What is pulp? > Pulp 1s a commercial fibrous material obtained from bamboo, wood, bagasse (waste material) etc. by mechanical and chemical means. Pulping means disintegration of bulky fibrous material to small fibres. There are mainly three modes of production of pulp: {a) Mechanical: Ground wood- debarked wood 1s mechanically shredded to form fibrous, which is used for mfg. of newsprint, toilet tissues, toweling and cheap paperback book where strength and ease of bleaching is not important. (b) Chemical: The cellulose from wood is freed from lignins and other non- Cellulose ingredients by reaction with chemical reagents. Yield: 40-65%, produced high strength & fine texture (c) Semi chemical: Wood chips are given a mild chemical treatment with dilute mixture. -used sulfite, sulfate, caustic soda or soda ash reagents High yield: 65-90% poor quality & bleach abilityPulp & Paper mill » Pulp mills separate the fibres of wood or from other materials, such as rags, waste paper or straw in order to create paper. > Paper mills primarily are engaged in manufacturing paper from wood pulp and other fibre pulp, and may also manufacture converted paper products.Cellulosic Material Used Principle Reaction Composition of Cooking Pulp Products Almost all kinds of wood (Soft or hard; Big logs or small chips) Hydrolysis of lignin to alcohols and acids; formation of mercaptens 12.5% solution of NaOH, Na,S and Na,CO, Brown colour; strong fibers; resistant to mechanical forces Strong brown bag, wrapping, paperboards Coniferous like spruce & Hard wood Balsam); Must be in good colour and free from phenolic compounds RC:CR’ + Ca(HSO,), > Lignin Sulphonation and (RCHCR’SO,),Ca Hemicellulose hydrolysis; formation of acetate and formate 7% by wt. SO, Na, buffered solution with Recent trend towards Mg(OH), _Na,CO, or Kraft green liquor and NH,OH Dull white colour; weaker fibers Stiff, dense paper of low opacity; White grade: book paper, fruit Unbleached: newsprint tissue, sanitary tissue Bleached: writing paper, offsetSulfate or Kraft pulp process > This process was invented in Germany in 1884 and Most popularly used process. Advantages: > Higher pulp strength Wide variety of wood may be used > > More effective at removing impurities like resins > The presence of sodium sulfide makes bleaching of pulp easier and the paper produced has better strength. Disadvantages: > Comparable yield is lowChemical Reactions: G)_ Digestion (hydrolysis and solubilization of lignin) R-R’ 4 NaOHPR"COONA + ROU R-R’ | NayS > Mercaptans Gi) Chemical recovery from black liquor (a) Smelting 2NaR + air > Na;CO; + CO, (lignin) Na,SO, + 2C > NayS + 2CO; (from R) (white liquor) (b) Causticizing NaxCOs (aq) + Ca(OH), (s) > NaOH (aq) + CaCO (s) (green liquor) (white liquor) CaCO; CaO + CO, CaO + HO Ca(OH)cmos (Sola) eciculso fra 2 a Blackliquor wood knots & undigestedsresidue Pulp story Pulp Hot water ‘Blow down a valve mama ‘ers | Pu Block iquor (to chemical recovery) Flowsheet for mfg. of pulpFig. III-1,, Preparation of woud pulp by sulfate process,4 oR ye mad ge. 30atms sx pb Steam ETtect | e835" Exaparator | [Solds systeny Lay a Canter or Green Sen 77 J ete (Boiler Feed > a8 Section — Siret SS Reeipitatoc [SO Combustion aackt ine] ‘ «| Chamber (15%. Sots) ix LI Makeup Cherrecals a ZL hsmet _f NagsQy"S Preheated Air 1F-2. Chemical recovery from sulfate pulp digestion liquor, Fig. UPaper products .d sheets of fibers usually cellulosic and jefined as matted or felte a water suspension. > Paper isd ‘ormed on a fine wire screen from generally fTypes of paper products > Wrapping paper -bag paper, grease -proof paper > Tissue paper-cigarette, carbon, toilet, towel, napkin paper > Writing paper-bond weight, linen papers > Groundwood printing paper-catalog,newsprint > Paperboard-Raw Materials 1) Fibrous raw mat.: > Paper pulp: Groundwood, bleached and unbleached sulfite and sulfate , semichemical pulps. > Reuse pulp- paper products like newspaper and { paperboard are repulped and mixed with new pulp for paper mill feedstock. 4-6% fiberous starting mat.Raw Materials > Miscellaneous cellulose pulp - straw, linen, cotton and rags. > Specialty pulp-inorganic fibers 2) Non-fibrous raw mat.: Large variety of mat. Required for fillers, sizing and coatings Inorganic : clay, talc, titanium oxide, zinc, calcium carbonate etc. Organic : rosin, glue, waxes, glycerol, dyestuffsBuip With a9.5%H20 water Mark Ro} Steam-Heated Drying Roll White Water Bleed Stream ration | Web Fe gout] feb Forming Pressing | Drying | eee \ Range ipo 80-82 60-65 ad os Paper productionPaper Peon * Paper Machine (Fourdrinier Machine * Paper machines have four distinct operational sections * Forming section- commonly called the wet end, is where the slurry of fibres filters out fluid a continuous fabric loop to form a wet web of fibre. Mod @®© & @n wm S.7 Aumcmnatc Poo - Calender section - Where the dried paper is smoothened under high loading and pressure. Only one nip (where the sheet is pressed between two rolls) is necessary in order to hold the sheet, which shrinks through the drying section and is held in tension between the press section (or breaker stack if used) and the calender. Extra nips give more smoothing but at some expense to paper strength. Paper Finishi * The characteristics. anne. arora ne -ghatastedstics 3arance and s:Paper Finishing * The characteristics, appearance and properties of paper and board are supplemented and enhanced by their final treatments. These may be simple processes where the reel is slit into a number of more narrow reels or cut into sheets or more complicated processes such as coating or super- calendering. Nor ©mMm @no Bm* Coating improves the —_ opachy, lightness, surface smoothness, lustre and colour-absorption ability of paper. * Coating means that a layer is applied to the paper The coat consists of a mix of pigments, extenders such as china clay and chalk For Even Smoother Paper Super- Calendering is Required (for magazines paper) is Paper | Manufacturing —~_@ @-—--— | . @2-fes ] yor @m @rsk & Sx eMAJOR ENGG. PROBLEMS ° Choice of processes ¢ Pollution & waste disposal ¢ By-product utilisation