9/26/2013
Glen A Harvey
Director Rolls Engineering Technology NA
Agenda
• Roll Covers
– Overview of different roll cover materials,
– Construction
– Factors considered for cover selection
• Press Optimization
– TIPS
– Effective Void Volume
– Innovations and cases studies
• SMART ROLL
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Why do we cover a roll?
• Protect the roll core
• Vibration dampening
• Traction (slippage of sheet)
• Release properties
• Pressure Intensity of a nip
– Clothing wear
– Sheet Characteristics
• Quality of sheet
• Improved drainage (open area of roll)
Roll Cover Materials
Rubber
Polyurethane
Composite
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Rubber Cover Technology
Typical Rubber Cover Construction
TOP STOCK
TIE-IN
BASE
CORE
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Effects of Press Loading
A rubber cover does not compress
It is displaced and assumes a different shape
Nip width is dependant upon modulus, thickness and load
Nip loading exerts both compressive and shear stresses on
the cover
Bonding system must
be able to withstand
the shear stress force
found at the bond line
Unloaded Loaded
Typical Press Roll Cover Base Construction
Rubber Cover Rubber Cover Rubber Cover
0-450 PLI 450- 800PLI & Suction > 800 PLI
Topstock Topstock
Topstock thks as thks as
thks as required required
required .125” Tie in
.125” Tie in
.125” Tie in .250” Base
.1875” Base
.125” Base
=
Cement Layer
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Bases
• Three Primary Functions
– Provides a high modulus material for
optimum mechanical bonding
strength.
• High hoop strength
• Minimize shear stress at core / base
interface
– Creates a modulus (psi) transition
between the lower modulus top
stock / tie-in and the high modulus
core
– Retards moisture permeation to the
core
Base Options
• Standard Bases
– Co-cured or pre-cured/pre-ground (majority co-cured)
• Chemical bonding with co-cured system
– 150°F bond line temperature limit
– Bond strength degrades as temperature increases
– Heat Transfer calculations are run for water cooling
requirements
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Base Options
• Lifegard I
– Composite base, very high hoop strength
– °
185 F bond line temperature capability
– Minimize or eliminate water cooling
– Specific water cooling temperature requirements
• Lifegard II
– °
240 F bond line temperature capability
– High bond strength at elevated temperatures
– Eliminate water cooling
– Top Stock may now be the limiting factor for temperature
Tie-in – Rubber Covers
• Intermediate layer between base
and top-stock
– Typically a mix of base stock and top Top Stock
stock material to provide a good
Tie-in
chemical bond. Base
– Provides an intermediate modulus Core
layer between the top stock and base
decreasing possibility of sheer stress
failure at high modulus/low modulus
interface.
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Compounding and Mixing
2-roll mills used to blend rubber components
Accurate cover specifications are essential to ensure the proper “recipe” for
the desired cover properties
Core Preparation
Blasting Cementing
Increases core surface Promotes adhesion
area for improved of base to core
bond
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Rubber Covering
Extruding Wrapping
Curing
Vulcanization
Reverse inside steam – steam flowing through core. Note that roll
heads must have vent holes and those holes must be plugged prior to
shipping roll.
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Grinding, Drilling, Grooving, Balancing
Reassembly, Paint, Wrap, Ship
Accurate bearing, grease and
paint specifications are essential.
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Polyurethane Technology
Polyurethane Working Rolls
Incline Cast JetCast Rotational Cast
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Typical Press Roll Cover Base Construction
Rubber Cover Rubber Cover Rubber Cover
0-450 PLI 450- 800PLI & Suction > 800 PLI
Topstock Topstock
Topstock thks as thks as
thks as required required
required .125” Tie in
.125” Tie in
.125” Tie in .250” Base
.1875” Base
.125” Base
Polyurethane Cover Polyurethane Cover
Non-suction Suction
=
Cement Layer
Topstock Topstock
thks as thks as
required required
.250” Epoxy Base
.1875” Epoxy Base
Rotational Cast
• Developed by SW Sweden
• Single pass application
• Many advantages
– Fast manufacturing process
– Elimination of molds
– Elimination of oversize waste
– Elimination of mold release
– Superior physical properties
equal to or better than mold
cast
– Possible reduction in rejects
and warranties
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Polyurethane Machine
Composite Roll Covers
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Composite Cover Construction
Top stock: Fiber reinforced epoxy
with various filler systems. .300” thick. Topstock
Generally 88-93 Shore D Hardness
Base Layer
Base Layer: Fiber reinforced epoxy.
.200” thick Steel Core
Side Total Thickness = .500” per side
Manufacturing: Wrap / Lamination Process
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Factors considered for cover selection
Critical Roll Cover Performance Properties
1. Hardness – static modulus 11. Coefficient of Friction
2. Dynamic modulus 12. Temperature capabilities
3. Hysteresis 13. Hardening properties
4. Moisture diffusion 14. Effect of thickness
5. Chemical resistance 15. Vibration dampening
6. Release properties properties
7. Abrasion resistance 16. Residual stress
8. Mark Resistance 17. Machining capabilities
9. Crack Resistance
Water Diffusion in Roll Covers
Concentration Gradient: Immersed cover sample will absorb water until
the concentration gradient disappears and the cover reaches saturation
Cover
Sample
Concentration
Gradient
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Water Diffusion in Roll Covers
Temperature Gradient forces water to the cooler
side and can result in Supersaturation - water in
excess of saturation.
°
Surface 115 F
Topstock
Base
Steel Core
Temperature
Gradient
Internal
°
Water Cooling
75 F
Water Diffusion Failure
Moisture Diffusion / Channeling Failure
Small “fingernail shaped” surface cracks
As the cover is tooled away, the cracks are found to open up into channels
that spiral around the cover
Many additional channeling areas are revealed at base
Cover Removal Process in Steps
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Press Optimization
TIPS - Total Innovative Press Solutions
1. Establish performance and quality objectives
2. Analyze current operating conditions and capabilities
3. Establish appropriate dewatering theory for specific grade and
machine design
4. Design roll covers to create optimum nip
intensity and width Total nip pressure
5. Design felts to handle water, transfer
Paper structure pressure
sheet and for pressing uniformity and
Pressure
sheet smoothness Hydraulic pressure
6. Design cover venting to compliment felt
design and dewatering theory
Press / Nip length
1 2 3 4
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TIPS - Objective
Optimizing machine conditions and performance to achieve a predetermined set of
goals
Press Studies have to be “Objective” driven
Production Goals Cost Reductions Sheet Qualities (Tests)
Increase moisture removal Fiber reduction Bulk / Smoothness / Caliper
Speed Increase Increased felt life Strength properties
Run-ability Energy savings Internal bond
Holes reduction Water savings Shadow marking
Blowing Maintenance cost Picking and linting
Moisture profile Felt Installation time “De-fiberization” energy
Basis weight Chemical cleaner Softness
Faster start up Seam mark
Breaks Batt felt mark
Drop offs Base fabric mark
Edge flipping
Vibration
TIPS - Total Innovative Press Solutions
Determine recommended pressure range from application guidelines
based on:
40 years of practical experience
Paper grade / Desired sheet properties
Press configuration
Incoming solids
Max load – normal load = Lost Impulse
Sheet densification
Crushing
Poor felt performance
Poor run-ability
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TIPS - Philosophy
Impulse is the driving force in sheet dewatering
Load (Kn/m, PLI)
Impulse =
Speed (mpm, fpm)
Develop ideal nip conditions at
the optimal press Impulse. Sheet
Maximize moisture removal Felt
Protect sheet qualities
Nip Curve
Sustain performance of rolls and
felts 1 2 3 4
Hydraulic
Pressure
TIPS - Optimize All Press Nips
Design press nips to compliment other nips for the best dewatering
efficiency and sheet quality
Engineer covers to
Nip Peak Pressure and Cumulative Nip Width
produce incremental 157.5 Kn/m
pressure increases 900 PLI
2nd Press
Original Arrangement
between presses at 3rd Press 4th Press 4th Press
full load 105 Kn/m
600 PLI 3rd Press
Maintain nip peak 1st Press 2nd Press
pressures at proper 52.5 Kn/m Optimized Design
levels to maximize nip 300 PLI
1st Press
width and dwell time
Example of existing machine
0
0 51 mm 2 102 mm 4 152 mm
inches inches 6 inches
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Benefits / Deliverables
Improved sheet qualities
Caliper / bulk
Strength tests
Smoothness
Improved paper machine performance
Increased sheet solids
Reduce steam usage
Incremental speed
Fiber Savings
Sustained performance of press felts
Less wear to roll covers
Effective Void Volume
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Venting Options
Grooved
Dri-Press - Engineered Blind Drilling
Dri-Press and Grooved
Suction
Suction Double Drilled
Suction Grooved
Suction Dri-Press / Suction Blind Drilled
Suction Dri-Press Grooved
Engineering Nip Venting
• Dri-Press patterns have been designed to provide the most uniform
open area
Typical Dri-Press Patterns
Hole Land Distance Land Distance Land Distance
Pattern # Open Area
Diameter A B C
14 25% .093” .0833 .0838 .0840
15 21% .085” .0913 .0918 .0920
16 28% .098 .0771 .0782 .0789
3 21% .098” .1169 .0870 .1170
4 21% .078” .0681 .0786 .1287
• New patterns: No. 32 and No. 50 with 0.140” and 0.109” hole
diameters and approx. 25% open area
• All patterns have a grooving option and all patterns can be
engineered with all holes intersecting a groove
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Engineered Nip Venting
Pattern 32 Pattern 68 Pattern 50
0.140” Hole Diameter 0.109” Hole Diameter 0.109” Hole Diameter
25% Open Area 32% Open Area 25% Open Area
Engineered Suction Venting Patterns
Suction Suction Dri-Press® Suction Suction Dri-Press®
14 – 18% OA 25 - 31% OA Grooved Grooved
(23 - 27% Up to 35% OA Up to 44% OA
double drilled)
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9/26/2013
Suction Roll Evaluation – Board and Pulp
Cover softness not suitable for grooving
Changed suction roll from straight
drilling to double drilling
Suction open area opened from 17% to
32%
Vacuum system, pans and doctors were
evaluated first for water handling capability
Felt was evaluated for flow rate tolerance
Application Benefits
1% increase in press solids into dryer
Engineering Value
Coordination
Cover design sets nip conditions
1000 PLI
Felt design controls sheet smoothness and
influences press performance
Engineered venting compliments felt design
Grooved
Recent example Bottom
Reengineered cover for appropriate nip
pressure
Evaluation kept existing felt design
Redesigned grooving pattern to reduce flow
restriction and increase void volume Now: 8 GPI 0.035” Wide x 0.125” Deep
Value
Improved sheet quality
Higher press solids / 5% speed increase
$3 million Value Results Was: 10 GPI 0.020” Wide x 0.100” Deep
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9/26/2013
1st Press Builds 2nd Press Performance
Engineered venting improved tandem
felt performance
Traditionally blind drilled bottom rolls
Redesigned 1st press bottom venting to
improve 2nd press performance.
1st press bottom changed to partial nip
dewatering
More felt void volume entering 2nd Nip
Less hydraulic forces in 2nd press Now: Blind Drilled Grooved 35% Open
Application Benefits
Customer A : 1.5 - 3 ton/hour increase
Customer B : 15 FPM increase on all grades
Was: Blind Drilled 21% Open
Hydrophobic Cover Material
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9/26/2013
Development of Surface Properties
Super-hydrophobic surface
properties
Non-plugging, clean
running
Support for water
handling concepts
Doctor elimination
potential
Primary Press Innovations
Soft Covers Over Grooved Rolls
Superior soft cover materials in top
positions generate proper nip
intensities while hard grooved bottom
roll that allows the moisture to escape
the nip. The open area reduces the
hydraulic forces and allows optimal
loading.
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9/26/2013
Soft Covers Over Grooved Rolls
Install 70 P&J top primary roll covers
Grooved 3 bottom primary rolls
Increased press load on 1st primary 190 PLI
Increase dwell time: 116% 1st, 30% 2nd, 22% 3rd , 17% main
Install 24 P&J, 1” thick cover with LGII base in main
Increase main press load 100 PLI
Opened primary felts for better water removal
2% Reduction WEM = 6% production Increase
Maintain sheet bulk / density
$198,000 / year value
Polyurethane and Rubber Advancements
– Super low hysteresis - cooler under pressure
– Long run life with superior abrasion resistance
– Superior ability to withstand wad impacts
– High performance bonding system
– Drier performance with greater stability
– Runs clean with less wax build-up and hole plugging
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9/26/2013
Polyurethane and Rubber Advancements
Unique high performance
polyurethane and rubber
elastomers run cooler
Increased bond strength from
lower operating temperature
More tolerant of biased loads
Extractor to Main Press
Covers are old, thin and harder than original covers
Generates higher nip intensity and less dwell time
Re-establish original condition – begin w/ extractor
4% increase in speed
Improved efficiency
Improved ply bond
$268.416
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New Concepts for
Maximum Performance,
Reliability, Life
Aquarius Armor
Soft rubber base produces low nip
intensity and wide nip width
Harder thin poly top offers hardness
and chemical stability, superior
abrasion resistance, and release
Harder Shell Poly Consistent operation – minimal
Top Coat change in hardness, thickness or CD
uniformity
Soft Rubber Minimal maintenance – 1 to 2 long
Substrate runs reduces handling, grinding, and
freight costs
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Nip width and
nip pressure CD history
Standard deviation
Shoe Press Application
First ever real time impulse curve from a shoe press nip
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Roll Technology
Customer : East Coast NA
Position : Suction Drum Rider Roll (SMART® Roll)
Speed : 700 fpm, 215 mpm
Grade : Packaging
Press load : 150-250 pli
Cover : Aquarius with
Hardness : 110 P&J
Performance
• SMART® Roll technology allowed the mill to have consistent nip profiles
• Improved sheet caliper profile
• Felt usage reduced from 10 felts annually to 4 felts annually
• ValueResults signed off for $60,000 per year!
Mid-West Board Machine
Value Results
$980,196 /Year
Incremental Tons
Steam Savings
Record Year 2011
2012 Record Pace
Proper Nip Intensity at Optimal Impulse 29% Increase - Total Nip Width
Additional 960 PLI Engineered Venting
Incremental Increase Between Presses
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White Pigeon Paper Company
Forming Section
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PRIMARY PRESS
• 150 PLI
• TOP FELTED
• TOP & BOTT ROLLS
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BLIND DRILLED SUCTION
26 25%
SOLIDS
OLD
TOP ROLL 70 P & J
BOTT ROLL 35 P & J
NEW
TOP ROLL 120 P & J
BOTT ROLL 60 P & J
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VR PRESS
• 250 PLI
• TOP FELTED
• TOP ROLL BLIND DRILLED
• BOTTOM ROLL BLIND
DRILLED WITH SUCTION
• SIDE ROLL SMOOTH
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OLD
TOP ROLL SUCTION
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26 35% TOP ROLL 35 P & J
SOLIDS BOTT ROLL 45 P & J
SIDE ROLL 1 P & J
NEW
NO SUCTION TOP ROLL
TOP ROLL 50 P & J
BOTT ROLL 55 P & J
SIDE ROLL 1 P & J
SECOND PRESS
• 1000 PLI
• TOP & BOTT FELTED
• TOP & BOTT ROLLS
BLIND DRILLED
26 46%
SOLIDS
26 TOP AND BOTT 20 P & J
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THIRD PRESS
• 2000 PLI
• BOTT FELTED
42 • TOP ROLL SMOOTH
48% • BOTT ROLL BLIND DRILLED
• 42” FINISHED O.D.
SOLIDS
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TOP AND BOTT 20 P & J
Summary
• Softer Nips in 1st Primary and VR Press
• Removed suction from VR Press top roll
• Overall improved machine runnability
• Increased production of 8%
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Press Optimization Summary
Define operating objectives and limitations
Select recommended pressure range
Choose the proper cover material – Top stock and base
Cover thickness to develop proper nip intensity at optimal press
impulse
Develop incremental increase in nip intensity
Utilize most effective void volume
Press Optimization Summary
“Soft over Grooved”
Low hysteretic material
Begin at extractors
Keep roll covers in like new condition
Smart Technology for additional operating insight and improved
qualities
Design felts to compliment conditions –
Handle the water
Transfer the sheet,
Pressing uniformity
Improve sheet smoothness
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