Coverage of Lecture Introduction Patio es rocc see Gre eee MESON mm AY Coo tracery) severe ite Come nAOee Meee nBaT oi Kraft Pulping Process Development In Pulping And Bleaching Pulping Of Rice Straw, Wheat Straw, Grasses Jute Sticks Dern ene MOL irl emmeseatureninin Mico ltesy Bagasse pulpingEis cnetCaa csi ¢ Paper industry uses wide variety raw materials employing different type of pulping and bleaching processes depending on the type of raw materials and requirement of pulp furnish for final paper making. + Both unbleached and bleached pulp is produced to meet the requirement of paper.Introduction Requirement of bleaching chemicals are also varying depending on the quality of paper and brightness and environmental considerations for cleaner and greener Moe Pulping and bleaching play important role in providing strength to paper depending on fibre length, cellulose icityPulping Process ¢ Acquisition of Raw Material: Hard wood, soft wood, bagasse, wheat and Rice straw, sabai grass etc. ¢ Raw Material Preparation : Debarking, Chipping, Cutting, Screening ¢ Pulping >» Chemical: Sulphate (Kraft), Soda Pulping, Sulphite Beat heybared Pao O) tele MN Tie) SIU | CSCO T Teun Cotit te! E NSSC.Pulping Processes > Mechanical Pulping: Stone Ground Wood (SGW), SU oc My Cco rT B aT OM Vico Me costo m\y Coo irtittet | Pulp (RMP) Cold Soda Refiner Mechanical Pulp (CRMP) Sulfite: Acid Sulfite higher % of free SO, (Ca, Mg, Na, Ammonia base), Bisulfite: (little or no free SO, (Ca, Mg, Na, Ammonia base). Washing and Screening: 3-4 stage washing, screening and cenri cleaningOxygen delignification Oxygen delignification offers many advantages over the conventional delignification processes and there is steady growth in worldwide production of oxygen delignified pulp. Pe eee ORCT RN mr Tone en RATT m eet number 30-50% lower than conventional kraft cooking methods SV e Nasri itecH mye ent OS In India some of the mills have also switched over to oxygen delignification.Oxygen delignification Oxygen delignification offers many advantages over the conventional delignification processes and there is steady growth in worldwide production of oxygen delignified pulp. Pe eee ORT RN onan RATT m ett number 30-50% lower than conventional kraft cooking methods. SV e aS TeunTi tec niyo ems ent OS In India some of the mills have also switched over to oxygen delignification.Commonly Used Terms in PulpingCommonly Used Terms in Pulping Bryn Description K.No.(Permangnate No. of 0.1 N KMnO, consumed by! numer) Sree Berto tccommm ltl foe IDM factor] DF = W -E (DE) W- Water added per ton of mass E-Water going in pulp per ton o! ao Bath Ratio Wood to liquor ratioCommonly Used Terms in Pulping eS J Description ROC hexose ‘Kappa No B.D. pulp/ total pulp weight (100gms )| i.e. wt of BD pulp in 100 gms of pulp| + water mixture INo of milligrams of metallic copper which is reduced from cupric| hydroxide to cuprous oxide in alkaline| medium by 100 gm of pulp '837+.0323*40 ml KMnO, No.Commonly Used Terms In Pulping evs Description PCat NaOH +Na,S Effective alkali NaOH+1/2 Na)S BRCM erly cele NaOH +Na,S+Na,CO,; Sulfidity Na,S/Titratable alkaliCommonly Used Terms in Pulping Muy Wreyout eto) Certain NaOH/ NaOH +Na,S Corton rites NaOH/ NaOH +Na,S )] x 100 Efficiency aCe ony Na)S/( Na,SO, + NaS ) Over all Recovery + black liquor stock/ san road froth liquor consumedKraft Pulping Process + Kraft pulping involves Chipping Pulping, Washing, Screening, Bleaching. + Pulping involves separation of fibre for chemical or mechanical pulping, een eee Rom OMe met nome came e chemical, rejects uncooked material, sand and other foreign PeeveKraft Pulping Process * Cooking of raw material is done batch digester, continuous digester. Spherical batch digester is commonly used for cooking agricultural residues. Cooking liqgour used in kraft pulping process is sodium sulphide, sodium carbonate.Chipping Chipping quality plays important role in the overall quality of pulp. Efficiency of debarking process, chip size- length, thickness, uniformity of size, removal of dust and fines are important factors affecting pulping efficiency and quality of pulp. In chipping of bamboo and wood drum chipper and Colom Nome Icom CetChipping/Cutting In case of bagasse depithing is very important in overall quality of pulp and paper. In case of agricultural residue size of the straw sand removal of dust also is importantKraft Pulping Process * Cooking cycle may be around 3-5 hr depending of raw material and extend of cooking in batch digester. Typical continuous digester consists of Upper heating zone, upper eee Niwot Owe ene eee mE OR WENN 0 teKraft Pulping Process CMe hen ecmo Meme tcltOn ie nee ee Tel cos Come eae nT Oms TTI nom presetting, liquor charging, heating up and pressure up period, cooking and blowing. Bulk density: 130-150 kg/m*. Bath ratio: 1:3, Sulphidity 15% *Cooking temp: ——_-170-175°e. Dee ey AUD Coen Temp to rise: 135°C 2 hr. SM Bini 135-140°C —2hr.Kraft Pulping Process + Some of the development has in pulping has been Pre- impregnation of chips with lower caustic, high sulphidity liquor, split addition of alkali charge as cook progresses, longer milder, lower temperature rere elieKraft Pulping Process + Another development has been oxygen delignification prior to bleaching to produce stronger pulp with higher strength and low bleaching requirements. * Use of additives like anthraquinone and polysulphide EMME Om nyo CantanteProblems In Utilization Of Hard Wood Dre etie4 Chipping problem — high density chips difficult to chip Higher reject Problem in washing due to more fines and foam Bleaching of mixed hardwood and bamboo pulp creates problem due to varying bleach Requirement Shade variation , darker shade Pe M mM Z Tere Higher percentage of hard wood affects runnability of machine lower strengthKraft Pulping and Bleaching Process * Bleaching of pulp involves bleaching of washed and screened pulp with bleaching chemicals — chlorine, caustic, hypochlorite, chlorine dioxide, ozone, hydrogen peroxide, sodium hydrosulfite. * Conventional used bleaching sequences were (CEHH, CEH, CEHDED, CEDED).Development in Pulping And Bleaching + Driving force in pulping and bleaching technology has been to produce pulp with lower possible lignin content while preserving the yield and strength of pete)Oa at hited And Bleaching + Lowering the bleaching requirements has been instrumental in making it possible to find alternatives to the traditional chlorine based bleachingaon Pip, |é - Extraction DI-Stage cWcI0. BLD TowerBach Digestor canePulping Of Rice Straw, Wheat Straw, Grasses Jute Sticks Se Mion Koerner nes eer nthe eee neri(ent Eten lice mop im eediciie mu tmaceeem tlie ritomPulping of Rice Straw, Wheat Straw, Grasses Jute Sticks Cutting and dusting. Cooking batch or rotary spherical or tumbler digester. BBs Ouviited Washing and screening, cntricleaning, Bleaching eee ome Ro nennecinyPa Le Ce OR aS COE Uist Cooking Condition Bulk density 130-150 kg/m3 Bath ratio: 1:6, “alkali 8-10% Cooking temp: 135-140 0c. Temp to rise: 135 °c Lhr. Time at: 135-140°c 2hr.Problems in Utilization of Cae Cem Coy lo} Perea MeTT Ito Problem in washing due to slow drainage ,high HCO Higher % silica create problem in evaporator Longer wire parts due to poor drainage Lower strength of pulp Low bulk density, seasonal availability, higher pollution load.UES Bagasse 60% fibre and 30% pith, 60% good quality STL cme Len Oe 0.25 ton of bagasse (dry) per tone of sugarcane. 3 tons of bagasse per ton of unbleached pulp Bagasse with 50% moisture & about 2-2.5% sucrose & water soluble materialBagasse Pulping Process of bagasse pulping involves Depithing and Pulping of depethed bagasse. Bleaching DEPITHING-Removal of pith is necessary before pulping as Pith has high ash, difficult to bleach and has little value in paper making, Various depithing processes are dry depthing, wet depthing, and combined depthing. Pulping washing and screening: Cooking of bagasse can be done in batch or continuous digester.Bagasse Pulping + Typical Cooking conditions for bagasse pulping Batch cooking10-12% NaOH, 160°C,6-7 kg/ash,2 hrs sbleaching requirement 5-6% 3- stage Brown stock washing is done which is followed by screening and rontate etniesRaw material Residues Duster Baganse| Depith | —| Bagasse ing. Duster eo | ants}| Bietched t pele Dust PieceNICSE Ce Vi yo bi ted * Mechanical pulping has significant importance in appear making because of the high yield and its requirement in News print. Conventional method of mechanical pulping was ground wood stone pulping which is being still used DAE mnTT Ey However many new generation mills has gone for OTM Tate tte Mmm NUL COMmE ice ecto pulping.Ground Wood Stone Pulping + Primary action in grinding zone involves compression and release of wood as the grit projecting from the pulp stone surface passes of the underneath of the SelectGround Wood Stone Pulping SUD ST oS Coo Team ba TEU EeCo LUT CARSIUT OM eT boa: Lo eee SamES CoO carbide, aluminum oxide and modified aluminum oxide. + Purpose of grinding is to fibre the wood with a minimum damage to fibres and to develop quality required for the end wood, thereby lowest consumption of energy and grinding PecMechanical Pulping sn] err) ren ron on a eee eres ee ee + 7 Cer a rarer = icc Penny CL, waste prea ettg Wins etRefinery Mechanical Pulping Fiberising of chips was earlier done by rod mill. The chips were fed in a rotating drum at one end, the defilation was achieved by the crushing action of a number of steel rods and the fibres is collected at the opposite end of the drum.RG iommy Coen el Bat yt * The variables in refining: are Speed of rotation, Disk inter distance ,Load, Temperature and Consistency CMe Cotto my coset (erl at esate H RMP involves mechanical reduction of chips in a precision double rotating disc refiner with use of two refiners in series. Stronger pulp than SWD in tensile, burst and tear strengthAdvantage of Thermo-mechanical arid titeg SMa Oren) CMU z7Ub CO ee MLC Ceren + Greater flexibility of raw material utilization enabling utilization of cheaper raw materials, as wood stacks, edgings, sawdust, shaving, and other refuse. * No of very little consumption of chemicals.Advantage of Thermo-mechanical aiytitsg + Pulp with good bonding properties and high content of long fibres, improved strength characteristics, yO eC CCL Aa Orie production, lower costs. Ooms ihremce nconlmetitems tele tet me (octet tered + Good bulk, improved quality and printability.Advantage of Thermo-mechanical Pulping IY TLE etme High yield and high strength resulting in either reduced or eliminated costly chemical pulp, improved quality and lower resin More and better utilization of the available raw material. No air-atmospheric pollution, little water pollution and reduced environmental damage. Renae cement enrornt content|Bleaching Of Mechanical Pulp Seirus Zine hydrosulphite and sodium hydrosulphite are commonly used for ground wood pulp and refiner pulp. Zine hydrosulphite is prepared by reacting zine dust with sulphuric acid. Sodium hydrosulphite can be generated by reacting sodium borohydride and bisulfite.Bleaching Of Mechanical Pulp ° Preoxide: Hydrogen peroxide and sodium peroxide are eceunl set eS oot hCoece rene Me rennet nen SME ioe don’t form chlorinated organic derivatives. They are particularly used in the bleaching of high lignin wood pulp and PREM iirc ecm une ne tier Bon Mo ere natesNews Print + News print one of the major portion of paper produced and playing important role in information, cultural, economic Pay + News print typical contains 70% chemi mechanical pulp from Eucolyptus and 30%chemical pulp from reed and bamboo.Advantage of Ground Wood Pulp in News Print Furnish Higher bulk-improves calendar action. iets Oi omncec cme mince ero Dereon canes) Better and improved opacity inhibits show through. Peele m ieclecer ai hying Absence of print through. Improved surfaceWood—+ Stone Cer Pid os + Bark " DIOP ATS O e me teu y ane Mechanical | Pulping Cra Pea Secu Sanne Bleaching Pra (oi ae Paper Rn Stock ated News Print manufactureQuality of Good News Print Runnability, good print ability, minimum two side uniformity. Pulp formation should need following Peele nncalhy Bice ne eles Specially good screeningQuality Of Good News Print Good pulp strength property Uniform pulp quality Controlled bleaching system to maintain required brightness Mechanical pulp has to have good wet end strength, good bondingBagasse Newsprint + Bagasse newsprint is made for 50% bagasse having good printing quality, runnability, opacity, rapid absorptionNews Prints Pulp: News Print Pulp Furnish Consist Of Kraft Pulp And Mechanical Pulp round wood pulpPeto tri (i bee SO, +H,O > H,S0,; CaCO, + 2 H2SO; >Ca (HSO;) +CO,+H,0 CaO + H,O Ca (OH), Ca (OH) , + H,SO; — Ca (HSO;), +2H,O Mg (OH), + H,SO; — Mg (HSO,) + 2H,0 Na,CO, + 2H,SO,—NaHSO, + H,O NH; + H,O >NH,OH NH,OH + H,SO; >NH,HSO, +H;0Continued... Rate of pulping NH;>Mg > Na Pressure: 620-755 kpa.Temperature:125 -160 °C Total cooking time 6-12 hr. Cooking acid 7% -8% of total SO,. ltonofpulp 175-220 kg of SO, 55 68 kg MgO.Important terms in Sulphite Process get aoe sulfurdioxide: Free SIT bance Corel (o Combined SO, BaTiO Total SO, as determined by an iodometric titration and expressed as PRES eDy Free SO, is the actual free SO, plus half of the SO, in the bisulfite of the base. It is also called available SO, Difference between total SO, and free Ney