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Industry: Andrada, Filmar Badua, Reynaldo Jr.A. Benito, Angelica Joyce Z. Cabaddu, Quennie

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INDUSTRY

ANDRADA, FILMAR
BADUA, REYNALDO JR.A.
BENITO, ANGELICA JOYCE Z.
CABADDU, QUENNIE
DEFINITION OF TERMS

PAPER – a thin material produced by pressing
together moist fibers of cellulose pulp derived from
wood, rags or grasses, and drying them into flexible
sheets.

PULP - a cellulosic fibrous material prepared by


chemically or mechanically separating cellulose fibers
from wood, grasses, fiber crops, waste paper, or rags.
RENEWABILITY IN NATURE

FOOD ANIMAL

PLANT DECOMPOSED

FERTILIZER
RENEWABILITY IN PULP AND
PAPER INDUSTRY
CASCADING USE OF WOOD
Paper(other sort)

Binders in drugs

Energy(electricity)

.
Handkerchief

Napkins

Energy
(electricity)
CASCADING USE OF WOOD

product
process
Trimmings
water recycling

Process water
Industrial Symbiosis

waste
Ash
(adsorbent)

biomass thermal electrical Water treatment in Pulp


plant waste Industry
Waste Biomass
(source of energy)
Industrial Symbiosis

Environmentally-friendly and a great asset in our economy

cost landfill Green job


HISTORY
2500-2000 B.C A.D 150 A.D 795
The manufacture of The first actual The first paper mill
a writing paper from manufacture was was created by
papyrus, a tall reed invented by Arabs
growing along Nile, chinese
was begun

1799 1750-1800 1690


A Frenchman, Holland beater America’s first
Louis Robert was developed paper mill was
invented a process and adopted established
for forming a sheet
on a moving wire
screen was
invented
1809
Cylinder machine was invented by
John Dickinson

1826 1827
Steam cylinders for First Fourdrinier was received in
drying were first America
used

1841 1853-1854
Keller Of Saxony had The soda
invented a mechanical
process for making
process was
pulp from wood developed by
Watt and
Burgesse
1866-1867
The American chemist, Tilghman was
granted the basic patents for the sulfite
process

1874
The manufacture of
sulfite pulp began

1908
The sulfate
process was
introduced into
the United States
FACTS

Top 5 Paper Producing Countries in the World


 Republic of Korea
 Germany
 Japan
 USA
 China
Most countries only recycles 50-60% of used paper

One ton of paper made from recycled pulp saves 17 trees

Did you know that you cannot fold any piece of paper in half,

(no matter what size), more than six times? Try it!
Cellulose: 38- 42 %
Glucomannan
Xylan
Other hydrocarbons
95% of the Lignin 20-30 %
Resins
fiber is from
wood Cellulose LIGNIN
Fiber
An organic compound
A polysaccharide consisting of several hundred to
cellulose many thousand of linked glucose
Most abundant organic polymer
Lignin 2nd most
abundant
natural polymer
in the world
Principal
constituent of cell
wall, binder for
cellulose fiber and
it is a complex
amorphous poly
phenol polymer
Lend rigidity and the
reason why chopped
woods does not rot
easily
Raw materials

Fiber Chemicals Energy Water

Non–wood Recovered/recycled
Softwood Hardwood fibers fibers
Soft wood
o Contain more lignin than
hardwoods Hardwood
o Longer and coarser fiber than o Provide Smooth surface
hardwoods o Primarily used in the production
o Strength to withstand stretching of printing paper
and tearing o E.g. Acacia, lemon, gum, birch,
o Include coniferous and non eucalyptus, pinus, patula, paper
coniferous woods mulberry, rubber plant wood etc..
o E.g.: pine, spruce

Non–wood fibers
o high cellulose content and low
lignin content
o often grown especially for paper
Recovered
production
/recycled
o e.g.: agricultural residues, Straw, fibers
Grasses and reeds
TYPES OF
PULPING

Mechanical Chemical Semi-


Pulping Pulping chemical

Ground Refiner Kraft


- Sulfite - Soda
Wood Mechanical (Sulfate)
process process
Process Pulping Process
Differences in Methods of Pulping
Chemical Pulping :Kraft , Sulfite and Soda Pulping

SULFATE or KRAFT SULFITE SODA


FIBROUS RAW Any kind of wood Coniferous; must be Limited to short-
MATERIAL (Soft or hard) good color and free fibered hardwoods
from phenolic because of low yields
compounds and pulp strength

COOKING LIQUOR 60% NaOH Composition depends 12.5% solution of


COMPOSITION 25%Na2S on process NaOH and Na2CO3, in
15% Na2C03 modifications, but all the ratio 85 to 15;
uses SO3 dissolving action due
a) Magnifite process: solely to NaOH
Mg(HSO3)2 + free
SO2 in acid media
b) Nuetral Sulfite
process: Na2SO3 ,
Na2CO3, NaHCO3
c) Acid Sulfite Process
: Na2CO3, NaHCO3
COOKING TIME: 2-5 hr TIME: 7-12 hrs TIME: 6-8Hrs
CONDITIONS TEMP: 340-3550F TEMP: 265-300 0F TEMP: 330-240 0F
PRESSURE: 100-125 PRESSURE: 70 -90 PRESSURE: 90 – 105
lb/in2 lb/in2 lb/in2

CHEMICAL RECOVERY most of process is SO2 relief gas liquor Sodium Hydroxide
devoted to recovery ,magnesium liquor recovered abd
of cooking 'chemicals recovered and reused as in kraft
with incidental reused after wood process , but make
recovery of heat digestion and pulp up chemicals is
through burning washing Na2CO3 instead of
organic matter Na2SO4
dissolved in liquor
MATERIALS FOR Digesters, pipe lines, Acid liquor requires Same as kraft
CONSTRUCTION pumps and tanks digester lining of acid materials
can be made of mild – prof brick; Fittings
steel or iron because of chrome- nickle
caustic liquor does steels (type 316),
not readily corrode lead , and bronze
them
Pulp characteristics • Brown color • Dull white color • Brown color
• Difficult to • Easily bleached • Easily bleached
bleach • Fibers are • Weaker than
• Strong fibers weaker than kraft or sulfite
• Resistant to kraft
Mechanical
refining
Typical paper • Strong brown • White grades: Usually blended
products bag and - Book paper with other pulps
wrapping - bread wrap • Book and
• Multiwall bags - fruit tissue magazine grade
• Gumming paper - sanitary tissue • Coated papers
• Strong white • Sanitary tissue
writing and
printing paper
• Cartons
Block Diagram of Pulp Production
Using Sulfate (kraft) Process
Feed
Debarking Chipping
(wood)

blowing cooking screening

washing screening thickening

bleaching
DEBARKING
- a process of removing bark from wood. Generally, they are
powered by hydraulic motors. The log is then pressed against
blades or knives which remove the bark while the log is turned
to ensure the removal of bark all around the log.

wood Barked log

bark
TYPES OF DEBARKER
• 1. Drum debarker -type of debarker used for centuries. Logs are loaded into a hopper
where a conveyor belt moves the logs into a drum. The drum is rotated and produces a
rolling action that tosses and throws the logs around inside it. The abrasion caused from
the logs hitting each other and being hammered against the inside of the drum wall
removes bark from the log.

• 2. Ring debarker –becoming the debarking method of choice for industries for it
produces a high value of lumber. It has a ring of cutting heads or knives mounted in a
circular position. The first ever ring debarker is developed in Sweden and called Cambio.

• 3. Flail debarker –consists of chains that are flung and whipped against the log. This
hammering action loosens and ultimately removes the bark from the log.
CHIPPING
-a process where logs are chipped into a smaller parts. This
process is basically performed in a disc chipper.

logs Chipped
logs screening

Length: 0.47-0.98 in
Width: 0.079-0.0394 in
COOKING
-a process where addition of chemicals are required to separate
cellulose fibers from other substances in a wood to produce a pulp.
Cooking process occur inside a digester.

25% steam
White liquor Lignin
50%
water
25%
Cellulose
COOKING
White liquor –is a cooking liquor and a mixture of chemical that contains Sodium hydroxide
(NaOH) and Sodium Sulfide (Na2S). This is used to entail the treatment of wood that breaks
the bonds of lignin, hemicellulose and cellulose.
steam White liquor

Wood chips
Digester
(pressurized vessel) Cellusolic fiber
3 hrs. (pulp)
T=170-175 C Brown stock
Black liquor

Turpentine

Black liquor – a black aqueous solution that contains lignin residues, carbohydrates
from the breakdown of hemicellulose, sodium carbonate, sodium sulfate and other
inorganic salts.
COOKING
Lignin structure
C9H10O2,C10H12O3,C11H14O4

Scission of ether ether


By the Bisulfide (SH-)ion

net reaction in depolymerization of lignin by SH− (Ar = aryl, R = alkyl groups).


BLOWING
A process where the cooked wood chips are blown to a collection tank called a
blow tank. Its purpose is to reduce the pressure level up to atmospheric
pressure. This releases steam and other volatile substances.

WASHING
The brownstock from the blow tank goes to the washing stages where some
remaining cooking liquor is separated from the cellulose fiber. Normally, a
brownstock undergoes 3-5 washing stages in series.
SCREENING
Process where the pulp is separated from shives, knots, dirt and other debris
that have failed to disintegrate in the cooking process. These fibers containing
knots are reprocessed or sent back to the digester. The content of knots is
typically 3% of the digester’s output

THICKENING
- Stage where a greater portion of the water is removed by a rotating fine
wire screen.
BLEACHING
It is a chemical process that is used to decrease the color of the pulp. The
brownish color of the pulp is actually caused by the 5% residual lignin that
is failed to disintegrate during the cooking stage. This process is often
referred to as delignification.
Bleaching sequence in 1950s Modern bleaching sequence
1. Pulp is exposed to chlorine 1. Pulp is treated with oxygen
2. Washed with a sodium 2. Treated with ozone
hydroxide solution to remove 3. Washed with sodium
lignin by chlorination hydroxide
3. Treated with sodium 4. Treated with alkaline
hypochlorite peroxide and sodium
4. Washed with sodium dithionite
hydroxide again
Totally Chlorine-Free (TFC)
5. and final treatment with
hypochlorite. To reduce emission of pollutants!
RECOVERY OF BLACK LIQUOR

Steam And Volatile 1.Organic compounds-broken down


Substance formed Heated air 2. Carbon is burnt away
(H2S,CH4S) 3. Inorganic chemicals are melted

Na2SO4 + 2C =Na2S +2CO2


Weak Black
liquor
Boiler

White liquor
Multi-effect
evaporator Na2S
smelt Slaked lime NaOH
1. Remove water water
So it can be burnt in the recovery
Boiler.
2. Produce water for the use of
other operations.
3.Concentrate the black liquor
Dissolving Green
Causticizing
tank liquor
Insoluble impurities tank
Na2CO3 + Ca(OH)2 = 2NaOH + CaCO3
WATER CONSERVATION
Paper Production Process
Stock Preparation

Beating
• includes fibre separation, cutting and fibrillation or
brushing effect
• takes place on a machine(Hollander or its
modifications)
• makes the paper more uniform, stronger, and more
dense
Refining(Disk Refiner/ Conical Refiner)

• Jordan engine(for Conical Refiner)


• develops different fiber properties in different ways for specific
grades of paper
• improves bursting strength, folding endurance, smoothness,
formation and other strength properties
• pulp is deformed, defibered and dispersed
• fillers, dyes and sizes are added
• Sizes- rosin from tall oil, wax emulsion
• -improve the sheet’s resistance to penetration by liquids
• Fillers-makes the surface of the paper smoother
Paper Machine
Finishing

Coating- treatment of the paper surface with clay or other pigments


and/or adhesives to enhance printing quality, color, smoothness,
opacity, or other surface characteristics

Supercalendering- Coated papers are passed through an off-line


supercalender made up of hard and soft rolls. These impart gloss to
the coated surface.
Recycle Paper
Soap and
Recycle paper Hydrogen
Compressed
air Peroxide

s
Pulping Screening De-Inking Bleaching

Water and Surface


Sodium Scum
Silicate Stock
Preparation
Pulping- happens in a pulper, Fibres swell,
loosening the ink and then begin to separate

Screening- fibers ar separated from


contaminants

De- inking- Ink sticks to the soap bubbles


forming a surface scum, which is removed

Bleaching- brightens the fibers


• Benefits of recycling
• For every ton of paper recycled:
• 30,000 tons of water is saved
• Enough energy is saved to power a 3 bedroom house for a
year
• 95% less air pollution is caused compared to virgin wood
• What does paper get recycled into?
• Top quality printers waste → Printing and writing paper
• Office waste/newspapers & magazines → Graphic paper,
tissues, newsprint
• Brown unbleached packaging → New packaging
• Mixed papers/directories → Middle layers of cardboard
packaging
Structural Boards
• generally used for insulation
Fiberboards • soft- or hardwoods, cull timber, and mill residues, and the
wood is pulped by mechanical, thermomechanical method

• uses sawdust, shavings, and wood flakes of special shapes t


Particleboard combine good physical properties with attractive appearance
• Uses synthetic resin adhesives

Paper-base • resin-treated paper bonded together under high pressure and


heat
laminates

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