Algae based paper

2. Introduction: Problem
Recognition of Problem
● “This year, for the first time since before the Ice
Age, CO2
will not fall below the 400 ppm mark.”
-NOAA (2016)
Algae could be used to sequester carbon
● Unless made into a product with a long useful
lifespan it will decay and re-release the CO2
Definition of Problem for South Carolina
● “Pithophora is a native algae to South Carolina
that is most commonly controlled through the use
of herbicides.” - DNR (2015)
http://www.esrl.noaa.gov/gmd/ccgg/trends/full.html

3. Introduction: Goals
Biological
- Design and model the process of making paper pulp from algae that can be
substituted for wood in traditional paper presses
- Improve bleaching processes through chlorophyll-related options
Structural
- Create a paper product that stands up to the TAPPI standards of store bought
wood pulp paper
Mechanical
- Develop a more sophisticated way to clean the filamentous algae.
- Determine a simplified paper making process utilizing the benefits of
algae-based pulp
- Decrease pulping and drying times

4. Introduction: Constraints
Skills - Lack of paper making knowledge
Budgetary - Algal paper production must be comparable in price to similar wood
pulp based papers
Space - Can only keep a limited amount of algae for testing at a given time
Logistics - Lab scale tests and procedures are very different from industrial
application
Time - Algae growth rate and seasonal weather limits algal biomass available for
testing

5. Introduction: Considerations
Ethical - North Charleston’s Kapstone plant uses
chemical pulping which must be heavily treated
before being released into the Cooper River.
Safety - Bioaccumulation of toxins could occur in
marine life living in or near the effluent flows of
paper mills if not treated properly.
Ecological - Grass Carp and Mozambique Tilapia
have been used in the past to try to control
blooms of filamentous algae, but have been found
to prefer other aquatic grasses.
http://www.kapstonepaper.com/location/charlesto
n-sc/

6. Introduction: Questions of User
Person using the finished paper.
● Will traditional pens and pencils write legibly on Algal paper?
● Is the algal paper as durable as comparable traditional papers?
● Will the paper last as long as traditional papers?

7. Introduction: Questions of Client
Paper press
- What is required to store algal pulp for processes?
- What kind of retrofitting would need to be done for the substitution to take
place?
- Can wood and algae pulp be mixed?

8. Introduction: Questions of Designer
Your’s Truly
- What quantity of pulp will be required to maintain an operation?
- What will be the required strength of the pressed paper?
- What type of algae will be used?

9. Governing Equations
Blending Scale-Up
● Reynolds Number
● Power in an unbaffled tank
● Limiting Vortexing Pbaffled
= ⅙ Punbaffled
● Power in a baffled tank P = kρN3
D5
http://mimoza.marmara
.edu.tr/~bilge.alpaslan/
enve301/Lectures/Chp
_6.pdf

10. Identifying the Algae
Scientific Name: Pithophora oedogonia
Common Name: Cotton-ball Algae/Horsehair Algae

11. Design: Small Scale
● Harvesting
● Cleaning
● Drying
● Rehydration
● Pulping
● Straining
● Pressing
● Redrying

12. Preliminary data: Drying
● Preliminary Trial:
○ Oven dried at 68℃ over 4 days
○ Algae was successfully dried with a
brown border
● Trial 1:
○ Oven was set to 103℃
○ Algae was weighed every
30 minutes for 5.5 hours
○ Drying occurred at 0.85
g/min

13. Preliminary data: Pulping
● Proctor Silex 59735 immersion
blender
● Tested dried and undried
samples
● Fiber lengths of pulped paper
averaged 6.45 mm.
http://www.paperonweb.com/pulppro.htm

14. Preliminary data: Pulping dried and undried
● Undried
○ Blends very quickly and easily
○ Cells do not rupture or shorten
○ Color stays very green
● Dried
○ Must rehydrate for easy pulping
○ Cells rupture and shorten
○ Color fades over time

15. Preliminary data: Pulping Dried and Undried
Undried Dried

16. Forming Handsheets for qualitative analysis of Pulp
● Based on TAPPI standards T 218 sp-11
● Utilized rehydrated dried algae from
preliminary drying test
● Proctor Silex 59735 immersion blender was
used for pulping

17. Forming Handsheets for Qualitative Analysis of Pulp
● 100 mm diameter Büchner
funnel was used to strain pulp
● Pressed between granite slabs
● Allowed to air dry overnight
● Achieved finished test weight of
60 g/m2

18. Bleaching Alternative: Ultraviolet Light
Day 1 Day 3 Day 4

19. Bleaching: Other Alternatives
● Ultra Violet light seems to be the best and least intrusive option
○ Requires significant time investment and does not completely whiten paper
● Repetitive drying and re-soaking of algae to wash out chlorophyll
○ Will be energy intensive
● Chemical Bleaching is another option to explore as it will most likely be the
most successful at completely removing all color
○ Effluent wastewater will have to be treated

20. Sustainability
● Can be used to help sequester
carbon
● Make use of problematic algal
blooms
● Chemical pulping techniques
are not required for algae as in
traditional paper pulping
● Bleaching can be
accomplished through drying
and UV light
http://www.clemson.edu/extension/natural_resources/water/stormwa
ter_ponds/problem_solving/aquatic_weeds/algae_filamentous/

22. Thank You!
Dr. Caye Drapcho
Dr. Terry Walker
Mr. Tom Jones
Cassidy Laird
Clemson University

23. References
Ayhan Demirbas, M. F. (2011). Importance of algae oil as a source of biodiesel. Energy Conversion and Management, Vol. 52,
163-170. <http://www.sciencedirect.com/science/article/pii/S0196890410002761>
Teschke, K. (n.d.). Chapter 72 - Pulp and Paper Industry. Encyclopedia of Occupational Health and Safety, Chapt. 72.
<http://www.ilocis.org/documents/chpt72e.htm>
Global Greenhouse Gas Reference Network (2016). Trends in Atmospheric Carbon Dioxide: Full Mauna Loa CO2 record. Earth
System Research Laboratory.<http://www.esrl.noaa.gov/gmd/ccgg/trends/full.html>
Ben Xu, P. L. (2013). Study of the Flow Mixing in a novel ARID raceway for algae production. Renewable Energy Vol. 62, 249-257.
<http://www.sciencedirect.com/science/article/pii/S096014811300342X>
Environmental Protection Agency (1990). Chemical Wood Pulping. Compilation of Air Pollutant Emission Factors, Ch 10 S02
<https://www3.epa.gov/ttnchie1/ap42/ch10/final/c10s02.pdf>
South Carolina Department of Natural Resources (2015). Fish Pond Management Information. Common Aquatic Plant Management
Problems.<http://www.dnr.sc.gov/water/aquaff/pithalgae.html>
Georgia Tech School of Economics (2003-16). Pulp Mills, Pulp & Paper Mills, Paper Mills in South Carolina. Center for Paper Business
and Industry Studies.<http://www.cpbis.gatech.edu/data/mills-online-new?state=South+Carolina>

24. References
Stein, T. (2016). Carbon dioxide levels race past troubling milestone. National Oceanic and Atmospheric Administration.
<http://www.noaa.gov/stories/carbon-dioxide-levels-race-past-troubling-milestone>
Kapstone. (2016). About Kapstone. Kapstone Paper and Packaging Corporation. <http://www.kapstonepaper.com/about-kapstone/>
Pokhrel, D., Viraraghavan, T. (2004). Treatment of pulp and paper mill wastewater--a review. Science of the Total Environment. Vol.
333, Issues 1-3. <http://www.sciencedirect.com/science/article/pii/S0048969704004279>.
Kocamemi, B. A., (n.d.). Environmental Engineering Unit Operations, Chapter 6 Mixing. Marmara University Department of
Environmental Engineering. <http://mimoza.marmara.edu.tr/~bilge.alpaslan/enve301/Lectures/Chp_6.pdf>.

25. Questions?
Preguntas?
Les questions?

26. Appendices
Handsheet notes and thickness calculations Blending notes and handsheet pressure calculations