The document summarizes the paper and pulp industries. It discusses that paper is made from cellulose fibers derived from wood, rags or grasses. The pulp and paper industry converts these fibers into pulp and paper. Wood is broken down mechanically or chemically into fibers, which are then mixed with water and dried to form paper. The key raw materials are fibers from wood or non-wood sources, chemicals for pulping, energy, and water. The major pulping processes are mechanical, chemical (kraft and sulfite), and semichemical. Paper is manufactured using a paper making machine that removes water from the pulp to form a continuous paper sheet.

1. PAPER AND
PULP
INDUSTRIES Vasu
Shiva
Vishrut

2. PULP
AND
PAPER INDUSTRIES
INTRODUCTION...

3. Paper is a thin material produced by pressing
together moist fibers- cellulose pulp , derived from
wood, rags or grasses, and drying them into flexible
sheets.
Basic raw materials include-
Fibrous : containing groundwood, paper products
(recycled) , asbestos and glass
Non-Fibrous: clay, talc ,glue , waxes , glycerol
,titanium dioxide , zinc sulfide , calcium carbonate
What is paper?

4. PRINCIPLE BEHIND ………
⬜ The pulp and paper industry comprises
manufacturing enterprises that convert cellulose
fibre into a wide variety of pulps, papers and
paperboards. About 95% of their fibre comes from
wood from forests, the balance from wastepaper
and a very small quantity of linen and cotton rags.
⬜ Wood is reduced to fibre by mechanical means or
by cooking in chemicals.
⬜ The fibres are then mixed with water, adhering to
one another as the water is removed by pressure
and heat.
⬜ This is the fundamental principle of papermaking.

6. RAW MATERIALS FOR THE
PULPING INDUSTRY

7. Major inputs for pulp production
▪ Fibre
softwood
hardwood
non wood fibres
recovered/recycled fibre
▪ Chemicals
▪ Energy
▪ water

8. Fibres
List of materials Cellulose (%) Lignin (%)
Wood
⬜ Coniferous (softwood) 40-45 26-34
⬜ Deciduous (hardwood) 38-49 23-30
Non wood
⬜ Rice Stalk 28-48 12-16
⬜ Wheat straw 29-51 16-21
⬜ Barley Stalk 31-45 14-15
⬜ Kenaf Bast 44-57 15-19
This table shows that
non woods fibre are
not just rich in cellulose
contain but their
composition of lignin is
also low. So, they can
be easily degraded and
consumed in short
period of time as
compared to the wood
fibres used in chemical
pulping process.

9. Sources for fibres
1. Wood mill chips
2. Bagasse
3. Cereal straw
4. Bamboo
5. Jute
6. Coniferous trees
7. Deciduous trees
8. Recycled paper

10. Chemicals
⬜ For chemical pulping:
⬜ Sodium sulphite, carbonate, or hydroxide.
⬜ In the kraft pulp process the active cooking
chemicals (white liquor) are sodium hydroxide
(NaOH) and sodium sulphide (Na2S)

11. Energy
⬜ Half of the wood raw material is utilized as chemical pulp
fibre. The other half is utilized as fuel for electricity and
heat generation. In fact, a pulp mill has two main lines. Wood
is turned into pulp on the fibre line.
⬜ Energy is produced on the chemical recovery line from
the wood material cooked in the liquor; the cooking
chemicals are recovered for reuse. In the chemical
recovery line, the black liquor is evaporated and
combusted in a recovery boiler, and the energy content
of the dissolved wood material is recovered as steam and
electricity.
⬜ The chemical pulping process generates more energy than
it uses.
⬜ A pulp mill generates energy for its own use and energy
to sell.

12. Water
⬜ Water is intricately associated with all the three stages of paper
production namely, pulp making, pulp processing, and paper/paper
board manufacturing, and their associated activities of cooking,
bleaching, and washing.
⬜ With more than 17,000 gallons of water used for every ton of pulp
produced, the pulp and paper sector remains the largest user of
industrial process water in the U.S. and the second largest in Europe.
⬜ About 85 percent of the water consumed in the pulp and paper
industry is used only for processing, thus, leading to the generation of
large volumes of contaminated wastewater.
⬜ It is also one of the largest producers of wastewater. The paper and
water industries have worked closely for years to achieve enormous
reductions in both fresh water use and the contaminants in
wastewater.

13. RAW MATERIALS FOR PAPER
PRODUCTION

14. Fibrous raw materials:
⬜ Paper pulp: groundwood, chemical, semi chemical
pulps- bleached or unbleached
⬜ Reuse pulp: recycled or repulped paper
products like newspapers, paperboard
etc..mixed with new pulp
⬜ Miscellaneous cellulose pulp: straw, linen, cotton,
jute, rags
⬜ Speciality pulp: inorganic fibres such as
asbestos and glass

15. Non fibrous raw materials:
⬜ For fillers, sizing and coating, finishing
processes
Inorganic:
⬜ Clay, talc, titanium dioxide, zinc sulfide, calcium
carbonate, calcium sulphate, barium sulphate,
alum etc..
Organic:
⬜ Rosin, glue, caesin, waxes, glycerol, dyestuffs
etc..

16. PULP MAKING

17. Types of Pulping Processes
⬜ Pulp can be divided into two principal types:
⬜ chemical
⬜ mechanical pulp.
⬜ In fact there are more than two types of
pulp . Pulp from recovered paper poses a
different challenge for the papermaker as
it often has to be de-inked and other
contaminants removed.

19. Mechanical pulping or
Groundwood pulping…..
⬜ The two processes of mechanical pulping are stone
groundwood (fiber is torn from the side of short logs
with grindstones) and refiner groundwood (wood chips
are passed through disc refiners). Mechanical pulping
does not separate the cellulose fiber from the lignin in
the wood, while chemical pulping does.
⬜ In chemimechanical pulping, the wood is softened with
chemicals before grinding. There is also a process called
thermomechanical pulping, where the wood is softened
with heat and then disc-refined under pressure.

20. Chemical pulping…..
⬜ Chemical pulping uses chemicals to separate the cellulose from the
lignin. This creates pulps with different properties that can be used
for higher quality paper. The three types of chemical pulping are
Kraft, Sulfite, and semichemical.
⬜ The Kraft process, also called the sulfate process, involves an
alkaline treatment with solutions of sodium sulfide and sodium
hydroxide. In 1987 Kraft pulping was 95% of the total chemical pulping.
⬜ Sulfite pulping began with the use of calcium as the sulfite liquor
base. Today the base has been changed to magnesium, ammonia, or
sodium. This allows for the recovery of spent liquor.
⬜ The semichemical pulping process involves cooking wood chips in a
neutral solution of sodium sulfite and sodium carbonate or sodium
hydroxide. Only some of the lignin is removed, and then the pulp
undergoes mechanical disintegration.

22. DE -
BARKING
CHIPPING
DIGESTOR
SCREENING
WASHINGBLEACHING
DRIED /
BALED

23. Debarking is the process of
removing bark from wood. Debarking generally involves
the use of industrial machinery into which the log or
stake is placed. Generally they are powered by hydraulic
motors.
1. DE-BARKING

24. 2.CHIPPING
Chipping is the process of cutting or chipping
down the large debarked log into smaller chips
so that they can be easily cooked into pulp

25. The wood chips are then cooked in pressurized vessels called
digesters. In a continuous digester, the materials are fed at a
rate which allows the pulping reaction to be complete by the
time the materials exit the reactor. Digestion is done to
remove the lignin and hemicellulose content .
Wood chips + NaOh + Na2S ------>
Black Liquor
3. COOKING

26. 4. SCREENING
Screening of the pulp after pulping is a process whereby
the pulp is separated from large shives, knots, dirt and
other undigested residues. The accept is the pulp. The
material separated from the pulp is called reject.
5. WASHINGCooking liquors are separated from the cellulose
fibers. Pulp washers use counter current flow
between the stages such that the pulp moves in
the opposite direction to the flow of washing
waters.

27. • Bleaching of wood pulp is the chemical
processing carried out on various types of wood pulp to
decrease the color of the pulp, so that it becomes
whiter.
6. BLEACHING
• Traditionally chlorine based oxidizing
agents were used for this process but
due to the formation of dioxins and other
undesirable products, the usage of
chlorine has been discontinued.
• In the modern and improved bleaching stage, hydrogen
peroxide is added along with sodium hydroxide, which
activates the peroxide.

28. Lignin
content
decreases.

29. PAPER
MANUFACTURING

30. 7.PAPER MAKING
In this process the prepared pulp is converted
into paper by the help of various rollers
The various rollers removes the water from
pulp and rolls the pulp into the paper

31. Method of paper making
Modern papermaking began in the early 1800s in Europe with the
development of the Fourdrinier machine, which produces a
continuous roll of paper rather than individual sheets. These
machines have become very large, up to 500 feet in length,
producing a sheet 400 inches wide, and operating at speeds of
over 60 mph (100 km/h).
The Fourdrinier press (paper making machine)

32. Working
The Fourdrinier machine is made of four
sections – Forming Section or Wet End, Wet
Press Section, Dryer Section and Calendar
Section.

33. Forming section / wet end
1.Headbox
2.Press Roll
3.Forming Board
4.Wire
5.Suction Boxes
6.Suction Couch Roll
7.Wire Driving Roll

34. Headbox
Because wood pulp fiber has a strong
tendency to clump, it needs to start off with a
very high percentage of water content,
allowing the pulp to have an even distribution,
the slurry (or furnish) held in the Headbox
which contains around 99% water.
Rollers
The furnish travels down the Slice onto the
revolving Wire at the Breast Roller point of
contact and then over a series of relatively
small, parallel rolls of steel or brass tubing
called "table rolls." It then passes over several
suction boxes, under a roll covered with woven
or parallel wires, called a "dandy roll," and over
one or more additional suction boxes. Basic
function-to keep the wire is at the desired
degree of tightness

35. Forming board
device found under the wire on Fourdinier paper machines, just after the
headbox; used to prevent premature removal of too much water during
sheet formation.
Wire
Fine mesh polyester fabric on which the paper sheet is formed by stock
draining through it
Suction boxes
aka ‘Uhle Box’ is found in the press section; used to remove water and
detergents from the press felts.
Suction couch rolls
Suction rollers hold the furnish to the mesh and help remove the water
content. By the time the paper or web has reached the Wet Press
Section the consistency has gone from 0.5% pulp content to 25%.
wire driving roll
It drives the wire with the furnish on top to the next section-the wet
press

36. Wet press section
The Wet Press Section carries the wet web between a series of rollers
under high pressure to squeeze more water from the paper, much like a
mangle. The Felts (polymeric fabrics) support the web and also aid water
removal by absorption. As the web enters the third section the paper web
consistency can be as high as 40%.
Wet web strength factors-
⬜ Fiber lengths
⬜ Moisture content
⬜ Latency(kinked,curled fibers)
⬜ Inter fiber friction (affected by refining , surfactants )
⬜ Surface tension
⬜ Process variations

37. Drying section
Steam heated rollers in the Dryer Section cause further water
removal through evaporation . It is in the Dryer Section that the web
will be treated with Sizing to change the characteristics of the paper
and via a coating unit, the surface will be covered with calcium
carbonate or china clay for coated papers such as gloss, silks and
velvet types. The stock is usually about 95% solids by the time it comes
off the last dryers.

38. Calendering
⬜ A calender is a device with two or more
rollers through which the paper is run.
The compression of the rollers and the
application of heat give the paper its
smooth and glossy properties. It also gives
it a more uniform thickness. The
pressure applied to the web by the
rollers determines the finish of the paper.
⬜ After calendering, the web has a moisture
content of about 6% (depending on the
furnish). It is wound onto a roll called
a tambour or reel, and stored for final
cutting and shipping
Finishing

39. • Coating
Coating improves the opacity, lightness, surface smoothness,
lustre and color-absorption ability of paper.
Coating means that a layer is applied to the paper, either directly
in the papermaking machine or separately.
Varieties of coated paper range from pigmented to cast-coated.
The coat consists of a mix of pigments, extenders such as china
clay and chalk, and binders such as starch or latex.
In addition, various chemicals are added to give the paper the
desired characteristics.

40. Why do we need to add additives?
⬜ Improves fiber to fiber bonding
⬜ Retain fiber & fines, giving better yield from
the same raw material
⬜ Better glaze & stiffness
⬜ Increase in breaking length, double fold, tear
factor & other strength properties w.r.t.
writing / printing paper industry.
⬜ Improves the formation of paper and fiber
distribution
Chemical additives

41. ⬜ Wet strength additive : ensures that the paper retains its strength
when wet. Very important for making tissue papers. Chemicals used
are urea formaldehyde ,poly-
amines
⬜ Dry strength additive : chemicals which enhance the strength of the
paper at its normal condition. includes compression strength, bursting
strength, tensile breaking strength etc. Typical chemicals used are as
cationic starch and polyacrylamide (PAM) derivatives--acts as binder of
fibers
⬜ Colorants : Basically used to give the paper a specific color,
improving the tone of the paper at the same time.
⬜ Optical brightening agents: makes paper more white by absorbing
UV light from fluorescence and re-emits in the blue region
Types of additives

42. WASTE GENERATED
Various wastes generated in paper industry are as
follow:-
1 Solid wastes
solid wastes generally consist of :
a) rejects from virgin pulp consist of sand barks etc
b) inorganic sludge formed from chemical pulping
c) chemical flocculation sludge
d) wastewater treatment sludge
e) rejects from recycle paper
f) wastes produce due to debarking
g) deinking sludge

43. 2 Air pollution
a) air pollution is mainly caused due to the burning of fuel in
boilers
b) transportation
c) fumes produce due to deinking
d) fumes produced by chemicals during chemical pulping and
finishing
General air pollutants consist of
Total reduced sulphur @ 0.3-3 kg/T
PM @ 75-150 kg/T
Sulphur oxides @ 0.5-30 kg/T
Nitrogen oxides @ 1-3 kg/T
VOC @ 15 kg/T

44. 3 water pollution
water is the major waste generated in paper
industry
wastewater generated in paper industry is
off different standard generated in
different stages out of which majority of
this wastewater can be reuse after some
treatment

45. 1. Wastewater are discharged @ 20-250m3/T
2. They are high in BOD @10-40 kg/T
3. The wastewater from chemical pulping contains
3-10 times more BOD as mechanical pulping
4. Wastewater from recycled paper also contains
lead and other chemicals which can be carcinogenic
too

46. SOURCE OF WASTEWATER
a) wastewater generated in pulping
b) wastewater generated due to bleaching
c) wastewater generated from paper making
d) wastewater formed due to maintenance
e) wastewater formed during deinking (contains
carcinogens )
f) wastewater generated from chemical recovery
g) Black and green liquor generated from Kraft
process
#out of these wastes around 70% of wastewater can
be reuse after some treatment

47. Characteristics of wastewater
effluent's

48. Wastewater treatment
⬜ The treatment of effluent's is done in two
stages
⬜ Primary treatment
Which is called chemical clarification
⬜ Secondary treatment
Which is called activated sludge process

50. In Primary treatment, chemical clarification is
done in three stages:
(i) Chemical coagulation with hydrated lime,
(ii) Chemical coagulation with (alum + lime) at pH 10.5 to
11.0 and
(iii) pH adjustment to 6-7. The first and 2nd stages are
followed by fluocculation and sedimentation. Thus with
primary treatment, we achieve removal of BOD and
COD up to 90% respectively.

51. In Secondary treatment the following process
takes place:
⬜ Activated sludge process
⬜ Aeration in aerated lagoons
⬜ Anaerobic treatment
⬜ Sequential treatment

52. In Secondary treatment, the activated sludge process
is capable of converting most organic waste (soluble
and insoluble) into more stable inorganic forms or to
cellular mass, resulting into highly reduced BOD and
COD values. The process is performed in presence
of heterogeneous microbial culture composed of
bacteria protozoa, and fungi.
After secondary treatment, the increased bio-mass is
disposed of and the remainder returned to aeration
units. After secondary treatment, DO level is also
maintained by air saturation technique

54. Pollution Prevention And Control
Prevention is better than cure
Pollution prevention program should focus on reducing
wastewater discharge minimizing air emission .. Following
process can be used for this purpose
1. Using energy efficient pulping processes
2. Minimizing the generation of effluents through process
modification
3. Recycling wastewater
4. Using wastepaper as raw product
5. Using chlorine free bleaching process
6. Utilizing black liquor to generate energy

55. Why should we recycle paper?
Recycling 1 tonne of paper :
1. Saves approximately 17 trees.
2. Don’t use approximately 380 gallons of
oil.
3. Saves 4000KW of power.
4. Saves 3 cubic yards of landfill space.
5. 7000 galloons of water.

56. OVERVIEW……

57. Some top paper producing
plants in India and their stats:
ITC Limited – PSPD
✓ Water and energy consumption per ton of
paper produced:
✓ Water: averaging around 43kL
✓ Energy: averaging around 1027 kWh
✓ Raw material base:
✓ Wood: around 52%
✓ Imported pulp: around 27%
✓ Waste paper: around 21%

58. Tamil nadu newsprint and papers limited (TNPL)
✓ Water and energy consumption per ton of paper produced:
✓ Energy: 1522 kWh
✓ Water: 55kL
✓ Raw material base:
✓ Bagasse pulp: 55%
✓ Hardwood pulp:35%
✓ De-inked pulp: 10%
Century pulp and paper (Mumbai, Maharashtra)
✓ Water and energy consumption per ton of paper produced:
✓ Water: 57 kL
✓ Steam: 8.37 tons
✓ Power: 1291 kWh
✓ Raw material base:
✓ Wood, bagasse and recycled fibre

59. Rainbow papers limited ( Ahmadabad, Gujarat)
⬜ Water and energy consumption per ton of paper produced:
⬜ Water: 15 Kl
⬜ Energy: 544 kWh
⬜ Raw material base:
⬜ Waste paper and ready pulp
Trident limited (dhaula, barnala, punjab)
⬜ Water and energy consumption per ton of paper produced:
⬜ Water: 48 kL
⬜ Energy: 981 kWh
⬜ Raw material base:
⬜ Wheat straw as agro residue raw material for straw pulp – (50-
80%)
⬜ Eucalyptus and veneer waste from plywood industries for wood
pulp -rest