PULP, PAPER AND BOARD

A seminar organized by the Commission of the European Communities,

Directorate-General for Science, Research and Development (Directorate G), under
the patronage of Dr Karl-Heinz Narjes, Vice-President of the Commission of the
European Communities.
 PULP, PAPER
AND BOARD

Edited by

I. F. HENDRY
Consultant to the Commission of the European Communities

and

W. J. H. HANSSENS
Commission of the European Communities

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Softcover reprint of the hardcover 1st edition 1987

British Library Cataloguing in Publication Data

Pulp, paper and board.
1. Papermaking 2. Paper board
3. Wood-pulp
I. Hendry, I. F. II. Hanssens, W. 1. H.
676 TSII05
ISBN-13: 978-94-010-7098-0 e-ISBN-13: 978-94-009-1345-5
DOl: 10.1007/978-94-009-1345-5

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 v

PRE F ACE

The scientific and technological results of the research carried

out under Research Area V (Pulp, Paper and Board) of the
Commission's first research and development programme on "Wood as
a Renewable Raw Material" were presented at this seminar by the
persons who were directly responsible for the research.

The programme was carried out under the responsibi l ity of the
Directorate General for Science, Research and Development. It
covered all aspects of the wood chain, ran for four years, and
terminated on 31 December 1985. Twenty research contracts were
placed in this particular section of the programme. The work was
carried out by specialized industries, universities and research
organizations in Community c6untries. In addition, Sweden
participated in the research as an equal partner as the result of
a Cooperation Agreement signed in June 1983 between the European
Communities and the Kingdom of Sweden.

In this context mention should also be made of an agreement

concluded in February 1985 between the European Communities and
the Swiss Confederation for coordination between the Swiss
national research programme on wood and the EC programme "Wood
as a Renewable Raw Material".

The objective of the "European Seminar on Pulp, Paper and Board"

was twofold :

- to disseminate the results of the EC R&D programme to

European industry, and
- to provide a forum for a free exchange of views between those
who were actively involved in the research and the represen-
tatives of industry.

Such a discussion was especially valuable in the llght of the new

Research Action Programme (1986-1989) on "Wood, including Cork,
as a Renewable Raw Material" which was being implemented by the
Commission at the time of the seminar, as it highlighted the
areas in which further research remained to be carried out.

These Proceedings contain the texts of all the presentations made

at the European Seminar on Pulp, Paper and Board.
 Vll

CON TEN T S

Preface v

OPENING SESSION

Introduction
Ph. BOURDEAU, Director, Commission of the European
Communi ties, Directorate-General for Science, Research and
Development 3

Opening address
K.-H. NARJES, Vice-President of the Commission of the
European Communities 5

WOOD DEFIBRING PROCESSES

BOS-038-F
The wood behaviour during mechanical defibring
R. CHARUEL and M. RUEFF, Ecole fran9aise de Papeterie 10

BOS-137-S
Chip refining : Influence of mechanical and chemical treatments
on the energy consumption during fatigue of wood
L. SALMEN, STFI, Swedish Forest Products Research Laboratory 18

HIGH YIELD PULPING

BOS-039-F
Search for new fibrous composition in order to upgrade low value
forest products
C. de CHOUDENS and G. LOMBARDO, Centre technique de
l'Industrie des Papiers, Cartons et Celluloses 26

BOS-040-F
Pulp delignification and bleaching with hydrogen peroxide
D. LACHENAL, Centre technique de l' Industrie des Papiers,
Cartons et Celluloses 33
 viii

BOS-043-F
New technology for bleached high yield pulp process
C. de CHOUDENS and R. ANGELIER, Centre technique de
l'Industrie des Papiers, Cartons et Celluloses 37

BOS-057-1
CTMP from hardwoods and their possible use in some paper grades
A. BOSIA, SIVA SpA, Centre tecnico industriale cartario e
grafico 43

BOS-085-UK
Use of anthraquinone as a pulping aid in the NSSC pulping of
European hardwoods
T. HUGHES, Divisional technical manager, St. Regis Paper
Company 52

THE PROBLEM OF STICKlES IN THE REUSE OF WASTE PAPER

BOS-Ol3-D
Formation mechanisms of stickies in waste paper pulp used in
papermaking
J. WEIGL and R. WILKEN, Papiertechnische Stiftung (PTS) 60

BOS-065-NL
The influence of zeta-potential on the agglomeration of stickies
on a tissue machine using waste
R.L. DE JONG, NV Papierfabriek Gennep 69

BOS-l22-1
Easily removable hot-melt adhesives for use in repulpable paper
products and related process
M. PIERONI, Isti tuto G. Donegani; A. CHIOLLE, Dutral SpA;
P. TREDICI, Bassi Marchini SpA; V. KOCH, Si va SpA;
G. CALMANT I and A. GATTI, Montefluos SpA 78

BOS-006-D
Optimization of bleaching and de inking of waste paper for
strength and brightness improvement
H.J. PUTZ and L. GOTTSCHING, Institut fUr Papierfabrikation,
Technische Hochschule Darmstadt 86

BOS-090-UK
The chemical treatment of fractionated stock from "freely
available" grades of waste paper
P. HOWLAND, Paper Industry Research Association 93

BOS-l04-DK
Production scale trials with fractionation of recycled fibres
G. LARSEN and S. NIELSON, H¢jbygaard Papirfabrik A/S 98
 ix

BOS-131-D
Optimization of waste paper fractionation to improve secondary
fiber quality for packaging papers
R. SCUDLIK and L. GOTTSCHING, Insti tut fUr Papierfabri-
kation, Technische Hochschule Darmstadt 108

BOS-005-D
Improvement of the efficiency of rosin size in the neutral
pH-range
U. BEYER, Klebstoffwerke Collodin 116

BOS-010-D
More filler in printing papers by optimizing forms and
distribution curve of filler particles
W. BAUMGARTNER and A. BREUNIG, Haindl Papier GmbH 121

BOS-088-UK
The development of processes to increase the filler content of
woodfree papers to 40%
P. HOWLAND, Pira 125

BOS-042-F
Study of the properties, applications and widening uses of
corrugated board impregnated by total dipping in a solution of
resin by a new process
G. GOLDSTEIN and M. MURE, Beghin-Say, Division Kaysersberg,
Direction Recherches et Developpement 130

PAPER MANUFACTURING

BOS-055-1
Paper drying under Z-direction restraint to improve the strength
properties of short-fiber high-yield pulps
G. CERAGIOLI, G. CAPRETTI and G. BIANCO, Stazione speri-
mentale per la Cellulosa, Carta e Fibre tessili vegetali ed
artificiali 138

BOS-135(I)-S
Effects of improved control of the cross profile of the paper
web
H. KARLSSON, STFI 149

BOS-135(II)-S
Improved papermaking with emphasis on energy savings and high
consistency technology
o. TERLAND, Paper Technology Department, Swedish Pulp and
Paper Research Institute 161
 x

OVERVIEW AND CONCLUSIONS

The future of the European paper industry as seen by CEPAC

G. DAUSCHA, President of CEPAC, Chairman of the Board of
Managing Directors of Zanders Feinpapiere AG 170

Wood as renewable raw material - Review and analysis of the

results
I.F. HENDRY, Consultant to the Commission 177

Plans for the future

W.J .H. HANSSENS, Direcorate-General for Science, Research
and Development, Commission of the European Communities 185

LIST OF PARTICIPANTS 191

INDEX OF AUTHORS 197

 OPENING SESSION

Introduction
Ph. BOURDEAU, Director, Commission of the European
Communities, Directorate-General for Science,
Research and Development

Opening address
K. -H. NARJES, Vice-President of the Commission of
the European Communities
 3

INTRODUCTION

Ph. Bourdeau

Director

Directorate-General for Science,

Research and Development

This seminar is in many ways similar to the one which we

organized here in Brussels in February 1982 to present to
European industry the results of the first EC R&D programme on
the Recycling of Paper and Board. That seminar was in fact
something of an experiment, being the first one of its kind
that we had organized. At the time it was favourably received
and we have since had ample proof of its success from the
number of practical applications of the techniques developed
during the first programme and which were presented at the
seminar.

The first programme on the Recycling of Paper and Board, which

ran from 1978 to 1981, aroused considerable interest. It was
consequently followed by a more ambitious programme launched
in 1982 and which terminated officially in 1985 - although
some of the contracts in fact ran until 1986. This second
programme covered the complete wood chain with research
carried out on wood production; wood harvest, storage and
transport; wood, as a material; wood processing without
modification of its basic structure; processing of wood and
related organic materials into fibre products; wood as a
source of chemicals.

Encouraged by the success of the first seminar we decided to

repeat the operation at the end of this second programme.
However, in view of the fact that 6 research areas were
covered by the programme with a correspondingly large number
of contracts involved, we have opted for a closing seminar in
three parts. Thus we are dealing here only with the research
carried out on Pulp, Paper and Board. Then on 14 and 15 April
1987 we will be holding a seminar in Munich on the Wood
Technology section of the programme. Finally, Forestry will
be covered at a seminar in Bologna on 2 and 3 June 1987. In
this way we will be providing ample scope for detailed
discussions between experts in the three broad sections of the
programme.

The Commission is now attaching great importance to in-depth

evaluation of its scientific/technical research and
development programmes. One of the reasons for this is that
the authorities who finance our research'activities now really
want "value for money".
 4

In effect. the Commission now undertakes a systematic

evaluation of all its research programmes. In the case of
pluriannual programmes this evaluation is normally made at the
mid-term of the second programme. in order to permit some
reorientation of the programme should this be necessary.

These evaluations are made in two parts. First the intrinsic

value of the scientific/technical research itself is examined.
Then follows an evaluation of the impact of the research upon
production. In this connection. however. it must be
remembered that application by laboratories. etc.. of the
results of the research can only be judged at a later stage.
As I have already mentioned. it is in fact only now that we
are witnessing the general application of the results of our
first programme on the Recycling of Paper and Board.

For the evaluation procedure the Commission naturally calls

upon independent experts who have been involved neither in the
choice of the programme nor in the selection of the research
proposals. I might add that by now the evaluation procedure
has become almost a science in itself. with its own
methodology. The Commission is fully aware of the importance
of impartial evaluation and is constantly seeking ways of
improving its procedures. Hence. we maintain contact with the
national authorities who carry out their own evaluations to
see if there is anything to be learnt.

This closing seminar on Pulp. Paper and Board is in fact being

held "while the iron is still hot" so to speak. It has been
organized by those who have been responsible for the selection
and execution of the programme. before an audience composed of
potential clients. It goes without saying. however, that the
fact that we are holding such a seminar will not in any way
preclude a more formal type of evaluation at a later date.
should this be considered necessary.
You will be interested to learn that this seminar is taking
place at a particularly important moment for the Commission as
far as scientific/technical research is concerned. In effect,
with the introduction of the "Single European Act"
technological development has become one of the key areas of
Community policy.

In concrete terms this means that the Framework Programme

currently before the Council and which covers the broad lines
of scientific research to be undertaken by the Commission from
now until 1991 must be approved unanimously. Thereafter. the
specific research programmes will need only qualified majority
approval. We are thus confident that once the new procedure
becomes operational. the decision-making process will be
considerably speeded up.

However. Vice-President Narjes is in a much better position

than I am to explain the future outlook to you, and I am
consequently pleased to hand over t~e microphone to him.
 5

OPENING ADDRESS

Dr. Karl-Heinz NARJES

Vice-President of the
Commission of the European Communities

I shouLd Like to begin by extending a hearty weLcome to the

representatives and experts from the pulp and paper industry. You have
come to BrusseLs to discuss the results of Community research work in
forestry and the wood industry and to reflect on the prospects for
continuing European cooperation in this field. The timing of this
seminar could hardly have been better, just a few weeks before the
decision on the new 5-year Community framework programme for research
and development is due to be taken. This forum therefore provides the
unique opportunity in advance of this important date to demonstrate
the significance and benefits of joint research and development
activities with practical examples from your own sector.

The situation of the pulp and paper industry is symptomatic of the

challenges and pressures to adjust with which European industry has
increasingly been confronted over the last few years. It is highly
dependent on the wor ld market and exposed to tough i nternat i ona l
competition.

The industry only stands a chance of surviving in the long term and
thus securing the jobs of the 175,000 people employed in it by
systematically using every means at its disposaL to improve
productivity and quaLity. I see your meeting here as a sign that your
industry accepts the need to adjust and that you are ready to draw the
corresponding conclusions. I hope that this seminar will help you in
this crucial but difficuLt task.

Fortunately, realisation of the need for greater European

technological cooperation is not confined to industry, but has now
also reached political circLes. Since the decisions of the Heads of
State and Government in Mi lan last June, creation of the European
technoLogy community has become a priority of Community policy,
together with completion of the internaL market by 1992. With its
incorporation in the Luxembourg agreement, known as the Single
European Act, the common technology poLicy has aLso acquired legal
form and now has a status equivalent to that of the other common
poL i cies.

At the same time the Commission was given the necessary instruments to
effect this qualitative leap forward. One such instrument is the
comprehensive multi-annual framework programme, to be adopted by
unanimous decision, which is to create the necessary conditions to
permit reliable medium-term planning and forges alL the individual
measures into a coherent overaLL concept. This will then serve as a
basis for the specific programmes, which can be decided by qualified
majority.
 6

With the deveLopment of the common technoLogy poLicy from its

beginnings in the EURATOM and ECSC Treaties to a genuine technoLogy
community, which wiLL be given concrete form by the imminent decision
on the new framework programme, the Community has demonstrated that it
can respond to dangers in the gLobaL economic cLimate. The overriding
motive was the reaLization that technicaL progress increasingLy hoLds
the key to securing growth and empLoyment. The race for tomorrow's
markets can onLy be won by keeping abreast with the deveLopment and
appLication of the Latest technoLogy.

The European States, whose resources are reLativeLy Limited compared

with the economic might of the USA and Japan, can succeed onLy if they
pooL their technoLogicaL and innovative potentiaL and direct it at
common strategic goaLs.

The need to join forces has become even more acute since technoLogy
and innovation, in addition to their function as a key parameter of
economic poLicy, have become an increasingLy important Lever
for impLementing generaL poLiticaL and strategic objectives. The
infLuence of the Great Powers is increasingLy becoming Linked with the
abiLity to assume worLd-wide technoLogicaL Leadership. Since enormous
State resources are dedicated to the achievement of such poLiticaL
ambitions - 4S biLLion doLLars in the case of the USA aLone for the
1986-1987 financiaL year - serious disadvantages inevitabLy resuLt for
the non-subsidized European competitors.

In the absence of a suitabLe response by the Community, the

participation of our industry in key areas of technoLogy, which is
essentiaL in order to have continuous access to the Latest technicaL
knowLedge, wouLd be in serious jeopardy. The concept of the European
technoLogy community is therefore nothing Less than an instrument to
safeguard the Long-term economi c and po Lit i ca L seL f-determinat i on of
Europe.

However, we have no intention of copying the technoLogy poLicy

strategies of, for exampLe, the USA or Japan. This wouLd be tantamount
to engaging in seLf-destructive, internationaL subsidy one-upmanship,
the outcome of which wouLd be the totaL demise of free worLd trade.
This is borne out by the figure of 7.7 bilLion ECU scheduLed by the
Commission for the framework programme for the period 1987-1991, which
contrasts with the estimated 1,000 bilLion ECU and 330 bilLion ECU
respectiveLy in private and pubLic funds to be made avaiLabLe for the
same period for R&D in the USA and Japan. Instead, the aim of the
new common technoLogy strategy is, firstLy,

- to promote the deveLopment of transnationaL cooperation structures

in the pre-competition fieLd;
- to assume a cataLyst function in centraL R&D areas to ensure that
important technoLogies are avaiLabLe to European industry in good time
- to take advantage of the potentiaL of a ContinentaL market of 320
milLion peopLe, in particuLar by pursuing the deveLopment of common
standards and opening nationaL pubLic procurement contracts to
Community-wide competition.
 7

The puLp, paper and board industry aLready puts into practice what
other sectors are still trying to achieve, nameLy meetings of
scientists and experts at European LeveL in order to seek solutions
jointLy to common problems. I should particularLy Like to mention the
exemplary cooperative spirit of the CEPAC and its Research Committee
in this connection.

This collaboration had deveLoped progressively over the years. The

first step was taken in 1978 with the Launch of a programme for the
recycl ing of waste paper. The primary objective at the time was to
increase the proportion of waste paper used in paper manufacture as a
contribution to redressing the negative balance of trade by reducing
raw materi aLi mports and to improve the economi c ut it i zat i on of raw
materials.

This programme has proved exceptionally successful, as demonstrated

not only by the evaluation of research results by a group of experts
on termination of the programme, but also by the fact that some of the
results were subsequently patented and are being applied in industry.
Thus the programme target was surpassed by far.

It can be said that the research programme enabled the share of waste
paper recycled in overall paper manufacture to be greatLy increased;
the figure now stands at 44 %.

The success of this modest research programme on the one hand, and the
significance, interrelationships and integration of forestry and the
wood processing industry on the other gave rise to a second programme
covering the period 1982 to 1985 on wood as a renewable raw materiaL,
which examined the whoLe chain from wood production and processing
through to the finished products, and in particular also the pulp and
paper production sector. One of the objectives of this programme was
to promote domestic' wood production, to improve raw material
utilization and enhance the quality of the finished products made of
wood.

The number of research applications exceeded our expectations. Many

research activities of value to the Community could not be granted
support owing to the limited financial resources.

The research agreements concluded under this programme aLso led to

better coordination of nationaL research work and thus heLped to avoid
unnecessary duplication of effort. The regular meetings of the
individuaL "contact groups" for a defined research sector also
permitted an efficient division of labour and an ongoing exchange of
information on progress.

This wood programme also found great resonance in non-member

countries. AccordinLgy, at the request of Sweden and SwitzerLand,
cooperation agreements were signed between the EEC and these countries
in 1983 and 1985 respectively. The purpose of the present seminar is
to present the research resuLts of this programme to scientists and
economic experts from the puLp and paper sector and to discuss their
practicaL industrial application.
 8

Thus, as weLL as the papers, the subsequent discussion is very

important. After aLL, the success of this programme depends LargeLy on
the extent to which the resuLts find practicaL appLication in
industry.

If I may anticipate one of the concLusions of this seminar, it is that

the probLems of forestry and wood processing research cannot be soLved
within four years. The Community therefore feLt there was a need to
continue research beyond 1985 in order to buiLd on the resuLts of the
first programme. Consequently, a foLLow-up programme for the period
1986-1989 was decided, one of whose aims is to improve the utiLization
of raw materiaL resources for paper and board manufacture by drawing
on previousLy negLected materiaLs and intensifying the expLoitation of
currentLy avaiLabLe resources.

The significance of this folLow-up programme must be viewed not Least

in the Light of the Community's agricuLture probLems. This incLudes
further research on faciLitating afforestation of Land no Longer being
cuLtivated which is suitable for forestry purposes.

The invitation to tender for this programme evoked a correspondingly

large response.

Regardless of the budgetary constraints affecting the new wood

programme, I am confident that the results will be of high quality.
The conclusions of this seminar will doubtless be of great assistance
to us in selecting the research projects on wood processing.

The research activities in the wood industry are a continuation of the

Community's efforts to place European industry on a sound competitive
basis so as to create the conditions for further progress in growth
and employment in Europe. The Community's role can only be to provide
incentives and, function as a catalyst. The main burden of
responsibility lies with scientists and industry. They must find the
courage to cross frontiers and enter into new forms of cooperation.
The technology community is not a forum for bureaucrats and officiaLs;
its life blood must be private initiative and a wi II ingness to get
involved.

Its r'eal purpose is to help these stimulating and creative forces to

come to play in a broad community, free from artificial barriers and
obstacles to mobility. Help us to make this vision reality soon.
 WOOD DEFIBRING PROCESSES

The wood beha~iour during mechanical defibring

Chip refining Influence of mechanical and chemical

treatments on the energy consumption during fatigue of
wood
 10

Contract nO BOS-038-F

THE WOOD BEHAVIOUR DURING MECHANICAL DEFIBRING

R. CHARUEL and M. RUEFF

Ecole Fran~aise de Papeterie

Summary
The study include two parts : "Behaviour of wood in a chip destruc-
turation press" and "The rheological characteristics of wood".
In the first part we study the effects of destructuration on the
morphology of fibres. Fibres of softwood and ring porous hardwood,
the structure of which is heterogeneous, can be the object of
an alteration ; on the contrary hardwood with a homogeneous structu-
re can be submitted to a thorough destructuration without damage
in the fine structure of the fibres. In the second part we study
the conservation modulus and loss modulus of a softwood and a
hardwood at different temperatures and dryness and different fre-
quencies. The increasing of the conservation modulus with frequency
can explain the energy saving with defibring equipments which
apply on wood low speed stress.

PART ONE

BEHAVIOUR OF WOOD IN A WOOD CHIP DESTRUCTURATION PROTOTYPE

1. INTRODUCTION

For the past few years we have been concerned by the kinetics
of heat and mass transfers in the processes of chemical pulp prepara-
tion (1,2,3). In conjunction with these studies of a basic character,
the Centre Technique du Papier has imagined the mechanical destructura-
tion of wood chil"s in order to increase the specific surface of
the raw material and in this way facilitate the heat and mass trans-
fers of which the kinetics are probably the limi tati ve phenomenon
in deIignification processes.
Destructuration is carried out in a cylinder press essentially
including two metallic cylinders 600 mm in diameter, turning in
opposite directions and of adjustable nip. The power of the prototype
press is 30 Kw and the tangential velocity varies from 17.5 m/mn
to 81 m/mn.
The water-saturated chips go through the cylinders in a single
layer and are subjected to stress which provokes a weakening of
the structure of the wood while conserving their general shape and
a certain degree of cohesion.
To characterize the amplitude of the action, the destructuration
rate is defined by the expression (1 - cylinder nip/thickness of
wood chips) x 100.
D. PECH (5) measured the specific surfaces of spruce chips at
different destructuration rates, whereas S. PORTUGAL (3) measured
the heat transfer coefficient by a unit of length for a circulation
of hot air through the mass of wood chips. These two parameters
 11

increase significantly with the destructuration rate.

These data show the possible interest of destructuration, however,
too thorough a destructuration (destructuration rate superior to
67 %) results in a reduction in the average length of fibres and
a notable decline in the tearing of chemical pulps (kraft). It seemed
timely therefore to study the effect of the mechanical stress applied
in the process of destructuration on the morphology of the fibres.
2. MICROSCOPIC STUDY OF DESTRUCTURED WOOD CHIPS. PREPARATION OF
SAMPLES
The destructured wood chips are fragile,' their texture is more
or less open depending on the destructuration rate and the preparation
of the samples must not modify their morphological characteristics.
The samples are set in an epoxy resin in order to "freeze" their
structure and avoid any alteration during the preparation of the
10 I'm thick cross-sections for optical microscope study and of 800
to 1000 angstroms for transmission electron microscope study. The
samples are preliminarily dehydrated by water-ethanol mixtures of
increasing concentration in ethanol up to 100 %, then by ethanol-
propylene oxide mixtures, of increasing concentration, finishing
with pure propylene oxide. The wood chips saturated by EPON 812
resin with added hardener and accelerator are submitted to a polymeri-
sation of the resin at 60°C in a conditioning oven for 54 hours.
The cross-sections intended for optical microscope study are washed
in bleaching water, rinsed in acetic acid and. stained with green
iodine in order to be mounted between slide and coverslip in a
balsam inclusion.
3. RESULTS
3.1. Softwoods - Spruce, Fir, Maritime Pine
In optical microscopy on maritime pine and in transmission elec-
tron microscopy at de~tructuration rates of 66 % and 90 %, we observe
that :
a) the structural modifications are identical at the extremities
and at the centre of the chip, whatever the destructuration rate.
b) the progression of destructuration relative to the destructuration
rate is not continuous :'
- up to rates of 50 % the morphological modification of the chip
is limi wd to the manifestation of fractures of about 20 fJ- m in
width localised in early wood and to the opening of the ligneous
ray cells in late wood.
- from a destructuration rate of 66 % on, wide fractures of about
300~ appear which, progressing into the totality of the material,
affect early wood and late wood. The ligneous ray cells open in
the whole of the wood.
- for destructuration rates superior to 66 % the number and width
of the fractures are amplified.
c) in early wood the fractures begin by the opening of the tracheids
of which the alteration is very clearly visible on the contours.
They generally develop in the radial direction and separate chains
of intact fibres.
For very high destructuration rates, we notice islets of tracheids.
Destructuration brings out the differences in behaviour under
 12

compression between early wood and late wood, the concentration

and intensity of the stress being more consequential in early wood
of inferior density.
d) observations in transmission electron microscope studies bring
complimentary information :
- in late wood small dimension microfractures appear (a few fAm)
which isolate the tracheids.
- the separation of late wood tracheids always takes place at the
S, layer of the adjacent fibre of which S2 is then bared.
- for destructuration rates of 80 % to 91 % separation takes place
between S1 and the middle lamella and the tracheids bordering the frac-
tures always keep the S, layer.
3.2. Hardwoods
3.2.1. In the case of hardwood the numerous observations made lead
us to distinguish between the ring porous hardwoods such as chestnut
and the diffuse structure hardwoods of which the Honrbeam is a charac-
teristic species.
3.2.2. Ring porous hardwoods
In optical microscopy as well as in transmission electron microsco-
py, we observe that:
a) the modifications are not identical for the whole of the chip,
the morphological degradation is clearly more significant at the
extremities of the chip than at the centre. We can think that the
stress exerted by the knives of the chipper fragilised the extremi-
ties.
b) the progression of destructuration is continuous, the number
and width of the fractures increasing with the destructuration rate.
c) the various elements of the wood behave differently :
- the ligneous ray cells burst and the vessels are open at a destruc-
ration rate of 50 % and from there on. For higher destructuration
rates, the ve~sels are practically all opened and finally destroyed
by a destructuration rate of 91 %.
- up to a destructuration rate of 50 % the fibres are not altered,
the fractures begin by the separation of the fibres at the middle
lamella level and continue from vessel to vessel.
- from a destructuration rate of 66 % on, the fibre walls are submit-
ted to alterations which are accentuated when the destructuration
rat.e increases, but only the fibres bordering the fractures are
altered.
d) the first fractures appear in early wood where they are always
more numerous and wider, but the behaviour of these two zones is
not fundamentally different.
e) transmission electron microscope studies show that :
- fibres are spared up to destructuration rate of 50 % and there
is no microfracture in the wall.
- for higher destructuration rates the fibres neighbouring the fractu-
res are seriously damaged.
3.2.3. Diffuse structure hardwoods. Typical species the Hornbeam
In optical microscopy as well as in transmission electron microsco-
py we observe :
a) a much greater homogeneity of the treatment on the entire chip
although the effects are a bit more .pronounced at the extremities.
 13

b) the progression of the destructuration is continuous. When the

destructuration rate increases, the number of fractures, as well
as their width, increases (80 ~m for a destructuration rate of 50 %
to 300 fLm for 80 %).
c) the walls of most of the vessels burst and the fractures progress
from vessel to vessel. The ligneous ray cells remain practically
intact. The fibre walls, including those bordering the fractures,
are not damaged even at a destructuration rate of 91 %.
d) transmission electron microscope studies show that the fractures
spread at the S1 level leaving S2 bare and that numerous microfractu-
res from 1 to 2 ~m begin.
e) the same observations have been made on the poplar, another diffuse
structure hardwood.
4. INTERPRETATION OF THE RESULTS
The wood chips submitted to the treatment of mechanical destruc-
turation were always immersed in water for 24 hours at 45°C in order
to obtain a 50 % moisture content. During this treatment a water
sol vatation of the accessible hydroxyl groups of the hemicelluloses
and the cellulose of the amorphous zones of the the microfibrils
occurs. This hydration which involves essentially S2 0 c cas ion s a
bulge that creates tensions but also plastifies the material. The
woods on which the study was conducted are representative :
on one hand of gymnosperms Spruce (Picea abies), Fir (Abies
pectinata), Maritime Pine (Pinus pinaster).
- on the other hand of dicotyledonous angiosperms : Chestnut (Castanea
sativa), Hornbeam (Carpinus betulus).
°

Softwoods only involve ligneous ray cells and tracheids quite,

different in early wood and late wood.
The anatomical structure of hardwoods is more elaborate and invol-
ves ligneous ray cels, fibres and vessels.
For ring porous hardwoods, such as the ches tnu t, there is, as
in softwoods, a pronounced difference between early and late wood.
The behaviour upon destructuration by press cylinders is very
closely linked to the morphology of the wood, the heterogenities
in structure inducing heterogeneous distributions of stress reaching
maximal values on the least dense parts of the vegetal. Thus the
response of hornbeam to destructuration is homogeneous, all the
fibres react in the same way without degradation of the walls. On
the contrary, vessels of greater diameter than the fibres and thinner
walled progress between the fibres separating them at level S2' Moreover,
a multitude of microfractures, detectibles in transmission electron
microscopy, are formed that create a microporosity favorable to
mass transfer.
For woods which have a pronounced heterogeneity, the behaviour
is very different. In the case of the chestnut, as soon as the des-
tructuration rate reaches 66 %, the fibres are altered, the effect
is accentuated in early wood.
The behaviour of softwood where the differentiation between the
two types of wood is clearly pronounced, we could schematize by
saying that early wood would have a behaviour, concerning tracheids,
parallel to that of ring porous hardwoods, whereas late wood would
behave like diffuse structure hardwoods.
Standard kraft cooking carried out on maritime pine give pulp
characteristics which are coherent with the conclusions of the prece-
ding study. Yields in screened pulp are always greater from
 14

destructured wood chips and the Kappa number is lower. The breaking
length, the elongation and the bursting index reach their maximum
at a destructuration rate of 50 %. The refining aptitude of the
pulps obtained from destructured chips is better. On the other hand,
the tear index decreases with the destructuration rate. This decrease
would be due essentially to a reduction in the average weight-length
of the fibres, verification was made of the stability of the jointive
jaw breaking length and of the degree of polymerisation of the cellu-
lose.
5. CONCLUSION
Mechanical destructuration of wood chips by a cylinder press per-
mi ts significant improvement in the kinetics of transfer phenomena
during the delignification of the wood. According to the initial
morphology of the vegetal characterised by the homogeneity of the
structure, the raw material may be the object of an alteration in
characteristics of the fibres following too high a local concentration
of stress. The behaviour of a heterogeneous structure species (soft-
wood or ring porous hardwood) will depend on the degree of heteroge-
neity linked to the conditions of growth. In the case of homogeneous
structure (diffuse structure hardwood) a destructuration even thorough
does not induce any alteration in the fine structure of the fibres.

PART TWO
STUDY OF THE RHEOLOGICAL CHARACTERISTICS OF WOOD
1. INTRODUCTION
The behaviour of wood submitted to alternative stresses is certain-
ly important to know in order to better understand the mechanisms
of defibring during the production of mechanical, thermomechanical
or chemico-thermomechanical pulp. The parameters influencing this
behaviour are, ,apart from the species considered, the temperature,
the degree of humidity, the intensity of a possible chemical treatment
and the frequency of the stress.
The object of this work is to explore on a softwood, the spruce
(Picea excelsa), and an European hardwood, the beech (Fagus silvati-
ca), the variation in rheological characteristics at different tempe-
ratures and degrees of humidity for frequencies varying from 7.8
to 1000 Hertz and, if possible, for irwulsions lasting O. 1 milliss'-
conds corresponding to a frequency of 10 Hertz.
The experimental techniques used necessitated a delicate set-up
and include :
- measurements in traction-compression on a Metravib viscoelasticime-
tre covering a frequency range from 7.8 to 1000 Hertz.
- the setting up of an assembly _ faIled split Hopkinson pressure
bars for impulsion durations of 10 millisecond.
2. MEASUREMENT OF THE COMPLEX MODULUS AND OF THE LOSS ANGLE WITH
THE HELP OF THE METRAVIB VISCOELASTICIMETRE
2.1. The Metravib viscoelasticimetre permits subjecting a sample
of solid material to sinusoidal stress of variable frequencies.
One of the measuring heads is connected to an electromagnet with
a permanent magnet which makes it possible to subject it to a sinusoi-
dal displacement of a given amplitude variable from 0 to 500 j.l. m.
This displacement is measured by a displacement sensor for frequencies
 15

inferior to 125 Hertz and by an accelerometer for superior frequen-

cies. The other measuring head is connected to a dynamometric ring
which records the force transmitted by the sample mounted between
the two measuring heads. This force can vary from O. 1 to 40 N. The
apparatus produces stress at pre-established frequencies 7.8, 15.6,
31.2, 62.5, 125, 250, 500, 1000 Hertz. It displays directly the
complex rigidity modulus and the dephasing between strain and force;
the rheological behaviour of the sample is interpreted according
to a Voight Kelvin model including a spring and a damper. We can
thus determine the conservation modulus E' (f) dependent on the
frequency and the loss modulus E" (f) by the following relations valid
for traction-compression tests :
E' (f) = ~.K (f).cos\f.F E" (f) = ~.K (f).sin'f.F
where L is the length of the sample (m), S the section of the normal
sample in the direction of the stress (m2), 'f the dephasing between
strain and stress, F a correction factor dependent on the geometry
of the sample.
At the measuring heads level a thermostat casing makes the execu-
tion of tests up to 130°C possible.
For correct operation o[ the app,ratus the rigidity modulus K( f)
must be included between 10 and 5.10 N/m which necessitates the adjust-
ment of the geometrical parameters of the sample dependent on the
size of the Young modulus of the material.
2.2. Sample preparation
The measurements made bore essentially on beech and spruce. The
samples were taken in two logs of each of the species for all the
measurements carried out. After cutting out a parallepiped of adequate
dimensions with a ribbon saw, cylinders having two bases are machined
on a lathe. The diameter of the extremities :is 16 mm to allow for
mounting between the jaws of the machine, the diameter of the cylinder
being adjusted so that the rigidity modulus is between the two limits
set by the constructor. It is situated between 5 and 10 mm. The
samples are taken in the lengthwise direction, stress is then exerted
either along the grain of the fibres or across the grain of the
fibres, perpendicular to them.
2.3. Mounting of the samples
Special ja~s had to be manufactured. The reliability of the fixing
system was checked by measurements made on well-identified polymeric
materials.
When the measurements are made on damp samples and at temperatures
superior to 100°C, they are mounted in an airtight casing.
2.4. Measurements performed
More than 10,000 measurements were made on the afore-m~tioned
species (density of beech 700 Kg/m 3 , density of spruce 402 Kg/m ). The
test temperature chosen were 20, 40, 60, 80, 100 and 120°C ; the
wood was either air dried (90 % dryness) or saturated (50 % dryness
for beech and 40 % for spruce).
For each series, the measurements were made on 7 to 9 samples
and for 4 levels of microstrain (66, 132, 330 and 660).
 16

2.5. Treatment of the results

Among the samples of a same individual, for the same conditions
of humidity and temperature and at the same frequency of excitation,
the dispersion of the results can be great. The variation coefficient
fluctuates a few percentages at 15 % on conservation moduli and
a few percentages at 30 %on the loss angles.
It should be noted that, in general, dispersion is greater on
dry wood than on damp wood.
A multiple regression was sought, giving for the different series
the connection between conservation modulus E' and loss modulus
En at temperature and frequency.
For the conservation modulus we find for the two wood species
the following relationship form :
- E' = - at + bf n + C multiple correlation coefficient between 0,9 and
0,99 and for the los~ modulus.
- En = exp Cd + gt).f n multiple correlation coefficient between 0,9
and 0,99 ; t is temperature, f frequency, a, b, c, d, g, n, n' numeri-
cal parameters, n is constant and equal to 0,25.
3. STUDY OF THE BEHAVIOUR OF WOOD USING THE METHOD OF SPLIT HOPKINSON
PRESSURE BARS
There being no extensometres to reach frequencies of 10 4 Hertz, we un-
dertook the assembly of a set-up called split Hopkinson pressure
bars.
The principle of the set-up is as follows
- a pneumatic gun sends a projectile called a hammer through a barrel
against a cylindrical bar called a tranmitter anvil.
the sample of material to be tested is immobilised between the
hammer and another bar of the same geometry and metal called recei-
ver anvil.
strain gauges measure, on the transmitter anvil, the incident
pressure wave and the reflected wave relative to the difference
in impedance of the material and the component metal of the bars.
- strain gauges measure, on the receiver anvil, the wave transmitted
throughout the material being tested.
The analysis of these signals permit the study of the rheological
behaviour of the material under very brutal stresses of very short
duration.
The amplitude of the stress is relative to the air pressure in
the guil and the duration of the impulsion is relative to the length
of the hammer.
A velocimetre measures the speed of the hammer as it leaves the
barrel.
The signals are compiled in the memory of an oscilloscope then
transferred onto a disk with the aid of an Apple microcomputer.
The data thus collected are treated on a Matra Data 100 minicomputer.
The execution of this set-up created numerous mechanical and metro-
logical problems and the number of measurements that we were able
to make, is not adequate enough to validly present results on so
heterogeneous a material as wood.
4. CONCLUSION
The dispersion of results, in spite of the great number of measure-
ments made, show the necessity of pursuing this experimentation,
 17

the methods having been well tried out. We can deduce, however,
that in the same conditions of humidity and temperature frequency
of the stresses applied significantly modify the conservation modulus.
To the extent where, parallel to the Leider and Nissan theory
developed for refining, we admit that the energy of elastic strain
is restored to the exterior surroundings and transformed into heat,
it appears that mechanical defibring should be done at low frequency.
This is perhaps the explanation of the energy savings obtained
upon defibring in the technologies exerting practically continuous
low speed stress, as in the case of the "bi-vis".
BIBLIOGRAPHY OF THE FIRST PART
1. CHARUEL R., COSTE G., RENAUD M., ROSSELET J.C., SERRA-TOSIO J.M.
Rapport general des etudes sur les transferts de chaleur dans les
procedes de mise en pate Document Ecole Frangaise de Papeterie
(1970).
2. HAGGERTY P. , Coefficients de transfert de chaleur it travers
un lit fixe de copeaux de bois ; Document Ecole Frangaise de Papeterie
(1980).
3. PORTUGAL S. ; Determination des coefficients de transfert de
chaleur par analyse thermique dans un lit fixe de copeaux de bois
Thesis of "Doctorat de 3eme cycle", INPG, Grenoble (1984).
4. Anonymous; Revue ATIP (1983), vol. 37, nO 2, p. 60.
5. PECH D. ; Etude de la permeabilite de lits compressibles constitues
de copeaux de bois partiellement destructures. Thesis of "Doctorat
de 3eme cycle", INPG, Grenoble (1984).
BIBLIOGRAPHY OF THE SECOND PART
L. SALMEN Temperature and water induced softening behaviour of
wood fibre based materials ; Thesis presented before the Royal Insti-
tute of Technology, February 26 (1982), Stockholm.
LIEDER, NISSAN ; Und~rstanding the disk refiners the mechanical
treatment of the fiber TAPPI, vol. 60, nO 10, p. 85-89 (1977).
G. BAUDIN, R. CHARUEL, J. SILVY , Comportement du bois soumis it
un effort de cisaillement , Actes du Colloque "Sciences et Industries
du Bois", Grenoble, 20-22 septembre 1982, Minis tere de la Recherche
et de la Technologie.
J. POUYET, J.L. LATAILLADE, C. SIGNORET ; Recherche de modeles rheolo-
giques pour les polymeres solides sOllicites it grande vitesse de
deformation. Problemes d' identification ; Cahiers du Groupe Frangais
de Rheologie, vol. 5, nO 6, p. 293-304 (1982).
A. HAMDY ; Realisation d'un dispositif it choc par barres de Hopkinson:
determination de lois de comportement de polymeres solides en compres-
sion Thesis presented at the Uni versi ty of Bordeaux I, June 29
(1981).
J.L. LATAILLADE, J. POUYET, A. HAMDY.; Essais en compression dynamique
de polymeres solides it grande vitesse de deformation ; C. R. Acad.
Sc. Paris, serie B - 59, tome 291 (15.9.1980).
J.L. LATAILLADE, J. POUYET, A. HAMDY ; Realisation d'un dispositif
it choc pour l'etude de l'amortissement des materiaux viscoelastiques
et de leur comportement dynamique sous contrainte repartie ; Mecani-
que, Materiaux, Electricite, nO 343-344, p. 325-329 (1978).
 18

Contract nO 80S-137-S

CHIP REFINING : INFLUENCE OF MECHANICAL AND CHEMICAL TREATMENTS

ON THE ENERGY CONSUMPTION DURING FATIGUE OF WOOD

L. SALMEN
STFI, Swedish Forest Products Research Laboratory

Summary
The energy consumption during fatigue of wood has been investigated
in order to elucidate ways of reducing the energy demand in thermo-
mechanical and chemithermomechanical pulping processes. Thus, wood
samples have been compressed cyclically under defined mechanical
conditions in an environment comparable to that prevailing in
ref iners. By the use of fatigue studies it has been possible to
deduce separately the influence of various process parameters on the
fiber flexibilization process occuring in refiners.
It is demonstrated that it is possible to extrapolate fatigue data
from laboratory experiments, in the Hz-range, to the conditions of
commercial refiners, i . e. in the kHz range. The fatigue studies
indicate that energy savings in refining might be achieved by either
increasing the temperature during refining or reducing the frequency
of the mechanical treatment, i.e. reducing the refiner speed.
Sulfonation is shown to reduce the energy demand during fatigue only
at high degrees of sulfonation. This is partly a result of the
greater differential between the refining temperature and the softe-
ning temperature for highly sulfonated wood, but, primarily a result
of the reduced stiffness of the wood fibers.

1. INTRODUCTION
It is foreseen that the use of thermomechanical and chemithermo-
mechanical pulps will increase in the future. Low investment costs as
well as high yields obtained are factors which favour these processes.
However, the large amount of electrical energy consumed poses a potential
threat to their development in view of increasing costs for the electric
power in the future.
The energy consumed in mechanical pulping far exceeds the energy required
for the physical separation and fibrillation of the fibers. This discre-
pancy is believed to be due to a large extent, to the kind of fatigue
process the wood fibers experience in the refining operation. In the
course of refining, the fibers collected on bars on one disk are worked
upon by the passing bars of the opposite disk (1,2). The treatment is a
cyclic compression across the fibers, which makes the fibers more
flexible, thus achieving improved strength properties of the paper produ-
ced. This fatigue process is necessary to make fibers suitable for high
quality paper products. In order to mininmize the energy demand in
refining it is thus essential to establish the optimal conditions for the
fatigue.
 19

In this respect work has been carried out in order to establish

fundamental knowledge on how chemical and mechanical treatments affect
the fiber flexibilazation process, i . e . to establish the effects on the
energy consumption and on the structural changes of the fibers under
fatigue. The use of fatigue studies to investigate the defibration
process is a new way of looking at the problem of how the basic action
of different process parameters can be separately studied .
Earlier work (3,4) has shown that the structural changes occuring
in wood fibers, in the form of solid wood , that have been subjected to
mechanical fatigue in laboratory tests are similar to the changes
occuring in the long fibers of a TMP produced in full scale. It follows
that laboratory studies of the fatigue of wood may indicate the basic
factors affecting fiber flexibilization in mechanical pulping processes .

2 . FATIGUE - FREQUENCY DEPENDENCE

Mechanical def ibration in ref iners and grinders generally takes
place at temperatures between 100 and 160°C and at frequencies in the
kHz range (5-7). These frequencies are appreciably higher than those
possible to achieve in laboratory studies of mechanical deformation of
wood. However, by estblishing the frequency dependence of the fatigue of
wood, it is possible to extrapolate the data at low frequencies to those
prevailing in commercial refiners (8).
Figure 1 shows how the fatigue, defined as the relative loss in
elastic modulus (3,4) , is affected by frequency of a cyclic compression
across the grain at a temperature of 120°C. The comparison is made at an
energy absorption level of 2000 J/m 3 per deformation cycle. Obviously ,
the lower the frequency of the mechanical treatment the higher is the
destruction of the wood compared at the same number of cyclic
compression, i.e. the same energy level. Thus, at a lower frequency less
energy is needed to reach the same level of destruction of the wood.

30

.
~
0
w 20
-..
W
<J
w
• 5 Hz
QI
:::J
.2'
'0 10
u.

120·C

10 100 1000 10000

Cycles ( n)

Figure 1.
Fatigue of wood across the grain at 120°C for t h e frequencies of 0 . 1 Hz,
0.5 Hz and 5 Hz at an energy absorption level of 2 kJ / m3 per cycle.
 20

The effect of temperature on the fatigue is illustrated in fig. 2

for 5 Hz. The higher the temperature the higher is the fatigue or the
destruction of the wood , as previously noticed (4). However , the
difference between the lowest temperatures studied, BOoe and 100 0 e is
small.
It can be concluded, as seen from fig . 3 , where the fatigue as a
function of frequency at the different temperatures is compared at an
energy absorption level of 1000 cycles at 2 kJ/m3 per cycle, that within
the range of frequency and temperature studied (0.1-5 Hz; BO-140 0 C) , the
fatigue of the destruction of the wood fibers is promoted by higher
temperatures and by lower frequencies. This is similar to the fatigue
behaviour of polymers , where i t has been shown that the crack growth
rate decreases with increasing frequency at a given stress amplitude (9) .

30 r----------------------,o~-.

.
~
Figure 2
Fatigue of wood across
the grain at a fre-
quency of 5 Hz for the
temperatures BOoC, 100 0 e
120 0 e and 140 0 e at an
energy absorption level
'"::>
Ol of 2 kJ/m 3 per cycle .
:g 10
LL

10 100 1000 10000

Cycles (n )

30 x

~
0
~ x
Figure 3
Fatigue of wood across
the grain at an energy

~:
0

--
W 20 absorption level of

.
W 11.0·C 1000 cycles at 2kJ/ m3
<l per cycle as a function
W
120·C of frequency at the
temperatures BOoe,
~+
CI)
=> 100 oe, 120 0 e and 140 oe .
.Q'l
0 10
~-----~
100·C
LL
80·C

0.1 0.5 5
Frequency (H z )
 21

The data in fig. 3 showing the measurements at the different tempe-

ratures can be combined into one curve spanning a larger frequency range
(8). The "master curve" obtained, fig. 4, spans a frequency range from
0.4 Hz to 4 • 10' Hz at the reference temperature 140°C . This means that
some prediction can be made of the fatigue at the frequencies applicable
to mechanical refining, i.e. frequencies of the order of 10· Hz.

\
30 x

o 140·C Figure 4.

\
~ x x 120·C "Master curve" of
UJ
0
20 .. 100·C fatigue of wood across
UJ .:. OO·C the grain at an energy
<I absorption of 1000
w cycles at 2kJ/m 3 per
111
:l cycle. The reference
,g>
temperature is 140°C .
;:; 10
LL ~~

-1 o 1 234 5 6
log (frequency [H z) )

As seen from the calculated frequency dependence of the fatigue in

fig. 5, as obtained from a series of "master curves" similar to the one
in fig . 4 (8), the higher the frequency, the lower the fatigue, although
the differences between frequencies diminish as the frequency increases.
However, a magnitude dec'rease in frequency from 30,000 to 3000 at 140°C
is estimated to give a clearly noticeable energy reduction. Thus, even
smaller frequency reductions in the 10 kHz range may give energy
reductions worth considering. These results are supported by the results
obtained by Lucander et al. on a laboratory grinder (10) who showed that
energy consumption was lower and pulp strength properties were better
when ground at a lower speed to the same freeness level .
Similar calculations on the effect of temperature on fatigue show
that at the high temperatures of refining, 1. e. in the kHz range, a
temperature increase still has a positive effect on the energy demand.
As the frequency increases the temperature will exert a progressively
smaller influence on the fatigue although in the kHz range the effect is
still significant .
As the fiber separation occurs most favourably at the softening
temperature of the wood, opposing process requirements are at hand.
However, if the chips are pre-steamed at a lower pressure than that
prevailing in the refiner, the chips entering the refiner would have a
lower temperature than that of the fibres in the refiner and the fibres
would be separated before the temperature had risen to that correspon-
ding to the refiner pressure. Thus, a more optimal fiber separation and
fiber flexibilization will occur in the refiner. This view is partly
confirmed by Sundholm and Mannstrom (11). They found that in TMP produc-
tion the energy consumption could be lowered by about 10% if the chips
were not pre-steamed.
 22

30

11.0·C
~
0
w 20 fr equenc y
-...
W Hz
<J
W 3.10 2
GJ- 3. 10 3
::l
3 ·10 '
.21 10
C
u..

0
100 200 500 1000 2000 5000 10'
Cycles ( n )
Figure 5.
Calculated fatigue of wood at a temperature of 140 0 C for the frequencies
300. 3000 and 30.000 Hz . The reduction in energy consumption (i.e. in
number of cycles to obtain a certain fatigue) when decreasing the
frequency one magnitude at 2000 cycles is indicated by dotted lines. The
mechanical action is applied across the grain.

3. EFFECTS OF SULFONATION
Treating the wood chips with sulfite prior to refining lowers the
softening temperature of the wood and gives a pulp with more fully sepa-
rated fibers. Thus. chemimechanical pulps contain more long fibers and
less shives than those of refiner mechanical pulps produced from untrea-
ted chips . However. the energy requirement for producing chemimechanical
pulps is about the same as that for mechanical pulps. considering chemi-
mechanical pulps with a degree of sulfonation below 1.2% S03- based on
dry wood (12). For such pulps the strength and density are also about
the same as those of the corresponding refiner mechanical pulps. It is
only ' when chips are sulfonated to sulfonate contents above 1.2% that
tensile strength and density increases. and the energy requirement
becomes lower than that required to produce comparable mechanical pulps
(12). This behaviour is reflected in the fatigue characteristics of
sulfonated wood. Figure 6 illustrates how the degree of sulfonation
affects the fatigue of the wood when compared at an energy absorption
level of 700 J/m3 per deformation cycle. Below 1.2% 503-' i.e. at
0.8% S03-' the fatigue (relative reduction in elastic modulus) is the
same as that of untreated wood. whereas above 1.2% S03 -. 1.e . at 1.7%
SO -. the fatigue is much higher at a given number of cycles. Thus. at
1 . 1% so - the sulfonation has reduced the energy demand for destructing
the wood. In examining the viscoelastic properties of sulfonated wood it
is noticed that. apart from the reduction of the softening temperature
achieved by the sulfonation. there is also a large reduction of the
modulus for the wood sulfonated to 1.7% S03-' It may well be that it is
this reduction of the modulus caused by the high degree of sulfonation
that is the essential factor affecting the energy demand in refining.
 23

30 . . . - - - - - -- -
'" feference
• sulfonated <: 1.2 0'0 S03-
o sulfonated >

w
W
<I
W

Q)
:J
g 10
o
LL
~~~~~/
=:;..;=-="--- a---
10 100 1000
Cycles (n)

Figure 6
Fatigue of wood across the grain at 100 oC, 5 Hz for wood with different
degrees of sulfonation
< 1.2% S03- (0.8% S03-)
> 1.2% S03- (1.7% S03-)
compared at an energy absorption level of 700 J/m3 per cycle .

4. CONCLUSIONS
The fatigue studies indicate that structural degradation due to
mechanical deformation of wood occurs faster at higher temperature and
lower frequencies. This means that an increased temperature and a
reduced speed of the refiner may be beneficial with respect to energy
consumption for flexibilizing the fibers in the present equipment for
mechanical pulp production. In practice, optimization with regard to
brightness reversion at high temperature and with regard to decreased
production at reduced frequencies have to be considered.
It is also foreseen that an increase in the load of the deforma-
tion, ei ther as a large precompression or as an increased load on the
refiners, as well as pre-steaming chips at a lower pressure than that
prevailing in the refiner would be beneficial to the energy consumption.
With the addition of sulfite, the energy demand is only reduced at
higher degrees (here 1.7 S03-) of sulfonation. This effect follows from
the reduced stiffness of the highly sulfonated wood. In order to reduce
the energy demand in refining it seems that a reduction of the softening
temperature of the wood is not sufficient, and a general reduction in
stiffness might be required.

5. EXPERIMENTAL
The wood used in these studies was heartwood of Norwegian spruce,
Picea abies. The wood samples used for the fatigue-frequency studies
were made with the longitudinal direction across the grain and with
necks of a cross section of 15 x 50 mm. Measurements of the effects of
 24

sulfonation were carried out on a rectangularly shaped specimen with a

cross section of 10 x 15 mm and a length of 70 mm.
Prior to testing. all wood samples were steam-treated for 1 hour at
130 0 C and then soaked in water to fully saturate the wood.
Sulfonation was carried out by first impregnating the wood with
either a 0.2 molll or a 0.95 molll sodium sulfite solution. then
heating the samples to 150 0 C in 30 minutes and holding them at that
temperature for a period of 5 and 30 minutes respectively.
The fatigue testing was carried out on a servohydraul1c materials
testing apparatus (MTS) equipped with an autOClave. which allowed the
temperature to be varied between 20 0 C and 140 0 C under water-saturated
steam conditions. The strain was measured using an extensometer. placed
on the wood sample. with a measuring distance of 25 mm.
Fatigue studies were carried out in compression by subjecting each
sample to a defined cyclic stress at a given amplitude. During a fatigue
test. viscoelastic properties of the sample were monitored at regular
intervals by decreasing the stress amplitude. In order to avoid effects
of creep. the sample was allowed to relax before the modulus was deter-
mined.
The fatigue is here defined as the relative loss in elastic modulus
as a function of the number of cyclic compressions. i.e. E6E/Eo '
where Eo is the initial modulus.
REFERENCES

(1) ATACK. D.. Fundamental differences in energy requirement between

the mechanical pulping processes. Sven. Papperstidn. 84 (14): 22
(1981) .
(2) PEARSON. S.J .• Towards a unified theory of mechanical pulping and
refining. Paper presented at the 1983 Mechanical Pulping Confe-
rence. Washington D.C .• June 14-17. 1983.
(3) SALMEN. N.L. and FELLERS. C.• The fundamentals of energy consump-
tion during viscoelastic and plastic deformation of wood. Trans.
Tech. Sec. (Can. Pulp Pap. Ass.) 9 (4):TR 93 (1982).
(4) SALMEN. L.. TIGERSTROM. A. and FELLERS. C. Fatigue of wood -
characterization of mechanical defibration. J. Pulp Pap. Sci. 11
(3):J 68 (19a5).
(5) IRVINE. G.M .• The significance of the glass transition of lignin in
thermomechanical pulping. Wood Sci. Technol. 19:139 (1985).
(6) BECKER. H.• HOGLUND. H. and TISTAD. G.• Frequency and temperature
in chip refining. Pap. Puu 59:123 (1977).
(7) ATACK. D. and MAY. W.D .• Mechanical pulping studies with a model
steel wheel. Tappi 45:145 (1962)
(8) SALMEN. L .• The effect of the frequency of a mechanical deformation
on the fatigue of wood. Paper presented at the 1985 Mechanical
Pulping Conference. Stockholm. May 6-10. 1985
(9) SKIBO. M.D .• The effect of frequency. temperature and materials
structure on fatigue crack propagation in polymers. Ph.D. Thesis.
Lehigh University. 1977.
(10) LUCANDER. M.• LONNBERG. B. and HAIKKALA. P .• The effect of stone
surface modification on groundwood properties. J. Pulp Pap. Sci. 11
(2): J 35 (1985)
(11) SUNDHOLM. J. and MANNSTROM. B. PRMP-TMP-properties without preheat-
ing. A preliminary study. Pap. Puu 64 (1):8 (1982).
(12) ATACK. D.• HEITNER. C. and KARNIS. A.• Ultra-high yield pulping of
eastern black spruce. Part 2. Sven. Papperstidn. 83 (5):133 (1980).
 HIGH YIELD PULPING

Search for new fibrous composition in order to upgrade

low value forest products

Pulp delignification and bleaching with hydrogen

peroxide

New technology for bleached high yield pulp process

CTMP from hardwoods and their possible use in some paper

grades

Use of anthraquinone as a pulping aid in the NSSC

pulping of European hardwoods
 26

Contract nO BOS-039-F

SEARCH FOR NEW FIBROUS COMPOSITION IN ORDER TO UPGRADE

LOW VALUE FOREST PRODUCTS

C. de CHOUDENS and G. LOMBARDO

Centre Technique de l'Industrie des Papiers, Cartons et Celluloses
(France)

Summary
The objective of this study is the perfecting of new fibrous
composition in order to reduce the cost of following type of
papers and boards (printing grades, newsprint, folding board)
wi thout modification of the quality of these papers and boards.
This cost can be reduced by using less expensive pulps in partial
or total substitution of conventionnal pulps (particularly the
chemical pulps) in the boards and papers composition. Among these
pulps, there are the chemimechanical and chemithermomechanical
pulps obtained from raw materials less valuable, for example
from chips coming from either wastes of sawmills or hardwoods.
Moreover the investments and exploitation costs for the manufacture
of these pulps are lower than those required for the manufacture
of chemical pulps. Among the high yield pulping technologies,
CTP in cooperation with CLEXTRAL Company and Pulp and Paper Compa-
nies develops a new technology for the chips fiberizing using
a bi-vis extruder. This new process presents the principal fol-
lowing advantages :
Reducing of the energy consumption (about 25 %) in comparison with
the conventionnal high yield pulping processes,
- Simplification of the high yield pulping technology by the pos-
sibility to realize simultaneously in the bi-vis extruder the
chips fiberizing and the bleaching.
Several fibrous compositions containing bi-vis pulps have been
optimized according to the mechanical and optical properties
required by the boards and papers selected in this study.

1. STUDY AT THE LABORATORY SCALE

The aim of this study at the laboratory scale is to determine
the optimal fibrous compositions containing bi-vis pulps.
Several lots of bi-vis pulps have been manufactured :
Bi-vis mechanical pulps from softwoods (mixture of fir and
spruce wastes of sawmills). The mechanical and optical properties
of theses pulps are given in table 1.
- Bi-vis mechanical pulp from hardwoods (poplar). The properties
of this pulp are given in table 2.
Bi-vis chemimechanical pulp from softwoods (wastes of sawmills
mixture of fir and spruce). The chips before fiberizing are pretreated
with a sodium sulfite solution (2 % expressed in S02 on dry wood basis)
at 130°C during 30 min. The mechanical and optical properties of this
pulp are indicated in table 3.
 27

Table 1
Mechanical and optical properties of softwood bi-vis mechanical pulps

°SR 60 75
--------------2-------------------------------·----------.----------
Grammage g/m . 60 . 50
--;:~~--~~3/;---------------------------------:---;~~~---:---;~;;---

Breaking length m 1500 2500

2
Burst kPa m /g 0.55 0.76
2
Tear mNm /g 3.5 4.0
Stiffness Gurley (220 g/m 2 )mg 5360
Delamination (220 g/m2) kPa 279
Brightness % Elrepho 64.2 63.0
Opacity % Elrepho 90.3 86.7

The bi-vis pulps at 60 0 SR is used for folding board, the bi-vis pulp at
75 °SR is used for newsprint.
Table 2
Mechanical and optical properties of hardwood bi-vis mechanical pulps

°SR 65
·-------------2------------------------------------·----------------
: Grammage g/m . 50
--------3-----------------------------------------·----------------
Bulk cm /g . 2.0
Breaking length m 2800
2
Burst kPam /g 1.1
2
Tear mNm /g 4.0
Brightness % Elrepho 78
Opacity % Elrepho 87

Conditions of pulp manufacture caustic soda : 6 % on dry wood

hydrogen peroxide: 2.5 % on dry wood
 28

Table 3
Mechanical and optical properties of softwood bi-vis chemi-mechanical
pulps

°SR 76
---;~~~~~;~---;/~2--------------------------------:-------~~-------

----------3---------------------------------------·----------------
Bulk cm /g . 1.96
Breaking length m 4200
2
Burst kPa m /g 2.18
2
Tear mNm /g 7.2
Brightness % Elrepho 78.0
Opacity % Elrepho 84.2

- Determination of pulps mixture laws and fibrous compositions

optimisation
The pulps mixture laws are determined by using a mathematical
method developped in CTP. The characteristics of a pulps mixture can
be presented by polynomial functions having as variables the pulps
mixture composition. As equation, the coefficients of which are calcula-
ted from the experimental results by mul til inear regressions, is as-
sociated with each characteristic. In ol"der to visualize and interpret
the results obtained, an abacus is established from these equations.
For example the figures 1, 2 and 3 give the fields where the pulps
compositions with bi-vis pulps have the same properties that the
conventionnal pulps mixture.
In order to manufacture newsprint, it is possible to reduce by
50 % the softwood'chemical pulp content and to use about 30 % of hardwood
bi-vis mechanical pulp.
In the pulps compositions for printing grades, it is possible
to use either 25 % of hardwood bi-vis mechanical pulp in place of
20 points of chemical pulp or 17 % of softwood bi-vis mechanical pulp
in place of about 10 points of chemical pulp. The table 4 gives the
principal properties of these papers.
The softwood chemi-mechanical pulp has been used in the manufacture
of the following papers :
- offset paper surfaced size-press (starch)
- offset paper light weight coated
- helio paper light weight coated two faces.
These papers have been manufactured with a pulps mixture containing
30 % of softwood bi-vis chemimechanical pulp. The principal characteris-
tics of these papers made with the dynamic sheet former are given
in table 5. The characteristics of the papers containing bi-vis pulp
are similar to those of the reference papers. In the same way, the
printing characteristics (surface, linting •.. ) of the bi-vis papers
are similar to those of the reference papers.
 29

Figure 1 - NEWSPRINT
Equivalent compositions
60 ..
Hudwood bl-vt. mecha.nlcal pulp In r.

.6
'\::".. J. - - - - - - ___ 0000"'

'\ \ 8R£AK1HC LEN<: TH

36
'\ ",.-- - - +*m
30

26
20 I ••

20

Figure 2 - Printing grades -

Equivalent compositions

BURST

40 ,,..- I.'
I

36 I

30

26

20 ~--~~--~----~----~--~~~~~
10 16 20 25 30 36 40
SOFTll'OOD CUII/ICAl PULP IN r.

Figure 3 - PRINTING GRADES

Equivalent composi tions
60 Softwood bl-vt. mecha.D.lcal pulp In r.

45
.0
36
30
25
20
15
10
5

°20L---~--~~========~~~~~
26 30 36 40 .6 60
SOFTll'OOD CHE)fICAl PULP IN r.
 30

Table 4
Mechanical and optical properties of news prints and non coated
printing grades manufactured with bi-vis pulps

Paper : Newsprint : Printing grades

----------------------------------- ------------- --------------------
; Ref. ; :. Ref. .:
----------------------------------- ..------ .. ------ .------ .. ------ .------
Composition in %
stone groundwood pulp 80 60 50 45 44
Chemical pulp (softwood) 20 10 50 30 39
Hardwood bi-vis mechanical pulp 30 25
Softwood bi-vis mechanical pulp 17

Mechanical and optical proEerties

3 1. 78 2.20 2.18 2.20
Bulkcm /g 1.88
Breaking l2ngth m 4900 4400 5200 4700 5000
Burst kP~m /g 1.31 1.15 1.50 1.45 1.50
Tear mNm /g 7.35 6.50 8.0 7.5 8.0
Brightness % Elrepho 60.0 60.0 77.0 77.0 77.0
Opacity % Elrepho 93.3 92.2 82.7 81.0 82.4

Table 5
Mechanical and optical properties of coated printing grades
manufactured with bi-vis pulps

:Offset starch: Offset LWC :Helio LWC(co-:

: surfaced : :ated two faces
Paper
--------------------------- ..------ .------ ..------ ..------ .------ .------
; Ref. ; : Ref. : ; Ref. ;

Composition in %
Chemical pulp (softwood) : 50 35 25 20 25 20
Chemical pulp (hardwood) : 50 35 25 20 25 20
Stone groundwood pulp 50 30 50 30
Softwood bi-vis chemi-
mechanical pulp 30 30 30
:---------------------------:------:------:------:------:------:
Mechanical and optical
prope rtiers
2
Grammage g/m 60 60 50 50 50 50
Bulk cm3/g 1.43 1.70 2.11 2.22 2.11 2.24
Breaking length m MD 6000 5400 5500 5400 5500 5450
CD 2300 2100 2000 2000 2050 2000
2
Burst kPam /g 2.57 2.07 1.87 1.95 1.88 1.94
Tear mNm2/g MD 4.7 4.6 3.3 3.5 3.2 3.6
CD 7.5 6.7 5.9 6.5 5.8 6.4
Brightness % Elrepho 80.4 76.1 59.0 62.0 59.4 61.9
Opacity % Elrepho 77.8 82 •. 3 88.0 84.8 87.2 84.6
 31

2. STUDY AT THE PILOT PLANT SCALE

From the results of the experiments at the laboratory scale,
trials of board and paper manufacture have been run in pilot plant.
2.1. A folding board (300 g/m2) has been manufactured with a
pulps mixture containing 50 % of poplar bi-vis mechanical pulp and
50 % of softwood bi-vis mechanical pulp in place of the softwood refiner
mechanical pulp in this type o! board. This pulps mixture has bp. 2n
used in the inner layer (142 glm ) and in the semi-inner layer (37 glm )
The results indicated in table 6 show that the specific characteristics
of the boards with bi-vis pulps are similar to those of the reference
boards.
2.2. Newsprints have been manufactured with either softwood bi-vis
mechanical pulp or hardwood bi-vis mechanical pulp or a mixture of
these bi-vis pulps.
The principal characteristics of the papers obtained are given
in table 7.
The results obtained show that :
- the softwood bi-vis mechanical pulp can replace the conventionnal stone
groundwood pulp,
- the hardwood bi-vis mechanical pulp can be used in the proportion of
30 % in partial substitution of softwoods stone groundwood pulp and
chemical pulp,
in the paper manufacture without modification of the newsprint quality.
scale:hese results confirm the results obtained at the laboratory

3. CONCLUSION
This study has shown the possibility to use in the manufacture of
board, newsprints, printing grades pulps mixtures constituted of new
pulps (bi-vis pulps) without modification of the quality of these boards
and papers.
A mathematical method giving the laws ruling the pulps mixtures
has been established after a systematic study of several pulps composi-
tions. The optimal compositions for the different board and papers
studied have been determined. Now by using this method we can determine
rapidly the effect of the introduction of a new pulp on the characteris-
tics of the papers boards and the maximal amount of this new pulp that,
it is possible to use without modification of the mechanical and optical
properties of the paper or board.
The ~substi tution of a part of chemical pulp by high yield pulps
obtained with the bi-vis technology in a paper composition is a means
to reduce his cost price.
 32

Table 6
Characteristics of folding boards manufactured with bi-vis pulps

Reference Boards with bi-vis

____~~~~~~_____ ________ E~~E~ _________ _
Boards
R1
.. R2
.. T1
.. T2
.
. T3
: :
------------------------------ : ------- : ------- : ------- : ------- : -------
2
Grammage g/m 298.0 298.2 297.7 300.2 299.7
Thickne~s m 485 488 480 464 490
Bulk cm /g 1.62 1.63 1.61 1.55 1.63
Delamination 32.5 30.0 33.5 32.0 34.0
Stiffness Tabor cm.g MD 316 313 300 310 303
CD 93 91 93 87 93
Ratio MD/CD 3.40 3.41 3.22 3.56 3.25

Table 7
Mechanical and optical characteristics of newsprints manufactured
with bi-vis pulps

Paper Ref. Tl T2 T3
: : :
---------------------------------- --------
:
-------- -------- : --------
:
Composition in %
Chemical pulp (softwood) 15 15 10 10
Stone groundwood pulp 85 60
Softwood bi-vis mechanical pulp: 85 60
Hardwood bi-vis mechanical pulp: 30 30

Mechanical and optical properties:

3
Bulk cm /g 1.7 1.5 1.7 1.6
Breaking length m MD 2290 2740 2380 2690
CD 1840 1990 1980 2140
2
Burst kPam /g 0.84 0.91 0.85 0.88
Tear mNm2/g MD 5.13 5.00 4.50 5.13
CD 5.02 4.96 4.18 5.05
Brightness % Elrepho 57.4 59.9 57.5 58.8
Opacity % Elrepho 96.6 94.1 95.1 91.6
 33

Contract nO BOS-040-F

PULP DELIGNIFICATION AND BLEACHING WITH HYDROGEN PEROXIDE

D. LACHENAL
Centre Technique de l'Industrie des Papiers, Cartons et Celluloses
(France)
Summary
Contrary to 02' H2 0 2 in alkaline medium is not a powerful deligni-
fying agent of kraft pulps. However a very efficient and selective
delignification was obtained by pretreating a kraft pulp with

or°
acidic solutions containing small amounts of an oxidizing agent
like Cl , NO 3 , The effect of this pretreatment could be
accounte<a fol by some modification of the residual lignin and
by the cleavage of some lignin-carbohydrates linkages.
Bleaching of high yield pulps with H2 0 2 was improved by the
same type of pretreatment even though the Dest oxidizing agents were
not exactly the same. C1 2 , CI0 2 , acidic H2 0 2 and NaCI0 2 were
found efficient. Pulps of very high brightness (82+) were ob~ained
by this process.

1. INTRODUCTION
Hydrogen peroxide is a rather widely used bleaching agent fpr
high yield pulps. It has been also demonstrated that it can partially
or totally replace chlorine or chlorine dioxide in the bleaching
of chemical pulps. The research undertaken was devoted to the improve-
ment of these processes in order to be able to offer solutions to
two of the major challenges of the pulp industry i.e. (I) the elimina-
tion of chlorinated. organic compounds in the bleaching effluent of
chemical pulps and (2) the production of high yield pulps of very
high brightness (~83 %).

2. IMPROVEMENT OF THE H202 DELIGNIFICATION OF CHEMICAL PULPS

Contrary to oxygen, hydrogen peroxide in alkaline medium is
not a powerful delignification agent of kraft pulps. Insight into
the chemistry of alkaline oxygen peroxide with kraft and residual
lignin indicated that two types of reaction took place simultaneously.
Nucleophilic attack of hydroperoxide anion HOO- to the carbonyl groups
of the side chain resulted in lignin depolymerisation. Oxidative
degradation of phenolic structures (ring opening) by hydrogen peroxide
decomposition products increased the hydrophilicity of the lignin
fragments.
These chemical considerations suggested that some modifications
of the residual lignin of a kraft pulp should be beneficial to H2 0
delignification like the increase of free phenolic {or qUinonlct
groups on which the H2 0 2 decomposition products were found to be

should allow a high temperature H °

very reactive. Moreover, making the residual lignin more reactive
treatment to be implemented
without any risk of carbohydrate degra~a~ion. Actually, a very efficient
and selective delignification was obtained by pretreating a kraft
pulp with acidic solutions containing small amounts (less than 1 %
on pulp) of an oxidizing agent like nitrogen dioxide, chlorine, ozone
 34

and operating at a temperature higher than 100°C. Results in table 1

refers to the treatment of softwood and hardwood kraft pulp (kappa
number 30.0 and 17.0 respectively) with and without pretreatment.
50 % to 80 % delignification (as measured by the reduction of kappa
number) was reached after H O2 treatment while the DP of cellulose
was maintained at an acceptabll revel.

Table 1
Influence of an oxidizing pretreatment on H202 delignification
of kraft pulps

:Pulp sample Softwood Softwood Softwood Hardwood Hardwood Hardwood:

:Kappa nO 30.0 30.0 30.0 17.0 17.0 17.0
: Pretreatment no 1% C1 2 1% N0 2 no 1% C1 2 1% 0 3
:Final Kappa nO 18.5 14.6 12.5 10.2 6.9 4.0
:DP of cellulose 1065 1300 1430 1140 1420 1380

H2 0 2 treatment : 120 o C, 90 min, 12 % consistency, 1 % H2 0 2 , 2 % NaOH

0.5 % MgS0 4 7H 2 O
C1 2 treatment 70°C, 10 min, 10 % consistency
N0 2 treatment 70 o C, 20 min, 35 % consistency
0 3 treatment 20 o C, 10 min, 35 % consistency, H2 S0 4 prewashing

Tentative explanations for this effect could be the formation

of new phenolic OH groups via demethylation of the lignin aromatic
ring or cleavage of some residual ether linkages in lignin. Higher
phenolic hydroxyl content should promote further attack by the active
species and improve dissolution of lignin. Besides one could not
exclude the cleavage of some lignin-carbohydrates linkages.

3. IMPROVEMENT OF THE H202 BLEACHING OF HIGH YIELD PULPS

H2 0 2 bleaching of high yield pulps is a well established process.
However one of the real keys to increased use of mechanical pulp
is the success with which its brightness level can be raised economical-
ly above the current ceiling of about 80 % ISO. Increasing the H2 0 2
charge showed that there did not seem to exist any impenetrable barrler
to very high brightness and that H2 0 2 can be used as the only bleaching
agent. However, in order to reacn '133 % brightness 10 % H2 0 2 should
be applied on a stone groundwood pulp out of which 6.5 % is actually
consumed. This dosage looks much too high to justify a commercial
developmemt.
It was found out that the selectivity of the H2 0 2 bleaching
reaction could be dramatically improved when the pulp had oeen previous-
ly pretreated with small quantities of some oxidizing agents like
chlorine, chlorine dioxide, acidic hydrogen peroxide and sodium chlorite.
Table 2 illustrates the effect of such a pretreatment on the peroxide
consumed during bleaching.
 35

Table 2
Influence of an oxidizing pretreatment on H222 bleaching
of a stone groundwood pulp (59 % brightness)

H2 0 2
Brightness Yield
Pretreatment consumed Final pH
% %
% on pulp
:-------------------------------------- ------------- - --------- -------
no 83.1 6.5 96.0 9.2
0.5 % C1 2 83 . 2 5.0 95.8 8.3
0.2 % CI0 2 83.5 5.0 95.5 8.4
0.3 % H2 0 2 83.2 4.8 95.8 7.9
0. 5 ~ NaCI0 2 84.2 4.6 96.0 8.5

H2 0 2 bleaching : 10 % H2 0 2 , 4 % NaOH, 5 % silicate (40°Be),

0.25 % DTPA (40% s.c), 15 % consistency, 50 o C, 4 h
Pretreatment 10 % consistency, 20 o C, 30 min, no washing after
pretreatment

Wi th the recent and sucessfu1 implementation of efficient systems

for recycling the spent bleach liquor, the way of calculating the
cost of bleaching has become completely different since this cost
does not depend any more on the quantity of chemicals initially present
wi th the pulp but on that actually consumed by the pulp to reach the
desired brightness level.
The basic design of the H2 0 2 bleaching system is shown in figure 1
Ahead of the bleach t qwer, there is a thickener, a decker and a twin
roll press delivering a pulp at 50 % consistency. The ox idative agent
can be introduced just before the thickener. Bleaching takes place
at 15 % consistency. After bleaching, the pulp is partly dewatered
to 50 % consistency in a second twin roll press. All of the residual
bleach liquor removed at this later location is recycled back for
dilution of the pulp just ahead of the bleach tower and after the
decker. As a n example, supposing the brightness target to be 82.5%
and 90 % of the residual peroxide to be active in the process, t he
actual consumption of H2 0 2 could be estimated at 4.5 % on pulp while
the minimum needed charge was 7 % H2 0 2 on pulp.
Chelllicals
C1 2 1

~I Wash Water
(down to 10\ consistency)
Figure 1 Schematic diagram of the single stage H2 0 2 b leachi n g process
 36

4. CONCLUSION
New H2 0 2 delignification and bleaching processes were investigated
during th~s study. The common characteristic of these process was
that the selectivity of the reaction of H2 0 2 toward lignin was
dramatically increased by implementing an oxidizing pretreatment
in acidic conditions prior to the H2 0 2 treatment.
It appeared that a hydrogen peroxide delignification could be
made as efficient as an oxygen delignification. One advantage of
the H2 0 2 treatment over an 02 treatment is that the H2 02 treatment
only needs a conventionnal equipment to be implemented~ However,
some progress have still to be made to change the cost figure which
still remains in favour of the oxygen treatment.
It was also shown that an high yield pulp could be bleached
to very high brightness with hydrogen peroxide. Combining the oxidizing
pretreatment and the recovery of the residual peroxide reduced the
chemical requirement to a much more reasonable level.
These results were protected by three patent applications.
 37

Contract nO BOS-043-F

NEW TECHNOLOGY FOR BLEACHED HIGH YIELD PULP PROCESS

C. de CHOUDENS and R. ANGELIER

Centre Technique de l'Industrie des Papiers, Cartons et Celluloses
(France)

Summary
This study is attached to a great development on the perfecting
of a new technology using a bi-vis extruder for the manufacture
of bleached high yield pulps
- with investments and exploitation costs reduced
- using softwoods and hardwoods
- allowing an aqueous effluent treatment
A bi-vis pilot plant having a capacity of 400 kg/h has been instal-
led at Lancey mill (AUSSEDAT REY Company). This unit running
continuously can produce mechanical or chemimechanical pulps
unbleached or bleached from softwoods or hardwoods.
The objectives aimed are following :
- improvement of the pulp quality by optimisation of several steps
of the process and particularly the chips impregnation and cooking,
the refining and the bleaching,
- manufacture of bi-vis pulps lots for using in the manufacture
of newsprints and printing grades on an industrial paper'machine,
the bi-vis pulps taking the place of a part of conventionnal
mechanical pulps and chemical pulps in the the paper compositions.
The work presented in this study comprises the following parts :
optimisation of the step chips impregnation and cooking with
a sodium sulfite solution,
bleaching study of the pulps in the bi-vis machine trials
with bleaching effluent recycling,
- manufacture of softwoods and hardwoods bleached bi-vis pulps lots,
- manufacture of newsprints with bi-vis pulp on an industrial paper
machine- and newspaper printing,
- manufactures of printing grades with bi-vis pulps on industrial
paper machines in several mills.

1. OPTIMISATION OF THE STEP CHIPS IMPREGNATION AND COOKING WITH A SODIUM

SULFITE SOLUTION
- Trials of chips sulfonation in the bi-vis machine
The bi-vis machine is equiped with four modules. The sodium sulfite
solution is introduced between the first and the second reverse screw.
The trials have been realized with sodium sulfite rates of 2 %, 4 %
and 6 % on dry wood (expressed in S02).
The results obtained show that:
- the sulfonation kinetic is fast. At the end of the bi-vis machine,
the sulfur rate fixed on the pulp is very near of the optimum,
- the mechanical properties of the pulps increase with the sulfonation
rate.
 38

- Trials of sulfonation and bleaching in the bi-vis machine

The fiberizing, sulfonation, washing and bleaching operations
have been realized simultaneously in the bi-vis machine equiped of
four modules.
The washing is made between the second and the third reverse screw;
the bleaching liquor is introduced before the fourth reverse screw.
The pulps obtaine d are a brightness level of 75 % elrepho by using
4 % of hydrogen peroxide (table 1). The results obtained show that
it is possible to realize the chips chemical treatment simultaneously
with chips fiberizing, washing and bleaching operations in the bi-vis
machine with a good efficacy.

Table 1
Sulfonation and bleaching in the bi-vis machine

:~ulf~nation: Without :
Conditions Sulfonation in bi-vis :In dlgester: If t' :
:130 o C-lO mn:su ona lon:
:
:Sodium sulfite intro-
: 2 4 3 0
~duced (% S02)
:Sulfur fixed on the
0.24 0.25 0.24 0
:pulp %
: Bleaching with 4%H 2 0 2 :
H2 0 2 consumed % 3.7 3.8 3.3 3.2
Brightness % elrepho 73.5 75.0 73.5 75.0
: Mechanical properties:
°SR 60-65 60-65 60-65 60-65
Breaking length (m) : 2200 2500 2700 l300
Burst factor,kPa.m2/g 0.90 1.00 1.20 0.50
Tear factor Nm2/kg 5.30 5.50 5.00 3.60

2. BLEACHING STUDY" OF THE PULPS IN THE BI-VIS MACHINE TRIALS WITH

BLEACHING EFFLUENT RECYCLING
During the bleaching trials of softwoods chemimechanical pulps
by the hydrogen peroxide, it has been established that a part (about 30%)
of hydrogen peroxide is not consumed. This part is in the bleaching
effluent.
The figure 1 presents the bleaching operation in the bi-vis machine
with bleaching effluent recycling. The hydrogen peroxide solution
is introduced between the second and the third reverse screw. A part
of the bleaching effluent is recovered before the fourth reverse screw
and reintroduced with the help of a pump between the first and the
second reverse screw.
Several bleaching have been realized with hydrogen peroxide rates
of 1, 2 and 3 % with and without bleaching effluent recycling. The
results are indicated in the table 2.
The brightness of the pulps obtained with bleaching effluent
recycling are higher than the brightness of the pulps obtained without
bleaching effluent recycling. The brightness gain is 2 points for
the trials with 2 % and 3 % of hydrogen peroxide and 1 point for
the trials with 1 % of hydrogen peroxide.
 39

FIGURE 1

BLEACHING IN THE BI-VIS MACHINE WITH EFFLUENT RECYCLING

J,111
H202

CHIPS ~~:oQI

111 B=rn,.--ING_CHE_MI_CA_LS -~
x x ":" X x
I

~=i=---=l
BLEACHING EFFLUENT
t
BLEACHED PULP

Table 2
Recycling of bleaching effluents in the bi-vis machine

H20 2 introduced % 0.95 1.00 1.91 1.86 3.00 2.91

H20 2 consumed % 0.85 0.85 1.35 1.30 2.40 2.40
H2 0 2 recycled % 0.26 0.70 0.80
Brightness % elrepho 61.0 62.0 65.0 67.0 71.0 73.0

3. INDUSTRIAL TRIAL OF NEWSPRINT MANUFACTURE CONTAINING SOFTWOOD BI-VIS

MECHANICAL PULP
A lot of 30 tons of bi-vis pulp has been manufactured in the Lancey
pilot plant from softwood chips (mixture fir-spruce-wastes of sawmills)
in the following conditions:
- average production : 330 kg/h
- hydrogen peroxide rate : 0.8 % to 1 % on dry wood
- caustic soda rate : 0.8 % to 1 % on dry wood
- sodium silicate : 4 % on dry wood
- DTPA : 0,1 % on dry wood
- temperature : 70°C - 80°C
 40

- latency time : 60 mn
In these conditions, it is obtained a bi-vis pulp having the
following mechanical and optical properties (at 70 - 75 °SR)
- brightness : 63 - 65 % elrepho
- opacity : 91 - 94 % e1repho
- breaking length : 2800 - 3200 m
- burst : 1.4 - 1.6 kPa.m2/g
- tear: 6.3 - 7.3 mN.m2/g
- bulk: 2.2 cm3/g
- shives (Sommerville) : 0.5 - 0.7 % 2
Wi th this bi-vis pulp, a newsprint (grammage : 45 g/m ) has been
manufactured on an industrial paper machine (former twin wire-machine
speed : 770 m/mn). The pulp compositions and the mechanical and optical
properties of the several papers samples taken during the trial are
given in table 3.
Table 3
Mechanical and optical properties of newsprint manufactured
with bi-vis pulps

Papers
_________________________ :: ___
Reference: Paper 1 Paper 2
__ : __________ : __________ Paper 3
: _________ _
.
E~E~~

Composition %
. . .
Chemical pulp 15 15 13 11
Stone groundwood pulp 66 41 42 43
Deinking pulp 19 19 19.5 20
Bi-vis pulp 25 25.5 26
------------------------- : ---------- : ---------- : ---------- : ----------
Properties
Grammage g/m2 45.1 45.4 46.1 45.1
Bulk cm3/g 1.60 1.72 1.67 1.65
Breaking length m MD 3580 3770 3700 3800
CD 1200 1190 1270 1240
Burst factor kPa.m2/g 1.02 1.12 1.13 loll
Tear factor N.m2/kg MD: 4.8 5.2 5.1 4.7
CD: 7.0 7.3 7.1 6.8
Brightness % elrepho 58.4 60.0 59.3 58.8
Opacity % elrepho 92.4 93.2 93.1 92.7

The newsprint containing 11 % of chemical pulp, 43 % of stone

groundwood pulp, 20 % of deinking pulp and 26 % of bi-vis pulp has
the same mechanical and optical properties that those the newsprint
daily manufactured in the mill, this paper containing 15 % of chemical
pulp. During the manufacture of the newsprint with bi-vis pulp no
incident has been observed on the paper machine running.
The use of bi-vis pulp has permitted a reduction of the chemical
pulp rate of 4 points (25 % of the chemical pulp amount used in the
mill) without modification of the newsprint quality.
The printing of a weekly newspaper with this paper (edition of
220 000 copies) has been carried out without problem. The printing
properties of the bi-vis paper are, at least, similar to those of
the conventionnal paper.
 41

4. INDUSTRIAL TRIALS OF PRINTING GRADES MANUFACTURES CONTAINING HARDWOOD

BI-VIS MECHANICAL PULP
A lot of 15 tons of bi-vis pulp has been manufactured from hardwood
chips (poplar) in the following conditions
- average production : 330 kg/ h
hydrogen peroxide rate : 3 % on dry wood
caustic soda rate : 6 % on dry wood
sodium silicate : 4 % on dry wood
DTPA : 0,1 % on dry wood
temperature : 70°C - 80°C
latency time : 60 mn
The bi-vis pulp obtained has the following characteristics (at 50 0 SR):
brightness : 76 - 78 % elrepho
opacity : 75.5 - 76.5 % elrepho
breaking length : 2 600 - 2 900 m
burst : 1.0 - 1.2 kPam2/g
tear: 4.45 - 4.55 mNm2/g
bulk: 2.00 - 2.08 cm3/g
shives (S~mmerville) : 0.25 - 0.35 %
Wi th this bi-vis pulp three printing grades have been manufactured
on an industrial paper machine (machine speed: 240 - 280 m/mn).
- Manufacture of a standard white printing grades (grammage : 64g/m2)
The pulp compositions and the values of the principal mechanical
and optical characteristics of the papers taken during the trial are
given in table 4.
It seems possible in this paper to replace partly the chemical
pulp and the stone groundwood pulp in the following proportions' :
use of 40 % of bi-vis pulp, reducing of 12 points of the chemical
pulp and of 28 points of stone groundwood pulp without modification
of the paper quality.
Table 4
Mechanical and optical properties of printing paper (white paper)
manufactured with bi-vis pulp

Reference:
Papers
____________________________________ : ___ Paper 1 : _________
__ : __________ Paper 2_
.. ..
E~E~~

CompositIon % ··
Chemical pulp 42 40 30
Stone groundwood pulp 58 30 30
Bi-vis pulp · . 30 . 40
------------------------------------ ···---------- ..---------- ...----------
Properties
Grammage g/m2 64.9 64.4 64.8
Bulk cm3/g 1.40 1.53 1.40
Breaking length m MD 3920 3880 3820
CD 1900 2090 2050
Burst factor kPa.m2/g 1.50 1.49 1.37
Tear factor N.m2/kg MD 5.11 5.09 4.60
CD 6.26 6.16 5.80
Brightness % elrepho 76.0 75.7 76.0
Opacity % elrepho 89.7 89.7 89.9
 42

_ Manufacture of a standard rose printing grades (grammage : 60 g/m2)

The pulps compositions and the mechanical and optical properties
of the several paper samples taken during the trial are indicated
in table 5. In the composition of this paper, it is possible to replace
partly the chemical pulp and the stone groundwood pulp used by the
mill in the following ratio use of 30 % of bi-vis pulp, reducing
of 12 points of chemical pulp and of 18 points of stone groundwood
pulp.
Table 5
Mechanical and optical properties of printing paper (coloured paper)
manufactured with bi-vis pulp

---------~~~~~~---------------------:-::;;;;~:::-~~~~~-=--:-~~~~~-=--
%
Composition
· . .
Chemical pulp 42 35 30
Stone groundwood pulp 58 45 40
Bi-vis pulp · . 20 30
------------------------------------ ···---------- .. ---------- ..----------
Properties
Grammage g/m2 59.0 60.2 61.6
Bulk cm3/g 1.47 1.51 1.51
Breaking length m MD 3880 4175 4040
CD 2100 2140 2090
Burst factor kPa.m2/g 1. 75 1.66 1.62
Tear factor N.m2/kg MD 5.12 5.31 4.90
CD 6.28 6.98 5.93
Opacity % elrepho 96.2 96.1 96.1

- Manufacture of a white pigmented printing grades (grammage : 70g/m2)

The mechanical and optical properties of the paper containing 25 %
of bi-vis pulp are similar to those of the reference paper. The use
of 25 % of bi-vis pulp at the place of a part of the chemical pulp
(10 points) and the stone groundwood pulp (15 points) does not modify
the paper quality.
The results of the printing tests realized at the laboratory
scale Hinting tests wi th printing on offset machine and IGT device)
on all paper samples have shown that the printing grades containing
bi-vis pulp were, at least, identical to those of reference papers.

5. CONCLUSION
The works realized until this day have permitted to rediscover
wi th the Lancey pilot plant running continuously the results obtained
discontinuously in the CTP pilot plant, concerning the pulps quali ty
and the energy gain. The mechanical properties of the bi-vis pulps
produced are even higher to those of some market high yield pulps.
The trials with the bi-vis pulps lots supplied to several paper
mills in order to manufacture printing grades on industrial paper
machines have shown that the use of softwood or hardwood bi-vis pulp
is characterized by' a reducing of several points of the chemical pulp
percentage used, without modification of papers quality.
The printing tests carry out on all the papers manufactured
indicate that the papers containing bi-vis pulps have a behaviour
towards the printing identical to this of reference papers usually
manufactured in the paper mills.
 43

Contract nO BOS-057-I

CTMP FROM HARDWOODS AND THEIR POSSIBLE USE IN SOME PAPER GRADES

A. BOSIA
SIVA SpA - Centro Tecnico Industriale Cartario e Grafico - Roma

Summary

Chemithermomechanical pulp were produced with SIVA's semin-

dustrial plant from different hardwoods some of which not yet
employed for paper-making purposes. The process was modified
to fit to the production of high yield pulps from hardwoods al-
though the utilized plant had been tailored for softwood pulps .
The properties bleached pulps from black locust, beech, iron
oak, poplars and eucalyptus globulus which are cultivated in Ita
ly, are presented. Some important factors that affect the pulp-
properties are also discussed. Papers of different grades with
the aforesaid high yield pulps were produced: the resulting pro-
perties are evaluated with reference to the particular kind of
wood. The paper will also present data of chemical analysis of
process effluents as well as those depolluted by means of a bio
logical treatment.

1. INTRODUCTION
The work was carried out on a semi-industrial pilot plant (capa
city 15 tons/day) installed in Rome at the Centro Tecnico Industriale-
of SIVA, a Company of Ente Nazionale Cellulosa e Carta (E.N.C.C.).
The pilot installation is to all intents and purposes conceived as
an industrial plant and this made it possible not only the assessment
of the pulps that were produced, but above all to study the individual
stages of the process and to define the most favourable operating co,!!
ditions for the industrial plant that could be used.
The woods used in the trials were some hardwood species: par-
ticular attention was paid to woods of a high density, including iron
oak. beech and robinia, which do not so far appear to have been used
for the production of high-yield (90%) pulps. The first trials were caE
ried out with euroamerican poplars and some species of eucalyptus and
made it possible to tune up the plant, achieve control over the process
variables and compare the results with those of poplar CMP published
 44

(~
-~
~EI
8
4

1J r
1 - Presteaming vessel
2 - Press
3 - Impregnation vessel
4 - Digester
5 Transport screw
6 - Pressurized refiner
6 7 - Screw press
8 - Refiner

FIGURE 1 - CTMP plant

in previous papers.
Figure 1 shows a schematic layout of the pilot plant used for the
trials. The constructional features of this plant make it particularly ~
table for the production of semichemical pulps from various types of
wood and chemithermomechanical or thermomechanical pulps from soft-
woods; for the production of CTMPs from hardwoods. on the other
hand, a number of measures had to be taken to adapt the plant to the
known pulping needs of chemically pretreated hardwoods.

2. PRELIMINARY LABORATORY ESPERIMENTS

Pilot pulping of anyone type of wood was always preceded by la
boratory trials that, as far as possible, sought to simulate the ope-
rations subsequently to be performed in the pilot plant. The purpose
of this work was to obtain appropriate indi cations regarding the pre-
treatment conditions necessary to ensure that the chips would become
impregnated with liquor as quickly and completely as possible.
The first pulping runs in the pilot plant had in fact made it quite
clear that impregnation had to be considered as one of the most im-
portant operations of the CTMP process. Optimal impregnation requi-
res the chips to have a high initial moisture content relative to their
particular physical structure and that they should subsequently be sub-
jected to presteaming before pressing and moving into the impregnation
vessel.
Given the particular case of our study. which aimed at obtaining
 45

high-yield pulps from different types of wood. it was therefore of d!

cisive importance that the pretreatment in each case should be opti -
mized for the type of wood under examination. Indeed. if the trials
were carried out with chips having a moisture content below the sa-
turation point. the resulting pulps would have poor physical proper -
ties and would not be comparable to the pulps that can be obtained
from the same wood species when processed in more favourable mois
ture conditions. Such preliminary tests were therefore performed on
eucalyptus globulus, poplars I 214 and deltoides~ beech, iron oak and
robinia, determining in each case the volume of liquor that can be ab
sorbed in our particular plant and for a given liquor composition.
The laboratory experiments consisted of the following tests:
a) prolonged immersion of the chips in water. thus ascertaining the
maximum quantity of water that each type of wood can absorb;
b) pres teaming the chips for ten minutes at 100· C;
c) passing them through a screw press for the purpose of a partial de
watering, thus facilitating impregnation during their subsequent ra-
pid immersion in a cold solution of chemicals.
The laboratory tests also made it possible to determine the mest
appropriate concentration of the liquor, which consisted of sodium hy-
droxide and sodium sulphite as well as the best proportion of the two
reagents and the liquor quantity required for each particular wood. The
only variable that could not be determined during the course of these
laboratory tests was the minimum time required to obtain the maxi-
mum impregnation at the various plant temperatures; this information
was however obtained during the first pilot trials by measuring the
liquor consumption at various liquid levels in the impregnation vesse:!.
while feeding chips at It constant rate.
Table 1 shows the average volume of residual moisture after
steaming and pressing, the volume of absorbed liquor, and the total
volume of the liquid cont~ined in 1 kg of b. d. wood. The table also
shows the average volume of water at saturation point plus free water
(= total imbibition) that 1 kg of b. d. wood can contain on the basis of
its porosity, which was determined via the apparent specific gravity
(x). The average total imbibition was determined for purely orientative
purposes after the laboratory tests had shown that the time required
to achieve total imbibition was rather long. especially in the case of
high density woods~ so that it was not always possible to complete
imbibition during the test.

(x) Total imbibition values were calculated from the formula:

1.5 - do
Umax = 0.3 +
1.5 x do
where:
Umax = Total imbibition
do = Apparent specific gravity
 46

Table 1 _ Residual water, absorbed liquor and total liquid contained in 1 kg

of b. d. wood after pres teaming, pressing and impregnation.

Residual Absorbed Total otal imbi-

Apparent water liquor liquid bition
Species Basic
spec.gmvlty
density cm 3 cm 3 cm 3 cm 3

Cottonwood (1) 0,33 0,37 830 1. 600 2.430 2.300

Poplar I 214 (2) 0,31 0,34 800 1. 650 2,450 2.350

BltEgum (3) 0.43 0,53 760 1.100 1. 860 1.550

Beech ( 4) 0.58 0,69 750 850 1; oDD 1. 280

Black locust (5) 0,57 0, 63 100 700 1.400 1.170
Iron oak (6) 0.59 0, 71 680 750 1.430 1.100

(1) Populus deltoides M; (2) Populus I 214; (3) Eucalyptus globulus;

(4) Fagus sylvatica L; (5) Quercus cerris L; (6-) Robinia pseudoacacia L.

The total imbibition values proved to be very useful for the Pl!!'
poses of the subsequent trial runs in the pilot plant, because - knowing
the basic density and the apparent speCific gravity - the volume of g
quor that the chips will absorb during the impregnation stage can be
estimated with a sufficient degree of approximation: the quantities of
the chemicals to be employed could therefore be determined before
the programmed trials. The total quantity of liquid contained in the
wood after pressing and impregnation is always greater than the ave!:
age total imbibition moisture. This can be readly explained when one
bears in mind that after pressing (and the consequent partial break-up
of their structure) the chips will retain a part of the absorbed liquor
on their considerably enlarged surface.

3. PILOT PLANT TRIALS

The experimental work connected with this study was carried out
in such a way as to process only wood that had a moisture content of
not less than saturation point. It was therefore necessary to employ
only freshly felled logs and, further, to keep spraying them with wa-
ter, especially during the hot summer months.
The liquor used in the trials consisted of a mixed solution of so-
dium hydroxide and sodium sulphite. The proportions by weight of the
two chemicals are shown in Table 2; they were varied according to the
particular wood that was being used and the mechanical and optical
pulp properties to be obtained.
Guided by the laboratory results, the trials with woods of low and
medium density (poplars, eucalyptus) were carried out with liquors mv
ing a total concentration of the two reagents of the order of 50-60 gf
litre, this concentration being raised to 70-80 g/litre in the case of
high density woods. Working in this manner, the total chemicals were
normally comprised between 6 and 8% on b. d. wood, both for lower
and for denser species. The maximum quantity of liquor was generally
absorbed within about 4 minutes in the case of poplar and eucalyptus ,
 47

Table 2 - Treatment conditions and physical properties of the pulps.

Poplar Southern
Cottonwood I 214 Biu gum Beech Iron oak Black locust
SPECIES
(1) (2) (3) (4) (5) (6)

Chemicals NaOH/Na2S03 1/1.3 1/1.5 1/0.8 1/2 1/0.8 1/1

Reagent/b.d. wood ~. 7.3 7 7.6 7.2 6.9 6.8

Impregnation time (liquid stage) min 4 4 4 5 5 5

Time in digester min 40 40 40 50 50 50

Digester temperature ·c 116 116 115 117 121 108

Refining temperature ·C 93 94 94 96 98 92

Specific energy kWh/kg 1.2 1,2 1.3 1.4 1,5 1.3

Yield % 89 89 88 90 90 89

Residual reagent:
0,2 0
,.
tot ale alkali % 1,05 0.7 0.8 0.1

- sulphite 2 2,1 1,4 1,7 0,15 0,13

Bleaching H 202 % 1 1 1.5 2 2 2.5

Pulp properties (%) . SR 60 Uob!. BI. Unbl. Bl. Unbl. Bl. Unbl. BI. Dnbl. BI. Dnbl. El.

Tensile index Nm/g 46,6 47,2 46,1 48,3 51, B 60,2 42,2 45,2 38,7 41,1 42,8 40,1
Burst index kPam 2 jg 2.2 1.9 2.1 2 2,6 3,4 1,8 2,1 1.3 1.5 2.2 1.9
Tear index mN m 2 /g 5 4.9 4,8 5 5.1 4,9 4.3 4.4 4,8 4.3 5.0 4.3

Density g/cm 3 0,62 0.49 0,60 0,54 0,54 0,50 0,45 0,44 0,51 0,47 0,56 0.4

Opacity unbleached % 89 90 92 90 88 95

,.
%
Opacity bleached 80,5 79 4.5 86 84 90,5

IRE unbleached 50.5 52 47 48 42 37

IRE bleached % 70,5 71.5 1.5 63 63,5 64,5
Yield of bleached pulp % 97 97 96 95 95 97
Bauer Me Nett.:
28 mesh % 3.8 1.2 4.1 1.8 1.1 2.4
28- 48 " % 25.2 33,4 31,8 5.7 33.4 28,6
30
48- 100 " % 35.5 31.6 ?5.4 29.7 35,3

100- 200 " % 14.7 13,8 13.6 10 12.8 12,7

20. B 25,1 32.5 21
)- 200 " % 20.0 23.0

(s) Determined on sheets of 80 g/m 2 ; the opacities determined on sheets of 60 g/m 2 .

1) Populus deltoides M.; 2) Populus I 214; 3) Eucalyptus globulus; 4) Fagus sylvatica L.; 5) Quercus cerris L.:
6) Robinia pseudoacacia L.

and within 5 minutes when woods of higher density were used.

The temperature difference between the steamed chips and the
cold liquor, which were fed simultaneously into the impregnation ves
sel, constitutes an important operating condition that can greatly fac..!
litate imbibition. If there is a relatively large drop between the temp~
rature of the steamed chips and the equilibrium temperature of the
chips in the liquor, this will cause the gases contained in the pores of
the wood to contract and will thus promote ready penetration of the
liquor. Following the immersion phase in the liquor, the impregnation
of the chips and the chemical reaction will continue in the digester
and its steam atmosphere.
The data shown in table 2 were obtained by maintaining the tem-
perature of the chips in the digester within the range llO-120·C. At
these temperatures, indeed. one can still obtain pulps with acceptable
optical properties and also ensure complete impregnation and a good
sulfonation of the encrusting materials within a reasonably short per'iod
 48

of time . The time during which the various types of wood were
steamed at these temperatures was varied from 15 to 60 minutes. It
was thus possible to note that woods of a low or medium density will
develop a satisfactory bonding capacity during the subsequent refining
stage if they remain in the digester for not less than 30 minutes.while
chips of high density have to be kept for at least 45 minutes ( see
Figures 2 and 3).

Tensile in ex
hi 9

/ E . globulus
50
/ P.
/ ",-' P .
/ Robinia P.
/ fagus S.
40 /'
/ Qu ercus C.

30

20
---
o ~~·----Ir-------rl-------rI-------'I-------'I----~
30 40 50 60
~I·~n-u7"t.s
-

FIG. 2 - Tensile index of CTMP at 60'SR. Influence of retention time

in digester
Tear Inde.
I N . • 2/g

E . glo bulu s
/ P . deltoide Rob; n;3 P .
5
/~/ I 21 4 OJereus C.
//
.,/;-:::' Fagus S.

o
L.~·~--~--~--~--~~
i
20 30
' i
40 50
I .inutes
60
FIG.3 - Tear index of CTMP at 60'SH. Influence of rentention time
in digester
 49

The fact that the temperature of the chips was maintained at or below
120· C also made it easier for them, to be fed into the refiner at a
temperature (90- 95· C) closer to the softening point of the partially su.!
fonated lignin. In fact, as already mentioned, the chips were cool-
ed by blowing cold air through the transport screw; it was thus poss..!
ble to avoid water coolin& which would have reduced the pulp consis
tency well below 30%. a figure that must be considered optimal if the
refining is to develop good mechanical properties. All the refining o-
perations were thus carried out at consistencies above 30%. using Ty-
pe 9821 discs. The discs used during the second refining stage. on 1re
other hand. were of Type 9811. The pulp conSistency during this sta-
ge amounted to about 25%. The pulps produced in this manner were
then diluted with hot water and kept in a chest for about 30 minutes
to eliminate latency.
The fibres at this stage were always perfectly separated from
each other and it therefore proved possible to avoid sorting and clean-
ing of the pulps. all the more so as bleaching was to be followed by
a further refining stage before the pulps were actually used for paper
making.

4. PAPERMAKING
The poplar. E. globulus. beech and robinia CTMPs were used
to produce three different types of paper. namely newsprint. base PlPlE'
for coating (LWC) and offset paper, on an experimental pape.r machi-
ne. The properties of these papers were compared with the average
properties of commercial grades of the same type.
Quite apart from the specific considerations applicable to each
particular type of paper. the obtained data. though representing only
the results of a first experimental approach. permit a positive asses-
sment of the possibilities offered by these pulps. Each type of paper.
however. would call for further research aimed at obtaining CTMPs
with properties specifically designed for the particular paper to be pro
duced and all!lo optimal stocks prepared with the necessary contents of
other fibrous materials. fillers. etc.
As far as newsprint is concerned. the mechanical properties of
the papers made with 90% of hardwood CTMP are. taken on the whole.
comparable with those of standard industrial products. In the particu-
lar case of eucalyptus pulps. rather. they would seem to be signifi -
cantly better.
Turning to the optical properties. the brightness obtained with
bleached eucalyptus pulp is far better than that found in commercial
newsprint, though both the opacity and the scattering coefficient are
appreciably inferior. It seems likely that these two properties could be
imroved by means of a less drastic bleaching process and of a higher
filler content, readily possible in view the good mechanical properties
of these pulps. A lower brightness would improve matters. not least
as a result of the higher absorption coefficient.
 50

The mechanical properties of the offset paper obtained from po-

plar and robinia CTMP were found to be very good and wholly comp~
rable with those of the best commercial grades. These results suggest
that it should prove possible to increase the percentage of CTMP in
these papers without having to fear an excessive quality reduction.
Sizing with synthetic polymers made it possible to have water a..!?
sorption values suitable for the use to which these papers are to be
put. The measured oil receptivity values are wholly normal and show
that the smoothness and surface absorption properties are quite ade-
quate to permit their extensive use in offset printing.
The CTMPs, given their good mechanical properties, also proved
suitable for making base papers for coating, all the more so as the 02
tical propel'ties are not particularly important as far as this use is
concerned.

5. BIOLOGICAL TREA TMENT OF A SPENT CTMP LIQUOR

Given the problems associated with black liquor disposal. a judg-
ment regarding the desirability of producing chemithermomechanical
pulps from hardwoods can hardly be expressed without first having as-
certained the efficacy of appropriate depollution treatments. A biologi-
cal treatment of the spent liquor discharged from the plant after the
production of CTMP from eucalyptus globulus was performed in an ac~
vated sludge plant.
The parameters of the spent liquor obtained after the screw press
of the unbleached pulp are summarized in Table 3.
Table 3 - Load of Spent Liquor
mg/litre kg /ton of pulp
Total COD 8800 114
Total BOD5 3200 41
Sulphites (Na2S03) 1400 18
Phenols (Folin) 890 11.5
pH 7.1 -
COD/BOD5 2.75 -
UBOD 4900 I 64
The results of this work make it clear that the treatment of an
effluent from a CTMP plant employing the technology considered in our
experiments would be very difficult and excessively costly. Studies in
this field will therefore have to concentrate on sulphur free processes
and effluent treatments that also comprise an anaerobic stage. Clearly,
however, this problem would lose most of its importance if the CTMP
plant could be integrated into a paper mill that is already producing
chemical pulps and where the black liquors could undergo joint treatrrHlt.

6. CONCLUSIONS
The experimental work here reported was carried out with a plant
originally conceived for the pulping of softwoods. The process conditions
were subsequently modified in the light of the results obtained and were
 51

thus gradually adapted to the production of hardwood C TMPs. The expe

rience obtained in this field would now seem to suggest some plant mf!..-
difications that would go a long way towards achieving the positive re-
sults that quite undoubtedly can be obtained when hardwoods are used
for CTMP production.
During our trials, of course, it did not prove possible to make ~
ny substantial or significant plant changes and this fact, together with
the difficulties deriving from the discontinuous use of a plant of esse~
ially industrial siz e, created a series of problems that made the car-
rying out of these experiments particularly difficult. Neverthless, the
results obtained proved satisfactory and can be summarized as follows:
- Particular attention must be paid to ensuring that the moisture con-
ent of the wood to be processed is not below saturation point;
- Impregnation of the wood by the liquor is greatly facilitated when
there is a large temperature difference between the presteamed chips
and the cold liquor with which they come into contact;
- The time during which the chips are retained in the digester and in
the presence of steam must be suffiCiently long. taking due account
of the density of the wood that is being used;
- The refining temperature must be lower than the temperature in the
digester and must in any case be kept below 100· C.
As regards the results obtained with different wood species. one
may note that as a general rule all the pulps had good mechanical prf!..
perties in relation to the rather high yield. Subject to appropriate trea..!
ments, they can therefore be used for making a wide range of diffe -
rent papers.
More particularly. the poplar pulps already display brightness
that permit their being' used for the production of normal quality pa-
per. Bleaching with modest quantities of peroxide raises the brightness
to a pOint where they can also be used for fine papers.
The pulps made from eucalyptus globulus are also very sensitive
to bleaching agents and are therefore once again suitable for making
papers of va~ious grades.
However, both these pulps tend to be deficient as far as the scat
tering is concerned, especially after bleaching. This is not the case-
of robinia pulps, where the scattering remains high even after bleach-
ing; bleaching of robinia pulps, however, calls for larger quantities of
peroxide than have to be used with beech, poplar or eucalyptus pulps.
The positive features of robinia pulps could be readily exploited by
using this wood in appropriate mixtures with other species having mf!..
re or less the same denSity.
Generally satisfactory results were also obtained with beech, wh~
re the final yield is greater than that of any of the other woods exa-
mined by us. Beech, of course. has a rather low bark content. The
pulps obtained from iron oak proved to have rather mediocre proper-
ties, though this does not exclude positive reeults when this wood is
used in mixtures with other wood species.
 52

Contract nO BOS-085-UK

USE OF ANTHRAQUINONE AS A PULPING AID IN THE N.S.S.C. PULPING

OF EUROPEAN HARDWOODS

T. HUGHES
DivisiQDal Technical Manager, St. Regis Paper Company

SUMMARY

A literature survey indicated that Anthraquinone could be used for

the N.S.S.C. pulping of hardwoods. The main benefits would be from
increased pulp yield, reduced chemical usage and savings on energy.
This research was aimed at identifying these benefits, the best areas
of application and values. It was carried out in three stages;
firstly a number of small scale laboratory digestions to study a wide
range of pulping process variables. Using results from this work, a
limited number of pulping process variables which showed the best
potential benefits from using Anthraquinone, were selected for further
investigation. Stage two was to study these variables using larger
scale laboratory digestions which enabled pulp quality, etc. to be
evaluated. From the results of this work, a production plant trial
was run to establish if the laboratory results could be reproduced on
a production unit. At the end of the three stages, it was concluded
that Anthraquinone could be used to pulp hardwoods by the N.S.S.C.
process with the following benefits: Reduced usage of pulping
chemical, reduced energy consumption and to some degree, improved
pulp quality. To enable Anthraquinone to be used effectively, the pH
of the pulping liquor needed to be raised to 12.5 before adding the
Anthraquinone.

BACKGROUND TO PROJECT

In the early 1980's, there were numerous publications issued on the

use of qnthraquinone in pulping processes. A literature survey was
carried Ollt which indicated that the use of anthraquinone had given a
number of benefits in various pulping operations.
At that time very little had been published on the use of
anthraquinone for pulping of hardwoods. In fact, no data was available on
its use in a N.S.S.C. pulping process.
The survey concluded that provided the pH of the N.S.S.C. pulping
liquor could be raised to approximately 12.0 with caustic soda, then the
use of anthraquinone was possible in the N.S.S.C. process. The Company
had, for a number of years, operated with its white liquor at this pH and
so an investigation into the use of anthraquinone was warranted.
It was also concluded that there were four areas worthy of
investigation as to the benefits of using this chemical. These were:
1. Increase of yield 1-3%
2. Reduction of Chemical Charge by 1-2%
3. Reduction of Process Temperature ie. Saving of Steam
4. Reduction of Electrical Energy for Pulp'Refining
 53

The anticipated maximum usage of anthraquinone could be justified on

a financial basis if a yield increase of 2% or a reduced chemical usage of
2% on wood, could be achieved.

PLANNING OF PROJECT
A plan for the project was drawn up with the knowledge that the
research would be carried out in a laboratory annexed to a N.S.S.C. pulp
producing plant.
With this knowledge, the plan was to carry out the investigation in
three stages:
1. Small scale laboratory digestion using approximately 300 gms of chips
to enable a broad band of a number of pulping variables to be studied.
2. From results obtained, select a number of pulping conditions which
give the best potential benefits of using anthraquinone. Carry out a
series of laboratory digestions using 3Kg of chips to investigate these
conditions. This work to include the evaluation of pulp quality.
3. Studying results from this second series of laboratory digestions,
select the pulping condition with the best potential for giving benefits
by the addition of anthraquinone and use these to carry out a mill trial.
The pulping variables studied were:-
a) Level of A.Q. to be used
b) pH of the 'white' pulping liquor
c) The relationship between A.Q. addition and on % cooking chemical used
d) The effect of using A.Q. on process reaction rate, ie. process
reaction time and temperature.

ANTHRAQUINONE USED
Anthraquinone is a fine yellow powder which is not easily dispersed
and its form and preparation can significantly affect its performance as
a pulping aid.
Firstly, a highly milled form of AQ (1-3 microns) is ideal, prepared
as a well dispersed suspension prior to its addition to the pulping liquo~
Secondly it requires to be added to a pulping liquor with a pH above
10.0 and be well dispersed in the liquor prior to adding the liquor to the
wood.
To meet these requirements, a 50% highly milled dispersion of AQ,
which is commercially available, was used for this project.
Other materials used in the project were standard wood chips, of
mixed hardwood species, collected from the Mill wood preparation plant.
A solution of ' sodium sulphite, prepared from commercially available
bi-product sodium sulphite, the pH of this solution being adjusted with
caustic soda.

PROCESS VARIABLES STUDIED

1. Levels of addition of A.Q. were up to 0.1% on BD wood at increments
of 0.01%.
2. Four levels of white liquor pH, 10.0, 11.0, 12.0, 13.0
3. At an optimum level of A.Q. (0.06%) levels of chemical addition (%
Sodium Sulphite on BD wood) between 10.0% and 13.0% were studied
4. The effect of varying process temperature between 155°c and 170% and
process reaction time between 70 and 80 minutes were studied at 0.06, 0.08
and 0.1% A.Q. addition at both 10.0% and 12.0% addition of sodium sulphite.

RESULTS OF SMALL SCALE LABORATORY DIGESTIONS

1. The levels of A.Q. studied indicated that A.Q. could not be used to
reduce process temperature or process reaction time and maintain a pulp
Ylela.
 54

Increasing levels of addition up to 0.1% did increase the consumption

of sodium sulphite by the wood. The effect became less above an addition
of 0.06% and it was concluded that this was the optimum level of addition.
2. The pH of the white liquor to which the A.Q. was added did not affect
the performance of the A.Q. provided the process pH was above 10.0 when
process temperature reached its desired level (165°c). To achieve these
conditions, a white liquor pH of 12.5 was considered the optimum to use.
3. Studying the relationship between A.Q. addition and consumption of
sodium sulphite indicated that the presence of A.Q. increased,the
consumption of sodium sulphite. This phenomena occurred at all levels of
addition of sodium sulphite and so indicated the potential to reduce the %
addition of sodium sulphite. Furthermore, pulps produced using lower
additions of sodium sulphite were not of higher yield.
4. The use of A.Q. to reduce process temperature and time did not appear
to have any real potential.
The conclusion reached at the end of this stage was that the use of
A.Q. to reduce the level of addition of sodium sulphite was worth further
investigation. This was made the principal objective of the second stage
of the project, using larger scale laboratory digestions.

RESULTS OF LARGE SCALE LABORATORY DIGESTIONS

It was found that measuring techniques limited the accuracy for
measuring pulp yield from these laboratory digestions. Variations of !
1.0% were found to be attributable to errors of measurement.
Results of this work showed that the addition of A.Q. promoted the
reaction of sodium sulphite in the pulping process, such that virtually
the same percentage was consumed at 10% addition as at 12% addition. The
pulp yields as measured with the previously described limitations, were
not measurably different.
Results for refining the pulp showed that the addition of A.Q.
reduced the refining energy required to obtain a specific pulp wetness.
At the lower sodium sulphite addition of 10% on wood the addition of 0.06%
anthraquinone reduced the refiner power consumption by 6% when refining
the pulp to a 45°$R Schopper Wetness.
Evaluation of pulp quality from these laboratory digestions obtained
on laboratory prepared hand sheets, indicated the following: Tensile and
Tear were not significantly affected by the use of A.Q. However, Ring
Stiffness values were marginally improved whilst Concora values were
marginally reduced by the use of A.Q.
The conclusion of this stage of the investigation was that the use of
A.Q. at an addition level of 0.06% on wood, could yield benefits to the
N.S.S.C. pulping process for hardwoods. The most significant benefit
would be to reduce the sodium sulphite addition by 2%. There could be an
additional benefit of reduced refiner energy with no adverse effect on
pulp/paper quality. Lastly, it may be possible to reduce steam usage for
the digester operation to maintain a normal pulp yield.
A plant trial in the Sud brook Pulp Mill would be carried out to
establish the reality of obtaining these benefits in a full scale process
plant.

PLANT TRIAL USING ANTHRAQUINONE

The Sud brook Pulp Mill comprises of a Kamyr liquor phase digester
system followed by a Primary Refiner (Sprout Waldron) and three Secondary
Refiners (Defibrator), in parallel. Wood pulped is mixed hardwood using
a solution of sodium sulphite as white liquor. The pH of this liquor is
adjusted to approximately 12.0 with caustic soda to maintain the black
liquor ex digester at a pH of 6.8 - 7.5.
 55

The digester has a feed system and liquor recirculation system which
effect white liquor impregnation of the chips at a temperature of 90-98°c
at 150 psi pressure. For this trial the 50% suspension of anthraquinone
was added to the liquor circulation of this feed system.
The trial was run for a 72 hour period which included a period at each
end when A.Q. was not used. Objective of the trial was to reduce the
chemical addition during the period of using anthraquinone. Two levels of
addition of A.Q., 0.06% and 0.1% were run to check if the conclusion of the
laboratory work, ie. 0.06% was optimum.
Operating conditions of the plant were monitored closely during the
trial. Conditions monitored relative to the use of A.Q. are shown as
Graphs I, II and III. It should be noted that the pulp yield recorded for
the process is for pulp after secondary refining, hence it is lower because
losses include those resulting from the pulp washing stage of the process.
The results of the trial show that the liquor was lowered by 2.5%
without any adverse effect on the pulping process or the paper quality
produced. Refiner power consumption did not change throughout the trial
other than normal variation found over this period of time.
The introduction of A.Q. appeared to increase the Vapour Phase temp-
erature required to hold the liquor phase (process temperature) set. This
vapour phase temperature was reduced at the end of the trial whilst using
A.Q. As a result liquor phase temperature was reduced and steam usage by
the digester was reduced by some 10%. Pulp yield rose as a result of this
lower process temperature. As a consequence of this it would appear that
paper quality was affected.
The increasing of the A.Q. addition to 0.1% did not appear to give any
benefits. It would then appear that the 0.06% level established as an
optimum in the laboratory was also optimum in the process plant.

CONCLUSIONS
The first stage of the laboratory work indicated that there were
potential benefits to using A.Q. in the N.S.S.C. pulping of hardwoods.
Most probable benefit was' in reducing usage of sodium sulphite (cooking
chemical). It also established that the sodium sulphite solution needed to
be treated with caustic soda to raise its pH to 12.5 prior to adding the
A.Q. The optimum level of the A.Q. addition was 0.06% on wood.
The second stage of the laboratory work confirmed that the usage of
sodium sulphite could be reduced. It also indicated thE pulp quality in
terms of fibre, stiffness was improved even at lower refiner power
consumption, when using A.Q.
The plant trial established that a reduced addition of sodium sulphite
could be achieved in a production plant by using A.Q. In this instance the
financial saving for sodium sulphite was twice the cost of the A.Q.
addition.
It also indicated that improved pulp, hence paper quality, in terms of
stiffness, was achievable. This could be taken as a benefit in its own
right. Alternatively, paper quality could be returned to its base level by
reduced steam usage. Lastly, there is the potential to return paper
quality to its base level by reducing refiner power consumption which is
probably the most cost effective means of using A.Q. as a pulping aid.

FORWARD
The Mill is presently running further trials with the use of A.Q. to
establish the most cost effective way to use this material. It is antici-
pated that ultimately, A.Q. will be in continuous use at the Mill as a
pulping aid.
 PU~P MI~~ P~ANT TRIA~ USING ANTHRAQUINONE

~
1. TOTAL KW HR!rONNE ~. REFINER KW HRI'1'ONNE ~. % LIQUOR ADDITION

55 0 13 ~N a.S O , O~AO 13-%Na,SO, O.06')', AO I l l. 51oNa J%Na,SO

ITOTAL KW RR/l'ONNE
500
450
400

550
300 1330

2501~10
230 290
VI
0\

,
1701230 \ /
, .;
15012 10 1 J' I
II'
I I
1301 190 ,
1101 170 1 % LIQUOR ADDITnbN
12 ,5

11,5

10-5

~ § ~ ·~ I ~ ~ § ~ ~ ~ ~
29. 10.85 )):10.85
 PULP MILL PLANT TRIAL USING ANTHRAQUINONE

GRAPH n
• Di ge ste r Steam Flow lbs/hr . 2. Vapour Phas e Temp. °c 3. Liquor Phase Temp. °c 4. Pul p Yield% 5. Pulp \~etnesa °SR

1 »Na. 50. O. 06%AO 111.S'IoNa, 50. 0.06%1\0 10 . Na.SO O . t "A-O 3"Na.SO

ba/Hr

VI
-J

".

~ ~ ~I~ ~
29,10.9)
 PULP MILL PLANT TRIAL USING ANTHRAQUINONE

GRAPH III

1. TENSILE/GSH 2. BURST/GSI' 3. RS/GSM 4. CMT/GSM

S O. O%AO l~Na,SO, 0 . 06%A O 1 11.5l1'oNa,SO. 0.06%AO 3~Na,SO

.3
VI
.6 00

.4 I RS/GSH
.3
.1

0 .9
.~ . OICMT/GSH

2. 8
2.6

~ ~ ~ ·~ I ~ ~ ~ ~ ~ ~ ~
29.10:95
 THE PROBLEM OF STICKlES IN THE REUSE OF WASTE PAPER

Formation mechanisms of stickies in waste paper pulp

used in papermaking

The influence of zeta-potential on the agglomeration of

stickies on a tissue machine using waste

Easily removable hot-melt adhesi ves for use in

repulpable paper products and related process

Optimization of bleaching and deinking of waste paper

for strength and brightness improvement

The chemical treatment of fractionated stock from

"freely available" grades of waste paper

Production scale trials with fractionation of recycled

fibres

Optimization of waste paper fractionation to improve

secondary fiber quality for packaging papers

Improvement of the efficiency of rosin size in the

neutral pH-range

More filler in printing papers by optimizing forms and

distribution curve of filler particles

The development of processes to increase the filler

content of woodfree papers to 40%

Study of the properties, applications' and widening uses

of corrugated board impregnated by total dipping in a
solution of resin by a new process
 60

Contract nO BOS-013-D

FORMATION MECHANISMS OF STICKlES IN WASTE PAPER PULP USED IN PAPERMAKING

J. WEIGL and R. WILKEN

Papiertechnische Stiftung (PTS)
Hess-Str. 130a, D - 8000 Mtinchen 40

Summary

Stickies derive from undesirable waste paper components that

have entered the treated waste paper pulp. These stickies are
found to occur in the form of small particles or they have gone
into colloidal or molecular dissolution. Substances of this kind
are of particular interest, since they cannot be eliminated with
modern mechanical cleaning elements at the pulping stage. Forming
part of the accept, stickies tend to cause production failures and
quali ty losses. The paper discusses five different mechanisms of
how stickies agglomerate from particles or dissolved substances.
These formation mechanisms require certain process engineering
conditions which in turn are influenced by characteristic changes
in the composition of waste papers that have been observed in
recent years. The findings suggest a few possibilities of stickies
control.

1. INTRODUCTION

By definition, stickies are mainly organic constituents of waste

papers originating in the first instance from paper converting aids and
processing additives including printing inks and which are tacky by
nature or become tacky during waste paper treatment and in the
manufacture of waste paper containing new papers. Components of this
kind are, for example, adhesi ves and plastic films as well as some
chemical additives used in papermaking, in particular binders contained
in coating colours.
Trouble-free production of paper from waste paper pulps depends on
an effective removal of stickies from the waste paper pulp. However,
modern cleaning elements are incapable of fully eliminating these
contaminants at reasonable cost. As increasing amounts of waste paper
are being used, the raw material situation deteriorates, too, since
lower-grade waste papers and waste paper mixes have to be accepted for
recycling.
Following a mild suspending process, waste paper pulping is
therefore aimed at removing stickies to the largest possible extent by
means of mechanical cleaning installations. To this end, mainly
screening elements employing perforated and slotted plates are used.
Since minimum slot size is limited to 0.15 mm for manufacturing reasons,
stickies of a smaller diameter are not retained by such screening
 61

elements. To remove certain types of stickies, flotation and washing

processes are employed in addition to mechanical cleaning procedures.
When stickies are clearly different in density from swelled fibrestock,
they may be effectively separated by means of hydrocyclones. There is a
further possibility of dispersing the residual stickies, i. e.
comminuting them to nearly invisible by means of kneading at high
consistencies. It has been reported that, at elevated temperatures,
fine-particled stickies melt onto the fibres and thus become less
disturbing in nature. Even if dispersed very finely, however, the
stickies that are left in the suspension entail the risk o·f
flocculation, coagulation and deposit forming.
For waste paper constituents that have gone int-; colloidal or
molecular solution, mechanical cleaning processes are entirely
ineffective. Substances of this kind include organics that are wholly or
partly soluble in water, such as starch or CMC, as well as redispersed
films of adhesive dispersions and binders of coating colours. It should
be mentioned in this connection that, apart from waste paper
contaminants, there are other sources of molecular dissolved or
colloidal substances which have a similar stickies potential: Besides
fibre extractives (hemicelluloses and lignin derivates), the substances
concerned are some chemical additives employed as production additives
(e.g. dispersants) or product additives (e.g. natural or synthetic
strength agents) in the field of papermaking.
Production failures are thus caused not only by differently sized
sticky particles originating from the waste paper, but also by tacky
substances formed by the interaction of molecular dissolved or colloidal
materials contained in the whitewater. The underlying mechanisms will be
elucidated later.

2. FORMATION OF DEPOSITS OF TACKY PARTICLES FROM THE WASTE PAPER

WHICH ARE ADSORBED TO MACHINE AND SYSTEM PARTS

As mentioned earlier, not even insoluble stickies can be separated

completely by mechanical cleaning, since the load forces, impingement
forces and shear forces occurring in waste paper treatment can comminute
even thick adhesive films down to a point where separation through
perforated or slotted plates is no longer possible. These particles may
be hydrophobic (low surface energy and low polarity) of hydrophilic
(high surface energy and high polarity). With respect to deposit
formation, hydrophobic particles are more critical in that, in an
aqueous medium, they have a strong tendency towards agglomerating and
thus forming larger aggregates.
A characteristic feature of these particles is their tendency
towards being adsorbed to the surfaces of certain solids. The tacky
particles accumulating on these surfaces frequently from the basis of
even larger deposits, since secondary deposits of, say, fillers, fibre
fines and aluminium hydroxides will form on an already tacky surface.
The solids surfaces that are particularly suitable for this
adsorption process are characterized by surface energy and polarity
levels largely coinciding with the corresponding values of the
(hydrophobic) tacky particles. Besides, coincidence of these pairs of
values is the necessary prerequisite for a maximum particle-to-surface
adhesion. As is evident from figure 1, polyester or polyamides as are
 62

being used as wire and felt material are solids that are particularly
suitable for adsorption.

low
surface _gy

I.
mJ / m'
20-40 ,esln, hol"",111 elc.
35-45 poIy.,lef, polyamide
ce.70 lelc
z:

200-300 callulase

I 500-600

ca.2700
kaolin

c~,

~ ca.3500 nlcke'

high
eurfaca - I I Y

Fig. 1 - Surface energies of selected materials

It has been found in practice that metal surfaces too, and

especially copper surfaces, may invi te adsorption, al though they are
hydrophilic in character on account of their high surface tension. In
the presence of fatty acids, however, esters of fatty acid and copper
will be formed on the copper surface, rendering the copper hydrophobic
(cf. figure 2)

fatty acid
R crhYdiophObiC
I
C=O R
o, Ihydrophilic
I
C=O
H
+ ...... I
o H
I I
o Cu 0 Cu 0 Cu 0 OCuOCuOCuO
WTffff,&/1,?}, ~M
polar hydrophilic non-polar hydrophobic
copper boundary surface copper boundary Surface

Fig. 2 - A way of hydrophobizing copper

Schematic of surface reaction between fatty acids and copper

It is well known from literature that the deposit forming tendency

of some stickies grows in the neutral and alkaline pH ranges, which is
attributed, among other things, to the increasing tackiness of these
substances.
Experiments have revealed that the polarity and surface energy of
copper changes when the pH is changed. For experimental purposes, copper
 63

sheets were first cleaned in boiling acetone and then in 15%

hydrochlorid acid (HCl). Following this, a copper sample was placed in
water (pretreatment 1), another sample in 15% HCl (pretreatment 2) and a
third copper sample in NaOH at pH 11 (pretreatment 3). Exposure time was
two hours in each case. As may be noted from Table I, surface energies
and polarities measured are very low in the presence of alkali. The low
polari ty is certainly the principal reason for the high affinity of
copper to stickies.

TABLE I - SURFACE ENERGY AND POLARITY OF COPPER SURFACES PRETREATED IN

DIFFERENT WAYS

Pretreatment Surface tension, mN/m Polarity, %

1 40 21

2 52 35

3 55 2

Finally, it should be added that hydrophobic particles show a

particular tendency to being adsorbed to boundary surfaces between water
and gas. Gases dissolved in the fibre suspension can be released due to
changes in physical conditions, such as by temperature increases or by
turbulences. In this process gas bubbles are formed, to which
hydrophobic particles are attached which are flotated an then found to
be present in enr~ched form in the foam at the surface of the
suspension. The process engineering parameters influencing the gas
content of the suspension will be presented later. Figure 3 shows the
basic process of flotation.

foam layer
hydrophobic
fiber
substances

deposits
gas bubbles

Fig. 3 - Schematic of flotation of stickies

 64

3. FORMATION OF STICKlES FROM COLLOIDAL SUBSTANCES

Many substances contained in waste paper, such as films of

dispersion adhesives, residues of wax dispersions and binders of coated
papers, can wholly or partly dissolve in the pulping process to form a
colloidal or finely dispersed solution. As long as the
emulsifier/protective colloid system of these systems remains intact,
their potential of forming stickies is very low. However, if the
emulsifier is fully or partly destroyed, the colloidal substance becomes
a higly instable system in which the colloidal particles have a high
mutual affinity. They readily agglomerate to form larger particles which
in turn - as mentioned before - show a strong tendency to being adsorbed
to suitable surfaces.
The emulsifier/protective colloid system of colloidal solutions is
already destroyed by mechanical stresses. For example, if wax
dispersions are forced through high-shear pumps, the emulsifier can be
destroyed, causing the wax to flocculate. These flocs produce the
so-called fish-eyes in the paper web.
Moreover, the emulsifier/protective colloid system may be
sensitive to electrolytes. Frequently, the mere presence of Ca ions in
water of sufficient hardness (carbonate hardness) causes colloidal
particles to flocculate. The same effect is produced by cationic
addi ti ves, such as strongly cationic fixing agents used in place of
aluminium sulphate in neutral papermaking.

4. FORMATION OF STICKlES FROM DISSOLVED SUBSTANCES

A more or less large proportion of the contents of waste papers -

even of contents generally considered insoluble - goes into molecular
solution. This is illustrated in figure 4 by way of a selection of tacky
waste paper components. The proportions of these dissolving components
are arrived at as follows: 55 g oven-dry material of the substances
mentioned were first soaked in 2 I of water at ph 7 and, in a second
test series, soaked for two hours at pH 12 and then defibrated in a
standard disintegrator for one hour. After coarse fibre components had
been separated by screening, the filtrate was centrifuged, the excess
boiled down and the residue extracted with trichloroethylene. The result
was that 0.6 - 0.9% of the substances mentioned had gone into molecular
solution (cf. Fig. 4). Evidently an alkaline medium helps to increase
the solubility of at least some tacky waste paper components.
It was ascertained by means of polyelectrolyte titration that the
dissolved molecules carried a negative charge, i.e. they were anionic.
Therefore, electrokinetic interaction between these substances is not
possible. The coagulation and formation of larger agglomerates as was
observed in lab-scale tests was due to interaction with cationic
polymers. In this case, a process takes place which is generally defined
as coacervate formation (cf. Fig. 5). Cationic polymers, such as
retention aids, assist in forming polymer complexes.
Coacervate formation means not only larger aggregates and thus a
stronger tendency towards deposit formation, but also an undesirable
consumption of cationic additives which are then no longer available for
their original task.
 65

DpH7
1,0
~ pH 12
*:!
~
g
u 0,5
.!!
~
:::J
'0
II)

aaphaH paper hotmelt bond

Fig. 4 - Proportions (dissolved in water and extracted with

trichloroethylene) of a few selected waste paper components
having a high disturbing potential

polysatt reaction

eat Ionic anionic

po/ye/eetrolyte polymer complex

(coaeervate complex)

Fig. 5 - Coacervate formation mechanism

As whitewater circuits are increasingly being narrowed in

papermills, concentrations of dissolved and colloidal anionic substances
are growing. Anionic substances entering the accept do not originate
from waste paper contaminants alone. Starch, for example, which is used
as strength agent, or common fibre extractives (hemicellulose and lignin
derivates) are equally important in this context. These anionic
molecules, too, have the mechanism of coacervate formation.
Consequently, via coacervate formation mechanisms, increasingly narrowed
wi thewater circuits may lead to system-generated stickies having their
origin in sources other than the waste paper input.
 66

5. PROCESS ENGINEERING CAUSES OF STICKIES FORMATION

When describing the formation mechanisms of stickies, reference

has already been made to a few process engineering boundary conditions
necessary for their development. In particular, the prime importance of
the alkaline medium has repeatedly been confirmed: in the alkaline
range, substances are extracted from stickies to an increased extent.
Moreover, a large number of stickies are more tacky in an alkaline
medium.
The shift of pH values from the neutral to the faintly alkaline
range, which has taken place in many papermaking processes over the past
few years, was mainly necessary in view of the changed waste paper
composition. Irt this connection, mention should be made of risong CaC0 3
contents : During the past 15 years, the consumption of CaC0 3 used by
the Western European paper industry as filler and coating colour pigment
has increased from 15 000 t/a to 1 200 000 t/a. As a result, CaC0 3
contained in waste paper re-enters the papermaking process in
ever-increasing amounts. The use of calcium-carbonate-containing waste
paper within the acid range increases the solubility of calcium
carbonate and thus the carbonate hardness of the water. In addition,
calcium carbonate is transformed into calcium sulphate (gypsum)
developing gasiform CO 2 which at first dissolves in water. The
dissolving power of water for CO 2 , which is far higher than for air,
depends in each case on prevaillng temperatures and pressures. Under
certain process engineering conditicns, such as jumps of temperature or
varying pressures, the dissolved CO 2 will be released in the form of gas
bubbles.
If these processes are to be restricted or prevented altogether,
the process water has to be set to neutral of faintly alkaline pH's
where CaCO is largely stable.
As pB values shift to the neutral or alkaline range for a large
number of paperma,king processes, dosages of aluminium sulphate are
reduced or left out altogether. The function of aluminium sulphate in
the papermaking process will in this case have to be taken over by other
chemical addi ti ves. Being polyelectrolytes themselves, these addi ti ves
can interact with dissolved substances contained in waste papers in the
manner described. Moreover, polyelectrolyte concentrations increase as
whitewater circuits are narrowed.
Another process engineering parameter worth mentioning is
mechanical stresses on substances, such as by shear forces in case of
turbulent flows. The resulting destruction of emulsifier systems has
already been dealt with in this paper. On the other hand, turbulences
are the prerequisite for the capacity of hydrophobic particles to adsorb
to the surfaces of machine parts, since their kinetic energy allows the
particles to come into direct contact with the wall surface covered with
a multiple layer of adsorbed water molecules. It goes without saying
that, contrary to laminar flows, turbulent flows bring even larger
numbers of tacky particles into contact with wall surfaces. Generally
speaking, in modern high-speed machinery, turbulence-induced influences
on the formation of deposits have become more important recently.
 67

6. STICKIES CONTROL

The various mechanisms of stickies formation in the stock water

system of papermills allow conclusions to be drawn as to stickies
control methods. However, all conceivable control measures are complex
and expensive whilst yielding results that are strictly speaking
unsatisfactory. Absolute priority should therefore be given to those
processes allowing the waste paper to be cleaned before or during the
suspending stage. As was demonstrated earlier, however, there are waste
paper contaminants that cannot be eliminated by mechanical cleaning at
all.
To date, stickies control measures applied during stock
preparation and accept production have only proven satisfactory for
particle-shaped stickies. In the first instance, the method of
inactivating stickies by encapsulating them in talc is worth mentioning
in this context. An example is given in figure 6.

I I
1000J,lm

Fig. 6 - Hotmelt particle inactivated by a talc envelope

Early dosage of mineral adsorbents and strongly cationic fixing

agents into the stock can reduce the contents of dissolved and colloidal
anionic substances. Controlled dosage of these addi ti ves at selected
dosage points helps to largely restrict the formation of stickies.
 68

7. CONCLUSIONS

It has been shown that substances
which tend to produce stickies may be
particles or colloidal or molecular
specific formation mechanisms with
boundary conditions. The individual
follows :
originating from waste paper and
present in the form of either
solutions. Each form has its
different process engineering
formation mechanisms are as

1. Adhesion of low-energy (hydrophobic) particles to low-energy and non

polar surfaces of solids,

2. formation of particles from colloidal substances by electrolyte

effects or through destruction of the emulsifier,

3. formation of coacervate complexes from molecular dissolved

substances,

4. flotation of hydrophobic particles in foaming process waters, and

5. adsorption of molecular dissolved substances by way of electrostatic

attraction.

It follows that measures for fighting tacky substances or

substances prone to form stickies by synergetic interaction must be
taken as early as possible during waste paper pulping. This illustrates
once more the importance of optimum mechanical cleaning operations at a
minimum of mechanical loading of the fibrestock during the suspending
stage. The inevitable loads on the accept call for stickies control to
start at the earliest possible stage. These fighting measures using
chemical or physical means, i.e. fixing agents or adsorbents, must have
started before the individual stock flows come together in the mixing
chest.
Against the background of the formation mechanisms of stickies via
coacervate formation, special attention has to be paid to the selection
of suitable additives and points of addition to the stock flow.
 69

Contract nO BOS-065-NL

THE INFLUENCE OF ZETA-POTENTIAL ON THE AGGLOMERATION OF STICKlES

ON A TISSUE MACHINE USING WASTE

R.L. DE JONG
N.V. Papierfabriek Gennep

Sununary

After experiencing severe problems with "stickies" when manufactu-

ring tissue containing secondary fibre, Papierfabriek Gennep inves-
tigated the influence of zeta-potential in the agglomeration of
"stickies". The pH, conductivity and zeta-potential of more than
750 process water samples were measured to determine the most fa-
vourable electrostatic climate: a conductivity above 900 microsie-
mens/cm and a zeta-potential of 0 to -10 millivolt. The electro-
static climate can be influenced by the addition of various chemical
additives such as CMC, cationic wetstrength resin, fluorescent whi-
tening agent, glue, and so on. The conductivity can be increased
by closing the water system and increasing the calcium waterhard-
ness. During the investigation "sticky" problems were attributed
to furnish changes, alterations in mechanical cleaning system, poor
retention, sudden changes or interactions of chemical additives,
and to a new water soluble glue·, sothat many factors can initiate
a "sticky" problem and each problem can have a different· solution.
Maintaining a favourable electrostatic climate for the retention
of anionic particles on anionic fibres will reduce potential "stic-
kies" to a minimum.

1. INTRODUCTION
Like many other paper manufacturers who use waste paper, Papier-
fabriek Gennep in the Netherlands (Page) has experienced numerous pro-
blems with "stickies" when using waste paper based furnishes on the two
tissue machines: the Beloit machine and the older Dorries machine.
Beloit machine: This suction breastroll machine produces tissue
with a finished basisweight of 17 to 30 gsm with a maximum speed of 1400
mimi_no When producing tissue from 100% secondary fibre, "stickies" often
caused wire, felt or roll fouling inspite of quality checks on each in-
coming truckload of waste paper and inspite of a deinking plant with
a combined flotation plus washing installation, centrifugal cleaners
and screens.
In 1981 a relationship was found between the occurence of "stic-
kies" which fouled the machine clothing, and the build-up of black depo-
sits on a copper coupon which was hung in the stock level box after the
refiners:
- when making kitchentowel with cationic wetstrength resin, there were
few "sticky" problems such as felt and wire fouling, but there was
also very little build-up of black deposits on the copper coupons.
- when making pink tissue with anionic dyes there were frequent "sticky"
problems and a lot of felt and wire fouling. At the same time the black
deposit on the copper coupon built up to a thick layer within 24 hours.
 70

The black deposit could be dispersed in a laboratory disintegrator

with a dispersing agent, whereafter these chemicals were added to the
thick stock before the refiners with success. There was less felt and
wire fouling, but the deposit build-up was transferred from felt and
wires to the rubber-covered rolls in the papermachine and to the em-
bossing rolls in the converting factory.
Dorries machine: The older Fourdrinier machine produces kitchen-
towelling with a basis weight of 22 gsm at speeds up to 600 m/min. The
furnish consists of cellulose and tissue waste. Although this machine
has no equipment for treating secondary fibres besides a selectifier
plus vibrating screen, no problems were experienced with the furnish
until August 1982, when a new attrition-type rotor was installed in the
pulper.

2. THEORY AND OBJECTIVES

After noticing black deposits in another tissue mill (who preferred
using secondary fibre in kitchen towelling to toiletpaper, since it
caused less "sticky" problems), it became evident that the addition of
cationic wetstrength resin must have a favourable influence on the elec-
trostatic climate of the tissue machine by either preventing the forma-
tion of .. stickies" or by retaining them in the tissue and removing them
from the system. According to Penniman (1) optimum retention could be
obtained at a zeta-potential of 0 to -8 millivolts. pH and electrolyte
concentration or conductivity can also influence the zeta-potential rea-
dings:
- fibres become less negatively charged when the pH is lowered and more
negatively charged when the pH is raised
colloid particles in waste water are negatively charged with the iso-
electric point occurring below pH 7. Increasing the electrolyte con-
centration can raise the pH of the iso-electric point above 7
- a higher conductivity will decrease the thickness of the electrostatic
double layer surrounding the particles. This will result in lower zeta-
potential charges in water with a high conductivity than in clean water
with a low conductivity.
Little information was found on the retention of anionic particles
on anionic fibres and how the retention is changed by increasing the
conducti vi ty or the pH. Presumably the retention of anionic particles
will improve when the fibres have the lowest anionic charge: Le. at
low pH and high electrolyte concentration. Conversely a build-up of anio-
nic pa1::ticles will occur when the pH is raised or the conductivity is
lowered. If the build-up of anionic particles also includes hydropho-
bic particles, then these anionically charged hydrophobic particles will
deposit on metal or plastic surfaces inorder to get out of the water-
phase. If there are potential "stickies" or latex particles present in
the system, than the anionically charged hydrophobic particles will try
to agglomerate around the nucleus of the latex particle until it grows
into a pernicious contrary which sticks to the felts and wires.
Inorder to investigate this theory, a fl. 152.000 research project
was submitted to the EEC in September 1982 with the following objec-
tives:
A. Investigate the cause of sudden felt and roll fouling
B. Investigate the influence of zeta-potential on the formation of "stic-
kies"
C. Investigate the theory that a low negative zeta-potential would re-
sult in the poor retention of negative particles on negative fibres,
sothat these negative particles build-up in the watercircuits until
they cause trouble due to for instance:
 71

the agglomeration of hydrophobic anionic particles on hydropho-

bic surfaces such as plastic wires or latex particles present
in the purchased waste paper
- the coagulation of anionically charged particles after the ad-
dition of a cation.

3. DESCRIPTION OF WORK DONE

A stereo-microscope and a Swedish REPAP zeta-potential meter were
purchased inorder to investigate over 750 process water samples obtained
from six sampling points on the Beloit machine and eight sampling points
on the Dorries machine. A few samples were also taken in the deinking
plant.
The zeta-potential was measured after diluting a 0.5ml sample to
10ml with water obtained by centrifuging the original sample for 10 mi-
nutes at 3000 rpm. The average speed of five particles moving towards
the electrodes was measured before and after reversing the voltage on
the electrodes. The zeta-potential therefore represents the average of
ten measurements.
The pH and conductivity of the process water samples were also mea-
sured. In this way it was possible to describe the electrostatic climate
of the papermachine and correlate it with the number of feltwashes per
week on the papermachine. An attempt was made to ascertain the direct
cause of each felt wash, but to avoid any ambiguity every felt wash has
been included in the statistics by dividing the total number of all felt
washes during a specified period by the number of weeks in that period.
A sankey diagram of the organic material which is extractable with
methylene chloride was made in November 1984 together with a supplier
and is shown in figure I. It can be seen that 107 kg per hour of extract-
able material are circulating through the headbox of the Dorries machine,
whereas 5.9 kg per hour are retained in the paper and only 0.02 kg per
hour is removed by the vibrating screen.
In response to the question how the electrostatic climate of the
papermachine can be influenced, the effect of several chemical additives
on pH, conductivity and zeta-potential was investigated in the labora-
tory by adding increasing amounts of the chemical additives to a fibre
suspension and measuring these parameters. The relationship between wa-
terhardness, calcium ion content and conductivity was also investiga-
ted with the aid of several analyses which a Dutch public water labora-
tory had car!ied out since 1977.

4. MACHINE TRIALS TO REDUCE "STICKlES"

Beloit machine: As shown in Table I the average number of feltwashes
remained below one feltwash per week. Some extra washes were caused by
a malfunctioning cleaner stage and the lowest number of washes (0.3 )
occurred after installing new cleaners with light rejects in May 1985.
The increase in 1986 was caused by cheaper furnish trials inspi te of
improvements to the high density cleaning system (rejectsorter + contami-
nex). Trials with a Uniflow cleaner on the light rejects from the centri-
fugal cleaners have demonstrated improved separation of "stickies" com-
pared to treatment of the rejects in a flotationcell. Pilotplant trials
with dispergers have also shown a difference in fibre length results:
one disperger curled the fibres whereas the other type lengthened the
fibres. The curled fibres are probably more effective in encapsulating
residual "stickies", sothat this type of disperger is preferred.
 72

Dorries machine: A good example of how zeta-potential can influence

the agglomeration of "stickies" was obtained in 1982/1983, after the
Dorries machine suddenly encountered more problems with "stickies" sothat
the felts had to be washed 3-5 times per week. Although several possible
causes were found (e.g. a plugged reject line from the selectifier
screen, a new attrition type rotor in the pulper which was changed,
etc.), the "sticky" problem persisted, inspite of these "causes" being
remedied.
It was then discovered that the zeta-potential of the white water
was -19 millivolt, sothat some trials were initiated in 1983 to obtain
a zeta-potential of -5 millivolt:
- a trial with dual polymers (anionic + cationic flocculants) on the
saveall to improve retention produced immediate feltfouling, sothat
the felt had to be cut out after eight hours
- opening the white water system in April and substituting the anionic
flocculant with a cationic flocculant in the saveall in May reduced
felt washes considerably but there were still specks in the sheet,
which disappeared when the saveall accepts were sewered
- increasing the distance /timelag between the anionic drystrength ad-
ditive in the machine chest and the cationic flocculant in the saveall
got rid of the specks
- as shown in Table I the result of these changes was: good running con-
ditions from June 1983 until the end of the year with record production
and a record felt life of 1120 hours in October.
The installation of a new high turbulent head box and stock approach
system on the Dorries machine during Christmas 1983 resulted in a lower
headbox consistency, improved formation, lower retention and increased
fel twashing frequency. Trials with dispersing agent and less alum were
unsuccesful. So were trials with continuous felt cleaning, different
furnishes, no chemicals and more alum. Switching from alum + dispersing
agent to 0.5% talcum powder on April 27th 1984 gave a temporary improve-
ment. After performing trials with ply bonded converting factory waste
containing a new, water soluble glue, felt washing frequency increased
to 8-11 times per week and the felt actually became "sticky" to touch.
As a result this waste was no longer used on the Dorries machine after
August 1984. Infra red analysis of the "stickies" removed from the felt
showed that the suspect glue contained an absorption peak at 1040 wave-
length, which was subsequently identified as a silicon-oxide group.
The new centrifugal cleaners with light weight rejects for deinked
stock,a new vibrating screen (since the old screen had become plugged
up with calcium carbonate), and installation of a high pressure shower
reduced feltwashing frequency to two per week.

5. RELATIONSHIP BETWEEN ELECTROSTATIC CLIMATE AND FELTWASHING FREQUENCY

As shown in Table I, the feltwashing frequency of the Beloit ma-
chine is much lower than the feltwashing frequency of the Dorries ma-
chine. As a result the electrostatic climate of the two machines was
compared in Tabel II and III by regrouping the 750 measurements of pH,
conductivity and zeta-potential into four conductivity ranges and four
zeta-potential ranges.
It was noticed that there were few zeta-potential measurements out-
side the desired range of 0 to -10 millivolt when the conductivity of
the process water was above 900 microsiemens/cm. Assuming that the zeta-
potential and conductivity ranges optimize retention of anionic particles
on anionic fibres, the following correlation between electrostatic cli-
mate and feltwashing frequency was made:
 73

Average Feltwashing Percentage measurements

Frequency during o to -10 mv. zeta-pot.
Machine ~ Reriod or > 900 eSicm condo
Beloit 1/83-6/86 0.6 93.1%
Dorries 1/84-6/84 5.2 46.3%
Dorries 7/84-6/85 4.1 62.8%
Dorries 7/85-6/86 2.1 73.3%

In this connection it is interesting to note that a fresh water

leak on the side hill screens resulted in black "sticky" deposits down-
stream from the leak. As shown in the Sankey diagram of figure I, the
potential "stickies" are always there: they just need the wrong electro-
static climate to agglomerate and deposit.

6. FACTORS INFLUENCING ZETA-POTENTIAL AND CONDUCTIVITY

Various chemical additives were added to samples of process water
in the laboratory in order to determine the influence of the additives
on the electrostatic climate. The results were:
- Wetstrength resin and PEl resin increase cationic charge
- Some dyes, fluorescent whitening agent, defoamer, anionic acrylamide
resin and carboxy methyl cellulose increase anionic charge
- Fluorescent whitening agent increases the conductivity
- Deinking and dispersing chemicals had no effect
- The "suspect" watersoluble glue from the converting factory increased
the anionic charge, whereas the standard glue decreased the charge.
After discovering that the addition of cationic wetstrength resin
and anionic green dye too close together can produce "stickies" and that
similar problems had occurred elsewhere with fluorescent whitening agent
plus wetstrength resin, it was decided to investigate the interaction
of carboxy methyl cellulose, fluorescent whitening agent, and wetstrength
resin and their influence on zeta-potential. The results of this labora-
tory investigation are ~hown in figure II.
- Addition of wetstrength resin to a system containing 40 ppm CMC + cel-
lulose fibres increased the zeta-potential from -25 mv to +30 mv
- Addition of Fluorescent Whitening Agent resulted in more negative rea-
dings
- This demonstrates that the zeta-potential changes as soon as CMC, FWA
or wetstrength resin quantities are changed. On one occasion the wet-
strength pump failed during the start of a trial with an alternative
wetstrength resin and within two hours the felts rapidly became dirty.
As shown in Table IV the conductivity of the process water has more
than doubled since 1977 due to increased waterhardness arising from cal-
cium carbonate in the waste paper, reduced waterconsurnption and the neu-
tral pH throughout the system.
 74

7. CONCLUSION
The combination of dispersing agent, new centrifugal cleaners with
light rejects and a favourable electrostatic climate for the retention
of potential "sticky" particles has reduced felt washing frequency to
a low level on the Beloit machine.
After installing a new headbox on the Dorries machine, felt washing
frequency suddenly increased to an average of more than five times per
week. After removing possible "sticky" sources from the furnish (such
as a new watersoluble glue) and after improving the mechanical separation
of "stickies" from the stock with improved cleaning equipment, it was
possible to reduce the number of felt washes to an acceptable level:
at the same time the electrostatic climate improved sothat more measure-
ments were between 0 and -10 millivolt for zeta-potential or above 900
microsiemens per cm for conductivity. Maintaining a favourable electro-
static climate for the retention of potential "sticky" particles on anio-
nic fibres, will result in fewer "sticky" problems on the papermachine.

8. ACKNOWLEDGEMENT
The investigation was made possible by an EEC grant of f 76.000.
The assistance of mr. A. Dechamps and A.K. Janssen with machine trials,
observations and measurements was greatly appreciated.

9. REFERENCES

1. Penniman, John G., Optimization of the Electrokineties of the Paper-

making System, 1980 Tappi Retention and Drainage Seminar.

TAB L E I

AVERAGE NUMBER OF FELTWASHES PER WEEK

ON TWO TISSUE MACHINES DURING '83-'86

Aver. number of
Feltwashef!.f~eek
Beloit Dorries Remarks during periode regarding
~ machine, machine Beloit machine (BM!+Dorries machine {DM!
1/83-6/83 0.7 2.3 DM: - Trials to reduce zeta-potential
7/83-l;!j83 0.8 0.7 BM: -Malfunctioning cleaner stage in Nov.
DM: - Record felt life in Oct.
New glue in conv. broke in Nov/Dec.

1/84-6/84 0.5 5.2 DM: - New Headbox in January

- Many trials during period
7/84-12/84 0 •. 6 4.5 DM: - New glue caused extra feltwashes
+ stopped using it after Aug.

1/85-6/85 0.5 3.6 BM: - New Cleaners with light rejects in-
stalled in de inking plant
DM: - New vibrating screen in March
- New high-pressure shower in June
7/85-12/85 0.3 2.1 BM: - Contaminex installed in Dec.

1/86-6/86 0.9 2.0 BM: - Cheaper furnish trials during period

- Rejectsorter installed in May.
 75

TABLE II
ELECTROSTATIC CLIMATE OF BELOITMACHINE (FEW STICKlES)
AND DORRIES MACHINE (MANY STICKlES)
(A= Number of measurements; B= % measurements; C= Average pH)
BELOIT MACHINE DORRIES MACHINE
1/83-6/86 1/84-6/84
0.6 Feltwashes/week 5.2 Feltwashes/week
CONDUCTIVITY C ZETA-POTENTIAL RANGE ZETA-POTENTIAL RANGE
RANGE 0 (millivolts) of 162 meas. (millivolts) of 123 meas.
( ,uS./em) D
E <-20 -20to-l0 -10toO >0 <-20 -20to-l0 -10toO 2.0
A 0 3 0 1 3 22 11 12
< 500 B 0 1.9 0 0.6 2.4 17.9 8.9 9.8
C 7.4 6.8 7.5 7.6 7.3 7.1
A 0 3 2 0 3 26 29 0
500-700 B 0 1.9 1.2 0 2.4 21.1 23.6 0
C 7.5 7.6 7.6 7.4 7.2
A 0 1 20 3 0 0 14 0
700-900 B 0 0.6 12.3 1.9 0 0 11.4 0
C 7.5 7.5 7.1 7.0
A 0 17 95 17 0 0 3 0
2. 900 B 0 10.5 58.6 10.5 0 0 2.4 0
C 7.2 7.3 7.0 6.6
~ 900 or
-10toO mv B 93.1 46.3
zeta-notent
TAB L E III
IMPROVED ELECTROSTATIC CLIMATE IN 1985-1986
OF DORRIES MACHINE (FEWER STICKlES)
(A= Number of measurements; B= % measurements; C= Average pH)
DORRIES MACHINE DORRIES MACHINE
7/84-6/85 7/85-6/86
4.1 Feltwashes/week 2.1 Feltwashes/week
CONDUCTIVITY C ZETA-POTENTIAL RANGE ZETA-POTENTIAL RANGE
RANGE 0 (millivolts) of 232 meas. (millivolts) of 165 meas.
( ,uS./em) D
E <-20 -20to-l0 -10toO >0 <-20 -20to-l0 -10toO >0
A 2 41 13 1 0 24 19 0
< 500 B 0.9 17.7 5.6 0.4 0 14.5 11.5 0
C 7.4 7.5 7.5 7.4 7.3 7.4
A 0 36 49 3 0 19 52 0
500-700 B 0 15.5 21.1 1.3 0 11.5 31.5 0
C 7.4 7.3 7.2 7.4 7.5
A 0 3 14 0 0 0 18 1
700-900 B 0 1.3 6.0 0 0 0 10.9 0.6
C 7.2 7.3 7.3 7.3
A 0 1 69 0 0 0 32 0
~ 900 B 0 0.4 29.7 0 0 0 19.4 0
C 6.9 6.9 6.9 0
~ 900 or
-10toO mv B 62.8 73.3
zeta-potent.
.- .. . -"-----"-
 76

Table IV: Increase in waterhardness and conductivity

Sample Waterhardness Calcium Conductivity
Location ...Y2L. ~German Degrees! Jr1l2ml ( ~S·Lcm)
Process water 1977 8 50 1300
Page 1981 31 170 2030
1985 102 676 2830
Effluent 1977 10 65 680
Page 1981 14 74 1000
1985 38 173 1180
Board mill 1985 930 6900

Figure I
Pulp
5,1·

Fanpump

T.blewoter Vibrating
94,6· screens
0,02

Headbox / 107

Wire

P.~r

5,9
• Calculated Effluent 7,0

DCM blloct diog,am (k;/hl ORGANIC TRASH · DIAGRAM

Slmp!;ng: Novernbir 1984 Tissue--mlchine Gennep
 77

Figure II

2ETAPOTENTIAL INFLUENCE OF F.W.A. and W.S. RESIN

mi llivolt ON 2ETAPOTENTIAL

.30
a ppm FWA-»-

+20

60 ppm FWA "0"

... ,0
120 ppm FWA-e-

ot-- ---.-- -f-,.---- -..------+- --A....---,L--.-----.------ ppm Wet Strength

200 600 800 1400 Resin

-10
1,/
f
,,;0

""
"" ..0'

_... - ......
-- o ~".
"

·40
Slandard W.S. R
esin
Dosage
 78

Contract nO BOS-122-I

EASILY REMOVABLE HOT-MELT ADHESIVES FOR USE IN REPULPABLE

PAPER PRODUCTS AND RELATED PROCESS

M. PIERONI, Istituto G. Donegani

A. CHIOLLE, Dutral SpA
P. TREDICI, Bassi Marchini SpA
V. KOCH, Siva SpA
G. CALMANT I and A. GATTI, Montefluos SpA

Summary

Stikies formation in paper recycling is due in great part to hot melt

and pressure sensitive adhesives. In Europe EVA copolymers are widely
used for their preparation. A new class of hot melt adhesives (UM) for
paper binding has been found, which is characterized by a low stickies
forming capabilities and an easy removability in the recycling pro-
cess. These UM belong to the class of saturated copolyesters and are
prepared starting from terephtalic and adipic acid esters with 1,4-
butandiole or monoethyleneglycole. Among the new UM formulated with
saturated copolyesters (COPES) the best set of properties, both for
application in book binding and for paper recycling, has been obtain
ed by using a copolymer prepared from monoethylenglycole blended with
minor amounts of two elastomeric copolyesters, colophony resin deriv~
tives and antioxidants. Removal from secondary fiber pulp is easily
carried out by using hydrocyclones owing to the low stickiness of UM
particles and to their density of about 1.2 g/cm 3 • A new evaluation
method, developed in the research, has shown a much lower tendency to
form stickies by reagglomeration in COPES HM than in EVA HM. Higher
prices of the new adhesives can be counterbalanced by lower recycling
operating costs and lower lost production.

1. INTRODUCTION
Efforts to remove stickies forming adhesives from recycled fiber pulp
by physical or chemical methods are not completely satisfactory (1,2,3,4,
5). Objective of this research is to find out new adhesives which can be
easily removed from fibers in the recycling process. Stickies are a mixture
of various products which in the recycling are collected together also in
large particles. Composition and behaviour of stickies are not completely
understood but it is well known that products which contribute to their fo~
mati on are thermoplastic polymers and elastomers (6,18) used in paper bind-
ing and coating, and various hydrophobic products which can be picked up by
the adhesive surfaces of particles.
The European consumption in 1980 of adhesives for paper (7) was the
 79

following:
- EVA HM 7,000 tons (EVA is for ethylene-vynilacetate)
- EVA pressure sensitive 1,000 tons
- STYRENE pressure sensitive 3,000 tons
- POLYVYNILACETATE and others 7,000 tons
Polyvynilacetate removal does not represent a problem because it loses ad-
hesion when dispersed in water. These figures show that HM and pressure
sensitive adhesives prepared from EVA are the main part of the stickies
forming adhesives. On the basis of this situation the present research pr~
gramme has been directed to finding products which could substitute EVA HM,
which are most diffused both for quantity consumed and number of applica-
tions.
2. NEW EXPERIMENTAL HOT MELTS
One of the tried methods for dealing with stikies involves the reduc-
tion of their stickiness in the recycling conditions. Adhesives which are
hydrolysed or well dispersed in alkaline conditions (8,9), and use of talc
to cover the surface of sticky particles have been studied and applied.
This research after a short exploratory period, has fOund new HM which have
shown easy removability from fiber pulp and very low stickies forming pro-
perties along with a good set of properties for application in paper bind-
ing.
These new adhesives (COPES) belong to the class of saturated copoly-
esters, which are random copolymers having plastomeric properties whereas
the currently used EVA copolymers are elastomers. In particular copoly-
esters of 1.4-butandiole and monoethylenglicole with terephtalic, isoph-
talic, isosulphophtalic and adipic acid have been studied for application
in paper binding. COPES h~ve been prepared by polycondensation of fused
monomers in micropilot and pilot plants (1 and 50 kg feed) according to
the process scheme of polybutylenterephtalate. Polymerization is obtained
in two steps in presence of titanium tetra.butylate:
1 - trans esterification under atmospheric pressure at 140-210°C
2 - polycondensation under vacuum (0.5 mm Hg) at 210-260 o C.
Combining the type and the quantity of the various monomers, and control-
ling the molecular weight it has been possible to obtain copolymers having
the required properties, in particular adhesion and cohesion, for paper
binding. In general properties of saturated copolyesters (10) are very in-
teresting when compared with EVA adhesives (see tab. 1), they have higher
melting temperature, higher density (about 1.2 versus 0.90-0.98 g/cm 3 ) and
lower water adsorption; all these properties play an important role in re-
moval from secondary fiber pulp because of their low tack at the process
operating conditions and of their density which facilitate the separation
by hydrocyclones.
Three types of copolyesters (COPES A10, A12, D12) have been selected
as adhesives to be used for the preparation of HM (see table 2); they are
obtained starting from dimethylterephtalate plus dimethyladipate and 1,4-
butandiole or monoethylenglycole. The introduction of small amount of is~
sulfophtalic acid improves in general the specific adhesion of these poll
mers. As for EVA copolymers, these copolyesters, can be mixed with anti-
 80

oxidants, adhesion promoters, viscosity modifiers and setting accelerators

in order to satisfy the required properties in application step and in the
final product. Very important are the requirements for book binding where
machines can be used running at 12000 books/hr. Owing to the chemical na-
ture of polyesters, mixing of some common additives with COPES in concen-
tration higher than 10-15% could be sometime impOSSible; glycerol esters
of colophony resin (Rokrasin 1887) have affinity improving adhesion and
reducing viscosity.
Three HM formulates have been extensively studied (see table 3). In
particular 50 kg of TFS 12075 (a blend of COPES A10 and D12) and of HMC
PILOT (COPES D12) have been prepared and used on industrial bookbinding
machines. Both products showed good general properties but setting time
and elasticity of the adhesive film needed to be improved. Thermal stabi-
lities were adequate to requirements if the temperature of the melted pr£
ducts was maintained under 180°C, twenty degrees lower than the limit of
EVA HM. On the basis of these results a third HM (ffi~C/C3) has been studied
starting from COPES D12 and adding two elastomeric copolyesters resulting
from block copolymerization of 1,4-butandiole, polyethylenglycole, poly-
tetramethylenglycole, terephtalic and isophtalic acids (see table 4). These
two elastomers (COPES 30CM and 46EM) improve elasticity, elongation under
stretching and setting time. Laboratory evaluation of HMC/C3 has been satis
factory and promising for the next development step. Because of the limited
time of the EEC research programme the new HM (COPES HMC/C3) has not yet
been developed, but studies will continue. A patent has been filed on the
HM here described (18).
3. REMOVAL OF THE NEW HOT MELTS FROM FIBER PULP
Selection of easy removable HM adhesives and of the related purific~
tion process has 'been possible by defining appropriate evaluation methods
(11, 12, 13, 14). The following methods have been studied and applied:
- A. Stickies counting. For the evaluation of stickies in fiber pulp a m~
thod has been selected to quantify their number and range of sizes; the
method is not absolute but it is very useful to compare the behaviour of
products and removal treatments. Visual measures are carried out on hand-
sheets after pressing between two thin white papers at 200°C and 3.5 kg/
cm 2 for 3 minutes. In these conditions stickies are fluid and diffuse
through the paper creating visible specks even if these are small or in-
side the sheet. EVA HM give rise to specks having an area 8 times larger
than the section of original particles, in the case of COPES HM the in-
crease is only 4 times due to their better set of properties. Laboratory
evaluation of HM removal from pulp is determined using 0.5% HM applied
from melt on paper sheets which are then treated in a pulper at room te~
perature and 2% dry matter density for 30 minutes. Pulp is finally passed
in a conical refiner to obtain small HM particles and then treated for
their removal.
- B. Stickies forming properties. Because of the tendency of small HM p~
ticles to agglomerate to form large stiskies, a method has been developed
for the evaluation of this behaviour. Clearly the smallest HM particles,
which cannot be completely removed from pulp, whatever the process used,
 81

are responsible for stickies formation when conditions for their agglomer~
tion happen. The laboratory stickies-forming method involves the treatment
of pulp in physical, chemical and mechanical conditions similar to those of
paper making cycle. In particular HM are mixed with the fiber pulp (2.5%
dry fibers) for 1 hr and then treated at 100 rpm for 15 minutes in a cen-
trifuge in which a free floating.cylinder simulates the mechanical actions.
The test takes place at three different temperature (25, 40, 60°C). As
starting materials 40-60 mesh HM particles in 2.5% weight on dry fibres are
used. The evaluation of the stickies forming properties is obtained by
counting the stickies having a specks area redoubled after the above des-
cribed treatment.
New HM adhesives obtained from COPES are easily and almost completely
removed by hydrocyclones (16, 17) while flotation (5, 15) is less effect~ve
than in the case of EVA HM. In laboratory conditions HM were tested feeding
an hydrocyclone with 450 1. pulp at .0.5% dry fiber density containing 0.5%
HM, at a flow rate of 150 l./minute and a pressure drop of 0.8-0.9 kg/cm2 •
The accepted pulp returned to the chest and after a time corresponding to a
complete passage of the pulp through the hydrocyclone cleaner, the removal
of stickies from the accepted pulp was almost complete. Starting from
pulps, from which handsheets are obtained having more than 100 sticky
specks, by these treatments pulps have been obtained having 0-5 specks/hand
sheet with an area generally less than 0.10 mm 2 , the few particles remain--
ing into the paper are very small and do not produce mechanical or optical
problems. Moreover, because of their reduced stickiness they have a very
low tendency to aggregate. These results have been confirmed also in a de-
inking pilot plant using a 5 inches TRICLEAN hydrocyclone (Beloit) opera-
ting at 0.6% dry matter density with a pressure drop of 2.6 atm. in pres-
ence of 3% Alvaran deinking agent (Ausind). More than 90% of COPES HM sti-
ckies has been removed by a single passage.
As above mentioned the stickies-forming properties of COPES HM are
very low compared to the EVA HM. Results obtained applying the new evalua-
tion method to COPES AlO, A12, D12, HMC/PILOTA and HMC/C3 are reported in
table 5. In general EVA HM under the test conditions give rise to agglome-
ration by simple mixing, the number of stickies formed increase with temp~
rature in the range 25-60 o C, when mechanical effect is added their number
becomes double or more. In the same conditions stickies formation from the
last COPES HM (HMC/PILOT and HMC/C3) has not been observed. The agglomera-
tion of EVA HM has been evaluated also in industrial pulp from waste paper.
For example for an Italian mill producing newsprint and LWC paper from de-
inked waste paper, the number of stickies counted in the thickened pulp
after the de~uking and cleaning steps was almost redoubled when treated
with our stickies-forming method at 40°C. Of course the visual count of
stickies is not sufficient on industrial pulps from waste paper, because
of the presence of other non-sticking specks; in this case stickies are
counted as adhesion points by carefull pulling apart handsheets treated
as above described.
The new HM removal can be therefore carried out in a conventional de-
inking plant without special devices Lut using the hydrocyclones of the
 82

plant. New HM does not need particular treatments or modification of the

paper recycling process and of the waste water treatment, moreover they do
not interfere with EVA HM and finally the mixture of the two can be removed
together.
4. ECONOMICAL CONSIDERATIONS
Raw material costs of COPES HM are about double of the corresponding
EVA HM, which have a price on the Italian market in the range 3300-4500
Lit/kg depending on the various polymer grades: as the HM consumption in
bookbinding is about 5 gm/kg of paper products, the additional cost is of
about 20 Lit/kg. This unfavourable situation can be counterbalanced if the
savings in the operating costs of de inking plants and in the reduction of
the lost productions are taken into account. Savings can be obtained in
particular from the following improvements:
1 - shorter pulping time and better withening owing to the possibility to
rise the temperature of the pulper up to 60-70 o C.
2 - higher quality of the produced paper and higher productivity of the
paper making machine owing to the lower accumulation of dirty.
3 - lower investment costs of the de inking and cleaning plants owing to the
higher efficiency in stickies removal.
The evaluation of these factors is not easy depending on the very different
situations and productions in mills. Benefits from the use of the new HM
are mainly expected by those companies which recover and deink their prints
because the higher costs in the bookbinding can be recovered by the mill.

REFERENCES
(1) KLUNGNESS, J.H., Recycled fiber properties as affected by contaminants
and removal processes. TAPPI,57, N° 11, Nov. 1974, 71-75.
(2) CUMMING, R.M., Pros and cons of waste paper. Part 2, Paper 191 N° 2,
Genn. 1979, 68-78.
(3) GBTTSCHING, L., STURME L., Altpapiereinsatz in der Pepierindustrie der
Bundesrepublik Deutschland. Teil II, Papier 32, N° 8, Aug. 1978, 360-
365.
(4) ATTWOOD, D., Fibre recycling - Introductory paper. EUCEPA 1983 Praha.
(5) HAMILTON, F.R., Current practices for identifying and removing sti-
ckies in deinking plants. TAPPI, 67, N° 4, April 1984, 56-58.
(6) BERGSTROM, W., Adhes~ve age. 21(10), (1978).
(7) SPRINGBORN MANAGEMENT CONSULTANTS, Hot melt adhesives, sealants and
coatings in the 80's.
(8) MC DONALD, M., Hot melt adhesives. Noyes Data Corp. (1971).
(9) BATEMAN, H., Hot melt adhesives. Noyes Data Corp. (1978).
(10) GIANDINOTO, G.V., PLIVELIC, I. and MALTONI, G.P., Materie plastiche
ed elastomeri. Luglio-Agosto 1981.
(11) KRUEGER, W.C. and BOWERS, D.F., Removing stickies from recycled fi-
ber. TAPPI,64, N° 7, July 1981, 39-41.
(12) SAURET, G., BERNARD, E. ed altri (CTP), Mise au point d'une nouvelle
technique de decontamination de~ vieux papiers destines au ricyclage
dans l'impresoion ecriture. Contract CEE n. 006-79 RCP-F Rapp. final.
 83

(13) BURROWS, P.R.M. and SMALL, J. (REED International Consultants), Rem£

val of sticky contaminants from waste-based papermaking furnishes.
Contract CEE n. 014-79 RCP-UK Final Report.
(14) ATTWOOD, D., The sticky contaminant problem in waste paper process-
ing. EUCEPA 1984, Torremolinos.
(15) ORTNER, H. and PFALZER, L., Process - Technological Solutions for Se
paration of sticky impurities. TAPPI Pulping Conf. 1983 Houston,
695-701.
(16) NUTTAL, G.H., Theory and operation of the Fourdrinier Paper Machine.
S.C. Philips and Co. Ltd. (London).
(17) BLISS, T., Reverse cleaning - its use in removing lightweight and
sticky contaminants. TAPPI 63, N° 6, June 1980, 87-90.
(18) Domanda di brevetto italiano AUSIMONT N. 21807 A/86 (25/9/86)
(19) BLAKE, F.D., TAPPI, 65(4), 59-63 (1982)

TABLE 1 - GENERAL PROPERTIES OF SATURATED COPOLYESTERS COPES AND OF EVA CO

POLIMERS

COPES EVA

Density (230C), g/cm 3 1.20+1.30 0.90+0.98

Softening point, °c 95+150 80+105
Glass transition temperature, °c 30+-60 -40+-80
Heat resistance good good
Hydrocarbon solvents resistence good good
Diluted acids resistence poor very good
Water adsorption poor good
 84

TABLE 2 - SATURATED COPOLYESTERS SELECTED FOR THE PREPARATION OF HM ADHE-

SIVES
COPES A10 COPES A12 COPES D12

Polymer composition:
1.4-butandiole X X
Monoethylenglycole X
Terephtalic/adipic acid
Esters weight ratio (*) 1 :1.30 1 :1.22 1 :1.22
Softening point (Ring & Ball),OC 110-115 118-130 133-136
Density, g/cm 3 1.21 1.23 1.30
Elongation at break, mm(**) 20-26 32-48 10-28
Tensile strength at break, kg(**) 42-86 7-38 20-50
Melt viscosity at 180°C, cps(***) 2500-6500 4000-8000 4000-8000

(*) Methyl esters used in the polymerization

(**) Norma ASSCHIM Pl/79
(***) Brookfield thermosel system (20 rpm)

TABLE 3 - PROPERTIES OF EXPERIMENTAL HM ADHESIVES

TFS 12075 HMC/PILOT HMC/C3 EVA HM(***)

HM composition (weight %):
COPES A10 84.3% D12 94.3% D12 69.3%
012 15% 30CM 10%
46EM 10%
Rokrasin 1887 5% 10%
Antioxidants 0.7% 0.7% 0.7%

Melt viscosity at 180 oC,cps(*) 5210 2520 9650 3700

Softening Point (Ring & Ball),oC 108 121 140 92
Density, g/cm 3 1.22 1.29 1.26 0.95
Elongation at break, mm (**) 23.5 31 74 200
Tensile strength, kg (**) 21 23 21 14
Open time, sec. 19-20 35-40 20-23 1-3
Setting time, sec. 15-20 8-9 6-7 3-4
Cold resistence good good good good
Thermostability 16 hr at 180°C good good good very good
Specific adhesion good good good good

(*) Brookfield thermoselsystem (20 rpm)

(**) Norma ASSCHIM P1/79
 85

TABLE 4 - ELASTOMERIC COPOLYESTERS SELECTED FOR BLENDING WITH COPES IN ffi~

PREPARATION

COPES 30 CM COPES 46 EM
Polymer composition
part by weight monomers:
Dimethylterephtalate 33.5 55
Dimethylisophtalate 6.3
1.4-butanediole 17.5 25
Polytetramethylenglycole 59 11
Po1yethylenglycole 33

Softening point (Ring & Ball), DC 142 172-180

Melt viscosity at 180°C, cps (**) 23000 8900
Tg, °C (1 Hz) -52 -50
Density, g/cm 3 1.15 1.17
Elongation at break, % (*) 900 850
Tensile strength at break, MPa (*) 16 26

(*) ASTM D 412

(**) Brookfield thermose1 system (20 rpm)

TABLE 5 - EVALUATION OF STICKlES FORMING CAPABILITY OF HM ADHESIVES

Number of stickies specks per handsheet with redoubled area
after treatment; starting HM particles area in the range
40-60 mesh

Treat Te!!lpe- GOPES COPES COPES HMC/ HMC/ MELTEX

ments rature A10 A12 D12 PILOT C3 TF346(*)

Mixing 25°C 0 0 0 0 0 0
Beating 25 DC 0 0 0 0 0 1

Mixing 40°C 0 0 0 0 0 6
Beating 40°C 1 0 0 0 0 21

Mixing 60°C 1 0 0 0 0 12
Beating 60 DC 3 0 1 0 0 34

(*) EVA ffi~ produced by Bassi Marchini

 86

Contract nO BOS-006-D

OPTIMIZATION OF BLEACHING AND DE INKING OF WASTE PAPER

FOR STRENGTH AND BRIGHTNESS IMPROVEMENT

H.-J. PUTZ and L. GOTTSCHING

Institut IUr Papierfabrikation, Technische Hochschule Darmstadt
Alexanderstrasse 22, D - 6100 Darmstadt

Summary
Chemical formulation and process parameters in flotation
deinking were optimized to achieve high brightness and
cleanliness of the deinked stock based on a mixture of
50 % newsprint and 50 % SC-paper.
Single-stage bleaching after flotation is more ef-
fective than bleaching before flotation. A high brightness
level can be reached with the combination of high consis-
tency slushing with peroxide and a hydrosulfite bleaching
stage after flotation. For brightness levels of about 70 %
two bleaching sequences (peroxide/hydrosulfite) after flo-
tation are necessary. Bleaching of deinked fiber material
in combination with mechanical pulp leads to good bright-
ness results, so existing bleaching plant capacity could
be used if secondary fibers will substitute groundwood.
Strength properties of deinked and bleached stock were al-
ways higher than of stone groundwood. An image-analyzer-
system was used for the characterization of residual ink
particles in deinked stock. The developed measuring pro-
gram can detect ink particles with a diameter of less
than 2 ~m. In laboratory scale stock preparation with de-
inking and bleaching of woodcontaining waste paper grades
for the application in high quality graphic papers gave
very promising results in terms of improvement of strength
and optical properties.

1. INTRODUCTION
Waste paper is the most important raw material of the pa-
per industry in the European Community. In 1984 the total pro-
duction of paper and board in the EEC has reached 30 Mio tons
and the waste paper utilization ratio has an average level of
45 %. This ratio differs very significantly between the vari-
ous European countries from 26 to 100 % (1). The dominating a-
mount of the utilized waste paper is applied in the production
of packaging papers and board (utilization ratio appro 80 %),
whereas graphic papers have a share of 45 % of the total paper
and board production. In those paper grades the waste paper
utilization ratio reached only 7.4 % in 1980 (2). The waste pa-
per utilization ratio can only be increased significantly if
increasing amounts of waste paper co~ld be used in the produc-
 87

tion of printing and writing papers.

For the utilization of waste paper in the production of
graphic papers cleanliness and brightness of the treated secon-
dary fiber stock is of significant importance.

2. OBJECTIVES
Therefore the main targets of the research project are di-
rected to:
1.) Improvement of the efficiency of the flotation deinking
process by the elimination of ink and non-fiber particles
for the benefit of strength and optical properties;
2.) Improvement of brightness by optimization of bleaching con-
ditions based on peroxide and hydrosulfite bleaching agents
in single and multi-stage bleaching sequences;
3.) Evaluation of the bleachability of various waste paper
grades and of mixtures of virgin and secondary fibers;
4.) Development of a testing method for the characterization
of residual ink particles in the deinked stock.

3. RESULTS
3.1. FLoTATIoN-DEINKING
The deinking process carried out in a laboratory flotation
cell of the Swemac-Hellberg-type with two porous sintered
bronze cones in the mixing chamber can be influenced by:
- volume of air
- distribution of air in the mixing chamber
- width of the gap in the mixing chamber
- stock volume in flotation resp. stock speed in the
flotation cell
- time of flotation
stock consistency in flotation.
All trials for the optimization of the flotation process
were carried out with a mixture of 50 % offset printed news-
print and 50 % SC-paper, rotogravure printed. Most important
parameters are consistency and flotation time as can be seen
in Fig. 1. The constant parameters like stock volume of 30
l/min, 2 mm width of gap, air volume of 10 l/min and cone were
found as the most effective conditions for flotation in labora-
tory scale. The higher the stock consistency, the lower is the
brightness increase. Strength properties are influenced by the
ash content of the deinked stock. Higher ash content reduction
by flotation will be reached with lower consistency.

3.2. SINGLE-STAGE BLEACHING

If peroxide is used in slushing increasing consistency im-
proves brightness before as well as after flotation (Fig. 2).
But more effective than bleaching before flotation is a bleach-
ing stage after flotation when disturbing substances like ink,
chemical additives etc. have been removed by flotation.
Depending on peroxide bleaching at different consistencies
before flotation and bleaching with peroxide or hydrosulfite
after flotation the gained brightness is higher with a bleach-
ing stage after flotation (Fig. 3). The plots in the figure re-
present lines of constant brightness. They show e.g. that a
brightness of 65 % cannot be reached with peroxide bleaching
and low consistency slushing. In high consistency slushing a
 88

total amount of 2,5 % H O2 is necessary. If hydrosulfite is

applied in bleaching af~er flotation in low consistency slush-
ing about 1 % of each bleaching agent is necessary and in high
consistency repulping 0,5 % of each bleaching agent is suffi-
cient. The result shows that brightness gain with one bleaching
agent is limited even if two stages are applied. The splitting
of bleaching agent addition in one peroxide share before flo-
tation at high consistency slushing - to avoid alkaline yellow-
ing - and a hydrosulfite share after flotation is the most ef-
fective way for getting highest brightness of woodcontaining
secondary fibers.
3.3. MULTI-STAGE BLEACHING
In two-stage bleaching both agents have a supplement ef-
fect because they decolorize different chromophoric groups.
With 1 % peroxide or hydrosulfite in the first bleaching stage
after flotation brightness of the unprinted siderun from all
papers (2 newsprint, 3 SC-papers) will be reached (Fig. 4) and
in two cases exceeded. The second bleaching stage with 0,5 and
1 % hydrosulfite after a 1 % peroxide bleaching stage will lead
to a 4-5 points higher level in brightness compared to the un-
printed paper. A waste paper mixture of 50 % newsprint and 50 %
SC-paper reached with these bleaching conditions after flota-
tion a brightness level of 70 %.
3.4. BLEACHING OF WASTE PAPER IN COMBINATION WITH VIRGIN FIBERS
A combined bleaching of groundwood together with deinked
secondary fiber mixtures was possible without any loss in
brightness (Fig. 5). The figures show the linear reduction in
brightness before and after various bleaching stages with
higher amounts of the waste paper mixture. Increasing amounts
of newsprint waste decreases brightness additionally. But re-
sults show that existing bleaching capacity of a groundwood
plant can be usid for bleaching if groundwood will be substi-
tuted partly by secondary fibers. The strength values (Fig. 6)
of waste paper mixtures raise after flotation with higher SC-
paper content because of the better raw material quality in the
former production of SC-papers compared to newsprint. But
strength values of 100 % groundwood produced by us were lower
than tnose of 100 % deinked secondary fibers - independent of
the waste paper mixture - because of the chemical pulp fibers
in the waste paper. Mixing deinked waste paper and mechanical
pulp before bleaching results in decreasing strength values be-
fore as well as after bleaching.
4. CONCLUSIONS
a) Adjusting of various flotation parameters (amount of air,
stock consistency, flotation time) are prerequisites for
getting a'well deinked stock.
b) Application of peroxide in slushing is necessary to avoid
alkaline yellowing, but for effective bleaching high consis-
tency in slushing is beneficial.
c) Bleaching after flotation is more effective than bleaching
before flotation because of the reduced amount of disturb-
ing substances in the pretreated,suspensions.
d) In a two-stage bleaching sequence peroxide /hydrosulfite
 89

highest brightness (70 r.) will be reached based on the

supplement decolorizing effect of both bleaching agents.
e) Bleaching with peroxide should be carried out under the
same conditions as in the case of groundwood bleaching. For
getting good results in hydrosulfite bleaching the pH in
waste paper bleaching should be in the range between 7 and
9 depending on the amount of the agent added.
f) Strength properties of waste paper stock depend primarily
on the ash content which can be controlled by flotation
conditions.
g) Strength properties of de inked stock are higher than those
of mechanical pulp for newsprint. Substitution of mechani-
cal pulp in higher paper grades should be possible, too.
h) Bleaching of groundwood together with deinked stock is pos-
sible without any restrictions.
i) For good bleaching results a high efficiency in flotation
removing of ink particles - visible and non-visible - is ne-
cessary. By application of an image-analyzer system and the
developed program for measuring residual ink particles up
to less than 2 ~m the following aspects have to be clari-
fied:
- How to control ink particle size?
- Which is the best way to remove ink of different par-
ticle size?
Which concept for stock preparation gives the clean-
est stock?
An answer to these questions is a prerequisite for the intro-
duction of lower waste paper grades in the production of high
quality graphic paper because the reached brightness level in
laboratory scale seems to be sufficient. Further investigations
are necessary about the influence of white water resp. disturb-
ing substances in stqck preparation and its effect on bleaching
results in commercial plants. Against this background the above
mentioned recommendations have to be proven in pilot plant and
/ or commercial scale before any industrial application.
REFERENCES

(1) VDP-Le~stungsbericht 1986.

Verband Deutscher Papierfabriken e.V., Bonn, 1986
(2) Holzhey, G.:
Altpapier als Rohstoff fOr die Papierindustrie.
Das Papier 38 (1984) Nr. 10 A, V91-V95
 58 I RL57 , 'I.
lI'aste Paper 65 JR 'S7."'.
ixture II /
/ after flotation
/ / _- - - -'II
56 , ,. ... ---
/ / ' 60
/ ' ......
/o / ' ;/ -- - --~
/ . I "", -
/ ...... /
/ ~/ / ...... • ~~s tock consis tency
54 ....0 55 / / o '~ stoc k consistency
", I /
I /
/
I ./ ,/ ' ........ ' I \0
. flotation
o
/I ,"
1/ .. / CONSTANTS
52
'/;.'1 /,/ ~~or~o~i~~g 56 . 51
stock speed 30 11m
. . . ~OCk
1/~/ . .Co~~~~:y gap width 2 mm
air input
0- -<> I. I ", per cone 10 11m
........ I.S '"
0---0 2.1 ".
5~1 I 1,0 2.0
0 5 10 15 20
H20 2 - added to pulper or impregnated%1
Time of f lotation in min ,

FIGURE 1 - Brightness as a function of flotation time FIGURE 2 - Brightness before and after flotation as
with varying stock consistencies function of added H20 2 at 4% and 25% stock
consistency
 91

~s:
C 0
·M . ..-t
.r.+,
o (I)
(I) +'
QJ 0 - - FIGURE 3
.-; .....
.0 ,,", 1.0 Constant-brightness curves
"0 s.. as a function of added H20 2
Cll Cll
:gt: during pre-treatment and
ro ro the addition of bleaching
o
N agent after flotation
:I:
N a) % H20 2 added in pulper
1.0 2.0 1.0 40 b) %. H202 added by impregna-
* a) b) tlon
c) % H2 0 2 added in pulper
d) %.H 2 02 added by impregna-
~C
tlon
C 0
. .-1 .....
.r.+'
o (I)
(I)+,
~ ~ I.O
.0 ....
'0 s..
Q) Q)
'O+'
'0 ....
ro (\)
<:r
o 2.0
N 2.0
C/)
N
ro
Z FIGURE 4
*

70 aID NQ: $:O,- B LEACH I NG

~ H:O,- BLE ACH I NG
C2ZZl AF fER FLOTAIION
~ aEFORE FLO fAllON
65

60

ss

so

liP DEPENDI NG ON WASTE PAPER GRADE AND DOSAGE

THO OF BLEACHING CHEMIC ALS
 92

1110 7'S 50 7'S z's b

WASTE PAPER. '/, WASTE PAPER. '"
RAW MATERI<IIL MIXTURE

or. BRIGHTNESS OF UNBLEACHED AND TWO-STAGE BLEACHED STOC~ FROW OEIH~ED u ..

'"0 NEWSPRINT I NPPI AND SC - PAPER I SCPI WITH GROUNOWOOD un

STRENGTH-VALUE,
N.mNm/m
STRENGTH-VALUE,
N.mNm/m t
FIGURE 5

140 140

120 120

10

80

01+-----~------r-----~----_4
o 25 75 1
OROUNOWOOO. '10
I
100 50 z's 0
WASTE PAPER. '1.
RAW Io4ATERIAL Io4IXTURE

STRENGTH-VALUE OF eLEACHEO AND UNeLEACHEO

liP ,ne
THO
STOCK FROM OEINKEO NEWSPRINT (NPPI 2758 - FIGURE 6
AND SC-PAPER (SCP) WITH GROUNOWOOO
 93

Contract nO BOS - 090 - UK

THE CHEMICAL TREATMENT OF FRACTIONATED STOCK FROM

"FREELY AVAILABLE" GRADES OF WASTE PAPER

P. HOWLAND
Paper Industry Research Association
Randalls Road, Leatherhead, Surrey, KT22 7RU, England

Summary
The use of fractionation to upgrade waste paper is established
technology in Europe, with over 50 installed units in operation.
The separate chemical treatment of stock fractions has been
investigated in order to assess whether or not additional benefits
can be obtained from this technology.
It was found that the performance of wet end starch was
unaffected by the fraction, long or short fibre, on to which it was
adsorbed.
Sizing chemicals performed more effectively when added to the
long fibre fraction, but only when the sizing level was quite low.
For hard sizing both treated long and short fibre fractions
performed equally well.
It was also found that considerable strength benefits were
observed when filler was co-flocculated with fibre fines. This
technology has several potential advantages over filler pre-
flocculation.
Overall, it was found that the benefits of separate chemical
treatment of stock fractions offered only limited benefits. In
specific cases, significant cost benefits may be realisable but
would not in themselves justify the installation of a fibre
fractionator.

1. INTRODUCTION
Wet end chemicals represent up to 11% of the raw material cost of
paper and board products. Clearly, techniques that enable their
utilisation to be improved will have immediate cost benefits to the
papermaker. Furthermore, improved strength aid utilisation not only
presents the possibility of reducing chemical costs but can also
increase the strength potential of a furnish. In waste based products
this would have the effect of "upgrading" secondary fibre thereby
permitting the use of lower grades of waste or improving product
quality.
The performance of wet end chemicals is, to a large degree,
determined by the efficiency with which they adsorb on to the paper-
making furnish. Considerable evidence exists to suggest that wet end
chemicals are preferentially adsorbed on to the fines fractions of the
 94

furnish and that chemical performance can be improved if adsorption is

restricted to the long fibre fraction. Fractionation technology enables
fines and fibre fractions to be separated and thus offers the advantages
that separate chemical treatment may bring.

2. THE PHYSICAL AND CHEMICAL NATURE OF FURNISH FRACTIONS

The adsorption of chemicals on to any substrate is a function of
two critical parameters:
(a) the physico-chemical interaction between the chemical and the
adsorbate (i.e. cellulose)
(b) the availability of adsorbate surfaces.
Htun (1) showed that the fines fraction of beaten bleached kraft
pulp consists of macro-fibrils with a diameter of between 0.5 and
0.05 x 16-6 m. He found that the fines fraction and the fibre fraction
were very similar in terms of carbohydrate composition but the fines
fraction was found to contain significantly more lignin. Htun also
found that the fines fraction was less crystalline than the coarse fibre
fraction. All these differences between the fines and the coarse
fraction will affect the response of wet end chemicals.
The surface areas of the long and short fraction have been
estimated by many workers (2,3,4). The hydrodynamic surface area of the
fibres is between 0.8 and 2.8 m2/ g and for the fines between 8 and
50 m2/g. The hydrodynamic surface area is determined by the liquid
permeabili ty method which is regarded as the most relevant measurement
with respect to chemical adsorption in water.
It should however be stressed that the surface area determined in
this way is a measure of external surface only. For small adsorbing
species such as metal ions it is probable that significant internal
surfaces are available. The internally available surfaces are best
measured by the N2 adsorption method. Marton (4) found N2 specific
surface areas of 10 and 47 m2/g for fibres and fines respectively in a
bleached kraft furnish. Marton also analysed both the N2 and
hydrodynamic specific surface area for filler clay and obtained a value
of 10.5 m2/g for both measurements. In other words, cellulose fibres
have a large internal surface but filler clay has none.

3. THE ROLE OF FINES IN WET END CHEMICAL UTILISATION

Not surprisingly the literature relating to this topic is chiefly
concerned with sizing and strength aid chemicals. The unifying
principle behind most of the published research has been that wet end
chemicals will be preferentially adsorbed by the fines fraction due to
their high specific surface area. Fines retention and the performance
of chemicals on fines surfaces is therefore very important.
The work of Sandstrom(6) strongly indicated that poor fines
retention dramatically reduced the performance of wet strength resins in
the production of tissue. This was because the wet. strength chemical
was preferentially adsorbed on to the fines which were themselves poorly
retained.
Marton has demonstrated (7) that rosin soap and dispersed size is
preferentially adsorbed on to the fines and filler fractions.
He later extended this work(8) to show that alkyl ketene dimer size
is also adsorbed preferentially on to the fines and filler fractions.
Furthermore a furnish in which the long fibre was treated separately
 95

with dispersed rosin size produced better sized paper than one in which
the longs and shorts were treated together.
Finally, Marton(4) has shown that starch behaves in a similar way,
being preferentially adsorbed on to the fines and filler fractions.

4. WET END CHEMICAL UTILISATION

The two classes of chemicals most commonly applied in the wet end
are strength aids and sizing aids. In the previous section it was shown
that there is considerable evidence which suggests that sizing aids
would perform more efficiently if applied to a "long" fibre fraction of
the furnish. In the case of strength aids little or no direct evidence
from published data exists to indicate whether or not these materials
would benefit from a more controlled addition to the long or short fibre
fractions of the furnish. This section describes the results from this
project, the purpose of which was to ascertain the extent to which
benefits could be obtained by adding sizing and strength aid chemicals
to a specified fraction of the furnish.
A standard procedure was. followed in all these experiments
consisting of four basic conditions :
(i) Control 1. No chemical added.
(ii) Control 2. Chemical added to whole furnish.
(iii) Chemical added to "longs".
(iv) Chemical added to "shorts".
In each case the total amount of chemical added was the same. For
the latter two conditions the treated fractions were then combined with
the untreated fraction to produce a "whole stock". Hand sheets were
then made and tested.
The "longs" and "shorts" fractions were produced using the Pira
laboratory fractionator. As with commercial fractionators, the main
difference between the two fractions was in the proportion of fibre
fines, there being a greater percentage of fibre fines in the "shorts"
fraction.

4.1 Cationic starch

The performance of cationic starch when added to separate fractions
of a furnish was studied for a range of waste paper furnishes.
A rather inconsi"stent picture emerged showing some furnishes
responding favourably to separate cationic starch treatment and others
not.
As a general observation however, no striking benefits emerged as a
result of seperately adding cationic starch to either fractions of the
furnish.

4.2 Sizing chemicals

Both rosin and alkyl ketene dimer sizes were tested. Only in cases
where soft sizing was achieved did any clear benefit appear when the
chemical was added to the long fibre fraction.

5. MODEL FURNISH STUDIES

The rather varied results obtained with sizing chemicals and with
cationic starch indicated that a more fundamental study was called for.
Experiments were carried out using a softwood furnish beaten to
different levels.
 96

When either of the fractions were treated with cationic starch the
breaking length was unaffected by which fraction was treated, for both
lightly and heavily beaten stocks.
The adsorption characteristics of cationic starch were studied and
confirmed that the fines adsorb starch preferentially in comparison to
the longs. A further experiments showed that, under the experimental
sheet forming conditions, cationic starch was irreversibly adsorbed.
Sizing experiments were also carried out, using alkyl ketene dimer
size. At low sizing levels the addition of size to the long fibre
fraction was more efficient.
It was also found that sizing was less effective in the less
refined furnishes. In this experiment it was again found that the
"longs" treated furnish was better sized.
The conclusions to be drawn from these experiments are :
(i) Sizing chemicals benefit from being situated on the long fibres.
(ii) At the point of near maximum sizing, this benefit is lost.
(iii) The orientation of cationic starch in the sheet structure is not
critical to its performance (in terms of it being adsorbed on to
the "longs" and "shorts" fraction).

6. FINES FILLER CO-FLOCCULATION

Filler pre-flocculation is a technique that reduces the detrimental
effects of filler on inter fibre bonding and hence strength. It also
enhances filler first pass retention. By co-flocculating fibre fines
and filler it has been suggested (9) that the benefits of filler pre-
flocculation may be further enhanced. To this end a furnish consisting
of hardwood and softwood pulp was fractionated to produce a fines rich
"shorts" fraction. This was then co-flocculated with chalk filler and
after being recombined with the "longs" was converted into paper. This
paper was then compared with similar paper produced with pre-flocculated
filler and untreated filler. No strength aids were added and co-
flocculation and pre-flocculation was achieved with the help of a
cationic polyacrylamide retention aid.
It was found that fines/filler co-flocculation provided strength
benefits very similar to those obtained with filler pre-flocculation.
The first pass filler retention however was greatly enhanced by the co-
flocculation process.

7. CONCLUSION
Ih most practical cases, chemicals do not perform better as a result
of being added separately to a "longs" or "shorts" fraction. The
chemicals studied were cationic starch and a range of sizes.
Some evidence suggests that sizing chemicals when used in soft
sizing applications are more effective when added to the "longs"
fraction.
The concept of fines/filler co-flocculation was shown to be an
effective way of enhancing the strength and filler retention of high
filler paper but has not been evaluated in terms of the critical optical
and surface strength parameters.

REFERENCES
(1) M. Htun, Ader Ruro, Svensk Papp ~ 1978, pp 507
(2) B. Steenberg, D. Wahren, Svensk Papp~ 1960, pp 347
 97

(3) W. Ingmansson, B. Andrews, Tappi ~ 1, 1959, pp 29

(4) J. Marton, Tappi ~ 4, 1980, pp 87
(5) J. Marton, T. Marton, Tappi Papermakers Conf Proc. April 1983
(6) E.R. Sandstrom, Pap Trade Jrn, Jan 1979, pp 47
(7) J. Marton, T. Marton, Tappi ~ 12, 1983, pp 68
(8) J. Marton, Oxford Fund Res Symp. 1985, pp 785
(9) P. Howland, Private Communication, 1982
 98

Contract nO BOS-104-DK

PRODUCTION SCALE TRIALS WITH FRACTIONATION OF RECYCLED FIBRES

G. LARSEN and S. NIELSON

(summarized by I. F. HENDRY)
Hojbygaard Papirfabrik A/S, Holeby. Denmark

Summary

Hojbygaard is a small economically run mill making corru-

gating medium on a single fourdrinier machine 3.24 m wide,
averaging 100 tonnes a day, from waste paper and straw. There are
only 84 employees and this was therefore a mill scale experiment,
carried out by the papermaker and analyzed by a temporary
laboratory assistant.
It consisted of installing a Voi th Mul tifraktor and seeing
whether separate treatment of the long and short fractions gave
improved CMT (concora) and CCT ( crush) resul ts ; without
influencing runnability.

BACKGROUND

CMT and CCT values may be increased to a certain extent by

refining, but the runabili ty of the fluting hereby deteriorates very
quickly. The level at which the strength values balance with the
runability depends on the raw material, and through the increased
recycling of waste paper there has in recent years been a deterioration
reducing the ability to use refining as strength-improving factor.
Starch can be added to the paper in the paper machine, very effectively
until a certain level is reached, whereafter any further addition is
valueless.
In view of this it was decided to examine fractionation more
closely. Waste paper consists of fibres of almost any size plus filler,
such as kaolin or CaC0 3 plus different substances which have been used
for surface treatment of the paper in connection with its earlier use,
starch for example. Beyond that, there are some impurities in the form
of plastic, sand, iron and so on.
In recent years it has been demonstrated that a better result of
refining may be obtained, if it takes place without the very small
fibres and filler. This is where fractionation is interesting, because
it is possible in this way to divide the mass of waste paper up into
fractions, and only lead the long-fibre fraction through a refiner, for
later mixture with the short-fibre fraction.
 99

DESCRIPTION OF PLANT

As shown in the block diagram (figure 1) the waste paper is pulped

and treated to remove staples, sand, glass, plastic, etc., before it is
passed on to fractionation. This preliminary cleaning is necessary, as
the impurities tend to collect in the long-fibre fraction and pass
through the refiner, where they will be cut into fine particles and will
therefore be difficult to remove in the second cleaning prior to the
paper machine.
The mill has a secondary pulp line where semi-chemical straw
cellulose is manufactured. We chose to let this line circumvent the
fractionating unit as there might be difficulties with clogging up the
machine, and the operation of the two lines would be very cumbersome.
The fractionator itself consists of a closed cylinder in which a
cylindrical screen has been mounted which is perforated with holes with
a diameter of 1.6 mm. Inside the strainer there is a rotor with many
blades which almost touch the wall of the strainer when operating.
The material is pumped in under pressure and the rotor forces the
fibres towards the holes of the screen tangentially, and the short
fibres and filler manage to pass through the holes, whereas the long
fibres do not have time to change flow direction, and are therefore kept
back. In this way there is an accumulation of longh fibres inside the
screen which pass out of the "reject" outlet.
In practice the quantities are adjusted by means of two adjustment
loops which control liquid valves. The loops are interconnected with a
ratio controller, and it has in this way been possible to operate with
ratios between long and short fibres from 30% LF /70% SF to 70% LF /30%
SF.
The rotor in the machine moreover has the function of keeping the
holes of the strainer open. The profile of the rotor blades has been
designed as the wing of an aeroplane. At the back of it there is
consequently a suction which pulls the layer of material away from the
holes and the material' can now pass freely with the pump pressure, until
a new clogging occurs; another blade will then pass the hole, and so on.
To operate the rotor, a 110 kW motor was mounted, and the rotor
rotates at 400 rpm. See also figure 2.
Voi th Heidenheim, the makers of the fractionation machine, were
approached about possible participation in the test.
The ~ompany, however, was not interested, and drew our attention
to the fact that many tests have been conducted by themselves, and that
the machine was now marketed as the standard solution for the prepara-
tion of material.
The Mul tifraktor, as Voi th calls their machine, was therefore
acquired as an open purchase, the conditions being that the machine may
be returned after three months, and payment is only to be made for
reconditioning the machine so that it appears like new.
In order to keep the test within a reasonable economic framework,
not least because the supplier did not wish to participate, machine data
were chosen which were based on earlier experience, and which should be
the best possible for our purpose.
As basis for the choice of machine data and test parameter, the
following literature has been used :
 100

1. Die Fraktionierung von Faserstoffen aus Altpapier (Fractionation of

fibres from waste paper) by W. Musselman, graduate engineer, Voith
Heidenheim.
2. Project nO 02 EEC Research Programme : "Cleaning of waste paper from
thermo plastical conglomerates for paper production". Papierfabrik
Adolf Jass GmbH & Co. KF, Fulda. This project also includes
fractionation.
As mentioned in the introduction, increased strength of the raw
material waste paper is badly needed, and Hojbygaard Papirfabrik was
prepared to buy the Mu1 tifraktor machine and incorporate it in the
preparation of the material, if positive results had been achieved.
A stainless steel pipeline was laid out in an arrangement which
could be made permanent, and a ,complete set of automatic controls was
installed.

The machine data chosen for the test were the following

Voith Multifraktor size 210

Strainer perforated with holes ¢ 1,6 mm

Capacity 130 t dry solids/24 t
Solid content 2-4%
Reject flow (long fibres) 50% of inlet
Rotor speed 440 rpm
Motor speed 1500 rpm
Power consumption 95 kW
Installed power 110 kW
Inlet pressure max. 6 bar
Outlet pressure min. 0,6 - 0,8 bar
Differential pressure strainer 0,2 bar

Data for refiner

Voith diskrefiner type lSD, the fittings characterized by

Knife width 4 mm
Knife interval 4 mm
Knife level 6 mm
Cutting angle 20,4 0
Cutting edge length 127,6 km/s
Hydraulic load fittings 70 t dry solids
Power consumption 160-180 kW
Power consumption unloaded 100 kW
Specific load 27,4 kWh/t

When the erection of the Mul tifraktor had been completed, the
machine was started for a test run and adjustment of the automatic
controls. It turned out that the power input was excessive, so that the
110 kW motor which had been fitted was overloaded.
No reason could be found for this, and in concert wi th Voi th,
calculations were made of another motor pulley, and when this had been
fitted, the input was 90 kW.
 101

TEST PLAN

1. Definition of fractionation ratio

When a percentage ratio between long and short fibre fractions is
mentioned in what follows, reference is made to the separation of
the flow of pulp which the machine produces at the two outlets, when
the consistency of material and the volume of the flow are taken
into account.
It is in other words no characterization of fibre lengths. Neverthe-
less the abbreviations LF(for long fibres) and SF (for short fibres)
will be used below.

2. It was planned that tests should be made with the fractionation

ratio 50% LF /50% SF, as recommended by Voi th, but also to try to
vary this from 30% LF/70% SF to 70% LF/30% SF, and then measure the
corresponding values.

3. A basic condition for this test was that saleable paper was to be
produced during the whole period. The test budget could not endure a
possible production breakdown, and a producing paper mill has
certain obligations, for instance guaranteed supplies.

4. The test was to be accomplished with the normal composition of raw

material consisting of corrugated waste and mixed waste, both
quali ties coming from collected waste paper. As the raw material is
not particularly homogenous, tests have to be made for abol!lt one
week for each adjustment/setting.
Similarly, representati ve values for production without the
Multifraktor had to be registered during one week.
It was furthermore necessary to choose periods where other factors
having an influence on the result of the test could be ruled out,
e.g. changes of the amount of starch added, changes in quality etc.

5. Samples had to be selected from the material before and after

fractionation for examination in the laboratory, whereas
measurements on finished paper were made by following the mill's
usual system of quality control.
The mill's laboratory is only equipped and manned for general
production and quality control measures, and it was therefore not
possible to make fibre analyses etc.
An extra laboratory hand had been hired for the duration of the
tests.
The measurements planned during the tests were the following

prior to Multifraktor LF SF

Consistency X X X
SRo X X X
Hand-made sheets X X
% ash on sheets X X
 102

without Multifraktor with Multifraktor

CMT on finished paper X X

CCT on finished paper X X
Densimeter Gurley X X
Furthermore: Power input for Multifraktor
Power input for refiner

6. Time schedule

Date
a. Dec. 1983 Delivery of Multifraktor
b. Jan-Feb. 1983 Erection
c. Feb. 1983 Initial test run and adjustment of
automatic controls
d. Feb. 1983 Ini tial tests with 50% LF /50% SF
setting
e. March 1983 Tests with 70% LF/30% SF setting
f. March 1983 Tests. with 30% LF /70% SF setting
g. March 1983 Arrangement of the following tests
based on the results of the above tests
h. April-May 1983 Tests with optimum setting according to
the above, and for as long as the
result remained representative
i. May 1983 Sampling of values from production
without Multifraktor, for as long as
the result remained representative
j. May 1983 Deliberations as to whether hand i
should be repeated
k. June 1983 Preparation of report.

PROJECT TEAM

Production manager/Chief Engineer

Laboratory staff
1 laboratory hand hired for the project

IMPLEMENTATION OF TEST

Part 1. - Initial test runs 7 March 1983

Following the above mentioned short test run where it was

established that the Multifraktor worked correctly as far as its
mechanical functions were concerned, the machine was put into service
for the preparation of material. The quantitites were set at the ratio
50% LF and 50% SF.
The test run went well, there was no tendency to clogging, and
there were apparently no problems in connection with the paper machine.
After 36 hours of production for the purpose of testing the machine, the
actual series of experiments was commenced.
(The previous week had been chosen as being representative for
production without the Multifraktor).
 103

Initial test 1
The machine was set for operation with 30% LF and 70% SF, and only
the long-fibre fraction was refined. There was no change of strength
value worth mentioning, the production went well for approx. five hours,
then paper breaks began occurring at the first press, and the frequency
arose very rapidly.
The Mul tifraktor was withdrawn from service, and the production
once more became regular. As we know from experience that our paper
machine is sensi ti ve to refining conditions the reason for the breaks
was probably due to the fact that an excessive part of long-fibres was
passed through to the short-fibre fraction at the ratio set, hereby
escaping refining.
The machine is run at relatively high consistency because the
drainage capacity of the wire section is somewhat limited the long
fibres agglomerate in the headbox. the fibre bundles are torn loose,
when they have been built up to a certain size, and give paper breaks at
the first press.
An evaluation of this test produced the following conclusions :
1. No change of strength value worth mentioning for the finished paper,
maybe a tendency t~a lower value.
2. Too unstable production in the paper machine.
3. It is not expected that a repetition will change the conditions, nor
is it considered expedient to change the fractionation ratio to 40%
LF/60% SF.

Initial test 2 21-22 March 1983

The machine was started and fractionation set at 70% LF /30% SF.
After five hours or so it was observed that the production proceeded
regularly in the paper machine, but that the CMT and CTT values for
strength dropped. An increase in refining was attempted, and this did
increase the strength values, but just as quickly increased the drainage
problem on the paper machine. This meant that nothing had been achieved
by the fractionation. 'An explanation of this phenomenon may be that when
more finely divided material accompanies the long-fibre fraction an
increased refiner load will quickly result in too "wet" material.
After the two preceding preliminary tests, a decision had to be
made about the setting of the machine, the actual experiment had to be
carried out, and it became obvious from the results of the first runs
that this bad to be made with the ratio 50% LF/50%SF, (in agreement with
the machine supplier's recommendations).

Part 2 - Test 11-19 April 1983

The Mu1 tifraktor machine was started and set at the ratio 50%
LF/50% SF.
Following stabilization the refiner load was adjusted to the
condi tions mentioned earlier, whereby the strength values CMT and CCT
are increased by the beating degree, but that a limit is reached for the
drainage on the paper machine. This limit is the same as the point at
which the paper's air permeability has deteriorated so much that
problems arise in conversion on the corrugated board machine. The mill
does not possess an exact evaluation in measurable sizes for this
phenomenon, but must rely on the experience it has gained as a producer
of fluting.
 104

After an optimizing period of approx. 24 hours, the logging

results started, and went on for seven days. Samples were collected as
described under Test plan, point 5.
From each finished reel, samples were selected from each for GGT,
GMT and densemeter, each reel representing approx. 1 hour's production.
On each sample, measurements are made in five places across the width of
the web, and an average calculated.
Seven days of production equals 700 tonnes of paper. Each reel
weighs abt. 5 tonnes, i.e. 700:5 = 140 reels.
Each value is an average of five measurements, and the number of
measurements per week is therefore :
140 x 5 = 700 individual measurements.
All samples were conditioned at 50% RH and 23°G.
For commercial reasons the mill cannot state the actual strength
values, but must indicate the values as relative, they will, however, be
equally important for the result of the trial.
After this week's tests followed a week where other paper
qualities were produced, and after that, the Multifraktor machine was
started again, on 2nd May 1983, and it operated for another seven days
for a repetition of the test.
A study of the results of the two weeks showed that they were
identical, and they have therefore been combined in the diagrams (see
figure 3).
In the same way values were collected for seven days after the
carrying out of the last trial which were identical with those of the
first seven days without Multifraktor, so these have also been combined
in the diagrams.

RESULTS

As it appears from the diagrams (see figure 3), it has been

possible to increase the GMT value by 2.8% and the GGT value by 2%,
while the air permeability of the paper has been improved by 6%.
The air permeability is evaluated here at the mill as an indirect
measure of the runability of fluting.
The increase o.f strength obtained is not sufficient to be able to
pay for the machine's power consumption and operation as these costs
have to be compensated for, either by using cheaper raw materials or by
using less starch.
It was expected that the GMT value could be increased by approx.
10%, and when this was not feasible, it may be due to the following:
Based on the machine supplier's evaluation on the results of the
tests, these results indicate that the fractionation possibly was not
precise enough. One of the reasons could be that the machine was too
large for the flow of material in question. Multifraktor, size 210, has
a max. capacity of approx. 200 tons/24 h, and in the tests it was only
loaded by about half that amount. This has the effect that the material
stays in the machine longer and in this way brings about another
relation between the speeds, tangential and radial, which the fibres
obtain when they pass through the screen. A smaller machine could not be
chosen, as the next size down was too small.
In addition to an optimization of the Mul tifraktor, an optimiza-
tion of the beating might also be conceivable. For the test, the mill's
 105

standard fittings were used in the refiner. These fittings have been
chosen as suitable for the normal production after many experiments. It
is, however, not a certainty that they are the very best for milling of
the LF fraction.
Various dis patterns constitute a parameter which might be
included in future tests.
Together with the fractionation the machine has a secondary
effect, as it appeared visually from a sample sheet that impurities
collect in the LF fraction, whereas the SF fraction is almost clean, and
this also applies to troublesome impurities like hot melt and bitumen.
The machine may therefore be of great importance in the future, as
one of the ways of rendering these impurities harmless is heat treatment
with subsequent dispersion. By doing the fractionation first, the size
of the dispersion plant can be cut in half, and great savings can be
realized on the consumption of energy.
It should also be added that in mills having two paper machines
for a twin wire machine, the two fractions could be used separately.
Subsequently fibre lengths of the LF and SF fractions were
measured at Pira, United Kingdom
An average LF fibre length of 2.24457 mm
An average SF fibre length of 1.64905 mm
In other words, a fractionation has been achieved of the waste paper
into short and long fibres.
Although the tests did not produce the results we had expected, we
do not doubt that fractionation of waste paper fibres will be of great
importance in the future. It will be extremely interesting to see the
results of the EEC research projects which are now in progress on this
subject, and we hope that our project has contributed to a greater
knowledge of fractionation.
 Dep . Dep . Dep . Dep .

.....
o
0\
3 r - - -
01
...,r..
<J)

Dep . Dep.
FIGURE 1
PROCESS DIAGRAM - HOJBYGAARD PAPIRFABRIK A/S
 107

rotor

i nl et

s hort fibr e

long fi bre

FIGURE 2
Pr i nci ple of Frak tionator

e eel Gurl ey densome te r

I JO

120

110
;:x
100 ' // / /
~
'////:
90

80

70
OIl OIl
C
60 .....C .....
...,
+>
(II ro
~o c c
0
.r< .....0
0 +> -I-'
() ()
to to
)0 I.. I..
c... c...
.c .c .c
20 ....-I-' -I-'
;::
....;::
-I-'

>
10

The hatched sections cover plus-minus 2 times standard deviation

FIGURE 3

The results with and without fractionating are sampled from equal
periods. Each figure represents 1400 individJal measurements. There are
used specific values. Measurements without using the Mul tifraktor are
set equal to 100.
 108

Contract nO BOS-131-D

OPTIMIZATION OF WASTE PAPER FRACTIONATION TO IMPROVE

SECONDARY FIBER QUALITY FOR PACKAGING PAPERS

R. SCUDLIK and L. GOTTSCHING

Institut rtir Papierfabrikation, Technische Hochschule Darmstadt
Alexanderstrasse 22, D - 6100 Darmstadt

Summary
The project dealt with the improvement of strength proper-
ties - particularly of compressive strength - of low
waste paper grades (mixed waste, department store waste)
for the production of liner and corrugating medium in com-
bination with energy saving in stock preparation. The
fractionation was carried out in commercial and pilot
plant scale with a fractionator of the pressurized screen
type.
Total stock, long fiber fraction as well as short
fiber fraction were activated applying common and un-
common beating conditions. Target of the activation steps
was the prevention of fiber length cutting and minimizing
changes of the freeness of the treated fiber material.
Against this background beating was performed at low and
high consistencies by altering the pH-level of the treat-
ed suspensions. Furthermore, the effect of specific edge
load and bar angle on the beating result were studied.
Priority was given to the question which improvement of
sheet properties is to be expected if the long fiber frac-
tion was activated, while the short fiber fraction was
not treated at all. After blending the activated long fi-
ber fraction and the unbeaten short fiber fraction it be-
comes evident that improved strength properties could be
obtained, in comparison to total stock treatment combined
with the advantage of reduced beating energy input.

1. I NTRODUCTlON
In the production of packaging papers the waste paper uti-
lization ratio has already reached a very high level in the EEC
with an average of appro 80 %. The dominating paper grades pro-
duced with waste paper are corrugating medium and liner (test-
liner) which are substituting to a high extent fluting and
kraftliner. To reduce furnish costs, medium and testliner pro-
ducing paper mills have to utilize low grades of waste paper
such as mixed waste and department store waste paper which con-
tain chemical pulp as well as high yield pulp fibers. The high
freeness level - in terms of Schopper-Riegler - the low average
fiber length and poor strength properties of these waste paper
graoes have a restrictive effect on various paper properties
 109

which are important for converting processes and for corrugated

boxes. Despite such limitations the manufacturers of packaging
paper have step by step improved their products in such a way
that they can compete successfully with packaging papers and
board based on virgin fibers. Nevertheless, development has to
be continued because pressure is given by the following fac-
tors:
- low waste paper grades are deteriorating;
- basis weight of paper will be reduced further;
- speed of converting plants will increase continuously;
- end-product requirements (e.g. of corrugated boxes)
will be raised.
To fullfil all these requirements, the papermaker has to
optimize his products by improved stock preparation - if pos-
sible with less energy consumption - by the utilization of
(minimized amount of) additives and by optimized sheet forma-
tion / consolidation combined with size press application. One
promising strategy in stock preparation of heterogenous waste
paper grades might be fractionation of the fiber suspension
followed by a different activation of the two fractions which
are named long fiber and short fiber fractions. The classifi-
cation and separate activation of the two fractions is the main
target of this research project. The evaluation of the improve-
ments gained are mainly based on characteristics like in-plane
compression strength and burst which are important for liner
and CMT being relevant for medium.

2. OUTLINE OF THE PROJECT

Fig. 1 shows the main steps of the trials carried out
mainly in laboratory and partly in pilot plant scale. Table I
specifies boundary conditions and variables of the various
treatments of the total stock and of the two fractions. To be
independent of the limitations of commercial stock preparation
plants, fractionation was performed with a pilot plant unit de-
livered by J.M. Voith GmbH/Germany. The flow sheet of the pilot
plant stock preparation is given in Fig. 2.
To avoid variations of the waste paper characteristics
(of mixed waste and department store waste paper) the trials
had been based on testliner which was produced with a mixture
of the two waste paper grades mentioned.

3. RESULTS
3.1. FRACTIONATION
The main parameters for getting an effective separation
of the total stock (inlet stock) into long fiber and short fi-
ber fractions are consistency and overflow ratio. The lower the
consistency of the inlet stock suspension, the better is the
separation effect with an optimal range of around 1 % consis-
tency. A low consistency minimizes the risk of plugging the
screen at low overflow ratios.
As can be seen in Fig. 3 the separation effect is charac-
terized by freeness (Schopper-Riegler value) of the long fiber
resp. short fiber fraction. While the inlet stock has - after
effective slushing and de flaking - a SR value of 50, the long
fiber fraction gets down to 20 SR at the minimum overflow ra-
tio of 25 %. Such a low freeness level of the long fibers of-
 110

fers the possibility of an activation to improve mechanical

sheet properties, even after blending the activated long fiber
with the unactivated short fiber fraction with its very high
freeness level.
We tried to identify the amount of chemical and mechani-
cal (high yield) pulp fibers in the inlet stock, the long fi-
ber and short fiber fractions by microscope - but without suc-
cess as expected. As an alternative to the visual identifica-
tion an analysis of the lignin content of the different stock
components was done. Fig. 4 makes evident that the long fiber
fraction contains at low overflow ratios less high yield pulp
fibers than the total stock while the short fiber fraction is
enriched with mechanical pulp fibers which are one reason for
the high freeness level of this fraction. Taking the different
chemical composition resp. the lignin content of the two frac-
tions into account, one has to optimize the activation process
individually for each fraction.

3.2. STOCK ACTIVATION

Fig. 5 refers to the influence of beating (at 5 % consis-
tency) of total stock and long fiber fraction (corresponding
to a share of 25 % of the total stock) on RCT of handsheets.
Furthermore, one can state the advantage when blending the
beaten long fiber fraction and the unbeaten short fiber frac-
tion. The most significant advantage of the separate long fi-
ber activation in comparison with the total stock activation
is the energy saving combined with a higher level of the RCT.
Secondly, one gets higher RCT values at a lower freeness level
which is beneficial for the productivity of the paper machine.
It is known since long that beating consistency plays an
important role in respect to fiber treatment and sheet proper-
ties (e.g. fiber cutting and tear). So far, high-consistency
beating is not common in secondary fiber activation. As one
can see in Fig. 6 the short span compression strength is im-
proved more significantly when beating at 20 % consistency
compared with 5 % consistency. This is evident in the case of
total stock beating as well as of the long fiber fraction
blended with the (unbeaten) short fiber fraction.
Improvements of mechanical properties by beating can be
achieved if the pH of the fiber suspension is raised up to 11
by adding sodium hydroxide. In Fig. 7 the short span compres-
sion strength of total stock and of a mixture of beaten long
fiber fraction and unbeaten short fiber fraction is plotted
against relative beating energy. The higher the pH, the lesser
energy is consumed.

4. SHEET FORMATION
Results of different parameters in handsheet formation are
presented in Fig. 8. Handsheets were made with raising basis
weight and by varying the number of plies from one to three
plies, every ply of the same furnish and basis weight respec-
tively.
The figures of ring crush test (RCT) raise linearly with
basis weight but there is nearly no influence by the multi-
layering technique. Activation of fiber furnish increases RCT
as expected but the increase by beating seems to be smaller at
 111

low basis weights than at higher basis weights.

5. CONCLUSIONS
a) Fiber fractionation is most effective at low stock consis-
tency and low overflow ratio.
b) When separating low waste paper grades (mixed waste and de-
partment store waste simulated by testliner) the short fi-
ber fraction contains a higher amount of high yield pulp fi-
ber than the total stock resp. the long fiber fraction.
c) In contrast to total stock activation, considerable energy
savings are achievable by beating the long fiber fraction
and blending with the unactivated short fiber fraction.
d) Further improvements of mechanical properties are gained by
beating at high consistency.
e) Beating in alkaline milieu results in further energy sav-
ings with less fiber cutting.
f) Multi-layered sheet formation consisting of plies of the
same total stock does not improve compression strength com-
pared to one-layer sheet.

Parameter Specifications

Waste Paper Grade Mixed Waste, Department Store

Waste (Testliner)

Slushing, Medium Consistency ( 5 ~n

De flaking

Fractionation Consistency: 1 - 3 ",0

(Multi fractor 010) Screen: 1.4 / 1.6 mm 0
0.6 mm 11
Flow: 400 l/min
Overflow Ratio: 20 - 95 %

Activation Beater: Escher Wyss

Lab Refiner,
PFr Mill
Consistency: 4, 5, 20 ,00'
pH: 7.5 - 12
Spec.Edge Load: 700-2800 Ws/km
Bar Angle: 8° , 30°
Freeness Range: 15 - 75 SR

Sheet Formation Rapid Ktithen Sheet Mould

(White Water Recirculation)
2
Basis Weight: 80 - 250 g/m
Number of Plies:l - 3

Pilot Paper Machine

(One-layer Medium / Liner)

TABLE r Boundary Conditions and Variables of Fractiona-

tion, Activation, and Sheet Formation
 112

FIGURE 1

liP Scheme : Fractionation and Activat ion 1986 FIGURE 2

THO of Secondary Fi bers 2870

lFM

IF'"

I FM : 'nduc:tiv. Flow Neter

TS , Total Stock
l F : l ongfibe, ·Froction
SF , Shortti ber-Frac tion

lIP 1986
THO
Flow Sheet of the Pilot Plant for Fractionat ion
2869
 113

Schopper - Riegl.r - Valu • • SR

80

ShorUib . r - FrQc t i o ~

60

TOl al Sl ock

40

20 Pl ugg ing

ConSiSltney : 1 "1.
Sc r•• n ',4 mm - __ FIGURE 3
----
O +-----~----r---~~--~----_T_
o 20 40 60 80 100
Ov.rflow Rat io. "Ie

II P Schopp.r - RI.gI.r - Valu. VI , Ov.rflow Ratio '986 FIGURE 4

THO Fractionation of Wast. Pap.r (Tnl li n. , ) 2874

lign in Content ."Io

--'
20
_ .-§-
/"t.i
18 Shortfiber - Fraction
/,.P'
o/~
16
Total Stock
A-

14

~
~on
12
a 20 40 60 80 100
Overflow Rat io, "!.

If P Li gn in Content (lAPP I T222 om - 83) of Longtib.r-ond 1986

TH O Shortti ber - Froction(Testl in.r) vs , Overflow Rat i o 2875
 114

RCT. kN/m

1.6

-- -- -.,.,-

------
1,4

1,2
_- - - TOlal Siock
- - - Longll b. r- FraCl ion
1,0 _,_ 25 'I. Lon glib. r- Fraclion, b.alen
0~__-r__~__-.r-7_§_~r,~Sh_o~r~
"~ib~
.r_-~
F rr~~I~io~n.~u~n~
b.~o~'.~n~
o 25 50 75 100
Ret. Beating Energy, ",.
RCT,kN/m

1,6

1.4

-
1.2
FIGURE 5
1,0

O+---.---~-----r----.---~r---~-
o 20 30 40 so 60 70
Schopper- Riegler- Volue . SR

FIGURE 6
lIP RCT vs " Beat ing Energy " resp,
1986
THO Schopper - Rlegler - Value 2872
e.aling Conditions : PFI-Mill, S·I.Consi".ncy , pH 7,5

STFI - SSCS. kN/m STFI- SSCS. kN/m

~ 25',. LF (b ealen)

/ 6 75% SF (u nbea ten)

6
I
0/
9"'A LC /
/ I'LC
5 / 5
/
"fo
/
"P
/
9" 0---0 S·/. Consistency
4
0---0 5 -I. Consistency
4 ./ _ 20 -'. Consistency ............ 20 -I. Consi stMCY

0 0
040 50 60 70 0 40 50 60 70
Schopper - Riegle r- Value, SR Schopper - Riegler - Value, SR

liP STFI - Short Span Compress ion Strength vs . 1986

TH 0 Schoppe r - Rie gler - Value I Handshuts : 1809/m2) 2871
 115

STFI- SSCS, kN/m STFI-SSCS,kN/m

2s'/, lF I boo"n I
15"1. SF "mb..,..n I
5
PFI - MiU PFI-Mill

<>-
-0 pH 7,5 <>- --<>
pH 1.5
4 ___ pH II 4 ___ pH II

o 25 50 100 0 25 50 100
ReI. Beating Energy , "J. ReI. Beating Ene rgy . ' I.

I,p STFI Short Span Compress ion Strength 'Is . ReI. Beating Energy 1986

THO Beating at 5°'. Consistency . ( Handsheets : 180g I m2 ) 2873

FIGURE 7

4 RCT, kN/m

Testliner
n 40 SR (u nbeaten)
3 ~ 48SR (beaten)

liP Ring Crush Test ReT of Handsheets (Testliner I ' 986

THO vs . Number of Pl i es and Basis Weight 28'16

FIGURE 8
 116

Contract nO BOS-005-D

IMPROVEMENT OF THE EFFICIENCY OF ROSIN SIZE IN THE NEUTRAL pH-RANGE

Dr. U. BEYER
Klebstoffwerke COLLODIN
Vilbeler Landstrasse 20, D - 6000 FRANKFURT/M 61

Summary

When dispersing pulp fibres in water and forming a sheet out

of it, the result is a highly absorptive structure, on which
writing or printing is not possible. In order to provide the paper
with the desired properties, it must be sized, Le., one adds
substances, which control the penetration of water or watery
sol utions into the paper. With the internal sizing, i • e. the
adding of chemicals to the dispersed paper fibres, the most
popular method is the sizing with rosin size with the addition of
aluminium sulfate at pH 4.5. The advantage of these products is
the universe applicability as well as the adjustment of a
graduated sizing grade; the disadvantage lies in the pH-range of
the effectiveness.
Goal of this project was the search for a sizing medium based
on rosin, whose effectiveness is still given in a higher pH-range.
Finally it is to be reported, that there were a number of
initial steps in the direction of a problem solving, but the final
breakthrough did not succeed.
It became obvious, that a normal rosin size cannot be fixed
satisfactory in the neutral range on the cellulose fibre with
customary retentive agents or combinations hereof.

1. INTRODUCTION

When dispersing pulp fibres in water and forming a sheet out of

it, the result is a highly absorptive structure, on which writing or
printing is not possible. In order to provide the paper with the desired
properties, it must be sized, i.e. one adds substances that diminish the
penetration of water or watery solutions into the paper.
To reach this goal, two ways are possible. Either the necessary
substances are added to the fibrous material dispersed in water before
sheet forming, or the surface of the finished paper is treated with
suitable chemicals.
Wi th the so-called pulp sizing, L e. the adding of chemicals to
the dispersed paper fibres, the most popular method is the sizing with
rosin size with the addition of aluminium sulfate at pH 4.5. Rosin size
is produced from the rosin of pines, which is either gained from the
living tree - similar to rubber latex -, or out of the cut tree when
producing pulp according to the sulfate procedure. Rosin consists of
 117

different acids of the sylvic acid type and can be condensed - according
to Diels-Alder - with dieneophile compounds. The compounds won via this
method can be dissolved as soap or dispersed.
The advantage of these products is the universal applicability as
well as the adjustment of a graduated sizing grade; the disadvantage
lies in the pH-range of the effectiveness.
Goal of this project was the search for a sizing medium based on
rosin, whose effectiveness is still given in a higher pH-range (approx.
7) •
Two ways seemed possible : On the one hand the modification of the
rosin, on the other hand the fixing of the cellulose fibre with other
chemicals, or a combination of both possibilities.

2. ROSIN SIZE FIXING WITH CHEMICALS

Different inorganic and organic compounds, as well as mixtures of

these compounds were used to fix the rosin size on the fibre surface.
The trials were carried out with dispersed rosin sizes and with rosin
soap sizes.

Polyethylenimine

Polyethylenimine gave satisfying results with respect to the

sizing efficiency but not with respect to the economy.
Lastly the addition of aluminium-salts could not be omitted, due
to the discoloration of the finished paper.

Dicyandiamide-compounds

Because of the fact that the molecular structure is similar to a

pigment and to follow the example of colour fixing, different fixing
agents were examined.
These compounds consist normally of dicyandiamide and formaldehyde
as well as urea. The results were comparable to the results got with
polyethylenimine.
Wi thout the addition of small amounts of aluminium salts sizing
was not economical.

Cationic starch

The sizing efficiency of dispersed rosin size combined with

cationic starch was significant better than with a size out of
saponified rosin. But the water penetration increased fast at pH-values
over 5.5 and the addition of aluminium salts were also necessary.

Carboxymethylcellulose

Carboxymethylcellulose improves the retention of fines and

chemicals in the papermaking process. Due to this and because the sizing
problem is at first a problem of the retention of the necessary amount
of rosin, carboxymethylcellulose was added in the original anionic form
and cationic modified. Both types showed no improvement of sizing in the
pH-range above 6.
 118

Inorganic compounds

Besides aluminiumsulphate other aluminium-compounds are

recommended to fix rosin size on the cellulose fibre surface. Actually
the most popular compound is aluminium-hydroxychloride which imparts the
cellulose fiber a higher zetapotential than sulphate at higher
pH-values.
Tests were carried out in the laboratory as well as in paper-
mills. The result was a slightly better size retention but compared with
the much higher price for these products, the use was not justified.
Addi tionally other inorganic polyvalent salts which are used for
crosslinking purposes were tested but the result was as negative as with
organic compounds.

3. ROSIN MODIFICATIONS

Rosin consists of different acids which are shown in table I. It

also shows the distribution of the acids in the two important types of
rosin - gum rosin and tall oil rosin. Whereas before 1950 the pure rosin
was saponified or dispersed and used as a size with aluminiumsulphate,
nowadays the rosin is chemically modified.
Because of the fact that the rosin acids contain mostly two
double-bonds, they are able to react according to the DIELS-ALDER-
REACTION which is shown in table II. This reaction means a coupling of a
double-bond of a cis butadiene compound with a diene which results in a
new six-ring-system. The diene has to be activated by carboxyl-groups or
similar groups which reduce the electrodensity at the double bond of the
diene.
According to the theory, only laevopimaric acid - nO 1 table I -
is able to react in this way but at the high temperatures the reaction
is carried out - approximately 180 0 - 210 0 C - it can be assumed that
the double bonds, shift. Although it functions, this has not yet been
confirmed by any research institute.
The most common chemicals to react with rosin according
DIELS-ALDER are maleic acid anhydride and fumaric acid. The amounts
added range from 8 to 12% and the resulting rosin which is called a
"fortified" rosin, has an approximately 20 0 C higher melting point and
the acid number ranges between 200 and 220 (mg KOH/g rosin) compared
with roughly 170 of the original gum or tall oil rosin. To evaluate, if
there is an influence of the acid or acid anhydride or the amount of
diene used, different trials were carried out.
The rosin which is fortified with maleic acid anhydride reacts
better with the cellulose fibre surface in the presence of aluminium
ions at higher pH-values than the similar rosin fortified with fumaric
acid.
Surprisingly, a combination of both reacts far better than both
alone.
Tall oil rosin gives better results than the very similar gum
rosin which contains very little residues of turpentine.
The acetylenedicarboxylic acid does not show any results.
Different other dienes with carboxylic or carbonylic rests were
also tested but did not work better than the above mentioned
combination. It seems to be that the anhydride of maleic acid is the
most reactive compound.
 EXPLANATIONS OF TABLE I

No. Name of rosin acid %(Gum rosin) %(Tall)

1 levopimaric 1-15 0
2 neoabietic 10-60 4
3 abietic 10-40 > 40
4 dehydrabietic 1-2 < 1
2 5 dihydrabietic 4 3
~ ~ 6 tetrahydroabietic 1
GOOH GOOH 7 primaric 8 1-2
8 isopimaric 8 1-2

3
~ ~ 4
.-
.-
\.0
GOOH

1800 G
~ ~ 5 6
~+ q:
COOH
GOOH m ~
~ •
7
~=GH2 ~GH2
TABLE I - ROSIN ACIDS TABLE II - DIELS-ALDER-REACTION OF LEVOPIMARIC
ACID AND MALEIC ACID ANHYDRIDE
 120

The reaction between fortified rosins and different amines such as

polyfunctional amines leads to products which gave slightly better
sizing results as dispersions but the amounts of amine to be added were
too uneconomical.
The increase of the molecular weight of the rosin acids by
reacting with polyfunctional alcohols or inorganics which should improve
the retention of the molecule or the particle in the fibre felt was
tendentious successful.
Lastly, it was tried to modify the hydrophobic part of rosin with
polymeric rosin and hydrocarbon resin but this also did not improve the
result.

4. CONCLUSIONS

Finally, it is to be reported, that there were a number of initial

steps in the direction of a problem solving, but the final breakthrough
did not succeed.
It became obvious, that a normal rosin size - be it a dispersion
or a soap - cannot be fixed satisfactorily in the neutral range on the
cellulose fibre with customary retentive agents or combinations hereof.
Of the inorganic products tested, there are only aluminium
derivates suitable, like sulfate, chloride or polychloride.
The modification with dienophiles showed an improvement with the
combination of maleic acid anhydride and fumaric acid.
After all these trials the bigger chance, therefore, for the
development of a rosin size effective in the neutral range should lie in
the emulsified type, i.e. in a rosin dispersion.
But because each paper mill has its very own characteristics, it
will take a long way to get a size which will be sui table for the
majority of the mills.
 121

Contract nO BOS-OIO-D

MORE FILLER IN PRINTING PAPERS BY OPTIMISING FORMS

AND DISTRIBUTION CURVE OF FILLER PARTICLES

W. BAUMGARTNER and A. BREUNIG

Haindl Papier GmbH, Augsburg

Summary
Type, form and distribution curve of the filler particles
influence strength and surface characteristics of printing
papers to a remarkable extent. For machine finished offset
paper other filler properties are preferable than for
supercalendered rotogravure paper. Different fillers re-
act on supercalendering differently. Modern equipment for
measuring the distribution curve of the filler particles
gives new inSights in the size and form of these partic-
les and enables fast and frequent quality controls of the
purchased and the used fillers. By reducing the variation
of the filler going to the paper machine more filler and/
or less chemical pulp can be used and also the variation
in printing quality is reduced.

1. MACHINE FINISHED OFFSET PAPER AND NEWSPRINT

More filler can be used if an appropriate filler type or
in the case of china clay an adapted quality is selected. We
found that 1,6 - 4,i labs. more of an well selected filler can
be used, compaired with papers filled with our standard clay,
if we wish the same breaking length. (From test we know that in
our case 75 m breaking length is gained by a reduction of 1 %
filler or is lost by 1 % more filler of the same type.)
If we wish to spare chemical pulp, with the filler content
remaining constant, we found for the mentioned example a reduc-
tion of 0,8 - 2,1 labs. possible, 1 %abs.- chemical pulp corre-
sponding with 150 m breaking length, with softwood sulfate used.

2. SUPERCALENDERED PAPER
We found in our studies with labaratory test sheets, that
the type of filler influences the changes of the paper strength
after supercalendering to a remarkable extent.
The breaking length of paper with leaflet struktured
china clay as a filler increases by supercalendering in our
case wi th,a large amount of fine groundwood. This increase in
breaking length varies with the size of the filler particles.
Fine clays gained up to 200 m, a rather coarse clay, which
showed high breaking length before supercalendering, gained
nothing. Papers filled with talc showed small gains or losses
 122

in breaking length after supercalendering, papers filled with

sphere structured calciumcarbonate or mixtures of the fillers
showed no significant influence in their breaking length after
the treatment in the supercalender.
The stretch of all the tested shee~ increased after
supercalendering, especially of the papers, which showed no
gain in breaking length.
The tear of all papers,measured with the Brecht-Imset-
tester, is reduced, and the gains by using an optimal filler
are smaller.
The changes of the strength properties after supercalen-
dering are certainly also influenced by the shape factor of the
filler particles and by the freeness of the used pulps.

3. PRINTING PROPERTIES
Especially coarser clays can increase the strength properties
of paper or allow a higher filler content or a reduction of
chemical pulp. We found this for machine finished and for
supercalendered paper.
For rotogravure paper a compromise between strength pro-
perties and printability is needed, because coarse clay reduces
here the printability. Mottling increases with coarser clays
and is reduced with growing proportions of particles smaller
than 2 microns. Regarding missing dots we found an optimum
with 50-55 % of the filler smaller than 2 microns.

4. MEASUREMENT OF THE DISTRIBUTION CURVE

If we measure these curves of filler particles size dis-
tribution by sedimentation with the sedigraph on one side and
with a lasergranulometer as an optical device on the other
side, we can get insights in the particle forms of the filler,
whickwe can gain otherwise only by the time consuming and limi-
ted use of the scanning eletromicroscope ( Figure 1 ).

5. MILL RESULTS
Due to the fact that the optimal fillers, which we found
with our laboratory tests, were not available on a commercial
scale or - because of production costs or transportation costs-
were not to use economically, we looked for a solution to re-
duce the variations of the filler properties of our clays and
to determin a good standard quality.
The Augsburg mill uses china clay from four sources to pro-
duce groundwood containing, supercalendered rotogravure and
offset papers. We used the newly aquired lasergranulometer and
sedigraph to intensify the quality control of the delivered
fillers and succeeded with an agreement with the filler produ-
cers for smaller tolerances, especially for the proportion of
particles smaller than 2 microns.
 123

To reduce the variations of the filler going to t~e paper

machine even more, we installed 3 large towers, 1000 m each,
for the clay storage in slurry form. The slurry is produced at
our mill from the delivered clay pellets. Two of the towers
contai~ only one grade, the third tower contains two grades
with very similar properties and from nearly the same location.
From these 3 towers the slurry foe the paper machines is mixed
in the wanted proportions. So we get nearly constant filler
properties, especially with regard of the particles smaller
than 2 microns, what we control re g ularly.
Figure 2 shows the correlation between the proportion of
the . clay and breaking length of laboratory ' sheets, filled with
our fractionated clay. By reducing the variation of the pro-
portion of the filler smaller than 2 microns at the fill e r
producer and at our mill ( figure 3 ) we could minimise the
variation of the paper strength. Maintaining our strength stan-
dard ~e could increase the filler content about 1 labs. and
reduce the sulfate pulp about 0,5 labs. Also the printability
of the papers gained and remained more constant.

t
so -

.
0

.!: 40 -
c:
0
b
-e
30
...c:
:f:
...
~
...
E 20 -
III
t:
0
:;:
L.
0
a.
~ 10
Q.

123 456789 11 12 13 14 20 21 22 23 24 30 31 32 33
Kaol ine Talc (a (03 Mixtures

o
Gr anulometer Sedigraph

~
FIGURE 1 - GRANULOMETER AND SEDIGRAPH

Measure different particles sizes,

shown here with the proportion of the filler smaller than 2 microns
 124

i "
.~
2200

2100

2000
""~ ~ FIGURE 2

Breaking length ver-

sus proportion of
particles smaller
I ~.
.c
a.
c than 2 microns .
.!!!

1'-.,
1900
'"
c
:.i:
...
..
41
1800
a:l

1700 ~
10 20 )0 40 SO 60 70

% filler <2 I'm

"1\1

.r
before continuous
9.0 control of pur-
7.9 chu.d cloy
6.8
~
5.6
4.5
14
2.2
t1
0

x
I

i
15 I
Il
12 alter continuous
10 control of pur-
U chued clay
-t 6.8
5.1 FIGURE 3
3.4
1.7
Variation of the
0
clays in % of the
proportion of par-
ticles smaller than
x 2 microns.
]0

1
26
23 after continuous
19 control and
-t IS
mixing of clay
II
U
3.'
40 44 5' 6O 64 61
46.4
 125

Contract nO BOS-088-UK

THE DEVELOPMENT OF PROCESSES TO INCREASE THE FILLER CONTENT

OF WOODFREE PAPERS TO 40%

P. HOWLAND
Pira, Randalls Road, Leatherhead, Surrey, England

Summary
The motivation for increasing the filler content of woodfree
paper lies in the raw material cost savings that can be achieved in
this way. The detrimental effects of filler in paper have been
identified and quantified for a wood free offset paper. Strength
losses and printing dust were found to be the most critical detri-
mental effects of high filler addition. Solutions to these
problems were sought in three broad areas of papermaking technology
- raw material selection and processing, chemical strength resins
and post production treatment.
Production trials indicated that the solutions showing the
greatest practical benefit were (a) increasing the mean fibre
length by the use of additional softwood pulp, (b) optimised size
press operation using high solids/low viscosity starch solutions
and pigmented size press applications.
A final trial on a production machine clearly showed that
functional woodfree offset paper could be produced with a filler
content of nearly 40%.

1. INTRODUCTION
Filler is added to printing paper in order to achieve good optical
properties and surface smoothness. Beyond a certain level, typically
around 15%, its function is primarily to reduce furnish costs.
For p~inting and writing grades addition levels of between 10 and
20% are typical. When the filler content of paper is substantially
increased, a number of problems are encountered. The paper becomes less
bulky, weaker and may have a tendency to dust. Strength losses are
incurred because filler interferes with inter fibre bonding and also
replaces the basic reinforcing component of the paper - cellulose fibre.
A production trial at the start of the project clearly identified
the problems. To overcome them, two approaches were followed.
As a first step, the standard papermaking raw materials and
processes were considered. Furnish types, refining strategies, strength
aids and size press chemicals were examined with a view to optimising
conditions for high filler paper production.
The second step was to develop and assess new approaches to over-
coming the problems. Processes such as filler pretreatment, the use of
mul ticomponent wet end strength aids, pigmented size press and paper
dedusting technology were examined.
 126

Cost effectiveness was the criterion by which each technological

solution to the problems of high filler content was assessed.

2. HIGH FILLER PAPER - THE PROBLEMS AND STRATEGIES FOR OVERCOMING THEM
A medium grade woodfree offset printing paper was chosen as the
product on which to base the project. This product was 100 gsm Hi-Speed
Cartridge produced by Wiggins Teape UK PIc, which in its standard form
contains 17% filler.
A production trial was carried out to identify and quantify the
problems and benefits of high filler paper. The trial set out to
examine production parameters as well as the final product properties.
Printing trials were also carried out to assess the printability of high
filler paper. Paper containing between 18% and 50% filler was produced.

2.1 Runnability
No major runnability problems were encountered when the filler
content of the paper was increased. The dry line shifted slightly
towards the dryers and the filler retention dropped slightly as the
filler content increased. The wet web strength was noticeably reduced
beyond 35% filler content and whilst this made it more difficult to
rethread the web after a break, it did not in itself lead to a
significant increase in machine breaks.

2.2 Physical Properties

The most critical physical properties for offset printing paper are
tear, stiffness, bulk, surface smoothness and surface strength (IGT
Pick).
All the paper strength properties were reduced by around 50% in
going from 20 to 50% filler. Tear was greatly reduced by filler as was
stiffness and bulk. The significance of bulk lies in its effect on
stiffness.
No statistically significant trends in Pick resistance and surface
smoothness were ob~erved.

2.3 Printability
Paper containing over 22% filler was "unacceptable" from a printing
point of view because of the high levels of dust that accumulated on the
printing blanket.
Analysis of this dust showed it to consist mainly of chalk
particles over 10 microns in diameter.

2.4 The options

The following options for overcoming these problems were identified
by extensive examination of the literature and through contacts with
other researchers.
(a) Increase furnish strength and bulk.
(b) Apply strength resins at the wet end.
(c) Improve performance of the size press.
(d) Physically remove surface dust.
(e) Use filler with a reduced dusting tendency.
Options (a) and (c) proved to be the most effective and are
described in this paper.
 127

3. FURNISH OPTIMISATION
Clearly, an important parameter in papermaking is the major raw
material, pulp, and the treatment applied to it prior to the paper
machine. The choice of furnish was based on pulp evaluation studies
carried out at Pira and Wiggins Teape on a range of pulps. The critical
parameters on which the choice was based were bulk, tensile strength and
tear. It was found that the Scandinavian softwoods gave the most
favourable combination of properties. The optimum refining energy was
identified at around 100 kwH/tonne.
Machine trials were carried out to establish the benefits of adding
a greatly increased proportion of the "optimal" softwood pulp in paper
containing 20% filler. The only two properties to benefit were tear and
burst. Stiffness was relatively unaffected by the softwood content at
this filler level and refining condition.

4. SIZE PRESS OPTIMISATION

The importance of the size press was very clearly demonstrated by
the first machine trial. At the end of this trial, two sets of paper
were produced with around 45% filler. The first set was treated
normally with the size press. The second was untreated and also
uncalendered.

Table 1 Size press treatment increases burst by 0.5 KNg- 1 .

Test Burst Index Stiffness mN Tear mN

KNg- 1 MD CD MD CD

Untreated 0.7 5.3 2.7 250 250

Size pressed 1.2 5.8 3.7 340 340

%difference 41 9 27 26 26

The results shown in Table 1 clearly show the importance of the

size press. In the case of stiffness the results were distorted because
the calender was not applied to the untreated paper; consequently the
difference would be even greater if both had been calendered.

4.1 High size press starch pick-up - trial results

Pilot size press trials with 30% filler paper indicated that at
100 m/min, a starch pick-up of up to 14.5% could be achieved without
encountering any runnability problems. The strength benefits obtained
by increasing the starch pick-up were considerable and are shown in
Table 2.
It was found that the additional starch pick-up produced paper with
greatly reduced dusting and improved printing quality. It was also
observed that paper containing high levels of starch had a "sticky"
feel. This may be of great importance in the marketing of such a paper.
 128

Table 2 Increased pick-up greatly improves strength properties.

Starch pick-up % % Increase (based on 4.5% pick-up)

Specific bending
Modulus

MD CD Burst factor

4.5 o 0 0
6.7 5 3 16
8.8 8 16 28
14.2 16 43 55
14.5 16 49 54

4.3 Pigmented size press

The application of additional pigment at the size press is of great
interest because the pigment is less likely to interfere with fibre
bonding. A pilot machine trial was carried out using a wood free
printing paper containing 30% filler.
A filler pick-up of 8% and a starch pick-up of 13.3% was achieved.
The main results are shown in Table 3.

Table 3 The effect of pigmented size press on strength.

Pigmented Normal

Loading 32.9 26.4

Starch pick-up 13.3 14.5
Burst factor (KNg- 1 ) 2.7 2.9
Specific bening modulus MD 549 590
CD 334 335

The size press added filler caused a reduction in the specific

strength properties. However the loss of strength is considerably less
than would have been expected from a comparable increase in internal
loading. It was also found that the pigmented size press produced a
paper with acceptable printing and dust characteristics.

5. PRODUCTION MACHINE TRIAL

A final production trial was carried out on a fourdrinier machine
at a speed of 200 m/min. This trial examined the advantages of an
 129

improved furnish containing increased softwood pulp (65%) and increased

starch addition at the size press (8% to 13% starch solids). Paper
containing 37% filler was produced and compared with the standard
product containing only 17% filler.
Considerable improvements in tensile strength were observed with
the improved furnish and also with the increased size press solids.
Increasing the size press sta"rch solids had a slightly detrimental
effect on tear and a surprisingly small effect on stiffness.
Cross-sectional staining of the paper with iodine showed that the
starch had penetrated deeply. It would be anticipated that greatly
improved stiffness results could be achieved if the starch distribution
was improved by using a different starch viscosity or type, or an
improved size press.
Paper from the trial was print tested and ran without difficulty.
No signs of excessive dusting were observed.

6. CONCLUSION
By the careful selection of pulps and refining levels and by
achieving high starch pick-up at the size press, it has been
demonstrated that woodfree offset paper containing nearly 40% filler can
be produced to a satisfactory specification.
 130

Contract nO BOS-042-F

STUDY OF THE PROPERTIES, APPLICATIONS AND WIDENING USES

OF CORRUGATED BOARD IMPREGNATED BY TOTAL DIPPING
IN A SOLUTION OF RESIN BY A NEW PROCESS

G. GOLDSTEIN and M. MURE

BEGHIN-SAY, Division Kaysersberg
Direction Recherches et Developpement

SUMMARY

BEGHIN-SAY has worked on a new process of impregnation of

corrugated board by total dipping in a solution of resin in a hot
organic solvent with solvent recycling. This cyclic process takes
place after all usual manufacturing steps including printing and
gluing.
Based on French Patent Nr 2 294 763, the process was widely
tested and improved, the improvements giving a new process with
enough industrial reproducability. The specific properties of
impregnated board were summarized ; stacking strength is for
instance improved after impregnation by 80 % in wet atmosphere.
Results' of Marketing and engineering studies, made at the
same time as the present research, bring BEGHIN-SAY to drop
impregnation as a research subject.

I - INTRODUCTION

Everybody knows that corrugated board and water generally do not

work well together. This problem has existed in our industry for many
years and we are all looking for a process which will enable us to
sell to our customers a new product, not water sensible, whether
liquid or gazeous.
The process we looked at since 1982 was patented by the French
company MECALIX in 1974, without any industrial application, perhaps
due to the uncommon solvent used, uncommon in the paper industry. This
process realizes an impregnation of all components of corrugated board
by total dipping of blanks or finished boxes in a solution of resin in
 131

organic solvent. The best way to know about the process is to look at
the original patent. You can get some quick ideas about this cyclic
process, based on the annexed scheme.
Impregnation takes place in a treatment vessel 4. Corrugated
board and boxes are introduced and air is extracted by a vacuum
pump 6. Then, pump 2 moves the hot impregnating solution (100 - 115°C)
from heating vessel 1 to treatment vessel 4. After total dipping of
the board, reversed pump 2 extracts solution back to heating vessel 1.
At this step, board in the treatment vessel is impregnated with resin
and solvent. The aim of the next step is to recover the solvent. This
is done by opening contact between treatment vessel (board near 100°C)
and condensor (near O°C). Displacement of solvent is due to tempera-
ture (and pressure) difference between these two parts of installa-
tion. At the end of this recycling step, pressure in treatment vessel
is close to 20 - 30 torrs and we have only to go back to atmospheric
pressure, using a neutral gas 5.
Researches were conducted on a small pilot plant, which had an
internal volume of 160 liters (nearly 40 kg corrugated board). Largest
dimensions of treated blanks were 2.4 x 2.4 meters. Our studies had a
triple purpose
- process reproducibility and industrial applications
- general properties of impregnated board
- summarize specific properties of treated boxes.

II - MODIFIED PROCESS - MATHEMATICAL MODEL

The first tests were made using the original process. We quickly
observed that :
- main caracteristics of board were greatly improved
- these improvements were non-homogeneous, the differences being
not due to fibrous compositions of papers.
So our first work was to obtain better regularity in processing. We
could s~e that resins deposits could, on a same blank, have differen-
ces of - 40 % of the mean value. Highest deposits were observed at the
entrance point of solution, lowest at points immersed at the end of
the filling step of the process.
After various hypothesises, we found the origin of this pheno-
menon. When the hot solution is introduced in the treating vessel, we
have a quick vaporisation of solvent which is condensed on the cold
non-immersed parts of the boards. Condensed Heptane is a barrier to
impregnation of the board by the resin. We now have a slow diffusion
process instead of a quick absorption process.
This vaporisation step could not disappear. The best way to
improve the process was then to build a regular "barrier" phenomenon.
This was obtained by a pre-impregnating step in which gaseous phase,
at top of heating vessel, was connected to cold corrugated board.
Heptane will condense on board, the process being controled by thermal
equilibrium.
Diffusion was also quickened, using the new pipe between treat-
ment and heating vessels. This pipe enabled us to do a closed circuit
of impregnating solution, motion of the solution near the board being
the best way to break steady states at poor resin concentrations in
the neighborhood of corrugated board.
 132

The main steps of the modified process are given in table I.

Tests made with t¥is improved process showed that resin deposits could
be kept within a - 10 % range around mean value. This modified process
was patented by BEGHIN-SAY.
During this work on the process, we could study the main parame-
ters of impregnation. In particular, we were able to do some calcula-
tions about heat and mass transfer during the main steps of the
process : pre-impregnating, impregnating and solvent recovery. The
mathematical formulas we wrote were tested on the pilot plant, ena-
bling us :
- to choose the best temperature for the solution of resin in
Heptane
- to know about gazeous transfers during pre-impregnating or
condensation steps.
These datas were used by our engineering department, which was working
on an industrial pilot plant project.

III - IMPREGNATED PAPERS - CARACTERISTICS

Present process 'cannot be used on papers. It could however be

interesting to know about caracteristics of impregnated papers.
Table II gives, at 20°C and 65 % RH, improvements obtained in adding
15 % resin to paper. What is interesting to us, corrugated box produ-
cers, is Ring Crush improvement, which is related to stacking strength
of boxes. On another hand, you will note that cohesion caracteristics
are not greatly improved by impregnation (bursting strength, tear or
traction resistance).

IV - IMPREGNATED BOARDS AND BOXES - CARACTERISTICS

We have done, on our pilot installation, near 400 impregnation

cycles (near 8000 kgms of treated board). The treated board or boxes
were tested in our laboratories. Boards were from double face to
triple wall types. On basis of these tests, we can give the mean
improvements of table III, in three atmospheres currently in use in
our laboratories :
- standard value of 20°C - 65 % RH
- cold rooms at 4°C - 90 % RH
- tropical atmosphere at 38°C - 95 % RH
On these values, we can observe that the highest improvements
were found on compression characteristics : Edge Crush Test or sta-
cking strength (61 to 87 % improvement depending on atmosphere). In
this case, the higher improvements are seen in the highest humidity,
i.e. in the most unfavourable atmosphere conditions for our corrugated
product.
. Our laboratory tests were extended to simulation of real use of
corrugated boxes. For instance, we looked at boxes under "standard"
rain. There we saw that life duration of boxes under load could be
improved, after impregnation, by factors close to 15 !
 133

Some of our customers could test use of treated boxes. We could

therefore have two main conclusions :
- satisfactory of these people was generally due to good behan-
dling of impregnated board in quite difficult uses : cold cham-
bers or underground stacking.
- impregnated corrugated board has in difficult cases a better
use than other products, due to its light weight or its setting
compliance.

v- CONCLUSION

Our research was done in the laboratories of BEGHIN-SAY's

Research Center, with financial help of the Commission of the European
Communities. Studies were realised between September 1983 and March
1985. At this time, two other studies gave their main results :
- first, a marketing survey which gave a figure of 6000 tons/year
as total potential for impregnated boards and boxes
- second, an engineering study, regarding an industrial prototype
with three treatment vessels and an annual capacity of 8000 tons,
which concluded to an investment close to 35 millions French
francs.
Based on these figures, BEGHIN-SAY did not retain impregnation of
corrugated board as a major development step, and research contract
with the Commission was, on general agreement, denounced.

TABLE I

BASIC PROCESS BEGHIN-SAY'S PROCESS

- Loading of the board and closing of Idem

the treatment vessel

- Air extraction out of treatment Idem

vessel

- Pre-impregnating with
heptane

- Loading of the treatment solution Idem

in the treatment vessel

- Contact between board and

solution and circulation

- Unloading of the solution Idem

- Solvent recovering on cold Idem
condensor

- Back to atmospheric pressure with

neutral gas Idem
- Unloading of the treated board Idem
 134

TABLE II

CARACTERISTICS IMPROVEMENTS

WEIGHT + 15 %
BURSTING STRENGTH + 19 %
TENSILE STIFFNESS MD and CD + 10 %
STRETCH MD +3 %
CD - 24 %
KODAK BENDING STIFFNESS MD + 29 %
CD + 60 %
RING CRUSH MD + 57 %
CD + 80 %
TEAR MD - 13 %
CD - 2 %

TABLE III

MEAN IMPROVEMENTS

20°C - 38°C -
65 % RH 95 % RH

WEIGHT + 15 % + 15 % + 15 %
BURSTING STRENGTH + 9 % + 45 % + 31 %
PUNCTURE TEST + 19 % + 24 % + 31 %
BENDING STIFFNESS + 73 % + 74 % + 96 %
EDGE CRUSH TEST + 85 % + 106 % + 103 %
STACKING STRENGTH + 61 % + 77 % + 87 %
 PILOT PLANT

•,
I

9 5
..-
10 w
Vl

1) Heating vessel 6) Vacuum pump

2) Cirulation pump 7) Vacuum reserve

3) Condensor 8) Solvent recovery

4) Treatment vessel 9) Cooling system

5) Neutral gas 10) Heating system

 PAPER MANUFACTURING

Paper drying under Z-direction restraint to improve the

strength properties of short-fiber high-yield pulps

Effects of improved control of the cross profile of the

paper web

Improved papermaking with emphasis on energy savings and

high consistency technology
 138

Contract nO BOS-055-1

PAPER DRYING UNDER Z-DlRECTION RESTRAINT TO IMPROVE THE STRENGTH

PROPERTIES OF SHORT-FIBER HIGH-YIELD PULPS

G. CERAGIOLI; G. CAPRETTI and G. BIANCO

Stazione Sperimentale per la Cellulosa, Carta e Fibre Tessili Vegetali
ed Artificiali, Piazza Leonardo da Vinci 26, 20133 Milano
Summary

This study was intended to evaluate the effects that the drying of the
sheet under Z-direction restraint (press drying) has on the properties
of papers made from high-yield, short-fiber pulps, as well as from
secondary fibers. The results confirmed the important role of pressure
in press drying. The temperature used is quite decisive to obtain a
very high wet strength. Press drying was found particularly effective
in the case of unbeaten fibers still very lignified.It was also
confirmed that press drying can result in sheets with a very high
wet strength. To achieve this result it is necessary to use very high
platen temperatures (greater than 170-180°C).The presence of lignin
seems to play an important role. These elevated levels of wet strength
of the sheet can cause problems in paper recycling, which may be more
serious that those encountered with normal wet-strength papers. Press
drying appears to be tailored for hardwood high-yield pulps.P~rticu1arly
high levels of strength were obtained in the case of semi chemical pulps
from hardwoods with thin cell wall fibers.In the case of high-yield
wheat straw pulps, press drying was not very effective. The 'improvements
obtained were usually slight and inferior to those obtained with hard-
wood high-yie14 pUlps. Secondary fibers did not respond very effectively
to press drying, even though the improvements obtained were better than
those with straw pulps. The improvements in the paper properties that
characterize the quality of corrugating medium were rather limited,
whereas the increments in the properties important for liners for
corrugated board were more marked. The high quantity of chemical fiber
present in secondary fibers could be responsible for the poor efficacy
of the process. The presence of fines did not have positive effects on
the results of press drying, whether their nature was totally
parenchymal (straw pulps) or whether they were composed of mineral
fillers and more or less lignified fibrous fragments as well as of
parenchyma cells (secondary fibers).

1. Introduction
The merits of press drying in the improvement of paper strength are
widely accepted. Our study was intended to evaluate the effects that press
drying has on the properties of papers made from high-yield short-fiber
pulps, as well as from secondary fibers.
First of all, the effects of some operative variables on sheet
 139

p~o.pertieswere investigated.
In the second part we evaluated the effects of fiber delignification
and pulp beating on the results of press drying. Hand-sheets of 200 and
120 g/m2 were made using a commercial eucalyptus NSSC pulp.
In a third phase the efficacy of press drying was investigated in the
case of:
-semichemical pulps of poor or intermediate quality prepared in the
laboratory from poplar and eucalyptus
-high-yield straw pulps
-commercial waste paper furinishes used for the manufacture of test liner
and corrugating medium.
2
Table 1-Effect of temperature (Pressure 25 kg/cm )

Temperature °C 20 100 200

3
Density kg/m 475 850 835
Tensile Nm/g 19 43 56
Modulus MPa 1100 3850 4300
Compress. Index Nm/g 15 35 43
CMT N 80 155 170
Wet Strength i. 0 3 29

2. Effect of temperature
Being one the factor responsible for the softening of the chemical
constituents of the fiber, the temperature used in press drying is very
important. As shown in Table 1 platen temperature was varied from 100 to
200°C. Such an increase resulted in a general improvement of strength
properties. Since density remains constant upon drying from 100 to 200°C,
an increase in bonding strength seems to occur. Noteworthy is the wet
strength which passed from negligible to very high values at the highest
drying temperature.

Table 2-Effect of pressure (Temperature: 200°C)

2
Pressure kg/cm 0 10 40
3
Density kg/m 475 750 870
Tensile Nm/g 19 50 58
Modulus MPa 1100 3850 4650
Compress. Index Nm/g 15 37 44
GMT N 80 175 175
Wet Strength i. 0 19 30

3. Effect of pressure
In Table 2 the effects of pressure are shown. An increase in pressure
improves most of the strength properties with the exception of CMT. Wet
strength seems to benefit from higher pressures especially at a high drying
temperature.
 140

Table 3-Effect of pulp beating

Drying Drainability, SR
20 50
3
Density kg/m atm 460 585
press 875 940
Tensile Nm/g atm 18 43
press 48 66
Modulus MPa atm 1200 2400
press 4400 5100
Compress. Index Nm/g atm 16 26
press 39 47
CMT N atm 75 185
press 150 190
Press drying: 100°C and 40 kg/cm 2

4. Effect of pulp beating

In Table 3 some results are reported relative to the effect of pulp
beating on press drying.
Here we have 20 SR for the unbeaten pulp and 50 SR for the beaten pulp.
For each pulp the values for atmospheric and press drying are reported.
As beating progresses the percentage increase in density for the press
dried sheet is lower than for the normally dried sheet. This holds for
tensile, modulus and compression index and is even more evident for CMT.
For the crush resistances press drying proved particularly effective on
unbeaten pulps.
Overall, our results show that press drying manifests its maximum
effectiveness on the unbeaten pulp. The strength properties of the press
dried sheet from unbeaten pulp are usually better than those obtained with
extended beating and normal drying.

5. Delignification and press drying (Fig. 1)

The eucalyptus semichemical pulp was progressively delignified with
chlorite from K Number 107 to 17. The decreased presence of lignin gives
to the fiber surface a greater bonding capacity, making the fibrous
structure less rigid and therefore capable to assume a ribbon-like shape in
the normal drying process. Press drying has a quite similar effect as a
result of a constraint action. Thus the consequence of delignification is a
narrower gap between the paper properties of the normally dried sheet and
those of the press dried sheet.
As can be seen here this feature is particularly evident for CMT and
RCT, as well as for density and modulus.
 141

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100 80 60 40 20
100 80 60 40 20
KAPPA NUMBER KAPPA NUMBER

Drying conditions (a )
( . )
20°C
150°C and 25 kg/cm
2

FIGURE 1

DELIGNIFICATION AND PRESS DRYING

 142

Table 4-Effect of press drying on wet strength

Temperature Pressure Wet Strength

2
°C kg/cm
100 40 3
150 40 7
200 40 30

6. Press drying and wet str~gth

As previously shown, the wet strength of the sheet dried normally or
under pressure at 100°C was negligible. However (Table 4)a slight increase
is observed when press drying at 150°C. Upon raising the platen temperature
to 200°C, the wet strength value reaches 30%. We have seen that wet str~
is affected by the applied pressure, but the essential condition is the
drying temperature.
The development of wet strength is not gradual with increasing
temperature: there seems to be a kind of threshold between 180 and 200°C
of platen temperature.
These improvements have been attributed to the modification in the
physical structure of lignin due to the lowering of its softening
temperature in the wet state. Around the water sensitive hemicellulose
bonds hydrophobic lignin bonds would form capable of exerting a protective
action and preventing water to break a sufficient number of water sensitive
fiber bonds.
Plasticisation of lignin would therefore be responsible for the
increased wet strength obtained with press drying.

Table 5-Effect of delignification on wet strength

Kappa Number Drying Conditions Wet Strength

°C kg/cm2 %
~7 9
150 25
37 5
107 30
200 25
37 20
107 20
62 200 10 16
13 10

To clarify these aspects we evaluated the wet strength of sheets

prepared with pulps progressively delignified and dried under atmospheric
or pressure conditions (Table 5).
Irrespective of the amount of residual lignin the sheet did not show
any wet strength when normally dried. When drying was carried out under
pressure, as shown in the Table, this property reached high values mainly
 143

in relation to the temperature used. It can be seen that, under equal

drying conditions, with progressive delignification there is a gradual
decrease in wet strength. This supports the validity of the hypothesis on
the fundamental role of lignin.
However, it is well known that a thermal treatment at high temperature
improves the wet strength of the sheet due to the formation of cross-
l~ed bonds between the fibers. Since the conditions necessary in press
drying to develop wet strength are appropriate for the occuring of auto-
crosslinking, this could be responsible for the improved wet strength.

Table 6-Heat treatment of the sheet and wet strength

Kappa Number Treatment Time Wet Strength

min %

107 0.5 0
2 0
30 25
60 20
17 30 12

We therefore subjected a normally dried sheet to an oven treatment at

200°C for times from 30 seconds to one hour and determined the corr~ing
wet strength (Table 6). The heat treated sheet showed a considerable
improved wet strength, but for this to occur long exposure times are
necessary. Moreover, even in this case a smaller lignin content corres~d
to a lower wet strength. The phenomenon of auto-crosslinking ~ould therefore
require a certain time to develop. However. it should be considered that
the mass heat transfer in the sheet is very rapid during press drying,
whereas is much slower during oven exposure. Thus our results add further
support to the major role of lignin in the development of a tigh wet
strength in press drying. However there is no certainity that this is the
only factor responsbile for its occuring.

Table 7-Disintegration of press dried sheets

Drying Wet Strength Disintegration

% min Rejects, %
Type °C
atm 20 0 5 0
press 100 0 20 0
press 175 7 150 1~2
press 200 32 180 12

7. Press drying and paper recycling

The high wet strength could create problems in the recycling of press
dried paper. In Table 7 we report the effects of press drying temperature
on wet strength and sheet disintegration. The time necessary to disintegrate
 144

the sheet increases with increasing drying temperature. For the sheet dried
at 200°C the reduction to elementary fibers was very incomplete even after
more than three hours disintegration with a substantial amount of non
disintegrated material. Thus problems arise when paper, as a result of
press drying, has acquired a high wet strength level.
Consequently, more drastic disintegration systems were investigated.
In one case the paper was treated with a caustic solution at high
temperature with no appreciable effect. A treatment with hydrochloric acid
resulted in a complete fiber separation but caused a very drastic L~parrment
of the strength properties.

8. High-yield hardwood pulps

Previous studies showed that press drying is very suitable for high
yield pulps. We turned our attention to two European hardwoods: one with a
low density and fibers with a thin cell wall (poplar), the other with a
high density and fibers with a thick cell wall (Eucalyptus). A series of
semichemical pulps were produced at yields varying between 85 and 70%.

Tfible 8-Eucalyptus NSSC pulps (16 SR)

Yield % 82 69
Drying atm pre'ss atm press
3
Density kg/m 360 755 460 820
Tensile Nm/g 11 39 22 53
Modulus MPa 680 3500 1460 4560
Compress. Index Nm/g 11 37 19 39
CMT N 45 140 100 165

In Table 8 some results of press drying in the case of unbeaten

Eucalyptus semichemical pulps at two yields are presented. The physical
properties of the normal sheet are rather poor. Press drying resulted in a
very remarkable improvement of the mechanical characteristics. The extent
of these increments does not differ much for the two yield levels, although
the process seems a little more effective on the higher yield pulp.
The considerations just expressed for Eucalyptus hold for poplar as
well. The positive effects of press drying were excellent particularly in
the case of the unbeaten pulps.
Table 9-Poplar NSSC pulps (beaten:36 SR)
Yield % 82 69
Drying atm press atm press
3
Density kg/m 620 875 870 950
Tensile Nm/g 60 90 90 110
Modulus MPa 3350 5820 5560 6760
Compress. Index Nm/g 33 52 43 51
CMT N 240 230 240 245
 145

As is shown in Table 9, the strength improvements obtained for beaten

poplar pulps at two different yields were still very good in the case of
the higher yield pulp, whereas the efficacy of the process decreased for
the lower yield pulp owing to the high values already achieved by normal
drying. We can observe here that the CMT of the beaten pulp does not change
as a result of press drying.
On the whole, press drying showed very effective in improving the
mechanical properties of sheets of semichemical hardwood pulps at yields of
more than 807. as well as around 707.. In many cases the differences in
mechanical properties found between pulps as a result of a lower yield were
considerably reduced by press drying. Finally the process was generally
much more effective on unbeaten than on beaten pulps.
Our results confirmed that press drying represents a technical tool
of extraordinary validity to obtain sheets with excellent physical
properties, even starting with pulp yields higher than 807., especially in
the case of hardwood fibers with thin cell wall. The quantitative
improvements particularly concern those physical properties that are
important in uses such as liners for corrugated board.

9. Wheat straw pulps

Due to shortage of wood, wheat straw has ever attracted the interest
of Italian papermakers. Corrugating medium from straw pulp was a typical
production that had to be abandoned for pollution problems. In the event
of its resumption we deemed it interesting to evaluate the effects of press
drying on the properties of high yield straw pulps.

Table 10-Straw pulps

Yield 76 61
Drying atm press atm press
3
Density kg/m 630 845 755 875
Tensile Nm/g 40 46 61 64
Modulus MPa 2600 4050 4150 5050
Compress. Index Nm/g 26 35 35 41
CMT N 155 150 215 200
CCT N 290 305 410 415

In Table 10 some results relative to two pulps at different yield are

presented. In spite of the marked increase in density, press drying
generally resulted in rather limited increments of the mechanical properties
of the sheet. The improvements mainly concern modulus and compression index,
whereas the effects on CMT and CCT were negligible or inexistent. Irrespective
of yield and type of pulping press drying was surprisingly little effective
on straw pulps. The magnitude of the improvements was very far from that
obtained with the high yield pulps from hardwoods and, as will be shown,
still inferior to that achieved with secondary fibers.
 146

10. Secondary fibers and press drying

The importance of secondary fibers for the production of test liner
and corrugating medium is well known. We deemed it appropriate to evaluate
the effects of press drying on furnishes used in Italy for the manufacture
of test liner and corrugating medium.

Table II-Waste paper furnishes for test liner

Furnish A B
Drying atm press atm press
3'
Density kg/m 590 815 640 880
Tensile Nm/g 27 41 36 48
Modulus MPa 1770 3550 2250 3940
Burst MN/kg 1.60 2.35 2.50 3.35
Compr.Index Nm/g 17 29 20 31

In Table 11 sono results are presented for two test liner furnishes.
The increased sheet density, consequent to press drying, provoked marked
improvements in strength properties. The entity of these increments was
greater for the lower grade furnish A. Thus the quality gap originally
existing between liners A and C tended to diminish with press drying.
Increments were particularly noticeable for modulus, compression index
and burst, that is properties especially important for a product such ~s
test liner.

Table 12-Waste paper furnish for corrugating medium

Drying atm press

3
Density kg/m 590 800
Tensile Nm/g 26 39
Compr.Index Nm/g 17 24
CMT N 105 lIS
CCT N 150 190

Table 12 shows the results relative to a commercial furnish from

mixed waste paper for the manufacture of corrugating medium. Here again,
due to press drying, rather substantial improvements in the physical
properties of the sheet were obtained and their extent is rather similar
to that observed for the test liner furnishes.
Overall, in the case of secondary fibers, press drying did not prove
to be as effective as for virgin high yield pulps from hardwoods.Specifically
the improvements relative to the paper properties that characterize the
quality of corrugating medium were rathe~ limited.
The reason of the lower efficacy of press drying in the case of
secondary fibers could be attributed to the fact that they always contain a
high percentage of chemical pulp (from 50 to 75%).
 147

Press drying shows its maximum effectiveness on rigid, poorly conformable

fibers, making them capable of bonding with adjacent fibers over very
extensive areas. This effect cannot manifest to the same extent in the case
of fibers already endowed with a high conformability as chemical pulps. It
is therefore reasonable to attribute the lower efficacy of press drying on
secondary fibers to the high presence of chemical pulp.

11. of fines in press drying

~ole
The role of parenchyma cells in high yield hardwood pulps has been
emphasized by several authors in relation to the increased strength
properties achieved by press drying. Press drying overcomes the negative
effects of a high lignin content, thus the presence of parenchyma cells,
even in considerable quantity, would no longer be disadvantageous.
In our investigation we were dealing with secondary fibers and straw
pulps, that is with pulps with a high fines content: so we deemed it
appropriate to evaluate the effects of their presence.
While, in the case of pulps from hardwoods and straw, fines are
constituted exclusively of parenchyma cells, fines of secondary fibers
have a different nature. Besides a considerable presence of mineral fillers,
the "fibrous" fines consist partly of true parenchyma cells and partly of
tracheid fragments.

Table 13-Furnish for test liner C: Effect of fines

Condition of pulp Whole Free of fines

Fines removed, % 17
Ash 6.6 1.5
Drying atm press atm press
3
Density kg/m 640 880 480 825
Tensile Nm/g 36 47 18 39
Modulus MPa 2250 3950 1300 4300
Folding End. log cycles 3.25 3.29 1.48 3.17
Compr.Index Nm/g 20 31 13 27

Table 13 refers to the removal of fines from a furnish for test liner.
When sheet drying was carried out normally, the removal of fines resulted
in a very marked decrease in strength. When the sheet free of fines was
press dried, a considerable recovery of strength was obtained, even though
the level achieved remained below the values of the whole sheet dried under
pressure. However the effectiveness of press drying resulted much greater
on the fines-free sheet than on the whole sheet.
 148

Table 14-Straw pulp (781 C): Effect of fines

Condition of pulp Whole Free of fines

Ash 9.8 3.9
Drying atm press atm press
3
Density kg/m 655 865 635 895
Tensile Nm/g 47 59 46 71
Modulus MPa 2600 4100 2450 4700
Compr.Index Nm/g 27 37 23 38
CMT N 155 155 130 150
CCT N 310 350 265 290

Table 14 refers to the removal of fines from a straw pulp; Here the
removal of fines does not result for the normal sheet in such a large
sacrifice of strength as experienced for the test liner furnish. Press
drying of the fines-free sheet determine a large improvement in many
physical properties, even with increments with respect to the values of the
whole sheet dried under pressure. Here again the presence of fines does
not seem to have favourable effects on press drying.
In spite of the constitutional differences existing between the fines
of straw pulp and those of secondary fibers, their presence does not
positively affect the results of press drying. In the case of the sheet
normally dried, the presence of fines was always advantageous for its
physical properties. Press drying was not so effective on sheets from either
secondary fibers or straw pulps; however its potential became fully evident
as a result of fines removal.

12. Conclusions
Our investigation has confirmed that press drying is a technical tool
of extraordinary potential for the improvement of paper strength.It appears
to be tailored for high yield pulps from hardwoods. Particularly high values
of strepgth may be achieved in the case of low density hardwoods.
The process manifests its maximum efficacy on unbeaten and lignified
pulps.
Using very high temperatures excellent levels of wet strength can be
obtained. For paper recycling this high wet strength can represent a more
serious problem than for normal wet strength papers.
Press drying was not so effective on
secondary fibers and even less so
on straw pulps. Here the effects on properties important for corrugating
medium were rather limited, whereas more marked improvements were obtained
on properties important for test liner.
Finally our results showed that press drying does not seem to benefit
from the presence of fines, irrespective of their nature and composition.
 149

Contract nO BOS-135(I)-S

EFFECTS OF IMPROVED CONTROL OF THE CROSS PROFILE OF THE PAPER WEB

H. KARLSSON
STFI

Summary

The control effects of two computer based control systems for

control of the slice lip of two different paper machines and
specially the effect on the moisture profile have been studied.
In both installations improvements of the moisture content cross
profiles are achieved. In one of the two installations the improve-
ments of the moisture content cross profile is very clear. The varia-
tions in the moisture content profile have decreased with 40% and the
mean moisture content in the web has been increased. The results have
been obtained with computer assisted manual control of the paper
machine.
The computer has balanced the CD-profiles of the slice lip, the
dry weight and the moisture content. This has led to an increased
attention to the moisture content profile.
The results show that it is even so that a slight increase in
the variations of dry weight has been accepted because of the higher
priority of the moisture content profile. This effect can be seen by
studying the autospectra for dry weight and moisture content for the
two periods.
The results thus show that energy savings can be made by im-
proved control of the slice lip. The savings are reached by an opti-
mal balance between moisture profiles and basis weight profiles. The
results are reached with a computer recommendation system and with
optimal control of' the slice lip profile.
The computer has in these two installations made the mathema-
tical calculations and the machine operators have followed the
instructions from the computer when adjusting the paper machine. The
possibility for further improvements seems more to be in the area of
actuators for moisture content cross profile control separately.

Introduction

It is often expressed from our industry that leveleness of the paper

product is more important than the quality level. Leveleness is thus a
target in itself and is more important than top quality. Leveleness is
also important in order to minimize use of energy and fibers.
We can divide quality variations into variations in the stock and
variations from the paper machine. Let's guess that 50% comes from the
stock and 50% from the paper machine. The paper machine variations can
then be divided into MD-variations and CD-variations. Let's say that 40%
comes from CD.
 150

Why do we have CD-variations? The paper machine is apparently a

deficient process. CD-control systems can be a cure. It is not the final
solution but it will help the paper maker to produce better paper.
Actuators for CD-control and CD-control systems are now rapidly
developed and several installations have already been made. This is a new
fast growing area of computer control of the paper making process.
Few reliable evaluations have been reported of such installations.
Especially CD-control of basis weight is a complicated control problem.
This evaluation shows possibilities and problems in this area.
The objective with the research was to evaluate two computer-based
CD-control systems for basis weight with respect to control performance
and effect on the moisture profile.
Since up to 99% of the water fed to the headbox is removed on the
wire it is easily understood that the effect of control actions in the
headbox and wire section can affect the moisture profile.

Data collection and signal analysis

Several CD-control projects regarding control of the slice profile have

started in Sweden. Two of these installations have been studied. Off-line
analysis has been combined with on-line measurements. One problem was to
collect and handle huge amounts of data.
Data has been collected from the sensors of the conventional measure-
ment and control system on the paper machine. This was done by a special
technique.
Data was collected under reference periods before and after installa-
tion of a CD-control system for control of basis weight and moisture. The
collected profiles was studied with respect to which streaks the control
system managed to eliminate.
The sensors in conventional measurement and control systems for paper
machines contain more information than normally are used by the computers
for control and display functions.
Profiles are'on many CD-control systems represented with a bad reso-
lution in the cross direction. Streaks with a widths of the same order as
the distance between two slice screws can often not be detected correctly
which is a serious limitation.
However, it is possible to extract the raw signals (before data
reduction) from the basis weight and moisture sensors and thus to analyse
this information separately. The CD-control systems, analysed in this
study, 'use high CD-resolution profiles. In this work the CD-resolution in
the analysis has been related to the shape of the dry weight response
which will set the limit for the control potential regarding which streaks
which are possible to control.
STFI has in a research project developed a computer program for
control and analysis of cross direction profiles. A mobile computer has
been used in order to read data from conventional PM-control systems for
the purpose of profile control.
A general signal analysis package (IDPAC) which is an off-line system
with an interactive operator communication and with all necessary func-
tions for evaluation of time series is also included. However, in order to
build up profiles with high resolution and to on-line prepare this
profiles a software system called the STFI-Profile Control Package, which
can deliver profiles to the signal analysis package, was developed.
 151

STFI-Profile Control Package (STFI-PCP) is a package for control and

evaluation of CD-profiles. The first installation is described in
reference 2. After that several systems have been installed in Sweden and
two of these systems are evaluated in this study.
STFI-PCP has several important functions. It is in fact a package for
on-line profile analysis. It was developed as a tool for development of a
slice lip profile control system. However, the system is very useful also
only as an on-line profile analysis tool. In this study (Case A) it is
used mainly to save profiles and deliver them to the signal analysis
package and to identify process models.
Our signal analysis package (Identification Package, IDPAC) is an
interactive software package for presentation and computations of measured
data. See reference 1. Functions is available which is necessary in order
to prepare data before signal analysis can be computed. Signal analysis
functions such as correlation analysis and autospectra can ,then for
example easily be performed.

Experience and results with the STFI-Profile Control Package

The STFI-developed system for profile control of the slice lip is based on
process models. The so called dry weight response describes how a change
in one slice screw affects the dry weight profile. Process models can be
based on the identification of such responses and are important to achieve
optimal CD-control systems for basis weight.
However, process models also give us other possibilities beyond
feedback control. If we have good process models then these models will
give us information about the controllability of the process by
simulations. We can for example easily see which streaks are possible to
control and which are not.
150 300 1.50 600 150 300 l,50 600
76 Dry we ight Manual Simulation Computer aided
control conlrol (CAC)
75 Ig/m21 Target : on even dry we ight
7l, profile

73
72
71

70 ~~~~~~~~~~~-,~~~~~~
Simulotiort Compu ter aided
10 Moisture Manual con trol
[% 1 control lorget : en even dry weight
9 profile

o 150 300 l,50 600 150 300 /.50 600

Cross direction lcml Cross direction lcrnl

Figure 1
Simulation of CD-control of the slice lip profile of a paper machine
producing sack craft.
 152

20

15

.
10

eK
~

~
;§ -5

-1 0

100 200 JOO 400 50U 600 (Cm) CO

100 300 SOD (un) CO

Figure 2 Figure 3

Mean difference of dry weight Mean difference of moisture

profiles before and after content profiles before and after
successive slice screw adjust- successive slice screw adjust-
ments (b.w. 150 g/m 2 ) ments (b.w. 150 g/m 2 )

Figure 1 shows current profiles of a paper machine to the left and

simulated results after control actions on the same machine to the right,
see reference 3. We can see how the evening out of the dry weight profile
affects the moisture profile. Notice the effect on the moisture profile
when the streak at the right arrow is eliminated by adjustment of the
slice screws. The moisture profile is consequently very important also
with respect to dry weight control. We can also see at the arrow to the
left one streak which not are affected from the control and consequently
is uncontrollable with the slice.
The normal way of expressing the improvement of a control system is
the 2a-values and ' this is not sufficient . Experience from CD-control
evaluations show that information about how different types of variations
(wave lengths for example) in the profiles are affected is of great
importance (Ref. 3). The resolution of the profiles and the noice of the
sensors will affect the result. The treatment of the sensor signal must
also be considered.
The effects of different streak widths and what effects this will
have on savings, paper properties and paper runnabilityare important.
Here are investigated how the different types of streaks can be controlled
with the slice profile in two case studies.

Case A

This evaluation was performed on a paper machine producing fluting. Two

basis weight levels were analysed, 115 g/m2 and 150 g/m2. The machine was
run at about 600 m/min respectively 500 m/min. The width oft he machine
was 7 m.
 153

Process identification

The controllability of the dry weight and moisture content by adjusting

the slice screws on the headbox was investigated by so called response
tests on 150 g/m 2 • This was done by changing screw number 14 and 34
several times upwards and downwards. The profiles before and after each
change of the slice profile were registered and the successive differences
in dry weight and moisture content profiles were computed. The mean
difference profiles were then computed and are shown in figure 2 and 3.
The amplitude of the dry weight response in the centre position is
21 g/m 2 /mm change of the slice lip in one position.
The amplitude of the moisture content response in the centre position
is 8%.
This means that a change in one slice screw which causes a change in
the dry weight profile with 1 g/m 2 will also change the moisture content
profile with 0.38% moisture content in the corresponding CD-position.

b.w. 150 g/m 2 b.w. 115 g/m 2

moisture content (%) moisture content (%)

level 2 level 2

after-before +1.16 -0.75 +0.80 -0.56

whole profile

after-before -0.45 -0.16

(high pass filtered
profiles, 200 cm

after-before +1. 20 -0.78 +0.72 -0.67

(without 27 cm
on each edge

Table 1

Effect of the slice lip control system on the mean value of the
CD-prof fIe of moisture content and on two-sigma of the moisture
content profile.

The total slice opening on this head box is 20 mm. The results show
that it is a very strong coupling between changes in the slice profile and
the dry weight profile and it is also a strong coupling between dry weight
and moisture content caused by the slice profile.

Data collection

Actual profiles from the paper machine were sampled before and after the
installation of the CD-control system. Data before the installation of the
control system for the slice lip profile were collected during 1983-11-08-
1983-12-02. Each dry weight and moisture content profile which is saved
for the evaluation is a mean profile of 6 conse'qutive scans.
 154

Data after the installation are from 1984-06-01 -- 1984-06-14. These

data were of practical reasons treated in a bit different way. For each
CD-position an exponential filter (weight factor 0.6) was used to achieve
the same effect as was performed with computing of mean profiles. These
profiles are saved with 8 hours intervals.
The autospectra are based on all available profiles. For the more
quantitative interval estimates CD-profiles close in time (simi1ary
profiles) has been avoided.

Results

Interval estimates .
Table 1 shows results computed from 90% confidence interval for mean
moisture content and "two sigma" for the whole profiles, for profiles
which are high pass filtered with wave lengths shorter than 200 cm left in
the profiles and profiles where 27 cm at each edge have been cut away.
The variation in the moisture content profiles measured as two sigma
has decreased with 0.75% moisture content (relative change of 40%) at
150 g/m2. The decrease of the spread has also made it possible to increase
the moisture content level with 1.2%. At 115 g/m2 the corresponding
decrease of the variations is 0.56% moisture content (relative change of
30%) and the increase of moisture content level is 0.8%.
In general a big part of the variations are in this case very broad
effects of the CD-profiles. The edges seems not to have been a big problem
either before or after installation of the control system.

Mean value of autospectra:

The objective of the project was to study the effect of the control
regarding different types of variations (broad and narrow streaks) in the
profiles.
The question is how to be able to do this in a statistically
acceptable way.

500 reference period

50 reference period optima I control
optimal control
' ue 400
';"
e
40
--
--
N
u \

N~
I
N~ 300
~
30
," ",
1 \ 0>

..,
"., ~
".,

.~ 200.
.~

<II
C
20 ....c:
....'" '"
oS ~ 100
10

-"
/ .. 1\ I ......

80 40 20 (em ) 80 40 20 ((m l
wave lengfh
wave length

Figure 4 Figure 5

Mean autospectrum of moisture content Mean autospectrum of basis weight

profile (b.w. 150 g/m 2 ) profiles (b.w. 150 g/m 2 )
 155

reference period reference period

60 optima I cont ro l
'e opt ima I ,ont ro l
v
N..... 50 , 400
E
v
N
.....
?J 40 300
~
v> >,

...c:
c: ~
OJ
30 200
'"
...
c:
QJ

oS

I ~',..
'r \
20 _ lOa
\J \
\ ," \

80 40 20 (Cm ) 80 40 20 (Cm )
wave l e ngth "/dVe leng th

Figure 6 Figure 7

Mean autospectrum of moisture Mean autospectrum of basis weight

content profiles (b.w. 115 g/m 2 ) profiles (b.w. 115 g/m 2 )

It was found that the best way to do this was with autospectra. By
computing autospectra for each CD-profile and compute averages of the
autospectra the mean autospectrum over a certain period could be produced.
This mean autospectrum shows how the streaks statistically have been
distributed during the actual period.
This type of evaluation is also specially suited to study control
effects of the process. The diagrams with mean autospectra confirm and
complement the results from the interval estimates.
It can clearly be seen how specially broader effects (longer waves)
in the moisture conterit profile have been attenuated for 150 g/m
(figure 4). A comparison with the corresponding basis weight autospectrum
shows an increase in the variations at the long wave lengths (figure 5).
The reason for this is that an even moisture content profile has been
given higher priority. By the possibility to balance the moisture content
profile with the basis weight profile given by the profile control system
a more opti~al way of running the process has established. A decrease of
the variations can be seen in the autospectra for both moisture content
and dry weight for shorter wave lengths.
The same pattern in the autospectra can be seen at basis weights of
115 g/m2 (figure 6 and 7).
Note especially that the maximum at 40 cm wave length has disappeared
for both moisture content and basis weight CD-profile.
(Examples of CD-profiles presented as mean values of 6 scans are
shown in figure 8-15. Note the scale of the y-acces. The moisture content
profile is better controlled after the installation. It seems not to be a
big problem with the edges.)

Discussion

An important question is how representative the data is. Six months

differs between the two data collection periods. During that time the
CD-control system has been installed, trimmed and also has been running
for some months in normal operation to come to a kind of steady state.
 156

The autospectra is a fingerprint of how the system is controlled and

one way of evaluating the change in the data before and after the
installation is to investigate if changes in the data are expected and
characteristic for the introduced changes in the process (in this case the
installation of a CD-control system). The changed balance between basis
weight and moisture content, which was a result from the installation of
the control system, gave characteristic results. The attenuation of short
wave lengths in the profiles is also an expected result from the improved
control.

.
400 500 600
CO (em)

Figure 8 Figure 9

Moisture content profile, reference Basis weight profile reference

period (b.w. 150 g/m 2 ) period (b.w. 150 g/m 2 )

o 10 200 300 400 500 600

CO (em)

Figure 10 Figure 11

Moisture content profile, optimal Bas'is weight profile, optimal

control (b.w. 150 g/m 2 ) control (b.w. 150 g/m 2 )
 157

~I

100 200 300 400 500 600 400 sao 6 0

CD (em) CD (Cm)

Figure 12 Figure 13

Moisture content profile, reference Basis weight profile, reference

period (b.w. llS g/m 2 ) period (b.w. llS g/m 2 )

~I

Figure 14 Figure 1S

Moisture content profile, optimal Basis weight profile, optimal

control (b.w. llS g/m2) control (b.w. 11S g/m 2 )
 158

The data before the installation was collected during a period with
stable opeation of the paper machine. This probably point towards that
these profiles were exampels on good profiles for the period before the
installation.

Case B

The effect of the installation of a CD-control system for control of the

slice lip profile was studied on a paper machine producing sack paper. Two
basis weight levels were analysed, 70 g/m2 and 110 g/m2. The machine was
run at about 650 m/min respectively 550 m/min. The width of the machine
was 650 cm.

Process identification

The shape and width of a typical dry weight response from a change in one
slice screw can be seen in figure 16. It is much broader than the corre-
sponding response for fluting. At this 70 g/m2 basis weight level 1 g/m 2
in the dry weight response means 1% moisture content in the corresponding
moisture content response.

Data collection

In mill B profiles from the scanning measurement system on the paper

machine were saved by the mill on paper copies for each tambour on a
regulary basis.
This was a good opportunity to collect good statistical data for
desired periods. The problem was that these profiles were samples with low
CD-resolution. One measurement represented 15 cm of the width of the paper
machine. On the other hand, the identified dry weight response on the
paper machine was quite wide on this machine compared for example with the
response of the paper machine in Case A.
A decision was made that the CD-resolution with respect to the wide
response would be satisfactory, since the interest was to study the
control effects performed by adjustments of the slice lip profile, and the
width and shape of the response limited this control effect.
Data was collected during a referens period, before the installation
of the slice profile control system, from 2 January to 10 March 1984.
After the installation a new period lasting from 8 April to 18 May was
studied.
50 profiles from each period were sampled in the form of paper copies
of basis weight (conditioned) and moisture content profiles.
These 200 profiles were analysed at STFI. Each profile consisted of
47 values. Each value was a mean value over 15 cm centred to the position
of one slice screw.
The profiles were digitized by a x/y-table to a computer.
 159

+>
.c
2
en
.~

<lJ
3:
t' ~
U N........

c: ~ 0
<lJ
en
c:
'"
.c
u -1

o 50 100 150 CD (CIIl)

Figure 16

Dry weight response (b.w. 70 g/m 2 , 690 m/min)

p' efel' CIICC pc";od ,-efe,-el1ce pel'iod

IlIallUa I cOrlt,-ol 30 - "'OllUO I COli tro I
30
-:e opti",ol cOl1t ro l , OUtOlll. t ic CO li t,-o I

.....5
--
v
N
N

!:.. 20
!! 20
t' t'
'"c: '"c:
~ :':
c:
10 " \0

'-.J_ . . . _
em
160 80 ~o
wave l ength
wave l ength

Figur e 17 Figure 18

Mean autospectra of moisture content Mean autospectra of moisture

pro f iles (b.w. 70 g/m 2 ) content profiles (b.w. 70 g/m 2 )

Results

Mean value of autospectra.

Autospectra were computed for each profile. Since a big uncertainty
is associated with one autospectrum a mean autospectrum was computed for
the whole period. The mean autospectrum thus consists of 50 autospectra.
This has been done for both basis weight and moisture content. In
figure 17 the mean autospectrum of the moisture content profiles before
and after installation of the control system is shown.
 160

It can be seen that wave lengths between 40 and 160 cm are

attenuated.
In this mill another CD-control system for automatic slice profile
control was installed, tested and removed in 1983 before this installa-
tion. A similar evaluation was performed on corresponding data for that
installation. A comparison based on mean autospectra of basis weight at
70 g/m2 shows an improvement with automatic control at wave lengths longer
than 80 cm. Wave lengths shorter than 80 cm has not been affected. A com-
parison between the corresponding mean autospectra for moisture content
for the reference period and the period with automatic control shows
increased variations with automatic control at wave lengths between 80 and
40 cm and at wave lengths longer than 160 cm. The variations have
decreased between 80 and 160 cm but the total variations (the variance)
has not decreased with this automatic control. The effect of the automatic
control is only a redistribution between different wave lengths in the
autospectrum. These results can be seen in figure 18.

Discussion

The identification of the basis weight response and the moisture content
response show that the effect from slice screw adjustments on the moisture
profile is of great importance. As can be seen from the results of the
control system the control has very much been directed towards control of
the moisture profile.
The two periods with manual control from 1983 and 1984 are very simi-
lar. If the results from the control system tested 1983 is compared with
the results from installation of the STFI-Profile Control System 1984 a
significant difference can be seen.
The latter system did a much better job between 40 and 80 cm wave
length. All wave lengths shorter than 160 cm have been attenuated. Longer
wave lengths have not been affected. This has a special reason. Control of
streaks results in computer recommendations to the machine tender on
rather few screws~ In order to control the long wave variations recommen-
dations on all slice screws are necessary and in this case it is better to
have motors on the slice screws.
Accordingly the control system was designed not to recommend actions
for the long waves and this explains the result in figure 17.

References

1. lUeslander, J: IDPAC Users Guide.

Report 7605, April 1976, Department of Automatic Control, Lund
Institute of Technology.

2. Karlsson, H., Haglund, L., and Hansson, A.:

Optimal Cross-Direction Basis Weight and Moisture Profile Control on
Paper Machines.
Pulp and Paper Canada 86:8 (1985).

3. Karlsson, H., Lundqvist, I., and Ostman, T.:

Principals and Potentials of CD-Basis Weight Control.
Eucepa Symposium, 11-14 May 1982, Stockholm, Control Systems in The
Pulp and Paper Industry.
 161

Contract nO BOS-135(II)-S

IMPROVED PAPERMAKING WITH EMPHASIS ON ENERGY SAVINGS

AND HIGH CONSISTENCY TECHNOLOGY

O. TERLAND
Paper Technology Department
Swedish Pulp and Paper Research Institute

Summary

The possibilities of reducing energy consumption in the papermaking

process have been studied. The approach was to improve the paper web
dewatering in the wire and press sections, by utilizing that an in-
crease in temperature improves the drainage of water. Starting with a
60°C headbox stock temperature, the temperature typically decreases
slowly along the wire, then rapidly at the couch and finally slowly
in the press section, ending at about 40°C. The rate of cooling was
studied as a function of the rate of dewatering by changing various
vacuum levels at different positions. The rate of cooling can be
decreased by increasing the ambient wet bulb air temperature. This
effect was shown by computer modelling. As a separate part of the
project, high consistency technology (HC) stock cleaning and forming
technologies were evaluated from an energy savings point of view.
Estimates based on full scale trials indicate that reductions of the
order of 50 % in electric energy to pumps and screens can be achieved
as a result of the reduced water flow. In addition, sheet formed at
high consistency is easier to dewater and results in increased press
dryness.

INTRODUCTION
The temperature of the white water system in a modern paper mill has
increased considerably during the last decades, primarily as a consequence
of the increasing system closure. Today, typical temperature levels are
above 50°C in newsprint and kraft paper mills. It is a well established
fact that an increase in temperature in the papermaking process improves
the drainage of water at the wet end. This is generally attributed to the
strong ten.perature dependence of the viscosity of water. An increase in
temperature from 30°C to 700C causes a 50 % reduction in the viscosity of
water. The resulting increase in the rate of dewatering decreases the
amount of water transferred to the drying section and thus reduces the
steam demand.
The scope of the first part of this project has been to examine the
influence of temperature on the dewatering of the paper web and, simul-
taneously, to investigate the cooling of the web as a function of the
ambient temperature and humidity.
High temperatures at the wet end can be caused not only by system
closure but also by steam showers. Their influence on wet-end temperatures
has also been included in this investigation. Steams showers are today
 162

widely used both on paper machine Fourdriniers and in press sections, and
their effects have been frequently reported (1-11).
The results of the trials within this project can be explained by ma-
thematical formulae derived from basic heat-transfer equations. It has
therefore been meaningful and possible to incorporate them into a computer
model. This model permits an energy optimization of the system to be made
and enables the effects of parameters such as ambient air humidity which
are not easily studied experimentally to be assessed.
The consequences of changed dewatering on vacuum demand and energy
requirements in the vacuum system or machine drives have not been studied.
A study of this optimization has been made at Valmet, Finland (1). Nor
have the increased energy losses in tanks and pipes as a result of elevat-
ed white water temperature here been studied. Some aspects of this ques-
tion have been discussed in references 12 and 13.
The second part of this project deals with high consistency tech-
nology in papermaking. Energy savings introduced by high consistency tech-
nology are quite obvious, for instance in terms of the lower electric
power demand for pumping the reduced water volumes. For a paper machine
operating at high consistency, an increase in paper dryness after the
press section compared with the conventional process has also been report-
ed (14). This improvement is attributed to the felted structure of the
high-consistency sheet, which has more z-oriented fibres than in a conven-
tionally formed sheet.

IMPROVED DEWATERING BY UTILIZING HIGH TEMPERATURE EFFECTS

All trials were carried out on the FEX pilot paper machine at STFI.
The forming and press sections are shown schematically in Figure 1. Two
different forming units were used, (A) roll forming in a twin wire and (B)
conventional forming on a fourdrinier. The flexibility in dewatering on
FEX is large and this facilitates considerable changes in vacuum leveis at
different positions.
The temperature of the system was varied by heating the stock in the
storage chests with steam. The temperature of the paper web was further
raised by direct heating from steam boxes at the end of the Fourdrinier
and in the press section. These steam addition points are marked with
arrows in Figure 1. The temperature of the paper web was also changed
directly in the press section by adding steam over a felt suction box and
by using hot water in the felt showers.

Fig. 1 The FEX-machine, + steam additiori.

 163

The temperature of the paper web after pressing is to a rough approx-

imation dependent upon the stock temperature in the headbox. This is illu-
strated in Figure 2 where the web temperature after the press section is
plotted as a function of headbox temperature for several different combi-
nations of machine conditions, such as pulp, grammage, speed etc. This re-
presents not only results from the FEX machine, but also results from
commercial machines and results obtained from Paprican (3). The divergence
from the 1:1 line indicates that the rate of cooling of the web increases
as the incoming stock temperature increases. When the temperature is about
600C in the head box , that of the web after pressing is normally just above
40°C. These losses are significant and lead to a decrease in the solids
content after the press section.

-
u
o

~ 40 50 60
Headbox temperature (O()

Fig. 2 Temperature of the paper web after the third press versus the
temperature of the stock in the headbox.

A temperature profile along the wet end is shown in Figure 3. The in-
coming headbox stock temperature is 60°C. The solid line shows a typical
profile while the lower and upper broken lines represent "worst" and
"best" cases, respectively. The worst case was obtained by running the
FEX-machine with exaggerated vacuum levels in wet, dry and felt suction
boxes and couch whilst the best case was obtained when a minimum of vacuum
was used .
It is obvious that most cooling occurs at the couch and that condi-
tions at the couch are the most variable since the dashed lines diverge
significantly in that region. Few publications dealing with cooling of the
web at the papermachine wet end have been found (1,3) but these few are in
good agreement with the results found here.
 164

60
LJ
!... ,,
4J
I- .. , .
::.
+-
50 .. ..
0
L-
4J
Cl.
e
~ 40
Headbox before after before after
muc h press
Fig. 3 Temperature of the web along the wet-end --- normal,
"best"l"worst" cases.

So far this report has dealt only with the wet end temperature pro-
files and how they can be changed by varying vacuum positions and levels .
A high temperature is, of course, not an end in itself; it is the conse-
quences of the high temperature that are interesting.
The benefits of maintaining the headbox stock temperature throughout
the wet end are not only that the energy demand in the first drying sec-
tion is lower if the web temperature is few degrees higher . More import-
ant, the dewatering in the wet end and particularly in the press section
is favoured by a higher web temperature , and this results in a smaller
quantity of water to be heated and evaporated in the dryer. Figure 4 show
the consistency after couch, pick-up and third press nip as a function of
temperature before couch.

-40 00-
;f!. 39 .....-COQ'fter press
+- 38 ~o
~ 37
1:

--
o
u
aftebJ!ick-{Jp
{g 18 o_~-o
"0
III
17 - 0 r\
0 .....-
>- 16 _ _ _ o-<t;Otter couch
15
L-
a
30 40 50 60 70
Temperature before couch fC)
Fig . 4 Dry solids content at different positions versus temperature
before couch. 50 g/m2, 800 m/ min.
 165

If the grammage is low as in Figures 4-6 (50 g/m2, 800 m/min) there
is no correlation betwen dry solids content before and dry solids after
press, but there is a correlation between the dryness and temperature
after press, which presumably reflects the level of the temperature before
the press. When the machine is run without vacuum in the couch, the in-
creased wetness of the web coming to the press is more than compensated
for by the fact that no cooling then occurs in the couch so that the web
is therefore warmer.

.
+--
C
~~ 41
°
COl
Oc:

"
u ·-

~ ~39
,
~
QQ
._
-
L.-
0-
SlL.-
41
~.t:: 37
DO

15 17 19 ~ 40 SO
Ory sol ids content Temperature after
before pressing (%) pressing (0C)

Fig. 5-6 Dry solids content after press versus dryness before press and
versus temperature after press. 9 standard vacuum in couch
, no vacuum in . couch

~ 39
>-
L.-
o
~ 40 SO 60
Temperatu re after press (o()

Fig . 7 Dry solids content after press versus temperature. The temperature
was varied by addi tion of steam in the 'press.
 166

It is today common practice to use steam boxes for heating the web in
the press sections. In one of the FEX trials the temperature of the paper
web was increased by direct heating with steam in a box situated against a
suction roll between the first and second nips. The results are shown in
Figure 7 as dry solids content versus temperature. In this case the speed
was 400 m/min, the grammage was 75 g/m 2 and dryness after the pick-up was
21 %.
A useful rule of thumb is that an increase in the web temperature of
about 10 DC will improve the dryness after pressing by 1 %. This has been
verified in several investigations (3-6,8-11). The increases are often
higher for mechanical pulps.
A computer model of a paper machine was designed in order to study
the consequences of e.g. decreasing the energy losses from the wet end by
increasing the ambient air temperature and humidity. Table I shows the
effect of increasing the ambient air from 30 DC 50 % RH to 45 DC 80 % RH by
means of an insulating hood over the wet end. The steam demand in the
dryers is reduced by 5 %.

Table I Calculated effect of an insulating hood over different parts of

the paper machine wet end. (State of the air in the hood
assumed to be 45 DC and 80 % R.H.)

Head box After press section Change in dryer

temp. DC temp. DC Dry solids steam consumpn.
content, % , %

without hood 60.3 41.0 43.0 0

hood over couch 60.7 43.5 43.3 - 1.8
hood over entire 62.7 49.1 43.8 - 5.7
wet end

ENERGY SAVINGS BY ~IGH CONSISTENCY TECHNOLOGY

There are two main directions of possible energy savings by utilizing

HC-technology:

1. The markedly reduced water volume drastically decreases the electric

power demand, mainly for pumping energy.

2. Improved dewatering in the paper machine wet end results in increased

dryness after pressing. Thus, the energy needed in the dryer section
decreases.

Estimates based on full scale trials indicate that reductions of the

order of 50 % in electric energy to pumps and screens can be achieved. If
HC screening and forming are implemented in a well designed process there
should be savings not only in energy costs but also in capital costs,
since e.g. smaller pipes, valves and pumps can be used.
If high consistency forming technologies are ever to be implemented
in full scale production, it is necessary to avoid any deterioration in
mechanical properties of the finished sheet. Only then will the savings in
energy consumption be of interest to improve profitability.
 167

A general conclusion is that properties such as tear- and compression

index, are independent of forming concentration whilst tensile- and burst
index deteriorate with lower dilution in the forming section. Z-direction
strength often increases when the sheet is formed at higher consistency.
Consequently, high consistency forming is primarily of interest for
board, carton or fluting production where z-direction and compression
strengths are essential. As an example, FEX-results, obtained with a CTMP
furnish (320 CSF, 2.5 % forming cons., 400 m/min, 90 g/m2) are shown in
Table II along with standard hand sheet characteristics.

Table II

Efficiency ratio
Hand- FEX HC-sheet
sheet HC-sheet hand sheet

Density (kg/m 3 ) 396 413

Tensile index (Nm/g) 34 29 0.85
Elongation to failure (%) 1.9 1.0
Scott Bond (J/m2) 84 232 2.8

This HC FEX trial indicates that it is possible to maintain 85 % of

the hand sheet tensile strength and to improve the z-direction strength by
a factor of 3.
It is a well established fact in all our HC trials that the dryness
after pressing is higher than in low consistency forming. One example from
the above mentioned trial is shown in Table III. The higher dryness is
explained by the more z-oriented fibers in the HC paper structure.

Table III

Dryness after press, % Mean t water/t paper

LC 36.9 36.4 36.8 36.3 36.6 1.73

HC 39.6 40.0 39.2 40.3 39.8 1.51 (- 13 %)

Thus, our conclusion is that the dryness after pressing is sign-

ificantly improved by HC forming and therefore the steam consumption will
be decreased considerably. Alternatively, if the machine is dryer limited,
a coniderable increase in machine speed speed will be possible.

ACKNOWLEDGEMENTS
The European Research and Development Programme is gratefully thanked
for financial support. The project leader also whishes to thank Mr E.
Stenberg for initiating this project, Mr K-J. Grundstrom and Prof. B.
Norman for their work with the high consistency techniques and all the FEX
staff.
 168

REFERENCES

(1) Goos, O.
"Energy saving in the sym-consept wet end", Paper 23 Nov. 1981.
(2) Hodges, C.R.
"Optimum use of steam showers for the paper machine"
Tappi Papermakers Conf. 1977, Chicago, 87-92.
(3) Batty, R.C., Davnais, R., Pye, I.T.
"Hot pressing of newsprint", CPPA 68th Annual Meeting 1982.
(4) Royo, M., Thorpe, B.
"The effect of direct steam heating on water removal", PIMA
September 1981.
(5) Lehtinen, A.
"Enginering &: design developments in press section operation", Paper
Age, Nov. 1979.
(6) Saaristo, M., Knuts, K., Laine, J.E.,
"Use of a steambox in the press section of PM3 at the Rauma Paper
Mill", Pulp &: Paper Canada 85: 1 (1984).
(7 ) Back, E. L .
The effect of wet web temperature in press nips on paper properties,
CPPA 71st Annual Meeting, 1985.
(8) Kaljunen, R., Kaasalainen; H.
"Increasing sheet temperature in press improve drainage profile.
Pulp Paper 54(5):158-159 (1980).
(9) Fitzka, K.
"Unterschungen iiber die Wirksamkeit von Dampfblaskasten in der
Pressenpartie".
Wochenblatt fiir Papierfabrikation 15, 1981, p. 541-542.
(10) Lehtinen, A., Verko, A.
"Possibilities to improve paper making economics and paper quality
by press part design".
EUCEPA Miinchen 1980, 26:1-23.
(11) Kiigele, M.
"Verbesserung in der Entwasseerung deuch Einsatz eines Dampt-
blaskastens auf dem Sieb".
Wochenblatt fAr Papierfabrikation 5, 1982, p. 153-154.
(12) Peck, R.R.
"Guidelines for reducing energy costs via insulation of a de inking
system" .
Paper Trade Journal, Jan 30, 1982, p. 54-55.
(13) "Insulation needs of boxboard mill determined by computer study".
Pulp Paper, Dec. 1981, p. 63.
(14) Grundstrom, K-J., Meinander, PO., Norman, B., Reiner. L., Waris, T.
"A high-consistency former".
Tappi 59 (1976) 3: 58-61.
 OVERVIEW AND CONCLUSIONS

The future of the European paper industry as seen by

CEPAC
G. DAUSCHA, President of CEPAC, Chairman of the
Board of Managing Directors of Zanders Feinpapiere
AG

Wood as renewable raw material - Review and analysis of

the results
I.F. HENDRY, Consultant to the Commission

Plans for the future

W.J.H. HANSSENS, Direcorate-General for Science,
Research apd Development, Commission of the European
Communities
 170

THE FUTURE OF THE EUROPEAN PAPER INDUSTRY AS SEEN BY CEPAC

P. DAUSCHA
President of CEPAC
Chairman of the Board of Managing Directors of
Zanders Feinpapiere AG
Bergisch GLadbach

It is a great pLeasure for me to have the opportunity of speaking to

you within this seminar on "Wood as a renewabLe raw materiaL".

Before starting I'd Like to especiaLLy greet Dr. KarL-Heinz NARJES,

Vice-President of the EC Commission, and connected with this my sincere
thanks to the EC Commi ss ion for arrangi ng and organi sing th is sure Ly
very usefuL seminar.

My speciaL greetings aLso to Mr. PhiLippe BOURDEAU, Director in the EC

Commission (DG XII) who kindLy agreed to chair this seminar. My
greetings are, of course, aLso addressed to his coLLeagues, especiaLLy
to Mr. Wim HANSSENS.

Let me aLso extend greetings towards a representative of our industry,

Mr. Ian F. HENDRY who as the former chai rman of the CEPAC R&D
Committee has deserved weLL of our industry especiaLLy regarding this
fieLd, and who prepared this seminar on the basis of his expert
knowLedge and experience on behaLf of and in co-operation with the ec
Commission. I'd Like to aLso greet aLL other members of the CEPAC R&D
Committee, headed by its present chairman, Dr. Heinrich BAUMGARTEN.

To start wi th I'd Like to breafLy dea L wi th the CEPAC. As you wiL L

know, the puLp and paper producers partLy formed their own nationaL
association a Long time ago, e.g. the COBELPA in BeLgium or the COPACEL
in France. In 1-957 after the EEC was founded it soon became obvious
that common interests and aims exist for the puLp and paper industry
within this economic area. This Led in 1963 to the gathering of the
nationaL associations of our industry in one internationaL
organisation, being the CEPAC whose president I have the honour to be
for the time being.

Today's CEPAC represents aLL nationaL associations of the EC countries.

The onLy exception forms the Greek paper industry which as yet has not
decided to form its own nationaL association, and, therefore, does not
beLong to the CEPAC.

It is the task of the CEPAC to represent on beha Lf of the nat i ona L

assoc i at ions the interests of the EC pu Lp and paper i ndust ry as to
trade and economic policy outside the CEPAC. Furthermore, the CEPAC
serves as an information centre and keeps contact with the EC
Commission. Contacts are aLso estabLished with the corresponding
association of our industry outside the EC, that is with those
countries and economic areas Like EFTA, the United States, or Canada in
which our industry pLays an important part.
 171

The structure of the CEPAC is surely well-known to you. Today I'd like
to especially refer to the "Groupements" and the "Committees and
Working Groups".
While the Groupements each represent a certain market segment, such as
Newsprint, Printing and Writing papers, packaging papers, boards, pulp,
the committees and working groups consider and deal with questions
which have a common bearing on all the various, afor'e-mentioned market
segments. There are for example the Forestry Committee, Waste paper
Committee as well as various technical committees for research,
standardization, etc.
The establishing of the mentioned Forestry Committee very well
indi cates that the CEPAC attaches great importance to wood as the
essential raw material for the pulp and paper industry. Before dealing
with the research programmes which are the subject of this seminar, I'd
like to speak about the European paper industry, keepi ng wi th the
headline printed out in the programme.
In 1985, the production of paper and board in the EC came to just 26
Mio.tons. Nearly 2 Mio.tons were exported into third countries.
Consumption was more than 35 Mio. tons. From third countries 11 Mio.
tons were imported, being an import rate of about 32 % compared with
the consumption. Due to Spain's and Portugal's entry into the EC, pulp
and paper production and consumption will each increase by about 3.5
Mio. tons. Because of this, the self-sufficiency rate of the EC of
about 68 % will be improved by 2 to 3 points of percentage. But also
the production of market pulp within the EC, being at the end of 1985
at about 1 Mio. tons, will be increased to 2.5 Mio. tons due to the
entry of the two mentioned countries.
In the first half of 1986 production and consumption of pulp and paper
compared to the same peri od of the previ ous year had deve loped as
follows :
While the production increased by 2.7 %, the consumption went up by
4 %.
We, in the CEPAC, anticipate that for the total year 1986 production
and consumption will increase by 2;5 %. For 1987 an increase of 2-3 %
can be expected.

Regarding the paper consumption seen over a longer period a very close
correlation exists with the general economic development. For example
in Germany the real gross national product (in prices of 1980)
increased by exactly those 39 % from 1970 to 1985 by which also the
paper consumption increased. If, however, a more longer period is
compared to that the increase of the paper production was even higher
than the one of the gross national product. This means that starting in
1960, hence a comparison over the last 25 years, the increase in paper
consumption was 12.5 points of percentage higher than the increase of
the gross national product.
 172

In the short-term view, that is from year to year, comparisons are, of

course, subject to deviations. The development of the paper consumption
shows a stronger swing than the corresponding total economic
development; and this not only as an upward but also as a downward
swing.
A characteristic example for this phenomenon is the development of the
years 1975 and 1976. While in Germany the gross national product of
1975 compared to the previous year actually decreased by 1.5 %, the
apparent consumption in paper went down by 15 %. But one year later the
apparent paper consumption increased by 18 %, whereas the gross
national product of 1976 increased by "only" 5.5 %.
This fact is mainly due to stock pi ling or stock reduction in the
pipeline between paper manufacturers, via wholesalers, printers, and
converters, to the commercial and private end users.
Concerning the medium- and long-term paper consumption we are
absolutely convinced that this wi II increase also in the future. We
don't share the prophecy often expressed by so-called "experts"
according to which the new electronic media wi II have a strongly
negative impact on the paper consumption. Thus, the FAO expects an
average yearly increase of pulp and paper consumption of 2.1 % for
Western Europe unti l 1995. As to printing and writing papers the
consumption increase is expected to be higher, that is 3.4 % per annum.
Within the CEPAC the opinion is shared with those who predict somewhat
lower increase rates. In this connection I'd like to briefly speak
about general data of the EC pulp and paper industry.
Compared to other industries like steel, automobile, chemical and other
industries, our industry is a relatively small but effective one, as
proved by comparative studies.
In less than 1.000 mills more than 30 Mio. tons of paper and board are
produced with about 170.000 people employed. These figures refer to the
running year which means the Spanish and Portuguese paper mills
included.
The last 10-20 years was a period of a considerable restructuring in
our inaustry aimed at the improvement and strengthening of its
efficiency. A large number of old, uneconomic paper mills were shut
down, and modern facilities were installed. By this the average output
of each paper machine was doubled within the same period of time.
It goes without saying that these restructuring measures were connected
with high capitat expenditure. This I'd like to illustrate with some
figures of the German paper industry. Here the average investment rate,
that is the level of investments compared to the turnover, was 7.9 % in
the last 20 years. In 1985 this rate was even slightly higher with
8.1%. The intensivity in investment, that is the investment per
employee, lay with DM 7.000- at the beginning of the Seventies. In 1985
it increased to about DM. 25.400-. These figures should show that the
paper industry is a strongly capital-intensive trade.
 173

Here it sureLy is worth mentioning that for environmentaL activities

our industry makes Large financiaL expenditures amounting to more than
10 % of the gross invested capitaL.
MeanwhiLe, in the surrounding of a reLativeLy stabLe generaL economic
upswing we can mark some positive "paper years" in which the profits
couLd be improved.
RecentLy it became known that - sureLy infLuenced by this encouraging
profit deveLopment investment pLans and intentions have been
intensified which because of their size wiLL extend by far the increase
in paper consumption in some segments in Hestern Europe, if they aLL
wiLL reaLLy be reaLized.

It is sureLy advisabLe to better adjust future investments to the

expected paper consumption because unused or not fuLLy used capacities
do, of course, not payoff or onLy very sLowLy, and in some cases they
even caused unsoLvabLe probLems to the one or other company. This gave
troubLe not onLy to the companies invoLved! To come to such a simpLe
discovery - Let me put it in a funny but absoLuteLy seriousLy meant way
- it needs, however, no speciaL research programme but just common
sense
After this Little excursion into the past and the future of our
industry I'd Like to comment on wood, that is on the research
programmes "Wood as a RenewabLe Raw MateriaL".

The importance of wood as a primary raw materiaL, thus the basis for
the production of chemicaL and mechanicaL puLp, and finaLLy of paper
wiLL best become obvious in view of the foLLowing figures:

In the today's EC countries, incLuding Spain and PortugaL, more than

30 Mio. tons of paper and board are LikeLy to be produced this year.
For this the foLLowing quantities are expected to be consumed:

approx. 16 Mio. tons chemicaL and mechanicaL puLp,

approx. 15 Mio. tons waste paper, and

approx. 4 Mio. tons pigments.

Even if the proportionaL furnish of waste paper and fi LLers and/or

pigments within the consumption of raw materiaLs in the paper
production shows as a trend a considerabLe increase in the Last 10-15
years the share of chemicaL and mechanicaL puLp with its share of 46 %
does have a most speciaL importance

50 % of the above mentioned 16 Mio. tons chemicaL and mechanicaL puLp

are imported from non-EC countries, mostLy as chemicaL puLp. For the
quantity of about 8 Mio. tons of chemicaL and mechanicaL puLp which are
produced in the EC a voLume of "puLp wood" (round wood, chips, saw miLL
waste of coniferous and deciduous wood) is used which amounts to nearLy
50 Mio. cbm.
 174

This voLume originates up to 95 % from the EC. The fact that nowadays
our miLLs nearLy take aLL the wood needed for paper making from our own
forests is a remarkabLe progress compared with the situation in the
Sixties and Seventies when we had to import a Lot of wood from
Scandinavia, USSR, and Canada.
The seLf-sufficiency rate of our industry within the EC must be
increased, not onLy regarding puLp but aLso regarding paper. Such an
inc rease, however, requi res an inc rease in the avai Labi Li ty of the
primary raw materiaL wood, and thus a better utilization of our
forests. Th is is why the research programmes have such a tremendous
importance.
The R&D programmes which are officiaLLy concluded with a seminar
aLready have a kind of t-radition. I'd onLy remind you of the R&D
programme for waste paper which was organised between 1979 and 1982.
As you may know, the now ending research programme "Wood as a renewabLe
materiaL" was pLanned for the period 1982 to 1985 and was proLonged
untiL 1986. The CEPAC with its committees Forestry, Waste Paper, and
Wood contributed a Lot to prepare this research programme and heLped
the DG XII to effect this programme. This shouLd, of course, prove that
a fruitfuL cooperation between administration and industry - I couLd
aLso say: between poLitics and free economy - is needed, sensibLe, and
feasibLe for the benefit of the Community.
Here I'd Like to aLso thank the EC Commission for financiaLLy
supporting this research programme with 12 Mio. ECU ; a programme which
in the end was effected by institutes and universities but aLso by
private companies as weLL as consuLting companies and consuLtants, and
did, therefore, demand a considerabLe financiaL engagement of aLL
invoLved.
In this now ending research programme about 120 contracting partners of
9 EC countries took part as foLLows:
about 60 - 70 % universities and institutes
about 30 - 40 % private and consuLting companies as
weLL as consuLtants.
Due to an agreement with the EC Commission Sweden aLso participated in
this programme. An exchange of the resuLts was agreed upon with
SwitzerLand which organised and executed its own programme.
It is not my duty to report on the resuLts of this research programme
as this seminar actuaLLy serves for this purpose. This afternoon we
aLready heard the reports on two major subjects. Let me stress that we
in the CEPAC attach great importance to research activities ; without
that a permanent progress regarding an economicaL use of the raw
materiaLs and energy, an efficient production, and a quaLity
improvement of the products is not possibLe. Scientific research and
its reaL istion into dai Ly practice are an essentiaL condition for
Lowering the costs per unit of output. And again, this is necessary
 175

in order to allow the companies to be able to stand their ground in a

tough competition toward thei r competitors outside the EC, and to
el iminate any disadvantage as to location towards companies outside
the EC by means of an efficient raw material basis. Because of these
reasons we in the CEPAC believe that our industry will thoroughly
consider the published results of these research activities in order to
realize as far as possible new findings in the individual mills.

Because of the importance research has for our industry it is more than
welcomed that the EC Commission will again organize a research
programme on "Wood as a renewable raw material" for the years 1986 to
1989. In the presence of representatives of the EC Commission I'd like
to take this opportunity to thank for a renewed financial support on
the one hand, but to state on the other that the amount of 10. Mio ECU
granted for this new programme seems to be more than limited. Our
opinion is based on the following reasons:

- For the 1982 to 1985 programme that ends with this seminar, an amount
of 12 Mio. ECU was regarded as necessary and then granted.

Out of the mere inflationary cost increase between the first

programme from 1982 to 1985 and the second one from 1986 to 1989, being
an interval of about 5 years, the amount granted should have been
higher than 12.Mio ECU

- In addition to that, Spain and Portugal became members of the EC as

of 1st January this year which is why also institutes and companies of
these countries will participate in the new research programme, meaning
that this requires an even larger financial contribution.

For the new research programme the CEPAC applied for a financial
support of 15 Mio. ECU to the EC Commission. As far as we see it the
CEPAC was very moderate as to the amount requested, especially in view
of the afore-mentioned reasons. Another important factor, however, is
that the CEPAC considers the costs for the new research programme to be
approx. 50 Mio. ECU which means that the companies and institutes
themselves have to make a considerable contribution to the financing.
Therefore, we do hope that on the part of the EC Commission the last
word on this matter has not yet been spoken, and that an amount
additionatly to the 10 Mio. ECU will be granted.

In connection with the contribution for the research programme I'd like
to make a further remark. The research programmes are supposed to serve
the compani es and i nst itutes wi th the EC! And bas i ca lly, we have no
objection if other countries, e.g. EFTA countries, participate in
programmes like these. It must, however, be a condition for taking part
that the financial contribution of these countries be more justly
determined than done in the past. Just the gross national products in
the EC and in the third countries involved can't be the only measuring
value.
 176

In the Nordic countries for example, the wood, pulp and paper
industries are of much greater importance relating to the gross
national product. In our opinion the relation for example of the
quantities sold in the corresponding branches of industry in the EC
towards each third country would be a fairer measure for calculating
the cost contribution of the third countries involved.

Clos i ng my statement I I d like to express on beha l f of the CEPAC,

sincere thanks and appreciation to all those who actively worked in and
for this research programme, thus making an essential
scientific-technial contribution.

On th i s occas i on I I d also like to wi sh success for the new research

programme for the sake of both the Community and our industry.

Thank you for your attention.

 177

WOOD AS A RENEWABLE RAW MATERIAL 1982 - 1985

Review and analysis of the results

I.F. HENDRY
Consultant to the Commission

1. RESUME OF ACHIEVEMENTS

Introduction

In summing up this programme I have no intention of analysing the

results of each contract and criticising the achievements in each
project. My concern is much more to determine how the programme as a
whole has added to the store of knowledge in the EEC pulp and paper
industry and whether the results can be properly exploited to the
benefit of the community of nations. To do this it is necessary to start
by looking at what the programme was intended to accomplish.
The basis of the programme was an inbalance of 12 billion ECU in
the forest industry of which about half was represented by imports of
wood for pulping and paper and board (1. 7 million cubic metres), wood
pulp (8 million tonnes) and paper and board (11. 2 million tonnes)
directly concerning the pulp and paper industry. The principal objective
of the programme was the development of technology which would permit
economic and environmentally acceptable working under Community
conditions through:
improvement in fibre yield,
reduction in raw material specifications,
better use of residues,
reduction in energy consumption,
reduction in pollution, and
better use of recycled waste paper and non wood fibres such as straw.
The emphasis was on the better use of Community raw materials and to the
development of promising technology.
I believe a review will show that these aims have been fully
achieved.
Next a comment on the dissemination of information. With due
respect to the excellent information services of the Commission, I would
suggest that they are far better at dealing with patentable inventions
and with high technology items than with the mundane matters of
industrial development, particularly in a non-glamorous capital
intensive industry such as pulp and paper. Nevertheless pulp and paper -
as was emphasized by many speakers, myself included, in the recent
EUCEPA symposium in Florence remains and will remain, a vital part of
our civilization for many years to come. The reason for having this
seminar is to inform the pulp and paper industry of what has been
achieved using funds which in many cases derive directly from taxes
industry has paid. If industry chooses not to come, that is its own
faul t. This set of speakers represents probably the highest powered
collection of representatives from uni versi ties, technical institutes
 178

and industry itself that can be assembled. Furthermore, the seminar

brings together the results of a coherent research programme - not the
presentations of a set of individuals.
It is this coherence which is the essential theme of my synthesis.

2. THE SCOPE OF THE PROGRAMME

At any given time, a vast amount of research is going on in the

pulp and paper industry. This programme is a microcosm wi thin that
totali ty, but nevertheless covers items throughout the whole field of
work.
Paper starts with pulp. Pulp generally starts with trees. Trees
are turned into pulp either by mechanical defibration or by chemical
dissolution of the lignin binding the fibres together. This programme
starts with the fundamentals of the separation of fibres and it then
goes into the various ways in which chemical treatment - preferably with
environmentally safe materials, can help this separation.
Another type of pulp is waste paper. Indeed for the Community,
which uses 36% more paper and board than it makes, waste paper is by far
the biggest indigenous raw material. It does, however, give considerable
problems in its use and wi thin this programme nearly all aspects of
dealing with those problems are evaluated.
Also available within the Community are large quantities of
mineral loading materials. Increased use of this material is dealt with
fully in the programme.
Finally, paper making itself is becoming more and more
complicated, and the programme deals with proposals for cost reduction
and product improvement.
This is thus a very well balanced programme and not only has it
produced some very valuable results which will be dealt with in detail,
it has also stimulated ideas on further action.

3. THE RESULTS FROM THE PROGRAMME

3.1 Defibring

In order to reduce the cost of defibring it is necessary to find

out what - happens when wood is crushed and where the energy use is
higher. However, it is equally important to de fibre with the least
damage to the fibres. In this respect CHARUEL's work has produced some
very interesting results. In particular his roll press pretreatment
showed differences between the effects on heterogenous wood (softwoods
and porous hardwoods) and homogenous wood (diffuse structure hardwoods).
The results on hornbeam for example, show a completely even progression
in fibre separation even up to high levels of destructuration. The
results apply equally to poplar. They are very important in relation to
the pretreatment of hardwoods for chemi-mechanical pulping and relate
directly to some of the results obtained by BOSIA. The second part of
CHARUEL's work and that of SALMEN both deal with the effect of
temperature and frequency on the repeated stressing of wood. This is
directly related to thermo-mechanical pulping. Both come to conclusions
on the ideal rate of defibring thou~h CHARUEL' s work was not
 179

completely conclusive - and both recommend low frequency refining.

SALMEN adds work on suI phonation and on temperature - and particularly
recommends refining at a higher temperature than pre-steaming
temperature - again a direct link with BOSIA's work.

3.2 Pulping

The programme has concentrated very much on the need to use

indigenous wood, and to get as much yield as possible from it. The
various ways of doing this - generically lumped together as CMP or CTMP
involve pretreating wood chips with a chemical which starts the
dissolution of lignin, they also involve saturating chips under pressure
and they involve mechanical treatment to separate out the fibres. There
exist substantial installations for doing this in Scandinavia and in
North America. The basis of such installations is the pressure
saturation of wood chips - either with water alone, or with a lignin
reducing chemical such as sodium hydroxide or sodium sulphite, followed
by treatment under pressure in a refiner. The current programme takes
this further, first by applying the processes to European hardwood and
second, by developing a new piece of equipment to do the disintegration.
This equipment, the bi-vis was a spin-off from the earlier EEC programme
on waste paper reutilization. It is truly a remarkable invention in that
in the same piece of equipment it is possible to treat the pulp with
chemicals, wash it, and bleach it. Within this programme a pilot plant
was successfully operated and a full scale plant installed.
Both this project by DE CHOUDENS and the more conventional Italian
project by BOSIA show that, using European hardwoods, it is possible to
make fully utilizable pulps which can substitute for conventional pulps
in corrugating medium, newsprint and a wide range of printing papers. It
is significant that both DE CHOUDENS and BOSIA had excellent results
wi th poplar - a fast growing, easily available hardwood, which should
work well according to the results from CHARUEL. There is no doubt from
the work in these two centres, and the results presented by BOSIA and
BERNARD, that this is the technology of the future. Whether the bi-vis
will prevail over conventional machinery is another matter.
Interestingly and significantly, both conventional and new systems
require a latency or stocking phase after the defibring station.
Still in semi-chemical pulping - which we should not forget has
been currept for at least 50 years - the use of anthraquinone was dealt
wi th by HUGHES. AQ has been known for years as a catalyst in the
suI phi te pulping field, and its successful use in suI phi te pulping is
truly a breakthrough. The results of HUGHES' work result from a very
well carried out set of experiments which leave no possibility of error,
confirmed by a successful mill trial.
However, all these pulping treatments produce effluent. BOSIA
quite specifically states that the CMP system he uses requires
conventional spent liquor treatment. The same applies to the bi-vis when
sodium sulphite is used, while the neutral sulphite mill of HUGHES
discharges to a tidal current. For this reason the work by LACHENAL is
highly significant. This ties in with some work being done in the USA
and New Zealand and suggests a way to environmentally satisfactory
pulping systems is possible. However, there is no doubt in my mind that
environmental considerations are now the biggest retardant to the small
scale development of high yield pulping.
 180

3.3 Reuse of waste paper

As I stated earlier, waste paper is the Community's largest source

of raw material. Some 19 000 000 tonnes disappears from the system each
year. However, to use this material is not easy. The work reported in
this programme makes a substantial contribution to assisting in this
reuse. The problems facing any reuse of waste - even selected waste, are
both solid contaminants and dissolved or colloidal products. The
equipment suppliers have produced a wide range of machinery which
extracts metal, plastic, wood and other foreign bodies from waste paper
during its defibring processes. They have not been able to overcome two
problems. The first is the build-up and precipitation of sticky
particles which clog the making machine, break the sheet and degrade the
product. The second is the fact the repulped waste paper is very
difficult to use. The more it is repulped, the more it loses its fibre
structure and becomes an untreatable mass.
Wi thin this programme work has been done on three areas. First
PIERONI has tried - and succeeded, in replacing noxious adhesives in
sticky tape with repulpable ones. The in depth chemistry of this project
deserves success but even a slight increased cost is often enough -
wi thout legislation - to impede environmental advance. Incidentally,
within DE JONG's paper is the ideal example where within a self
contained factory, doing exactly what PIERONI recommends, had a big
effect in influencing cost efficiency.
Next, BAUMGARTEN and DE JONG both attack the problem of the
colloids and solutions. What they both state is the obvious - it is not
the presence of the solution that is the problem but the establishment
of conditions in which the stickies precipitate out. DE JONG's work
should constitute required reading of anyone using, or contemplating the
use of, large quanti ties of waste paper. There are conditions wi thin
which sticky precipitation can be reduced, but there are many more
perturbating factors than can easily be enumerated. What is quite
worrying is that' often the very conditions being established to run
without problems are those that create problems. DE JONG gives one good
example the introduction of fresh water into the system, while
BAUMGARTEN gives another - the use of cationic starch. Neither of these
papers gives a solution to the sticky problem but both give a lot of
information for use in further investigations. In particular both
emphasise the care needed in using CMC or anionic dyestuffs, while
DE JONG in particular lists the many factors which can cause sudden
problems. Incidentally I can corroborate the usefulness of light extr.act
cleaners.
The other problem of waste reuse - the continual degeneration of
the fibres, has been tackled on a commercial scale by "fractionating" -
splitting the pulp into long and short fibre fractions. The introduction
of the fractionator gave rise to very many claims as to its ability to
improve the stock, reduce energy, separate out stickies and so on. Some
of these claims have been confirmed, other refuted, in the literature.
Within this programme, however, very definitive results have been
produced. Let us examine them.
First NIELSEN, on a mill scale, established that a Mul tifraktor
does indeed separate the stock into fractions and that indeed, the
contaminants attach themselves preferentially to the longer fraction.
Unfortunately, the mill was unable to treat the fractionated stock
sufficiently well to benefit from the fractionation.
 181

Next GRANVILLE has established as not proven the postulation that

chemical treatment of the long fibre fraction alone is more efficient
than that of the total mass - in some cases it is, in some it is not.
Third GOTTSCHING has set out in elegant detail the parameters of
operation of a fractionator. The results tie in very well with NIELSON's
work and confirm his conclusions that by specially slzlng the
fractionating unit it should be possible to obtain strength increases
which justify the cost of the installation.
Finally, if you get usable deinked pulp, how can it be used in
higher grade papers by bleaching. GOTTSCHING has evaluated the
possibilities in considerable detail and succeeded in producing nearly
white pulp from deinked stock. He concludes importantly that bleaching
is more effective after deinking, but that multi stage bleaching is more
effecti ve with two different agents than with one. Significantly it is
possible to blend deinked waste with mechanical pulp in multistage
bleaching than existing groundwood bleaching installations can be used
if waste paper is introduced.
Again these results contribute very substantially to improved
reuse of waste paper and if properly disseminated, could well help a lot
of companies.

3.4 Use of filler

Several years ago rumours reached the world of work at STFI that
had attained a paper with 40% filler. Since then the EEC paper industry
has been trying unsuccessfully to achieve the result. The beauty of this
programme is that it relates to the real world of industrial scale
papermaking. HAINDL in the field of magazine papers and WIGGINS TEAPE in
the field of fine printing papers, are world renowned companies. The
work reported (in the case of WT by PIRA) is a very comprehensive study
of what can be achieved - and of the pitfalls lurking for the unwary.
BAUMGARTNER gives a lot of detail about the effects of china clay, chalk
and talc both before and after supercalendering. It is quite significant
that by a correct choice of filler particle size, an increase in
strength can be obtained - particularly after calendering, so that a
reduction in fibre content is possible. The achievement of a
specification for filler which can be met by the suppliers may well
require blending at the mill, which is able to stock 3 x 1000 tonnes of
filler to achieve these results. In the GRANVILLE study, on the other
hand, practicality reigns. As he states, the final trial produced a
paper at 37% filler which was made without runnability problems on the
paper machine and which ran well on the printing press, producing print
of an acceptable and high quality. As a by-product a new dust test was
identified, and as an important lead to the future, the project
identified the developments in papermaking and machinery which are
required to make a further substantial increase in the filler content of
wood-free paper.
The work in this project was done with chalk - which is not
useable at pH below about 6.6. It requires non acid sizing or it
effervesces with fascinating results in the system. Rosin size works
only at pH below about 5.8, so special sizes must be used. BEYER did his
best, in a well thought out set of experiments, to try to modify rosin
to work at 6.5 pH and above - unfortunately without success. However,
the results may give pointers to the future.
 182

3.5 Papermaking

If you can reduce cross machine moisture variations you can run at
lower substances and save fibr'e. If you can reduce cross machine
moisture variations, you can run at higher moisture contents and save
fibre. Intensive work in recent 'years has led to various commercial
systems which act on measured profiles and impose changes. KARLSSON IS
work shows that the theory and practice are somewhat far apart - and by
an elegant theoretical analysis, improves the practice. The project
shows how considerable benefits arise from having the resources of an
institute like STFI behind this sort of work. Meanwhile another project,
by TERLAND this time, looks at the ways in which energy can be saved :
just by increasing stock temperature to give better drainage - and more
importantly, better press section water removal. Provided the stock is
not cooled too much - and running without a couch was more effective,
for this reason, than running with a couch, the steam energy used to
heat the stock is much less than that saved in the dryer section.
Even more energy saving is possible by reducing water use and here
Swedish developments in high consistency forming are very promising. The
equation is simple - at 0.2% solids you have 500 parts water to one
fibre, at 2.0% only 50 parts water. A combination of high consistency
and hot stock could give very considerable energy savings.
Meanwhile CERAGIOLI has studied a concept first developed by the
makers of insulating boards some decades ago - the high temperature high
pressure treatments of pulp - particularly hardwood pulps. The results
show dramatic increases in strength and at high temperatures,' in w~t
strength - indeed sheets are formed that are impossible to disintegrate.
It is also very interesting that straw pulps did not respond as well as
high yield hardwood pulps, nor did waste paper pulps.
Finally, a project successful technically, but not viable
economically in present economics the impregnation of corrugated
cases, which may well see fruition in other economies.

4. DISCUSSION AND CONCLUSIONS

First a criticism. In one or two cases work has been done which
"reinvents the wheel" because a proper literature survey has not been
undertaken. In this programme these instances are very much more rare
than in the first "Recycling of Paper and Board" Programme. 1m a sure
that in the continuation of this programme such cases will be
non-existant.
Next the plus points. As I said at the start, such a programme is
a coherent microcosm of the R&D activities in the Pulp & Paper Industry.
It can by no means cover everything, but the fact that the resources
behind the project leaders are vast, means that these resources are
available. There has been criticism from the Commission - and it is
repeated in the basic document for the continuation programme
-XII/396l/85EN that there is insufficient contact between researchers in
pulp and paper in the Community. As this programme developed, those
contacts have increased. The holding of sub-group meetings - at the
instigation of Mr FASSOTTE - and this final seminar, are evidence of the
value of such a programme in promoting contact. Indeed, many of the
 183

project proposals for the continuation programme are from several

researchers acting in unison.
Without this programme, quite a few projects would never have got
off the ground. I believe this to be particularly true of several which
together present a vast amount of detailed information modifying
rosin, non sticky forming adhesives, mill scale fractionation,
anthraquinone insulphite pUlping.
It is a pity that only summaries are available for publication,
because in the final reports there is a wealth of information that
deserves much wider circulation than just lying in the Commission
archives. If I take only five. The parameters of fractionation are well
worth summarizing in a small booklet and distributing to all users of
such equipment. The information relating to stiffness or rigidity in the
GRANVILLE work on high loading is worthy of a paper in itself. The
detailed accounts of the changes made in machine operation by DE JONG
deserves wider distribution and very detailed analysis. The behaviour of
cationic materials reported by GRANVILLE and BAUMGARTEN in very
different contexts is worthy of a further detailed study. LACHENAL' s
work on hydrogen peroxide and GOTTSCHING's on bleaching waste paper have
a lot in common and deserve deeper synthesis.
In fact, every project contains information that can be of immense
value to the future researcher, or the present day papermaker and I hope
that in some way the detailed final reports can be made available.

5. WHAT OF THE FUTURE

At the recent (22nd) EUCEPA congress in Florence, Professor

STOCKMAN in one keynote address and I in the other, made very similar
points. Pulp and papermaking is entering an era of considerable change.
Non polluting pulping, bright high yield pulps, bleached waste paper,
high loading contents, 'computer control, interactive processing such as
press drying : - the list is almost endless. (Incidentally, I would
recommend strongly to anyone interested in current research thinking
that they buy, beg, borrow or obtain the proceedings of the 22nd EUCEPA
conference - they cover most of the current ground). However, out of the
list spring several dominating themes.

i) High yield pulping of European hardwoods is here but the

pollution problems associated have yet to be solved.

ii) The increasing and need to be increased further use of waste will
demand new treatments for sticky elimination and bleaching - and
again the pollution problems appreciated with deinking residues
need to be solved.

iii) Increasing loading use, lower water use, more waste paper use,
more organic chemical use has led to a situation where the wet end
chemical dynamics of the paper mill is almost a mystery.
Interestingly a first international conference on Paper Mill
Chemistry will be held in Stockholm in 1988.
 184

i v) Lower energy use will be forced on the paper industry (the pulp
industry is already nearly at zero energy input) and

v) total computerisation will become a norm.

In all this I believe the Commission has a major part to play

because, through its research programmes, it can force the sharing of
research effort and the combined projects which will be necessary to
meet the challenge.
 185

PLANS FOR THE FUTURE

W.J .H. HANSSENS

Directorate-General for Science,
Research and Development

So far during this seminar you have heard presentations

on twenty or so research contracts covering pulp, paper and
board. However, we must not overlook the importance to you and
the industry which you represent of the results obtained from
the research carried out under the other 100 contracts which
made up the balance of the 1982/1985 Wood "as a Renewable Raw
Material Programme. Although the pulp, paper and board
manufacturers only intervene at the end of the wood chain,
what happens beforehand in the previous links of the chain is
also of direct concern to them.
If we look at the work carried out in some of the other
research areas of the programme, we see that the latest
developments in forest tree breeding will certainly lead to
qualitative as well as quantitative improvement in wood
harvesting. Research has demonstrated that these improvements
will be principally achieved by means of a better selection of
forest reproductive material (this area was covered by 6
research contracts); improved growth rates for indigenous
forest tree species (5 contracts); faster propagation of the
best adapted tree species either by the utilisation of new
methods such as in vitro, or by the improvement of traditional
methods such as cutting, grafting, seed orchards, etc.
(6 contracts).
In particular, the utilisation of high-quality clones to
create coniferous monocultures of equal age will be one of the
developments leading to the establishment of an intensive
system of sylviculture. It goes without saying that the pulp,
paper and board industry will be the first to reap the
benefits of these n~w methods. In addition, research which has
been carried out on protection of forest stands from damage by
biotic and abiotic agents, and especially damage by fungus,
will be of particular interest to the pulp manufacturers. This
is obvious if we consider for a moment the losses which are
incurred from heart rot fungi and the impact this has on your
log rese rves.

Moreover, reafforestation of abandoned farmland and

marginal lands with fast-growing species such as poplars in
the North and eucalyptus in the South will provide your
industry in the first place with a new source of thinnings,
and at a late r stage with clear cuttings.
 186

Forest harvesting is the finaL phase in the activity of

the syLvicuLturist, whereas it is the first phase in the
activity of the wood industry. It is consequentLy the point
where the financiaL interests of the forest owner and of the
buyer converge. These two phases in the wood chain are thus
cLearLy compLementary; thinnings carried out too Late wi LL
adverseLy and irrevocabLy affect the future of the forest
stands, and hence of your suppLies.
Even if the syLvicuLturist does not cLaim a Large profit
from thinnings carried out to improve the quaLity of the
stand, industry must bear in mind that whenever the financiaL
gain faLLs beLow a certain LeveL or ceases even to exist the
inevitabLe consequence - at Least as far as privateLy-owned
forests are concerned - wiLL be for timber suppLies to dry up.
In this connection I shouLd perhaps mention that the forest
owners are just as concerned as the manufacturers at the high
LeveL of forestry Labour costs for harvesting operations as
weLL as for transport to the factory. In fact, over the past
thi rty years much effort has gone into rationaLizing forest
expLoitation so as to minimize the economic effects of these
high costs of forestry Labour. In this connection, I wouLd
suggest that an effort aLong paraLLeL Lines shouLd be made by
the puLp manufacturers. This rationaLization of forest
expLoitation has been directed particuLarLy towards increased
mechanization at a European LeveL of harvesting operations, as
weLL as towards the introduction of new syLvicuLturaL methpds
which wi LL provide access to mechanized cutting machines for
thinning operations, even on young stands. These new methods
incLude reguLar, Large-scaLe thinnings, wideLy-spaced
pLantations, etc.

Eight contracts under our fi rst programme were in fact

concerned with these particuLar areas of research. However, it
is obviousLy not the pLace here to give a detaiLed account of
this previous work, nor wouLd it be appropriate for me to give
too many of my own views. Suffice it to say that in generaL
research carried out so far Leads to the concLusion that the
optimum degree of mechanization has to be estabLished
individuaLLy for each working site or group of working sites,
and that this LeveL wiLL depend to a Large extent on the teams
avai LabLe Locally as weLL as on the degree of sophistication
of their equipm.nt.

Thus for the moment it cannot be assumed that totally

mechanized harvesting guarantees optimum profitabiLity.
Indeed, in many instances the maximum economic benefit is
derived from onLy partiaLLy-mechanized but weLL thought out
harvesting methods. One of the reasons for this is that the
cost of using a speciaL mechanised cutter, with operater, is
high; it is often in fact the equivaLent of a three-man team
of woodcutters equipped with mechanicaL saws.
 187

Another reason is that the specific nature of hilLy

terrain (thin soiL covering, presence of rocks, and of steep
sLopes, etc.) aLso has a direct bearing on harvesting costs,
and can even render a high degree of mechanization impossibLe.
It thus ensues that a high mechanization LeveL can onLy be
envisaged or appLied on Lands affording easy access to rather
heavy and speciaLized machines, (which often have to be
brought over Long distances with their operators), where the
surface to be worked is reLativeLy Large and the terrain of a
fairLy homogenous nature, and where no good and weLL-equipped
forestry Labour force exists LocaLLy.

As far as the harvesting machines are concerned, an

impressive series of forwarders is now in use. These
forwarders are principaLLy used for Logs of smaLL and medium-
sized dimension, most of which are destined for your puLp and
paper milLs.

ObviousLy, other factors of a structuraL and poLiticaL

nature aLso affect the probLem. For exampLe, a reguLar suppLy
of puLpwood wiLL LargeLy depend on whether or not a forest is
in private hands, whether it beLongs to a pubLic entity, or to
a paper milL. The nationaL forestry poLicy of individuaL
Member States can aLso create a much more favourabLe cLimate
for puLpwood. In this respect I have in mind such measures as
newsprint being cLassed as a strategic commodity; the
encouragement of Long-term contracts Linking forest-owners
with industry; favourabLe financiaL LegisLation, etc.

European syLvicuLture is now faced with the exampLe of an

increasingLy intensive system of European agricuLture,
producing on the one hand an enormous variety of food stuffs
and dai ry products, whi Lst consuming on the other hand vast
quantities of fertiLizers, insecticides and fungicides. In
such a criticaL context we must now ask ourseLves what is the
most desirabLe type of syLvicuLture, and aLso what the outcome
is LikeLy to be.

If syLvicuLture is to deveLop aLong similar Lines and

become an intensive type of forestry, we wi LL see a Large
deveLopment of monocuLture stands of high-yieLd trees
(especiaLLy coniferous trees). Every type of operation wiLL be
necessary on such stands, ranging from mechanized pLanting;
thorough and compLete soiL treatment inevitabLy invoLving
Large quantities of fertiLizers and herbicides; rigorous
seLection of pLants for their fast-growing quaLities; an
increased emphasis on cLonaL deveLopment; wideLy-spread
pLanting to aLLow direct access by machines; 3 or 4 Large-
scaLe earLy thinnings; a finaL cLear-cut foLLowed immediateLy
by repLanting.
 188

This type of syLvicuLture wilL resuLt in a maximum yield of

ligneous material. The negative aspect of such an intensive
system, however, wilL probably be an increased proportion of
young wood in the overaLL volume, as weLL as more irreguLar
and shorter trees with relatively large branches where there
has been no pruning.
The second type of sylviculture, which wilL be conserved
principaLLy in state forests and other large public estates,
wilL be a fairly cLassic form of forestry where there wiLL be
a preponderance of the main long-revolution, broad-Leaved tree
species. Here the principal objective wilL be the production
of high-quaLity indigenous wood, (for example, oak, cherry,
walnut, beech, etc.) to provide the European wood processing
industry with good timber for construction and veneer, in the
face of diminishing and increasingly expensive supplies of
tropicaL wood. It is obviously desirable that the large
private estates with their traditional type of syLviculture
producing high quality timber should continue to remain in
existence. We must reaLize, however, that where the sale of
timber constitutes the owner's principal source of revenue, he
will find it increasingly difficult to preserve this
traditional type of forest which yields less profit.
As has been the case in the past with traditional
forestry methods, large amounts of wood wilL continue to be
avai LabLe to the pulp and paper industry, from thinnings of
stands where the trees are of differing ages, as well as from
certain selected types of conifers, from trees of slightly
inferior quality and from coppice wood of varying age.
In addition to the two main types of syLviculture
outlined above; it is probable that many other intermediate
systems will be developed concurrently in order to produce the
type of wood in most general demand.
For your particular sector, new methods will incLude high
fibre yieLd, fast-growing monocuLtures such as radiata and
maritime pines, eucalyptus and short rotation popLar and
willow, etc.
In conclusion, I would like to say a word about the prospects
as I see them for the year 2000 and beyond, as far as the
supply of pulpwood for the community paper industry is
concerned. There is no doubt that an increased voLume of wood
wi II be avai LabLe to your industry as a resuLt of better
selection and improvement of existing tree species, more
advanced syLvicultural techniques involving, inter alia,
thinnings being carried out on a wider scale, more emphasis on
trees of shorter revolution, as well as the deveLopment of
plantations essentially for the production of Ligneous fibre.
 189

It wiLL then be for the puLp and paper industry to make

the best possibLe use of the wood produced as a resuLt of aLL
the Latest improvements in syLvicuLturaL methods. However, as
yours is an industry with a reLativeLy inexpensive raw
materiaL but high processing costs, I venture to suggest that
it wiLL be necessary for you to make every endeavour to keep
manufacturing costs as Low as possibLe. On this wiLL depend
the uLtimate success of the puLp and paper industry.
 191

LIST OF PARTICIPANTS

O. ALSHOLM STORA, SAFFLE, SWEDEN

J.L. ASENJO MARTINEZ INSTITUTO PAPELERO ESPANOL, Madrid

E.J. BALDWIN ECC INTERNATIONAL, ST. AUSTELL, U.K.

W. BAUMGARTNER HAINDL PAPIER, AUGSBURG

E. BERNARD C.T.P. GRENOBLE

R. BERNARD PAPETERIES DE BELGIQUE, BRUSSELS

G. BERWART elE CELLULOSE DES ARDENNES, HARNONCOURT

U. BEYER eOLLODIN, FRANKFURT

A. BOCKENFORDE FELDMOHLE A.G., DUSSELDORF

B. BaCKING VERBAND DEUTSCHER PAPIERFABRIKEN, BONN

A. BOSIA SIVA, ROME

C. BROOKE DOW CORNING EUROPE, BRUSSELS

H. BOTTEZ GEBR. BUHL, DETTINGEN ERMS, GERMANY

G. CAPRETTI STAZIONE SPERIMENTALE CELLULOSA, MILAN

M. CASTA MINISTERE DE L'INDUSTRIE, PARIS

R. CHARUEL ECOLE FRANCAISE DE PAPETERIE

ST MARTIN D'HERES
 192

P. COGNARD CONSEILLER CTP, PARIS

P. DAUSCHA PRESIDENT, C.E.P.A.C.

C. DE CHOUDENS C.T.P., GRENOBLE

R.L. DE JONG PAPIERFABRIEK GENNEP, GENNEP

NETHERLANDS

A. DE MONTS C.E.P.A.C.

M. DUCOM C.T.P. GRENOBLE

M. DULION L'AIR LIQUIDE, PARIS

L. ERIKSSON S.T.F.I., STOCKHOLM

A. GARCIA ALVAREZ FORESA, CALDAS DE REYES, SPAIN

L. G(jTTSCHING TECHNISCHE HOCHSCHULE, DARMSTADT

R.A. GRANVILLE PIRA, LEATHERHEAD, U.K.

S.A. HALLIN FRaVI, SWEDEN

M. HARITAKIS ATHENS PAPERMILL S.A., ATHENS

I. HENDRY ILKLEY. YORKS U.K.

CONSULTANT TO THE COMMISSION

R. HICK K.N.P., MAASTRICHT, NETHERLANDS

J.Y. HOAEN DEPT. OF TRADE AND INDUSTRY, LONDON

T. HUGHES ST.REGIS PAPER COMPANY, NEWPORT, U.K.

H.J. HULSCHER CELTONA BV., LANGE LINDEN, NETHERLANDS

 193

B. HYLANDER ASSI, STOCKHOLM

F. IGLESIAS EMPRESA NACIONAL CELULOSAS,

JUAN BRAVO, SPAIN

H. KARLSSON S.T.F.I. STOCKHOLM

H.G. KOCH M.D. PAPIERFABRIKEN, DACHAU, GERMANY

V. KOCH SIVA, ROME

D. LACHENAL C.T.P. , GRENOBLE

M. LAMORT E.M. LAMORT, VITRY-LE-FRANCOIS, FRANCE

R. LAUTEL PRESIDENT OF THE C.G.C.

C. LESAS BEGHIN-SAY S.A., MUNTZENHEIM, FRANCE

S.F. LOVEDAY TOWNSEND HOOK LTD.

SNODLAND, KENT, U.K.

A.G. MARRIOTT BPBIF, FETTER LANE, LONDON

M.ME P. MOLKENTIN-MATILAINEN TECHNOLOGY DEVELOPMENT CENTRE, HELSINKI

K. MOLLER NATIONAL AGENCY OF ENVIRONMENTAL

PROTECTION, COPENHAGEN

M. MURE BEGHIN-SAY S.A., MUNTZENHEIM, FRANCE

P. NORER HOLMENS BRUK, NORRKOPING, SWEDEN

J. PAPAKYRIAKOS ATHENS PAPERMILL S.A., ATHENS

F. PASTINA CONSULTANT TO THE COMMISSION, ROME

P. MERIKAS ATHENS PAPERMILL S.A. , ATHENS

 194

H. O'BRIEN "PULP AND PAPER INTERNATIONAL", BRUSSELS

M. PIERONI ISTITUTO DONEGANI, NOVARA

S.G. PONTON SCA TEKNISK AB, SUNDSVALL, SWEDEN

H.J. PUTZ INSTITUT FUR PAPIERFABRIKATION, DARMSTADT

M. RICHOUX ACIERIES ET FORGES D'ANOR, FRANCE

M.S. SALKINOJA-SALONEN UNIVERSITY OF HELSINKI

L. SALMEN S.T.F.I., STOCKHOLM

R. SCUDLIK I.F.P., DARMSTADT

S. SIDAWAY PIRA, LEATHERHEAD, U.K.

D.F. SMEDES KAPPA KARTON B.V., OUDE PEKELA, NETHERLANDS

M. SMINK V. N. P., HAARLEM, NETHERLANDS

L. SIERRA GRANADOS ESCUELA TECNICA SUPERIOR DE INGENIEROS

DE MONTES, MADRID

R. SPRUYT CYPRUS INDUSTRIAL MINERALS CO., GENT

M. STIRLING WIGGINS TEAPE, BEACONSFIELD, U.K.

O. TORLAND S.T.F.!, STOCKHOM

J. TROESCH SANDOZ, BALE

M. VANBEVER SOLVAY, BRUSSELS

G. VAN DORTH T N 0, DELFT

R. WILKEN P.T.S., MUN,ICH
 195

COM MIS S ION

Ph. BOURDEAU DIRECTOR, DG XII-G

w. HANSSENS DG XII-G-3

R. FLIES DG XII-G-3

M. DONOHOE DG XII-G

l. PELS DG XII-G-3

l. BIOlATTO DG XII-G-3

C. BAIllET DG VI-F-3

J. TEN GEUZENDAM DG III-C-3

W. GOFFARD DG III-C-3

E. FASSOTTE DG XII-A-3, LUXEMBOURG

P.P. ROTONDO DG XIII-A-2, LUXEMBOURG

 197

I N D E X OF AUTHORS

ANGELIER, R., 37 KARLSSON, H., 149

KOCH, V., 78
BAUMGARTNER, W., 121
BEYER, U., 116 LACHENAL, D., 33
BIANCO, G., 138 LARSEN, G., 98
BOSIA, A, 43 LOMBARDO, G., 26
BOURDEAU, P., 3
BREUNIG, A., 121 MURE, M., 130
CALMANT I , G., 78 NARJES, K.-H., 5
CAPRETTI, G., 138 NIELSON, S., 98
CERAGIOLI, G., 138
CHARUEL, R., 10 PIERONI, M., 78
CHIOLLE, A., 78 PUTZ, H.J., 86
DAUSCHA, G., 170 RUEFF, M.
DE CHOUDENS, C., 26, 37
DE JONG, R.L., 69 SALMEN, L. 18
SCUDLIK, R., 108
GATTI, A., 78
GOLDSTEIN, G., 130 TERLAND, 0., 161
GOTTSCHING, L., 86, 108 TREDICI, P., 78
HANSSENS, W.J.H., 185 WEIGL, J., 60
HENDRY, I.F., 177 WILKEN, R., 60
HOWLAND, P., 93, 125
HUGHES, T., 52