Paper Manufacturing 061109
Transcript of Paper Manufacturing 061109
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Paper Manufacturingfrom Pulp to Market
By: Mubarak A. AlKhater
CEO, Saudi Paper Group
Date: 6 December 2009
AICHE, 6 Dec 2009
Le Meridian, Khobar, KSA
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Corporate Introduction
Saudi Paper Group was established in 1989 in
Dammam, KSA with production starting in 1992
Public Joint Stock Company, with operations
covering Middle East & North Africa
Main business units: Paper Recycling, Paper
manufacturing and converting (Paper, aluminimum
foil, plastics packaging)
Markets served are global
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Existing Converting Plant
Existing Mill
Existing Collection Plants
Operations
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Consumer Products
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TISSUE MANUFACTURINGa brief introduction
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Pulp is a cellulose fiber material, produced bychemical or mechanical means, from whichpaper and paperboard are manufactured.Sources of cellulose fiber include wood,cotton, straw, jute, bagasse, bamboo, hempand reeds.
Pulp is a suspension of cellulose fibers inwater.
WHAT IS PULP?
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TYPES OF PULP
Forest of the world contains a great number of species,whichmay be divided into two groups:
1. Coniferous trees (usually called SOFTWOOD)Softwood cellulose fibres measure from about 2 to 4 millimeters(0.08 to 0.16 inch) in length.
2. Deciduos trees (usually called HARDWOOD)Hardwood cellulose fibres measure from about 0.5 to 1.5 millimeters
(0.02 to 0.06 inch) in length.
The greater length of softwood fibers contributes strength topaper; while the shorter hardwood fibers fill in the sheet andgive opacity and smooth surface.
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TISSUE PAPER MACHINE
A machine for manufacturing paper, such as tissuepaper, includes a twin-wire former made up of a rotary
forming roll and a pair of endless fabrics, each of whichmay be a wire or felt, lapped around the rotary formingroll to provide twin-wire web formation therewith. Atthe location where these endless fabrics travel beyondthe forming roll they diverge from each other to definebetween themselves a diverging space where one ofthe endless fabrics has an upwardly directed surface onwhich the web is carried beyond the forming roll. Thislatter endless fabric carries the web to a press sectionwhere this latter endless fabric travels with the webthrough a first press nip of the press section definedbetween an inner press roll situated within the loop ofthe latter endless fabric and an outer press roll situated
outside of the latter loop.
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TISSUE PAPER MACHINE contd
This outer press roll is lapped by an additional endlessfabric structure so that the web is situated at the first
press nip between the latter additional fabric structureand the endless fabric which carries the web away fromthe forming roll. The web travels with the additionalfabric structure around the outer press roll, to becomedetached from the endless fabric which carries the webaway from the forming roll, and this outer press rollcooperates with a drying cylinder of a drying section ofthe paper machine to define therewith at least a secondpress nip.
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Yankee
Disintegrating
purchased pulp
SOFT WOOD
PULPER
HIGH DENSITY
CLEANERSeparate heavy
impurities ie
stone,metal,rope..
CL BOX Constant level box andsupply pulp with uniform
pressure to refiner
REFINERFibre brushing to achieve strength
Blending
fibers by
ratio
Stock tank to
keep m/c run
stable
HARD WOOD
PULPER
HD CLEANER
DE FLAKERFibre separation without
cutting & damaging
CLOSED
LEVEL BOX
Over flow
BASIS WEIGHT
VALVEPrecision control
of pulp flow
M/C REFINER
LOW DENSITY CENTRY CLEANERS
Removing light dense particle
sand,dirt, ink,specks by centry
fugal force
FAN PUMP
Stock & recirculated
water are mixed
Final stage
screening ,
separate shives
and other large
size particles
from pulp slurry
PRESSURE
SCREEN
HEAD BOX
Pressurised device that
delivers uniform flow
across deckle
WIRE PART
Tissue formation
crescent former
Felt section
SPR
Suction press roll equiped with
suction box to remove water by
mechanical energy ( nip load )
Evaporate remaining
water in paper web by
heat transfer
POPE REEL
Dried paper wounds on spool
that rotates against a drum
Cy 4.5%
Cy 4.0 %
Cy 4.5%
Cy 4.5%
Cy 4%
Cy
controller
Cy controller
CL BOX
Cy 1%
Cy 0.2%
Cy 20%
Cy 41%
Cy 94%
SW
REFINED
PULP CHEST
HW
PULP CHEST
BLEND
CHEST
Cy 4.5 %
M/C
CHEST
HOOD Blow hot air
SILO
TYPICAL TISSUE MACHINE FLOW DIAGRAM
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TYPES OF TISSUE MACHINE
1. TWIN WIRE MACHINE
Paper machine in which pulp slurry is injected between twoforming wires, and water is drained from both sides of the paperweb.
2. CRESCENT FORMER MACHINEThe sheet is formed between a forming wire and felt that wrap asolid forming roll. When the drainage is completed, the formedsheet is already on the felt. The felt carries the sheet directly tothe pressure roll and the Yankee dryer. This eliminates the pick-upfunction that other machine concepts require.
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TISSUE MANUFACTURING PROCESS
StockPreparation
ApproachSystem
SheetForming
Pressing
Drying
Reeling Winding
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DE-INKING PLANTA brief introduction
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WHAT IS DE-INKING?
De-inking of pulp fibers is essentially a laundering orcleaning process where the ink is considered to bethe dirt. Chemicals along with the heat andmechanical energy are used during the re-pulpingstage to dislodge the ink particles from the fibersand disperse them in the stock suspension. The inkparticles are then separated from the so-called greystock by a series of flotation or washing steps, or byapplying both separation techniques.
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DE-INKING PLANT PROCESS
Pre-FlotationCoarse ScreeningHigh Density CleaningPulping
CleaningFine ScreeningWashingThickening
Dispersing Post Flotation Washing
WaterClarification
Coarse ScreeningHigh Density Cleaning Pre-FlotationCoarse ScreeningHigh Density Cleaning
Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
Washing Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
Thickening Washing Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
Dispersing
Thickening Washing Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
Post FlotationDispersing
Thickening Washing Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
WashingPost FlotationDispersing
Thickening Washing Fine Screening Cleaning
Pre-FlotationCoarse ScreeningHigh Density Cleaning
WashingPost FlotationDispersing
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse
Screening
High Density
Cleaning
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DE-INKING PLANT STAGES
1. PULPING
Pulper is the brain of the de-inking system.
Its function is to defiber the paper and to detach the ink
particles from the fibers, while keeping the contraries large
enough to be removed by the cleaners and screens.
2. HIGH DENSITY CLEANING
The high density cleaner cleans pulp suspensions of sortedand unsorted wastepaper with consistencies up to 4%.
It eliminates heavy impurities such as bolts, nuts, nails, staples,
glass splinters, etc.
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DE-INKING PLANT STAGES
3. SCREENING
Stock screening operation is required to remove oversized troublesome and unwanted
particles from good papermaking fibers. The major types of stock screens are vibratory,gravity centrifugal and pressure screens (centrifugal or centripetal). They all depend on
some form of perforated barrier to pass acceptable fiber and reject the unwanted
material. It is the size of the perforations (usually hole or slots) that determine the
minimum size of debris that will be removed.
All screens are equipped with some type of mechanism to continuously or intermittently
clean the openings in the perforated barrier. Otherwise, the plate would rapidly plug up.Methods of cleaning employed include shaking and vibration, hydraulic sweeping action,
back-flushing, or most common, pulsing the flow through the openings with various
moving foils, paddles, and bumps. The most important consideration for stable, efficient
operation is to maintain flow and consistency near optimum levels.
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SCREENING
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DE-INKING PLANT STAGES
4. FLOATATION
At the heart of the floatation process is the
floatation cell, of which several designs are available.
Here, air in the form of small bubbles is blended with
the grey stock. The air bubbles become attached to
ink and dirt particles, causing them to rise to the cell
surface where they are removed as a dirt-laden froth.
Depending on the level of dirt in the stock a series of
floatation cells are required for efficient ink removal.
The froth is subsequently cleaned in a secondary stage
to recover good fiber.
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DE-INKING PLANT STAGES
5. CLEANING
The centrifugal cleaners removes unwanted particles from pulp and paper stock by a
combination of centrifugal force and fluid shear. Therefore, it separates both on thebasis of density differences and particle shape. All centrifugal cleaners work on the
principle of a vortex generated by a pressure drop to develop centrifugal action. The
power source is the feed pump.
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DE-INKING PLANT STAGES
6. WASHING
Washing basically is water extraction. The dispersed ink especially those that are
broken down into very fine particles is subsequently separated from the pulp bymulti-stage dilution/ thickening washing sequence. The separation of ink in the washingprocess corresponds to a stock thickening process, whether accomplished by
washing equipment or by screens.
If the ink particles are extremely small,
the amount removed is theoreticallyproportional to the amount of water
removed.
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DE-INKING PLANT STAGES
7. BLEACHING
Bleaching refers to a number of processes intended to increase the brightness of pulp, reduce colorreversion, increase purity of cellulose and to preserve the fiber strength at the same time. It involvescontacting/treating unbleached cellulose material under controlled conditions of : stock pH,consistency, Temperature, retention time and concentration of bleaching chemical. Bleaching isachieved through a continuous sequence of process stages utilizing different chemicals andconditions in each stage, usually with washing between stages. The entire bleaching process mustbe carried out in such a way that strength characteristics and other papermaking properties arepreserved.
8. DISPERSING
Even after all cleaning and screenings steps, there will be some ink specks and other contaminantsremaining in the stock. Disperger is used to break up and finely distribute these contaminants andloosen particles of difficult inks which are still attached to the fibers.
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DE-INKING PLANT STAGES
9. WATER CLARIFICATION
In wastewater treatment operations, the processes of coagulation and flocculation are employed toseparate suspended solids from water. Although the terms coagulation and flocculation are oftenused interchangeably, or the single term "flocculation" is used to describe both; they are, in fact, twodistinct processes. Knowing their differences can lead to a better understanding of the clarificationand dewatering operations of wastewater treatment.
Finely dispersed solids (colloids) suspended in wastewaters
are stabilized by negative electric charges on their surfaces,
causing them to repel each other. Since this prevents these
charged particles from colliding to form larger masses, called
flocs, they do not settle. To assist in the removal of colloidalparticles from suspension, chemical coagulation and flocculation
are required. These processes, usually done in sequence, are a
combination of physical and chemical procedures. Chemicals are
mixed with wastewater to promote the aggregation of the suspended
solids into particles large enough to settle or be removed.
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LegendConsumption & Capacities in MT 000
Net Trade in MT000 ( +ve Exports, -veImports)
Global Demand-Supply & Forecast
Source: RISI Outlook for WorldTissue Business Forecast 2009
N. AmericaConsumption2007: 8,0152011: 8,4232016: 9,022
Prod 2007: 7,761 (217)Net Trade 2007: -89
JapanConsumption2007: 1,800
2011: 1,8802016: 1,940
Prod 2007: 1,793(186)Net Trade 2007: -28
L. AmericaConsumption2007: 2,9232011: 3,5382016: 4,522
Prod 2007: 2,700 (197)Net Trade 2007: -72
W. EuropeConsumption2007: 6,2272011: 6,9452016: 7,868
Prod 2007: 5,960(234)Net Trade 2007: -51
Asia Far EastConsumption2007: 1,4812011: 1,8022016: 2,259
Prod 2007: 1,387(231)
Net Trade 2007: -51
OceaniaConsumption
2007: 3672011: 4162016: 488
Prod 2007: 271(13)Net Trade 2007: -85
ChinaConsumption2007: 4,2712011: 5,8052016: 8,335
Prod 2007: 4,259(1741)Net Trade 2007: 308
E. EuropeConsumption2007: 1,2412011: 1,6572016: 2,325
Prod 2007: 1,081(129)Net Trade 2007: -33
Near & Middle EastConsumption
2007: 7122011: 9412016: 1,342
Prod 2007: 607 (48)
Net Trade 2007: -52
AfricaConsumption
2007: 4662011: 5782016: 773
Prod 2007: 426 (72)
Net Trade 2007: -9
Tissue Industry Market Overview
Ti I d t M k t O i
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Legend
Consumption in MT 000
Mill Capacities are rated capacities
PM4 for SPMC is not included
GCCConsumption
2007: 1982011: 2652016: 380
Prod 2007: 152Mill Cap 08: 257 (11)Net Trade 2007: -33
IranConsumption
2007: 532011: 702016: 105
Prod 2007: 29Mill Cap 08: 30 (3)
Net Trade 2007: -19
TurkeyConsumption
2007: 2252011: 3152016: 470
Prod 2007: 238Mill Cap 08: 359 (13)Net Trade 2007: 33
SyriaConsumption
2007: 492011: 642016: 92
Pod 2007: 27Mill Cap 08: 65 (5)
Net Trade 2007: -18
Lebanon
Consumption2007: 362011: 452016: 60
Prod 2007: 37Mill Cap 08: 60 (6)Net Trade 2007: 3
Jordan
Consumption2007: 182011: 232016: 32
Prod 2007: 39Mill Cap 08: 96 (4)Net Trade 2007: 23
IraqConsumption
2007: 122011: 172016: 26
Prod 2007: xMill Cap 08: x
Net Trade 2007: -10
Near & Middle EastConsumption2007: 7122011: 9412016: 1,342
Prod 2007: 607Mill Cap 2008: 975 (48)
Net Trade 2007: -52
Near & Middle East
Source: RISI 2009
Tissue Industry Market OverviewContd
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Thank you