The Developers of the New Millennium Paper Coating and Sizing Technology
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The Developers of the New Millennium Paper Coating and Sizing Technology
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FOR IMMEDIATE RELEASE
Directors announce preliminary results from high speed pilot tests in Finland
We are happy to report that the latest pilot tests in sizing board grade papers have been a great success with consequences. The preliminary test results confirm that we can now make a film press quality starch layer on paper surface at any desired starch loading level and at the same time even control the starch CD profile. This revolutionary process offers the paper makers a major high return investment opportunity. Discussions with the potential clients have started.
USPTO issued the patent US Patent 7,217,342, see the announcement below.
USPTO has just confirmed a new patent for Dryad Technology. This patent covers low pressure spray forming of the paper substrate itself including sizing, coating, and other treatments.
In addition to paper re-surfacing the spray technology offers also an opening to a revolutionary technology to manufacture engineered paper and board grades layer by layer in a continuous flow. First the paper or board substrate is formed by spraying the fibers at up to 5% solids making one or several fiber layers with same or different composition. All existing paper machines can be retrofitted to this spraying processes. Regardless how the substrate is formed the process continues with spray filling, spray sizing and spray coating with final touch through moisture spray profiling as is done today. It is noteworthy that spraying allows profiling at each phase. This integrated spraying process affords flexible customizing per client requirements and will be the most economical way of paper production in the future. Stay tuned.
Dryad Technology, Inc., received a joint US Patent No. 6,969,012 together with VIB Systems GmbH (VIB), Germany. This patent describes a spray nozzle that was developed from the existing VIB's re-moisturizing nozzle that is known worldwide as the premier nozzle for re-moisturizing and profiling applications. By late 90's Dryad team had concluded that markets did not have a well suited nozzle for it's technology. The high pressure nozzles tested already in early 1970's worked best, but in final analysis they were inadequate in 24/7 continuous production. However, a re-moisturizing nozzle manufactured by VIB offered the most promising nozzle concept to be developed further. A joint effort was initiated to see the merits of this specific nozzle in both sizing and coating applications and to recommend changes if tests were successful. The result was this patent application. Unfortunately this joint effort was cut short for coating development, causing regrettable further delays for the overall development.
Dryad Technology, Inc., has exclusive rights to US Patent No. 6,866,207 covering all applications related to paper and board manufacturing. The shown multipurpose nozzle structures project a powerful but controlled mini-tornado tangentially to disperse all liquids entering it's dispersion zone. The strength of this tornado can be increased to such level that it will disperse practically all liquids or even liquids containing solid particles to mist while maintaining stable and to some extent dynamically controllable spray pattern (including even the solid particles). The requirements for a coating color nozzle are presented in our recent article in Paperi ja Puu (1/2006).
In paper sizing solids up to 15%+ can be sprayed easily and in coating most currently used coating colors can be used though we expect the paper industry to develop a multitude of new coating colors for this technology like is has developed for air knife and blade coating systems. The nozzle materials and the optional third channel solves the past plugging problems in this highly desired low pressure environment. The superior efficiency in dispersion will make this nozzle competitive also for the paper re-moisturizing applications.
As this nozzle can spray solid particles mixed with liquids it is also suitable for paper manufacturing from fiber suspensions up to 5%+ in solids. The high solids paper manufacturing was tried already 30 years ago in Finland by using a special Head Box as a "single nozzle". To accomplish this goal would mean major energy use reduction in paper making, and at the same time the water consumption of the process would be reduced to a fractional level from the present.
The instant complete mixing is also highly desired property in combustion applications as this would allow to lower the combustion air amount in the furnish while still maintaining the complete combustion. In many cases this would offer a sizeable fuel savings opportunity. Also with increasing fuel prices and environmental concerns the ability to mix refined small solid particles like rubber or wood waste with fuels are becoming increasingly interesting.
It is also ideal to all applications where high evaporation or distillation separation rates are desired with lowest possible thermal energy use. Water evaporation plants and also the new ethanol plants should benefit from this. It's powerful dispersion or "atomizing" impulse could also be used as a chemicals mixer in special applications.
It could also be used also in automatic fire extinguishing systems by using plain CO2 gas to generate the dispersion force for the water. This nozzle is also suitable for snow making machines to extend the ski season on slopes and also inside the ski tubes.
Dryad received final approval for their Canadian Patent 2,148,505 covering the method for paper surface smoothening in combination of paper coating with spray technology.
The DRYAD surface treatment Beta-test trials on a U.S.-based pilot machine were successfully completed during the week of September 30 – October 5, 2002. The low-pressure spray test-unit applied both sizing and sizing combined with pigmentation on a linerboard substrate. The test applicator performed as expected and we were ready to move forward to the next development stage.- click for the SEM pictures.