Lesson 1Paper machine sections: forming, press, drying, calendering basicsThis lesson details the primary sections of the paper machine for woodfree paper types: forming, pressing, drying, and calendering. It covers how water is removed, the sheet is strengthened, moisture is managed, and the surface is finished, showing how machine adjustments influence the final paper qualities in practical settings.
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 factories. It explains simple control loops, the functions of DCS and SCADA, and how these tools help ensure safety, uphold quality, and increase efficiency in daily 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 explores preparing stock for printing and writing papers, covering refining principles, screening and cleaning setups, mixing processes, and controlling dilution. It highlights effects on paper strength, formation, drainage rates, and overall machine steadiness in production lines.
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 explains the flow of water and steam in a paper factory, from intake and treatment to returning condensate. It focuses on integrating heat, measuring specific usage, identifying pinch points, and assessing impacts on costs, emissions, and operational reliability in resource-conscious environments.
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 covers the initial stages of the supply chain: sourcing wood, transporting it, storing supplies, removing bark, and chipping materials. It stresses chip quality standards, managing bark waste, and how variations in raw materials affect pulping efficiency and final paper standards.
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 sourcing, sorting, and readying recycled paper, followed by basic deinking methods for graphic papers. It covers contaminants, key unit processes, yield rates, brightness levels, and how the quality of deinked pulp influences smooth machine running and output.
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 kraft pulping, including cooking reactions, liquor cycles, and fibre characteristics. It explains the recovery boiler, causticizing processes, and recausticizing, emphasising energy production and achieving chemical balance in the system.
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 describes post-machine finishing steps, such as handling reels, rewinding, cutting into sheets, and optional off-machine coating. It addresses removing defects, ensuring roll quality, packaging standards, and how finishing customises products to meet customer needs effectively.
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 introduces the full integrated process for making uncoated woodfree paper, connecting pulp supply, stock preparation, machine sections, and finishing stages. It emphasises material movements, essential equipment, quality controls, and primary factors driving costs and energy use.
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 bleaching goals, sequences, and stage roles for kraft pulps, alongside environmental limitations. It discusses ECF and TCF approaches, reducing AOX, optimising chemicals, and linking to effluent treatment in line with sustainable practices.
Brightness targets and pulp cleanlinessCommon bleaching stages and notationECF, TCF, and oxygen delignificationChemical consumption and cost controlBleach plant effluents and AOX limits
