Patent Application
20090302140
Not applicable.
1. Technical Field
The present invention relates to disk refiners and more particularly to improvements in refiner plates and mounting assemblies therefore.
2. Description of the Related Art
Disk refiners are used in the paper manufacturing industry to prepare the cellulose fibers of a paper pulp into a desired condition prior to delivering the pulp to the papermaking machine. Double disk refiners, such as described in U.S. Pat. No. 4,083,503, have refiner plates attached to a rotating disk, or rotor, and complementary refiner plates attached to an opposing, non-rotating disk, or stator. Multiple disk refiners, such as described in U.S. Pat. No. 4,783,014, have a plurality of rotatable and non-rotatable refiner plates interleaved within a refining chamber of the refiner. Counter-rotating disk refiners, such as described in U.S. Pat. No. 4,129,263, have two counter-rotating refining disks each mounted to its own motor-driven shaft.
There are many different disk refiners of differing configurations and diameters. There are also many different types of refiner plates. One type of a refiner plate is a complete annular plate which is cast or otherwise manufactured as a one-piece member. A major disadvantage of complete annular refining plates is the high cost of fabrication, and difficulties associated with the transport and installation of such a large, heavy component. These issues are avoided by a refiner plate which comprises a plurality of individual segments which cooperatively form an annular plate when fitted together. U.S. Pat. Nos. 4,039,154 and 5,425,508 provide examples refiner plates having a plurality of individual segments, which are assembled to form a complete annular plate.
Moreover, refiner plates have a working refining surface that is typically formed by a plurality of spaced apart, raised, rib-like projections, generally called “bars”. There are many refiner plate patterns which are well-known within the paper industry. The bars and other portions of the working surface are gradually abraded or worn away from use, and are subject to damage from excessive loading, such that they require replacement periodically. Thus, another advantage in using segmented refiner plates pertains to replacement of worn or damaged bars. Replacing an entire annular refiner plate due to wear or damage in a discrete part of the refiner plate is inefficient and costly compared to replacing only the segment or segments that are worn or damaged.
Furthermore, regardless of the refiner plate type or bar pattern, the mounting arrangement can vary by refiner manufacturer, and even a single refiner manufacturer may utilize different plate mounting arrangements in terms of the number, size and spacing of the mounting bolts, especially when the overall size of the plates vary considerably. Consequently, a refiner plate manufacturer supplying refiner plates for several manufacturer's refiners have been required to manufacture numerous different refiner plates of the same diameter to be used in the many different disk refiners, even if the same bar configuration is used.
This latter situation can be improved by using an adapter to mount the refiner segments. U.S. Pat. No. 5,934,585, assigned to the assignee of the present invention, and hereby incorporated be reference herein, provides an example of mounting assembly in which an adapter has holes that match the standard bolt pattern of the refiner disk. Refiner segments then mount to the adapter using a clamping ring. Since only the adapter bolts to the refiner disk, and since the adapters are not wear parts, for any given bar pattern refiner manufacturers can supply a single replacement refiner segment type for different disk refiners.
Additionally, while the refiner plate bars can be sized and aligned in many different ways, they generally narrow in the radial outward direction to facilitate courser to finer refining of the pulp and are also aligned in some way that facilitates flow of the pulp between the bars toward the outer periphery of the refiner plate. One additional issue with existing refiner plates, is that it is inefficient to refine pulp, for example at finer bars located in a radially outer region of the refiner segment, that has already been sufficiently refined to an acceptable size. U.S. Pat. No. 7,347,392, which is also assigned to the assignee of the present invention, and hereby incorporated as though fully set forth herein, provides an example of refiner plates that have internal flow channels through which steam and “accepts” can be carried away from the refining surface between the refiner plates so that they are not refined further. While this provides a significant improvement in efficiency when compared to conventional large refiner segments, it complicates the manufacturing process. Sand casting, a less accurate and more costly technique, is used to create sand core in the casting mold that forms the internal flow channels in the segment. This can lead to imperfections or defects in the cast refiner segment as a result of the release gas into the molten steel as the sand is burned off during the casting process.
A refiner plate assembly and method provides for improved refining by evacuating steam and acceptably refined pulp fiber at an early, intermediate stage of the refining zone so that an increased concentration and volume of unrefined fibers can be passed to later stages of the refining zone. This is accomplished in a refiner plate assembly in which adapter subplates, designed for use with a particular disk refiner, mount universal refiner segments that can be readily replaced when worn or damaged without removing the adapter subplates.
Steam and/or accepts are evacuated via filter passages at a radially intermediate location in one or more refiner segments which communicate with a recess or channel in one or more associated adapter subplates that direct the steam and accepts through outlet ports in the outer rim of the adapter subplate(s). Thus, refining efficiency is provided in a universal refiner plate assembly by eliminating steam volume and already refined pulp from outer portions of the refining zone. The filter section(s) can be placed at an optimal location of high volume fraction of pulp fibers where mounting hardware is typically located in conventional refiner segments.
Specifically, in one aspect the invention provides a refiner plate assembly for refining pulp in a disk refiner having a refiner plate mounting surface. The refiner plate assembly includes an adapter subplate and a refiner segment. The adapter subplate defines a segment mounting surface and an evacuation channel leading from an intermediate location of the refiner plate assembly to an outer periphery of the adapter subplate. The refiner segment has a filter section defined by a plurality of passages extending between its refining surface and its undersurface. The passages are sized to permit steam and accept pulp fibers at the intermediate location of the refiner plate assembly to pass from the refining surface to the evacuation channel of the adapter subplate. The adapter subplate is mountable to the refiner plate mounting surface of the disk refiner and the refiner segment is releasably mountable to the segment mounting surface of the adapter subplate such that the refining surface of the refiner segment is at a refining zone of the disk refiner.
In another aspect the invention provides a refiner plate assembly including: at least two substantially flat annular refiner plate mounting surfaces defined by opposing disks of a disk refiner defining a refining zone therebetween; a plurality of adapter subplates mounted to each refiner plate mounting surface end to end in an annular arrangement; and a plurality of refiner segments, with refining bars, mounted to each segment mounting surface end to end in an annular arrangement. At least one of the annular adapter plate arrangements has a segment mounting surface defining a part of an evacuation channel extending from an intermediate location radially between inner and outer peripheries of the adapter subplate arrangement to an opening in its outer rim. At least one annular refiner disk arrangement is associated with adapter subplate arrangement having an evacuation channel and includes a filter section with a plurality of passages extending between the refining surface and an undersurface thereof. The plurality of passages are sized to permit steam and accept pulp fibers at the intermediate location to pass from the refining surface to the evacuation channel of the adapter subplate arrangement.
In yet another aspect the invention provides a method of refining pulp in a disk refiner of the type previously described. The method includes: (a) passing pulp into a refining zone between the two refiner disks; (b) establishing relative rotation of the refiner disks; (c) passing pulp along a refining surface of the annular refiner segment arrangement from an inner periphery; (d) passing steam and accept pulp fiber through at least one filter section at an intermediate location of the annular refiner segment arrangement, the filter section including a plurality of passages extending between the refining surface and an undersurface and are sized to permit the accept pulp fiber at the intermediate location to pass through the annular refiner segment arrangement; and (e) passing the accept pulp fiber from the filter passages to an evacuation channel formed in the annular adapter subplate arrangement.
The objects, features, and advantages of the invention will become readily apparent to those skilled in the art upon reading the description of the disclosure in conjunction with the attached drawings.
With reference to the accompanying drawings, wherein like numbers refer to similar parts, a universal refiner plate assembly 20 shown in
The counter-rotating disk refiner 22 has a first refiner plate assembly 24 and a second refiner plate assembly 25 respectively mounted to two refiner plate mounting surfaces 26 and 27 of two counter-rotating disks 28 and 29. The two counter-rotating disks 28 and 29 are each mounted on a shaft 30 and 31, each of which is driven individually by motors (not shown). The disk refiner 22 has a feed funnel 32 for guiding slurry or in some situations wood chips to an opening 34 which transports the slurry to a refining zone 36 located between the first 24 and second 25 refiner plate assemblies. A housing 38 is provided with an accepts collection area to collect the refined slurry after the refined slurry flows out from the refining zone 36.
The first 24 and second 25 refiner plate assemblies can be constructed in the same manner, and therefore, only the first refiner plate assembly 24 will be discussed in detail. The first refiner plate assembly 24 includes as primary components an adapter subplate 40 and a refiner segment 42 along with associated adapter subplate fasteners 44 and refiner segment fasteners 46. The adapter subplate fasteners 44 bolt the adapter subplate 40 to the disk 28 and the refiner segment fasteners 46 bolt the refiner segment to the adapter subplate 40. There can be a plurality of adapter subplates 40 arranged end to end into an annular ring, when the refiner mounting surface 26 is annular, as shown in
Referring to
Interspersed amongst the bars 48 are mounting holes 54, whereby the refiner segments 42 can be bolted or screwed to the segment mounting surface 56 of the associated adapter subplate 40, which has a corresponding bolt pattern, via refiner segment fasteners 46. Note that the five-hole bolt pattern shown in the figures is exemplary, and could be replaced with another pattern. However, in any case it can be a standardized pattern used by the refiner plate manufacture universally for various different disk refiners and diameters, regardless of disk refiner make. When the refiner bars 48 become worn or damaged from use, the associated refiner segment(s) 42 can be replaced simply by removing the refiner segment fasteners 46.
Also clustered amongst the refiner bars 48, in a flat area uninterrupted by the refiner bars 48, are a plurality of relatively small passages 60 defining one or more filter sections 62. A single one, some or all of the refiner segments can have a filter section 62. The passages 60 extend through the body of the refiner segment 42, for example in a generally axial direction perpendicular to the bars 48 at the refining surface 53. The passages 60 can have the same or different opening sizes or cross-sectional profiles, but in any event are sized to permit passage of pulp fibers from the slurry to that have been sufficiently refined, or for whatever reason are of an acceptable size, which are commonly referred to as “accepts”. Typical sizing is 2 to 4 millimeters.
The filter section 62 is located at an intermediate location radially between the inner and outer peripheries of the refiner segment 42 so that the accepts, as well as steam generated by the pressurization of the liquid slurry, can be redirected away from later stages, or radially outer areas, of the refining zone. Removing the accepts and steam at this intermediate stage improves refining efficiency by subjecting a greater volume fraction or density of pulp fiber that needs refining to the later stages, or outer portions, of the refining zone, since this space is not otherwise occupied by steam or accepts. The filter section 62 is best located at the area of the highest volume fraction of fibers. The volume fraction of fibers is generally the highest at the area of lowest velocity and maximum pressure in the refining zone. This location can be obtained through empirical study of the refiner plate assembly in use. Specifically, temperature sensors can be embedded in an opposing refiner segment at different radii along the length of that refiner segment. Then, the temperature data can be used to determine the high pressure location. Empirical study for the refiner assembly of the present invention indicates that the high pressure area occurs within a range of radii approximately 1/2 to 2/3 of the radial length of the refiner segment, and thus, the filter section is located at approximately 1/2 to 2/3 of the radial length of the refiner segment. Conventional refiner segments are typically bolted to the refiner plates along an arc or line corresponding to the low velocity/high pressure to ensure the bolting forces securely mounting the refiner segments. Consequently, conventional refiner segments do not provide optimal results because either the bolt holes interfere, limit or prevent locating the filter section along the low velocity/high pressure area, which reduces the evacuation of accepts and steam from the intermediate location, thereby reducing refining efficiency, or the bolt holes are moved to another location away from the low velocity/high pressure center, which can adversely impact proper mounting of the refiner segments.
In addition to the location of the passages 60, the configuration and orientation of the filter section 62 can affect accepts evacuation throughput and thereby refining efficiency. In
Referring to
The adapter subplates 40 also have a recess 76 formed in the segment mounting surface 56 that defines an evacuation channel that communicates with the passages 60 of the filter section 62 in the refiner segment 42. The evacuation channel and the passages 60 effectively combine to create the overall evacuation passage 78 that spans two discrete components for the steam and accepts to exit from the intermediate radial location. One, some or all of the adapter subplates 40 can be formed with such evacuation channels, and in the case of adapter subplates 40 that hold multiple refiner segments 42, as shown in
Thus, since the adapter subplate 40 defines the radially extending recesses 76, and thus the majority of the evacuation passage 78 rather than the refiner segments 42, the refiner segments are much thinner and lighter than conventional refiner segments with an evacuation channel cast in its interior. Moreover, creating smaller refiner segments, and in particular refiner segments without an integral hollow core, enables refiner plate manufacturers to utilize a different casting process. Investment casting is not feasible to make the conventional large refiner plate segments because of the high cost in utilizing this process. Making smaller refiner plates will make it economically feasible to use investment casting. Investment casting small refiner plate segments is on par economically with casting large refiner segments using the conventional sand casting method. Drawbacks to the sand casting method include the potential for the segments to warp, not completely filling the area reserved for the refiner bars, and the difficulty associated with getting the volume of metal to fill the cast evenly and at the same time. Also, imperfections can result from sand casting as a result of gas contamination of the molten steel from the sand that is burned off during casting. Moreover, investment casting is a much more precise method of casting metal pieces than the sand casting method. As a result, the refiner plate segments of the invention have more uniform refiner bar widths, groove widths, and groove depths. Further, thinner refiner segments 42 allow for more cost effective and accurate milling operations, such as laser and water jet cutting techniques, to be used on the refiner segments, such as to define the periphery of a refiner segment.
Due to the corrosive environment of a paper refiner, the adapter subplates 40 and the refiner segments 42 are made out of a strong, corrosion-resistant material, such as stainless steel. The adapter subplates 40 are custom made to match the mounting pattern of each different disk refiner manufacturer for a given refiner diameter. The refiner segments 42 can now be universalized and mass produced and assembled in any disk refiner of a given diameter. This represents a universal retrofit of refiner segments 42 of the same refiner bar pattern for all the same diameter refiners of any type, including double disk, multiple disk, or counter-rotating disk refiners regardless of manufacturer.
With reference to FIGS. 1 and 11-13, in operation, pulp slurry is fed into the disk refiner 22 through feed funnel 32 and into the center, or radially inner part, of the refining zone 36 between the disks 28 and 29. Pressure within the disk refiner 22 and forces from the counter-rotating disks 28 and 29 drive the pulp radially outer through the refining zone 36. The pulp fibers come into contact with the bars 48 of the refining surfaces of the refiner segments 42. The larger bars at the radially inner part of the refiner surfaces begin to break down and refine coarse fibers. The bulk of partially refined coarse fibers continue through the refining zone 36 and are further broken down by the progressively smaller bars of the refining surfaces until the fibers pass through the outer periphery of the refiner segments 42 and the accepts are collected in an accept area within the housing 38. However, not all fibers entering the refining zone 36 are the same size. Some fibers are small enough upon entering the refining zone 36, while other fibers need only the initial stage of refinement to become acceptably small. Those accepts that pass along the intermediate location of the filter section 62 can thus be redirected through the passages 60 axially outwardly into the recesses 76 in the adapter subplates 40 and radially through the recesses 76 to be expelled through the radial outlet openings 80 for collection in the accepts area of the housing 38. Furthermore, steam within the refining zone 36 created by pressurization of the pulp slurry is also evacuated with the accepts fibers through the passages 60, recesses 76 and outlet openings 80. Accepts and steam are thus carried away from the intermediate location of the refining zone 36 through the evacuation passage 78 so that the volume adjacent the refining surfaces of the refiner segments 42 are not occupied by steam and already refined fibers. Refining efficiency of the disk refiner is thus improved, on the order of a 50% improvement when compared to conventional systems in which the refined fibers and steam are not evacuated from the intermediate location of the refining zone. Importantly, this improved efficiency is provided in an assembly of adapter subplates 40 and refiner segments 42, with the aforementioned benefits with regard to the smaller, more universal refiner segments. Thus, the evacuation passage 78 is formed by a combination of components such that the evacuated steam and fibers passes across an interface between the refiner segment 42 and adapter subplate 40 components.
It should be appreciated that merely certain embodiments of the invention have been described above. However, many modifications and variations to the described embodiments will be apparent to those skilled in the art, which will be within the spirit and scope of the invention.
For example, while the present invention has been described herein in connection with a counter-rotating disk refiner, it should be understood that the adapter subplate and refiner segment assembly could be utilized in double disk and multiple disk refiners. The adapter subplate and refiner segment assembly could be mounted to one or all of the rotating rotors and stationary stators in double disk or multiple disk refiners. Additionally, in the above-described counter-rotating disk refiner, the same adapter subplate and refiner plate assembly as described above with respect to disk 28 could be utilized on disk 29, as shown in
Therefore, the invention should not be limited to the described embodiments. To ascertain the full scope of the invention, the following claims should be referenced.
This application claims benefit to U.S. provisional application Ser. No. 61/074,622, filed Jun. 21, 2008, and is a continuation-in-part of U.S. application Ser. No. 12/041,379, filed Mar. 3, 2008, which is a divisional of U.S. application Ser. No. 11/068,4909, now U.S. Pat. No. 7,347,392, issued Mar. 25, 2008.
| Number | Date | Country | |
|---|---|---|---|
| 61074622 | Jun 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11068490 | Feb 2005 | US |
| Child | 12041379 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12041379 | Mar 2008 | US |
| Child | 12488268 | US |
