Paper manufacturing from pulp to market
This presentation is the property of its rightful owner.
Sponsored Links
1 / 26

Paper Manufacturing from Pulp to Market PowerPoint PPT Presentation


  • 349 Views
  • Uploaded on
  • Presentation posted in: General

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. Corporate Introduction. Saudi Paper Group was established in 1989 in Dammam, KSA with production starting in 1992

Download Presentation

Paper Manufacturing from Pulp to Market

An Image/Link below is provided (as is) to download presentation

Download Policy: Content on the Website is provided to you AS IS for your information and personal use and may not be sold / licensed / shared on other websites without getting consent from its author.While downloading, if for some reason you are not able to download a presentation, the publisher may have deleted the file from their server.


- - - - - - - - - - - - - - - - - - - - - - - - - - E N D - - - - - - - - - - - - - - - - - - - - - - - - - -

Presentation Transcript


Paper manufacturing from pulp to market

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


Corporate introduction

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


Paper manufacturing from pulp to market

Operations

Existing Mill

Existing Converting Plant

Existing Collection Plants


Consumer products

Consumer Products


Tissue manufacturing

TISSUE MANUFACTURING

a brief introduction…


What is pulp

WHAT IS PULP?

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.


Types of pulp

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.


Tissue paper machine

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.


Tissue paper machine cont d

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.


Paper manufacturing from pulp to market

TYPICAL TISSUE MACHINE FLOW DIAGRAM

CL BOX

Constant level box and supply pulp with uniform pressure to refiner

Cy 0.2%

Cy 4.0 %

SW REFINED PULP CHEST

SILO

Cy controller

CLOSED LEVEL BOX

Cy 4.5%

SOFT WOOD

PULPER

HIGH DENSITY

CLEANER

Separate heavy impurities ie stone,metal,rope..

REFINER

Over flow

FAN PUMP

Fibre brushing to achieve strength

Stock & recirculated water are mixed

Disintegrating purchased pulp

Cy 4.5%

Cy 4.5 %

Cy 1%

M/C CHEST

BLEND CHEST

Final stage screening , separate shives and other large size particles from pulp slurry

BASIS WEIGHT VALVE

CL BOX

PRESSURE SCREEN

Blending fibers by ratio

Stock tank to keep m/c run stable

Precision control of pulp flow

HW PULP CHEST

LOW DENSITY CENTRY CLEANERS

Removing light dense particle sand,dirt, ink,specks by centry fugal force

Cy 4%

HARD WOOD

PULPER

Cy controller

Cy 4.5%

DE FLAKER

M/C REFINER

HD CLEANER

Fibre separation without cutting & damaging

HEAD BOX

Pressurised device that delivers uniform flow across deckle

HOOD

Blow hot air

Tissue formation –crescent former

Yankee

WIRE PART

Cy 41%

Evaporate remaining water in paper web by heat transfer

Felt section

Cy 94%

POPE REEL

SPR

Cy 20%

Suction press roll equiped with suction box to remove water by mechanical energy ( nip load )

Dried paper wounds on spool that rotates against a drum


Types of tissue machine

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.


Tissue manufacturing process

TISSUE MANUFACTURING PROCESS

Stock

Preparation

Approach

System

Drying

Sheet

Forming

Pressing

Reeling

Winding


De inking plant

DE-INKING PLANT

A brief introduction…


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.

WHAT IS DE-INKING?


De inking plant process

DE-INKING PLANT PROCESS

Pulping

High Density Cleaning

High Density

Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

High Density Cleaning

Coarse Screening

Coarse Screening

Coarse Screening

Coarse Screening

Coarse Screening

Coarse Screening

Coarse

Screening

Coarse Screening

Coarse Screening

Coarse Screening

Coarse Screening

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Pre-Flotation

Thickening

Thickening

Thickening

Thickening

Thickening

Thickening

Washing

Washing

Washing

Washing

Washing

Washing

Washing

Fine Screening

Fine Screening

Fine Screening

Fine Screening

Fine Screening

Fine Screening

Fine Screening

Fine Screening

Cleaning

Cleaning

Cleaning

Cleaning

Cleaning

Cleaning

Cleaning

Cleaning

Cleaning

Dispersing

Dispersing

Dispersing

Dispersing

Dispersing

Post Flotation

Post Flotation

Post Flotation

Post Flotation

Washing

Washing

Washing

Water

Clarification


De inking plant stages

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.


De inking plant stages1

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.


Screening

SCREENING …


De inking plant stages2

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.


De inking plant stages3

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.


De inking plant stages4

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.


De inking plant stages5

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.


De inking plant stages6

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.


Paper manufacturing from pulp to market

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

W. Europe

Consumption

2007: 6,227

2011: 6,945

2016: 7,868

Prod 2007: 5,960(234)

Net Trade 2007: -51

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

Asia Far East

Consumption

2007: 1,481

2011: 1,802

2016: 2,259

Prod 2007: 1,387(231)

Net Trade 2007: -51

L. America

Consumption

2007: 2,923

2011: 3,538

2016: 4,522

Prod 2007: 2,700 (197)

Net Trade 2007: -72

Oceania

Consumption

2007: 367

2011: 416

2016: 488

Prod 2007: 271(13)

Net Trade 2007: -85

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

Global Demand-Supply & Forecast

Source: RISI Outlook for World Tissue Business Forecast 2009

  • Legend

  • Consumption & Capacities in MT ’000

  • Net Trade in MT’000 ( +ve Exports, -veImports)


Paper manufacturing from pulp to market

Tissue Industry Market Overview – Cont’d

Near & Middle East

Source: RISI 2009

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

Iraq

Consumption

2007: 12

2011: 17

2016: 26

Prod 2007: x

Mill Cap 08: x

Net Trade 2007: -10

Lebanon

Consumption

2007: 36

2011: 45

2016: 60

Prod 2007: 37

Mill Cap 08: 60 (6)

Net Trade 2007: 3

Iran

Consumption

2007: 53

2011: 70

2016: 105

Prod 2007: 29

Mill Cap 08: 30 (3)

Net Trade 2007: -19

Jordan

Consumption

2007: 18

2011: 23

2016: 32

Prod 2007: 39

Mill Cap 08: 96 (4)

Net Trade 2007: 23

GCC

Consumption

2007: 198

2011: 265

2016: 380

Prod 2007: 152

Mill Cap 08: 257 (11)

Net Trade 2007: -33

Near & Middle East

Consumption

2007: 712

2011: 941

2016: 1,342

Prod 2007: 607

Mill Cap 2008: 975 (48)

Net Trade 2007: -52

  • Legend

  • Consumption in MT ’000

  • Mill Capacities are rated capacities

  • PM4 for SPMC is not included


Paper manufacturing from pulp to market

Thank you


  • Login