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Pulp and Paper Industry FINAL
Pulp and Paper Industry FINAL
INDUSTRY
P R E S E N T E D B Y:
GROUP 4
C E L E S T R A , N AT H A L I E
D E M I T I O N , PAT R I C K
GARCIA, TRIXIA
PRADO, RONBER
PULP
RAW MATERIALS
IN THE
PROCESSING OF
PULP
WOOD
• Principal source of cellulose,
which is used in papermaking
OTHER CELLULOSE SOURCES CAN BE
EITHER
•
• Have the advantage that they can be floated in streams to the mill, in
contrast to poplar which sinks soon after immersion, also has a high
pulp yield
• Results in little removal of lignin content thus, producing papers
that is not of as a high quality as other pulping methods
• Mechanical pulps are primarily used in newsprint, as well as papers
used in telephone directories, catalogues, "pulp" magazines, and
paper towels and tissues.
• Mechanical pulps are bleached, but not to any great degree.
Although some lignin is removed from ground wood pulps
by bleaching (and some lignin is softened and lost by the heat
generated by the grinding process), extensive bleaching can result in
a decrease of pulp yield, defeating the primary advantage of the
process.
• About 23% of the pulp used in the world is mechanical pulp. In
most usages, however, ground wood pulp is combined with pulps
produced chemically, to counteract the disadvantages of paper made
with mechanical pulps.
Kraft Pulp or Sulfate Pulp
• The most prevalent method of chemical pulping used in
papermaking (or a term for the pulp itself).
• The kraft process derived from the soda process, developed in the
mid-nineteenth century that dissolved wood chips using a strong
base (alkaline solution) such as lye.
• In 1879, sodium sulfate was added to the process, and a stronger
pulp was produced. As a result, the process became known as the
sulfate process.
• The addition of bleaching systems to increase the brightness and
decrease the lignin content of the pulp also helped make the kraft
process the most popular pulping process.
• The term "kraft" is also used to refer to paper or paperboard made
using unbleached pulp produced by the kraft process.
• Unbleached kraft pulp is generally dark brown in color and strong.
Papers produced from unbleached kraft pulp include brown
wrapping paper, paper bags, envelopes, etc.
• Almost any kind of wood may be used, hard or soft, although
coniferous wood is mostly employed.
• Process was developed especially to remove the large amounts of oil
and resin in the wood.
• The Chemical Reactions are rather indefinite but involves
hydrolysis of the lignin to alcohols and acids.
• This hydrolysis also produces mercaptans and sulfides,which are
responsible for the familiar bad odor of the sulfate pulp mills.
Soda Pulp
• Paper pulp produced using the soda process.
• Used to prepare white paper
• Alkaline process
• The wood used is of the deciduous or broadleaf variety.
Sulfite Pulp
• Paper pulp produced using the sulfite process.
• On the basis of quantity produced, this process ranks second to the
sulfate process.
THREE WAYS OF
FIBERIZING OR
PULPING
Mechanical Pulping
• Method of converting logs or wood chips into paper pulp for use in
papermaking accomplished by mechanical grinding, as opposed to
chemical pulping.
• Traditional mechanical pulping involves forcing logs against a
revolving stone, which grinds the logs into pulp by abrasive action.
• The stone is sprayed with water to remove fibers from the pulp
stone, and to prevent fiber damage due to friction-generated heat.
• It causes rapture of the fiber walls and gives pulps which contain
substances of little value for many purposes
Four main types of Mechanical
Pulping
• Stone groundwood (SGW) pulping: In the SGW process, small logs
are ground against artificial bonded stones made of silicon carbide
or aluminum oxide grits.
• The process gives a high yield, but the fibers produced can be very
short and often must be combined with expensive chemical fibers to
be strong enough to pass through the paper machine and subsequent
coating and printing processes.
• Refiner mechanical pulping (RMP): In RMP wood feedstock is
ground between two grooved discs.
• The process keeps the high yield advantages of the SGW process,
while producing somewhat longer fibers with greater strength.
• This permits lighter weight paper to be used for printing and result
in more print media per ton of feedstock.
• The RMP process can use wood feedstock other than logs, such as
wood scraps and sawdust from lumber mills.
• Thermomechanical pulping (TMP): In TMP wood chips are first
steamed to soften them before being ground in the same manner as
the RMP process.
• The TMP process generates the highest grade mechanical pulp but is
also a high energy intensity process due to its steam use.
• This process can also produce a darker pulp that is more costly to
bleach.
• Despite these drawbacks, TMP is the most common mechanical
process in use today.
• Chemi-thermomechanical pulping (CTMP): CTMP involves the
application of chemicals to wood chips prior to refiner pulping.
• The chemical pre-treatment of wood chips allows for less
destructive separation of fibers from the feedstock, resulting in
longer fibers, higher fiber content, and far fewer shives.
• The CTMP process also produces more flexible fibers (which
provide higher sheet density, burst strength, and tensile strength)
and higher pulp brightness than the TMP process.
• Its primary drawback, like TMP, is that it is a high energy intensity
process
Chemical Pulping
• In chemical pulping lignin is separated from the rest of the wood in
a digester under pressure and with the use of cooking chemicals.
• Methods produce high-quality papers as the chemical cooking
dissolves most of the lignin and hemicelluloses present in the wood,
resulting in better separation of the cellulose fibers.
• There are two primary methods of Chemical Pulping: Sulfite
Process and Kraft Process
Sulfite Process
• The sulfite process cooks wood chips in sulfurous acid combined
with limestone to produce calcium bisulfite.
• The combination of sulfurous acid and calcium bisulfite dissolves
the lignin in the wood and liberates the cellulose fibers.
• Sulfite pulp is soft and flexible, is moderately strong, and is used to
supplement mechanical pulps (most typically in newsprint).
• Problems with the process (including limitations on the types of
trees for which it is suitable, strict pollution laws, and the inability
to recover some of the chemicals ejected by the system) have
resulted in new chemicals being used in the process, and the
wholesale adoption of new processes.
Kraft Process/Sulfate Process
• The sulfate process is now the most widely used chemical pulping
system.
• It evolved from the soda processes developed in the nineteenth
century, which used strong bases (alkaline solutions) such as lye to
digest wood.
• Pulpers began adding sodium sulfate to the soda process, and a
significantly stronger pulp was produced.
• Incorrectly termed the "sulfate" process (it was much later that
chemists discovered that the active ingredient was actually sodium
sulfide, it is perhaps more accurately known as the kraft process
("kraft" is the German and Swedish word for "strength").
• The advantages of kraft pulping include not only increased pulp
strength, but also a better heat- and chemical-recovery system which
reduces processing costs, its effectiveness in digesting nearly every
known species of tree, and the insertion in the process of bleaching
processes which increase pulp brightness.
Semi-Chemical Pulping
• Method of converting wood chips to paper pulp for papermaking
utilizing a combination of chemical and mechanical means.
• In semi-chemical pulping, wood chips are first subjected to mild
cooking in, most commonly, sodium sulfite combined with a small
quantity of alkaline salts, such as sodium carbonate, sodium
bicarbonate, or sodium hydroxide.
• The cooked chips are then sandwiched in a disk refiner—or two
rotating serrated disks—that separate the individual fibers of
cellulose. The pulp is then washed to remove the chemicals.
• Pulp yields in semi-chemical processes are generally from 60-80%
of the original wood, and much of the residual lignin still remains.
• Semi-chemical pulping results in stiff fibers, and the process is used
to make corrugated paperboard, cardboard roll cores, and
containers.
MANUFACTURING
PROCESS OF
ABACA PULP
FIBER PREPARATION AND
COOKING
• Machine stripped abaca fibers are fed
into the digesters. Lignin, carbohydrates
and sugar content of the fiber are
extracted and cellulose are separated into
individual fibers.
DEFIBERIZING AND WASHING
• Cooked pulp is diluted and pumped
to a drum thickener where removal of
spent liquor takes place. Screening,
defiberizing and refining follows. A
screw-type water extractor does
washing.
BLEACHING, WASHING, AND
SCREENING
• Bleaching is done by a batch system (single-
stage) utilizing one up-flow and another down-
flow agitators. The bleached pulp is then
passed thru a rotary drum washer to remove
excess bleaching chemicals; then, thru rotary
vibrating screens to remove impurities; and
thru centrifugal cleaners to remove heavy
particles like sand, pebbies, etc.
PULP DRYING AND FINISHING
• The diluted stock is pumped to a mold former
where stock is formed into pulp sheets. The pulp
sheets are then pressed through a two-stage press
section to dewater the sheet before entering
dryers. Drying, slitting and cutting follows. The
finished product (abaca pulp) is stocked and
transferred to a weighing scale to baling and
wrapping.
PREPARATION OF
COOKING
CHEMICAL AND
TREATMENT
Evaporation of waste liquor
Long flat felt conveyer part Has a forming part of cylinder cage or net cage
which is cylinder shaped
Also called long net paper machine Also called round net paper machine
For all kinds of paper Mostly used for producing paper, towel paper, and
sometimes printing paper
CALENDARING
• process of smoothing and compressing a
material (notably paper) during production
by passing a single continuous sheet
through a number of pairs of heated rolls.
• Provide a smooth, glossy finish.
FINISHING & PACKAGING
• The reels are sold directly to
customers or are further processed into
folio sheets or packaged into cutsize
products for daily use
QUALITY CONTROL
OF FINISHED
PRODUCTS
QUALITY CONTROL
SUBSTANCE
• Defined as weight per unit of area
• Measured by weighing a standard size piece of
the material on a specially calibrated balance.
CALIPER
• Determination of thickness
• Indicative of strength of material
QUALITY CONTROL
BURST
• Determination of bursting strength if paper by measuring
hydrostatic pressure.
TEAR
• Measuring the average force required to tear a single sheet
of paper after tear has started
QUALITY CONTROL
OPACITY
• Importance in preventing “slow-through”
WATER ABSORBENCY
• Amount of water absorbed after the paper has been
subjected to water at constant pressure over a standard area
for a specified time.
QUALITY CONTROL
SMOOTHNESS
• Quantifies the surface finish of paper and measures air
leakage
FREENESS TESTING
• Determine drainage characteristics of pulp
RECYCLING OF
WASTE PAPER
RECYCLING
• Recycling is a process to change waste materials into new usable
products
RECYCLING INFORMATION
POST-CONSUMER WASTEPAPER (PCW)
• Waste that has been used by a consumer and has served its intended purpose
• Separated from solid waste to be recycled into new paper
RECYCLING INFORMATION
REDUCING THE HARM OF BLEACHING
• The process in which chlorine is used to achieve the whiteness of
paper
• Bleaching with chlorine is harmful to the environment
– Produces dioxins (highly carcinogenic)
• Use Totally Chlorine Free (TCF)
RECYCLING INFORMATION
ALTERNATIVE FIBERS IN PAPER
• Kenaf and Hemp
– alternative fiber sources
• Agricultural waste
– From existing land use and not an
international crop that requires new
land
PROCESS
COLLECTION
• Paper is taken from the bin and
deposited in a large recycling
container along with paper from other
recycling bins
PROCESS
SORTING
• Paper is taken to a recycling facility
where it is separated into types and
grades
• Then it is wrapped into bundles and
sent to paper mills for further
processing
PROCESS
PULPING
• Paper moves by conveyor to a big vat called a pulper, which
contains water and chemicals.
• Paper is chopped into small pieces then water is added
• Mixture is then heated to further break down the fibers
– Appearance of mushy pulpy bulk
PROCESS
SCREENING or FILTERING
• Once the pulp is made, it is pushed
through screens that contain small holes
and slots having different sizes and
shapes
– Contaminants such as plastic tapes are
removed
– Carried out several times
PROCESS
CLEANING
• Big cone-shaped cylinders are used for
further cleaning the pulp by carrying out
spinning process
• Larger pulp fibers are separated into
smaller fibers, and any remaining bulk
materials such as staples and paper clips
are removed
PROCESS
DE-INKING
• removes printing ink and sticky materials such as glue
residue and adhesives, and involves the following two
processes:
– WASHING - small ink particles are cleaned by rinsing the
pulp with water
– FLOTATION - bigger ink particles are removed with the
help of air bubbles
– surfactants are added to the pulp that force
the remaining ink and sticky materials to
the top and allow for easier removal from
the clean pulp.
PROCESS
REFINING, COLOR-STRIPPING, and
BLEACHING
• During refining, the pulp is beaten to make the recycled fibers
swell, making them ideal for papermaking
• If the paper pulp contains any dyes, color-stripping chemicals
are added to remove them
• If white paper is desired, the paper pulp may be bleached with
hydrogen peroxide, chlorine dioxide, or oxygen to make it
white and to brighten it
• If brown recycled paper is being made, such as that used for
industrial paper towels, the pulp does not need to be bleached.
PROCESS
PAPERMAKING
• The recycled fiber can be used alone, or blended
with new wood fiber (called virgin fiber) to give it
extra strength or smoothness
• The pulp is mixed with water and chemicals in
which the water content is around 99.5 percent
• The pulp is then sprayed onto wire screens, which
drains the water and bonds the recycled fibers to
form a watery paper sheet
PROCESS
PRESSING
DRYING
REELING, WINDING, and SHEETING
FINISHING AND PACKAGING
WASTE TREATMENT
• Refers to the activities required to ensure that waste has the least
practicable impact on the environment
WASTE TREATMENT
PRIMARY TREATMENT
• All wastewater from the mill goes first to clarifiers where all
settleable solids are removed
– Settleable - Material heavy enough to sink to the bottom of a wastewater treatment tank
• These solids are then returned to the mill, where they are dewatered
and burned in the mill’s boilers
WASTE TREATMENT
SECONDARY TREATMENT
• Liquid is now pumped to large lagoons
• The natural self-cleaning process through its naturally-occurring
microbes
• Treated water is then released to secondary clarifiers for final
treatment
WASTE TREATMENT
SANITARY LANDFILL
• Solid waste is compacted into the smallest possible volume and
hauled to a landfill area
PHILIPPINE
PAPER
INDUSTRY
PHILIPPINE PAPER INDUSTRY
• The Philippine paper industry seeks to attain the capability
to serve all major pulp and paper requirements of the
country and develop high-value and quality pulp and paper
products in the long-term, in a manner that is
internationally competitive and environmentally-
sustainable.
GOALS
• To improve the country’s wastepaper recovery and recycling rate;
• To upgrade the levels of manufacturing technologies and
environmental performance of local paper mills;
• To establish local sources of pulp, based on sustainably-managed
tree plantations and non-wood fibers from agricultural wastes and
annual crops; and
• To enable the local mills in achieving economic competitiveness
and thus, contribute to poverty alleviation and national
development.
PHILIPPINE PAPER INDUSTRY
• At present, the Philippines has twenty-four (24) non-integrated
paper mills with a total production capacity of 1.3 million tons of
paper and paperboard per year.
• In the last five years, almost all grades produced in the Philippines
have a recycled fiber content of 95-100%, compared to the
minimum recycled content of 25-35% implemented in developed
countries.
PHILIPPINE PAPER INDUSTRY
• Noah’s paper mills INC.
– Southest Marcos highway, Tayug Marikina Metro Manila
• Asia Paper Industrial Corp.
– Cabuco cavite
• Tahochi Trading and Indutrial Supply
– Valenzuela City
• Aclem Paper Mills INC.
– Binondo Manila
• Star Paper Corporation
– Quezon City, Metro Manila
INDUSTRY
UPDATES
INDUSTRY UPDATE
• Deep Eutectic Solvent (DES)
– produced by plants, opens the way to produce pulp at low temperatures and
at atmospheric pressure. Using DES, any type of biomass could be
dissolved into lignin, cellulose and hemicellulose with minimal energy,
emissions and residues. They could also be used to recover cellulose from
waste and dissolve ink residues in recovered paper.
• DryPulp for cure-formed paper
– Imagine a papermaking process that uses no water. This is it. Fibres are
treated to protect them from shear, and then suspended in a viscous solution
at up to 40% concentration. The solution is then pressed out and the thin
sheet cured with a choice of additives to deliver the end-product required.
REFERENCE:
• http://ietd.iipnetwork.org/content/chemical-pulping
• http://ietd.iipnetwork.org/content/pulp-and-paper
• http://ietd.iipnetwork.org/content/mechanical-pulping
• http://printwiki.org/Chemical_Pulping
• http://printwiki.org/Semichemical_Pulping
• http://printwiki.org/Mechanical_Pulping
• http://printwiki.org/Kraft
• http://www.paperonline.org/paper-production/pulping/types-of-pulping-processes
• http://www.paperonline.org/paper-making/paper-production/pulping/pulp-varieties
• http://www.upmpulp.com/materials-for-pulp-products/what-is-pulp/Pages/Default.aspx
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