Because some of the critical events during the removal of water before the dryer section on a paper machine happen very rapidly within enclosed spaces – such as wet-press nips – there have been persistent challenges in understanding the governing mechanisms. In principle, a fuller understanding of the controlling mechanisms, based on evidence, should permit progress in achieving both higher rates of production of paper and more reliable control of paper attributes. In addition, energy can be saved, reducing environmental impacts. The goal of this article is to review published work dealing both with the concepts involved in water removal and evidence upon which existing and new theories can be based. The scope of this review includes all of the papermaking unit operations between the jet coming from the headbox and the final wet-press nip of an industrial-scale paper machine. Published findings support a hypothesis that dewatering rates can be decreased by densification of surface layers, plugging of drainage channels by fines, sealing effects, flocculation, and rewetting. Ways to overcome such effects are also reviewed.

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This investigation used numerical models to describe forming section sheet dewatering at the high vacuum suction boxes. Three different fabric structures were examined with numerical models for single-phase flow of air and for two-phase flow of air and water. This was done to evaluate how forming fabric structure influences sheet dewatering. The numerical models were compared with an experimental study of the same fabrics investigated on a laboratory suction box. The small differences in dewatering rate in the experimental study could be simulated with the models, which confirmed the validity of the models. This implies that these numerical models can be used to describe new fabrics and how they will respond in the papermaking process.

Energy use, together with consumption of raw materials, machine clothing, and wet end chemicals, are some of the most critical aspects in successful tissue making today. This work was aimed at developing a laboratory-scale method of estimating dewatering mechanisms, vacuum efficiency, and energy use of Through Air Drying (TAD) of tissue. When compared to pilot data, the results of the new laboratory method for investigating dewatering during TAD were in the same magnitude, around 24 to 26% dryness after vacuum dewatering, and 27 to 29% dryness after TAD molding. Sheet properties, such as caliper and surface profile, were evaluated and compared to commercial tissue sheets. The results indicate that it will be possible to precisely measure accurate dryness development and penetrated air volume for tissue sheet forming and TAD molding at a laboratory scale. This can contribute to the efforts of implementing a circular forest-based bioeconomy by increasing the fundamental understanding of dewatering of tissue paper materials, which is facilitated by improvements in energy use. The new method developed in this work will make it easier to assess ideas that are difficult to bring to pilot scale or full scale before learning more of the dewatering capabilities. The authors are convinced that improved knowledge of tissue dewatering mechanisms, forming, and material transport during and after TAD dewatering can increase the efficiency of the industrial manufacturing processes.

The addition of polyvinylamine (PVAm) in the wet-end of the papermaking process was investigated. The changes in pulp drainage, vacuum dewatering, tensile strength, and air permeance were measured with and without PVAm. Both chemi-thermomechanical pulp (CTMP) and bleached kraft pulp were used. The dewatering and drainage abilities of the different pulps was examined by measuring the dewatering resistance (°SR), the water retention value (g/g), and the vacuum dewatering. The tensile strength and air permeance values were tested on paper sheets. The results showed that the initial dewatering was faster for pulps with PVAm, and this effect was greater for the CTMP and at higher basis weights. The strength increased when PVAm was added but only if the pulp was washed before sheet forming. The unwashed pulp with PVAm had worse formation, which resulted in lower tensile strength values. The air permeance of the sheets was higher with the addition of PVAm, primarily as a result of higher flocculation. Adding PVAm to the stock suspension in the wet-end of the paper machine has great potential for end-products that require high air permeance and tensile strength properties. PVAm could also act as a dewatering enhancing agent, but caution must be taken regarding the potential of formation problems.