Paper Recycling Technology

Dr. Richard A. Venditti

Dept. of Wood and Paper Science

North Carolina State University
 Dr. Richard Venditti
z Faculty member in the Wood and Paper Science Dept at
NCSU
z PhD in Chemical Engineering, BS in Pulp and Paper Science
and Chemical Engineering
z Research areas:
Paper recycling
Utilization of forest/agricultural materials for new applications
z Classes Taught:
Process Control
Unit Operations for Pulp and Paper
Paper Recycling (Distance)
z Director of Hands On Workshop for Pulp and Paper Basics,
co-sponsored through TAPPI, on-campus and in-mill
z Technical services projects for over 20 companies
 Dr. Richard Venditti:
Research Projects in Paper Recycling

z The detection of adhesive contaminants, tracking through

mills
z The changes in fibers upon recycling
z Automatic sorting of recovered papers
z Flotation deinking surfactants
z Agglomeration deinking
z Screening phenomena and pressure sensitive adhesives
z Deposition of adhesive contaminants
z Alternate recycling processes
Ultrasonic deinking
Supercritical carbon dioxide to extract wax from OCC
 Course Outline

z The Paper Recycling US Industry

z Contaminants
z Effect of Recycling on Fibers/Paper
z Unit Operations
Pulping,Cleaning, Screening, Washing,
Flotation, Dispersion, Bleaching,
z Image Analysis, Deinking Chemicals
z System Design
 Course Activities
z Viewing of the Videos of Lectures
Base lectures by Venditti
Guest lectures from industry leaders
z Reading assignments from Recycled Fiber and
Deinking, Book 7 of the Series: Papermaking
Science and Technology
z Reading assignments: selected research papers
z Homeworks: 6 assignments
z Final Project: Literature Review and Research
Proposal
 Course Objectives

z Broad understanding of paper

recycling science and technology
z Develop an expertise in a selected
research topic in paper recycling
 Critical Issues in Recycling:

z Going deeper into the wastepaper stream

=> poor quality material
z Meeting paper specifications, which are
getting more stringent
z Increased demands for paper from
emerging countries
z Environmentally benign operations at the
same time both of the above are being
satisfied
Recovered fiber, not
Wastepaper
 Recovered Fiber, not
Wastepaper

z Learning objectives
Understand the trends of paper recycling in
the industry
Identify the major grades of recovered fiber
Identify the major types of contaminants in
recovered fiber
 Global Paper and Board Demand
Overall Positive Growth

Slide by: Richard B. Phillips, PhD

Source: RISI
Adjunct Professor WPS NCSU
 GDP Growth Major World Economies
China, Eastern Europe Dynamic Growth Regions

China

Eastern
Europe

Slide by: Richard B. Phillips, PhD Source: RISI

Adjunct Professor WPS NCSU
 Paper & Paperboard Consumption vs GDP
Increases with Wealth Levels Off

Slide by: Richard B. Phillips, PhD

Adjunct Professor WPS NCSU Source: 2007 FAO Forest Resource Assessment
 Asian Supply has Grown to Match Demand
Little Incentive for others to develop export strategy

Slide by: Richard B. Phillips, PhD

Source: RISI
Adjunct Professor WPS NCSU
 Use of Recovered Paper
Growing in China, Europe flat in USA

Slide by: Richard B. Phillips, PhD

Source: RISI
Adjunct Professor WPS NCSU
 Use of Recovered fiber Flat in USA
Moving increasingly to Asia

Slide by: Richard B. Phillips, PhD

Source: RISI
Adjunct Professor WPS NCSU
 Recycled Fiber Definitions
z Secondary Fiber: fibers that have previously been
used in a manufacturing process and have been
reclaimed as raw material for another process.
z Pre-consumer waste: any waste, printed or
unprinted, generated in the fabrication or
conversion of finished paper. Before use by a
consumer as a final end product.
z Post-consumer waste: Paper that has passed
through the end usage as a consumer product.
z Internal broke: off-specification paper that is
repulped and used at the same site, not considered
secondary fiber.
 Recycled Fiber Definitions
z Recovery Rate (RR)
how much paper is diverted from landfill
Tons of Wastepaper Collected
RR = 100%
Tons of Paper Consumed

z Utilization Rate (UR)

fraction of recycled fibers contained in paper

Tons of Wastepaper Consumed at Mills

UR = 100%
Tons of Paper Produced
 Supply1 Recover Recover
(000 ed (000 y Rate2
tons) tons)

1993 91,538 35,460 38.70%

1994 95,718 39,691 41.50%

1995 95,971 42,189 44.00%

1996 94,529 43,076 45.60%

1997 99,557 43,989 44.20%

1998 101,183 45,076 44.60%

1999 105,316 46,818 44.50%

2000 102,810 47,311 46.00%

2001 97,395 46,996 48.30%

2002 98,949 47,645 48.20%

2003 98,016 49,255 50.30%

2004 101,882 50,287 49.40%

2005 99,618 51,272 51.50%

2006 100,198 53,488 53.40%

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
Utilization of Recovered Paper in the US

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
 Paper Paper
Recovered Landfilled
(000 tons) (000 tons)

1993 35,460 38,399

1994 39,691 38,118

1995 42,189 36,118

1996 43,076 34,331

1997 43,989 37,174

1998 45,077 38,329

1999 46,818 41,255

2000 47,311 39,568

2001 46,996 35,894

2002 47,645 37,601

2003 49,255 36,032

2004 50,287 39,107

2005 51,272 36,846

2006 53,488 35,660

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
 Pkging Material
Recovered, 2006

Paper 22.9
Glass 2.8
Metal 2.2
Plastic 1.3
Other 1.3
Total 30.5

(000,000 tons)

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
Source: AF&PA, 2006 Recovered
Paper Annual Statistics
 Exports and Imports of Recovered Paper

18

16 Exports
Imports
14
Millions of Tons

12

10

0
1990 1992 1994 1996 1998 2000 2002 2004 2006
Year

Recovered Paper Statistical Highlights, 2005 Edition, AF&PA

 Major Recovered Paper Grades

z Mixed Papers: mixed papers, low quality office

waste, magazines, catalogs, telephone directories,
recycled boxboard cuttings, tissue paper
converting scraps if mainly composed of recycled
fiber, mill wrappers, specialty grades, all other
grades not specified
z Newspapers: old newspapers, special news,
groundwood computer printout, coated
groundwood sections, publication blanks, mixed
groundwood and flyleaf shavings
 Major Recovered Paper Grades

z Corrugated: old corrugated containers, container

cuttings, kraft paper and bags, old solid fiber
containers, kraft bag clippings, carrier stock and
its clippings
z Pulp Substitutes and high grade deinking:
bleached chemical pulped office papers and CPO
suitable for deinking, or as a pulp substitute if
unprinted, bleached sulfite and sulfate cuttings
including tissue paper converting scrap if
predominantly composed of bleached chemical
pulp fiber, coated book stock
 Grades of Recovered Paper
z Mixed Paper z Publication Blanks
z Super Mixed Paper z Flyleaf Shavings
z Boxboard Cuttings z Coated Soft White Shavings
z Mill Wrappers z Hard White Shavings
z News z Hard White Envelope Cuttings
z Special News z New Colored Envelope Cuttings
z Special News De-ink Quality z Semi Bleached Cuttings
z Over-Issue News] z Manila Tabulating Cards
z Magazines z Sorted Office Paper
z Corrugated Containers z Sorted Colored Ledger
z Double Sorted Corrugated z Manifold Colored Ledger
z New Double-Lined Kraft Corrugated Cuttings z Sorted White Ledger
z Used Brown Kraft z Manifold White Ledger
z Mixed Kraft Cuttings z Computer Printout
z Carrier Stock z Coated Book Stock
z New Colored Kraft z Coated Groundwood Sections
z Grocery Bag Scrap z Printed Bleached Board Cuttings
z Kraft Multi-Wall Bag Scrap z Misprinted Bleached Board
z New Brown Kraft Envelope Cuttings z Unprinted Bleached Board
z Mixed Groundwood Shavings z #1 Bleached Cup Stock
z Telephone Directories z #2 Printed Bleached Cup Stock
z White Blank News z Unprinted Bleached Plate Stock
z Groundwood Computer Printout z Printed Bleached Stock

Scrap Specifications Circular, Guidelines for .Paper Stock

By: Institute of Scrap Recycling Industries, Inc.
 Definitions
z Outthrow:
all papers that are so manufactured or treated or are in such a
form as to be unsuitable for consumption as the grade
specified
z Prohibitive Material:
material in excess of specified maximum make the recovered
paper unusable as the grade specified
Any materials that may be damaging to the equipment

z News, De-ink Quality #7. Consists of sorted, fresh

newspapers, not sunburned, containing not more than the
normal amount of rotogravure and colored sections.
Prohibitive Materials None Permitted
Total Outhrows may not exceed of 1%
Scrap Specifications Circular, Guidelines for .Paper Stock
By: Institute of Scrap Recycling Industries, Inc.
 Recovery of Paper and Paperboard (000 tons)
Grade-Year At Export/ Total Total RR%
Molded Prod
mills Recov Supply
OCC-1993 13.5 2.3/0 15.9 26.9 59.1
OCC-2006 20.0 5.2/0 25.2 33.0 76.4
ONP-1990 3.8 0.9/0.7 5.5 15.9 35.0
ONP-2006 5.5 2.5/1.5 9.6 13.2 72.3
Mixed-1993 5.3
Mixed-2006 12.7 49
Pulp Sub-1993 3.3 100
Pulp Sub-2006 2.4 100
HG DI-1993 3.7 100
HG DI-2006 3.6 100

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
 16.4 million t/yr 7.0 million

Source: AF&PA, 2006 Recovered

Paper Annual Statistics

4.2 million 3.5 million 1.6 million

 Ctn Bd 15,153
NP 0
Packg 398
Ind Cvt
Paper Bd 3,946
Tissue 167
Export 5,218
Other 303
Total 25,185

(000 tons)

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
Ctn Bd 1
RecPBd 1,172
Tissue 698
News 3,213
P&W 353
Other 1,615
Export 2,513
Total 9,565

(000 tons)

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
Newsprint 380
Tissue 2,680
P&W 1,200
Other 1,000
Export 7,300
Total 15,690

(000 tons)

Source: AF&PA, 2006 Recovered

Paper Annual Statistics
Recovered Paper Prices, $/ton
US Paper Spot Market
Prices May 24, 2007
Corrugated Container 105
Old Newsprint 85
Boxboard 71
Old Magazines 19
Mixed Paper 28
Sorted Office Paper 104
White Ledger 266
White Envelope 370 ScrapIndex.com
 Recovered Paper Prices
450

400
Sorted W hite Ledger
350
ONP
300 OCC
Mixed Paper
250
$/ton

200

150

100

50

0
1970 1975 1980 1985 1990 1995 2000 2005
Year
 Cost of DIP

z System
MOW to deinked, bleached pulp (DIP)
Flotation (2), washing, oxidative bleaching,
complementary processes
Produce 200 ODTPD
Yield = 67%

z Total Capital Cost Installed= $42 MM

z $6 MM/yr depreciation for 7 years
z MOW Cost =$220/ton delivered
 Cost of DIP: Variable Costs
Description Quantity Unit Unit Cost, $ Contribution,
$/ton
Fiber 1.5 ton 220 330
NaOH 0.024 ton 400 9.6
Peroxide 0.024 ton 600 14.4
Sodium Silicate 0.022 ton 500 11.0
Flotation Aid 0.0027 ton 1000 2.7
Sludge Dewater Polymer 0.00115 ton 1200 1.4
Clarifier Flocculant 0.00014 ton 1600 0.2
Clarifier Bentonite 0.00085 ton 1600 1.4
Electricity 310 kWhr 0.045 14.0
Steam 790 kPa 0.25 mton 6 1.5
Waste Water Treatment 1.236 m3 0.53 0.7
Waste Disposal 0.984 mton 36 35.4
Process Water 4.8 m3 0.53 2.5
Total Variable Prod. Cost 424.8
 Cost of DIP: Fixed Costs

Fixed Costs $ Per Year $ / ton

Maintenance 4,000,000 57
Labor 2,000,000 29
Operating Materials 1,700,000 24
Depreciation (7 yr
straight line) 6,000,000 86
Business Overhead 1,100,000 16

Total Fixed Costs, $/ton 211

 Cost of DIP: ROI
Total Costs, $/ton produced 636
Total Costs per year, $ 44,532,716
Selling Price of ton DIP, $/ton 600
Income, $/yr 42,000,000
Profit before taxes, $ -2,532,716
Taxes (25%) -399,537
Profit after taxes, $ -2,133,179

ROI (%) -1
 Paper Recycling Review
z Of the about 100 million tons of paper consumed in the US, ___ % is recycled

z Name 3 contaminants in recovered paper: _________________

_________________ _______________

z Name 4 major categories of recovered paper

____________ ___________ ___________ ____________

z ____________ is a recycling operation used to remove large contaminants

z ____________ is a recycling operation used to remove heavy contaminants

z Name the two major de-inking operations: _________ and _________

z The largest variable production cost in paper recycling is typically _____________

z True or False. Basically, all recycle systems have the same # and type of unit
operations.
z The yield of useable fiber
A. Is about 100% for all systems
B. Ranges from 20-80% depending on the system
C. Ranges from 60-94% depending on the system
D. Is 50% for all systems
Common Contaminants in
Waste Paper
 Common Contaminants in Wastepaper

z Large Junk
metals: nuts, screws, foil, cans
plastics: films, bags, envelopes
dirt
cloth, yard waste, leather, etc.,

z Inks & toners

z Stickies
z Coatings
z Fillers
z Papermaking additives
 Inks & Toners
Type Component Drying System Ink Resin Film Particle Size End Products
(microns)
Simple Letter Pigment + Absorption Weak 1-15 Letterpress
Press Mineral Oil into Web Early
Newsprint
Newsprint and Pirgment + Penetration of Soft Film 2-30 Newsprint,
Offset Soft Resin & Vehicle into Books
Mineral Oil Web + Resin
Oxidation Hard Film We Offset,
Letter Press
Rotogravure Pigment Solvent Hard Film 2-250 Magazines,
+Hard Resin & Evaporation Catalogues
Solvent
Flexographic Pigment + Amine Water N/A Newsprint
Resin & Water Absorption, Resistant Film inserts,
Emulsification Evaporation Corrugated
UV Cured Pigment UV Non swelling, 50-100 High Speed
+Monomer Photopolymeri Non saponif. Coated
zation Hard Film Papers
Specialty Various Heat set or Hard, 40+ Xerography
Pgiments and Other Coherent Laser Printers
Rosins Films Electronic
Forms
 Stickies
z Currently the most challenging problem in paper recycling
z Stickies: contaminants in pulp that have the potential to
deposit on solid surfaces
z Typically organic materials:
Man made stickies: adhesives, coatings
Natural stickies: pitch, resins..
z May deposit on papermachine wires, press felts, dryer
fabrics, calendar rolls and cause significant down-time on
machine
z Are hard to remove in recycling due to often having a
neutral density, and an ability to flow and change shape
 Coatings as a Contaminant

z Coatings typically contain inorganic fillers and

polymeric binders
Coating binders can behave as stickies,
sometimes termed white pitch
Coating fillers are washed out of the pulp and
lower the overall yield of the recycling process
z Board is often coated with wax
Wax can cause recycled paper to be weak and
slippery
Wax can deposit on machinery
 Fillers as a Contaminant

z Fillers are washed out of the pulp and lower

the overall yield of the recycling process
Common fillers:
clay
CaCO3
TiO2
Fillers are not desirable in some paper
products such as tissue paper
 Papermaking Additives

z Additives such as starch, gums, retention aids, etc.,

are lost during recycling and lower yield
z Additives such as dyes can cause the fibers to not
make color specifications, this is also a problem with
fluorescent dyes
z Wet strength additives cause the paper to be
unpulpable in many cases, making the entire paper
product unusable and thus, a contaminant
Contaminant Removal
Contaminant Size vs. Removal Efficiency
 Recovered fiber, not
Wastepaper: Review-Quiz

z True/False: The percentage of paper that is

recycled overall is about 50%
z The four major grades of recovered paper are:

z True/False: Basically contaminants are

similar in shape, strength, density, etc.,
Effect of Recycling on Fiber
Properties
 Effect of Recycling on Fiber
Properties

z Learning objectives
Understand how recycling affects
chemically pulped fiber
Understand how recycling affects
mechanically pulped (lignin containing)
fibers
Effects of Recycling on Chemical Pulps

z Mechanical damage
z Loss of fines
z Hardening and stiffening (hornification)
z Weakening of bonding
less fiber conformability
less absorptive
loss of hemicellulose

z Decreased cleanliness
 Effect of Chemical Pulping

Fiber wall structure as in the tree. Chemical pulping removes

lignin from cell wall
 Hornification: Irreversible

A Wet kraft fiber before drying

B 30% consistency (Irreversible processes begin to occur)
C 30-75% consistency
D >75% consistency
 Hornification: Irreversible

Never Dried Fiber Swollen Dried Collapsed

Fiber With Water Fiber - Hornified

Rewetting Does not Re-swell

Effects of Recycling on Chemical Pulps
 Effect of Recycling on Chemical Pulps

z Chemically pulped fibers that have never been dried:

have the ability to swell with water which makes the fibers flexible
can be mechanically treated (refining) to increase the flexibility
z The flexible never dried fibers are able to conform in the paper
sheet which increases the fiber bonded area making strong
paper
z When dried, the fibers become rigid, termed hornification
 Effect of Recycling on Chemical Pulps

z Previously dried fibers, upon exposure to water, do not swell and

do not become flexible
z These rigid fibers break upon refining: causing fines
z When paper is made, the rigid fibers do not conform in the paper
sheet and the resulting low fiber bonded area produces a weak
sheet

Flexible Fibers Stiff fibers

Effect of Recycling on Mechanical Pulps

80 % 70 % 60 %

20% 30% 40%

1st Use 2nd Use 3rd Use

Effects of Recycling on Mechanical Pulps
 Effect of Recycling on Mechanical Pulps

z Wood containing pulps from mechanical pulping processes have

lignin (a three-dimensional crosslinked polymer) which makes
fiber walls stiff and deters water swelling
z The stiff, somewhat round cross section fibers make paper with
low fiber bonded area and weak fiber bonds
z Therefore, the strength of never dried mechanical pulps is
generally lower than of never dried chemical pulps
z Recycling may improve properties of mechanical pulps by
flatening and flexiblizing the fibers
z Different behavior than chemical pulps on recycling
 Effects of Recycled Fibers on the
Papermaking Process

z Lower freeness: decrease machine

speeds or add drainage aid
z Lower paper strength: more sheet breaks
z Low efficiency of chemical additives (fines
and anionic trash)
z Increased deposits
z Decreased cleanliness
 Paper Strength vs. Number of Times Recycled
(Howard and Bichard, 1st Res Forum on Recycling, Oct 1991, CPPA)

10

8
Burst Index (kPa m^2/g)

4 Bleached Kraft (Chemical Pulp)

3 Groundwood (M echanical Pulp)

0
0 1 2 3 4 5
Number of Recycles
 Effect of Recycling on Fiber
Properties: Review Quiz

z True or False: A pulp produced for

newsprint using a CTMP process should
have almost equal or better strength
properties after recycling.
Paper Recycling Operations

An Example: OCC Recycling

 Paper Recycling Operations
An Example: OCC Recycling

z Learning objectives
Identify
major sub-operations in a typical
OCC recycle mill
Understand the purpose and how each
sub-operation works
Why is contaminant removal so difficult?

z Contaminates vary by
size
density
shape
surface properties
solubility
strength
z No single separation device can remove all of the
different types of contaminants
z Thus, recycling processes consist of many sub-
operations that complement each other
 Major Recycling Steps
z Pulping
z Cleaning
z Screening
z Deinking --- used to produce printing or tissue
Washing
Flotation

z Dispersion and Kneading

z Bleaching --- used to produce printing or tissue
z Water Treatment
z Solid Waste Handling
 Example: An OCC Recycling Process

z In the next section, we will take a look at the sub-

operations in an OCC recycling process
z The process has the following operations:
Pulping
High Density Cleaning
Screening
Forward Cleaning
Through Flow Cleaning
Thickening
Dispersion
Water Clarification
Pulping of Recovered Paper
 Pulping of recovered paper

Definition

Pulper : A device whose main objective is to

convert recovered paper into a slurry of well
separated fibers and other waste paper
components.
 Pulping of recovered paper
The pulping operation is the first and probably the
most critical operation in paper recycling.

Proper pulping is a requirement if unit operations

downstream (cleaning, screening, flotation..) are
to be effective.

Incorrect pulping conditions can irreversibly damage

fibers making them inappropriate for papermaking
uses.
 Pulping
Main Function : Disperse recovered paper into separated fibers.

Several sub-objectives that are also important:

1. Detach contaminants from fibers.
2. Mix paper with water and chemicals at the correct ratios.
3. Maintain contaminants as large as possible to aid subsequent
removal processes.

4. Avoid damage to the fibers (fiber cutting).

5. Removal of large debris from system.
 Basic Pulping Categories :
Batch vs. Continuos Pulping

Batch Pulping : The feed recovered paper, water

and chemicals are all charged at the beginning of
the process and are removed all at once at the end
of the process. The batch process is repeated.

Continuos Pulping : The feed recovered paper,

water and chemicals are continuously added to the
pulper and at the same time, the pulped product is
also being continuously removed.
 Basic Pulping Categories :
Low vs High Consistency
Consistency (solids) 100 * solids wt =%K
solids wt + liquid wt

Low Consistency Pulping: Typically

from 3-6 % K. Produces a relatively
easily pumpable fluid. The fluid is
pourable.

High Consistency Pulping: Typically

from 8 - 18 % K. Produces a thick,
slurry that will not flow under the
influence of gravity alone.
 General Parts of a Pulper

z 1. Wastepaper feed method (conveyor).

z 2. Pulper tub.
z 3. Rotor - spinning device for agitation, mechanical energy input
z to the system.
z 4. Baffles - protrusions to assist in mixing and prevent swirling.
z 5. Dilution water.
z 6. Pulper exit.
 Forces in a Pulper

z Mechanical Forces
These are caused when
the fast moving rotor
impacts material in the
relatively slower body of
pulp stock around it.
z Faster rotor speeds
cause more intense
mechanical forces in the
pulper.
 Pulper Forces
z Hydraulic Forces :
z These are caused by the
motion of fluid that is caused by
the spinning rotor (not by the
direct impact of the rotors).
z When two adjacent portions of A
a fluid are moving in different
directions ( or at different
speeds) a shear force is
present. An example in the
picture would be at point A.
 Forces in a Pulper
z Attrition
z Mechanical shearing forces that
occurs between the moving
rotor and a static extraction
plate near the rotor.
z The rotor forces fiber bundles
between the rotor and extraction
plate. Intense hydraulic forces
act to cut the fiber bundles and
fibers. This can cause
significant damage to fibers.
z Used only for low % K pulping
because the pulp must be
screenable.
 Low Consistency Pulping
z Consistency from 3 -6 %.
z Low profile rotor that
rotates at high speeds.
z Motion of rotor causes a
vortex of pulp stock. The
baffles are used to
improve mixing.
z High mechanical force due
to impacts of rotor can
damage fiber and break
contaminants.
 Pulper Types: High Consistency
z Typically 8-18 %.
z High profile rotor used. The
helical screw type rotor is
needed to pull down the
non-fluid like high % K
stock, from the top to the
bottom of the pulper.
z At the high % K, fiber-fiber
(solid-solid) rubbing
dominates the forces
experienced in the pulper.
 Comparison of Low vs High Consistency Pulping

z Rotor/ tank volume is much higher for

high % K pulping. This is needed to
maintain proper motion of non - fluid pulp
stock at high % K.
z Specific power is higher for high % K due
to the higher viscosity pulp stock that
must be pulped.
z However, the specific power consumption
per ton of paper is significantly lower for
high % K pulping.This is due to high % K
pulping having more tons of fiber for the
amount of same pulping volume as a low
% K pulper. Also, the relatively less
amount of water at high % K pulping
causes less energy to be expended on
moving water.
Comparison of Low vs High Consistency Pulping

z Rotor speed is slower for high % K, causing less

damage to fibers via mechanical forces of rotor.
z Attrition forces are not used for high % K pulping. This
decreases fiber cutting and contaminant breakage.
z RESULTS of above: higher tensile, burst and tear
strength for high %K pulping
z High consistency pulping includes more fiber to fiber
rubbing.
z RESULTS of above: This action increases detachment
of contaminants from fiber surfaces. The detachment
of ink from fibers is especially important for washing
and flotation deinking.
 Comparison of Low vs High Consistency
Pulping

z Printing and writing grades consist of a high content

of fully bleached hardwood and softwood fibers that
are susceptible to damage => gentle high consistency
pulping is preferred
z Further printing and writing grades need ink
detachment => high consistency pulping with lots of
fiber-fiber rubbing is preferred
z OCC recycling, a historically older technology,
typically has low consistency pulping because
unbleached fibers are less susceptible to damage
 Screening and Junk Removal in Pulper
One of the sub- objectives of pulping is to remove large
debris that enters the system.
Examples of large debris :
z wood
z wet-strength paper
z plastics
z baling wire
z nails and bolts
The removal of debris serves two important functions.
z Protects equipment downstream from damage.
z Prevents plugging of downstream equipment.
 Examples of Debris Removal Methods

Different pulpers have different methods to remove debris,

examples of common methods follow.

High Consistency Batch Pulping

z HC pulper with Dilution Zone
z HC pulper with Detrasher

Low consistency Pulping

z Continuos Low consistency pulper with Ragger and junk
tower.
z Continuos Low consistency pulper with a de-trashing
system
High Consistency Batch Pulper with
Dilution Zone
z The pulper is designed so
that during pulping at 15 -
18% K the pulper volume is
only partially full.
z At the end of the pulping
cycle, dilution water is added
to achieve a 5 - 6 % K.
z After dilution, accepted stock
passes through an extraction
plate with holes about 3/4 - 1
inch diameter.
z Finally, large debris is
flushed from the pulper
through a large rejects
opening on the side.
 High Consistency Batch Pulper with
External Detrasher
z The pulper is full at high
consistency during pulping.
z At the end of the pulping dilution
water is added at the bottom of
the pulper diluting the pulp in the
bottom to less than 6 %.
z A large opening on the
bottom/side of the pulper is used
as the exit for the pulper
contents.
z The pulp and debris are
separated by an external
detrasher.
z Note : There is no extraction
plate in the pulper.

Note: drawing not to scale.

 Continuos Low Consistency Pulper with
Ragger and Junk Tower
z Low consistency continuos pulper
typically have an extraction plate
that accepts pulped fibers and
rejects debris and unpulped flakes.
z The extraction plate/ rotor can cause
attrition, resulting in fiber cutting.
z A junker is used to collect
unpulpables such as bolts or rocks.
This debris is thrown out of the
pulper into a junk tower where it is
removed.
z A ragger is also used in many cases
to remove bale wire, strings,
plastics, etc. The ragger is a
continuos rope formed by
entangled debris. The rope is
continously pulled out of the pulper
and cut into sections and disposed.
Common in OCC mills.
Recovered OCC bale storage
Loading OCC bales on pulper conveyor
Wire bale cutter
Pulper conveyor
Bale falling into pulper

Pulper
Ragger removing debris
from the pulper surface
Ragger pulling rejects
out of pulper
Junker Claw
 Continuos Low Consistency Pulper with
Ragger and Junk Tower
z Low consistency continuos pulper
typically have an extraction plate
that accepts pulped fibers and
rejects debris and unpulped flakes.
z The extraction plate/ rotor can cause
attrition, resulting in fiber cutting.
z A junker is used to collect
unpulpables such as bolts or rocks.
This debris is thrown out of the
pulper into a junk tower where it is
removed.
z A ragger is also used in many cases
to remove bale wire, strings,
plastics, etc. The ragger is a
continuos rope formed by
entangled debris. The rope is
continously pulled out of the pulper
and cut into sections and disposed.
Common in OCC mills.
Example Detrashing Process
recycle

Light rejects

Rotor with screen plate

Heavy
rejects

Accepts
 Drum Pulping
z A continuos, high
consistency pulping method.
z Most often used for pulping
old newsprint.
z Consists of an inclined
rotating drum 11 -17 rpm
through which the paper/
pulp travel down. The drum
is very large approximately
10 feet high and 100 feet
long.
High Consistency Drum Pulper

High % K
Zone Screening
Zone
Rejects
Conveyor

Accept
Pulp
 Drum Pulping
Two Zones
z High Consistency pulping zone
z Low consistency pulping zone.
High Consistency Pulping Zone
z Paper ,water and chemicals
added to ^ 15% K.
z Baffles on the walls of the drum
lift the paper and drop causing
defibering in a gentle manner.

Low Consistency Screening zone

z Water is added to dilute stock 3-
4% K.
z Pulped fibers pass through 6
mm holes and are accepted
from the pulper.
z Large rejects continue through
the pulper and are4 discharged
at the end.
 Drum Pulping
Two Zones
z High Consistency pulping zone
z Low consistency pulping zone.
High Consistency Pulping Zone
z Paper ,water and chemicals added to ^ 15% K.
z Baffles on the walls of the drum lift the paper and drop causing
defibering in a gentle manner.

Low Consistency Screening zone

z Water is added to dilute stock 3-4% K.
z Pulped fibers pass through 6 mm holes and are accepted from
the pulper.
z Large rejects continue through the pulper and are4 discharged
at the end.
Overview
Rejects
 Drum Pulping
Paper Feed
Advantages
z Gentle pulping
keeps contaminants
large and minimizes
fiber degradation.
z Simple operation
that includes
screening.
Disadvantages
z High capital cost.
z Not an aggressive
pulping method
(example: cannot
pulp wet strength rejects exit
papers).
 Pulping Summary
z Several methods to pulp
z Main objective: defiberize
z Secondary Objectives:
Remove Large Debris
Detach contaminants
Not destroy fibers
Mix
z Final Thought: If pulping is not done properly,
subsequent processing steps will be
ineffective and product quality will be
unacceptable
High density cleaners
High Density Cleaner: removes large
heavy rejects from pulp

Objective: separate large

heavy contaminants from fibers
to protect downstream
equipment from damage and
pluggage

How it works: centrifugal

forces separate materials
mainly due to density/size
 Light weight
Rejects

Detrasher

Heavy
Rejects out
the back

Feed

Accepts
Example detrashing unit

z Top View

Objective: pulp unpulped

pieces of paper/board and
separate contaminants using a
screen or centrifugal forces to
protect downstream equipment
from damage and pluggage
 Deflakers

Objective: impart mechanical energy to break up flakes of unpulped material.

 Screening
z Screening separates
contaminants based
mainly on size, but
also on shape and
deformability
z Performed by
presenting a barrier
for large
contaminants (slots
or holes) that allow
fibers to pass through
Screening
 Modes of Removal
1. Stiff particles with all 3 dimensions larger than width of
slot or diameter of hole are rejected

2. Stiff particles with one or two dimensions smaller than

width/diameter have a probability of rejection.

Rejection Probability, %

100%

1-dimension (rod)< slot size

50%

2-dimension (plate) < slot size

0%
1 2 3 4 5

Number of screen contacts

 Screening Types and Conditions
Screen Screen Rotor Consistency Range
Type Openings, circumference
mm speed,m/s
MC MC LC
<6% <4.5% <1.5%
Disk Hole 20-30 Yes
2-3

Cylindrical Hole 10-30 Yes

0.8-1.5

Cylindrical Slot 10-30 Yes Yes

0.1-0.4
 Screening

z Types of perforations
coarse holes .110 in or 2.7 mm
fine holes .060 in or 1.52 mm
coarse slots .010 in or .254 mm
fine slots .006 in or .152 mm

z Also, the fibers offer a resistance to passage,

related to the consistency
Example of Disk Screen
Pressure screen
Pressure Screen Principle to Prevent
Blinding of Screen

The leading edge of the

rotating foil accelerates the
stock.

The negative pulse under the

sweeping foil momentarily
reverses the flow, effectively
purging the screen openings.
Pressure Screen Flow
Configurations
 Screen Plates

z Holes

z Slots

z Contoured
 Effect of Reject Rate & Plate
Opening on Screen Cleanliness
Screening Factors
 Screen Performance Variables
z Stock characteristics
fiber type, debris characteristics, debris level
z Screen design
flow configuration, plate cleaning mechanism,
perforation type (holes or slots), rotor speed
z Operating variables
stock flow rate (pressure drop across screen),
feed consistency, reject rate, screen plate
perforation size, stock temperature, dilution flow to
screen
Screening
 Screen Layout:
Always have cascaded screens to save fiber.

Primary Screen
Accepts

Secondary Screen

Tertiary Screen
Rejects
Open Gravity Screen
Summary Pressure Screen:

Objective: separate large

contaminants from fibers

Can act as barrier screen or

probability screen

Typically cascaded to save

fiber

Typical conditions to promote

increased throughput can have
negative impact on cleanliness
efficiency.
Cleaning
 Centrifugal Cleaning

z Remove impurities from the pulp stream

z Centrifugal cleaners remove
metals
inks
sand
bark
dirt
etc.,
 Centrifugal Cleaning

z Principles of operation
Centrifugal cleaner uses fluid pressure to create
rotational fluid motion in a tapered cylinder
Rotational movement causes denser particles to
move to the outside faster than lighter particles
Good fibers carried inward and upward to the
accepted stock inlet
Dirt held in the downward current and removed
from the bottom
 Three Basic Cleaner Types:
z High Density Cleaner: separates very large, heavy
contaminants such as rocks, staples, glass. Used
after pulping (early in the process) to protect
downstream equipment. Diameter = 300-700 mm.
z Forward Cleaners: separates fine, heavy
contaminants such as a sand and inks. Also called
cyclones, hydrocyclones, or cleaners. (Described
above) Diameter = 70-400 mm
z Through Flow Cleaner: separates fine, light
contaminants such as glues, adhesives, plastics,
foam. Also called light-weight cleaners or reverse
cleaners. Diameter = 100-400 mm
 Types of Cleaners: Functional Differences

z Consistency
z HC cleaner: 2-4.5% K, MC: 1-2, LC: 0.5-1.5

z Centrifugal Acceleration (acceleration due to gravity =9.8 m/s2)

z HC cleaner: <60 g, MC: <100g, LC: <1000 g

z Reject Rate by mass/stage

z HC cleaner: 0.1-1% , MC: 0.1-1, LC: 3-30
Centrifugal Cleaner: Features and Flow
 Bank Arrangement of Cleaners

Accepts Header

Feed Header

Rejects Header

Several cleaners are piped in parallel fashion.

A single cleaner is not capable of providing enough
through put for typical industrial flows.
Forward Cleaners
 Cleaners

z Canister
Cleaners Pump
Cascade Arrangement of Cleaners
Dilution Water
ACCEPTS
FEED
Primary
Cleaners

Secondary Dilution Water

Cleaners

Dilution Water Tertiary

Cleaners

REJECTS
 Typical Cleaner Curve

Effective
Separation

Separation Ratio:

m(in) m(acc) / m(in) Equal

Distribution
m= mass flow contaminant

Reject Ratio: OD mass flow reject / OD mass flow inlet

High Density Cleaner
High density cleaners
Through Flow Cleaner

Feed

Rejects
Accepts
Thru-flow cleaners
 Centrifugal Cleaner Performance Variables

z Stock Characteristics
fiber type
contaminant characteristics (size, shape, density),
dirt level
z Cleaner Design
body diameter, feed inlet configuration, accept
diameter, cylindrical section height, cone angle,
spiral grooves application, reject rate control
method (fixed orifice and back pressure)
 Parameters Affecting Hydrocyclone
Cleanliness Efficiency
Operating Cleanliness Sensitivity to
Variable increase in: Efficiency Variable
Pressure Difference Incr/Decr High
Volumetric Flow Incr/Decr Medium
Cyclone Diameter Decrease High
Consistency Decrease High
Flake Content Decrease Medium
Temperature Increase Low
Reject Rate Increase Medium
Flushing Flow Decrease Medium
 Effect of Particle Properties on Separation

z Particles with large density differences wrt

water are removed more effectively
z Particles with density near 1 g/cm3 may
separate from fibers
z Larger particle at same density will be
removed more effectively than smaller particle
z Particles of the same density but with
favorable hydrodynamic shape (cwAp)
separate more effectively, eg, a sphere is
better than a flat plate
Fundamentals

Force balance on a single particle in a hydrocyclone

axial

Fd
Fd

Fc
Fg

radial
Radial direction:
Net centrifugal force Drag force
Axial direction:
Net gravitational force Drag force
Tangential direction:
Assume: particles move along with fluid
Fundamentals

z One dimension analysis of single particle

Fd
Fc (or Fg)

Assume the time for particle to reach

its terminal velocity is very brief

dU s
m = Fc (or Fg ) Fd
dt
0 = Fc (or Fg ) Fd

Fc (or Fg ) = Fd
z Particle slip velocity, Us = velocity of water
velocity of particle

Net centrifugal force

Drag force

ut2 ut2 1
p l V p = lU s Ap Cd
2

r r 2

ut2 V p p l 1
Us = 2 for radial direction
r Ap l Cd

Cd = drag coefficient p , l = density of particle and fluid

r = radial position ut = tangential velocity of fluid
Vp = volume of particle Ap = projected area of particle
Fundamentals
ut2 V p p l 1
Us = 2
Why is the slip velocity important ? r Ap l Cd

For high Us

Us
Reject stream

For low Us

Accept stream
Us

High ut (tangential velocity)

Fiber tends to be rejected
High p (particle density)
Low Cd (drag coefficient)
 Cleaner Summary
z Several types of cleaners
z Objective: remove high/low density
contaminants
z Must reject material to operate effectively
z Several forces/operational variables/particle
characteristics that combine to determine
effectiveness in removal
 Paper Recycling Operations
An Example: OCC Recycling Process: Review Quiz

z Match the following:

high density cleaner removes light weight contaminants

pulper tries to hide contaminants
screens thickens pulp stock
disperser breaks paper/board into fibers
thru flow cleaner uses size differences
vacuum disk filter uses centrifugal forces
clarifier allows us to re-use process water