U.S. patent application number 16/249003 was filed with the patent office on 2019-07-18 for system for collecting and diluting pulp for analysis.
The applicant listed for this patent is Andritz Inc.. Invention is credited to Peter Antensteiner, Milind Karkare.
Application Number | 20190218715 16/249003 |
Document ID | / |
Family ID | 67212745 |
Filed Date | 2019-07-18 |
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United States Patent
Application |
20190218715 |
Kind Code |
A1 |
Antensteiner; Peter ; et
al. |
July 18, 2019 |
SYSTEM FOR COLLECTING AND DILUTING PULP FOR ANALYSIS
Abstract
A system and process for continuously extracting and diluting a
pulp sample from a pulp production line for the purpose of
conducting near real time analysis of pulp fibers while mitigating
the loss of production due to outdated sample data and the amount
of pulp extracted for analysis but not utilized. The system
comprises several inline mixers and pulp and dilution lines
configured to successively dilute an initial pulp sample for
analysis while collecting waste for re-concentration and
re-introduction into the production pulp line.
Inventors: |
Antensteiner; Peter;
(Lewisburg, PA) ; Karkare; Milind; (Decatur,
GA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Andritz Inc. |
Glens Falls |
NY |
US |
|
|
Family ID: |
67212745 |
Appl. No.: |
16/249003 |
Filed: |
January 16, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62618302 |
Jan 17, 2018 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D21F 7/00 20130101; D21F
1/08 20130101; D21G 9/0018 20130101 |
International
Class: |
D21F 1/08 20060101
D21F001/08; D21G 9/00 20060101 D21G009/00 |
Claims
1. A continuous serial pulp sample dilution system comprising: a
pulp source; a first sample conduit configured to transfer an
initial pulp sample from the pulp source to a first inline mixer; a
dilution fluid source; a first dilution conduit configured to
transfer a dilution fluid to the first inline mixer, wherein the
dilution fluid and the initial pulp sample mix in the first inline
mixer to create a first dilute pulp solution; a second pulp sample
conduit configured to transfer a portion the first dilute pulp
solution from the first inline mixer to a second inline mixer; a
first withdraw conduit configured to withdraw a remaining portion
of the first dilute pulp solution from the first inline mixer; a
second dilution conduit configured to transfer the dilution fluid
from the dilution source to the second inline mixer, wherein the
dilution fluid and the first dilute pulp solution mix in the second
inline mixer to create a second dilute pulp solution being more
dilute than the first dilute pulp solution; a third pulp sample
conduit configured to transfer a portion of the second dilute pulp
solution from the second inline mixer to a third inline mixer; a
second withdraw conduit configured to withdraw a remaining portion
of the second dilute pulp solution from the second inline mixer;
and a third dilution conduit configured to transfer the dilution
fluid from the dilution source to the third inline mixer, wherein
the dilution fluid and the portion of the second dilute pulp
solution in the third inline mixer mix to create a third dilute
pulp solution being at least 100 times more dilute than the initial
pulp sample.
2. The continuous serial pulp sample dilution system of claim 1
further comprising a fourth pulp sample conduit configured to
transfer a portion of the third dilute pulp solution from the third
inline mixer to a fourth inline mixer; a third withdraw conduit
configured to withdraw a remaining portion of the third dilute pulp
solution from the third inline mixer; a fourth dilution conduit
configured to transfer the dilution fluid from the dilution source
to the fourth inline mixer, wherein the dilution fluid and the
portion of the third dilute pulp solution mix in the fourth inline
mixer to create a fourth dilute pulp solution.
3. The continuous serial pulp sample dilution system of claim 1,
wherein the first, second, and third inline mixers are static
inline mixers.
4. The continuous serial pulp sample dilution system of claim 1
further comprising a measurement device configured to receive the
third dilute pulp solution from the continuous serial pulp sample
dilution system.
5. The continuous serial pulp sample dilution system of claim 4
further comprising a sample tank configured to receive the third
dilute pulp solution, wherein the measurement device is configured
to receive the third dilute pulp solution from the sample tank.
6. The continuous serial pulp sample dilution system of claim 4,
wherein the measurement device comprises a light microscope and a
video camera linked to a video display or similar fiber analyzing
equipment.
7. The continuous serial pulp sample dilution system of claim 1
further comprising a recirculation conduit fluidly communicating
with the first sample conduit and the pulp source, wherein the
recirculation conduit is configured to convey a portion of the
initial pulp sample from the first sample conduit back to the pulp
source or some other use.
8. The continuous serial pulp sample dilution system of claim 1
further comprising a pulp fluidly communicating with the pulp
sample dilution system and configured to convey the initial pulp
sample from the pulp source to the first inline mixer.
9. The continuous serial pulp sample dilution system of claim 1
further comprising a dilution pump fluidly communicating with the
pulp sample dilution system and configured to convey the dilution
fluid from the dilution source to the first inline mixer.
10. The continuous serial pulp sample dilution system of claim 1
further comprising dilution valves configured to selectively
restrict an amount of dilution fluid injected into the inline
mixers.
11. The continuous serial pulp sample dilution system of claim 1
further comprising a pulp valve configured to restrict an amount of
the initial pulp conveyed into the first inline mixer.
12. A continuous serial pulp sample dilution system comprising: a
pulp source; a first sample conduit configured to transfer an
initial pulp sample from the pulp source to a first inline mixer; a
dilution fluid source; a first dilution conduit configured to
transfer a dilution fluid to the first inline mixer, wherein the
dilution fluid and the initial pulp sample mix in the first inline
mixer to create a first dilute pulp solution; a second pulp sample
conduit configured to transfer a portion the first dilute pulp
solution from the first inline mixer to a second inline mixer; a
first withdraw conduit configured to withdraw a remaining portion
of the first dilute pulp solution from the first inline mixer; a
second dilution conduit configured to transfer the dilution fluid
from the dilution source to the second inline mixer, wherein the
dilution fluid and the first dilute pulp solution mix in the second
inline mixer to create a second dilute pulp solution being more
dilute than the first dilute pulp solution; a third pulp sample
conduit configured to transfer a portion of the second dilute pulp
solution from the second inline mixer to a third inline mixer; a
second withdraw conduit configured to withdraw a remaining portion
of the second dilute pulp solution from the second inline mixer; a
third dilution conduit configured to transfer the dilution fluid
from the dilution source to the third inline mixer; a fourth pulp
sample conduit configured to transfer a portion of the third dilute
pulp solution from the third inline mixer to a fourth inline mixer;
a third withdraw conduit configured to withdraw a remaining portion
of the third dilute pulp solution from the third inline mixer; and
a fourth dilution conduit configured to transfer the dilution fluid
from the dilution source to the fourth inline mixer, wherein the
dilution fluid and the portion of the third dilute pulp solution
mix in the fourth inline mixer to create a fourth dilute pulp
solution being at least 450 times more dilute than the initial pulp
sample.
13. The continuous serial pulp sample dilution system of claim 12
further comprising a measurement device configured to receive the
third dilute pulp solution from the continuous serial pulp sample
dilution system.
14. The continuous serial pulp sample dilution system of claim 13
further comprising a sample tank configured to receive the third
dilute pulp solution, wherein the measurement device is configured
to receive the third dilute pulp solution from the sample tank.
15. The continuous serial pulp sample dilution system of claim 13,
wherein the measurement device comprises a light microscope and a
video camera linked to a video display or similar fiber analyzing
equipment.
16. The continuous serial pulp sample dilution system of claim 12,
wherein the first, second, third, and fourth inline mixers are
static inline mixers.
Description
RELATED APPLICATION
[0001] This application claims the benefit under 35 U.S.C. .sctn.
119(e) to the provisional patent application number 62/618,302
filed on Jan. 17.sup.th, 2018, the entirety of which is
incorporated herein by reference.
BACKGROUND OF THE INVENTION
Technical Field
[0002] The present disclosure relates generally to fiber analysis
and more particularly to systems and processes for collecting and
diluting fibers for analysis in the pulp, paper, and nonwovens
industries.
Related Art
[0003] Pulp from lignocellulosic biomass is the primary ingredient
in many useful products. Pulp mill operators typically produce pulp
from raw materials in one of three ways, i.e. (1) through chemical
pulping, (2) through mechanical pulping, or (3) through a hybrid
approach using techniques from both chemical pulping and mechanical
pulping. Pulp mill operators may sell the pulp to various
downstream mill operators, who produce the pulp into useful
articles including for example paper of various qualities and
grades, tissue papers, packaging material, filler material, and
absorbent materials.
[0004] No matter the primary or secondary production process,
operators employ technicians to sample the pulp at various
production stages. These technicians evaluate the pulp's physical
and chemical qualities. This practice allows operators to infer
final product's quality; and, if needed, allows the operators to
adjust process conditions to obtain desired qualities.
[0005] Typically, operators pressurize the pulp in a pulp line, so
operators or technicians extract a small sample of pulp through a
burst nozzle to minimize pressure loss. The operators or
technicians then transfer the sample to a lab or other testing
facility. Analytical equipment producers typically calibrate their
analytical equipment to evaluate pulp samples at a specific
concentration. If the sample is too concentrated, the sample will
clog the equipment. If the sample is too dilute, the analysis
equipment will not return useful data. For example, a technician
may use an image analyzer configured to measure the average length
of pulp fibers. To do this effectively, the image analyzer, or the
person operating the image analyzer, should be generally able to
see and record the lengths of individual fibers.
[0006] The pulp sample from the pulp line is typically at a higher
concentration than the concentration at which the analytical
equipment functions. Therefore, technicians manually dilute the
sample to the desired concentration prior to testing. However, this
practice of collecting and preparing samples in batches can create
significant delay between collection, analysis, data
interpretation, and process condition adjustment. That is, the
samples tend to represent pulp that has passed through the process
possibly hours before. The represented pulp that was around the
burst nozzle at the time the technician took the sample may be
waiting in a storage vessel or may already be incorporated into a
final product by the time mill operators adjust process conditions
based upon the sample analysis. In extreme cases, if the sample
results indicate that the represented pulp did not meet mill or
customer standards, the product may be discarded or sold at a lower
price, thereby resulting in significant production loss.
[0007] In addition to batch samples not being representative of the
current pulp at the sample source, collecting samples in batches
increases the risk that a particular sample may not be
representative of the pulp. Whether due to human error,
contamination, or a mixing fluke, the batch sample may have never
represented the surrounding pulp, or an error in the testing
processes may have rendered the resulting data non-representative
of the pulp in the line. Therefore, the batch practice further
increases the risk that mill operator will adjust operating
conditions based upon inaccurate data, thereby potentially
producing an inferior product and resulting in production loss.
SUMMARY OF THE INVENTION
[0008] As can be seen, the batch testing practice creates a problem
of delay in extracting, analyzing, evaluating, and utilizing pulp
data to adjust process conditions. The batch practice also
increases the risk that decisions will be made based on upon
inaccurate data. To address these problems, Applicant has conceived
an exemplary serial pulp dilution system as more fully described
herein.
[0009] An exemplary continuous serial pulp dilution system may
comprise: a pulp source, a first sample conduit configured to
transfer an initial pulp sample from the pulp source to a first
inline mixer, a dilution fluid source, a first dilution conduit
configured to transfer a dilution fluid to the first inline mixer,
wherein the dilution fluid and the initial pulp sample mix in the
first inline mixer to create a first dilute pulp solution, a second
pulp sample conduit configured to transfer a portion the first
dilute pulp solution from the first inline mixer to a second inline
mixer, a first withdraw conduit configured to withdraw a remaining
portion of the first dilute pulp solution from the first inline
mixer, a second dilution conduit configured to transfer the
dilution fluid from the dilution source to the second inline mixer,
wherein the dilution fluid and the first dilute pulp solution mix
in the second inline mixer to create a second dilute pulp solution
being more dilute than the first dilute pulp solution, a third pulp
sample conduit configured to transfer a portion of the second
dilute pulp solution from the second inline mixer to a third inline
mixer, a second withdraw conduit configured to withdraw a remaining
portion of the second dilute pulp solution from the second inline
mixer, a third dilution conduit configured to transfer the dilution
fluid from the dilution source to the third inline mixer, a fourth
pulp sample conduit configured to transfer a portion of the third
dilute pulp solution from the third inline mixer to a fourth inline
mixer, a third withdraw conduit configured to withdraw a remaining
portion of the third dilute pulp solution from the third inline
mixer, and a fourth dilution conduit configured to transfer the
dilution fluid from the dilution source to the fourth inline mixer,
wherein the dilution fluid and the portion of the third dilute pulp
solution mix in the fourth inline mixer to create a fourth dilute
pulp solution being at least 650 times more dilute than the initial
pulp sample.
[0010] It is contemplated that previous attempts to create a
continuous dilution system may have been hindered by the amount of
water or other dilution fluid needed to dilute the pulp sample to
concentrations that analytical equipment could interpret. A
continuous analytical system has a continuous flow of sample into
the piece of analysis equipment at the desired concentration. For
example, if the analytical equipment is configured to process a
pulp sample at a concentration of 25 microliters (".mu.L") of pulp
per liter ("L") every minute ("min"), (collectively, 25 .mu.L/L per
min.) and if the technicians pulled a liter of initial pulp sample
having a 4% concentration every minute, the technicians would need
to use 1,600 L of dilution fluid every minute to dilute the initial
pulp sample to the desired concentration for the analysis
equipment.
[0011] Others may have been dissuaded from attempting a continuous
dilution system in the pulp and paper industries due to this
enormous amount of dilution fluid required and the considerable
amount of waste such a system would generate.
[0012] Without being bounded by theory, it is contemplated that the
stepwise or serial approach used by the exemplary systems and
processes described herein may allow operators or technicians to
collect pulp samples continuously while minimizing the amount of
water needed to dilute the initial sample. Furthermore, by
directing a portion of the diluted sample to a waste collection
tank after each dilution step, the exemplary systems and methods
described herein may mitigate dilution fluid waste.
[0013] Systems and processes in accordance with the present
disclosure may allow operators to "singularize" pulp fibers for
analysis, that is, the pulp sample may be brought to a low
consistency (e.g. about 0.0025% pulp fiber to dilution liquid) from
a pulp source, wherein the initial pulp sample from the source has
a consistency about 4% to about 6% pulp per dilution fluid.
[0014] It is contemplated that the systems and processes described
herein may allow operators to conduct near real-time analysis of
physical and chemical pulp properties while the pulp is still in
the production line and thereby allow mill operators to adjust
process conditions in response to the analysis to produce pulp,
paper, or other pulp-based products of desired quality.
[0015] Exemplary systems described herein may further obviate the
need for burst nozzles, or other wear parts configured to control
the egress of pulp from the pulp line for purposes of sample
collection. Pulp can be abrasive, and the pulp may wear on burst
nozzles over time, thereby resulting in production loss due to
leaking and shutdown for repair.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The foregoing will be apparent from the following more
particular description of exemplary embodiments of the disclosure,
as illustrated in the accompanying drawings. The drawings are not
necessarily to scale, with emphasis instead being placed upon
illustrating the disclosed embodiments.
[0017] FIG. 1 is a schematic representation of an exemplary pulp
sample dilution system comprising four inline mixers.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The following detailed description of the preferred
embodiments is presented only for illustrative and descriptive
purposes and is not intended to be exhaustive or to limit the scope
and spirit of the invention. The embodiments were selected and
described to best explain the principles of the invention and its
practical application. One of ordinary skill in the art will
recognize that many variations can be made to the invention
disclosed in this specification without departing from the scope
and spirit of the invention.
[0019] Similar reference characters indicate corresponding parts
throughout the several views unless otherwise stated. Although the
drawings represent embodiments of various features and components
according to the present disclosure, the drawings are not
necessarily to scale and certain features may be exaggerated in
order to better illustrate embodiments of the present disclosure,
and such exemplifications are not to be construed as limiting the
scope of the present disclosure.
[0020] Except as otherwise expressly stated herein, the following
rules of interpretation apply to this specification: (a) all words
used herein shall be construed to be of such gender or number
(singular or plural) as to circumstances require; (b) the singular
terms "a," "an," and "the," as used in the specification and the
appended claims include plural references unless the context
clearly dictates otherwise; (c) the antecedent term "about" applied
to a recited range or value denotes an approximation within the
deviation in the range or values known or expected in the art from
the measurements; (d) the words "herein," "hereby," "hereto,"
"hereinbefore," and "hereinafter," and words of similar import,
refer to this specification in its entirety and not to any
particular paragraph, claim, or other subdivision, unless otherwise
specified; (e) descriptive headings are for convenience only and
shall not control or affect the meaning or construction of any part
of the specification; and (f) "or" and "any" are not exclusive and
"include" and "including" are not limiting. Further, the terms,
"comprising," "having," "including," and "containing" are to be
construed as open-ended terms (i.e., meaning "including but not
limited to").
[0021] References in the specification to "one embodiment," "an
embodiment," "an exemplary embodiment," etc., indicate that the
embodiment described may include a particular feature, structure,
or characteristic, but every embodiment may not necessarily include
the particular feature, structure, or characteristic. Moreover,
such phrases are not necessarily referring to the same embodiment.
Further, when a particular feature, structure, or characteristic is
described in connection with an embodiment, it is submitted that it
is within the knowledge of one skilled in the art to affect such
feature, structure, or characteristic in connection with other
embodiments whether or not explicitly described.
[0022] To the extent necessary to provide descriptive support, the
subject matter and/or text of the appended claims is incorporated
herein by reference in their entirety.
[0023] Recitation of ranges of values herein are merely intended to
serve as a shorthand method of referring individually to each
separate value falling within the range of within any sub ranges
there between, unless otherwise clearly indicated herein. Each
separate value within a recited range is incorporated into the
specification or claims as if each separate value were individually
recited herein. Where a specific range of values is provided, it is
understood that each intervening value, to the tenth or less of the
unit of the lower limit between the upper and lower limit of that
range and any other stated or intervening value in that stated
range or sub range hereof, is included herein unless the context
clearly dictates otherwise. All subranges are also included. The
upper and lower limits of these smaller ranges are also included
therein, subject to any specifically and expressly excluded limit
in the stated range.
[0024] It should be noted that some of the terms used herein are
relative terms. For example, the terms "upper" and "lower" are
relative to each other in location, i.e. an upper component is
located at a higher elevation than a lower component in a given
orientation, but these terms can change if the device is flipped.
The terms "inlet' and "outlet" are relative to a fluid flowing
through them with respect to a given structure, e.g. a fluid flows
through the inlet into the structure and flows through the outlet
out of the structure. The terms "upstream" and "downstream" are
relative to the direction in which a fluid flows through various
components, i.e. the flow of fluids through an upstream component
prior to flowing through the downstream component.
[0025] The terms "horizontal" and "vertical" are used to indicate
direction relative to an absolute reference, i.e. ground level.
However, these terms should not be construed to require structure
to be absolutely parallel or absolutely perpendicular to each
other. For example, a first vertical structure and a second
vertical structure are not necessarily parallel to each other. The
terms "top" and "bottom" or "base" are used to refer to
locations/surfaces where the top is always higher than the
bottom/base relative to an absolute reference, i.e. the surface of
the Earth. The terms "upwards" and "downwards" are also relative to
an absolute reference; an upwards flow is always against the
gravity of the Earth.
[0026] FIG. 1 is a schematic representation of a preferred
embodiment of an exemplary serial pulp dilution system 100. The
exemplary serial pulp dilution system 100 comprises a pulp source
102 and a dilution fluid source 134. A first sample conduit 108 has
a first end 103 engaging the pulp source 102 and a distal end 113
engaging a feed end 109 of a first inline mixer 110. In this
manner, the first sample conduit 108 fluidly communicates with the
pulp source 102 and the first inline mixer 110 and is thereby
configured to convey an initial pulp sample 115 from the pulp
source 102 to the first inline mixer 110. Similarly, a first
dilution conduit 128.sub.a has a first end 133 engaging the fluid
source 134 and a distal end 143 engaging the feed end 109 of the
first inline mixer 110. In this manner, the first dilution conduit
128.sub.a fluidly communicates with the fluid source 134 and the
first inline mixer 110. The first dilution conduit 128.sub.a is
thereby configured to convey a dilution fluid 125 from the fluid
source 134 to the first inline mixer 110. Unless otherwise
specified, "conduits" are understood to have a first end (see for
example, 103, 135, and 145), and a distal end (see for example 113,
137, and 147) distally disposed from the first end. The respective
ends engaging separate elements (for example, the pulp source 102,
first inline mixer 110, withdraw line tank 124, etc.) in the
exemplary system 100 allow the conduits to fluidly communicate with
the named elements and thereby convey a substance (for example an
initial pulp sample 115, dilute pulp solutions 127, 160, 170, 180,
dilution fluid 125, etc.) between the named elements.
[0027] In operation, the first sample conduit 108 conveys an
initial pulp sample 115 from the pulp source 102 to the first
inline mixer 110. The pulp source 102 may be any source of pulp and
may include pulp lines in a pulp mill, or a tank of pulp in a
laboratory for example. It is contemplated that the exemplary
serial pulp dilution system 100 may be disposed at several
locations in a pulp mill and may be configured to tap a pulp line
at several locations along a pulp line to evaluate changing
characteristics of the pulp fibers as the fibers progress through
the production process.
[0028] If desired, operators may tap a pulp source 102 continuously
for an initial pulp sample 115. A pump 104 pumps the initial pulp
sample 115 through the first sample conduit 108. The pump 104 may
be configured to pump the initial pulp sample 115 through the
entire serial pulp dilution system 100 together with a dilution
pump 138 if desired. The system 100 further comprises a first valve
V1 through which operators may control the rate at which the
initial pulp sample 115 enters the first inline mixer 110.
[0029] The initial pulp sample 115 desirably moves through the
first sample conduit 108 as a slurry. The consistency of the
initial pulp sample 115 may vary depending upon the production
process and the type of pulp produced. In certain exemplary
processes, the initial pulp sample 115 may be a low consistency
pulp sample in which about 10 percent of the initial pulp sample
115 is pulp fibers, the remainder being dilution fluid 125. In
other exemplary systems and processes, the initial pulp sample 115
may be diluted to having a 10 percent pulp fiber concentration
prior to entering the serial dilution system 100.
[0030] The exemplary serial pulp dilution system 100 may further
comprise a recirculation conduit 106 fluidly communicating with the
first sample conduit 108 and the pulp source 102. The recirculation
conduit 106 transports a portion of the initial pulp sample 117
from the first sample conduit 108 back to the pulp source 102. By
returning excess initial pulp sample 117 to the pulp source 102,
the recirculation conduit 106 reduces production loss due to
continuous sample collection.
[0031] A first inline mixer 110 disposed downstream of the pulp
source 102 has a discharge end 111 distally disposed from the feed
end 109 along a body 105. Several baffles 107 are disposed within
the body 105. The inline mixers 110, 120, 130, and 140 may be
static inline mixers, meaning that the baffles 107 are static and
that the initial pulp sample 115, and portions of the first dilute
pulp solution 127.sub.a, second dilute pulp solution 160.sub.a,
third dilute pulp solution 170.sub.a, and fourth dilute pulp
solution 180.sub.a (collectively, "pulp sample") mix along the
length of each inline mixer 110, 120, 130, 140 due to the flow of
the pulp sample through the inline mixers 110, 120, 130, and 140
and the turbulence created by the baffles 107. Static inline mixers
may be preferable because the static inline mixers do not require
an external power source to mix the pulp samples.
[0032] However, in other exemplary embodiments, the inline mixers
110, 120, 130, and 140 may be dynamic inline mixers characterized
by having mixing elements (e.g. baffles, mixing arms, rotary
blades, or other elements disposed in the inline mixer 110, 120,
130, and 140 configured to impart turbulent forces on a pulp sample
disposed within the inline mixer) configured to move in response to
an external force, for example, an external power source or the
force of the pulp sample on the mixing elements.
[0033] In the first dilution step 165, the initial pulp sample 115
and the dilution fluid 125.sub.a mix in the initial inline mixer
110 to create a first dilute pulp solution 127. In certain
exemplary processes, ten parts dilution fluid 125.sub.a may be
added per one part of initial pulp sample 115. For example, if the
initial pulp sample 115 and dilution fluid 125 flow through the
system 100 in liters per minute ("L/min"), operators can introduce
the initial pulp sample 115 into the first inline mixer 110 at a
rate of 1 L/min. Similarly, operators may introduce the dilution
fluid 125.sub.a into the first inline mixer 110 at a rate of 10
L/min.
[0034] A portion of the first dilute pulp solution 127.sub.a,
typically having a pulp concentration of about 1% or less, flows
from the first end 135 to the distal end 137 of a second pulp
conduit 112 and thereby enters the feed end of a second inline
mixer 120. The first end 135 of the second pulp conduit 112 engages
the discharge end 111 of the first inline mixer 110 while the
distal end 137 engages the feed end 119 of the second inline mixer
120. The second inline mixer 120 is disposed downstream of the
first inline mixer 110 and has a discharge end 121 distally
disposed from the feed end 119 along a body 105.
[0035] A first withdraw conduit 114 engages the first inline
mixer's discharge end 111 at the first withdraw conduit's first end
145. The first withdraw conduit's second end 147 engages a withdraw
line tank 124. The remaining first dilute pulp solution 127.sub.b
flows through the first withdraw conduit 114 away from the serial
pulp dilution system 100. In certain exemplary processes, the
remaining first dilute pulp solution 127.sub.b may flow away from
the serial pulp dilution system at a rate of about 10 L/min. In
this manner, the first withdraw line 114 fluidly communicates with
the first inline mixer 110 and is configured to withdraw the
remaining portion of the first dilute pulp solution 127.sub.b. As
with all remaining portions of the dilute pulp solutions
(127.sub.b, 160.sub.b, 170.sub.b) the remaining portion of the
first dilute pulp solution 127.sub.b may be discarded. In other
exemplary embodiments, the remaining portion of the dilute pulp
solution 127.sub.b, 160.sub.b, 170.sub.b may be re-concentrated and
reintroduced into the pulp process line (see 102) to mitigate
waste.
[0036] In the second dilution step 175, additional dilution fluid
125.sub.b flows through a second dilution conduit 128.sub.b into
the feed end 119 of the second inline mixer 120. The second
dilution conduit 128.sub.b has a first end 133 and a distal end 155
distally disposed from the first end 133. The distal end 155
engages the feed end 119 of the second inline mixer 120. In certain
exemplary processes, the additional dilution fluid 125.sub.b may be
introduced into the second inline mixer 120 at a rate of about 10
L/min.
[0037] In the second inline mixer 120, the additional dilution
fluid 125.sub.b and the portion of the first dilute pulp solution
127.sub.a mix to create a second dilute pulp solution 160. A
portion of the second dilute pulp solution 160.sub.a, typically
having a pulp concentration of less than about 0.1%, flows through
a third pulp conduit 118 into a third inline mixer 130 disposed
downstream from the second inline mixer 120. The third pulp conduit
118 has a first end 142 engaging the discharge end 121 of the
second inline mixer 120 and a distal end 146 engaging the feed end
129 of the third inline mixer 130. The third inline mixer 130
comprises a feed end 129 distally disposed from a discharge end 131
along a body 105.
[0038] The remaining portion of the second dilute pulp solution
160.sub.b flows through a second withdraw conduit 116 into a
withdraw tank 124. A first end 144 of the second withdraw conduit
116 engages the discharge end 121 of the second inline mixer 120. A
distal end 157 of the second withdraw conduit 116 engages the
withdraw tank 124. In certain exemplary processes, the remaining
portion of the second dilute pulp solution 160.sub.b may flow away
from the exemplary serial pulp dilution system 100 at a rate of
about 10 L/min.
[0039] Similarly, in the third dilution step 185, a further
dilution fluid 125 flows through a third dilution conduit 128 into
the feed end 129 of the third inline mixer 130. This further
dilution fluid 125 may be introduced into the third inline mixer
130 at a rate of about 10 L/min. The third dilution conduit 128 has
a first end 133 and a distal end 148 distally disposed from the
first end 133. The distal end 148 engages the feed end 129 of the
third inline mixer 130.
[0040] The further dilution fluid 125 and the portion of the second
dilute pulp solution 160.sub.a mix in the third inline mixer 130 to
create a third dilute pulp solution 170. A portion of the third
dilute pulp solution 170.sub.a, typically having a pulp
concentration of less than 0.01%, flows through a fourth pulp
conduit 126 into a fourth inline mixer 140 disposed downstream from
the third inline mixer 130. The fourth pulp conduit 126 has a first
end 154 engaging the discharge end 131 of the third inline mixer
130 and a distal end 158 engaging the feed end 139 of the fourth
inline mixer 140. The fourth inline mixer 140 comprises a feed end
139 distally disposed from a discharge end 141 along a body 105.
The remaining portion of the third dilute pulp solution 170.sub.b
flows through third withdraw conduit 122 into a withdraw tank 124.
A first end 152 of the third withdraw conduit 122 engages the
discharge end 131 of the third inline mixer 130. A distal end 167
of the third withdraw conduit 122 engages the withdraw tank 124.
The remaining portion of the third dilute pulp solution 170.sub.b
may flow away from the serial pulp dilution system 100 at a rate of
about 10 L/min. in certain exemplary processes.
[0041] Likewise, in a fourth dilution step, still further dilution
fluid 125.sub.d flows through a fourth dilution conduit 128.sub.d
into the feed end 139 of the fourth inline mixer 140. The fourth
dilution conduit 128.sub.d has a first end 133 and a distal end 156
distally disposed from the first end 133. The distal end 156
engages the feed end 139 of the fourth inline mixer 140. The still
further dilution fluid 125.sub.d and the portion of the third
dilute pulp solution 170.sub.a mix in the fourth inline mixer 140
to create a fourth dilute pulp solution 180. The fourth dilute pulp
solution 180 flows through a fifth pulp conduit 132 into a
measurement device 136 disposed downstream from the fourth inline
mixer 140. The fifth pulp conduit 132 has a first end 162 engaging
the discharge end 141 of the fourth inline mixer 140 and a distal
end 164 engaging the measurement device 136. In this manner, the
initial pulp sample 115 may be extracted from pulp source 102
continuously and diluted by a factor of more than 1,500 prior to
entering the measurement device 136. In other exemplary
embodiments, the initial pulp sample 115 may be diluted 2,000 times
or more prior to entering the measurement device 136. Depending
upon the application, an exemplary serial pulp dilution system 100
may dilute the initial pulp sample 115 by 100 times or more, 450
times or more, 500 times or more, or 650 times or more.
[0042] In certain exemplary embodiments, the measurement device 136
may be a light microscope attached to a video camera and a monitor.
The fourth dilute pulp solution may flow into the measurement
device 136 at a rate of about 11 L/min. The light microscope and
video camera may be configured to record the fourth dilute pulp
solution 180 passing under the microscope and display the recording
on the display. In this manner, operators may visually evaluate
physical properties of the pulp fibers.
[0043] In other exemplary embodiments, the measurement device 136
may be an image analyzer.
[0044] Operators may control the rate at which dilution fluid 125
enters the several inline mixers 110, 120, 130, 140 using a series
of valves V2-V6 disposed along the dilution conduit 128. In FIG. 1,
V6 is the master valve. Operators may use V6 to control the access
of dilution fluid 125 to all inline mixers 110, 120, 130, 140. V2
is disposed within the first dilution conduit 128.sub.a, V3 is
disposed within the second dilution conduit 128.sub.b, V4 is
disposed in the third dilution conduit 128, and V5 is disposed
within the fourth dilution conduit 128.sub.d. Operators may control
the rate of dilution into the respective inline mixers 110, 120,
130, 140 using the respective valves V2-V5.
[0045] It is contemplated that in certain exemplary systems and
processes, the initial pulp sample 115 may be extracted, diluted,
and sent to a measurement device 136 in as little as three to five
minutes after leaving the pulp source 102. Depending upon the
processing speed of the measurement device 136, operators may
obtain near real time data analysis of an active pulp line.
[0046] While the invention has been described in connection with
what is presently considered to be the most practical and preferred
embodiment, it is to be understood that the invention is not to be
limited to the disclosed embodiment, but on the contrary, is
intended to cover various modifications and equivalent arrangements
included within the spirit and scope of the invention.
* * * * *