Paper production

By far the major use of cellulose is in paper and cardboard production. In 2006 160 million tonnes of pulp were produced from 530 million m of wood. 95% of this was made from plantation wood. It is estimated by the United Nations Food 

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A fatal accident and some other disasters, which were caused by small cracks, lead to a more strict consideration of the security of these steam drums. Parallel to these the economical pressure, due to the globalisation of the today s industry, lead to the increase of the pressure and the rotation speed of the paper production machines for a higher output of the production, which means, that all safety aspects from the design and the material will be exploited totally. On the other hand cast iron is also not a ductile and comfortable material, like the most steels for the pressure equipment. 

It is also extensively used in the production of paper products, dyestuffs, textiles, petroleum products, medicines, antiseptics, insecticides, food, solvents, paints, plastics, and many other consumer products. 

Starch is a polysaccharide found in many plant species. Com and potatoes are two common sources of industrial starch. The composition of starch varies somewhat in terms of the amount of branching of the polymer chains (11). Its principal use as a flocculant is in the Bayer process for extracting aluminum from bauxite ore. The digestion of bauxite in sodium hydroxide solution produces a suspension of finely divided iron minerals and siUcates, called red mud, in a highly alkaline Hquor. Starch is used to settle the red mud so that relatively pure alumina can be produced from the clarified Hquor. It has been largely replaced by acryHc acid and acrylamide-based (11,12) polymers, although a number of plants stiH add some starch in addition to synthetic polymers to reduce the level of residual suspended soHds in the Hquor. Starch [9005-25-8] can be modified with various reagents to produce semisynthetic polymers. The principal one of these is cationic starch, which is used as a retention aid in paper production as a component of a dual system (13,14) or a microparticle system (15). 

Urea—formaldehyde resins are also used as mol ding compounds and as wet strength additives for paper products. Melamine—formaldehyde resins find use in decorative laminates, thermoset surface coatings, and mol ding compounds such as dinnerware. 

Flexographic Inks. Fluorescent toners such as the Radiant GF, Lawter HVT, and Day-Glo HM and HMS Series toners are used in flexographic ink formulations. These products are soluble in blends of alcohol (80%) and ester solvents (20%) and are compatible with modifying materials such as nitroceUulose resins and acryHc solution polymers. Flexographic inks of this type are used most commonly to print products such as ceUophane and polyethylene film for packaging, and also to print paper products such as gift wrap and price labels. 

The wide range of types of paper products results in a variety of sludges. SoHd wastes result from several sources within the mill, eg, bark, sawdust, dirt, knots, pulpwood rejects, flyash, cinders, slag, and sludges. Sludges often are disposed of in combination with residuals from other sources. Approximately 300 kg of soHd waste per ton of finished product is generated by the pulp and paper industry. 

Papermaking additives can be categorized either as process additives or as functional additives. Process additives are materials that improve the operation of the paper machine, such as retention and drainage aids, biocides, dispersants, and defoamers they are primarily added at the wet end of the paper machine. Functional additives are materials that enhance or alter specific properties of the paper product, such as fillers (qv), sizing agents, dyes, optical brighteners, and wet- and dry-strength additives they may be added internally or to the surface of the sheet. 

Paper Production and Properties. During the paper production process, the wood pulp is mixed into an aqueous slurry, which is poured onto a continuously moving wire mesh and drained by gravity. Additional water is then squee2ed out of the paper by a felt web pressed from above. This pressed side, referred to as the felt side, has smaller, finer fibers and is therefore smoother. It is also the preferred printing side. 

Secondary Fiber. Increasing costs of taw fiber, legislative mandates for recycling (qv), and avadabdity of inexpensive waste papers have contfibuted to the increased use of recycled fibers. The use of secondary fiber in the United States has grown from 22% of pulp from all sources in 1978 to close to 31% (24 x 10 metric tons) in 1993 (3). Recycled fibers ate sometimes used in special writing papers, but the principal use is for the manufacture of linetboatd, newsprint, tissue, cereal boxes, towels, and molded paper products such as paper plates and egg cartons (see Packaging materials, containers AND INDUSTRIAL materials). 

This reduces pulp tensile strength but improves tear strength not because of fiber degradation but because the hemiceUuloses bond chemically to give added tensile strength in the final paper product. To overcome this loss in hemiceUulose polymers, starch is added on the wet end of the paper machine as a dry strength additive. 

Dispersants (qv) have been added to the pulper to maintain stickies in a colloidal state. The small particle size reduces the problems stickies cause on the paper machine and in paper products. Among the chemicals that have been used are fatty alcohol ethoxylates, alkylphenol ethoxylates, lignosulfonates, and naphthalene sulfonates (18). 

In 1993, nearly 36 million tons of paper were recovered in the United States, twice as much as in 1980 (54). Eor the first time, more paper was recovered in the United States than landfilled. As a result, 11 million fewer tons of paper were landfilled in the United States in 1993 than in 1987. This saved more than 69 X 10 m (90 x 10 yd ) of landfill space. In 1995, recovered paper accounted for 31.5% of the fiber used to manufacture 84.1 million metric tons of paper products (54). Annual capital spending for paper recycling projects from 1995 to the year 2000 is estimated to average 2 biUion (55). The American Eorest Paper Association (AE PA) estimates U.S. consumption of recovered paper will increase 4.9% per year through the year 2000, nearly twice the total paper industry capacity growth rate (56). Consumption of recovered paper in U.S. mills in 1997 is estimated at 35.6 million tons (57). 

The demand for sodium sulfate leveled off in the first half of the 1990s and is expected to begin to rise again with increased U.S. population and as the demand for kraft paper products and powdered detergents rises. 

The principle uses of Na2S04 are in the manufacture of paper, soaps, and detergents. These accounted for 65% of U.S. consumption from 1990 to 1995, representing a significant shift from 1980 when paper production alone consumed 67%. Pulp (qv) and paper consume only 25% (2). The kraft paper process uses a mixture of sodium sulfide and sodium hydroxide to digest wood chips. Both the sulfide and hydroxide are generated, starting with sodium sulfate as the raw material. 

Low DS hydroxyethyl starches are used as paper coatings and sizes to improve sheet strength and stiffness. They are also employed as paper-coating color adhesives, and to increase fiber bonding in paper products. Hydroxyethylstarches are also used as textile warp sizes. 

Ammonium Sulfamate. A number of flame retardants used for ceUulosic materials, including fabrics and paper products, are based on ammonium sulfamate (56). These products are water-soluble and therefore nondurable if treated fabrics are washed or exposed to weathering conditions. For most fabric and paper constmctions, efficient flame retardancy can be provided with no apparent effect on color or appearance and without stiffening or adverse effects on the feel of the fabrics. A wide variety of materials are treated, including ha2ardous work-area clothing, drapes, curtains, decorative materials, blankets, sheets, and specialty industrial papers (57). 

Paper Products. Paper (qv) products account for about 2% of sulfur demand. The largest single segment of demand is in the manufacture of wood pulp by the sulfite process (see Pulp). In this process, the main sulfur intermediate is sulfur dioxide, which is generally produced at the plant site by burning elemental sulfur. Some sulfur dioxide, however, is produced as a by-product at smelter operations, purified andUquefied, and shipped to the pulp mills. The sulfur dioxide is converted to sulfurous acid, and the salt of this acid is a principal component of the cooking Hquor for the sulfite process. 

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