Pilot-Scale 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	10-1500 lbs / 3000 ft2
Theoretical Cellulose Production	750lbs / day
Theoretical Metal Production	3000lbs / day

In 2002, IntraMicron acquired a pilot-scale paper machine that 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 usage. The base data for the metal fiber conversion was supplied by years of research and development. This machine, to the best knowledge of IntraMicron, is the most advanced metal-fiber-product production machine in use. The machine is now capable of producing a variety of nonwovens including a carbon-metal fiber product that is superior for filtering chemical agents, such as those typically associated with terrorism.

Significant upgrades including state-of-the-art support equipment and control systems were added during the engineering design and construction. Since the microfibrous media production process is proprietary, key elements will not be described. The following process changes were 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 bhp (boiler horse power) 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 handsheet Mold
• 8" handsheet mold
• Handsheet dryer

The associated auxiliary equipment included a stock preparation system with tanks, agitators, pumps, hydrapulper, high-density pulper, refiner, and appropriate sensors including several stock-mass flow meters.