At SAPPI-Tugela a continuous Kraft wood chip digester operates in EMCC mode (extended modified continuous cooking). Chips are initially exposed to a NaOH / Na2S liquor at high temperature in the top section. The chips move downward in plug flow passing circumferential screens used to draw liquor for various circulations. About midway down the spent black liquor is removed and the chips enter the cooler bottom section where some further reaction and washing occurs. Liquor level and chip level are maintained close to each other near the top. Chips require 8-12 hours to pass through the digester, depending on the chip feed rate. The key parameter of interest at the digester exit is the Kappa number, which is a measure of the extent of delignification which has occurred. Different board and paper products require different Kappa number pulp feed. (Final properties such as tensile, tear and bursting strengths will also depend on the way fibres have been modified in the digestion). The objective of this investigation is to predict the Kappa number of the product pulp in real-time, thus facilitating quicker reaction than the present dependence on laboratory analysis permits, possibly even allowing closed-loop control. The extent of delignification depends on liquor strength, temperature and exposure time, with final Kappa number also depending on the properties of the chip feed (wood type and moisture content). Compensation to maintain a steady Kappa number is made difficult by the long and varying residence time, and the fact that any changes apply to the whole profile held up in the digester. A number of static models for Kappa number prediction have been developed by previous workers, but these do not compare well with plant measurements. The collection of data from the Sappi-Tugela reactor, and the pulp quality reports, have been used to determine an efficient model. This step required a considerable data collection exercise, and similar results to the quality reports have been obtained using a simple linear model based on this data. The problem of model error is being reduced by arrangement as a Smith Predictor, in which the model is intermittently corrected by available laboratory analyses. At the same time, an interface was created, in order to synchronise measurement data for the chips presently leaving the reactor. In order to deal with the dead time, each parcel of chips entering the reactor is effectively tracked, and the changes in Kappa number integrated for reaction time under the varying conditions in transit. Knowing the present inventory of the reactor, this model can also be run forward in time as a predictive controller, to determine optimal control actions for maintenance of the target Kappa number. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, 2005.

At Mondi Paper Ltd, Merebank, South of Durban, Paper Machine 2 has recently been transferred onto a Distributed Control System (DCS). This was seen as a good opportunity to enhance the control of the pulp feed to the machine. A prime concern in operating a paper machine is to ensure consistent set-point paper properties in the Cross-Direction (CD: ie. across the paper width) and in the Machine-Direction (MD: ie. along the paper length). Sophisticated adjustments are available to ensure an even feed of the stock (consistencies around 2% m/m wood fibres in water) from the head-box across the receiving width of the paper machine. The properties of prime interest as the pulp is pumped through the head-box distributor onto the receiving belt of the machine are the basis weight (fibre mass per unit area) and moisture content (per unit area). However, the distribution system is highly dependent on the properties of the stock as it arrives at the head-box. Variations in upstream chest levels, the supplied pressure, flow-rate and fibre/water ratio, all cause MD and even CD variations. The problems of maintaining steady conditions at the head-box are well known, and are understood to arise from sub-optimal control in the preceding section involving a blend chest and machine chest, amongst other items, where several pulp streams and dilution water are combined. A number of control loops are involved, but appear to require different tuning for different paper grades. Often individual loops are taken off-line. In this study, an understanding of the controller interactions in the stock preparation section has been developed by detailed dynamic modelling, including all of the existing control loops. The model is built up in a modular fashion using a basic element, having one input (which can collect multiple streams originating elsewhere) and four outputs, linked through a vessel of variable volume. Several basic elements are linked together to form the overall system. All of the necessary properties can be defined so that the model allows the simulation of all features of the network: vessels, pipes, junctions, valves, levels and consistencies. A set of first order differential equations is solved which includes total water balance, species mass balances, derivatives of flow controller action, and derivatives of supervisory controller action. Supervisory controllers for consistency or level cascade onto flow controllers. Flow controllers manipulate valves which give a first-order dynamic response of actual flow. Where valves are manipulated directly by the supervisory level, the flow controller is effectively bypassed. This study involves a constraint problem around the blend chest, resulting in a loss of specification at the paper machine. This was solved by the implementation of a static optimiser. Its objective function penalizes deviations from setpoint of five parameters (ratios, consistency and level) using respective weight factors. Both the model and its optimiser were included in a simulator designed with the graphical user interface (GUI) of Matlab. The simulator has then been used to explore control performance over the operating range, by means of a set of scenarios. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2004.

The pulp and paper industry holds a reputation in the public eye for being a large consumer of water. This dissertation analyses water usage within the industry with a particular application to the South African pulp and paper industry. Unlike in other paper-producing countries, water in South Africa is a scarce commodity with a wide range of consumers. Faced with this, it is important for the leaders of the paper industry to have a tool with which to manage water consumption. This dissertation analyses the water usage aspects (including volumes needed and water quality needed) of the different processes, as well as the impact of different products, describing the reasons for water usage in each process. The application of best available technologies for water reduction is discussed. A theoretical or expected range and norm for water usage for each of seventeen South African mills is derived, based on each mill's particular processes, capacities and products. The actual water usage by each mill was surveyed by personally interviewing personnel at each mill. Comparisons are made between expected and actual water usage, and the total daily water consumption of the industry is derived. Only two mills operate below the expected norm level, most smaller mills operate close to the norm level, while five of the larger mills need to apply various techniques to reduce their water usage. The approximation of mill water usage to the predicted or expected norm clearly supports the hypothesis that water usage can be predicted by analysing process and capacity, and indicates that this dissertation can be used as a tool to manage water usage within the industry. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2004.

The pulp and paper industry holds a reputation in the public eye for being a large consumer of water. This dissertation analyses water usage within the industry with a particular application to the South African pulp and paper industry. Unlike in other paper-producing countries, water in South Africa is a scarce commodity with a wide range of consumers. Faced with this, it is important for the leaders of the paper industry to have a tool with which to manage water consumption. This dissertation analyses the water usage aspects (including volumes needed and water quality needed) of the different processes, as well as the impact of different products, describing the reasons for water usage in each process. The application of best available technologies for water reduction is discussed. A theoretical or expected range and norm for water usage for each of seventeen South African mills is derived, based on each mill's particular processes, capacities and products. The actual water usage by each mill was surveyed by personally interviewing personnel at each mill. Comparisons are made between expected and actual water usage, and the total daily water consumption of the industry is derived. Only two mills operate below the expected norm level, most smaller mills operate close to the norm level, while five of the larger mills need to apply various techniques to reduce their water usage. The approximation of mill water usage to the predicted or expected norm clearly supports the hypothesis that water usage can be predicted by analysing process and capacity, and indicates that this dissertation can be used as a tool to manage water usage within the industry. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2004.

SAPPI SAICCOR is a pulp and paper mill situated in Umkomaas, 50 kms south of the port of Durban in South Africa. It was the first company to produce high grade dissolving pulp from the Eucalyptus tree and is currently the world's largest manufacturer of chemical cellulose. SAICCOR is one of the few pulp and paper mills that produces its dissolving pulp by the acid sulphite process using both calcium and magnesium as bases in the form of calcium bisulphite and magnesium bisulphite. Four streams of effluent are produced during their process, namely, the calcium spent liquor, the magnesium pulp condensate and two streams from the bleaching stages. An acid hydrolysis of the effluent streams yielded a range of organic compounds such as lignans and lignin - type precursors as well as a triterpenoid. Column chromatography and thin layer chromatography, using various ratios of hexane, dichloromethane, ethyl acetate and methanol, were carried out in isolating and purifying the compounds. The structures of these compounds were determined using NMR spectroscopic and mass spectrometric techniques. / Thesis (M.Sc.)-University of Natal, Durban, 2003.

The pulp and paper industry holds a reputation in the public eye for being a large consumer of water. This dissertation analyses water usage within the industry with a particular application to the South African pulp and paper industry. Unlike in other paper-producing countries, water in South Africa is a scarce commodity with a wide range of consumers. Faced with this, it is important for the leaders of the paper industry to have a tool with which to manage water consumption. This dissertation analyses the water usage aspects (including volumes needed and water quality needed) of the different processes, as well as the impact of different products, describing the reasons for water usage in each process. The application of best available technologies for water reduction is discussed. A theoretical or expected range and norm for water usage for each of seventeen South African mills is derived, based on each mill's particular processes, capacities and products. The actual water usage by each mill was surveyed by personally interviewing personnel at each mill. Comparisons are made between expected and actual water usage, and the total daily water consumption of the industry is derived. Only two mills operate below the expected norm level, most smaller mills operate close to the norm level, while five of the larger mills need to apply various techniques to reduce their water usage. The approximation of mill water usage to the predicted or expected norm clearly supports the hypothesis that water usage can be predicted by analysing process and capacity, and indicates that this dissertation can be used as a tool to manage water usage within the industry. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2004.

SAPPI SAJCCOR, whose factory is situated south of Durban, South Africa, is one of the few paper and pulp mills that uses the acid sulphite process with calcium and magnesium bases to produce a high-grade cellulose pulp. Four streams of effluent, namely, the calcium - spent liquor stream, the magnesium condensate stream and two streams from the bleaching effluent are produced during this sulphite pulping process and they contain a variety of organic compounds extracted from the wood. Characterisation of the effluent was based on isolation using column chromatography and identification using NMR techniques. A range of constituents, such as lignans and lignin - type precursors, a trilerpenoid and fatty acids were isolated and identified. X-ray diffraction was used to identify an inorganic residue obtained from the calcium - spent liquor stream and gas chromatography/mass spectrometry was used to identify a wax residue. which builds up in the process. In addition to this, the carbohydrate content of the four streams of effluent was detennined using UV/visiblc spectroscopy. / Thesis (M.Sc.)-University of Natal, Durban, 2001.

Submitted in the fulfillment of the requirements for the degree of Master of Technology, Durban University of Technology, Durban, South Africa, 2011. / The main objective of this study was to evaluate the feasibility of conversion of crude tall oil and tall oil fatty acids into biodiesel. During the Kraft pulping process, Crude Tall Oil originates as tall oil soap, which is separated from recovered black liquor. The soap is then converted to Crude Tall Oil by acidulation with sulphuric acid. The Crude Tall Oil is then fractionated by distillation to produce tall oil fatty acids (TOFA), rosin and pitch. There were a number of conversional methods that were considered but proved to be inappropriate. A base-catalyzed method was inappropriate with due to the high free fatty acid content on the feedstock, and the acid-base catalyzed method was inappropriate due to the long reaction times and large excess of methanol required. An enzyme based conversion method was also found to be inappropriate because of the high price attached to the purchasing of the enzymes and the stability of the enzyme. A procedure of choice was the supercritical methanol treatment, due to the fact that it requires no separate catalyst. A procedure was developed for both the feedstocks (i.e. crude tall oil and tall oil fatty acids) using the supercritical methanol treatment. In supercritical methanol treatment, feedstock and methanol were charged to a reactor and were subjected to temperatures and pressures beyond the critical point of methanol (Tc = 240 °C, Pc = 35 bar). The maximum biodiesel yield obtained from Crude tall oil was 66% and was 81% for the tall oil fatty acids that was produced in a single stage process. The temperature and methanol to feedstock ratio effects was also found to yield a maximum biodiesel yield at 325°C and 40:1 respectively. A 20 minutes reaction time was found to be appropriate for the maximum yield of biodiesel. The final biodiesel produced was also evaluated against a commercial biodiesel product and its parameters measured. The biodiesel resulting from the tall oil fatty acid yielded parameters that were acceptable according to ASTM D6751 specifications for biodiesel. The biodiesel produced from the crude tall oil did not meet the ASTM D6751 specification, and this was mostly attributed to the presence of unsaponifiables which hindered the conversion of oil into biodiesel. / M

Graduation date: 1995

Graduation date: 1994