Pilot-Scale Paper Machine
IntraMicron's Pilot Paper Machine
General Paper Machine Specifications: |
|
| Manufacturer | MARTCO, Inc |
| MO# | 13115 |
| Drawing# | 76E102 |
| Trim Width | 12 in |
| Max untrimmed width | 13 in |
| Speed Range | 4-50 fpm (20 typical) |
| Basis weight Range | 10-200 lbs / ft2 |
| Theoretical Cellulose Production | 750lbs / day |
| Theoretical Metal Production | 3000lbs / day |
In 2002, IntraMicron a pilot scale paper machine which was manufactured by Martco, Inc (now MTR) for Monsanto Corporation in 1979. Following acquisition the machine was installed and converted to a metal fiber product manufacturing machine. While it is still capable of running wood-fiber-based paper trials, the machine has been extensively modified and upgraded to produce premium metal fiber products. To achieve these results, eight months of extensive machine trials and modifications were required to convert from wood fiber to metal fiber. The base data for the metal fiber conversion was supplied by years of research and development. This machine, to our knowledge, is the most advanced metal fiber product production machine in use. The machine is now capable of producing a variety of non-wovens including a carbon-metal fiber product that is superior for filtering chemical agents, including those typically associated with terrorism.
Significant upgrades to state-of-the-technology support equipment and control systems were required during the engineering design and construction. Since this metal fiber process is proprietary, key elements will not be described. The following are process changes implemented on the base pilot paper machine:
- A new Yokogowa Distributed Control System (DCS) with computer HIS (Human Interface Station) was installed and programmed for control of this delicate process.
- A new 480 volt Motor Control Center (MCC) was installed with new breakers, distribution switches, and 14+ variable speed drives.
- A new 100 KW transformer was installed to supply electric power requirements.
- The drying steam controls were extensively upgraded with new automatic control valves and a new steam condensate collection tank.
- The existing 4 Hp (BHp) electric steam generator was rebuilt, and a 7 Hp electric steam generator was added.
- Newly modified headbox
- Fourdrinier with 2 vacuum dewatering elements, and new 3D Polymer wire
- Press section with 3 presses (with new top & bottom press felts)
- Main dryer section including one "Yankee" and three regular dryers (steam heated), each dryers temperature is individually controllable
- Spray bars for coating Yankee Dryer.
- New doctor blades and brackets to keep all the dryers clean
- Size press
- After dryer section with four more dryers (steam heated)
- Four roll calendar stack (one rubber, three steel)
- Reel
- New air compressor and drying unit
- All motors are on A/C Vector drives
- 6" TAPPI Standard Hand Sheet Mold
- 8" Hand Sheet Mold
- Hand Sheet Dryer
The associated auxiliary equipment included a stock preparation system with tanks, agitators, pumps, hydra-pulper, high-density pulper, refiner, appropriate sensors including several stock mass flow meters.