CHEMICAL PROCESS INDUSTRIES

Assignment 3

MARYAM FATIMA
FA19-CHE-083
SECTION A
SEMESTER 3
Table of Contents
Question:...............................................................................................................................................2
Paper and Pulp Industries:...................................................................................................................2
History:.............................................................................................................................................2
Production of pulp:..............................................................................................................................2
Manufacturing methods:.................................................................................................................2
Raw material:..................................................................................................................................3
Process of pulping:..........................................................................................................................3
1. Wood preparation:..............................................................................................................3
2. Cooking:...............................................................................................................................3
3. Pulp washing:.......................................................................................................................3
4. Pulp screening:.....................................................................................................................4
5. Bleaching:.............................................................................................................................4
Process flow diagram:.....................................................................................................................4
Recovery process:................................................................................................................................5
Process flow diagram:.....................................................................................................................5
Paper making:......................................................................................................................................6
In Pakistan industries are producing Paper and Pulp:....................................................................6

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Question:
Sketch the process flow diagram depicting the production process of pulp and
paper production along with chemical recovery process. How many pulp and paper
industries are present in Pakistan and mention the production technique which they are
using for production.

Paper and Pulp Industries:

History:
The name paper is derived from the papyrus plant's name which grows mainly along the
Nile River in Egypt. In ancient times, the strands within the stem of the plant were removed,
set aside, and then fell to the right side with another row of layers arranged in the same
manner. The sheet formed thus reduced and compressed. When dried, the plant's vapor,
which acts as a glue, holds the layers together. Finishing finishes, which are an important
factor in modern paper making, did not occur in the preparation of papyrus sheets. Papyrus
was the most widely used writing instrument in ancient times, and many papyri are still in
existence.
First Paper making was introduced about AD 105 Ts’ai Lun made paper using marble and
other bast fibers as well as fishing nets, old rags and hemp debris, when he official attached
to China’s Imperial court. Paper-making art slowly westward in 751 reached Samarkand
Central Asia; and in 793 the first paper was made in Baghdad during the time of Haroon AR-
Rashid, a period of Islamic tradition that brought paper making to European borders. By the
14th century, many paper elements existed in Europe, especially in Spain, Italy, France, and
Germany. The invention of printing in the 1450's brought the greatest demand for paper. By
the 18th century the process of making paper remained unchanged, and linen and cotton
fabrics provided the basic materials for use. Paper mills continued to suffer from shortages; in
the 18th century they even advertised and publicly asked for donations. It was clear that the
process of using too much material was needed.

Production of pulp:
Manufacturing methods:
Wood is the main source of paper and pulp making. The initial stages of production are
fragile and cracked. Main processes are of three main types:
 Mechanical
 Chemicals, or cooking with additional chemicals
 Semichemical, or a combination of heat or chemical treatment and subsequent reduction
of fibers.
Pulp production ranges from about 40 percent by chemical means to 95 percent by
mechanical means.
Chemical processes are based on acids (Sulfite pulping) or alkalis (alkaline pulping,
including soda and sulfate processes. and paper washing.

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Making paper includes beating or refining (cleaning) the press, size and filling or loading
(introducing various additives) and inserting the press into the appropriate machine.
 Kraft pulping
 Mechanical
 Semi-chemical
 Sulphide
 Dissolving

Raw material:
 Non-woody material
 Wheat straw
 Bagasse
 Cotton linter
 Rice straw
 Cotton stalk
 Grasses
 Woody material:
 Poplar (hard wood)
 Eucalyptus (hard wood)
 Douglas fir (soft wood)
 Water
 Na2S
 Air
 ClO2

Process of pulping:
1. Wood preparation:
Pulpwood can reach the mill as bolts 1.2 meters (4 meters) long or as full logs. The logs are
cut short, and the bolts are thrown into large rotating drums to remove the bark. Marked
wood is next sent to mills, where the moisture content is important to facilitate grinding and
flour quality. The moisture content should be at least 30 percent and preferably 45 to 50
percent. Low-density wood is placed in a pond or sprayed with water.
2. Cooking:
Extracted from the digestive tract at the beginning of the "cook," chips are heated in a mixture of
sodium hydroxide NaOH and white liquor (sodium sulphide Na2S) in a pressure cooker that
breaks the bonds that link lignin and cellulose cooking time is 1½ hour at 1700. The pressure
is then released suddenly, causing the chips to fly apart into fibbers.
The chip thus produced along with adhering liquor are known as brown stock. In mass cooking, after
the grinder is charged with chips, some method of heat recovery from this material usually precedes
the washing step, a mixture of “black liquor,” alcohol used from a previous cook, and “white
alcohol,” a solution of sodium hydroxide and sodium sulfide from a chemical recovery plant, is
released.

3. Pulp washing:
Fibers are separated, and there is a large amount of debris (fine). Also, groundwood contains
all the chemical components of wood, including lignin, hemicellulose, resin, and a variety of

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dyes. This means that paper containing earth timber is subject to discoloration (yellow) when
light and heat are obtained and after aging. The yellow of the newspaper and the bulk of the
paper are an example of this. Because the wood fibers of the soil are relatively short and have
only a limited ability to assemble, the sheets containing them do not have high strength. On
the other hand, paper containing ground wood has good light; they are large and have good
printing properties.
4. Pulp screening:
Then the product is passed through a sieve which is used to remove knots and clumped
together uncooked fibbers from the pulp. It removes the impurities from pulp, improve
the quality, save the bleaching agent, and protect the screening equipment.
5. Bleaching:
In the bleach plant, the uncreated ginger is convinced. Three to four percent of the chlorine
gas is immediately mixed with ginger at a temperature of 21 ° to 27 ° C (70 ° to 80 ° F); the
mixture is quite acidic due to the chlorine acid. Chlorine is highly absorbed to react with non-
carhydrate components of the pulp, without the effect of light and a slight dissolution of
lignin. In the next step the alkaline extraction with dilute caustic soda dissolves the
chlorinated compounds and is then washed. In its simplest sequence the final phase consists
of a treatment with very alkaline hypochlorite reducing solution, followed by a final bath.
With the use of small amounts of ClO2 in the latest stages of whitening, it is possible to
achieve high levels of purity and light without cellulose degradation.
The brightness of the paper and other objects is determined by special display meters
containing photoelectric cells that measure the amount of light of the selected length reflected
on the surface. Freshly prepared pure magnesium oxide is 100 on the light scale. On this scale
they are covered with sulfite and uncut ground planks from a distance of about 50 to 62;
peroxide cleaned ground logs, 66 to 72; single phase hypochlorite sulfite, 80 to 85; multistage
bleached pulp, 85 to 88; and multistage containing chlorine dioxide, 90 to 94.

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Process flow diagram:

Recovery process:
The main functions of the Kraft recovery program are: to convert black sulfur compounds into black
alcohol into Na2S; stimulates NaOH; to produce a large amount of steam from the heat of organic
products; and reducing or eliminating the potential source of contamination by destroying organic
matter (especially lignin) dissolved during cooking.

 Evaporation:
Most dehydration of the soft black liquid, up to 55% solids, is usually done with multiple
evaporators.

 Oxidation of black liquor:

H2S generation results in a direct contact evaporator where sodium sulphide of black alcohol
reacts with carbon dioxide in gases in a furnace. This can be largely eliminated by adding sodium
sulphide oxygen and air, or oxygen, to the sodium thiosulphite.

 Recovery furnace:
The black furnace for carrying alcohol continues to focus on the solidity of the alcohol. The heavy
black liquor from the steam is heated and blown into a furnace. Water evaporates from solid
liquids and is naturally heated to reduce oxidized sulfur components into sulfur.

 Regeneration:
In recycling, sodium carbonate (Na2CO3) in smelt is converted to NaOH, an active cooking
chemical. The smell from the rescue furnace will melt in a tank with a weak wash to form a green
liquor. After being clarified, the raw alcohol is mixed with the melted lime to form sulfur and stir

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 at high temperatures to form lime mortar. White alcohol is clarified in lime mud by dissolution.
The mud of the lemon then goes to the lime of the tongue to be counted.

Process flow diagram:

Paper making:
In a paper machine, interrelated mechanisms operating in unison receive paper stock from the beater,
form it into a sheet of the desired weight by filtration, press and consolidate the sheet with removal of
excess water, dry the remaining water by evaporation, and wind the traveling sheet into reels of paper.
Paper machines may vary in width from about 1.5 to 8 meters (5 to 26 feet), in operating speed from a
few hundred meters to 900 meters (about 3,000 feet) per minute, and in production of paper from a
few tons per day to more than 300 tons per day. The paper weight (basis weight) may vary from light
tissue, about 10 grams per square meter (0.03 ounce per square foot), to boards of more than 500
grams per square meter (1.6 ounces per square foot).
Traditionally, paper machines have been divided into two main types: cylinder machines and
Fourdrinier machines. The former consists of one or more screen-covered cylinders, each rotating in
a vat of dilute paper stock. Filtration occurs by flow action from the vat into the cylinder, with the
filtrate being continuously removed. In the Fourdrinier machine a horizontal wire-screen belt filters
the stock.
For every ton of paper dried on the paper machine, approximately two tons of water are evaporated
into the atmosphere. About 50 to 60 tons of air are required to remove the water vapor, with about
2,700 kilograms (6,000 pounds) of steam required by the dryers.

In Pakistan industries are producing Paper and Pulp:

Currently, Pakistan has 100 units in both formal and informal sectors. Many of these use kraft pulping
process and some are using NSSC to produce pulp. These units produce paper and print paper, folding

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and packing paper, White duplex camera, blank board, chip board and other board. More than 70% of
the mills are in Punjab province, 20% in Sindh province and 10% in Khyber Pakhtunkhwa province.
 Sadiq Paper and Mills Pvt Ltd.
Situated 10km, G.T. Road Shahdara Lahore (Pakistan).

It uses Kraft Pulping process.

 Naseer Paper and board Mills Ltd.

Plot 660, Sundar Industrial Estate, Lahore, Kasur, Punjab (Pakistan).

It uses Kraft pulping process.

 Century Paper & Board Mills Ltd.

67 km Lahore-Multan Road District Kasur
Uses Kraft pulping process for manufacturing of paper with a total installed capacity of 230,000 M.
Tons per annum.
 Flying Kraft paper Mills.
Uses Kraft pulping process for manufacturing of paper.
With their production capacity of 30,000 tons per annum.
 Premier Paper Mill Ltd.
8km Lahore Rd, Sheikhupura, Punjab
Uses Kraft pulping process for manufacturing of paper. Premier Paper Mills Limited, have a capacity
of 25,000 M Tons per annum.
 Kertas paper and board mills.

Hattar Industrial Rd, Khyber Pakhtunkhwa.

Uses Kraft pulping process for manufacturing of paper. They monthly produce 1200 Tons.