Lesson 1Paper machine sections: forming, press, drying, calendering basicsDetails the main sections of the paper machine for woodfree grades: forming, press, dryer, and calender. It explains water removal, sheet building, moisture management, and surface finishing, connecting settings to paper qualities important for 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 instruments, control valves, and automation systems used in pulp and paper mills. It covers basic control loops, DCS and SCADA functions, and how these tools support safety, quality, and efficiency in everyday 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 controlExplores stock preparation for printing and writing papers, including refining principles, screening and cleaning setups, mixing, and dilution control. It highlights effects on strength, formation, drainage, and machine steadiness for better yields.
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 millExplains water and steam flow in a paper mill, from intake and treatment to returning condensate. Emphasis is on heat linking, usage amounts, key points, and effects on costs, emissions, and reliability in resource-conscious settings.
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, chippingCovers the start of the chain: sourcing wood, transport, storage, removing bark, and chipping. It stresses chip quality factors, bark management, and how varying raw materials impact pulping and paper quality in local contexts.
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 getting, sorting, and preparing recycled paper, then deinking methods for graphic papers. Focus includes impurities, process steps, yield, brightness, and how deinked pulp quality affects machine running in sustainable practices.
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 running, including cooking reactions, liquor cycles, and fibre traits. It explains recovery boiler, causticizing, and recausticizing, noting energy production and chemical recycling for efficiency.
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 alternativesDescribes steps after the paper machine, like handling reels, rewinding, sheeting, and optional coating off-machine. It addresses fixing defects, roll quality, packaging, and tailoring products to meet customer needs effectively.
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 flowIntroduces the full process for uncoated woodfree paper, connecting pulp supply, stock prep, machine sections, and finishing. Focus is on material flows, key machines, quality controls, and main cost and energy factors.
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 constraintsPresents bleaching goals, sequences, and stage roles for kraft pulps, plus environmental limits. It discusses ECF and TCF ideas, AOX cutting, chemical balancing, and waste treatment links for eco-friendly operations.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
