BBE 4314/5314 Pulp and Paper Operations
II: Papermaking Processes and Process Engineering Laboratory (3
credits)
| Catalog Description: |
Theory/practice of design/operation of paper machines
and associated finishing/coinverting equipment. Experiments
illustrate/apply principles of momentum, heat, and mass
transfer. Operation/performance optimization of pilot-plant
paper machine. Process engineering studies of industrial
production systems.
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| Prerequisites: |
BP 4305, BP 4313, ChEn 4001, ME 3321, ME 3322
- Basic 2 years of college level math including differential
equations, physics and chemistry
- Basic understanding of mass and energy balances,
fluid mechanics, heat and mass transfer
- Computer and Internet skills (such as word processing,
browsing the Web, uploading and downloading files,
and using e-mail with file attachments).
- Printer and near-daily access to the Web
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| Class/Laboratory Schedule: |
You are required to follow the online material, completing
the modules and assignments as scheduled and participating
in online discussions arranged by the instructor.
|
| Location: |
online
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| Instructors: |
Shri
Ramaswamy
|
| Text: |
TBA
|
| Grading: |
A-N
|
Course Introduction
In this course you will learn in greater detail the various unit
operations involved in the papermaking process, namely stock preparation,
beating and refining, screening and cleaning, approach flow, headbox,
sheet forming, dewatering, pressing, drying, calendaring, winding
etc. In each of the process stages, we will focus on the application
of the fundamental principles of mass and energy balances, fluid
mechanics and heat and mass transfer. In the first course in this
series we reviewed the basic principles of mass and energy balances,
fluid mechanics, and heat and mass transfer. We also studied the
application of these principles in pulp and paper unit operations.
Here, we will focus on the application of these fundamental principles
in papermaking processes. As part of the process engineering laboratory
we will study practical applications of these principles in a laboratory/industrial
setting. Detailed understanding of the process is necessary to
improve fiber utilization, energy efficiency, cost efficiency and
environmental performance.
Course Objectives
- Learn the basic principle of mass and energy balances, fluid
mechanics, heat and mass transfer
- Gain experience in applying the basic principles in solving
technical problems
- Learn the details of various unit operations involved in paper
manufacture
Course Structure
Each of the unit operations in paper manufacture namely stock
preparation, beating and refining, screening and cleaning, approach
flow, headbox, sheet forming, dewatering, pressing, drying, calendaring,
winding etc will be studied in greater detail applying appropriate
engineering fundamentals. The material for paper making processes
is obtained from variety of pulp and paper reference texts including Pulp
and Paper Manufacture Volume 7. Paper Machine Operations by
M. J. Kocurek and technical journal articles. Materials related
to basic principles of fluid flow, heat transfer and mass transfer
are primarily taken from the text, Transport Processes and
Unit Operations by Christie J. Geankoplis. Homework problems
are designed to help you learn the principles and their applications
in each of the unit operations. The laboratory portion of the course
is designed to give you practical examples of application of basic
transport processes principles in papermaking in a laboratory/industrial
setting.
Syllabus
Stock preparation, batch and continuous, principles, design and
operation, stock and white water systems, short and long circulation,
closing white water system, process management, white water clarification
and classification, savealls, fiber and fine recovery, stock deaeration
and deculators, piping design, stuff boxes, broke system design
and operation, broke handling, wet/dry broke
Beating and refining, principles, design and operation, fiber
swelling, WRV, specific surface and specific volume, design parameters:
inch-cuts per minute, impacts per fiber, severity of impact
Screening and Cleaning – Introduction, Objectives and Theory,
Screening system process design, Centrifugal Cleaners – forward
and reverse cleaners, principles of operation, drag vs centrifugal
force, design and operating parameters, screening and cleaning
efficiency for multistage systems, material and flow balances for
systems with recycle
Approach flow systems, principles, design and operation, stock
distribution, effect on fiber orientation and sheet uniformity
Head boxes, principles, design and operation, headbox hydrodynamics,
roll headboxes vs hydraulic headboxes, slice evolution, distributor
rolls, level control, stock delivery and impingement, vena contracta,
turbulence, scale and intensity, oriented shear, wake formation,
stock velocity, pressure calculations and their influence on papermaking,
application of Bernouille equation
Sheet forming, principles and operation, velocity vs pressure
forming, multilayer forming, wedge design, jet angle, L/b jet/wire
ratio, J-curve, forming equipment, high consistency forming, dry
forming, forming fabrics, drainage and dewatering, filtration vs
thickening, vacuum water removal, vacuum system design, pump and
piping design
Paper machines, principles, design and operation, Fourdrinier
paper machines, twin-wire paper machines, cylinder molds, types
of formers, sheet transfer, MD, CD variation and control, machine
drives, energy and machine performance evaluation, machine showers
and doctors, vibration monitoring and analysis, on-line measurement
and control
Pressing, principles, design and operation, phases of dewatering,
type of presses, mechanical and hydraulic pressures, nip pressure,
pli, press clothing, felt conditioning, modern press designs, extended
nip press, effect of pressing performance on sheet quality, crown
Drying, paper machine drying, basic theory, design and practice,
warm-up, constant rate and falling rate, heat transfer and mass
transfer, evaporation, pocket ventilation, hoods and hood exhaust,
dryer fabrics, multicylinder drying section, steam and condensate
system, Yankee dryer and air system, design and operation, Through
Air Drying, tissue and towel manufacturing process, creping
Calendering, theory and practice, roll design, temperature control,
reel building, supercalenders, effect on paper properties
Winding, theory and practice, structure control, slitting, unwinding,
machine productivity
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