Understand the operating principles, processes and variables associated with pulp bleaching

1. Understand the operating principles, processes and variables associated with pulp bleaching

2. P&P4EL Quality P&P4EL SHE P&P4EL Basics of the bleaching process P&P4EL Auxiliary systems P&P4EL Standard Operating Procedures P&P4EL Maintenance Understand the operating principles, processes and variables associated with pulp bleaching Topics Modules Notional Hours 15 8 8 8 5 6 10 15 10 5 100 PE402 Understanding pulp bleachingprocesses PE402Understanding the bleaching process feedstock, intermediate and final products PE402Understanding variations in the process PE402Applying sampling practices PE402Understanding potential by-products PE402Understanding the purpose of auxiliary systems associated with the process PE402Understanding Operating Procedures in the process PE402Applying Standard Operating Procedures to the process PE402Applying first line maintenance PE402Applying SHE in the process Total Notional Hours

3. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding pulp bleaching processes Be able to explain the chemical reactions taking place in the different bleaching processes as well as the surface theory relevant to ink particle removal Understand the principles for mass balancing, mass transfer, combustion, heat transfer and how these are applied in the recovery process Understand the basic properties and characteristics of all chemicals used and produced in the bleaching process Understand the fundamental operating principles associated with each of the types of bleaching process Be able to identify each of the major pieces of process equipment Be able to trace the basic process flow within each of the types of bleaching processes (chlorination, alkali, hypo chloride, C1O2, O2, ozone) and brightening (Naso3, H2o2) Understand the different bleaching sequence options Understand the purpose of these processes and how it fits into the overall process

4. Notional Hours 15 Topic Specification: PE402 The pulp bleaching processes Learning Activities Assignment Description Topic assessment criteria Use Multi media Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. WHAT • The assessor will observe and confirm that learners: • Understand the purpose of these processes and how it fits into the overall process • Understand the different bleaching sequence options • Are able to identify each of the major pieces of process equipment • Are able to trace the basic process flow within each of the types of bleaching processes • Understand the fundamental operating principles associated with each of the types of bleaching process • Understand the basic properties and characteristics of all chemicals used and produced in the bleaching process • Understand the principles for mass balancing, mass transfer, combustion, heat transfer and how these are applied in the recovery process • Are able to explain the chemical reactions taking place in the different bleaching processes as well as the surface theory relevant to ink particle removal Self Study Plant investigation Collect Information Media search HOW Interview experts • Learners are provided with relevant plant and equipment information / manuals • Inspect the plant and determine the process flow through all the bleaching processes • Draw a block diagram to show where this process fits into the overall process, specifically noting suppliers and customers of this plant • Draw a basic layout sketch of this area • In a discussion with a plant specialist, identify: • the purpose of these processes • the different bleaching sequence options • the different equipment used • the fundamental operating principles associated with each of the types of bleaching processes • the basic properties and characteristics of of all chemicals used and produced in the bleaching process • the principles for mass balancing, mass transfer, combustion, heat transfer and how these are applied in the recovery process • the chemical reactions taking place in the different bleaching processes as well as the surface theory relevant to ink particle removal. • Learners complete a questionnaire to indicate findings Attend lectures Group Discussions Sketch Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

5. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding the bleaching process feedstock, intermediate and final products Be able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Be able to carry out quality checks on the feedstock and final products Understand the properties of the feedstock, intermediate and final products Know the typical specifications for the feedstock, intermediate and final products in each of the process Understand the reasons for quality standards in raw materials, intermediate and final products Know the suppliers of feedstock and the customers for the products produced.

6. Notional Hours 8 Topic Specification: PE402 The bleaching process feedstock, intermediate and final products Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Know the suppliers of feedstock and the customers for the product produced. • Understand the reasons for quality standards in feedstock, intermediate and final products • Know the typical specifications for the feedstock, intermediate and final products in each of the processes • Understand the properties of the feedstock, intermediate and final products • Are able to carry out quality checks on the feedstock and final products • Are able to construct a spreadsheet with throughputs, specifications, typical results and reasons for each specification Individual or group training. Obtain basic product and supplier information by discussions with production experts. Apply knowledge in a practical quality check. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures • Learners are supplied with information on feedstock quality • Have a facilitated group discussion in the plant to determine: • by whom feedstock is supplied and routes into the plant • the typical grades and properties of the feedstock • the typical properties and specifications used for the final products • the customers for the product produced • the reasons for quality standards in feedstock, intermediate and final products • Draw-up a quality checklist/spreadsheet with throughputs, specifications, typical results and reasons for each specification • Carry out quality checks on the final product using the checklist/spreadsheet and report findings Group Discussions Educational games Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

7. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding variations in the processes Know the effect of variations and deviations on the processes and products Understand what process variations could occur in the processes Understand how a deviation in the properties of the feedstock will impact on the processes Understand what feedstock variations could occur in the processes Be able to complete all log sheets

8. Notional Hours 8 Topic Specification: PE402 Variations in the processes Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Are able to complete all log sheets. • Understand what feedstock and process variations could occur in the processes. • Understand how a deviation in the properties of the feedstock will impact on the processes. • Know the effect of variations and deviations on the processes and products Individual or group training. Use the information on the feedstock obtained earlier to list quality variations. A facilitated discussion to identify possible process deviations and the downstream effects. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures • Learners are supplied with log sheets and assisted to complete them with the help of a production specialist • Individually list the feedstock and process variations that could occur and the effect each type of variation could have on the final product and / or in downstream processes or products • In a facilitated discussion at the site, identify and list the effect each type of deviation could have on the final product and / or in downstream processes or products • Tabulate all variations and deviations, their effects and the broad rectification action required and compile the information into a report Group Discussions Educational games Case studies Analyse, plan and make decisions List / Tabulate Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a questionnaire

9. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Applying sampling practices Be able to interpret the test results in terms of the impact on the process and customers Be able to construct a basic spreadsheet for product sources and sample results Be able to do sampling according to plant standards Understand the principles of sampling used in the bleaching process

10. Notional Hours 8 Topic Specification: PE402 Apply sampling practices Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Understand the principles of sampling used in the bleaching process • Are able to do sampling according to plant standards • Are able to construct a basic spreadsheet for different sources and sample results • Are able to interpret the test results in terms of the impact on the process and customers Learners are given a short lecture on the statistical basis of sampling practice. Sampling is demonstrated and then done under supervision. A spreadsheet showing required and typical feedstock and final product qualities is drawn up. Self Study Plant investigation Collect Information Expert demonstration Interview experts Attend lectures Group Discussions HOW Educational games Case studies Analyse, plan and make decisions • Learners are given a lecture on the statistical basis of sampling practice and tied into the sampling practice in the bleaching area. • A typical sampling procedure is outlined and a simple checklist compiled • Learners view a demonstration of sampling and take a full range of samples under supervision • The results of samples are compared to specifications and typical values previously obtained • A short report outlines findings List / tabulate Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test

11. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding potential by-products Know what the potential advantages and disadvantages are of producing the potential by-products Understand the basic processes of recovering the potential by-products Know what potential by-products could be produced in the bleaching process

12. Notional Hours 5 Topic Specification: PE402 Understanding potential by-products Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT Learners are given material explaining the recovery of by-products in the bleaching process. Learner groups investigate the recovery of these products and make a rough estimate of the benefits vs. costs (actual or potential). Various sources can be involved in estimating costs, laboratory analysis, sales prices, etc. • The assessor will observe and confirm that learners: • Know what potential by-products could be produced in the bleaching process. • Understand the basic processes of recovering the potential by-products. • Know what the potential advantages and disadvantages are of producing the potential by-products Self Study Plant investigation Collect Information Media search Interview experts Attend lectures Group Discussions Sketch HOW Case studies Analyse, plan and make decisions Do calculations Develop recommendations • Each group assess the following: • a basic plant layout for the recovery of each by-product • approximate capital costs • the quantity of each product recoverable • the value of each product • running costs • costs involved in non-recovery • A short presentation on the findings is made by each group Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire

13. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding the purpose of the auxiliary systems associated with the processes Understand the fundamental operating principles associated with each auxiliary system Be able to trace the flows in the auxiliary systems Be able to identify each piece of equipment in each auxiliary system associated with this process Understand the purpose, use and application of each auxiliary system and how it fits into the process

14. Notional Hours 6 Topic Specification: PE402 Purpose of auxiliary systems associated with the process Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. • The assessor will observe and confirm that learners: • Understand the purpose, use and application of each auxiliary system as well as the fundamental operating principles associated with the system. • Are able to identify the components and trace the flow of each system. Self Study Plant investigation Collect Information Media search Interview experts HOW Attend lectures Group Discussions • Inspect the equipment and determine the interaction of each auxiliary system (e.g. steam) with the plant • Draw a block diagram showing the main components of each auxiliary system relevant to the plant. • In a discussion with a specialist on the auxiliary system, identify: • what the purpose, use and application of the system is • how it supports the process • the different components of the system, and • the fundamental operating principles of the system • Compile all the obtained information in a short report Sketch Summarise Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire

15. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding Operating Procedures in the process Understand the sequence and reason for correcting deviations Understand the sequence and reason for shut-down and emergency shut-down procedures Understand the reason for maintaining normal running conditions and the consequences of losses caused by inefficient operation Understand the sequence and reasons for every pre-check Understand the sequence and reasons for start-up procedures Understand the reasons for having pre-check-, start-up-, normal running-, shutdown- and deviation correction procedures Understand the different responsibilities in terms of compiling, authorization, layout / format and safety procedures contained in the Standard Operating Procedures Know any other plant / process rules and regulations applicable to the plant Know the purpose of Standard Operating Procedures

16. Notional Hours 10 Topic Specification: PE402 Understanding “Standard Operating Procedures” Learning Activities Assignment Description Topic assessment criteria Use Multi media A facilitated group discussion is used to clarify the logic behind controlled procedure systems. Individual procedures are studied in detail or in terms of key steps as indicated. Indices and summaries for procedures are created for easy future reference. WHAT • The assessor will observe and confirm that learners: • Know the purpose of these procedures • Know other applicable plant rules and regulations • Understand the reason for responsibility control and document control procedures • Understand the reasons for having • pre-checks • start-up procedures • maintaining normal running condition procedures and the consequences of losses caused by inefficient operation • shut-down and emergency shut-down procedures • correcting deviation procedures • Know procedures and sequences in detail or in terms of key steps as required Self Study Plant investigation Collect Information Media search Interview experts Attend lectures HOW Group Discussions • Learners are supplied with the operating procedures for the plant and individual equipment and any other relevant plant rules and regulations • In a facilitated group, the document control system is shortly explained. The purpose of the procedures, responsibility control, document control and having procedures for each operating phase (pre-check, etc.) is discussed and summarised • Procedures and sequences are studied in detail (esp. emergency procedures) or in terms of key steps as required. Practical understanding and knowledge is essential • Learners should compile a file containing an index (with subheadings / keywords as necessary) of each procedure • A theoretical test will proof competence Educational games Summarise Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a theoretical test

17. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Applying Standard Operating Procedures to the process Be able to bring product variations under control Be able to shut the process down Be able to bring process variations under control Be able to maintain normal running conditions Be able to monitor the process Be able to start the process up Be able to do pre-checks on the process Be able to use and interpret instrument readings

18. Notional Hours 15 Topic Specification: PE402 Applying “Standard Operating Procedures” Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Are able to: • use and interpret instrument readings • do pre-checks on the process • start the process up • monitor the process • maintain normal running conditions • bring process and product variations under control • shut the process down Group or individual training sessions where, through demonstration, the learner first observes the implementation of operating procedures and then implements the procedures himself under supervision Self Study Plant investigation Collect Information Media search Expert demonstration Attend lectures HOW Group Discussions Summarise • By using relevant checklists and operating procedures, learners will first observe and then, under supervision, implement the following procedures: • do pre-checks on the process • start the process up • use and interpret any instrument readings • monitor the process • maintain normal running conditions • bring process and product variations under control • shut the process down • Complete any relevant pre-check, start-up, etc. reports as normally required • A practical test will proof competence Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a practical test

19. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Applying first line maintenance Be able to carry out maintenance and pre-maintenance duties on the processes Know documentation requirements for maintenance functions

20. Notional Hours 10 Topic Specification: PE402 Applying first line maintenance Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Understand the documentation requirements for maintenance functions • Are able to carry out maintenance and pre-maintenance duties on the processes. Individual or group training. Study given materials regarding first line maintenance. A discussion / demonstration of first line maintenance duties are facilitated at the plant. Carry out first line maintenance under supervision. Self Study Plant investigation Collect Information Media search Expert demonstration Attend lectures Group Discussions HOW Summarise Case studies Analyse, plan and make decisions • Learners are supplied with documentation required for first line maintenance on the plant and machines • A discussion / demonstration of typical first line maintenance procedures and their sequence is facilitated in the plant • A checklist is drawn up • Under supervision, carry out pre-maintenance and maintenance duties on equipment as prescribed • Complete pre-maintenance and maintenance reports / log sheets Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire

21. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Applying SHE in the process Understand the potential environmental impact of the process Be able to identify all potential hazards and indicate actions to reduce/avoid hazards Know the relevant sections of the OHS Act Understand the application of fire prevention, lock-out and emergency procedures Know the safety standards, procedures and safety equipment relevant to the process

22. Notional Hours 5 Topic Specification: PE402 Applying SHE in the process Learning Activities Assignment Description Topic assessment criteria Use Multi media WHAT • The assessor will observe and confirm that learners: • Know the relevant OHS Act, safety standards, procedures, and equipment in the plant. • Understand the application of fire prevention, lock-out and emergency procedures in the plant, as well as the potential environmental impact of the processes. • Are able to identify all potential hazards in the processes and indicate actions to reduce / avoid / minimise the impact of these hazards. Learners obtain information through self study. Individuals evaluate the plant area for safety features, potential hazards and environmental impact. Self Study Plant investigation Collect Information Media search HOW Interview experts Attend lectures • Learners are supplied with a copy of the safety procedures and the relevant section of the OHS Act • Learners individually undertake a plant inspection and identify all potential hazards. They also assess the potential impact of the plant on the environment. • Learners should also sketch the area and indicate the position of all safety equipment and safety features (e.g. alarm buttons, emergency exists) on it • Recommendations are made to reduce / avoid these hazards, the impact of possible hazards and the plant’s impact on the environment • A short presentation on the findings is made Group Discussions Educational games Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire

23. Critical Cross-field Outcomes Identify and solve problems Work effectively with others Communicate effectively Organise and manage myself and my activities Collect, analyse, organise and critically evaluate information Use science and technology effectively and critically Demonstrate an understanding of the world as a set of related systems Use mathematics Learner and societal development US: U0008 Understand the operating principles, processes and variables associated with pulp bleaching PE402 Understanding the brightening / whitening process of mechanical pulp Be able to draw a basic diagram of the process flow in a typical brightening / whitening section and identify the major hazards in the section and the key safety precautions required Know what tools and chemicals are used in each of the phases in the brightening / whitening process Know what the inputs and outputs of each of the phases in the brightening / whitening process is Be able to identify all the major pieces of equipment used in the brightening / whitening process and describe the function of the pieces of equipment Understand what the purpose of the brightening / whitening process is and how it fits into the total paper making process

24. Notional Hours 10 Topic Specification: PE402 Understanding the brightening / whitening process of mechanical pulp Learning Activities Assignment Description Topic assessment criteria Use Multi media Individual or group training. Do self study to develop key plant operation questions. Answers are obtained by discussions with production experts and plant investigation. WHAT • The assessor will observe and confirm that learners: • Understand what the purpose of the brightening / whitening operation is and how it fits into the total paper making process • Be able to identify all the major pieces of equipment used in the brightening / whitening process and describe the function of each • Know what the inputs and outputs of each of the phases in the brightening / whitening process is • Know what tools and chemicals are used in each of the phases in the brightening / whitening process • Be able to draw a basic process flow diagram of a typical brightening / whitening section and identify the major hazards in the section and the key safety precautions required Self Study Plant investigation Collect Information Media search HOW Interview experts • Learners are provided with relevant plant and equipment information / manuals • Inspect the plant and determine the process flow through the process • Draw a block diagram to show where this process fits into the overall process, specifically noting suppliers and customers of this plant • Draw a basic layout sketch of this area • In a discussion with a plant specialist, identify: • the purpose of these processes • the different bleaching sequence options • the different equipment used • the fundamental operating principles of the process • the basic properties and characteristics of all chemicals used and produced in the process • the chemical reactions taking place in the process • Learners complete a questionnaire to indicate findings Attend lectures Group Discussions Educational games Case studies Analyse, plan and make decisions Use checklists Develop recommendations Job assignment Make presentation Complete documents Execute, test and evaluate Draft a report Complete a test/questionnaire