Lesson 1Paper machine sections: forming, press, drying, calendering basicsThis lesson details the primary sections of the paper machine for woodfree paper types: forming, pressing, drying, and calendering. It covers water removal methods, sheet strengthening, moisture regulation, and surface smoothing, connecting machine adjustments to paper characteristics in local production.
Headbox design and jet‑to‑wire ratioForming table drainage and retention aidsPress section loading and dewateringDryer section steam and hood controlCalendering impact on gloss and smoothnessLesson 2Common process instrumentation and control elements (sensors, valves, SCADA)Introduces essential field devices, control valves, and automation systems in pulp and paper factories. It explains simple control systems, roles of DCS and SCADA, and how these tools aid safety, quality, and efficiency in Botswana operations.
Level, pressure, flow, and consistency sensorsControl valve types and sizing basicsPID control loops and tuning conceptsDCS architecture and operator interfacesSCADA, alarms, and data historian useLesson 3Stock preparation: refiners, screens, cleaners, mixing and dilution controlExamines stock preparation for printing and writing papers, covering refining principles, screening and cleaning setups, mixing, and dilution management. It highlights effects on paper strength, formation, drainage, and machine steadiness in regional contexts.
Refining mechanisms and fiber developmentPrimary and secondary screening systemsCentrifugal cleaners and heavy reject handlingConsistency control and dilution profilingWet end additives and mixing strategiesLesson 4Water and steam balance in a paper millDescribes water and steam flow in a paper factory, from intake and treatment to returning condensate. Emphasis is on heat recovery, usage rates, critical points, and influences on costs, emissions, and dependability for Botswana facilities.
Fresh water intake and treatment stepsProcess water loops and closure levelsBoiler house and steam generation basicsCondensate recovery and flash steam useWater, steam, and energy performance KPIsLesson 5Raw material handling: wood logistics, debarking, chippingDiscusses the initial supply chain: sourcing wood, transporting, storing, removing bark, and chipping. It stresses chip quality standards, bark management, and how material variations impact pulping and paper quality in local sourcing.
Wood sourcing, species mix, and contractsLog yard layout and inventory managementDebarking technologies and bark disposalChipping systems and chip size controlChip screening, storage, and homogenizationLesson 6Recycled fiber handling and deinking basicsCovers collecting, sorting, and readying recycled paper, followed by deinking methods for print papers. Focuses on impurities, process steps, yield, whiteness, and how deinked pulp quality affects machine performance in Botswana recycling.
Recovered paper grades and specificationsContaminant types and removal strategiesPulping, screening, and cleaning stagesFlotation deinking and washing principlesDeinked pulp quality control and testingLesson 7Chemical pulping fundamentals: kraft process and kraft recoveryIntroduces kraft pulping chemistry and methods, including cooking reactions, liquor cycles, and fibre traits. Explains recovery boilers, causticising, and recausticising, noting energy production and chemical recycling for sustainable operations.
White liquor composition and active alkaliDigester operation and kappa number controlBrownstock washing and filtrate handlingRecovery boiler combustion and smeltCausticizing, lime kiln, and chemical balanceLesson 8Finishing operations: rewinding, cutting, coating alternativesOutlines post-machine finishing: handling reels, rewinding, cutting sheets, and optional coating. Addresses removing flaws, roll standards, packaging, and customising products for Botswana markets.
Parent reel handling and storage safetyRewinder operation and defect managementSheeting, ream formation, and packagingOff‑machine coating types and functionsFinished product inspection and labelingLesson 9Overview of uncoated woodfree paper production flowPresents the full process for uncoated woodfree paper, connecting pulp supply, stock prep, machine sections, and finishing. Stresses material flows, key machines, quality controls, and major cost and energy factors in local production.
Process block diagram and main unit operationsFiber, water, and energy flow interactionsTypical mill layout and logistics interfacesKey quality parameters and product gradesMajor cost centers and efficiency leversLesson 10Bleaching sequence concepts and environmental constraintsCovers bleaching goals, sequences, and stage roles for kraft pulps, plus environmental limits. Discusses ECF and TCF methods, AOX cuts, chemical efficiency, and waste treatment links for eco-friendly Botswana practices.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
