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"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm
"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm
"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm
Volume A
Chapter 1 - Introduction
1 Wood fibers.........................................................................................................................13
2 Pulping ................................................................................................................................13
2.1 Washing, screening, and bleaching .....................................................................................14
2.2 Recovery of chemicals .........................................................................................................15
1 Introduction ......................................................................................................................513
2 Industry standard for continuous pulping systems .....................................................515
3 Overview description of process and equipment.........................................................515
3.1 Pre-steaming ......................................................................................................................519
3.2 Chip metering and feeding process pressure ....................................................................522
3.3 Top circulation lines and top separator ..............................................................................528
3.4 Impregnation zone .............................................................................................................530
3.5 Primary heating zone .........................................................................................................532
3.6 Screen and screen header design .....................................................................................536
3.7 Cooking and extraction zones............................................................................................539
3.8 Countercurrent Hi-Heat washing........................................................................................541
3.9 Blow dilution and cold blowing ...........................................................................................544
3.10 Process gases....................................................................................................................545
4 Modified cooking processes...........................................................................................546
4.1 Isothermal cooking (ITC)....................................................................................................549
4.2 Lo-Solids pulping................................................................................................................552
4.2.1 Process objectives.................................................................................................552
4.2.2 Basic principles of Lo-Solids pulping .....................................................................552
4.2.3 Configuration of process equipment......................................................................553
4.2.4 Lo-Solids pulping in practice..................................................................................553
4.2.5 Decreases in time and concentration profile of dissolved wood solids .................553
4.2.6 Pulp strength, EA consumption, and bleachability ................................................554
4.2.7 Digester extraction capacity and brownstock washing ..........................................555
4.2.8 Scaling and heat distribution..................................................................................555
5 Recent developments in the technology of continuous digesters .............................556
5.1 Black liquor impregnation (BLI) ..........................................................................................556
5.2 Diamondback chip bin........................................................................................................559
5.3 Lo-Level feed system .........................................................................................................563
6 Future developments in technology of continuous digesters ....................................566
References .........................................................................................................................569
1 General ................................................................................................................................37
2 Black liquor properties ......................................................................................................37
2.1 Composition of black liquor dry solids..................................................................................37
2.2 Physical properties of black liquors......................................................................................38
3 Principles of evaporation ..................................................................................................40
3.1 Multiple effect evaporation ...................................................................................................41
3.2 Vapor compression evaporation ..........................................................................................42
3.3 Flash steam evaporation......................................................................................................43
3.4 Evaporator plant coupling ....................................................................................................43
3.5 Concentrator coupling ..........................................................................................................45
3.6 Stripper column integration ..................................................................................................45
4 Evaporator design features...............................................................................................46
4.1 Rising film (RF) evaporator ..................................................................................................46
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
4.2 Falling film (FF) evaporators ................................................................................................47
1 General ..............................................................................................................................135
1.1 Characterization of the liquors ...........................................................................................136
1.2 Recausticizing chemistry....................................................................................................139
1.3 Chemical reactions in lime reburning.................................................................................141
2 White liquor plant material balances .............................................................................141
3 Sodium and sulfur balances ...........................................................................................142
4 Environmental issues ......................................................................................................144
5 Nonprocess elements in white liquor preparation .......................................................145
5.1 Nonprocess elements in recausticizing..............................................................................145
5.2 Nonprocess elements in lime reburning.............................................................................147
5.3 Reducing NPE in the lime cycle .........................................................................................149
6 Future challenges ............................................................................................................150
7 Green liquor treatment ....................................................................................................150
7.1 Separation of solid impurities .............................................................................................151
7.1.1 Clarification ............................................................................................................152
7.1.2 Filtration .................................................................................................................154
7.2 Green liquor cooling ...........................................................................................................157
7.3 Dregs handling ...................................................................................................................158
7.3.1 Dregs washer clarifier ............................................................................................158
7.3.2 Vacuum precoat filtration .......................................................................................158
7.3.3 Pressure disc precoat filtration ..............................................................................159
7.3.4 Chamber filter press filtration.................................................................................159
8 Recausticizing ..................................................................................................................161
8.1 General...............................................................................................................................161
8.2 Process ..............................................................................................................................161
8.2.1 Slaking ...................................................................................................................162
8.2.2 Causticizer train .....................................................................................................164
8.2.3 White liquor separation ..........................................................................................165
8.2.4 Storage tanks for white liquor and weak white liquor ............................................170
8.2.5 Lime mud dewatering ............................................................................................170
8.2.6 Modifications of white liquor...................................................................................172
8.3 Automation .........................................................................................................................174
8.3.1 Process requirements............................................................................................174
8.4 Field instrumentation..........................................................................................................174
8.5 Process controls.................................................................................................................175
8.5.1 Manual control .......................................................................................................175
8.5.2 Conductivity measurement and control .................................................................175
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
8.5.3 Automatic process titrator and control ...................................................................176
1 Introduction ......................................................................................................................205
1.1 Operating principle of steam boilers ..................................................................................205
1.2 Cogeneration steam cycles................................................................................................207
2 Physical and chemical properties of fuels ....................................................................208
2.1 Fuels and their composition ...............................................................................................208
2.2 General terminology and properties of fuels ......................................................................208
2.3 Bark, wood, and hog fuel ...................................................................................................212
3 Calculation of combustion ..............................................................................................214
3.1 Combustion reactions ........................................................................................................214
3.2 Combustion air demand .....................................................................................................215
3.3 Flue gas composition .........................................................................................................217
3.4 Adiabatic temperature of combustion ................................................................................219
3.5 Emissions from combustion ...............................................................................................220
3.6 Heat transfer properties of flue gases................................................................................223
4 Combustion technologies of bark ..................................................................................224
4.1 Grate firing..........................................................................................................................224
4.2 Introduction to fluidized bed combustion............................................................................227
4.3 Bubbling fluidized bed (BFB) combustion ..........................................................................231
4.4 Circulating fluidized bed (CFB) combustion.......................................................................233
4.5 Environmental aspects of fluidized bed combustion ..........................................................237
4.6 Gasification.........................................................................................................................239
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
5 Boiler processes ..............................................................................................................241
1 Introduction ......................................................................................................................303
2 Heat and power demand in pulp and paper manufacturing ........................................303
3 Heat and power demand of chemical pulp mills...........................................................305
3.1 Wood yard ..........................................................................................................................306
3.2 Cooking ..............................................................................................................................306
3.3 Washing and screening......................................................................................................306
3.4 Bleaching............................................................................................................................307
3.5 Bleach stock cleaning ........................................................................................................307
3.6 Drying machine ..................................................................................................................307
3.7 Evaporation ........................................................................................................................308
3.8 Recovery boiler ..................................................................................................................309
3.9 Causticizing and lime kiln...................................................................................................311
3.10 Bleaching chemicals preparation .......................................................................................311
3.11 Water and effluent..............................................................................................................312
3.12 Power boiler .......................................................................................................................312
3.13 Steam turbines and water cooling......................................................................................312
3.14 Other ...............................................................................................................................314
4 Heat and power balance of chemical pulp mill .............................................................314
4.1 Installed power vs. demand ...............................................................................................314
4.2 Heat generation..................................................................................................................315
4.3 Heat and power balance ....................................................................................................318
4.4 Steam turbines ...................................................................................................................318
4.5 Back pressure power process............................................................................................322
4.6 Co-generation alternatives .................................................................................................326
5 Paper mills ........................................................................................................................329
5.1 Heat and power balance of newsprint production..............................................................330
5.2 Heat and power generation in SC and LWC production....................................................331
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
6 Time dependent variation in power demand.................................................................333
1 Introduction ......................................................................................................................337
2 Secondary heat ................................................................................................................337
2.1 Definition of secondary heat...............................................................................................337
2.2 Secondary heat production in the pulp mill ........................................................................338
2.2.1 Continuous cooking ...............................................................................................338
2.2.2 Displacement batch cooking..................................................................................340
2.2.3 Conventional batch cooking...................................................................................341
2.2.4 Warm water production from surface condenser...................................................343
2.2.5 Secondary condensates from evaporation ............................................................344
2.2.6 Secondary heat production of hot water from drying machine ..............................347
2.2.7 Lime kiln flue gas scrubber ....................................................................................347
2.2.8 Production of hot water from drying machine ........................................................347
2.2.9 Other secondary heat sources in pulp mill ............................................................349
2.3 Secondary heat consumption.............................................................................................350
2.4 Optimizing of secondary heat system ................................................................................351
2.4.1 Optimizing of warm water production ....................................................................351
2.4.2 Optimizing hot water production ............................................................................352
2.5 Mill wide secondary system ...............................................................................................355
2.5.1 Design considerations ...........................................................................................355
2.5.2 Water quality control ..............................................................................................355
2.5.3 Secondary heat system applications .....................................................................356
3 Process integration techniques .....................................................................................360
3.1 Basic principles of pinch technology ..................................................................................360
3.1.1 Composite curves ..................................................................................................360
3.1.2 Grand composite curve..........................................................................................364
3.1.3 Total site analysis ..................................................................................................366
3.1.4 Advantages and limitations....................................................................................368
3.2 Process integration using mathematical programming techniques ...................................368
3.2.1 Overview of techniques .........................................................................................369
3.2.2 Advantages and limitations....................................................................................370
3.3 Exergy analysis ..................................................................................................................371
References .........................................................................................................................373
1 Turpentine.........................................................................................................................375
2 Soap and tall oil................................................................................................................378
2.1 Introduction.........................................................................................................................378
2.2 Chemistry ...........................................................................................................................378
2.2.1 General ..................................................................................................................378
2.2.2 Composition of tall oil.............................................................................................379
2.3 Soap recovery system design ............................................................................................379
2.3.1 Skimming and storage of soap ..............................................................................379
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
2.3.2 Soap handling ....................................................................................................................381
2.4 Tall oil plant design ............................................................................................................382
1 Introduction ......................................................................................................................411
2 Organosolv pulping methods .........................................................................................411
3 Delignification chemistry in organosolv processes.....................................................412
4 Technical and economic demands on new processes ................................................413
5 Alcell ...............................................................................................................................414
6 Organocell.........................................................................................................................416
7 IDE ...............................................................................................................................418
8 ASAM ...............................................................................................................................418
9 Methanol-reinforced kraft pulping..................................................................................421
10 Acetosolv, Acetocell, and Formacell .............................................................................421
11 Milox ...............................................................................................................................423
12 Future of Organosolv processes....................................................................................425
References .........................................................................................................................427
"Chemical Pulping"
Edited by Johan Gullichsen
And
Carl-Johan Fogelholm
Chapter 21 - Process calculations and simulation
1 Simulation principles.......................................................................................................429
2 General structure of a simulator ....................................................................................430
3 Applications......................................................................................................................434
Chapter 22 - Closed cycle systems for manufacture of bleached chemical wood pulp
1 Introduction ......................................................................................................................441
2 The effluent-free mill........................................................................................................442
2.1 Concept ..............................................................................................................................442
2.2 The first commercial application.........................................................................................443
2.3 Lessons and projected requirements.................................................................................446
3 System aspects ................................................................................................................447
3.1 Basic technologies .............................................................................................................447
3.2 Water, chemical, and energy balances..............................................................................449
3.3 Nonprocess elements ........................................................................................................455
3.4 Economics..........................................................................................................................456
4 Mill-scale developments..................................................................................................457
4.1 Champion International Corporation, Canton Mill ..............................................................457
4.2 Louisiana-Pacific Corporation, Samoa Mill ........................................................................459
4.3 Union Camp Corporation, Franklin Mill ..............................................................................460
4.4 Modo, Husum Mill ..............................................................................................................461
4.5 Munksjö Ab, Aspa Bruk Mill ...............................................................................................462
4.6 Södra Cell, Värö Mill ..........................................................................................................463
4.7 SCA, Östrand Mill...............................................................................................................463
4.8 Metsä-Rauma, Rauma Mill.................................................................................................463
5 Relevant technologies under development...................................................................464
6 Minimum impact mill concepts.......................................................................................465
References .........................................................................................................................469