PAPER

AND PULP
INDUSTRIE
S
 Paper has a rich, colourful history which has
spanned the world's geography and its cultures.
Tracing its development , offers us insight into
humanity's relentless imagination, creativity and
sometimes folly.
 It was introduced in Korea in the 4th century
and spread to Japan in 6th.
• Papermaking spread slowly throughout Asia to
Nepal and later to India. It made its true
push westward in 751AD
 The birth of the modern paper and printing industry
is accredited to JOHANN GUTENBURG
 Papermaking today is a large, capital-intensive industry,
characterized by high-speed machines and complex systems of
control for manufacturing to close tolerances thousands of
products vital to education, communications, marketing, packaging,
construction, etc.

 Throughout the 19th century, pulp and paper was largely a domestic
industry, serving the gradually increasing needs.

 With the 1960s came the greatest surge of expansion in the

industry since the 1920s, spurred by provincial governments’
eagerness for new industrial investment .
 Over the past 20 years the most significant development in
the
industry's fibre requirements has been the tremendous
increase in
the use of wood chips, reject lumber and other wood residues
 These paper mills are manufacturing industrial
grades, cultural grades and other specialty papers.
The paper industry in India could be classified into
3 categories according to the raw material
consumed.
 Wood based
 Agro based &
 Waste paper based
 The Indian Paper Industry is among the top 12 Global
players today, with an output of more than 13.5 Million
tonnes annual with an estimated turnover of Rs. 35000
Crores.
 Paper Industry in India is moving up with a strong demand
push and is in expansion mode to meet the projected
demand of 20 Million tonnes by 2020. Thus
paper industry in India is on the growth trajectory and is
expected to touch 8.5% GDP in the coming years.
Therefore, the growth of Industry will out span the present
growth rate of 6.5%.

 The average salary for a chemical engineer in the Indian

paper and pulp industry is around 7 l.p.a.
 The pulp and paper industry comprises
manufacturing enterprises that convert cellulose fibre into a
wide variety of pulps, papers and paperboards. About 95% of
their fibre comes from wood from forests, the balance from
wastepaper and a very small quantity of linen and cotton
rags.

 Wood is reduced to fibre by mechanical means or

by cooking in chemicals.

 The fibres are then mixed with water, adhering to one

another as the water is removed by pressure and heat.
 This is the fundamental principle of papermaking.
 Fiber
softwood

hardwood
non wood fibres
recovered/recycled fibre
 Chemicals
 Energy
 water
 Softwood
 Contain more lignin than hardwoods
 Longer and coarser fibre than hardwoods
 Strength to withstand stretching and tearing
 Improves the runnability of paper on the machine.
 Greater amount of lignin means that more amount of chemicals and
energy
 E.g.: pine, spruce
etc..
 Hardwoods
 Provide Smooth surface
 Primarily used in the production of printing paper because short
fiber pulp improves the printing properties of paper
 E.g...... Acacia, lemon, gum, birch, eucalyptus, pinus,
patula, paper mulberry, rubber plant wood etc..
 Non wood fibres
 Annual crops: flax, kenaf, hemp etc.- often grown especially
for paper production
 agricultural residues: rye, wheat straw, bagasse, etc.. (
vegetable wastes, fruit pulp etc.. – newer alternatives
being
researched on) - byproducts of crops grown for other
uses
 Grasses and reeds:
Straw: rice, lemon, panni,
wheat, bagasse, Ulla,
barley, siru, etc..
reeds, munji,
 Sabai grass, bamboo etc...
 ADVANTAGES OF NON WOOD
Non wood fibers can reduce the amount of chemicals needed
FIBRES:
 for pulping as well as shorten time, thus saving energy.
 The high cellulose content of cotton linter (85% to 90%)
compared to that of wood (35% to 49% cellulose) and the
low lignin content of hemp (3%) make these non wood fibers
valuable for papermaking
 Recovered fibre (recycled paper)
 Grade determined by the process used in
manufacturing the virgin pulp when the paper
was first made and contaminants added to or
picked up by paper in recovery from solid waste
or recycle collection process.
 Contaminants: ink, wax and clay coatings, non
fibre filler materials used in paper, adhesives,
tape, staples, pieces of plastic, metal, dirt etc
 Ample supply
 Available to pulp mill throughout the year
 Should not deteriorate in storage
 High yield of quality fibre
 Capable of being collected and stored in a small
area and transported, if necessary at low cost
 Cost of conversion to paper must be low
 Quality of paper made must be competitive
 Must not have a higher priority use
 The largest paper producing countries like
China, US, Germany, Japan, Canada, use
predominantly wood.
 Bamboo is an ideal raw material. India is the
first country in the world to use bamboo as
the basic raw material for making paper.
 Bamboo and pulpable timber continue to be
the basic raw materials for the paper
industry in India.
 Paper pulp: groundwood, chemical, semi
chemical pulps- bleached or
unbleached
 Reuse pulp: recycled or repulped paper
products like newspapers, paperboard
etc..mixed with new pulp
 Miscellaneous cellulose pulp:
straw, linen, cotton, jute, rags
 Speciality pulp: inorganic fibres such as
 For fillers, sizing and coating,
finishing processes
Inorganic:
 Clay, talc, titanium dioxide, zinc sulfide,
calcium carbonate, calcium sulphate, barium
sulphate, alum etc..
Organic:
 Rosin, glue, caesin, waxes, glycerol,
dyestuffs etc..
 Pulp can be divided into two principal types:
 chemical
 mechanical pulp.
 In fact there are more than two types of
pulp . Pulp from recovered paper poses a
different challenge for the papermaker as it
often has to be de-inked and other
contaminants removed.
Pulping processes
Pulping aims to separate cellulose fibers from
the wood structure.
Possible types of pulp production
are:
 Kraft (68%)

 mechanical (22%)

 semi-chemical (4%)

 sulphite
 (4%)
 Chemical pulping uses chemicals to separate the cellulose from the
lignin. This creates pulps with different properties that can be used
for higher quality paper. The three types of chemical pulping are
Kraft, Sulfite, and semichemical.
 The Kraft process, also called the sulfate process, involves an
alkaline treatment with solutions of sodium sulfide and sodium
hydroxide. In 1987 Kraft pulping was 95% of the total chemical
pulping.
 Sulfite pulping began with the use of calcium as the sulfite liquor
base. Today the base has been changed to magnesium, ammonia, or
sodium. This allows for the recovery of spent liquor.
 The semichemical pulping process involves cooking wood chips in a
neutral solution of sodium sulfite and sodium carbonate or sodium
hydroxide. Only some of the lignin is removed, and then the pulp
Kraft Pulping
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%.
7
 The two processes of mechanical pulping are stone
groundwood (fiber is torn from the side of short logs
with grindstones) and refiner groundwood (wood chips
are passed through disc refiners). Mechanical pulping
does not separate the cellulose fiber from the lignin in
the wood, while chemical pulping does.
 In chemimechanical pulping, the wood is softened with
chemicals before grinding. There is also a process called
thermomechanical pulping, where the wood is softened
with heat and then disc-refined under pressure.
 DE - CHIPPING SCREENING
BARKING

BLEACHING WASHING DIGESTOR

DRIED
pulp
Debarking is the process of
removing bark from wood. Debarking generally involves
the use of industrial machinery into which the log or
stake is placed. Generally they are powered by
hydraulic motors.
The wood chips are then cooked in pressurized vessels
called digesters. In a continuous digester, the materials
are fed at a rate which allows the pulping reaction to
be complete by the time the materials exit the
reactor. Is
iosodocn.heiptso +reNmaOveh t+heNali2gSnin--a-n-d-hemicellulose
content
W -> Black Liquor
• Reduces the pressure of steam from 80 to 10
atm before entering the blow
ank.t

• Steam from the hot slurry passing through the tank

is recovered. This steam is used for the
preheating of chips. This tank
Screening of the pulp after pulping is a process
whereby the pulp is separated from
large shives, knots, dirt and other undigested
residues. rom
The accept is the pulp. The material separated
f the pulp is called reject.
ose
Cooking liquors are separated from the
cellul fibers. Pulp washers
use counter current flow between the stages
• Bleaching of wood pulp is the chemical
processing carried out on various types of wood
pulp to decrease the color of the pulp, so that it
Becames white
• traditionally chlorine based oxidizing agents were
used for this process but due to the formation of
dioxins and other undesirable products, the usage
o Ifn ctheolrmni oedehrans abnedenimproved bleaching stage,
• d
hydrogen pesi rcooxnitdienuiesda.dded along with sodium
 Lignin
content
decreases.
Q. WHY THIS PROCESS?
1.Pulp produced is stronger than that made by
other pulping processes.

2. Acidic sulfite processes degrade cellulose more than the

kraft process, which leads to weaker fibers.

3.Mechanical pulping processes leave most of the lignin in

the fibers.

4.The kraft process can use a wider range of fiber sources

than most other pulping processes.
The black liquor (lignin-rich) produced
•

from the Sulfate pulp production

contains 95-98% of digested chemicals.

To reduce air and water pollution and

•
to balance economy of operation, these
chemicals should be removed before
disposal.
• It is a series of
effect
single evaporators of 5-6
stages of calandria
equipment followed by disk
evaporators .
• After the first step
the
black liquor is
about 30% solids. 20 -

 The weak black liquor is

further evaporated to 65%
or even 80% solids and
The combustion is
•

carried out such that

sodium sulphate is
reduced to sodium
sulphide by the reaction :
NaR(lignin salt) +air
Na2CO3 + CO2
•Molten slag is
produced
•Here organic
carbon present in
black liquor
is burned.
•High pressure 28
atm to 30atm steam
is produced.
•The reaction that
takes place
inside furnace
is :
 The molten salts from the recovery
boiler are dissolved in a process
water known as weak wash.
 This process water, also known
as
weak white liquor is composed
of all
liquors used to wash lime mud
and green liquor precipitates.
The resulting solution of sodium
carbonate and sodium sulphide is
known as "green liquor .
 This liquid is mixed with calcium
oxide , which becomes calcium
hydroxide in solution, to
regenerate
the white liquor used in the pulping
process through an equilibrium
 A clarifier is
used as a filter
to
remove solid
particulates or
suspended
solids from
liquid
 It separates
as filtrate and
sludge .
 Filtering
medium is
monel metal .


Impurities
are washed
away in
this tank
after
clarifying.
 Calcium
carbonate precipitates from
the white liquor and is
recovered and heated in
a lime kiln where it is
converted to calcium
oxide (lime):
 CaCO3 → CaO + CO2
 Calcium oxide (lime) is reacted
with water to regenerate the
calcium hydroxide used in
reaction :
 CaO + H2O → Ca(OH)2
 It precipitates lime mud.
Carbonate is causticized
by adding Ca(OH)2 .
An Overview
 Definition
 ‘ fourdrinier ‘ method of

production
 Finishing

 Chemical additives
 Paper is a thin material produced by pressing
together moist fibers- cellulose pulp , derived
from wood, rags or grasses, and drying them
into flexible sheets.
Basic raw materials include-
Fibrous : containing groundwood, paper products
(recycled) , asbestos and glass
Non-Fibrous: clay, talc ,glue , waxes , glycerol
,titanium dioxide , zinc sulfide , calcium
carbonate
The Fourdrinier
press

Modern papermaking began in the early 1800s in Europe with

the development of the Fourdrinier machine, which produces a
continuous roll of paper rather than individual sheets. These
machines have become very large, up to 500 feet in length,
producing a sheet 400 inches wide.
The Fourdrinier machine is made of four
sections – Forming Section or Wet End, Wet
Press Section, Dryer Section and Calendar
Section.
1.Headbox
2.Press Roll
3.Forming Board
4.Wire
5.Suction Boxes
6.Suction Couch Roll
7.Wire Driving Roll
Headbox
Because wood pulp fiber has a strong
tendency to clump, it needs to start off
with a very high percentage of water
content, allowing the pulp to have an even
distribution, the slurry (or furnish) held in
the Headbox which contains around 99%
water.
Rollers
The furnish travels down the Slice onto
the revolving Wire at the Breast Roller
point of contact and then over a series
of relatively small, parallel rolls of steel
or brass tubing called "table rolls." It
then passes over several suction boxes,
under a roll covered with woven or parallel
wires, called a "dandy roll," and over one
Forming board
device found under the wire on Fourdinier paper machines, just after
the headbox; used to prevent premature removal of too much water
during sheet formation.

Wire
Fine mesh polyester fabric on which the paper sheet is formed by
stock draining through it

Suction boxes
is found in the press section; used to remove water from the
press felts.
Suction couch rolls
Suction rollers hold the furnish to the mesh and help remove the
water content.By the time the paper or web has reached the Wet
Press Section the consistency has gone from 0.5% pulp content to
The Wet Press Section carries the wet web between a series of
rollers under high pressure to squeeze more water from the paper,
much like a mangle. The Felts (polymeric fabrics) support the web and
also aid water removal by absorption. As the web enters the third
section the paper web consistency can be as high as 40%.
Wet web strength factors-
 Fiber lengths
 Moisture content
 Latency(kinked,curled fibers)
 Inter fiber friction (affected by refining , surfac
tants
 Surface tension )
 Process variations
Steam heated rollers in the Dryer Section cause further water
removal through evaporation . It is in the Dryer Section that the
web will be treated with Sizing to change the characteristics of
the paper and via a coating unit, the surface will be covered with
calcium carbonate or china clay for coated papers such as glass,
silks and velvet types. The stock usually about 95% solids by
is the
time it comes off the last dryers.
Calendering
 A calender is a device with two or
more rollers through which the paper is
run. The compression of the rollers and
the application of heat give the paper
its smooth and glossy properties.
It also gives it a more uniform
thickness.
The pressure applied to the web by
the rollers determines the finish of
the paper.
 After calendering, the web has a
moisture content of about 6% d
(depending on the furnish). It is
woun
onto a roll called a tambour or reel,
and stored for final
• Coating
Coating improves the opacity, lightness, surface smoothness,
lustre and color-absorption ability of paper.

Coating means that a layer is applied to the paper, either

directly in the papermaking machine or separately.

Varieties of coated paper range from pigmented to cast-

coated.

The coat consists of a mix of pigments, extenders such as

china clay and chalk, and binders such as starch or latex.

In addition, various chemicals are added to give the paper

the desired characteristics.
Why do we need to add additives?

Improves fiber to fiber bonding

Retain fiber & fines, giving better yield from
the same raw material

Better glaze & stiffness

Increase in breaking length, double fold, tear
factor & other strength properties w.r.t.
writing / printing paper industry.

Improves the formation of paper and fiber
distribution
 Wet strength additive : ensures that the paper retains its
strength when wet. Very important for making tissue papers.
Chemicals used are urea formaldehyde ,poly-
amines
 Dry strength additive : chemicals which enhance the
strength
of
the paper at its normal condition. includes compression
strength, bursting strength, tensile breaking strength etc.
Typical
chemicals used are as cationic starch and polyacrylamide
(PAM)
derivatives--acts as binder of fibers

 Colorants : Basically used to give the paper a specific color,

 Paper can be produced with a wide variety of properties, depending on
its intended use.

 For representing value: paper money, bank

note, cheque, voucher and ticket
 For storing information: book, notebook, magazine, news paper, art
& letters.
 For communication: between individuals and/or groups of
people.
For packaging: corrugated box, paper bag, envelope, Packing & Wrapping
 Paper, and wallpaper.
 For cleaning: toilet paper, handkerchiefs, paper towels and facial
tissue
For construction: paper planes, quilling, paper

honeycomb, used as a core material in composite materials, paper
engineering, construction paper and paper clothing
 For other uses: emery paper, sandpaper, blotting paper, litmus
paper, universal indicator paper, paper chromatography, electrical
insulation paper (see also dielectric and permittivity) and filter paper
ITC Limited – PSPD
 Water and energy consumption per ton of
paper produced:
 Water: averaging around 43kL
 Energy: averaging around 1027 kWh
 Raw material base:

 Wood: around 52%

 Imported pulp: around 27%
 Waste paper: around 21%
Tamil nadu newsprint and papers limited (TNPL)
 Water and energy consumption per ton of paper produced:
 Energy: 1522 kWh
 Water: 55kL
 Raw material base:
 Bagasse pulp: 55%
 Hardwood pulp:35%
 De-inked pulp: 10%
Century pulp and paper (Mumbai, Maharashtra)
 Water and energy consumption per ton of paper produced:
 Water: 57 kL
 Steam: 8.37 tons
 Power: 1291 kWh
 Raw material base:
 Wood, bagasse and recycled fibre
Rainbow papers limited ( Ahmadabad, Gujarat)
 Water and energy consumption per ton of paper produced:
 Water: 15 Kl
 Energy: 544 kWh
 Raw material base:
 Waste paper and ready pulp
Trident limited (dhaula, barnala, punjab)
 Water and energy consumption per ton of paper produced:
 Water: 48 kL
 Energy: 981 kWh
 Raw material base:
 Wheat straw as agro residue raw material for straw pulp –
(50-80%)
 Eucalyptus and veneer waste from plywood industries for
wood pulp -rest
 Half of the wood raw material is utilized as chemical
pulp fiber. The other half is utilized as fuel for
electricity and heat generation. In fact, a pulp mill has
two main lines. Wood is turned into pulp on the fiber
line.
 Energy is produced on the chemical recovery line from
the wood material cooked in the liquor; the cooking
chemicals are recovered for reuse. In the
chemical recovery line, the black liquor is
evaporated and
combusted in a recovery boiler, and the energy content
of the dissolved wood material is recovered as steam
and electricity.
 The chemical pulping process generates more energy
 Water is intricately associated with all the three stages of paper
production namely, pulp making, pulp processing, and paper/paper
board manufacturing, and their associated activities of cooking,
bleaching, and washing.
 With more than 17,000 gallons of water used for every ton of
pulp produced, the pulp and paper sector remains the largest user
of industrial process water in the U.S. and the second largest in
Europe.
 About 85 percent of the water consumed in the pulp and paper
industry is used only for processing, thus, leading to the
generation of large volumes of contaminated wastewater.
 It is also one of the largest producers of wastewater. The paper
and water industries have worked closely for years to achieve
Recycling 1 tonne of paper :

1. Saves approximately 17 trees.

3. Saves 4000KW of power.
4. Saves 3 cubic yards of landfill space.
5. 7000 galloons of water.