C H A P T E R

14
Water Circuits in Paper Mill
14.1 INTRODUCTION demands from environmental authorities and
also the desire of many companies to be consid-
Water is one of the key components of paper- ered environmentally friendly. Several
making. The pulp and paper industry uses a lot strategiesdbasic conservation and water reuse
of water in its processes. Large amounts of water and water recyclingdprovide a systematic
and energy in the form of steam and electricity approach to water resource management.
other than the raw materials are necessary for Implementation of these strategies requires not
paper manufacturing. Water appears to play only increased financial investment but also
several essential roles during manufacture of increased better utilization of water resources.
paper. It acts as a swelling agent for the fibers, The ultimate objective for pulp and paper com-
promoting the process of refining and the devel- panies is to have effluent-free factories with no
opment of contact area between fibers. It serves negative impact on the environment.
as the solvent for a variety of chemical additives
to the process. It serves at the suspending
medium for the solids, making it possible to 14.2 WATER CONSUMPTION
disperse them and then form them into a fairly LEVELS
uniform sheet as the paper is dewatered on a
forming fabric or between a pair of fabrics. In the earlier days, paper was produced with
And finally, it facilitates the formation of high specific water consumption. The paper
hydrogen bonds within the paper structure, industry has been able to reduce its water
which are a characteristic feature of paper. consumption significantly and has improved its
A market study has shown that about 85% of processes in the last few decades for economic
the water that the pulp and paper industry and ecologic reasons. This could be possible
consumes is only used for processing, ultimately because of the increasing closure of in-mill water
producing large volumes of contaminated circuits and consistent reuse of clarified process
wastewater. Owing to its high competence in water by former freshwater consumers. A
closing water circuits, the paper industry pres- survey conducted by Papiertechnische Stiftung
ently counts among the most advanced indus- (PTS) and the German Pulp and Paper Associa-
trial sectors regarding water efficiency. New tion showed that the average specific effluent
processes and other technological developments volume of Germany’s pulp and paper industry
have reduced freshwater consumption over the reduced from 46 to 9 L/kg of product produced
years. This progress has been stimulated by stern between the1970s and today. In spite of that, the

Biermann's Handbook of Pulp and Paper: Paper and Board Making

https://doi.org/10.1016/B978-0-12-814238-7.00014-3 311 Copyright © 2018 Elsevier Inc. All rights reserved.
312 14. WATER CIRCUITS IN PAPER MILL

paper industry remains one of the biggest con- water. This results in relatively large quantities
sumers of industrial water. The consumption of contaminated water and necessitates the use
levels are found to vary from mill to mill because of wastewater treatment solutions onsite. Strate-
of both general and process-related reasons, such gies include primary treatment such as clarifica-
as raw materials used, paper grades produced, tion to remove solids and particulate matter and
and plant structure. Moreover, local boundary secondary biological treatment processes for
conditions, such as requirements on wastewater removing biodegradable organic matter and
discharge, have an impact on the consumption reducing the effluent toxicity. Process water is
level. High specific effluent volumes occur required for several process stages (Table 14.1).
particularly in the production of specialty paper The amount is very much dependent on the
grades. These mills are often faced with struc- type of process and chemicals used in the
tural handicaps causing increased specific process. The discharged water effluents can
effluent volumes: small paper machines, low contain significant amounts of toxic substances,
production rates, frequent grade changes and which can cause death to the living organisms
often very high quality requirements on the final in receiving waters and affect the terrestrial
product. The lowest water requirements can be ecosystems negatively. The effluents can also
seen in mills that produce packaging papers, cause thermal impact, slime growth, scum
such as corrugated base paper or board. Some formation, and loss of aesthetic beauty in the
of these mills have succeeded to close their water environment. Considerable volumes of cooling
circuits completely, resulting in a zero effluent water are also used because of the high energy
production. intensity of the processes. This water is normally
not contaminated and does not affect the
environment negatively if not reused as process
14.3 PROCESS WATER water or discharged to small recipients where
temperature increase is a limiting factor.
Paper mill waters carry significant quantities The quality of the process water is lower than
of fiber (losses with effluent 0.5%e5% of total fi- that of fresh water because of its content of solid,
ber amount), filler, fines, and other wet-end ad- colloidal, and dissolved substances. Major
ditives that contribute to the total suspended process changes in paper production in the last
solids (TSS), the chemical oxygen demand 2 decades (Table 14.2) have led to steadily
(COD), and the biological oxygen demand
(BOD). TSS in paper mill waters varies signifi-
cantly from mill to mill based on the type of in- TABLE 14.1 Requirement of Process Water in
Several Process Stages
ternal clarification equipment used, equipment
arrangement, and design philosophy. COD Raw materials preparation (wood chip washing)
depends on the amount of suspended solids, Cooking
such as fiber, fines, and other chemically oxidiz-
Pulp washing
able wet-end additives such as starch. BOD is
high because of the presence of large amounts Screening
of oxidizable materials, such as fiber, fines, Bleaching
starch, wet and dry strength resins, drainage
Transportation
aids, dyes, sizing materials, and other dissolved
organics. Dilution
Approximately 85% of the water used in the Formation
pulp and paper industry is used as process
 14.4 WATER CIRCUITS 313
TABLE 14.2 Major Process Changes in Paper causing defects in paper as well as resulting in
Production in the Last Two Decades paper web breaks. Detrimental substances
Increased use of recovered paper include anionic oligomers and polyelectrolytes
as well as nonionic hydrocolloids. Their content
Change from acid to neutral systems in the paper machines
in the water circuits is usually measured with
Reduction of freshwater consumption. the help of sum parameters as so-called anionic
trash, measured as cationic demand by polyelec-
trolyte titration in a streaming current device or
growing problems due to an increased content of as COD. Inorganic dissolved substances, i.e.,
so-called detrimental substances in the water salts, are measured as increased conductivity.
loops. Detrimental substances originate from Salts are also detrimental to the process perfor-
wood components such as resin or lignin deri- mance and potentially for the paper properties.
vates; from freshwater such as humic acids; Electrolytes reduce the swelling potential of
from broke and recovered paper such as coating fibers and chloride and especially lead to corro-
binders, glues, and adhesives; from additives sion of machine parts. The content of detrimental
such as fatty acids or silicates, starch, and others. substances in paper mill water circuit systems
Table 14.3 shows the composition and origin of depends on the input of raw materials, on the
detrimental substances in the process water. output by bleeding through wastewater
Detrimental substances can cause a lot of disposal, as well as by the degree of transfer to
problems throughout the whole papermaking the final paper, on the loop design, and on the
process, such as reduced efficiency of additives, presence of “kidney” technologies in the mill.
reduced optical and strength properties, poor For different applications, such as sprays in the
sizing, bad odor, negative effects on drainage paper machine, solids (mainly fibers, fines, and
and drying, and therefore reduced paper fillers) in the process water are also disturbing
machine speed. These substances are the main and have to be removed before the water is used.
reasons for deposits and foam generation

14.4 WATER CIRCUITS

TABLE 14.3 Detrimental Substances
There are three process water circuits in a
Sodium silicate
(from peroxide bleaching, deinking, recovered paper) paper mill: the primary circuit, the secondary
circuit, and the tertiary circuit. A scheme of the
Polyphosphate
water circuits in a paper mill is shown in
(from filler dispersing agent)
Fig. 14.1. In the primary circuit (short circula-
Polyacrylate tion), the fiber, fines, and filler-rich water
(from filler dispersing agent)
obtained in the sheet-forming zone of the wire
Starch section (white water I) are recycled for stock
(from coated broke, recovered paper) dilution in the stock approach flow system. The
Humic acids primary circuit is maintained as closed as
(from fresh water) possible.
Lignin derivates, lignosulfonates, hemicelluloses Excess water from the sheet-forming section,
(from chemical and mechanical pulp) suction and press water, as well as cleaning
water are called white water II and are circulated
Fatty acids
(from mechanical pulp, deinking) in the secondary circuit (long circulation). The
white water draining from the wire is typically
314 14. WATER CIRCUITS IN PAPER MILL

Raw water Water flow

Tertiary circuit (outer circle)
Fiber flow

Raw water treatment Sludge

treatment
Secondary circuit Fresh
water
(long circulation)
Stock preparation

Stock
Primary circuit
(short circulation)

Paper machine Partial

wastewater
Excess stream
White water I water

Save-alls for stock

recovery and water
clarification
White water II
Excess
water
(Recovered stock)
Wastewater treatment plant Sludge
treatment

Effluent to recipient

FIGURE 14.1 Simplified scheme of water and stock streams in a paper mill. Based on European Commission (2001).

treated through a so-called save-all, which may usually added to aid in the filtration of fines.
be a sedimentation or flotation plant or a filtra- Dissolved air flotation (DAF) equipment is also
tion unit, such as a drum or disc filter. This water used for flotation save-alls in many mills. Such
is then called clarified water. The function of a processes are designed so that fiber fines and
save-all is to remove fines, fiber http://www4. other solids rise to the top of a shallow chest
ncsu.edu/whubbe/FINE.htm, and other solids where they can be skimmed off and recovered.
from the white water. The clarified white water A precoat disc filter conditioned with raw
can then be used for various purposes for pulp produces stocks with highest consistency
showers, stock dilution, and for make-down of (10%e30%) and is designed to achieve a three
certain types of chemical products. It can also (or four)-way separation of the white water
be stored with a much-reduced chance of into fiber, a first draw of cloudy water and
materials becoming settled as deposits. This subsequent draws of clear and superclear
clarified white water from a save-all also may filtrate. The cloudy filtrate is usually recycled
be discharged to wastewater treatment, reducing back to the filter as dilution water but can also
the loss of solids from the process. The most replace fresh water in the process or be used
commonly used types of save-alls use disc or for the dilution of the stock. A higher recycling
drum screens. Some long fiber or broke is rate of cloudy filtrate back to the disc filter
 14.4 WATER CIRCUITS 315
results in a cleaner filtrate. The concentration of usually a high degree of water recirculation in
suspended solids in the clear filtrate (fines and different water loops. About 1e1.5 m3/t of
fillers) is generally about 10e150 mg/L for vir- paper is usually evaporated in the dryer section
gin pulp or 100e400 mg/L with recycled pulp. of a machine and lost from the process. “Dry”
Flotation systems are also used as save-all. At paper product in equilibrium with a normal
optimum conditions, the efficiency of flotation atmosphere is around 6%e10% water. Water
systems for solids removal is often almost management is absolutely required for every
100%, resulting in concentration of suspended modern paper mill. Table 14.4 shows major
solids of 10e50 mg/L (for virgin pulp). The principles to be followed for successfully manag-
consistency of the floated sludge is between 3% ing the water circuit system.
and 10%. Flotation plants consist of a clarifying The paper machine loop consists of the white
basin with sludge removal, aeration equipment waters I and II and the save-all unit. White water
for a partial stream of clarified water, and a I, originating from the wire section, is used to
dosing plant for the flotation chemicals. The directly dilute the main stock flow after the
advantage of flotation is that small-size colloidal machine chest in the approach flow system and
material also can be removed (if suitably floccu- for profile control in the headbox. White water
lated before flotation). This is a great advantage II originates from the forming section but addi-
in deinking of recycled fibers, where a large tionally from the press section after removal of
part of the solid material in the process water is felt hairs, usually with a bow screen, from broke
colloidal (in a deinking plant, the floated sludge
is pumped to sludge dewatering instead of being
recycled to the process). Sedimentation installa- TABLE 14.4 Major Principles to Be Followed for
tions are suitable for the clarification of filler- Successfully Managing the Water
loaded process water but require large volumes Circuit System
and large space requirement. Efficient loop separation, i.e., transferring stock from one
The fiber stream that is recovered in save-alls process loop to the following one only at high consistency
is returned to the stock chest, and the different (preferably 30%), which means at low water content, to
avoid, to the greatest possible degree, transferring
quality waters are returned to different use
detrimental substances from one water loop to the following
relevant to their quality where it replaces fresh one.
water. The tertiary circuit contains excess water
Application of countercurrent flow, meaning fresh water is
from the secondary circuit and, in addition, all
added only at the paper machine, excess water from each
other process water which is not, or is not loop must only be sent backward, and wastewater is
directly reusable because of its degree of contam- disposed of only from the first loop in fiber preparation
ination. It is treated in chemomechanical and/or (lowest quality water).
biological wastewater treatment plants. Up to No mixing of water from different production lines in mills
now, reuse of purified water is not fully appli- where more than one paper machine is operated
cable for all paper grades. In some cases, purified
No mixing of water from different fiber preparation lines
water is partially returned to the process and/or pulp preparation plants
depending on product quality and local condi-
Use of kidney technologies for removal of solids and/or
tions. Closed water circuits are only realized in
detrimental substances
a few paper mills producing corrugating
medium based on recovered paper processing Adequate sizing of the water buffers for each water loop in
accordance with the stock storage volumes for avoiding
or board.
uncontrolled overflows in start-up, shutdown, or paper
At the wet end of a paper machine, a very machine sheet break situations.
large quantity of water is involved, and there is
316 14. WATER CIRCUITS IN PAPER MILL

thickening, and from the overflow of white water is sent, from the save-all unit backward, as
water I. White water II is sent to a buffer tank makeup water to the stock preparation, thus
and from there it is used at the end of stock following the countercurrent principle. This
preparation to dilute stock from high consistency makeup water is often additionally treated in a
(12%e30%) to storage consistency (4%e12%) DAF using coagulation and flocculation chemi-
and for slushing and diluting broke. A defined cals for removing the harmful substances before
amount of white water II, preferably the majority feeding it backward. In some cases, the water
of it, plus the trimmings from the forming circuit system of a paper mill consists of only
section are fed to the save-all unit. Save-alls one water loop, for example, when chemical
have two functions: stock recovery and water pulp is the only fiber source or in case of lower
clarification. Most of the modern paper machines quality packaging paper production. In case of
are equipped with a disc filter save-all treating a systems using mechanical fibers and/or recov-
certain volume of white water II by filtering it ered paper, the strict separation of the water
through a fiber mat. This mat is formed by loops in stock preparation from the paper
adding a so-called sweetener stock to the white machine loop is very important for meeting
water II filter. For sweetener stock, usually the high runnability and quality demands because
best dewatering stock component used at the this strategy keeps harmful substances away
paper machine is selected for limiting the size from the paper machine. Depending on the
of the disc filter. The disc filter save-all applica- required quality of the prepared fiber stock and
tions also produce a superclear filtrate with thus on the design of the stock preparation
very low solids content in addition to cloudy system, the water circuit system in the stock
and clear filtrate. This filtrate is used as a fresh- preparation can consist of from one to three
water substitute for spray applications in the water loops. The loops are separated by the
paper machine. The clear filtrate is stored in a thickening/dewatering process stages (disc filter
buffer tank. The cloudy filtrate is generally fed plus wire press or screw press). The filtrates of
directly back to the inlet of the disc filter, these stages are sent backward for dilution pur-
whereas the “used” sweetener, including the poses in the same loop, where the excess water
recovered stock, is fed back to the thick stock (usually clear filtrate from the disc filter) replen-
in the approach flow system. DAF-type save- ishes the preceding loop. A water buffer tank,
alls are used in older machines and these days usually fed by clear filtrate from the disc filter
when a certain degree of ash and fines removal in loop I, avoids uncontrolled overflow to the
from the process is demanded. In this case, the wastewater treatment plant. Wastewater is
sludge of the DAF is rejected. The benefits of a disposed of from the first water loop as filtrate
disc filter save-all compared with a DAF save- from reject and sludge thickening, as these
all are higher filtrate quality, no chemical con- filtrates are of low quality. Usually they are
sumption, and reduced space requirements. treated chemically/mechanically in a DAF unit.
There are two reasons why there is always an Depending on the freshwater consumption, a
excess of water present in the paper machine certain amount of this treated filtrate can be
loop. First, the paper machine loop is continu- recycled into the process. To reduce the content
ously fed with fresh water, used for spraying, of harmful substances within a water loop,
and chemical dilution. Second, the incoming DAF units are used as so-called kidneys for
water content of the stock is higher (consistency circuit water cleaning, usually in the second
12%e30%) than the water content in the sheet loop of the stock preparation. In this case, a com-
after the press section (consistency up to 50% bination of coagulants and flocculation aids are
and more). In the form of clear filtrate, this excess added to part of the disc filter clear filtrate in
 14.4 WATER CIRCUITS 317
loop II to precipitate and flocculate harmful sub- before it enters the paper machine system. In
stances into a floatable form and subsequently this way, the carryover of process disturbing
remove them from the process in the DAF. A compounds to relatively clean process water
high ash content in recovered paper is also prob- systems is reduced. The separation of the water
lematic for some paper grades. Here, washing loops is carried out with thickeners such as
stages in the stock preparation only make sense dewatering screws and wire presses or a
when large amounts of ash are required to be washing stage, i.e., a thickening step. The extra
removed. Therefore currently the filtrates of thickener leads to an improved separation of
screw presses are often deashed for achieving a the “dirty” stock preparation and the “clean”
reduction in ash content in the final stock. Usu- paper machine and thus to significant reduction
ally the screw press filtrate is precalibrated in a of organic substances that enters the paper ma-
spray filter for fiber saving, and the fiber-free chine loop. This process-integrated measure
but ash-containing filtrate is then also sent to a can be applied to both new and existing plants.
DAF unit after the addition of flocculation aids. The main achieved environmental perfor-
mance is reduction of freshwater consumption,
possible reduction in the discharge load of
Separation of Water Loops for Reducing COD, and no increase in concentration in the
Freshwater Consumption paper machine water loop, thus enhancing the
runnability of the process. The reduction rate
In the recycling of process water in integrated
depends mainly on the situation before the
pulp and paper mills, the white-water flow from
improvements and the wastewater system
paper mill to pulp mill should be taken counter-
applied afterward. Strict separation of water
current to the product flow. In case of an
loops generates good opportunities for in-line
integrated pulp and paper mill, the pulp depart-
treatment to remove disturbing substances.
ment, the bleaching department, and the paper
Measures for reduction of emissions to sur-
mill each have its own white-water circulation,
face water are often closely related to reduction
from which the excess water goes backward to
of fresh water. Water system closure does not
the previous department where water quality is
reduce the pollution load but generates less
less demanding. The excess white water from
wastewater with increased contamination levels.
the paper machine is used instead of fresh water
As a result, the efficiency of the wastewater treat-
in the bleaching department, and the excess
ment can be improved. Less wastewater has to
water from the bleaching department is used
be purified, and in general concentrated waste-
instead of fresh water in the pulp mill. With
water flows can be treated more effectively. By
this type of arrangement, substantial amounts
recirculation of process waters and increase of
of fresh water can be saved. Fresh water is
storage capacity, the wastewater amounts can
mainly only needed as makeup into the paper
be reduced but not in the same extent as by col-
machine system. However, in a tissue mill,
lecting and separating clean, warm cooling
sometimes a lot of fresh water is required for
waters.
efficient washing of machine felts.
Advantages of reduced freshwater consump-
It is of great importance to reduce the white
tion and water loop closure are as follows:
water from going in the same direction as the
product flow, i.e., from bleaching plant to the 1. Lower volumes to external effluent treatment,
paper machine. This is done by substracting as i.e., the treatment plant can be built with
much water as possible from the fiber flow smaller hydraulic capacities and lower
before it enters the bleaching system and again investment costs. Contaminants are more
318 14. WATER CIRCUITS IN PAPER MILL

concentrated in the effluent, which But potential drawbacks of water system closure
contributes often to higher removal need to be controlled. Otherwise, the buildup of
effectiveness suspended solids as well as dissolved organic
2. Lower costs of raw water and inorganic substances in the white-water
3. Lower losses of fibers and fillers system may cause negative effects.
4. Lower energy consumption The costs of this measure depend on the
5. Higher temperatures in the process water number and nature of water circuit rearrange-
systems result in faster dewatering on the ments necessary and the type of additional
paper machine wire. installation needed. The driving force for recy-
cling process water is to decrease the wastewater
The need for fresh water in a modern recov-
load from integrated recycled fiberebased mills
ered paper preparation plant can be reduced to
(CEPI, 1997; P€oyry, 1994; Senhorst, 1997).
approximately 1 m3/ton. Consequently, only
about 10% of the total freshwater demand in a
modern integrated newsprint mill based on 14.5 LIMITS ON WATER SAVING
recycled fibers (z10 m3/ton) is consumed in
the recovered paper preparation plant. Howev- When reducing the specific effluent volume,
er, in a tissue mill, sometimes a lot of fresh water some typical limits have to be considered: fresh-
is required for efficient paper machine felt water volume that is used for cooling before its
washing. In recycled fiberebased mills without final use; water volume that is discharged with
deinking, no fresh water is needed in the stock the rejects; maximum COD value that the prod-
preparation. uct can tolerate in the white water. In a selected
The separation of water loops by insertion of circuit, this value also corresponds to a mini-
thickeners leads to considerable change in the mum effluent volume for the system concerned.
composition of the paper machine water loop These limits differ in every individual system.
with respect to the levels of organic and The factors that influence these limits include
inorganic substances. This will lead to a changed the existing plant technology, raw materials
additive regime in the wet end that, in turn, will used, and paper grades produced. Low specific
have its effect on the COD levels. In certain effluent volumes result in growing system loads
applications, the insertion of an extra water in process waters in terms of dissolved and
loop may drop the temperature in the paper colloidal materials that can cause severe losses
machine loop, e.g., when the paper machine in quality and productivity. This situation is
loop is separated from the disperger and refiner aggravated by the use of paper for recycling as
that act as a heating device for process water. raw material. If the specific effluent volume is
The main principle, white water flowing back- to be reduced successfully, the impact of such
ward in the system, countercurrent to the prod- measures on the papermaking process must
uct, can be applied only in integrated pulp and also be taken into consideration. Loop separation
paper/board mills. Recovered paper plants are, and countercurrent arrangement enable the
with very few exceptions, integrated with a paper mills to reduce the transfer of detrimental
paper mill. In stock preparation, the cleanness substances coming from highly loaded loops
of the process water is less critical than in the (e.g., stock preparation) into subsequent process
white water of the paper machine. Therefore steps, thus relieving the paper machine loop. The
the stock preparation utilizes to a very large increasing closure of water loops involves many
extent excess clarified white water from the problems, but it is bound to be part of industry’s
paper mill and internally clarified white water. future development.
 14.6 CLOSED CYCLE OPERATION 319
Several paper mills producing packaging require extensive treatment facilities already in
grades from paper for recycling run their place and their product quality standards are
processes in a closed water circuit. However, a less demanding in comparison with many other
further reduction in effluent volume is often paper products. With closed cycle operation,
prevented by the abovementioned enrichment water leaves the process via dryer evaporation,
of harmful substances and its consequences. To with wet solid wastes such as from the rejects
further reduce the water demand in the paper handling system, and as moisture in the paper
industry, it is important to solve the current product. To achieve zero discharge operation,
obstacles (for example, scaling and fouling) to less water must be added to the process on a
the implementation of advanced water treat- continuous basis than that required to make up
ment techniques, enabling the mills to reduce losses from the paper machine dryers. To main-
the amount of dissolved substances in the tain the overall balance, zero discharge mills
process water. Smurfit Kappa Z€ ulpich Papier have segregated rain water, cooling water, and
GmbH, Z€ ulpich,Germany, has pioneered the noncontact pump seal water. These streams are
biological treatment of process water in a closed not part of the water balance, and the allowable
water circuit. Forced by increasing amounts of freshwater makeup can be used for more critical
odorous compounds in its water loops, the applications. On an average, slightly over 1 m3/t
company decided to install an integrated biolog- freshwater makeup to process is required to
ical treatment plant consisting of an anaerobic compensate for losses, mainly due to evapora-
and an aerobic stage in the 1990s. Several other tion in the dryers. This implies that larger pro-
installations followed. This example also shows duction mills have a greater freshwater
how much effort it takes to achieve circuit makeup requirement with zero discharge opera-
closure. But there are also more recent examples tion. Some of the critical applications that must
of a successful further reduction in effluent vol- remain on fresh water, such as trim squirts and
ume. Membrane treatment is becoming a major felt cleaning showers, are not directly related to
technology, as it is also enabling the mills to production level, so it is easy for larger produc-
reduce the inorganic load. The world’s first tion mills to obtain zero discharge.
membrane bioreactor with subsequent reverse Typical process modifications required to
osmosis in a paper mill was installed at Koehler implement zero discharge operation at paper-
Pappen, a cardboard mill in Germany. Holmen board mills have been reviewed. The process
Paper uses a combination of membrane technol- equipment items used to achieve zero discharge
ogy and UV disinfection at its mill in Madrid for operation are not sophisticated and generally
the final treatment of municipal wastewater include primary treatment, sufficient water stor-
which is replacing the complete freshwater vol- age, stainless steel metallurgy, and often a segre-
ume used in the papermaking process. Besides gated cooling water system. Chemical programs
these examples, there are several further uses must obtain consistently high first-pass retention
of membrane technology in the paper industry of fines, clays, size, and colloidal contaminants
opening up a huge field of applications. such as pitch. Recycled water must replace fresh
water for most applications, including gland
water and paper machine shower water. In a
14.6 CLOSED CYCLE OPERATION typical effluent treatment installation for a closed
cycle paperboard mill, the loop is comprised first
Paperboard and roofing felt mills using of suspended solids removal by either a primary
recycled fiber are good candidates for zero clarifier, dissolved air flotation unit, or screening
discharge operation because they mostly do not equipment. Often, the sludge recovered in this
320 14. WATER CIRCUITS IN PAPER MILL

treatment stage can be returned to the pulper to white-water systems. Figs. 14.4 and 14.5 show
be incorporated into the board product. Clarified effluent-free process water system of Z€ ulpich
effluent is sent to a large storage tank, which is mill of Kappa Paper, Germany, and process
sized to hold the mill. Finally, recovered water water treatment plant at paper mill Julius
is passed over sidehill screens to protect down- Schulte S€ohne, Germany. In cases where high
stream equipment from clarifier upsets. Screened degrees of system closure were achieved, corro-
water is then used throughout the mill to replace sion and bacterial growth in the paper machine
fresh water. Most effluent treatment facilities at area were observed. Several mills are attempting
existing zero discharge mills can be divided to achieve complete closure by treating the
into the following three main categories: effluent stream biologically and reusing the
treated effluent as the freshwater source.
1. Mills which invested in facilities able to
remove suspended solids effectively and
achieve lean white-water qualities under
14.7 ANNOTATED BIBLIOGRAPHY
200 mg/L suspended solids
2. Mills which have small or nonexistent
Auhorn W (1984). Das St€ orstoff-Problem bei
primary treatment facilities, whose TSS in the
Verringerung der Spezifischen
recycled water are often above 1500 mg/L
Abwassermenge, Wochenblatt Papierfabrik.
and can be as high as 5000 mg/L. Mills in this
1984, 2, 37.
category typically have problems such as
The reduction of the specific wastewater
plugged showers
quantity is discussed in this paper.
3. Mills which have biological treatment
Allender B, Covey, G, Shore, D (2010).
facilities
Low-effluent Recycled Paper Mills, 64th
Figs. 14.2 and 14.3 show totally closed process Appita Annual Conference and Exhibition,
water loops without and with integrated purifi- Melbourne 18e21 April 2010: Conference
cation systems. Several recycled paperboard Technical Papers
mills have already implemented the closed

Fresh Water

Evaporation

Raw Material Paper

Stock Preparation Paper Machine

Save-all
Long Circuit
Zero-Effluent
Solids
FIGURE 14.2 Totally closed process water loop without integrated purification systems (kidneys). Reproduced with
permission from Hamm and Schabel (2007). IWA Publishing.
 14.7 ANNOTATED BIBLIOGRAPHY 321
Fresh Water
Evaporation

Raw Material Paper

Stock Preparation Paper Machine

Kidney
Technologies

Save-all
Kidney
Technologies

Disposal of
Residual Solids

FIGURE 14.3 Totally closed process water loop with integrated purification systems (kidneys). Reproduced with permission
from Hamm and Schabel (2007). IWA Publishing.

Exhaust Air
Biogas Utilization

Fresh Water

Aeration 1

Recovered
Paper UASB-
Paper Production
Reactors

Aeration 2
Paper

Biowater Sand Filter Secondary

to Production Clarifying

FIGURE 14.4 Effluent-free process water system of Z€ulpich Mill of Kappa Paper, Germany. Reproduced with permission from
Hamm and Schabel (2007). IWA Publishing.

The types of problems that might be treatment, up to fully liquid effluent-free mills
encountered in low-effluent recycled paper are described.
mills and how these have been tackled in Bajpai P, Bajpai PK (1999) Recycling of
cases from mills employing very simple process water for closed mill systems. PIRA
closure, through extensive biological International, Leatherhead.
322 14. WATER CIRCUITS IN PAPER MILL

Torch/
Biogas Purification Energetic
Utilization
Dosage of Nutrients

N P Aeration
Reactor I

Conditioning Sand
IC-Reactor
Preacidification Filter
After Cooling

Aeration
Reactor II
Surplus Sludge
to Mill

Biowater to Mill

FIGURE 14.5 ohne, Germany. Reproduced with permission from

Process water treatment plant at paper mill Julius Schulte S€
Hamm and Schabel (2007). IWA Publishing.

Closed cycle concepts do offer increased various fibrous materials in integrated and
flexibility in the siting of new mills, including nonintegrated pulp and paper mills.
the consideration of freshwater-limited mill Hamm U, Schabel S (2006). http://www.
locations and increased opportunities to celso-foelkel.com.br/artigos/outros/22_
maintain or expand production at 2006_Effluent-free%20papermaking.pdf
environmentally sensitive sites. Closed cycle This presentation discusses latest
may also provide a durable solution to future developments in effluent-free papermaking.
environmental standards. This book reviews Hamm U, Schabel S (2007). Effluent-free
the advances in purification and recycling of papermaking: industrial experiences and
process water in terms of strategies, latest developments in the German paper
processes, equipment, and machinery and industry. Water Sci Technol; 55(6):205e11
systems etc. for closing the water loop. The This paper presents a comprehensive survey
areas of further investigations are also of the pros and cons of closed process water
discussed. systems followed by significant examples of
European Commission (2001). Integrated effluent-free production of corrugating
Pollution Prevention and Control (IPPC). medium and test liner. Operation experiences
Reference Document on Best Available and economic aspects are also discussed.
Techniques in the Pulp and Paper Industry. Holik H (2006). Handbook of paper and
Institute for Prospective Technological board. Weinheim Wiley-VCH.
Studies: Seville This is a comprehensive handbook on the
This reference document presents the best subject; describes all the manufacturing
available techniques in the pulp and paper processes used in industry for various types
industry. It covers the relevant environmental of papers, including writing and printing
aspects of pulp and papermaking from paper; tissue paper; packaging paper; board
 EXERCISES 323
and cardboard; as well as their quality Fapet OY, Helsinki, 2000, Ch. 6, p. 211.
characteristics, wastepaper treatment, and This paper looks at design of recycled fiber
economical aspects. processes for different paper and board grades
Jung H, Kappen J (2014). Water in the paper Weise U, Terho J, Paulapuro H (2000). Stock
industry. www.ptspaper.com/fileadmin/.../ and Water Systems of the Paper Machine,
PTSPAPER/.../2014_PPM_Water_ Paper Making Science and Technology, Book
PaperIndustry.pdf. 8, Paper Making Part 1, Stock Preparation and
The paper industry nowadays counts among Wet End, Fapet OY, Helsinki, 2000, Ch. 5, p.
the most advanced industrial sectors 180.
regarding water efficiency. The current The stock and water systems of the paper
situation and future options are discussed in machine are discussed in this chapter.
this paper Zippel F (2001). Water Management in Paper
Linhart F, Auhorn W, Degen J, Lorz HJ (1987). Mills, Deutscher Fachverlag, Frankfurt, 2001,
AnionicTrash: Controlling Detrimental “Preface” by L. G€ ottsching.
Substances, Tappi, 10, 79. This paper deals with a number of issues
This paper looks at some of the principal facts faced by paper and board mills and wishes to
about detrimental substances to give some identify and implement process
new details about their interaction with other improvements, in particular the reduction of
materials and to give a few examples of paper water and chemical usage, and wastewater
mills where the whole papermaking process and effluent costs.
was improved by adding process chemicals
in spite of a large amount of detrimental
substances in the paper stock or in the raw EXERCISES
material.
Reichart A (2013). Water circuits and water 1. How much water used in the pulp and paper
balances www.igep.in/live/hrdpmp/ industry is process water?
hrdpmaster/igep/content/.../05_BAT_ 2. What is primary treatment?
watercircuits.pdf 3. What is secondary biological treatment?
This paper looks at best available techniques 4. From where the do detrimental substances in
for water circuits and water balances. the water loops generate?
Countercurrent flow and separation of water 5. What is the effect of detrimental substances
cycles is state of the art in Europe. Recycling present in the water loops?
of process water is possible; its extent 6. Name different process water circuits in a
depends on paper grade and required quality. paper mill.
Closed water circuits are possible for certain 7. What is white water?
paper grades (brown packaging). 8. What is the most commonly used types of
Schwarz M (2000). Design of Recycled Fiber save-alls?
Processes for Different Paper and Board 9. How DAF works?
Grades, Paper Making Science and 10. What are the advantages of reduced
Technology, Book 7, Recycled Fiber and freshwater consumption and water loop
Deinking. closure?