published_or_final_version / abstract / Dentistry / Master / Master of Dental Surgery

<p>Hallsta paper mill uses large amounts of water during the pulp and paper making processes. The wastewater is treated in two separate activated sludge processes referred to as BIO 1 and BIO 2. The main aim is to reduce the organic substance content, measured as COD (Chemical Oxygen Demand) before the wastewater is released into the environment. Since the effluent produced is very rich in organic substances, the addition of nitrogen (N) and phosphorus (P) are necessary to give satisfactory treatment results. Problems with sludge bulking sometimes occur which lead to increased levels of suspended matter and nutrients in the effluent. Periods of high concentration of phosphorus is also of great concern. The aim of this study is to investigate the causality behind the sludge bulking, with the help of scientific literature and analysis of previously compiled data using multivariate data analysis. COD and nutrients present in the influent will also be surveyed to identify variations in concentration caused by the paper making process.</p><p>The scientific literature points toward low nitrogen and phosphorus levels as the major causes of the bulking sludge, as this leads to increased growth of filamentous bacteria to the detriment of the preferred flocculating species. A full scale experiment was conducted in an attempt to evaluate sufficient dosage levels of N and P to reduce this problem. The experiment has produced stabile results with low percentages of suspended organic matter and nutrients.</p><p>Evaluation of the previously collected data using Multivariate Data Analysis did not lead to any correlation between variables being found, other than the impact of sludge concentration on COD-reduction. No relevant explanation to periods of high phosphorus levels could be found neither in the scientific literature nor in the multivariate data analysis.</p><p>Bleaching of the paper pulp, with hydrogen peroxide and lye, results in a subsequent increase in COD concentration in the wastewater. The study shows an increased COD in the water approximately 12 hours after the increased dosing of these bleaching agents. Also the amounts of easily degradable COD increases following increased dosage of hydrogen peroxide and lye. The content of easily accessible phosphorus in the influent represents a minimum of 25 % and 20 % of the amount theoretically required for BIO1 and BIO2 respectively. The influent levels of nitrogen represents 33 % and 100 % for BIO1 and BIO2 respectively.</p><p>From this study it has been possible to deduce that a controlled dosage of nutrients in relation to the incoming level of COD, is of great importance to the efficient treatment of COD rich effluent in the systems under investigation at Hallsta Papermill.</p> / <p>Vid Hallsta Pappersbruk används stora mängder vatten vid tillverkningen av massa och papper. Det förorenade processvattnet renas i två separata anläggningar, BIO1 och BIO2, båda med biologisk rening av typen aktivt slam. Avloppsvattnets höga halter av kolföreningar, vilka analyseras som COD (Chemical Oxygen Demand), kräver extra tillsats av kväve och fosfor för att erhålla tillfredsställande reningsresultat. I den biologiska reningen uppstår periodvis problem med slamsvällning, något som resulterar i höga utsläpp av suspenderat material och organiskt bundna näringsämnen. Även perioder med höga fosforutsläpp förekommer. Syftet med examensarbetet är att genom litteraturstudier och analys av historiska data, med hjälp av multivariat dataanalys, utreda orsakerna till problemen. Även en kartläggning av variationerna i inkommande avloppsvatten med avseende på COD och lättillgängliga näringsämnen genomförs.</p><p>Utifrån information från litteraturen tyder problemen med slamsvällning ofta på bristande tillgång på kväve och fosfor vilket bland annat kan resultera i kraftig tillväxt av filamentösa bakterier. För att komma till rätta med problemen startades ett styrt försök med beräknade optimala doseringskvoter. Försöket resulterade i stabil drift för båda anläggningarna med låga utsläppsnivåer av både suspenderat material och näringsämnen.</p><p>Resultatet från utvärderingen av driftsdata med multivariat analys visar att slamhalten har betydelse för COD-reduktionen i BIO1. Någon förklaring till problemen med höga fosforutsläpp har inte framkommit vare sig ur litteraturstudie eller multivariat dataanalys.</p><p>Vid alkalisk oxiderande blekning av termomekanisk pappersmassa ökar den totala COD-koncentrationen i avloppsvattnet i samband med höjd dosering av blekkemikalier. Studien visar att en ökad COD-koncentration kan observeras i vattnet in till BIO1 ca 12 timmar efter förhöjd dosering av blekkemikalier. Samtidigt ökar andelen lättnedbrytbart COD till följd av ökad blekningsgrad. Kartläggningen av inkommande vatten visar att mängden lättillgängligt kväve i avloppsvattnet in till biologierna motsvarar ca 33 % och 100 % av det teoretiskt beräknade behovet för BIO1 respektive BIO2. För fosfor uppgår motsvarande till minst 25 % respektive 20 % för BIO1 och BIO2.</p><p>Under examensarbetets gång har det kunnat konstateras att dosering av närsalter i förhållande till inkommande mängd COD är av stor vikt för en väl fungerande rening av det COD-rika avloppsvattnet vid Hallsta Pappersbruk.</p>

<p>This thesis work was made for Södra Cell Mörrums bruk in Blekinge. The purpose of the work was to develop a computer model in the simulation program Extend for the removal and balance of organic oxygen consuming substances, measured as COD (Chemical Oxygen Demand), in the new biological treatment plant in the mill. The plant produces two different pulp products, TCF- (Totally Chlorine Free) pulp and ECF- (Elementary Chlorine Free) pulp, for sale. The different bleaching procedures affect the characteristic of the wastewater and thus the effectiveness of the biological treatment plant.</p><p>In the model that was developed the COD in the wastewater was divided into five different COD-fractions: soluble easily degradable (SS), soluble hardly degradable (SR), soluble inert (SI), particulate inert (XI) and particulate biomass (XB). To create the model FlowMac™ was used as a base. FlowMac™ is a library module in Extend adapted for pulp and paper mills. Some of the blocks only needed a slight modification while others, for example the sedimentation basin and the bioblocks, had to be done from scratch. The calibration of the model was made from data from a period of eleven weeks and a validation was made from data that differed as much as possible from the calibration data. Then the model was used to find out in what way an increase in production to 480 000 annual tons should affect the discharge of organic oxygen consumption substances.</p><p>Results from the model indicates that the goals for the total COD-discharge will be hard to achieve with an increase in production to 480 000 annual tons. Despite the fact that production of TCF-pulp generates more COD than ECF-production the total discharge of COD is lower at TCF-production. The reason is that easier degradable COD is generated in TCF-bleaching. One of the major problems is that the torrent of water that is bypassed the biological treatment plant contains a large amount of COD and the efficiency of the treatment plant must be very high if the goals for the total COD-discharge shouldn’t be exceeded.</p> / <p>Det här examensarbetet gjordes för Södra Cell på Mörrums Bruk i Blekinge. Arbetet bestod i att göra en modell i simuleringsprogrammet Extend över nedbrytningen och massbalansen av organiska syreförbrukande ämnen, mätt som COD (Chemical Oxygen Demand), i den nybyggda biologiska reningsanläggningen på bruket. Mörrums bruk är en sulfatmassafabrik som producerar både TCF- (Totally Chlorine Free) och ECF- (Elementary Chlorine Free) massa för avsalu. De olika blekningsmetoderna påverkar sammansättningen på avloppsvattnet och därmed också den biologiska reningsanläggningens reduktion av COD.</p><p>I modellen som utvecklades delades inkommande COD i obehandlat vatten upp i fem olika COD-fraktioner: löst lättnedbrytbart (SS), löst svårnedbrytbart (SR), löst inert (SI), partikulärt inert (XI) och partikulärt nedbrytbart COD i form av biomassa (XB). För att bygga modellen användes FlowMac™ som utgångspunkt. FlowMac™ är en biblioteksmodul i Extend avpassad för pappersbruk. En del block behövde bara modifieras medan andra block, t.ex. sedimenteringen och bioblocken, fick byggas till. Modellen kalibrerades med medelvärden från en elvaveckorsperiod och en validering gjordes med data från några veckor med mer extrema värden på inkommande vatten. Med modellen gjordes en simulering för att undersöka vad en produktionsökning till 480 000 årston skulle innebära med avseende på utsläppen av organiska syreförbrukande ämnen.</p><p>Resultat från modellen tyder på att det vid en ökning av produktionen till 480 000 årston blir svårt att nå de uppställda totala utsläppsmålen för COD. Vid produktion av TCF-massa bildas mer COD men utsläppsmängderna är lägre än vid ECF-produktion. Anledningen är att den COD som bildas ut vid TCF-blekning innehåller en större mängd lättnedbrytbart COD. En bidragande orsak till att det blir svårt att hålla utsläppsmålen för COD är att de flöden som leds förbi reningsanläggningen innehåller mycket COD vilket gör att verkningsgraden över reningsanläggningen måste vara hög för att klara målen för totala COD-utsläppet.</p>

Due to the opportunity for afforestation in South Africa being severely limited, extensive research is being carried out on obtaining more wood per given area, improving the quality and value of the wood and on gaining a better understanding of how wood properties influence the characteristics of the pulp it produces. The last mentioned is the main focus of this study. If the variations in pulp, due to variations in wood properties, are better understood, then the existing fibre resource could be more efficiently managed and utilised to maximise its value. The main objective of this study was to determine how variation in physical and chemical properties, from the existing P.patula resource drives variation in pulp strength properties. It is well known that differences in tree age and site index lead to major sources of variation of various wood properties. These two easily measured variables were used in this study to capture a significant amount of variation in the wood of the aforementioned genus that enters a mill. Samples were obtained from two extremes in site quality, as measured by site index, (viz. good and poor sites) and three age ranges (viz. 9-10 years, 13-14 years and 20-21 years) from the KwaZulu-Natal Midlands. Wood chips from each of the six sites were pulped for various lengths of time, using the Kraft pulping method and under the same pulping conditions. A wide range of anatomical and chemical properties of wood and pulp were measured to characterise these samples as extensively as possible. All pulp samples were beaten in a PFI mill, at four different levels. The freeness values of the beaten samples were measured. The physical properties measured on handsheets made from the pulp included sheet density, burst index, tear index, tensile index, tensile energy absorbed, stretch and zero-span tensile strength. Regression models were developed to quantify the impact of the measured variables on each of the strength properties. Principal component analysis was performed on the wood characteristics measured and indicated that tree age is a more critical source of variation in wood properties than site index. The predictions of whole tree wood properties from the properties measured at breast height were excellent. Pulping studies showed that pulp yield, at kappa 20-30, increased with tree age. Wood cellulose proved to be a very good predictor of pulp yield. Xylose and mannose appeared to be most resistant to degradation during pulping. The low yield pulps were easier to refine than those with high yield. This has important implications when considering high yield pulping processes. With regard to pulp strength, the younger material could not achieve the high tear strengths obtained by the older material. However, the tear strengths achieved by these younger sites were comparable with, if not higher than, that obtained by hardwood species. The implications of this is that younger P. patula trees could be used for grades of paper where very high tear strength is not essential, but tensile is (e.g. tissue paper) and that older material can be better used for the purpose of providing the high tear strength needed by certain paper grades (e.g. linerboard and sackkraft). The maximum tensile strength achieved by the younger material was higher than that of the older material. When compared at constant freeness or sheet density, longer cooking times had a deleterious effect on strength properties. Strong predictions of pulp strength from basic wood properties were obtained when strength results were compared at constant freeness and sheet density. Because of the great influence of fibre morphology and chemistry on refining rates and on the resultant strength properties, the results of the study suggest that fibres of greatly different chemical and anatomical characteristics should not be refined together, if beating energy and pulp strength are to be optimised. However, further work is required to evaluate if the separation of fibre resources, to improve pulp quality, would be economically viable. / Thesis (M.Sc.Eng.)-University of KwaZulu-Natal, Durban, 2005.

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.

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.

An experiment was designed to test the hypothesis that each softwood pulp is unique and requires a specific, well defined mechanical treatment to derive its maximum strength potential. Three bleached softwood Kraft pulps and respective wood samples were sourced from both the Northern and Southern Hemispheres. The raw fibre characteristics of P. patula (Southern Hemisphere), P. menziesii (Northern Hemisphere) and P. mariana (Northern Hemisphere) were measured and compared. The raw pulp sheets were refined at different energies and intensities under controlled laboratory conditions using a 12” single disc pilot refiner. Results were assessed to determine the raw fibre characteristics, optimum refining conditions and the relative refined strength potential for each of the three samples. Results from anatomy measurements on the three wood samples differed significantly. P. patula exhibited a relatively high proportion of springwood growth in the early growing years. As the P. patula aged and formed mature wood there was a significant increase in the frequency of latewood formation. This was characterized by an abrupt and significant increase in the wall thickness, beyond that of the two Northern softwood samples. When the cell wall thickness increased, the lumen width and fibre diameter of the P. patula decreased significantly, yielding extremely coarse, stiff fibres. The Northern P .mariana and P. menziesii samples were characterized by a relatively consistent transition between high and low densities from the pith to the bark of the tree. The Southern P. patula had a unique density trend with an increasing frequency of high density peaks indicative of an increased latewood formation from the pith to the bark. The slower growing Northern P. menziesii and P. mariana samples did not have as clear a differentiation in fibre characteristics between juvenile and mature wood formation. The Northern samples did however contain a significantly higher proportion of juvenile latewood growth than the P. patula. However, the difference in fibre characteristics between earlywood and latewood formation was not as significant as that noted with the Southern P. patula Fibre morphology measurements on the unrefined bleached Kraft pulps also revealed significant differences between the three samples. The average MORFI LAB01 results on the P. patula defined fibres with a high coarseness and relatively low number of fibres per gram of pulp. The extremely coarse latewood fibres formed during mature wood growth being the most likely source. However, P. patula was also characterized with a high fibre flexibility and large lumen, characteristics consistent with earlywood fibres. The Pulmac Z-Span 3000 was used to define the individual fibre strength, when due consideration was given to the number of fibres per gram, the corrected Pulmac results suggested P. patula had the strongest fibres. When refined, using a standard disc refining programme, P. patula exhibited a fast freeness development. Conventional thinking would suggest that this was an indication of a weaker fibre. However, this species had a robust morphology compared to the Northern Hemisphere woods. The theory developed in this dissertation suggests that the effect of coarseness and the concomitant number of fibres per gram plays a significant role. These two parameters are not included in the “traditional” refining calculations. The applied refining load and intensity was calculated on the flow of the pulp passing through the refiner. The calculation did not consider the actual number of fibres present in that specific volume. The implication is that when a fixed refining load is applied to a pulp with coarse fibres there may be a higher effective load on those fewer fibres (resulting in fibre cutting and fines generation). In this case, the Northern samples have a comparatively low coarseness and more fibres per gram with each receiving a smaller portion of the total load and intensity. In terms of refined pulp properties, P. patula developed a relatively high bulk and tear index consistent with coarse, rigid fibres. The Northern P. mariana and P. menziesii samples produced a pulp with good tensile properties, consistent with a greater number of finer, collapsible fibres with a higher relative bonding area. P. patula fibres were extremely heterogeneous in nature containing the smallest relative lumen width during latewood formation and the largest lumen width during earlywood growth. As a result, P. patula contains extremes of both fine and coarse fibres in the same blend. It may be more beneficial for this species than the others to improve both the tear and tensile properties through fibre fractionation with appropriate development of the separate accepts and rejects streams. In terms of fibre development, low intensity refining parameters maximized the tensile strength of the Southern P. patula. The Northern P. mariana and P. menziesii samples had a greater number of fibres per gram of pulp requiring both a higher refining energy and intensity to develop the pulp to its maximum potential. To develop optimum tear results, high intensity refining, with a relatively low specific energy provided optimum results for all 3 samples. Results confirmed that there were significant differences in the fibre morphology both between the three different species and between the two Hemispheres. There was strong evidence that the fibre characteristics dictate the manner in which a fibre responds to refining which in turn determines the relative contribution to specific refined pulp properties. It may be possible to use fibre characteristics to determine the appropriate refining parameters for optimal fibre development which will enhance the value of the end product. To derive the maximum strength potential from P. patula pulp samples, it is recommended that further studies investigate Hydracyclone fractionation and the concomitant benefits of refining the separate streams. Furthermore, a separate study on fibre morphology and refining characteristics of the same species grown in both the Northern and Southern Hemisphere would provide valuable insight. / Thesis (M.Sc.Eng)-University of KwaZulu-Natal, Durban, 2009.