纳尔科化学品.pdf

challenges and new technologies related to increasing filler content in graphic papers 11/10/2010 qinglong rao, yulin zhao and weiguo cheng nalco shanghai technology center 2010 4thisetpp 2 outline effects of fillers on sheet properties filler content filler type challenges of increasing filler content effects of nalco fillertektmtechnology on sheet properties pilot machine study case study of commercial application summary 2010 4thisetpp 3 fillers in papermaking fillers were introduced into papermaking for improving sheet properties optical properties printing quality smoothness fillers are significantly cheaper than fibers dramatic size difference between filler and fiber fillers have much larger specific surface area interference with fiber-fiber bonding interference with wet-end chemicals retention aids sizing agent strength agent 2010 4thisetpp 4 why is high filler content desired? fiber substitution - cost savings kraft 850$/ton; pcc 100$/ton energy savings sheet performance formation, printability, brightness, opacity, smoothness 400 500 600 700 800 900 1000 1/3/20086/1/200810/29/2008 3/28/20098/25/20091/22/20106/21/2010 time pulp price in us ($/tonne) sbsk nbhk 2010 4thisetpp 5 challenges for increasing filler loading low strength of dry sheet filler interferes with fiber-fiber bonding dry strength agents do not work due to the interference from filler poor machine runnability low wet web strength press picking filler retention and sheet formation fillers are harder to retain increased use of retention chemicals leads to poor formation economics possible bulk loss expensive filler treatment program 2010 4thisetpp 6 nalco fillertektm based on the ability to increase filler particle size in a controlled manner and reduce the interference with fiber- fiber bonding 0 4 8 12 16 20 0.11101001000 particle size (m) volume percentage (%) untreated pcc prefloc pcc 2010 4thisetpp 7 effects of fillertektmon sheet properties pilot machine trial conditions eurofex gap-former pilot machine at innventia machine speed: 1000 m/min grade: 75 gsm sheet at 20%, 25% and 30% ash levels furnish and additives furnish: 85/15 eucalyptus (26 sr) / pine (22 sr) untreated or prefloc. syncarb f0474-go dispersed pcc omya 7.5 kg/ton cargill 35844 c* bond starch 4.5 kg/ton tinopal np oba 6 kg/ton nalco 74003 akd nalco core shell74553 cationic flocculant (dosage varied) 5 kg/ton nalco positek 3g 8699 microparticle 2010 4thisetpp 8 effects of fillertektmon sheet strength pilot machine trial the ash level can be increased by 9 points without a loss in internal bond strength as measured by z-directional tensile (zdt). 2010 4thisetpp 9 effects of fillertektmon sheet opacity pilot machine trial opacity loss with prefloc filler can be recovered with a 5 point filler increase. 2010 4thisetpp 10 case study i of commercial application ucfs 75 gsm 10% broke, 63% hwk and 27% swk pcc/gcc blend. initial ash level 18% fillertektmhas been running across all grades for over one year 18%ash 18% untreated filler22.5% prefloc. filler 2010 4thisetpp 11 impact of fillertektmon sheet properties case study i of commercial application untreated fillerfillertektmtreatment sheet property valuestd. dev.valuestd. dev. impact of fillertektm technology sheet ash (%)17.70.5022.20.50+4.5 pt ash increase basis weight (gsm)76.331.1774.870.92lower bulk (cm3/g)1.380.021.380.01equal internal bond (zdt, kpa)571.718.0574.010.6equal tensile index (nm/g)54.322.9752.732.73equal, within std dev bending resistance (mn)103.59.391.18.6reduced porosity (ml/min)115787119866equal, within std dev pps roughness (m)6.430.326.010.11smoother sheet sizing, hst (sec)69.1525.361.4325.4equal, within std dev opacity at 75 gsm (%)94.430.7694.630.52equal brightness (%)91.200.0891.090.20equal 2010 4thisetpp 12 z-directional filler distribution case study i of commercial application 0 5 10 15 20 25 30 0102030405060708090100 relative basis weight, % ash, % untreated pcc/gcc blend treated pcc/gcc blend 2010 4thisetpp 13 summary with increasing fiber prices, increasing the ash content in graphic paper can significantly decrease the production costs nalco fillertektmtechnology was proven capable of helping papermakers increase filler content by 3% to 5% while ma