Pulp and Paper

Introduction
Manufacture of pulp
Type of Pulp
Preparation method for making pulp
Manufacture of paper,
Calendaring
Uses
Clean technology in agro waste Industry,
Ecological problems of Indian pulp and paper Industry
 PULP AND PAPER
Introduction:-
• Cellulose, a most imp. Organic compound, which is extensively
used in manufacturing of paper and other related products.
• Formerly, paper was manufactured exclusively from linen rages.
• In the 1800s, there was a shift away from using cotton rags for
paper production. Wood became the most important source of
cellulose and fiber.
• Now, the pulp and paper industry converts wood or recycled fibre
into pulp and primary forms of paper.
• First mechanical and then chemical methods have been developed
to produce pulp from wood.
Pulping and paper manufacturing
• Pulping is process to separate the fibres of wood or
from other materials, such as rags, waste paper or
straw in order to create pulp.

• Manufacturing of Paper primarily are engaged in

the formation of paper from wood pulp and other
fibre pulp, and may also manufacture converted
paper products.
Wood to paper
Manufacture of pulp:- First time introduced in
China.
Five Methods of pulping
1) Mechanical Pulping
2) Chemi-mechanical
3) Thermo-mechanical
4) Chemi-mechanical and Thermo-mechanical Pulping (CTMP)
5) Chemical Pulping
Important Facts:- The chemical method is the most popular
because it produces a highest quality paper than mechanical
pulping. 80-85% Pulp now a days prepared by the use of chemical
pulping.
Mechanical pulping is used for 8-10 %. Low grade paper generally
prepared by mechanical pulping.
Wood (this is what we have) Fibers (this is what
we want)

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 Mechanical Pulping
• Uses mechanical energy with little or no chemicals
• Two main processes
a)Grinding: logs are forced against a revolving abrasive(sarp) stone continuous
rotating cylindrical drums
b)Mechanical friction: Refining: wood chips are fed between two metal discs –
one of them rotating

Refiner Pulping :-
This process uses wood chips as its
raw material
Two main processes:
•Thermo-mechanical Pulping (TMP) –
chips are pre-steamed
•Chemi-thermomechanical Pulping
(CTMP) – chips are given light
chemical treatment

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 Chemical Pulping:-
• Obtained high grade paper from this pulp
• Uses chemicals and heat to dissolve lignin
• Leave cellulose and some hemicellulose
• Major processes:
Kraft process - Caustic
NaOH and Na2S
Soda Process - Caustic
NaOH
Sulfite Process - acid
SO2 and Base: e.g. Mg(OH)2, Ca(OH)2, NH4(OH)
Industrial setup of pulping
 Type of chemical Pulping
1) Sulfate or Kraft pulping was invented in Germany in 1884 and
remains the dominating technology today.

Advantages:
– higher pulp strength
– wider variety of wood species may be used
– more effective at removing impurities like resins.

Disadvantage:
– the pulp yield is low, less than 50%.
– Fairly complicated processes are required for bleaching the pulp
 Method of Kraft pulping
Step 1 - Wood preparation
• The bark is removed from in-coming logs, and these are then
chipped. Sometimes, the wood arrives at the plant already
chipped.
•
Step 2 - Cooking
• The wood chips are heated in a solution of NaOH and Na2S in a
pressure cooker, during which time a lot of the lignin (the
reinforcing substance that make tree cells wood hard and 'woody'
rather than soft like those of other plants) is removed from the
wood.
• The pressure is then released suddenly, causing the chips to fly
apart into fibres.
• Three type of water is generated in given order
Black, Green, and White respectively.
Step 3 - Pulp washing
•The pulp is washed with water to wash out the cooking
chemicals and lignin from the fibre so that they will not
interfere with later process steps.

Step 4 - Pulp screening

•A sieve is used to remove knots(loop) and clumped-together
uncooked fibres from the pulp.

Step 5 – Thickening and Bleaching

•Thicker pulp is treated with Cl2 to remove the remaining
lignin (bleached). The washed pulp be re-thickened to
convert it into sheets, dry enough to fold into bundle, called a
lap: having 50-60% air dry fibre.

Step 6 - Paper making

Step 7 – Recovery of chemicals
 Sulphite pulp
• The salts used in the pulping process are either sulfites (SO32−), or
bisulfites (HSO3−), depending on the pH.
• Magnesium was the standard counter ion until calcium replaced it in
the 1950s.
I. Because waste liquor from calcium bisulphite process can not be
used again.
II. Disposal of waste liquor from calcium bisulphite process is a serious
pollution problem.
• Sulfite pulping is carried out between pH 1.5 and 5, depending on the
counter ion to sulfite (bisulfite) and the ratio of base to sulfurous
acid.
• The pulp is in contact with the pulping chemicals for 4 to 14 hours
and at temperatures ranging from 130 to 160 °C (266 to 320 °F)
 Sulphite pulp
• Burning sulfur with the correct amount of oxygen to give
sulfur dioxide

Care must be taken to avoid the formation of sulfur trioxide.

• The cooking liquor is prepared by adding the counter ions as
hydroxides or carbonates.
 Soda pulp

Wood Reactor (350oF) Pulp

Washer
– Dissolve all
lignin ¼
NaOH carbohydrates
in water

Steam Evaporate water

Steam
Furnace
Excess steam (dry paper)

Excess electricity
Rag pulp
• Pulp made by disintegrating new or old cotton or linen rags
and cleaning and bleaching fibers.

• Steps are-
 Passing through the thrasher
 Over magnets
 Digested with caustic lime or caustic soda with soda ash
 Remaining process will be same.

General properties of finished paper

 Proper surface
 Opacity
 Feel
 Strength
 To get the finest pulp
Process to get the pulp having the general
properties
• Beating
• Refining
• Filling
• Sizing
• Colouring
• Addition of alum
 Manufacturing of paper
• Paper making is the process whereby pulp fibres are mechanically
and chemically treated, formed into a dilute suspension, spread
over a mesh surface, the water removed by suction, and the
resulting pad of cellulose fibers pressed and dried to form paper.
• Bathing of size
• Pass through squeezing rolls
• Through drying rolls
The whole process is carried out mechanically by making use of a
machine, called Fourdrinier.
Calendering
• Irregular and the rough sheets of paper become
more compact more smooth and receive the
fine finish, passed through a series of hot and
polished rolls; called polishing cylinders, known
as Calendering.
Environmental problems
Regulated wastes and emissions from the pulp and
paper industry include liquid and solid wastes, air
emissions, and wastewater.
• Air emissions related with this process are: sulphur
dioxide, nitrous oxides, particulate matter,
methanol, polycyclic organic matter, hydrogen
chloride, formaldehyde, chloroform, phenol and
chlorinated phenolics, dioxins, furans and other
chlorinated compounds.
• Wastewater releases include chlorinated phenolics,
dioxins, furans and other chlorinated compounds,
phosphates and suspended sediments.
• Solid Waste:-Paper mills also produce non-hazardous
solid waste such as sludge derived from their pulping
and bleaching operations. Dirty wood chips or fibers as
well as bark. The broken, low-quality fibres are
separated out to become waste sludge. All the inks, dyes,
coatings, pigments, staples and "stickies" (tape, plastic
films, etc.) washed off the recycled fibres.
• Raw water use:- Pulp mills are big water users.
Consumption of fresh water can seriously harm habitats
near mills, reduce water levels necessary for fish, and
change water temperature, a critical environmental
factor for fish.
Pollutants in effluents:- The most common organic
pollutants are suspended solids (SS):
lost cellulose fibre,
dissolved organic compounds such as dissolved
lignin compounds, carbohydrates, starch and
hemi-cellulose
Acidic Compounds:-Acidic compounds are
predominantly natural resin acids.
Chlorinated organics:- Chlorinated organics are
found if elemental chlorine is used in the process.
 Energy use :-
The pulp and paper industry uses 84% of the fuel energy consumed by the
forest products industry as a whole.

• It is one of the largest producers of greenhouse gas (GHG) emissions.

• Over the past few years, the pulp and paper industry has considerably
reduced its GHG emissions by introducing energy conservation projects and
by increasing its use of biomass as an energy source.

• A modern Kraft pulp mill is essentially self-sufficient in energy. The only oil
consumer is the causticing oven, which however can be replaced with bio-
fuel.

• A paper mill requires between 400 and 1000 kWh electricity/ton paper and 4 –
8 GJ heat/ton for drying in the paper machine.

• In an integrated pulp and paper mill this energy is provided from the recovery
boiler.
Cleaner production measures (Raw materials)
• Maintaining moisture content of the raw materials
constant all year around.
• Keeping chemical range to a minimum and buying small
containers of infrequently used materials.
• Labelling storage area for hazardous substances.
• Providing collection systems during storage.
• Genetically modifying forest trees.
 Genetically modified trees
• Lignin is the main wood component that must be
effectively removed from the pulp.
• It has been possible to use genetic engineering
to modify lignin content and/or composition in
poplars.

Advantages of genetic modifications

• Genetic modifications improved characteristics,
allowing easier delignification, using smaller
amount of chemicals, while yielding more high-
quality pulp.

• Owing to the genetic modification savings in

energy and pollutant chemicals are achieved,
thus leading to an environmentally more
sustainable process.
 Cleaner production measures
(Wood-yard)

• Pulp mills integrated with lumbering facilities: acceptable

lumber wood is removed during debarking; residual or waste
wood from lumber processing is returned to the chipping
process; in-house lumbering rejects can be a significant
source of wood furnish.

• Avoiding hydraulic debarking – saving energy and water

consumption, reducing wastewater amount.

• Reusing leachate water.

• Co-production from bark: mulch, ground cover, charcoal.
• Burning bark from debarking and small chips from chipping
for energy production (depends on the moisture content).
 Cleaner production measures
(Pulp production)

•Increasing brown stock washing efficiency. Any remaining cooking liquor

will increase the chemical consumption in subsequent stages.

•Water reuse from evaporators. The evaporation plant is always one of the
largest steam consumers in the mill. Condensate might be used instead of
fresh water in the mill.

•Repulping the rejects from screening rather than putting them into the
landfill.

•Using pulp centrifuging to remove any remaining impurities.

•Sludge utilization by means of land-spreading. This method of sludge
disposal is an area of concern, as sludge constituents are not well identified.
•Air emissions control devices.
•Providing spill containment and collection system.
Cleaner production measures (Chemicals recovery)

• Using of new technologies (Heat transfer, heat exchanger).

• Improvements technical parameters of recovery boiler or furnace

(geometrical shape etc.).

• Using light gas strippers and gas collection systems which will remove
hazardous and foul smelling pollution from the air and increase workplace
safety.

• Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.

• Air emissions control devices.

• Providing spill containment and collection system.

Cleaner production measures (Bleaching)

 Avoiding chlorine bleaching.

 Continuing research on biotechnological bleaching and
electrochemical bleaching.
 Air emissions control devices.
 Providing spill containment and collection systems.
 Cleaner production measures
(Paper production)

• Cleaning the roll in the paper machines to avoid broken paper

line.
• Adjustment of edge cutter to reduce side trimming loss.
• Use of soft water as a boiler feed water.
• Recycling water evaporated from drying process by condensing.
• Optimizing the thermal effects on water used in the paper
machine and stock preparation area.
• Repulping rejected paper in a closed loop manner.
 Cleaner production measures
(Products processes and recycling)

Increasing recycling rates. Recycling reduces energy consumption,

decreases combustion and landfill emissions, and decreases the amount
of carbon dioxide in the atmosphere. This process also saves money.

Possibility for easy packaging recycling.

Using “green” fuel for transportation.

Recycling:-
In Europe an average of 56% of used paper
is recovered. The recycling process includes
following stages:
– Sorting
– Dissolving
– De-inking
– Mixing
– Papermaking process
Ideal paper mill:-
• From cleaner production point of view is a chlorine-free
and zero-discharge one, with minimized quantity and
toxicity of air pollution and solid wastes.

• It is seen that closed loops represent the most effective

approach to save both energy and resource consumption
and at the same way to decrease all kind of wastes
production.

• Such an approach is developed in the form of paper

recycling, different types of substances re-use during
production processes, co-production and chemicals
recovery.

• Future research can develop more sustainable reuse

options for Kraft pulping solid wastes, as well as pulping
methods that result in purified by-products that can serve
as feedstock for other manufacturing processes.
 Clean Technologies in Agro Based Industries

Industries based of agricultural products known as Agro based Industries such

as Sugar, Dairy, Textile, paper, food, medicine etc.
Most of the Agro based industries are responsible of pollution on large scale.
Thus its very necessary to change the method of production of different type of
products to reduce pollution and other environmental problems.

Waste Minimization Practices in different Agro based Industries:-

• Accounting and balancing of raw material and other resources.
• Characterization of process water and waste water.
• Segregation of waste streams
• Bagasse Utilization
• Press mud-A source of energy(Sugarcane juice product).
• Molasses
• Distillery Industry
• Biomethanation
• Composting
• Incineration