CHEN 6110 Pulp and Paper Engineering

Department of Chemical Engineering

Auburn University, AL 36849

Date: Nov 26, 2018

To: Dr. Bill Josephson
From: Jisung, Jang ,JSJ
Subject: CHEN5110/6110 FALL 2018 – Project 03

1.Overall Balance of the system

The Overall Balance of the system is similar with this flowchart.

𝑚𝑠1
̇ 𝑚𝑠2
̇ 𝑚̇ 3 𝑚̇ 8
Dryer 𝑚̇ 0 Pressing 𝑚̇ 1 F&S Head Box 𝑚12̇ 𝑚11
̇ Regulator Stock Chest Baled Pulp

𝑚̇ 2 𝑚̇ 4 𝑚̇ 6
Felt pit overflow Wire pit Recycling1

Recycling2 Dividing Makeup Wtr

𝑚̇ 7 Effluent 𝑚̇ 9

𝑚10
̇

With this diagram and Operating conditions, the overall material balance for producing a tissue can
be located in this operation with a proper procedure. First part should be interpreting several given
conditions in Pressing & Forming Section. After calculating it, deciding the Overflow rate and how
many fibers will be discarded through the Effluent with an excess amount of water as waste. ROI
would be then approximately proposed with a certain amount of baled pulp input for this system.

2. Pressing & Forming Balance

In this system, it produces 100lb of fiber as a tissue after drying the slurry leaving the pressing
section. With the Operating conditions and Other information, the material balance of the Pressing
& Forming Section can be isolated among other streams.

F/W Fresh Water 𝑚̇ 3 𝑚̇ 8

Pressing 𝑚̇ 1 75% Forming/Screening Head Box
𝑚̇ 0 25%
𝑚̇ 2 𝑚̇ 5 𝑚̇ 4 𝑚̇ 6
Felt Pit Overall Flow Wire Pit
 𝑚̇ 7

From this flow stream with the Operating Conditions, 𝑚̇ 0 would be 100lb of fibers with 233.33lb
of water because of its 30% Sheet consistency leaving the press section. 𝑚̇ 1 is then be, according
to operating condition, calculated as 100.408lb of fiber and 903.676lb of water. 𝑚̇ 2 would also be
defined as 0.408441lb of fibers and 3173.926lb of water under operating conditions. From the
Forming section, 75% of fibers in this one heads into the Pressing section in which it is already
calculated as 𝑚̇ 1 . Fibers in 𝑚̇ 3 would be 133.878lb. Water that flows from Head Box for 1min can
also be calculated in below equation with an operating condition. The flow rate of 𝑚̇ 4 would then
be calculated in 33.47lb of fibers and 63227.67lb of water.

144𝑓𝑡 2 𝑓𝑡 𝑔𝑎𝑙𝑙𝑜𝑛 𝑙𝑏
0.5inch × 144inch × 𝑖𝑛𝑐ℎ2
× 2000 𝑚𝑖𝑛 × 7.48 𝑓𝑡 3
× 8.34 𝑔𝑎𝑙𝑙𝑜𝑛 = 62387.5 𝑙𝑏⁄𝑚𝑖𝑛 ...... (1)

62387.5 𝑙𝑏⁄𝑚𝑖𝑛 − 133.878 𝑙𝑏⁄𝑚𝑖𝑛 = 62253.7 𝑙𝑏⁄𝑚𝑖𝑛 …... (2)

For the further analysis of this system, the Overflowing rate and recycling that goes into the Flow
regulator from Wire pit should be isolated. In this regard, it is essential to identify how many fibers
will be in the Overflow, through which the Makeup Water’s consistency and the amount of water
collected into the Flow Regulator can be isolated. In this calculation, there are two assumptions that
I took for it. One is that the consistency of 𝑚̇ 5 and 𝑚̇ 6 should be same. The other one is that the
Baled Pulp should compensate the fibers leaking out through the Effluent as a waste. Below the
table is the current system balance in given conditions.

𝑚̇ 0 𝑚̇ 1 𝑚̇ 2 𝑚̇ 3 𝑚̇ 4 𝑚̇ 5 𝑚̇ 6 𝑚𝑠1
̇ 𝑚𝑠2
̇
Fiber(lb) 100 100.408 0.4084 133.878 33.4695 - - - -
Water(lb) 233.333 903.675 3173.925 62253.67 63227.67 - - 2503.58 1877.69
CY(%) 30% 10% 0.01287% 0.21% 0.0529% - - 0% 0%

3. Overflow and Makeup Water analysis

In Wire-pit, fibers and water represent 33.47lb and 63227.67lb respectively. If the fiber entering
into Felt pit because of excess Fresh Water held too much of it from Wire-Pit, Makeup Water after
discarding the significant amount of water with fibers through the Effluent also enters into Flow
Regulator with Baled Pulp with an excessive amount of water. If 1% of fibers in Wire-pit, which is
0.3347lb of fibers, were mixed with 𝑚̇ 2 , the leaving materials from Felt-Pit (𝑚̇ 7 ) would hold 0.743lb
of fibers and 3806.2lb of water, which represents 0.0195% of Consistency. In this regard, controlling
how many fibers would leave through Effluent is imperative to determine whether installing the
Save-all can be justified. For 1% of fibers leaked out through the Effluent, 0.00743lb of fibers with
38.062lb of waters would be disposed of a waste, which will be compensated in the Baled Pulp. The

rest of materials from 𝑚̇ 7 , after discarding 38.07lb through the Effluent, would constitute the
Makeup Water which is 0.7357lb of fibers and 3768.14lb of water. With the Makeup water, 117.656lb
of baled pulp with 100.00743lb of fibers mixed in the Flow Regulator. On the other hand, the leaving
slurry from Wire-Pit to the Head Box before mixing with the flow of Regulator is defined as 33.1348lb
of fibers and 62595.4lb of water in which it is possible to compare the value based on the limitation
of input and output for the Head Box. In this case, after mixing two streams, 4160.7lb of excess
water would go into Headbox which is not acceptable for a well-developed operation. This also
invalidates for 3% consistency in the Stock Chest. Although it satisfies the 3% consistency of the
Stock Chest by discarding 14.88% of fibers in 𝑚̇ 7 through the Effluent, it still affects to the system
negatively with an excess 3632.4lb of water. From 1% to 99% of fibers in 𝑚̇ 7 , it is unacceptable for
this system with boundary errors ranged from 4160.7lb to 430.71lb of water between the input and
output of the Headbox. Therefore, it is critical, through an economic approache, to set the fiber in
the Overflow for minimizing the difference for the Head Box’s input and output.

Forming Headbox 𝑚12

̇ 𝑚11
̇ Stock Chest
𝑚̇ 2 𝑚̇ 4 𝑚̇ 3 𝑚̇ 8
Felt Pit Overflow 𝑚̇ 5 Wire-Pit 𝑚̇ 6 Recycling1
𝑚10
̇
Recycling2 Makeup
𝑚̇ 7 Effluent
𝑚12
̇
Below Chart is the 1% of fiber leaving from Wire-Pit and 14.88% of fiber in the Effluent.

𝑚̇ 5 𝑚̇ 7 ̇ (14.88%)
𝑚12 𝑚10
̇ 𝑚̇ 8 𝑚11
̇ 𝑚̇ 6 𝑚12
̇

Fiber(lb) 0.3347 0.7431 0.1106 0.63255 100.1106 100.7431 33.1348 133.8779

Water(lb) 632.2767 3806.2025 566.363 3239.84 17.6666 3257.506 62595.4 65886.03
Total(lb) 632.6114 3806.9456 566.4735 3240.47 117.777 3358.25 62628.5 66019.912
CY (%) 0.0529% 0.0195% 0.0195% 0.0195% 85% 2.9999% 0.0529% 0.203%

In 𝑚11
̇ , 3% of consistency is located properly. However, 𝑚12
̇ is not matched with 𝑚̇ 3 leaving from
Head Box. When it comes to the difference between 𝑚12 and 𝑚̇ 3 could be defined as insignificantly
low enough to operate this system, it is safe to discuss whether installing the Save-all can be
justified.

In an attempt to determine the Overflow rate from 1% to 30% of Fibers in Wire-Pit, setting up
6.8% of fibers in Wire-Pit, which is 2.273lb of fibers, can be, as an example, developed in this system
with a little amount of loss from the Effluent. Among 2.6815lb of fibers in 𝑚̇ 7 with 0.0359% of
consistency, in this case, it fits into the given conditions when 55.78% of fiber is leaking out from
the Effluent. When 1.4958lb of fiber with 4165.848lb of water among 7467.97lb of 𝑚̇ 7 leaves the
system as a waste, Makeup Water would consist of 1.1857lb of fibers and 3302.123lb of water.
Mixing with 119.407lb of Baled Pulp in the Stock Chest is then be isolated in 102.68lb of fibers and
3320.0344lb of water, which fits into the 3% consistency of given condition. At the same time, for
the input of Headbox from Wire-Pit, 31.1964lb of fiber goes into it with 58933.624lb of water which
will be mixed before entering into Head Box. As for the mixed slurry from Stock Chest and Wire-Pit
before entering into Headbox, the water and fiber contents of it should be the same amount of the
leaving amount of Head Box. After mixing two streams (𝑚11
̇ 𝑎𝑛𝑑 𝑚̇ 6 ), it represents 133.8779lb of
fibers and 62253.65888lb of water. It seems similar enough to consider the system as a well-
designed superficially. In Stock Chest with 3% of Consistency according to this set-up, however,
water in Stock Chest should be technically 3320.034793lb which is not well-matched with
3320.0344lb of water in Makeup and Baled Pulp Moisture. The difference between two numbers left
only a nominal difference.

4. Results and discussion

This approach is apparently based on the trial-and-error method in an attempt to find the most
plausible number. With this method, a waste leaving through the effluent would be disposed of
1.495811lb of fiber (376.944ton/yr) and 4165.848lb of water (1049793ton/yr).

𝑙𝑏 60𝑚𝑖𝑛 24ℎ𝑟 350𝑑𝑎𝑦 𝑡𝑜𝑛

1.495811 × × × × = 378.944 𝑡𝑜𝑛⁄𝑦𝑒𝑎𝑟…. (3)
𝑚𝑖𝑛 1ℎ𝑟 1𝑑𝑎𝑦 1𝑦𝑒𝑎𝑟 2000𝑙𝑏

Considering the increasing price of baled pulp with increasing amount of fibers and water which
should be one of the most significantly essential value in recovery system for PBP(Payback Period)
𝑁𝑒𝑡 𝑃𝑟𝑜𝑓𝑖𝑡/𝑌𝑒𝑎𝑟
with respect to ROI( ), this result can also be acceptable among others. Although
𝑇𝑜𝑡𝑎𝑙 𝐼𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
there is a little short supply for the Stock Chest from the Makeup Water, in this preliminary design
procedure, calculated numbers may acceptable only if the calculations and assumptions were valid
enough to behold.