Century Paper and Board Mills Limited

(CPBM)

PULP & PAPER

INDUSTRY
Prepared for
Training Department
Century Paper and Board Mills Limited

July 2010

Prepared by:
MUSHAHID ALI
Intern at Production Site
Email: mushahidali143@gmail.com
Contact: 03457441340
School of Chemical and Materials Engineering
(SCME)

National University of Sciences and Technology, Islamabad

i
Summary
For any given industry, each topic could alone be the subject of a lengthy volume. However
in order to produce a manageable document, this article focuses on providing summary
information for each topic. This format provides the reader with a synopsis of each issue,
and references where more in depth information is available. In this article, a brief
description related to Paper Industrial processes specially used by the Century Paper and
Board Mills is provided. Text within each profile was researched from a variety of sources,
discussions, and was usually condensed from more detailed sources pertaining to specific
topics. This approach allows for a wide coverage of activities that can be further explored
based upon the citations and references listed at the end of this report.

ii
Acknowledgement
Author is thankful to Almighty Allah,

For His unlimited blessings and bounties,

And for keeping him sane, sound and successful;

His parents and friends,

For all their support and trust in him and his aims;

His teachers and guides,

For teaching him things he knew not;

NUST Career Development Centre,

For bringing the opportunity of this excellent learning and exposure;

And last and the most important

Management and Employees of Century Paper and Board Mills

Especially his mentor Mr. Nadeem the Production Manager

And all the shift coordinators, supervisors, trainee engineers, board men and area operators at
Plant

For their utmost help, guidance and time

Which made author make most of his internship at plant site;

iii
 Table of Contents
Introduction: ...................................................................................... 1
Chemical House: ............................................................................... 2
Objective: ........................................................................................................................... 2
Sodium Sulfite: .................................................................................................................... 2
Procedure:....................................................................................................................... 2
Strength of Sodium Sulfite: ................................................................................................ 3
Sodium Hypochlorite: ........................................................................................................... 5
Procedure:....................................................................................................................... 5
Strength of Sodium Hypochlorite:....................................................................................... 5
Major Instruments used in Chemical House: ........................................................................... 7
Steam Pits: ...................................................................................................................... 7
Furnace: .......................................................................................................................... 7
Cooling Tower: ................................................................................................................. 7
Blower: ........................................................................................................................... 7
Valve:.............................................................................................................................. 7
Reactor: .......................................................................................................................... 7
Heat Exchanger: ............................................................................................................... 7

Important Definitions: .................................................................... 8

Cooking House: ................................................................................. 9
Objective: ........................................................................................................................... 9
Straw Plant:......................................................................................................................... 9
Primary Cleaning: ............................................................................................................. 9
Secondary Cleaning: ......................................................................................................... 9
Cooking plant: ....................................................................................................................10
Calculation for the amount of Sodium Sulfite added: ...........................................................10
Major Instruments used in Cooking House: ............................................................................12

Bleaching House: ............................................................................ 13

Objective: ..........................................................................................................................13
Washing Plant: ...................................................................................................................13
Bleaching plant: ..................................................................................................................15
Calculations for the amount of Sodium Hypochlorite: ..........................................................15

iv
 Major Instruments used in Bleaching House:..........................................................................17
Dewatering Filter or Rotary Drum Vacuum Filter (RDVF): .....................................................17
Blow Tank: ......................................................................................................................17
Johnson Screen: ..............................................................................................................18
Centre-cleaners: ..............................................................................................................18
Thick Stock Pump: ...........................................................................................................18

Stock Preparation Plant: .............................................................. 19

Objective: ..........................................................................................................................19
Waste Paper Plants: ............................................................................................................19
Waste paper plant 1: .......................................................................................................19
Major Instruments used in Waste Paper Plant 1: ....................................................................22
Dewatering Filter or Rotary Drum Vacuum Filter: ................................................................22
High Pressure Screen: ......................................................................................................22
Turbo Separator: .............................................................................................................22
Deflaker: ........................................................................................................................22
Separ Plast:.....................................................................................................................23
Centre-Cleaner: ...............................................................................................................23
Refining Plants: ...................................................................................................................24
Refining Plant 1: ..............................................................................................................25
Refining Plant 2: ..............................................................................................................27
Refining Plant 3: ..............................................................................................................29
Refining Plant 4: ..............................................................................................................31
Refining Plant 5: ..............................................................................................................33
Refining Plant 6: ..............................................................................................................35
Major Instruments used in all the Refining Plants: ..................................................................37
Double Disk Refiner: ........................................................................................................37

Machine Hall: .................................................................................. 38

Approach Flow System: .......................................................................................................38
Paper Machine: ..................................................................................................................40
Process:..........................................................................................................................40
Calculation for the flow and head on the Machine: .............................................................41
Major parts of the Machine: .................................................................................................41
Wire Part: .......................................................................................................................41

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 Press Part: ......................................................................................................................44
Dryer Part: ......................................................................................................................47
Difference between Paper and Board Machine:......................................................................50

Coating Plant: ................................................................................. 56

Objective: ..........................................................................................................................56
Preparation of chemical: ......................................................................................................56
Process: .............................................................................................................................57

Box Plant: ......................................................................................... 59

Objective: ..........................................................................................................................59
Preparation of Glue: ............................................................................................................59
Quality tests for the Glue: ................................................................................................59
Corrugators Plant: ...............................................................................................................59

vi
 Pulp and Paper Industry
INTRODUCTION:
Paper is very useful for our daily life. We get lots of new information and ideas in our daily
life but these ideas and information may lose if we don't save it. And the paper is very basic
and cheaper way of saving the information and knowledge. Paper and Pulp Industry is the
major Industry of any country which performs a major role for the growth and development
of a literary society in any country.
The first known operating paper mill was in operation in 794 in Baghdad. From here, the
technology spread to Europe. Today, paper mills use great amounts of water, energy, and
wood and follow a complex process in order to produce paper. These modern machines are
as much as 500 feet in length and move at speeds of over 100 mph, which makes them
capable of producing sheets of paper as much as 400 inches wide.
A paper mill is a type of factory that makes paper from wood pulp and other special
ingredients. This is accomplished through a variety of special machines, including a tree
chipper, a digester, and a paper machine. Due to the Kraft process used to separate the
lignin from the plant products used in the paper making process resulting in a sulfur
byproduct, paper mills are associated with unpleasant smells.
The undesirable smell associated with paper mills only occurs if the mill is also a pulp mill. In
some cases, mills focus on only pulp processing or paper processing. All of the major mills,
however, engage in both processes. The offensive smell is caused by the cooking process
used to soften the pulp in order to form it into paper. Despite the bad smells they emit, the
airborne particles are not harmful to a person’s health.
Century Paper Mill is one of the largest Mills in Pakistan. It has been showing its tremendous
performance for many years and still it is the best. I have added a brief introduction related
to processes involved for the production of Pulp and preparation of different quality of
papers from the pulp in the Century Paper Mill.
Century Paper Mill has divided its work into different departments to maintain its efficiency
level. And I will discuss each department here and explain all the programs working in all the
respective departments.

1
CHEMICAL HOUSE:
Chemical House is the first approach towards the preparation of Paper. Two plants are
installed in the Chemical House. One is for the preparation of Sodium Sulfite and the other is
for Sodium Hypo-Chloride. Sodium Sulfite is used in the Cooking House for the cooking of
Wheat Straw and Bagasse while Sodium Hypo Chloride is used in the Bleaching House for
the Bleaching of Unbleached Pulp.

Objective:
The objective is to provide the continuous flow of Sodium Sulfite and Sodium Hypochlorite
to the respective departments.

Sodium Sulfite:
In Century Paper Mill the procedure followed for the preparation of Sodium Sulfite is given
below;
Procedure:
First of all, the sulfur in powdered form is poured onto the steam pits manually. With the
help of steam pits, sulfur melts and converts into the melted form. This melted sulfur is
transferred to the Furnace with the help of Dozing Pumps. These are actually Centrifugal
Pumps. These pumps transfer the melted sulfur to the furnace. The temperature of the
furnace is maintained from 900 oC to 1100 oC. A continuous supply of oxygen is maintained
to the furnace with the help of blower. The reaction takes place and sulfur dioxide is
produced according to the following equation.
S + O2 ------------> SO2

Sulfur dioxide produced in the furnace moves towards the cooling tower. It reduces the
temperature of sulfur dioxide. In the cooling tower there is a counter-current flow occurs
between sulfur dioxide and water and direct interaction occurs between them. And the
temperature of the sulfur dioxide decreases up to 60 oC to 65 oC. During this reaction a few
of the sulfur dioxide converted into liquid form and drain out from the cooling tower. While
most of the sulfur dioxide move towards the reaction chamber. On the other hand the
second reactant is Sodium Carbonate (Soda Ash) which comes in the powdered form. This
powdered soda ash is poured into a dissolver tank where it is mixed with the water. Solution
of soda ash and water is prepared. Now Soda Ash moves towards the reaction tower. Sulfur
dioxide enters from the lower side of the reaction tower and meets with the counter-
current flow of the liquefied Soda Ash. It is to be noted that Soda Ash is always be used in
the presence of water. Century Paper Mill gets Soda Ash from ICI Pakistan. During the
reaction Sodium Sulfite and Carbon Dioxide is produced according to the following equation.
Na2CO3 + SO2 ------------> Na2SO3 + CO2

The carbon dioxide gas is drain out from the chimney of the reaction chamber. While on the
other hand the required product is shifted to the storage tank. As sodium sulfite is a very
acidic chemical so to make the solution basic or to increase the pH of the solution, 50%
solution of Caustic Soda NaOH is added to sodium sulfite so it may not be dangerous for the
material of the storage tank.

2
Strength of Sodium Sulfite:
The required strength of Sodium Sulfite is 140 grams/liters. To maintain the required
strength of it, we use specific amounts of the reactants. To calculate the exact quantity of
reactants, we follow the method of Stoichiometry.
Basis = 1 liter
The chemical equation for the process is
Na2CO3 + SO2 ------------> Na2SO3 + CO2
(106 g) (64 g) (126 g) (44 g)
According to the equation:
To produce 126 grams of Na2SO3, 106 grams of Na2CO3 is required
To produce 1 gram of Na2SO3, 106/126 grams of Na2CO3 is required
To produce 140 grams of Na2SO3, 106/126 * 140 = 117.78 grams of Na2CO3 will be required
And
To produce 126 grams of Na2SO3, 64 grams of SO2 is required
To produce 1 gram of Na2SO3, 64/126 grams of SO2 is required
To produce 140 grams of Na2SO3, 64/126 * 140 = 71.11 grams of SO2 will be required

Amount of CO2 produced can be calculated as

106 grams of Na2CO3 will produce 44 grams of CO2

1 gram of Na2CO3 will produce 44/106 grams of CO2
117.78 gram of Na2CO3 will produce 44/106 * 117.78 = 48.89 grams of CO2

3
4
Sodium Hypochlorite:
Sodium hypochlorite is a chemical compound with the formula NaOCl. Sodium hypochlorite solution,
commonly known as Bleach, is frequently used as a disinfectant or a bleaching agent. In Century
Paper Mill, the procedure followed for the preparation of Sodium Hypochlorite is given below;

Procedure:
First of all, liquid Chlorine is brought in the Chemical House. Chemical House buys this
chlorine from Sitara Chemical Industry. This chlorine is kept in the cylinders and then with
the help of small pipe lines the liquid chlorine is transferred to the Evaporator. The
evaporator works on the principle of a Heat Exchanger. In the evaporator there is a counter
current flow of the liquid chlorine and steam. After exchanging the heat, chlorine converted
into gas form. And after changing the physical state of the chlorine it is passed from the
reactor. On the other hand the NaOH in the form of liquid is first passed through a heat
exchanger to reduce its temperature. After reducing the temperature it moves towards the
reactor. An exothermic reaction occurs in the reactor. Sodium hypochlorite is produced in
the reactor. The reaction can be explained with the help of following chemical equation:
2NaOH + Cl2 ---------> 2NaOCl + H2
Due to its high temperature it moves towards a heat exchanger. Heat Exchanger used chilled
water to reduce the temperature of the sodium hypochlorite. As the reaction is continuous
so the flow of chilled water passes through the heat exchanger which comes from a chiller is
also continuous. After passing through the heat exchangers sodium hypochlorite moves
towards the storage tank.
Strength of Sodium Hypochlorite:
The required strength of Sodium Hypochlorite is 40.4 grams/liters. To maintain the required
strength of it, we use specific amounts of the reactants. To calculate the exact quantity of
reactants, we follow the method of Stoichiometry.
Basis = 1 liter
The chemical equation for the process is
2NaOH + Cl2 ---------> 2NaOCl + H2
(80 g) (71 g) (149 g) (2 g)
According to the equation:
To produce 149 grams of NaOCl, 80 grams of NaOH is required
To produce 1 gram of NaOCl, 80/149 grams of NaOH is required
To produce 40.4 gram of NaOCl, 80/149 * 40.4 = 21.7 grams of NaOH will be required
And
To produce 149 grams of NaOCl, 71 grams of NaOH is required
To produce 1 gram of NaOCl, 71/149 grams of NaOH is required
To Produce 40.4 grams of NaOCl, 71/149 * 40.4 = 19.25 grams of NaOH will be required

Amount of H2 produced can be calculated as:

149 grams of NaOCl produces 2 grams of H2

1 gram of NaOCl produces 2/149 gram of H2
40.4 grams of NaOCl produces 2/149 * 40.4 = 0.54 grams of H2

5
6
Major Instruments used in Chemical House:
The details of instruments used in the chemical house are given below:
Steam Pits:
Pits are used to heat the sulfur and convert into the melted or paste like form. These pits
are small pipes and steam passes through them when sulfur is poured onto these pits, the
heat which evolves from these pits it converts the sulfur into liquid form.
Furnace:
Furnace is used to heat the sulfur and oxygen to make the reaction possible in the required
conditions. It maintains the required temperature and pressure. Different types of furnaces
can be used according to the demand. In Chemical House the furnace used is heated with
the help of fire which is promoted by diesel. The furnace has nickel coating on the outer side
and in the inner side the asbestos sheet is used and the top inner side the fire bricks are
used to insulate the furnace and to reduce the loss of heat.
Cooling Tower:
Cooling Tower is used to reduce the temperature. Two types of flow may occur in the
cooling tower.
 Counter current flow
 Co-current flow
The flow of SO2 and water is counter current flow.
Blower:
Blower is used to supply the air. A 100 hp of motor is used in the blower. It maintains the
continuous supply of air and oxygen in the furnace during the preparation of SO2 .
Valve:
Valve is the instrument used to control the flow rate of any liquid or gas. Although many
different types of valves are used to control the flow of fluids, the basic valve types can be
divided into two general groups: stop valves and check valves.
The valves used in the chemical house are Stop Valves. The names of the valves are given
below.
 Butterfly valves
 Gate valves (Fixed Stem)
 Two way valves
Reactor:
Two different types of reactors are used in the chemical house. The major difference
between them is of size. The material used for both the reactors is Aluminum so that the
solutions of low pH may not spoil it.
Heat Exchanger:
Heat Exchanger is a device used for efficient heat transfer from one liquid to another
without mixing them into one another. In Chemical House, the type of heat exchangers
Plate heat exchanger. One is composed of multiple, thin, slightly-separated plates that have
very large surface areas and fluid flow passages for heat transfer. This stacked-plate
arrangement can be more effective, in a given space, than the shell and tube heat
exchanger.

7
IMPORTANT DEFINITIONS:
Before moving towards the Cooking House and Bleaching House, some important
definitions should be explained to make the up-coming information easy and
understandable.
Pulp:
Fibrous material in wheat straw and Bagasse is called Pulp.
Crude pulp:
Pulp attained by cooking of Straw/Bagasse is called Crude Pulp.
Unbleached Pulp:
Pulp achieved after washing and cleaning of crude pulp is called Unbleached Pulp.
Bleached Pulp:
Pulp achieved be chemical treatment of Un-bleached pulp is called Bleached Pulp.
Consistency:
Oven dried weight of pulp in 100 ml of suspension is called Consistency.
Accept:
Useful fiber is called Accept.
Reject:
Un-wanted fiber is called Reject.
Residual:
Remained bleaching chemicals in pulp are called Residual.
SRo:
Degree of freeness
Freeness:
Amount of water drained from pulp suspension is called freeness.
GEo:
Degree of brightness
Back Water:
Removed after from washing and bleaching filters is called back water.

8
COOKING HOUSE:
Cooking House is the second step towards the preparation of paper. Two plants are being
operated in the cooking house. First is the straw plant and the second is for the cooking of
wheat straw. Cooking House is doing a tremendous job for the preparation of fine Pulp.

Objective:
The objective of cooking plant is to provide a continuous flow of quality pulp to the
bleaching house after adding liquor up to required consistency.

Straw Plant:
Straw plant is used for the primary and secondary cleaning of the wheat straw. Processes
involved in this plant are discussed below:
Primary Cleaning:
For this purpose the raw wheat straw that comes in the form of bales is manually shifted to
a conveyer belt. The belt moves and takes the straw towards a suction pipe. The suction
pipe is connected with the blower. In the start of the suction pipe, heavy stones are
separated in the stone collector. The suction pipe transfers the wheat straw to the double
shaker. In the double shaker the unwanted material is separated from wheat straw. There is
a screen in the double shaker which vibrates and helps to separate the unwanted material.
The size of the holes in the screen is round about 8mm. another suction pipe continuously
extracts the wheat straw next to the cleaner. The double shaker is air tight so that the
vacuum inside the chamber is maintained. And the flow of straw remains continuous. And
passing through the vibrating screen the wheat straw is shifted to the cleaner in the same
chamber. There is also a screen in the cleaner which separates the unwanted material. The
size of the holes in the screen of the cleaner is between 2.5mm to 3mm. Two brushes
named Scrapers continuously clean the holes to avoid the blockage. In the cleaner, dust
particles and sand is removed from the wheat straw. A cyclone is attached with the cleaner
that extracts the low weight particles from the wheat straw with the help of blower. A
continuous supply of water is provided in the cyclone due to environmental hazards. These
low weight particles are drained out in the water. The last point of the pipe of cyclone is
continuously dipped into the water to keep the atmosphere clean. Now the useful wheat
straw is shifted to the single shaker. A special type of exhauster is used to maintain the
vacuum during the transfer of straw. The vacuum is necessary for the suction. Single shaker
is the last step of Primary Cleaning of wheat straw. Single shaker also removes the
unwanted material from the wheat straw. It has a screen which vibrates and separates the
unwanted material.
Difference b/w Double Shaker and Single Shaker:
The working principle of both shakers is the same. The only difference exists in the holes of
the sheets. The holes in the sheet of the double shaker are about 8mm and the holes in the
sheet of single shaker are about 3mm.
Secondary Cleaning:
Wheat straw is extracted from single shaker to the Dust Cleaner with the help of suction
pipe. Dust Cleaner is a first stage of Secondary Cleaning of straw. This is the same dust
cleaner that was used in the Primary Cleaning after the double shaker. The screen of the

9
dust has the holes of 3mm. After that the wheat straw is transferred to the Scale Belt giving
way towards the mixer. An exhauster is used to maintain the vacuum in the cleaner.

Cooking plant:
After the secondary cleaning, the raw wheat straw is shifted to the Scale Belt. Scale belt
takes the straw towards the mixer. Sensors on the scale belt calculate the weight of wheat
straw according to the unit "ton/hour". Two shafts rotate in the mixing chamber. One
rotates in clockwise direction and the other rotates in anti-clockwise direction. A motor
having power of 40hp is used to rotate these shafts. These shafts have speed of 1470 rpm. A
known quantity of water and sodium sulfite is added to the mixer. The consistency of liquor
which is added in the mixer is 13%. These rotating shafts have side wings attached on equal
distances to help the process of mixing. From the mixing chamber raw material is shifted to
a conveyer belt. The conveyer belt poured wheat straw into the digester. There are total ten
digesters installed in the cooking plant. There are six digesters having the capacity of 60m3
and four digesters having the capacity of 50m3. The raw material is poured into the digester
according to its capacity. The digester is closed and heating is started. Steam is used for the
heating process. The temperature of the digester rises slowly. The heating time is 1 hour
and 5 minutes. And the cooking time is 4 hours and 5 minutes. The pressure of the steam is
maintained at 7 to 7.2 bars. And the temperature is 165 to 168 oC. A motor of 10 hp is used
to rotate the digester continuously during the process of cooking to homogenize the
material present in it. A gear system is attached to control the speed of the motor. As the
reaction is endothermic so heat is absorbed by the system. After completing the required
cooking time the pulp is prepared which moves towards the blow tank. The movement of
the pulp from digester to blow tank is due to the pressure of steam. And vacuum is
maintained throughout the movement of pulp to stop the leakage of steam. The steam
pipes are totally insulated with led and wool coating to avoid heat loss.
Calculation for the amount of Sodium Sulfite added:
Before calculations, we must know about the following abbreviations,
A.D. = Air dried;
O.D. = Oven dried;
Liquor = Sodium Sulfite;
As we know that,
A.D. = O.D. + water
Mass flow rate on A.D. basis = 8ton/hour;
Moisture contents measured = 19%;
So
8 * 0.19 = 1.52;
Now
Mass flow rate on A.D. basis = 8 – 1.52 = 6.48 ton/hour;
Required consistency of liquor = 13%;
So
Amount of liquor added = (O.D. * liquor consistency) / (liquor strength)
= (6.48 * 0.13) / (140.4) = 0.006 ton/hour.

11
11
Major Instruments used in Cooking House:
The details of instruments used in the chemical house are given below:
Dust screens
Shakers
Digester
Mixer
Exhauster

12
BLEACHING HOUSE:
Bleaching house is third step for the preparation of paper. Two processes are operated
here. First is the washing of pulp and the second is towards the bleaching of pulp. Bleaching
house collects the pulp from cooking house and after cleaning processes and bleaching
processes it transfers it to the next plant. Bleaching house is working through a continuous
process for the cleaning and bleaching process. Bleaching house has two lines for both
washing and bleaching. Capacity for washing of line 1 is 100 ton/day and for line 2 is 150
ton/day. The bleaching capacity of line 1 is 80 ton/day and of line 2 is 70 ton/day.

Objective:
The objective is to clean and bleach the pulp to produce a better quality pulp and forward it
continuously towards the Stock Preparation Plant which is the next step for the preparation
of paper.

Washing Plant:
The pulp obtained from the cooking plant is received in the blow tank. An agitator works in
the blow tank to make the pulp homogeneous throughout the tank. Next the pulp is
transferred to a chest. There is a cage in the chest which separates the stones or heavy
particles from the pulp. Now the pulp is transferred to a stone collector with the help of
pump. This stone collector works with the help of centrifugal force and separates the stones
and other particles from the pulp. In this way the quality of the pulp is improved. Now the
pulp is sent to a vibratory screen. This screen is called Johnson screen. This also helps to
improve the quality of the pulp with the help of its vibratory screens. It separates the
unwanted material and drains it and shifts the required pulp for the further processes. Next
the pulp comes in the washing plants. Four rotary drum filters are used for the washing of
pulp. During washing of pulp, known amounts of lignin, salts, iron and sand particles are
removed and we try to get the more refined form of un-bleach pulp. After passing through
3rd rotary drum filter, the pulp passed through the centre-cleaners. Three stage centre-
cleaners are installed in the mill to give the quality pulp for the process of bleaching. Pulp
passes through these cleaners with the help of pump. These centre-cleaners work with the
help of centrifugal force and help to remove the reject more effectively. From these
cleaners it moves towards the de-watering filter. It reduces the water from the pulp and
increases the pulp consistency 8 to 10%. And in the last of the washing plant the pulp is
shifted to the back water chest. And it transfers it to the storage tower.

13
14
Bleaching plant:
It is the second process working the bleaching house. In this plant, we bleach the pulp with
the help of bleaching agent sodium hypochlorite. Sodium hypochlorite is provided by the
chemical house. In this process the un-bleach pulp from the storage tank of washing plant is
transferred to buffer chest with the help of pump. Water is also added to the chest to
decrease the pulp consistency up to 3%. And from the buffer chest it moves towards the
pre-hypo filter. This pre-hypo filter is also a rotary drum filter. In this filter 3.5% of sodium
sulfite is added to the pulp. In this way, the consistency of pulp decreases up to 1%. This
pre-hypo filter transfers the pulp to single shaft mixer which further forwards it to the Thick
Stock Pump. Thick Stock Pump has the power 60 hp and works accordingly. Thick Stock
Pump transfers the pulp to the hypo-tower 1. In the hypo-tower, the temperature of the
pulp increases slowly round about 40 to 42 oC. 5% of sodium hypochlorite is also added on
O.D. bases. The reaction time in the reaction tower is given up to 2.5 hours. An agitator also
works in the tank to make the solution homogeneous. After reaction time is completed, the
pulp moves towards hypo filter 1 which again filter the pulp and try to develop more refined
form of pulp. It transfers the pulp to another thick stock pump which transfers the pulp to
hypo tower 2. In this tower the same process is repeated again under the same physical
conditions. After the reaction the tower transfers the pulp to high density tower in which
the consistency of pulp is 8 to 10%. And from this tower the pulp is shifted to the Stock
Preparation Plant. It is to be noted that total water requirements for washing and bleaching
is 16.77 liters/sec.
Calculations for the amount of Sodium Hypochlorite:
As we know that
A.D. = O.D. + water;
Volumetric flow rate on A.D. basis = 2200 liters/min;
Volumetric flow rate = Mass flow rate / Consistency (density);
Mass flow rate = Volumetric flow rate * Consistency;
Mass flow rate = 2200 liter/min * 0.03;
Mass flow rate = 66 kg/min;
Mass = 66 kg;
5% of 66 kg = 66 * 0.05 = 3.3;
So
3.3 kg/min of Sodium Hypochlorite is added in 66 kg/min of slurry.

15
16
Major Instruments used in Bleaching House:
Major instruments used in the Bleaching House are discussed below.
Dewatering Filter or Rotary Drum Vacuum Filter (RDVF):
The process of the RDVF is continuous. Each revolution of the drum consists of cake
formation, cake washing (if needed), dewatering or drying, and cake discharge.
1- As the drum rotates, it is partially submerged in the feed slurry.
2- Vacuum draws liquid through the filter medium (cloth) on the drum surface which
retains the solids.
3- The vacuum pulls air (or gas) through the cake and continues to remove moisture as
the drum rotates.
4- If required, the cake can be washed to remove impurities or to extract more product.
Additional drying of the cake follows washing.
5- Finally, the cake is discharged from the drum to a conveyor or chute to the next
process step.
6- The filtrate and air pulled through the medium flow through internal filtrate pipes
and pass though the rotary valve and into the filtrate receiver.
7- The liquid stream is separated from the vapor stream in the receiver.
8- Liquid filtrate is then pumped to the next step in the process.
9- Vacuum is applied using a liquid ring vacuum pump or other means.

Blow Tank:
In batch digestion, the pulp and black
liquor are mechanically conveyed or
"blown" into an atmospheric blow
tank upon completion of the cooking
cycle. The tank is a large cylindrical
vessel which functions as
intermediate storage of the cooked
pulp, and from which the pulp (now
called "Brown Stock" due to its color)

17
is discharged in an even flow to a washing process.
Johnson Screen:
There is machine used for screening purposes named Johnson Screen. It helps to separate
the unwanted fibers during its vibration. It has a screen having holes in it. The required pulp
passes through the screen but the reject does not pass through it and drains out.
Centre-cleaners:
Paper stock contains impurities that, if not removed, would affect the quality of paper
produced and cause damage to the wire. Cleaners are used to remove small, heavy, dense
contaminants, such as shives, sand, pipe scale, and metal flakes. The smaller impurities are
easily removed by the cleaners. This process improves the appearance of the paper and
increases the life of the wire and the calendar rolls. Multiple stage
cleaners are used to prepare the stock for the paper machine for
two reasons:
 Cleaners are only able to process a little stock at a time.
 Cleaners reject a small portion of good fibers as well as
contaminants in the cleaning process.
“It works on the principle that centrifugal force acts on different
bodies proportional to their mass/unit volume.”
Higher the force more swirl will be generated. A small pressure
difference is provided to facilitate the separation of the less
swirling substance. Due to centrifugal force the heavy materials
moves downward and light material moves upward streams and
then the heavy and light material is collected from their
respective points.
Thick Stock Pump:
It is a pump which has two basic functions. The first function is to screen the unwanted material
from solution of high consistency and second function of the pump to transfer the material towards
the next process.

18
STOCK PREPARATION PLANT:
Stock Preparation Plant is the fourth step for the preparation of paper. It is the only
department which controls the nine different processes separately. In these nine processes
3 processes are of waste paper treatment and 6 processes are of refining of different types
of wood pulp.

Objective:
The objective is to provide a continuous flow of pulp for the machine chest after preparing
the recipe of customer's demand.

Waste Paper Plants:

There are total three waste paper plants working in the Century Paper Mill. I am going to
discuss waste paper plant 1 here. The flow diagrams of all three plants are attached in the
report.
Waste paper plant 1:
First of all, the waste paper collected from different parts of country is brought into the Mill.
This paper is manually transferred onto the conveyer belt. It moves and pours all the
material into the pulper. There are different supplies of back water in the pulper. The pulp
consistency is maintained 3.5 to 4.5% in the pulper. An agitator continuously rotates in it
which helps to mix the pulp with back water. After the mixing time, the material moves
towards the ditch. Ditch is a tank which collects the pulp. It separates the stones and un-
wanted heavy material on the basis of gravity which drain out. The required pulp is shifted
to the chest. Next the pulp moves towards the High Density Cleaners (HDC) with the help of
pump. There are three high density centre-cleaners that clean the pulp and stones like
materials depending on their density are separated with the help of centrifugal force. The
pulp goes to the first H.D.C. The reject of it moves towards the second H.D.C. And the
required material goes towards the Turbo-Separator. Accept of the second H.D.C. goes
towards the dump chest and again goes to the first H.D.C. The reject of the second centre-
cleaner goes towards the third H.D.C. Accept of the third H.D.C. goes towards the first
H.D.C. and cycle goes on. Accept of the first H.D.C. that goes to the turbo-separator. Turbo-
separator separates the solid particles from the raw material. It has a round large size plate
having holes of 3mm in it. The material that passes through the holes is called accept and
the material that does not pass through the holes is reject. Light reject and heavy reject are
separated. Heavy reject is drain out and light reject is shifted to the Separ Plast. Separ plast
helps to remove additives of plastic like PVC present in it. Accept of separ plast goes to the
dump chest again while reject is drain out. Accept of Turbo separator moves towards the
Deflaker. It is a motor which also tries to remove solid particles from raw material and
separates fibers. All processes are carried out to enhance the quality of raw pulp. Next the
pulp passes through three stages centre-cleaners. Each stage of centre-cleaner consists of
multiple centre-cleaners. Accept of first stage centre-cleaner moves towards the chest and
the by-pass stream moves towards the de-watering filter. While on the other hand, reject of
the first stage centre-cleaner moves towards the second stage centre-cleaner. Accept of the
second centre-cleaner goes to the inlet of the first stage centre-cleaner. Reject of the
second centre-cleaner moves towards the third stage centre-cleaner. Accept of the third
stage centre-cleaner goes to the inlet of the second stage centre-cleaner and reject is drain
out. These three stages of centre-cleaners try to improve the quality of pulp. Chest transfers

19
the pulp to high pressure screen. This screen has a round plate having holes of 3mm in it
that separates unwanted particles. Accept of HPS transfers to the de-watering filter. A small
quantity of accept is shifted to the pulper to enhance the properties of pulp in the pulper.
On the other hand, reject of HPS moves towards F00 Screen. This screen also has sieve
plates in it which helps to remove unwanted material. Accept goes to the inlet of HPS again
and reject drains out. Dewatering filer has a rotary drum which has holes in it. The water
removes through suction produce in the small pipe lines present in the inner side of the
drum. Waste water goes to the thickener water chest. Thickener water chest supplies water
to the various equipments in the plant. The water is called back water. Accept of de-
watering filter goes to the storage chest with the help of pump and this storage chest
supplies pulp to the machine chest to make a recipe for a perfect paper.

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Major Instruments used in Waste Paper Plant 1:
The major instruments used in the waste paper plant 1 are discussed below.
Dewatering Filter or Rotary Drum Vacuum Filter:
I have discussed it with all details in the previous section of Bleaching House.
High Pressure Screen:
The principle of pressure screen is that the leading edge of the rotating foil accelerates the
stock and then, in back, vacuum is produced, the impurities remains in vacuum section
while the accept moves through openings. This is a mechanical separation technique reliant
on exploiting the physical size difference between a fiber and the contaminant to be
removed.

Turbo Separator:
It is used for effective separation of heavy and light
impurities. The minimum fiber loss is 3.4%. The accept
stock passes through the screen fitted behind the rotor. In
Turbo Separator, a force vortex is formed in the separator
by a Stainless Steel rotor. The heavy particles are carried
outward by Centrifugal force into the junk trap. The rotor &
screen are designed to slush paper chips and remove all
the non fibrous material which goes out as light reject and
further treated in secondary separator of Johnson Screen.
Deflaker:
The aim is to mechanically treat
the fiber flakes and bundles of
fibers in the stock in order that
they are broken down into
individual fibers in a suspension if
possible. This is done for a
number of reasons and in a
number of positions within the
system. It can be installed to
reduce remaining flakes after a
pulper, in the broke system to

22
reduce flakes going back to the machine from the broke pulpers and can also be used in the
final stages of a screening system in a recycled fiber line to treat the concentrated rejects
and the flakes contained within it.

Separ Plast:
Separ Plast is used for the separation of unwanted materials of
polymer and plastics from the pulp. It is formed by a cylinder carrying
hardened tip blades, rotating at high peripheral speed inside a
perforated basket, accommodated into housing supplied with
inspection and out-let doors. Its operating consistency is 3.5 to 5%. The
screen hole Size 3.5 to 6 mm depending on the grade of furnish and on
the cleanliness requirements.

Centre-Cleaner:
Centre Cleaners have been discussed in the Bleaching House with full details.

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Refining Plants:
These plants are used to refine the wood pulp. Wood pulp is imported from different
countries by the Century Paper Mill. It has different types. The names of some of the types
which are used by the Century Paper Mill are given below:
Soft Bleach Kraft Pulp (SBKP):
The pulp use to produce white paper is called Bleach Kraft Pulp. The chemicals used to
bleach pulp have been a source of environmental concern, and recently the pulp industry
has been using alternatives to chlorine, such as chlorine dioxide, oxygen, ozone and
hydrogen peroxide.
Bleach Chemical Thermo Mechanical Pulp (BCTMP):
Thermo mechanical pulp is pulp produced by processing wood chips using heat (thus
thermo) and a mechanical refining movement (thus mechanical). It is a two stage process
where the logs are first stripped of their bark and converted into small chips. These chips
have a moisture content of around 25-30% and a mechanical force is applied to the wood
chips in a crushing or grinding action which generates heat and water vapor and softens the
lignin thus separating the individual fibers. The pulp is then screened and cleaned; any
clumps of fibers are reprocessed. This process gives a high yield of fiber from the timber
(around 95%) and as the lignin has not been removed, the fibers are hard and rigid.
Un-bleach Kraft Pulp (UKP):
Kraft pulp is what you get after you place a chip of wood in a pressurized vessel in the
presence of hot caustic soda and sodium sulfide. The cooking process attacks and eventually
dissolves the phenolic material called lignin that glues the fibers to each other in the wood.
The word "Kraft" means "strong" in the language of its origin. German manufactures of pulp
discovered that addition of the sulfur to a "soda cook" improved the selectivity of the
process - dissolving the lignin with less damage to the cellulose. The fibers initially liberated
by kraft pulping usually are brown, similar to a typical grocery bag (paper type) or
corrugated box. Kraft pulps tend to be more flexible than fibers produced by purely
mechanical refining of pulp.
Hard Bleach Kraft Pulp (HBKP):
This is a type of pulp which we get by bleaching of hard wood. This type of pulp is used for the
preparation of multi-layers board.

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Refining Plant 1:
This plant is used to refine the wood pulp. The type of pulp which is refined in the Refining
plant 1 is called SBKP. This is an abbreviation of Soft Bleach Kraft Pulp. First of all, pulper is
filled with 12m3 of water. And 2 bales of wood pulp are poured into the pulper. An agitator
continuously rotates in the pulper to dissolve the wood pulp in the water and helps to make
a homogeneous solution. The pulper shifts the pulp to the chest with the help of pump. In
the chest heavy stones lay down due to gravity. Next the pulp is shifted to double disk
refiner. There are three double disk refiners installed in series in the refining plant 1 that
refine the pulp with the help of motor. All the three refiners help to separate the fibers and
transfer the pulp to storage chest. A block diagram of Refining Plant 1 is shown.

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Refining Plant 2:
The type of wood pulp which is refined in Refining Plant 2 is called SBKP. This is the same
wood pulp which is refined by Refining Plant 1. But the procedure of refining in the second
plant is a bit different. First of all we add the bales of pulp with the fresh water in the pulper
according to required consistency. Pulper transfers the mixture into the Dump Chest. Dump
Chest separates heavy particles present in the mixture with the help of gravity. Next the
pulp moves towards the Double Disk Refiner. It refines the pulp and transfers it to the
storage chest. In the previous plant, we had three Double Disk Refiners available for refining
but here we have only one refiner. In this way the required pulp is in less refined form.

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Refining Plant 3:
The type of wood pulp which is refined in this plant is called BCTMP. This is an abbreviation
of Bleach Chemical Thermo-mechanical Pulp. There are two pulpers installed in this plant.
These pulpers are installed in the series. The wood pulp is added with the fresh water into
the pulpers according to required consistency. Both the pulpers transfer the pulp into the
Dump Chest. Heavy Particles are separated due to gravity in the dump chest. Next the pulp
moves towards High Density Cleaner. The cleaner removes the stones of high density and
helps to clean the pulp. From the cleaner the accept moves toward the deflaker. Deflaker
separates the fibers and the pulp transfers to the Double Disk Refiner. There are two
refiners installed in this plants that enhances the refining capability of the plant. After
passing through these two refiners the pulp moves towards the storage chest. There are
two storage chests. First has the capacity of 70 m3 and second has the capacity of 20 m3.

29
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Refining Plant 4:
The type of wood pulp which is refined in this plant is called UKP. This is an abbreviation of
Un-bleach Kraft Pulp. First of all the wood pulp is added with the fresh water into the pulper
according to required consistency. The pulper transfers the pulp into the dump chest with
the help of pump. Heavy particles are separated in the chest due to gravity. Dump chest
transfers the pulp to High Density Cleaner with the help of pump. It removes the heavy
particles from the pulp and enhances the quality of pulp. HDC transfers accept to Single Disc
Refiner. There are two single disc refiners installed in this plant that use for refining
purposes. These two refiners are connected in series. After passing through the refiners the
pulp moves towards the F00 screen. The screen helps to remove unwanted particles from
the pulp. And next the pulp finally transfers to the storage chest having capacity of 37 m 3.

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Refining Plant 5:
The type of wood pulp which is refined in this plant is called UKP. This is an abbreviation of
Un-bleach Kraft Pulp. UKP is added with fresh water in the pulper. After having specific time
in the pulper, pulp shifts to the Dump Chest. Heavy particles are separated due to gravity in
the chest. Next the pulp moves towards the High Density Cleaner. Cleaner tries to remove
the contaminants present in the pulp and transfers accept towards the deflaker. Deflaker
separates the fibers from each other and transfers the pulp towards the Pilao. Two pilaos
are installed in this plant in the series. An agitator works in the pilao. In the last step of
refining the pulp shifts to the storage tank having capacity of 80m 3.

33
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Refining Plant 6:
The type of wood pulp which is refined in this plant is called HBKP. This is an abbreviation of
Hard Bleach Kraft Pulp. First of all wood pulp is added with fresh water into the pulper. After
having specific time in the pulper it moves towards the Dump Chest. Heavy particles are
separated due to gravity. Next the pulp transfers to the deflaker. Deflaker separates the
fibers from each other and transfers the pulp to Pilao. Pilao shakers the pulp and make a
homogeneous solution. In the last step, the pulp transfers to the storage tank.

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36
Major Instruments used in all the Refining Plants:
Double Disk Refiner:
A double disk refiner and inducer for the same that mixes fiber in low consistency (6% or
less by weight) stock and urges it towards both pairs of refiner disks of the double disk
refiner. In a preferred embodiment, the inducer comprises an impeller that has at least one
flight extending radially outward from an inner hub. Each flight is angled and also can be
curved so as to substantially continuously mix and urge stock toward the disks. In one
preferred embodiment, the inducer is an impeller that has two helical flights that are axially
spaced from one another but that overlap in an axial direction. In a preferred method, the
low consistency stock is urged by the inducer toward the disks preventing clumping of fibers
in the stock and breaking up any clumps already present in the stock. As a result, the gap
between the disks can be increased from between one thousand and three thousandths of
an inch to increase the output of the refiner.

37
MACHINE HALL:
Machine Hall is the strongest department of Century Paper Mill. There are total six Paper
Machines in Machine Hall. Among these machines there are three paper machines and
three board machines. All the machines are producing different quality of paper and board.
All the administration and workers of Machine Hall are performing a tremendous job to
maintain the quality of production. Before shifting pulp to the head box of machine, the
process which is controlled by machine hall administration is called Approach Flow System.
This is the last process used to control the quality of pulp.

Approach Flow System:

The term approach flow includes the piping system present in between recycling chest and head
box. The components discussed in the approach flow system are:

 Recycling Chest
 Machine chest
 White water tank
 Fan Pump
 Cleaners
 Pressure screens
 Head Box
Recycling Chest (Or Recycling Tank):
The various pulp and broke stock are proportionally mixed in the blend pipe and then
delivered to the Blend Chest. The Recycling Chest receives its stock from the Blend Chest
and sent to Machine Chest. The over flow of the Machine Chest is recycled to Recycling
Chest. The basic purpose of Recycling Chest is to provide stock to Machine Chest in such a
way that the level of Machine Chest remains constant.
Machine Chest (Or Recycling Tank):
The Machine Chest is last storage volume of stock before it is diluted and pumped to the
head box. The basic Purpose of Machine Chest is to provide constant flow of stock at the
inlet of fan pump. Level of Machine Chest is maintained constant to provide constant head
at the inlet of Machine Chest pump.
White Water Tank:
The white water tank is a large holding tank that is located behind the breast roll end of the
wire in the stock approach system. The tank receives the white water as it drains through
the wire, away from the forming paper web. The cleaner pump pulls white water from the
tank for diluting the stock to less than 1% consistency. The level of the tank should remain
constant, excess white water from the tank overflows to the excess tank.
Fan Pump:
This is an axial flow pump that uniformly mixes stock with white water. It's impeller is like a
close impeller. Fan pump takes water from tank. During the operation tank head should be
constant and white water in the tank should be free of air.
Centre Cleaner:
I have previously discussed Centre Cleaners in the Bleaching House with full details.

38
Pressure Screen:
I have previously discussed Pressure Screen in Waste Paper Plant with full details.

Head Box:
The Head box distributes stock at an even rate across the width of the paper machine. The
flow of stock through circular pipes must be converted to a horizontal or linear flow. This
enables the stock to be spread evenly across the entire width of the paper machine. The
basic components of a Head box are the stock inlet and the slice.
The stock inlet feeds stock into the Head box. The stock then flows out of the slice and onto
the forming fabric (wire). The slice has an adjustable slice (top) lip and apron lip (bottom).

Early Head boxes were simply open rectangular tanks that held the stock. Weight of the
column of stock or head pressure provided force to push the stock through the slice.
Adjusting Head box height varied the head pressure, therefore it influenced machine speed.
Maximum practical height of the box limited the operating speed of machine and therefore
flow speed limited onto the wire. To achieve higher operating speeds pneumatic and
hydraulic Head boxes were developed. They are sealed units pressurized by air or by the
liquid stock.
The following are important criteria for good Head box design.
 No surging of feed entering the Head box
 No dead (no flow) areas inside the Head box
 No sharp internal corners or edges to catch the stock
 Maintain a uniform fiber dispersion
 Eliminate entrained air
 Distribute stock uniformly across the full width of the machine
Head box Design:
There are following different types of head boxes on the basis of design.

39
Pressurized Head box:
Pressurized Head boxes have a cushion of air in the Head box. The air pressure regulates the
rate, or jet velocity, of the stock out of the Head box. Increasing the air pressure increases
the jet velocity.
Stock flows from a set of laterals into a chamber. The stock fills the chamber to a level over
two perforated rolls. These rolls, which are called rectifier rolls, break up small clumps of
fibers and keep the fibers in the stock dispersed. The rolls also smooth out small variations
in the stock flow by keeping the flow going in one direction toward an opening called a slice.
The slice is adjusted to regulate the stock flow from the Head box to the forming section.
Hydraulic Head box:
Hydraulic Head boxes are designed differently from pressurized Head boxes. The Head box
and the entire line from the stuff pump to a hydraulic Head box are completely filled with
stock, so this type of system behaves much like a hydraulic system. The dynamic liquid
pressure established by the fan pump forces the stock through the box and to the slice.
The stock flow and the jet velocity are generally higher with hydraulic Head boxes than with
pressurized Head boxes. Hydraulic Head boxes are often used with high speed paper
machines.
Head box Tapered Header:
The purpose of the tapered header is to keep stock flow uniform across the width of the
paper machine and to maintain an even pressure along the entire length of the header.
Tapered header gets its name from the tapered pipe that supplies stock to the Head box. It
extends across the width of the machine. The taper keeps the pressure at one end of the
header close to the pressure at the other end. The taper evens the pressure that is felt
across the width of the Head box. The major parts of the tapered header are:
 Recirculation line
 Balance line

Paper Machine:
After passing through approach flow system, pulp moves towards the machine. The process
operated on the machine is given below.
Process:
First of all the pulp is equally distributed on the wire part of the machine by the head box of
machine. Wire part of the machine helps to remove water present in the pulp. it increases
the pulp consistency 20 to 24%. A breast roll present just below the head box. First the pulp
passes through the forming board. This is the first step towards the formation of the paper.
It also helps to remove water initially. After passing through the forming board, pulp passes
through hydro foils, vacuum foils and vacuum boxes. These foils and boxes are used to
reduce the water content present in the pulp and helps to increase the consistency of the
pulp. A roll named Dandy Roll is also used in between the vacuum foils and vacuum boxes.
This is the first step towards the formation of sheet of the paper. At the end of the wire
part, sheet of the paper moves towards the press part of the machine. In the press part,
sheet of paper is pressed by applying pressure. The major equipment used in the press part
is called Nipko Press. Next the sheet moves towards the Dryer Part. In the dryer part of the
machine, sheet passes through rotary drums. These rotary drums are heated with the help
of steam. The water present into the steam and sheet dries. There are two types of dryers in

41
the machine. One is the Pre-dryer and second is the post dryer. In the pre-dryer, only a
single felt is used to transfer the sheet while on the other hand in the post dryers two
different felts are used to transfer the sheet. After passing through the dryer part of
machine, sheet moves towards the online sizing process. Again the sheet is dried after
sizing. The process of sizing gives quality to the paper. After passing through the dryer, it
moves towards the calendar. Calendar controls the caliber and thickness of the sheet by
passing in between the pressure rolls. Next the sheet moves towards the pope where a roll
is winding and sheet is collected on that roll.
Calculation for the flow and head on the Machine:

Flow Calculation:
Flow (lit/min) = {Speed(m/min) x Deckle(m) x Grammage(g/m2)} / {Consistency (g/100ml) x
10}
Head Calculation:
2gh = V2
h = V2/2g
where:
h = head box head of machine (m)
V =Machine Speed (m/min)
g = Acceleration due to Gravity (m/sec2)
Through put = Machine Speed x Deckle x Grammage

Major parts of the Machine:

There are three major parts present on the machine.

Wire Part:
After the head box pulp is delivered to wire section through forming board. This section through
forming board pays basic role in the sheet formation since the quality of paper product and its
suitability for the market place is often determined by formation. The wire allows the water to
drain away from the stuff, leaving a fibrous mat that is carried toward the press section.
The purpose of the wire section of the paper machine is to:
 Receive diluted stock from the Head box
 Remove water from the fibers
 Generate the proper activity (turbulence) to ensure a good, even formation of the
fibers throughout the sheet
The wire removes water from the sheet, increasing consistency from less than 1% to 20% off
the couch roll. It is important that dewatering of the sheet is maximized on the wire,
because it is more economical than on the press and dryer sections.
WIRE COMPONENTS:
The wire accepts and supports the stock coming from the slice on the head box. Wire
components drain water from the sheet so that it is strong enough to withstand the forces
that are exerted on it without breaking in the press section.
i. Breast roll
ii. Forming board
iii. Foil boxes
iv. Vacuum foils

41
 v. Flat boxes
vi. Water Cutters
vii. Dandy roll
viii. Couch roll
ix. Forward drive roll
x. Guide roll
xi. Stretch roll

42
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Press Part:
The primary objective of pressing is to remove as much water as possible mechanically
before the sheet enters the dryer section. In addition, the press section consolidates the
web by forcing the fibers closer together without harming or degrading the quality of sheet.
There are two main causes of press part:
i. Water removal
ii. Consolidation the web
The press operation is an extension of the water-removal process that starts at the paper
machine forming section. It is far more economical to remove water by mechanical means
than by heat. Water removal should be uniform across the machine so the pressed sheet
has a level moisture profile when it enters the dryer section.
Sheet consolidation is a crucial phase of papermaking. It is here that the fibers are forced
into close contact so that good fiber-to-fiber bonding develops during drying. If the
consolidation phase were to take place after the dryers, the product would invariably be
weak and bulky.
Press section equipment is important in terms of mill economics. It is far more economical
to remove water mechanically in the press section than to produce steam and remove
water through evaporation in the dryer section.
Water Removal:
Pulp leaves the head box at less than 1% consistency. Initially, water removal from the
sheet is performed easily and readily. However, as sheet consistency increases, the removal
of water becomes gradually more difficult and more expensive in terms of both the capital
and operating costs.
As the sheet travels down the forming table, the forces of gravity, vacuum, and centrifugal
force bring the sheet from the low consistency to about 18% to 20% consistency.
The gravity dewatering is the most economic means of removing water. At a certain point,
the water can no longer be removed by gravity or vacuum, so a mechanical compression
must be applied. The vacuum and the air flow it generates will eventually no longer be able
to remove water since it is not free water, which means it is bound in some way to the
fibers.
An attempt is made to maximize the sheet dryness out of the press section with the value
varying by grade. Some press configurations on specific grades have been able to achieve
dryness in excess of 50%. In fine papers, the sheet consistency after the last press varies
from about 35% to 45%.
The water that remains in the sheet after the last press must be evaporated by means of
steam-heated dryers. The drying of paper is a comparatively long and expensive
process. The figure below represents the relative cost of water removal in each section of
the paper machine.
The sheet leaving the former is about 80% water. Some of this water is carried in the void
areas between the fibers, and the remainder is carried in the fibers. The press loads are
normally increased in each successive press, but as the sheet dries, the water becomes
harder to remove.
Paper Consolidation:
By raising the solids content of the sheet, the tensile strength of the sheet is significantly
increased. The tensile strength is needed to minimize sheet breaks on fast machines.

44
The wet pressing improves machine operation, and efficient pressing makes the machine
more economical to operate, but it also changes the sheet characteristics, such as:
 Smoothness
 Tensile Strength
 Density
 Thickness
 Tear strength
The moisture profile must also be uniform with a uniform basis weight profile. If the
moisture profile is non-uniform, the weight profile is usually adjusted to compensate, and
this can result in over drying, increased cost, poor operation, and off-quality paper.
Prior to the press section, the fibers in the sheet have not made good fiber-to-fiber bonds.
The consolidation that occurs in the press section is critical to the final strength of the sheet
after drying. The pressing process mechanically forces the fibers into close contact. This
results in good fiber bonding. The well-bonded sheet is able to travel through the rest of
the machine without breakage.
In a press nip, the wet web is pressed between two rolls, which may be separated by either
one or two press fabrics. The water that is pressed out of the sheet either goes through the
fabrics and into the voids in the press rolls or is absorbed by the press fabric. The water that
is absorbed by fabric is carried by the press fabric to the Uhle boxes, where it is removed by
vacuum. The water that finds its way through the fabric to the press roll is either doctored
off the roll surface, thrown out by centrifugal force into a saveall, or vacuumed into the roll
(press suction roll).

45
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Dryer Part:
Dryer part is the heaviest part of any machine. There are more than thirty rotating drums
that are used for the drying purpose. These drums are heated with the help of steam which
is supplied by the boiler. There is a complete lining system within the rotating tank that
accepts the steam and drain out the liquid water. It is to be noted that each dryer must have
the speed according to the movement of the sheet given by the previous parts.

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49
Difference between Paper and Board Machine:
To know the difference between paper and board machines, we first need to know the
difference between paper and board. Paper is a single layer product and board is a
multilayer product. Board machine is different from paper machine due to multi-layers of
board. Board machine of century paper mill is producing three layers board. The major
difference that is present in the start of the machine is number of head boxes. There are
three head boxes for each separate layer. One is for top layer, second is for back layer and
third head box is for filler. Usually the mid layer or filler is made of waste paper while on the
other hand top and back layers are made of fresh wood pulp. In the dryer part of the board
machine, yankee is the major part of dryers. Yankee has the same objective for drying but
the main importance of yankee is due to its large cross sectional area provided for the
drying of board. Infrared heating system is also installed on the machine for drying purposes
just after the online coating process. I have added a picture to show the differences
between paper and board machine.

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COATING PLANT:
Board that is manufactured in the machine hall is brought to the coating plant. Coating is
done to enhance the quality and to give an extra shine to the paper or board. Another
purpose of coating is to increase the gramage of board round about 20 g/m2 to 30 g/m2

Objective:
The objective is to maintain the quality of the board according to the requirement.

Preparation of chemical:
There are two steps for coating of board and for each step, chemicals are prepared
separately.
For pre coating the names and quantity of the chemicals are given below.

No. Names Quantity (Kg) Used as

1 No.2 CaCO3 1200 Pigment

2 Poly salt S 5 Dispersant
3 Caustic 1 pH Controller
4 Hydro carb - 90 375 Pigment
5 No.2 China Clay 375 Pigment
6 Titanium dioxide 50 Pigment
7 Binder 600 Binder
8 Sterocoll FD 26 Thickener
9 Busan 1078 1 Preservative
10 Etingal – S 1 De-foamer

All the above chemicals are added into the given sequence in the mixing tank. An agitator
works continuously in the mixer and mixes all the chemicals to make the solution
homogeneous. The preparation time for the final product is one hour and thirty minutes. In
the last step the chemical moves to the storage tank. Final product must have the following
qualities.
1. 62% to 63% solid contents
2. 11g/m2 to 12 g/m2 coat weight
3. 500 cps to 1000 cps viscosity
For top coating the names and quantity of the chemicals are given below:

No. Names Quantity (Kg) Used as

1 Water 500 liters Solvent
2 Poly salt S 10 Dispersant
3 Caustic 1 pH Controller
4 Anti-mussol 1 Anti foam
5 Leucopher U60 14 OBA
6 Hydro carb - 90 625 Pigment
7 No.1 China clay 1250 Pigment
8 Sterofan 125 Plastic Pigment
9 PVA GL-05 1 Rheology modifier

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10 Binder 620 Binder
11 Carta-bond 20 Synthetic Insolubilizer
12 Sorbitol 10 Stabilizer
13 Sterocoll FD 7 Thickener
14 Busan 1078 1 Preservative
15 Etingal - S 1 De-foamer

All the above chemicals are added according to the given sequence into the mixing tank. An
agitator continuously works in the tank to make the solution homogeneous. The
preparation time is given up to 1.5 hours and finally the chemical transfers to the storage
tank.
Standard product must have the following properties.
1. Solid Contents 62% to 63%
2. Coat weight 14 g/m2 to 15 g/m2
3. Viscosity 1800 cps to 2300 cps

Process:
First of all, the chemical is brought into a chest with the help of pump. There is another
pump that shifts the chemical to the high pressure filter. It helps to obtain the better quality
of the chemical after removing the reject. The roll of paper is attached to the un-winder.
After passing through different rolls, the paper is pressed between two rolls. Next the paper
moves towards the pre coating stand. It has two rolls and chemical for coating is applied
here to the paper. A metallic plate is attached to the roll that controls the quantity of
chemical stick to the paper. As the process is continuous so the paper moves towards the
next step of coating. The paper reaches on the Top coating stand. Same process is revised
and paper moves towards the dryers. There are total five tunnel dryers working on the
coating machine. Steam is used to heat the metallic plates of the dryers. The phenomenon
of heat exchanging happens and sheet of the paper is dried. After passing through the
tunnel dryers, sheet moves towards the rotary drum dryers. These are the same dryers that
were used in the paper machine. Steam is used to heat the dryers. Sheet of the paper
passes through these dryers and moves towards the pope. The coated sheet is packed on
the roll and forwarded towards the finishing plant.

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BOX PLANT:
Box is basically a combination of more than one layer of paper and board. In box plant of
Century Paper and Board Mill, two types of boxes are produced. One is three layers box and
the other is five layers box.

Objective:
The objective is to produce the three and five layers boxes continuously while maintaining
the quality according to the demand of customer.

Preparation of Glue:
The major component that is used in the box plant is glue. It helps to stick the layers of
board with channels of corrugators. The procedure for the preparation of glue is discussed here.
First of all, 180 liters of water is taken in a tank. The tank is known as Primary Tank. The temperature
of 60 to 65 oC is maintained in the primary tank. 60 kg of Starch Sure bond (Corn Starch) is added
into the water. The mixture is agitated continuously in the tank. After 5 to 10 minutes of mixing, 17
kg of caustic soda is added in the breaks. Caustic Soda is added in 20 to 25 minutes. Now 480 liters of
water is taken in another tank. This tank is known as Secondary Tank. Temp of 38 to 39 oC is
maintained in the tank. Then 5.5 kg of Borax is added. Next 250 kgs of Coragon Maize (Corn) Starch
is added to the solution. The mixing time of 15 minutes is given to the solution.
Now two solutions are prepared. Add the solution of primary tank into the secondary tank slowly in
25 minutes. The agitator also works slowly but continuously during the mixing process. Now the
reaction time is given to the solution upto 15 minutes. Viscosity is checked and that should be 60 to
70.

Quality tests for the Glue:

Following tests are done to check the quality of glue in the lab.
i. Viscosity Test
ii. Jell Point Test
iii. Concentration of solid contents

Corrugators Plant:
It is a plant where box is prepared. First of all, according to the demand it is decided that
either we have to prepare three layers box or five layers box. I am going to discuss the
preparation of five layers boxes for the reader's understanding. No. of corrugators are also
selected according to the demand and the budget requirement. If the budget is high the no.
of corrugators in one meter of the paper will be large and vice versa.
Firstly three layers box are prepared and secondly another two layers are pasted with the
help of Glue. So for the preparation of three layers box, a role of straight paper is attached
on the machine. There are two types of straight papers. One is the Duplex Liner and second
is the Test Liner Paper. And this is selected according to the demand. Just above the role of
the straight paper there is another role of paper attached with the Corrugator Roll. The
sheet of that paper passes through the Corrugator roles and channels of the corrugators are
produced. This sheet of the paper passes through the different roles and come towards the
Single Facer No.1. The straight paper is passed through the preheater where a steam dryer
is used. The temperature and pressure within the heat dryer is maintained at 140 to 180 oC
and 9 to 13 bars respectively. Next sheet moves towards the Single Facer No. 1. Another
role of the Corrugator Medium paper is attached on the opposite side of the Single Facer
No. 1. That sheet of the paper also passes through another preheater present on the

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opposite side of the Single Facer No.1 and after passing through the preheater, this sheet
also moves towards the Single Facer No.1. This Single Facer No.1 combines these three
layers of the paper with each other in such a way that the corrugator paper in the middle
and straight paper on the top and bottom sides of the corrugator paper. These layers are
attached permanently with each other due to the presence of the Glue. After this
formation, if one meter of paper has 120 to 130 channels of corrugators we may call this
sheet as C-Flout. It is measured according to International Recognized Standards. After this
the sheet moves towards another operation. There are another two roles of different
papers. The sheets of the papers are attached with the help of glue and next this layers
sheet of the paper moves towards the previously manufactured three layers sheet. Both the
layers pass through the Duplex Heater separately on different roles. After passing through
the Duplex Heater the temperature of the sheets increases and on the next roles the glue is
pasted on the sheets and these two sheets make their way towards turning roles. Turning
roles presses these sheets and the five layers sheet moves towards the Double Baker for
heating. After the Double Baker, sheet passes through the Slitter. Slitter is a round cutter
that cuts the sheet length according to the measurements given by the computer. These
cuttings are made according to the demand of the customer. And after that it moves
towards the storage compartment.

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