In actual production, if a refiner begins to exhibit fluctuations in refining current, increased energy consumption, reduced refining efficiency, or difficulty in maintaining stable refining quality, many people first suspect the pulp or the process parameters.
However, a crucial factor that is often overlooked is the wear condition of the refiner plates.
Whether in a double disc, conical refiner, the refiner plate is the core component that directly exerts multiple actions on the fibrous raw material during operation.
As operating time increases, compounded by factors such as refiner plate material, tooth profile design, and operational practices, issues such as tooth wear, groove clogging, and the formation of metal burrs (commonly known as “little tails”) gradually emerge. These problems not only impair refining efficiency but also alter fiber treatment, ultimately affecting pulp quality and paper properties.
Therefore, understanding the relationship between refiner plate wear and pulp clogging is of great significance for enhancing refining stability and reducing production line costs.
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Why Refiner Plate Wear Matter More Than You Think
It is well known that pulp raw materials influence the beating effect during the operation of a pulp line.
However, what is often overlooked is that the refiner plates also impact the quality of the resulting pulp and paper, as well as production efficiency.
Here, we can categorize the factors affecting the beating effect into three major groups.
| Pulp Factors | Refiner Plate Factors | Process Factors |
| Pulp Grade | Refiner Plate Tooth Geometry | Pulp Consistency |
| Pulping Process | Tooth Pattern and Groove Design | Temperature |
| Degree of Pulping | Groove Depth | Process Medium and Chemical Additives |
| Bleaching Treatment | Dam Design | Throughput |
| Average Fiber Length and Distribution | Refiner Disc Material | Specific Energy Input |
| Average Fiber Coarseness | Refiner Plate Wear Pattern | Refining Pressure |
| Chemical Composition (Lignin, Cellulose, Hemicellulose, etc.) | Tooth Angle | Rotational Speed |
Why does Refiner Plate Wear Lead to Pulp Clogging
During the long-term operation of refiner plates, deformation, the formation of “tails,” and the development of sawtooth-like wear tend to increase the amount of fiber flocs. This reduces pulp fiber uniformity and adversely affects the formation and strength properties of the final paper product.
Even more challenging is the fact that cleaning becomes extremely difficult when fiber accumulation and clogging occur at sites of serrated wear or “small tail” formations. Neither high-pressure water jets nor steel needles are effective at flushing or picking them out.
How Refiner Plate Wear Affects Refining Quality
The impact of refiner plate wear extends beyond a mere reduction in service life. It progressively affects the entire refining process.
Deformation of the refiner teeth and the formation of metal burrs alter the stress conditions acting on the fibers, preventing some of them from undergoing the uniform shearing and kneading intended by the design.
Clogging of the grooves also impairs pulp flow efficiency within the refining zone, preventing some fibers from fully entering the effective refining area; this weakens the refining action and reduces overall refining efficiency.
These factors affect the disruption of the primary wall and the outer layer of the secondary wall, significantly hindering fiber swelling and fibrillation, and thereby impacting the splitting and fraying (brushing out) of the fibers as well as the improvement of bonding strength.
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How to Reduce Refiner Plate Wear and Prevent Pulp Clogging
Refiner wear and the resulting pulp-clogging issues warrant attention, particularly because this phenomenon is likely to compromise the uniformity of the finished paper. Consequently, the need for disc replacement, along with pulp wastage and paper scrap generation, significantly drives up production costs.
Below, Sun Hong offers the solutions based on our 30+ years of experience.
Use Refiner Plates with Uniform Material Properties
Metal refiner plates with non-uniform material properties are more prone to developing wavy or serrated wear patterns during use. This not only tends to cause pulp clogging but also leads to significant fluctuations in refining current, thereby compromising refining quality.
Strict Process Control
Keep the slurry clean and prevent foreign objects such as stones, wire, or bolts from entering the refiner chamber. Properly control the consistency, pressure, feed method, operating steps, and current to prevent tooth breakage and excessive wear on the refiner plates.
Optimize Refiner Plate Material
Select refiner plate materials with high impact strength and wear resistance, such as coarse-grained multi-component alloy refiner plates with good self-sharpening properties or bimetallic stainless steel refiner plates.
Refiner plate wear implies not only a shortened service life for components but also a shift in how fibers are processed.
The progressive accumulation of sawtooth wear, groove clogging, and metal burrs triggers a chain reaction affecting refining quality, production efficiency, and paper properties.
Rather than constantly adjusting process parameters, it is far more important to establish a system for the regular inspection and maintenance of refiner plates and to select materials offering superior wear resistance and self-sharpening capabilities. This addresses the risk of clogging at the source and ensures consistent, long-term refining performance.