Pulp and Paper

Industries
• Types of paper

• End Use of paper

Types/Uses of Paper
• Currency paper
• Writing paper
• Tissue paper
• Card board
• Blotting paper
• Kraft paper
• Laminated paper
(The kind of paper that can be made is determined
by the wood fiber and other raw or recycled
materials used and the pulping method.)
BOARD..
CORRUGATING
NEWSPRINT..
FINE PAPER.
TISSUE.
Quality of paper / Grading
• Strength
• Flexibility
• Colour
• Brightness
• Burst test
• Moisture
• Weight of fibers in paper
• Moisture content in paper
 GSM
• Grams per square meter
• gm/m2

• Weight / area

• 60gsm , 80 gsm 120 gsm

• Find the area of the sheet you are using.
 Raw Materials

• Waste paper
• Sheet of barks of trees
• Fibrous sources
• Cellulosic fibers
 What is Cellulose ?
• Physically : hair like structure having
typical tensile strength
• Chemically: Carbohydrate
• Mono Saccharides ?
• H2O + CO2  Cm (H2O)n
• C6H12O6
• Poly saccharides  Starches and
Cellulose
 Derivatives of cellulose
• Purest form of cellulose is Cotton, which
is above 90% cellulose
• Cellulose can be nitrated to give NC
(Gun Cotton : explosive)
• Cellulose hydrolysed to simpler
carbohydrates
Cementing of Cellulose in Plants/trees

• Adhesion of cellulosic fibers in plants

are by LIGNIN
• Lignin is cementing material
• Chemically undefined structure
• Can be hydrolysed in presence of
strong alkaline conditions and high
pressure, temperature.
Types of Plants on basis of cellulose

• Plants and trees like bamboo, pine,

eucalyptus, wheat-straw, cotton stakes,
kahi grass etc
• Hard wood
• Soft wood
• Types of fibers different : Long and
short fibers, strength of fibers
Separation of cellulose

• Mechanical Beating
• Chemical digestion
 Pulping Techniques
• Mechanical pulping uses mechanical abrasion
to separate cellulose fibers which are held
together by a material called lignin. In
the process called "Groundwood" wet
wood is ground by large stones.
• In Thermo Mechanical Pulping (TMP), metallic
plates rub steam heated chips at high speeds,
separating fibers
• Chemical Pulping Uses chemicals to dissolve lignin.
Kraft pulp is most common pulp.
• Semichemical Pulp Uses chemicals to soften
lignin, and mechanical abrasion in refiners.
 Pulp Mill Paper Mill
Paperboard Mill
• Pulp Making (separating the cellulose fibers
from other impurities in wood or used paper)
• Paper Making (matting these fibers into a
sheet. )
• Converted Paper products like paperboard
container, corrugated, Laminated sheets etc
(various cutting and shaping techniques and
includes coating and laminating activities)
Processes
PAPER MANUFACTURING STEPS
1- Raw Materials
2- Processing of Raw material
a) wood debarking
b) Wood chipping
3- Digester (Cooking)
4- Washing of pulp
4a- Recovery of chemicals
5- Bleaching of pulp
6- Refining
7- Sheet/paper making
 Raw materials

• Cellulosic Fibrous Material

Hardwood (Euclayptus)
Softwood (Pine etc)
straw, baggas, wood, bamboo
Waste Paper
 Types of Pulping
• Mechanical (Mechanical pulping uses
mechanical abrasion to separate
cellulose fibers which are held together
by a material called lignin. ) Thermo
Mechanical
• Chemical (Uses chemicals to dissolve
lignin.)
• SemiChemical (Uses chemicals to
soften lignin, and mechanical abrasion
in refiners )
 Pulp & Paper
Manufacturing Processes
CHEMICAL PULPING
 Chemical Pulping
Kraft Sulfate Process

Sulfite Process

Neutral Sulphite Semi-Chemical Process

• Chips from the storage bins are fed into a
digester to which chemicals have been
added. The woodchips are then 'cooked'
to remove lignin.
Digester
 over size chips
digester

log

P-2 screen
chip bin
blow tank

chip bin
DebarkingE-2 Drum chipper
thickener brown stock
water
chips

bleach knots

storage chest screen

pulp washer
block tank pulp washer

stock tank
water

thickener
E-21
thickner
dryer

dry pulp storage

paper section Pulp Manufacturing Section
 Changes in Chemical Pulping
According to Raw Materials
• Alkaline Chemical Process
• Organic Catalyst to High Yield Pulping
• Bamboo and hardwood pulping by
anthraquinone catalysed-kraft-process
• Mixture of bamboo and mixed hardwoods
• Agricultural residues (Whaet straw, Rice
Straw, Baggas, cotton staks, Kahi Grass)
• Composites of Jute, Rayon, and cotton fibre
• Recycled Fibres
Paper Making Process
 Other Chemical Processes
• Bleaching
• Sizing
• Recovery of chemicals
• Waste reduction and treatment
De-Barking
 De-barking

• Bark is stripped from the logs by

knife, drum, abrasion, or
hydraulic barker. The stripped
bark is then used for fuel or as
soil enrichment
Chipping Machine
 NSSC
• Neutral sulfite semi-chemical pulping process (NSSC) is
one of the most common pulping methods in Pakistan and
wheat straw is used as a raw material. The pulping liquor
used in NSSC process is a solution of sodium sulfite
containing sodium bicarbonate or sodium hydroxide as a
buffer to keep the PH around 7. The NSSC process consist
of four steps (a) steaming of raw material for 30 min at
atmospheric pressure, (b) addition of pulping chemical and
application of 100 psi pressure at a temperature of 120-125
centigrade for 60 min, (c) third step is the removal of excess
liquor not absorbed by the raw material, (d) lastly digestion
at 140-160 centigrade for 1- 6 h. The yield of this process is
65-90% depending upon raw material, buffering agent and
cooking time.
 STEPS after digestion
• Washing
• Bleaching
• Beating
• Refining
• Additives
• Paper/sheet making
 Hydra Pulpers

Hydra Pulpers used

mainly for handling
waste paper
are fitted with
special devices for
removing
unwanted contraries
such as wire, plastic etc
 Waste Paper Processing
• Pulping
• Deinking
• Screening & Cleaning
• De-ashing, Dispersing, Bleaching
• Thickening
Pulp Bleaching
 Bleaching Agents
Chemical or process used and Letter designation

• Chlorine C
• Sodium hypochlorite H
• Chlorine dioxide D
• Extraction with sodium hydroxide E
• Oxygen O
• Alkaline hydrogen peroxide P
• Ozone Z
• Chelation to remove metals Q
• Enzymes (especially xylanase) X
• Per-acids (per-oxy acids) PAA
• Sodium dithionite (sodium hydrosulfite)Y
 Bleaching
Chlorine and hypochlorite
Chlorine replaces hydrogen on the aromatic rings
of lignin via aromatic substitution, oxidizes
pendant groups to carboxylic acids and adds
across carbon carbon double bonds in the lignin
side chains. Chlorine also attacks cellulose, but
this reaction occurs pre-dominantely at pH 7,
where un-ionized hypochlorous acid, HClO, is
the main chlorine species in solution. To avoid
excessive cellulose degradation, chlorination is
carried out at pH <1.5.
 Bleaching contd.

Cl2 + H2O H+ + Cl- + HClO

At pH >8 the dominant species is hypochlorite,
ClO-, which is also useful for lignin removal.
Sodium hypochlorite can be purchased or
generated in situ by reacting chlorine with
sodium hydroxide
2 NaOH + Cl2 NaOCl + NaCl + H2O
The main objection to the use of chlorine for
bleaching pulp is the large amounts of soluble
organo-chlorine compounds produced and
released into the environment
 Paper Making Machine
• Slurry
• Dispersion
• Consistency
• Chemicals (Sizing)
• Weight of fiber and water
• Sheet making
• Water Mark
Fourdrinier
Sections of Fourdrinier Machine

• Headbox
• Wire Section
• Press Section
Paper Making Machine
 Paper Making Machine
• Head Box - receives the liquid pulp, with all
ingredients ready to make the paper Flow
Spreader - controls the pulp distribution on the
Table Fourdrinier Table - a perforated conveyor
belt that supports the pulp solids and allows the
water to drain through Press Section - rollers
that squeeze water from the pulp
• Dryer Section - typically steam drums (cans) that
progressively dry the pulp as it turns to paper;
the drying section may also include electric or
gas infrared heaters and convection heating
hoods. Calendar Stack - metal rollers that
compress the paper to form uniform thickness;
may be smooth or include some sort of pattern
Paper Machine: Pressing
Tissue Paper Manufacture
Machine
 Tissue Papers
• Tissue Machines are very similar to paper
machines in over-all process, but they are
much smaller in size and have a different kind
of dryer section. Tissue is what is used to
make toilet paper, paper towels, napkins, etc.
Like paper, tissue is made from a pulp
material, but is more often recycled and much
lower quality materials. It is made in large
rolls and later in a separate process
"converted" to its final product.
 Yankee Dryer
• Yankee Dryer The Yankee Dryer uses a very
large steam cylinder (18 - 25 ft diameter)
surrounded by an air cap (hood). The hood
supplies hot, high velocity air that impinges on
the sheet. This way, drying is accomplished by
a combination of conduction (the steam drum)
and convection (moving air). The drying work is
about evenly divided between the drum and
hood.
 Paper Coating
• Paper Coating Many papers require a "coating" to
be complete. The coating process may be
connected to the paper machine where the
machine is dedicated to making only one kind of
paper, or may be a complete separate process in
a totally different location.
• Common coatings include various clays to
improve whiteness and absorption (such as
premium ink jet papers) and silicone for water
resistance and release for things like labels. The
coating will make the paper wet or require curing.
Dryers used on coaters are typically non-contact
convection hoods and/or electric or gas infrared.
 Paper Brightness
• Brightness is a measure of how much light is
reflected by paper under specified conditions
and is usually reported as a percentage of
how much light is reflected, so a higher
number represents a brighter or whiter paper
News Print ranges from 55-75 ISO brightness.
Writing and printer paper would typically be
as bright as 104 ISO.
• Testing of paper
• Strength /colour etc
• Environmental aspects of Paper
Industry
• Water Usage
• Packages Pvt Limted
• Flying Paper mills
• Century paper Mills
• Premier Paper Mills
• Mandiali paper Mills
Installed Capacity
 Pollution
• Pakages
• Shifted
• Waste Water
• Pollutants
• Treatments
• By products
Beating and Paper Strength