Lesson 1Paper machine sections: forming, press, drying, calendering basicsCovers the primary sections of the paper machine for woodfree grades: forming, press, dryer, and calender. It details dewatering methods, sheet consolidation, moisture management, and surface finishing, connecting machine settings to paper properties for better production outcomes.
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 in pulp and paper mills. Explains basic control loops, roles of DCS and SCADA, and how instrumentation aids safety, quality assurance, and operational efficiency in local contexts.
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 controlExamines stock preparation for printing and writing papers, covering refining principles, screening and cleaning systems, mixing, and dilution controls. Highlights effects on strength, formation, drainage, and machine stability to optimise mill performance.
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 millDescribes water and steam circulation in a paper mill, from intake and treatment to condensate recovery. Focuses on heat integration, consumption rates, pinch analysis, and influences on costs, emissions, and operational reliability in sustainable practices.
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, chippingDiscusses the initial value chain stages: wood sourcing, transport, storage, debarking, and chipping. Emphasises chip quality standards, bark management, and how raw material variations impact pulping efficiency and final paper quality in regional supply chains.
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 basicsAddresses sourcing, sorting, and preparation of recycled paper, followed by deinking methods for graphic papers. Covers contaminants, unit processes, yield, brightness, and how deinked pulp quality affects machine runnability and product standards.
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 characteristics. Explains recovery boiler, causticising, and recausticising processes, highlighting energy production and chemical recycling for eco-friendly 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 alternativesOutlines post-machine finishing steps, including reel handling, rewinding, sheeting, and optional off-machine coating. Discusses defect elimination, roll quality, packaging, and customising products to meet customer specifications 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 flowProvides an overview of the integrated process for uncoated woodfree paper, connecting pulp supply, stock preparation, machine sections, and finishing. Stresses material flows, key equipment, quality controls, and primary 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, alongside environmental regulations. Discusses ECF and TCF methods, AOX minimisation, chemical efficiency, and effluent treatment to comply with local sustainability standards.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
