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Pulp and Paper Industry (Pulp Mill, Paper Mill, Printing and Writing Papers, Corrugating Medium Paper, Newspapers Hardboards)
Pulp and Paper Industry
(Pulp Mill, Paper Mill, Printing and
Writing Papers, Corrugating Medium
Paper, Newspapers Hardboards)
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Introduction
Pulp and paper are manufactured from raw materials containing
cellulose fibers, generally wood, recycled paper, and agricultural
residues. In developing countries, about 60% of cellulose fibers
originate from non wood raw materials such as bagasse, cereal
straw, bamboo, reeds, esparto grass, jute, flax, and sisal. The main
steps in pulp and paper manufacturing are: Raw material
preparation and handling, Pulp manufacturing, Pulp Washing and
Screening, Chemical recovery, Bleaching, Stock Preparation, and
Papermaking.
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Pulp is a lignocellulosic fibrous material prepared by chemically or
mechanically separating cellulose fibres from wood, fiber crops or
waste paper. Paper is made by pulping wood, bleaching this pulp
and then spreading it out into sheets to make it into paper.
Paper is a major product of the forestry industry, and is used widely
in our society. Paper products are used not only in their obvious
applications in the publishing industry and for writing on, but also
in a variety of specialty papers, cardboards, brown papers etc. In
addition, various chemicals are produced as a byproduct of the pulp
and paper industry.
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The use of paper for various purposes is an
essential feature of the modern society. Therefore
pulp and paper manufacturing is very important
part of modern industry. Pulp and paper production
is based on the use of bamboo as raw material, but
also on the consumption of large-scale chemicals,
like chlorine, sodium hydroxide, etc.
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Bamboo is a fast-growing, evergreen plant belonging to the
botanical family of grasses. It has long been used as a
construction material and as a source of implements, weapons,
and ornaments in several global regions, particularly in Asia.
In these regions, bamboo pulp has also been used to make
high-grade papers for many years. Bamboo-based paper also
perpetuates the wood-based paper status quo because —
unlike perennial agricultural fibers — it can be chipped in
existing wood-based mills.
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Globally paper Industry is one of the high priority industries
having a bearing on the socio-economic development. In India too
this industry plays a vital role in the overall industrial growth.
Indian paper industry is one of the world’s fastest growing
industries.
The paper industry in India has become more promising as the
domestic demand is on the rise. Increasing population and literacy
rate, growth in GDP, improvement in manufacturing sector and
lifestyle of individuals are expected to account for the growth in
the paper industry of India.
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The Indian Paper Industry has the top 15 Global
players with an output of more than 6 millions
tonnes annually with an estimated turnover of Rs.
150000 millions. Indian paper industry is riding on
a strong demand and on an expanding mood to
meet the projected demand of 8 million tonnes by
2010 & 12 million tonnes by 2020.
Some of the fundamentals of the book are bleaching of bamboo
cold, high yield semi chemical pulping of mixture of bamboo
and mixed hardwoods, sulphate semi chemical process, kraft
green liquor semi chemical process, neutral sulphite semi
chemical process, thermo mechanical pulps for newsprint, zeta
potential concept in paper sizing, sodium carbonate in alkali
extraction during bleaching bamboo , maintenance engineering
in pulp and paper industry, design and application of refiners in
stock preparation, paper machine effluent etc.
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This book explains about the various raw material, their
processing and utilizations and also the possible waste
treatment of such paper and pulp making industry. To
draw attention for manufacturing quality product with
all possible latest technologies is the main purpose of
this book. The book is very resourceful for new
entrepreneurs, technocrats, existing units and research
scholars.
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Table of Contents
1. BLEACHING OF BAMBOO COLD SODA PULPS
Results and DiscussionsConstant ConditionsPretreatment with AcidPretreatment with AlkaliBleaching Conditions in Different StagesEffect of Peroxide in Alkali PretreatmentPretreatment with DyeBleaching Conditions in Different StagesConclusionsExperimentalRaw MaterialsBleaching
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2. HIGH YIELD SEMI-CHEMICAL PULPING OF MIXTURE OF BAMBOO AND MIXED HARDWOODS
Raw MaterialExperimental and ResultsSulphate Semi-Chemical ProcessKraft Green Liquor-Semi-Chemical ProcessNeutral Sulphite Semi-Chemical ProcessDiscussionSulphate Semi-Chemical ProcessGreen Liquor Semi-Chemical ProcessNeutral Sulphite Semi-Chemical ProcessConclusion
3. DEVELOPMENT IN HIGH YIELD PULPING PROCESS
Mechanical ProcessSemichemical ProcessChemical ProcessAlkaline Chemical Process
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Sulfite processOrganic Catalyst to High Yield PulpingAQ Pulping TechnologyPolysulfide-AQ ProcessAlkaline Sulfite-AQ PulpingExperimental
4. THERMO-MECHANICAL PULPS FOR NEWSPRINT MANUFACTURE FROM TROPICAL PINES
Raw MaterialsExperimentalPreparation of Thermo-Mechanical PulpsResults and Discussions
5. A STUDY ON REPLACEMENT OF SODIUM SULPHATE BY AQ-LARGE SCALE TRIAL
Anthraquinone an Aid to PulpingLaboratory Scale Investigations at Central Research Laboratory, Dalmianagar
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Plant Trial with AQEvaluation of Mill PulpDiscussion and ResultsConclusions
6. ZETA POTENTIAL CONCEPT IN PAPER SIZING
Electro Kinetic (Zeta) Potential-A ConceptThe Theory of Electrical Double LayerStern Modified Double LayerThe Meaning and Limitations in the Application ofElectro Kinetic Theoryto the Paper SizingBehaviour of Alum in WaterElectro Kinetic Properties of Alum-rosinSize Precipitate and the Sized FibreConclusionNomenclatureGreeks
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7. ECONOMICS OF BAMBOO AND HARDWOOD PULPING BY ANTHRAQUINONE CATALYSED-KRAFT-PROCESS
Experimental Design & ObservationsResults & DiscussionsConclusion
8. EFFECT OF BLEACHED PULP VISCOSITY ON STRENGTH PROPERTIES OF BAMBOO SULFATE PULP
ExperimentalPulpingBleachingPhysical Strength PropertiesChemical AnalysisObservations and DiscussionsConclusion
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9. ALKALI/OXYGEN DELIGNIFICATION AND BLEACHING OF SODA BAMBOO PULP
ExperimentalDiscussionsConclusions
10. ALKALI/OXYGEN DELIGNIFICATION AND BLEACHING OF SODA BAMBOO PULP, BAMBOO + MIXED HARD WOOD PULP (70 : 30) AND MIXED HARDWOOD PULP
Experimental and ResultsDiscussionsConclusion
11. SODIUM CARBONATE IN ALKALI EXTRACTION DURING BLEACHING BAMBOO (D. STRICTUS) PULP
ExperimentalStudy on Sequentially Chlorinated (H/C) PulpStudy on Chlorinated Pulp
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Results and DiscussionConclusions
12. EFFECT OF HEMICELLULOSES ON UNBLEACHED SOFTWOOD KRAFT PULP
Materials and MethodsEnzyme TreatmentsBleaching ExperimentsChemical Composition and Kappa Number AnalysesMicroscopic AnalysisNumerical Measurement of ColourResults and DiscussionChemical Changes After Enzyme TreatmentBleaching ExperimentsGraff C StainNumerical Measurement of Colour
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Accessibility Changes and Simons StainDeuterium Oxide ExchangeSimons StainConclusions
13. THERMODYNAMIC FUNCTIONS OF THE REACTION BETWEEN LIGNIN AND HYDROGEN PEROXIDE DURING BLEACHING
ExperimentalIsolation of ThioligninPreparation of Hydrogen Peroxide SolutionReaction of Thiolignin with Hydrogen PeroxideResults and DiscussionAnalysis of Kinetic DataOrder of the Reaction and Variation of RateConstant with Reaction ParametersValidity of Arrhenius Equation (Reaction Rates andTemperature Changes)Estimation of various Thermodynamic FunctionsConclusions
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14. SEQUENTIAL BLEACHING
Experimental ProcedureDiscussions of the ResultsBleach ConsumptionPhysical and Chemical PropertiesPollution Load of the FiltrateConclusion
15. MANUFACTURE OF CORRUGATING MEDIUM PAPER UTILIZING 100% BAGASSE FURNISH
Process Suggested for MakingCorrugating Medium from 100% BagasseFibre PreparationDepithing at Paper MillsDigestion CycleStock Preparation
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16. EFFECTIVE UTILIZATION OF CHEMICALS IN PULP AND PAPER MILLS
Digester HouseChemical Recovery SectionBleach PlantChemical and Stock PreparationEffluents
17. EFFECTIVE USE AND RECOVERY OF CHEMICALS IN COLD SODA PULPING
ExperimentalChemical Treatment of E. TereticornisEta Reed Sulphate PulpingEvaporation and Burning Properties of Kraft andCold Soda Spent liquorsResults and DiscussionsChemical Consumption
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Pulp PropertiesComposition of Liquors Pollution LoadsProperties of Spent LiquorsMaterial BalancesConclusions
18. EFFECTIVE USE AND RECOVERY OF CHEMICALS IN COLD SODA PULPING WITH PARTIALLY CLOSED SYSTEM
Chemical Treatment of E. TereticornisResults and DiscussionsConclusions
19. MAINTENANCE ENGINEERING IN PULP AND PAPER INDUSTRY
InspectionLubricationServicingMaintenance Problems
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20. LIMITATION TO SATISFACTORY OPERATION OF WET END OF PAPER MACHINE
Basis Weight ProfileHead Box PulsationDrainage Formation and Sheet StructureThe Head BoxRectifier Roll Head BoxesMicro Turbulence Head BoxesWeb FormersTwin Wire FormingSchmidt ClassificationNorman ClassificationHigh Consistency FormingAncillary EquipmentsWet Web StrengthLimitations of Water Removal on PressingConclusion
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21. DESIGN AND APPLICATION OF REFINERS IN STOCK PREPARATION
Conical RefinersShallow Angle RefinerSteep Angle RefinersDouble Disc RefinersSafety DevicesInfluence of Machine Variables on RefiningBatch RefiningMachine Refiners
22. WET FELT DESIGNING TECHNIQUES
PressingCase StudyRecommendations
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23. MODERNIZATION AND OPTIMUM UTILIZATION OF EVAPORATORS FOR HARDWOOD BLACK LIQUORS-MILL EXPERIENCE
Hardwood Black LiquorsRecovery Boilers and Required LiquorSolidsOriginal Evaporator UnitsInstallation of a Pump in Between FirstPass and Second Pass of Concentration Effects ofBoth UnitsConversion of Concentration Effect ofFirst (OLD) Unit to a FinisherIntroduction of a New Finisher EffectUtilization of Vent Vapour from FinisherChanging the Liquor Entry from Tangential to Radial andModification of Flash ChamberUtilization of Vapour from Improvised Finisher ofOld StreetConclusions
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24. PAPER MACHINE EFFLUENT
ExperimentalDiscussionsMode of Treatment for Paper Machine EffluentResultsConclusion
25. CONICAL REFINERS AND WIDE-ANGLE REFINERS IN CONTINUOUS AND BATCH REFINING SYSTEMS FOR BAMBOO AND HARDWOOD FURNISH
IntroductionTypes of Refining Systems in the MillConical and Wide Angle Refiners Strength, Development and Power Consumption
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26. USE OF NO PICK ROLL IN PAPER MACHINE PRESS SECTION BASED ON SHORT-FIBRED TROPICAL HARDWOODS AND AGRICULTURAL RESIDUES
Theoretical ConsiderationsThe ProblemPress Section Before ModificationPress Section After ModificationDiscussionConclusions
27. CONSUMPTION OF FURNACE OIL IN RECOVERY BOILERS
StorageViscosityVelocityTurbidity & CausticitySilicaInverse SolubilityOrganic Content and Calorific Value
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28. NECESSITY TO RENOVATE AND MODERNIZE PAPER MACHINE
Fourdrinier PartPress PartDryer SectionCalender StacksPope ReelConclusion
29. WET END OPERATION OF A PAPER MACHINE
Approach FlowHead BoxThe SliceApproach System, Head Box and Slice at W.C.P.M.Sheet Formation and Drainage on the FourdrinierShakeSuction Boxes
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Dandy RollThe CouchConclusion
30. CLEANING SYSTEM-SHOWER FOR PAPER MACHINE
Mechanical CleaningClassification of Water ShowerWire Cleaning ShowerKnock off ShowerTrim Knock-off ShowerCouch Roll Cleaning ShowerReturn Roll Cleaning ShowerDandy Cleaning ShowerFelt ShowerSpecial Features of Water ShowersMaterial of Construction
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Insert Type NozzleProtective ShellProgrammingFilters
31. SUITABILITY OF KENAF CTMP FOR LINERBOARD
ExperimentalRaw MaterialParticle SizeReduction and WashingInjection ProcessFiberizing and RefiningKraft PulpingPulp Testing and Handsheet Formation and TestingResults and DiscussionAndritz Sprout-Bauer Pulping TrialsFPL Pulping Trials
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Kenaf and Loblolly Pine Pulp BlendsConclusions
32. NEWSPRINT FROM BLENDS OF KENAF CTMP AND DEINKED RECYCLED NEWSPRINT
ExperimentalResults and DiscussionConclusion
33. FEASIBILITY OF USING KENAF CHEMITHERMOMECHANICAL PULP IN PRINTING AND WRITING PAPER
Results and DiscussionAndritz Sprout-Bauer and FPL Pulping TrialsPostbrightened Kenaf Thermomechanical PulpConclusionsExperimentalRaw Material, Particle Size Reduction, and Material Wash
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Injection ProcessFiberizing and Refining ProcessTesting of Pulp and Forming and Testing of HandsheetsPostbrightening of Kenaf TMPBrightness Reversion
34. MESTA/KENAF AS RAW MATERIAL FOR KRAFT PULPING
Raw MaterialExperimentalChemical Constituents of MestaPulping and Sheet MakingDiscussionPhysical CharacteristicsChemical ConstituentsPulping Bleaching and Black Liquor CharacteristicsMorphological StudiesProperties of Pulp SheetsFibre Classification ResultsConclusions
35. RESPONSE OF KENAF VARIETY, HC-583 TO DIFFERENT LEVELS OF NITROGEN
Materials and MethodsResults and DiscussionPlant HeightBasal Diameter of StalkDry Yield of StalkIncrease in Dry Yield of Stalk per Kg. N AppliedConclusion
36. PREHYDROLYSED KRAFT COOKING OF JUTE STICK (EFFECT OF PREHYDROLYSIS CONDITION)
ExperimentsRaw MaterialsDigestionBleachingChlorine Water Bleaching
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Analysis of the PulpResults & DiscussionA. Effect of Prehydrolysis Treatment on the Chemical Composition of Jute StickB. Loss of ï Cellulose and Lignin after Prehydrolysis and Kraft Cooking of Jute StickResults of Bleached PulpsConclusions
37. HIGH YIELD PULP FROM JUTE STICKS
38. GREASE PROOF PAPERS FROM SULPHITE JUTE STICK PULP
Raw MaterialPulpingConclusion
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39. CHEMICAL RECOVERY BOILERS FOR PULP MILLS USING AGRICULTURAL RESIDUES AS RAW MATERIALS
Present and Future Prospects of Agricultural Residue Usage in IndiaAdvantages of Use of Agricultural ResiduesSpecial Shelter Type Design for Smaller Units
40. PROBLEMS IN BL EVAPORATION IN INDIAN RAW MATERIALS
Black Liquor ScreeningBlack Liquor Soap ProblemCarbonaceous DepositsScale Formation and its RemovalResults AchievedTechnicalVapour Side ScaleMethod of Feeding Black LiquorMixed FeedQuintuple Effect & Forced Circulation EvaporatorForced Circulation Evaporator
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41. UTILIZATION OF UNCONVENTIONAL RAW MATERIALS
Advantages at a Glance for New ProcessCooking Liquor and Position of pH (Cold) during PulpingPulping Conditions and DelignificationYield and General Properties of PulpChemical Composition of Unbleached PulpBleaching of PulpPaper Making PropertiesBlack Liquor and RecoveryEnvironmental ProtectionAir ProtectionWater ProtectionFuture LooksSulfite Shuttles into Space
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42. UTILIZATION OF AGRICULTURAL RESIDUES USING MECHANO-CHEMICAL PULPING PROCESS
Pilot Plant Trials at Cellulose and Paper Branch,Forest Research institute and colleges, DehradunProduction of Rice Straw PulpProduction of Wheat Straw PulpProduction of Bagasse PulpProduction of PaperMechano Chemical Pulping on Industrial ScaleChemical PreparationCookingSearch for Alternative Raw MaterialVariables in the ProcessModification of Bagasse Pulping by Partial Replacement ofSodium Hydroxide by Sodium CarbonateAddition of Sodium Sulphide in Cooking Liquor inBagasse PulpingConclusion
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43. FEASIBILITY OF RECYCLED NEWSPAPERS HARDBOARDS
Experimental Design and AnalysisMaterialsProcessingAcetylationAdhesive ApplicationBoard ManufactureTestingResults and DiscussionStatic Bending PropertiesTensile Strength PropertiesWater Absorption and Thickness SwellLinear ExpansionConcluding Remarks
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44. RESTORING BONDING STRENGTH TO RECYCLED FIBERS
Dry-Fiberized Fiber CharacteristicsMechanical TreatmentFractionationStrength AdditivesChemical TreatmentsBlending with Virgin FiberPapermaking VariablesWet-Formed PapersPressingAir-Formed PapersConclusionsMethods and Materials
45. CHEMICAL MODIFICATION OF AGRO-FIBER FOR THERMOPLASTICIZATION
Experimental ProceduresEsterification Procedure
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Thermal AnalysisPressing of Esterified FiberElectron Microscopy of Pressed FiberSwelling of Pressed Fiber in WaterResults and DiscussionEsterification of LignocellulosicsThermal AnalysisSwelling of Pressed Fiber Pellets in WaterConclusions
46. POTENTIALS FOR COMPOSITES FROM JUTE AND ALLIED FIBERS
Plant Utilization for CompositesPotential Composites for Agro-ResourcesGeotextilesFiltersSorbentsStructural Composites
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Non-structural CompositesMolded ProductsPackagingCombinations with Other ResourcesChemical Modification for Property ImprovementConclusions
47. AN APPROACH TO INPLANT COLOUR REDUCTION OF BLEACH PLANT EFFLUENT USING CALCIUM HYPOCHLORITE
ExperimentalDiscussion
48. DESILICATION OF SULPHATE WEAK BLACK LIQUOR BY THE ADDITION OF LIME
ExperimentalProcedure of DesilicationResults & Discussion
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49. TREATMENT OF PULP & PAPER MILL WASTES
Pulp and Paper Industry WaterConsumptionNature and Effect of ImpuritiesPrimary TreatmentSedimentation UnitsSludge Handling & DisposalSecondary Treatment
50. DECOLOURIZATION OF WASTE WATER FROM BLEACHED-KRAFT PULP & PAPER MILL USING ALUM AND CLAY
Materials and MethodsResults and DiscussionSludge BlanketEffluent QualityColour Removal
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Removal of Suspended SolidsCOD ReductionConclusion
51. REMOVAL OF SOLUBLE SILICA FROM SULPHATE GREEN LIQUOR
ExperimentalCarbonationGreen Liquor AnalysisResults & Discussion
52. TRENDS IN ASH CONTENT OF STRAW PULPS-AN EXPLANATION
Experimental
53. MINI LIME TREATMENT OF DISSOLVING PULP MILL COLOURED EFFLUENT
Sources of Colour in the Pulp MillEffluentPresent Work
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Chlorination of Lime Treated EffluentCalcining of Effluent SludgeCausticization Using Lime Obtained from Effluent SludgeConclusion
54. COLOUR AND COD REDUCTION OF BLEACH EFFLUENTS
ExperimentalResults and DiscussionsColour of the EffluentsPhenolic CompoundsRate of Colour ReductionChemical Oxygen DemandConclusions
55. EFFECT OF pH ON SULPHITE PULPING OF HOLOCELLULOSE OF E. TERETICORNIS
ExperimentalPreparation of Cooking Liquor
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Titration of Cooking LiquorSulphite PulpingNeutral Sulphite PulpingPreparation of Cooking LiquorChemical Analysis of Sulphite andNeutral Sulphite Cooked HolocelluloseResults and Discussion Effect of pH andCooking Time on YieldEffect of pH and Cooking Time on Klason LigninEffect of pH and Cooking Time on Alpha-CelluloseEffect of pH and Cooking Time onPentosansEffect of pH and Cooking Time onAcidic SugarEffect of pH and Cooking TimeOn Methoxyl and Acetyl Groups
56. UTILIZATION OF AGRICULTURAL RESIDUES FOR PULP, PAPER AND BOARD
Rice StrawWriting and Prints PaperGrease Proof PaperWrapping PaperStraw BoardFibre BoardsWheat StrawWriting & Printing PaperGreaseproof PaperStraw BoardJute SticksWriting and Printing PaperWrapping Paper Pulp Yield and Sheet CharacteristicsStraw BoardNewsprint Grade Refiner Groundwood Pulp
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Constitution of HemicelluloseGreaseproof Paper, Strength Properties of Standard SheetBuilding BoardBagasseWriting and Printing PaperWrapping PapersRayon Grade PulpsGreaseproof paperStraw BoardFiber BoardNewsprintCotton StemWriting and Printing PaperMiscellaneous Raw MaterialsArecanut HuskGround Nut ShellsTea StemCaster Stems (Ricinus Communis, linn)
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Sun Flower StalkArhar Sticks (Cajanus SP) and Jawar Stalk (Sorghum SP)Sugar Cane LeavesPaddy Husk
57. PROVISION OF CAPTIVE POWER GENERATION IN A 30 TPD AGRO-BASED PAPER PLANT AS A MEANS OF IMPROVING CAPACITY UTILIZATION
Capacity UtilizationPower AvailabilityCaptive Power PlantRecommended SchemeFeatures of the SchemeFixed CostsVariable CostsAverage Cost of Power GenerationEconomics and DiscussionConclusion
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58. ENERGY CONSERVATION IN PULP AND PAPER INDUSTRY SOME THOUGHTS
Paper IndustryDeliberationsTotal Energy ConceptIn-Plant Power GenerationEnergy Distribution and UtilizationOverdesign and Capacity Utilization of the Equipment Energy AduitShort Term-Long Term Action ProgrammeShort Term SchemesLong Term SchemesGenerationShort TermLong TermTransmission
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Short TermLong TermUtilizationShort TermLong TermWaste StreamsEnergy Conservation ApproachesFactor Affecting Energy EfficiencyResearch and DevelopmentNational Energy ProgrammeSummary and Conclusions
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