Lesson 1Paper machine sections: forming, press, drying, calendering basicsDetails the primary sections of the paper machine for woodfree grades: forming, press, dryer, and calender. It explains dewatering processes, sheet consolidation, moisture management, and surface finishing, connecting machine settings to paper properties and quality.
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, roles of DCS and SCADA, and how instrumentation ensures safety, maintains quality, and boosts efficiency in 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 paper grades, including refining principles, screening and cleaning systems, mixing processes, and dilution control. It highlights effects on paper strength, formation, drainage rates, and overall machine stability.
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 the circulation of water and steam in a paper mill, from intake and treatment to condensate recovery. Focuses on heat integration, specific consumption levels, pinch analysis points, and their impacts on operational costs, emissions, and system 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 5Raw material handling: wood logistics, debarking, chippingCovers the initial stages of the supply chain: wood procurement, transportation, storage, debarking, and chipping. Emphasises chip quality standards, bark management, and how variations in raw materials influence pulping efficiency and final 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 6Recycled fibre handling and deinking basicsCovers sourcing, sorting, and preparation of waste paper, followed by deinking principles for graphic paper grades. Focuses on contaminants removal, unit operations, yield optimisation, brightness enhancement, and how deinked pulp quality affects machine runnability.
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 operations, including cooking reactions, liquor cycles, and fibre properties. Explains recovery boiler functions, causticising, and recausticising processes, highlighting energy production and chemical recovery cycles.
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 post-paper machine finishing steps, including reel handling, rewinding, sheeting, and optional off-machine coating. Addresses defect detection and removal, roll quality standards, packaging, and how finishing customises products for customer needs.
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 integrated process for producing uncoated woodfree paper, connecting pulp supply, stock preparation, paper machine sections, and finishing operations. Emphasis on material flows, key equipment, quality control levers, and major 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 functions for kraft pulps, along with environmental regulations. Discusses ECF and TCF bleaching methods, AOX minimisation, chemical optimisation, and connections to effluent treatment systems.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
