INPLANT TRAINING

MAHATMA GANDHI POLYTECHNIC. MECHANICAL

ENGINEERING
INPLANT TRAINING

lIntroduction 2
VCoating

□ Thebenefitsofcoatedpaper 11
□ Coatingmachine 11
llWoodproduction
□ Coatingpreparation 12

□ Woodastherawmaterial 3
VlFinishing
lllPulpproduction
□ Calender 12
□ Rewinder 13
Pulpingprocess
□ Slitterrewinder 13
□ Mechanicalandchemicalpulp 4
□ Crosscutter 13
□ Sulphateandsulphiteprocess 4
□ Guillotine 13
□ Intermediatepulptypes 5

Pulpbleaching 5
VllPackingandstorage 14

lVPaperproduction
VIIIPaperproperties 15

Rawmaterials
□ Preparationofthefibresintherefiner 6
lX Concludingremarks 16
□ Additionalrawmaterialsforthebasepaper 6

Papermachine
□ Suspensionattheheadbox 7
□ Sheetformationinthewiresection 7
□ Filtration/Thickening 7
□ TwinformerandGapformer 8
□ De-wateringinthepresssection 9
□ Dryersection 9
□ Endgroup 9

Surfacetreatment
□ Sizepress 10
□ Filmpress 10

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

lIntroduction
Thoughwemaytakeitforgranted,paperisalwayswithus,docum
enting our world and reminding us of the
limitlesspossibilitiesoflife.InventedbytheChinese2,000yearsa
go,paperhasbeenusedeversinceasacommunicationmedium.I
nitially, paper was made out of fibres from mulberry
bark,papyrus,straworcotton.Woodonlyemergedasthechief
rawmaterialforpapermassproductionasrecentlyasthemid1
9thcentury.

Theprintedpageisimmediate,itsmessagecuttingacrosscult
ures;atactileexperiencethatdemandsattentionandcreates
desire. It is a passport to knowledge, a storagemedium,
a persuasive tool and an entertaining art form.Paper is a
sustainable resource and a permanent docu-ment. It is
the universal medium on which we chronicle ourevery-
dayhistory.Papercarriesthepast.Itisthecanvasonwhich we Theinteriorofahistoricalpapermill
live the present and the blueprint upon which
wedesignourfuture.
This brochure shows how we make this first class
Papertouchesthelivesofeveryindividualonthisplanet,andat paper.Starting with the production of the most
Sappi,weneverstopthinkingaboutthisfact.WeareproudthatSa important rawmaterial, wood. The pulping process
ppiisthelargestandmostsuccessfulproducerof coated fine converts this woodinto the most appropriate type of pulp.
papers in the world. At Sappi, we are relent- The paper machinethen converts the pulp into a thin base
lesslydevelopingnewstandardsforthepaperindustry. paper, which, at theend of the production process, is
coated to give it a
Drawing on centuries of experience, and the superbflatsurfaceandbrightshade.Followingthedescription
craftsmanshipandexpertiseofitsownpeoplesupportedby21 ofthis
stcenturypapermaking technology, Sappi will lead the process,wewilltakealookatthepropertiesusedtomeasurethe
industry toensure that this creative communication qualityofpaper.
medium, paper, isthebestitcanbe!

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

llWoodproduction
Wood as theraw material

Approximately25,000plantswithawoodystemareregisteredund
erthetermwood.However,thedifferentvarietiesclearlydifferint
ermsofusabilityfortheproductionofpaper.

Conifersarepreferredasthefibresarelongerthan,forexample,fibr
esofdeciduoustrees.Longerfibresformafirmerfibrousweband,
hence,afirmerpaperonthepapermachine.

Conifers used are mainly spruce, fir and pine,

whereasbeech, birch, poplar and eucalyptus are the most Beechtrunks
importantdeciduousvarietiesusedforpaper.

Atrunkofatreeisnotahomogeneousbodycomposedofidentic This means that the wood supplied to the paper mill has
alcells.Thecellsdifferaccordingtotype,age,seasonof tobe debarked before it can be used to produce one of
origination and arrangement in the trunk. At the thevarietiesofpulp–
outside,there is the bark, below are the bast and the thebasematerialfortheproductionofpaper. The debarked
cambium,which form the growth tissue. By cell division, trunks are either pulped to fibres(mechanical wood pulp)
the or processed to chips for chemicalpulp.
cambiumgrowsoutfromthecentreofthetree.Growthstagnat
ionduringthewintermonthsresultsintheannualrings.Thetru Thewoodfindsitwaydirectlytothepapermillintheformoftrunkso
nkwithitsdifferentcellswhichareresponsibleforthetranspor rintheformoftimbermillwaste(slabs,chips).
t of the nutrients and the saps can be used
forpaperpulp,butnotthebark.

Woodtrunks Chips

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

lllPulpproduction pulpproducedbythisprocessiscalledwoodfree.Itisthistypeo
fpulpwhichisusedforallSappifinepapers.
Pulpingprocess
Thesulphateprocessisanalkalineprocess.Itallowsfortheproc
Pulping of wood can be done in two ways: mechanically essingofstronglyresinouswoodtypes,butthisrequiresexpensiv
orchemically. einstallationsandintensiveuseofchemicals.

Mechanicalpulp Thesulphiteprocessutilisesacookingacidconsistingofaco
mbinationoffreesulphuracidandsulphuracidboundasmagne
In the case of mechanical pulp, the wood is processed siumbi-sulphite(magnesiumbi-sulphiteprocess).
intofibreformbygrindingitagainstaquicklyrotatingstoneundera
dditionofwater.Theyield*ofthispulpamountstoapprox.95%.T Inthesulphiteprocess,thecookingliquidpenetratesthewood
heresultiscalledwoodpulporMP–mechanicalpulp. inthelongitudinaldirectionofthefibres,whicharealignedinthi
ssamelongitudinaldirectioninthechips.Whenthe cooking
The disadvantage of this type of pulp is that the fibre liquid penetrates the wood, it decomposes
isstronglydamagedandthatthereareallsortsofimpuritiesinthe thelignin,which,duringtheactualcookingprocess,isconvertedi
pulp mass. Mechanical wood pulp yields a high ntoawater-
opacity,butitisnotverystrong.Ithasayellowishcolourandlowlig solublesubstancethatcanbewashedout.Thedecompositionpro
htresistance. ductsofthecarbohydratesareincludedinthecookingliquidassug
ar.
Chemicalpulp
When the waste fluids are concentrated in order to
Fortheproductionofwoodpulp,thepurefibrehastobesetfree,w recyclethechemicals,thesesugarsareprocessedtoalcoholan
hichmeansthattheligninhastoberemovedaswell.Toachievethi dethanoic acid. In this stage, the sulphite pulp is
s,thewoodchipsarecookedinachemicalsolution. slightlybrownandthereforehastobebleachedtoobtainabase
colour suitable for white papers. This bleaching process,
In case of wood pulp obtained by means of inwhich no chlorine or chlorine compounds are used,
chemicalpulping, we differentiate between sulphate and alsotakesplaceinthepulpmillasanintegratedpartoftheover-
sulphitepulp,dependingonthechemicalsused.Theyieldofche alloperation.
micalpulpingamountstoapproximately50%.Thefibresinthe
Thestrengthofsulphitepulpsislessthanthatofsulphatepulps
.Sappiusesonlythemagnesiumbi-sulphiteprocess
resultingpulpareverycleanandundamaged.Thewood initsownpulpmills. *yield=usablepartofthewood

Pulpingprocess

Mechanical Thermo-mechanical Chemical- Chemical

thermo-mechanical

MP TMP CTMP Sulfateprocess( Sulphiteprocess(

MechanicalPulp Thermo- Chemi-Thermo- alkali) acid)
Mechanical- Mechanical-
yield90-96% Pulpyield90- Pulpyield85-90% yield43-52% yield43-52%
96%

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Pulpbleaching
Intermediatepulptypes:
Initially,woodpulphasabrownorbrownishcolour.Toobtainthebri
TMPThermoMechanicalPulp ghtnessrequiredforwhitepapers,ithastobebleached.During
In this procedure, chopped waste wood is this process of bleaching, the remaining lignin
vaporisedand then beaten into single fibres in isremovedaswell.Inpracticalterms,bleachingisacontinuationof
refiners undervapourpressure. the chemical cooking process, taking place directly after-
wardinthepulpmillasanintegratednextstepoftheoverallproce
CTMPChemi- dure. Bleaching is a complex process, consisting
ThermoMechanicalPulp(woodpulp) ofseveralchemicalprocesssteps,withwashingtakingplaceb
This process consists of a combination etweenthevariouschemicaltreatments.
ofimpregnation(mixingwithachemicalpulp),cooking,r
efiningandbleaching.Thepulpingyieldamounts The wood pulp can be bleached with chlorine /
to90%. chlorinecompounds, ozone / oxygen in different forms
as well ashydrogenperoxide.
Thefibrelengthandtherelatedstrengthofthepaperare
controllable. CTMP contains a certain amount Basedonthenegativeimpactofsomechlorinecontainingdeco
oflignin,atenacious,toughsubstancefromthecellwalloft mposition products, there are, however,
hewoodwhichstronglyturnsyellow. environmentalobjectionsagainsttheuseofchlorineandchlorine
products.

For this reason, Sappi has long ago switched to chlorine-

freeprocesses.

These processes are referred to as Totally Chlorine

Free(TCF).

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

lVPaperproduction carbonate(chalk),whichhastheadditionaladvantageofmaki
ngthepapermoreresistanttoageing.Thetotalper-
Rawmaterials centageoffillersusedcanbeashighas30%ofthestock.Inindustr
ialpaperproduction,therespectivequantitiesanddensity
Preparationofthefibresintherefiner ratios are regulated by computer controlled propor-
tioningsystems.Thisistheonlywaytoguaranteeauniformquality
Thetypeofrefiningwhichtakesplaceintherefinerhasadecisiv standardintheproductionofhigh-qualitybrandpapers.
e influence on the properties of the paper to
beproduced.Arefinerisarefiningaggregatewithrotatingand Butbyfarthemostimportantprocessmaterialiswater.Foreach
kilo of paper approximately 100 litres of water
arerequired.Inourtime,theonlyjustification–
economicallyaswellasecologically–
fortheuseofsuchenormousquantitiesofwater,isclosedcirculatio
nandeffectivewastewatertreatment.

The Sappi paper mills have the highest expenditures for en-
vironmentalprotection,evenwhencomparedtothehighnatio
nalstandards.

Intheproportioningsystemwater,stuffsandfillersarebroughttoge
ther in mix tubs. The so-called constant part of a
papermachine constitutes the transition from pulp
preparation tothe headbox of the paper machine. Another
element of
thisconstantpartisthesortingunit,whereimpurities,foreigns
ubstancesandpatchesareremoved.

Refinerforstockpreparation

stationary cutters, the so-called rotors and stators. Fillers: Calcium

Thevariablepositioningoftheserotorsandstatorsinrelationtoea carbonate,Clay,
chotherdetermineswhetherthefibresarebeingcut(freestock Titaniumdioxide
refining) or fibrillated (wet refining). Fibrillating is a
finebleedingofthefibreends,resultinginaclose- Additives: Dye,
knitconnectionbetweentheindividualfibres.Inthefinalpaperthi Opticalbrighteningagent
s,inturn,resultsingreaterstrength.
Binders: Latexandstarchproducts
Additionalrawmaterialsforthebasepaper

Processmaterialsincludewater,fillers,sizingsubstances,dye
sandadditives.

Fillersservemultiplepurposes:theymakethepapermoreopa
que,moreclosedinitssurface,brighterinshadeaswellas softer
and more flexible depending on the
requirement.Besidesminerals,suchaskaolinandchinaclay,the
modernproductionprocessofpapermakesextensiveuseofcalci
um
MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING
INPLANT TRAINING

Papermachine GratkornPM11

Suspensionattheheadbox Filtration

Afterdilutionandsortingintheconstantpart,thesuspensionoffib Inthecaseoffiltration,asharptransitionisgeneratedbetweenthef
res,processmaterialsandwaterhastobeledtothewirepartunifor ibrelayerbuildinguponthewireandthesuspensionabove. In
mlydistributedacrossthewidthofthepaperweb.Inprinciple,the this liquid phase, the pulp concentration is
speedatwhichthesuspensionexitsfromtheheadboxontothewi nearlyconstantandthefibrescaneasilymovetoeachotherinthec
rehastobeequaltothespeedofthewireonwhichthesheetisfor orrespondingratio.
med.Toachievethis,pressureis applied to the suspension in
the headbox, in order Thickening
toaccelerateittothewirespeed.Apartfromthat,turbulenceisge
neratedjustbeforetheexitpointoftheheadboxtoavoidharmfulfl Inthecaseofthickening,thereisnocleardivisionbetweenthegene
ockformation. rated fibre mat and the suspension. The
concentrationincreases linearly from top to bottom and
Thesuspensionleavestheheadboxatthedischargelip.Atthis the fibres aredemobilised in the suspension. At the same
point, the suspension flowing onto the wire can have time, waterdrains out from all layers of the suspension, to
athicknessofupto18mm. be collectedforreuse.

Theelementswithwhichthesheetformationcanbecontrolled
aredividedinfourmaingroups:

1. Runningelements

□ theendlesswire
□ theupperandlowerwire

2. Rotatingelements

□ tableroll
□ formingroll
□ suctionroll
□ squeezeroll
EhingenPM6
□ egoutteur

3. Stationaryelements
Sheetformationinthewiresection
□ wiretable
Oncethesuspensionhaslefttheheadboxandcomesintoconta □ hydrofoil
ctwiththewire,thepaperfibresmovetothewireasaresultoftheir □ vacufoil
naturalflowresistance,thusformingalayeroffibresonthewirew □ suctionbox
hichaccumulatestowardsthetopofthestock.Atthesametime,
waterdrainsawayatthebottom,and this combination of 4. Mechanicalelements
processes leads to two
differentformsofsheetformation,dependingonthefreedomofm □ screenadjustmentoftheheadbox
otionof the fibres in the suspension: through filtration □ wireshaking
and bymeansofthickening.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Twinformer

Sheet formation takes place in the screen part of the

papermachine.Itisinfactanon-
goingbattlebetweenfiltrationand re-flocculation. The wire
part can have different designfeatures. The most common
design is the endless wire con-
cept.Itisauniversallyapplicablesystemallowingforhighflexib
ility with regard to basic weight and sheet
properties.However, these endless wire paper machines Gapformer
have aserious performance limitation in that they are
strictly one-
sided:drainagetakesplaceonlyatthebottom,notatthetop. Gapformer
And so, new designs were considered to
increasedrainage efficiency. This led to the development Afurtherdevelopmentinmodern,high-speedpapermachinesare
of theso- the so-called gap formers. In these formers, drainage
calledtwinformer,whereadditionalequipmentisinstalledon the iscarried out to both sides simultaneously as the
rods of the endless wire. The twinformer is a designwhich suspensionis injected directly between the two wires
provides for drainage of the suspension to the topside as directly from theheadbox. Upon leaving the headbox, the
well, by means of an added upper wire and a seriesof pulp mass
suction boxes. With this additional equipment, the isimmobilisedinamatterofmilliseconds,thuspreventinglaterdr
paperstock can now be drained on both sides – from the ainage elements from affecting the sheet structure
bottombymeansofgravity,andfromthetop,bymeansofsuction. whichisnowbeginningtoform.Thefibrewebisfrozen–literally–
Drainage time is significantly reduced, which results in a theseconditcomesoutoftheheadbox.
farmoreefficientproductionprocess,withtheaddedadvantageo
freducedtwo-sidednessofthepaper. This process sets high demands on the quality of the head-
boxandtheconstantpart.

Twinformer

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

De-wateringinthepresssection short,firstphase,onlyheatistransferredtothepaper.Thereis no
vaporisation. This takes place during the secondphase,
Afterformationofthesheet,aprocesswhichdeterminesthem when the wet paper starts to convey its humidity tothe
ostimportantsheetproperties,thepapersheethastobe further surrounding air. In other words, the water contained inthe
drained and compressed. In this next phase,mechanical paper starts to evaporate. In the third phase, the
pressure exerted vertically to the sheet surfaceis used to papersurfacehasalreadybeendriedtothemaximumextent,and
further increase the proportion of dry content. Inthe press heattransmissionintothedrypaperstimulatesvaporisationinsid
section, the web runs between a series of rollswhich ethepaper.
exert specifically set amounts of pressure. The
waterpressedoutofthepaperisabsorbedbyfeltsandtransporte
doff. Endgroup

In recent years, shoe presses have been developed After conclusion of the drying process, the paper is
toincreasetheefficiencyofthetraditionalrollpresses.Inthesepr oftensubjected to glazing in machine calenders. Besides
ess units, one of the rolls is replaced by a machinecalenders,whichusesteelrolls,therearealsosoftcalend
hydraulicallypressed shoe. This creates a bigger press nip, ers,consistingofpairedrollswhereoneismadeofsteelandtheoth
which makestheprocessmoreeffective. eroneiscoatedwithasoft,plasticmaterial.Thisproducesa better
overall glazing effect and eliminates the problem ofso-
called“blackglazing”.

Attheendofthemachine,thepaperistakenuponsteelcores,
the so-called tambours. Most paper machines
pressure

usepoperollers.Thetambourpressesagainstthebigpoperollera
ndtakesupthepaperinuniformwindingsandatconstantcircumf
time web
speed erentialspeed.
Pressniplength

Inthepapermachine,therearevariousmeasuringframesatdiffe
rent positions, continuously measuring and controllingthe
selected quality parameters, such as base
weight,moistureandashcontents,brightnessandopacity.

nippressure

Shoepress

Dryersection

Whenthepaperleavesthepresssection,ithasadrycontentofupt
o50-55%.Now,theremainingwaterhastoberemovedby
vaporisation. The most common type of paper drying
iscontactdryingoncylindersheatedwithvapour.Here,thehea
tenergyistransferredfromtheoutsidewallsofthedryingcylinder
stothepapersurfacebydirectcontact.Thedryersection
consists of a succession of drying cylinders and
thepaperwebistransportedoverandbetweenthesecylinders,th Dryingsection
epaperalternatelymakingcontactwiththeupperandthelower
side.Dryingtakesplaceindifferentphases.Inthe

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Surfacetreatment

Sizepress

Thesimplestformofrefinementissurfacetreatmentinthesizepre
sswhichisintegratedinthepapermachine.

Here,starchisappliedtostrengthenthepapersurface.Atthes
ametime,this“closes”thesurfaceofthepaper,thuspreventin
g problems like dusting or picking from
occurringinthelaterprintingprocess.Inmanycases,treatmentin
thesizepressisusedtopreparethepaperforthesubsequentpr
ocessofcoating. Filmpress

Thesizepressconsistsofapairofsoftrolls,oftencoatedwithru
bber,whichpressagainsteachotherasthepaperwebisguided Filmpress
throughthenipbetweentherolls.Thesizesolutionistransferr
edtothepaperthroughthisnip,whichalsoservestocontrolthed Asmachinespeedincreasedalongwiththequalitydemandsfo
oseofsizingbeingapplied.Inthesizepress,thequantityofapplied rpigmentedandmachinecoatedpapers,newmultiple roll
pigmentsislimited. systems were developed which allowed forpre-
dosingofthecoating.

These modern press systems use a precisely pre-dosed

filmof coating, which is transferred to the paper in the
nipbetween the application rolls. In this case, however,
thecoatingisappliedonthebacksideoftheroll,usingadesignsimi
lartothatofacoatinginstallation.Thesefilmpressesrunathig
hspeedandtheycanoperatewithhighconcen-
trationsinthesizingandpigmentingsystem.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

VCoating Coatingmachine

Thebenefitsofcoatedpaper Aprimaryreel,onwhichpaperdeficienciescanberemoved,is
superposed to the coating machine. To bridge set-
Inrecentdecades,printmediahavehadtomeetincreas-ingly uptimesatthecoatingmachine,thisprimaryreelhastooperateat
high demands, in terms of visual aspects and in termsof ahigherspeedthanthepapermachine.Ithasanunwindingsyste
printability. To meet these demands, coated papers m,designedforuseofaflyingsplice.Next,thepaperiscoated.First
wereintroducedmanyyearsago. ononeside,followedbydrying.Thentheotherside is coated
and dried. For drying purposes, infrared-dryers, airfoils
Coatingapaperenhancesitsopticalandtactilecharacte- and drying cylinders are used. Rolls
ristics – whiteness and shade, gloss and smoothness – withgyratorygroovesandwideplug-
butitalsoimprovesitsprintingbehaviour,allowingtheuseofve inreelsprovidesafereelguidancethroughthecoatingmachine.
ry fine screens, yielding more colour in thinner ink
layersandproducingmorecontrastinprintedimages. Theheartofthecoatingmachine,however,isthecoatingunit
with the integrated coating aggregate. Under
Whenpaperiscoated,acoveringlayerofpigments,bindingagent eachcoatingunit,aworkstationpumpsupthecoatingmassfromt
sandprocessmaterialsisappliedtothesurface.Toachieve he preparation tanks, where the colour is mixed.
optimal results, all elements involved in the Thesetanks,madeofstainlesssteel,arecooledtoavoidcoatin
processmustbeperfectlytunedformutualsupport,andthisinclu gsticking to the walls and clot formation. The coating has
desthecoatingcolour,thecoatingmethod,thecoatingmachinea tobepermanentlyfilteredandaeratedtoavoiddeficiencies,su
nd its specific settings and the paper itself. One ch as blade streaks. Automatic control systems conti-
coatingmachine can apply multiple layers of coating, all nuouslymonitorandadjustcoatingquantityandhumidityofthec
dependingontheintendeduseofthepaperandallapplicationsofc oating.
oa-
tingrequiringtheirowndryingtimes.Therearesinglecoatedpap AtSappi,differentmethodsandtechniquesofcoatingareused
ers,doublecoatedpapersandtriplecoatedpapers.Inmanyca .Thetwomaincoatingtechniquesarefilmcoatingandbladecoati
ses,severalmethodsofapplicationarecombinedforanendre ng.
sultthatbenefitsfromeachoftheindividualadvantages.
In film coating and roll coating a uniform layer of coating
isapplied to the base paper. The surface contours of
thepaper remain visible. This is why the process is also
Coating
knownas“contourcoating”.

Inbladecoating,anexcesslayerofcoatingisfirstappliedtothepap
Basepaper er,whichisthenpartiallyscrapedoffagain(“doctored”)withasteel
blade.Thepressureexertedbythisdoctorbladeproducesaunifo
Filmcoating rmsurface.Thecavitiesofthepaperarefilledwithcoatingandth
efibrebacksremainnearlyuncovered.

Coating

Basepaper

Blade coating

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Coatingpreparation

Coatings mainly consist of pigments (chalk, clay or

talcum).In themselves, however, these are powdery
substanceswhichwouldbeblownoffthepapersurfacelikedust.
There-fore, binding agents must be used to provide
adherence
toeachotherandtothepaper.Dependingontheintendeduseof
the paper and the type and structure of the
pigmentsused, different quantities of binding agents are
required.Bindingagentscanhaveanaturalbasis(caseinorstarc
h)orasyntheticcomposition(syntheticdispersions).

Process materials add specific properties to the

coating.One commonly used process material is optical
whitener. Itconverts invisible, ultraviolet light into visible
bluish whitelight,givinganimpressionoftruewhiteness.

In the so-called “coating kitchen”, these individual compo- Supercalender

nents, taken form large storage silos, are mixed in
stainlesssteeltanks.Afterhavingbeenthoroughlyscreened,natu
rally.Each specific coating has its own recipe, exactly VlFinishing
prescribingthe quantities of each component. To preserve
consistencyfrompreparationtopreparation,thewholeprocesso Calender
fcoatingproductionisfullyautomated.
Calendersareusedtomakethepapersurfaceextrasmoothand
Inthecoatingunits,measuringframesmonitortheweightofthe glossy. A calender consists of a number of rolls,
coating being applied to the paper and the wherepressureandheatisappliedtothepassingpaper.Thereare
resultingglossofthepaperitself. many different types of calenders. Some can be
integratedaspartofthepapermachine,othersareoperatedsepa
Usually,thecoatingkitchenisalsoresponsibleforpreparationoft rately,as stand-alone installations. These separate
hestarchsolutionusedinthesizepress(withorwithoutpigmenta installations,the so-called supercalenders, can include up
tion), which is an integrated part of the papermachine. to 16 rolls.Theserollscanhavedifferentsurfaces–
theycanhavesteelwalls or coverings with elastic materials,
depending on thedesiredextentofglazing.

Depending on type, the paper is ready after it leaves

thecoatingmachineorthecalender.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Rewinder

Thefunctionoftherewinderistorewindthereelsfromonetambo
ur to another tambour. Here, the web run can
bechanged,fromtheoutertotheinnerside,thereeledgesmay
becutanddeficienciesinthepapercanberemoved.

Slitterrewinder

Thefinishedpaper,whichonthetambourstillhasthefullmachi
newidth,iscuttosmallerreelsontheslitterrewinder.Circularkni Crosscutter
vescutthetambourtoreelsofspecifiedwidthwhilethetambou
risbeingunwound.Dependingonpapertype,thesereelsareno
wreadyfordeliverytothecustomer,or they are transported to Oneimportantaspectisthatthecuttingprocessmustbeperfec
a cross cutter where the paper iscuttosheets. tly synchronised to produce the exactly right size
andsquareness. A conveyor belt directly after the knife
sectionholds the sheets in position and transports them
at
highspeedtoasecondconveyorbelt.Here,thespeedisreduceda
nd the sheets are laid out in overlapping arrangement
forfurthertransporttothefinalstackedlayout.

Modern cross cutters do more than just cutting. They

checkthequalityofthepapersurface,removefaultysheets,coun
tthesheetsandinsertcountingstrips.Someevenallowfora“flyin
gchange”processofcontinuousoperation,inwhichfullpallets
areautomaticallytransportedoffandnewpalletsmovedintoposi
tionwithouthaltingthemachine.

Reelcutter
Guillotine

Guillotinetypecuttersareusedforcuttingrelativelysmallquan
Crosscutter titiesofpaperinspecialsizes.Inthesecases,completelyrefittingt
hecrosscutterwouldnotbeeconomicallysensible.Guillotines
Inacrosscutter,thesmallerreelsthathavebeencuttosizefromta are also used for the so-called four-sided
mboursbytheslitterrewinder,arecuttosheetsofaspecified trimwhichisnecessaryforcertainprintjobs.
size. Several reels can be processed simultane-
ously,dependingonthedesignofthecrosscutterandthe“cutti
ngweight”ofthepaper.Theimportantthinghereistoproduce
sheets with clean cutting edges, in other words,
topreventcuttingdustfromclingingtotheedges,sincethiswo
uld cause problems in the printing process. The
paperreelsfedintothecrosscutteraretrimmedonbothedges
andseparatedinlongitudinaldirectionbycircularknives.Thewebi
sthencutofftotherequiredsizebythechopperknife.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

VllPackingandstorage
Packingofpallets
Finally,thepaperispackagedfortransporttothecustomer.Thep
ackingisimportanttoavoidtransportdamagesandtoprovide
protection against moisture. Transport The defined packing units are taken off the stack
methodsandmeansdeterminethetypeofpacking. beforereaching the ream wrapping machine and
transported incorrectalignmenttothefirstwrappingunit.
Automatic reel packing machines perform the
followingtasks: Thepackingpaperiscutoff,wrappedaroundthepaperandglued
in place. The packed reams are then stacked
A bar code identifies the reel. While the reel is positioned andlabelled.
inthe centre, interior side caps are applied on both
sides.Basedonthesequencebelongingtothebarcode,amachin Palletswithsheetsizepaper(reamedorbulk-
ewrapsthereelwithpre- packed)arewrappedvapourtightwithshrinkingorwrappingf
selectedpackingpaper,usingacertainnumber of windings oil.Fortransport over longer distances, a covering plate is
and a specific type of gluing. appliedand the packed pallets are reinforced with loops of
Finallyexteriorsidecapsareadded,thereelisweighedandthelab steel orplasticbanding.
elsareattached.Thereelthengoestothetransportdepartmentvi
aaconveyorbelt. Palletspackedinvapourtightwrappingdonotrequireafullair-
conditioningwheninstorage.Theycanbestoredinlightand
water protected areas. Paper producers and whole-
salersoftenusehighshelfstocks,inwhichthepalletscanbesto
redrandomly,tobepickedbycomputer-
controlledpickingsystems.

Packingofreels

Sheetsize paper can be packed in reams or delivered

asbulk-packed goods, with pallet packing only. Reams
cancontain100,250or500sheets.Inthecaseofsmallerordersor
special sizes, ream wrapping is carried out
manually.Largestockordersinstandardsizesarereamedonr
eamwrappingmachines.

Thepackingmaterialisdesignedaccordingtocustomers’requ
ests.Protectionagainstdamageandmoistureisthemainconcern
, but ream wrapping can be used as an Automaticwarehouse
advertisingmediumaswell.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

VlllPaperproperties PPSroughness

Thedatasheetslistthemostimportantqualitycharacteristicsoft Thegeometricformofapapersurfaceisdefinedasdeviationfromt
hepaper. heidealflatlevel.Themorethesurfaceapproachestheideal
Theseinclude: level, the smoother the paper is. The
measuringmethod(PPS)isbasedonthemeasurementofairle
Basisweight akagebetweenthepapersurfaceandtheevenmeasuringhead.I
nthecaseofPPSroughness,theaverageporedepthoveradefi
The basis weight of a paper means the weight in grams ned circular area is measured. The higher the
persquaremeter(g/m 2)underconditionedcircumstances.Thee measuredvalueis,the“rougher”thepapersurfaceis.
ntiremassisthesumoffibrousmaterials,fillers,processmateri
alsandwater. Opacity

Brightness Theopacityisameasurefortheopacitydegreeofthepaper,expre
ssed in percent in relation to the reflected light.
Thebrightness(ISO)isameasureforthebrightnessdegreeof Paperwhichletsalotoflightthrough,istransparent;paperthat
the paper expressed in percent compared with lets little light through, is opaque. The higher the value,
thebrightnessstandard(magnesiumoxide=100%).Thehigher themoreopaquethepaperis.
thebrightnessvalue,thebrighterthepaperis.
Relativehumidity
Gloss
At a given temperature, there is a maximum to the
Theglossfigureinthedatasheetsindicatesthepercentageofrefl amountofwatervapourthattheaircanabsorb.Relativehumid
ectedlightwithadefinedangleofincidence.Ahighergloss leads ityindicates the percentage of this maximum which is
to stronger light reflections and higher glossvalues. actuallyintheair(i.e.betweenthesheetsofastackorthewindings
ofareel).

pHvalue

The value in the data sheets defines the pH value of

thesurface.ThepHvaluesareindicatedonascalefrom0to14.Th
evalue7markstheneutralpointwhichcorrespondstodistilled
water. Values below 7 refer to “increasingly acid ”,values
above 7 stand for “increasingly alkaline”.
PapersshouldhaveapHclosetotheneutralpointinordertomeeti
dealrequirementsforprintingandfurthertreatment.

Specificvolume

Paperthicknessisexpressedinmicrometer(μm).Tocomparethe
thicknessofpaperswithdifferentbasisweights,specificvolumei
sused.

volume= thickness
(μm)basisweight(g
Colour space /m 2)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2. OutlineofPrincipalManufacturingProcesses
2.1. Chemicalpulpmanufacturingprocess(kraftpulpprocessing)
InJapan,mostchemicalpulpisproducedusingKP (kraftpulpprocessing)because this
method produces strong pulp, is highly adaptable to any wood species,and pulping
chemicals can be recovered and recycled. Another big advantage is thatthe method
converts constituents other than wood fiber, such as lignin, into heatenergy using
boilers in the chemical recovery process and then makes use of suchenergy.
Seventy percent of wood material for paper is imported in the form of
woodchips from advanced nations that manage
forestssustainably,andmanyresidualwood products resulting from lumbering and
lumber from thinning are also used.Residualwood accounts for morethan 50 percent
ofdomestic lumber used.
As for environmental measures, a system combining biological treatment
andcoagulating sedimentation treatment is used for wastewater. To ensure the
preventionagainstairpollution,desulfurizers,denitrificationequipmentandelectrostaticpr
ecipitators have been installed. Deodorizing equipment is also indispensable for
theKP method. Incineration processing is applied to high-density odorous gases.
Besidethesemethodsthatprocesspollutantstobereleasedoutside,theindustryhasintroduce
d many internal measures to prevent the release of pollutants by changingbleaching
systems, combustion methods for boilers, etc., and by introducing low-odorrecovery
boilers that produce little odor. For the dioxins problem, which has beendiscussed a
great deal recently, the whole industry has made a concerted effort topromote the
installation of oxygen bleaching facilities, which has solved the problemcompletely.
The industry is now advancing to the stage of adopting the ElementalChlorineFree
(ECF) method to further reduce environmental load.
(1) Cooking process
Woodchips and chemical (white liquor: NaOH + Na2S) are placed in a
digester,cookedatahightemperatureandpressure(about160℃and10atmosphericpressur
es),and separated into cellulose fibers and lignin, etc.
The cellulose fibers are continuously washed in warm water and sent to
thebleaching process after uncooked materials are removed with a screen. To be
usedas kraft paper for corrugated cardboard, they are sent directly to the
papermakingprocesswithout bleaching.
(2) Bleachingprocess
The fibers are brownish after the cooking process, as they still contain
someamount of lignin, etc. Higher brightness can be obtained by removing the
remaininglignin with chlorinate bleach chemicals (chlorine, hypochlorite, and
chlorine dioxide)and caustic soda in several phases.
At present, most mills adopt an oxygen bleaching process to remove lignin
priortothechlorinebleachingprocesstoreducetheenvironmentalloadinthesubsequent

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

processthatuseschlorinatedchemicals.Thiscanreducedioxinsemissioninbleachingwaste
water almost to the limit of identification.
It is expected that an increasing number of mills will adopt the ECF
method,which does not use chlorine to further reduce environmental load. Thus, the
ECFmethod,whichhasneitherchlorinationnorhypochloriteprocessesthatgeneratechlorof
orm, can reduce the chloroform released to wastewater and air to an
almostnegligiblelevel.
(3) Chemicalrecovery process
Lumberingredients(ligninandhemicelluloseexcludingfibers),whichareseparated
at the cooking process, and the remaining liquid chemicals are sent to
thechemicalrecoveryprocess.Thechemicalcompound(blackliquor)isburnedinrecovery
boilers after being concentrated by vacuum evaporators and is
effectivelyusedasheatenergy.Hydrazinehydrate,whichisusedasadeoxygenationagentint
heboilers,is decomposed and consumedin the boilers and is not releasedoutside.
ResidualdrossfromblackliquoraftercombustionisacompoundofNa2CO3and Na2S.
After Na2CO3reacts with lime (Ca(OH)2) in the caustic process to beconverted to
NaOH and CaCO3, NaOH and Na2S are used for cooking as white fluid.CaCO3 is
converted to CaO by using a kiln. CaO is slaked with lime and water
toproduceCa(OH)2which is then usedto react withNa2CO3.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2.2. Groundpulp manufacturingprocess

Becausegroundpulpismerelycrushedwood,mostlumberingredientsthemselves
become pulp. Therefore, the amount of pulp made from lumber is
greaterthanchemicalpulp.Itstwodisadvantagesarethatconiferoustreeswithcomparativel
y longer fibers should be used because finely crushed fibers make thepaper weaker,
and milling requires a large amount of electric power. A large amountof lignin
content prevents a high degree of whiteness in paper, although it is
possibletoproducethinpaperwithhighopacity.
Mechanical pulp is classified into RGP (refiner groundwood pulp), GP
(groundpulp), and TMP (thermo mechanical pulp) according to manufacturing
methods. Weexplaina typical exampleof RGPbelow.

RGP wasintroducedasamechanicalpulpmanufacturingmethodfromtheviewpoint
of effectively utilizing resources. It uses refiners to process wood
chipsmadefromscrap timbersofsawmillsthat hadbeenscrappedorburnt before.
(1) Processofdeliveryandwashingofchips
An electromagnetic feeder adjusts the amount of chips that are supplied from
achip silo via a flow conveyor. Next, a measuring conveyer continuously
measurestheir weight. The chips are then sent to the next process after foreign matter
such asmetallicmaterials, soil and sand is removed.
(2) Disaggregationprocess(refinerprocess)
Arefinerisequippedwithtworotatingdisksthat face eachother.Radial
groovesarecutintothesurfacesofthedisks.Chipsarepassedbetweenthedisksanddisaggreg
ated (ground). The two types of refiners are; a single-disk refiner with onefixed disk
and one rotating disk, and a double-disk refiner whose two disks rotate inopposite
directions.
(3) Screeningprocess
The two types of screening equipment are cleaners and screens. Screens are
usedtoseparaterawmaterialsfrom foreign objectsdependingonthesizeandshape.Round
holes or thin slits are made in a screen plate to allow the raw materials to
passthroughthem and the foreign objects remain on the screen plate.
Cleaners, which are usually shaped as oblong cones, are used to separate
rawmaterials from foreign objects by differences in specific gravity. Raw materials
areplacedinalargeopeningatthetopoftheequipmenttoflowandswirldownalongthe
tangential line. During this time, centrifugal force ejects unwanted objects withlarge
specific gravity, which then hit the surrounding walls, fall down and are drainedout as
dross.
The foreign objects removed by screens and cleaners are sent to the
wastewatertreatmentprocess or burnedafterthedewateringprocess.
(4) Bleachingprocess

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Parts of the screened raw materials are bleached and some are not.
Targetedbrightness can be obtained by changing the additive rate of bleaching
chemicals (suchas sodium hydrosulfite and hydrogen peroxide). Volatile materials
(e.g., chloroform)maybereleasedtoair,dependingonchemicalsused.
(5) Drainage process
Becausetheconcentrationofpulpsentfrom
thepreviousprocessislow,thepulpisdrainedwiththickenertoincreasetheconcentration,an
dthencontinuouslystoredinthechest.Thedrained(white)liquorissent to thewastewater
treatmentprocess.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2.3. Processof pulp derived fromwastepaper

The Law on Promoting Green Purchasing will come into effect on April 1,
2001to further improve the social foundation for the use of recycled paper. The
paperindustry, which had set a target to achieve a wastepaper utilization rate of 56
percentfor 2000, achieved the target almost one year earlier. The industry has started
a newscheme to achieve utilization rate of 60 percent by 2005 in order to further
improvethewastepaper utilization rate.
The processes of pulp derived from wastepaper can be divided roughly into
fourparts: (1) defiberization, (2) dirt removal, (3) deinking, and (4) bleaching.
Whilepaperboardmanufacturingonlyrequirestheprocessesof(1)and(2),papermanufactur
ingrequires(1)through(4)tosatisfyqualityrequirements.
(1) Defiberization process
Collectedwastepaperandwaterareputinapulpertomakethetreatmentconcentration
about 3 to 5 percent. High-speed mechanical churning for 30 to 60minutes reverts
wastepaper back to the state of pulp. Heating or chemical substancesare sometimes
applied to facilitate defiberization. A new type of pulper that cancontinuously process
wastewater with a high concentration (12 - 18 percent) has
beenintroducedtoreplaceconventionallow-
concentrationbatchtypeprocessingequipment.
(2) Removalof foreign objects
Wastepapercontainsvariousobjects,e.g.,papermakingchemicalssuchasloading
materials and paper durability promoter, printing ink, hot melt (resin starch),plastic,
and staples. Wastepaper containing such foreign objects cannot be
recycled,thereforetheyarecarefullyremoved with cleaners and screens.
(3) Deinking process
Meredefiberizationcannotmakeprintedwastepaperagoodrawmaterialbecause the
fibers contain a large amount of ink. Deinking is one way to remove
thecoloringmatterortocleanstainedrawmaterials.Inkisflakedoff,dispersed,suspended,
and separated from fibers in wastepaper by using mechanical power inaddition to
alkali and chemicals such as surface-active agents. In Japan, the paperindustry mainly
adopts flotators that deink wastepaper by separating the ink
withbubblesfloatinginaliquorthatuses littlechemicals and water.
(4) Bleachingprocess
Inordertofurtherimprovethequalityofdeinkedwastepaper,ableachingprocessisappl
iedtoincreasebrightness.Wastepaperpulpwiththedegreeofbrightness(55-
75percent)requiredforparticularapplicationsuchas(newspaperand fine paper) is
achieved by using bleaching chemicals such as hydrogen
peroxide,sodiumhydrosulfite andsodiumhypochlorite.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2.4. Preparationprocess
This is a process to finally prepare and send out raw materials for
papermaking.Specifically, this process consists of defiberization of purchased pulp
and broke,beating of raw materials, blending of raw materials, addition of fillers,
sizers, andchemicals,dustremoval,andde-
aeration.Lowconsistencypulpersareusedfordefiberizationofpurchasedpulpandbroke,an
dcleanersandscreensareusedfordust removal. Pulpers use rotating blades in the tank to
generate a vortex in the
watertocarryoutdefiberization.Lowconsistencypulperscarryoutdefiberizationinconcent
rations of 3.5 - 5.5 percent. Cleaners and screens use the same principle andsimilar
structures as those described in the “mechanical pulp manufacturing
process”paragraph.
The following is a description of the beating of raw materials, blending of
rawmaterials,and the addition offillers, sizes, and chemicals.
(1) Beatingof rawmaterials
Fundamental factors of beating are to swell fibers, increase the flexibility
andsurface area of fibers, fibrillate (making fibers fibril), and cut (trimming fibers)
bybeatingfiberswithadiskrefiner,etc.Themorefibersarebeaten,themoretheirwaterretenti
on is improved and sheet formation isfacilitated.
(2) Blendingof rawmaterials
Importantfactorsofblendingrawmaterialsaretorecyclebrokegeneratedduring the
papermaking, coating, and finishing processes and to blend raw
materialsandrecoveredwhitewaterreleasedoutsidefrompreparationandpapermakingpro
cesses. Keeping these procedures reduces raw materials loss as much as
possible,improves retention, and reduces wastewater treatment load. White water
refers to thewater that contains flour (minute fibers), which is drained from the wire
part of papermachines at the papermaking process, at a concentration of about 0.5
percent. Brokegenerated at the dryer part of paper machines, coating, and finishing
processes isdefibrated by pulpers.
Raw materials are beaten individually according to the tree species, mixed
withother different types of pulp, such as wastepaper pulp or broke, and are added
torecovered white water in the mixer. Specified quantities of different types of pulp
areblendedandstoredinamixingchest.
(3) Additionoffillers,sizingagents,andchemicals
The main purpose of fillers is to improve opacity, brightness, smoothness,
andinkreceptivitybyfillingthevoidbetweenfiberstoimproveprintabilityandappearance
after printing. They are also effective at making paper thick, tight, andsoft. Although
kaolin and talc have been traditionally used as fillers, recently anincreasing amount of
calcium carbonate is used due to the increase of neutralizedpaper.
Sizingtreatmentisdesignedtopreventinkfeatheringonthepaperforprinting

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

orwriting,ortoaddwaterresistancetowrappingpaperandboardlinersforcorrugated
fiberboard due to their content and usage conditions. Although rosin (pineresin) and
its fixing agent-aluminium sulfate-have been used as sizing agents (acidicsizing
papermaking method), the neutral sizing papermaking method uses calciumcarbonate
as the filler and alkylketene dimers or alkenyl succinic anhydride as sizingagents.
Sizing agents that give water-resistance to paper include melamine resin,
ureaformaldehyderesinandwater-solublethermosettingresinssuchas polyethylenimine.
Other chemicals, such as retention aids (that reduce retention loss with
fixingflour),strengtheningagentsforpaper(thatimprovesheetstrengthofpaperbyincreasin
g the number of fiber bonding points), slime control agent (that keeps
slimefromdevelopingbysterilizingmicroorganisms),antifoamingagent,anddyes,etc.,are
added as required.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2.5. Papermakingprocess
The papermaking process is to dilute and disperse the prepared materials,
orpaper stock, spray the paper stock on wirecloth to form a paper sheet, and
drainwaterfromthesheetanddryit.A
papermachineconsistsofapapermachinemainframeandauxiliaryequipment.Thepaperma
chinemainframeconsistsofastock inlet, wire part, press part, dryer part, size press,
calender, and reel along theflow of materials. The auxiliary equipment consists of a
driving unit, approach
pipesthatsupplyrawmaterialsandcirculatewhitewater,avacuumsystemthatdrainswater
from the wire part and press part, a drainage system that supplies and recyclessteam
for the dryer bank, an air system that circulates and uses air for drying
andrecoverswasteheat,etc.PapermakingmachinesareroughlyclassifiedintotheFourdrini
er machine and the cylinder machine according to the type of wire part,
andthemultiplecylinderdryerandtheYankeedryeraccordingtothetypeofdryerpart.
(1) Dewateringprocess
Materials with which pulp, filler, and sizing agent, etc., are blended are put in
amachine chest as mother stock, diluted with white water in the system, and jetted
outonawirenetthroughthestockinlet.
TheFourdriniermachineusesacontinuouswirenet.Themotherstockissprayed or
dropped onto the moving wire net. After the water is drained, a paper sheetis formed
on the wire net. Table rolls and hydrofoils are arranged in the wire net
parttooptimizedrainagekineticsforsheetformation.Paperstockisfirstdriedonthewire net
by suction generated by the rotation of table rolls or contact between thehydrofoil and
wire net, and its concentration becomes about 20 percent where
thesheetleavesattheendofthewirenetpart.
Acylindermoldrotatesinthevatofthecylindertypepapermachine,andmotherstockfor
msapapersheetonthenet ofthe cylinder mold as it rotates.
The wet paper sheet (paper on the paper machine) contains too much water
andits tensile strength is small when it is away from the wire net part. The press
partcompresses and drains it to form a stronger sheet. A wet paper sheet with
highmoisture content breaks under high pressure, therefore the concentration of the
wetpaper sheet is raised from 20 percent (moisture content: 80 percent) to 40 - 50
percent(moisture content: 60 - 50 percent) by gradually increasing pressure by several
pressrolls.
Whitewaterdrainedinthewirenetpartiscirculatedwithinthesystem,butwhitewaterdr
ainedatthepresspartis senttoawastewater treatment process.
(2) Drying process
After the press part, the wet paper sheet is heated with the dryer to a
moisturecontent level of 6 - 10 percent. Usually at the dryer part, there are several
tens ofcast-iron cylinders measuring 1.2 - 1.8 m in diameter and they hold the wet
papersheetwithcanvasandcontactwiththesurfaceofthecylindersevaporatesthepaper

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

sheet’smoisture.TheYankeedryerwithonecylinderthatmeasures2.4-4.5mindiameteris
used to produceglazed paper.
Iftheusedchemicalsarevolatile,theymaybereleasedtotheairatthedryer
part.
(3) Sizepress coating process
The size press machine applies starch to paper in the middle of the dryer
processin order to give water resistance and surface strength to the paper. The size
press waspopularized with the progress of offset printing. Typical models of size
press coaterare the inclined type and the gate roll type. The inclined-type size press
coater has aso-called dip coating structure with two inclined rolls that contact each
other withpigment supplied between the rolls. Paper passes through the rolls.
Although thestructure is simple, concentration of the pigment is as low as 4 - 5
percent. The
gaterollcoaterhasastructureconsistingofseveralrollsandappliespigmentataconcentration
of 10 - 20 percent withthe same function of coating machines.
(4) Calendering andreel process
A calender consists of several steel rolls, or calenders, that rub the surface of
thepaper sent from the dryer part, to smooth and gloss it. Friction between calender
rollsand paper generates heat, which may cause the diameter of rolls to slightly
change inany direction. Therefore the calender has a device that blows out cool air to
preventthermalexpansion ofrolls and tofinish auniform thickness ofpaper.
The paper sent out of the calender is wound on a reel and shipped as a
productafter finishing.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

2.6. Wastewatertreatmentprocess
Pulp and paper mills use a large amount of water as reaction media and
washingwaterinthepulpandpapermanufacturingprocesses.Atthechemicalpulpmanufact
uring process and the mechanical pulp manufacturing process, organic wasteliquor
containing lignin and other polysaccharides, which are principal constituents ofwood,
is generated. The process of pulp derived from wastepaper generates
wasteliquorcontainingfines,ink,andfiller(powderymineralmatterblendedtogiveopacityt
opaper).Pollutantscontaminatingtheliquorareprocessedtosatisfylawsandregulations
and released to bodiesof water.
The main wastewater treatment processes are pH adjustment using acid or
alkali,removal of SS (suspended solids) using clarifiers, and decrease in BOD and
COD bymeans of biological treatment and coagulative precipitation (flotation). The
actualwastewatertreatmentisacombinationofthem.Inthissection,weexplainwastewater
treatment using the flow diagram, “Typical process diagram for pulp andpaper
production.”
The explanation includes the treatment of sludge generated from the
wastewatertreatmentprocess.
(1) Neutralization process
The waste liquor ranges from a low pH area to a high pH area depending on
thetreatment conditions at the source of release. Such waste liquor is adjusted to a
pHsuitableforactivatedsludgetreatment(biologicaltreatment)byaddingacidoralkali.
(2) Activatedsludgetreatment
After the adjustment, waste liquor to be treated is sent to an aeration tank and
air(oxygen) is blown in with aerobic bacteria (return sludge) to decompose and
removeorganicsubstances(BODingredients).Inthisprocess,volatilesubstances(e.g.chlor
oform) in the liquor to be treated are released to the air because air is blown intothe
aeration tank or a cooling tower which is used when the temperature of liquor
tobetreatedishigh.
(3) Coagulativeprecipitation(clarifier)
Wastewater from the pulp manufacturing process contains colloidal
particlessuchaslignin,whichisdifficulttoremovebybiologicaltreatmentmeans.Coagulati
ng agents (inorganic or organic macromolecules) are used to remove thecolloidal
particles and large flocs are formed and precipitated. In this process, filler
inwastewaterfromthepapermakingprocessandwastepaperpulpprocessarealsoprecipitate
dandremoved.
(4) Dehydration process
Wastewater treatment sludge (paper sludge) that is naturally precipitated in
theclarifier are pulled out as solid content at a concentration of about 3 percent, sent
to adehydrator, and dewatered to 40 - 60 percent in the solid content. Some of
thedewateredproductsareeffectivelyusedassoilconditionerbutmostofthemare

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

incineratedinsludgeincinerators.
(5) Incinerationprocess
Dehydratedsludgeisincineratedinvarioustypesofincinerators,suchasfluidized bed,
fixed bed, and cyclonic incinerators. Organic substances in sludgebecome carbon
dioxide and water, and inorganic substances become incinerated
ash(includingsmokedust).Mostoftheincineratedashiseffectivelyusedassoilconditioner,s
teel-
makingheatinsulant,andrawmaterialsforcement.Thisincineratorisdesignatedasaspecifie
dfacilityunderLawConcerningSpecialMeasuresagainstDioxins.Specificallyspeaking,re
gulatorystandardfiguresarefixed with respect to exhaust gas, incinerated ash, smoke
dust, and - if wet processtreatment of exhaust gas is carried out - comprehensive
wastewater, and measurementatleast once a year isobligatory.
Inhomogeneous combustion in incinerators sometimes generates benzene as
abyproduct and this is releasedto theairintheexhaustgas.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

3. TypicalClassIDesignatedChemicalSubstances(ClassISubstances)relatedtothe
industry

Cabinet
OrderNo. CASNo. Class I Substances Process in which thesubstancesare used Remarks
Zincsulfate[water-soluble
1 7733-02-0 compoundofzinc] Coatedpaper(cast-coatpaper)

2 79-06-1 Acrylamide(monomer) Coagulatingagentmanufacturing Thewhole amount is polymerized.

16 141-43-5 2-aminoethanol Specialtypaper(rust-preventive agent)

65 107-22-2 Glyoxal Specialtypaper (wet paperstrengthadditives) Coating afterreactiontobinder(PVA)

95 67-66-3 Chloroform BKPbleaching process Byproduct

Desensitizationchecker Rawmaterials = products

145 75-09-2 Dichloromethane
Cleaningagent Usedamount =released quantitytoair

172 68-12-2 NN-dimethylformamide Solvent forantisepticagent, slime controlagent

179 - Dioxins BKPbleaching process,incinerator of waste Byproduct

227 108-88-3 Toluene Solvent

Hydrazine hydrate/Cas No.7803-57-
253 302-01-2 Hydrazine Deoxygenation agent scavenger forboiler 8 is alsoincluded.
299 71-43-2 Benzene Wastegas from waste incinerators Byproduct
Hydrationresistanceagents suchas starchand
PVA
Antiseptic agent

310 50-00-0 Formaldehyde Encapsulant Nocarbonrequiredcopyingpaper

Flame retardant Guanidine

Wet paperstrengthenhancing additives

Note:Requiring notification
Annualquantityofbenzenehandled:0.5t/yearormore(Specificclass1substance)Annualqu
antity of class 1 substances handled:1 t/ yearor more

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

4. Wastemanagement

Waste

Landfill Waste

*Stablel Administratedla
andfills ndfills

On- Industrialwaste On- Industrialwaste

sitelan processor sitelan processor
dfill dfill

Release(on Releases(on
Transfers Transfers Transfers
-sitelandfill) -sitelandfill)

PRTR
PRTR
* Forlandfilltype,”stable”or“administrated”isdesignatedbytheLaw.
Incasewastewassoldforrecycling,reportingisnotrequired.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5. ProceduresandExamplesofCalculatingReleasesandTransfersinTypicalProc
esses
5.1. Zincsulfate(Zinccompounds(water-soluble))
5.1.1. Processflowandreleasesand transfers

Name ofsubstance Zincsulfateheptahydrate

CAS No. 7733-02-0
CabinetorderNo. 1 Requiringnotification 1.0t /year
Conversioncoefficient 0.227
Use Coatedpaper(Castcoat)

Processflowexample(releaseandtransfer)

Zinc
sulfate1 PRTR
00%

Pulpmanufacturing,Bl Papermaking, Product94

eachingprocess Coatingprocess .7%

Waste Releaseto
watertreat waterbodies
ment
Wastetrea
Wastepaper tment
(Dehydration)

Transfer
Waste Sludge
inwaste

Wastetrea
tment Air
(Incineration)

Transfer
Waste4.9 Incinerateda
inwaste
% sh
0.4%

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.1.2. Calculationmethod
[Calculationprocedure]
Quantitiesofpigmentingredientsreleasedandtransferredthroughoutthecoatingandfi
nishingprocessesarecalculated accordingtothefollowingprocedure:

Quantityofcolorhandled
(1)CalculationofthehandledquantityofClassISubs ×
tancescontainedincoatingcolor Contentofsubstanceincoatingcolor

Quantityofcolorhandled
×
(2)Calculationofquantitiesshippedinproducts coatingyield
×
finishingyield

Quantityofwastecolorandbrokegenerated
(3) Calculation of the transfers of
×
chemicalsubstancescontainedinwastecolorand contentofchemicalsubstancesinwastecolorandbroke
broke

(4)Calculationofmaximumpotentialrel Quantityofchemicalsubstanceshandled
easestotheenvironment - quantityshipped
- transfersinwaste

(5)Calculationofthereleasestowaterbodies Maximumpotentialreleasestotheenvironment

Figure: Proceduresforcalculatingquantitiesofcoloringredientsreleasedandtransferredthro
ughoutthecoatingandfinishingprocesses
(Worksheetforcoating/finishingprocesses)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.1.3. Calculationexamples
Thefollowingareexamplesofhowtocalculatethereleasesandtransferswithfacilitiesa
nd under the conditions below:
(Overviewoffacilities)
Process: coating process of cast-coated
paperEquipment used: coating machine
Wastewater treatment equipment: activated sludge treatment (removal
efficiency:100%)
Coating color used: cast-coat color [zinc sulfate (7 hydrate) Content: 5
%]Annualamountofcoatingcolorused:500tons/year(totalamountisused)

(1) Calculationofannualquantityofzincsulfatehandled
Annual quantity of zinc compound handled is calculated by using the amount
ofcoating color used, content of zinc sulfate (7 hydrate) contained in the coating
color,and conversion factor from zinc sulfate (7 hydrate) to zinc.
(Annualquantity of zinc handled)
= (amount of coating color used) x (content (%) in the coating
color)x (conversion factor)
=500tons/yearx1,000kg/tonx5%/100x0.227
= 5,675 kg/year
(2) Calculationofthequantity shippedinproducts
Thequantityshippedinproductsiscalculatedbyusingtheannualquantityofzinc handled,
coating yield, rate of broke in the coating process, and finishing yield.(Quantityshipped
in products)
=(annual quantityof zinchandled) x(coatingyield)
x (1- rate of broke in the coatingprocess)x(finishingyield)
= 5,675 kg/year x 99.6%/100 x (1 - 3%/100) x 98%/100
= 5,373 kg/year
*(Coating yield)
=(quantitycoatedonpaper)/(quantityincoating colorused)x100(unit:%)
*(Rateof broke in the coating process)
=(quantityofbrokeinthecoatingprocess)
/ (total quantity of coated paper transferred from coating
process)x100(unit:%)
*(Finishingyield)
= (quantity shipped in products)
/ (totalquantity transferred to finishing process) x100(unit:%)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

(3) Estimationofquantityofchemicalsubstancestransferred inwaste

For the transfers of chemical substances in waste, those in waste coating
colorandbrokegeneratedintheprocessesofcoatingandfinishingaresubjecttoestimations.
①
Wastecolorinthecoatingprocessiscalculatedbyusingthecoatingyield.Wastecolorisadded
asindustrialwastetothetransfers､throughthewastetreatment
process.(dewateringandincinerationtreatmentprocess;treatmentefficiency:100%).
(Transfersofchemicalsubstancesinwastecolor)
=(annualamountofzinchandled)x[1-(coatingyield)] x(treatment efficiency)
=5,675kg/yearx(1-99.6%/100)x100%/100
= 22.7 kg/year
②Thequantityofwastegeneratedthroughcoatingandfinishingprocessesiscalculatedbyus
ingtherateofbrokeincoatingprocessandfinishingyield.Broke,
which is usually off-site recycled, is added to transfer in waste, in case handed
overto industrial waste collectors. When broke is sold for recycling, PRTR
reporting isnot required.
(Transfersofchemicalsubstancesinbroke)
=(annualamountofzinchandled)
x {(coating yield) x (rate of broke in coating process) + (coating
yield)x (1 - rate of broke in coating process) x[1 - (finishing
yield)]}
= 5,675 kg/year x [99.6%/100 x 3%/100
+99.6%/100x (1 - 3%/100) x (1 - 98%/100)]
= 279 kg/year
(4) Calculationofmaximumpotentialreleases
Themaximumpotentialquantityreleasediscalculatedbysubtractingthequantity of
zinc shipped in products and transfers in waste from annual quantity ofzinc handled.
(Maximumpotentialreleases)
=(annualquantityof zinchandled)- (quantityofzinc shippedinproducts)
-(quantityofzinctransferredinwaste)
=5,675kg/year-5,373kg/year-(22.7kg/year+279kg/year)
= 0.3 kg/year
(5) Calculationofreleasestowaterbodies
The whole maximum potential quantity of zinc sulfate (7 hydrate)
released,which is notvolatile, is regarded asthequantityreleasedtowaterbodies.
(Releasestowaterbodies)
=(maximumpotentialreleases)
= 0.3 kg/year

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.2. 2-Aminoethanol
5.2.1. Processflowandreleasesand transfers

Name ofsubstance 2-Aminoethanol(monoethanolamine)

CAS No 141-43-5
CabinetorderNo. 16 Requiringnotification 1.0t /year
Use Specialpaper (Anti-corrosiveagent )

Processflowexample(releaseandtransfer)

2- PRTR
Aminoethan
ol100%
Papermaking,Coa
Pulpmanufacturing,Bl Product92
tingprocess,
eachingprocess .1%
Finishingprocess

Release
Waste
towater
watertreat
bodies0.5%
ment

Wastetreatment(
Waste
Dehydration)
paper3.4
%
Transfer
Waste Sludge inwaste
4.0%
Wastetreatment(
Incineration) Air

Incinerateda Transfer
Waste
sh inwaste

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.2.2. Calculationmethod
[Calculation procedure]
Quantitiesofcoatingcoloringredientsreleasedandtransferredthroughoutthecoatingandfinis
hingprocessesarecalculatedaccording to thefollowing procedure:

Quantityofcolorhandled
(1)CalculationofthehandledquantityofClassISubs ×
tancescontainedincoatingcolor Contentofsubstanceincoatingcolor

Quantityofcolorhandled
×
(2)Calculationofquantitiesshippedinproducts coatingyield
×
finishingyield

Quantityofwastecolorandbrokegenerated
(3) Calculation of the transfers of
×
chemicalsubstancescontainedinwastecolorand contentofchemicalsubstancesinwastecolorandbroke
broke

(4)Calculationofmaximumpotentialreleasestot Quantityofchemicalsubstanceshandled
heenvironment - quantityshipped
- transfersinwaste

(5)Calculationofthereleasestowaterbodies Maximumpotentialreleasestotheenvironment

Figure: Proceduresforcalculatingquantitiesofcoloringredientsreleasedandtransferredthro
ughoutthecoatingandfinishingprocesses
(Worksheetforcoating/finishingprocesses)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.2.3. Calculationexamples
Thefollowingareexamplesofhowtocalculatethereleasesandtransferswithfacilitiesa
nd under the conditions below:
(Overviewoffacilities)
Process: coating process of anti-corrosive
paperEquipment used: coating machine
Wastewatertreatmentequipment:activatedsludge(removalefficiency:90%)
Coatingcolorused:coatingcolorforanti-corrosivepaper[2-
aminoethanolcontent: 2 %]
Annualamount of coating color used:10tons / year (total amountis used)
(1) Calculationofannualquantityof 2-aminoethanol handled
Annualquantityof2-
aminoethanolhandlediscalculatedbyusingtheamountofcoatingcolor usedand contentof
2-aminoethanol inthe coatingcolor.
(Annualquantity of2-aminoethanol handled)
=(amount ofcoating color used)x(content (%)in thecoating color)
= 10 tons/year x 1,000 kg/ton x 2 %/100
= 200 kg/year
(2) Calculationofthequantity shippedinproducts
The quantity shipped in products is calculated by using the annual quantity
ofzinc handled, coating yield, rate of broke in the coating process, and finishing
yield.The quantity of 2-aminoethanol shipped in products is assumed to be calculated
as(theannualquantityof2-aminoethanolcoatedminustheannualquantityof2-
aminoethanolin the broke) times (finishing yield).
(Quantityshippedinproducts)
=(annualquantityof2-aminoethanolhandled)x(coatingyield)x (1-
rate of broke in the coatingprocess)x(finishingyield)
= 200 kg/year x 95.5%/100 x (1 - 5%/100) x 97%/100
= 184.3 kg/year
*(Coating yield)
=(quantitycoatedonpaper)/(quantityincoating colorused)x100(unit:%)
*(Rateof broke in the coating process)
=(quantityofbrokeinthecoatingprocess)
/ (total quantity of coated paper transferred from coating
process)x100(unit:%)
*(Finishingyield)
= (quantity shipped in products)
/ (totalquantity transferred to finishing process) x100(unit:%)
(3) Estimationofquantity transferredinwaste
Forthetransfersof2-
aminoethanolinwaste,thoseinwastecoatingcolorandbrokegeneratedintheprocessesofcoatin

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

① Waste color in the coating process is calculated by using the coating yield.
Wastecolor is added as industrial waste to the transfers ､ through the waste
treatmentprocess.(dewateringprocess;treatment efficiency:90%).
(Transfersof2-aminoethanolinwastecolor)
=(annualamounthandled)x[1-(coatingyield)] x(treatment efficiency)
= 200 kg/year x (1 - 95.5%/100) x 90%/100
= 8.1 kg/year
②Thequantityofwastegeneratedthroughcoatingandfinishingprocessesiscalculatedbyus
ingtherateofbrokeincoatingprocessandfinishingyield.Broke,
which is usually off-site recycled, is added to transfer in waste, in case handed
overto industrial waste collectors. When broke is sold for recycling, PRTR
reporting isnot required.
(Transfersof2-aminoethanolinbroke)
=(annualamountof2-aminoethanolhandled)
x {(coating yield) x (rate of broke in coating process) + (coating
yield)x (1 - rate of broke in coating process) x[1 - (finishing
yield)]}
= 200 kg/year x [95.5%/100 x 0.5%/100 +95.5%/100 x (1 -
0.5%/100)x (1 - 97%/100)]
= 6.7 kg/year
(4) Calculationofmaximumpotentialreleases
Themaximumpotentialquantityreleasediscalculatedbysubtractingthequantity of
2-aminoethanol shipped in products and transfers in waste from annualquantityof2-
aminoethanol handled.
(Maximumpotentialreleases)
=(annualquantity of2-aminoethanolhandled)
- (quantityof2-aminoethanolshipped in products)
- (quantityof2-aminoethanoltransferredinwaste)
=200kg/year-184.3kg/year- (8.1kg/year+6.7kg/year)
= 0. 9kg/year
(5) Calculationofreleasestowaterbodies
The whole maximum potential quantity of 2-aminoethanol released, which
iseasilysolubleinwater,isregardedasthequantityreleasedtowaterbodies.
(Releasestowaterbodies)
=(maximumpotentialreleases)
= 0.9 kg/year

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.3. Chloroform
5.3.1. Processflowandreleasesand transfers

Name ofsubstance Chloroform(trichloromethane)

CASNo 67-66-3
SubstanceNo. 95 Requiringnotification 1.0t /year
Use Byproductfrombleachingprocessofkraftpulp
Self-managementplanoftoxicanpollutant
Note (Japan paperAssociation)

Incasefacilityhasthedata,usethatfigures.Whennodataisavailable,calculationshould
bedoneasfollows.
Amount of chloroform generated (g / 1ton of pulp produced) = {87.8 x (
amountof chlorine added(%) - 92.7} + {401 x amount of sodium hypochlorite added
(%) -15}
And usually; amount of chloroform generated = release to air (75%) + release
towater bodies (7.5%) + amount removed at wastewater treatment equipment
(17.5%),asshowninthefollowingfig..(Exampleoftheprocesswherecoolingtowerisequip
pedbefore wastewater treatment facility)

Chloroform10 PRTR
0% Releaseto
air
75%
Pulpmanufacturing,Bl Papermaking,Co Product
eachingprocess atingprocess 0%

Wastewatertr Release
Removal eatment towaterbodi
efficiency17 process es
.5% 7.5%
Waste
treatment(Deh
ydration)
Transfer
Waste Sludge
inwaste

Wastewatertr
eatment Air
(Incineration)

Incinerateda Transfer
Waste
sh inwaste

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.3.2. Calculationexample(Chloroform; CabinetOrderNo.95)

Thefollowingareexamplesofhowtocalculatereleasesandtransferswithfacilitieswhe
re no data is available.
(Overviewoffacilities)
Process:bleachingprocesswithchlorinatebleachchemicalsmanufacturingbleached
kraft pulp (BKP)
Wastewater treatment equipment: activated sludge treatment (removal
efficiency: 17.5 %) with cooling
towerChlorinatebleach chemicalsused: chlorine, sodiumhypochlorite
Operatingconditions;amountofBKPproduced:1,000t/dayWor
kingdays: 340days / year
Amountofchlorineadded: 1.5%
Amountof sodiumhypochlorite added: 0.5 %
(1) Calculationofannualquantityofchloroformgenerated(handled)
Annualquantityofchloroformgeneratedisthetotaloftheamountofchloroformgenerat
edatchlorinebleachingprocessandtheamountofthatathypochloritebleaching process.
①Annualquantityofchloroformgenerated(handled)fromchlorinebleachingprocess
=(87.8xamountofchlorineadded(%)-92.7)(g/t)
x amountof BKPproduced(t / day) x working days(days / year) ÷ 1,000,000(g / t)
=(87.8 x 1.5 - 92.7) (g / t) x 1,000 (t / day) x 340 (days / year) ÷ 1,000,000 (g / t)
= 13.3 (t /year)
②Annualquantityofchloroformgenerated(handled)fromhypochloritebleachingprocess
={401xamountofsodiumhypochloriteadded(%)-15}
x amountof BKPproduced(t / day) x working days(days / year) ÷ 1,000,000(g / t)
=(401x0.5-15)(g/t)x1,000(t/day)x340(days/year)÷1,000,000(g/t)
= 63.1(t /year)
③Annualquantityofchloroformgenerated(handled)frombleachingprocess
①+②
=13.3 (t /year) +63.1(t /year)
= 76.4 (t /year)
(2) Calculationofannualquantity released to air
Bymodelexampleaforementioned(fig.),annualquantityreleasedtoairiscalculatedas
③x75%
= 76.4 (t /year) x 75÷ 100
= 57.3 (t /year)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

(3) Calculationof annual quantityreleasedtowaterbodies

Bymodelexampleaforementioned(fig.),annualquantityreleasedtowaterbodiesiscal
culatedas③x 7.5%
= 76.4 (t /year) x 7.5÷ 100= 5.7 (t /year)
(4) Calculationofannualquantityremovedat wastewatertreatmentequipment
By model example aforementioned (fig.), annual quantity removed
atwastewatertreatment equipment is calculated as③x 17.5%
=76.4(t/year)x17.5÷100=13.4(t/year)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.4. N,N-dimethylformamide
5.4.1. Processflowandreleasesand transfers

Name ofsubstance N,N-Dimethylformamide(DMF)

CASNo 68-12-2
CabinetorderNo. 172 Requiringnotification 1.0t /year
Use Solventforantisepticagent,slimecontrolagent

Processflowexample

N,N-dimethylformamide PRTR
100% Releaseto
air
0.5%
Pulpmanufacturing, Papermaking,C Product
Bleachingprocess oatingprocess 0%

Wastewatertr Releasetowa
Removalefficiency eatment terbodies95.
4.4% process 1%

Wastetreatment(
Dehydration)

Transferinwa
Waste Sludge
ste

Wastewatertr
eatment Air
(Incineration)

Incinerateda Transferinwa
Waste
sh ste

AsN,N-
dimethylformamide(DMF)ishighlywatersoluble,99.5%oftheamountusedinpapermakingo
rcoatingprocessistransferredtowastewater,andonly0.5%isreleasedtoair.Inactivatedslu
dgetreatmentofwastewater,4.4%isremovedand95.1%isreleasedtowaterbodies.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.4.2. Calculationprocedure
ThereleasesofN,N-
dimethylformamideusedassolventforantisepticagentandslimecontrol agent
areestimated accordingtothefollowingprocedure:

Quantityofantisepticagenthandled
(1) Calculation of the handled quantity of Class I
×
Substancescontainedintheantisepticagentand
Contentofsolventinantisepticagent,etc.
slimecontrolagent

Quantityhandled
(2)Estimationofmaximumpotentialreleasestoair
- transfers

Releasestoairinthedryingpartofthep
(3)Estimationofreleasestoair
apermakingprocess

Maximumpotentialreleasestotheenvironment
(4)Estimationofreleasestowaterbodies
- releasestoair

Figure: Estimationprocedureforthereleasesandtransfersofsolventingredientsofantiseptic
agent/slimecontrol agent

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.4.3. Calculationexample
Thefollowingareexamplesofhowtoestimatequantitiesreleasedandtransferred in
the process below:
(Overviewoffacilities)
Process: sterilization of surroundings of paper machines and inside of tanks
andpipes
Wastewatertreatmentfacilities:activatedsludgetreatment(Efficiencyofremoval is
4.4 %; quoted from “Safety data of existing chemical substances under theLaw
Concerning the Examination and Regulation of Manufacture, etc. of
ChemicalSubstances” issued by Japan Chemical Industry Ecology-Toxicology &
InformationCenter on October 1992)
Agentsused:antisepticagentandslimecontrolagent(ContentofN,N-
dimethylformamide:5%)
Annualquantityofantisepticagent andslimecontrolagent used:20tons/year
(1) Calculationofannualquantityof N,N-dimethylformamidehandled
Annual quantity of N,N-dimethylformamide handled is calculated by using
thequantityofantisepticagentandslimecontrolagentusedandthecontentofN,N-
dimethylformamidein them.
(AnnualquantityofN,N-dimethylformamidehandled)
= (quantity of antiseptic agent and slime control agent
used)x (content of solvent %)
= 20 tons/year x 1,000 kg/ton x 5%/100 = 1,000 kg/year
*The quantity shipped is zero because antiseptic agent and slime control
agentare not contained in products. The quantity shipped is therefore omitted
fromthe work procedure.
*The antiseptic agent and slime control agent are used up and no waste
isgeneratedthroughtheprocess.ThereforethequantityoftransferredN,N-
dimethylformamideinwasteiszeroandisomittedfromtheworkprocedure.
(2) Estimationofmaximumpotentialreleases
In this process, the annual quantity of N,N-dimethylformamide handled itself
isequaltothemaximumpotentialquantityreleased.
(Maximumpotentialreleases)
=(annualquantityofN,N-dimethylformamidehandled)=1,000kg/year
(3) Estimationofreleasestoair
Although antiseptic agent and slime control agent are used in the open
air,estimation should be made to assume that 0.5 percent of N,N-dimethylformamide
isreleasedtoair,onlyinthedryingpartofthepapermakingprocess,becauseitishighly water
soluble.
(Releasestoair)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

=(maximumpotentialreleases)x(ratioofreleasestoair)
= 1,000 kg/year x 0.5%/100
= 5 kg/year
(4) Estimationofreleasestowaterbodies
Thequantityreleasedtowaterbodiesiscalculatedbysubtractingthereleasestoairfromt
he maximumpotential releases.
(Potentialreleasestowaterbodies)
=(maximumpotentialreleases)-(releasestoair)
= 1,000 kg/year - 5 kg/year
= 995 kg/year
Then, the quantity released after treatment is calculated using the efficiency
ofremoval in the activated sludge treatment process. It is assumed that the
quantitytransferredinthesludgegeneratedthroughtheactivatedsludgeprocessiszerobecau
seN,N-dimethylformamide is highly water soluble.
(Releasestowaterbodiesaftertreatment)
=(potentialreleasestowaterbodies) x [1- (efficiencyof removal)]
= 995 kg/year x (1 - 4.4%/100)
= 951 kg/year

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.5. Dioxins
5.5.1. Processflowandreleasesand transfers

Name ofsubstance Dioxins

CASNo -
CabinetorderNo. 179 Requiringnotification All
Wastewater…Byproductfrombleachingprocessofkraftpulp,incin
eratorofwaste(incaseofwatertreatmentofventgas)
Use, etc. Releasetoair…Incineratorofwaste
Transferinwaste…Incineratedash,dustfromincinerator

Dioxins100
% PRTR

Pulpmanufacturingbl Papermaking,Co Product0

eachingprocess atingprocess %

Wastewatertr
Releaseto
eatment
process waterbodies

Wastetreatment(
Dehydration)

Sludge

WastewaterT
reatment ReleasetoAi
(Incineration) r

Transfer Incinerateda On-

inwaste sh,dust sitelandfil
l
Requiringnotificationfordioxins(examples)
• Specifiedfacilitiesby“LawConcerningSpecialMeasuresagainstDioxins“shouldreportrelea
sesandtransfersbasedonthemeasuredfigures.
• Facilitieswhichhavechlorinatebleachingprocessofkraftpulpand/or
incineratorofwastewithwatertreatmentofventgasshouldmeasurecontentofdioxinsinwaste
wateratleastonceayearbytheLaw.So,releasetowaterbodiesiscalculatedbyannualamounto
fwastewatertimescontentofdioxins.
• Content of dioxins in exhaust gas, incinerated ash and dust from incinerator
shouldalsobemeasuredatleastonceayearbytheLaw.Releasetoairandsoonshouldalsobecal
culatedinthesameway.

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

5.5.2. Calculation example

(Dioxins)[Example - 1 ]
Thefollowingareexamplesofhowtocalculatequantitiesreleasedandtransferred in
the process below:
(Overviewoffacilities)
Process: Incinerator of waste ( no water treatment of vent gas
)(Releaseandtransfer)
Release to air: Exhaust gas from
incineratorTransfer in waste: Ash and dust from
incinerator(Operatingconditionforcalculation)
Theamountofexhaustgasfromincineratorandcontentofdioxinsinexhaustgas (
3
measured ) are 9,900 Nm /hour ( working hours: 8,000 hours / year ) and 0.09ng-
TEQ / Nm3.,respectively. The annual amount of incinerated ash transferred formixing
in raw materials for Portland cement, is 5,100 tons and content of dioxins
inincineratedashis0.0019ng-TEQ/g.

Calculationofreleasetoair:Exhaust gas fromincinerator

0.09ng-TEQ /Nm3x 9,900Nm3/hour x8,000 hours/ year ÷1,000,000 ng /mg
=7.13 mg-TEQ/ year
Calculationoftransferinwaste:Inincineratedash
0.0019ng-TEQ / g x 5,100 tons / yearx 106g/ton÷1,000,000ng/mg
=9.7 mg-TEQ/ year
Thereisnoreleasetowater bodies in this case,

[Example - 2 ]
Thefollowingareexamplesofhowtocalculatequantitiesreleasedandtransferred in
the process below:
(Overviewoffacilities)
Process: Incinerator of waste (water treatment of exhaust
gas)(Releaseandtransfer)
Releasetoair:Exhaustgasfromincinerator
Releasetowaterbodies:Wastewaterusedforexhaustgastreatmentfromincinerator
Transfer in waste: Ash and dust from
incinerator(Operatingconditionforcalculation)
Theamountofexhaustgasfromincineratorandcontentofdioxinsinexhaustgas (
3
measured ) are 6,670 Nm /hour ( working hours: 8,000 hours / year ) and 0.042ng-
TEQ/Nm3,respectively.Theannualamountofdustfromincineratorandincinerated ash,
transferred for mixing in raw materials for Portland cement, etc.
are800tonsand7,300tonsrespectively.Contentofdioxinsinthemare0.00012ng-TEQ

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

/gand0.00011ng-TEQ/grespectively.
Wastewater used for exhaust gas treatment from incinerator is released to
waterbodies,throughwastewatertreatmentfacility.Theamountofwastewaterfromwastew
ater treatment facility and content of dioxins in wastewater (measured)
are4,000m3/hour(workinghours:8,280hours/year)and1.2pg-TEQ/liter.,respectively.

Calculationofreleasetoair:Exhaust gas fromincinerator

0.042ng-TEQ /Nm3x 6,670Nm3/hour x8,000 hours/ year ÷1,000,000 ng /mg
=2.24 mg-TEQ/ year
Calculationofreleasetowaterbodies
1.2pg-TEQ/literx 4,000m3/hour x8,280hours/yearx 1,000liter/ m3
=39.7x109pg-TEQ/year=39.7mg-
TEQ/yearCalculationoftransferinwaste
①Dustfromincinerator*(transferred)
0.00012ng-TEQ / g x 800 tons / yearx 106g/ton÷1,000,000ng/mg
=0.096 mg-TEQ/ year
②Incineratedash *(transferred)
0.00011ng-TEQ/ gx7,300 tons/year x106g/ton÷1,000,000ng/mg
=0.80 mg-TEQ/ year
*When sold forrecycling and soon,reportingisnotrequired.

[Example - 3 ]
Thefollowingareexamplesofhowtocalculatequantitiesreleasedandtransferred in
the process below:
(Overviewoffacilities)
Process: Kraft pulp processing (bleaching, non-bleaching), waste
incinerator(Releaseandtransfer)
Releasetoair:Exhaustgasfromincinerator
Release to water bodies: Wastewater from bleached kraft pulp
manufacturingprocess
Transfer in waste: Ash and dust from
incinerator(Operatingconditionforcalculation)
Theamountofexhaustgasfromincineratorandcontentofdioxinsinexhaustgas
(measured) are 15,000 Nm3/hour (working hours: 8,000 hours / year) and 0.095ng-
TEQ / Nm3, respectively. The annual amount of dust and ash from
incinerator,transferred for mixing in raw materials for Portland cement, etc. are
10,400 tons andcontent of dioxins in them is 0.0052 ng-TEQ / g .
Wastewaterfrombleachingprocessistransferredtowastewatertreatmentfacilityandt
henisreleasedtowaterbodies.Theamountofwastewaterfrom

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

wastewater treatment facility and content of dioxins in wastewater (measured)

are6,700m3/hour(workinghours:8,280hours/year)and0.39pg-TEQ/liter.,respectively.

Calculationofreleasetoair:Exhaust gas fromincinerator

0.095ng-TEQ /Nm3x 15,000Nm3/hour x8,000 hours/ year ÷1,000,000 ng /mg
=11.4mg-TEQ/year
Calculationofreleasetowaterbodies
0.39pg-TEQ/literx 6,700m3/hourx 8,280hours/year x1,000liter/ m3
= 21.6 x 109pg-TEQ/ year = 21.6 mg-TEQ /
yearCalculationoftransferin waste:Incineratedash
0.0052ng-TEQ / g x 10,400 tons / yearx 106g/ton÷1,000,000ng/mg
=54.1 mg-TEQ/ year

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Diagram1:Typicalpulpandpapermanufacturingprocesses
(1) Pulpmanufacturingprocess Highconcentratedchest(s
Chemicalpulpproductionprocess
torageofpulp)
Digester KPwasher
Chipsilo Feeder
Bleachingequipment
Thickener
Screen

Chips
(rawmaterials)

Blackliquor

Mechanicalpulpproductionprocess
Whiteliquortank
Feeder Cleaner
Causticizing Chipsilo
Bleachingequipment
equipment
Screen
Evaporator

Limekiln Recoveryboiler Refiner

(grindingofchips) Chest
(storageofpulp)

Thickener
(Transferinwaste) Cleaner
Processofpulpderivedfromwastepaper

Screen
(dirtremoval)
Wastepaper(r
awmaterial)
Refiner Flotators( ThickenerBleaching Refiner(b Chest
deinking) equipment eating) (storageofpulp)

Pulper(defiberization
ofwastepaper)

Wastewater Wastewater

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Diagram1:Typicalpulpandpapermanufacturingprocesses
(2) Papermakingprocess

Preparationprocess Papermakingprocess

Refiner
(beating)
Wirepart Presspart Dryerpart Sizepress Calender Reel

Product

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING

INPLANT TRAINING

Diagram1:Typicalpulpandpapermanufacturingprocesses
(3) Wastetreatmentprocess

Wastewatertreatmentprocess
(Incinerator)

Bagfilter
Wetscrubber
Dehydrator (Sludge)
incineratorCyclone
Wastewaterclarifier
(dustcollector)
Clarifier

NeutralizingtankActivatedsludge

Stack

(Bodiesof water) (Transferinwaste) (Transferinwaste)

MAHATMA GANDHI POLYTECHNIC. MECHANICAL ENGINEERING