Lesson 1Paper machine parts: forming, pressing, drying, and basic calenderingThis lesson details the main sections of the paper machine for woodfree paper types: forming, pressing, drying, and calendering. It explains how water is removed, the sheet is made solid, moisture is controlled, and the surface is finished, showing how machine settings affect paper qualities.
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 tools for process checking and control: sensors, valves, SCADAThis lesson introduces important field tools, control valves, and automation systems used in pulp and paper mills. It explains simple control loops, the roles of DCS and SCADA, and how these tools help with safety, quality, and efficiency.
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 3Preparing stock: refiners, screens, cleaners, mixing and water controlThis lesson looks at preparing stock for printing and writing papers, including how refining works, screening and cleaning systems, mixing, and controlling water addition. It highlights effects on paper strength, formation, water drainage, and machine steadiness.
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 flow in a paper millThis lesson explains how water and steam move through a paper mill, from taking in water and treating it to returning condensate. It focuses on combining heat, specific use amounts, key points, and effects on costs, pollution, and reliability.
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 5Handling raw materials: wood transport, removing bark, chippingThis lesson covers the start of the process: getting wood, moving it, storing it, removing bark, and chipping. It stresses chip quality measures, handling bark, and how changes in raw materials affect pulping and paper quality.
Wood sourcing, species mix, and contractsLog yard layout and inventory managementDebarking technologies and bark disposalChipping systems and chip size controlChip screening, storage, and homogenizationLesson 6Handling recycled fibre and basic deinkingThis lesson covers getting, sorting, and preparing used paper, then basic deinking for print papers. It focuses on dirt, process steps, yield, brightness, and how quality of deinked pulp affects machine running.
Recovered paper grades and specificationsContaminant types and removal strategiesPulping, screening, and cleaning stagesFlotation deinking and washing principlesDeinked pulp quality control and testingLesson 7Basics of chemical pulping: kraft process and recoveryThis lesson introduces kraft pulping chemistry and operations, including cooking reactions, liquor cycles, and fibre qualities. It explains the recovery boiler, causticizing, and recausticizing, highlighting energy making and chemical recycling.
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 work: rewinding, cutting, coating optionsThis lesson describes finishing steps after the paper machine, including handling reels, rewinding, cutting sheets, and optional coating off-machine. It covers removing faults, roll quality, packing, and how finishing fits products for buyers.
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 making uncoated woodfree paperThis lesson introduces the full process for uncoated woodfree paper, connecting pulp supply, stock preparation, paper machine parts, and finishing. It stresses material flows, key machines, quality controls, and main costs and energy uses.
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 10Ideas on bleaching steps and environment limitsThis lesson presents goals of bleaching, steps, and functions for kraft pulps, with environment limits. It discusses ECF and TCF ideas, reducing AOX, optimizing chemicals, and connecting to waste treatment.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
