"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm

"Chemical Pulping"
Edited by Johan Gullichsen

And
Carl-Johan Fogelholm
Item Number: 0202FIN06

ISBN: 952-5216-06-3
2 volumes, Volume A - 693 pages, Volume B - 497 pages
Volume A
Chapter 1 - Introduction
1 Wood fibers.........................................................................................................................13
2 Pulping ................................................................................................................................13
2.1 Washing, screening, and bleaching .....................................................................................14
2.2 Recovery of chemicals .........................................................................................................15
Chapter 2 - Fiber line operations
1 Principles of wood chip delignification ...........................................................................19

1.1 Properties of wood chips......................................................................................................19
1.1.1 Structure of wood.....................................................................................................19
1.1.2 Chemical composition of wood ................................................................................23
1.2 Chemical pulping methods...................................................................................................28
1.3 Principles of chemical pulping reactions ..............................................................................32
1.4 Alkaline processes ...............................................................................................................38
1.4.1 The kraft process .....................................................................................................38
1.4.2 Modified kraft processes..........................................................................................52
1.4.3 Principles of industrial cooking ................................................................................60
1.4.4 Heat and material balances in kraft pulping ............................................................73
1.5 Acid processes .....................................................................................................................86
1.5.1 Sulfite pulping ..........................................................................................................86
1.6 Process variables in sulfite cooking .....................................................................................96
1.6.1 Principles of industrial..............................................................................................98
1.6.2 Process variables and fiber quality........................................................................101
1.7 Semichemical and chemimechanical pulping methods .....................................................102
1.7.1 Neutral semichemical pulping................................................................................103
1.7.2 NSSC pulping principle..........................................................................................103
1.7.3 NSSC pulping and its process variables ...............................................................104
2 Pulp washing ....................................................................................................................107
2.1 Principles of washing .........................................................................................................108
2.1.1 Terminology ...........................................................................................................108
2.1.2 Principles of washing .............................................................................................108
2.1.3 Washers.................................................................................................................109
3 Screening and cleaning of pulp......................................................................................117
3.1 Typical solid impurities .......................................................................................................118
3.2 General principles of screening and cleaning ....................................................................122
3.2.1 Equipment and flow sheet symbols .......................................................................122
3.2.2 Principles of screening...........................................................................................124
3.3 Screening operations .........................................................................................................125
3.3.1 Knotting..................................................................................................................125
3.3.2 Brownstock screening............................................................................................126
3.3.3 Flow balance of brown stock screening.................................................................127
3.3.4 Typical screening equipment .................................................................................129
3.3.5 Screening layout considerations............................................................................131
3.3.6 Screen plates .........................................................................................................131
"Chemical Pulping"
And
3.3.7 Medium-consistency screening .............................................................................132
3.3.8 Principles of cleaning.............................................................................................133
3.3.9 Cleaner applications ..............................................................................................134
3.3.10 Hydro-cyclone systems..........................................................................................135
4 Oxygen delignification.....................................................................................................137
4.1 Short history .......................................................................................................................138
4.2 The basic process ..............................................................................................................138
4.3 The basic chemistry of oxygen delignification....................................................................139
4.3.1 Selectivity...............................................................................................................140
4.3.2 Reaction rates and mass transfer..........................................................................141
4.3.3 Chemical consumption and reaction products.......................................................141
4.4 Processes and equipment..................................................................................................141
4.4.1 Process variables ..................................................................................................144
4.4.2 Placing oxygen delignification in a pulping line .....................................................144
4.4.3 Quality of oxygen delignification ............................................................................146
5 Bleaching of pulp .............................................................................................................146
5.1 Optical properties of pulp ...................................................................................................146
5.1.1 Stability of brightness.............................................................................................150
5.2 Bleaching chemicals and reaction principles .....................................................................150
5.3 Bleaching sequences .........................................................................................................156
5.4 Process variables and equipment in bleaching stages......................................................158
5.4.1 The gas-liquid-fiber system....................................................................................158
5.4.2 Chlorination............................................................................................................158
5.4.3 Alkaline extraction..................................................................................................176
5.4.4 Chlorine dioxide bleaching.....................................................................................180
5.4.5 The standard chlorine and chlorine dioxide bleaching sequence..........................188
5.4.6 Hypochlorite and hypochlorous acid bleaching .....................................................190
5.4.7 Ozone delignification .............................................................................................194
5.4.8 Hydrogen peroxide bleaching ................................................................................202
5.5 Displacement bleaching .....................................................................................................213
5.5.1 Process applications of displacement bleaching ...................................................216
6 Cooking, washing, screening, and bleaching process units ......................................219
7 Drying of pulp ...................................................................................................................225
7.1 Sheet dryers .......................................................................................................................226
7.2 Flash drying........................................................................................................................228
7.3 Quality aspects of drying....................................................................................................228
7.4 Heat and mass transfer in pulp drying ...............................................................................229
References .........................................................................................................................231
Chapter 3 - Chemical engineering principles of fiber line operations
1 Physics and fluid mechanics ..........................................................................................245

1.1 Cooking of chips.................................................................................................................245
1.1.1 Anatomy of wood chips..........................................................................................245
1.1.2 Compressibility of chip columns and their resistance to liquid flow.......................255
1.2 Fiber phase operations ......................................................................................................260
1.2.1 Fiber rheology ........................................................................................................260
1.2.2 Pumping of fiber suspensions................................................................................269
1.2.3 Mixing.....................................................................................................................275
1.2.4 Reactors and tanks................................................................................................277
1.2.5 Screening and cleaning .........................................................................................280
1.2.6 Filtration, displacement, and pressing ...................................................................287
"Chemical Pulping"
And
2 Reaction kinetics and mass transfer .............................................................................291
2.1 Reaction kinetics in kraft cooking.......................................................................................291
2.1.1 Kinetics of lignin reactions .....................................................................................291
2.1.2 Kinetics of carbohydrate reactions ........................................................................294
2.2 Mass transfer in kraft cooking ............................................................................................295
2.2.1 Steaming................................................................................................................295
2.2.2 Penetration.............................................................................................................297
2.2.3 Diffusion .................................................................................................................298
2.2.4 Sorption..................................................................................................................301
2.2.5 Applications and examples ....................................................................................301
2.3 Mass transfer and kinetics in fiber phase processes .........................................................304
2.3.1 Mass transfer in bleaching.....................................................................................304
2.3.2 Reaction kinetics in bleaching ...............................................................................308
2.4 Mass transfer in washing ...................................................................................................313
2.4.1 Displacement efficiency in washing .......................................................................314
2.4.2 Diffusion and sorption phenomena in washing......................................................316
2.4.3 Comparison of efficiency of different washing systems.........................................320
2.4.4 Fractional washing.................................................................................................323
3 Heat transfer .....................................................................................................................323
3.1 Heat capacity and heat balances of solid-liquid-gas mixtures ...........................................323
3.2 Rate of heat transfer ..........................................................................................................325
References .........................................................................................................................326
Chapter 4 - Wood handling applications
1 Measuring, storing, and pretreatment of roundwood ..................................................331

1.1 Measuring incoming wood raw material.............................................................................332
1.1.1 Wood weighing ......................................................................................................332
1.1.2 Scanning image scaling.........................................................................................335
1.2 Wood storage arrangements at the mill site ......................................................................337
1.2.1 Storage area ..........................................................................................................338
1.2.2 Storage time...........................................................................................................338
1.2.3 Wood unloading.....................................................................................................338
1.3 Deicing, cutting, and feeding to debarking.........................................................................342
1.3.1 Receiving conveyor ...............................................................................................343
1.3.2 Deicing ...................................................................................................................344
1.3.3 Receiving deck ......................................................................................................346
1.3.4 Slasher deck ..........................................................................................................347
1.3.5 Sorting....................................................................................................................347
1.3.6 Waste handling ......................................................................................................348
1.3.7 Feed into debarking ...............................................................................................348
2 Debarking..........................................................................................................................351
2.1 Tumble debarking ..............................................................................................................356
2.2 Parallel debarking ..............................................................................................................362
2.3 Ring debarking ...................................................................................................................363
2.4 King debarking ...................................................................................................................366
2.5 Hydraulic debarking ...........................................................................................................367
2.6 Small diameter wood debarking.........................................................................................367
2.7 Chain flail debarking...........................................................................................................368
3 Chipping............................................................................................................................369
3.1 Horizontally fed chippers....................................................................................................379
3.2 Gravity fed chippers ...........................................................................................................380
"Chemical Pulping"
And
3.3 Drum chippers ....................................................................................................................382
3.4 Chipper feeding..................................................................................................................383
4 Chip screening .................................................................................................................386
4.1 Coarse screen ....................................................................................................................396
4.2 Gyrating screens ................................................................................................................396
4.3 Disc screens.......................................................................................................................399
4.4 Roll screens........................................................................................................................401
4.4.1 Diamond pattern fines screen................................................................................402
4.4.2 Pocket roll fines screen..........................................................................................404
4.5 Bar screens ........................................................................................................................405
4.5.1 Optimize bar screens.............................................................................................406
4.6 Wave screens ....................................................................................................................407
4.6.1 Flip flow screen ......................................................................................................407
4.6.2 Wave mat screen...................................................................................................408
4.7 Rechippers .........................................................................................................................409
4.8 Slicers ...............................................................................................................................410
4.9 Chip conditioners ...............................................................................................................411
4.9.1 Pyramid pattern chip conditioner ...........................................................................413
4.9.2 Chip optimizer ........................................................................................................414
5 Chip storage and transportation ....................................................................................418
5.1 Chip piles............................................................................................................................423
5.2 Automatic chip piles ...........................................................................................................425
5.3 Chip silos............................................................................................................................428
5.4 Aging chip silo ....................................................................................................................429
5.5 Chip transport to storage....................................................................................................432
5.6 Chip transport to digester...................................................................................................445
5.7 Purchased chip handling....................................................................................................452
6 Bark handling ...................................................................................................................455
6.1 Bark dewatering .................................................................................................................459
6.2 Bark screening ...................................................................................................................460
6.3 Bark shredding ...................................................................................................................461
6.4 Bark pressing .....................................................................................................................465
6.4.1 Cycle press ............................................................................................................466
6.4.2 Multipress...............................................................................................................467
6.4.3 Step press..............................................................................................................468
6.4.4 Single-pass press ..................................................................................................468
6.5 Bark storage .......................................................................................................................469
6.6 Bark transport.....................................................................................................................470
7 Water handling .................................................................................................................472
7.1 Circulation water system ....................................................................................................475
7.2 Thawing water system .......................................................................................................475
8 Wood handling systems..................................................................................................476
8.1 Wood handling plant layout................................................................................................477
8.2 Woodroom layout ...............................................................................................................479
8.3 Screening layout ................................................................................................................479
8.4 Chip storage layout ............................................................................................................481
8.5 Process control and personnel plan...................................................................................482
8.5.1 Process optimization..............................................................................................483
8.5.2 Staffing plan ...........................................................................................................485
8.6 Raw material ......................................................................................................................486
8.6.1 Installation for cleaning and chipping of stumps....................................................486
8.6.2 Whole tree chip cleaning process..........................................................................488
"Chemical Pulping"
And
8.6.3 Pulp chip method ...................................................................................................489
References .........................................................................................................................490
Chapter 5 - Batch cooking applications
1 Principles of displacement batch cooking ....................................................................494

2 Pulping performance of batch cooking .........................................................................496
3 Description of displacement batch cooking operations..............................................501
3.1 Displacement batch cooking plant .....................................................................................501
3.2 Cooking cycle .....................................................................................................................503
3.3 Heat recovery .....................................................................................................................507
3.4 Soap separation .................................................................................................................507
3.5 Malodorous gases..............................................................................................................508
3.6 Control system ...................................................................................................................509
References .........................................................................................................................511
Chapter 6 - Continuous cooking applications
1 Introduction ......................................................................................................................513
2 Industry standard for continuous pulping systems .....................................................515
3 Overview description of process and equipment.........................................................515
3.1 Pre-steaming ......................................................................................................................519
3.2 Chip metering and feeding process pressure ....................................................................522
3.3 Top circulation lines and top separator ..............................................................................528
3.4 Impregnation zone .............................................................................................................530
3.5 Primary heating zone .........................................................................................................532
3.6 Screen and screen header design .....................................................................................536
3.7 Cooking and extraction zones............................................................................................539
3.8 Countercurrent Hi-Heat washing........................................................................................541
3.9 Blow dilution and cold blowing ...........................................................................................544
3.10 Process gases....................................................................................................................545
4 Modified cooking processes...........................................................................................546
4.1 Isothermal cooking (ITC)....................................................................................................549
4.2 Lo-Solids pulping................................................................................................................552
4.2.1 Process objectives.................................................................................................552
4.2.2 Basic principles of Lo-Solids pulping .....................................................................552
4.2.3 Configuration of process equipment......................................................................553
4.2.4 Lo-Solids pulping in practice..................................................................................553
4.2.5 Decreases in time and concentration profile of dissolved wood solids .................553
4.2.6 Pulp strength, EA consumption, and bleachability ................................................554
4.2.7 Digester extraction capacity and brownstock washing ..........................................555
4.2.8 Scaling and heat distribution..................................................................................555
5 Recent developments in the technology of continuous digesters .............................556
5.1 Black liquor impregnation (BLI) ..........................................................................................556
5.2 Diamondback chip bin........................................................................................................559
5.3 Lo-Level feed system .........................................................................................................563
6 Future developments in technology of continuous digesters ....................................566
References .........................................................................................................................569
Chapter 7 - Pulp washing applications
1 The atmospheric diffuser ................................................................................................573

"Chemical Pulping"
And
1.1 Brownstock washing ..........................................................................................................574
1.2 Post oxygen washing .........................................................................................................574
1.3 Bleach plant washing .........................................................................................................574
1.4 Design ...............................................................................................................................575
1.5 Operation............................................................................................................................576
1.6 Washing .............................................................................................................................577
2 The pressure diffuser ......................................................................................................577
2.1 Mechanical design and operating principle........................................................................578
2.1.1 The Ahlstrom design..............................................................................................578
2.1.2 The Kvaerner design .............................................................................................579
2.2 Operating experiences .......................................................................................................582
3 The Drum Displacer .........................................................................................................582
3.1 Fractionated washing .........................................................................................................582
3.2 Operating principle of DD washer ......................................................................................584
3.3 Instrumentation ..................................................................................................................585
3.4 Brownstock washing plant layout.......................................................................................586
3.5 Brownstock washing experience........................................................................................586
4 The GasFree filter.............................................................................................................588
4.1 Special features of the GF washer.....................................................................................588
4.2 Operating principle of the GF filter .....................................................................................589
4.4 Layout ...............................................................................................................................590
4.5 Applications ........................................................................................................................591
5 Press washing ..................................................................................................................592
5.1 Wash press (Kvaerner) ......................................................................................................592
5.1.1 Design....................................................................................................................592
5.1.2 Operation ...............................................................................................................594
5.1.3 Washing .................................................................................................................594
5.2 Press washing (Sunds Defibrator) .....................................................................................594
5.2.1 Displacement wash press......................................................................................594
5.2.2 Wash systems .......................................................................................................596
5.3 The wash master wash press ............................................................................................597
5.3.1 Basic mechanical design .......................................................................................597
5.3.2 Operating principle.................................................................................................598
5.3.3 Special features of the WM press..........................................................................599
5.3.4 Layout ....................................................................................................................599
References .........................................................................................................................601
Chapter 8 - Pulp screening applications
1 Knot screening .................................................................................................................619

2 Knot washing....................................................................................................................621
3 Fine screening ..................................................................................................................622
3.1 Pressure screens ...............................................................................................................622
4 Cleaners ............................................................................................................................626
5 Screening system ............................................................................................................629
Chapter 9 - Bleaching applications
1 Equipment used in bleaching systems..........................................................................617

1.1 Pumping and handling of medium-consistency fiber suspensions ....................................617
"Chemical Pulping"
And
1.1.1 Fluidization.............................................................................................................617
1.1.2 Air content..............................................................................................................618
1.1.3 Medium consistency pumps ..................................................................................618
1.1.4 Pumping applications.............................................................................................619
1.2 Mixing of chemicals and steam ..........................................................................................626
1.3 Reactors .............................................................................................................................631
2 Post cooking delignification and bleaching stages .....................................................634
2.1 Oxygen delignification ........................................................................................................635
2.1.1 Process parameters...............................................................................................635
2.1.2 Oxygen stage systems ..........................................................................................636
2.1.3 Post oxygen delignification washing......................................................................637
2.1.4 Process optimization..............................................................................................640
2.2 Chlorine dioxide stages......................................................................................................641
2.3 Alkaline extraction ..............................................................................................................643
2.4 Hypochlorite bleaching stage .............................................................................................645
2.5 Ozone stage .......................................................................................................................645
2.6 Peroxide bleaching stage...................................................................................................650
2.7 Chelation ............................................................................................................................653
2.8 Acid hydrolysis ...................................................................................................................654
2.9 Peracid stage .....................................................................................................................655
2.10 Multi-chemical stages.........................................................................................................655
3 Bleaching sequences ......................................................................................................656
3.1 Chlorine chemical bleaching (CCB) ...................................................................................656
3.2 Oxygen chemical bleaching (OCB)....................................................................................662
4 Bleach plant liquid circulation closure ..........................................................................664
Chapter 10 - Pulp drying applications
1 Drying machine wet end..................................................................................................667

1.1 Headbox .............................................................................................................................670
1.2 Forming table .....................................................................................................................671
1.3 Wire presses ......................................................................................................................672
1.4 Press section......................................................................................................................673
1.5 Drying machine accessories ..............................................................................................673
2 Dryer section ....................................................................................................................675
2.1 Pulp drying with airborne web ............................................................................................675
2.1.1 Background............................................................................................................675
2.1.2 Description .............................................................................................................676
2.1.3 Drying of different pulp types .................................................................................678
2.1.4 Cooling...................................................................................................................679
2.1.5 Drying economy.....................................................................................................679
2.1.6 Control ...................................................................................................................681
2.1.7 Maintenance and service.......................................................................................681
2.2 Pulp flash drying.................................................................................................................682
2.2.1 Background............................................................................................................682
2.2.2 Description .............................................................................................................682
2.2.3 Drying economy.....................................................................................................684
2.2.4 Environmental aspects ..........................................................................................684
3 Pulp bale handling ...........................................................................................................684
"Chemical Pulping"
And
Volume B
Chapter 11 - Chemical recovery
1 Overview of kraft recovery ..................................................................................................7

1.1 Kraft recovery unit operations ................................................................................................7
1.1.1 Evaporation................................................................................................................8
1.1.2 Recovery boiler ..........................................................................................................9
1.1.3 Lime kiln...................................................................................................................10
1.1.4 Causticizing..............................................................................................................10
1.2 Gasification...........................................................................................................................11
1.3 Direct alkali recovery............................................................................................................12
2 Properties of kraft recovery process streams ................................................................12
2.1 Black liquor properties..........................................................................................................12
2.1.1 Composition of black liquor......................................................................................13
2.1.2 Elementary analysis of black liquor dry solids .........................................................14
2.1.3 Heating value ...........................................................................................................16
2.1.4 Density .....................................................................................................................18
2.1.5 Specific heat capacity ..............................................................................................19
2.1.6 Boiling point rise ......................................................................................................20
2.1.7 Thermal conductivity................................................................................................20
2.1.8 Viscosity...................................................................................................................21
2.1.9 Surface tension ........................................................................................................24
2.2 Smelt properties ...................................................................................................................24
2.2.1 Enthalpy ...................................................................................................................24
2.2.2 Heat of formation .....................................................................................................25
2.2.3 Heat of reduction .....................................................................................................25
2.3 Flue gas and air properties ..................................................................................................26
2.3.1 Density .....................................................................................................................26
2.3.2 Enthalpy ...................................................................................................................28
2.3.3 Specific heat capacity ..............................................................................................28
2.3.4 Conductivity .............................................................................................................29
2.3.5 Viscosity...................................................................................................................30
2.4 Air .........................................................................................................................................31
2.5 Properties of green liquor.....................................................................................................32
2.6 Properties of miscellaneous chemical compounds ..............................................................33
References ...........................................................................................................................34
Chapter 12 - Evaporation of black liquor
1 General ................................................................................................................................37
2 Black liquor properties ......................................................................................................37
2.1 Composition of black liquor dry solids..................................................................................37
2.2 Physical properties of black liquors......................................................................................38
3 Principles of evaporation ..................................................................................................40
3.1 Multiple effect evaporation ...................................................................................................41
3.2 Vapor compression evaporation ..........................................................................................42
3.3 Flash steam evaporation......................................................................................................43
3.4 Evaporator plant coupling ....................................................................................................43
3.5 Concentrator coupling ..........................................................................................................45
3.6 Stripper column integration ..................................................................................................45
4 Evaporator design features...............................................................................................46
4.1 Rising film (RF) evaporator ..................................................................................................46
"Chemical Pulping"
And
4.2 Falling film (FF) evaporators ................................................................................................47
4.3 Concentrators (first effect evaporators) ...............................................................................50

4.4 Evaporator plant auxiliary equipment...................................................................................51
4.5 Stripping column and menthol liquification...........................................................................53
4.6 Direct contact (DC) evaporator ............................................................................................55
5 Heat transfer .......................................................................................................................56
5.1 Heat transfer of evaporators ................................................................................................56
5.2 Heat transfer theory and calculation in multiple effect evaporation .....................................59
5.3 Heat balance ........................................................................................................................62
5.4 Evaporator calculation..........................................................................................................64
5.5 Multiple effect evaporation ...................................................................................................67
6 Evaporation systems and applications ...........................................................................72
6.1 Application of vapor compression evaporation (VCE) .........................................................72
6.2 Application of flash steam evaporation ................................................................................73
6.3 High solids concentrators.....................................................................................................75
6.4 Liquid heat treatment (LHT) method ....................................................................................76
6.5 Pressurized tank method .....................................................................................................78
6.6 Typical liquor specification for black liquor evaporation.......................................................79
7 Design .................................................................................................................................79
7.1 Evaporator plant design .......................................................................................................79
7.2 Storage tank design .............................................................................................................82
8 Soap skimming...................................................................................................................82
8.1 Soap separation theory ........................................................................................................83
8.2 Soap skimming procedures..................................................................................................85
9 Scaling of the heat transfer surfaces...............................................................................88
9.1 Scaling and heat transfer .....................................................................................................88
9.2 Reasons for scaling..............................................................................................................88
9.3 Types of scales ....................................................................................................................89
9.3.1 General ....................................................................................................................89
9.3.2 Calcium carbonate scaling.......................................................................................89
9.3.3 Calcium carbonate scale control..............................................................................89
9.3.4 Sodium carbonate and sulfate scaling.....................................................................90
9.3.5 Sodium carbonate and sulfate scale control............................................................91
9.3.6 Fouling by fiber and soap ........................................................................................91
9.3.7 Aluminum silicate scaling.........................................................................................91
9.3.8 Aluminum silicate scale control................................................................................92
References ...........................................................................................................................93
Chapter 13 - Recovery boiler
1 Evolution of recovery boiler design.................................................................................96

1.1 Two drum recovery boiler.....................................................................................................96
1.2 Modern recovery boiler ........................................................................................................97
1.3 Future recovery boilers ........................................................................................................99
2 Material and energy balance ...........................................................................................100
2.1 Material balance.................................................................................................................100
2.2 Energy balances ................................................................................................................104
2.3 High dry solids....................................................................................................................105
3 Combustion of black liquor.............................................................................................108
3.1 Drying ...............................................................................................................................110
3.2 Devolitilization ....................................................................................................................110
3.3 Char combustion ................................................................................................................111
"Chemical Pulping"
And
3.4 Smelt reactions ..................................................................................................................112
3.5 Combustion of black liquor droplet in the furnace..............................................................113

4 Dimensioning of boiler heat transfer surfaces .............................................................114
4.1 Main design criteria ............................................................................................................114
5 Boiler processes ..............................................................................................................121
5.1 Air system...........................................................................................................................121
5.2 Flue gas system .................................................................................................................122
5.3 Water and steam................................................................................................................122
6 Recovery boiler operation...............................................................................................123
6.1 Soot blowing control...........................................................................................................123
6.2 Enrichment of potassium and chlorides to dust .................................................................126
References .........................................................................................................................130
Chapter 14 - White liquor preparation
1 General ..............................................................................................................................135
1.1 Characterization of the liquors ...........................................................................................136
1.2 Recausticizing chemistry....................................................................................................139
1.3 Chemical reactions in lime reburning.................................................................................141
2 White liquor plant material balances .............................................................................141
3 Sodium and sulfur balances ...........................................................................................142
4 Environmental issues ......................................................................................................144
5 Nonprocess elements in white liquor preparation .......................................................145
5.1 Nonprocess elements in recausticizing..............................................................................145
5.2 Nonprocess elements in lime reburning.............................................................................147
5.3 Reducing NPE in the lime cycle .........................................................................................149
6 Future challenges ............................................................................................................150
7 Green liquor treatment ....................................................................................................150
7.1 Separation of solid impurities .............................................................................................151
7.1.1 Clarification ............................................................................................................152
7.1.2 Filtration .................................................................................................................154
7.2 Green liquor cooling ...........................................................................................................157
7.3 Dregs handling ...................................................................................................................158
7.3.1 Dregs washer clarifier ............................................................................................158
7.3.2 Vacuum precoat filtration .......................................................................................158
7.3.3 Pressure disc precoat filtration ..............................................................................159
7.3.4 Chamber filter press filtration.................................................................................159
8 Recausticizing ..................................................................................................................161
8.1 General...............................................................................................................................161
8.2 Process ..............................................................................................................................161
8.2.1 Slaking ...................................................................................................................162
8.2.2 Causticizer train .....................................................................................................164
8.2.3 White liquor separation ..........................................................................................165
8.2.4 Storage tanks for white liquor and weak white liquor ............................................170
8.2.5 Lime mud dewatering ............................................................................................170
8.2.6 Modifications of white liquor...................................................................................172
8.3 Automation .........................................................................................................................174
8.3.1 Process requirements............................................................................................174
8.4 Field instrumentation..........................................................................................................174
8.5 Process controls.................................................................................................................175
8.5.1 Manual control .......................................................................................................175
8.5.2 Conductivity measurement and control .................................................................175
"Chemical Pulping"
And
8.5.3 Automatic process titrator and control ...................................................................176
8.5.4 Temperature difference control..............................................................................178

8.5.5 Fuzzy control..........................................................................................................178
9 Lime reburning .................................................................................................................178
9.1 Lime reburning process and equipment selection .............................................................179
9.1.1 Mechanical dewatering ..........................................................................................180
9.1.2 Lime reburning process in the kiln .........................................................................181
9.1.3 Brick lining..............................................................................................................183
9.1.4 Firing equipment ....................................................................................................184
9.1.5 Dust handling .........................................................................................................185
9.1.6 Scrubber ................................................................................................................185
9.2 Limestone burning..............................................................................................................186
9.2.1 Limestone quality...................................................................................................187
9.3 Material heat and balance..................................................................................................187
9.3.1 Factors influencing heat balance ...........................................................................188
9.4 Combustion ........................................................................................................................190
9.4.1 Fuel oil and natural gas .........................................................................................191
9.4.2 Noncondensible gases (NCG) ...............................................................................191
9.4.3 Tall oil and methanol..............................................................................................192
9.4.4 Wood waste and other solid fuels..........................................................................193
9.5 Emissions ...........................................................................................................................193
9.5.1 Formation of SO2, TRS, CO, particulate, and Nox................................................194
9.5.2 Emission control ....................................................................................................195
9.6 Automation of rotating kiln..................................................................................................196
9.6.1 Lime kiln field instrumentation ...............................................................................196
9.6.2 Lime kiln control .....................................................................................................198
9.7 Maintenance.......................................................................................................................199
References .........................................................................................................................201
Chapter 15 - Combustion of bark
1 Introduction ......................................................................................................................205
1.1 Operating principle of steam boilers ..................................................................................205
1.2 Cogeneration steam cycles................................................................................................207
2 Physical and chemical properties of fuels ....................................................................208
2.1 Fuels and their composition ...............................................................................................208
2.2 General terminology and properties of fuels ......................................................................208
2.3 Bark, wood, and hog fuel ...................................................................................................212
3 Calculation of combustion ..............................................................................................214
3.1 Combustion reactions ........................................................................................................214
3.2 Combustion air demand .....................................................................................................215
3.3 Flue gas composition .........................................................................................................217
3.4 Adiabatic temperature of combustion ................................................................................219
3.5 Emissions from combustion ...............................................................................................220
3.6 Heat transfer properties of flue gases................................................................................223
4 Combustion technologies of bark ..................................................................................224
4.1 Grate firing..........................................................................................................................224
4.2 Introduction to fluidized bed combustion............................................................................227
4.3 Bubbling fluidized bed (BFB) combustion ..........................................................................231
4.4 Circulating fluidized bed (CFB) combustion.......................................................................233
4.5 Environmental aspects of fluidized bed combustion ..........................................................237
4.6 Gasification.........................................................................................................................239
"Chemical Pulping"
And
5 Boiler processes ..............................................................................................................241
5.1 Handling of bark .................................................................................................................241

5.2 Handling of auxiliary fuels ..................................................................................................242
5.3 Air and flue gas circuit, fans ...............................................................................................245
5.4 Dust separation methods for flue gas cleaning..................................................................252
5.5 Feed water pumping ..........................................................................................................255
5.6 Water-steam circuit ............................................................................................................262
5.7 Main controls of boilers ......................................................................................................266
6 Structure and design of boiler heat exchangers ..........................................................268
6.1 Introduction.........................................................................................................................268
6.2 Corrosion of heat delivery surfaces ...................................................................................269
6.3 Furnace tubes ....................................................................................................................271
6.4 Superheaters......................................................................................................................272
6.5 Economizers (feed water preheaters)................................................................................274
6.6 Air preheaters.....................................................................................................................275
6.7 Cleaning of heat delivery surfaces.....................................................................................277
6.8 Thermodynamic design of heat exchangers ......................................................................281
7 Boiler efficiency and losses............................................................................................289
7.1 Determining efficiency with the direct method ...................................................................289
7.2 Determining efficiency with the indirect method.................................................................293
References .........................................................................................................................301
Chapter 16 - Heat and power co-generation
1 Introduction ......................................................................................................................303
2 Heat and power demand in pulp and paper manufacturing ........................................303
3 Heat and power demand of chemical pulp mills...........................................................305
3.1 Wood yard ..........................................................................................................................306
3.2 Cooking ..............................................................................................................................306
3.3 Washing and screening......................................................................................................306
3.4 Bleaching............................................................................................................................307
3.5 Bleach stock cleaning ........................................................................................................307
3.6 Drying machine ..................................................................................................................307
3.7 Evaporation ........................................................................................................................308
3.8 Recovery boiler ..................................................................................................................309
3.9 Causticizing and lime kiln...................................................................................................311
3.10 Bleaching chemicals preparation .......................................................................................311
3.11 Water and effluent..............................................................................................................312
3.12 Power boiler .......................................................................................................................312
3.13 Steam turbines and water cooling......................................................................................312
3.14 Other ...............................................................................................................................314
4 Heat and power balance of chemical pulp mill .............................................................314
4.1 Installed power vs. demand ...............................................................................................314
4.2 Heat generation..................................................................................................................315
4.3 Heat and power balance ....................................................................................................318
4.4 Steam turbines ...................................................................................................................318
4.5 Back pressure power process............................................................................................322
4.6 Co-generation alternatives .................................................................................................326
5 Paper mills ........................................................................................................................329
5.1 Heat and power balance of newsprint production..............................................................330
5.2 Heat and power generation in SC and LWC production....................................................331
"Chemical Pulping"
And
6 Time dependent variation in power demand.................................................................333
6.1 Variations in energy production .........................................................................................334

6.1.1 Variations in power demand in industry.................................................................335
6.1.2 Power balance drawings........................................................................................335
Chapter 17 - Secondary heat systems and pinch technology
1 Introduction ......................................................................................................................337
2 Secondary heat ................................................................................................................337
2.1 Definition of secondary heat...............................................................................................337
2.2 Secondary heat production in the pulp mill ........................................................................338
2.2.1 Continuous cooking ...............................................................................................338
2.2.2 Displacement batch cooking..................................................................................340
2.2.3 Conventional batch cooking...................................................................................341
2.2.4 Warm water production from surface condenser...................................................343
2.2.5 Secondary condensates from evaporation ............................................................344
2.2.6 Secondary heat production of hot water from drying machine ..............................347
2.2.7 Lime kiln flue gas scrubber ....................................................................................347
2.2.8 Production of hot water from drying machine ........................................................347
2.2.9 Other secondary heat sources in pulp mill ............................................................349
2.3 Secondary heat consumption.............................................................................................350
2.4 Optimizing of secondary heat system ................................................................................351
2.4.1 Optimizing of warm water production ....................................................................351
2.4.2 Optimizing hot water production ............................................................................352
2.5 Mill wide secondary system ...............................................................................................355
2.5.1 Design considerations ...........................................................................................355
2.5.2 Water quality control ..............................................................................................355
2.5.3 Secondary heat system applications .....................................................................356
3 Process integration techniques .....................................................................................360
3.1 Basic principles of pinch technology ..................................................................................360
3.1.1 Composite curves ..................................................................................................360
3.1.2 Grand composite curve..........................................................................................364
3.1.3 Total site analysis ..................................................................................................366
3.1.4 Advantages and limitations....................................................................................368
3.2 Process integration using mathematical programming techniques ...................................368
3.2.1 Overview of techniques .........................................................................................369
3.2.2 Advantages and limitations....................................................................................370
3.3 Exergy analysis ..................................................................................................................371
References .........................................................................................................................373
Chapter 18 - Byproducts of chemical pulping
1 Turpentine.........................................................................................................................375
2 Soap and tall oil................................................................................................................378
2.1 Introduction.........................................................................................................................378
2.2 Chemistry ...........................................................................................................................378
2.2.1 General ..................................................................................................................378
2.2.2 Composition of tall oil.............................................................................................379
2.3 Soap recovery system design ............................................................................................379
2.3.1 Skimming and storage of soap ..............................................................................379
"Chemical Pulping"
And
2.3.2 Soap handling ....................................................................................................................381
2.4 Tall oil plant design ............................................................................................................382
2.4.1 Tall oil yield ............................................................................................................382

2.4.2 Design parameters ................................................................................................383
2.4.3 Selection of process ..............................................................................................383
2.4.4 Selection of equipment ..........................................................................................384
2.4.5 Tall oil handling and storage..................................................................................386
2.5 End use of tall oil products .................................................................................................386
2.5.1 Typical tall oil products ..........................................................................................386
2.5.2 Special tall oil products ..........................................................................................387
3 Other byproducts .............................................................................................................387
3.1 Byproducts from acidic pulping ..........................................................................................387
References .........................................................................................................................389
Chapter 19 - Preparation and handling of bleaching chemicals
1 Manufacture and handling of chlorine...........................................................................391

1.1 Preparation of chlorine caustic...........................................................................................392
1.2 Chlorine gas handling ........................................................................................................394
1.3 Handling of caustic soda ....................................................................................................396
2 Manufacture of hypochlorite...........................................................................................396
3 Generation and handling of chlorine dioxide................................................................396
3.1 Short chemistry ..................................................................................................................396
3.2 Generation systems ...........................................................................................................397
3.3 Safe handling of chlorine dioxide .......................................................................................402
4 Hydrogen peroxide ..........................................................................................................402
4.1 Manufacture of hydrogen peroxide ....................................................................................402
4.2 Peroxy acids.......................................................................................................................403
5 Oxygen ..............................................................................................................................404
5.1 Manufacture of oxygen.......................................................................................................404
5.2 Transportation and handling of oxygen..............................................................................405
6 Ozone ...............................................................................................................................406
6.1 Ozone manufacture............................................................................................................406
References .........................................................................................................................409
Chapter 20 - Organosolv pulping
1 Introduction ......................................................................................................................411
2 Organosolv pulping methods .........................................................................................411
3 Delignification chemistry in organosolv processes.....................................................412
4 Technical and economic demands on new processes ................................................413
5 Alcell ...............................................................................................................................414
6 Organocell.........................................................................................................................416
7 IDE ...............................................................................................................................418
8 ASAM ...............................................................................................................................418
9 Methanol-reinforced kraft pulping..................................................................................421
10 Acetosolv, Acetocell, and Formacell .............................................................................421
11 Milox ...............................................................................................................................423
12 Future of Organosolv processes....................................................................................425
References .........................................................................................................................427
"Chemical Pulping"
And
Chapter 21 - Process calculations and simulation
1 Simulation principles.......................................................................................................429
2 General structure of a simulator ....................................................................................430
3 Applications......................................................................................................................434
Chapter 22 - Closed cycle systems for manufacture of bleached chemical wood pulp
1 Introduction ......................................................................................................................441
2 The effluent-free mill........................................................................................................442
2.1 Concept ..............................................................................................................................442
2.2 The first commercial application.........................................................................................443
2.3 Lessons and projected requirements.................................................................................446
3 System aspects ................................................................................................................447
3.1 Basic technologies .............................................................................................................447
3.2 Water, chemical, and energy balances..............................................................................449
3.3 Nonprocess elements ........................................................................................................455
3.4 Economics..........................................................................................................................456
4 Mill-scale developments..................................................................................................457
4.1 Champion International Corporation, Canton Mill ..............................................................457
4.2 Louisiana-Pacific Corporation, Samoa Mill ........................................................................459
4.3 Union Camp Corporation, Franklin Mill ..............................................................................460
4.4 Modo, Husum Mill ..............................................................................................................461
4.5 Munksjö Ab, Aspa Bruk Mill ...............................................................................................462
4.6 Södra Cell, Värö Mill ..........................................................................................................463
4.7 SCA, Östrand Mill...............................................................................................................463
4.8 Metsä-Rauma, Rauma Mill.................................................................................................463
5 Relevant technologies under development...................................................................464
6 Minimum impact mill concepts.......................................................................................465
References .........................................................................................................................469

"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm

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"Chemical Pulping" Edited by Johan Gullichsen and Carl-Johan Fogelholm

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"Chemical Pulping"

Edited by Johan Gullichsen

Item Number: 0202FIN06

Chapter 2 - Fiber line operations

1 Principles of wood chip delignification ...........................................................................19

Chapter 3 - Chemical engineering principles of fiber line operations

1 Physics and fluid mechanics ..........................................................................................245

Chapter 4 - Wood handling applications

1 Measuring, storing, and pretreatment of roundwood ..................................................331

Chapter 5 - Batch cooking applications

1 Principles of displacement batch cooking ....................................................................494

Chapter 6 - Continuous cooking applications

Chapter 7 - Pulp washing applications

1 The atmospheric diffuser ................................................................................................573

Chapter 8 - Pulp screening applications

1 Knot screening .................................................................................................................619

Chapter 9 - Bleaching applications

1 Equipment used in bleaching systems..........................................................................617

Chapter 10 - Pulp drying applications

1 Drying machine wet end..................................................................................................667

1 Overview of kraft recovery ..................................................................................................7

Chapter 12 - Evaporation of black liquor

4.3 Concentrators (first effect evaporators) ...............................................................................50

Chapter 13 - Recovery boiler

1 Evolution of recovery boiler design.................................................................................96

3.5 Combustion of black liquor droplet in the furnace..............................................................113

Chapter 14 - White liquor preparation

8.5.4 Temperature difference control..............................................................................178

Chapter 15 - Combustion of bark

5.1 Handling of bark .................................................................................................................241

Chapter 16 - Heat and power co-generation

6.1 Variations in energy production .........................................................................................334

Chapter 17 - Secondary heat systems and pinch technology

Chapter 18 - Byproducts of chemical pulping

2.4.1 Tall oil yield ............................................................................................................382

Chapter 19 - Preparation and handling of bleaching chemicals

1 Manufacture and handling of chlorine...........................................................................391

Chapter 20 - Organosolv pulping

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