paper manufacturing

1. Paper Manufacturing
from Pulp to Market
By: Mubarak A. AlKhater
CEO, Saudi Paper Group
Date: 6 December 2009
AICHE, 6 Dec 2009
Le Meridian, Khobar, KSA

2. 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

3. Existing Converting Plant
Existing Mill
Existing Collection Plants
Operations

4. Consumer Products

5. TISSUE MANUFACTURING
a brief introduction…

6. Pulp is a cellulose fiber material, produced by
chemical or mechanical means, from which
paper and paperboard are manufactured.
Sources of cellulose fiber include wood,
cotton, straw, jute, bagasse, bamboo, hemp
and reeds.
Pulp is a suspension of cellulose fibers in
water.
WHAT IS PULP?

7. TYPES OF PULP
 Forest of the world contains a great number of species,which
may 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 to
paper; while the shorter hardwood fibers fill in the sheet and
give opacity and smooth surface.

8. TISSUE PAPER MACHINE
A machine for manufacturing paper, such as tissue
paper, includes a twin-wire former made up of a rotary
forming roll and a pair of endless fabrics, each of which
may be a wire or felt, lapped around the rotary forming
roll to provide twin-wire web formation therewith. At
the location where these endless fabrics travel beyond
the forming roll they diverge from each other to define
between themselves a diverging space where one of
the endless fabrics has an upwardly directed surface on
which the web is carried beyond the forming roll. This
latter endless fabric carries the web to a press section
where this latter endless fabric travels with the web
through a first press nip of the press section defined
between an inner press roll situated within the loop of
the latter endless fabric and an outer press roll situated
outside of the latter loop.

9. TISSUE PAPER MACHINE cont’d
This outer press roll is lapped by an additional endless
fabric structure so that the web is situated at the first
press nip between the latter additional fabric structure
and the endless fabric which carries the web away from
the forming roll. The web travels with the additional
fabric structure around the outer press roll, to become
detached from the endless fabric which carries the web
away from the forming roll, and this outer press roll
cooperates with a drying cylinder of a drying section of
the paper machine to define therewith at least a second
press nip.

10. Yankee
Disintegrating
purchased pulp
SOFT WOOD
PULPER
HIGH DENSITY
CLEANER
Separate heavy
impurities ie
stone,metal,rope..
CL BOX Constant level box and
supply pulp with uniform
pressure to refiner
REFINER
Fibre brushing to achieve strength
Blending
fibers by
ratio
Stock tank to
keep m/c run
stable
HARD WOOD
PULPER
HD CLEANER
DE FLAKER
Fibre separation without
cutting & damaging
CLOSED
LEVEL BOX
Over flow
BASIS WEIGHT
VALVE
Precision 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

11. TYPES OF TISSUE MACHINE
1. TWIN WIRE MACHINE
Paper machine in which pulp slurry is injected between two
forming wires, and water is drained from both sides of the paper
web.
2. CRESCENT FORMER MACHINE
The sheet is formed between a forming wire and felt that wrap a
solid forming roll. When the drainage is completed, the formed
sheet is already on the felt. The felt carries the sheet directly to
the pressure roll and the Yankee dryer. This eliminates the pick-up
function that other machine concepts require.

12. TISSUE MANUFACTURING PROCESS
Stock
Preparation
Approach
System
Sheet
Forming
Pressing
Drying
Reeling Winding

13. DE-INKING PLANT
A brief introduction…

14. WHAT IS DE-INKING?
De-inking of pulp fibers is essentially a laundering or
cleaning process where the ink is considered to be
the dirt. Chemicals along with the heat and
mechanical energy are used during the re-pulping
stage to dislodge the ink particles from the fibers
and disperse them in the stock suspension. The ink
particles are then separated from the so-called “grey
stock” by a series of flotation or washing steps, or by
applying both separation techniques.

15. DE-INKING PLANT PROCESS
Pre-Flotation
Coarse Screening
High Density Cleaning
Pulping
Cleaning
Fine Screening
Washing
Thickening
Dispersing Post Flotation Washing
Water
Clarification
Coarse Screening
High Density Cleaning Pre-Flotation
Coarse Screening
High Density Cleaning
Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Washing Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Dispersing
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Post Flotation
Dispersing
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Washing
Post Flotation
Dispersing
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse Screening
High Density Cleaning
Washing
Post Flotation
Dispersing
Thickening Washing Fine Screening Cleaning
Pre-Flotation
Coarse
Screening
High Density
Cleaning

16. 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 sorted
and unsorted wastepaper with consistencies up to 4%.
It eliminates heavy impurities such as bolts, nuts, nails, staples,
glass splinters, etc.

17. 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.

18. SCREENING …

19. 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.

20. 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 the
basis 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.

21. 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 by
multi-stage dilution/ thickening washing sequence. The separation of ink in the washing
process 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 theoretically
proportional to the amount of water
removed.

22. DE-INKING PLANT STAGES…
7. BLEACHING
Bleaching refers to a number of processes intended to increase the brightness of pulp, reduce color
reversion, increase purity of cellulose and to preserve the fiber strength at the same time. It involves
contacting/treating unbleached cellulose material under controlled conditions of : stock pH,
consistency, Temperature, retention time and concentration of bleaching chemical. Bleaching is
achieved through a continuous sequence of process stages utilizing different chemicals and
conditions in each stage, usually with washing between stages. The entire bleaching process must
be carried out in such a way that strength characteristics and other papermaking properties are
preserved.
8. DISPERSING
Even after all cleaning and screenings steps, there will be some ink specks and other contaminants
remaining in the stock. Disperger is used to break up and finely distribute these contaminants and
loosen particles of difficult inks which are still attached to the fibers.

23. DE-INKING PLANT STAGES…
9. WATER CLARIFICATION
In wastewater treatment operations, the processes of coagulation and flocculation are employed to
separate suspended solids from water. Although the terms coagulation and flocculation are often
used interchangeably, or the single term "flocculation" is used to describe both; they are, in fact, two
distinct processes. Knowing their differences can lead to a better understanding of the clarification
and 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 colloidal
particles 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.

24. Legend
• Consumption & Capacities in MT ’000
• Net Trade in MT’000 ( +ve Exports, -ve Imports)
Global Demand-Supply & Forecast
Source: RISI Outlook for World
Tissue Business Forecast 2009
N. America
Consumption
2007: 8,015
2011: 8,423
2016: 9,022
Prod 2007: 7,761 (217)
Net Trade 2007: -89
Japan
Consumption
2007: 1,800
2011: 1,880
2016: 1,940
Prod 2007: 1,793(186)
Net Trade 2007: -28
L. America
Consumption
2007: 2,923
2011: 3,538
2016: 4,522
Prod 2007: 2,700 (197)
Net Trade 2007: -72
W. Europe
Consumption
2007: 6,227
2011: 6,945
2016: 7,868
Prod 2007: 5,960(234)
Net Trade 2007: -51
Asia Far East
Consumption
2007: 1,481
2011: 1,802
2016: 2,259
Prod 2007: 1,387(231)
Net Trade 2007: -51
Oceania
Consumption
2007: 367
2011: 416
2016: 488
Prod 2007: 271(13)
Net Trade 2007: -85
China
Consumption
2007: 4,271
2011: 5,805
2016: 8,335
Prod 2007: 4,259(1741)
Net Trade 2007: 308
E. Europe
Consumption
2007: 1,241
2011: 1,657
2016: 2,325
Prod 2007: 1,081(129)
Net Trade 2007: -33
Near & Middle East
Consumption
2007: 712
2011: 941
2016: 1,342
Prod 2007: 607 (48)
Net Trade 2007: -52
Africa
Consumption
2007: 466
2011: 578
2016: 773
Prod 2007: 426 (72)
Net Trade 2007: -9
Tissue Industry Market Overview

25. Legend
• Consumption in MT ’000
• Mill Capacities are rated capacities
• PM4 for SPMC is not included
GCC
Consumption
2007: 198
2011: 265
2016: 380
Prod 2007: 152
Mill Cap 08: 257 (11)
Net Trade 2007: -33
Iran
Consumption
2007: 53
2011: 70
2016: 105
Prod 2007: 29
Mill Cap 08: 30 (3)
Net Trade 2007: -19
Turkey
Consumption
2007: 225
2011: 315
2016: 470
Prod 2007: 238
Mill Cap 08: 359 (13)
Net Trade 2007: 33
Syria
Consumption
2007: 49
2011: 64
2016: 92
Pod 2007: 27
Mill Cap 08: 65 (5)
Net Trade 2007: -18
Lebanon
Consumption
2007: 36
2011: 45
2016: 60
Prod 2007: 37
Mill Cap 08: 60 (6)
Net Trade 2007: 3
Jordan
Consumption
2007: 18
2011: 23
2016: 32
Prod 2007: 39
Mill Cap 08: 96 (4)
Net Trade 2007: 23
Iraq
Consumption
2007: 12
2011: 17
2016: 26
Prod 2007: x
Mill Cap 08: x
Net Trade 2007: -10
Near & Middle East
Consumption
2007: 712
2011: 941
2016: 1,342
Prod 2007: 607
Mill Cap 2008: 975 (48)
Net Trade 2007: -52
Near & Middle East
Source: RISI 2009
Tissue Industry Market Overview –
Cont’d

26. Thank you