33 PULP AND PAPER MILLS
Processes
A number of processes, grouped by type as mechanical,
chemical, and semi-chemical (or hybrid), are used in
the preparation of wood pulp. In 1990 (according to
Lockwood’s Directory) the distribution of pulp mills in
Ontario and Quebec was as follows:
In chemical pulping, the wood chips are cooked, using
heat and a chemical solution that depends on the type of
process being used. The lignin binder, a natural glue that
holds the wood cells (fibres) together, is dissolved.
The two common forms of chemical pulping are
1) the dominant “alkaline” or “kraft” process, and
2) the “acid pulping” or “sulphite” process.
Acid pulping has generally declined but is still in use. The
digester liquor is a solution of sulphurous acid, H2SO3,
mixed with lime (CaO) or other base (magnesium,
sodium, or ammonium) to form bisulphites.
Mechanical processes produce the highest yield from the
wood, but have high energy demands. Mechanical pulping
generally incorporates thermal or chemical pre-softening
of the wood chips, resulting in lower energy requirements.
Some chemical processes include mechanical features.
The division is not distinct and is generally based on
efficiency of production from dry wood.
Figure 22.2 provides a flow diagram for a semi-chemical
pulp mill.
Of the chemical processes, alkaline pulping – the kraft
or sulphite process – is the most common and is shown in
Figure 22.3.
PULP AND PAPER MILLS
Chemical Processes Semi-chemical Mechanical Total
Kraft Sulphite
Ontario 94 2 15 30
Quebec 10 8 2 41 61
Figure 22.1: Number of pulp mills by type in Ontario and Quebec
Process Type
33 – 2
Kraft Process
The kraft process consists of three principal operations:
1) cooking and washing
2) evaporation and alkali recovery
3) causticizing and lime recovery.
Following debarking and chipping, the chipped wood is
"cooked" or digested with steam at a pressure of
approximately 150 psig (1034.1 kPa) in the digester with a
solution of sodium hydroxide (NaOH) and sodium sulphide
(NaS2) known as white liquor. After cooking for about six
hours, the lignin binder is dissolved and the cellulose
fibres, now called pulp or “brown stock,” are separated
from the spent cooking liquor (black liquor) in the pulp
washers. The kraft process is associated with strongsmelling
gases – organic sulphides – which are an
environmental concern.
The dilute or “weak” black liquor (10-15% solids) comes
from the washers. After concentration by removal of water
in the multiple-effect evaporator using steam, the resulting
"heavy" black liquor usually goes through further
concentration in a direct-contact evaporator.
The concentrated black liquor then goes to the mix tank
where the sodium sulphate (salt cake) is mixed with the
liquor to make up the chemical losses in the system. The
"heavy" black liquor (60-70% solids), with its salt cake
burden, is heated to lower its viscosity and pumped to the
recovery furnace where it is sprayed on the walls for
dehydration prior to final combustion of the dried “char” on
the hearth. Sodium sulphate dust in the boiler gases is
removed by an electrostatic precipitator.
The intense heat in the furnace fuses the inorganic
elements of the black liquor (mainly sodium carbonate and
sodium sulphide) to form what is known as smelt. The smelt
is tapped from the furnace and runs into a dissolving tank
where it is mixed with water to form “green liquor.”
Carbon and other impurities in the green liquor are settled
out in a clarifier, filtered, and sent to landfill. The clarified
green liquor is subjected to a causticizing treatment with
hot lime, Ca(OH)2, in a lime slaker to convert sodium
carbonate into sodium hydroxide. The insoluble calcium
carbonate mud produced is settled out and reused. The
resulting sodium of sodium hydroxide and sodium
sulphide, now called “white liquor”, is reused as cooking
liquor for the wood chips in the digester.
The bleaching of brown pulp to white pulp is usually
accomplished with chlorine, followed by extraction with
sodium hydroxide, then calcium or sodium hypochlorite,
and finally a chlorine dioxide treatment.
Hazards
Maintenance work in operating pulp and paper mills can
present a number of special hazards to construction
workers. In addition to the trade hazards associated with
what is commonly encountered in new construction, there
are other hazards:
1) hazardous process chemicals
2) piping systems
3) heat
4) noise
5) pinchpoints and moving equipment.
The following information is provided to help construction
crews recognize, assess, and control these hazards in
pulp and paper mills.
1) Hazardous Process Chemicals
General
Of the many different hazardous chemicals used, most
are found in the parts of the mill that digest or break down
the wood fibres. The cooking liquors described above
(white liquor, green liquor, and black liquor) all tend to be
very corrosive and
33 PULP AND PAPER MILLSProcessesA number of processes, grouped by type as mechanical,chemical, and semi-chemical (or hybrid), are used inthe preparation of wood pulp. In 1990 (according toLockwood’s Directory) the distribution of pulp mills inOntario and Quebec was as follows:In chemical pulping, the wood chips are cooked, usingheat and a chemical solution that depends on the type ofprocess being used. The lignin binder, a natural glue thatholds the wood cells (fibres) together, is dissolved.The two common forms of chemical pulping are1) the dominant “alkaline” or “kraft” process, and2) the “acid pulping” or “sulphite” process.Acid pulping has generally declined but is still in use. Thedigester liquor is a solution of sulphurous acid, H2SO3,mixed with lime (CaO) or other base (magnesium,sodium, or ammonium) to form bisulphites.Mechanical processes produce the highest yield from thewood, but have high energy demands. Mechanical pulpinggenerally incorporates thermal or chemical pre-softeningof the wood chips, resulting in lower energy requirements.Some chemical processes include mechanical features.The division is not distinct and is generally based onefficiency of production from dry wood.Figure 22.2 provides a flow diagram for a semi-chemicalpulp mill.Of the chemical processes, alkaline pulping – the kraftor sulphite process – is the most common and is shown inFigure 22.3.PULP AND PAPER MILLSChemical Processes Semi-chemical Mechanical TotalKraft SulphiteOntario 94 2 15 30Quebec 10 8 2 41 61Figure 22.1: Number of pulp mills by type in Ontario and QuebecProcess Type33 – 2Kraft ProcessThe kraft process consists of three principal operations:1) cooking and washing2) evaporation and alkali recovery3) causticizing and lime recovery.Following debarking and chipping, the chipped wood is"cooked" or digested with steam at a pressure ofapproximately 150 psig (1034.1 kPa) in the digester with asolution of sodium hydroxide (NaOH) and sodium sulphide(NaS2) known as white liquor. After cooking for about sixhours, the lignin binder is dissolved and the cellulosefibres, now called pulp or “brown stock,” are separatedfrom the spent cooking liquor (black liquor) in the pulpwashers. The kraft process is associated with strongsmellinggases – organic sulphides – which are anenvironmental concern.The dilute or “weak” black liquor (10-15% solids) comesfrom the washers. After concentration by removal of waterin the multiple-effect evaporator using steam, the resulting"heavy" black liquor usually goes through furtherconcentration in a direct-contact evaporator.The concentrated black liquor then goes to the mix tankwhere the sodium sulphate (salt cake) is mixed with theliquor to make up the chemical losses in the system. The"heavy" black liquor (60-70% solids), with its salt cakeburden, is heated to lower its viscosity and pumped to therecovery furnace where it is sprayed on the walls fordehydration prior to final combustion of the dried “char” onthe hearth. Sodium sulphate dust in the boiler gases isremoved by an electrostatic precipitator.The intense heat in the furnace fuses the inorganicelements of the black liquor (mainly sodium carbonate andsodium sulphide) to form what is known as smelt. The smeltis tapped from the furnace and runs into a dissolving tankwhere it is mixed with water to form “green liquor.”Carbon and other impurities in the green liquor are settledout in a clarifier, filtered, and sent to landfill. The clarifiedgreen liquor is subjected to a causticizing treatment withhot lime, Ca(OH)2, in a lime slaker to convert sodiumcarbonate into sodium hydroxide. The insoluble calciumcarbonate mud produced is settled out and reused. Theresulting sodium of sodium hydroxide and sodiumsulphide, now called “white liquor”, is reused as cookingliquor for the wood chips in the digester.The bleaching of brown pulp to white pulp is usuallyaccomplished with chlorine, followed by extraction withsodium hydroxide, then calcium or sodium hypochlorite,and finally a chlorine dioxide treatment.HazardsMaintenance work in operating pulp and paper mills canpresent a number of special hazards to constructionworkers. In addition to the trade hazards associated withwhat is commonly encountered in new construction, thereare other hazards:1) hazardous process chemicals2) piping systems3) heat4) noise5) pinchpoints and moving equipment.The following information is provided to help constructioncrews recognize, assess, and control these hazards inpulp and paper mills.1) Hazardous Process ChemicalsGeneralOf the many different hazardous chemicals used, mostare found in the parts of the mill that digest or break downthe wood fibres. The cooking liquors described above(white liquor, green liquor, and black liquor) all tend to bevery corrosive and
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