Lesson 1Paper machine parts: forming, pressing, drying, and calendering basicsThis lesson details the key sections of the paper machine for woodfree paper types: forming, pressing, drying, and calendering. It explains how water is removed, the sheet is made strong, 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 introduces important field tools, control valves, and automation systems used in pulp and paper mills. It explains simple control loops, roles of DCS and SCADA, and how these tools help with safety, quality, and better work in the mill.
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 explores preparing stock for printing and writing papers, including how refining works, screening and cleaning systems, mixing, and controlling water amount. It shows effects on paper strength, formation, water drainage, and steady machine running.
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 explains how water and steam move through a paper mill, from taking in water and treating it to returning condensate. Focus is on joining heat well, how much is used, tight spots, and effects on costs, smoke, and steady work.
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 moving, removing bark, chippingThis covers the start of the work chain: getting wood, moving it, storing, 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 fiber and basic deinkingThis covers getting, sorting, and preparing old paper, then basic deinking for print papers. Focus includes dirt, unit works, yield, brightness, and how deinked pulp quality 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 kraft recoveryThis introduces kraft pulping chemistry and work, including cooking reactions, liquor cycles, and fiber qualities. It explains recovery boiler, making caustic, and recausticizing, showing energy making and chemical closing.
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 works: rewinding, cutting, coating choicesThis describes finishing steps after the paper machine, including handling reels, rewinding, cutting sheets, and optional coating off-machine. It addresses 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 paper flowThis introduces the joined process for uncoated woodfree paper, linking pulp supply, stock preparing, paper machine parts, and finishing. Stress is on material flows, key tools, quality controls, and main cost and energy drivers.
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 steps ideas and environment limitsThis shows bleaching goals, steps, and stage works for kraft pulps, with environment limits. It talks about ECF and TCF ideas, reducing AOX, chemical best use, and waste water treatment links.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
