Biermann Ch. Handbook of Pulping and Papermaking
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-Handbook
of.
PULPING
AND
PAPERMAKING
SECOND EDITION
This Page Intentionally Left Blank
Handbook
of.
PULPING
AND
PAPERMAKIM
SECOND EDITION
Christopher
J.
Biermann
DEPARTMENT OF FOREST PRODUCTS AND
CENTER FOR ADVANCED MATERIALS RESEARCH
OREGON STATE UNIVERSITY
CORVALLIS. OREGON
ACADEMIC PRESS
An
Imprint
of Elsevier
Cover photo: Working model of Louis Robert's papermaking machine at the Science
Museum, South Kensington. Reproduced with permission of
the
the Trustees of
the
Science Museum (Neg. No. 1013/52).
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Copyright © 1996 by ACADEMIC PRESS
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Academic Press
An
Imprint
of Elsevier
525 B Street, Suite 1900, San Diego, California 92101-4495
United Kingdom
Edition
published by
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Library of Congress Cataloging-in-Publication Data
Biermann, Christopher J.
Handbook of pulping and papermaking / by Christopher
J.
Biermann,
- 2nded.
p.
cm.
Includes indexes.
ISBN -13: 978-0-12-097362-0
ISBN -10:
0-12-097362-6
1.
Wood-pulp. 2. Papermaking. L Title.
TS1175.B54 1996 96-20451
676-dc20 CIP
PRINTED IN THE UNITED STATES OF AMERICA
05 06 07 08 / 9 8 7 6
CONTENTS
Preface to the Second Edition ix
Preface to the First Edition x
Acimowledgments xi
Abbreviations xiii
List of Color Plates xv
1 Introduction and the Literature
1.1 Introduction to Papermaking 1
1.2 Introduction to the Literature .... 3
1.3 Abstract Indices 6
1.4 Technical and Trade Journals .... 6
1.5 Reference Books 8
1.6 Textbooks 8
1.7 Chemistry Reference Books .... 10
1.8 Other References 10
1.9 Annotated Bibliography 10
Exercises 11
2 Wood and Fiber Fundamentals
2.1 Wood and Bark 13
2.2 Wood Chips and Sawdust ..... 21
2.3 Wood Chip Preparation and Handling
at the Pulp Mill 22
2.4 SoHd Wood Measurement 30
2.5 Wood Chip Measurement 31
2.6 Wood Chemistry 32
2.7 Wood and Fiber Physics 40
2.8 Properties of Selected Wood Species 42
2.9 Nonwood and Recycled Fiber
Considerations 42
2.10 Annotated Bibliography 50
Exercises 53
3 Pulping Fundamentals
3.1 Introduction to Pulping 55
3.2 Mechanical Pulping 62
3.3 Chemi-mechanical Pulping 69
3.4 Related Pulping Methods 70
3.5 Semi-Chemical Pulping 71
3.6 General Chemical Pulping 72
3.7 Soda Pulping 86
3.8 Kraft Pulping 86
3.9 Sulfite Pulping 91
3.10 Other Pulping Methods 96
3.11 Market Pulp 97
3.12 Annotated Bibliography 97
Exercises 100
4 Kraft Spent Liquor Recovery
4.1 Chemical Recovery 101
4.2 Pulp Washing 101
4.3 Liquor Evaporation 103
4.4 Recovery Boiler 107
4.5 Cooking Liquor Regeneration—The
Causticizing Process 112
4.6 Annotated Bibliography 118
Exercises 121
5 Pulp Bleaching
5.1 Introduction 123
5.2 Bleaching Mechanical Pulps ... 123
5.3 Measurement of Lignin Content . 124
5.4 Bleaching Chemical Pulps .... 127
5.5 Annotated Bibliography 134
Exercises 136
6 Refining and Pulp Characterization
6.1 Introduction to Refining 137
6.2 Refining 142
6.3 Pulp Characterization 149
6.4 Pulp Properties versus Performance 153
6.5 Annotated Bibliography 154
Exercises 157
7 Paper and Its Properties
7.1 Introduction 158
7.2 General Grades of Paper 158
7.3 Specific Types of Paper 160
7.4 Basic Paper Properties 163
7.5 Physical Properties of Paper ... 165
7.6 Mechanical Properties of Paper . 174
7.7 Chemical Analysis of Paper ... 182
7.8 Basic
Optical Tests
of Paper ... 185
7.9 Sheet Splitting of Paper 187
7.10 Annotated Bibliography 188
Exercises 189
8 Stock Preparation and Additives for
Papermaking
8.1 Introduction 190
8.2 Fiber Preparation and Approach . 191
8.3 Raw Materials 193
8.4 Functional Additives 194
8.5 Control Additives 201
8.6 Wet End Chemistry 205
8.7 Annotated Bibliography 206
Exercises 208
VI
CONTENTS
9 Paper Manufacture
9.1 Introduction 209
9.2 The Paper Machine 209
9.3 The Headbox 211
9.4 The Fourdrinier Wet End .... 214
9.5 Twin Wire Formers 230
9.6 The Cylinder Machine 234
9.7 The Press Section 235
9.8 The Dryer Section 240
9.9 Post Drying Operations 245
9.10 Paper Machine Broke System .. 251
9.11 Conversion 252
9.12 Coating 254
9.13 Annotated Bibliography 258
Exercises 262
10 Fiber from Recycled Paper
10.1 Introduction 263
10.2 Recycled Fiber Preparation .... 263
10.3 Recycled Fiber Recovery 266
10.4 Annotated Bibliography 279
Exercises 282
11 Enviromnental Impact
11.1 Introduction 283
11.2 Water Pollution 284
11.3 Water Quality Tests 285
11.4 Aqueous Effluent Treatments . . 287
11.5 Air Pollution 290
11.6 Air Quality Tests and Control . . 290
11.7 Solid Waste Disposal 293
11.8 U.S. Regulations 294
11.9 Annotated Bibliography 295
Exercises 296
12 Metric and English Units and Unit Analysis
12.1 Metric Units 297
12.2 English and Metric Units 297
12.3 Unit Analysis 308
Exercises 311
13 Introductory Chemistry Review
13.1 The Elements 312
13.2 Ionic and Covalent Bonds .... 314
13.3 Hydrogen Bonding 315
13.4 The Mole and Mass Percentage . 316
13.5 Equivalency, Molarity, and
Normality 317
13.6 Acids, Bases, and the pH Scale . 318
13.7 The Law of Mass Action 323
13.8 Solubility Products 324
13.9 Oxidation-Reduction Reactions . 326
13.10 Electrochemistry 327
13.11 Practical Aspects of
Electrochemistry 330
13.12 Properties of Gases 331
13.13 Annotated Bibliography 333
Exercises 333
14 Analytical and Coordinate Chemistry
14.1 Strong Acid—Strong Base Titrations 335
14.2 pH Properties of Weak Acid-
Conjugate Base Pairs ....... 336
14.3 pH Indicators 337
14.4 Titration of a Weak Acid with a
Strong Base or Weak Base with a
Strong Acid 338
14.5 Reduction-Oxidation Titrations 339
14.6 Colorimetric Analysis 342
14.7 Coordinate Chemistry 343
14.8 Miscellaneous Considerations . . 346
14.9 Annotated Bibliography 346
Exercises 347
15 Calculations of Wood, Paper, and Other
Materials
15.1 Wood Moisture Content and Density 348
15.2 Pulpwood Measurement 351
15.3 Tensile Strength and Breaking Length
of Materials 352
15.4 Paper Properties 354
Exercises 357
16 Pulping Calculations
16.1 General Chemical Pulping
Definitions 359
16.2 Kraft Liquor—Chemical
Calculations 359
16.3 Kraft Liquor—Chemical Analysis 363
16.4 Specific Gravity and Viscosity of
Kraft Liquors 367
16.5 Importance of Black Liquor pH . 368
16.6 Kraft H-Factor and Other Process
Control Equations 368
16.7 Sulfite Liquor Calculations .... 372
16.8 Sulfite Liquor Analysis 375
16.9 The Chemistry of Sulfiir 376
16.10 Calcining Equations 377
16.11 Annotated Bibliography 377
Exercises 378
17 Bleaching and Pulp Properties Calculations
17.1 Dilution Water Calculations ... 379
17.2 Chlorine Bleaching 379
CONTENTS
Vll
17.3 Chlorine Dioxide 381
17.4 Chemical Analysis of Bleaching
Liquors and Chlorine Equivalency 381
17.5 CSF Correction Equations .... 385
17.6 Computer Simulation of Fiber
Cleaning Systems 385
17.7 Paper Machine Calculations . . . 386
17.8 Properties of Dilute Pulp Slurries,
Flocculation 390
17.9 Strength of Wet Fiber Mats ... 390
17.10 Fiber Physics 392
17.11 Annotated Bibliography 392
Exercises 393
18 Polymer Chemistry
18.1 Introduction and Types of Polymers 395
18.2 Addition Polymers 396
18.3 Condensation Polymers ...... 398
18.4 Molecular Weights of Polymers . 399
Exercises 402
19 Carbohydrate Chemistry
19.1 Introduction . . '. 403
19.2 Nomenclature 403
19.3 Forms of Monosaccharides .... 403
19.4 Selected Reactions of Carbohydrates 406
Exercises 410
20 Total Quality Management
20.1 Introduction to TQM and SPC ... 411
20.2 Statistical Process (Quality) Control,
SPC,
SQC 413
20.3 Statistical Process Control Tools 415
20.4 Implementing TQC and SPC ... 417
20.5 Miscellaneous Topics 418
20.6 Equations 419
20.7 Annotated Bibliography 419
Exercises 419
Appendix—Generating Random Data
with a Normal Distribution . . . 420
21 Colloid and Surface Chemistry
21.1 Introduction 421
21.2 Colloid Chemistry 421
21.3 Polyelectrolytes 429
21.4 Surface Tension and Sizing .... 429
21.5 Surfactants 431
21.6 Foam 434
21.7 Emulsions 435
21.8 Light Scattering by Colloids .... 435
21.9 Annotated Bibliography 436
Exercises 437
Appendix 437
22 Papermaking Chemistry
22.1 Introduction 438
22.2 Polymeric Additives 440
22.3 Colloid Chemistry 442
22.4 Retention, Formation, and Drainage 443
22.5 Internal Sizing 449
22.6 Wet and Dry Strength 451
22.7 Monitoring Wet End Chemistry . . 453
22.8 Papermaking Chemistry Control . . 457
22.9 Other Considerations 458
22.10 Annotated Bibliography 459
Exercises 462
23 Printing and the Grapic Arts
23.1 Introduction 463
23.2 Letterpress 464
23.3 Lithography 464
23.4 Gravure 467
23.5 Screen Printing 468
23.6 Other Printing Methods 468
23.7 Halftone Printing 469
23.8 Color Printing 470
23.9 Common Aspects of Printing . . . 473
23.10 Ink and Ink Application 473
23.11 Paper Properties and Printing ... 475
23.12 Specific Products 477
23.13 Computers and Printing 478
23.14 Bindery Operations 480
23.15 Annotated Bibliography 483
Exercises 486
Appendix 486
24 Optical Properties of Paper
24.1 Introduction 487
24.2 Behavior of Light Rays 488
24.3 Color 489
24.4 Tristimulus Systems 494
24.5 Blackbody Radiation and Other Light
Sources 500
24.6 Kubelka-Munk Theory 502
24.7 Annotated Bibliography 508
Exercises 512
Appendix . 513
25 Wood and Fiber—Grov^th and Anatomy
25.1 Introduction 516
25.2 Sample Preparation for Identification
or Microscopy 529
25.3 Wood Variation 532
25.4 Silviculture and Wood Quality ... 534
25.5 Annotated Bibliography 537
Exercises 540
VIU
CONTENTS
26 Softwood Anatomy
26.1 Gross Anatomy of Softwoods ... 541
26.2 Microscopic Anatomy of Softwoods 543
26.3 Anatomy of Softwood Species . . . 549
26.4 Non-American Species 581
27 Hardwood Anatomy
27.1 Gross Anatomy of Hardwoods . . . 583
27.2 Microscopic Anatomy of Hardwoods 586
27.3 Anatomy of Hardwood Species . . 589
28 Wood Fiber Anatomy and IdentiHcation
28.1 Fiber Analysis 628
28.2 Softwood Fiber 629
28.3 Hardwood Fiber 631
29 Nonwood Fiber Use in Pulp and Paper
29.1 Introduction 633
29.2 Pulping Methods for Nonwood
Fibers 635
29.3 Considerations for Nonwood Fiber
Use 637
29.4 Other Fiber Types 639
29.5 Annotated Bibliography 639
30 Hydraulics
30.1 Flow of Liquids 641
30.2 Pump Basics 641
30.3 Positive Displacement Pumps . . . 642
30.4 Centriftigal (Dynamic) Pumps . . . 644
30.5 Valves 648
30.6 Hydraulic Power Systems 655
30.7 Troubleshooting Hydraulic Power
Systems 659
30.8 Annotated Bibliography 660
31 Process Control
31.1 Introduction 663
31.2 Sensors 663
31.3 Temperature Sensors ........ 664
31.4 Mechanical Sensors 665
31.5 Controllers 668
31.6 Actuators 670
31.7 Annotated Bibliography 670
32 Corrugated Containers
32.1 Introduction 671
32.2 Manufacture 672
32.3 Test Methods 674
32.4 Annotated Bibliograhy 676
33 Miscellaneous Topics
33.1 Viscosity and Surface Tension of
Water from 0 to 100°C 678
33.2 Vapor Pressure of Water from 0
to 280°C 679
33.3 Properties of
Air
and Water 680
33.4 Water Conditioning 680
33.5 Boiler Feedwater Treatment .... 683
33.6 Corrosion 685
33.7 Safety Practices for Hazardous
Chemicals 686
33.8 Transportation Safety 687
33.9 Operations Management 690
33.10 Process Simulation 690
33.11 Superabsorbency 692
33.12 Bearings 692
33.13 Electric Circuit Symbols 694
33.14 Annotated Bibliography 694
Appendix 697
34 Updates and Bibliography
34.1 General Pulp and Paper 698
34.2 Wood 699
34.3 Roundwood Properties 700
34.4 Wood Chemistry 701
34.5 Recycling and Secondary Fiber . . 702
34.6 Properties of Pulps 705
34.7 Mechanical Pulping 705
34.8 Chemical Pulping 706
34.9 Kraft Recovery 707
34.10 Bleaching 709
34.11 Fiber Physics and Preparation ... 710
34.12 Papermaking 712
34.13 Paper 713
34.14 Coating and Converting 713
34.15 Flexible Packaging 716
34.16 Environmental 716
34.17 Miscellaneous Topics 717
34.18 Testing Methods 718
Answers to Selected Problems 721
Author Index 733
Subject Index 741
PREFACE TO THE SECOND EDITION
The first edition of this book, under the title
of Essentials of Pulping and Papermaking, was
designed primarily as a teaching tool, but also
found wide use by industry as a current source of
information. The second edition of this work
keeps the first 20 chapters with only minor alter-
ations. In order to increase the dual use of this
work, it has been expanded to include key areas of
paper chemistry and optical properties, wood and
fiber anatomy, paper use, and processing equip-
ment, including a useful pump troubleshooting
guide. The comprehensive nature of the work
now merits the modified title of Handbook of
Pulping
and
Papermaking.
The first eleven chapters of this book are
introductory in nature for beginning students and
workers in the field who desire some knowledge
of the entire mill. The remainder of the book
provides detailed information on topics central to
the production and use of paper. Throughout,
numerous references lead the reader to further
information.
Several areas, such as pulp bleaching, envi-
ronmental issues, and papermaking chemistry, are
changing so rapidly that the reader will need to
consult current journals to stay abreast of these
fields. Nevertheless, this work provides the back-
ground and context for the improvements the
industry is realizing in these areas.
I am grateful for the help of many people
who provided information and figures and who
reviewed portions of the manuscript. The Infor-
mation on clay was supplied by F. Camp Bacon,
Jr.
of Evans Clay Co., Stuart Pittman of Thiele
Kaolin Co., Robert F. Hurst of Huber Clay, and
John A. Manasso of Dry Branch Kaolin Co.
Mankui Chen provided material on transpor-
tation safety. R.L. Krahmer and A.C. VanVliet
provided most of the macroscopic cross section
photographs of woods in Chapters 26 and 27.
Gary Vosler of Willamette Industries re-
viewed the section on corrugated containers. Fred
Green and Carter P. Hydrick of Keystone Interna-
tional, Inc. provided information and figures on
valves. Kelly Lacey provided the figure of a
progressing cavity pump.
Todd Chase reviewed material for clarity.
Reviews of selected material were provided by
Kevin Hodgson and Richard Gustafson, both of
the University of Washington, and Mahendra
Doshi of Doshi and Associates, although the
author is solely responsible for any deficiencies in
the text.
IX