Features Pulp Water & Chemicals

Technical paper: Kappa number

variability during kraft pulping
May 30, 2023 By Augusto Quinde

Kraft digester operators control their cooking operations either by monitoring Kappa
numbers (i.e., Kappa target) and/or by controlling digester levels. The most important
responsibilities of a digester operator are to produce good pulp quality and to keep
the wood chip column moving.
In order to attain stable and uniform cooking operations most or all of the wood
chips must go through the same chemical and energy treatment; otherwise, the
result will be an unstable cooking that may result in several problems including
higher reject levels, lower yield, bleachability issues, poor pulp quality, etc.

A Kappa number controls the cooking degree by measuring the amount of lignin that
is left in the pulp after going through the digester or after the different bleaching
stages. This very important pulping parameter can be used not only to measure the
cooking degree but also to predict the quality of the final products (i.e., pulp, paper).

Kappa numbers can measure the quality of a cooking process and usually is the only
parameter measured on-line (Rantanen 2006).

A very common problem for pulp producers is to supply a uniform pulp of high
standards that would minimize variations and extra problems during downstream
operations (i.e., bleaching chemical charges) or pulp or paper machine runnability
issues (i.e., breaks frequency). The production of a consistent high-quality pulp is a
great challenge for digester operators due to the complex nature of the
delignification process and the crucial residence times in the different zones of a
continuous digester.

The main goals of a kraft pulping process are uniform delignification (i.e., low Kappa
number variability), high cooking yield (i.e., lower reject levels), high pulp quality, high
screen room efficiency, and low recovery load (i.e., organic & inorganic). All these
goals can be achieved only if the mill can secure high-quality wood chips, high-quality
white liquor and a stable digester control strategy.

Sources of Kappa number variability

Kappa number variability is a big concern in the pulp production business and there
are a few sources causing this variability. The four main sources of this variability are:
Wood chips quality variability, white liquor quality variability, cooking conditions
complexity and digester disturbances (See figures 1 & 2).
 On a continuous
digester the pulping
parameters to monitor
closely are wood chip
quality (i.e., chips size
distribution, chip
thickness, moisture
content, fresh vs dry
chips); Liquor-to-Wood ratio; alkali charge (i.e., EAW, AA and EA percentages, white
liquor concentration); white liquor split addition; digester alkali profile in g/l or lb/ft3
(i.e., in the upper cooking zone, lower cooking zone, extraction zone, blowline
residual alkali); Kappa number profile; H-Factor, sulphidity percentage, etc. These
parameters need special and close attention in order to secure a uniform kraft pulp
(See figure 2).

Wood chips quality

When looking at the quality of the wood chips (i.e., variability) the wood chip size
distribution and the moisture content seem to be the variables that need special
attention; however, the wood chip size distribution is perhaps the most important
variable with regard to wood chip quality. In some countries, the chip size distribution
is the basis for payment of sawmill chips, for control of chippers and for monitoring
the wood chips for digesters. A mill having the proper chip screening system might
show close figures as those expected in an ideal wood chip size distribution (See
Table 1 and figures 2, 3 & 5).

When pulping a whole log, one must consider its wide range of wood densities, pH,
lignin contents, moisture content and so on. Thus, even pulping only one wood
species, the resulting pulp is not expected to be uniform due to the different
chemical and physical characteristics. This explains the non-uniformity of the kraft
 pulping
process
(i.e.,
product
ion of
rejects,
Kappa
number
variabili
ty, etc).
If two
or more
wood species are used for pulping, then the number of variables will increase
accordingly.

White liquor
quality – Alkali
charge and
residual
effective alkali
When working with
continuous digesters, it
is important to monitor
the residual effective alkali from top to bottom of the digester using an alkali profile
control strategy to get a more stable reading of the digester alkali profile. Online
control of the residual effective alkali at a few points will help to reduce the variability
of the effective alkali throughout the digester to give smoother digester operations
and to reduce the Kappa number variability, therefore reducing over-cooking or
undercooking (See figures 2 & 5). It seems that a residual effective alkali profile
dictates the quality of the pulp and of the black liquor. Pulp quality and black liquor
composition are intimately related (Quinde 2019).

Modern white liquor plants must generate a high and consistent quality of white
liquor in order to produce an optimal pulp quality and to avoid
fluctuations/disturbances in the digester. (Quinde 2022).

Digester disturbances, wood chips quality and Kappa

number variability:
Most continuous cooking digesters are working above their original design by almost
50 to 60 percent, and the most difficult task for the operators to maintain the
digesters running is to keep the chip column moving. Frequent disturbances in chip
column movement can cause problems in the digester to achieve stable operations
that can result in Kappa number variability, channelling, blow line consistency
variations and problems with the chip level control (Valmet 2014). See figures 2,3 & 5.

Chip compaction – Channelling – Screen plugging

Chip compaction or packing of the chips, increases towards the bottom of the
digester as a function of the Kappa number, the production rate, the chip level,
dilution factor, and, to a minor degree, the liquor-to-wood ratio. At lower Kappa
numbers the void volume between the wood chips is reduced and they are more
easily compressed. Then, at high Kappa numbers occurs the opposite and the
digesters can be taller than low Kappa digesters without developing excessive
compaction.

In cases where the compaction is too low, there are two scenarios: a) the wood chips
can be pulled from the chip column into the screens and ultimately plug them; and b)
there is a risk of channelling through the chip column. However, if the compaction is
too high, the channelling can be along the digester walls. Channeling is a very
common disturbance in a continuous digester that contributes to variability of Kappa
numbers (Valmet 2014, Jansson 2009). See figure 3.

As per Puolakka and Kortela (2005), the chip compaction is an important factor to
control the cooking process and the quality of the pulp. When knowing the chip
compaction in the digester then the disturbances in the digester are easier to identify
and rectify.

Chip column movement

Uneven wood chip size distributions contribute to poor cooking conditions and a
variable pulp quality. Pin chips tend to plug the void between chips, causing a higher
flow resistance in the chip bed. Reduction in the overall percentage of undersized
chips (See Table 1) in the digester feed improved the circulation rate and increases
yield by reducing overcooking of undersized chips (Quinde 2020).

If there is a slow movement of wood chips along the digester walls, then the result is
a poor wiping of the digester screens and consequently a strong contribution to
screen plugging. Then, later, when the chips near the digester walls come out, they
must be over-cooked, giving large Kappa number swings at the blow line.

Liquor circulation is the appropriate way to add the liquor(s) to the digester, which
affects the temperature uniformity at the periphery (i.e., circumferential temperature
gradient). Furthermore, uniform distribution of filtrates influences chip column and
liquor flow patterns in the different zones of the digester. Channeling flow of chips
and/or liquor affect the variability of some pulping parameters (i.e., residence time,
cooking chemicals profile and temperature profile when passing through the
different zones in the digester, resulting in higher reject levels and lowered screened
yield.
Reducing the proportions of undersized wood chips in the digester feed must
improve the liquor circulation rates and also increase the pulp yield by reducing
overcooking of undersized chips. This reduction can help to shrink the white liquor
application and, in turn, reduce the load in the recausticizing area.

Digester chip level

A steady digester chip level secures an optimum chip pressure, chip compaction and
chip column movement in the digester. The downward velocity of the wood chips
changes through the digester due to a few factors: liquid flow, degree of
delignification, the height of the chip column, and the liquid level in the digester.

Daily average Kappa numbers versus daily range Kappa

numbers – Softwood cooking – Bleachable grade
Most kraft pulp mills submit (i.e., technical mill meetings) their digester Kappa
numbers usually as the daily average figures. Using daily average data is misleading
as explained in the following example for Jan.1.2022 (See Table 2)

The
Kappa
number
average
for
Jan.1.20
22 is 29
and is
very close to the target Kappa number of 30. When comparing the daily averages
versus the target Kappa number there is not too much differences between them and
it would be assumed that the digester is performing very well. However, the hourly
Kappa numbers data (Table 2) show a serious variability with a minimum Kappa
number of 17 (i.e., 3:00PM) and a maximum of 43 (i.e., 12:00AM) that equates to 26
Kappa units difference for that day showing a “poor” cooking operation of this
digester. The hourly Kappa number distribution shown in Table 1 can be observed
almost every day in some kraft pulp mills. This variability can be correlated with pulp
quality and strength (Albadvi 2010).

The daily or monthly average Kappa numbers do not reflect the high variability
observed in the hourly data. When running an audit of cooking operations (i.e.,
continuous or batch digester) a very important parameter to evaluate is the Kappa
number data that should include: hourly figures and target Kappa number. See figure
4.

Low Kappa numbers versus high Kappa numbers (i.e.,

Softwood cooking – Bleachable grade)
Low Kappa numbers (24-25) or very low (17-18) may indicate that the cooking has
been forced drastically and that the effects of this situation would be: a) lower pulp
yield (Esteves at al. 2021; Segura et al. 2016), b) losing pulp strength, c) generating too
much black liquor solids (BLS) that would affect black liquor carryovers, d) higher
and/or inaccurate chlorine dioxide (ClO2) charges, etc.

“High Kappa number digesters can be taller than low Kappa number digesters
without developing too high a compaction factor” (Valmet 2014).

Effects of low and high Kappa number in a kraft mill

Some of the effects of low and high Kappa numbers are shown in Table 3.
How to reduce or minimize Kappa number variability
It is very common to hear that the white liquor concentration changes every 2 hours,
or that the sulfidity changes every 5-7 hours, or that there are channeling issues
every 12-18 hours, etc, etc. However, there is no information on how the wood chip
quality going to the digester is changing. There is little or no information going to the
digester control room about the proportions (i.e., %) of the oversize chips and/or
overthick chips and/or fines that are responsible for digester disturbances. The size
and the size distribution (i.e., proportions in percentage) of the wood chips is very
important not only because of the effects during the pulping operations (i.e., pulp
yield, pulp quality, digester operations) but also for the consequences on the post-
digester handling (i.e., washing, screening, cleaning and refining) of the pulp (Quinde
2020).
At present, there are a few software applications being offered that would help Kraft
pulping digester operators to monitor white liquor parameters (i.e., concentration,
sulfidity, etc) and/or H-Factors (i.e., cooking temperature) and/or the Residual
effective alkali profile and/or to use a Predictive Kappa number control and/or Kappa
number profile control (Kayihan 1998) and/or Kappa number predictions (Lemmetti
1998), and/or to measure variability within kraft digesters (Albadvi 2010), etc. All these
advanced systems will give the digester operators the current levels of the above
parameters but because there are so many changes going on at the same time; then,
it is almost impossible that a human being would be able to control all these changes.
Therefore, a software package (Advanced Process Control) is necessary to predict
and/or to correct and/or to control all the pulping parameters. Modelling has been
utilized for control purposes of cooking degree in conventional and modified
continuous pulping processes (Rantanen 2006, Rantanen et al. 2005, Rahman et al.
2018, Jansson 2009).

As per Fairbank (2019), process variability can be originated by a number of causes

that might include raw material variation (i.e., wood chips quality), grade changes
and/or human factors. Implementing an Advanced Process Control (APC) application
can minimize the variability of key pulping parameters (i.e., Kappa number) by
applying a combination of predictive control and pulp tracking techniques. When
producing off-spec pulp for 10 minutes at the digester, then, the system can predict
when the bad pulp will reach the various downstream operations (i.e., bleaching).
These systems help in taking corrective actions before the damage is done as
opposed to conventional controls that react after off-spec quality is detected. When
using an advanced process control (APC) in a continuous digester the following
variables can be controlled: Kappa numbers, Residual effective alkali, digester chip
levels, blow consistencies, etc. Then, implementing an APC application can minimize
Kappa number variability.

As per Lampela et al. (2019), cooking is a very complex or highly interactive process
that requires a close and sophisticated control. Furthermore, they me
 ntioned that “Kappa
number and residual
alkali measurements
provide an accurate
estimate of pulp yield
and with enhanced
control of
delignification and
alkali profile, the mill
can increase pulp yield
while maintaining steady blow Kappa level.” See figure 5.

It is very common to have a remarkable product quality variability even with good
Kappa control (Kayihan 1998). A pulp mill can have a very sophisticated control (i.e.,
Kappa profile control, APC applications, etc) but if the wood chip size distribution is
poor, then digester disturbances (i.e., chip column movement, channeling) can result
in Kappa number variability.

Before considering the whole list of pulping parameters that needs a close control
and monitoring for getting reliable kappa numbers, it is essential to emphasize the
different results that can be obtained when relying either on the operator control
(i.e., risky option) or by using a computerized online system for this monitoring (i.e.,
reliable or necessary option).

References
1. Albadvi, E. (2010) “Measuring Uniformity in Kraft Digesters Using Flow-
Following Sensors”. M.Sc. Thesis. The University of British Columbia, Vancouver,
Canada. 84 pp
2. Andrews, J.D. and Hart, P.W. (2013) “Improving pulp yield for integrated
southern hardwood kraft mills – significance and impact on chemical
recovery, steam and power generation and bleaching”. TAPPI Journal
12(2):41-53.
3. Colodette, J.L., Gomide, J.L., Junior, D.L., and Pedrazzi, C. (2007) “Effect of pulp
delignification degree on fiber line performance and bleaching effluent
 load”. BioResources 2(2): 223-234.
4. Esteves, C.V., Sevastyanova, O., Östlund, S. and Brännvall, E. “Differences and
similarities between kraft and oxygen delignification of softwood fibers:
effects on chemical and physical properties”. Cellulose 28: pp 3149–3167
(2021).
5. Fairbank, M. (2019) “Taking Control of Variability in the Pulp Mill”. Pulp &
Paper Canada 120(4):18-19.
6. Jansson, J. “Digester modelling for diagnostics and control”. Doctors’ Thesis.
Mälardalen University, Västerås, Sweden. 86 pp (2009)
7. Kayihan, F. “Kappa Number Profile Control for Continuous Digesters”. In:
Berber, R. and Kravaris, C. (eds) “Nonlinear Model Based Process Control” pp
805-829. Springer, Dordrecht. Available at: https://doi.org/10.1007/978-94-011-
5094-1_26
8. Lampela, K., Zuver, D. and Carwile, D. (2019) “GPI West Monroe digester
optimization project”. TAPPI PEERS. Pulping.Engineering.Environmental.
Recycling. Oct.27-30, 2019. Valmet Inc. and Graphic Packaging Intl. collaborated
project. pp 9. Available at:
https://www.tappi.org/content/Events/19PEERS/19PEE11.pdf
9. Lemmetti, A., Leiviskä, K. and Sutinen, R. (1998) “Kappa number prediction
based on cooking liquor measurements”. Technical report: A No 5, May 1998.
Control Engineering Laboratory, University of OULU, Finland.

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