PAPER INDUSTRY

GROUP 4:
BASIL JULIAN ASHARAF DIPU BEULLAH HARI KRISHNAN

INTRODUCTION In day to day life the use of paper is increasing. In all fields or industry we can find paper as a major element, which is an unavoidable material ever made by human. The demand for paper and board in India will certainly continue to grow as the country's economy develops over the coming decades. Per capita consumption is expected to rise from the present 2.5 kg to 6 kg by the year 2012. This figure is still rather low compared with consumption per capita in many industrialized countries. Total production of paper and board in India is predicted to rise in the next six years from 2.2 million to 6 million tonnes. A look at the main functional uses of paper and board shows the diversity of products. Paper is used for collection, distribution and storing of information, for packaging of goods, for hygienic purposes (personal care, cleanliness, disease prevention) and a large variety of special applications. In order to meet the customers needs the paper industry manufactures different products such as newsprint, printing and writing papers, magazine paper, packaging paper, boxes, tissue (toilet paper, kitchen towels, napkins, etc.) and a large number of special papers (e.g. stamps, air filters, coffee filters, baking paper etc.). Each of these categories demands specific properties of the product and the most appropriate manufacturing route to these products may differ substantially. HISTORY OF PAPER Formed from wood pulp or plant fiber, paper is chiefly used for written communication. The earliest paper was papyrus, made from reeds by the ancient Egyptians. Paper was made by the Chinese in the second century, probably by a Chinese court official named Cai Lun. His paper was made from such things as tree bark and old fish netting. Recognized almost immediately as a valuable secret, it was 500 years before the Japanese acquired knowledge of

the method. Papermaking was known in the Islamic world from the end of the eighth century
A.D.

Knowledge of papermaking eventually moved westward, and the first European paper mill was built at Jativa, in the province of Valencia, Spain, in about 1150. By the end of the 15th century, paper mills existed in Italy, France, Germany, and England, and by the end of the 16th century, paper was being made throughout Europe.

RAW MATERIALS USED . Probably half of the fiber used for paper today comes from wood that has been purposely harvested. Coniferous trees, such as spruce and fir, used to be preferred for papermaking because the cellulose fibers in the pulp of these species are longer, therefore making for stronger paper. These trees are called "softwood" by the paper industry. Deciduous trees (leafy trees such as poplar and elm) are called "hardwood." Because of increasing demand for paper, and improvements in pulp processing technology, almost any species of tree can now be harvested for paper. . The remaining material comes from wood fiber from sawmills, recycled newspaper, some vegetable matter, and recycled cloth MANUFACTURING PROCESS

1. Making pulp
Several processes are commonly used to convert logs to wood pulp. In the mechanical process, logs are first tumbled in drums to remove the bark. The logs are then sent to grinders, which break the wood down into pulp by pressing it between huge revolving slabs. The pulp is filtered to remove foreign objects. In the chemical process, wood chips from de-barked logs are cooked in a chemical solution. This is done in huge vats called digesters. The chips are fed into the digester, and then boiled at high pressure in a solution of sodium hydroxide and sodium sulfide. The chips dissolve into pulp in the solution. Next the pulp is sent through filters. Bleach may be added at this stage, or colorings. The pulp is sent to the paper plant. A. Timber
Timber used for papermaking comes from well managed forests where more trees are planted than harvested to ensure sustainable growth. Papermakers usually use only the parts of the tree that other commercial industries don't want - such as saw mill waste and forest thinnings.

B.

De-Barker

Bark is stripped from the logs by knife, drum, abrasion, or hydraulic barker. The stripped bark is then used for fuel or as soil enrichment C.

Chipping Machine

Stripped logs are chipped into small pieces by knives mounted in massive steel wheels (used in chemical pulping process). The chips pass through vibrating screens, whereby both undersized chips, dust etc and oversized chips are rejected. Accepted chips are then stored in huge bins ready for the next process. D.

Chemical Pulping Process

Chips from the storage bins are fed into a digester to which chemicals have been added. The woodchips are then 'cooked' to remove lignin. Lignin is the binding material which holds the cellulose fibres together. The chips are 'cooked' by heat and pressure in caustic soda and sulphur. The chemical process is energy self-sufficient as nearly all by-products can be used to fire the pulp mill power plant. The chemical pulping process produces lower fibre yield than mechanical pulping, typically 50-60%. E.

Mechanical Pulping Process

Mechanical pulp yields over 90% of the wood as fiber is produced by forcing debarked logs, about two meters long, and hot water between enormous rotating steel discs with teeth that literally tear the wood apart. Alternatively, logs can be pressed against grindstones which is why this process is also known as ground wood pulp. Trees contain up to 30% lignin, a material which is sensitive to light and degrades, and turns brown in sunlight, which explains why papers made from mechanical pulp will discolor. An example of this is newsprint. Newsprint is designed to have a short life span, and if left for a long period of time will lose its whiteness and strength. The special advantages of mechanical pulp are that it makes the paper opaque and bulky.
F.

Hydrapulper

When the bales of wood pulp or waste paper arrive at the paper mill they are loaded onto a conveyor and passed into a circular tank containing water. This has a very powerful agitator at the bottom which breaks up the bales into small pieces. The pulp mass created begins to look like thick porridge. This machine is known as a Hydrapulper. It operates automatically and when the disintegrating process is complete it discharges the pulp into large storage tanks. Hydrapulpers used mainly for handling waste paper are fitted with special devices for removing unwanted contraries such as wire, plastic, paper clips, staples etc.

The pulp is next put through a pounding and squeezing process called, appropriately enough, beating. Inside a large tub, the pulp is subjected to the effect of machine beaters. At this point, various filler materials can be added such as chalks, clays, or chemicals such as titanium oxide. These additives will influence the opacity and other qualities of the final product. Sizings are also added at this point. Sizing affects the way the paper will react with various inks. Without any sizing at all, a paper will be too absorbent for most uses except as a desk blotter. A sizing such as starch makes the paper resistant to water-based ink (inks actually sit on top of a sheet of paper, rather than sinking in). A variety of sizings, generally rosins and gums, is available depending on the eventual use of the paper. Paper that will receive a printed design, such as gift wrapping, requires a particular formula of sizing that will make the paper accept the printing properly

2. Pulp to paper
In order to finally turn the pulp into paper, the pulp is fed or pumped into giant, automated machines. One common type is called the Fourdrinier machine, which was invented in England in 1807. Pulp is fed into the Fourdrinier machine on a moving belt of fine mesh screening. The pulp is squeezed through a series of rollers, while suction devices below the belt drain off water. If the paper is to receive a water-mark, a device called a dandy moves across the sheet of pulp and presses a design into it.

A. Blend Chest
The stock passes to a blend chest where numerous chemicals can be added to obtain the required characteristics to the finished paper. Dyes are also added, as necessary, to color the paper. Dyes fix themselves to the cellulose fibers and are fast to light and water. Each grade of paper and board requires a very accurate blend of pulps and additives and the properties of the paper are continually monitored by computers during manufacture.

B. Screening and Cleaning

Pulps contain undesirable fibrous and non-fibrous materials, which should be removed before the pulp is made into paper or board. Cleaning involves removing small particles of dirt and grit using rotating screens and centrifugal cleaners.

The paper then moves onto the press section of the machine, where it is pressed between rollers of wool felt. The paper then passes over a series of steam-heated cylinders to remove the remaining water. A large machine may have from 40 to 70 drying cylinders

3. Finishing

Finally, the dried paper is wound onto large reels, where it will be further processed depending on its ultimate use. Paper is smoothed and compacted further by passing through metal rollers called calendars. A particular finish, whether soft and dull or hard and shiny, can be imparted by the calendars. The paper may be further finished by passing through a vat of sizing material. It may also receive a coating, which is either brushed on or rolled on. Coating adds chemicals or pigments to the paper's surface, supplementing the sizings and fillers from earlier in the process. Fine clay is often used as a coating. The paper may next be supercalendered, that is, run through extremely smooth calendar rollers, for a final time. Then the paper is cut to the desired size.

Papermaking Machine

The Paper Machine is a very large piece of machinery. A typical machine is about the length of two football pitches and around 4 metres wide. It can run up to speeds of 2000 m per minute - or 60 miles per hour! The machine itself consists of 7 distinct sections. The flow box, wire, press section, drier section, size press, calendar and reeling up. The first section of the machine is called the 'Wet End'. This is where the diluted stock first comes into contact with the paper machine. It is poured onto the machine by the flow box which is a collecting box for the dilute paper stock. A narrow apperture running across the width of the box allows the stock to flow onto the wire with the fibres distributed evenly over the whole width of the paper machine.

The machine is operated by computer control. The computer will monitor the paper for moisture content, weight etc and computer screens will show pictures of the process and should any adjustments need to be made, an alarm will sound.

Conversion and Printing

Once the paper is made, a great deal of it is converted into a product. Converters specialize in transforming reels and sheets of paper and board into a vast array of finished products for distribution such as boxes, cartons and stationery. Converters sell their products to the public or to other manufacturers. Not all paper and board is processed by converters. Some papermakers do their own converting, for example, the manufacturers of soft tissues market their own products and sell directly to the public. The printing industry converts large quantities of paper and board, much of which reaches the customer as newspapers, magazines or books.

Quality Management for the Pulp and Paper Industry

The Quality Management System is ABB's unique Industrial IT solution for the pulp and paper industry for data management throughout the mill complex, from the powerhouse through the pulping and papermaking processes, all the way to the scale line. It monitors and reports production quality for operations managers, sales personnel, and customers, reduces losses due to quality problems, and increases customer satisfaction.

1. Improving Customer Satisfaction through Valuable Benefits The Quality Management System provides cost savings and improves customer satisfaction by Assuring the quality required by the customer Minimizing customer complaints customer specific quality requirements Providing complete traceability - direct and prompt answers to customer complaints Improving productivity and product quality- developing existing quality processes

The Quality Management System enables mill personnel to plan, coordinate, and control production quality, from raw materials to delivered product, and to gather and analyze data captured at every step of the process. The result is reduced costs through better quality determination, faster grade changes, reduced waste, higher revenues and strengthened trading partnerships from increased customer satisfaction

2. Laboratory Management The Quality Management System supports multiple lab devices, as well as product and machinespecific test suites. The test results and remarks can be entered for a reel, set, roll, or sample time. For mills without automatic paper testing systems, the system offers lab management functions that improve the efficiency and accuracy of manual operations.

3. On-line Monitoring and Reporting what data to keep and how long to keep it and the database is sized accordingly. There are no limits for the scalability and the size of the Real Time Database.

4. Reporting Quality Data The Quality Management System provides the mill personnel with the information they need to respond promptly and directly to problems as they arise, and to report and analyze quality information for process and production improvement. The system includes a broad set of standard reports that can be printed on demand or to a predefined schedule. Managerial reports can be generated e.g. per shift, day, month or year.