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 explains how water is removed, the sheet is strengthened, moisture is managed, and the surface is smoothed, showing how machine adjustments influence the final paper's qualities like strength and appearance.
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 roles of DCS and SCADA, and how these tools help ensure safety, uphold quality standards, and enhance 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 delves into stock preparation for printing and writing papers, covering refining principles, screening and cleaning setups, mixing processes, and dilution management. It highlights how these steps affect paper strength, sheet formation, drainage rates, and overall machine performance 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 millThis lesson explains the flow of water and steam throughout a paper mill, from initial intake and treatment to returning condensate. The emphasis is on integrating heat effectively, monitoring specific usage, identifying pinch points, and understanding effects on costs, emissions, and system reliability in local conditions.
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 supply chain: sourcing wood, transporting it, storing it, removing bark, and chipping. It stresses the importance of chip quality, managing bark waste, 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 covers collecting, sorting, and preparing recycled paper, followed by basic deinking methods for graphic papers. It focuses on dealing with contaminants, key unit processes, yield rates, brightness levels, and how the quality of deinked pulp influences smooth paper machine operations.
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 circulation, and fibre characteristics. It explains the recovery boiler, causticising, and recausticising processes, underscoring energy production and the closed-loop chemical 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 the post-machine finishing stages, such as handling reels, rewinding, cutting into sheets, and optional off-machine coating. It addresses removing defects, ensuring roll quality, packaging, and tailoring the product to meet customer specifications 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 provides an overview of the integrated process for producing uncoated woodfree paper, connecting pulp supply, stock preparation, paper machine operations, and finishing. It emphasises material flows, essential equipment, quality control points, and major 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 the goals of bleaching, typical sequences, and functions of each stage for kraft pulps, alongside environmental limitations. It discusses ECF and TCF approaches, reducing AOX, optimising chemicals, and integrating with 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
