Lesson 1Paper machine sections: forming, press, drying, calendering basicsThis lesson covers the primary sections of the paper machine for uncoated woodfree papers: the forming section, press section, dryer section, and calender. It describes water removal processes, sheet formation, moisture management, and surface smoothing techniques, showing how adjustments influence final paper characteristics.
Headbox design and jet-to-wire speed ratioForming table water removal and retention chemicalsPress section pressure and water extractionDryer section steam systems and hood ventilationCalendering effects on paper shine and evennessLesson 2Common process instrumentation and control elements (sensors, valves, SCADA)This lesson introduces essential field devices, control valves, and automation systems in pulp and paper operations. It covers basic control systems, roles of distributed control systems (DCS) and supervisory control and data acquisition (SCADA), and how these tools enhance safety, product quality, and operational efficiency in Eritrean mills.
Sensors for level, pressure, flow, and pulp consistencyTypes of control valves and basic sizingPID control systems and adjustment methodsDCS setup and operator displaysSCADA systems, alerts, and data recordingLesson 3Stock preparation: refiners, screens, cleaners, mixing and dilution controlThis lesson examines stock preparation processes for printing and writing papers, including fiber refining principles, screening and cleaning equipment, mixing operations, and dilution management. It highlights effects on paper strength, sheet formation, water drainage, and overall machine performance stability.
Refining processes and fiber quality enhancementMain and fine screening equipmentCentrifugal cleaners and heavy particle removalPulp consistency management and dilution systemsWet end chemicals and mixing approachesLesson 4Water and steam balance in a paper millThis lesson explains the circulation of water and steam in paper production facilities, from initial intake and purification to condensate recovery. Emphasis is placed on heat recovery methods, consumption rates, critical balance points, and their influence on operational costs, emissions, and system dependability in Eritrean settings.
Fresh water intake and purification processesProcess water cycles and recycling levelsBoiler operations and steam productionCondensate collection and steam reuseKey performance indicators for water, steam, and energyLesson 5Raw material handling: wood logistics, debarking, chippingThis lesson addresses the initial stages of production: sourcing wood, transportation, storage, bark removal, and chipping. It stresses chip quality standards, bark management, and the effects of raw material variations on pulping efficiency and final paper quality in local Eritrean operations.
Wood procurement, tree types, and supply agreementsLog storage area design and stock controlBark removal methods and waste handlingChipping equipment and size regulationChip sorting, storage, and quality blendingLesson 6Recycled fiber handling and deinking basicsThis lesson covers the collection, sorting, and processing of waste paper, followed by deinking methods for printing papers. It discusses contaminant removal, processing steps, yield rates, brightness levels, and how deinked pulp quality impacts machine operations and paper performance.
Waste paper categories and quality standardsTypes of contaminants and removal techniquesPulping, screening, and cleaning processesFlotation deinking and washing methodsQuality checks and testing for deinked pulpLesson 7Chemical pulping fundamentals: kraft process and kraft recoveryThis lesson introduces the chemistry and operations of kraft pulping, covering cooking reactions, chemical cycles, and fiber characteristics. It explains recovery boilers, chemical regeneration processes, and recausticizing, underscoring energy production and chemical recycling benefits.
White liquor makeup and active chemicalsDigester controls and lignin removal measuresBrown pulp washing and liquid managementRecovery boiler burning and chemical recoveryLime handling, kiln operations, and chemical equilibriumLesson 8Finishing operations: rewinding, cutting, coating alternativesThis lesson describes post-machine finishing processes, including reel management, rewinding, cutting into sheets, and optional external coating. It covers defect detection, roll quality assurance, packaging, and customization to meet customer specifications in Eritrean markets.
Large reel handling and safe storageRewinder functions and defect correctionSheet cutting, bundle forming, and packingExternal coating methods and purposesFinal product checks and labeling proceduresLesson 9Overview of uncoated woodfree paper production flowThis lesson provides an integrated view of uncoated woodfree paper manufacturing, connecting pulp supply, stock preparation, machine sections, and finishing. It focuses on material movements, essential equipment, quality controls, and primary cost and energy factors relevant to Eritrean production.
Production flow diagram and key processesInteractions of fiber, water, and energy flowsStandard mill layout and material handlingMain quality measures and paper typesPrimary expense areas and efficiency improvementsLesson 10Bleaching sequence concepts and environmental constraintsThis lesson outlines bleaching goals, process sequences, and stage roles for kraft pulps, alongside environmental regulations. It discusses elemental chlorine-free (ECF) and total chlorine-free (TCF) methods, pollutant reduction, chemical efficiency, and wastewater management interfaces.
Target brightness and pulp purity levelsStandard bleaching steps and symbolsECF, TCF, and oxygen-based delignificationChemical use optimization and expense managementBleach plant wastewater and pollutant controls
