Low Consistency Refiner Plates

For stock preparation, our continuous improvement approach offers custom solutions to optimize fiber development and specific energy consumption in low consistency refiner plate applications.

Recent advancements in casting and metallurgical technology have resulted in lower energy, reduced furnish costs and faster paper machine speeds. One of our engineers can audit your system and recommend a low consistency refiner plate design to meet your paper machine productivity goals.

J&L’s “Six Step Refiner Optimization Process” (shown below right) helps to identify your mill’s most challenging situations and helps create custom solutions. We will enhance your refiner productivity by sharing application expertise while matching refining parameters to achieve pulp/paper/board properties through plate design and alloy technology.

Plate design techniques are carefully crafted to:

  • Reduce Bar Breakage
  • Reduce Fiber Plugging
  • Reduce Pulp & Paper Mill Shive Levels
  • Reduce Furnish Costs
  • Reduce Energy Consumption
  • Enhance Plate Life

Together, the steps in our proven process will result in:

  • Increased Plate Life
  • Reduced Plate Breakage
  • Reduced Plate Plugging Problems
  • Improved Pulp Strength or Quality
  • Reduced Sheet Breaks
  • Lower Shive Levels
  • Reduced Fines
  • Lower Furnish Costs
  • Increased Refining Capacity
  • Energy Savings
  • Higher Production Rates
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 Capacity IncreasePulp Quality / Efficiency ImprovementLife IncreaseEnergy Savings

Stock Preparation Case Studies

Milled Bar
Reverse Flare
Dammed Pattern
Underhung

Mechanical Pulping Case Studies

Stabilizer Plate
Steam Groove
Conical Discs

Our Low Consistency Refiner Plate series and designs include:

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Uniquely different refiner plates because of the many options they present, they incorporate alternating deep groove design with maximum customization flexibility.

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These refiner segments are a lighter and safer alternative to constant angle designs and are available in all our own pattern designs with unique overhang possibilities.

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Provide lower intensity and more bar edge crossings than comparable constant angle designs.

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Our groundbreaking PowerCast Technology (which optimizes hardwood, OCC and DIP applications) produces the tallest, sharpest-edged fine bars possible for low intensity refiner plate applications. It also allows limitless pattern designs, increased pulp strength and enhanced plate life in tandem with our excellent breakage-resistant alloys.

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Machined bars and grooves that produce  high precision bars and grooves in cast plates. An outstanding option in ultra-low intensity bleached hardwood applications.

Milled Bar Case Study

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Optimizes pulp flow, extends plate life and improves feeding capacity and fiber quality.

Our low consistency refiner plates can be engineered with the following features:

Reverse-Flare

ReverseFlare patterns allow greater pattern flexibility in contaminant environments resulting in longer plate life, improved efficiency and lower costs.

ReverseFlare Case Study

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Prevents stock from “channeling” through grooves unrefined. An excellent de-fibering and shive reduction tool.

Dammed Pattern Case Study

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Underhung plate designs are appropriate in certain situations and have the potential to save a mill a significant amount in electrical energy or improve refining efficiency.

Underhung Case Study

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Refiner Plate Design

Different refiner applications require different plate designs as system optimization is undertaken.

Fiber treatment, hydraulic capacity and breakage resistance are three critical parameters that must be considered when designing and applying low consistency refiner plate patterns.

A paper mill can optimize its low consistency refining operations on two fronts:

  • Monitoring and eliminating as many detrimental hydraulic, mechanical and process conditions as possible.
  • Ensuring that the proper plate designs and alloys have been selected.

By working together with our papermakers, J&L Fiber Services seeks to develop strategies to optimize the unique needs and performance of a particular paper mill.

Given the difficulties of being able to control all of the many process variables, refiner plate design becomes extremely critical. The key design parameters, relative to delta P (refiner pressure control) are: groove depth, groove profile, number of bars & total pumping angle.

The intensity of refining that is required will determine the bar width/groove relationship,or pitch. However, groove width should be altered to optimize the throughput rate. This can be done without changing the pitch or intensity by altering the bar width correspondingly.

A special caution when altering groove depth for flow control: While no appreciable negative effect will occur when groove depth is reduced for lower flow rates, increasing groove depth poses some risks. First, it is less efficient than increasing groove width. Second, it can have a negative effect on energy efficiency, because increasing groove depth increases the no-load energy required to spin the rotating element in the stock slurry.

Bar angle is significant to the extent that it affects the delta P and is a tool for hydraulically balancing the refiner.

The relatively infrequently used practice of running the low consistency refiner plates in the holdback position can effectively compensate for low flow conditions which are detrimental to fiber quality, plate life, etc. During holdback, the intersecting bar angle between the rotor and the stator is moving towards the center line of the refiner rather than towards the periphery of the disc, as in pumping position. Holdback will increase the turbulence in the grooves and the plate gap.