paper manufacturing 061109

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Paper Manufacturingfrom Pulp to Market

By: Mubarak A. AlKhater

CEO, Saudi Paper Group

Date: 6 December 2009

AICHE, 6 Dec 2009

Le Meridian, Khobar, KSA


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Corporate Introduction

Saudi Paper Group was established in 1989 in

Dammam, KSA with production starting in 1992

Public Joint Stock Company, with operations

covering Middle East & North Africa

Main business units: Paper Recycling, Paper

manufacturing and converting (Paper, aluminimum

foil, plastics packaging)

Markets served are global


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Existing Converting Plant

Existing Mill

Existing Collection Plants

Operations


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Consumer Products


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TISSUE MANUFACTURINGa brief introduction


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Pulp is a cellulose fiber material, produced bychemical or mechanical means, from whichpaper and paperboard are manufactured.Sources of cellulose fiber include wood,cotton, straw, jute, bagasse, bamboo, hempand reeds.

Pulp is a suspension of cellulose fibers inwater.

WHAT IS PULP?


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TYPES OF PULP

Forest of the world contains a great number of species,whichmay be divided into two groups:

1. Coniferous trees (usually called SOFTWOOD)Softwood cellulose fibres measure from about 2 to 4 millimeters(0.08 to 0.16 inch) in length.

2. Deciduos trees (usually called HARDWOOD)Hardwood cellulose fibres measure from about 0.5 to 1.5 millimeters

(0.02 to 0.06 inch) in length.

The greater length of softwood fibers contributes strength topaper; while the shorter hardwood fibers fill in the sheet andgive opacity and smooth surface.


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TISSUE PAPER MACHINE

A machine for manufacturing paper, such as tissuepaper, includes a twin-wire former made up of a rotary

forming roll and a pair of endless fabrics, each of whichmay be a wire or felt, lapped around the rotary formingroll to provide twin-wire web formation therewith. Atthe location where these endless fabrics travel beyondthe forming roll they diverge from each other to definebetween themselves a diverging space where one ofthe endless fabrics has an upwardly directed surface onwhich the web is carried beyond the forming roll. Thislatter endless fabric carries the web to a press sectionwhere this latter endless fabric travels with the webthrough a first press nip of the press section definedbetween an inner press roll situated within the loop ofthe latter endless fabric and an outer press roll situated

outside of the latter loop.


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TISSUE PAPER MACHINE contd

This outer press roll is lapped by an additional endlessfabric structure so that the web is situated at the first

press nip between the latter additional fabric structureand the endless fabric which carries the web away fromthe forming roll. The web travels with the additionalfabric structure around the outer press roll, to becomedetached from the endless fabric which carries the webaway from the forming roll, and this outer press rollcooperates with a drying cylinder of a drying section ofthe paper machine to define therewith at least a secondpress nip.


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Yankee

Disintegrating

purchased pulp

SOFT WOOD

PULPER

HIGH DENSITY

CLEANERSeparate heavy

impurities ie

stone,metal,rope..

CL BOX Constant level box andsupply pulp with uniform

pressure to refiner

REFINERFibre brushing to achieve strength

Blending

fibers by

ratio

Stock tank to

keep m/c run

stable

HARD WOOD

PULPER

HD CLEANER

DE FLAKERFibre separation without

cutting & damaging

CLOSED

LEVEL BOX

Over flow

BASIS WEIGHT

VALVEPrecision control

of pulp flow

M/C REFINER

LOW DENSITY CENTRY CLEANERS

Removing light dense particle

sand,dirt, ink,specks by centry

fugal force

FAN PUMP

Stock & recirculated

water are mixed

Final stage

screening ,

separate shives

and other large

size particles

from pulp slurry

PRESSURE

SCREEN

HEAD BOX

Pressurised device that

delivers uniform flow

across deckle

WIRE PART

Tissue formation

crescent former

Felt section

SPR

Suction press roll equiped with

suction box to remove water by

mechanical energy ( nip load )

Evaporate remaining

water in paper web by

heat transfer

POPE REEL

Dried paper wounds on spool

that rotates against a drum

Cy 4.5%

Cy 4.0 %

Cy 4.5%

Cy 4.5%

Cy 4%

Cy

controller

Cy controller

CL BOX

Cy 1%

Cy 0.2%

Cy 20%

Cy 41%

Cy 94%

SW

REFINED

PULP CHEST

HW

PULP CHEST

BLEND

CHEST

Cy 4.5 %

M/C

CHEST

HOOD Blow hot air

SILO

TYPICAL TISSUE MACHINE FLOW DIAGRAM


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TYPES OF TISSUE MACHINE

1. TWIN WIRE MACHINE

Paper machine in which pulp slurry is injected between twoforming wires, and water is drained from both sides of the paperweb.

2. CRESCENT FORMER MACHINEThe sheet is formed between a forming wire and felt that wrap asolid forming roll. When the drainage is completed, the formedsheet is already on the felt. The felt carries the sheet directly tothe pressure roll and the Yankee dryer. This eliminates the pick-upfunction that other machine concepts require.


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TISSUE MANUFACTURING PROCESS

StockPreparation

ApproachSystem

SheetForming

Pressing

Drying

Reeling Winding


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DE-INKING PLANTA brief introduction


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WHAT IS DE-INKING?

De-inking of pulp fibers is essentially a laundering orcleaning process where the ink is considered to bethe dirt. Chemicals along with the heat andmechanical energy are used during the re-pulpingstage to dislodge the ink particles from the fibersand disperse them in the stock suspension. The inkparticles are then separated from the so-called greystock by a series of flotation or washing steps, or byapplying both separation techniques.


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DE-INKING PLANT PROCESS

Pre-FlotationCoarse ScreeningHigh Density CleaningPulping

CleaningFine ScreeningWashingThickening

Dispersing Post Flotation Washing

WaterClarification

Coarse ScreeningHigh Density Cleaning Pre-FlotationCoarse ScreeningHigh Density Cleaning

Cleaning

Pre-FlotationCoarse ScreeningHigh Density Cleaning

Fine Screening Cleaning


Washing Fine Screening Cleaning


Thickening Washing Fine Screening Cleaning


Dispersing



Post FlotationDispersing



WashingPost FlotationDispersing



WashingPost FlotationDispersing


Pre-Flotation

Coarse

Screening

High Density

Cleaning


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DE-INKING PLANT STAGES

1. PULPING

Pulper is the brain of the de-inking system.

Its function is to defiber the paper and to detach the ink

particles from the fibers, while keeping the contraries large

enough to be removed by the cleaners and screens.

2. HIGH DENSITY CLEANING

The high density cleaner cleans pulp suspensions of sortedand unsorted wastepaper with consistencies up to 4%.

It eliminates heavy impurities such as bolts, nuts, nails, staples,

glass splinters, etc.


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3. SCREENING

Stock screening operation is required to remove oversized troublesome and unwanted

particles from good papermaking fibers. The major types of stock screens are vibratory,gravity centrifugal and pressure screens (centrifugal or centripetal). They all depend on

some form of perforated barrier to pass acceptable fiber and reject the unwanted

material. It is the size of the perforations (usually hole or slots) that determine the

minimum size of debris that will be removed.

All screens are equipped with some type of mechanism to continuously or intermittently

clean the openings in the perforated barrier. Otherwise, the plate would rapidly plug up.Methods of cleaning employed include shaking and vibration, hydraulic sweeping action,

back-flushing, or most common, pulsing the flow through the openings with various

moving foils, paddles, and bumps. The most important consideration for stable, efficient

operation is to maintain flow and consistency near optimum levels.


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SCREENING


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4. FLOATATION

At the heart of the floatation process is the

floatation cell, of which several designs are available.

Here, air in the form of small bubbles is blended with

the grey stock. The air bubbles become attached to

ink and dirt particles, causing them to rise to the cell

surface where they are removed as a dirt-laden froth.

Depending on the level of dirt in the stock a series of

floatation cells are required for efficient ink removal.

The froth is subsequently cleaned in a secondary stage

to recover good fiber.


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5. CLEANING

The centrifugal cleaners removes unwanted particles from pulp and paper stock by a

combination of centrifugal force and fluid shear. Therefore, it separates both on thebasis of density differences and particle shape. All centrifugal cleaners work on the

principle of a vortex generated by a pressure drop to develop centrifugal action. The

power source is the feed pump.


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6. WASHING

Washing basically is water extraction. The dispersed ink especially those that are

broken down into very fine particles is subsequently separated from the pulp bymulti-stage dilution/ thickening washing sequence. The separation of ink in the washingprocess corresponds to a stock thickening process, whether accomplished by

washing equipment or by screens.

If the ink particles are extremely small,

the amount removed is theoreticallyproportional to the amount of water

removed.


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7. BLEACHING

Bleaching refers to a number of processes intended to increase the brightness of pulp, reduce colorreversion, increase purity of cellulose and to preserve the fiber strength at the same time. It involvescontacting/treating unbleached cellulose material under controlled conditions of : stock pH,consistency, Temperature, retention time and concentration of bleaching chemical. Bleaching isachieved through a continuous sequence of process stages utilizing different chemicals andconditions in each stage, usually with washing between stages. The entire bleaching process mustbe carried out in such a way that strength characteristics and other papermaking properties arepreserved.

8. DISPERSING

Even after all cleaning and screenings steps, there will be some ink specks and other contaminantsremaining in the stock. Disperger is used to break up and finely distribute these contaminants andloosen particles of difficult inks which are still attached to the fibers.


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9. WATER CLARIFICATION

In wastewater treatment operations, the processes of coagulation and flocculation are employed toseparate suspended solids from water. Although the terms coagulation and flocculation are oftenused interchangeably, or the single term "flocculation" is used to describe both; they are, in fact, twodistinct processes. Knowing their differences can lead to a better understanding of the clarificationand dewatering operations of wastewater treatment.

Finely dispersed solids (colloids) suspended in wastewaters

are stabilized by negative electric charges on their surfaces,

causing them to repel each other. Since this prevents these

charged particles from colliding to form larger masses, called

flocs, they do not settle. To assist in the removal of colloidalparticles from suspension, chemical coagulation and flocculation

are required. These processes, usually done in sequence, are a

combination of physical and chemical procedures. Chemicals are

mixed with wastewater to promote the aggregation of the suspended

solids into particles large enough to settle or be removed.


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LegendConsumption & Capacities in MT 000

Net Trade in MT000 ( +ve Exports, -veImports)

Global Demand-Supply & Forecast

Source: RISI Outlook for WorldTissue Business Forecast 2009

N. AmericaConsumption2007: 8,0152011: 8,4232016: 9,022

Prod 2007: 7,761 (217)Net Trade 2007: -89

JapanConsumption2007: 1,800

2011: 1,8802016: 1,940

Prod 2007: 1,793(186)Net Trade 2007: -28

L. AmericaConsumption2007: 2,9232011: 3,5382016: 4,522

Prod 2007: 2,700 (197)Net Trade 2007: -72

W. EuropeConsumption2007: 6,2272011: 6,9452016: 7,868

Prod 2007: 5,960(234)Net Trade 2007: -51

Asia Far EastConsumption2007: 1,4812011: 1,8022016: 2,259

Prod 2007: 1,387(231)

Net Trade 2007: -51

OceaniaConsumption

2007: 3672011: 4162016: 488

Prod 2007: 271(13)Net Trade 2007: -85

ChinaConsumption2007: 4,2712011: 5,8052016: 8,335

Prod 2007: 4,259(1741)Net Trade 2007: 308

E. EuropeConsumption2007: 1,2412011: 1,6572016: 2,325

Prod 2007: 1,081(129)Net Trade 2007: -33

Near & Middle EastConsumption

2007: 7122011: 9412016: 1,342

Prod 2007: 607 (48)

Net Trade 2007: -52

AfricaConsumption

2007: 4662011: 5782016: 773

Prod 2007: 426 (72)

Net Trade 2007: -9

Tissue Industry Market Overview

Ti I d t M k t O i


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Legend

Consumption in MT 000

Mill Capacities are rated capacities

PM4 for SPMC is not included

GCCConsumption

2007: 1982011: 2652016: 380

Prod 2007: 152Mill Cap 08: 257 (11)Net Trade 2007: -33

IranConsumption

2007: 532011: 702016: 105

Prod 2007: 29Mill Cap 08: 30 (3)

Net Trade 2007: -19

TurkeyConsumption

2007: 2252011: 3152016: 470

Prod 2007: 238Mill Cap 08: 359 (13)Net Trade 2007: 33

SyriaConsumption

2007: 492011: 642016: 92

Pod 2007: 27Mill Cap 08: 65 (5)

Net Trade 2007: -18

Lebanon

Consumption2007: 362011: 452016: 60


Jordan

Consumption2007: 182011: 232016: 32


IraqConsumption

2007: 122011: 172016: 26

Prod 2007: xMill Cap 08: x

Net Trade 2007: -10

Near & Middle EastConsumption2007: 7122011: 9412016: 1,342

Prod 2007: 607Mill Cap 2008: 975 (48)

Net Trade 2007: -52

Near & Middle East

Source: RISI 2009

Tissue Industry Market OverviewContd


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Thank you

paper manufacturing 061109

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