Abstract:
A screen plate for a cellulosic material puling vessel, the screen plate including: slots having curved inlet corner edges adjacent an inside surface of the screen plate and facing a pulp flow.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/880,959 filed Jan. 18, 2007, the entirety of which is incorporated by reference. 
         [0002]    The present application is generally directed to making pulp and is more specifically directed to screen assemblies for pulp digesters. 
         [0003]    Wood chips and other cellulosic fibrous material are treated in digesters to chemically separate fibers in the chips and material by, for example, removing lignins. A digester is a vessel in which wood chips are treated with heat, liquid, and chemicals to convert the chips to pulp. A continuous digester vessel is typically an upright cylinder with an upper inlet to receive chips in a continuous flow. The chips flow slowly through the digester vessel, 100 to 300 feet tall (30 to 100 meters) in a generally downward direction. 
         [0004]    As the chips move through the continuous digester, the lignins binding fibers together in the chips release the fibers and the chips are converted to pulp. The pulp is removed through a bottom outlet of the digester. Chips are continually added to a continuous digester while the chips already in the digester vessel are processed and pulp is discharged from the bottom of the vessel. In a batch digester, chips are first loaded in a vessel, the loaded chips are processed as a batch and thereafter the processed chips are discharged to empty the vessel. In a batch digester the chips tend to remain in substantially the same location in the vessel. 
         [0005]    Chemicals, e.g., cooking liquor, in a digester process the chips, cause lignins to unbind fibers and convert the chips to pulp. The chemicals are included in cooking liquor that is continuously pumped into and out of batch and continuous digesters. Screen plates are used in conventional digesters for the production of chemical cellulose pulp, e.g. kraft pulp, for both continuous and batch digesters. Screen plates are filters that allow liquor to be extracted from a digester but prevent the extraction of fibrous material. Screen plates are generally arranged around an inner circumference of a digester. An inner surface of the plate is exposed to the chip slurry in the digester and an outer surface of the plate forms a wall to a liquor extraction chamber. The screen plate may have multiple rows of narrow slots through which liquor (but not fiber) is extracted from the chip slurry and flows into the extraction chamber. 
         [0006]    The slots in screen plates tend to clog or plug with fibers and have been a source of a decrease in pulp process quality. Various types of slot designs have been developed to reduce the tendency of clogging and plugging. For example, orienting the slots diagonally to the vertical axis and horizontal planes of the digester has been found to reduce clogging and plugging of slots. See U.S. Pat. No. 6,165,323. However, clogging and plugging of the diagonal slots still occurs and there continues to be a long felt need for devices that further reduce the tendency of slot clogging and plugging. 
         [0007]    A concern has arisen that chips in a digester clog the slots of a digester screen. Slots are narrow to block chips from being withdrawn from a digester along with the cooking liquor. While narrow, there is a risk that chips become logged in slots. This risk is relatively large with vertical slots in a continuous digester where chips move in the same direction of the slots. This risk is decreased with diagonal slots in which chips move vertically and at an angle with respect to the slots. As chips move across the diagonal slots, the chips may catch on the slots and clog the slots. 
         [0008]    There is a long felt need for slots, especially diagonal slots, in a screen plate that have reduced risk of being clogged or plugged by chips. The need arises from the difficulties that occur when chips clog slots and prevent the flow of cooking liquor through the screen and out of the digester. While the need is greatest with respect to continuous digesters, there is also a need for clog free slots in screen plates for batch digesters, especially for diagonal screen plates. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0009]    A novel screen plate has been developed comprising slots having curved inlet edges to minimize chips begin caught on the edges and deflect chips into the pulp flow. The curved inlet slot edges are adjacent an inside surface of the screen plate and face the pulp flow. The curved inlet slot edges may be rounded, sloped or inclined. For example, inlets may have a generous radius of curvature equal to one third to two thirds the thickness of the plate. The curved inlets may be only on the lower side surface of a slot or on the upper and lower slot side surfaces. A curved inlet only on the lower side surface is suitable for a continuous digester in which the pulp flow is generally downward and chips tend to impinge on the inlet edge of the lower sides of slots. Curved inlets on both the upper and lower side surfaces of slots is suitable for both continuous and batch digesters. In addition, the lower side surface of the slot may be horizontal in cross-section or be inclined upward from the inside surface of the plate to the outer surface. Such a horizontal or upwardly inclined lower slot surface tends to deflect chips in the slot out of the slot and into the pulp stream. 
         [0010]    A screen plate for a cellulosic material puling vessel, the screen plate including: slots having curved inlet corner edges adjacent an inside surface of the screen plate and facing a pulp flow. 
         [0011]    A screen plate assembly has been developed for a continuous digester vessel for pulping cellulosic material, the assembly comprising: a plurality of screen plates for a cellulosic material puling vessel, each plate having a arc shape in cross-section, and said screen plates being assembled to form an annulus attached to an inside surface of the digester vessel, and each screen plate including slots having curved inlet corner edges adjacent an inside surface of the screen plate and facing a pulp flow. 
         [0012]    A method has been developed for extracting a liquid from a continuous digester vessel, the method comprising: processing cellulosic material and a liquid in the vessel, wherein the cellulosic material flows through the vessel until the material is discharged from a discharge output of the vessel; extracting a portion of the liquid through a screen plate assembly, wherein the screen plates are assembled to form an annulus attached to an inside surface of the digester vessel, and each screen plate includes slots having curved inlet corner edges adjacent an inside surface of the screen plate and facing a pulp flow, and deflecting cellulosic material flowing through the vessel with the curved inlet corner edges to avoid the material become caught in the slots. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a front view of a conventional continuous digester shown schematically and partially cut away. 
           [0014]      FIG. 2  is a front view of a conventional inner screening assembly and wall of the digester shown schematically. 
           [0015]      FIG. 3  is a front view of several assembled screen plates in a conventional screening assembly. 
           [0016]      FIGS. 4 and 5  are front and back views, respectively, of a portion of a conventional screen plate. 
           [0017]      FIG. 6  is a partial cross-section of a conventional screen plate taken along line  6 - 6  in  FIG. 5 . 
           [0018]      FIG. 7  is a front view of a first embodiment of a screen plate having diagonal slots with curved, e.g., rounded, inlet edges. 
           [0019]      FIG. 8  a cross-sectional side view of the first embodiment of a screen plate, where the view is taken along line  8 - 8  in  FIG. 7 . 
           [0020]      FIG. 9  is a front of a second embodiment of a screen plate having diagonal slots with rounded inlet edges. 
           [0021]      FIG. 10  a cross-sectional side view of the first embodiment of a screen plate, where the view is taken along line  10 - 10  in  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0022]      FIG. 1  is a side view of a continuous vertical digester  10  for processing cellulosic fiber material, e.g., wood chips, into fiber pulp. Though a vertical continuous digester is shown, the screen plates and screen slots described herein are applicable to other types of cylindrical continuous and batch digesters. While the novel screen plates disclosed herein are shown in the context of a continuous digester, the screen plates are applicable to batch digesters. 
         [0023]    A slurry of comminuted cellulosic fibrous material and cooking chemical is introduced at the top  12  of the digester and a slurry of fully-cooked pulp and spent cooking liquor is discharged at the bottom  14 . The digester  10  comprises a cylindrical shell  16  that typically forms a column of, for example, 100 feet (30 meters) tall. Within the cylindrical shell are several cylindrical screen assemblies  18 . 
         [0024]      FIG. 2  is an inside view of a screen assembly  18  having an multiple elevations of cylindrical screen sections  20 . The screens may include screen plates  22  assembled to form the cylindrical screen section. The screen plates are attached to a frame  24  on the inner wall of shell  16 . The frame  24 , for example, comprises metal bars, angle irons, or like structural elements which are connected directly to the digester outer shell  16 , although the frame  24  may be distinct and detachable from the digester. Each screen section forms generally an annular ring around the inside wall of the cylindrical shell  16  of the digester  10 . 
         [0025]      FIG. 3  is a schematic diagram of a portion of a screen section  20  in a screen assembly  18 . The section includes an array of metal screen plates  26 . Each plate has rows of trapezoidal screen slot regions  34  (shown schematically in  FIG. 3 ). These slot regions define rows of screen slots, such as the slot rows  34  shown in  FIGS. 4 and 5 . Between the slot regions  34  on a screen plate are land areas  38  that are parallel to the slot regions. 
         [0026]    The slot regions  34  are shown as horizontal rows in  FIG. 3  and as vertical columns in  FIG. 2 . The orientation of the slot regions may vary from digester to digester; from screen assembly to assembly in a single digester; from screen section to screen section, and from slot region to slot region in a single screen section or screen plate. While the slot regions  34  are generally oriented vertically or horizontally, they may also be arranged on a diagonal with respect to the digester. 
         [0027]    The screen plates have narrow slots or apertures (collectively referred to as slots) that extend through the thickness of the plate  26  and allow liquor, but not fibers, to pass through the plates. The slots may be arranged in various orientations such as vertically, horizontally, or at an oblique angle, such as at a 45-degree angle from the vertical. Diagonal slots have been found to be more resistant to becoming clogged/plugged with fibers, that are vertical and horizontal slots. 
         [0028]    An annular chamber  28  for collecting the liquor is generally behind each screen assembly  18 . Liquor is withdrawn through each screen from the flow (F) of the pulp slurry moving generally downwardly through the digester. Beneath each annular chamber  28  are generally smaller annular cavities  30 , commonly referred to as “internal headers”, for collecting the liquor from the chambers  28 . Liquor collected in the cavities  30  is discharge through liquor removal conduits  32 . Though these chambers and cavities are shown as being located internal to the shell  16 , they may also be located external to the shell, that is, “external headers” may be used. 
         [0029]    The screen assembly  18  is shown as having a continuous cylindrical screen surface formed of a screen plate  26 , where the plate has sections, e.g., rows, of screen slots. However, the screen surface may not be continuous or cylindrical. For example, the screen surface may also comprise multiple individual circular screens, or the screen surface may comprise alternating screen surfaces and blank plates, commonly referred to as a “checker board pattern”. More than one such screen assembly  18  can be used in the same digester vessel  10 . Further, the screen assembly may be tapered such that the diameter of the bottom of the screen assembly may be greater than the diameter at the top. Tapered screen assemblies may be used to span a region of increasing diameter in the digester vessel. 
         [0030]    Each screen assembly  18  is shown as having a screen sections with multiple screen plates, for example three elevations, e.g., upper, middle and lower. The number of screen plates  26  in each section  20  and assembly  18  may vary from assembly to assembly in a single digester, and from digester to digester. The width of the slots in the screen plate can be, for example, in a range of 3 mm to 9 mm. Further, the slot shape, sizing and orientation in each section  20  screen plates may vary. For example, the width of slots in the upper section may be approximately 3 mm to 4 mm, which may be narrower than the width of the slots in the middle section, e.g. approximately 4-5 mm. Similarly, the width of slots in the middle section may be narrower than the width of slots in the lower section, e.g. approximately 5-6 mm. By using slots of increasing width at lower screen in a screen assembly  18  is believed to reduce the tendency of the slots to clog with fibers from the pulp slurry. Moreover, the length of the slots in a screen plate may be uniform, even from one section to another section. 
         [0031]    As shown in  FIG. 4 , the slots regions  34  shown in the screen plate  38  are diagonal and form an angle (α) with respect to horizontal. The orientation of the slots may vary from digester to digester; from screen assembly to assembly in a single digester; from screen section to screen section, and from row to row of slots in a single screen or screen plate. 
         [0032]    Individual machined slots  40  generally form a horizontal row that comprise a slot region  34 .  FIG. 4  shows an outer surface  42  of the screen plate  26 , where the outer surface faces the liquor chamber  30 .  FIG. 5  shows an inner surface  44  of the screen plate  26 , where the inner surface faces the chip slurry in the digester vessel. The screen plates are secured to the frame  28  by pins  46  that extend through pin holes  48  in the plate. Several pin and pin holes may be used to secure each screen plate  26  to the frame  28 . 
         [0033]    Each of the schematically illustrated slots  40  are diagonal and are oriented at an angle alpha α with respect to the vertical axis or a horizontal plane of the digester vessel. While slots may be aligned vertically or horizontally with respect to the pulp flow (F) direction, diagonal slots are less prone to clogging/plugging. The slot angle at ( FIG. 4 ) may be between 30 to 60 degrees, and is preferably about 45 degrees. The slot angle is the angle formed by the axis of the slot parallel to the plate with respect to a vertical axis of the vessel. 
         [0034]    Each of the slots  40  is spaced from an adjacent slot by a horizontal distance  50  of about one inch, e.g., between 0.75-1.5 inches. Each of the slot regions  34  has a vertical dimension  52  of between 1.5 to three times the distance  50  between adjacent slots  40 . 
         [0035]    The land areas  38  have a vertical dimension  54 , which preferably is approximately equal to the slot  40  vertical dimension  52 , e.g. about two inches. Preferably the slot vertical (or horizontal) dimension  52  for each of the slot region (row)  34  and the vertical (or horizontal) dimension  54  for the land areas  38  are substantially the same in any particular screen plate, although under some circumstances they may vary. Also, preferably the slot angle at is the same for all the slots  40  from one slot region  34  to the next in a screen plate, although again there may be variations from region to region. Also preferably all of the slot regions  34  within a given screen plate  26  have the same orientation, but from one screen plate  26  to the next, vertically, the slots  40  may have opposite orientations (that is for one screen plate the slots  40  may slant up left to right from top to bottom, and the other right to left from top to bottom). 
         [0036]    As shown in  FIG. 6 , the slots  40  in each slot region  34  have a narrow opening at the inner surface  44  of the plate  36  and a wide opening at the outer surface  42  of the plate. The width (W) of a slot may be taken the narrow dimension of the slot, as compared to the length (L) of the slot (as shown in  FIG. 4 ). The thickness (T) of the slot is the thickness of the plate  36 . If the slot is tapered along its thickness (T), the angle of the taper may be beta (β) ( FIG. 6 ), e.g., 30 degrees. In a specific embodiment, the width (W) may be measured at the narrowest opening of the slot, such as at the outer surface  42  of the plate  36 . Generally, all slots  40  in a slot region  34  (and even in a screen plate) have uniform widths (W), lengths (L), thicknesses (T) and tapers (β). However, the slot width (W) may vary from slot region to region, from screen plate to plate, and/or from screen section to screen section within a screen assembly. 
         [0037]      FIGS. 7 and 8  are a front and a cross-sectional side views, respectively, of a first embodiment of a screen plate  50  having diagonal slots with rounded inlet edges. The screen plate shown in  FIGS. 7 and 8  are most suitable for continuous digesters in which the pulp slurry moves past the slots in a downward direction. The plate  50  may also be applied in a batch digester. The slots  52  are diagonal and arranged in rows of slot regions  54 . Chips  56  in a pulp slurry flow in a direction (F) generally downward in a continuous digester and may be generally stationary in a batch digester. An inside surface  58  of the plate faces the flow (F) of chip and an outside surface  60  faces the liquor collection chambers. The width (X) of the slots at their throat is the narrowest section of the slot. The width (X) may be, for example, 2 to 9 millimeters. 
         [0038]    A lower side  62  of each slot extends the length of the slot and is on the downstream side of the slot with respect to the flow (F) direction. The lower side has a curved inlet  64  which may be, for example, rounded, angled, sloped, chamfered, beveled and slanted. The curved inlet  64  is less susceptible to catching chips  56  in the pulp flow (F). Sharp inlet edges, especially the edges of the lower side of slots, found on prior art slots are more likely to catch chips and thus allow chips to clog the slot. The curved inlet  64  on the slot shown in  FIGS. 7 and 8 , and especially on the lower side of the slot, tends to deflect chips back into the flow (F) and away from the slot. 
         [0039]    The curvature of the slot inlet may be defined by a radius of the curvature. The radius may be, for example, one-third to two-third of the thickness (T) of the plate. In view of the curved inlet, the narrowest region of the slot (X) may be inward of the inlet  64 . The narrowest region may be a throat just beyond the inlet and between the inner surface  58  and outer surface  60  of the plate. 
         [0040]    The lower side surface  64  of each slot  52  may form an inclination angle (ω) of between zero to 15 degrees, and preferably 5 to 15 degrees, with respect to horizontal. This inclination angle causes the cross-section of the lower side surface to be parallel to horizontal or have an upward incline with respect to the inside surface  58  of the plate. The lower side surface with a horizontal or inclined slope tends to deflect chips that are drawn into the slot back into the pulp flow (F) and away from the slot. The slope of the lower side surface is inward on the plate of the curved inlet  64 . The combination of the curved inlet and horizontal or inclined lower side enhances the ability of the slots  52  to deflect chips into the pulp flow and avoid clogging. 
         [0041]    The slots  52  in the plate  50  have an expanding opening with an opening angle (β) that facilitates the movement of liquor (FL) through the slot and the screen plate. In view of the slope of the lower side surface  62 , the opening angle (as indicated by the angle of arrow FL) is offset at an upward incline equal to the sum of one half the opening angle (β) and the inclination angle (ω) of the lower side of the slot. The offset upward opening angle results in the liquor flowing (FL) through the slot at a greater upward angle that with a conventional slot. In addition, the upper side  66  of each slot has an angle selected to provide the desired opening angle opening angle (β). For example, an angle of 45 degrees of the cross-section of the upper side  66  and a angle (ω) of 15 degrees for the lower side  62  provides an opening angle opening angle (β) of 30 degrees and an offset angle of 30 degrees, where the offset angle is illustrated by the average flow (FL) direction through the slot. 
         [0042]      FIGS. 9 and 10  are a front and a cross-sectional side views, respectively of a second embodiment of a screen plate  70  having diagonal slots  72  and rounded inlet edges  74 . The plate  70  is more suitable for a batch digester in which the pulp slurry is relatively stationary with respect to the plates, but may be applied in a continuous digester. The plate  70  has a curved inlet edge  74  similar to the curved inlet edge  64  shown in  FIG. 8 . The plate  70  has curved inlets  74  on the upper side wall  76  and lower side wall  78  of the slot, in contrast to a curved inlet edge only on the lower slot sidewall in the plate shown in  FIG. 8 . The curved inlets  74  on the upper and lower slot sidewalls  78  may be, for example, rounded, angled, sloped, chamfered, beveled, and slanted. The curvature of the slot inlets  74  may be defined by a radius of the curvature. The radius may be, for example, one-third to two-third of the thickness (T) of the plate. In view of the curved inlet, the narrowest region of the slot (X) may be inward of the slot inlet. The narrowest region may be a throat just beyond the inlet and between the inner surface  58  and outer surface  60  of the plate. 
         [0043]    The upper and lower slot sidewalls may each be slanted to form an expanding opening angle (β) of thirty degrees. The opening angle for the slots shown in  FIGS. 7 to 10  may vary and preferably is in a range of 10 to 30 degrees. The opening angle for slot  72  is not offset is the angle for the slot  52  in  FIG. 8 . The opening angle for slot  72  is symmetrical about a horizontal line. 
         [0044]    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 appended claims.