Future Manufacturing Concept for deinking Saurabh Kumar, Benjamin Fabry, François Julien Saint Amand, Bruno Carré
PTS-CTP DEINKING SYMPOSIUM 12-14 May 2014 MUNICH GERMANY
Paper for recycling
CEPI 2012
High recycling rate 2
Paper for recycling
CEPI 2012
Recycled fibres average utilisation rate extremely variable: newsprint grade ~92%; graphic/fine papers ~10% Opportunity to optimise recycling & recycled fibre utilisation rate with NEW manufacturing concept(s)?
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Manufacturing concept
Old Magazine grade (OMG)
Old Newsprint grade (ONP)
Cellulose fibres Cellulose fines
Pulping
Screening & cleaning
Deinking
Thickening
Dispersing
Mineral fillers Reject
Is this “linear & full-stream” process the best adapted? Towards a rationalization of deinking lines through the implementation of dedicated treatments to specific pulp fraction 4
Future manufacturing concept! Towards a rationalization of deinking lines through the implementation of dedicated treatments to specific pulp fraction Pulping
Today: conventional materials
Future: layered materials, tailor made structure
Long fibres
Fines
Specific treatment
Specific treatment
Fractionation
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Future manufacturing concept! Towards a rationalization of deinking lines through the implementation of dedicated treatments to specific pulp fraction Pulping
4000
ERIC (ppm)
3000
Fractionation Fines
Specific treatment
Specific treatment
Long fibres
Fines selective separation important
50% ONP 50% OMG
Fines contain maximum ink
100% ONP
2000 1000 0 R 14
P14 R28
P28 R48
P48 R100
P100 R150
McNett fractions
P150 R200
P200
Kumar S 2012
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Objectives 2 objectives Deinking pulp
(1)
Fibres
(2)
Finer
Coarser
Separation by size (length)
Fines
Fibrils
Flakes
Dedicated treatment
Separation by Development (surface characteristics)
How to achieve selective fines separation ? How to further valorise the Fibre and fines?? 7
How to achieve using INDUSTRIAL equipment 1st step: Micro-hole (250µm) pressure screening
2nd step: Hydrocyclone • Developed, fibrillated , thin cell wall-fibres • Fibrillar fines Base fraction
Inlet
Accept Fines fraction
Reject
Fibres fraction
Micro-hole offers a high selectivity for fines separation into accepts (cf: Kumar S, PhD thesis 2012)
Apex fraction
• Coarse, undeveloped, thick cell-wall fibres, shives. • Low specific surface area fines-flakes
Presssure screening systems fractionate on the primarily basis of fibre length Hydrocyclones fractionate on the basis of fibre and fines development 8
Pilot plant trials Helico pulper Neutral conditions 45°C, 16% cy 75/25 OMG/ONP Micro-hole 250 µm 1st stage: 11 g/L, 0.3 m/s Vp 20% Rv, 56% Rm Flotation cell 300% air ratio
f1
2g/L – 50°C Rm: 48%
f2 F1
5g/L – 50°C Rm: 50% Vp: Passing velocity Rv: Volumetric reject rate Rm: Mass reject rate
F2 9
Results: Optical properties 45% ISO 1052 ppm 32% ash 62%ISO HW 82ppm HW 45.1% ISO 1255 ppm 57% ash
Very less ash content in the final fibre fractions. Brightness and ERIC of F1 & F2 fractions reaches that of Initial starting hyperwashed pulp ~68-70% ink removal index 56% ISO 406 ppm 38.5% ash
f1
54.6% ISO 450 ppm 42% ash
f2
56.8% ISO 318 ppm 32.5% ash
F1
Brightness on pulp pads without UV ERIC: effective residual ink concentration, ppm Ash content (in blue Hyperwashed pulp)
F2
62.3 %ISO 72 ppm 1.4% ash 62% ISO 102 ppm 1.7% ash 10
Results: Bauer McNett results (mass fraction) R28
20.5
R48 R100 R200 P200
12.4 8.8 5.8 52.5
R28
0.4
R48 R100 R200 P200
1.7 4.4 4.8 88.7
89% of fines in micro-hole accepts and very less short fibres Higher fines content in the hydrocyclone apex Fraction R28
0.5
R48 R100 R200 P200
3.5 8 10 78
f1
f2 F1
F2
R28
0.32
R48 R100 R200 P200
2.2 5.3 8 84.5
R28
0.6
R48 R100 R200 P200
3.8 11 12 72.6
R28
51
R48 R100 R200 P200
21 12 6.6 10.4
R28
47.4
R48 R100 R200 P200
25 14 7 6.6
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Results: Morphological fibre characteristics Short fibres in the Micro-hole accepts Higher fibre width in the hydrocyclone apex Fraction
1.12 mm 24.4 µm
0.48 mm 22.0 µm 0.47 mm 25.0 µm
Fibre length lw (mm) Fibre width (µm)
f1
0.48 mm 22.0 µm
f2
0.54 mm 24.3 µm
F1
1.23 mm 25.4 µm
F2
1.24 mm 26.8 µm 12
Results: Specks Micro-hole pressure screening allows to concentrate specks Which are further selectively concentrated in the F2 hydrocyclone fraction 2600mm²/m²
f1 2370mm²/m²
f2 F1
146mm²/m²
F2
2552mm²/m² 13
Results: Mass flow along pilot plant operations Fractionation deinking: limited flow to flotation cells and very less probability of long fibre removal by flotation 15 In 100 In 44 In
29 In
f1
15 In
f2
14 In
F1
28 In
F2
28 In
56 In The fines from the 2nd and 3rd stage (washing) were not floated/no loss was considered
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Fractionation-deinking flotation yield Different set of trials 75% OMG 25%ONP Hélico pulping
Flotation loss: 23.7% Ink removal efficiency: 83%
100gPulp 900ppm ERIC
2-stages of micro-hole pilot plant screening 3rd stage simulated 100gPulp 900ppm ERIC
st 1 1st
Lab flotation 200% air 7min flotation time
76.3gPulp 200ppm ERIC
Flotation loss: 39% Ink removal efficiency: 81.0%
Lab flotation Results of 1st stage applied to the addition of the 3 micro-hole accepts
77.4gPulp 234ppm ERIC
2nd 3rd 42gPulp 127ppm ERIC
Possible energy savings on fibre fraction (dispersing) Potential flotation benefits Slightly higher yield (flotation not optimised)
Can be a single screening unit of 3-stages
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Reminder: Future manufacturing concept! Towards a rationalization of deinking lines through the implementation of dedicated treatments to specific pulp fraction Pulping
Today: conventional materials
Long fibres
Fines
Specific treatment
Specific treatment
Fractionation
Future: layered materials, tailor made structure
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The Future manufacturing concept! Fractionation deinking and fractions productions Patent CTP (in process) : Bruno Carré et al.
S
Pulping
W
T
Surface layer DIP
T
Middle layer DIP
D
Ink splitter F F F
The economic advantages (options) simulated • 3 to 7% raw material saving (2 to 5 pts of yield), • 10 to 25% sludge reduction, • 15 to 30% energy saving.
leading to 8 to 20% running cost saving for a recovered paper price fixed at 100 €/t compared to 2 conventional 17 deinking loops
Principal conclusions Application to deinking: towards new process designs Production of fractions with dedicated treatments Ink containing (fines) and ink depleted (fibres) Dipersing fibre fraction only (50-75% energy savings if coupled with hydrocyclones) Fines flotation: no fibre losses (Work to be done to further improve this stage) A window for raw material & energy savings
Fractionation as a solution for tailoring paper properties Separation of fines with different properties through their differences in specific surface area Addition of different fines type in paper: increase in sheet mechanical properties with higher specific surface area and more fibrillated fines
A New Future manufacturing concept for DIP pulp has been proposed offering economic advantages and boosting competitiveness even if not stratified paper
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Thank you for your attention!
[email protected] The present research has been performed in the framework of the European project BoostEff European Community's 7th Framework Programme under Grant Agreement n°246059
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