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Beschreibung

Papermaking is a fascinating art and technology. The second edition of this successful 2 volume handbook provides a comprehensive view on the
technical, economic, ecologic and social background of paper and board. It has been updated, revised and largely extended in depth and width including the further use of paper and board in converting and printing. A wide knowledge basis is a prerequisite in evaluating and optimizing the whole process chain to ensure efficient paper and board production. The same is true in their application and end use.

The book covers a wide range of topics:

* Raw materials required for paper and board manufacturing such as fibers, chemical additives and fillers
* Processes and machinery applied to prepare the stock and to produce the various paper and board grades including automation and trouble
shooting
* Paper converting and printing processes, book preservation
* The different paper and board grades as well as testing and analysing fiber suspensions, paper and board products, and converted or
printed matters
* Environmental and energy factors as well as safety aspects.

The handbook will provide professionals in the field, e. g. papermakers as well as converters and printers, laymen, students, politicians and other interested people with the most up-to-date and comprehensive information on the state-of- the-art techniques and aspects involved in paper making, converting and printing.

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Veröffentlichungsjahr: 2013

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Table of Contents

Related Titles

Title Page

Copyright

Contents to Volume 1

Preface

List of Contributors to the Second Edition

Chapter 1: Introduction

1.1 Paper and Board Today

1.2 Paper and Board Manufacturing – an Overview

1.3 Economic Aspects

1.4 Historical Background and General Aspects

1.5 A Philosophy of Papermaking: Life Lessons on the Formation of Paper and People

References

Further Reading for Section 1.3

Further Reading for Section 1.5

Chapter 2: Fibrous Materials for Paper and Board Manufacture

2.1 Overview

2.2 Chemical Pulp

2.3 Mechanical Pulp

2.4 Recovered Paper, Recycled Fibers

2.5 Wood Pulp Fiber Suspensions

References

Chapter 3: Mineral Fillers in Papermaking

3.1 History of the Use of Mineral Fillers in Papermaking

3.2 Global Mineral Consumption in the Paper and Board Industry

3.3 Why Use Mineral Fillers in Paper and Board?

3.4 Filler Loading Increase via Surface Application

3.5 Choice of Fillers

3.6 Characterization of Fillers

3.7 Main Mineral Fillers

3.8 Specialty Filler Pigments

3.9 Preservation of Pigment Slurries

3.10 Outlook

Acknowledgment

References

Chapter 4: Functional Chemicals

4.1 Overview

4.2 Starches in Papermaking

4.3 Colorants

4.4 Optical Brightening Agents (OBA), Fluorescent Whitening Agents (FWAs)

4.5 Sizing Agents

4.6 Wet-Strength Resins (WSR) and Dry Strength Resins (DSR)

4.7 Properties of Specialty Papers and Related Chemical Additives

References

Further Reading for Section 4.2

Further Reading for Section 4.5

Further Reading for Section 4.6

Chapter 5: Coating Colors — Components, Make Down, and Properties

5.1 Overview

5.2 Coating Color Components

5.3 Properties of Coating Colors

5.4 Coating Color Preparation

Further Reading

Chapter 6: Process Chemicals

6.1 Overview

6.2 Aluminum Compounds

6.3 Retention Aids and Drainage Accelerators

6.4 Fixatives and Charge Control

6.5 Deposit Control and Biocides

6.6 Defoamers and Deaerators

6.7 Chelating Agents

6.8 Additives for Repulping

6.9 Deinking Additives

6.10 Cleaning Agents and Fabric Conditioning

6.11 Internal Water and Effluent Treatment

6.12 Interactions of Chemical Additives

References

Further Reading for Section 6.5

Chapter 7: Unit Operations

7.1 Overview

7.2 Fiber Materials Feeding

7.3 Disintegration

7.4 Screening

7.5 Centrifugal Cleaning

7.6 Selective Flotation

7.7 Nonselective Flotation (Dissolved Air Flotation DAF)

7.8 Fractionation

7.9 Dewatering

7.10 Washing

7.11 Mixing and Storing

7.12 Bleaching of Secondary Fibers

7.13 Refining

7.14 Dispersion

References

Further Reading for Section 7.6

Further Reading for Section 7.13

Chapter 8: Systems for Fiber Stock Preparation

8.1 Objectives

8.2 Historical Review of Stock Preparation Systems

8.3 Systems for Primary Fiber Preparation

8.4 Systems for Secondary Fiber Preparation

8.5 Systems for Broke Treatment

8.6 Peripheral Systems in Secondary Fiber Preparation

8.7 Process Engineering and Automation

References

Further Reading

Chapter 9: The Integrated Recycled Paper Mill (IRPM)

9.1 Environmental Aspects and Profitability

9.2 Subsystems and Peripheral Systems of the Integrated Recycled Paper Mill

9.3 Subsystems for Water, Reject, and Sludge (WSR)

9.4 Water Circuits

9.5 Reject Systems

9.6 Sludge Dewatering Systems

9.7 Wastewater

9.8 Reject and Residual Disposal, Waste to Energy, Replacement Fuels for Incineration

References

Chapter 10: Paper and Board Machines and Their Components

10.1 Overview

10.2 Rolls in Paper and Board Machines

10.3 Roll Covers and Coatings

Contents to Volume 2

List of Contributors to the Second Edition

Chapter 11: Fabrics for Paper and Board Production

11.1 Forming Fabrics

11.2 Press Felts

11.3 Dryer Fabrics

11.4 Fabrics in Operation

11.5 Changing of Fabrics

References

Further Reading for Section 11.4

Chapter 12: Approach Flow System

12.1 Definition and Tasks of the Approach Flow System

12.2 Metering and Mixing of the Stock Components and Feed to the Headbox

12.3 Final Cleaning and Screening

12.4 Air in the Papermaking Process and Its Removal

12.5 Further Aspects

12.6 Approach Flow Design

References

Chapter 13: Headbox

13.1 Overview and Principle Aspects

13.2 Historical Review

13.3 State-of-the-Art Headboxes

13.4 Influence of Operational and Design Parameters on Technological Results

References

Chapter 14: Wire Section

14.1 Overview and Theoretical Aspects

14.2 Historical Review

14.3 State-of-the-Art Web Forming Designs

14.4 Machine Elements

14.5 Wires

14.6 Operational and Technological Aspects

References

Chapter 15: Press Section

15.1 Introduction

15.2 Theoretical Aspects of Press Dewatering

15.3 State-of-the-Art Press Sections

15.4 Historical Review

15.5 Further Approaches in Pressing

15.6 Operational and Technological Aspects

15.7 Impact of Wet Pressing on Paper Surface Properties

Acknowledgments

References

Chapter 16: Dryer Section

16.1 Overview

16.2 Drying Principles and Basics

16.3 Basics Related to Paper Drying

16.4 Dryer Sections

References

Chapter 17: Surface Sizing and Coating

17.1 Surface Sizing

17.2 Coating

17.3 Coated Paper and Board Grades

References

Further Reading

Chapter 18: Calendering

18.1 Objective and General Description of the Calendering Process

18.2 History of Calendering

18.3 The Different Calender Types

18.4 The Main Calendering Methods for Various Paper and Board Grades

References

Further Reading

Chapter 19: Reeling

19.1 Objectives and Basics

19.2 History

19.3 New Generation Reels

19.4 Reel Drum Design

19.5 Turnup Systems

References

Chapter 20: Paper, Packaging, and Carton Board Machines

20.1 Graphic Paper Machines

20.2 Packaging Paper Machines

20.3 Carton Board Machines

20.4 Tissue Machines

20.5 Specialty Paper Machines

Chapter 21: Finishing

21.1 Reel Slitting

21.2 Roll Handling

Chapter 22: Control Systems for Paper Machines

22.1 Objective and General Terms of PM Control Systems

22.2 Quality Control System (QCS)

22.3 Information Systems

Chapter 23: Uniformity of Paper Web Properties

23.1 Overview

23.2 MD Profiles

23.3 CD Profiles

23.4 Some Aspects of MD and CD Basis Weight Profile Tests in the Laboratory

23.5 Symmetry in z-Direction

23.6 Formation

References

Chapter 24: Paper and Board Converting and Printing

24.1 Converting Processes for Paper and Board

24.2 Testing of Converting Products

24.3 Printing Technologies

24.4 Requirements on Paper

References

Further Reading for Section 24.2

Further Reading for Section 24.3

Chapter 25: Health and Safety

25.1 Occupational Health and Safety

25.2 Noise Abatement and Protection

References

Chapter 26: Plant Engineering and Energy

26.1 Plant Engineering

26.2 Energy

Chapter 27: Environmentally Friendly Paper and Board Production

27.1 Background

27.2 Environmental Relevance along the Value Chain of Paper and Board Production

27.3 Sustainability

27.4 Resource Utilization in Paper and Board Production

27.5 Evaluation and Communication of Environmental Impacts

27.6 Practical Implementation of Environmental Issues

References

Chapter 28: Paper and Board Grades and Their Properties

28.1 The Material Paper: A Survey

28.2 Types of Paper, Board, and Cardboard

References

Further Reading

Chapter 29: Testing of Fibers, Suspensions, and Paper and Board Grades

29.1 General Aspects

29.2 Testing of Fibrous Material

29.3 Testing of Fiber Suspensions

29.4 Testing of Paper and Board

References

Further Reading

Chapter 30: Book and Paper Preservation

30.1 Introduction

30.2 Mechanisms of Paper Deterioration

30.3 Development of Mass Deacidification Processes

30.4 Current Commercial Processes

30.5 Strengthening Old and Brittle Paper

30.6 Commercial Prospects

References

Chapter 31: Paper Associations

Index

Related Titles

Bajpai, P.

Environmentally Friendly Production of Pulp and Paper

2010

ISBN: 978-0-470-52810-5

Rijk, R., Veraart, R. (eds.)

Global Legislation for Food Packaging Materials

2010

ISBN: 978-3-527-31912-1

Sixta, H. (ed.)

Handbook of Pulp

2006

ISBN: 978-3-527-30999-3

The Editor

Dipl.-Ing. Herbert Holik

Montelimarstr. 18

88213 Ravensburg

Germany

All books published by Wiley-VCH are carefully produced. Nevertheless, authors, editors, and publisher do not warrant the information contained in these books, including this book, to be free of errors. Readers are advised to keep in mind that statements, data, illustrations, procedural details or other items may inadvertently be inaccurate.

Library of Congress Card No.: applied for

British Library Cataloguing-in-Publication Data

A catalogue record for this book is available from the British Library.

Bibliographic information published by the Deutsche Nationalbibliothek

The Deutsche Nationalbibliothek lists this publication in the Deutsche Nationalbibliografie; detailed bibliographic data are available on the Internet at <http://dnb.d-nb.de>.

© 2013 Wiley-VCH Verlag GmbH & Co. KGaA, Boschstr. 12, 69469 Weinheim,\hb Germany

All rights reserved (including those of translation into other languages). No part of this book may be reproduced in any form — by photoprinting, microfilm, or any other means — nor transmitted or translated into a machine language without written permission from the publishers. Registered names, trademarks, etc. used in this book, even when not specifically marked as such, are not to be considered unprotected by law.

Print ISBN: 978-3-527-33184-0

ePDF ISBN: 978-3-527-65252-5

ePub ISBN: 978-3-527-65251-8

mobi ISBN: 978-3-527-65250-1

oBook ISBN: 978-3-527-65249-5

Contents to Volume 1

Preface

Paper: A major commodity in our life.

During its long history, paper has changed from a rare artisan material to a commodity product, with high practical value in communication and in educational, artistic, hygienic, sanitary, and technical applications. Today, nobody can imagine a world without paper. A large variety of paper grades are produced to suit the special requirements of each application: graphic paper grades, packaging papers and board, hygienic papers, and speciality paper grades. Paper can be impregnated, coated, laminated, creped, molded and so on. Paper products embellish our homes, and sanitary products made of paper ease our daily life. An easier life is also more likely with a sufficient number of banknotes in the briefcase. Packaging papers and board grades support supermarket logistics and product presentations. Computer printouts and other graphic papers such as newspapers, magazines, and books accompany us through our life. Even today, in our digital world paper is a reliable means of long-time documentation and data preservation.

A concise description of the fascinating art and technology of papermaking is given in this second edition of this handbook. It also includes the further use of paper and board in converting and printing. So a comprehensive view on the technical, economic, ecologic and social background of paper and board is provided. In-depth knowledge is a prerequisite for evaluating the optimum choices needed for the efficient production of paper and board. Converters and final customers need to be considered. Converters also have to build up some knowledge in papermaking, just as the papermaker needs to appreciate the conversion processes more. Waste handling and energy supply are even more in focus today. Economic success now requires more appreciation of all these sectors.

The first edition of this handbook found high interest worldwide. It has been widely accepted used in offices, universities, training, and as lecturing material, and general resource. The second edition is an updated and largely extended version and provides both the technical and technological state of the art in paper making in a concise form and as important information on paper-related technologies.

More than 60 authors have contributed to this project. They are all professionals from practice, companies, institutes, and universities from several countries–well-known experts or young specialists–each of them with detailed knowledge in their areas. The variety of their points of view is certainly one of the advantages of this book. My thanks go to these colleagues for their cooperation in sharing their knowledge in spite of their daily work load, and to the individual companies for providing information material. All these efforts resulted in the second edition of the “Handbook of Paper and Board” which is thought to provide professionals in the field, papermakers, converters and printers, as well as lay readers, students, politicians, and other interested people with most recent information on the state of the art of all the techniques and aspects involved in paper making and converting.

March 2013

Herbert Holik

List of Contributors to the Second Edition

Juergen Abraham
Voith Paper Fabrics
50 Northwoods Boulevard
Germany
Manfred Anders
Zentrum für Bucherhaltung
04347 Leipzig
Germany
Christian Bangert
Voith Paper
89522 Heidenheim
Germany
Rogério Berardi
Voith Paper
02995-000 Sao Paulo
Brazil
Jürge Blechschmidt
Wachbergstr. 31
01236 Dresden
Germany
Christoph Blickenstorfer
Kolb Distribution Ltd.
8908 Hedingen
Switzerland
Ingrid Demel
Papiertechnische Stiftung
80797 Munich
Germany
Hubert Dörrer
BK Giulini GmbH
67065 Ludwigshafen
Germany
Edgar Dörrer
Technische Universität Darmstadt
64289 Darmstadt
Germany
Geoffrey G. Duffy
3/70 Churchill Road
Murrays Bay
Auckland 0630
New Zealand
Johan Einarsson
Voith Paper Fabrics
89522 Heidenheim
Germany
Rüdiger Feldmann
Voith Paper Finishing
47803 Krefeld
Germany
Franz Grohmann
Voith Paper Rolls
2632 Wimpasing
Austria
Daniel Gronych
Voith Paper
89522 Heidenheim
Germany
Arne Hörsken
Sachtleben Wasserchemie GmbH
47198 Duisburg
Germany
Ute Höötmann
BK Giulini GmbH
67065 Ludwighafen
Germany
Winfried Harren
Berufsgenossenschaft
55127 Mainz
Germany
Sabine Heinemann
Oy Keskuslaboratorio
02150 Espoo
Finland
Jan-Luiken Hemmes
Kemira
51377 Leverkusen
Germany
Joachim Henssler
Voith Paper
88212 Ravensburg
Germany
Harald Heß
Voith Paper
89522 Heidenheim
Germany
Matthias Höhsl
Voith Paper Fabrics
89522 Heidenheim
Germany
Jochen Hoffmann
Akzo Nobel Chemicals GmbH
67065 Ludwighafen
Germany
Herbert Holik
Montélimarstrasse 18
88213 Ravensburg
Germany
Silvia Hubschmid
Omya International
4665 Oftringen
Switzerland
Bernhard Hunke
Blankophor GmbH & Co. KG
67065 Ludwighafene
Germany
Rainer Klein
PTS Papiertechnische Stiftung
01809 Heidenau
Germany
Günter Klug
Blankophor GmbH & Co.KG
67065 Ludwighafen
Germany
Gunnar Kramer
BK Giulini GmbH
67065 Ludwighafen
Germany
Klaus-Peter Kreutzer
Clariant Service AG
67065 Ludwighafen
Germany
Wilhelm Kufferath von Kendenich
Haldenstrasse 59
4632 Trimbach/SO
Switzerland
Maximilian Laufmann
Omya International AG
4665 Oftringen
Switzerland
Stevan Lomic
Voith Paper
3100 St. Pölten
Austria
Oliver Lüdtke
Voith Paper
Fiber & Environmental Solutions
88212 Ravensburg
Germany
Thomas Mack
Voith Paper
89522 Heidenheim
Germany
Roland Mayer
Voith Paper
89522 Heidenheim
Germany
Lucas Menke
Meri Environmental Solutions
81673 Munich
Germany
Martina Miletic
PTS Papiertechnische Stiftung
01809 Heidenau
Germany
Peter Mirsberger
Voith Paper
88212 Ravensburg
Germany
Thomas Moldenhauer
Verband Deutscher Papierfabriken
53113 Bonn
Germany
Antonius Moormann-Schmitz
BASF Aktiengesellschaft
67056 Ludwigshafen
Germany
Johann Moser
Voith Paper
89522 Heidenheim
Germany
Günter Müller
Papiertechnische Stiftung
80797 Munich
Germany
Wolfgang Müller
Voith Paper
Fiber & Environmental Solutions
88212 Ravensburg
Germany
Rudolf Müller
Voith Paper
89522 Heidenheim
Germany
Stefan Nierhoff
Sachtleben Wasserchemie
47198 Duisburg
Germany
Andreas Opalka
Sachtleben Wasserchemie
47198 Duisburg
Germany
Kathrin Otto
Kolb Distribution Ltd.
8908 Hedingen
Switzerland
Roland Pelzer
BK Giulini
67065 Ludwighafen
Germany
Irene Pollex
Papiertechnische Stiftung
01809 Heidenau
Germany
Hermann-Josef Post
Voith Paper
89522 Heidenheim
Germany
Hans-Joachim Putz
Technische Universität Darmstadt
64289 Darmstadt
Germany
Jörg Rheims
Voith Paper Finishing
47803 Krefeld
Germany
Thomas Ruehl
Voith Paper
89522 Heidenheim
Germany
Reinhard Sangl
Papiertechnische Stiftung
80797 Munich
Germany
Heinz-Joachim Schaffrath
Technische Universität Darmstadt
64289 Darmstadt
Germany
Thomas Scherb
Voith Paper
02995-000 Sao Paulo
Brazil
Matthias W. Schmitt
Voith Paper Fabrics
89522 Heidenheim
Germany
Johan Schrijver
Tate & Lyle
1541 KA Koog aan de Zaan
The Netherlands
Yang Shieh
Voith Paper
Neenah, WI 54956-4040
USA
Simon Stahl
Technische Universität Darmstadt
64289 Darmstadt
Germany
Dominik Stumm
BK Giulini GmbH
67065 Ludwighafen
Germany
Peter F. Tschudin
Basler Papiermühle
4052 Basel
Switzerland
Renke Wilken
Friedenstraße 12
82194 Groebenzell
Germany
Matthias Wohlfahrt
Voith Paper
89522 Heidenheim
Germany

Chapter 1

Introduction

1.1 Paper and Board Today

Herbert Holik

The history of paper is also the history of human culture and civilization. The Egyptians, Greeks, and Romans wrote on “papyrus,” a paperlike material. The kind of paper used now was first developed and used in China. Paper was the most important carrier of information in the past. It was only with increasing paper production that the transfer of knowledge, education, art, and information to a larger part of society became possible. With paper, emperors were able to administrate large empires more easily. In former times, paper was a valuable product, and papermaking an art – an art that was often kept secret because of the outstanding advantages of the product.

The worldwide consumption of paper will further increase. Owing to CEPI (Confederation of European Paper Industry), the paper consumption will increase from about 400 million t year−1 in 2010 to about 530 million t year−1 in 2020 and 605 million t year−1 in 230. The growth in individual countries can be mostly related to their increase in gross national product and to their growth in population. So the consumption and production in countries such as China or India have increased over recent years on a large scale. In mature markets such as Central Europe, Japan, and North America production and consumption have stagnated or even decreased.

The ratio of the worldwide consumption of the different paper and board grades has changed in the past and will change in the future according to technical, economical, and social evolution and developments in the individual countries and in the world as a whole. Packaging grades have increased, graphic paper grades have stagnated, and newsprint consumption has declined. The pressure from increased sales of industrial products, the growth in internet shopping, and the sharp upward demand for small packaged foods have all increased the demand on packaging materials. The newsprint sector has suffered from the big increase in internet and phone download users as these technologies impact on the need for the printed page. The demand for copy paper and home printing papers for holding as “hard copy” is still important for easy access of preselected information. The impact of e-book on paper usage has yet to be felt.

The paper and board market is global, and so is the paper industry where an evident consolidation has occurred over the last decades. The concentration of companies has continued under globalization, and the economic ups and downs have affected rising markets and various geographical areas unevenly. The investment costs for new production facilities are high. The capital demand for a new mill lies in the order of magnitude of more than €500 million. The most recent new paper and board mills were mainly installed in the Far East. These high-tech mills show the distinct progress in papermaking, in both technique and technology and new world records in production and machine speed have been set. So it seems that the paper comes back to its roots: China has developed in the last few years to the largest paper and board producer in the world.

The furnish used in paper and board production worldwide are secondary fibers from recovered paper, primary fibers (chemical pulp, mechanical pulp), pigments, and chemical additives. Paper is mainly based on fibers from cultured woods, and is a renewable and recyclable raw material as its strength is given by natural bonding between the individual fibers, which is then loosened by water during recycling.

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