Pulp Machine Research Articles

Understanding the energy and emission implications of new technologies in a kraft mill: Insights from a CADSIM Plus simulation model

Kraft mills play a vital role in energy transition because they have significant potential to reduce their own energy utilization and produce energy/products to decarbonize other sectors. Through biomass combustion and potential biogenic carbon emissions capture, these mills can contribute to offsetting emissions from other sectors. This research investigates the departmental and cross-departmental implications of technology upgrades on energy, steam, emissions, water, and chemicals using a CADSIM Plus simulation model. The model provides a comprehensive analysis of mass and energy balances, offering valuable insights into the benefits and limitations of each technology. The model facilitates scenario analysis and comparisons of process configurations, enabling data-driven decision-making for sustainable and competitive operations. Six high-impact technologies, including additional evaporator effects, weak black liquor membrane concentration, belt displacement washer for brownstock washing, oxygen delignification, and improvements to the pulp machine shoe press and vacuum pumps, are evaluated. Individual technologies resulted in energy savings of 1.2% to 5.4%, biomass consumption reductions of 8.6% to 31.6%, and total emissions reductions of 1.6% to 5.9%. Strategic decision-making must consider existing mill limitations, future technology implementation, and potential production increases. Future research will explore product diversification, biorefineries, and pathways to achieve carbon-negative operations, aiming to reduce emissions and secure a competitive future for kraft mills.

Physical and mechanical properties of Arabica coffee (Coffea arabica L.) cherries and beans in Rwanda

Arabica coffee is worldwide predominated and accounts for about 97% of Rwandan coffee production. Up to 70% of exported washed coffee is pulped using high-capacity coffee pulping machines while the remaining is pulped by smallholder farmers. However, the lack of information on coffee beans can affect depulping activity, especially when using locally-made pulping machines. Therefore, this study aimed to investigate Arabica coffee's physical and mechanical properties from eight districts of Rwanda to improve the pulping process. The coffee parameters were investigated using precision measuring instruments and statistically analysed using One-Way ANOVA, one-sample t-test, and the Turkey multi-comparison method in GraphPad Prism 9.3.1 software. The investigation found the mean length of 15.40 mm, 12.12 mm and 11.85 mm, the width of 13.03 mm, 8.26 mm and 8.15 mm, the thickness of 13.03 mm, 4.88 mm and 4.87 mm for Arabica cherries, wet parchment beans and dried parchment beans, respectively. Their corresponding average mass of 1.53 g, 0.43 g, and 0.173 g, the density of 1.006 g/mL, 0.894 g/mL and 0.390 g/mL for Arabica cherries, wet parchment beans, and dried parchment beans, respectively. The Arabica showed a true volume of 1.531 mL and 0.271 mL for cherries and dried coffee beans, respectively. The wet parchment coffee was dried from 29.9 to 10.8% wb. The dried parchment beans showed a coefficient of static-friction and fracture force of 0.585 and 29.85±6.81 kgf, respectively. The other parameters evaluated for cherries and dried parchment coffee beans include moisture content, true volume, density, porosity, sphericity, and angle of repose. The results showed that coffee's size, mass, densities, and diameters from different districts are significantly different at Pvalue < 0.05 and also showed a perfect correlation. Each of the above coffee parameters provides the general information needed to develop a pulping machine for cherries. Therefore, the small-scale coffee pulping machine should be developed, and properly adjusting the pulping unit to enhance the performance of the machine based mainly on the size, fracture force, and density of the coffee.

Design and comparative analysis of beater knife mechanism for mango pulp extraction

The purpose of this research work was to design, fabricate and evaluate an enhanced fruit pulp extraction unit to convert the available fruit into pulp to increase profitability and to limit post-harvest losses. This study introduced a newly developed mechanism with beater-type blades having serrated knives. As compared to the existing screw-type pulpers this newly developed pulping machine is quite lightweight, cheap, easy to fabricate, requires low maintenance, and has a low running cost. The major factors that were considered while planning included cost-effectiveness, manufacturing ease, high efficiency and user-friendly operation. The machine works by applying shearing and centrifugal forces on the fed fruits through an innovatively designed set of blades. The data like mass of fruits and residual waste, extracted juice volume and time taken for juice extraction were collected and used to calculate the key performance indicators (KPIs) which included juice yield, extraction efficiency and extraction loss of the unit. The mango types like Sindhri, Chaunsa and Langra were used and maximum average juice yield and extraction efficiency were obtained for Chaunsa variety at 600 rpm with 700-micron diameter sieve mesh size and 25 mm beater and sieve mesh clearance. The beater-type and screw-type pulpers have juice yield percentages of 63.40% & 34.56%, extraction efficiencies of 56.70% & 54.15%, power consumption of 1HP & 2.5HP and manufacturing costs of USD1275 & USD2000 respectively. The processing capacity of this pulp processing unit is 60-70kg/h.

Design and Development of Archives Blender Tool using ADDIE Framework

Records are organizational assets in the form of documnet that contain information about activities or events, so that the existence of records is important for the organization. Even though records have an important role for the organization, without a disposal process, records will increase and accumulate from time to time. Uncontrolled addition of records volumes will result in various problems such as space provision and costs. For this reason, disposal activities are needed, one of which can be done through destruction. The purpose of this study was to study the design and development of an effective and safe paper-based records pulping machine. This study uses the Research & Development (R&D) method with the ADDIE framework. The results of this study indicate that the development of the tool started with an analysis of the needs for records destruction equipment, designing the tool design, developing the tool at an early stage, implementing the tool, and evaluating the function of the tool.

PERHITUNGAN EFISIENSI RECOVERY BOILER PADA PT TOBA PULP LESTARI TBK

PT Toba Pulp Lestari, Tbk is one of the companies in Indonesia whose main activity is to produce pulp. The company uses eucalyptus wood as the main material. Broadly speaking, pulp making begins with the digesting process, which is the process of cooking chips with the addition of white liquor and steam. Then distributed to washing and screening, then O2 delignification which produces unbleached pulp. then bleached in the bleaching process in three stages. After that, the pulp is made into sheet pulp in the pulp machine process. In addition, the supporting process for producing the pulp, one of which is the recovery boiler. The recovery boiler has two functions, namely the main function as a steam generator and the side function of producing green liquor from recovery to be produced again into white liquor as a cooking liquid in the digester. The performance condition of an equipment can be measured based on the efficiency of an equipment. In thermodynamics, thermal efficiency is a dimensionless measure that shows the performance of thermal equipment such as internal combustion engines and so on.

Simulation and Experimental Validation on the Effect of Twin-Screw Pulping Technology upon Straw Pulping Performance Based on Tavares Mathematical Model

Rice straw is waste material from agriculture as a renewable biomass resource, but the black liquor produced by straw pulping causes serious pollution problems. The twin-screw pulping machine was designed by Solidworks software and the straw breakage model was created by the Discrete Element Method (DEM). The model of straw particles breakage process in the Twin-screw pulping machine was built by the Tavares model. The simulation results showed that the highest number of broken straw particles was achieved when the twin-screw spiral casing combination was negative-positive-negative-positive and the tooth groove angle arrangement of the negative spiral casing was 45°−30°−15°. The multi-factor simulation showed that the order of influence of each factor on the pulp yield was screw speed > straw moisture content > tooth groove angle. The Box-Behnken experiment showed that when screw speed was 550 r/min, tooth groove angle was 30°, straw moisture content was 65% and pulping yield achieved up to 92.5%. Twin-screw pulping performance verification experiments were conducted, and the results from the experimental measurements and simulation data from the model showed good agreement.

Design and simulation of an artificial vision sorting machine and cocoa pulping machine

This research project is focused on the design of an agricultural machine that allows to pulp the cocoa beans quickly and optimally by means of an artificial vision system to classify the beans and to obtain the mentioned product in a shorter production time with optimal quality. Cocoa has been placed in third place in production after sugar and coffee, this is due to the growing demand for chocolate, which is one of the most consumed derivatives in the world. Prior to the design, the manual and traditional methods used on the farms were investigated in order to take a mechanical design alternative. Of the three alternatives proposed, it was decided to take as an example alternative C, using a sieve with a constant translational movement. This machine was designed with the help of SOLIDWORKS software, allowing to obtain plans and dimensions suitable for its construction. A finite element analysis was performed to evaluate its deformations with the loads to which it will be subjected. The design of this machine aims to open new fields in agricultural production and maximize the income of small farmers, taking advantage of the reduction of labor used in the cocoa pulping process.

Application of the QFD method to the design of a cocoa pulping machine

Application of the QFD method to the design of a cocoa pulping machine

Mehanske lastnosti in absorbcija vode izbranih naravnih vlaken kot zamenjava za azbest

This work investigates the influence of banana (Musa Sapientum) and jute fibers as a reinforcement in a cement/waste brown paper pulp matrix for applications in housing construction in Nigeria. The natural fibers were extracted from banana trunk and cocoa sack and, thereafter, treated with 1-M sodium hydroxide (NaOH) for 2 h to expose the lignin and cellulose and thus expose the hemicellulose content of the fibers. The treated fibers were allowed to dry in air for 7 days before cutting into short fibers of 10 mm length. Paper pulp was prepared by soaking waste brown cardboard papers in water for 24 h, thereafter, it was grinded in the paper pulp machine to form a paper pulp slurry, and then sun-dried for 5 days. The treated fibers were thoroughly mixed with the dried paper pulp to develop Fiber Cement Board (FCB) samples of varied weight content (5, 10, 15, and 20) w/% using the hand lay-up technique with the aid of a cold compacting machine. Thereafter, an appropriate quantity of cement as binder and treated sugarcane bagasse as filler material were added to the mix. The developed FCB samples were allowed to cure in air in the laboratory for 28 days before testing. Flexural, compressive, thermal conductivity, and water absorption tests were carried out on the samples using a universal testing machine, Lee's disk apparatus, and the percentage weight of different immersed samples in water, respectively. The results of the mechanical properties examined showed that FCB sample D containing (10 w/% banana fiber, 10 w/% jute fiber, 15 w/% cement/bagasse and 65 w/% paper pulp) gave the optimum results for the flexural and compressive properties with a respective value of 0.843 MPa and 7.333 MPa, while FCB sample F gave the best results for the thermal conductivity and water-absorption property.

Pemanfaatan Limbah Kulit Jagung Sebagai Upaya Pengembangan Usaha IKM Pembuat Kertas Seni

Design and manufacture of paper pulp machine with raw corn skin waste as one of the efforts in the development of IKM in the countryside, and other purposes to manage and utilize corn skin waste into pulp pulp so that it becomes a useful value, can even improve the economy of the community, especially in rural areas. Corn skin waste is very abundant and mostly burned, resulting in reduced soil fertility rates even feared to cause air populations. Corn skin waste processed with environmentally friendly insights, this condition that makes researchers conduct technology-based development appropriately. The manufacture of appropriate technology for the manufacture of pulp machines including: (1) design, (2) construction manufacturing, (3) trials. The results of the design and trials conducted at pulp production capacity of 200 kg/h, then the technical specifications are: (1) length = 1,250 mm, (2) width = 1,000 mm, (3) height= 1,500 mm, (4) weight= 200 kg, (5) motor power= 8 PK. From the results of operation and calculation of economic analysis is known the amount of selling price per unit is Rp 30,000,000 and the price of corn skin waste pulp is around Rp 4000 -Rp 5000/kg. The development of pulp bubr paper made from corn skin waste in collaboration with small craftsmen to make art paper, map, bag, egg place, fruit tembat, souvenirs, frames, invitation cards and others. It is expected that the machine is feasible to be applied to increase the added value of farmers, the creation of jobs and local native income (PAD).

Job Methods – An Approach to Increase Human Resource Productivity in Pandemic COVID-19 (A Case Study of Parason Group, India)

Apart from multidimensional challenges and fierce competition, COVID-19 has created immense stress on manufacturing industries to work with limited human resources due to social distancing and other safety measures. During this tough time (COVID-19) companies are in great pressure to manage their costs, one of the significant cost is labour cost. Labour productivity is a division of worth of goods or services produced and labour hours used to produce that, thus productivity improvement can be done by producing more with same labour hours or producing same with less labour hours. There is a process of producing goods or services, each process may have one or more activity and each activity will have some methods to accomplish. Each process is also having its completion time which ultimately depends on number of activities and methods. If somehow the number of activities can be reduced or methods to accomplish the activity can be simplified in terms of easiness and less time without impacting quality of products or services, the completion time of that process will be reduced and eventually a gain in productivity will be achieved to help companies to be more productive and profitable without addition of manpower. The facilities and technology enhancement what the manufacturing world is enjoying today, is the result of improvement in production methods, e.g. automobile, mobile phones, laptops, home appliances etc. The TWI - Job Methods program is a structured program to identify and eliminate non value adding activities and to improve the existing methods of doing a job with available resources. Job Methods programme is focused on making the methods of work smarter and better. TWI – Job Methods is the best tool for involving all supervisor and workers in an organization for improvement activities. It also helps to involve the supervisors with the workforce and bring out collaborative solutions for different obstacles that occurs while working. Job Methods programme also provides a systematic improvement proposal to management to communicate so that decision making about new methods or process can be effective and quick. The case study had completed during Jan and Feb 2020 and focused on the practical application of Job Methods (JM) to improve productivity by using same number of human resources in producing refiner plates in a leading paper and pulp machine manufacturing company in India. TWI-JM technique is very relevant during tough time (COVID-19) when manpower availability is a concern and raise in productivity is required. Keywords - Training within industry (TWI), Job Methods (JM), Job Breakdown Sheet (JBS), Inner Diameter (ID), Outer Diameter (OD) DOI: 10.7176/EJBM/12-16-01 Publication date: June 30th 2020

СХЕМА ПЕРЕРАБОТКИ ТЕХНИЧЕСКОЙ КОНОПЛИ В ОДНОТИПНУЮ ПЕНЬКУ

Industrial hemp as a source of fiber is a valuable industrial raw material. In modern conditions, the lines of its primary processing should produce the same type of fiber with different characteristics, depending on the requirements for the properties of the finished fiber. The purpose of the work is to substantiate the scheme for processing industrial hemp based on the characteristics of hemp. Five primary processing lines were compared, including domestic flax equipment (M-110L2 grinding machine, DLV-2 disintegrators, and TG-135L shaker machines with a lower comb field). As raw materials the industrial hemp from Penza region, harvested in the spring, was used. The mass of one handful is 100 g, the loading density is 0.5 kg/m, the twist is three times. Raw materials were loaded into each machine manually. After primary processing by instrumental methods, hemp grade and characteristics were determined according to GOST 9993-2014. The scheme of the line for primary processing of industrial hemp in the form of tangled mass of stems of various lengths, which allows the production of the same type of hemp with different values of technological characteristics, has been developed. For the production of the same type of hemp with an average mass length of fiber 142 ... 144 mm, a mass fraction of bonfire of 1.6 ... 2.2%, a weighted average linear density of 11 ... 12 tex, the line should include a pulping machine, a disintegrator, two shaking machines; with characteristics respectively 235 mm, 7 ... 8% and 12 ... 13 tex - a disintegrator and two shaking machines; 219 mm and 15 ... 16%, 18 ... 19 tex - pulley and two shaking machines. Using the studied set of equipment provides a reduction in capital costs, in comparison with the lines of other manufacturers, by 3 ... 4 times, energy costs - up to 40%

Analysis of the Overall Equipment Effectiveness (OEE) to Minimize Six Big Losses of Pulp Machine: A Case Study in Pulp and Paper Industries

Overall Equipment Effectiveness (OEE) is a method of measuring the usage effectiveness of the equipment. This method is known as an application of a Total Productive Maintenance (TPM) program. The ability to clearly identify the source of problem and it causal factors is the main advantage of this method since the improvement effort becomes focused. Pulp and Paper Industries is one of the manufacturing companies that produce dissolving pulp products (rayon fibre). Based on data from the fibre line department, for the period of January - July 2016, the production process of rayon fibre often experienced constraints due to the high downtime and losses in the pulp machine. This is caused of using production process equipment that had not operate optimally. It is important to find out the source of the problem and its causal factors before the company makes any improvement effort. This study aims to identify equipment losses and measure the achievement of OEE values in the pulp machine. The measurement result shows that the average of the effectiveness of pulp machine for the period of January - July 2016 was 74.01% and based on Japan Institute of Plant Maintenance (JIPM) the value has not reached the standard that is > 85%, however, there is still possibility for improvement. One of the loss factors that give the most significant effect on the overall equipment effectiveness of the pulp machine is the reducing speed, where it comprises 27.6% of the loss. One way to minimize the loss is by maintaining the actual speed of operation and maintaining wear on each pulp machine roll.

Analysis of the Overall Equipment Effectiveness (OEE) to Minimize Six Big Losses of Pulp machine: A Case Study in Pulp and Paper Industries

Overall Equipment Effectiveness (OEE) is a method of measuring the effectiveness of the use of equipment. This method is known as an application of a Total Productive Maintenance (TPM) program. The ability to clearly identify the source of problem and it causal factors is the main advantage of this method since the improvement effort becomes focused. Pulp and Paper Industries is one of the manufacturing companies that produce dissolving pulp products (rayon fibre). Based on data from the fibre line department, for the period of January - July 2016, the production process of rayon fibre often experienced constraints due to the high downtime and losses in the pulp machine. This resulted in the use of production process equipment that had not been optimal. It is important to find out the source of the problem and its causal factors before the company makes any improvement effort. This study aims to identify equipment losses and measure the achievement of OEE values in the pulp machine. The measurement result shows that the average of the effectiveness of pulp machine for the period of January - July 2016 was 74.01% and based on Japan Institute Of Plant Maintenance (JIPM) the value has not reached the standard that is > 85%, however, there is still possibility for improvement. The losses that give the most significant effect on the overall equipment effectiveness of the pulp machine is reduce speed that was equal to 27.6%. One way to minimize the losses is by maintaining the actual speed of operation and maintaining wear on each pulp machine roll.

Determination of product density for calculating the safety pressure on the walls of sieve drum in pulping machine

Pulping machines are an integral part of production lines for the processing fruits and vegetables. To meet the ever-growing demand for these agricultural products, it is necessary to introduce innovative solutions to modernize equipment not only for increasing its productivity but also for ensuring its safety. The article proposes a pulping machine that helps to increase the productivity by using the entire area of the sieve drum. The productivity also depends on reliable and safe equipment operation, elimination of downtime during product pulping. One of the main factors affecting the reliable and safe operation is the pressure of pulped product on the walls of the sieve drum, and this pressure depends on the product density. It has been experimentally shown that the density of pulped product can vary significantly even for different varieties of vegetable marrow. As the calculations show, in this case the pressure inside the sieve drum of the pulping machine changes considerably (more than 10%). Therefore, the density of the product should be taken into account when calculating the design parameters of the pulping machine; it helps to ensure its reliable and safe operation and hence to reduce the probability of downtime and to improve the productivity.

Decreased water usage in a softwood ECF bleaching sequence—full mill simulations

In this study, an elemental chlorine free (ECF) bleach plant with a D0(EOP)D1(EP)D2 sequence was studied with the aim of identifying options for significantly decreasing (fresh) water usage in the bleach plant and decreasing the effluent volume. A base-case simulation model for a softwood kraft market pulp mill was made based on a reference model representing the best available techniques as well as data produced in an extensive laboratory pulp bleaching study. This model was used to evaluate increased closure within the bleach plant and the recirculation of bleach plant effluent to the brownstock system and their effects on both the bleach plant and the recovery cycle. The results indicate that it is possible to reduce the fresh water consumption from 15 metric tons/a.d. metric ton in the base case to about 2 metric tons/a.d. metric ton, without increasing the carryover of chemical oxygen demand (COD) to the pulp machine. Nonprocess elements in wood contribute to the levels of metals found in the bleach plant and thus to the risk of precipitates such as calcium oxalate, barium sulfate, and calcium carbonate. The risk of precipitates forming is a key factor determining the possible degree of closure. In addition, chloride concentration in the black liquor is another important factor that is affected by recirculating bleach plant filtrate to the brownstock washer and by the grade of the sodium hydroxide used in the mill.

Biochemical characterization of blackberry fruit (Rubus sp) and jellies

The present study aimed to quantify the phenolic compounds, carotenoids, anthocyanins and antioxidant activity using 2 different methods in blackberry fruits harvested at 3 different harvest points along the storage time and jellies made from these fruits and the quantification of ascorbic acid in the fruits. The harvesting points used were defined visually, being: 100% red (T1); 50% red and 50% black (T2) and 100% black (T3). After harvest, the fruits were selected, washed and packed in PET boxes with capacity for 200g of fruit and stored for 15 days at 2 degreesC, being evaluated every 3 days and for the manufacture of the jellies, the fruits were first pulped in stainless steel pulping machine being the jellies prepared with 50:50 (fruit: commercial crystal sugar) in open pan. The results show that the loss of phenolic compounds, anthocyanins and carotenoids was small when fruits and jelly were compared, as well as the antioxidant activity, and this shows that the processing of this fruit does not cause losses in relation to these evaluated parameters.

Design, fabrication, and testing of a pulper for Kendu (Diospyros melanoxylon Roxb.)

AbstractKendu (Diospyros melanoxylon Roxb.) is a minor forest produce commercially grown in India for its leaves for traditional cigarette‐making. Though the fruit has high nutritive value, it is not used for diet purpose. This may be due to the difficulty in extracting the pulp. To address this issue, a brush type pulping machine was developed for Kendu. The pulper consists of the feed hopper, feed rollers, barrel housing, stainless steel cylinder, and a shaft with two nylon brushes. The feed rollers are provided with conical spikes to compress and shear the hardcover of the fruit. The pulper has an overall dimension of 1.2 m × 0.75 m × 0.40 m and a throughput of 50 kg/hr. The housing field area of the machine is 1.130 m2. The overall extraction efficiency of the pulper is 78.36% at an optimized speed and feed rate of 260 rpm and 2.5 kg/min, respectively.Practical applicationsA small‐scale pulper has been designed and fabricated for Kendu fruit, an underutilized minor forest produce. As such, there is no machine to extract pulp from Kendu. Manual removal of hardcover and seeds and separation of the pulp are labor intensive and time consuming. This problem limits the potential use of the fruit. The designed machine will serve as a milling cum pulping machine and would address the issue of underutilization of the fruit. The highly nutritious pulp thus extracted by the pulper can be further processed to various value‐added products. This would certainly increase the commercial use of the fruit and boost income generation to support the livelihood of the people. The designed pulper can also be used for other fruits of similar structure.

Seeking optimality in fruit pulping schedules: A case study*

The process of scheduling fruit pulping for the production of fruit juices is of great importance in the beverage industry. Decisions have to be made regarding available processing time, the disposal of fruit that will not be pulped before stock loss due to spoilage, the fulfilment of customer demand and an optimal financial position. Sheduling depends on the capacity of the work force, pulping machine limitations and delivery deadlines. However, the situation is often encountered where the plant manager has to decide which fruit batches (usually from stock piles of overwhelming proportions during the harvesting season) are to be pulped in order to minimize losses due to fruit deterioration. Such decisions are usually done manually, based on intuition and experience. A mathematical model is presented here which constructs a pulping strategy while minimising cascading financial losses associated with fruit grade drops within the stock pile. It is shown in particular that a minimisation of fruit losses is not a good criterion for optimality, and that substantial financial gains may be accomplished when minimising financial losses in stead of fruit losses, which is currently standard practice at most fruit pulping plants.

Assessment of pulp machine white water quality at market kraft pulp mills

The bleaching of pulp is a significant cost, yet the brightness achieved in the bleaching plant can be diminished in the pulp machine because of white water (WW) quality. Monitoring WW quality can control these losses. A method was developed to assess WW quality that allows differentiation between the effect of fibers, fines, and dissolved solids (DS) in the WW. It was found that the quality of the WW varied greatly from mill to mill. The brightness loss was mainly affected by the presence of fines, through a combination of their concentration and color. The DS were significantly less detrimental to the optical properties of the final furnish. None of the constituents present in the pulp machine WW caused significant brightness reversion (except the hardwood fine fractions). It is therefore recommended that a monitoring procedure for WW quality at the mill site be used to diagnose and prevent the occurrence of brightness problems. Such monitoring offers a way to reduce bleaching costs.