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Pulp refining demands a tight balance between fiber development and specific energy. Mills aim to stabilize CSF, avoid over‑refining, and extend wear life while mitigating sand/contaminant damage.
- Fiber development vs. energy: achieve target bond area with the lowest kWh/t.
- CSF control and stability: reduce variability across shifts and furnish changes.
- Wear management: predictable plate life and consistent gap over service.
- Contamination tolerance: geometries and alloys that resist sand and tramp metals.
Prometals designs and manufactures advanced refining sets that address these constraints for hardwood and softwood pulps.
Recommended Refining Sets
Configurations and Compatibility
Example configurations by refiner model:
- Andritz DD600–D2: Pegasus rotor + stator for hardwood micro‑fibrillation and CSF control.
- Voith Platten RF4: Nanoax rotor + stator set for softwood tensile gains with preserved bulk.
- Sprout 401: Taitan rotor + stator to resist sand and maintain throughput.
Compatibility and guidance:
- Interchangeability with OEM bolt patterns and hub interfaces.
- Recommended clearances and groove depths to reduce plugging.
- Maintenance: inspect wear land every 500–800 h; target uniform wear to preserve gap linearity.
Performance KPIs
We engineer for measurable outcomes. Typical impacts (indicative, application‑dependent):
- CSF: ±50–120 mL control range tightening; reduced drift over 8–12 h.
- Tensile: +8–20%; +5–12%.
- TEA: +10–25% with NANOAX micro‑fibrillation patterns.
- Bulk: preserved within −1 to −4% when targeting strength gains.
- Specific energy: −5–15% at equal CSF, via optimized bar density and groove design.
KPI selection is aligned with furnish, target grade, and machine constraints.
Case Snapshots
- Brazil, HW kraft liner: Pegasus + Nanoax reduced energy 11% at constant CSF 320 mL; tensile +9%.
- Mixed furnish tissue: Pegasus delivered smoother gap behavior, cut breaks by 18% month‑over‑month.
- SW kraft sack paper: Tritan raised TEA 17% with bulk change −2%.
See detailed methodologies, baselines, and longer‑term stability results in our case library.
Consulting and Support
Prometals supports pulp and paper mills from diagnosis to sustained performance:
- Advisory and optimization: refining curves, CSF control plans, energy benchmarking.
- Commissioning and post‑installation: plate alignment, vibration checks, control tuning.
- Training and workshops: operator best practices, KPI dashboards, data‑driven tuning.
- Spare parts and maintenance: wear tracking, planned changeouts, alloy selection.
