According to estimates of the United Nations Environment Programme (UNEP), more than 1.8 billion people will be living in countries or regions with absolute water scarcity by 2025. The pressure on water resources is increased not only in arid and semiarid regions, but also in fast growing megacities around the world as a result of, amongst other factors, the changing nutritional and consumer behavior (rising living standards). Over 90 % of the annual water consumption of the newly industrializing and developing countries in the arid and semiarid climate zone is used for agricultural irrigation to ensure the nutrition of the population. Thus, since the beginning of the 20th century, the planned/controlled reuse of wastewater has developed into a central task of the sustainable water resources management. Wastewater represents a valuable resource in view of its composition (e. g. nutrients P, N for soil fertilizing) and its reliable, weather-independent availability in every household. The establishment of a closed-loop water management can enhance the efficiency of water usage. Therefore, activities in research and development are currently focused on decentralized and semi-centralized concepts, since their structures offer better conditions for the establishment of closed-loop systems and innovations in wastewater technology can be implemented more easily. In general, the hygienic quality requirements for wastewater reuse are predominantly oriented towards the planned usage. These are, in turn, regulated by thresholds and guidance values, e. g. for faecal indicator bacteria (e. g. faecal coliforms: E. coli), in widely differing norms and legal provisions specific to the respective countries. In Germany since 2005, small wastewater treatment plants can obtain the discharge class +H by the German Institute for Civil Engineering (DIBt: Deutsches Institut für Bautechnik) if secondary effluents contain less than 100 faecal coliforms (E. coli) per 100 mL. This ensures a safe effluent seepage in karst and water protection areas. Due to the infectious risk caused by a multitude of pathogens (bacteria, viruses, worm eggs, protozoa) which are still contained in wastewater after mechanical-biological treatment, specific disinfection methods are indispensable for their satisfactory reduction. Demands on disinfection methods for wastewater reclamation are quite complex. They should be characterized by a high and constant disinfection efficiency at low or moderate formation of disinfection by-products. The reclaimed wastewater should be able to be stored safely. Moreover, the disinfection method should be technically simple, scaleable, space-saving, subjected to low maintenance and realized at moderate investment and operating costs without applying external toxic chemicals. Established methods in decentralized wastewater disinfection are mainly based on membrane and UV technologies. However, these methods are currently working under high operating costs (high maintenance and cleaning efforts). Furthermore, the high investment costs of the membrane filtration are disadvantageous. In addition, both methods do not provide a disinfection residual. Thus, further research is required for the development and testing of alternative disinfection technologies. Against this background, the applicability of the electrolysis and UV/electrolysis hybrid technology for the decentralized wastewater reclamation was investigated and assessed in this dissertation. Results have shown that the electrochemical disinfection of biologically treated wastewater represents an efficient method at temperatures of > 6 °C, pH values of < 8.5 and DOC con-centrations of < 22 mg L-1. Under these conditions, an E. coli reduction of four log levels was achieved at a concentration of free chlorine ranging from 0.4 mg L-1 to 0.6 mg L-1 and at an after-reaction time of 15...20 min. However, it becomes simultaneously apparent that low temperatures, high pH values and high DOC concentrations are limiting parameters for this disinfection method to reclaim biologically treated wastewater. A high energy consumption of the electrolysis cell equipped with boron-doped diamond (BDD) electrodes (2...2.6 kWh m-3) represents a further unfavourable effect. Moreover, the undesired formation of chlorate (c = 1.3 mg L-1) and perchlorate (c = 18 mg L-1) at BDD electrodes can be considered as critical, since these disinfection by-products are, amongst others, human-toxicologically relevant. The concentration of adsorbable organically bound halogens (AOX) and trihalomethanes (THMs) proved to be marginal to moderate. Due to the synergistic effect of the combined application of UV irradiation (primary disinfection method) and electrolysis, the disadvantages of the single methods can be compensated. Decisive drawbacks of UV irradiation are photo and dark repair mechanisms of reversibly damaged bacteria. It was observed that the reactivation of reversibly UV-damaged E. coli even occurs at low temperatures (T = 10 °C) and strongly differing pH values (pH = 5.7...8.1) as well as at low light intensities and in darkness to an extent excluding a safe usage and storage of the reclaimed wastewater. The reactivation processes might be lowered by increased UV fluences. However, this is limited by high concentrations of total suspended solids (TSS). In spite of high UV fluences of > 400 J m-1, no complete removal of E. coli bacteria can be achieved at TSS concentrations of > 17 mg L-1. Therefore, it is indispensable to prevent bacterial reactivation caused by photo and dark repair processes. This topic was studied in the current work by electrochemically produced oxidants using an electrolysis cell positioned downstream of the UV unit. Results have shown that photo and dark reactivation were completely prevented by oxidants in a total concentration of 0.5...0.6 mg L-1 at a TSS concentration of 8...11 mg L-1, at pH values ranging from 5.7 to 8.1 and at temperatures ranging from 10 °C to 30 °C (t = 24....72 h). Even at a high TSS concentration of 75 mg L-1, the reactivation of E. coli (ctotal oxidants = 1.8 mg L-1) and, up to a TSS concentration of 32 mg L-1, the reactivation of total coliforms (except E. coli, ctotal oxidants = 1.0 mg L-1) can be prevented at a high initial germ concentration of 2…3 105 per 100 mL. The lowest energy consumption could be observed when mixed oxide electrodes (MOX electrodes) were applied. This result and the fact that no chlorate and perchlorate were observed at MOX electrodes argue for the application of these electrodes in practice. All in all, the UV/electrolysis hybrid technology represents an energy-efficient method for reclamation of biologically treated wastewater with TSS concentrations ranging from < 11 to 32 mg L-1 (E = 0.17…0.24 kWh m-3, MOX electrodes). Thereby, the reclaimed wastewater meet the hygienic quality requirements for a multitude of reuse categories starting from agricultural irrigation to urban and recreational reuse. Moreover, the requirements of the discharge class +H (100 faecal coliforms (E. coli) per 100 mL) are complied with reliably. The operational stability of the UV/electrolysis hybrid technology should also be ensured within the required maintenance intervals (t > 6 months). The undesired formation of coverings caused by biofouling processes on quartz glass surfaces could be prevented by electrochemically produced oxidants in a total concentration of 1 mg L-1 within an experimental duration of 5.5 months. However, the application of the UV/electrolysis hybrid technology is limited by increased particle concentrations and faecal loadings (initial E. coli concentration). The resulting enhanced demand of electrochemically produced oxidants for the prevention of bacterial reactivation results in a considerable increase of the electric charge input and energy consumption.

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According to estimates of the United Nations Environment Programme (UNEP), more than 1.8 billion people will be living in countries or regions with absolute water scarcity by 2025. The pressure on water resources is increased not only in arid and semiarid regions, but also in fast growing megacities around the world as a result of, amongst other factors, the changing nutritional and consumer behavior (rising living standards). Over 90 % of the annual water consumption of the newly industrializing and developing countries in the arid and semiarid climate zone is used for agricultural irrigation to ensure the nutrition of the population. Thus, since the beginning of the 20th century, the planned/controlled reuse of wastewater has developed into a central task of the sustainable water resources management. Wastewater represents a valuable resource in view of its composition (e. g. nutrients P, N for soil fertilizing) and its reliable, weather-independent availability in every household. The establishment of a closed-loop water management can enhance the efficiency of water usage. Therefore, activities in research and development are currently focused on decentralized and semi-centralized concepts, since their structures offer better conditions for the establishment of closed-loop systems and innovations in wastewater technology can be implemented more easily. In general, the hygienic quality requirements for wastewater reuse are predominantly oriented towards the planned usage. These are, in turn, regulated by thresholds and guidance values, e. g. for faecal indicator bacteria (e. g. faecal coliforms: E. coli), in widely differing norms and legal provisions specific to the respective countries. In Germany since 2005, small wastewater treatment plants can obtain the discharge class +H by the German Institute for Civil Engineering (DIBt: Deutsches Institut für Bautechnik) if secondary effluents contain less than 100 faecal coliforms (E. coli) per 100 mL. This ensures a safe effluent seepage in karst and water protection areas. Due to the infectious risk caused by a multitude of pathogens (bacteria, viruses, worm eggs, protozoa) which are still contained in wastewater after mechanical-biological treatment, specific disinfection methods are indispensable for their satisfactory reduction. Demands on disinfection methods for wastewater reclamation are quite complex. They should be characterized by a high and constant disinfection efficiency at low or moderate formation of disinfection by-products. The reclaimed wastewater should be able to be stored safely. Moreover, the disinfection method should be technically simple, scaleable, space-saving, subjected to low maintenance and realized at moderate investment and operating costs without applying external toxic chemicals. Established methods in decentralized wastewater disinfection are mainly based on membrane and UV technologies. However, these methods are currently working under high operating costs (high maintenance and cleaning efforts). Furthermore, the high investment costs of the membrane filtration are disadvantageous. In addition, both methods do not provide a disinfection residual. Thus, further research is required for the development and testing of alternative disinfection technologies. Against this background, the applicability of the electrolysis and UV/electrolysis hybrid technology for the decentralized wastewater reclamation was investigated and assessed in this dissertation. Results have shown that the electrochemical disinfection of biologically treated wastewater represents an efficient method at temperatures of > 6 °C, pH values of < 8.5 and DOC con-centrations of < 22 mg L-1. Under these conditions, an E. coli reduction of four log levels was achieved at a concentration of free chlorine ranging from 0.4 mg L-1 to 0.6 mg L-1 and at an after-reaction time of 15...20 min. However, it becomes simultaneously apparent that low temperatures, high pH values and high DOC concentrations are limiting parameters for this disinfection method to reclaim biologically treated wastewater. A high energy consumption of the electrolysis cell equipped with boron-doped diamond (BDD) electrodes (2...2.6 kWh m-3) represents a further unfavourable effect. Moreover, the undesired formation of chlorate (c = 1.3 mg L-1) and perchlorate (c = 18 mg L-1) at BDD electrodes can be considered as critical, since these disinfection by-products are, amongst others, human-toxicologically relevant. The concentration of adsorbable organically bound halogens (AOX) and trihalomethanes (THMs) proved to be marginal to moderate. Due to the synergistic effect of the combined application of UV irradiation (primary disinfection method) and electrolysis, the disadvantages of the single methods can be compensated. Decisive drawbacks of UV irradiation are photo and dark repair mechanisms of reversibly damaged bacteria. It was observed that the reactivation of reversibly UV-damaged E. coli even occurs at low temperatures (T = 10 °C) and strongly differing pH values (pH = 5.7...8.1) as well as at low light intensities and in darkness to an extent excluding a safe usage and storage of the reclaimed wastewater. The reactivation processes might be lowered by increased UV fluences. However, this is limited by high concentrations of total suspended solids (TSS). In spite of high UV fluences of > 400 J m-1, no complete removal of E. coli bacteria can be achieved at TSS concentrations of > 17 mg L-1. Therefore, it is indispensable to prevent bacterial reactivation caused by photo and dark repair processes. This topic was studied in the current work by electrochemically produced oxidants using an electrolysis cell positioned downstream of the UV unit. Results have shown that photo and dark reactivation were completely prevented by oxidants in a total concentration of 0.5...0.6 mg L-1 at a TSS concentration of 8...11 mg L-1, at pH values ranging from 5.7 to 8.1 and at temperatures ranging from 10 °C to 30 °C (t = 24....72 h). Even at a high TSS concentration of 75 mg L-1, the reactivation of E. coli (ctotal oxidants = 1.8 mg L-1) and, up to a TSS concentration of 32 mg L-1, the reactivation of total coliforms (except E. coli, ctotal oxidants = 1.0 mg L-1) can be prevented at a high initial germ concentration of 2…3 105 per 100 mL. The lowest energy consumption could be observed when mixed oxide electrodes (MOX electrodes) were applied. This result and the fact that no chlorate and perchlorate were observed at MOX electrodes argue for the application of these electrodes in practice. All in all, the UV/electrolysis hybrid technology represents an energy-efficient method for reclamation of biologically treated wastewater with TSS concentrations ranging from < 11 to 32 mg L-1 (E = 0.17…0.24 kWh m-3, MOX electrodes). Thereby, the reclaimed wastewater meet the hygienic quality requirements for a multitude of reuse categories starting from agricultural irrigation to urban and recreational reuse. Moreover, the requirements of the discharge class +H (100 faecal coliforms (E. coli) per 100 mL) are complied with reliably. The operational stability of the UV/electrolysis hybrid technology should also be ensured within the required maintenance intervals (t > 6 months). The undesired formation of coverings caused by biofouling processes on quartz glass surfaces could be prevented by electrochemically produced oxidants in a total concentration of 1 mg L-1 within an experimental duration of 5.5 months. However, the application of the UV/electrolysis hybrid technology is limited by increased particle concentrations and faecal loadings (initial E. coli concentration). The resulting enhanced demand of electrochemically produced oxidants for the prevention of bacterial reactivation results in a considerable increase of the electric charge input and energy consumption.

Sizing (hydrophobization) is one of the most important process steps within the added-value chain of about 1/3rd of the worldwide produced paper & board products. Even though sizing with so-called reactive sizing agents, such as alkenyl succinic anhydride (ASA) was implemented in the paper industry decades ago, there is no total clarity yet about the detailed chemical and physical mechanisms that lead to their performance. Previous research was carried out on the role of different factors influencing the sizing performance, such as bonding between ASA and cellulose, ASA hydrolysis, size revision as well as the most important interactions with stock components, process parameters and additives during the paper making process. However, it was not yet possible to develop a holistic model for the explanation of the sizing performance given in real life application. This thesis describes a novel physico-chemical approach to this problem by including results from previous research and combining these with a wide field of own basic research and a newly developed method that allows tracing back the actual localization of ASA within the sheet structure. The carried out measurements and trial sets for the basic field of research served to evaluate the stock and process parameters that most dominantly influence the sizing performance of ASA. Interactions with additives other than retention aids were not taken into account. The results show that parameters, such as the content of secondary fibers, the degree of refining, the water hardness as well as the suspension conductivity, are of highest significance. The sample sets of the trials with the major impacting parameters were additionally analyzed by a newly developed localization method in order to better understand the main influencing factors. This method is based on optical localization of ASA within the sheet structure by confocal white light microscopy. In order to fulfill the requirements at magnification rates of factor 100 optical zoom, it was necessary to improve the contrast between ASA and cellulose. Therefore, ASA was pretreated with an inert red diazo dye, which does not have any impact on neither the sizing nor the handling properties of ASA. Laboratory hand sheets that were sized with dyed ASA, were analyzed by means of their sizing performance in correlation to measurable ASA agglomerations in the sheet structure. The sizing performance was measured by ultrasonic penetration analysis. The agglomeration behavior of ASA was analyzed automatically by multiple random imaging of a sample area of approx. 8650 µm² with a minimum resolution for particles of 500 nm in size. The gained results were interpreted by full factorial design of experiments (DOE). The trials were carried out with ASA dosages between 0% and 0.8% on laboratory hand sheets, made of 80% bleached eucalyptus short fiber kraft pulp and 20% northern bleached softwood kraft pulp, beaten to SR° 30, produced with a RDA sheet former at a base weight of 100 g/m² oven dry. The results show that there is a defined correlation between the ASA dosage, the sizing performance and the number and area of ASA agglomerates to be found in the sheet structure. It was also possible to show that the agglomeration behavior is highly influenced by external factors like furnish composition and process parameters. This enables a new approach to the explanation of sizing performance, by making it possible to not only examine the performance of the sizing agent, but to closely look at the predominant position where it is located in the sheet structure. These results lead to the explanation that the phenomenon of sizing is by far not a pure chemical process but rather a more physical one. Based on the gained findings it was possible so far to optimize the ASA sizing process in industrial-scale by means of ~ 50% less ASA consumption at a steady degree of sizing and improved physical sheet properties.

Sizing (hydrophobization) is one of the most important process steps within the added-value chain of about 1/3rd of the worldwide produced paper & board products. Even though sizing with so-called reactive sizing agents, such as alkenyl succinic anhydride (ASA) was implemented in the paper industry decades ago, there is no total clarity yet about the detailed chemical and physical mechanisms that lead to their performance. Previous research was carried out on the role of different factors influencing the sizing performance, such as bonding between ASA and cellulose, ASA hydrolysis, size revision as well as the most important interactions with stock components, process parameters and additives during the paper making process. However, it was not yet possible to develop a holistic model for the explanation of the sizing performance given in real life application. This thesis describes a novel physico-chemical approach to this problem by including results from previous research and combining these with a wide field of own basic research and a newly developed method that allows tracing back the actual localization of ASA within the sheet structure. The carried out measurements and trial sets for the basic field of research served to evaluate the stock and process parameters that most dominantly influence the sizing performance of ASA. Interactions with additives other than retention aids were not taken into account. The results show that parameters, such as the content of secondary fibers, the degree of refining, the water hardness as well as the suspension conductivity, are of highest significance. The sample sets of the trials with the major impacting parameters were additionally analyzed by a newly developed localization method in order to better understand the main influencing factors. This method is based on optical localization of ASA within the sheet structure by confocal white light microscopy. In order to fulfill the requirements at magnification rates of factor 100 optical zoom, it was necessary to improve the contrast between ASA and cellulose. Therefore, ASA was pretreated with an inert red diazo dye, which does not have any impact on neither the sizing nor the handling properties of ASA. Laboratory hand sheets that were sized with dyed ASA, were analyzed by means of their sizing performance in correlation to measurable ASA agglomerations in the sheet structure. The sizing performance was measured by ultrasonic penetration analysis. The agglomeration behavior of ASA was analyzed automatically by multiple random imaging of a sample area of approx. 8650 µm² with a minimum resolution for particles of 500 nm in size. The gained results were interpreted by full factorial design of experiments (DOE). The trials were carried out with ASA dosages between 0% and 0.8% on laboratory hand sheets, made of 80% bleached eucalyptus short fiber kraft pulp and 20% northern bleached softwood kraft pulp, beaten to SR° 30, produced with a RDA sheet former at a base weight of 100 g/m² oven dry. The results show that there is a defined correlation between the ASA dosage, the sizing performance and the number and area of ASA agglomerates to be found in the sheet structure. It was also possible to show that the agglomeration behavior is highly influenced by external factors like furnish composition and process parameters. This enables a new approach to the explanation of sizing performance, by making it possible to not only examine the performance of the sizing agent, but to closely look at the predominant position where it is located in the sheet structure. These results lead to the explanation that the phenomenon of sizing is by far not a pure chemical process but rather a more physical one. Based on the gained findings it was possible so far to optimize the ASA sizing process in industrial-scale by means of ~ 50% less ASA consumption at a steady degree of sizing and improved physical sheet properties.:Acknowledgment I Abstract III Table of Content V List of Illustrations XI List of Tables XVI List of Formulas XVII List of Abbreviations XVIII 1 Introduction and Problem Description 1 1.1 Initial Situation 1 1.2 Objective 2 2 Theoretical Approach 3 2.1 The Modern Paper & Board Industry on the Example of Germany 3 2.1.1 Raw Materials for the Production of Paper & Board 5 2.2 The Sizing of Paper & Board 8 2.2.1 Introduction to Paper & Board Sizing 8 2.2.2 The Definition of Paper & Board Sizing 10 2.2.3 The Global Markets for Sized Paper & Board Products and Sizing Agents 11 2.2.4 Physical and Chemical Background to the Mechanisms of Surface-Wetting and Penetration 13 2.2.4.1 Surface Wetting 14 2.2.4.2 Liquid Penetration 15 2.2.5 Surface and Internal Sizing 17 2.2.6 Sizing Agents 18 2.2.6.1 Alkenyl Succinic Anhydride (ASA) 19 2.2.6.2 Rosin Sizes 19 2.2.6.3 Alkylketen Dimer (AKD) 23 2.2.6.4 Polymeric Sizing Agents (PSA) 26 2.2.7 Determination of the Sizing Degree (Performance Analysis) 28 2.2.7.1 Cobb Water Absorption 29 2.2.7.2 Contact Angle Measurement 30 2.2.7.3 Penetration Dynamics Analysis 31 2.2.7.4 Further Qualitative Analysis Methods 33 2.2.7.4.1 Ink Stroke 33 2.2.7.4.2 Immersion Test 33 2.2.7.4.3 Floating Test 34 2.2.7.4.4 Hercules Sizing Tester (HST) 34 2.2.8 Sizing Agent Detection (Qualitative Analysis) and Determination of the Sizing Agent Content (Quantitative Analysis) 35 2.2.8.1 Destructive Methods 35 2.2.8.2 Non Destructive Methods 36 2.3 Alkenyl Succinic Anhydride (ASA) 36 2.3.1.1 Chemical Composition and Production of ASA 37 2.3.1.2 Mechanistic Reaction Models 39 2.3.1.3 ASA Application 42 2.3.1.3.1 Emulsification 42 2.3.1.3.2 Dosing 44 2.3.1.4 Mechanistic Steps of ASA Sizing 46 2.3.2 Physico-Chemical Aspects during ASA Sizing 48 2.3.2.1 Reaction Plausibility 48 2.3.2.1.1 Educt-Product Balance / Kinetics 48 2.3.2.1.2 Energetics 51 2.3.2.1.3 Sterics 52 2.3.2.2 Phenomena based on Sizing Agent Mobility 53 2.3.2.2.1 Sizing Agent Orientation 54 2.3.2.2.2 Intra-Molecular Orientation 55 2.3.2.2.3 Sizing Agent Agglomeration 55 2.3.2.2.4 Fugitive Sizing / Sizing Loss / Size Reversion 56 2.3.2.2.5 Sizing Agent Migration 58 2.3.2.2.6 Sizing Reactivation / Sizing Agent Reorientation 59 2.3.3 Causes for Interactions during ASA Sizing 60 2.3.3.1 Process Parameters 61 2.3.3.1.1 Temperature 61 2.3.3.1.2 pH-Value 62 2.3.3.1.3 Water Hardness 63 2.3.3.2 Fiber Types 64 2.3.3.3 Filler Types 65 2.3.3.4 Cationic Additives 66 2.3.3.5 Anionic Additives 67 2.3.3.6 Surface-Active Additives 68 2.4 Limitations of State-of-the-Art ASA-Sizing Analysis 69 2.5 Optical ASA Localization 71 2.5.1 General Background 71 2.5.2 Confocal Microscopy 72 2.5.2.1 Principle 72 2.5.2.2 Features, Advantage and Applicability for Paper-Component Analysis 74 2.5.3 Dying / Staining 75 3 Discussion of Results 77 3.1 Localization of ASA within the Sheet Structure 77 3.1.1 Choice of Dyes 77 3.1.1.1 Dye Type 78 3.1.1.2 Evaluation of Dye/ASA Mixtures 80 3.1.1.2.1 Maximum Soluble Dye Concentration 80 3.1.1.2.2 Thin Layer Chromatography 81 3.1.1.2.3 FTIR-Spectroscopy 82 3.1.1.3 Evaluation of the D-ASA Emulsion 84 3.1.1.4 Paper Chromatography with D-ASA & F-ASA Emulsions 85 3.1.1.5 Evaluation of the D-ASA Emulsion’s Sizing Efficiency 86 3.1.2 The Localization Method 87 3.1.2.1 The Correlation between ASA Distribution and Agglomeration 88 3.1.2.2 Measurement Settings 89 3.1.2.3 Manual Analysis 90 3.1.2.4 Automated Analysis 92 3.1.2.4.1 Automated Localization / Microscopy Measurement 92 3.1.2.4.2 Automated Analysis / Image-Processing 93 3.1.2.5 Result Interpretation and Example Results 96 3.1.2.6 Reproducibility 97 3.1.2.7 Sample Mapping 98 3.1.3 Approaches to Localization-Method Validation 102 3.1.3.1 Raman Spectroscopy 102 3.1.3.2 Confocal Laser Scanning Fluorescent Microscopy 102 3.1.3.3 Decolorization 103 3.2 Factors Impacting the Sizing Behavior of ASA 104 3.2.1 ASA Type 105 3.2.2 Emulsion Parameters 107 3.2.2.1 Hydrolyzed ASA Content 107 3.2.2.2 ASA/Starch Ratio 109 3.2.2.3 Emulsion Age 110 3.2.3 Stock Parameters 111 3.2.3.1 Long Fiber/Short Fiber Ratio 111 3.2.3.2 Furnish Type 112 3.2.3.3 Degree of Refining 114 3.2.3.4 Filler Type/Content 116 3.2.4 Process Parameters 119 3.2.4.1 Temperature 119 3.2.4.2 pH-Value 120 3.2.4.3 Conductivity 122 3.2.4.4 Water Hardness 123 3.2.4.5 Shear Rate 125 3.2.4.6 Dwell Time 127 3.2.4.7 Dosing Position & Dosing Order 128 3.2.4.8 Drying 130 3.2.4.9 Aging 131 3.3 Factors Impacting the Localization Behavior of ASA 132 3.3.1 Degree of Refining 132 3.3.2 Sheet Forming Conductivity 135 3.3.3 Water Hardness 136 3.3.4 Retention Aid (PAM) 137 3.3.5 Contact Curing 138 3.3.6 Accelerated Aging 139 3.4 Main Optimization Approach 141 3.4.1 Optimization of ASA Sizing Performance Characteristics 142 3.4.2 Emulsion Modification 144 3.4.2.1 Lab Trials / RDA Sheet Forming 146 3.4.2.2 TPM Trials 147 3.4.2.3 Industrial-Scale Trials 149 3.4.2.4 Correlation between Sizing Performance Optimization and Agglomeration Behavior on the Example of PAAE 152 3.5 Holistic Approach to Sizing Performance Explanation 154 4 Experimental Approach 157 4.1 Characterization of Methods, Measurements and Chemicals used for the Optical Localization-Analysis of ASA 157 4.1.1 Characterization of used Chemicals 157 4.1.1.1 Preparation of Dyed-ASA Solutions 157 4.1.1.2 Thin Layer Chromatography 157 4.1.1.3 Fourier Transformed Infrared Spectroscopy 157 4.1.1.4 Emulsification of ASA 158 4.1.1.5 Paper Chromatography 159 4.1.1.6 Particle Size Measurement 159 4.1.2 Optical Analysis of ASA Agglomerates 160 4.1.2.1 Microscopy 160 4.1.2.2 Automated Analysis 163 4.1.2.2.1 Adobe Photoshop 163 4.1.2.2.2 Adobe Illustrator 164 4.1.2.3 Confocal Laser Scanning Fluorescent Microscopy 166 4.2 Characterization of Used Standard Methods and Measurements 166 4.2.1 Stock and Paper Properties 166 4.2.1.1 Stock pH, Conductivity and Temperature Measurement 166 4.2.1.2 Dry Content / Consistency Measurement 167 4.2.1.3 Drainability (Schopper-Riegler) Measurement 167 4.2.1.4 Base Weight Measurement 168 4.2.1.5 Ultrasonic Penetration Measurement 168 4.2.1.6 Contact Angle Measurement 169 4.2.1.1 Cobb Measurement 169 4.2.1.2 Air Permeability Measurements 170 4.2.1.3 Tensile Strength Measurements 170 4.2.2 Preparation of Sample Sheets 171 4.2.2.1 Stock Preparation 171 4.2.2.2 Laboratory Refining (Valley Beater) 171 4.2.2.3 RDA Sheet Forming 171 4.2.2.4 Additive Dosing 173 4.2.2.5 Contact Curing 174 4.2.2.6 Hot Air Curing 174 4.2.2.7 Sample Aging 174 4.2.2.8 Preparation of Hydrolyzed ASA 175 4.2.2.9 Trial Paper Machine 175 4.2.2.10 Industrial-Scale Board Machine 177 4.3 Characterization of used Materials 178 4.3.1 Fibers 178 4.3.1.1 Reference Stock System 178 4.3.1.2 OCC Fibers 179 4.3.1.3 DIP Fibers 179 4.3.2 Fillers 180 4.3.3 Chemical Additives 180 4.3.3.1 ASA 180 4.3.3.2 Starches 181 4.3.3.3 Retention Aids 181 4.3.3.4 Poly Aluminum Compounds 181 4.3.3.5 Wet Strength Resin 181 4.3.4 Characterization of used Additives 182 4.3.4.1 Solids Content 182 4.4 Description of Implemented Advanced Data Analysis- and Visualization Methods 183 4.4.1 Design of Experiments (DOE183 4.4.2 Contour Plots 184 4.4.3 Box-Whisker Graphs 185 5 Conclusion 186 6 Outlook for Further Work 191 7 Bibliography 192 Appendix 207 7.1 Localization Method Reproducibility 207 7.2 DOE - Coefficient Lists 208 7.2.1 Trial 3.3.4 – Impact of Retention Aid (PAM) on Agglomeration Behavior and Sizing Performance 208 7.2.2 Trial 3.3.5 – Impact of Contact Curing on Agglomeration Behavior and Sizing Performance 208 7.2.3 Trial 3.3.6 – Impact of Accelerated Aging on Agglomeration Behavior and Sizing Performance 209