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ABSTRACT
History-> The word paper derives from the Greek term for the ancient Egyptian writing material called papyrus, which was formed from beaten strips of papyrus plants. The soda process for making pulp from wood was developed by Watt & Burgess in 1851. NSSC pulping yields highest fibers up to 65%-80% which results in reduced stream pollution problems. But quality and bleachability is low. Types-> Chemical pulp is of three types 1) Kraft or Sulfate Pulp (Alkaline) 2) Sulfite Pulp (Acid) 3) Neutral Sulfite Semi-Chemical (NSSC) Pulp Density->The density of paper ranges from 250 kgm-3 (16 lbft-3) for tissue paper to 1500 kgm-3 (94 lbft-3) for some specialty paper. Printing paper is about 800 kgm-3 (50 lbft-3). In BILT, Unit: Kraft Process is employed for pulping. Veneer, Veneer chips, Bamboo, Poplar wood and Poplar rulla, Eucalyptus wood & rulla etc. are the raw materials used in that unit due to their easily availability in nearby areas

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INTRODUCTION :
Recovery of chemicals has always been considered as the backbone of pulp and paper industry in the phase of increase of pulping chemicals. Strict laws of pollution control and power crisis arising from mushrooming of industries the recovery of pulping chemicals has become more important.

THE KRAFT PROCESS


INTRODUCTION: o Kraft process is one of the main chemical pulping . o Kraft or sulfate pulping is an alkaline process . o It is cooked with a strong (12%) solution of NaOH and Na2CO3. The material added to the cooking liquor for the Kraft process is Na2SO4, hence the common name of sulfate process. o The cooking however is done with a solution containing Na2S, NaOH and Na2CO3 formed from the sulfate during preparation and recovery of the cooking liquor. o All sorts of wood can be cooked by the Kraft process and the fibers produced are bleachable and strong. o It is very important that the chemicals used can be recovered and recycled, reducing or even eliminating stream pollution.
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Flow sheet of Kraft Process

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ABBREVIATIONS USED:
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Chipper House Chip Silo Digester Blow Tank Brown Stock Chest Pulp Washers Degassing Tank Stock Tank Knitters, Rifflers and Screens Beater Jordan Head Box Fourdrinier Dryer Calendar Stack Finished Paper Roll Weak B/L Storage Multiple Effect Evaporators Steam Line

20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

To Sewer Condensate Strong B/L Storage Recovery Boilers ESP & Chimney Smelt Dissolving Tanks G/L Storage Tank G/L Clarifier Stationary Slaker Causticizing Tanks W/L Clarifier Mud Washers W/L Storage Tank Vacuum Drum Filter Lime Kiln Dregs Producer Gas Plant

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Pulping Procedures in Kraft Process


Cellulosic raw material Principal reaction in the digester Composition of cooking liquor

: Almost any kind of wood,soft/hard : Hydrolysis of lignin to alcohols and acids : 12.5% solution of NaOH, Na2S; 58.6% NaOH, 27.1% Na2S, 14.3% Na2CO3.

Cooking conditions

: Time 2-5 hours; Temperature 170 to 176C; Pressure 660-925kPa. : through burning of organic matter dissolved in the liquor from the wood.

Chemical Recovery

Material of construction Pulp characteristics

: can be made of mild steel or stainless. : Brown color, difficult to bleach, strong fibers, resistant to mechanical refining. Strong brown bag, gumming paper, building paper, strong white paper, paperboards and liquid containers.

Paper products
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RECOVERY OF THE BLACK LIQUOR


The B/L removed from the pulp washer contains 95 to 98% of the total chemicals charged to the digester. Organic sulfur compounds are presented in combination with sodium sulfide. Na2CO3 is present as are also small amounts of Na2SO4, salt, silica and traces of lime, Fe2O3, alumina and potash. Total solids usually average about 20%. Then black liquor is concentrated, burned and limed. In the smelting furnace any remaining organic compounds are broken down, the carbon burned away and the inorganic chemicals melted. At the same time the following reaction takes place: Na2SO4 + 2C Na2S + 2CO2 The carbon comes from the organics in the wood.

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Soda Recovery-Flow Diagram:

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Soda Recovery sub-sections:


Evaporator Section
Boiler Section Causticizing Plant Lime Kiln Producer Gas Plant
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In this section black liquor is concentrated to a required concentration and sent to the recovery boilers for heat recovery & formation of green liquor. The black liquor is concentrated with the help of evaporators. In this section there are mainly two types of evaporators, one is free flow falling film evaporator (FFFF) and other is short tube vertical effect evaporators (STVE).
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FORCED-CIRCULATION EVAPORATORS:

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SHORT-TUBE VERTICAL EVAPORATORS:


Principal use :evaporation of canesugar juice. Heating surface is induced by boiling in the tubes, which are usually 50.8 to 76.2 mm (2 to 3 in) in diameter by 1.2 to 1.8 m (4 to 6 ft) long. Body: vertical cylinder, usually of cast iron, and tubes are expanded into horizontal tube sheets Circulation rate through the tubes is many times the feed rate; so there must be a return passage from above the top tube sheet to below the bottom tube sheet. Most commonly used :central well or down-take
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ROLE OF RECOVERY BOILERS


Feed - concentrated B/L coming from the evaporators. At both of these boilers B/L is fired to recover the heat content of the spent cooking liquor in form of production of high pressure steam. The lignin in the liquor is burnt away and what remain are the chemicals (in the form of smelt). This smelt is then dissolved in weak white liquor coming from Causticizing Plant, which gives a characteristic green color (hence called green liquor; G/L). This G/L contains some solid impurities which are separated out by means of a clarifier. The main aim of these boilers is to recover all unused chemicals from the B/L stream in form of G/L. Chemical composition of G/L is as follows: Na2CO3 (70%); NaOH (15%); Na2S(15%)

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Recovery Boilers

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RECOVERY BOILERS:
TYPES

ABL boiler
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JMW boiler

Differences b/w ABL & JMW Boilers


Points
Firing

ABL
wall firing at the bottom after the ESP & gives fine gases to chimney centre base at the top

JMW

smelt Dissolving

tank agitator FD fan


sump pump soot blowers

Steam used for ESP Pumps

before the ESP & gives fine gases to ESP used for mixing salt cake for better mixing same mixing tank is used for mixing of two both ESP ash & salt cake. all are retractable type only 5 are retractable type and rest of 17 are non-retractable Automatic soot blowing Soot blowing is done manually taken from the steam produced by itself uses steam produced by other soot-blowing boiler for the same Two are used one is used four pumps being used; two for recirculation two to serve both the purposes and two for transferring liquor to Causticizing Plant

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CAUSTICIZING PLANT:
Purpose-> To convert available Na2CO3 in useful NaOH by reacting it with Ca(OH)2 thus converting the supplied G/L into W/L in a number of steps. consists of-> causticizers, clarifiers, mud washers, filters, dreg washers and grit classifiers etc. Process-> G/L at 500-600C from the smelt dissolving tank is pumped to raw G/L storage tank. G/L is screened over the storage tank to separate solids. Screened G/L is allowed to fall in a clarifier to separate out dregs. The temperature is always kept at 95-100C so that slaking and causticizing reaction may take place in the causticizer tanks at desired rate. Clarified green liquor from the storage is supplied to splitting box. Lime is introduced in the slaker where G/L meets it from the splitter box in the slaker by two lines one in head and another in tale. Lime is transferred from lime bin. In the slaker causticizing reaction is completed around 80-90%. The slaking reaction is as follows:CaO + H2O Ca (OH) 2 + Heat (486 Btu/lb) The resultant Ca(OH)2 reacts with sodium carbonate to form NaOH this reaction is called causticizing reaction: Ca (OH) 2 + Na2CO3 2NaOH + CaCO3 Na2CO3(15%); NaOH(70%); Na2S(15%)

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Details of Causticizing Plant


Daily G/L intake (ABL) G/L clarifier capacity Storage tank capacity Lime bin capacity W/L clarifier capacity (Old) New mud washers capacity Steam line used for heating Dryness of mud after filter Daily lime consumption Number of clarifiers Number of mud washers Filter type filter Production(W/L ) Temperature in each step
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: : : : : : : : : : : : : :

510 m3 (JMW), 810 m3 280 m3 (Both) 165 m3 (All) 150 ton 650 m3(New), 400 m3 565 m3 (Both) 3 Kgcm-2 & 7 Kgcm-2 64% 77 ton 4 4 Rotary vacuum drum 855 m3 per day 90-110C

LIME KILN
Basically consists of :
mud filters, lime kiln, ESP and

chimneys etc
In this unit we have one filter

(Rotary Vacuum Drum Filter type), one lime kiln, one ESP and an ID fan.

Basic reaction that takes place inside a lime kiln is as follows: CaCO3 CaO + H2O +
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Constructional & working details


Length Diameter Feed end temperature Outlet zone temperature Feed rate Average CaO in lime prepared from kin Dryness of mud % CaO in mud at feed end % free NaOH in mud at feed end Daily oil consumption Kiln speed Kiln motor speed Inlet & outlet draught for ESP

: : : : : : : : : : : : :

55 m 2.5 m 200-250C 900-1000C 150 ton per day 80-82 % 65-68 % 0.2 % 0.4 % 6000 m3 0.667 rpm 1300-1400 rpm 12mmWC

& 120mmWC

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PRODUCER GAS PLANT:


Producer Gas (PG) is made by passing air stream through a bed of hot coal or coke. Temperature of the fuel bed depends on the fusion point of the fuel ash is to use up as much as possible, the exothermic energy from the reaction between C and O2 to supply the endothermic reaction between the C and steam:

C + Air CO2 + C C + H2O CO + H2O

CO2 + N2 2CO CO + H2 CO2+ H2

(H1000C= -395.4 MJ/ Kmol) (H1000C= +167.9 MJ/ Kmol) (H1000C= +135.7 MJ/ Kmol) (H1000C= -32.18 MJ/ Kmol)

PG thus produced is used in lime kiln as fuel. Steam pressure helps in maintaining axial flame length while oil atomization controls radial flame spread.
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PRODUCER GAS PLANT-Few details


Coal feed rate LCT-1 temperature LCT-2 temperature Furnace jacket temperature Blast Saturation Temperatur Blast Air pressure Gas flow rate Air flow rate LCT-2 pressure Steam pressure CO leakage level Gas outlet temperature Daily tar production
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: : : : : : : : : : : : :

20 ton per day 135C 142C 75C 55C 280 mmWC 2730 m3/hour 1170 m3/hour 125 mmWC 0.4 Kgcm-2 10-250ppm 106C 1200 liter

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