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Water chemistry challenges in pulping and papermaking • fundamentals and practical insights: Part 1: Water chemistry fundamentals and pH, TAPPI Journal June 2022
ABSTRACT: Water is an essential component of the papermaking process. Nevertheless, papermakers often overlook its importance compared to fibers and chemical additives. A better understanding of water properties and chemical interactions associated with water at the wet end leads to a sound foundation for high-quality paper production and smooth operation. Not all fresh water and process water is the same. Fresh water varies from mill to mill, primarily due to the location and availability of water sources. Some industrial trends, such as enhancing water conservation and production yield, gradually shift process water quality over time. The current work serves as a primer on water and water chemistry fundamentals to help the papermaker prepare for the future challenges of increased contamination of process water associated with reduced fresh water usage. This paper focuses on basic water chemistry definitions and discusses the impact of pH on wet-end operation. It is clear that pH is a fundamental factor that directly affects the process and impacts other factors relevant to the papermaking process. It is crucial to understand what pH represents, how it is measured, how to select the proper pH and carefully control it, and how to closely maintain the process at target setpoints. Understanding the sensitivity of operation to pH change will lead to an appropriate focus on these issues. In addition to basic theory, we also review onsite experience and practical mill cases. It is imperative to stress that, although critical, pH is not the only chemical parameter impacting papermaking operations. Other factors, such as ionic concentration measured by conductivity, surface, soluble charge, and hardness, are critical and will be discussed in Part II of this series. As pH is a primary and independent factor that impacts various forms of charge and conductivity, the authors decided to start the current series of papers by discussing pH.
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Rewet suppression through press felt engineering, TAPPI Journal June 2022
ABSTRACT: Due to the immense energy and associated financial cost of drying paper, achieving a drier web entering the dryers is a key objective in paper manufacture. One major research thrust has been finding a way to increase press solids by mitigating or eliminating rewet in the press section. For decades, solutions to this problem have remained elusive. In this work, we develop a novel approach that significantly reduces rewet by rupturing the liquid channels between felt and web. We illustrate the effects that altering the mechanical and surface properties of the press felt matrix have on the stability of these liquid channels. In a laboratory-scale platen press, a 40% reduction in the residual water of 120 g/m2 southern bleached softwood kraft (SBSK) pulp handsheets after pressing was observed, corresponding to an increase in press solids from 48% to 61%. For reference, pressing under identical conditions with paper blotters, in which minimal rewet is presumed to occur, resulted in 64% solids. Furthermore, we observed enhanced dewatering across a range of basis weights, applied pressures, and felt types. In addition to measuring the solids content of pressed sheets, we capture and analyze video evidence of the mechanisms at play in our improved dewatering technology.
Journal articles
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The Influence of the Fine Structure of Cellulose on the Action of Cellulases, TAPPI Journal June 2022
ABSTRACT: In the hydrolysis of cellulose with enzymes of Aspergillus niger at 47°C., it shown that a great decrease in the rate occurred in the late stage of the reaction, usually with considerable cellulose still reamaining undissolved.
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Editorial: Reflections on the Page equation, laboratory work, and new concepts, TAPPI Journal May 2022
ABSTRACT: I began teaching paper physics to undergraduates in the late 1980s when the recognized giants in the field were still actively debating their subjects in the literature and scientific conferences.
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Improving refining efficiency with deflocculation, TAPPI Journal May 2022
ABSTRACT: The ability to load a refiner requires the formation of a fiber mat between opposing refiner bars. One of the consequences of this is the formation of flocs that persist through the refiner grooves and exit the refiner. These flocs interfere with sheet strength, requiring additional energy to make up the strength deficit. In addition, flocs can initiate string formation, resulting in machine efficiency issues such as cross-machine profile deterioration and the downtime required to correct it. Novel refiner plate modifications have been shown to improve refining efficiency in otherwise identical refiner plates. Energy savings are typically around 15% of gross refining energy on the basis of the treated stock, although much higher reductions have also been seen. Addressing this previously underappreciated flaw in conventional refining enables greenhouse gas reduction and other benefits related to sheet strength and machine efficiency.
Journal articles
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Web instability in the open draw and the impact on paper machine efficiency, TAPPI Journal May 2022
ABSTRACT: Paper is most likely to break in the first open draw on a paper machine where it is unsupported, wettest, and weakest. Tension is applied to peel the web from the roll surface, as well as minimize web flutter in the open draw. The average tension is well below the breaking point and is often set by adjusting the speed difference between the press and the next machine element by visually observing the behavior of the web. However, machine direction variations caused by instabilities in the paper machine can cause tension swings that exceed the strength of the web. Measurement of the web’s release point from press rolls on pilot and commercial paper machines was used to identify the cause of tension instabilities. Variations in the speed of the paper machine drives and the work of adhesion from the press roll surface were identified as key factors. Fluctuations of paper moisture, which affects the elastic modulus and strength of the web, appear to be less important.
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Application of fuzzy TOPSIS in the Analyze phase of the DMAIC cycle to aid decision-making, TAPPI Journal April 2020
ABSTRACT: This paper reports the use of multicriteria analysis in the Analyze phase of the DMAIC (Define-Measure-Analyze-Improve-Control) cycle for continuous improvement. The research was carried out in a tissue paper factory located in southern Brazil. A sample of 64 parts of 16 different reels of recycled paper was used. A problem regarding paper quality variability was detected, presenting a scrap index ranging between 9% and 23%, compromising machine productivity and product sales. This motivated the implementation of a structured project supported by the application of the DMAIC cycle. The project team (machine operators, maintenance staff, supervisor, and data analyst) defined the evaluation criteria and determined the control intervals and their equivalence with linguistic variables to support the necessary evaluations for the application of fuzzy TOPSIS (Technique for Order of Preference by Similarity to Ideal Solution). The criteria were C1-Longitudinal Strength (Kgf), C2-Longitudinal Elongation (mm), C3-Cross-strength (kgf), C4-Cross-elongation (mm), C5-Weight (g/m²), and C6-Humidity (%). The results showed that samples with the same ranking had the lowest scrap indexes in the subsequent process. Also, the criterion C5 had a more significant impact on the quality of the product than the other criteria, which was determined from the DMAIC sequence. Improvements related to C5 should be prioritized. The fuzzy TOPSIS method presented is a flexible tool, adapting itself to the solution of the problem and contributing to the decision-making process.
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Guest Editorial: Still working (overtime): Life-saving nonwovens and continued innovation, TAPPI Journal August 2021
ABSTRACT: Recently, the United States federal government has recommended the need for a booster shot to combat COVID-19, highlighting the highly contagious nature of its Delta variant. This variant is surging in countries as far apart as Thailand, Brazil, and the United States. While the availability of the vaccine is not an issue in the United States, African, Latin American, and South Asian countries are in dire need of the vaccine. This scenario necessitates the need for continued safety measures. Among the recommended safety measures, use of face masks has been proven to be effective. Recent analysis showed that two-thirds of the 32 states in the United States with face mask mandates found them helpful for lowering infection rates.
Journal articles
Magazine articles
Multifunctional starch-based barrier materials, TAPPI Journal August 2021
ABSTRACT: Natural and renewable polymer-based barrier materials play an inevitable role in a sustainable economy. Most commercially available barrier materials are either based on multiple layers of synthetic polymers or petroleum-based chemicals. Tremendous amounts of research are being done in academia and industry to replace these synthetic barrier materials with natural and environmentally friendly materials. The current work summarizes the application of starch-based materials for various barrier applications, such as water vapor, oxygen, liquid water, oil, and grease. Also, exotic starch-based barrier materials for the application of sound, ultraviolet, and thermal barrier applications are reviewed. The potential of starch-based materials to offer antimicrobial and antiviral properties is discussed. Finally, commercially available starch-based barrier materials have been summarized.
Magazine articles
A waste management program for paper mill sludge high in ash, TAPPI JOURNAL, April 1990, Vol. 73(4)
A waste management program for paper mill sludge high in ash, TAPPI JOURNAL, April 1990, Vol. 73(4)