Karnaphuli Paper Mills Ltd

Chittagong Urea Fertilizer Factory Ltd

Usmania Glass Sheet Factory Ltd
TSP Complex
Rubber Garden Factory, Ramu
Karnaphuli Paper Mills Ltd
• Established in the year 1951 by the Pakistan Industrial
Development Corporation (PIDC)

• The factory went into production in 1953 with an

installed capacity of 30,000 tons of paper per year.

• It produces 30,000 MT of writing, printing and

wrapping paper annually using 70% bamboo and 30%
tropical hard wood as its principal raw materials.

• It has a complete chemical recovery plant. It is an

enterprise of Bangladesh Chemical Industries
Corporation (BCIC).
Raw Materials
Fibrous Material
1. Bamboo (Muli, Baria, Mittinga etc)
2. Pulp Grade Wood (Acacia, Rain Tree etc)
3. Foreign Pulp.
4. Recycled paper “Broke”.
Raw Material Collection
Chipping House

Cutting of selected pulp wood logs and beaten

bamboos into standard size as mentioned 1/2
inch to maximum 5/4 inch (18 mm to25mm)
by means of machines known as
“Chippers”

Why “chipping”?

“Cooking liquor may penetrate”

Chip Cleaner Chip Crushing

Rechipper

Chip Conveyors

Weighing and Sampling

Chip Bins
Chip Driers
Pulp Mill

Pulp is the suspension of cellulose fibers in

water
Softwood
grown in cold climates
longer fibers

Hardwood
grown in tropical climates
shorter fibers
• Cellulose Fiber

Molecular structure of cellulose

Hemicelluloses
A constituent of woods that is, like cellulose, a
polysaccharide, but less complex and easily hydrolysable.
Holocellulose
The total carbohydrate fraction of wood
Hemicelluloses +cellulose → holocellulose
Lignin
A complex constituent of the wood that cements the cellulose
fibers together. Lignin is brown in color.
Holocellulose +lignin → extractive free wood
Extractives
Alpha Cellulose
will not dissolve in 17.5% NaOH (Sodium Hydroxide)
solution at 20oC.
Bark
Delignification and pulping
Kraft Process
Kraft liquors (Cooking liquor) contain,
• Sodium Hydroxide (NaOH
• Sodium Carbonate (Na2CO3),
• Sodium Sulfide (Na2S).

Sodium Sulfide hydrolyzes in water according to the

equation:
Na2S + H2O = NaOH + NaHS

In Kraft pulping, alkali can be expressed as either

• active alkali (NaOH + Na2S) or
• effective alkali (NaOH + ½ Na2S).
• Liquor-to-wood ratio
• Chemical charge on wood
• Alkali concentration in the liquor.
Defiberation (Fiberization) of sulfate pulp
After digestion the contents are discharged
into ‘blow tank’
Washing and Screening of Unbleached Pulp
• Separation of the cooked chips into individual fibers.
• Removal of soluble solids from these fibers.
• Elimination of particles of uncooked wood and of nonfibrous
impurities.
Bleaching
Chlorination washing Alkali Extraction washing
Hypo treatment Washing Alkali extraction
Washing Hypo treatment Bright pulp

Hypo treatment is done with Ca(OCl)2

Reaction with lignin & Cl2
Substitution:
Lig-H + Cl2 Lig-Cl + HCl

Oxidation:
Lig-H + Cl2 + H2O Lig-OH + 2HCl

Addition:
Lig-CH = CH-Lig + Cl2 + H2O Lig-CHCl-CHOH-Lig + HCl
Recovery of chemical from alkaline cooking liquor
( Black Liquor)
sodium carbonate and sodium sulfide
SR Boiler

Na2SO4 + 2C → Na2S + 2CO

Paper House
• Stock Preparation
Pulp Preparation
Refining
• (Cellulose-Hemicellulose) ……..micro fibril
• (Micro fibril) n…………………..fibril
• (Fibril)……………………………fiber
Machineries
Principally of two types as follows
1. Conical refiner
- Wide angle refiner
- Narrow angle refiner
2. Disc refiner
-double disc refiner (DDR)
- Tri disc refiner (TDR
Figure: Beater; it is replaced by refiner
Figure: Conical refiner
double disc refiner (DDR)
White water
Filler.
Sizing agent.
Coloring agent.
Strength additives.
Dry strength additives.
Wet strength additives.

Control additives are those are used to affect the performance of the
stock at the wet end of the paper machine. Examples are as follows:
Retention aids
Inorganic salts.
Organic polyelectrolyte

Defoaming Agent.
Stimicides & bactericides.
Pitch control agents.
Figure : Head Box or Flow Box or Breast Box
Figure : Fourdrinier machine
Figure :Suction Box (Vacuum Box)
Figure : Dandy Roll with Pan
Figure :Couch roll
Figure : Dryer
Cutting Section
1. Simplex cutter
2. Duplex cutter.
Finishing Section
White printing paper:
White cartridge paper: (115gsm)
Duplication paper: (70gsm)
Paper Converting Section
Brown papers are converted into various end
products as follows:
• Bitumen paper.
• Cartoon paper or Corrugated paper board.
• Gum paper.
• Cement bag.
• Paper bag.
Triple wall
Utility services

Water Treatment plant of Karnaphuli Paper Mills LTD.

 STEAM GENERATION AND POWER HOUSE
John Thomson Boiler

1. Boiler feed water conditioning

2. Boiler and steam generation
3. Turbine generator and electricity
4. Steam distribution, condensate collection
and cooling
CAUSTIC CHLORINE PLANT
– Caustic soda
– Chlorine
– HCl
– Alum
Non-Fibrous materials
1. Caustic Soda
2. Sodium Sulphate
3. Paper Maker’s Alum, Al2 (SO4)3.14H2O
4. Bleaching Agent (Elemental Chlorine, Hypo)
5. Sizing Agent (Natural & Synthetic)
6. Coloring Agent
7. Filling Agent (Talc, PCC, GCC, Clay)
Keep Yourself Safe