"Paper Machine Design and

Operation--Descriptions and
Explanations"
By Gunnar Gavelin

1998., 222 pp., Published by Angus Wilde

Item Number: 08AWPMD
ISBN: 0-9694628-2-4

This new book offers an update on current paper machine developments and operating
practices and compares design approaches by major paper equipment manufacturers.
Seven chapters cover the following topics: Approach Flow, Headboxes, Fourdrinier Wet
End, Twin Wire Formers, Press Section, Drying of Paper, Surface Treatment of Paper.

TABLE OF CONTENTS

PREFACE vii

ACKNOWLEDGEMENTS viii

CHAPTER 1 -- APPROACH FLOW

1.1 Introduction – Basics of Papermaking 1

1.2 Definitions and Nomenclature 2
1.3 White Water System 3
Short Circulation 3
Long Circulation 5
1.4 Machine Refiners 5
1.5 Stuff Box 5
1.6 Basis Weight Valve 6
1.7 Basis Weight Variations 6
1.8 Fan Pump 7
1.9 Headbox Feed Pump 8
1.10 Centricleaners 8
1.11 Deaeration 8
1.12 Screens 10
References 12

CHAPTER 2 – HEADBOXES

2.1 Headbox With Air Cushion 13

Flow Spreader 14
Flow Distributor 14
Headbox Proper 15
Perforated Rolls 15
Air Cushion 17

2.2 Hydraulic Headbox 18

2.3 Slice 19
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
2.4 Acceleration of Flow in the Headbox 20
2.5 Fiber Angle 21
2.6 Dilution Control 22
Voith Module Jet 23
Beloit System 25
Valmet system 26
2.7 Precision Demands on Headbox Surfaces 28
2.8 Hydraulic Headbox Developments 28
Beloit converflo 30
2.9 Multichannel Headbox 32
Why Multichannel Headboxes? 34
2.10 Headbox Effects on formation
and MD/CD Ratio 35
2.11 Length of the Free Jet 35
2.12 Efflux Ratio 35
2.13 Automation of Headbox Operation 37
References 38

CHAPTER 3 – FOURDRINIER WET END

3.1 Fourdrinier Components 40

Breast Roll 41
Deckle Rulers 41
Forming Board 41
Table Rolls 42
Foils (Foil blades) 42
Wet Suction Boxes 44
Dry Suction Boxes 44
Dandy Roll 45
Couch Roll 47
Couch Press 48
Wire Turning Roll 49
3.2 Closed Transfer 49
3.3 Forming Fabric 50
Fabric Designs 50
Seaming 51
Fabric Quality 52
3.4 Auxiliary Rolls 54
Guide and Stretch Rolls 54
Bowed Roll 56
3.5 Fabric Cleaning 58
High Pressure Showers 58
Voith Jetcleaner 60
3.6 Drainage Along the Wire Table 61
3.7 Elements of the White Water System 62
Dry Suction Box Seal Pit 62
Wire Pit 63
White Water Tanks 63
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
White Water Cleaning 64
3.8 Broke System 66
Couch Pit 66
Dry Broke 67

3.9 Wire Retention 68

3.10 White Water system Closure-
Reducing Fresh Water Usage 69
3.11 Cleaning of Paper Mill Effluent 70
References 71

CHAPTER 4 – TWIN-WIRE FORMERS

4.1 Blade Former 73

Drainage Process on a Blade Former 74
4.2 Roll Former 75
Drainage Process on a Roll Former 75
4.3 Hybrid Former 77
Valmet Sym-Former 77
Beloit Bel Bond 79
Voith DuoFormer D 80
4.4 Roll-blade Former 81
4.5 New Blade Forming Technology 82
4.6 Geometry of the Entering Nip 82
Problems of Two-Sidedness 84
4.7 Description of Specific Formers 84
Valmet Speed Former 85
Valmet Speed Former MB 86
4.8 Speed Former and Paper Quality 87
4.9 Blade-Roll Former 88
4.10 Description of Specific Formers 88
Bel Baie III 88
Bel Baie IV 90
Voith DuoFormer CFD 91
4.11 Horizontal Gap Former 94
4.12 Forming Fabrics 95
4.13 Theory of Two-Sided Drainage 95
4.14 Forming Unit Alternatives 96
Membranes in the Slice Area 96
Optimization of Roll Drainage 97
Blade Section Drainage 97
4.15 Paper Quality Considerations 98
4.16 High-Consistency Forming 99
4.17 Paperboard Machine Formers 101
4.18 Tissue Machine Formers 103
Valmet “C-Wrap” 103
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
Valmet Crescent Former 104
Valmet Performer Noveau 104
References 105

CHAPTER 5 – PRESS SECTION

5.1 The Process of Pressing 106

Rewetting Problem 107
5.2 Plain Press 107
5.3 Suction Press 108

Other Suction Roll Applications 109

Suction Roll Shells 109
Roll Shell Covers 110
5.4 Grooved Press 112
Grooved Steel Roll 112
Grooved Press Geometry 113
5.5 Blind-Drilled Press 114
5.6 Fabric Press 114
5.7 Long-Nip Press 115
5.8 Large-Roll Press 116
5.9 Shoe Press 116
Design Principle 116
Effect of Shoe Pressing on Paper Quality 118
Press Sections With Shoe Presses 119
5.10 Double-Felted Press 122
5.11 Types of Rolls 123
Antideflection (Controlled Crown) Rolls 123
Granite Rolls 125
Composite-Covered Rolls 126
Peeler Rolls 126
5.12 Examples of Press Sections 127
Two-Nip Press Sections 127
Three-Nip Press Sections 127
Fourth Nip 129
5.13 Pressing at High Temperature 130
Steam Boxes 130
Hot Presses 131
5.14 Open-Draw Presses 134
Theory and Practice of Open Draws 135
5.15 Closed Transfer – Press Section to Dryers 137
5.16 Economics of Pressing 137
5.17 Press Felts 138
Felt Construction 138
Performance Requirements 139
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
Seamed Press Felts 139
Felt Suction Boxes 140
High-Pressure Showering 140
Cost of Paper Machine Clothing 140
5.18 Vacuum Pumps 140
Water-Ring Vacuum Pump 140
Water-Ring Pump Heat Recovery 141
Turbo Compressor 142
5.19 Pressing and Paper Quality 143
Shadow Marking 143
5.20 Future Development of Pressing 143
References 147

CHAPTER 6 – DRYING OF PAPER

6.1 Cylinder Drying 149

Heat Transfer Considerations 149

Process Considerations 150

6.2 Yankee Cylinder and MG Cylinder Drying 151
Yankee and MG Hoods 152
6.3 Multicylinder Drying 153
6.4 Steam and Condensate Systems 155
Condensate Behavior 156
Turbulence Generators 159
Condensate Dams 160
Condensate Removal 160
Blow-Through Steam 160
Control of Steam and Condensate Flows 162
6.5 Syphon Designs 166
Rotating Syphons 166
Stationary Syphons 167
Syphon for Yankee Dryer 168
Syphon Dimensions 169
6.6 Dryer Fabrics 170
Air Permeability 170
Cleaning 171
6.7 Multicylinder Drying – Ventilation 172
6.8 Sheet Flutter and Closed Sheet Transfer 174
6.9 New Multicylinder Dryer Designs 176
Beloit 178
Valmet 178
Voith 180
6.10 Effect of Closed Transfer on Sheet Shrinkage 181
6.11 Steam Consumption 182
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
6.12 Hood Ventilation 183
Heat Recovery 183
Hood Air Humidity Control 184
Hood Air Humidity Control 185
The Dew Point 186
Variable Speed Fans 187
Scrubber for Exhaust Air 188
6.13 Other Types of Paper Drying Systems 188
Air Impingement Drying 188
Drying with Hot Air 190
Through Drying 191
Infrared Drying 192
Impulse Drying 192
Condebelt Process 194
6.14 Drying and Paper Quality 195
6.15 Control of MD and CD Moisture Profiles 197
References 197

CHAPTER 7 – SURFACE TREATMENT OF PAPER

7.1 Smoothing Press 199

7.2 Breaker Stack 199
Pre-Calendar 200
7.3 Size Press 200

Traditional Size Press 200

Film Size Press 202
7.4 Conventional Hard-Nip Calender 206
Cooling and Control 208
7.5 Soft Calender 209
Soft Calendering Process 210
Soft Calendering or Supercalendering? 212
7.6 Reel 213
7.7 Paper Machine Drives 214
References 215

CREDITS 216

INDEX 218
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin

INDEX behavior ...................................... 156-159

dams .................................................. 160
removal .............................................. 160
A systems ....................................... 160-166
acceleration of headbox flow .................... 20-21
controlled crown roll .............................. 123-124
air cushion headboxes ..............................13, 17
cost of papermachine clothing...................... 140
air drying ...............................................190-191
couch pit .................................................. 66-67
air impingement drying .........................188-190
couch press.................................................... 48
antideflection roll ...................................123-124
couch roll .................................................. 47-48
approach flow .................................................. 4
cylinder drying....................................... 149-151
ash content, control of ..................................... 6
auxiliary rolls ................................................. 54
D
dandy roll .................................................. 45-46
B deaeration ................................................... 8-10
basis weight................................................. 2, 6
deckle ruler .................................................... 41
profile control ....................................... 19
dew point in the hood ............................ 186-187
basis weight valve .................................6, 22-26
dilution of stock before headbox....................3-5
basis weight variations.................................. 6-7
dilution control headboxes......................... 22-27
Beloit,
Beloit system ................................... 25-26
Bel Baie III former ........................... 88-90
Valmet system...................................... 26
Bel Baie IV former........................... 90-91
Voith Module Jet.............................. 23-25
Bel Bond former .............................. 79-80
disc filter .................................................. 64-65
Converflo headbox.......................... 30-32
doctor ........................................................ 111
dryer section .......................................178
dominating fiber angle............................... 21-22
Extended Nip Press......................116-117
drainage
TNT Reel ............................................212
blade section ........................ 74-75, 97-98
Ultra Rock press roll ............................126
on fourdrinier ................................... 61-62
blade former .................................................. 73
on roll formers ........................... 76-77, 97
blade former drainage............................... 74-75
draws .. ............................................... 135-136
blade forming technology............................... 82
drives, paper machines ......................... 213-214
blade section drainage................................... 93
dry broke handling.......................................... 67
bowed rolls ............................................... 56-57
dryer designs, new ................................ 176-181
breaker stack .........................................199-200
dryer fabric............................................ 170-172
breast roll ...................................................... 41
air permeability ............................ 170-171
broke system ............................................ 66-67
cleaning....................................... 171-172
dryer hood
C dew point control ......................... 185-187
calender heat recovery............................... 183-184
hard-nip........................................205-206 humidity control ........................... 185-187
soft...............................................208-211 pressure control ........................... 184-185
calendering............................................205-212 ventilation.................................... 183-187
calender rolls, yankee................................................ 152
cooling and control of ...................207-208 dryer section
centricleaners .................................................. 8 cascade ....................................... 160-163
ceramic press rolls........................................126 thermocompressor....................... 163-166
closed transfer drying
press to dryers ....................................137 air impingement........................... 188-190
within dryers.................................174-181 Condebelt .................................... 194-195
effect on shrinkage....................181-182 cylinder........................................ 149-151
wire to press......................................... 49 hot air .......................................... 190-191
closing up the paper machine ........................ 69 impulse........................................ 192-194
composite-covered press rolls ......................126 infrared ............................................... 192
condensate multicylinder ................................ 153-155
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
temperature profile..............................155 quality.............................................. 52-54
through................................................191 seaming................................................ 51
yankee cylinder ............................151-152 speed ................................................... 54
drying and paper quality.........................195-197 stability ................................................. 53
drying process .......................................150-151 wear ..................................................... 52
ventilation ....................................172-174 forming roll................................................ 76-77
dry line .................................................... 44-45 forming shoe ............................................. 78-79
dry suction boxes...................................... 44-45 fourdrinier forming section......................... 41-46
drainage profile................................ 61-62
E fresh water consumption ................................ 69
economics of pressing ...........................137-138
effluent from paper mills ................................ 70 G
efflux ratio ................................................ 35-37 granite roll ............................................. 125-126
guide roll ................................................... 54-55
F
fan pump ...................................................... 7-8 H
felts (see press felts) headbox
fiber angle ...........................................21-22, 35 air cushioned .................................. 13, 17
flat boxes.................................................. 44-45 automation of operation ................... 37-38
flotation clarification.................................. 65-66 effects on formation.............................. 35
foils ….. ............................................................. 42-43 effects on MD/CD ration ....................... 35
feed pump ...........................................7-8
formers flow dilution for
Beloit Bel Baie III .......................74, 88-90 basis weight control ...................... 22-27
Beloit Bel Baie IV ............................ 90-91 flow distributor ...................................... 14
Beloit Bel Bond ............................... 79-80 flowspreader ......................................... 14
for paperboarad machines............101-103 free jet length ....................................... 35
for tissue machines ......................103-104 hydraulic.......................................... 18-31
gap........................................72-77, 81-82 membranes in slice......................... 30, 96
twin-wire.......................................... 72-94 multichannel .................................... 32-35
Valmet Crescent Former .....................104 perforated rolls ................................ 15-16
Valmet C-Wrap ...................................103 slice................................................. 19-20
Valmet Periformer Noveau..................104 surfaces demands ................................ 28
Valmet Speed Former ..................... 85-86 surge tank............................................. 17
Valmet Speed Former MB............... 86-87 headbox proper .............................................. 15
Valmet Sym-Former........................ 77-79 heat recovery
Voith Duoformer CFD...................... 91-94 in drying....................................... 183-184
Voith Duoformer CV ............................. 88 vacuum pump.............................. 141-142
Voith Duoformer D .......................... 80-81 heat transfer equation .................................. 149
formers and paper quality ......................... 87-88 high-pressure showers.........58-59. 140, 171-172
forming horizontal gap formers ................................... 94
gap hot pressing .......................................... 130-133
blade............................................ 73-75 hybrid former............................................. 77-79
blade-roll ........................................... 88 hydrogen bonding............................................. 1
horizontal .......................................... 94
roll................................................ 75-77 I
roll-blade ...................................... 81-82 impulse drying....................................... 192-194
high-consistency ............................99-100 Isotuner (for fiber angle testing)...................... 21
forming board ........................................... 41-42
forming fabric ...........................50-54, 58-61, 95
L
cleaning .......................................... 58-59
long circulation ................................................. 5
Voith jet cleaner ........................... 60-61
lumpbreaker roll ............................................. 47
design ............................................. 50-51
drainage capacity ................................. 53
effect on paper quality.......................... 54 M
fiber penetration ................................... 53 machine chest...............................................3-4
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
machine screens....................................... 10-11 with shoe presses ........................ 119-122
MD/CD ratio.........................................21-22, 35 with two nips ....................................... 127
membranes in the slice area .....................30, 96 with three nips ............................. 127-128
MG cylinder ...........................................151-152 with four nips ...................................... 129
moisture ratio................................................... 2 profile control
moisture profile control .................................195 basis weight.......................................... 19
multichannel headboxes ........................... 32-35 moisture ............................................. 195
multiply paperboard formers ..................101-103 pulsation dampening ...................................... 17

O R
open draws ............................................134-136 reel ……................................................ 212-213
refiner, machine ............................................... 5
P rewetting in press nips.................................. 107
paperboard machines ............................101-103 roll-blade former........................................ 81-82
paper quality considerations roll former ................................................. 75-77
drying...........................................195-197 roll former drainage............................. 76-77, 97
forming process ................................... 54
pressing ............................... 118-119, 143 S
peeler rolls....................................................126 screen plates.................................................. 11
perforated rolls in headboxes.................... 15-16 screens ..................................................... 10-11
pre-calender .................................................200 scrubber for dryer hood exhaust ............ 187-188
presses shadow marking ........................................... 143
blind-drilled .........................................114 sheet flutter ........................................... 173-174
double-felted ................................122-123 sheet shrinkage ..................................... 181-182
fabric............................................114-115 sheet transfer (see wet web transfer)
grooved........................................112-113 shoe press............................................. 116-122
hot ...............................................131-133 effect on quality ........................... 118-119
large roll..............................................116 principle....................................... 116-118
long nip ...............................................115 short circulation.............................................3-4
open-draw ...........................................134 single-felting for drying .......................... 175-181
plain ....................................................107 size press
shoe.............................................116-122 film .............................................. 201-204
smoothing ...........................................199 traditional..................................... 200-201
suction .........................................108-109 slice …. .............................................................. .19-20
press felt slice bar .................................................... 19-20
construction..................................138-139 soft calender ......................................... 208-209
costs of ...............................................140 soft calendering process........................ 209-212
high-pressure showering......................140 steam and condensate
performance requirements ..................139 flow control .................................. 162-163
seaming ..............................................139 systems ............................... 160, 163-165
press felt suction boxes ................................140 steam, blow-through.............................. 160-161
press impulse ...............................................115 steam boxes in pressing........................ 130-131
pressing steam economy in drying ...................... 182-183
economy of .........................................137 step diffusors (in headboxes)..................... 14-15
effect on paper quality.......... 118-119, 143 stock flow control ............................................. 6
future developments ....................143-146 stretch roll ................................................. 54-55
hot ...............................................130-133 stuff box ........................................................... 5
press rolls suction boxes
antideflection................................123-125 dry ................................................... 44-45
ceramic ...............................................126 on press felts ...................................... 140
composite covered ..............................126 wet ....................................................... 44
elastomeric covered .....................110-111 suction box seal pit................................... 45, 62
granite.................................................125 suction press ......................................... 108-109
grooved...............................................112 suction rolls ........................................... 108-109
suction .........................................108-109 suction roll shells................................... 109-111
press sections supercalendering................................... 211-212
 "Paper Machine Design and
Operation--Descriptions and
Explanations"
By Gunnar Gavelin
surge tank...................................................... 17
syphon (for condensate removal) W
dimensions..........................................169 water ring vacuum pump ....................... 140-141
rotating.........................................166-167 heat recovery............................... 141-142
stationary .....................................167-168 web transfer
yankee dryer ................................168-169 closed................................................. 137
open ............................................ 134-136
wet suction box .............................................. 44
T wet web strength ...................................... 1, 135
table rolls....................................................... 42 white water
take-off angle (from press rolls) .............135-136 cleaning, internal ............................. 64-66
thermo compressor dryer section ...........163-165 filters ............................................... 64-65
thermo roll (in calendering) ....................206-207 flotation ........................................... 65-66
through drying...............................................191 system.................................................3-5
tissue machine formers..........................103-104 system closure................................. 69-70
transfer belt ..........................................120, 137 tanks..................................................... 63
turbulence generator wire (see forming fabric)
in dryers .......................................159-160 wire pit .......................................................... 63
in headbox ........................................... 18 wire retention ................................................. 68
twin wire formers ...................................... 72-94 wire turning roll............................................... 49
two sided drainage, theory of ......................... 95
two sidedness of paper, Y
problems of .......................................... 84 yankee cylinder ............................................ 151
yankee hood ................................................ 152
V
vacuum pumps
turbo compressor .........................142-143
water ring .....................................140-141
Valmet
Crescent Former .................................104
C-Wrap Former...................................103
impingement drying module .........189-190
Optireel ........................................212-213
Periformer Noveau..............................104
Speed Former ................................. 85-86
Speed Former MB........................... 86-87
Sym-Flo headbox................................100
Sym-Former.................................... 77-79
Sym-Sizer ....................................201-202
Vac Roll dryer section ..................178-180
Valroc press roll ..................................126
Ventilation
of dryer hoods ..............................183-187
of dryer pockets ...........................172-174
ventilation fans
variable speed control .........................187
Voith
DuoCleaner.........................................172
Duoformer CFD............................... 91-93
DuoFormer CV..................................... 88
DuoFormer D .................................. 80-81
DuoStabilizer dryer section..................180
GR press roll .......................................126
Jet cleaner ...................................... 60-61
Module Jet ...................................... 23-25
Top Duo Run dryer section...........180-181