Paper Manufacturing from Pulp to Market

1. Paper Manufacturing from Pulp to Market By: Mubarak A. AlKhater CEO, Saudi Paper Group Date: 6 December 2009 AICHE, 6 Dec 2009 Le Meridian, Khobar, KSA

2. Corporate Introduction • Saudi Paper Group was established in 1989 in Dammam, KSA with production starting in 1992 • Public Joint Stock Company, with operations covering Middle East & North Africa • Main business units: Paper Recycling, Paper manufacturing and converting (Paper, aluminimum foil, plastics packaging) • Markets served are global

3. Operations Existing Mill Existing Converting Plant Existing Collection Plants

4. Consumer Products

5. TISSUE MANUFACTURING a brief introduction…

6. WHAT IS PULP? Pulp is a cellulose fiber material, produced by chemical or mechanical means, from which paper and paperboard are manufactured. Sources of cellulose fiber include wood, cotton, straw, jute, bagasse, bamboo, hemp and reeds. Pulp is a suspension of cellulose fibers in water.

7. TYPES OF PULP • Forest of the world contains a great number of species,which may be divided into two groups: 1. Coniferous trees (usually called SOFTWOOD) Softwood cellulose fibres measure from about 2 to 4 millimeters (0.08 to 0.16 inch) in length. 2. Deciduos trees (usually called HARDWOOD) Hardwood cellulose fibres measure from about 0.5 to 1.5 millimeters (0.02 to 0.06 inch) in length. • The greater length of softwood fibers contributes strength to paper; while the shorter hardwood fibers fill in the sheet and give opacity and smooth surface.

8. TISSUE PAPER MACHINE A machine for manufacturing paper, such as tissue paper, includes a twin-wire former made up of a rotary forming roll and a pair of endless fabrics, each of which may be a wire or felt, lapped around the rotary forming roll to provide twin-wire web formation therewith. At the location where these endless fabrics travel beyond the forming roll they diverge from each other to define between themselves a diverging space where one of the endless fabrics has an upwardly directed surface on which the web is carried beyond the forming roll. This latter endless fabric carries the web to a press section where this latter endless fabric travels with the web through a first press nip of the press section defined between an inner press roll situated within the loop of the latter endless fabric and an outer press roll situated outside of the latter loop.

9. TISSUE PAPER MACHINE cont’d This outer press roll is lapped by an additional endless fabric structure so that the web is situated at the first press nip between the latter additional fabric structure and the endless fabric which carries the web away from the forming roll. The web travels with the additional fabric structure around the outer press roll, to become detached from the endless fabric which carries the web away from the forming roll, and this outer press roll cooperates with a drying cylinder of a drying section of the paper machine to define therewith at least a second press nip.

10. TYPICAL TISSUE MACHINE FLOW DIAGRAM CL BOX Constant level box and supply pulp with uniform pressure to refiner Cy 0.2% Cy 4.0 % SW REFINED PULP CHEST SILO Cy controller CLOSED LEVEL BOX Cy 4.5% SOFT WOOD PULPER HIGH DENSITY CLEANER Separate heavy impurities ie stone,metal,rope.. REFINER Over flow FAN PUMP Fibre brushing to achieve strength Stock & recirculated water are mixed Disintegrating purchased pulp Cy 4.5% Cy 4.5 % Cy 1% M/C CHEST BLEND CHEST Final stage screening , separate shives and other large size particles from pulp slurry BASIS WEIGHT VALVE CL BOX PRESSURE SCREEN Blending fibers by ratio Stock tank to keep m/c run stable Precision control of pulp flow HW PULP CHEST LOW DENSITY CENTRY CLEANERS Removing light dense particle sand,dirt, ink,specks by centry fugal force Cy 4% HARD WOOD PULPER Cy controller Cy 4.5% DE FLAKER M/C REFINER HD CLEANER Fibre separation without cutting & damaging HEAD BOX Pressurised device that delivers uniform flow across deckle HOOD Blow hot air Tissue formation –crescent former Yankee WIRE PART Cy 41% Evaporate remaining water in paper web by heat transfer Felt section Cy 94% POPE REEL SPR Cy 20% Suction press roll equiped with suction box to remove water by mechanical energy ( nip load ) Dried paper wounds on spool that rotates against a drum

11. TYPES OF TISSUE MACHINE 1. TWIN WIRE MACHINE Paper machine in which pulp slurry is injected between two forming wires, and water is drained from both sides of the paper web. 2. CRESCENT FORMER MACHINE The sheet is formed between a forming wire and felt that wrap a solid forming roll. When the drainage is completed, the formed sheet is already on the felt. The felt carries the sheet directly to the pressure roll and the Yankee dryer. This eliminates the pick-up function that other machine concepts require.

12. TISSUE MANUFACTURING PROCESS Stock Preparation Approach System Drying Sheet Forming Pressing Reeling Winding

13. DE-INKING PLANT A brief introduction…

14. De-inking of pulp fibers is essentially a laundering or cleaning process where the ink is considered to be the dirt. Chemicals along with the heat and mechanical energy are used during the re-pulping stage to dislodge the ink particles from the fibers and disperse them in the stock suspension. The ink particles are then separated from the so-called “grey stock” by a series of flotation or washing steps, or by applying both separation techniques. WHAT IS DE-INKING?

15. DE-INKING PLANT PROCESS Pulping High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning High Density Cleaning Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Coarse Screening Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Pre-Flotation Thickening Thickening Thickening Thickening Thickening Thickening Washing Washing Washing Washing Washing Washing Washing Fine Screening Fine Screening Fine Screening Fine Screening Fine Screening Fine Screening Fine Screening Fine Screening Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Cleaning Dispersing Dispersing Dispersing Dispersing Dispersing Post Flotation Post Flotation Post Flotation Post Flotation Washing Washing Washing Water Clarification

16. DE-INKING PLANT STAGES 1. PULPING Pulper is the “brain” of the de-inking system. Its function is to defiber the paper and to detach the ink particles from the fibers, while keeping the contraries large enough to be removed by the cleaners and screens. 2. HIGH DENSITY CLEANING The high density cleaner cleans pulp suspensions of sorted and unsorted wastepaper with consistencies up to 4%. It eliminates heavy impurities such as bolts, nuts, nails, staples, glass splinters, etc.

17. DE-INKING PLANT STAGES… 3. SCREENING Stock screening operation is required to remove oversized troublesome and unwanted particles from good papermaking fibers. The major types of stock screens are vibratory, gravity centrifugal and pressure screens (centrifugal or centripetal). They all depend on some form of perforated barrier to pass acceptable fiber and reject the unwanted material. It is the size of the perforations (usually hole or slots) that determine the minimum size of debris that will be removed. All screens are equipped with some type of mechanism to continuously or intermittently clean the openings in the perforated barrier. Otherwise, the plate would rapidly plug up. Methods of cleaning employed include shaking and vibration, hydraulic sweeping action, back-flushing, or most common, pulsing the flow through the openings with various moving foils, paddles, and bumps. The most important consideration for stable, efficient operation is to maintain flow and consistency near optimum levels.

18. SCREENING …

19. DE-INKING PLANT STAGES… 4. FLOATATION At the heart of the floatation process is the floatation cell, of which several designs are available. Here, air in the form of small bubbles is blended with the “grey stock”. The air bubbles become attached to ink and dirt particles, causing them to rise to the cell surface where they are removed as a dirt-laden froth. Depending on the level of dirt in the stock a series of floatation cells are required for efficient ink removal. The froth is subsequently cleaned in a secondary stage to recover good fiber.

20. DE-INKING PLANT STAGES… 5. CLEANING The centrifugal cleaners removes unwanted particles from pulp and paper stock by a combination of centrifugal force and fluid shear. Therefore, it separates both on the basis of density differences and particle shape. All centrifugal cleaners work on the principle of a vortex generated by a pressure drop to develop centrifugal action. The power source is the feed pump.

21. DE-INKING PLANT STAGES… 6. WASHING Washing basically is water extraction. The dispersed ink especially those that are broken down into very fine particles is subsequently separated from the pulp by multi-stage dilution/ thickening washing sequence. The separation of ink in the washing process corresponds to a stock thickening process, whether accomplished by washing equipment or by screens. If the ink particles are extremely small, the amount removed is theoretically proportional to the amount of water removed.

22. DE-INKING PLANT STAGES… 7. BLEACHING Bleaching refers to a number of processes intended to increase the brightness of pulp, reduce color reversion, increase purity of cellulose and to preserve the fiber strength at the same time. It involves contacting/treating unbleached cellulose material under controlled conditions of : stock pH, consistency, Temperature, retention time and concentration of bleaching chemical. Bleaching is achieved through a continuous sequence of process stages utilizing different chemicals and conditions in each stage, usually with washing between stages. The entire bleaching process must be carried out in such a way that strength characteristics and other papermaking properties are preserved. 8. DISPERSING Even after all cleaning and screenings steps, there will be some ink specks and other contaminants remaining in the stock. Disperger is used to break up and finely distribute these contaminants and loosen particles of difficult inks which are still attached to the fibers.

23. DE-INKING PLANT STAGES… 9. WATER CLARIFICATION In wastewater treatment operations, the processes of coagulation and flocculation are employed to separate suspended solids from water.  Although the terms coagulation and flocculation are often used interchangeably, or the single term "flocculation" is used to describe both; they are, in fact, two distinct processes.  Knowing their differences can lead to a better understanding of the clarification and dewatering operations of wastewater treatment. Finely dispersed solids (colloids) suspended in wastewaters are stabilized by negative electric charges on their surfaces, causing them to repel each other.  Since this prevents these charged particles from colliding to form larger masses, called flocs, they do not settle.  To assist in the removal of colloidal particles from suspension, chemical coagulation and flocculation are required.  These processes, usually done in sequence, are a combination of physical and chemical procedures. Chemicals are mixed with wastewater to promote the aggregation of the suspended solids into particles large enough to settle or be removed.

24. China Consumption 2007: 4,271 2011: 5,805 2016: 8,335 Prod 2007: 4,259(1741) Net Trade 2007: 308 E. Europe Consumption 2007: 1,241 2011: 1,657 2016: 2,325 Prod 2007: 1,081(129) Net Trade 2007: -33 W. Europe Consumption 2007: 6,227 2011: 6,945 2016: 7,868 Prod 2007: 5,960(234) Net Trade 2007: -51 N. America Consumption 2007: 8,015 2011: 8,423 2016: 9,022 Prod 2007: 7,761 (217) Net Trade 2007: -89 Japan Consumption 2007: 1,800 2011: 1,880 2016: 1,940 Prod 2007: 1,793(186) Net Trade 2007: -28 Asia Far East Consumption 2007: 1,481 2011: 1,802 2016: 2,259 Prod 2007: 1,387(231) Net Trade 2007: -51 L. America Consumption 2007: 2,923 2011: 3,538 2016: 4,522 Prod 2007: 2,700 (197) Net Trade 2007: -72 Oceania Consumption 2007: 367 2011: 416 2016: 488 Prod 2007: 271(13) Net Trade 2007: -85 Near & Middle East Consumption 2007: 712 2011: 941 2016: 1,342 Prod 2007: 607 (48) Net Trade 2007: -52 Africa Consumption 2007: 466 2011: 578 2016: 773 Prod 2007: 426 (72) Net Trade 2007: -9 Tissue Industry Market Overview Global Demand-Supply & Forecast Source: RISI Outlook for World Tissue Business Forecast 2009 • Legend • Consumption & Capacities in MT ’000 • Net Trade in MT’000 ( +ve Exports, -veImports)

25. Tissue Industry Market Overview – Cont’d Near & Middle East Source: RISI 2009 Turkey Consumption 2007: 225 2011: 315 2016: 470 Prod 2007: 238 Mill Cap 08: 359 (13) Net Trade 2007: 33 Syria Consumption 2007: 49 2011: 64 2016: 92 Pod 2007: 27 Mill Cap 08: 65 (5) Net Trade 2007: -18 Iraq Consumption 2007: 12 2011: 17 2016: 26 Prod 2007: x Mill Cap 08: x Net Trade 2007: -10 Lebanon Consumption 2007: 36 2011: 45 2016: 60 Prod 2007: 37 Mill Cap 08: 60 (6) Net Trade 2007: 3 Iran Consumption 2007: 53 2011: 70 2016: 105 Prod 2007: 29 Mill Cap 08: 30 (3) Net Trade 2007: -19 Jordan Consumption 2007: 18 2011: 23 2016: 32 Prod 2007: 39 Mill Cap 08: 96 (4) Net Trade 2007: 23 GCC Consumption 2007: 198 2011: 265 2016: 380 Prod 2007: 152 Mill Cap 08: 257 (11) Net Trade 2007: -33 Near & Middle East Consumption 2007: 712 2011: 941 2016: 1,342 Prod 2007: 607 Mill Cap 2008: 975 (48) Net Trade 2007: -52 • Legend • Consumption in MT ’000 • Mill Capacities are rated capacities • PM4 for SPMC is not included

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