Steam box with multiple valves and diffuser plates and related system

A steam box system comprising:

• a steam box housing;
• a diffuser housing disposed within the steam box housing, wherein the diffuser housing comprises a top, and walls extending downwardly from the top,
• wherein the top of the diffuser housing and the walls of the diffuser housing define multiple diffuser chambers in the diffuser housing disposed adjacently in a machine direction, and
• wherein the multiple diffuser chambers further comprise a first diffuser chamber adjacently disposed to a second diffuser chamber;
• a diffuser plate engaged to the steam box housing distal from the top of the diffuser housing and adjacent to the multiple diffuser chambers to define an exhaust side, the diffuser plate having orifices defining multiple steam exhaust orifice areas,
• wherein a first steam exhaust orifice area of the multiple steam exhaust orifice areas is disposed at the exhaust side adjacent to the first diffuser chamber,
• wherein a second steam exhaust orifice area of the multiple steam exhaust orifice areas is disposed at the exhaust side adjacent to the second diffuser chamber;
• multiple valves,
• wherein each valve of the multiple valves has a valve outlet,
• wherein each valve of the multiple valves is configured to have an open position and a closed position,
• wherein a first valve outlet of a first valve of the multiple valves fluidly communicates with the first diffuser chamber,
• wherein a second valve outlet of at least a second valve of the multiple valves fluidly communicates with the second diffuser chamber,
• wherein the first steam exhaust orifice area has a first value,
• wherein the second steam exhaust orifice area has a second value, and
• wherein the second value is equal to an exponentiation wherein “v” is the first value, and “n” is a real number excluding 0;
• a sensor disposed downstream of the steam box, wherein the sensor is configured to obtain a measurement of a CD moisture profile of a fibrous web at a time interval;
• and
• a controller configured to receive the measurement and to compare the measurement to a desired CD moisture profile, wherein the controller is further configured to open or close at least one valve of the multiple valves to adjust an amount of steam output.

A method to adjust the amount of available steam exiting a steam box comprising:

• a. measuring a CD moisture profile of a fibrous web in a paper, tissue, or non-woven manufacturing line to obtain a CD moisture profile measurement;
• b. comparing the CD moisture profile measurement to a desired CD moisture profile;
• c. adjusting valves of a steam box from an open position to a closed position, or from the closed position to the open position to change the amount of available steam introduced into a diffuser chamber of a steam box;
• and
• d. repeating steps a. through c. until the CD moisture profile measurement equals the desired CD moisture profile,
• wherein the valves are disposed in the steam box,
• wherein the steam box comprises a diffuser housing disposed within a steam box housing, the diffuser housing comprising a top, walls, and a plurality of diffuser plates,
• wherein the top, the walls, and a first diffuser plate of the plurality of diffuser plates define a first diffuser chamber in the diffuser housing,
• wherein the top, the walls, and a second diffuser plate of the plurality of diffuser plates define a second diffuser chamber in the diffuser housing,
• wherein a first valve outlet of at least a first valve of the valves fluidly communicates with the first diffuser chamber,
• wherein at a second valve outlet of at least a second valve of the valves fluidly communicates with the second diffuser chamber,
• wherein the first diffuser plate defines a first steam exhaust orifice area having a first value,
• wherein the second diffuser plate defines a second steam exhaust orifice area, and
• wherein the second steam exhaust orifice area has a second value, the second value being equal to an exponentiation wherein “v” is the first value, and “n” is a real number excluding 0.

A steam box assembly comprising:

• a steam box housing;
• a diffuser housing disposed within the steam box housing, wherein the diffuser housing comprises a top, and walls;
• a diffuser plate slidably engaged to a bottom of the steam box housing,
• wherein the top of the diffuser housing and the walls of the diffuser housing define multiple diffuser chambers, and a first diffuser plate of the plurality of diffuser plates define a first diffuser chamber in the diffuser housing,
• wherein the top of the diffuser housing, the walls of the diffuser housing, and a second diffuser plate of the plurality of diffuser plates define a second diffuser chamber in the diffuser housing;
• and
• multiple valves, wherein each valve of the multiple valves has a valve outlet,
• wherein each valve of the multiple valves is configured to have an open position and a closed position,
• wherein a first valve outlet of at least a first valve of the multiple valves fluidly communicates with the first diffuser chamber,
• wherein at a second valve outlet of at least a second valve of the multiple valves fluidly communicates with the second diffuser chamber,
• wherein the first diffuser plate defines a first steam exhaust orifice area having a first value,
• wherein the second diffuser plate defines a second steam exhaust orifice area, and
• wherein the second steam exhaust orifice area has a second value.