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Environmentally Friendly and Cost-Effective Method for Manufacturing Absorbent Grade Paper

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Environmentally Friendly and Cost-Effective Method for Manufacturing Absorbent Grade Paper CELLULOSE CHEMISTRY AND TECHNOLOGY ENVIRONMENTALLY FRIENDLY AND COST-EFFECTIVE METHOD FOR MANUFACTURING ABSORBENT GRADE PAPER DHARM DUTT Department of Paper Technology, Indian Institute of Technology Roorkee, Saharanpur campus, Saharanpur, 247 001, India Received August 13, 2012 Absorbent paper is characterized by some of its important specific properties like water klemn, castor oil penetration and wet strength. An absorbent grade pulp was manufactured from a mixture of Eucalyptus tereticornis and veneer waste of poplar (15:85) by three distinct processes: (a) delignification at high alkali dose and longer cooking time (at 170 °C), followed by enzyme treatment (method-I), (b) delignification under normal pulping conditions, followed by semi-bleaching (CEOP) (method-II), and (c) delignification under normal pulping conditions, followed by oxygen treatment (method-III). Method-I required 7.15 h for pulp processing and the cost of pulp was US$ 2481.72/digester. The cost of pulp produced by method-II was comparatively lower (US$ 2272.69/digester). However, it required a longer time (9.45 h) and was not environmentally benign because of generation of chloro-organic compounds. The pulp produced by method-III was environmentally friendly, required a cooking time of 12.45 h, and was also economical (US$1936.32/digester), compared to the other methods. Keywords: Eucalyptus tereticornis, veneer waste of poplar, pulping, semi-bleaching, oxygen delignification, cost effectiveness, absorbent grade paper INTRODUCTION Broadly, papers are classified into four efficiency, and dust holding capacity in beer, categories, namely writing and printing, coffee, beverage, and tea bag filter paper.9 packaging and wrapping, tissue papers, and Absorbent paper especially is a normal kraft, specialty papers. Specialty papers have certain hydrophilic, porous medium with a high degree of special properties above and beyond the basic water absorption. It is made of clean, low kappa properties shown by the three preceding grades. kraft pulp, and has to have a good uniformity. The Absorbent grade is a highly specialized paper due paper must have maximal unbound fiber surface to the introduction of certain special properties area, porosity, bulk, pore volume, wet strength, like uniform thickness, toughness, tear strength castor oil penetration value, and water klemn.10 and fire retardant in wax match paper,1 opacity However, softness is a subjective property, which and brightness in barrier paper,2 demarcation in depends on thickness (bulk), and flexibility, and top and bottom sides in padding paper,3 laying of can be induced by treating with plasticizers, such 25 µm thin copper film as a top layer in pictorial as diethylene glycol, polyethylene glycol or circuit board,4 fire retardant in dark brown dipropylene glycol.11 Normally, semi-bleached Turkish (DBTU) paper,5 ivory colour in ivory kraft pulp of permanganate number 10 with base paper,6 toxicity in seed germination paper,7 average COP (Castor Oil Penetration) value of 25 pore size and filtering rate in car and industrial s and water klemn of 27 mm is required for filter paper,8 resistance to flow, filtration unbleached absorbent kraft paper.10 Cellulose Chem. Technol., 47 (9-10), 783-792 (2013) DHARM DUTT In order to survive in a competitive washed unbleached pulp was subjected to chlorination international market in the midst of tough using 5% molecular Cl2 at ambient temperature, 3% competition owing to imports, the Indian pulp and consistency, pH 2.6±1 and a retention time of 60 min. paper industry has been compelled to enhance The chlorolignin formed in the pulp during the product quality and reduce costs. The best option chlorination stage was extracted during the alkali extraction stage, using 3.6% NaOH (as such) is therefore to bring down the production cost by reinforced with 1% H2O2 and 0.45% O2 at 10% augmenting in-house research and development consistency, initial pH 11.5, end pH 10.5, temperature activities. Indian pulp and paper industries 70 °C and retention time 120 min. manufacture absorbent kraft paper by the semi- In the 3rd set, blended wood chips were digested bleaching process. This method is not and delignified pulp was washed as per method environmentally benign due to generation of described in the 2nd set of experiments. Further, the adsorable organic halides. Against this unbleached pulp was subjected to extended background, two more methods were developed delignification with 1.8% O2, 2% NaOH (as such) and 0.5% MgSO4 at a consistency of 11%, temperature of for the production of absorbent grade pulp in st laboratory and followed by plant trials. The 65-70 °C during the I stage and 90-100 °C during the IInd stage, a retention time of 30 min during the Ist stage absorbent grade pulps produced by three distinct and 60 min during IInd stage, a pressure of 7.5 kg/cm2 methods were studied as to total pulp production during the Ist stage and 3.5 kg/cm2 during the IInd stage cost and time required per digester, pollution load and end pH 10.4 to 10.8. generated and paper properties. In all the three cases, the pulps were washed and passed through a fine screen (Voith, GmbH EXPERIMENTAL [Germany]) to separate shives and slivers. The pulp Pulping was evaluated for permanganate number (TAPPI T 214 The whole debarked Eucalyptus tereticornis logs su 71 “Permanganate number of pulp), brightness and veneer waste of poplar (Populus species) were (TAPPI T 452 om-02 “Brightness of pulp, paper, and disintegrated into chips using a Vecoplan Chipper paperboard [directional reflectance at 457 nm]”) and (Vecoplan LLC, High Point, North Carolina, USA). viscosity (TAPPI T 206 os-63 “Cupprammonium Screened chips of eucalyptus, and veneer waste of disperse viscosity of pulp”).12 poplar were blended in the ratio of 15:85. Mixed wood chips were digested in a cylindrical digester of 85 m3 Effluent analysis capacity (Larsen & Toubro) heated indirectly with The effluents generated during the three distinct medium pressure steam by the kraft pulping process, sets of experiments were analyzed for COD (IS 3025: using 20% active alkali (as Na2O), 18.95% sulphidity, Part 58 [1984] “Chemical oxygen demand”), 120 min time from ambient temperature to 162 °C suspended solids (IS 3025: Part 17 [1984] “Non- (max. temp.), 90 min time at max. temp., 7.5 kg/cm2 filterable residue [total suspended solids]”), dissolved digester pressure and 3:1 liquor to wood ratio. The solids (IS 3025: Part 16 [1984] “Filterable residue pulp was blown in a blow tank, screened through a [total dissolved solids]”), total solids (IS 3025: Part 15 knotter screen (Voith, GmbH [Germany]) and finally [1984] “Total residue [total solids - dissolved and washed through four stage counter current brown stock suspended]”), pH (IS 3025: Part 11 [1983] “pH washers (Dorr-Oliver, Ahlstrom model DD3040.3 value”), chlorides (IS 3025: Part 32 [1988] MCV). The pulp of brown stock washer number four “Chloride”)13 and AOX by column method14 with an was washed with condensate collected from the blow AOX Analyzer Dextar ECS 1200. tank and fresh water. The unbleached pulp was prebleached with xylanase enzyme (Advanced Pulp refining and sheet making Enzymes Co., Mumbai) at a dosing of 0.5 kg/MT of The pulp was refined in a double disk refiner pulp for a retention time of 60 min. Enzyme was added (Parason Machinery, India) at 3% consistency to get a in a drum washer where there was no need of adding Schopper–Riegler degree (0SR) of 27±1. The pulp was extra water. mixed with 1% melamine formaldehyde in order to Likewise, in another set of experiments, blended develop crosslinking and machine finished paper of wood chips were digested with 16% active alkali (as basis weight 70 g/m2 was manufactured on a paper Na2O), 18.95% sulphidity, 120 min time from ambient machine (Bentley and Jackson, England), having a temperature to 162 °C (max. temp.) and 75 min time at Fourdrinier wet end part equipped with table rolls and max. temp., while keeping the other conditions hydrofoils, bi-nip presses and steam dryer cylinders. constant, as mentioned above. The cooked pulp was The paper taken from the pope reel was conditioned at passed through a knotter screen and washed through a relative humidity of 65±2% and temperature of 25±1 four stage counter current brown stock washers. The °C and evaluated for grammage (T 410 om-02 784 Paper “Grammage of paper and paperboard [weight per unit hydrolysis (depolymerization) of the area]”), castor oil penetration (TAPPI T 462 om-01 polysaccharide chains occurred and was subjected “Castor-oil penetration test for paper”), wet strength to further degradation reactions (secondary (TAPPI T 456 om-03 “Tensile breaking strength of peeling).16,17 Further, a decrease in pulp yield was water-saturated paper and paperboard [wet tensile due to the release of lignin-carbohydrates strength]”), and water klemn (TAPPI T 432 cm-99 “Water absorbency of bibulous papers”).12 complexes (LCC) as a result of enzyme attack on the pulp, because reducing sugars would continue to be generated by xylanase hydrolysis of the soluble oligosaccharides. These oligosaccharides RESULTS AND DISCUSSION were released by the initial depolymerization of Table 1 reveals that the screened chips of E. 18 the xylan coating on the fiber surface. The tereticornis and the veneer waste of poplar, mixed bonds between carbohydrates and lignin would be in the ratio of 15:85, cooked at a high alkali dose partly cleaved by enzymes. In addition, Hortling (20% as Na O) and an increased cooking time 19 20 2 and Tamminen and Jääskeläinen et al. also (time at temperature 90 min), which was then reported a high yield of residual lignin in followed by an enzymatic treatment, produced a enzymatic isolation procedures.
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