UNIT – IV PULP AND PAPER AND MANUFACTURE OF PAPER

 Introduction to Pulp and Paper Manufacturing:

a. Historical Significance:
 Papermaking has a rich historical background, evolving from ancient methods to modern industrial
processes.
b. Raw Material - Wood Pulp:
 Primary raw material for paper production is wood pulp, obtained from various wood sources like
softwood and hardwood.
c. Diversity of Paper Products:
 Paper industry produces a diverse range of products, including printing paper, packaging materials,
tissue papers, and specialty papers.
d. Pulp Preparation:
 Wood is processed into pulp through mechanical or chemical methods, breaking down fibers for
papermaking.

 Manufacture of pulp:
a. Raw Material Selection:
The process begins with selecting suitable raw materials, typically wood fibers from trees like pine, spruce,
or eucalyptus.
b. Chipping or Pulping:
The selected wood logs are chipped into small pieces or processed through pulping methods like chemical
pulping, mechanical pulping, or semi-chemical pulping.
c. Chemical Pulping:
In chemical pulping, wood chips are cooked in a chemical solution to dissolve lignin, leaving behind cellulose
fibers. This process often uses chemicals like sulfite or sulfate.
d. Mechanical Pulping:
Mechanical pulping involves mechanically grinding or pressing the wood chips to separate fibers without
chemical treatment. This process yields pulp with higher lignin content compared to chemical pulping.
e. Bleaching (Optional):
Depending on the desired quality of the pulp, bleaching may be done to remove impurities and improve
brightness. Bleaching agents like chlorine, chlorine dioxide, or hydrogen peroxide are commonly used.
f. Pulp Washing:
After pulping and bleaching, the pulp is washed to remove residual chemicals and impurities.
g. Pulp Drying:
The washed pulp is then dried using various methods such as air drying or drying through industrial
machines. This step removes excess moisture from the pulp.
h. Pulp Packaging:
Once dried, the pulp is packaged into bales or rolls for transportation to paper mills or other facilities where
it will be used to manufacture paper products.

 Types of pulp:

sulphate or craft pulp

Sulfate or Kraft Pulp:
a. Raw Material:
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  Primarily produced from wood chips obtained from softwood trees, such as pine, spruce, or fir.
 Softwood fibers contribute to the strength and durability of the resulting pulp.
b. Kraft Pulping Process:
 Cooking Phase:
 Wood chips are treated with a mixture of sodium hydroxide (caustic soda) and sodium
sulfide in a large vessel called a digester.
 High temperature and pressure break down lignin, separating it from the cellulose fibers.
 Delignification:
 The cooking process removes lignin from the wood chips, leaving behind cellulose fibers.
 Lignin is dissolved and becomes a byproduct known as black liquor.
c. Byproducts:
 Black Liquor:
 A byproduct of the kraft pulping process containing dissolved lignin, chemicals, and other
impurities.
 Can be used for energy generation through recovery boilers.
 Lignin:
 Separated from cellulose fibers during the pulping process.
 Used for various applications, including energy generation, chemicals, and as a bio-based
material.
d. Characteristics of Kraft Pulp:
 Strength and Durability:
 Kraft pulp is known for its high tensile strength and durability.
 Suitable for applications requiring strong and resilient paper products.
 Neutral pH:
 The process results in pulp with a relatively neutral pH, reducing the need for extensive
bleaching.
 Enhances the stability and compatibility of the pulp in papermaking.
 Versatility:
 Kraft pulp is versatile and can be used for a wide range of paper and board grades.
 Commonly used in packaging materials, printing papers, and various specialty papers.
e. Bleaching (Optional):
 While kraft pulp is naturally brown due to residual lignin, it can undergo bleaching to achieve higher
brightness.
 Bleaching agents may include chlorine, chlorine dioxide, or hydrogen peroxide.
f. Applications:
 Packaging Papers:
 Widely used in the production of kraft papers for packaging, including corrugated boxes and
paper bags.
 The strength of kraft pulp contributes to the durability of packaging materials.
 Printing Papers:
 Used in the manufacturing of printing papers where strength and quality are essential.
 Produces papers suitable for newspapers, magazines, and other printed materials.
 Specialty Papers:
 Finds applications in the production of specialty papers, such as kraft paperboard and
certain industrial papers.
Soda Pulp:
1. Raw Material:
 Produced from a variety of hardwoods, including species like oak, birch, or beech.
 Hardwood fibers are typically used in the soda pulping process.
2. Soda Pulping Process:

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  Cooking Phase:
 Wood chips are treated with a solution of sodium hydroxide (soda) and water in a digester.
 The cooking process aims to break down lignin and separate it from the cellulose fibers.
 Delignification:
 Sodium hydroxide reacts with lignin, solubilizing it and allowing its removal from the wood
chips.
 Cellulose fibers are retained, forming the soda pulp.
3. Byproducts:
 Spent Liquor:
 The byproduct solution containing sodium hydroxide and dissolved lignin.
 It requires proper treatment and disposal.
 Recovered Chemicals:
 Efforts are made to recover and reuse the chemicals from the spent liquor for sustainability.
4. Characteristics of Soda Pulp:
 Lower Strength:
 Soda pulp tends to have lower strength compared to kraft pulp.
 The process is less selective in removing lignin, affecting fiber strength.
 Brighter Color:
 Soda pulp often has a brighter natural color compared to kraft pulp.
 This may reduce the need for extensive bleaching.
 Limited Applications:
 Due to its lower strength, soda pulp is not as widely used as kraft pulp.
 Commonly employed in the production of papers where high strength is not a primary
requirement.
5. Bleaching (Optional):
 Soda pulp can undergo bleaching processes to achieve higher brightness if required for specific
applications.
 The choice of bleaching agents depends on the desired level of brightness and environmental
considerations.
6. Applications:
 Tissue Papers:
 Soda pulp is used in the production of tissue papers, where strength requirements may be
lower than in other paper grades.
 Specialty Papers:
 Finds applications in certain specialty papers where lower strength may be acceptable.
 Limited use in applications where high strength is crucial.
Rag Pulp:
1. Raw Material:
 Produced from textile waste, old clothes, and rags.
 Typically made from cotton or linen fibers obtained from discarded textiles.
2. Pulping Process:
 Rag Cutting:
 Old clothes and textiles are collected and sorted.
 Rags are cut into smaller pieces to facilitate the pulping process.
 Hydration:
 Cut rags are hydrated with water to soften the fibers.
 This step prepares the material for pulping.
 Pulping:
 Rags undergo mechanical or chemical pulping processes to break down fibers.
 Chemical pulping may involve the use of caustic soda or other pulping chemicals.

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 3. Byproducts:
 Waste Streams:
 Byproducts from rag pulping may include waste materials and impurities.
 These need to be properly managed and treated.
4. Characteristics of Rag Pulp:
 Short Fibers:
 Rag pulp generally consists of shorter fibers compared to wood pulps.
 Fiber length impacts the strength and quality of the resulting paper.
 Soft Texture:
 Rag pulp can produce paper with a soft and smooth texture.
 Used in applications where softness is desirable, such as fine writing papers.
 Bright White Color:
 Depending on the source and processing, rag pulp can yield a bright white paper without the
need for extensive bleaching.
5. Applications:
 Fine Writing Papers:
 Commonly used in the production of high-quality writing and printing papers.
 Produces papers with a smooth surface suitable for printing and writing.
 Archival Papers:
 Rag pulp is often used in the manufacture of archival papers.
 These papers have long-term stability and resistance to yellowing.
 Specialty Papers:
 Finds applications in specialty papers, including art papers and certain premium packaging
materials.
 Used where unique textures and qualities are desired.
Pulp Processing Techniques for Kraft, Soda, and Rag Pulp:
1. Kraft (Sulfate) Pulp:
Beating:
 Involves mechanical treatment of kraft pulp to improve fiber flexibility and bonding ability.
 Enhances the paper's strength, formation, and printability.
 Controlled beating ensures desired paper properties without excessively breaking down fibers.
Refining:
 Kraft pulp can undergo refining processes using equipment like refiners.
 Refining enhances fiber flexibility, bonding, and sheet density.
 Balancing refining intensity is crucial to achieve the desired paper quality.
Filling:
 Involves adding mineral fillers to kraft pulp to improve opacity, brightness, and surface smoothness.
 Common fillers include calcium carbonate or kaolin.
 Filling enhances printability and paper surface properties.
Sizing:
 Chemical sizing is applied to kraft pulp to control its water absorption characteristics.
 Rosin or synthetic sizing agents are added to improve resistance to water penetration.
 Important for applications like printing where ink absorption needs to be controlled.
Colouring:
 Bleaching processes are employed to remove residual lignin and color from kraft pulp.
 Bleaching agents like chlorine, chlorine dioxide, or hydrogen peroxide are used.
 Achieves a brighter and whiter appearance in the final paper product.
2. Soda Pulp:
Beating:
 Soda pulp undergoes beating to enhance fiber flexibility and conformability.

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  Beating influences paper softness and smoothness.
 Controls the pulp's ability to hold water and interact with other additives.
Refining:
 Refining of soda pulp is employed to improve fiber properties and sheet density.
 Influences the pulp's ability to form strong and uniform paper.
 Balanced refining is essential to prevent excessive fiber damage.
Filling:
 Similar to kraft pulp, soda pulp may undergo filling processes to improve certain paper properties.
 Fillers enhance opacity, brightness, and surface smoothness.
 Selection of fillers depends on the desired characteristics of the final paper.
Sizing:
 Soda pulp can be sized to control its water absorption characteristics.
 Sizing agents are applied to influence the pulp's interaction with water.
 Essential for applications where water resistance is important.
Colouring:
 Bleaching processes are applied to soda pulp to achieve specific brightness levels.
 Selection of bleaching agents depends on environmental considerations and desired pulp characteristics.
 Brightens the final paper product and removes color impurities.
3. Rag Pulp:
Beating:
 Rag pulp undergoes beating to improve fiber flexibility and bonding properties.
 Influences the softness and texture of the final paper.
 Requires controlled beating to achieve the desired characteristics.
Refining:
 Refining is applied to rag pulp to enhance fiber quality and sheet density.
 Improves paper strength and uniformity.
 Optimal refining conditions prevent excessive fiber damage.
Filling:
 Rag pulp may undergo filling processes to enhance certain paper properties.
 Fillers are added to improve opacity, brightness, and surface smoothness.
 Selection of fillers depends on the intended use of the paper.
Sizing:
 Sizing agents may be applied to rag pulp to control water absorption characteristics.
 Ensures the paper meets specific requirements for printing or writing applications.
 Influences the paper's interaction with inks and water.
Colouring:
 Bleaching processes can be employed to achieve desired brightness levels in rag pulp.
 Selection of bleaching agents considers environmental impact and end-use requirements.
 Improves the visual appearance of the final paper product.
Calendaring in Paper Industries in India:
1. Calendaring Process:
 Definition:
 Calendaring is a finishing process in papermaking that involves passing the paper through a series of
rollers to improve its surface characteristics.
 Roller Configuration:
 The calender stack typically consists of multiple rollers.
 These rollers can be made of steel, paper, or a combination, and they exert pressure on the paper as
it passes through.
 Surface Smoothing:
 Calendaring smoothens the paper surface, enhancing its finish and printability.

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  Reduces roughness and unevenness, creating a more uniform surface.
 Sheet Compression:
 The rollers compress the paper, reducing its thickness.
 Achieves a more compact and denser sheet, impacting properties like opacity and gloss.
 Temperature Control:
 Calendering may involve the application of controlled heat to the paper.
 Heat aids in the plastic deformation of fibers, contributing to surface smoothness.
2. Uses of Calendaring in Paper Industries in India:
Improved Printability: - Calendaring enhances the paper's surface, making it more suitable for printing. - Smoother
surfaces allow for better ink adhesion and sharp image reproduction.
Enhanced Gloss: - Glossiness is improved through calendaring, contributing to a more attractive appearance. - Often
employed for papers used in magazines, brochures, and high-end packaging.
Opacity Enhancement: - Calendering reduces the porosity of paper, improving its opacity. - Beneficial for
applications where opacity is crucial, such as in book printing.
Surface Finish Options: - Calendaring allows for the creation of various surface finishes, including matte, satin, or
glossy. - Paper manufacturers can tailor finishes based on customer preferences and application requirements.
Uniform Surface: - Irregularities and surface variations are minimized through calendaring. - Achieves a more
consistent and uniform appearance across the paper.
Increased Smoothness: - Calendaring imparts a higher degree of smoothness to the paper surface. - Important for
applications like writing papers and fine stationery.
Calendered Coated Papers: - Calendaring is often used in conjunction with coated papers. - Coated papers undergo
calendaring to enhance their smoothness and finish.
3. Paper Industries in India:
Printing and Publishing: - Calendared papers find extensive use in the printing and publishing industry. - Magazines,
newspapers, and books often utilize calendared papers for enhanced print quality.
Packaging: - Calendered papers are employed in various packaging applications. - High gloss and smooth surfaces
contribute to the visual appeal of packaging materials.
Stationery: - Writing papers, notebooks, and stationery items benefit from calendaring. - Improved smoothness
enhances the writing experience and appearance.
Labeling and Specialty Papers: - Labels and specialty papers with specific surface requirements utilize calendaring. -
Achieves desired finishes for specialized applications.
Art and Craft Papers: - Calendared papers are used in art and craft applications. - Surface smoothness is desirable for
artistic creations and craft projects.
Luxury Packaging: - Industries producing luxury packaging often opt for calendared papers. - High gloss and smooth
surfaces enhance the perceived quality of the packaging.
Promotional Materials: - Calendared papers are preferred for promotional materials like brochures and catalogs. -
Improved printability and visual appeal contribute to effective marketing.
Educational Materials: - Calendared papers are utilized in the production of educational materials. - Textbooks and
workbooks benefit from enhanced print quality and durability.
4. Technological Advancements:
 Modern calendaring equipment incorporates advanced technologies for precise control of pressure,
temperature, and other parameters.
 Automation and computerized systems contribute to efficient and consistent calendaring processes.
5. Environmental Considerations:
 The paper industry in India is increasingly adopting environmentally friendly practices.
 Calendaring processes may incorporate sustainable technologies to minimize environmental impact.

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