Wood Based Panels [PDF]

Zitiervorschau

Center for Wood Sciences

CASWoodͲBased Panels Module1:Process Technology

Particle generation Prof.Dr.JoergB.Ressel September7Ͳ 12,2015– Biel,CH

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Wood-Based Panels

Content

Particle Generation • Particle generation • Particle generation – conversion paths • Log debarking – drum and ring debarker • Flake generation for PB • Crusher – pre-breaker • Drum chipper • Impact hammer shredder • Impact hammer mill • Knife ring flaker • Drum flaker • Hammer mill • Prallfiner – impact mill – sieve ring mill • Waste wod processing

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

• Strand generation for OSB • Long log ring flaker • Knife ring flaker • Fibre generation for MDF • Defibration process steps • Refiner and refiner plates • Refiner – additional equipment

Wood-Based Panels

Particle generation

Raw materials (summarised) ƒ Logs – round wood Æ forests (industrial wood Æ timber harvest) ƒ Forest residues Æ forest management actions (thinnings), small diameter logs, large branches … ƒ Residual wood Æ by-products from primary wood processing …

Round Wood

ƒ Slabs, sidings, off-cuts ƒ Chips (Æ chipper-canter lines), shavings ƒ Sawdust ƒ Peeler cores ƒ Veneer residues

ƒ Reclaimed wood – waste wood Æwithout chemical pre-treatment, packaging materials, demolition wood ƒ Agricultural residues / annual plants … seasonally harvested ! Æ cereal straw, bagasse, rice husks … plantation residues Æ rubber wood, palms Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Sawmill Residues

Straw

Industrial Wood

Reclaimed Wood

Wood-Based Panels

Particle generation

Conversion of raw materials Æ Particle generation Depending on the raw materials used particle generation is done stepwise; often interrupted by screening and cleaning steps. Screening Æ output fractions are: ƒ Fines fine particles … dust Æ energy generation ƒ Accepts ƒ Overs

Chips

convenient particles Æ panel production oversized particles Æ chopped up again

ƒ Impurities removed particles (metals, soil, sand, stones, knots ...) to avoid any damage to processing equipment and panel milling machinery Storage bunkers and bins ensure continuous material supply. Material transport occurs by suitable conveying and feeding systems particle generation by …

(Maier 03/2005)

MRZ knife ring flaker MSZ beating flaker MPF prallfiner (mill type) MPM impact mill

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Impurities (removed)

Strands (from logs)

Flakes MRZ

Beaten flakes MSZ

Fine flakes MPF/MPM

Wood-Based Panels

Particle generation

Conversion paths to achieve suitable particles for typical WBPs Specific particles, e.g., for OSB, PB and MDF, and different raw materials require customized process technologies to achieve an optimal result. The chart shows some alternative conversion paths without intermediate screening, grading, storage and further disintegration of particle fractions. Round wood, long logs

Chips Slabs, off-cuts (Sawmill by-products) (Sawmill residues)

Round wood, short logs ...

Reclaimed wood Waste wood Crusher (Prebraker)

Debarking

Cut to length

Direct flaker (KRF)

Drum flaker

Process technology

Product Output

Impact mill

OSBStrands

PB flakes

PB flakes

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Chips

Debarking Drum chipper (OSB)

Drum chipper

Wood Preparation Raw material - Input

Round wood, logs

Sawdust (Sawmill residues)

OSB chips

Knife ring flaker

Prallfiner

Impact mill

Strand flaker

PB flakes

PB flakes

PB flakes

OSBStrands

Drum chipper

Chips

Refiner

MDF Fibres

Wood-Based Panels

Particle generation

Conversion paths to achieve suitable particles for typical WBPs Specific particles (Æ flakes) for Particle Board

Round wood, long logs

Chips Slabs, off-cuts (Sawmill by-products) (Sawmill residues)

Round wood, short logs ...

Reclaimed wood Waste wood Crusher (Prebraker)

Debarking

Cut to length

Drum chipper

Drum flaker

Raw material - Input Process technology

Product Output

Impact mill

PB flakes

PB flakes

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Sawdust (Sawmill residues)

Chips

Knife ring flaker

Prallfiner

Impact mill

PB flakes

PB flakes

PB flakes

Wood-Based Panels

Particle generation

Conversion paths to achieve suitable particles for typical WBPs Specific particles (Æ strands) for Oriented Strand Board

Round wood, long logs

Round wood, short logs ...

Slabs, off-cuts (Sawmill residues)

Reclaimed wood Waste wood

Debarking

Cut to length

Raw material - Input

Direct flaker (KRF)

OSB chips

Strand flaker

Process technology

Product Output

Drum chipper (OSB)

OSBStrands

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

OSBStrands

Wood-Based Panels

Particle generation

Conversion paths to achieve suitable particles for typical WBPs Specific particles (Æ fibers) for Medium Density Fibreboard (MDF … HDF)

Chips (Sawmill by-products

Round wood, logs

Debarking Drum chipper

Raw material - Input Process technology

Product Output

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Sawdust (Sawmill residues)

Chips

Refiner

MDF Fibres

Wood-Based Panels Conversion of raw materials

Particle generation i.e. the raw material recipe

Production step preferably starts with … ƒ A more or less constant blend of raw material sorts, particularly related to different wood species to ensure uniform panel properties at the end of the overall process. ƒ Debarking, only required for high quality, bright surface layers; for core layer particles rough debarking during timber harvesting is sufficient; most bark particles will be removed later during various screening steps preferably after the particle drying. ƒ Raw material cleaning (wet or dry log or chip cleaning, dust/sand/soil removal). ƒ Metal detection and removal of contaminated pieces and contaminants.

Particle dimensions (… the required pre-product of this production step) The first flaking process determines particle length and thickness; particle thickness - unlike length and width of a particle - cannot be changed anymore in following process steps! Î Particle slenderness: length to width ratio (Ɛ/w-ratio) Î Particle size and shape (geometry) influence resin consumption, mat densification behaviour, and panel properties, e.g., thickness swelling, MOE, MOR … Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Wood-Based Panels

Particle generation

Log debarking Round wood or logs are either debarked separately or as a bunch of individual stems. Debarkingofabundleoflogs

Debarkingofindividuallogs

 Simultaneously,continuouslyor  batchwise ƒ Drum debarker

o

Ring debarker

ƒ Rotary or cradle debarker

o

Flail debarker 1

o

Rosserhead debarker 2

ƒ Mobile debarker 3 1 2 3

Debarking by means of rotating chains Debarking by means of rotating cutter head Debarking machinery installed on a mobile platform

1, 2

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

… without any importance for WBP industry

Wood-Based Panels

Particle generation

Rotary debarker Æ dry multiple stem debarking ƒ Fixed tub (trough) assembly containing pairͲwise openings in the bottom with rotors equipͲped with debarking plates; rotating plates cause the logs to spin and to hit each other

http://www.fujikogyo.co.jp/HP-English/king/barker/ crosssection20080327.jpg / 23.08.2011

ƒ Debarker is installed at a declined angle, enͲsuring continuous log movement towards the discharge end during debarking

Rotor Debarking plate Slit Fixed drum Rotor

Fuji Kogyo 2005

(http://www.fujikogyo.co.jp/HP-English/king/barker/crosssection20080327.jpg / 12.08.2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Movement of logs [ ] Rolling – rotating of each log on its own axis [ ] Rocking – bouncing up and down of each log [ ] Rotating – rotation of the entire batch of logs

Wood-Based Panels

Particle generation

Rotary debarker SAVICO, QC/CAN Debarking depends on ƒ ƒ ƒ ƒ ƒ ƒ

Wood specie + age, Log shape, Log dimensions, Operating temperat., Bark retention, Accept. fibre loss

three rotors ! (http://www.savico.com/en/debarker.html / 12.08.2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

12 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Rotary debarker FUJI Kingside Debarker Outfeed Æ cleaning belt Æ chipper

(http://iem.ca/images/forestry-projects/upm_blandin_project.jpg / 12.08.2015)

http://www.fujikogyo.co.jp/HPEnglish/king/barker/kingbarker.html / 12.08.2015)

Debarking tools, shape depending on wood species / bark type; mounted on the rotor

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

13 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum debarker ƒ Stationary plant with rotating drum, feeding devices and adjustable discharge gate ƒ Drum dimensions: length 6…60 m, diameter 3…4.5 m; (Æ recommended ratio log length / drum diameter is < 0.7) ƒ Debarking capacity up to 350 m3 h-1 ÅÆ rotary debarker 5…30 m3 h-1 ƒ Continuous or batch-wise feed-in of logs ƒ Processing either tumbling mode or parallel mode (log length > drum diameter) ƒ Low wood losses (log breakage and “brooming” of log ends) ƒ Achievable cleanliness ” 1 % remaining bark ƒ Additional equipment: o Particular infeed system, including optional de-icing station ahead (infeed conveyor) o Bark separation section integrated in outfeed conveyor Parallel mode o Integrated process control Tumbling mode

Metso panelboard 2005 Andritz 2002

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

14 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum debarker Bark removal slots Drive unit Debarking drum Housing

Pallmann PDD Technical data Drum diameter Drum length Log length Capacity

3–5 m 12 – 32 mm 1–8 m 40 – 350 m³ h-1 Discharge gate

Fulghum Drum Debarker [0:13 m]

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Pallmann 2011

Bark removal conveyor 15 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Ring debarker ƒ Debarking of single logs by passing trough a rotating ring, equipped with curved, scraping-tipped tools. ƒ Tools are pressed against the fed logs by particular devices (springs, rubber bands, hydraulic, pneumatic pressure elements). ƒ Special tools available for particular debarking challenges, e.g., stringybark, thick, fibrous bark Æ Eucalyptus ssp.

Principles of ring debarking / debarking knife (Fronius 1989)

ƒ Rotation speed is 90…450 min-1, feeding speed is 20…60 m min-1. ƒ Ring debarkers are equipped with either one single debarking ring or as tandem debarker carrying two successive rings.

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Debarking ring and pressure elements Æ variable pressure air seal, bellow and air cell (Nicholson 2004) 16 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Ring debarker

VK Air Seal Debarker (Valon Kone 2015 – 2:30 min)

Formax™ replaceable debar-ker tool arms and tips

VK5000HD-Combi-2R VK tool for stringybark logs

(http://www.valonkone.com/media/images/2R%20new.jpg / 12.08.2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

17 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Particle generation for different Wood-Based panels ƒ Flake generation for particleboard – PB ƒ Waste wood processing – residual wood treatment

(ĺ Slide 19) (ĺ Slide 47)

ƒ Strand generation for oriented strand board - OSB

(ĺ Slide 50)

ƒ Fibre generation for medium density fibreboard - MDF

(ĺ Slide 54)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

18 2015Ͳ08Ͳ05

Wood-Based Panels Flake generation

Particle generation

crusher

Flow chart example for raw material processing to generate flakes for particle board production

Impact hammer mill

ƒ Stepwise processing ƒ Different raw materials ƒ Logs (long, short) ƒ Slabs, offcuts, chips from ƒ Waste wood

\ sawmill

ƒ Screening

Maier 03/2005

ƒ Overs / rejects breakdown ƒ Fines / dust ĺ heat generation ƒ Impurities / contaminants ƒ Intermediate storage ƒ Adapted conveying/feeding systems Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

19 2015Ͳ08Ͳ05

Wood-Based Panels

Flake generation Exemplary flow chart for raw material processing to generate flakes for particleboard production Prof.Dr.JoergB.Ressel Maier 03/2005 www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Wood-Based Panels

Particle generation

Crusher / Shredder / Pre-braker Slowly rotating crushing rotor, equipped with particular teeth to disintegrate wood residues, waste wood (Æ pallets, packaging materials, etc.), generating coarse, prebroken raw material, requiring less volume and easier handling and transport. After removal of contaminats (metals, plastics …) the precrushed material is further processed, e.g. in a beater mill.

http://www.holzmatic.com/wpcontent/uploads/2008/12/shredd er.jpg

ƒ Large feeding hopper for bulky materials ƒ Hydraulic drive protection from overload ƒ Discharge sizing grid for pre-crushed material Horizontal grinder

(http://media.westsalem.com/machines/titan-grinder-f1-img1.jpg / 12/08/2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Maier 08/2015

21 2015Ͳ08Ͳ05

Wood-Based Panels Grinder – vertical / horizontal feed

Particle generation (WSM, West Salem Machinery, OR)

Horizontal feed grinder

Vertical feed grinder

(http://media.westsalem.com/landing/mulch-grinders-shredders-screens.v3.jpg / 12/08/2015)

(http://westsalem.com/wpcontent/uploads/2014/05/titan-grinder-ill.jpg / 12/08/2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

(http://media.westsalem.com/machin es/vertical-grinder-f1-img1.jpg / 12/08/2015)

22 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Impact crusher – Impact shredder

2 or 4-rotor shredder for windscreens, wood, plastics ... http://www.prall-tec.de/cms/upload/bildergalerie/PTG4.bmp / 26.08.2011

http://www.prall-tec.de/cms/upload/bilder/Schredder_zhne.jpg / 26.08.2011

Flake generation

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

23 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum chipper

Knife

… used to produce high quality chips from long and short logs, slabs, edgings, thinnings, veneer waste or board trims. Chips are easy to handle, storage is without difficulties and chips allow precise metering into fiberizers and flakers.

Wedge clamping Infeed rollers

A belt or vibratory conveyor delivers the material to the chipper. Draw-in rollers with coarse gripping serration assure certain and continuous feeding. The fed material is chopped inside the case by means of a very robust rotor into quality chips and dis-charged via a heavy breaker screen. ƒ ƒ ƒ ƒ

High throughput capacity Applicable for very different feed materials High chip quality Robust, easy maintenance, trouble-free continuous operation ƒ Low operating costs ƒ Fully hydraulic opening of the housing cover, stator knife carrier, knife clamping, lifting and damping of the swing Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Screen

Stator knife Pallmann 2015

Pallmann drum chipper - complete system (2013)

Discharge example

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Wood-Based Panels

Particle generation

Drum chipper Rotor brake and turning device Screen Electro-hydraulic quick-change attachment, heavy duty screen basket for accommodation of the screen plates (wear resistant Hardox steel)

Feed rollers special teeth (surface hardened; high wear resistance. Hydraulic / pneumatic cylinders to regulate the pressure of the upper feed rollers and to open the upper feed rollers for maintenance and easy cleaning Chain drive of the feed rollers

Counter knife / anvil (stator knife) Electro-hydraulic assisted changing of counter knife / anvil http://www.fordaq.com/www/news/2007/Bruks_Kloeckner_Trommelhacker.jpg / 25.08.2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

25 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum chipper

Vecoplan 2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Flake generation 26 2015Ͳ08Ͳ05

Wood-Based Panels

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

27 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Disk chipper …

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

28 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Disk chipper Used for chipping logs – high quality chips (Æ fiberboard, pulp) Disc chipper consists in a heavy rotating disc (Diameter 1… 3 m) with 4 or more knives. Particle thickness is determined by the angle between in-feed spout and chipping disc

Conventional horizontally fed disk chipper

HHQTM disk chipper

(Andritz 2010)

(Andritz 2010; Bruks 2011)

Disk chipper with chute (Bruks 2011)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

29 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Disk chipper …

United States Patent 6976516 http://www.freepatentsonline.com/6848486-0-large.jpg / 8/25/2011

United States Patent 6976516 http://www.freepatentsonline.com/6976516-0large.jpg / 8/25/2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

30 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Disk chipper Gravity feed chipper …

Metso Paper, Inc. 2010

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

31 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Disk chipper Horizontal feed chipper …

Metso Paper, Inc. 2010

MDF fiber generation Metso Paper, Inc. 2010

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Flake generation

32 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Impact hammer shredder … converting pre-crushed waste wood particles into raw material for reutilization in panel production or energy generation. Also contaminated materials can be fed into the shredder. Foreign matter, travelling in the feed stock, is separated and automatically discharged. Material is vertically feed from above into the shredder. Heavy rotating hammers hit in an upward action against the feed material and throw it against the inside of the housing top above the rotor where it is pre-broken by impact. The wood pieces are split along the grain, metal contaminants enclosed into the wood are set free in the special feed chute because of their different ballistic curve. The final preparation is effected by stationary breaker and comb bars. The openings of the heavy grid defines the (http://www.pallmann.eu/language/upload/bilderleiste/PHP S3.JPG / 13.08.2015) finished product size. ƒ High throughput capacity at low specific energy consumption Impact Hammer Mill PHPS (Pallmann 2015) ƒ Separation and removal of foreign matter ƒ Insensitive against contaminants and feed fluctuations Flake generation ƒ Easy maintenance and access to the rotor Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

33 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Impact hammer mill … particularly used for processing waste wood, e.g., pallets, crates, boxes, scrap wood, wood residues, bushes, branches, industrial waste wood. The process outcome is valuable raw material for the panel industry or for energy generation. A vibro-feeder or an apron conveyor hauls the material towards the machine mouth. Bulky feed material is hydraulically continuously guided towards the rotor, equipped with free-swinging tools, i.e. hammers, steel strips, where it is shredded stepwise by iterated impacts. Material discharge goes downwards through a heavy screen-cage, determining the particle size. ƒ ƒ ƒ ƒ ƒ ƒ ƒ

Very high throughput capacity Insensitive against foreign matter Homogeneous final product Vibration free operation Hammers easy to change Low operating cost Low maintenance

Impact Hammer Mill PHPH Grizzly (Pallmann 2015)

Pallmann 2004

Flake generation

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

(http://www.pallmann.eu/language/uploa d/bilderleiste/agrizzly.jpg / 13.08.2015)

http://www.pallmann.eu/language/upload /bilderleiste/Grizzly1.jpg / 13.08.2015)

34 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Knife ring flaker … production of high quality flat flakes from chips, veneer residues, purchased flakes and coarse material of any kind, i.e., also low priced wood assortments can be processed with the knife ring flaker.

Chips

A quick rotating impeller leads the chips to the knives of the counter-rotating knife ring. This principle of counter-rotation from the impeller and the knife ring guarantees a troubleand obstruction-free operation of the machine even with very wet material, a uniform wear of exchangeable knives and counter knives and therewith an excellent flake quality. ƒ ƒ ƒ ƒ ƒ ƒ

Excellent flake quality High throughput rates Quick, economic knife change Economical prize for the performance No clogging at high moisture content Efficient wear protection Maier / Dieffenbacher MRZ (Maier 2011 – 6:06 min)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Pallmann 2011

Flakes 35 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Knife ring flaker

Maier 2011

ƒ Vibro-feeder ƒ Metal separator ƒ Heavy particle separator ƒ Contaminant separator ƒ Controlled air-flow

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

36 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Knife ring flaker Cutting process

Pallmann 2011

(1) (2) (3) (4)

Wear plate Beater plate Wear shoe Knife

(5) (6) (7) (8)

Wear segment Impeller Knife carrier ring Knife carrier

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Additional information Globus Knife Ring Flaker for particleboard production https://www.youtube.com/watch?v=tEBaPiLrz5w [10:17 m] / 8/14/2015

37 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Knife ring flaker Ring assembly

50 knife konfiguration increases production capacity

Holder assembly

Adjustable knife settings for fine mircrometer knife adjustments that can be made in the ring assembly

Precise fit for conventional knife ring flakers

4-bolt ring attachment allows for quick and easy base assembly removal

3-bolt spring clamping for quick and easy knife release and clamping

Dovetail locking assembly increases strength of system, decreasing the chance of parts releasing during operation

(http://www.keyknife.com/features/images/details/ringslicer_left2.jpg / 28.08.2011)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

38 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Knife ring flaker ƒ Flaker components: vibrating feeder, metal separator (removal of ferrous contaminants), wind selector ( removal of heavy pollutants) and the flaker itself. ƒ High capacities Æ KRFs arranged in series. ƒ High performance and excellent flake quality requires quick knife ring exchange facilities and particular sharpening and setting equipment

Chips, sawdust Magnetic drum

Vibrating feeder Ferrous contaminants

Wind selector

Knife ring flaker

Heavy Contaminants

Flakes Pal 2005

Drum flaker Pallmann 2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Flake generation 39 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum flaker … designed for high production capacities of flat flakes from round wood cut to length (” 2 m). Feed in logs are pushed against the rotating drum by suitable clamping devices. Flake length is determined by a particular knife design (Æ double comb knife); the flakes are crushed to width parallel to grain in the knife pockets.

Double comb knife Clamping strip

Knife fixing plate

Two types of constructions are in use: ƒ Drum flaker with stationary rotating drum; continuous flaking of cut to length logs. Wear plate

ƒ Drum flaker with rotating drum moving forth and back; discontinuous flaking of random length round wood

Knife Knife fixing plate Clamping strip Drum body

Counter knife

Bridges Flake pockets

Deppe, Ernst 2000; Figs. 3.1-22, 26, 29, 30

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

40 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum flaker – Processing steps 1. Feeding the raw material (logs, slabs …) into the processing area 2. Vertical and horizontal adjustment of the raw material by automatic clamping 3. Drawing or scoring cut parallel to grain

Knife types Æ … determine flake length 1. Scarifying knife

2. Comb knife

3. Slitting knife

4. Full knife

c

d e

Hombak 2011

4. Cutterblock and clamping system move back to start position Æ discontinuous process

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

f

41 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Drum flaker

Cross conveyor

Longitudinal conveyor Hombak 2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Flake generation

Particle generation

Hammer mill – Beating Flaker … used for production of core layer and surface layer material for particleboard from waste wood chips, core waste wood particles and annual plants, dry or wet.

Maier MSZ 2015

Wood-Based Panels

The material is feed in vertically from above. A gravity separator separates heavy contaminants from the infeed material. Flat steel beaters (steel strips) rotating with high speed split the feed material mostly parallel to the grain. The openings of the installed screens determines the particle size. Stationary refining elements integrated into the mill assist the size reduction. Particle discharge can be effected either pneumatically or mechanically with an additional secondary suction. ƒ High throughput capacity ƒ Uniform material preparation at low specific energy consumption ƒ High versatility and easy adaptation to various feed materials ƒ Maximum utilization of all wear parts ƒ Dual operation direction increases economic efficiency ƒ Robust and easy to maintain ƒ High availability Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Pallmann PHMS 2011

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Wood-Based Panels

Particle generation

Prallfiner – Impact mill – Sieve ring mill

Maier MPM 2015

… are used for generating fine particles. Wood particles are thrown against a grinding path by rotating impeller blades and split up mainly along the fibre length. Subsequently particles have to pass a stationary or counter-rotating screen ring; grinding path patterns, screen perforations and shape determine the final particle size of these versatile disintegrating machines.

Sieve Ring Mill MPS

Impact Mill MPM

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Prallfiner MPF

Maier MPF 2015

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Wood-Based Panels

Particle generation

Prallfiner 1Vibrationconveyor 2Metalseparator(Magnet) 3Infeed(vibro chute) 4Rotor 5Grindingtrack 6Distributiondisc 7Suctionpipe 8ByͲpass

[4] [5]

[5]

[5]

Flake generation

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Maier MPF 2015

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Wood-Based Panels

Particle generation

Waste wood processing – residual wood Two stage recycling plant – dry process

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Crushing – pre-braking Separation of ferrous material Sorting Second disintegrating stage Separation of ferrous material Screening Separation of heavy contaminants Sifting of light particles Separation of non-ferrous material

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Particle generation

Waste wood processing – residual wood Two stage recycling plant – dry process

1. Stage waste wood recycling crushing - cleaning - screening

Urban waste wood (PAL 2003 – 4:30 min)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Crushing – pre-braking Separation of ferrous material Sorting Second disintegrating stage Separation of ferrous material Screening Separation of heavy contaminants Sifting of light particles Separation of non-ferrous material

2. Stage waste wood recycling beating - cleaning - screening

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Wood-Based Panels

Particle generation

Waste wood processing – residual wood

Bunkers for separated and cleaned residual wood fractions

Containers for re-moved materials (plastics, non-ferrous metals, …)

Deppe, Ernst 2000, Fig. 2-1.37

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Infeed belt Belt conveyor Drum screen Transport belt Flat screen Transport belt 0/24 Transport belt 0/24 Metal separator Transport belt 0724 Belt for fuel material Separation belt 24/80

12. 13. 14. 15. 16. 17. 18. 19. 20. 21.

Separation belt 80/150 Separation belt 150L Collecting funnels Transport belt 24/80 Transport belt 150L Transport belt 80/150 Wind screen 80/150 Wind screen 24/80 Control panel Transport belt

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Wood-Based Panels

Particle generation

Decomposition of UF-bonded and laminated particleboard Semy-dry two stage chemo-thermo-mechanical batch process, annual capacity of one decomposition unit up to 20.000 t/a of particles in three shifts

Vacuum pump

Recycled furniture, production residues, rejects

Heat Crusher infeed

Pre-crusher (breaking up)

t = 1…10 min

Pre-impregnation (possibly after vacuum treatment)

Impregnation liquid (caustic soda solution, urea, water)

Slowly rotating pre-braker

Discharge condensate and surplus Impregnation liquid

Heat-treatment t § 20 min T = 110 ºC (chemical-hydrolytic process) Water, urea and additives

Screening

Wood particles

Coating and edge banding materials

Reaction bin (insulated) including quick closing lid and discharge device

Particleboard

Refiner MDF

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Moving floor Stoker discharge Bin for preparation and storage of the impregnation liquid

Particles (to dryer and screen)

Coarse wood particles, metal parts, plastic and coating materials

Drum screen

Pilot plant for processing urea bonded particleboard – used furniture and production residues (WKI 1996) Particle recovery process from urea bonded particleboard (according to Michanickl and Boehme, WKI 1996) 49 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Strand generation for OSB – Long log (knife) ring flaker … particular knife ring flaker for producing precise strands with specific length, width and thickness from either fixed length logs or random length logs. The long log ring flaker is mostly used for flake generation for Oriented Strand Board. Pallmann 2011

The logs are batchwise fed into the flaking chamber with an integrated water injection system. Particular vertical swords hold down the logs during the cutting stroke. A closing gate hydraulically clamps the log bundle at the flaking chamber and closes the flaking chamber during the final cutting stroke. The wood is cut parallel to grain; this cutting action results in rectangular flakes with smooth surfaces and a minimum of fines. OSB strand generation

Pallmann 2011

(Siempelkamp 2013 – 1:45 min)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Particle generation

Strand generation for OSB – Long log (knife) ring flaker

Pallmann 2008

Pallmann 2008

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Particle generation

Strand generation for OSB – Disc strander … cuts tree length or batch fed logs into strands for OSB production. The clamping system secures the logs in place while the strander, which is carriage mounted, extends into the cutting chamber. Discmounted knives strand the wood within the cutting chamber and the carriage returns automatically to repeat the sequence. The knives on the strander extend to the outer edge of the precision ground disc, allowing the disc to advance through the batch of logs during stranding while maintaining consistent strand thickness..

Disc Strander

Kadant Carmanah 2015

(Kadant Carmanah 2015 – 0:20 min)

Disc Strander for long logs Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

… for short logs – Block Strander 52 2015Ͳ08Ͳ05

Wood-Based Panels

Particle generation

Strand generation for OSB – Knife ring flaker Two-step process for strand generation developed by Maier (2002) Raw Green wood (logs, thinnings, tree tops), sawmill residues materials (slabs, offcuts) and residual wood Step 1

Step 2

Drum chipper HRL/OSB ĺ chipping raw material into OSB chips; chip dimensions have to meet the requirements for desired strand length.

1

Knife ring flaker MSF ĺ converting OSB chips into strands.

Quantity of surface and core layer strands and the content of fine material obtained hardly differ from the respective quantities obtained from conventional strand production. The two-step process supports inexpensive plant concepts with an increased flake capacity of existing plants, to install medium-size plants at lower investment expenditure, or to produce novel board types from recycling wood. Fines are usable for particle board production or as fuel.

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

2

Drum chipper HRL/ OSB (Maier 2011)

Knife ring flaker MSF (Maier 2011)

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Wood-Based Panels

Fibre generation

Fibre generation for MDF … based on a two step process. Initially cleaned wood (washing, debarking of logs) is converted into chips or are purchased, e.g., as sawmill by-product. In the second wet process step the chips are converted into fibres by means of a refiner; also sawdust can be processed in the refiner (requires particular grinding plates).

Chipping and storage

Chip preparation and fibre production Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Chip generation Chips purchased either as raw material from sawmills (Æ particular quality requirements) or directly made from green wood (logs, sawmill residues) by means of a drum chipper or a disc chipper (the latter is the most common chipper in pulp mills). Cleanliness of chips, uniformity of chip size and clear cut surfaces are very important for even conversion into fibres in the following pressurized defibration process. Disc chipper types (Andritz 2002)

Chip storage • Open air storage or storage in suitable metal/concrete bins/silos • Material losses due to thermal degradation and/or fungi attack

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Defibration process Steam flow Material flow

Chip bin (preheating)

8…19 bar abs. Digester

Refiner (grinding chamber) Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

H. Roll (2008)

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Wood-Based Panels

Fibre generation

Defibration process Energy consumption – reference values Steam – Refining Process Nominalvalues 500– 850kg/tfibre Practical values 250– 450kg/tfibre

ChipBin (target ੥chips at outfeed 60°C)

35%… ƒ љwith discharge limitations Æ steam digester, Æ energy consumption fibre dryer ј ƒ јif chips are frozen (inpractice +50…60%; designvalue approx. +100%)

Digester

60%

Grinding Chamber

4%(depend.onȴpDig.ͲRef.,Blow valve opening

Others

1%(max.200…250kg/h)

Mechanical Energy (Elektricity)– Refining Proces Softwood (Spruce)

80– 170kWh/tfiber o.d.

Hardwood (Beech)

90– 150kWh/tfiber o.d.

Sawdust 100%

250– 400kWh/tfiber o.d.

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

H. Roll (2008)

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Wood-Based Panels

Fibre generation

Defibration Process steps 1. Screening of chips (uniform chip size and shape, removal of over-sized chips and contaminants) 2. Chip conditioning by means of a moistening screw 3. Double mixing screw to feed chips into the pre-steaming bin. Pre-steaming reduces the temperature difference to the affiliated cook-ing process. The forming condensate in the pre-steaming bin can easily squeezed out in the plug screw feeder and chips have to be only heated up in the digester from pre-steaming to cooking tem-perature. Condensate reduction in the chips also significantly saves energy in the fibre drying process. 4. To prevent from steam blow-out from the digester (temperature and pressure drop) a blow back valve is located opposite the plug screw feeder to close the digester infeed opening if necessary. 5. The digester is used to heat up and cook the chips. Retention time – an important parameter to fibre quality - is determined by flow rate and digester level indicated by a radioactive level mea-suring device. Digester discharge is accomplished by particular discharge unit underneath the digester on customers indications on wood species, bulk density and chip moisture content. Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Defibration process steps (cont.) Before chips enter the refiner they have to pass a ribbon feeder, which operates at constant speed and feeds the material continuously into the refiner. At the same time it allows steam, generated in the refiner to flow back into the digester trough the steam equalization line. 6. Typically the refiner is designed as single disc pressurized refiner with a rotating and a sta-tionary plate holder. The rotor is adjustable in horizontal direction to the stator which is mounted stationary onto the door. While at lower throughputs the plate gap will be electromechanically adjusted the large refiners use a most precise and reliable hydraulic plate gap adjustment. By adjusting the rotor against the stator the power consumption of the refiner main drive motor can be increased or decreased, which allows adjusting the specific energy to the refining process, considering different raw materials and the required end products. To increase the refiner speed, e.g., for processing sawdust, an additional high speed gear is built in. (Andritz 2005)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Chip washing process Chips

Chip washing is essential for producing board with low mineral content.

Increasing use of purchased chips, e.g. from sawmills, results in an everincreasing need for chip washing. Existing impurities, as metal parts, stones and sand, must be removed Closed water before the chips enter the process. circuit

(Æ CleanMax System) Metso 2010

Waste water processing

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation Chip treatment and refining

Blow back valve

Metso 2010 Metso 2010

FeedMax Æ screw feeder upgrade provides uniform feeding, optimized dewatering and reduced energy consumption

Metso 2010

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Metso 2010

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Wood-Based Panels Refiner unit

Fibre generation Top view

Side view

Metso 2011

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Refiner unit

Pallmann 2015 Æ http://www.pfalz-express.de/wp-content/uploads/2013/02/Pallmann-Refiner.jpg / 17/08/2015

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Refiner unit

Single-Disc refiner

EVO-series Defibrator™

Metso 2011

Energy saving EVO helical discharge.

Andritz 2011

Traditional radial discharge. Metso 2006

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

VALMET Evolution Defibrator Series (former METSO - EVO-series Defibrator™) Development objectives Æ reduced energy consumption and better fibre quality by improved furnish flow into and through the refiner by ƒ particular high-speed screw feeder, ƒ efficient dewatering ĺ reduced mc in pre-heater, less steam demand, less mc at dryer inlet ƒ new infeed geometry in coarse breaker bar section of the segment area and improved centre plate design, ƒ low-energy unidirectional refiner segments,

Metso panelboard 2006

Metso 2010

ƒ helical discharge – instead former radial discharge - combined with blow valve. Specific energy saving approx. 25 … 50 kWh/ton softwood fibres, i.e., approx. 10 % for all fibre qualities compared with the M54 Defibrator. Additional reduction of specific steam consumption by 25…45 % Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Refiner and refiner plates

ƒ ƒ ƒ ƒ ƒ ƒ ƒ

Refiner plate details (Durametal Corp. / Andritz 2004)

Refiner … main machine for chip conversion into fibres. Softened chips are feed in the central area of the pressurized defibration zone between particularly designed refiner plates mounted on the stator and rotor respectively. Refiner plates consist of replaceable segments with a special bar and groove pattern. Pattern design (mostly depending on wood species) and adjustable distance between the two discs determine for refiner energy consumption and fibre quality. Additional refiner characteristics are: Mechanical sealing Hydrodynamic axial bearing Radial roller bearing Electromechanical disc adjustment Disc diameter: 44”, 50”, 56”, 64”, 70”, 74” Throughput: 10…65 to.d./h Power supply main drive: § 5…20 MW

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Refiner plates … design reduced energy consumption + increases fibre quality 58°

Inconsistant cutting angle

30°

Constant cutting angle of 30°

(http://www.andritz.com/service-pprefinerplatesandfillings-mdf-spiral-en.pdf / 17.08.2015)

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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Wood-Based Panels

Fibre generation

Refiner – additional equipment Blow valve - directly attached to the discharge opening of the refiner and actuated by means of a pneumatic actuator and electro-pneumatic positioner as well as a manual remote station. The purpose is to gradually adjust the opening to the blow line to allow the actual fibre steam mixture being safely discharged from the refiner.

Andritz 2004

Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

Three way fibre diverter valve is used when different raw materials (chips, sawdust …) are processed in the refiner to meet the required velocities for the glue injection by using different piping diameters. The fibre diverter valve is a rotating diverter driven by two pneumatic cylinders attached to a base frame.

Start-up cyclone guarantees a safely start-up of the system. After checking the fibre quality at the starting cyclone and rechecking if all characteristic values have levelled off and remain constant the valve is switched to production.

Andritz 2004

Andritz 2004

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Wood-Based Panels

Overview / Intro Prof.Dr.JoergB.Ressel www.biologie.uniͲhamburg.de/zentrumͲholzwirtschaft.html

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