Lesson 1Paper machine sections: forming, press, drying, calendering basicsThis lesson details the primary sections of the paper machine for producing woodfree paper grades, including forming, pressing, drying, and calendering. It explains how water is removed, the sheet is consolidated, moisture is managed, and the surface is finished, showing how machine settings influence the final paper properties for optimal performance.
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)This lesson introduces essential field instruments, control valves, and automation systems used in pulp and paper mills. It covers basic control loops, the functions of DCS and SCADA, and how these tools enhance safety, product quality, and operational efficiency in everyday mill 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 controlThis lesson examines stock preparation processes for printing and writing papers, covering refining principles, screening and cleaning equipment, mixing techniques, and dilution management. It highlights how these steps affect paper strength, formation, drainage rates, and overall machine stability to produce high-quality sheets.
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 millThis lesson describes the flow of water and steam throughout a paper mill, from initial intake and treatment to the return of condensate. The emphasis is on integrating heat effectively, monitoring specific consumption levels, identifying pinch points, and understanding effects 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, chippingThis lesson addresses the initial stages of the production chain, including wood sourcing, transportation, storage, debarking, and chipping processes. It stresses the importance of chip quality standards, proper bark management, and how variations in raw materials impact pulping efficiency and the quality of the final paper product.
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 basicsThis lesson discusses the collection, sorting, and preparation of recycled paper, followed by basic deinking methods suitable for graphic paper grades. Key areas include managing contaminants, unit operations, yield optimisation, brightness improvement, and how the quality of deinked pulp influences paper machine performance and 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 recoveryThis lesson introduces the chemistry and operations of the kraft pulping process, including cooking reactions, liquor circulation, and resulting fiber characteristics. It also explains the recovery boiler, causticizing, and recausticizing steps, underscoring energy production and the closed-loop chemical recovery system essential 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 alternativesThis lesson outlines the post-machine finishing processes, such as handling reels, rewinding, cutting into sheets, and optional off-machine coating. It covers defect detection and removal, ensuring roll quality, packaging standards, and how finishing customises products to meet specific customer requirements in the market.
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 flowThis lesson provides an overview of the integrated production flow for uncoated woodfree paper, connecting pulp supply, stock preparation, paper machine operations, and finishing stages. It focuses on material movements, essential equipment, quality control mechanisms, and the primary drivers of costs and energy use in the process.
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 constraintsThis lesson presents the goals, sequences, and functions of bleaching stages for kraft pulps, alongside key environmental limitations. It discusses ECF and TCF bleaching methods, strategies to reduce AOX, chemical usage optimisation, and connections to effluent treatment systems for eco-friendly production.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
