PAPER CHEMISTRY LABORATORY, INC.
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EXTRA SPECIAL Summer 2005 Newsletter Maximizing Cost-Efficiency of Paper and Board Production |  John Penniman |
Objectives The principal scientific objectives are to increase intermolecular contact, and maximize all the available attractive forces. They are extremely powerful, and they are free! Included are van der Waals Force, hydrogen bonding, preferential wetting, electrostatic attraction and interparticulate coupling. Minimizing Cost on the Reel Nanotechnology data is combined with raw material costs, usage rates, machine speed and the relevant Product Information (PI) information. A running calculation of actual cost on the reel is continuously up-dated. Machine management is free to adjust any operating parameters so that the most cost-effective operation is continuously achieved. The data is analyzed by neural network, fuzzy logic software, thereby ensuring that even the most obscure beneficial relationships are exposed and exploited. Papermakers willing to confront a disruptive new paradigm can look forward to unparalleled quality while maximizing productivity at minimum cost. Steps The first step is to add an appropriate amount of the most cost-effective charge-neutralizing cationic chemical. The second step is to mix the cationic component thoroughly, so that stock and chemical are homogeneous. In the absence of homogeneity, it is impossible to maximize intermolecular contact and realize its many benefits. Third, the anionic nanoparticle is added at the precise addition rate that fully neutralizes the electrostatic charge of the cationic stock. The residual repulsive surface charge must be fully neutralized in order to permanently maximize (instead of impair) strength properties It is also mixed to homogeneity. The nanotechnology chemicals form a structure that provides the best possible balance between formation and retention, with optimum water removal properties. Several important benefits result. Positive and negative charges have been balanced, and residual repulsive charge has been completely eliminated so that strength will be maximized. The best possible balance has been reached between retention and formation. Water removal can be optimized by closed loop control of chemical feed rates. Control Drainage is measured and controlled over a wide range by increasing or decreasing the flow of cationic component and anionic microparticle to control water removal, thereby maximizing productivity and machine operating efficiency. Increase in product strength resulting from inter-molecular proximity is substantial, enabling use of less expensive raw materials, such as filler and recycle fiber. Enhanced intermolecular contact has the counter-intuitive effect of making possible a significantly increased sheet ash increase accompanied by greater strength. Raising the bar on quality and performance while simultaneously reducing both operating and raw material cost requires sensors that measure homogeneity. Thoroughness of mixing chemicals with stock is of critical importance. Cost-efficiency is continuously maximized by closed loop control of chemical feed rates.
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| John G. Penniman |
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