DEVELOPMENT OF A TOTAL CLOSED WATER SYSTEM FOR

A D E I N K I N G PLANT

Milos K r o f t a , P.E., Ph.D., P r e s i d e n t

Krof t a Engineering Corporation, Lenox, MA 01240 USA
Lawrence K. Wang, P.E.,
Ph.D., Manager
LenOX I n s t i t u t e f o r Research Inc., Lenox, MA 0 1 2 4 0 USA
ABSTRACT

Waste paper i s r e c y c l e d as p u l p f o r r e p r o d u c t i o n of p a p e r s
o r boards.
The p u l p c o n t a i n i n g secondary f i b e r s needs t o
A t o t a l c l o s e d water
be p u r i f i e d i n a deinking p l a n t .
system has now been developed f o r water r e c l a m a t i o n i n
deinking p l a n t s .
The p u l p w i t h i n k s is f i r s t processed
w i t h a foaming u n i t (Foamer) and t h e n a washing u n i t (Stock
Washer).
The waste water is c l a r i f i e d by a d i s s o l v e d a i r
f l o t a t i o n c l a r i f i e r ( S u p r a c e l l ) f o r water reclamation.
A
fractionator
(Spray F i l t e r ) is a d d i t i o n a l l y u s e d f o r
The s l u d g e i s
recovery of long f i b e r s from washing water.
t h i c k e n e d on a t h i c k e n e r (Twin W i r e p r e s s ) .
The newly
developed water r e c l a m a t i o n and deinking system i n I t a l y is
h i g h l y e f f i c i e n t and c o s t - e f f e c t i v e .
For academic and
e n g i n e e r i n g c o n t r i b u t i o n s s p e c i a l emphasis is p l a c e d on t h e
d e s i g n of
i n d i v i d u a l t r e a t m e n t u n i t s and t h e e n t i r e
d e i n k i n g / r e c l a m a t i o n system.
[Key Words1 Innovation, Water Reclamation, Zero Discharge,
Waste Paper, Pulp, Deinking, Secondary F i b e r s , F l o t a t i o n ,
Dissolved A i r F l o t a t i o n , Dispersed A i r F l o t a t i o n , Stock
Washer, Spray F i l t e r , Thickening
INTRODUCTION

Since 1 9 6 5 Krof t a Engineering Corporation, Lenox, MA, has

been developing equipment f o r r e u s e of wastepaper and water
r e c l a m a t i o n i n deinking p r o c e s s e s .
High raw m a t e r i a l p r i c e s , combined w i t h high energy c o s t s
and p r o g r e s s i v e l y s t r o n g e r e f f l u e n t p o l l u t i o n c o n t r o l a r e
making
wastepaper
deinking
always more
economically
f e a s i b l e and c l o s i n g of
t h e deinking water systems
imperative.
U n t i l r e c e n t l y wastepaper was used e x c l u s i v e l y f o r t h e
lowgrade boards or f o r m u l t i p l e l a y e r board a s i n t e r n a l
gray f i l l e r .
I n t h e near f u t u r e , it i s expected t h a t more
and more wastepaper recovered from municipal s o l i d w a s t e
treatment p l a n t s w i l l be used f o r t h i s purpose and more
p r i n t e d wastepaper w i l l i n c r e a s e i n v a l u e a s a raw m a t e r i a l
f o r b e t t e r g r a d e s of paper, i f t h e deinking technology is
s u f f i c i e n t l y developed.
P r e s e n t l y t h e b u l k of wastepaper deinking i s c o n c e n t r a t e d
on newsprint waste deinking.
The r e a s o n s are:
(a) The
d a i l y c o l l e c t i o n of o v e r i s s u e s p r o v i d e s f o r a s t e a d y raw
m a t e r i a l flow; and ( b ) The requirements f o r degree of
b r i g h t n e s s f o r newsprint i s n o t t o o high.
881

The next
group of
present
wastepaper
deinking
1s
c o n s i d e r a b l y smaller and used f o r t h e p r o d u c t i o n of t i s s u e
papers.
The g e n e r a l t r e n d toward always h i g h e r and h i g h e r
b r i g h t n e s s and s o f t n e s s of t i s s u e paper p l a c e s c o n s i d e r a b l e
demand f o r a continuous improvement of t h e d e i n k i n g
technology

With c o n s i d e r a b l e d i s t a n c e f o l l o w s t h e d e i n k i n g of p r i n t e d
books w i t h a v e r y high b a s i c v a l u e of t h e o r i g i n a l paper
f i b e r but w i t h a l s o very high demand on c l e a n l i n e s s and
brightness.
For decades two p r i n c i p a l d e i n k i n g systems have been
( a ) Foam f l o t a t i o n d e i n k i n g , e x t r a c t i n g i n k by
competing:
foam. - Mineral f i l l e r and paper f i n e s a r e mainly recovered
t h e r e f o r e t h e y i e l d i s h i g h b u t t h e p h y s i c a l s t r e n g t h of
t h e deinked s t o c k i s poor; and ( b ) Washing d e i n k i n g where
i n k , mineral f i l l e r and f i b e r f i n e s a r e washed o u t a t high
d i l u t i o n and a papermaking f i b e r of good q u a l i t y is
o b t a i n e d w i t h s a c r i f i c e of lower y i e l d .
Both above systems a r e p r e f e r e n t i a l f o r c e r t a i n wastepaper
g r a d e s and f i n a l u s e s of deinked s t o c k without much
f l e x i b i l i t y t o a d j u s t t o d i f f e r e n t wastepaper g r a d e s o r
d i f f e r e n t f i n a l usage.
DESIGN
OF
FACILITIES

INDIVIDUAL

DEINKING

AND

WATER

RECLAMATION

I n o r d e r t o o b t a i n t h e maximum of d e i n k i n g e f f i c i e n c y ,
Krofta
Engineering C o r p o r a t i o n h a s i n c o r p o r a t e d b o t h
systems and o p e r a t e s w i t h f i r s t foaming ( K r o f t a Foamer;
F i g u r e 1) and t h e n washing ( K r o f t a Stockwasher; F i g u r e 2)
and o b t a i n s a c l o s e d water system w i t h c l a r i f y i n g t h e
washwater w i t h a d i s s o l v e d a i r f l o t a t i o n c l a r i f i e r ( K r o f t a
Supracell; Figure 3)
A f r a c t i o n a t o r (Krof t a Spray F i l t e r ;
F i g u r e 4 ) is a d d i t i o n a l l y used f o r recovery of l o n g e r
f i b e r s from washing w a t e r .
The s l u d g e is t h i c k e n e d on a
twin wire p r e s s ( K r o f t a Twin-Wirepress; F i g u r e 5).

The
was
the
and

combination of b o t h p r i n c i p l e s of foaming and washing

made p o s s i b l e w i t h o u t r a i s i n g t h e i n s t a l l a t i o n c o s t of
d e i n k i n g p l a n t by u s i n g advanced methods f o r foaming
washing.

X r o f t a Foamer

--

iSDerSed A i r F l o t a t i o n Deinkina C e l l ,

K r o f t a Foamer u s e s t h e p r i n c i p l e t h a t foam e x t r a c t i o n i s
p r o p o r t i o n a l t o t h e s u r f a c e area and n o t t h e volume of t h e
foaming machine.
T h e r e f o r e a l a r g e s u r f a c e w i t h a low
d e p t h ( 8 0 c m ) is used and l a r g e amounts of foam a r e e a s i l y
produced i n a n i n e x p e n s i v e foaming tank.
The Foamer i s s p e c i f i c a l l y designed f o r d e i n k i n g of waste
paper.
It removes i n k from waste paper by producing foam
a r t i f i c i a l l y . T h i s foam c o l l e c t s i n k and when t h e foam i s
e x t r a c t e d , t h e i n k i s s e p a r a t e d from t h e waste paper.
The
c o n s t r u c t i o n of t h e Foamer i s designed f o r low power and
s p a c e r e q u i r e m e n t s a s w e l l as f o r s i m p l e o p e r a t i o n and low
equipment
cost.
The
froth
(foam)
removes
ink
882

F r e f e r e n t i a l l y and t h e subsequent washing can be made i n

ewer s t a g e s o r can r e s u l t i n a b r i g h t e r pulp.

As shown i n F i g u r e I, t h e Foamer i s composed of a shallow

tank 111 with a f e e d w e l l [ 2 1 where t h e waste paper s l u r r y
e n t e r s w i t h approximately 4% bone dry c o n s i s t e n c y .
The
paper s l u r r y is d i l u t e d a t t h e e n t r a n c e w i t h r e c y c l e d
c l a r i f i e d water t o approximately 0.8% c o n s i s t e n c y and some
A recycle
foaming chemicals a r e added a t t h e same s p o t .
pump E31 f e e d s a n e j e c t o r [ 4 1 t h a t d i s c h a r g e s t a n g e n t i a l l y
i n t o t h e tank [ 1 1 c r e a t i n g a c i r c u l a r movement of s t o c k i n
t h e tank.
With a blower [51 a i r i s added i n t o t h e e j e c t o r
a t low p r e s s u r e .
This a i r i s d i s p e r s e d i n t h e e j e c t o r and
e n t e r s i n t o t h e tank, producing a l a r g e amount of foam t h a t
t r a v e l s on t h e t o p of t h e c i r c u l a t i n g s t o c k .
The foam i s
c o n t i n u o u s l y c o l l e c t e d by t h e foam c o l l e c t o r [61 and
e x t r a c t e d i n t o t h e foam s u c t i o n t a n k 171, where a s u c t i o n
blower h o l d s a l i g h t vacuum.
The foam c o l l a p s e s i n t h e
foam s u c t i o n tank and i s e x t r a c t e d c o n t i n u o u s l y by a water
l o c k and d i s c h a r g e d i n t o t h e s l u d g e c o l l e c t i o n tank.
The
cleaned s t o c k i s d i s c h a r g e d i n t h e c e n t e r of t h e tank [11
a t t h e bottom opening and overflows t h e t e l e s c o p i c
a d j u s t a b l e weir [ 8 1 .
From t h e r e i t is pumped t o t h e
c l e a n e r s and t o t h e K r o f t a Stock Washer.
S t o c k Washer
K r o f t a Stock Washer i s a n improvement of t h e t r a d i t i o n a l
s i d e h i l l washer by having a n u p h i l l slowly moving s c r e e n
A triple
and m u l t i p l e dams f o r t h e downflowing s t o c k .
washing i s e f f e c t e d i n t h e same space a s a conventional
s i n g l e s i d e h i l l screen.
The s c r e e n is c o n t i n u o u s l y
cleaned and a p r e s s e x t r a c t s a d d i t i o n a l mineral f i l l e r from
t h e stock.
With t r i p l e washing w i t h r e c y c l e d c l a r i f i e d w a t e r , a h i g h
d e g r e e of b r i g h t n e s s i s o b t a i n a b l e , p a r t i c u l a r l y a f t e r t h e
removal of t h e ink i n t h e K r o f t a Foamer.
With m u l t i p l e
washing i t i s f u r t h e r p o s s i b l e t o c o n t r o l t h e washing o u t
of t h e f i l l e r and f i n e s from t h e f u r n i s h .
shown i n F i g u r e 2 , t h e K r o f t a Stock Washer has a n
i n c l i n e d upward moving s c r e e n 111 t h a t r e t u r n s back t o t h e
bottom t h i c k e n i n g drum 121.
The s t o c k t o be washed and
t h i c k e n e d e n t e r s on t o p [31 with a c o n s i s t e n c y of 0.6 1 . 0 % . Flowing down over t h e upper part of t h e s c r e e n , t h e
s t o c k is p a r t i a l l y dewatered and accumulates a t t h e f i r s t
cross barrier
[41.
The p a r t i a l l y thickened s t o c k is
d i l u t e d w i t h r e c y c l e d c l a r i f i e d water and o v e r f l o w s t o t h e
second b a r r i e r [51.
P a r t i a l l y thickened s t o c k is t h e r e
d i l u t e d a g a i n , overflows t h e b a r r i e r and f l o w s and rolls
down t h e s c r e e n and t h e s t a t i o n a r y i n c l i n e d board [61 u n t i l
it e n t e r s i n t o t h e n i p between t h e r e t u r n i n g s c r e e n and t h e
drum. The s t o c k i s p r e s s e d by t h e s c r e e n on t h e drum. The
s c r e e n wraps around t h e drum and t h i c k e n s t h e s t o c k t o high
A p r e s s 181 s q u e e z e s t h e deinked s t o c k t o
consistency.
h i g h e r c o n s i s t e n c y 9 - 14%.
A transversely
mounted
r o t a t i n g screw e x t r a c t s t h e thickened s t o c k and d i s c h a r g e s
i t a t t h e s i d e 171.
As

883

The e f f l u e n t from t h e t h r e e t h i c k e n i n g p h a s e s i s s e p a r a t e l y
c o l l e c t e d and d i s c h a r g e d i n t o t h e K r o f t a Spray F i l t e r f o r
f u r t h e r f i b e r recovery. The e f f l u e n t from t h e Spray F i l t e r
i s f i n a l l y d i s c h a r g e d i n t o K r o f t a Supracell f o r water
t r e a t m e n t and r e c l a m a t i o n .
. .
K r o f t a Supra c e l l -- A D i s s o l v e d A i r F1o t a t i o n C l a r i f i e y
Progressively f o r l a r g e i n s t a l l a t i o n s a separate Supracell
c l a r i f i e r i s i n s t a l l e d on t h e a l k a l i n e p u l p e r - e x t r a c t o r
l o o p for recovery of chemicals and h e a t .
F i g u r e 3 shows t h e S u p r a c e l l d e s i g n . The i n l e t 18 and 1 1 1 ,
o u t l e t [ 2 1 , and s l u d g e removal mechanisms [61 are c o n t a i n e d
i n t h e central rotating section.
This s e c t i o n and t h e
s p i r a l scoop [61 r o t a t e around t h e tank a t a speed
Waste water, f i r s t p a s s i n g
synchronized w i t h t h e flow.
t h r o u g h t h e a i r d i s s o l v i n g t u b e , is r e l e a s e d through a
r o t a r y j o i n t [51 i n t h e c e n t e r of t h e tank.
It t h e n p a s s e s
i n t o t h e d i s t r i b u t i o n d u c t [111 t h a t moves forward w i t h t h e
same v e l o c i t y as t h e incoming water t h u s c r e a t i n g "Zero
Velocity".
The f l o t a t i o n p r o c e s s e s t a k e p l a c e i n t h i s
The p a t e n t e d S p i r a l Scoop [61 t a k e s up
quiescent state.
t h e f l o a t e d s l u d g e , pouring i t i n t o t h e s t a t i o n a r y c e n t e r
s e c t i o n where i t is d i s c h a r g e d by g r a v i t y f o r d i s p o s a l .
C l a r i f i e d water i s removed by e x t r a c t i o n p i p e s [91 which
a r e a t t a c h e d t o t h e moving c e n t e r s e c t i o n .
The c l a r i f i e d
water which normally c o n t a i n s less t h a n 30 mg/l of
suspended s o l i d s i s r e c y c l e d i n t h e p r o c e s s f o r reuse.
Wiper b l a d e s a t t a c h e d t o t h e moving d i s t r i b u t i o n duct
s c r a p e t h e bottom and t h e s i d e s of t h e tank [41 and
d i s c h a r g e s e t t l e d s l u d g e i n t o t h e b u i l t - i n sump [31, f o r
p e r i o d i c purging.
The v a r i a b l e speed g e a r motor 1101
d r i v e s t h e r o t a t i n g e l e m e n t s and scoop [61.
Electrical
c u r r e n t f o r t h e g e a r motor f e e d s from a r o t a r y c o n t a c t 151
mounted on t h e c e n t r a l s h a f t .
The u s e of K r o f t a S u p r a c e l l f o r wastewater t r e a t m e n t and
water r e c l a m a t i o n h a s been f u l l y demonstrated (1-10).

Sprav F i l t e l ;
The K r o f t a Spary F i l t e r , shown i n F i g u r e 4 , is s p e c i f i c a l l y
d e s i g n e d f o r t h e f r a c t i o n a t i o n of e f f l u e n t s c o n t a i n i n g from
20 - 5000 mg/l of suspended s o l i d s .
A f i n e mesh c l o t h w i t h
openings from 74 t o 500 microns i s used as t h e f i l t e r
media, e i t h e r t o s e p a r a t e l o n g f i b e r s from c l a y and f i l l e r
or a s s a f e t y f i l t e r f o r showers u s i n g c l a r i f i e d water. The
Spray F i l t e r meets t h e need f o r a h i g h t h r u p u t u n i t which
I t is
can handle wide v a r i a t i o n s i n s o l i d s content.
equipped w i t h a c l e a n i n g shower which g r e a t l y reduces t h e
need t o remove t h e c l o t h for c l e a n i n g .
All p a r t s i n
c o n t a c t w i t h t h e water a r e b u i l t of 304 s t a i n l e s s steel.
The access door h a s a p l e x i g l a s s window.
All b e a r i n g s
s u r f a c e s a r e made of corrosion-proof p l a s t i c m a t e r i a l s .
Twin Wirepress

The Twin Wirepress,

shown i n F i g u r e 5 ,
884

is designed f o r

sludge t h i c k e n i n g ,

and dewatering.

I n o p e r a t i o n , t h e s l u d g e i s f e d by pump from t h e s l u d g e
tank t o t h e v e r t i c a l f l o c c u l a t i o n compartment on t o p of t h e
p r e s s and
composed
of
adjustable
undulated
plates.
F l o c c u l a t i n g chemicals a r e f e d i n along w i t h t h e sludge.
The f l o c c u l a t e d s l u d g e l e a v e s t h e f l o c c u l a t i n g compartment
a t t h e bottom and e n t e r s t h e v e r t i c a l mixing compartment
where m u l t i p l e h o r i z o n t a l p l a t e s g e n t l y a g i t a t e t h e sludge.
The wire coming o u t of t h e mixing department i s i n c l i n e d
upwards and t h e f i r s t dewatering t a k e s p l a c e .
Then t h e
wire with t h e s l u d g e t u r n s downward i n t o t h e wedgeshaped
compartment - composed of two wires - which squeeze t h e
sludge between them.
The two wires w i t h t h e s l u d g e sandwiched between them, run
wrapped f o r h a l f t u r n around t h e l a r g e p e r f o r a t e d drum
After
which i s l o c a t e d a t t h e lower s i d e of t h e p r e s s .
l e a v i n g t h e drum, t h e double wires move up around s e v e r a l
rollers
for
further
dewatering.
The
rollers
have
p r o g r e s s i v e l y s m a l l e r diameter f o r b e t t e r dewatering.
t h e two wires s e p a r a t e .
Each h a s
i t s own rubber-covered pickup r o l l w i t h a s c r a p e r f o r
s l u d g e d i s c h a r g e i n t o a hopper.

A t t h e t o p of t h e p r e s s ,

The two wires have i n d i v i d u a l wire g u i d i n g d e v i c e s

(pneumatically o p e r a t e d ) and manually-operated
tension
rolls. Each wire has a shower w i t h shower water c o l l e c t i n g
pan.
The Krofta Twin Wirepress h a s a c a p a c i t y of approximately
bone dry s l u d g e per 3 f t . 3 i n . ( 1 . 0 m) wire
width.
This r e f e r s t o primary p a p e r m i l l s l u d g e w i t h
adequate chemical c o n d i t i o n e r .
The i n l e t c o n s i s t e n c y is
1.5
4.0% and t h e d i s c h a r g e h a s a d r y n e s s of 30
35%.
1 0 TPD of

D E S I G N OF COMPLETE SEMI-INDUSTRIAL D E I N K I N G PLANT I N ITALY

Wastepaper deinking i s a complex procedure and cannot be

demonstrated and t e s t e d s u f f i c i e n t l y on a l a b o r a t o r y s c a l e .
Krofta
I t a l i a S.A.
with
t h e cooperation
of
Krofta
Engineering C o r p o r a t i o n , Lenox, MA i n USA, and t h e Lenox
I n s t i t u t e f o r Research Inc. , has e r e c t e d a complete
deinking p l a n t for a c a p a c i t y of 5 TPD. This i n s t a l l a t i o n
is l o c a t e d a t t h e Papermill
Cartiera
d i Vidardo,
approximately 3 5 km ( 2 2 miles) from t h e c i t y of Milano,
Italy.
This i n s t a l l a t i o n i s
papermill operations.

completely

separated

from

other

The i n t e n t i s t o g i v e t o p o t e n t i a l customers who a r e

i n t e r e s t e d i n i n s t a l l i n g a deinking p l a n t t h e p o s s i b i l i t y
t o b r i n g t h e i r wastepaper and t o determine a11 t h e f a c t o r s
and r e s u l t s of t h e d e i n k i n g procedures.
885

Following such s e m i - i n d u s t r i a l t e s t s i t can be determined:

( a ) The o b t a i n e d q u a l i t y of t h e deinked s t o c k ( b r i g h t n e s s ,
c l e a n l i n e s s , mineral f i l l e r s and f i n e s c o n t e n t ) ; (b) Y i e l d
and f i b e r and f i l l e r l o s s under d i f f e r e n t procedures; ( C )
Consumption of chemicals, power, water and h e a t ;
(d)
S p e c i f i c c a p a c i t y of equipment (pumping t i m e , chemicals
a c t i n g t i m e , foaming product i o n , c l e a n i n g requirements ,
stockwashing parameters,
r e c y c l e d water
clarification
requirements, etc.) ; (e) O v e r a l l economic a s p e c t of t h e
deinking; ( f ) S p e c i f i c d e s i g n of t h e deinking p l a n t and t h e
i n d i v i d u a l machines c a p a c i t y .
The s e m i - i n d u s t r i a l deinking p l a n t can be u s e f u l l y o p e r a t e d
a l s o by chemical companies manufacturing s p e c i a l chemicals
for
deinking
a p p l i c a t i o n i n order
t o evaluate the
performance of t h e new chemicals.
S u f f i c i e n t amounts of deinked s t o c k c a n be produced i n
o r d e r t o make paper s h e e t s on s m a l l paper machines and t o
e l a b o r a t e t h e combination of t h e s t o c k w i t h o t h e r raw
materials

The deinking p l a n t was designed w i t h a maximum of

versatility,
allowing
different
combinations
of
the
deinking process.
I t can o p e r a t e w i t h foaming and washing t o g e t h e r o r only
with foaming o r w i t h washing.

Each phase
d e s i red

can

be

operated

Figures 6,
7 and 8 show
S e m i - I n d u s t r i a l Deinking P l a n t .

by
the

repeated

recycling

composition

of

if
the

Loadina P1a t f o r m I1 1 and PulPer [2L

The Loading P l a t f o r m [ll i s f o r accumulation of t h e waste
paper b a l e s and s c a l e s f o r measuring and f e e d i n g i n t o t h e
Pulper E21 with a volume of 3 m3.
The a g i t a t o r has a
h o r i z o n t a l s h a f t and a p e r f o r a t e d p l a t e w i t h 8 mm h o l e s
p a s s i n g t h e pulped s t o c k .
The c o n s i s t e n c y is k e p t ,
depending on t h e requirements, from 3 - 6 % bone d r y , having
90 - 1 8 0 kg of dry waste paper f o r each batch.
The p u l p i n g
time i s 20
30 minutes.
I n c l u d i n g l o a d i n g and d i s c h a r g i n g
time,
each b a t c h
c o n t a i n s approximately
45 minutes
r e s u l t i n g i n a maximum l o a d of 5.7 MT/24h.

Addition of chemicals u s u a l l y is made f o l l o w i n g a r e c i p e i n

t h e p u l p e r t o o b t a i n t h e r e q u i r e d chemical r e a c t i o n s :
(a)
S a p o n i f i c a t i o n of o i l s combining t h e p r i n t i n g i n k s ; ( b )
D i s p e r s i o n of ink p a r t i c l e s i n t o a c o l l o i d a l s t a t e ; ( c )
S u r f a c t a n t a c t i o n t o c o l l e c t i n k on foam; ( d ) D e t e r g e n t s
f o r s e p a r a t i o n of c o l o r e d pigments w i t h t h e r e s i d u a l s of
t h e s a p o n i f i c a t i o n w i t h t h e water hardness; ( e ) Oxydation
f o r b l e a c h i n g purpose; and ( f ) Steam f o r keeping t h e s t o c k
t e m p e r a t u r e a t approximately 6 0 d e g r e s s C.
U e n s i t v Cleaner [3L

886

;t is . f o r t h e s e p a r a t i o n of c o a r s e i m p u r i t i e s .
Such
i m p u r i t i e s should be e x t r a c t e d ahead of def i b e r i n g a c t i o n
for easier e l i m i n a t i o n .

s t o c k Chest i s provided w i t h slow running v e r t i c a l

agitator.
Required s t o r a g e of t h e s t o c k i s approximately
one hour.
I f r e q u i r e d , a d d i t i o n a l steam h e a t i n g c a n be
provided i n t h e c h e s t s .

D e f l a k e r I51
Deflaker i s used a f t e r t h e s t o c k c h e s t s o r between t h e two
s t o c k c h e s t s i n o r d e r t o f i n e l y s e p a r a t e a l l f i b e r bundles.
fleadbox I71
The headbox over t h e Foamer i s used f o r metering t h e s t o c k
t o t h e continuous o p e r a t i o n of t h e s u c c e s s i v e p l a n t .
C l a r i f i e d water i s r e c y c l e d t o d i l u t e t h e s t o c k t o a
consistency
required
for
further
processing.
The
1.8%.
Additional
c o n s i s t e n c y can be set between 0.8
foaming a g e n t s may be added c o n t i n u o u s l y a t t h e p o i n t of
d i 1u t ion.

K r o f t a Foamer I81
The Foamer o p e r a t e s w i t h d i s p e r s e d
amounts of foam (See F i g u r e 1).

air

producing

large

The Foam e x t r a c t i o n i s p r o p o r t i o n a l t o t h e foaming s u r f a c e

and n o t t h e depth of t h e foaming tank.
Therefore t h e
K r o f t a Foamer o p e r a t e s w i t h only 80 c m water depth.
A very f i n e d i s p e r s i o n of a i r i s e s s e n t i a l and w i t h Foamers
m u l t i p l e i n j e c t o r s a f i n e bubble foam i s c r e a t e d .
A
r e c y c l i n g pump f e e d s t h e second i n n e r c i r c l e of t h e
i n j e c t o r n o z z l e s w i t h t h e s t o c k a l r e a d y foamed i n t h e o u t e r
circle.
The s t o c k i s i n t h i s way s u b j e c t t o m u l t i p l e
foaming w i t h l a r g e amounts of foam.

The n o z z l e s - i n j e c t o r s provide a c i r c u l a r movement i n t h e

foaming t a n k t h a t can be a d j u s t e d by r e g u l a t i n g t h e flow,
a i r a d d i t i o n and d i r e c t i o n of t h e nozzles.
The s t o c k
c l e a n e d by foaming is d i s c h a r g e d i n t h e c e n t e r a t t h e
bottom of t h e Foamer.
I f d e s i r e d , t h e s t o c k can be passed s e v e r a l times through
t h e foamer.

The c o n s t r u c t i o n of t h e Foamer i s very simple and low c o s t

The foaming
f a b r i c a t i o n i n s t a i n l e s s steel i f p o s s i b l e .
tank i s open and a l l o w s easy s u p e r v i s i o n , o b s e r v a t i o n and
cleaning.
The foam is sucked by r a d i a l foam a s p i r a t o r and passed i n t o
a cyclone where i t i s a d d i t i o n a l l y c o l l a p s e d by spraywater.
The a i r a s p i r a t e d

by

t h e foam a s p i r a t o r

am

keeps t h e room

clean.
Because of t h e l a r g e s u r f a c e and low volume t h e r e t e n t i o n
t i m e i n t h e Foamer i s low (5-10 m i n u t e s ) .
Cvclon [91
The cyclon i s f o r Foam e x t r a c t i o n and c o l l a p s i n g , and
discharges
collapsed
foam d i r e c t l y
into the
sludge
compartment [151.
V i b r a t i n a Screen [lO l
The v i b r a t i n g s c r e e n i s used t o a d d i t i o n a l l y s c r e e n t h e
foamed
stock
and
eliminate
coarser
impurities.
A l t e r n a t e l y t h e v i b r a t i n g s c r e e n can a l s o be used ahead of
t h e Foamer, s c r e e n i n g s t o c k b e f o r e foaming.
The rejects
a r e f e d i n t o t h e s l u d g e tank.
T r i c l e a n and Elu t r i c o n e

[llL

They a r e s u p p l i e d by B i r d Company and u s e d f o r a d d i t i o n a l

elimination
of
light
and
heavy
contaminants.
The
c l e a n l i n e s s of t h e deinked s t o c k i s as i m p o r t a n t as t h e
b r i g h t n e s s and removal of t h e i n k and t h e r e f o r e t h e KrOfta
Deinking P l a n t i s provided w i t h a l l p r e s e n t l y a v a i l a b l e
stock cleaning devices.
X r o f t a S tock Washer

Llu

K r o f t a Stock Washer i s i l l u s t r a t e d i n F i g u r e 2.
As i t i s
known, t h e foaming e x t r a c t s o n l y ink p a r t i c l e s over 20
micron s i z e and t h e rest of t h e c o l l o i d a l d i s s o l v e d i n k
p a r t i c l e s a r e e x t r a c t e d by washing.
K r o f t a Stock Washer o p e r a t e s similar t o a m u l t i p l e s i d e h i l l
s c r e e n , combined w i t h a t h i c k e n e r and p r e s s .
No f i l t e r i n g
f i b e r m a t i s formed and t h e s t o c k r o l l s over t h e upwards
moving p l a s t i c wire s c r e e n i n t h r e e s e c t i o n s .
A t each
s e c t i o n t h e s t o c k c a n be d i l u t e d and t h e washing p r o c e s s
improved.
The Stock Washer g i v e s a wide p o s s i b l e v a r i a t i o n of t h e
washing p r o c e s s .
I f t h e f i n e s and f i l l e r s h o u l d n o t be
removed and c o l l o i d a l i n k o n l y , t h e n t h e washing i s done i n
one s e c t i o n only and t h e Stock Washer o p e r a t e s as a
t h i c k e n e r w i t h o u t forming a m a t .
The outgoing c o n s i s t e n c y of t h e deinked s t o c k from t h e
The water used f o r
Stock Washer i s 9 - 14% bone dry.
washing i s t h e r e f o r e t h e water coming w i t h t h e d i l u t e d
s t o c k i n t o t h e Stock Washer.
If m i n e r a l f i l l e r and f i n e s should be removed by d e i n k i n g
of magazine c o a t e d waste paper w i t h h i g h a s h c o n t e n t , t h e n
t h e m u l t i p l e washing t a k e s e f f e c t and t h e o r i g i n a l s t o c k
w i t h 20 o r more p e r c e n t ash c o n t e n t c a n be reduced t o some
3
5% a s h c o n t e n t .
T h i s is p a r t i c u l a r l y i m p o r t a n t f o r
some t i s s u e manufacturing o p e r a t i o n .

888

Kro_ffaav

Filter 1131

Krofta Spray F i l t e r i s a f r a c t i o n a t o r t o recover l o n g e r

f i b e r s from t h e Stock Washer e f f l u e n t .
such e f f l u e n t is
sprayed through a f i n e mesh s c r e e n ( 1 0 0 - 2 0 0 micron).
Longer f i b e r s a r e recovered and added t o t h e deinked s t o c k .
At
larger
installations
the
fiber
recovery
is of
c o n s i d e r a b l e economical importance.
The Stock Washer does n o t form a mat and t h e r e f o r e washes
o u t t h e c o l l o d i a l ink p a r t i c l e s and mineral f i l l e r and
f i n e s , f a r b e t t e r t h a n any drum t h i c k e n e r or d i s c f i l t e r
t h a t always forms a mat and r e t a i n s c o l l o i d a l ink i n t h e
stock.
However a t t h e same time some l o n g e r f i b e r s e s c a p e
and such f i b e r s a r e recovered w i t h t h e Krofta Spray F i l t e r
t h a t i s a r a t h e r i n e x p e n s i v e machine.

. .

K r o f t a S u D r a c e l l C l a r i f i e r [14L
The K r o f t a S u p r a c e l l C l a r i f i e r i s i l l u s t r a t e d i n F i g u r e 3 .
The S u p r a c e l l is widely used i n many of t h e l a r g e s t
deinking p l a n t s over t h e world and i s a n e s s e n t i a l p a r t of
such deinking i n s t a l l a t i o n s .
With t h e S u p r a c e l l a l l Stock
There is no
Washer e f f l u e n t is c l a r i f i e d and recycled.
e x c e s s water l e a v i n g t h e deinking p l a n t . A makeup water i s
r e q u i r e d a s t h e waste paper e n t e r s w i t h only 1 0 % m o i s t u r e
and t h e deinked s t o c k i s d i s c h a r g e d w i t h 9 0 % moisture.
I n g e n e r a l we can
Some water i s l o s t a l s o w i t h t h e sludge.
c a l c u l a t e t h a t i f sludge i s thickened t o 2 0 % and s l u d g e
water r e c y c l e d ,
t h e t o t a l water consumption f o r t h e
deinking p l a n t i s approximately 1 0 l/kg.
Because of high r e c y c l i n g of t h e c l a r i f i e d w a t e r , t h e h e a t
c o s t s a r e low and t h e o p e r a t i n g t e m p e r a t u r e can be kept
high.
C l a r i f i e d Water Tank [l5 1
The C l a r i f i e d Water Tank i s a n e s s e n t i a l p a r t of t h e
deinking p l a n t .
The v a l u a b l e high temperature c l a r i f i e d
water m u s t be s t o r e d t o be a v a i l a b l e t o f e e d t h e p u l p e r i n
Also change i n t h e washing and foaming
t h e batch p r o c e s s .
d i l u t i o n r e q u i r e promptly a v a i l a b l e c l a r i f i e d warm water.
Additional r e f e r e n c e s f o r t h e t o t a l c l o s e d water systems i n
m i l l s can be found elsewhere (11-17).
REFERENCES

1.

Krofta, M.,
L. K. Wang, D. B a r r i s and J. Janas,
"Treatment of P i t t s f i e l d Raw Water f o r Drinking Water
Production by I n n o v a t i v e P r o c e s s Systems, 'I U.S. Dept.
of Commerce, National Technical Information S e r v i c e ,
S p r i n g f i e l d , VA., Report No. PB82-118795, 87 p., Feb.
1981.

2.

Krofta,
M.,
D.
G u s s and L,
K.
Wang,
"Improved
Biological
Treatment w i t h a Secondary F l o t a t i o n
C l a r i f i e r ",
C i v i l Ena i n e e r i n s f o r P r a c t i c i u
Desiqn Enain
' eera I
VOI..
2,
p.
307-3241
1983.
889

(NTIS-PB82-154196)
"Investigation
and
Design . of
A
Filter",
C i v i l Engineering f O r t
, Vole 3 , p. 347-362,
1984. (NTIS-PB82-199803)

3.

Wang,
L.
K.,
Denitrification

4.

Krofta! M. and L. K. Wang, "Design of Dissolved A i r

F l o t a t i o n Systems f o r I n d u s t r i a l P r e t r e a t m e n t and
and Energy
Municipal Wastewater Treatment--Design
Considerations",
American m
Enaineers. Na t i o n a l Conference, Houston, Texas, March
(NTIS-PB83-232868)
27-31, 1983 3 0 pages.

5.

K r o f t a , M. and L. K. Wang, "Design of Dissolved A i r

F l o t a t i o n Systems f o r I n d u s t r i a l P r e t r e a t m e n t and
Municipal
Wastewater
Treatment--Case
History
of
Practical
A p p l ica ti o n s " ,
American I n s t i t u t e of
C
h
'0
o e
ce,c
Houston,
Texas,
March
27-31,
1983 ,
25
pages.
( NTIS-PB8 3 - 23 2 850 1

6.

K r o f t a , M., L. K. Wang, B. C. Wu and C. C. J. Bien,

"Recent Advances i n Titanium Dioxide Recovery, F i l l e r
Dept. of
R e t e n t i o n and White Water Treatment", U.S.
Commerce,
N a t i o n a l Technical I n f o r m a t i o n S e r v i c e ,
Technical Report No. PB83-219543, 39 p., June 1983.

7.

K r o f t a , M., L. K. Wang, L . Kurylko and A. E. Thayer,

" P r e t r e a t m e n t and Ozonation of Cooling Tower Water,
P a r t I " , U.S.
Dept. of Commerce, National Technical
VA,
Report
Information
Service,
Springfield,
PB84-192053, 34 p., A p r i l , 1983.

8.

K r o f t a , M., L. K. Wang, L. Kurylko and A. E. Thayer,

" P r e t r e a t m e n t and Ozonation of Cooling Tower Water,
P a r t I I " , U.S. Dept. of Commerce, National Technical
VA,
Report
Information
Service,
Springfield,
PB84-192046, 29 P., August, 1983.

9.

Wang, L. K.,
D. Barris, P. Milne, B. C. Wu and J.
Hollen, "Removal of Extremely High Color from Water
Containing Trihalomethane P r e c u r s o r by F l o t a t i o n and
U. S.
Dept.
of
Commerce,
National
Filtration",
Technical
Information
Service,
Springfield,
VA,
Technical Report No. PB83-240374, 11 p., A p r i l 1982.

10.

L.
K* I
"Design
of
Innovative
Wan9 ,
F l o t a t i o n - F i l t r a t i o n Wastewater Treatment Systems f o r
A Nickel-Chromium
Plating Plant",
U.S.
Dept.
of
Commerce,
N a t i o n a l Technical I n f o r m a t i o n S e r v i c e ,
S p r i n g f i e l d , VA., 50 p., Jan. 1984.

11.

"Closed water C i r c u i t s i n Board M i l l s " ,

K r o f t a , M.,
WochenBlatt Fur P a D i e r f & r i k a t ion,
No.
99:
pp.
781-784, (1971).

12.

" I n v e s t i g a t i o n of Closed Water Systems i n

Brecht, W.,
Another Waste Paper P r o c e s s i n g P l a n t " , HWhenEAatt FUL
Paaierfabrikation, NO. 101: pp. 113-119, (1973)
890

13.

Dalpke, H. L.,
"Special D i f f i c u l t i e s with E n t i r e l y
Closed Water C i r c u i t s " ,
D a s Pap iec,
( J u n e ) : pp.
236-240, (1975)

14.

S t r e e k i n , L. E., "Water Reuse i n a Paper Reprocessing

P l a n t , EPA-600/2-76-232,
(October 1976)

15.

S p r i n g e r , A. M.,
"The R e l a t i o n between P r o c e s s Water
Q u a l i t y C h a r a c t e r i s t i c s and I t s Reuse P o t e n t i a l i n
Combination Board M i l l s " , W B u l l e t i n , No. 282,
(September 1 9 7 5 ) .

16.

Ladmiral, D., "La S o c i e t e D e s Usines Royeres Supprime

Sa P o l l u t i o n A Uzerche",
H'Eau e t L' Environment,
( J u n e ) : pp. 8-12, (1975).

17.

GUSS,
D. B.,
"Closed Water Systems i n M i l l s
Secondary
F i b e r ",
s e c o n d a r v F i b e r s Conf erenc e, Nov. 1977.

891

Using

a3

W
N

F i g u r e 1.

K r o f t a Foamer--Dispersed

A i r Flotation D e i n k i n q C e l l

m
m
co

UJ

1 R O T A T I N G C E N T E R SECTION
2 CLARIFIED WATER OUTLET

3 S E T T L E D S L U D G E SUMP
4 SETTLED SLUDGE OUTLET
5
R O T A R Y CONTACT
6
S P I R A L SCOOP
7 FLOATED SLUDGE OUTLET
8 UNCLARlFlED WATER INLET
9 C L A R I F I E D W A T E R E X T R A C T I O N PIPES
10 G E A R M O T O R
11 D I S T R I B U T I O N D U C T

F i g u r e 3.

A
B
C
D

DlAMETERofSUPRACELL
DEPTHofSUPRACELLTANK
D E P T H of S U P R A C E L L T A N K w i t h B O T T O MSUPPORT
M I N I M U M O V E R A L L HElGHTofSUPRACELL

K r o f t a Supracell--Dissolved

Air F l o t a t i o n C l a r i f i e r

W
W
m

Figure 4.

Spray F i l t e r

F i g u r e 5.

Twin Wirepress

CYCLON

HOMOGE NIZATOR

I
I
03

SCREEN;

T R IC 1E ANS

<KRoFTA) C L A R l f I t R

14

i
i
ii

i
I I '

ELUTRICONE

L.-.

C L A R I F I I O WATER T A N K

Figure 6 .

r'-'--

-.
STOCK W A S H E R

Flow D i a g r a m of A S e m i - I n d u s t r i a l D e i n k i n g P l a n t U s i n g T o t a l
C l o s e d Water S y s t e m

_._._CLARIFIED WATER

-STOCK
- _ -WHITE

WATER

-SLUDGE

6 REJECT

m
W

10

Figure 8.

11

12

Over V i e w of A Semi-Industrial Deinking Plant in Italy