The purpose of the headbox is to convert a flow of fiber suspension to a jet, with a thickness between 4 and 20mm and a width between 3 -8meters, depending on the paper machine model. To adjust the beam thickness, the lip adjustment arrangement is used. This master thesis was written to develop the headbox and the lip adjustment system, for paper machines with a width over 6 meters. In the beginning of the project much focus was layed on understanding the problem and develop the product and customer requirements of the Headbox. In order to utilize the entire idea space a number of idea generation methods were used. The evaluation of concepts were conducted with the method Analytic hierarchy process (AHP), which is a method for clarifying the decision pattern. From the evaluation of the concept, two concepts were chosen. A modification of the existing headbox and a new concept, which adjusts the slice opening with a number of elastic pockets and a wedge. To further evaluate the modified headbox concepts the Finite Element Method was used. During the simulations the elastic deformation was compared between the current and the modified solution. The second concept was developed by describing the new design and motivated the chosen material and structures.   Overall it can be said that the modification of the current headbox solves the main problem and maintains the current quality on the paper. The new and innovative solution enables a more exact adjustment of the lip opening and allows a larger potential of modularization. / Syftet med inloppslådan är att den ska transformera ett flöde av fibersuspension till en stråle som är mellan 4 och 20 mm tjock och 3-8 m bred, beroende på pappersmaskinsmodell. För att justera strålens tjocklek används läppjusteringsanordningen. Målet med detta arbete var att utveckla inloppslådan och dess läppöppningsarrangemang så att den kan användas till en pappersmaskin som är breddare än 6 meter. Projektet inleddes med att skapa en förståelse för problemet samt att undersöka vilka produkt- och kundkrav det finns på inloppslådan. För att utnyttja hela iderymden användes ett antal idegenereringsmetoder. Utvärdering av koncepten genomfördes med hjälp av en metod som heter Analytic hierarchy process (AHP) som är en metod som används för att tydliggöra beslutsvägen. Utifrån utvärdering med AHP valdes två koncept ut. En modifierad lösning av det nuvarande läppöppningsarrangemangen och ett nytt koncept vilket justerar läppöppningen med hjälp av ett antal trycksatta fickor och en vinge. För att ytterligare utveckla den modifierade inloppslådan användes Finita Elementmetoden. Under simuleringen jämfördes elastisk deformation i den nuvarande och den modifierade lösningen. Det nya konceptet utvecklades genom att den nya konstruktionen beskrevs utifrån struktur, materialval och tillverkningsmetoder. Sammantaget kan det sägas att den modifierade inloppslådan löser problemställning och bibehåller den nuvarande kvalitén på pappret. Den innovativa och nya lösningen möjliggör en mer exakt justering av läppöppningen och ökar möjligheten att modularisera inloppslådan.

The head box in a tissue machine distributes the fiber suspension to a flat jet along the width of the machine. By adjusting the so-called lip opening, the flow is regulated and the jet is accelerated to match the machine speed. In this work, ideas for alternative solutions for lip opening mechanism is generated and evaluated with a focus on making a cost saving. One of the concepts has been selected for a deeper analysis with respect to the design, strength and cost. The selected concept is based on reducing the number of jacks required by using one jack operating a shaft parallel to the apron beam. Levers convey the movement to the apron beam. The analysis show that the shaft is exposed to high torque which results in large elastic twisting of the shaft, which means that the force that supports the apron beam will not be equal over the entire width. If the difference in force is too big, the apron beam will twist which results in an uneven lip opening. The shaft stiffness is therefore crucial. For the head box with a width of 2946 mm, the number of jacks is reduced from three to one. Wider head boxes may need more than one jack since the shaft cannot be made to long without getting too much twisted. A lip opening mechanism of the current design with six 20 ton jacks can be compared to the new concept in which only two jacks is needed and the cost is reduced by 18%. There is further potential for savings if the jack, separate gear and electric motor are replaced with an actuator that has the motor mounted directly. / Inloppslådan i en tissuemaskin har till uppgift att fördela fibersuspensionen till en flat stråle längs maskinens bredd. Genom att justera den så kallade läppöppningen regleras flödet och strålen accelereras för att passa maskinhastigheten. I detta arbete har idéer till alternativa lösningar för läppöppningsmekanismen genererats och utvärderats med fokus på att göra en kostnadsbesparing. Ett av koncepten har valts ut för en djupare analys med avseende på konstruktion, hållfasthet och kostnad. Det valda konceptet bygger på att reducera antalet domkrafter som behövs genom att en domkraft driver en axel parallell med utloppsbordet. Hävarmar överför rörelsen till utloppsbordet. Analysen visar att axeln utsätts för ett stort moment vilket ger en stor elastisk vridning av axeln, vilket gör att kraften som håller emot utloppsbordet inte blir lika stor över hela bredden. Om skillnaden i kraft är för stor ger det en förvridning av utloppsbordet som resulterar i en ojämn läppöppning. Axelns styvhet är alltså avgörande. För den undersökta lådan med bredden 2946 mm har antalet domkrafter reducerats från tre stycken till en. För bredare inloppslådor behövs fler domkrafter då axeln inte kan göras för lång utan att få för mycket vridning. Ett läppöppningsarrangemang som idag har sex stycken domkrafter kan jämföras med det nya konceptet där det krävs endast två domkrafter och kostnaden minskas med ca. 18%. Ytterligare potential till besparing finns om man byter ut domkraft, separat växel och elmotor till ett ställdon som har motorn direktmonterad.

The purpose of this thesis is to investigate an alternative control strategy for a multi-variate non-linear process in a paper machine called the headbox. The proposed solution was intended to be able to be adopted on two different headbox types, currently controlled by different concepts. The methodology was to first create black-box models of the two different systems based on measurements, at one working point. Secondly, various control strategies were investigated. A more sophisticated multi-input multi-output controller MPC, or model predictive control, and a less sophisticated one, a single-input single-output, decentralised PI-controller. With help of simulations the performances of the both strategies were tested. Finally, only the decentralised control solution was implemented and evaluated through trial runs on a pilot machine. The main issue regarding the decentralised controller was the input-ouput pairing. Since the multi-variate system had four outputs and only three inputs, analysis had to be made in order to select three of those four, to form a square system. This analysis was based on the relative gain array (RGA). The resulting performance of the decentralised controller showed stability and adequate response times, surpassing the older system and making one component obsolete through the pairing changes. The MPC controller showed even better performance during simulations and shall also be taken into account if further investigatin is possible.

The dynamics of fiber orientation is of great interest for efforts to predict the microstructure and material properties of a suspension flow system. In this research a fiber-level, hybrid simulation method, LBM‒EBF (coupled lattice‒Boltzmann method with the external boundary force method) is undertaken to advance the current understanding of the hydrodynamic interaction induced rotational diffusion mechanism for rigid fibers in semidilute suspension of low Reynolds number flow. The LBM‒EBF simulations correctly predict the orbit constant distribution of fibers in a sheared semidilute suspension flow. It is demonstrated that an anisotropic, weak rotary diffusion model can fit the orbit constant distribution very well, but it can not describe the asymmetry in Stokes flow observed in semidilute suspension. The rotational diffusion process is then characterized with a three dimensional spatial tensor representation of the rotational diffusivity. A scalar measure of the rotational diffusion‒'scalar Folgar‒Tucker constant', C[subscript I], is extracted from this tensor. The study provides substantial numerical evidence that the range of C[subscript I] (0.0038 to 0.0165) obtained by Folgar&Tucker (J. reinf. plast. and comp, v.3, 1984) in a semidilute regime is overly diffusive, and that the correct magnitude is of O(10⁻⁴). The study reveals that the interactions among fibers become more frequent with either the decrease of fiber aspect-ratio, r[subscript p] (keeping nL³ constant, where n is the fiber number density, and L is the fiber length) or with the increase of nL³ (keeping r[subscript p] constant) in the semidilute regime, which in consequence causes an increase in C[subscript I]. The rheological properties of sheared semidilute suspension are also computed with direct LBM‒EBF simulations. The LBM‒EBF investigation is extended to characterize the fiber orientation in a linearly contracting channel similar to a paper machine 'headbox'. It is found that the rotational diffusion is the predominant term over the strain rate in the semidilute regime for a low Reynolds number flow, and it results in a decreasing trend of rotational Peclet number, Pe, along the contraction centerline. Lastly, in order to improve the numerical consistency of the existing LBM‒EBF approach, a modification to the body force term in the LB equation is suggested, which can recover the exact macroscopic hydrodynamics from the mesoscale.

<p>The purpose of this thesis is to investigate an alternative control strategy for a multi-variate non-linear process in a paper machine called the headbox. The proposed solution was intended to be able to be adopted on two different headbox types, currently controlled by different concepts. </p><p>The methodology was to first create black-box models of the two different systems based on measurements, at one working point. Secondly, various control strategies were investigated. A more sophisticated multi-input multi-output controller MPC, or model predictive control, and a less sophisticated one, a single-input single-output, decentralised PI-controller. With help of simulations the performances of the both strategies were tested. Finally, only the decentralised control solution was implemented and evaluated through trial runs on a pilot machine. </p><p>The main issue regarding the decentralised controller was the input-ouput pairing. Since the multi-variate system had four outputs and only three inputs, analysis had to be made in order to select three of those four, to form a square system. This analysis was based on the relative gain array (RGA). </p><p>The resulting performance of the decentralised controller showed stability and adequate response times, surpassing the older system and making one component obsolete through the pairing changes. The MPC controller showed even better performance during simulations and shall also be taken into account if further investigatin is possible.</p>

The main goal of this work was to develop numerical models for studying the behaviour of fibres in an accelerated flow. This is of special interest for e.g. papermaking. The early stage of the paper manufacturing process determines most of the final properties of a paper sheet. The complexity of studying the flow of fibre suspensions both experimentally and numerically emphasises a need for new ideas and developments. By means of solving the evolution of a convective-dispersion equation, i.e. the Fokker-Planck equation, a fully 3D approach with respect to the position and the two fibre angles, polar and azimuthal angles, following a streamline is presented. As an input to the fibre orientation model the turbulent flow field is solved by Computational Fluid Dynamics (CFD) with second-order closure in the turbulence model. In this work two new hypotheses have been presented for the variation of the non-dimensional rotational diffusivity with non-dimensional fibre length, Lf /η and the Reynolds number based on the Taylor micro-scale of the turbulence, Reλ Parameters for the two new hy- potheses and earlier models are determined with the aim of achieving a general relation and a value of the rotational dispersion coeffcient of stiff fibres in an anisotropic turbulent fluid flow. Earlier modelling work has been focused on solving the planar approach, i.e. assuming all fibres to be in one plane. This planar approach is discussed and compared with the fully 3D approach and its validity is evaluated. The optimization of parameters for the different hypotheses correlated on a central streamline, showed a good agreement with an independent experimental result in the undisturbed region. Moreover, it is particularly interesting that the boundary layer region and the wake region are predicted fairly well and the phenomena are well described, which has not been the case earlier. It seems that the new hypothesis based on the variation of the non-dimensional fibre length, Lf /η gives the best correlation in these shear-layer regions. Further- more it was established that the planar approach fails to predict shear layers, i.e. the boundary layer and the wake regions. As emphasized in the theory section, the planar formulation is strictly valid only if all fibres are oriented in one plane, which is not the case in the shear layers. In the undisturbed region, the 3D and the planar approaches, agree in their results. This leads to the conclusion that both approaches are suitable when shear layers are not studied. / QC 20100812

Process industries are in general depending, in one way or the other, on fluid mechanics.Specifically, paper manufacturing, which probably is the dominant processindustry in Sweden, is depending on the flow of cellulose fibres suspended in water.As a part of the process the suspension, consisting of fibres in water, is spread out onor between two moving permeable weaves, i.e. wires. The speed of this is usually 10–30 m/s and the suspension is spread out by a plane jet issuing from a headbox nozzle.It has been show that the conditions in the headbox and jet have a large influence onthe quality of the final paper sheet. Primarily, streaks in the paper sheet are believedto be the result of streamwise streaks in the headbox jet.The thesis is aimed at the flow phenomena which occur in the headbox jet. Theinvestigations have been made with numerical calculations, stability theory and modelexperiments using water, as well as experiments with a real paper machine headboxand fibre suspension. In the thesis an introduction to the hydrodynamics of planeliquid jets is presented together with a description of the paper forming process andthe fluid mechanics of headbox flow.The basic flow and stability of a two-dimensional plane liquid jet has been investigatedby numerical calculations, stability theory and experiments. The calculationsof the laminar basic flow is successfully compared to pitot-tube measurements of thestreamwise velocity profile. By visualisations of the flow it is found that wave disturbanceson the jet has a severe effect on the flow. These waves can be predicted bylinear stability theory, which shows the presence of five convectively unstable modes.These can be divided into three types and by comparison with the experiments thetype of the visible waves is determined. These waves seem to initiate a break-up ofthe jet, which leads to strong streamwise streaks inside the jet.By flow visualisation of headbox flow of an experimental paper machine, togetherwith analysis of the resulting paper structure using the wavelet method the correspondencebetween flow disturbances and paper quality was investigated. It was shownthat the wave instability, which is present on the low Reynolds number water jet, alsocan be found in the real the headbox jet. It is shown that these waves play an importantrole in the dynamics of the headbox jet and also have an influence on the final papersheet. / QC 20100825

Four different trials of stratified three-layered fine paper, of sulphate pulp, were performed to investigate if stratified fine fraction or fibres from birch can improve the properties of a paper compared to a reference sheet. All trials had five different scenarios and each scenario was calendered with different linear load. All sheets had a grammage of 80 g/m2.In the first trial, the paper contained birch, pine and filler of calciumcarbonate (marble), and was manufactured with the pilot paper machine XPM and the stratified headbox Formator at RCF (Stora Enso Research Center in Falun). The furnish consisted of 75% birch and 25% pine.The second trial contained coated sheets with paper from trial one as the base paper. The coating slip contained calciumcarbonate and clay and the amount was approximately 10-12 g/m2.The third trial, also with birch and pine but without filler, was performed at STFI (Skogsindustrins Tekniska Forskningsinstitut in Stockholm) with the laboratory scaled paper machine StratEx and the stratified headbox AQ-vanes. The furnish consisted of 75% birch and 25% pine, except for one scenario which contained of 75% pine and 25% birch.The last trial contained fractionated pulp of birch and pine and was performed at STFI. 50% was fine fraction and 50% was coarse fraction.This test does not show any clear benefits of making stratified sheets of birch and pine when it comes to properties such as bending stiffness, tensile index and surface smoothness. The retention can be improved with birch in the surface plies. It is possible that the formation can be improved with birch in the surface plies and pine in the middle ply. It is also possible that fine fraction in the surface plies and coarse fraction in the middle ply can improve both surface smoothness and bending stiffness. The results in this test are shown with confidence intervals which points out the difficulties of analysing sheets manufactured with a pilot paper machine or a laboratory scaled paper machine.

Abstract This study focused on web forming at a 5–10% consistency range, termed Ultra High Consistency (UHC). The study continued work done by Gullichsen with his research groups (1981–2007) and combined it with the HC forming research done by Valmet (HC, 1999–2004). The hypothesis was that by utilizing a rotor to fluidize suspension and a wedge to eliminate the free jet and thus prevent reflocculation, web forming at UHC is feasible at commercial speeds. The research method was experimental. The bulk of the research was conducted at pilot scale. A new UHC headbox was designed and mounted on a pilot former. The key elements of the headbox are the rotor and the wedge. As fluidization forms the base for UHC forming, this was evaluated at the pilot former using image analysis. In addition, fluidization was studied using a laboratory-scale device. Besides basic paper analysis, X-ray microtomography and sheet splitting methods were utilized to analyze the sheet structure. The results show that forming is possible within the focus area, 5–10% consistency and machine speeds of 150–600 m/min, although the operation potential of the UHC former is even wider. The results demonstrate that the wedge is needed for successful UHC forming, but the rotor is not required, providing the flow rate is sufficiently high. This indicates that various forces induced by the flow itself can be adequate to fluidize suspension for forming. The critical Reynolds number of full fluidization was found to be 200–250. The Reynolds numbers were estimated utilizing the linear dependencies found between the apparent viscosity and consistency, using the maximum mean flow velocities inside the headbox, and neglecting the possible rotation of the rotor. The corresponding critical flow velocities at 10% consistency are 12 and 19 m/s for a eucalyptus and pine pulp. The velocities are on average 70 and 60% lower than those given in the literature (40–50 m/s). The results reveal that the fiber orientation of UHC sheets is planar, the floc size of the web increases with consistency, the internal bond increases linearly with the floc size, and the tensile strength appears to decrease with increasing floc size. In consequence, it is postulated that the increase in the out-of-plane strength at the expense of in-plane strength with the consistency increase results from a more flocculated structure. / Tiivistelmä Tutkimus keskittyi rainanmuodostukseen 5–10 % sakeudessa. Sakeusalue nimitettiin ultra korkeaksi (lyhenne UHC). Tämä työ jatkoi Gullichsenin ja hänen tutkimusryhmiensä tutkimustyötä (1981–2007) ja samalla yhdisti sen Valmetin tekemään suursakeusrainaustutkimukseen (HC, 1994–2004). Työn hypoteesina oli, että käyttämällä roottoria massan fluidisoimiseen sekä ns. wedgeä eliminoimaan vapaa suihku ja estämään jälleenflokkaantuminen, rainanmuodostus UHC-sakeudessa on mahdollista kaupallisissa nopeuksissa. Tutkimusmetodi oli kokeellinen. Pääosa tutkimuksesta suoritettiin koekonemittakaavassa. Uusi UHC-perälaatikko suunniteltiin ja asennettiin koeformeille. Perälaatikon pääelementit ovat pyörivä roottori ja wedge. Koska fluidisointi muodostaa UHC-rainauksen perustan, fluidisointia evaluoitiin koekoneella käyttäen kuva-analyysiä sekä tutkittiin lisäksi käyttäen röntgenmikrotomografia ja arkin halkaisu -metodeja. Tulokset osoittavat, että rainaaminen on mahdollista määritellyllä fokusalueella, 5–10 %sakeudessa ja konenopeudella150–600 m/min, joskin UHC-formerin toimintapotentiaali on vieläkin laajempi. Tulokset osoittavat, että wedge tarvitaan onnistuneeseen UHC-muodostamiseen, mutta roottoria ei tarvita, mikäli virtausnopeus on riittävän suuri. Tämä tarkoittaa, että virtauksen aikaansaamat voimat voivat itsessään olla riittäviä massan fluidisoimiseksi rainaamista varten. Täyden fluidisaation kriittisen Reynoldsin luvun havaittiin olevan välillä 200–250. Reynoldsin luvut arvioitiin käyttäen löydettyjä viskositeetin ja sakeuden välisiä lineaarisia riippuvuuksia, päävirtauksen maksiminopeuksia perälaatikossa ja jättäen huomioon ottamatta mahdollinen roottorin pyöriminen. Reynoldsin lukuja vastaavat kriittiset virtausnopeudet 10 % sakeudessa ovat eukalyptus- ja mäntymassalla 12 ja 19 m/s. Nopeudet ovat keskimäärin 70 ja 60 % pienempiä kuin kirjallisuudessa annetut (40–50 m/s). Tulokset osoittavat, että UHC-arkeissa kuituorientaatio on tasomainen, rainan flokkikoko kasvaa sakeuden kasvaessa, palstautumislujuus kasvaa lineaarisesti flokkikoon kanssa ja vetolujuus näyttäisi laskevan flokkikoon kasvaessa. Näin ollen esitetään, että sakeuden kasvaessa tapahtuva palstautumislujuuden kasvu tasolujuuksien kustannuksella johtuu flokkaantuneemmasta rakenteesta.