Characterization of Microparticle Retention Systems with Retention Process Analyzer

In the literature survey retention mechanisms, factors effecting retention and microparticles were studied. Also commercial microparticle retention systems and means to measure retention were studied. Optical retention measurement with RPA and Lasentec FBRM was studied. The experimental part contains study of different cationic polyacrylamides, anionic silica, bentonite and new generation micropolymer. In these studies the dosage, dosing order and dosing history were changing factors. The experimental work was done with RPA-apparatus with which, the retention process can be followed in real time. In testing was found that silica yielded better retention, when dosed nontraditionally before the polymer. Also silica was very dependant on the polymer dosage. With bentonite good colloidal retention was achieved with relatively low doses. Unlike silica bentonite was not dependant on polymer dosage. The relation of bentonite and polymer dosage is more defining when high retention is wanted. With 3-component systems using bentonite very high retention was achieved. With silica no improvement in retention was found in 3-component systems compared to dual component systems.

Retentiojärjestelmän optimointi kartonkikoneella

Diplomityössä tutkittiin kartonkikoneen retentiojärjestelmää ja eri mahdollisuuksia retention ja vedenpoiston tehostamiseen. Tavoitteena oli parantaa etenkin runkokerroksen retentiota ja vedenpoistoa. Työssä testattiin kilpailevan kemikaalitoimittajan mikropartikkelia kartonkikoneella. Lisäksi runkokerroksessa testattiin retentiotärkkelyksen vaikutus kartongin palstaumislujuuteen, suoritettiin käytössä olevan mikropartikkelin annostuksen optimointi sekä testattiin alunan käyttöä retentioainesysteemin tehoaineena. Kirjallisuusosassa tarkasteltiin pinta- ja kolloidikemian perusteita, retentioainejärjestelmiä ja niissä käytettäviä kemikaaleja sekä retentioaineilla tehtävään flokkaukseen vaikuttavia tekijöitä. Laboratoriokokeilla tutkittiin kokeellisessa osassa eri mikropartikkelijärjestelmien toimivuutta kartonkikoneen eri kerroksien massoilla. Toimivimmaksi osoittautuneella mikropartikkelilla suoritettiin pilot-koeajo runkokerroksen massalla. Lisäksi suoritettiin toinen pilot-koeajo, jossa tutkittiin mikropartikkelin vaikutuksia saostuman aiheuttajana. Pilot-koeajoissa saavutettiin samat retentiotasot kuin referenssisysteemillä lähes puolet pienemmällä kemikaalin kulutuksella. Kartongin laatuominaisuuksista huokoisuus, formaatio ja AKD-liiman retentio muuttuivat viiraretention mukaan. Saostumakoeajossa ei todettu retentioaineen vaikuttavan saostumien syntyyn. Täyden mittakaavan koeajossa tarkoituksena oli testata kilpailevan mikropartikkelin toimivuus kartonkikoneella. Koeajossa etsittiin optimaalinen mikropartikkelin annostus eri kerroksiin. Pintakerroksen tuhkaretentio nousi hiukan ja vedenpoisto parani. Runko- ja taustakerroksessa saavutettiin samat retentiotasot sekä vedenpoistot. Samat retentiotasot saavutettiin n. 25 % pienemmällä mikropartikkelin kulutuksella. Kartongin laatuominaisuuksista seurattiin palstautumislujuutta, formaatiota ja AKD-liiman retentoitumista. Kartongin palstautumislujuus heikkeni. Vastaavasti runko- ja taustakerroksen AKD-liiman retentio oli hiukan korkeampi koeajetulla mikropartikkelilla. Formaatiossa ei tapahtunut merkittäviä muutoksia. Jatkokokeet tehtiin kartonkikoneen runkokerroksessa. Kokeissa todettiin retentiotärkkelyksen vaikuttavan kartongin palstautumislujuuteen. Käytössä olevan mikropartikkelin annostelun optimointikokeissa ei saavutettu parannusta retentioon eikä vedenpoistoon. Mikropartikkelilla saavutetaan tietty retentiotaso, jonka jälkeen sillä ei ole enää vaikutusta retentiotasoon. Alunan annostelukokeissa ei alle yksi kg/t annosmäärällä ole vaikutusta retentioon ja vedenpoistoon.

Dewatering of hard-to-dewater pulps

Nanocellulose has much potential for enhancing the tensile strength of paper but it slows down significantly drainage, restricting its use in industrial scale. Main objective of the work was to find ways to improve the dewatering of nanocellulose-containing papers. The effects of cationic potato starch, microparticle system and filler addition on dewatering and such key properties as formation, tensile strength and air permeance of manufactured paper were studied. Test points had 0, 4 or 8 % CNF and 0, 15 or 30 % PCC content. Based on earlier studies, 25 mg/g starch dosage was added to some test points. Modern microparticle system, consisted of cationic polyacrylamide and amorphous silica, was used in few test points. Dosages for both components were 0.3 and 0.6 mg/g, following the recommendations of the supplier. Also, the influences of CNF and filler on drying behaviour after different stages (drainage, wet pressing and cylinder drying) were estimated. Following trends were observed. Starch does not have unambiguous influence on dewatering. In some cases, it improved drainage slightly but effects on the properties of end product were discovered small. Filler quickened dewatering but large proportions were noticed to be detrimental for the drainage, air permeance and tensile strength. Microparticle system improved drainage notably, especially if CNF dosage was high. In addition, microparticle system increased tensile strength and decreased air permeance. However, its effects on formation were detrimental. Dewatering of nanocellulose-containing furnishes is treatable up to a certain point. In the end, such drainage times that were measured from test points which consisted only of pure kraft pulps are awkward to reach.

Utilization of retention chemicals in non-wood containing furnishes

The usage of the non-wood pulps in furnishes for various paper grades is the real alternative for substitution of wood fibres in the papermaking. This is especially important now, when the prices for wood are increasing and forest resources are depleting in many regions of our planet. However, there are several problems associated with utilization of such pulps. In terms of the papermaking process one of the main problems is the poor dewatering of the non-wood pulps. This problem can be partially solved by means of retention aids. In the literature part were described technological features of the non-wood pulps as the raw materials for paper production. Moreover, overviews of the retention chemicals and methods for retention measurement were done; special attention was paid to the mechanisms of retention and drainage. Finally, factors affecting on the drainage and retention of non-wood pulps were considered holistically. Particular emphasis was put on the possibility of enzyme treatment for drainage improvement. It was stated that retention aids can significantly improve dewatering of non-wood pulps. In the experimental part the goal was to investigate influence of various microparticle retention aids on the drainage, retention and formation of furnish containing wheat straw pulp, obtained by novel pulping process (Formico™Fib). The parallel test were performed with reference furnish containing only wood pulps. It was found that Bentonite-CPAM retention aid can significantly improve drainage and retention; however formation seems be suffer from such additives. It was stated that performance of the Silica-Starch retention aid significantly depends on the starch dosing sequence and wet-end conditions; this system have shown better formation than other tested retention aids. Silica-CPAM retention aid have provided comparable results in retention and drainage with Bentonite-CPAM, while Silica-starch did not improve dewatering and yielded in lowest filler retention among other aids. Ultimately, optimal dosages for the tested retention chemicals have been suggested.

Advanced orbital pipe welding

Since the introduction of automatic orbital welding in pipeline application in 1961, significant improvements have been obtained in orbital pipe welding systems. Requirement of more productive welding systems for pipeline application forces manufacturers to innovate new advanced systems and welding processes for orbital welding method. Various methods have been used to make welding process adaptive, such as visual sensing, passive visual sensing, real-time intelligent control, scan welding technique, multi laser vision sensor, thermal scanning, adaptive image processing, neural network model, machine vision, and optical sensing. Numerous studies are reviewed and discussed in this Master’s thesis and based on a wide range of experiments which already have been accomplished by different researches the vision sensor are reported to be the best choice for adaptive orbital pipe welding system. Also, in this study the most welding processes as well as the most pipe variations welded by orbital welding systems mainly for oil and gas pipeline applications are explained. The welding results show that Gas Metal Arc Welding (GMAW) and its variants like Surface Tension Transfer (STT) and modified short circuit are the most preferred processes in the welding of root pass and can be replaced to the Gas Tungsten Arc Welding (GTAW) in many applications. Furthermore, dual-tandem gas metal arc welding technique is currently considered the most efficient method in the welding of fill pass. Orbital GTAW process mostly is applied for applications ranging from single run welding of thin walled stainless tubes to multi run welding of thick walled pipes. Flux cored arc welding process is faster process with higher deposition rate and recently this process is getting more popular in pipe welding applications. Also, combination of gas metal arc welding and Nd:YAG laser has shown acceptable results in girth welding of land pipelines for oil and gas industry. This Master’s thesis can be implemented as a guideline in welding of pipes and tubes to achieve higher quality and efficiency. Also, this research can be used as a base material for future investigations to supplement present finding.

Eri MAG-hitsausprosessien ja -parametrien vaikutus suurlujuusteräksestä valmistetun otsapienahitsin äärikestävyyteen, muodonmuutoskykyyn ja vauriomuotoon

Työssä tutkittiin Ruukki Oyj:n suorasammutetusta S960QC-teräksestä valmistetun kuormaakantavan levyjen ristiliitoksen pienahitsien lujuutta, muodonmuutoskykyä ja vaurioitumismekanismia laajaan kokeelliseen aineistoon perustuen. Tärkeimpänä muuttujana koematriisissa olivat eri MAG-hitsausprosessit. Perinteisen kuumakaarihitsauksen vertailukohteena oli Kemppi Oy:n uusi adaptiivinen valokaaren pituutta säätävä WiseFusion-hitsaustoiminto kuuma- ja pulssikaarihitsauksessa. Näiden kolmen hitsausprosessin rinnalla varioitiin erisuuruisia a-mittoja, eri hitsauslisäaineita ja hitsin erikylkisyyttä. Lisäksi juuritunkeuman estämisen vaikutusta hitsien käyttäytymiseen tutkittiin täydentävällä koesarjalla, jossa tunkeuman muodostuminen estettiin levyjen väliin asetetulla volframilevyllä. Työn perimmäisenä tavoitteena oli selvittää syy aiemmassa tutkimuksessa havaitulle pienahitsien vaurioitumiselle leikkautumalla sularajaa pitkin. Sularajan suhteellista pituutta saadaan kasvatettua estämällä hitsin juuritunkeuma ja absoluuttista pituutta saadaan lisää kateettipoikkeaman avulla. Lisäksi tutkimuksessa oli tarkoitus tuoda esille suurlujuusteräksisen liitoksen eri mitoituslähtökohdat (mm. lämmöntuonnin kontrollointi). Tämän vuoksi hitsausparametrit mitattiin jännitteen ja virran hetkellisiin arvoihin perustuen, jolloin kuuma- ja pulssikaarihitsauksen laskennalliset hitsaustehot ovat vertailukelpoisia. Koehitseistä valmistettiin hieet hitsien tarkan geometrian määrittämiseksi ja liitoksen mekaaniset ominaisuudet tutkittiin vetokokeella. Tulosten perusteella sularajavaurio aktivoituu pulssikaarella hitsatuissa koekappaleissa. Tämä aiheutunee pulssi- ja kuumakaarihitsauksen sularajan mikrorakenteiden eroavaisuudesta. Sularajavaurio näyttää huonontavan hitsien muodonmuutoskykyä, mutta jatkokokeita tuloksen verifioimiseksi on tehtävä. S960QC-teräkselle ominaisen pehmenneen vyöhykkeen vaurio ei aktivoitunut, vaikka Ruukin antamat jäähtymisaikasuositukset ylitettiin reilusti.

Weld joint characteristics by nano-materials addition

The need for industries to remain competitive in the welding business, has created necessity to develop innovative processes that can exceed customer’s demand. Significant development in improving weld efficiency, during the past decades, still have their drawbacks, specifically in the weld strength properties. The recent innovative technologies have created smallest possible solid material known as nanomaterial and their introduction in welding production has improved the weld strength properties and to overcome unstable microstructures in the weld. This study utilizes a qualitative research method, to elaborate the methods of introducing nanomaterial to the weldments and the characteristic of the welds produced by different welding processes. The study mainly focuses on changes in the microstructural formation and strength properties on the welded joint and also discusses those factors influencing such improvements, due to the addition of nanomaterials. The effect of nanomaterial addition in welding process modifies the physics of joining region, thereby, resulting in significant improvement in the strength properties, with stable microstructure in the weld. The addition of nanomaterials in the welding processes are, through coating on base metal, addition in filler metal and utilizing nanostructured base metal. However, due to its insignificant size, the addition of nanomaterials directly to the weld, would poses complications. The factors having major influence on the joint integrity are dispersion of nanomaterials, characteristics of the nanomaterials, quantity of nanomaterials and selection of nanomaterials. The addition of nanomaterials does not affect the fundamental properties and characteristics of base metals and the filler metal. However, in some cases, the addition of nanomaterials lead to the deterioration of the joint properties by unstable microstructural formations. Still research are ongoing to achieve high joint integrity, in various materials through different welding processes and also on other factors that influence the joint strength.