2006 International Conference on Nanotechnology, April 26-28, 2006 Atlanta, GA Impact Of Nano-particles on Yield in Paper and Board Manufacture Presented by: Duncan Carr Title Company Senior Papermaking Specialist Eka Chemicals
Montmorillonite Silica Nanoparticles Organic Microparticle 0 500nm 1um
The Original Microparticle Primary Dispersed Particles No surface modification - O O Na + Si O Si O O Si OH O O Si O Si O O- Na+ 5nm
Microparticle Classic Characteristics Retention FPR and system Drainage and Drying Strength Wet web and Dry Reflocculation Increased Production Improved Quality with the tool Improved Profitability
Fines Retention % 85 80 75 70 65 60 55 50 45 40 35 Microparticle Effect Curves 0.3 0.6 0.9 1.2 1.5 #/ton dry Microparticle 10#/ton starch 20#/ton starch 30#/ton starch
Floc formation with Nanoparticle Microparticle Effect Fine H 2 O Filler/Fines dispersed in furnish Addition Of CS Fine Addition of NP Fine Formation of a floc loosely held together high water content penetration of colloid charge neutralization water release smaller/denser floc
Monthly Sewer Losses Sheet Ash % FPR % FPAR % Fiber Loss t/day Filler Loss t/day CPAM Baseline 15.46 79.2 44.6 3.63 4.53 NP + CS 15.42 82.4 50.2 1.39 1.83
Silica- Nanoparticle Microparticle Effect 5nm particle size Unmodified 500 m²/g Nanoparticle Effect Medium Structure 2-3nm particle size Surface Modified 750 m²/g Nanoparticle Effect Highly Structured 2-3nm particle size Surface Modified >850 m²/g
Nanoparticle Effect CPAM + NP
Nanoparticle Effect CPAM + NP
Nanoparticle Effect CPAM + NP Bridging Mechanism
Effect Of Starch On COD 800 700 Starch A + CPAM Starch A + CPAM + NP Starch B + CPAM + NP 600 500
Starch Configuration Active Inactive
WOOD COMPONENTS Wood Components Wood Lignin Carbohydrates Extractives Cellulose Hemicellulose
Colloidal Retention Mechanism Anionic Trash Catchers (ATC s) charge neutralize extractives 0.1 to 1.2 micron complexes increased in size to retainable particles up to 10 microns Purging extractives from the wet end Increases yield Increases production cleaner machine Increases sheet strength
Strategies to Improve Yield Deal with extractive directly and remove from the sheet extractive replaces fiber Increase fines retention and reduce exposure time to extractive stronger sheet allows filler replacement of fiber. Both strategies create opportunities to increase yield further by increased degree of closure.
2 1.5 1 0.5 0 Effect Of NP On Headbox DCM Extractives 2 1.5 1 0.5 0 17-Oct 4-Nov 10-Nov 2-Oct Extractives % Extractives % TMP Headbox Baseline Headbox With NP
GC Analysis Of Retained Extractive Comparison Of Different Solvents 6 5 mg/g 4 3 2 1 Fatty Acids Resin Acids Sterols Steryl Esters Triglycerides 0 Pretrial NP Pretrial NP Pretrial NP Acetone Acetone DCM DCM MTBE MTBE
Effect Of LC Fines On Strength Dilution headbox divided into 8 CD zones Ash and fines consistency in slice delivery calculated for each zone. Fines retention and sheet ash increased by increased CPAM dosage NP constant LC fines profiles in slice delivery correlate with internal bond profiles Internal Bond increased despite higher sheet ash
Exploit Dry Strength Increase Reduction in extractives adsorbed on fines positively impacts dry strength Roll dewatering on gap formers negatively impacts internal bond strength Retention Trial Increased CPAM constant NP dosage Increase sheet ash with constant headbox ash content.
Basesheet CD Ash Profiles Lower Retention Sheet Ash 8 High Retention Sheet Ash Sheet Ash % 7 6 5 4 3 1 2 3 4 5 6 7 8 Position Across CD
Internal Bond Against LC Fines-Low Retention 0.6 360 LC W ood Fines In Slice g/l 0.55 0.5 0.45 340 320 300 280 Internal Bond LC Fines Consistency g/l Internal Bond J/M2 0.4 260 1 2 3 4 5 6 7 8 Position Across CD
Internal Bond Against LC Fines-High Retention 0.5 490 LC W ood Fines In Slice g/l 0.45 0.4 0.35 470 450 430 410 390 370 Internal Bond LC Fines Consistency Internal Bond J/M2 0.3 350 1 2 3 4 5 6 7 8 Position Across CD
Strategies in Boardmaking Target a caliper meeting nominal basis weight not critical if quality is good. Caliper impacted by refining if starch retention is improved added strength may allow less refining. Improved drainage and plybond may allow lower press loading to reduce basis weight without loss of machine speed. Use the nano-particle tool to reduce table vacuum and reduce basis weight.
How To Exploit The Tool NP Provides Increased Drainage Can expect to be drier to Top Wire or Dandy Roll Natural Instinct is to Open Slice Opening the slice A LITTLE may be good for formation and texture Key for fiber reduction is to ensure some vacuum is removed to restore optimum Top Wire or Dandy Roll consistency.
Dewatering Profile ISO 1 ISO 2 ISO 3 ISO 4
Dewatering Profile Without NP With NP ISO 1 ISO 2 ISO 3 ISO 4
1140 Effect Of NP on Basis Weight and Speed Effect Of Nanoparticle On Steam Use And Basis Weight 18 Point SBS Boxboard 18 Point SBS Boxboard 196 FPM Reel Sp eed 1130 1120 1110 1100 1090 1080 1070 1060 1050 Reel Speed Basis Weight Nanoparticle introduced 194 192 190 188 186 184 182 # Basis W eig ht Day 1 Day 2 Day 3 D ay 4
Stock Flow Per 1000ft Reel Speed 18 Point SBS Boxboard 4.6 4.6 4.5 Starch Alone Starch + NP 4.55 4.5 4.45 gal/1000ft 4.4 4.3 4.2 4.1 4.4 4.35 4.3 4.25 4.2 4.15 4.1 Day 1 Day 3 Day 4
4.05 Effect Of Table Vacuum On Fiber Yield -16 Point Starch Alone Starch+NP Late Vacuum 10.0 9.0 Gal Stock Flow/1000 ft 3.95 3.85 3.75 3.65 8.0 7.0 6.0 5.0 4.0 3.0 2.0 Vacuum Inches Day 1 Day 2 Day 3 Day 4
Basis Weight 200 195 190 185 180 175 Starch Alone How Not to Use The Drainage Tool 18 Point SBS Boxboard Slice opened from 2.5 to 2.7" and table vacuum restored. Caliper lost. Starch + NP Caliper increase allows B.Wt reduction
Dewatering Profile Slice Opened too much No vacuum Removal No caliper increase ISO 1 ISO 2 ISO 3 ISO 4
Additional Benefits Increased Speed Steam Savings Improved Texture Improved ZDT and Plybond Improved Sizing Reduced Dye usage
Thank You PRESENTED BY Name Title Company Duncan Carr Senior Papermaking Specialist Eka Chemicals