Shredder (E-1)

F1 P1

109.41 metric 109.41 metric

tons tons

Corn Stovers Corn Stovers

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
109.41 metric 109.41 metric
Corn Stover Shredded Corn Stover
tons tons

Basis: 109.41 MT feed; 1 day operating time

Assumption: 100% yield

Overall Material Balance

F1 = P1

109.41 MT = P1
Duster (E-2)

P1 P2

109.41 metric 109.08 metric tons

tons Corn Stovers
Shredded Corn
Stovers

W1

0.33 metric
tons

Waste

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
109.41 metric 109.08 metric
Corn Stover Corn Stover
tons tons
Waste 0.33 metric tons

Assumption: Dust Removed = 0.3% of pulp fed

W1 = 0.003(109.41 MT)

W1 = 0.33 MT

Overall Material Balance:

P1 = P2 + W1

109.41 MT = P2 + 0.33 MT

P2 = 109.08 MT

Corn stover in the product of Duster (E-2) = 109.08 MT

(Corn stover pulp ranger from 35-45%. Reference: Rymsza, Thomas A., “Agricultural Residues in Pulp and
Paper Discussion Paper)
0.35 (109.08 MT) = 38.18 MT pulp

Mixer – 1 (E-3)

F2 F3

1.15 metric tons 8.39 metric tons

Caustic Soda Water

P3

NaOH 1.15
Water 8.39
Total (solution) 9.54 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Caustic Soda 1.15 metric tons Caustic soda solution 9.54 metric tons
Water 8.39 metric tons

Assumption:

NaOH = 12% solution

4 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑝𝑢𝑙𝑝
𝑡𝑜𝑛 𝑜𝑓 𝑁𝑎𝑂𝐻 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
(for rice straw and bagasse around 12 to 14%. Reference: Handbook on Pulp and Paper Industries-SIRI
Board of Consultants and Engineers)

Corn stover in the product of Duster (E-2) = 99.7 MT

(Corn stover pulp yields from 35-45%. Reference: Rymsza, Thomas A., “Agricultural Residues in Pulp and
Paper Discussion Paper)
0.35 (109.08 MT) = 38.18 MT pulp

Ton of NaOH solution needed

4 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑝𝑢𝑙𝑝 38.18 𝑀𝑇 𝑝𝑢𝑙𝑝
= (𝑃) 𝑀𝑇 𝑜𝑓 𝑁𝑎𝑂𝐻 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛
𝑡𝑜𝑛 𝑜𝑓 𝑁𝑎𝑂𝐻 𝑠𝑜𝑙𝑢𝑡𝑖𝑜𝑛

P3 = 9.54 MT caustic soda solution

Caustic Soda (NaOH) in the solution = 0.12P

Caustic Soda (NaOH) in the solution = 0.12 x (9.54 MT)

Caustic Soda (NaOH) in the solution = 1.15 MT NaOH = F2

F3 = 9.54 x (1-0.12)

F3 = 8.39MT
Digester (E-4)

P3

NaOH 1.15
Water 8.39
Total (solution) 9.54 metric tons

P2 F4

109.08 metric tons 9.77 metric tons

Corn Stovers Steam

P4

Corn Stover to pulp 38.18

Unconverted corn 70.9
stover
Caustic soda 9.54
solution
Water 9.77
Total (pulp) 128.39 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Corn Stover 109.08 metric tons Pulp 128.39 metric tons
NaOH solution 9.54 metric tons
Steam 9.77 metric tons

Assumption:

 Lignin (35%)
 Cellulose (65%)
 Corn Stover composition (Reference: Flandez et al. (2012). “Corn Stalks in PP-composites,”
Bioresources)

Yield of corn stover to pulp:

(Corn stover pulp yields from 35-45%. Reference: Rymsza, Thomas A., “Agricultural Residues in Pulp and
Paper Discussion Paper)

Corn Stover in the product = 0.35 (109.08) = 38.18 MT pulp

Unconverted Corn stover: (109.08) (1-0.35) = 70.9 MT

Energy Balance:

Q = mCp∆T = m (Hv – Hl)

𝑚𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 𝐶𝑝𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 ∆𝑇 + 𝑚𝑤𝑎𝑡𝑒𝑟 𝐶𝑝𝑤𝑎𝑡𝑒𝑟 ∆𝑇 + 𝑚𝑁𝑎𝑂𝐻 𝐶𝑝𝑁𝑎𝑂𝐻 ∆𝑇
𝑚𝑠𝑡𝑒𝑎𝑚 =
(𝐻𝑣 −𝐻𝑙 )

𝑚𝑠𝑡𝑒𝑎𝑚
𝐾𝐽 𝐾𝐽 𝐾𝐽
(109.08𝑀𝑇) (1.33978 ) (170 − 25)𝐾 + (8.39𝑀𝑇) (4.167 ) (170 − 25)𝐾 + (1.15𝑀𝑇)(0.00451402 )(170 − 25𝐾)
= 𝑚𝑜𝑙 ∙ 𝐾 𝑚𝑜𝑙 ∙ 𝐾 𝑚𝑜𝑙 ∙ 𝐾
𝐾𝐽
(2793.3 − 104.89)
𝑚𝑜𝑙

F4 = 9.77 MT

Overall Material Balance:

P2 + P3 + F4 = P4

(109.08+9.54+9.77) MT = P

P4 = 128.39 MT
 Blow Tank (E-6)

P4 P5

Corn Stover to pulp 38.18 Corn Stover to pulp 38.18

Unconverted corn 70.9 Unconverted corn 70.9
stover stover
Caustic soda solution 9.54 Caustic soda 9.54
Water 9.77 solution
Total (pulp) 128.39 metric tons Total (pulp) 118.62 metric tons
R1

9.77 metric tons

Steam

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Pulp 128.39 metric tons Pulp 118.62 metric tons
Steam 9.77metric tons

Overall Material Balance:

P4 = P5 + R1

128.39 MT = P5 + R1

Component Balance (Converted Corn Stover):

Corn Stover in Feed = Corn Stover in Product

38.18 MT = Corn Stover in Product

Component Balance (UnConverted Corn Stover):

Corn Stover in Feed = Corn Stover in Product

70.9 MT = Corn Stover in Product

Component Balance (Caustic Soda)

Caustic Soda in Feed = Caustic Soda in Product

9.54 MT = Caustic Soda in Product

P5 = 38.18 MT + 70.9 MT + 9.54 MT

P5 = 118.62 MT

R1 = P4 – P5

R1 = 128.39 MT – 118.62 MT

R1 = 9.77 MT
 Washer 1 (E-7)

F5

68.17 metric tons

Water

P5 P6
Corn Stover to pulp 38.18 Corn Stover 70.9
Unconverted corn 70.9 NaOH 1.15
stover Water 51.30
Caustic soda 9.54 Total (Black liquor) 123.35 metric
solution tons
Total (pulp) 118.62 metric tons
P7

Corn Stover 38.18

Water 25.26
Total (pulp) 63.44 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Pulp 118.62 metric tons Pulp 63.44 metric tons
Water 68.17 metric tons Black Liquor 123.35 metric tons

Assumptions:

Water added – 70% of the pulp fed

Black Liquor Composition

 All NaOH fed

 All unconverted corn stovers
 67% of total water fed

(118.62 − 70.9)
𝐹5 =
0.70
F5 = 68.17 MT

Black Liquor Composition:

 All NaOH fed = (9.54 MT)(0.12) = 1.15 MT

 Corn Stover = 70.9 MT
 Water = 0.67[(9.54)(1-0.12) + 68.17 MT] = 51.30 MT

P6 = 1.15 + 70.9 + 51.30 = 123.35 MT

Overall Material Balance:

P5 + F5 = P6 + P7

P7 = P5 + F5 – P6

P7 = 118.62 MT + 68.17 MT – 123.35 MT

P7 = 63.44 MT

Composition in P7

Corn Stover = 38.18 MT

Water = (1-0.67)[(9.54)(1-0.12) + 68.17 MT] = 25.26 MT

 Screen (E-8)

P7 P8

Corn Stover 38.18 Corn Stover 38.18

Water 25.26 Water 6.31
Total (wet pulp) 63.44 metric tons Total (pulp) 44.49 metric tons

P9

18.95 metric tons

Water

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Pulp 63.44 metric tons Wet Pulp 44.49 metric tons
Wastewater 18.95 metric tons

Assumptions:

Water removed = 75% of total water input

P9 = 23.09 MT (0.75)

P9 = 17.32 MT

Overall Material Balance

P7 = P8 + P9

63.44 MT = 18.95 MT + P8

P8 = 44.49 MT
 Bleacher (E-9)

P8 F6
Corn Stover 38.18 NaOCl 0.3818
Water 6.31 Inerts 2.17
Total (pulp) 44.49 metric tons Total (solution) 2.55 metric tons

P10

NaOCl 0.3818
Inerts 2.17
Pulp 44.49
Total (solution) 47.04 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Pulp 44.49 metric tons Pulp 47.04 metric tons
NaOCl solution 2.55 metric tons

Assumptions:
1 𝑡𝑜𝑛 𝑁𝑎𝑂𝐶𝑙
109.41 𝑡𝑜𝑛𝑠 𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟
NaOCl solution bleaching agent (15% NaOCl, 85% inert)

F6 composition:
1 𝑡𝑜𝑛 𝑁𝑎𝑂𝐶𝑙 𝑥 𝑡𝑜𝑛 𝑁𝑎𝑂𝐶𝑙
NaOCl = 100 𝑡𝑜𝑛𝑠 𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 = 38.18 𝑡𝑜𝑛𝑠 𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 = 0.3818 metric tons NaOCl

F6(0.15) = 0..3818

F6 = 2.55 Metric tons

Overall Material Balance:

P8 + F6 = P10
 44.49 metric tons + 2.55 metric tons = P10 ; P10 = 47.04 metric tons

Washer 2 (E-10)

F7

67.19 metric tons

Water

P10 P12

NaOCl 0.3818 Pulp 36.27

Inerts 2.17 Water 22.05
Pulp 44.49 Total (wet pulp) 58.32 metric tons
Total (solution) 47.04 metric tons

P11

NaOCl solution 2.55

Pulp 1.90
Water 51.45
Total (liquor) 55.90 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Pulp 47.04 metric tons Pulp 58.32 metric tons
Water 67.19 metric tons Liquor 55.90 metric tons

Assumption:

Water added = 70% of feed

Water Removed = 5% pulp, all NaOCl solution, 70% total H2O (waste)

47.04 𝑚𝑒𝑡𝑟𝑖𝑐 𝑡𝑜𝑛𝑠

F7 = = 67.19 metric tons
0.70
P11 Compostion:

All NaOCl solution = 0.3818 + 2.17 = 2.55 metric tons

5% pulp = 0.05 x 38.18 = 1.90metric tons

70% total H2O = 0.70 [6.31 + 67.19] = 51.45 metric tons

P11= 2.55 + 1.90 + 51.45 = 55.90 metric tons

Overall Material Balance:

P10+ F7 = P11 + P12

P12 = 47.04 + 67.19 – 55.90

P12 = 58.32 metric tons

 Mixer 2 (E-11)

F8

7.30 metric tons

Water
P13

Starch 4.35
Talc 4.53 F9
Water 7.30
Talc 4.53
Total (solution) 16.18 metric tons
Starch 4.35
Total (solution) 8.88 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Solution 8.88 metric tons Solution 16.18 metric tons
Water 7.30 metric tons

Assumptions:
8 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑝𝑢𝑙𝑝
Talc =
1 𝑡𝑜𝑛𝑠 𝑡𝑎𝑙𝑐

Starch = 12% of pulp fed

(Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers)

8 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑝𝑢𝑙𝑝 36.27 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑝𝑢𝑙𝑝

Talc = = = 4.53 metric tons of talc
1 𝑡𝑜𝑛𝑠 𝑡𝑎𝑙𝑐 𝑥 𝑡𝑜𝑛𝑠 𝑜𝑓 𝑡𝑎𝑙𝑐

Starch = 0.12(36.27 pulp) = 4.35 metric tons of starch

Water added = 0.8220(4.53 + 4.35) = 7.30 metric tons of water

Refiner (E-12)

F10

Alum 3.627
Rosin 3.627
Total (solution) 7.25 metric tons

P14

117.11 metric tons

Treated pulp

P12

Pulp 36.27
Water 22.05
F11 Total (wet pulp) 58.32 metric tons

Recycled Water 18.95

Fresh Water 16.41
Total (water) 35.36 metric tons

P13

Starch 4.35
Talc 4.53
Water 7.30
Total (solution) 16.18 metric tons

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Wet pulp 58.32 metric tons Treated pulp 117.11 metric tons
Starch, Talc solution 16.18 metric tons
Alum, Rosin solution 7.25 metric tons
Water 35.36 metric tons
Assumptions:

Alum = 10% of pulp fed

Rosin = 10% of pulp fed

(Handbook on Pulp and Paper Industries-SIRI Board of Consultants and Engineers)

Alum = 0.10(36.27) = 3.627 metric tons alum

Rosin = 0.10(36.27) = 3.627 metric tons rosin

Recycled Water from Screen = 18.95 metric tons water

Total water = 16.41 + 18.95 metric tons = 35.36 metric tons

Overall Material Balance:

P14 = F10 + P12 + P13 + F11

P14 = 117.11 metric tons

Fourdrinier Machine (E-13)

F12

19.72 metric tons

Steam

P16 P14

50 metric tons 117.11 metric tons

Paper Treated pulp

P15

86.83 metric tons

Water

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Treated Pulp 117.11 metric tons Water 86.83 metric tons
Steam 19.72 metric tons Paper 50 metric tons

Assumptions:

Water evaporated from the wet pulp = 94.5% water fed

Energy Balance (Steam needed):

𝑚𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 𝐶𝑝𝑐𝑜𝑟𝑛 𝑠𝑡𝑜𝑣𝑒𝑟 ∆𝑇 + 𝑚𝑤𝑎𝑡𝑒𝑟 𝐶𝑝𝑤𝑎𝑡𝑒𝑟 ∆𝑇
𝑚𝑠𝑡𝑒𝑎𝑚 =
(𝐻𝑣 − 𝐻1)
𝑚𝑠𝑡𝑒𝑎𝑚
𝐾𝐽 𝐾𝐽
{(38.18 𝑀𝑇) (1.33978 ) (170 − 25)𝐾 + (71.02 𝑀𝑇) (4.187 ) (170 − 25)𝐾 + 2260.872}
= 𝑚𝑜𝑙 − 𝐾 𝑚𝑜𝑙 − 𝐾
(2793.3 − 104.89)𝐾𝐽/𝑚𝑜𝑙𝑒
Msteam = 19.72 MT

Water evaporated = 0.945(71.02 MT) = 67.11 MT

P15 = Water evaporated + Steam

= 67.11 MT + 19.72 MT = 86.83 MT

Overall Material Balance:

P16 = F12 + P14 – P15

P16 = 50 MT
Boiler (E-5)

F13 F4
29.49 metric tons 9.77 metric tons
Water Steam (supplied to the
digester)

F12

19.72 metric tons

Steam (supplied to the

fourdrinier machine)

INLET STREAM OUTLET STREAM

Stream Description Mass In Stream Description Mass Out
Water 29.49 metric tons Steam (supplied to the digester) 9.77 metric tons
Steam (supplied to the
fourdrinier machine) 19.72 metric tons

Overall Material Balance:

F13 = F12 + F4

F13 = 9.77 MT + 19.72 MT

F13 = 29.49 MT
 TECHNOLOGICAL INSTITUTE OF THE PHILIPPINES

363 P. Casal Street Quiapo, Manila

COLLEGE OF ENGINEERING AND ARCHITECTURE

CHEMICAL ENGINEERING DEPARTMENT

EQUIPMENT DESIGN
CHE 505

PRODUCTION OF PAPER FROM CORN STOVERS

Submitted By:

Fernandez, Anne Jhunette

Punzalan, Rafael Bernard

Tuba Ang, Cathleen Anne

Submitted To:

Engr. Jan Guiller Vergara