Patent Grant
11982053
The present disclosure relates generally to refiner plates configured to grind fibrous material and more particularly to refiner plate segments configured to grind wood chips or other lignocellulosic material.
Processed cellulosic material can be a primary component in several fiber-based products, including for example, pulps, papers, medium density fiberboard (“MDF”), fibrous packaging materials, and liquid-absorbent filler materials. To produce these products commercially, operators often start with lignocellulosic material as a raw material. Lignocellulosic material is generally plant-based matter that comprises celluloses and hemicelluloses chemically bonded to the protein lignin. Examples of lignocellulosic plant matter include wood chips, corn stover, sugar cane bagasse, and recycled paper.
To produce MDF for example, operators may feed lignocellulosic material (commonly in the form of wood chips, wood waste products, sawdust, wood shavings, discarded construction material, or agricultural waste products) through a mechanical refiner.
A mechanical refiner typically comprises two or more opposing refiner assemblies. Each assembly has a pattern of raised refiner bars on a refiner side. Grooves separate adjacent refiner bars. Typically, these refining assemblies are either circular discs, annular discs, nested conical frustums, or nested cylinders configured to rotate around a common axis. Each refiner assembly may comprise several annular sector-shaped segments secured to a backing structure to form the circular disc, annular disc, conical frustum, or cylinder. The refiner sides of the opposing refining assemblies face each other and a narrow refining gap separates the opposing refining assemblies. At least one of the refining assemblies is a rotor configured to rotate around the axis. As the rotor refining assembly rotates at high speeds, operators feed lignocellulosic material or other feed material through the refining gap to separate, develop, and cut the component fibers. As the mechanical refiner breaks down lignocellulosic material, some water may be released in the form of steam.
The inlet of the refining gap is disposed nearer to the center of rotation than the outlet to the refining gap. As the rotor refining assembly rotates, the feed material passes radially outward through the refining gap.
The problem of increased energy usage in mechanical refiners over the working life of a mechanical refiner is mitigated by the use of an exemplary refiner plate segment having a refiner side and a back side distally disposed from the refiner side, refiner bars engaged to a substrate of the refiner side, wherein the refiner bars have a refiner bar height, and wherein adjacent refiner bars and the substrate define grooves between the adjacent bars, and protrusions disposed in the grooves, wherein the protrusions have a protrusion height, wherein the protrusion height is 25% or less of the refiner bar height and wherein the protrusions are configured to wear over time.
A problem with low-consistency refining is that new refiner plate segments can have excessive flow capacity due in part to the initial volume of the grooves. This is particularly true with tall refiner bars, which in turn create grooves of greater volume. Refiner plate segments with greater flow capacity allow more dilute feed material to pass through the refining section over a given amount of time. If the flow capacity exceeds the refining capacity, the refiner will generate more pumping and the energy required to rotate the refiner will be higher, thereby resulting in energy losses that are greater than usual. The process may create a high-pressure outlet flow, which can cause further trouble downstream.
The foregoing will be apparent from the following more particular description of exemplary embodiments of the disclosure, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, with emphasis instead being placed upon illustrating the disclosed embodiments.
The following detailed description of the preferred embodiments is presented only for illustrative and descriptive purposes and is not intended to be exhaustive or to limit the scope and spirit of the invention. The embodiments were selected and described to best explain the principles of the invention and its practical application. One of ordinary skill in the art will recognize that many variations can be made to the invention disclosed in this specification without departing from the scope and spirit of the invention.
Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of various features and components according to the present disclosure, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate embodiments of the present disclosure, and such exemplifications are not to be construed as limiting the scope of the present disclosure in any manner.
References in the specification to “one embodiment”, “an embodiment”, “an exemplary embodiment”, etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiment selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure.
The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Numerical values should be understood to include numerical values, which are the same when, reduced to the same number of significant figures and numerical values which differ from the states value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.
To the extent necessary to provide descriptive support, the subject matter and/or text of the appended claims is incorporated herein by reference in their entirety.
Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range of within any sub ranges there between, unless otherwise clearly indicated herein. Each separate value within a recited range is incorporated into the specification or claims as if each separate value were individually recited herein. Where a specific range of values is provided, it is understood that each intervening value, to the tenth or less of the unit of the lower limit between the upper and lower limit of that range and any other stated or intervening value in that stated range or sub range hereof, is included herein unless the context clearly dictates otherwise. All subranges are also included. The upper and lower limits of these smaller ranges are also included therein, subject to any specifically and expressly excluded limit in the stated range.
As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about” and “substantially,” may not be limited to the precise values specified. The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “from about 2 to about 4” also discloses the range “from 2 to 4.”
It should be noted that many of the terms used herein are relative terms. For example, the terms “upper” and “lower” are relative to each other in location, i.e. an upper component is located at a higher elevation than a lower component in a given orientation, but these terms can change if the device is flipped. The terms “inlet” and “outlet” are relative to a fluid flowing through them with respect to a given structure, e.g. a fluid flows through the inlet into the structure and flows through the outlet out of the structure. The terms “upstream” and “downstream” are relative to the direction in which a fluid flows through various components, i.e. the flow of fluids through an upstream component prior to flowing through the downstream component.
The terms “horizontal” and “vertical” are used to indicate direction relative to an absolute reference, i.e. ground level. However, these terms should not be construed to require structure to be absolutely parallel or absolutely perpendicular to each other. For example, a first vertical structure and a second vertical structure are not necessarily parallel to each other.
The terms “top” and “bottom” or “base” are used to refer to locations/surfaces where the top is always higher than the bottom/base relative to an absolute reference, i.e. the surface of the Earth. The terms “upwards” and “downwards” are also relative to an absolute reference; an upwards flow is always against the gravity of the Earth.
The term “directly,” wherein used to refer to two system components, such as valves or pumps, or other control devices, or sensors (e.g. temperature or pressure), may be located in the path between the two named components.
For large diameter mechanical disc refiners 702, one or more rings of intermediate refiner plate segments can be disposed between a breaker bar segment 729 and an outer refiner plate segment 700. However, it will also be understood that such intermediate rings are rare. Bolts or fasteners can extend through fastener holes 788 to engage the refiner plate segments 700, 729 to the backing structure 786 and thereby fixedly engage the annular sector-shaped refiner plate segments 700, 729 to the backing structure 786. It will be understood that other known ways to affix refiner plate segments to a backing structure are considered to be within the scope of this disclosure and within the scope of the term, “fixedly engage.”
As used herein and unless otherwise specified, “refiner plate segment” 700, 729 can refer to a refiner plate segment 700 having an integrated refining section 707 and breaker bar section 734, breaker bar segments 729 (see
Although
Cylindrical and conical mechanical refiners can have a rotor assembly (see 703, 603) and a stator assembly (704, 604). Other disc, conical, twin flow, and cylindrical refiners can have counter-rotating refining assemblies, or multiple rotor assemblies facing (or nested in) opposing stator assemblies. It will be appreciated that refiner plate segments configured for a conical refiner or a cylindrical refiner are adapted to form a truncated conical frustum or a cylinder when fully assembled on the corresponding refining assembly.
Although
In a typical mechanical refiner, as at least one of the rotor assemblies 703, 603 rotates, one edge of each refiner bar 125 (
A typical rotor assembly 703, 603 spins in a range of 900 to 2,300 rotations per minute (“rpm”) for high consistency refining and for MDF production and is configured to transfer significant kinetic energy to the feed material 669 as the feed material 669 moves through the refining gap 619. In low-consistency refining, the rotor may rotate at speeds of 400 to 1500 rpm. As a rotor refiner assembly 603 rotates, the leading edges 135 of the refiner bars 625 on the opposing refiner assemblies 603, 604 successively overlap and entrap feed material 669 between the opposing refiner bars 625, 625z. As the rotor refiner assembly continues to rotate, the opposing bars shear the feed material 669 to develop, separate, and cut the fibers. That is, the successively overlapping bars 625, 625z compress the feed material 669, thereby transferring more energy to the feed material 669 and performing more work on the feed material 669.
As the rotor refiner assembly 603 continues to rotate, the opposing bars 625, 625z will pass each other and adjacent opposing grooves (see 130,
The accumulation of feed material 669 in the refining gap 619 and in the grooves 130 creates a fiber pad. Successive instances of compression and expansion in the fiber pad are believed to be the primary location where mechanical refining occurs. That is, forceful movement of feed material 669 against adjacent feed material 669 in the fiber pad contributes primarily to fiber development, separation, and cutting.
Over time, contaminants that may be present in the feed material 669 wear down the refiner bars 625, 125. Because the space between adjacent bars 125, 125z (
The excess energy in the thicker fiber pad tends to over-refine the feed material 669 to create an excess of shives. “Shives” are thin slivers of refined material that are undesirable for use in the final product. As a result, as the refiner plate segments wear, the product quality degrades assuming that the energy input remains constant. Eventually, refiner bar wear becomes so severe that the refiner plates segments 600 will need to be replaced. This usually occurs when energy consumption per unit of acceptable fiber produced becomes unacceptably high, or when shive production becomes so pronounced that an acceptable final product can no longer be produced.
Too high a shive content in the final product would render the final product unsuitable for its intended purpose. For example, in MDF production, if there are too many shives in the medium density fiberboard, the board will likely not have the requisite properties (e.g. strength, durability, etc.). Therefore, as bars wear, the energy within the mechanical refiner increases without improving product quality. Stated another way: as the bars wear, operators expend more energy to produce inferior fiber, which leads to an inferior final product (e.g. MDF), which is often sold at lower prices. To address this problem, operators periodically deactivate the mechanical refiners 602, 702 to replace the refiner plate segments 600, 700 that comprise the refining assemblies 603, 703, 604, 704. This downtime contributes to further production loss.
Some manufacturers have tried to increase the refiner bar height to address this problem. Increasing the refiner bar height also increases the depth of the adjacent grooves. However, the taller refiner bars tend to result in poorer initial performance. Excessively tall bars in MDF and high-consistency refining (e.g. about 8 mm or taller) can lead to unstable operation, an increase in untreated material (and can create more shives), and can contribute toward difficulty in applying refining load because not enough of the feed material 669 is kept in the refining gap 619. These negative factors offset any potential gains in wear life. Furthermore, excessively tall refiner bars (relative to refiner bar widths) in MDF, high-consistency, and low-consistency refining can increase the risk of a refiner bar breaking during operation. Metal debris in a mechanical refiner can rapidly escalate refiner plate segment wear and degradation.
In the case of low-consistency refiners, tall bars create a high pumping effect and a high outlet pressure, which results in higher pumping energy and increased operating costs. As such, the cost (in terms of energy and capital) of running new low-consistency refiners with excessively tall refiner bars (e.g. about 8 mm or taller) exceeds the value that can be derived from feed material 669 that has been processed through such a low-consistency refiner. These costs offset any gains in refiner plate segment operating life. As the bars wear down, the pumping energy reaches cost-competitive values. When as bars' height becomes too low, the refiner will not be able to handle the flow and pumping requirements, which leads to further unprocessed feed material 669. As such, low-consistency refiners have a narrow range of bar heights at which efficient refining can occur. This negatively affects the useful lifetime of low-consistency refiner plate segments.
Exemplary embodiments in accordance with this disclosure permits a wider range of refiner bar heights (i.e. the refiner bars have more distance to wear) without incurring the additional problems of higher energy consumption and/or poor product quality. The problem of increased energy usage in mechanical refiners over the working life of a mechanical refiner is mitigated by the use of an exemplary refiner plate segment having a refiner side and a back side distally disposed from the refiner side, refiner bars engaged to a substrate of the refiner side, wherein the refiner bars have a refiner bar height, and wherein adjacent refiner bars and the substrate define grooves between the adjacent bars, and protrusions disposed in the grooves, wherein the protrusions have a protrusion height, wherein the protrusion height is 25% or less of the refiner bar height and wherein the protrusions are configured to wear over time.
The depicted refiner plate segment 100 is a refiner plate segment for a disc refiner. It will be understood that exemplary refiner plate segments can be used in all types of mechanical refiners, particularly in conical refiners and cylindrical refiners. Further, exemplary refiner plate segments as described more fully herein can be configured for all thermomechanical refining applications, including that of high-consistency refining, low-consistency refining, and in the production of medium density fiberboard. In operation, the first end 113 of the refiner plate segment 100 abuts the second end 116 of an adjacent refiner plate segment 100 (see
Breaker bars 123 and refiner bars 125 engage a substrate 120 on the refiner side 105. Adjacent refiner bars (see for example 125z and 125zz) and the substrate 120 define grooves 130 between the adjacent refiner bars 125z and 125zz to thereby form a pattern of refiner bars 125 and grooves 130 throughout the refining section 107 (e.g. area of pattern of refining bars 125 and grooves 130 enclosed by dotted line in
As feed material 169 approaches the refining gap 619 (
The pattern of refiner bars 125 and grooves 130 depicted in
Full-surface dams 140 block grooves 130 and are designed to direct feed material 169 into the refining gap 619. Dams 140, 145 are disposed infrequently in grooves 130 compared to protrusions 150. Some exemplary refiner plates have protrusions in combination with only surface dams, or protrusions in combination with only subsurface dams. Other exemplary refiner plate segments lack dams. Furthermore, a dam 140, 145 has a greater cross-sectional area than a protrusion 150 disposed in the same groove 130 (see
In other exemplary embodiments, the refiner bars 125 have an initial height of 12 mm-15 mm or any height in between and the protrusions have an initial height of 2 mm-3 mm and any height in between. In other exemplary embodiments, the refiner bars 125 are taller than 15 mm. In yet other exemplary embodiments, the protrusions can have greater heights when the height required for functional designs is low. In low consistency refiners for example, the refining bar height for pumping and flow purposes may be 4 mm-6 mm. In such low-consistency refiner plate segments, the initial refiner bar height is 12 mm-16 mm and the initial protrusion height is 4 mm-6 mm. Preferably, such an arrangement in a low consistency refiner plate segments have thin protrusions (relative to any comparable dams 140, 145), are made from softer material than the refiner bars 125, or are both thinner than dams 140, 145 and are made from softer material than the refiner bars 125
As a comparison, the subsurface dams 145 may be 1 mm-3 mm long at a subsurface dam top 387 (
Preferably, multiple protrusions 150 are disposed within a groove 130 such that the protrusion's first side 582 (
Without being bound by theory, it is believed that disposing the protrusions 150 at regular intervals within a groove 130 every 6 mm-25 mm can effectively behave the same as raising the bottom of the groove 130 to form a secondary groove bottom 273 (
In
It will be understood that the protrusions 150 can be embodied in a variety of shapes provided that the protrusions 150 be configured to wear away over time preferably at an equal or slower rate than the refiner bars 125. This wear can be due to exposure of contaminants in the feed material. A non-exhaustive list of exemplary protrusion shapes can include: a rectangle, a rectangular prism, a rectangular prism segment, a triangular prism, a triangular prism segment, a prism where the number of sides exposed to feed material is four or more or a segment thereof, a polyhedron, a polyhedral segment, a triangular pyramid, a triangular pyramid segment, a quadrilateral pyramid, a quadrilateral pyramid segment, a pyramid having five or more faces exposed to feed material or a segment thereof, a pyramidal frustum, a pyramidal frustum segment, a spherical dome, a spherical dome segment, a spheroid dome, a spheroid dome segment, a parabolic prism, a parabolic prism segment, a frustum parabolic prism, a frustum parabolic prism segment, a cone, a cone segment, a spheroid cone, a spheroid cone segment, an elliptical cone, an elliptical cone segment, a conical frustum, a capsule, a cylindrical segment, an ellipsoid conical frustum, an ellipsoid conical frustum segment, a cylinder, a cylinder segment, an elliptic cylinder, an elliptic cylinder segment, a sphere, a sphere segment, a spheroid, a spheroid segment, or combinations or permutations of any of the foregoing shapes.
In an exemplary embodiment, the protrusions 150 wear at substantially the same rate as the refiner bars 125. In other exemplary embodiments, the refiner bars 125 wear at a faster rate than the protrusions 150.
The protrusions 150 can be cast with the refiner plate segment 100. In other exemplary embodiments, the protrusions 150 can be machined from cast protrusions. In other exemplary embodiments, manufacturers can machine the protrusions 150 from the cast groove substrate (see 120). In still other embodiments, manufacturers can use additive manufacturing techniques such as welding or three-dimensional (3D) printing to add the protrusions 150 within the grooves 130. In still other exemplary embodiments, manufactures can cast an exemplary refiner plate segment by having protrusions 150 disposed in a casting mold before the manufactures pour molten metal into the casting mold. The molten casting metal can then fuse with the protrusions 150 inlaid in the casting mold. In still other exemplary manufacturing techniques, manufactures can glue the protrusions 150 to the substrate 120. In still other exemplary manufacturing embodiments, manufacturers can press or hammer discrete protrusions 150 into a groove between adjacent refiner bars 125z, 125zz such that the protrusion 150 is effectively securely wedged between the adjacent refiner bars 125z, 125zz.
In still other exemplary manufacturing methods, the exemplary refiner plate segment 100 can be fabricated from metal sheets and bars. In such methods, the protrusions 150 may extend from refiner bars 125 and manufactures can glue, fuse, or otherwise fasten the refiner bars 125 to the substrate 120 to form a pattern of alternating refiner bars 125 and grooves 130. On other fabrication methods, a manufacturer can add the protrusions 150 separately to the refiner bars 125 (see
In certain exemplary embodiments, the protrusions 150 can be made of the same material as the refiner bars 125. In still other exemplary embodiments, the protrusions 150 comprise a different material than the refiner bars 125. In certain exemplary embodiments, the protrusions 150 comprise a material selected from the group consisting of: aluminum, copper, brass, steel, plastic, wood, and epoxy resin.
Without being bound by theory, Applicant believes that the distance between the top 257 of the protrusion 250 and the top 228 of an adjacent refiner bar 225 forms an effective groove depth 226. The protrusion intervals 263 are desirably sufficiently small to allow feed material 269 to flow above the protrusions 250 under normal operating conditions. In this manner, the tops 257 of the multiple protrusions 250 and the velocity at which the feed material 269 passes the tops 257 of the multiple protrusions 250 can function as a secondary groove bottom 273 disposed above the groove substrate 220.
Over time, the top 228 of the refiner bars 225 and the top 257 of the protrusions 250 wear away. The rate of wear can vary depending upon the type of refining and the type and quality of the material being refined. As the refiner bars 225 wear down, the adjacent grooves 330 (
It should be noted that the refiner plate segments 100 and 300 depicted in
In this manner, protrusions 250 disposed in a groove 230 at intervals 263, in which the protrusions 250 have a protrusion height h that is 25% or less of an adjacent bar height H, mitigates the problem of having a thicker, denser fiber pad between opposing refiner assemblies (see 603, 604) due to grooves 130 that become shallower over time. Without being bound by theory, the effective groove depth 226 functions similarly to a traditional groove of the same depth and therefore allows for the fiber pad to be maintained at a desirable thickness for longer periods. Because the difference in refiner bar height H and protrusion height h defines the effective groove depth 226, the effective groove depth 226 moves closer to the substrate 220 over time while still serving the function of a groove 230.
In embodiments in which the refiner bars 225 wear at a faster rate than the protrusions 250, the loss of effective groove depth 226 is a fraction of the loss of actual refiner bar height H thereby delaying decline in the refiner plate segment's performance.
The reference bar volume 368 is the volume of the adjacent refiner bar 325z, 325zz that shares a length Lz with the longest length l of a protrusion 350. Likewise, the reference bar base 359 coextends with an adjacent protrusion base 358 along the longest protrusion length l. The refiner bar's width W multiplied by the coextending length Lz defines the refiner bar reference base 359. The coextending length Lz extends the same length as the protrusion length l. In the depicted embodiment, the protrusion length l at the protrusion base 358 is longer than the length at the top 357 of the protrusion 350. It will be understood that in embodiments in which length l of a protrusion 350 is non-uniform, the coextending length Lz of the reference bar volume 368 is measured from the longest length l of the protrusion 350 form the portion of the protrusion disposed closest to the inner arc 110 to the portion of the protrusion disposed closest to the outer arc 115.
The reference refiner bar volume 368 varies based upon the three dimensional shape the refiner bar 325. In the depicted embodiment, the draft angle Δ between the leading face 321 and the substrate 320 and the draft angle Δ between the trailing face 324 and the substrate 320 define the refiner bar 325 as a trapezoidal prism. Therefore, the formula, ½(W+(Wz))(Lz)H provides the reference bar volume 351 in the depicted embodiment. Where W is the refiner bar width at the refiner bar reference base 359, Wz is the refiner bar width at the top 328 of the refiner bar 325, Lz is the length that the reference bar 325 shares with the adjacent protrusion length l, and H is the height of the portion of the reference bar 325 adjacent to the protrusion 350. Exemplary protrusions 350 have a volume that is less than 40% of the reference bar volume 368.
In other exemplary embodiments, protrusions 350 can have a volume that is greater than 0% but less than 25% of the reference bar volume 368. It is contemplated that the ratio of the protrusion volume 351 relative to the reference bar volume 368 will remain within the disclosed range throughout the working life of the refiner plate segment 100 due the rates at which the protrusions 350 and refiner bars 325 wear. Without being bound by theory, it is believed that an exemplary protrusion 350 having a volume that is less than 40% of the reference bar volume 368 and having a height that is 30% or less of the adjacent refiner bar height H will allow the protrusion 350 to create an effective groove depth 326 that will operate within a margin of error to achieve desirable refiner performance and product quality.
A full-surface dam 340 has a full-surface dam base 338 engaging the substrate 320. The full-surface dam base 338 comprises a full-surface dam length fl and a full-surface dam width fw. The full-surface dam volume 371 varies based upon the three dimensional shape of the full-surface dam 340. The reference bar's coextending length Lz extends the same amount as the longest full-surface dam length fl as measured from the portion of the full-surface dam disposed closest to the inner arc 110 and the portion of the full-surface dam disposed closest to the outer arc 115.
In contrast to the exemplary protrusions, subsurface dams 345 have a subsurface dam volume 361 that is 40% and 60% of the reference bar volume 368z. Similarly, the full-surface dam 340 has a full-surface dam volume 371 that is 60% to 100% of the reference bar volume 368″
For example, the protrusion 450a has a curved protrusion leading face 467 configured to direct feed material 469 over the top 457 of each protrusion 450. The cross-sectional area of protrusion 450a can be calculated by adding the area of the square component (i.e. the length l multiplied by the height h) to the remaining area. By way of another example, the cross-sectional area 742 of the other depicted protrusions 450 in
In the depicted embodiments, the refiner bars 425, 525 have a generally trapezoidal shape. However, it will be understood that refiner bars 425, 525 can manifest in a number of possible shapes. The lateral cross-sectional area 546 of a trapezoidal refiner bar 525 can be calculated with the formula A=½(W+Wz)H, where A is the lateral cross-sectional area 546, W is the width of the refiner bar 525 at the refiner bar's base 359, Wz is the width of the refiner bar 525 at the top 528 of the refiner bar 525, and H is the height of the refiner bar 525. The reference refiner bar 525 is adjacent to the protrusion 550.
In an exemplary embodiment, the protrusion's longitudinal cross-sectional area 472 is not more than 20% the adjacent refiner bar's lateral cross-sectional area 546. For example, a typical protrusion 450 can have a longitudinal cross-sectional area 472 of 3-4 mm2 while the adjacent refiner bar 425z typically has a lateral cross-sectional area 546 of 30-50 mm2. As comparison, a subsurface dam 445 generally has a longitudinal cross-sectional area 474 of 12-25 mm2 (i.e. between 24% and 83% of the lateral cross-sectional area 546 of a typical refiner bar 425, 525) as a minimum. However, subsurface dams 445 typically have an even greater longitudinal cross-sectional area 474. Similarly, full-surface dams 440 have a longitudinal cross-sectional area 476 that is 60%-100% of the lateral cross-sectional area 546 of the adjacent refiner bar 425, 525 depending upon the shape of the full-surface dam's longitudinal cross-sectional area 476.
The protrusion's lateral cross-sectional area 562, subsurface dam's lateral cross-sectional area 544, full-surface dam's lateral cross-sectional area 542 and refiner bar's lateral cross-sectional area 546 will vary based upon the shape of the protrusion 550, subsurface dam 545, full surface dam 540, and refiner bar 525 respectively. In the depicted embodiment, the lateral cross-sectional areas 562, 544, 542, and 546 are trapezoids. Accordingly, the cross-sectional area of each is given by the formula: ½(w+(wz))h. In an exemplary embodiment, the protrusion's longitudinal cross-sectional area 472 is not more than 20% the refiner bar's lateral cross-sectional area 546. For example, a typical protrusion 550 can have a longitudinal cross-sectional area 472 of 3-5 mm2 while the adjacent refiner bar 525z typically has a lateral cross-sectional area 546 of 20-50 mm2. As comparison, a subsurface dam 545 generally have a minimum lateral cross-sectional area 544 of 10 mm2 (i.e. between 20% and 67% of the lateral cross-sectional area 562 of a typical refiner bar 525). However, subsurface dams 545 typically have an even greater lateral cross-sectional area 544. Similarly, full-surface dams 540 have a lateral cross-sectional area 546 that is typically equal or even greater than the lateral cross-sectional area 562 of the adjacent refiner bar 525z.
In other exemplary embodiments, the longitudinal cross-sectional area 472 of a protrusion 550 is not more than 15% of the lateral cross-sectional area 546 of the corresponding adjacent refiner bar 525z. In still other exemplary embodiments, the longitudinal cross-sectional area 472 of a protrusion 550 is not more than 15% of the lateral cross-sectional area 546 of the corresponding adjacent refiner bar 525z. In yet other exemplary embodiments, the lateral cross-sectional area 562 of a protrusion 550 is not more than 10% of the lateral cross-sectional area 546 of the adjacent refiner bar 525z. In still other exemplary embodiments, the lateral cross-sectional area 562 of a protrusion 550 is not more than 15% of the lateral cross-sectional area 546 of the adjacent refiner bar 525z.
In low-consistency refining, operators generally dilute the feed material 869 significantly before pumping the feed material 869 into the mechanical refiner (see 702). For example, low-consistency feed material 869 may be diluted in the range of 2%-6%.
A problem with conventional low-consistency refiner plate segments with excessively tall refiner bars (e.g. about 10 mm or taller) is that these tall bars created a high pumping effect and a high outlet pressure, which resulted in higher pumping energy and increased operating costs. As such, the cost (in terms of energy and capital) of running new low-consistency refiners with excessively tall refiner bars (e.g. about 10 mm or taller) exceeded the value that could be derived from feed material that had been processed through such a low-consistency refiner. These costs offset any gains in refiner plate segment operating life. When as refiner bars' height becomes too low, the refiner will not be able to handle the flow and pumping requirements, which creates a capacity limitation. As such, low-consistency refiners have a narrow range of bar heights at which efficient refining can occur. This negatively affects the useful lifetime of low-consistency refiner plate segments.
In other exemplary embodiments, only the first restrictor end 855 engages the leading face 821. In yet other exemplary embodiments, only the second restrictor end 854 engages the trailing face 824.
It will be understood that the flow restrictor 850b, 850c, 850d is a type of protrusion 850. As such, any description relating to a protrusion (see 150, 250, 350, 450, 550 in
A non-exhaustive list of exemplary flow restrictor shapes includes: a rectangle, a rectangular prism, a rectangular prism segment, a triangular prism, a triangular prism segment, a prism where the number of sides exposed to feed material is four or more or a segment thereof, a polyhedron, a polyhedral segment, a triangular pyramid, a triangular pyramid segment, a quadrilateral pyramid, a quadrilateral pyramid segment, a pyramid having five or more faces exposed to feed material or a segment thereof, a pyramidal frustum, a pyramidal frustum segment, a spherical dome, a spherical dome segment, a spheroid dome, a spheroid dome segment, a parabolic prism, a parabolic prism segment, a frustum parabolic prism, a frustum parabolic prism segment, a cone, a cone segment, a spheroid cone, a spheroid cone segment, an elliptical cone, an elliptical cone segment, a conical frustum, a capsule, a cylindrical segment, an ellipsoid conical frustum, an ellipsoid conical frustum segment, a cylinder, a cylinder segment, an elliptic cylinder, an elliptic cylinder segment, a sphere, a sphere segment, a spheroid, a spheroid segment, or combinations or permutations of any of the foregoing shapes.
Exemplary refiner plate segments 800 comprising flow restrictors 850b, 850c, 850d can have the flow restrictor disposed at any elevation within the groove 830 provided that the flow restrictor 850b, 850c, 850d does not engage the substrate 820 of the groove 830 in which the flow restrictor 850b, 850c, 850d is disposed. In certain exemplary embodiments, the flow restrictor 850b, 850c, 850d 850b, 850c, 850d can be disposed partially above the groove 830 (i.e. partially above the adjacent refiner bars 825z, 825zz). It is generally thought that that flow restrictor 850b having a generally cylindrical shape can be desirable for many refining applications because the cylindrical shape is thought to wear more uniformly over time compared to other shapes. However, a flow restrictor 850b with a slight budge in the middle can also be desirable.
Flow restrictor 850c has a generally rhomboidal shape with leading faces 867a, 867b oriented to direct feed material 869 around the flow restrictor 850c. Flow restrictor 850d has the general shape of a quadrilateral prism having a leading face 867 oriented to face oncoming feed material 869.
Without being bound by theory, it is contemplated that flow restrictors 850b, 850c, 850d disposed at regular or irregular intervals 963 (
Additionally, flow restrictors 850b, 850c, 850d disposed near the top 828 of the refiner bars 825 will wear with the refiner bars 825 as the height H of the refiner bars 825 reach the level of the flow restrictor 850b, 850c, 850d. This will gradually eliminate some of the uppermost flow restrictors 850b, 850c, 850d, thus gradually reducing restriction as bar height H decreases.
In other exemplary embodiments, the flow restrictors 850b, 850c, 850d can be configured to wear at a slower rate than the refiner bars 825. In such embodiments, it is contemplated that the flow capacity will reduce over time, but the refining capacity will increase.
As
Flow restrictors 950b, 950c, 950d, 950e are shown as examples. Flow restrictor 950b has a generally cylindrical shape and cross-sectional area 872. Flow restrictor 950c has a generally rhombic shape oriented such that the leading faces 967a and 967b deflect feed material 969 around the flow restrictor 950c. Flow restrictor 950d is a quadrilateral prism having a leading face 967 oriented to face the feed material 969 directly. Flow restrictor 950e has the shape of an elliptic cylinder and has an oval cross-sectional area 972.
Flow restrictor 1050f illustrates that certain exemplary flow restrictors 1050f can have the first flow restrictor end 1055 disposed at a different elevation than the second flow restrictor end 1054 within the groove 1030.
The protrusion's lateral cross-sectional area 1062, subsurface dam's lateral cross-sectional area (544,
In exemplary embodiments, the longitudinal cross-sectional area 972 of a protrusion 1050 is not more than 20% of the lateral cross-sectional area 1046 of the corresponding adjacent refiner bar 1025z. In still other exemplary embodiments, the lateral cross-sectional area 1062 of a protrusion 1050 is not more than 15% of the lateral cross-sectional area 1046 of the adjacent refiner bar 1025z.
In the depicted embodiment, two or more notches 1137 are laterally aligned among adjacent peaks 1130x, such that a single protrusion 1150 can be supported by a line of laterally aligned notches 1137 to thereby span a plurality of adjacent peaks 1130x. It is contemplated that such an embodiment is the most efficient way to cast refiner plate segments 1100 in accordance with the exemplary process. In other exemplary embodiments, the notches 1137 are not laterally aligned among adjacent peaks 1130x. In still other exemplary embodiments, the to-be-inserted protrusions 1150 can be a lattice or other complex shape, wherein the lattice or other complex shape disposes a protrusion 1150 at different lengths along the groove length GL. In still other exemplary embodiments, the lattice or other complex shape places protrusions 1150 at different groove lengths among different grooves 1130. In this manufacturing method, the protrusion insert 1150 (
When the molten metal or alloy that will become the refiner plate segment 1100 is poured into the casting mold 1194, the molten metal or alloy fuses with the inlaid protrusions 1150, thereby creating a durable bond. Manufactures thereby pour molten metal or alloy into the casting mold 1194 (represented by step 1185), allow the molten metal to cool and solidify (represented by step 1170) and extract the refiner plate segment 1150 from the casting mold 1194 (represented by step 1160). This is usually done by breaking the casting mold 1194.
An exemplary method comprises: arranging protrusions in the positive grooves of a casting mold to define inlaid protrusions, the protrusions having a protrusion height, wherein the protrusion height is no more than 25% of a negative refiner bar height in the casting mold, pouring molten metal into the casting mold, fusing the inlaid protrusions with the molten metal, permitting the molten metal to cool to define a cast refiner plate segment, removing the cast refiner plate segment from the mold. An exemplary method can further comprise: machining cast refining bars and cast refining protrusions on a refiner side of the cast refiner plate segment.
Another exemplary method comprises: pouring molten metal into the casting mold, permitting the molten metal to cool to define a cast refiner plate segment, removing the cast refiner plate segment from the mold, and machining a groove substrate to define protrusions, wherein the protrusions have a protrusion height, wherein the protrusion height is no more than 25% of a refiner bar height adjacent to the protrusions.
An exemplary a refiner plate segment comprises: an inner arc, an outer arc distally disposed from the inner arc, a first end distally disposed from a second end, the first end and second end extending between the inner arc and the outer arc, a substrate disposed between the inner arc, first end, second end, and the outer arc, a refiner side and a back side distally disposed from the refiner side, refiner bars engaged to the substrate on the refiner side, wherein the refiner bars have a refiner bar height, and wherein adjacent refiner bars and the substrate define a groove between the adjacent refiner bars, and a protrusion disposed in the groove, the protrusions having a protrusion height, wherein the protrusion height is no more than 30% of the refiner bar height.
An exemplary refiner plate segment can further comprise multiple protrusions, wherein the protrusions are disposed at regular intervals of between 6 millimeters to 25 millimeters within the groove. An exemplary refiner plate segment can further comprise multiple protrusions, wherein the protrusions are disposed at irregular intervals.
An exemplary refiner plate segment can further have a shape of a rectangle, a rectangular prism, wherein the protrusion has a leading face disposed at an angle relative to the substrate on the refiner side of the refiner plate segment, and wherein the angle is an obtuse angle.
In an exemplary embodiment, the protrusion comprises a material selected from the group consisting of: aluminum, copper, brass, steel, plastic, wood, and epoxy resin.
In an exemplary embodiment, the refiner bars have an initial bar height of 12 mm-15 mm and the protrusion has an initial protrusion height of 2 mm-3 mm. In yet another an exemplary embodiment, the refiner bars have an initial bar height of 10 mm-20 mm and the protrusion has an initial protrusion height of 2 mm-5 mm. In still other exemplary embodiment, the refiner bars have an initial bar height of 12 mm-15 mm and the protrusion has an initial protrusion height of 2 mm-3.5 mm. In an exemplary embodiment, a protrusion length is no more than 10% of a refiner bar length.
An exemplary refiner plate segment comprises: an inner arc, an outer arc distally disposed from the inner arc, a first end distally disposed from a second end, the first end and the second end extending between the inner arc and the outer arc, a substrate disposed between the inner arc, first end, second end, and the outer arc, a refiner side of the substrate and a back side of the substrate distally disposed from the refiner side, refiner bars engaged to the substrate on the refiner side, wherein the refiner bars have a refiner bar height, and wherein adjacent refiner bars and the substrate define a groove between the adjacent refiner bars, and protrusions disposed in the groove, the protrusions having a protrusion top, a protrusion base, and a protrusion height between the protrusion top and the protrusion base, and a side connecting the protrusion top and the protrusion base, wherein a protrusion of the protrusions has a longitudinal cross-sectional area measured from a plane disposed along the longest length of the protrusion as measured from a portion of the protrusion disposed closest to the inner arc to a portion of the protrusion disposed closest to the outer arc, wherein an adjacent refiner bar of the refiner bars has a lateral cross-sectional area measured from a plane intersecting the refining section transversely to a refiner bar length, and wherein protrusion longitudinal cross-sectional area is less than 20% of the adjacent refiner bar lateral cross-sectional area.
In an exemplary embodiment, the refiner plate segment further comprises a difference between the protrusion height and the refiner bar height, wherein the difference between the protrusion height and the refiner bar height is an effective groove depth.
In an exemplary embodiment, the refiner plate segment further comprises dams, wherein the dams have a dam longitudinal cross-sectional area and wherein the dam longitudinal cross-sectional area is greater than 20% of a reference bar longitudinal area, wherein the reference bar longitudinal area comprises a length and a height, wherein the reference bar length coextends with a longest length of the dam.
In an exemplary embodiment, the protrusions are disposed at irregular intervals.
In an exemplary embodiment, a protrusion of the protrusions has a shape of a trapezoidal prism, wherein the protrusion has a leading face disposed at an angle relative to the substrate on the refiner side of the refiner plate segment, and wherein the angle is an obtuse angle.
An exemplary refiner plate segment comprises: an inner arc, an outer arc distally disposed from the inner arc, a first end distally disposed from a second end, the first end and the second end extending between the inner arc and the outer arc, a substrate disposed between the inner arc, first end, second end, and the outer arc, a refiner side of the substrate and a back side of the substrate distally disposed from the refiner side, refiner bars engaged to the substrate on the refiner side, wherein the refiner bars have a refiner bar height, and wherein adjacent refiner bars and the substrate define a groove between the adjacent refiner bars, and a protrusion disposed in the groove between two adjacent refiner bars, wherein the protrusion is a flow restrictor having a first restrictor end distally disposed from a second restrictor end, wherein the first restrictor end engages a leading face of a first refiner bar of the two adjacent refiner bars, and wherein the flow restrictor is disposed above the substrate of the groove.
In an exemplary embodiment, the flow restrictor has a longitudinal cross-sectional area measured from a plane disposed along the longest length of the flow restrictor as measured from a portion of the flow restrictor disposed closest to the inner arc to a portion of the flow restrictor disposed closest to the outer arc, wherein the first refiner bar of the two adjacent refiner bars has a lateral cross-sectional area measured from a plane intersecting the refining section transversely to a refiner bar length, and wherein flow restrictor longitudinal cross-sectional area is less than 20% of the adjacent refiner bar lateral cross-sectional area.
In an exemplary embodiment, a second restrictor end engages a trailing face of a second refiner bar of the two adjacent refiner bars.
An exemplary embodiment further comprises multiple protrusions, wherein the multiple protrusions are flow restrictors.
In an exemplary embodiment, a first flow restrictor of the multiple flow restrictors is disposed at a first flow restrictor height, and wherein a second flow restrictor of the multiple flow restrictors is disposed at a second flow restrictor height.
In an exemplary embodiment, the first flow restrictor end is disposed at a different elevation than the second flow restrictor end.
While this invention has been particularly shown and described with references to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims.
This application claims the benefit under 35 U.S.C. § 119 (e) of the earlier filing date of U.S. Provisional Patent Application No. 62/744,391 filed on Oct. 11, 2018, the entirety of which is incorporated herein by reference.
| Filing Document | Filing Date | Country | Kind |
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| PCT/US2019/054999 | 10/7/2019 | WO |
| Publishing Document | Publishing Date | Country | Kind |
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| WO2020/076700 | 4/16/2020 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20220034035 A1 | Feb 2022 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62744391 | Oct 2018 | US |
