UltraBar/PowerCast

Designed with our innovative PowerCast™ Technology, these UltraBar™ patterns offers taller fine bars to maximize low intensity applications. With virtually zero-degree bar draft angles, the UltraBar designs optimize hardwood, Old Corrugated Cardboard [OCC], DIP and Post Mechanical refining applications.

These patterns are available in the revolutionary C96 alloy to extend life and consistently deliver a sharp bar edge.

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UltraBar PowerCast Series: Reverse Flared Parallel Bar, Single Zone Design w/ Low Draft Angles

ComparisonUltra-Bar Patterns with PowerCast TechnologyFabricated Fine Bar Technology
AlloyC96 Surface Hardened Duplex Stainless Steel17-4 Stainless Steel
Bar Bending39% Additional Strength 34,900 lbs. bend strength25,0000 lbs. bend strength
Bar Wear20% loonger life; 50 Rc36 Rc
ConstructionPrecision Zero-Degree CastFabricdated/brazed

FEATURES

  • Low Draft Angles
  • High Bar Edge Crossings
  • ReverseFlare
  • Radial Feed Grooves
  • Single or Multizone
  • Strategically Placed Dams
  • Overhung
  • Underhung

Combine advantages like Zero-Degree Bar Draft Angles, Limitless Pattern Designs, Sharper Bar Edge and Maximum Resistance to Bar Bending & Breaking and Ultra-Bar Patterns with PowerCast Technology are the only choice to maximize life, improve fiber development and prevent bar bending and breakage in tough applications.

 Ultra-Bar PowerCast advantages

  • Increased Pulp Strength Low intensity patterns allow maximum fiber development for hardwood, OCC, DIP and Post Mechanical Refining applications
  • Longer Plate Life Taller bar heights, a superior C96 alloy and virtually Zero-Degree Bar Draft Angles extend refiner plate life
  • Higher Refining Capacity Greater master plate angle with deeper grooves and virtually Zero-Degree Bar Draft Angles maximize hydraulic capacity
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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.