Upscaling of foam forming technology for pilot scale

Jani Lehmonen (Corresponding Author), Timo Rantanen, Karita Kinnunen-Raudaskoski

Research output: Contribution to journalArticleScientificpeer-review

Abstract

The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water-and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing. Application: Use of aqueous foam as a process fluid instead of conventional water permits enhancement to paper and board production and products. Enhancement in dewatering and increased dryness after wet pressing enable savings in drying energy consumption and offer improved formation, higher bulk of the web, and light-weighting of current products
Original languageEnglish
Pages (from-to)461-471
JournalTappi Journal
Volume18
Issue number8
DOIs
Publication statusPublished - 2019
MoE publication typeA1 Journal article-refereed

Fingerprint

Foams
Water
Dewatering
Wire
Costs
Industry
Drying
Energy utilization
Fluids

Cite this

Lehmonen, Jani ; Rantanen, Timo ; Kinnunen-Raudaskoski, Karita. / Upscaling of foam forming technology for pilot scale. In: Tappi Journal. 2019 ; Vol. 18, No. 8. pp. 461-471.
@article{9fb703376bbf4aa5a7027d3b5a50174f,
title = "Upscaling of foam forming technology for pilot scale",
abstract = "The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water-and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing. Application: Use of aqueous foam as a process fluid instead of conventional water permits enhancement to paper and board production and products. Enhancement in dewatering and increased dryness after wet pressing enable savings in drying energy consumption and offer improved formation, higher bulk of the web, and light-weighting of current products",
author = "Jani Lehmonen and Timo Rantanen and Karita Kinnunen-Raudaskoski",
year = "2019",
doi = "https://doi.org/10.32964/TJ18.8.461",
language = "English",
volume = "18",
pages = "461--471",
journal = "Tappi Journal",
issn = "0734-1415",
publisher = "TAPPI Press",
number = "8",

}

Upscaling of foam forming technology for pilot scale. / Lehmonen, Jani (Corresponding Author); Rantanen, Timo; Kinnunen-Raudaskoski, Karita.

In: Tappi Journal, Vol. 18, No. 8, 2019, p. 461-471.

Research output: Contribution to journalArticleScientificpeer-review

TY - JOUR

T1 - Upscaling of foam forming technology for pilot scale

AU - Lehmonen, Jani

AU - Rantanen, Timo

AU - Kinnunen-Raudaskoski, Karita

PY - 2019

Y1 - 2019

N2 - The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water-and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing. Application: Use of aqueous foam as a process fluid instead of conventional water permits enhancement to paper and board production and products. Enhancement in dewatering and increased dryness after wet pressing enable savings in drying energy consumption and offer improved formation, higher bulk of the web, and light-weighting of current products

AB - The need for production cost savings and changes in the global paper and board industry during recent years have been constants. Changes in the global paper and board industry during past years have increased the need for more cost-efficient processes and production technologies. It is known that in paper and board production, foam typically leads to problems in the process rather than improvements in production efficiency. Foam forming technology, where foam is used as a carrier phase and a flowing medium, exploits the properties of dispersive foam. In this study, the possibility of applying foam forming technology to paper applications was investigated using a pilot scale paper forming environment modified for foam forming from conventional water forming. According to the results, the shape of jet-to-wire ratios was the same in both forming methods, but in the case of foam forming, the achieved scale of jet-to-wire ratio and MD/CD-ratio were wider and not behaving sensitively to shear changes in the forming section as a water forming process would. This kind of behavior would be beneficial when upscaling foam technology to the production scale. The dryness results after the forming section indicated the improvement in dewatering, especially when foam density was at the lowest level (i.e., air content was at the highest level). In addition, the dryness results after the pressing section indicated a faster increase in the dryness level as a function of foam density, with all density levels compared to the corresponding water formed sheets. According to the study, the bonding level of water-and foam-laid structures were at the same level when the highest wet pressing value was applied. The results of the study show that the strength loss often associated with foam forming can be compensated for successfully through wet pressing. Application: Use of aqueous foam as a process fluid instead of conventional water permits enhancement to paper and board production and products. Enhancement in dewatering and increased dryness after wet pressing enable savings in drying energy consumption and offer improved formation, higher bulk of the web, and light-weighting of current products

UR - http://www.scopus.com/inward/record.url?scp=85073497836&partnerID=8YFLogxK

U2 - https://doi.org/10.32964/TJ18.8.461

DO - https://doi.org/10.32964/TJ18.8.461

M3 - Article

VL - 18

SP - 461

EP - 471

JO - Tappi Journal

JF - Tappi Journal

SN - 0734-1415

IS - 8

ER -