Refiner Plate for Double Disc Refiners
The refiner plate is the “heart” of the refiner, a consumable component. In addition to achieving good refining effects, the refiner plate is also required to possess strong wear resistance, mechanical toughness to withstand certain impact loads, high reliability and applicability, high comprehensive mechanical properties, high strength and hardness, corrosion resistance, high metallurgical quality and casting performance, high dimensional accuracy, and high dynamic and static balance requirements. It should reduce labor workload for workers, have low production costs, and maintain stable refining effects while reducing fluctuations in pulp quality. There are hundreds of different tooth widths, tooth heights, tooth spacings, and tooth arrangements, including radial, tangential, and parabolic types. The significant variation in wall thickness transitions makes modeling and casting difficult. As a cast part, the refiner plate not only needs to be free of sand holes, shrinkage cavities, shrinkage porosity, cracks, etc., but also requires high dimensional accuracy and good surface finish of the casting. The material of the refiner plate directly affects its service life, the output of the refiner, and the stability of pulp quality.
The refiner plate is particularly prone to wear and even tooth breakage during operation. Apart from damage caused by foreign objects entering, the main reason is due to the material used.
Types and Applications of Refiner Plate
Wear resistance is related to the hardness and toughness of the refiner plate material. Therefore, refiner plate commonly use nickel hard cast iron, high chromium white cast iron, and stainless steel. The high chromium white cast iron used in grinding discs typically consists of three series: Cr15, Cr20, and Cr25, supplemented with other alloy elements such as nickel, tungsten, and molybdenum, forming multi-element alloy high chromium cast iron. A new type of refiner plate formula contains 0.25% to 3.30% carbon, 2.2% to 17.5% chromium, 0.25% to 4.90% nickel, 0 to 0.8% molybdenum, and the remaining part is iron. This refiner plate has the advantages of corrosion resistance, wear resistance, stable performance, and good dynamic balance performance. Nickel-chromium alloys have higher hardness and impact toughness than ordinary alloy materials, and the refiner plate produced from them are generally used in domestic refiners with a diameter of less than 600mm. For processes such as APMP and CTMP, the metal materials used for refiner plate have a higher carbon content to ensure its hardness and wear resistance. For beating of defibrated fiber materials, refiner plate with relatively lower material hardness are generally selected, which have a relatively weaker cutting effect on the fibers and are conducive to fiber splitting and flocculation.
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The material of the refiner plate is primarily selected based on the type of pulp being processed. For instance, ordinary cast iron or cast steel refiner plate cannot be used in the production of electrolyte insulating paper. Non-metallic materials can also be used for it. For example, the cast alloy refiner plate used in disc refiners typically exhibit a black color within 2 tons of refined pulp after each replacement. This black pulp must be processed, which reduces production efficiency and increases production costs; the discs generally need to be replaced after 1 to 2 months of operation, affecting production efficiency; cast alloy discs are heavy, and the energy consumption required to rotate the discs is high. Nano-polyamide 6 has high strength, good wear resistance, and low specific gravity, which can effectively reduce the weight of the refiner plate and improve its processability; carbon fiber can enhance mechanical strength and wear resistance; montmorillonite can improve the rigidity, strength, and heat resistance of the refiner plate, significantly increasing its operating temperature; white fused alumina can enhance hardness and wear resistance; molybdenum disulfide not only improves wear resistance but also has a lubricating effect, extending its service life; graphite powder has wear resistance and corrosion resistance, extending the service life. A disc refiner that does not produce black pulp during operation has a long service life, is lightweight, consumes little energy, and does not pollute the environment. It is composed of 60% to 70% nano-polyamide 6, 13% to 17% carbon fiber, 5% to 8% montmorillonite, 5% to 7% white fused alumina, 3.5% to 5.5% molybdenum disulfide, and 1.5% to 3.0% graphite powder. Various components can significantly improve the performance of the refiner plate. Since the refiner plate made of this material can ensure pure pulp color and excellent quality, it significantly improves the yield of finished paper, making it particularly suitable for the production of high-quality thin paper, high-grade sanitary paper, and high-speed cigarette paper that requires slitting.
Sun Hong Refiner Plate Customization for Pulping Applications
Sun Hong specializes in the design and manufacture of refiner plates for double disc refiners and conical refiners used in the paper industry. We offer a wide range of tooth profiles, materials, and configuration options to suit various pulping processes and fiber types. With precise manufacturing processes and strict quality control, Sun Hong’s refiner plates help improve refining efficiency, optimize fiber performance, and extend service life. We can provide customized solutions based on your refiner model and operating conditions.