Paper and Pulp

Technological turning point in the Indian paper industry is given below:
• Efficient management of depleting resources with sustainable forest productivity

through improved resource planning, better plantation technique, good harvest
management
• Conservation of natural resources
• Effective waste utilization and recycling of fibre
• Improved cleaning efficiency
• Better environmental management for reducing or eliminating toxicity
• Better fibre properties
• Improved runnability
• Improved product appeal (Higher Brightness).
• Odorless mill
Advances in Pulp and Paper Industry
• Mechanical: Thermo mechanical Pulping, Refiner technology
• Biotechnology Application: Bio-pulping, Bio--bleaching, Enzymatic Deinking,

Enzymatic Refining
• Washing And Screening: Drum Displacer, Pressure Diffuser, Displacement

Presses, Combined Deknotting and Fine Screening, High Temperature Screening
Before Washing, Reverse Cleaners
• Bleaching: Instead Of Dioxin Free Pulp, Now, Pulp Are Classified As Chlorine
Free (CGF), Chlorine Chemical Free (CCF), Molecular Chlorine Gas Free(MCGF), Non Chlorine
Compound ((NCC), Active Chlorine Free (ACF),Absolutely Chlorine Free (ACF), Almost Chlorine Free
(ACF), Elemental Chlorine Free Modified (ECFM), Totally Chlorine Free (TCF).
• Evaporation and Recovery: Agro based paper mills require more energy to
recovery of chemicals since it has high silica content. Black liquor losses from
mils without recovery pose a serious environmental problem and result in energy
inefficiencies.
• Fibre Modification: Enhancing the opacity of fibre through pigment particles,

better fibre loading, pressurized sensitive adhesives (PSAS)
• Paper Making: High Speed Machine with Sophisticated Instrumentation and

control; closed hood and insulation of dry cylinder end; installation of trinip press.
MAJOR CHALLENGES AND SHORT COMINGS

Poor infrastructure
Too many administrative hurdles, tedious bureaucratic methods
Poor to non-existent commitment to innovation
High cost of normal method of financing, recent setback from raising capital
through equity for new companies/ developing projects
Rising cost of inputs: fibrous raw materials, chemical, labour, energy
Uneconomic size and obsolete technology in many mills
High cost of production
Poor productivity
Poor instrumentation
Low availability of forest raw materials and poor forest management
Poor recycling of waste paper
Recovery of chemicals from agro-based black liquor
Decolourisation and detoxification
Air pollution problem
High energy consumption.
Raw Material:
Paper industry consumes a wide variety of raw materials – cellulosic derived from forest, agricultural
residues and waste paper; non-cellulosic coal, chlorine, lime, sodium hydroxide, sodium sulphide, fuel oil,
talcum powder etc. Major raw materials used by paper industry is bamboo, wood, bagasse, waste paper and
agricultural residue like wheat straw, rice straw, jute sticks, hemp, kenaf, grasses, sea weed etc. Apart from
this, paper industry consumes large amount of chemicals like caustic soda, sodium sulphide, sodium
carbonate, chlorine, hypochlorite, mineral acid; coal, talcum powder etc.
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
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.
In chipping of bamboo and wood drum chipper and disc chipper are used
KRAFT PULPING PROCESS

Kraft pulping involves Pulping, Washing, Screening, Bleaching. Pulping involves
separation of fibre for chemical or mechanical pulping, removal of knots, washing of
pulp for recovery of chemical, rejects uncooked material, sand and other foreign
material. 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). Many of the mills in India have also gone
for oxygen delignification and newer bleaching sequences Cooking of raw material
is done batch digester, continuous digester. Spherical batch digester is commonly
used for cooking agricultural residues. Cooking liqour used in kraft pulping process
is sodium sulphide, sodium carbonate. 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 cooking zone, lower cooking zone, and washing zone.
Sequence of operation in coking in digester are chip filling, presetting, liquor
charging, heating up and pressure up period, cooking and blowing
Cooking temp: 170-175 oc.

Pressure:7-7.5 kg/cm2
Temp to rise: 135 oC 2 hr.
Time at: 135-140 oC 2hr.
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 pulp.
Lowering the bleaching requirements has been instrumental in making it possible to
find alternatives to the traditional chlorine based bleaching Oxygen delignification
and ozone bleaching has been introduced chlorine free bleaching. Other
development has been use of peroxide, peroxy acids, enzyme etc.
Problems in Utilization of Agricultural Residues
Higher % of silica
Problem in washing due to slow drainage ,high dilution
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.
Bleaching of Mechanical Pulp
Hydrosulphite
Zinc hydrosulphite and sodium hydrosulphite are commonly used for ground wood
pulp and
refiner pulp. Zinc hydrosulphite is prepared by reacting zinc dust with sulphuric acid.
Sodium hydrosulphite can be generated by reacting sodium borohydride and
bisulfite.
Peroxide: Hydrogen peroxide and sodium peroxide are recognized as effective
economical
bleaching agents, they don’t form chlorinated organic derivatives. They are
particularly used in the bleaching of high lignin wood pulp and as a final stage in
chemical pulp bleaching.
SULPHITE PROCESS
Sulphite process was earlier use for pulping, however it has been replaced with
Kraft pulping.
Acid Sulphite: The process in which the cooking acid contains a high % of free
SO2 pH 1.2-
1.5. Not suitable for resinous wood.
NaHSO3 + SO2
Bisulphate: The process in which the cooking liquor contains a predominance of

bisulphate ion in the 3.6 pH ranges with no free SO2.
NaHSO3
SO2 + H2O → H2SO3
CaCO3 + 2 H2SO3 →Ca (HSO3) +CO2+H2O
CaO + H2O →Ca (OH) 2
Mg (OH) 2 + H2SO3 → Mg (HSO3) + 2H2O
Na2CO3 + 2H2SO3→NaHSO3 + H2O
Pressure: 620-755 kpa.Temperature:125 -160 oC

Total cooking time 6-12 hr.
Cooking acid 7% -8% of total SO2.
KRAFT RECOVERY
Recovery of chemicals from black liquor is very important for overall economy of
paper
industry.
Evaporation section and further concentration: Multiple effect evaporator, direct
contact, cascade evaporator, Cyclone evaporator, venture scrubber
Recovery furnace: Furnace, ESP [Figure M-III 3.2]
Dissolving Tank and Green liquor generation
Causticizing and clarification
Lime sludge reburning
Black Liquor Oxidation: Black liquor oxidation has become integral part of
recovery section for reducing the emission of volatile sulphur compounds. Oxidation
of
black liquor by air reduces the emission of odorous sulphur compounds.
Mecrcaptans and
other sulphur compounds are oxidized into less volatile chemicals. Both weak black
liquor and concentrated black liquor oxidation has been reported.
Concentration of black liquor with inlet 12-18percent and outlet 40-50 percent
long tube evaporator. Normally five to six effect evaporator is used. As the black
liquor become highly viscous, further concentration is done by direct contact
evaporator and falling film evaporator
Further concentration in direct contact evaporator to 60%. Using cyclone
evaporator, cascade evaporator and venturi scrubber. In some of the mill Falling
film evaporator is being used to achieve higher concentration of black liquor
which is not possible with conventional evaporator. Other
The concentrated black liquor is sprayed in the furnace where black liquor is
incinerated to yield smelt and flue gases. A typical recovery furnace consists of
air preheater, economizer, furnace and boiler, cyclone, ventury scrubber/
electrostatic precipitator.
Addition of makeup chemicals Na2SO4 (salt cake) in thick concentrated black
liquor which is reduced to Na2Sin the furnace in presence of carbon
Incineration of Black Liquor in recovery furnace
Reducing zone in bottom to burn organic
The main reactions are (1-3 predominantly)
Na2O+CO2→Na2CO3
Na+ + H+ + S2-→NaHS
Na + OH-→NaOH
Na2O+SO2+1/2 O2→Na2SO4
Na2S+2O2→Na2SO4
Na2SO4+Na2S+O2→2Na2S2O3
and other reactions:

Na2SO4+2C→Na2S+CO2
Na2SO4+4CO→Na2S+4CO2
Dissolving smelt in dilute wash liquor or water to produce green liquor.
Containing sodium carbonate and sodium sulphide.
Causticising of green liquor with lime to produce white liquor, lime sludge. A
typical causticising section consist of lime slaking with green liquor, dreg
clarifier, causticising tank, clarifiers, rotary filter, lime kiln.
Na2CO3+CaO +H2O 2NaOH+ CaCO3

Burning of lime sludge to produce lime.
CaCO3 CaO + CO2
Paper consists of a matted or felted sheet of fibres formed from water suspension of
fibre. The pulp obtained from pulp mill after washing, screening and bleaching are
not yet satisfactory for making and require further processing to develop good fibre
bonding and impart several characteristics like surface smoothness, sizing, colour
addition of sizing chemicals, colour and additives and other chemicals like foam and
pitch control, retention aids etc.
“Beating” and “Refining” are the operation of mechanically treating the pulp fibres.
Refining usually refers to fibre separation and cutting; whereas beating action may
include the above two effects and also fibrillation or bruising effect of the fibre. There
are three main types of Beating/Refining equipments,
i) Beaters
ii) Conical Refiners
iii) Disc Refiners
Beaters -Beating includes fibre separation, cutting and fibrillation or brushing
effect.
However the action of the beater is primarily of rubbing or crushing nature.
Blending and Mixing of Chemicals: Stock preparation section involves

blending and mixing of rosin, alum, loading material (talcum powder, calcium
carbonate, titanium dioxide), dyes, whitening agent, starch, gum, sodium silicate,
wax emulsion mixing chest, Refined pulp stock of required quantity is taken and
chemicals are added according to grade of paper and board
Sizing: Paper making fibre have strong tendency to interact with water due to
hydrophilic nature of cellulosic fibre. The process which imparts resistance to water
penetration is called sizing process.
Other Chemicals & Additives:

i) Whitening Agent: This compound also called optical whitener, optical bleaching
agents. The compound when added to paper and board, it absorbs light in the
Ultraviolet range and reemits it in the visible range, thus making the paper appear
whiter.
ii) Starch & Gums: Starch and Gums are used for improving physical strength
properties of paper and board due to better bonding of fibres. Refining energy is
also reduced with this use.
Sodium Silicate: Addition of Sodium Silicate improves stiffness and rattle,
improve finish, reduced fluff, increases retention of filler. It also helps in
improving ash% and bursting strength.
iv) Wax Emulsion: Wax emulsion is used with Rosin size for reducing Rosin
consumption per tonne of paper and it is cheaper than Rosin. As partial substitute
of Rosin.

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Technological turning point in the Indian paper industry is given below:

• Efficient management of depleting resources with sustainable forest productivity

Advances in Pulp and Paper Industry

• Mechanical: Thermo mechanical Pulping, Refiner technology

• Biotechnology Application: Bio-pulping, Bio--bleaching, Enzymatic Deinking,

• Washing And Screening: Drum Displacer, Pressure Diffuser, Displacement

• Fibre Modification: Enhancing the opacity of fibre through pigment particles,

• Paper Making: High Speed Machine with Sophisticated Instrumentation and

MAJOR CHALLENGES AND SHORT COMINGS

KRAFT PULPING PROCESS

Cooking temp: 170-175 oc.

DEVELOPMENT IN PULPING AND BLEACHING:

Bleaching of Mechanical Pulp

Bisulphate: The process in which the cooking liquor contains a predominance of

Pressure: 620-755 kpa.Temperature:125 -160 oC

The main reactions are (1-3 predominantly)

and other reactions:

Na2CO3+CaO +H2O 2NaOH+ CaCO3

Blending and Mixing of Chemicals: Stock preparation section involves

Other Chemicals & Additives:

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