1.32 | 1.31 | 1.42 | 1.29 | 1.30 | 1.25 | 1.26 |
| Pulp conc., % | 59.0 | 61.2 | 59.6 | 60.7 | 61.4 | 45.0 | 43.7 | 45.5 | 48.0 | 48.6 | 49.0 | 49.7 | 48.7 | 44.3 | 44.4 |
| Freeness, ml CSF | 190 | 194 | 194 | 203 | 205 | 262 | 270 | 259 | 252 | 253 | 214 | 235 | 244 | 286 | 295 |
| Fiber length (ww), mm | 2.29 | 2.24 | 2.22 | 2.24 | 2.19 | 2.33 | 2.39 | 2.39 | 2.34 | 2.37 | 2.34 | 2.38 | 2.35 | 2.33 | 2.38 |
| CWT, μm | 7.8 | 7.8 | 7.9 | 7.8 | 8.0 | 7.8 | 7.8 | 7.8 | 7.8 | 7.9 | 7.9 | 7.8 | 7.7 | 7.6 | 7.7 |
| Fibrillation, % | 6.3 | 6.3 | 6.4 | 6.29 | 6.2 | 5.92 | 6.03 | 6.05 | 6.03 | 6.12 | 6.16 | 6.05 | 6.04 | 5.91 | 6.12 |
| Curl, % | 14.7 | 14.5 | 14.5 | 14.9 | 14.4 | 13.7 | 14.0 | 13.6 | 14.0 | 13.9 | 14.2 | 13.9 | 14.1 | 13.8 | 13.9 |
| Somerville, % | 0.86 | 0.76 | 0.75 | 0.80 | 0.64 | 1.75 | 2.00 | 1.66 | 1.75 | 1.72 | 1.32 | 1.42 | 1.75 | 2.24 | 2.28 |
| Density, kg/m3 | 372 | 375 | 376 | 381 | 373 | 333 | 329 | 340 | 340 | 338 | 348 | 333 | 329 | 331 | 327 |
| Tensile index, Nm/g | 34.2 | 33.8 | 33.9 | 33.5 | 32.1 | 27.9 | 26.8 | 28.5 | 29.1 | 28.8 | 31.2 | 29.0 | 27.2 | 26.0 | 25.8 |
| Elongation, % | 1.80 | 1.83 | 1.81 | 1.91 | 1.82 | 1.76 | 1.71 | 1.76 | 1.81 | 1.76 | 1.85 | 1.78 | 1.78 | 1.68 | 1.75 |
| Tear index, mNm2/g | 7.44 | 7.51 | 7.74 | 7.54 | 7.12 | 7.18 | 6.88 | 7.16 | 7.14 | 7.10 | 7.35 | 7.26 | 6.92 | 6.75 | 6.44 |
| Light scatt. coeff. m2/kg | 46.6 | 47.2 | 47.1 | 46.5 | 47.1 | 43.2 | 43.0 | 42.8 | 43.4 | 43.5 | 44.5 | 43.5 | 43.1 | 42.0 | 41.9 |
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