Starch-based boxmaking adhesive preparation plants

The concept is based on standard used adhesive preparation processes of ”Steinhall”,”No-carrier” or ”Minocar” types with or without measuring viscosity. The equipment is designed and delivered according to the particular process conditions and customers’ specifications.

The delivery scope can include a starch storage equipment, an adhesive preparation unit, powder and liquid borax dosage systems, caustic soda (sodium hydroxide NaOH) storing and dosing systems, storage tanks incl. transport pumps, recirculation loops from the corrugator back to storage tanks incl. respective pumps.

The optional parts of the accessories are external stations for another powder starch sort designed for using “Big-Bags“ incl. lifting devices or alternatively hoppers for filling from paper sacks. Starch is furnished to a cooker by means of a worm conveyor electronically controlled by means of a frequency converter.

Equipment parameters Powder starch storage capacities

• High volume silo 50-100m ,material GPR
• Low-volume silo for filling from ”Big3 Bags”3-10m
• ”Big-Bag” station with hopper 1.2m
• Hopper for filling from sacks 0.4-1m

Adhesive preparation unit

• Cooker 1.5-3.3m
• Borax dosing device
• NaOH dosing device
• Controlled steam direct heating system
• High-efficient dispersing agitator with “Z” type disper sing disc
• Built-in strain gauges for precise powder weigh in gpowder starch
• Inductive flowmeter and precise water dosing control system
• On-line NaOH dilution circuit for adhesive viscosity fine control
• System soptionally utilize flushing water
• Cooker vent with filter
• Electric switchboard with control system using brand-name control board with LCD touch panel.

The machinery design and safety comply with the EU and EAC industrial standards

The equipment is designed according to the particular local conditions. The equipment is delivered with a single pipeline or with two independent ones enabling using two various “ready-mixes“. The equipment is composed of 1 or 2 hoppers for one or two various “ready-mixes“, a dispersing tank and a system pumping ready-made adhesive to a storage tank

Main parts of the ”ready-mix”based adhesive preparation equipment

• Storage hopper(1 or 2 items)
• Dosing worm electronically controlled by means of a frequency converter
• Automatic shutting flaps on the dosing worm outlet protecting humidity penetration from the dispersing tank
• Dispersing tank with a high-performance dispersing “Z”agitator
• Transport pneumatic pump
• Water dosage control circuit
• Electric switch board with a control system
• Support frame

Parameters of the equipment

• Hopper volume2m
• Dispersing tank volume 0.8m
• Ready-made adhesive storage tank 3 volume 1 m (can be modified as per specifications)
• Batch volume 0.5-0.7m
• Pumping speed 60-220l/min

Rebuilds of adhesive plants made by other manufacturers

PAPCEL offers modifications and rebuilds of existing adhesive preparation plants according to the customers’ requirements in a needed scope. Rebuild machinery parts or new control systems can be delivered as well as modifications in another scope can be carried out based on an agreement with the customer

The machinery design and safety comply with the EU and EAC industrial standards.

Fillers

Fillers (pigments, filling agents) are insoluble particles filling empty places in paper structure; furthermore they are used to colour paper and to increase opacity. Pigments are added into pulped stock or coating mixtures. Generally they improve paper printability. They are sorted out in organic and inorganic ones and also by their chemical composition. They are for example limestone (calcium carbonate CaCO ), titanium white (titanium 3 dioxide TiO ), china clay (kaolin), talc (soap- 2 stone), barite (barite, blanc fixe, barium sulphate BaSO ) and others. Conserving and 4 plasticizing admixtures are used to stabilize liquid fillers.

Sizing agents

Sizing agents (sizes) improve paper resistance to water. They are added into stock or spread on paper surface in size press. Sizing agents are modified natural rosins or synthetic substances, for example AKD (alkyl ketene dimer), ASA (alkenyl succinic anhydride), styrene-acrylate based compounds.

Starch

They improve creating interfibrous bonds, paper and board dry strength, and they decrease printing surface dusting. They are made from potatoes, wheat, corn etc. Starch is sorted out in:

• Mass-dosed – cationic starch
• Surface-spread – oxidized or native starch,
  the latter to be treated by means of enzymatic or thermo chemical conversion

Native – non-modified starch

To be spread onto paper surface in size press. They are the cheapest; potato, corn or wheat native starch is usually used. They are modified by means of enzymatic conversion (enzyme-treating starch in a continuous reactor to cut starch molecule chains) or by means of thermo chemical conversion (the starch molecules are cut by means of oxidizing agents). The equipment preparing starch for further use is generally called jet cookers

Cationic – modified starch

To be dosed in stock. The cationic charge increases capacity of starch absorption in cellulose fibres.

Oxidized

Oxidation in a starch plant is the most frequent way of starch molecule degradation. The oxidized starch sorts are spread onto paper surface in size press. They are also used as a base to prepare adhesives for box making.

Retention agents

The aim of using retention agents is to catch as much input raw material as possible on the paper machine wire and to speed up dewatering. They improve white water quality. They are made of liquid or powder products. The retention agent dosing systems are designed as single-, double- or triple component ones. The retention systems consist of:

flocculants : substances speeding up creating floccules
coagulants: substances supporting floccule precipitation
bentonite: used as one part of multi component retention systems or to clean effluents polluted by oil products, emulsions, color colloids or heavy metals

JC, TCC, EKK starch cookers technical data

Starchsort: native or oxidized (cationic)
Starch origin: potato, corn, wheat, tapioca 
Starch cooking: oxidized, cationic – continuous cooking in JC cookers
                                     native thermo chemical conversion using oxidants in TCC cookers 
Filling cookers: native – enzymatic conversion in EKK cookers from paper sacks or “Big-Bags” directly into a cooker
                              hopper (compact cooker)
                              from a small- or large-volume silo (divided cooker)

Cooker design: compact – all the components installed in a support
                              frame divided – the slurry unit installed separately from the cooking unit, above                                all for TCC or EKK cookers filled from large volume silos.
Oxidant sort: ammonium or potassium persulphate
Enzyme sort: α (alpha) – amylase
Cooking time: JC cookers – 2 minutes, TCC cookers – 4 minutes
Conversion time: EKK cookers – 20 minutes conversion + 2 minutes enzyme inactivation
Viscosity control: on customers’ demand for TCC and EKK cookers
Cooker capacities: JC cookers – 50 to 1,000 kg/hr
                                     TCC and EKK cookers – 350 to 3,000 kg/hr
Slurry concentration: up to 30 % for oxidized and native starch 
                                           up to 12 % for cationic starch
Output concentration: adjustable as per the process requirements,
                                            – for oxidized and native starch 6 up to 15 %
                                            – for cationic starch 1 up to 4 %
Electric grid: 3x 400 VAC/50 Hz or 60 Hz
Rated power input: 5 – 36 kW
Fresh water: no mechanical impurities, pressure min. 3 bar
Instrument air: pressure min. 5 bar, dew point -20°C
Saturated steam: 4 – 5 bar abs

Dyes and optical brightening agents

Dyes are intensively coloured organic compounds soluble in water or other solvents. They are used to achieve a required colour shade. Mass or surface dyes are used; the latter applied in size press. Optical brightening agents (OBA) are utilised to improve light reflectivity. They are colourless or slightly coloured, water soluble. They are applied in stock or on surface in size press.

Biocides

They are used to kill, suppress or prevent a growth of bacteria and other microorganisms arising in various places of paper making machinery. The most frequent occurrence of bacterial cultures is on the walls of tanks, machines and pipelines where they create slime deteriorating water quality and possibly causing paper breaks.

Defoaming agents

Used to suppress creating foam. Applied into stock or into starch solutions and coating mixtures.

Pitch control

Agents used to catch and separate free rosin and other undesirable matter in stock able to stick on various machinery parts like doctors, dewatering blades, paper machine clothing and others. E.g. talc is often used

Coating mixtures

They are used for surface coaters. Generally they are composed of pigments, adhesives, binders, OBAs, dyes, dispergators and pH control agents. They significantly improve paper surface properties, above all of the printing papers.

Emulsifiers

Agents used to prepare emulsions, i.e. reducing an inter phase tension. They are used e.g. for preparing oil-in-water“ type emulsions

pH controllers

They are used for pH-control of coating mixtures or to optimise functions of auxiliary papermaking agents in stock. If caustic soda (sodium hydroxide, NaOH) solution is used, it must be heated by means of steam or electric heaters to prevent recrystallization. Other pH controllers are alum [aluminium sulphate,Al (SO ) .xH O), sulphuric acid (H SO ), 2 4 3 2 2 4 polyaluminium chloride (Al (OH) Cl , PAC) n m 3n-m and other

Binders

They bind and connect pigment particles one to another and connect the pigment particles to paper surface. Usually used in coating and sizing mixtures. Sorted out in natural and synthetic binders, e.g. starch, casein, polyvinyl alcohols (PVA), acrylates, latexes and others.

Other auxiliary chemicals

• Fixative agents like PAC – improving retention, fixing chemicals, purifying process water and effluents
• Cleaning agents – for continuous chemical cleaning felts
• WSR (water strength resins) – imparting to paper mechanical resistance to water or humidity (synthetic resins based on PAE (polyamido-amine-epichlorohydrin), UF (urea-formaldehyde and others) 

Belt press VANEX is designed to continuously dewater various sorts of sludges.

The constituents separated in the dewatering process are:

• Solid constituent (sludge paste transportable by conveyors)
• Liquid constituent (filtrate ready to be further processed)

Main parts

• Steel frame (1)
• Air system (2)
• Rolls and troughs (3)
• Electric system (4)
• Hoppers (5)
• Filtration screens (6)
• Filtrate drainage (7)
• Machine drive (8)

Material

• Machine structure is made of steel
• Troughs, hoppers and covers are made of polypropylene
• Joining material is made of stainless steel

Machine design and work safety are in compliance with the EU standards and EAC.

Continuous cooking cationic and oxidized starch sorts in semi-automated or fully automated modes.

Performancegroups: JC100-JC1000
Performance range: 100to1000kg/hr
Slurry concentration: 6to10% (cationic starch)
Slurry concentration: 25to30% (oxidizedstarch)
Outlet concentration: 1to4% (cationic starch)
Outlet concentration: 10to15% (oxidizedstarch)
Powerinput: 2.2to4kW

Function brief description

Powder starch is dosed by means of precise worm dosing device into a slurry tank where it is mixed with water and slurry is formed. The slurry concentration depends on the starch sort and use. Starch slurry is continuously pumped by means of screw pump into a static mixer where saturated steam is injected into slurry. That is the beginning of the cooking process being underway in a cooking tube following the mixer. The cooking temperature is set by means of control circuit on a preset value depending on the starchsort. The cooking tube is followed by yester static mixer bringing diluting/cooling water into the cooked starch solution

The machinery design and safety comply with the EU and EAC industrial standards.

The outlet concentration is controlled by means of dilution water quantity. Its throughput is controlled by control circuit. Starch diluted onto a required outlet concentration and cooled down to 60 to 85°C enters the storage tank and it is ready for further use. The process is identical for both cationic and oxidized starch.

Cooker main parts

• Powder starch source – a hopper integrated in a support frame or certain type of a lowor high-volume silo for higher starch demand (the silo accessories are designed separately or particular applications)
• Precise worm dosing device with a drive and arms preventing arising cavities
• Slurry tank with a high-performance agitator
• System controlling water throughput into the slurry tank-depends on the cooker type
• Slurry pump with or without performance control-depends on the cooker type
• Slurry filter screening coarse mechanical impurities
• Static mixer for steam injection
• Circuit for automatic cooking temperature control
• Cooking tube
• Static mixer for dilution/cooling water input
• Circuit for an automatic/manual dilution /cooling water throughput control
• Set of measuring & control elements
• Electric switchboard (wherever required)
• Support frame

An example of a cooker design for installation in a limited space. In such case the cooking tube is put below the slurry tank next to the slurry pump so that the device floor dimensions were as small as possible. The cooker is filled from sacks or “Big-Bags”.

Cooker concept

K
Compact– slurry unit installed in the frame together with the cooking part

O
separate– slurry unit installed separately from the cooking part

Control system

–
none– – the cooker is controlled by means of an external control system

S
Simatic– the cooker is equipped with a PLC based on Simatic type S7

L
logo– the cooker is equipped with a simple programmable controller

Filling slurry tank with water

A
automatic– water throughput into the slurry tanks is controlled by an automatic control valve

P
float– water throughput into the slurry tank is controlled by a float valve

Slurry throughput control

F
frequency converter– the slurry pump is controlled by a frequency converter the slurry pump without a performance control

– the slurry pump without a performance control

Back pressure control

A
automatic– the cooking tube pressure is controlled by an automatic control valve

M
manual– the cooking tube pressure is controlled by a manual valve

Dilution control

A
automatic– the dilution water flow through the cooking tube is controlled by an automatic control valve

M
manual– the dilution water flow through the cooking tube is controlled by a manual valve

Flushing

P
water for quick flushing is connected to the slurry pump suction side

– flushing cooker enabled by water connected to the slurry tank

Cooker performance control

A 
automatic– – the cooker works with a performance proportional control

– the cooker works with a constant performance in an on/off mode

Starch hopper

N
– a starch hopper installed in the support frame is part of the cooker

– no hopper, the starch source is a silo

The JC type cooker with an integrated hopper equipped with a device for easy filling from paper sacks. In this case starch is poured into a small hopper and then delivered by means of worm conveyor to a cooker hopper. The design is advantageous wherever the ceiling height is not sufficient.

Software

The JC cookers are delivered including SW enabling a fully automated cooker operation in predefined steps – sequences. The sequences enable cooking and flushing automated modes at reproducible values before and after finishing the cooking process. The cooker can be switched to a manual mode and the operation can be carried out by means of a control board installed on the switchboard front door. During the cooker operation the cooking process conditions like media parameters, functions and statuses of particular cooker key elements and control circuit statuses are monitored; if any parameter deviates from control range an alarm message is generated and saved in an alarm bank.

The cooker performance is usually controlled depending on the cooked starch storage tank level height either in an on/off mode (the cooker works with a constant performance, starts on the bottom level and stops after reaching the top level) or it works with a variable performance depending on the storage tank level fall speed.

Technical data

Starch sort: cationic or oxidized
Starch origin: potato, corn, wheat, tapioca
Starch source: volume integrated in the cooker support frame 3(volume 100 to 400 dm) medium or large volume silo (volume 5 to 150 m )
Starch packing: paper sacks 25 to 40 kg “Big-Bags” 600 or 1 000 kg road tanker, starch stored in a high-capacity silo
Starch dosing: precise worm dosing device with a drive and arms preventing arising cavities, driven by an electric motor and arms drive final gear
Cooking time: 1 minute for potato and tapioca starch 2 minutes for corn and wheat starch
Heating medium: saturated steam 4 to 5 bar abs
Water: fresh or treated without mechanical impurities,minimum pressure 3.5 bar
Instrument air: dew point -20°C, pressure 5 bar
Performance change speed: dQ = 5 kg/min or a ramp change

Examples of JC cookers process diagrams with various starch filing modes

An example of JC cooker diagram with an integrated hopper, water throughput into the slurry tank controlled by an automatic control valve and an automatic control circuit with an automatic control valve. The cooker is controlled by a Simatic based PLC.

An example of JC cooker diagram filled from a medium silo, water throughput into the slurry tank controlled by an automatic control valve and an automatic control circuit with an automatic control valve. The cooker is controlled by a Simatic based PLC.

An example of JC cooker diagram filled from a large-volume silo, water throughput into the slurry tank controlled by an automatic control valve and an automatic control circuit with an automatic control valve. The slurry part is installed in a separate support frame below the silo output cone and connected to the cooking part by a pipeline. The cooker is controlled by a Simatic based PLC.

Continuous cooking thermochemically degraded native starch sorts in semi-automated or automated modes. The degrading agent is a strong oxidant, usually ammonium or sodium persulphates. The starch solutions prepared this way are suitable for usage as surface applications in size or film presses

Performance groups: TCC450,TCC1100
Performance range: 450to1100kg/hr
Slurry concentration: 22to28%
Power input: 2.2 to 8 kW

Function brief description

Powder starch is dosed by means of precise worm dosing device into a slurry tank where it is mixed with water and slurry is formed. The slurry concentration depends on a starch sort and use. Starch slurry is continuously pumped by means of a screw pump into a static mixer where saturated steam is injected into slurry. Before the steam inlet, the oxidizing agent is dosed into slurry in an exact ratio to starch.
That is the beginning of the cooking process being underway in a cooking tube following the mixer. The cooking temperature is set by means of control circuit on a preset value depending on the starchsort. The cooking tube is followed by another static mixer bringing diluting/cooling water into the cooked starch solution. The outlet concentration is controlled by means of dilution water quantity. Its  through put is controlled by control circuit.

Starch diluted onto a required outlet concentration and cooled down to 60 to 85°C enters the storage tank and it is ready for further use. The process is identical for both cationic and oxidized starch. The oxidant dose controls the cooked starch final
viscosity

Cooker main parts

• Powder starch source – a hopper integrated in a support frame or certain type of a lowor high-volume silo for higher starch demand (the silo accessories are designed separately for particular applications)
• Precise worm dosing device with a drive and arms preventing a rising cavities
• Slurry tank with a high-performance agitator
• System controlling water throughput into the slurry tank-depends on the cooker type
• Slurry pump with or without performance control-depends on the cooker type
• Slurry filter screening coarse mechanical impurities
• Static mixer for steam injection
• Circuit for automatic cooking temperature control
• Cooking tube
• Static mixer for dilution/cooling water input
• Circuit for an automatic/manual dilution /cooling water throughput control
• Set of measuring & control elements
• Electric switchboard (wherever required)
• Support frame
• Device for preparation of oxidizing agent

Device for preparation of oxidizing agent

• Plastics (PP, PE) or AISI 304/316 grade stainless steel depending on the used product
• Dilution tank with agitator, integrated pumping chamber and measuring &
  control(M&C)elements
• Solution storage tank with accessories and M&C elements
• Precise diaphragm dosing pump with oxidant capacity control
• Dilution tank support frame (oxidant storage tank is installed in the cooker frame)

The machinery design and safety comply with the EU and EAC industrial standards.

Cooker concept

K
Compact– slurry unit installed in the frame together with the cooking part

O
separate– slurry unit installed separately from the cooking part

Control system

–
none– – the cooker is controlled by means of an external control system

S
Simatic– the cooker is equipped with a PLC based on Simatic type S7

L
logo– the cooker is equipped with a simple programmable controller

Filling slurry tank with water

A
automatic– water throughput into the slurry tanks is controlled by an automatic control valve

P
float– water throughput into the slurry tank is controlled by a float valve

Slurry throughput control

F
frequency converter– the slurry pump is controlled by a frequency converter the slurry pump without a performance control

Back pressure control

A
automatic– the cooking tube pressure is controlled by an automatic control valve

M
manual– the cooking tube pressure is controlled by a manual valve

Dilution control

A
automatic– the dilution water flow through the cooking tube is controlled by an automatic control valve

M
manual– the dilution water flow through the cooking tube is controlled by a manual valve

Flushing

P
water for quick flushing is connected to the slurry pump suction side

–
flushing cooker enabled by water connected to the slurry tank

Cooker performance control

A
automatic– – the cooker works with a performance proportional control

–
the cooker works with a constant performance in an on/off mode

Starch hopper

N
– a starch hopper installed in the support frame is part of the cooker

–
no hopper, the starch source is a silo

Examples of TCC type cooker process diagrams with various starch filling modes

An example diagram of a TCC type cooker with an integrated hopper, with a slurry diluting water throughput controlled by means of an automatic control valve and an automatic control circuit with a control valve. An oxidant preparing and dosing system is included. The cooker is controlled by means of a Simatic based PLC.

Software

The TCC cookers are delivered including SW enabling a fully automated cooker operation in predefined steps – sequences. The sequences enable cooking and flushing automated modes at reproducible values before and after finishing the cooking process, including a precise oxidant dosing control. The cooker can be switched to a manual mode and the operation can be carried out by means of control board installed on the switchboard front door.

During the cooker operation the cooking process conditions like media parameters, functions and statuses of particular cooker key elements and control circuit statuses are monitored; if any parameter deviates from a control range an alarm message is generated and saved in an alarm bank. The system controls the oxidant preparation as well. 

The cooker performance is usually controlled depending on the cooked starch storage tank level height either in an on/off mode (the cooker works with a constant performance, starts on the bottom level and stops after reaching the top level) or it works with a variable performance depending on the storage tank level fall speed.

Technical data

Starch sort: native 
Starch origin: potato, corn, wheat, tapioca
Starch source: hopper integrated in the cooker support frame 3 (volume 100 to 400 dm )
Starch packing: paper sacks 25 to 40 kg “Big-Bags” 600 or 1 000 kg road tanker, starch stored in a high-capacity silo
Oxidant dosing: precise dosing pump with performance control and flow measuring
Cooking time: 4 minutes for all starch sorts
Heating medium: saturated steam 4 to 5 bar abs
Water: fresh or treated without mechanical impurities, minimum pressure 3.5 bar
Instrument air: dew point -20°C, pressure 5 bar
Performance change speed: dQ = 5 kg/min or a ramp change

An example of TCC cooker diagram filled from a medium silo, water throughput into the slurry tank controlled by an automatic control valve and an automatic control circuit with an automatic control valve. The system preparing and dosing oxidant is
included as well. The cooker is controlled by a Simatic based PLC.

An example of TCC cooker diagram filled from a large-volume silo, water throughput into the slurry tank controlled by an automatic control valve and an automatic control circuit with an automatic control valve. The system preparing and dosing oxidant is included as well. The slurry part is installed in a separate support frame below the silo output cone and connected to the cooking part by a pipeline. The cooker is controlled by a Simatic based PLC.