METHOD OF PAPERMAKING HAVING ZERO LIQUID DISCHARGE

Abstract: A method of papermaking having zero liquid discharge. A cellulosic pulp composed of either virgin or recycled materials is initially cleaned, the cleaned pulp is then washed and the washed pulp is then utilized in the papermaking process. The contaminants are separated from the liquid residue resulting from the pulp cleaning operation (3), preferably by floatation clarification (4), and the effluent from the clarification is evaporated to produce steam along with an evaporated residue. The evaporated residue is combined with the suspended solids and the combined residue is then subjected to a mechanical dewatering operation (5) so that the dewatered material can then be either landfilled or incinerated. The condensate from the evaporation is combined with fresh water and used in the papermaking process (9) and water recovered from the papermaking process (9) is recycled to the washing operation (8). Water recovered from the washing operation (8) can be recycled to the pulp cleaning (3) and pulping operations (1).

Description: METHOD OF PAPERMAKING HAVING ZERO LIQUID DISCHARGE Background of the Invention Most paper or paperboard operations discharge tremendous quantities of liquid which contain suspended solids, such as wood fibers, clay, calcium carbonate, titanium dioxide, sand, and wood bark, along with oxygen demanding organic compounds, such as starches, lignins, and hemicellulose. In addition, the liquid discharge can also contain trace chemicals, such as chlorinated organic compounds, polychlorinated biphenols, metals such as barium, aluminum, and other trace elements. The adverse environmental impact of this liquid discharge from a papermaking operation is well documented. There are several reasons for the liquid dis- charge from a papermaking operation. In some cases, the liquid discharge is due to careless, excessive use of water and, if excess water is used, it must be discharged from the operation. In other cases, the liquid discharge is the result of poor water system design, which results in inadvertent use of fresh water. In still other instances, excess water has been employed in an attempt to keep the suspended and dissolved solid levels at a low enough level to ensure optimum paper machine conditions. In this latter case, the added water effects a reduction in suspended and dissolved solids, but produces a corresponding increase in effluent flow. Typically the most highly contaminated water discharged from a conventional papermaking operation utilizing recycled waste paper, results from the cleaning of the recycled pulp. The liquid residue from the cleaning operation is normally subjected to floatation clarification, in which the lighter weight solid material is recovered as a floating layer which can be burned or landfilled. The liquid effluent from the clarification process, which contains dissolved solids and oxygen demanding compounds, then must be treated by either an aerobic or anaerobic process before it can be discharged to the sewer system. Evaporation of the liquid effluent has not been feasible due to the tremendous volume of effluent. Summary of the Invention The invention is directed to a papermaking operation having zero liquid discharge. In accordance with the invention, a cellulosic pulp produced by conventional techniques and composed of either virgin pulp, or recycled pulp, or a combination of both, is initially subjected to a cleaning operation. The cleaning operation in itself is conventional, and normally includes a number of stages in which various types of suspended solids or particulate material are removed from the pulp. In a typical cleaning operation, debris and heavy material, such as stones, metal, glass, and the like are initially removed from the pulp by a liquid cyclone, and the pulp is then subjected to a coarse screening, followed by a secondary finer screening to remove large and small size contaminants. Following this, the pulp is subjected to a forward cleaning opera¬ tion utilizing a liquid cyclone to remove sand, small fiber bundles, ink, and the like. Several stages of forward cleaning are normally employed. The sand, dirt, and other solid material that is removed during the forward cleaning is then subjected to compaction, and the liquid phase from the compaction is discharged to a clarifier. After the forward cleaning, the pulp is then passed through a slotted screen cleaner, which removes smaller particles of plastics, hot melt, adhesives, and the like. The solid residue from the slotted screen cleaner is again compacted and liquid removed during the compaction is sent to the clarifier. Following the slotted screen cleaning the pulp is subjected to reverse cleaning utilizing a liquid cyclone, in which lighter material, such as wax, latex, hot melt, is separated from the heavy material, which is the pulp. Again, the reverse cleaning is normally carried out in a number of stages, and the separated light phase is sent to the clarifier. In the clarifier, which is preferably a floatation clarifier, the solid materials are separated as a floating upper layer or sludge which is discharged to a mechanical solid waste dewatering unit, such as a sludge press, while the liquid effluent from the clar¬ ifier is delivered to an evaporator. In the evaporation, the liquid effluent from the clarifier is heated by a low pressure steam discharged from the dryer section of the papermaking machine. High pressure steam, at a pressure normally about 160 psig, from a steam generating plant is supplied to the dryers in the dryer section of the papermaking machine and a mixture of low pressure steam at a pressure of perhaps 50 psig, and steam condensate, are discharged from the dryers to a condensate tank where the low pressure steam is separated from the condensate. The low pressure steam is then delivered to the evaporator and used as the best source to evaporate the liquid effluent from the clarifier. The condensate from the dryer steam as well as the condensate from the vaporized liquid effluent can be combined and delivered to a water storage tank, or alternately the condensate from the dryer steam, which is relatively pure, can be recycled to the steam generating plant. The evaporated residue or crystals from the evaporator is transferred to the solid waste dewatering unit where it is combined with the sludge from the clarifier. The combined residues are dewatered in the dewatering unit to produce a residue containing about 30 to 50% solids, and this material can then either be landfilled or incinerated. The pulp, after cleaning, is subjected to a water washing operation to remove dissolved and suspended solids resulting from the pulping operation. When using recycled pulp from reclaimed waste material, such as newsprint, used corrugated cartons, white office waste and the like, the washing will also remove fillers, such as of clay and calcium carbonate. Following the washing, the pulp undergoes normal stock preparation and can then be utilized in the papermaking process. The condensed dryer steam and the condensate resulting from the evaporation of the liquid effluent from the clarifier can be combined with fresh makeup water in the water storage tank or chest, and this water is then employed in the papermaking process to be used in portions of the process that require relatively pure water with a minimum mineral content, such as for example, the showers and pump sealing water. Water recovered from the papermaking process is recycled back to the pulp washing operation and used to wash the pulp, and similarly, water recovered from the washing operation, can be recycled back and employed in pulp cleaning and pulping. With the process of the invention, there is zero liquid discharge from the papermaking operation, the only discharge being solid residue that can be either landfilled or incinerated. As a further advantage, the process of the invention produces a higher fiber yield, as no small fibers or fines are lost in water discharge. The process of the invention also requires less energy than conventional papermaking processes. In a conventional process, water at an elevated temperature of approximately of 120°F to 160°F, is used as the incoming water in the papermaking operation, and the water is normally heated to this temperature either through direct heating or sparging with steam. In the process of the invention, the only required heat source is the heat needed for evaporation of the liquid effluent from the clarifier, and the steam from that evaporation will meet the heat requirements for the incoming water. Further, the process of the invention saves the energy normally required in the aerobic or anaerobic treatment of the liquid being discharged to the sewer system. As a further advantage, the process of the invention results in a considerably lesser water consump¬ tion than normal papermaking operations. This is an important factor when the papermaking mill is located in an arid region of the country. Other objects and advantages will appear in the course of the following description. Description of the Drawings The drawing illustrates the best mode presently contemplated of carrying out the invention. In the drawings: FIG. 1 is a flow diagram illustrating the process of the invention. Description of the Illustrated Embodiment Fig. 1 is a flow diagram illustrating the papermaking process of the invention having zero liquid discharge. A pulp slurry is initially produced in a pulping vessel 1 using conventional techniques. The cellulosic material used in producing the pulp can either be virgin material, such as wood chips, or recycled material which can include used corrugated containers, wastepaper, white office waste, or the like. As the recycled material can contain debris and solid contamin¬ ates and also include a substantial quantity of fillers, such as clay and calcium carbonate, as well as ink, which normally would not be present in virgin pulp, the process for treating recycled pulp differs in certain respects from that of treating virgin pulp, as will be hereinafter described. In the pulping operation, a caustic material such as sodium hydroxide, is added to the pulp, along with water, and conventional surfactants to wet the fibers. In addition, when using recycled pulp, sodium silicate can be used as a deinking aid and hydrogen peroxide as a brightener. In the pulping vessel 1, the pulp is maintained at a temperature generally in the range of 120°F to 160°F, and is subjected to agitation or a shearing action to break down the fiber bundles. The pulping can either be a continuous opera¬ tion, in which materials are continuously fed and discharged from the pulper, or a batch pulping operation. With a batch operation the pulp is maintained in the pulper at the above-noted temperature and with agitation for a period generally in the range of 15 to 35 minutes. The consistency of the pulp in the pulping operation can vary depending upon the type of paper being produced. When producing corrugated medium for use in corrugated cartons, the pulp may be at a consistency in the range of 3% to 5% by weight of solids. On the other hand, when producing more sophisticated grades of paper, such white office paper, the pulp may have a consistency of 10% to 15% by weight of solids. After pulping, the pulp is discharged to a pulp chest 2. With a batch-type pulping operation, the pulp chest serves as a storage facility for the pulp, and the pulp is then discharged continuously from the pulp chest through the remainder of the papermaking process. When a continuous pulping process is employed, the pulp chest will serve to compensate for variations in flow from the pulper 1 and provide a consistent flow throughout the papermaking process. The pulp is then pumped from the dump chest 2 to a pulp cleaner 3 , which acts to remove suspended solids and particulate material from the pulp. The cleaning operation is, in itself, conventional and consists of a series of sequential cleaning procedures. More particularly, large and heavy debris, such as bark, stones, glass, metal pieces, and the like, are initially removed from the pulp slurry, preferably by a liquid cyclone. The pulp then undergoes a coarse screening operation to remove larger-sized contaminants. Following the coarse screening, the pulp is subjected to a finer secondary screening, in which the pulp is to a shearing action, and smaller sized solids or contaminants are removed. After the secondary screening, the pulp slurry then undergoes a forward cleaning to remove small partic¬ les of sand, fiber bundles, ink, and the like. At this stage the pulp generally has a consistency of about 1.5% solids, and a liquid cyclone is employed for the forward cleaning, with several stages being utilized. The solid particulate material removed from the pulp during the forward cleaning is then transferred to a compactor and the liquid resulting from the compaction process is discharged to a clarifier 4. Following the forward cleaning the pulp slurry is passed through a slotted screen cleaner which acts to remove plastics, hot melt adhesives, and the like from the slurry. The residue from this cleaning operation is compacted and the liquid recovered from the compaction operation again is transferred to the clarifier 4. At this stage the pulp may still contains small quantities of wax, latex, hot melt adhesives, and the like, and the pulp is then subjected to a reverse clean¬ ing operation in a liquid cyclone. In this operation, the lighter weight materials, such as wax, latex, and the like, are removed from the heavier pulp, and again the reverse cleaning can be carried out in a plurality of stages. The lighter phase, which is removed during the reverse cleaning, is also transferred to the clarifier 4. The clarifier, in itself, is a conventional type and is preferably a floatation clarifier. The upper floating portion of the material in the clarifier is in the form of a sludge and has a solids content in the range of about 10% to 15%. The sludge is conveyed to a solid waste dewatering mechanism 5, while the liquid effluent from the clarifier 4 is transferred to an evaporator 6. In a typical papermaking process, steam from a steam generating plant is supplied to the dryers in the dryer section of the papermaking machine. The typical papermaking machine may contain approximately twenty to one hundred dryers and the paper web supported by a dryer fabric is passed over the dryers to dry the paper. It is customary to use a cascading steam system in the dryer section of the papermaking machine, in which high pres¬ sure steam at a pressure of about 160 psig, is supplied to a first group of dryers and lower pressure steam discharged from the first group of dryers is supplied to a second group, of dryers. This cascading system is continued, so that low pressure steam at perhaps a pressure of 50 psig, along with steam condensate, is discharged from a last group of dryers in the section and either condensed and returned to the steam generating plant, or discharged to the atmosphere. In accordance with the invention, low pressure steam discharged from the dryer section of the papermak¬ ing machine 9 is utilized as the power source to evapor¬ ate the liquid effluent from the clarifier. In this regard, the steam, at a pressure of perhaps 50 psig, and condensate from the dryers is discharged to a condensate tank where the steam is separated from the condensate. The condensate can then be employed as a heat source to heat incoming process water to the papermaking machine. The low pressure steam from the condensate tank, at perhaps a pressure of 45 psig, is supplied to evaporator 6 to evaporate the liquid effluent. The evaporation is preferably carried out by a multiple effect evaporator, such as that sold by Goslin-Birmingham of Birmingham, Alabama. The low pressure steam from the dryer section is utilized to heat the liquid effluent to produce water vapor and organic vapors, due to the fact that the effluent may contain small amounts of volatile organic constituents. The vapor resulting from the evaporation of the liquid effluent is then condensed and transferred to a water storage tank 7. The condensed dryer steam from evaporator 6 can be combined with the condensate from the vaporized liquid effluent in tank 7, or alternately, as the condensate from the dryer steam is relatively pure, it can be recycled to the steam generating plant, as shown in the flow diagram. While a typical papermaking operation utilizes a cascading steam system in the dryer section, a non- cascading system is preferred in the invention, with high pressure steam being supplied to all of the dryers in the dryer section. The reason this is preferred is that all dryers may be maintained at maximum pressure, which maximizes the drying rate and therefore minimizes the investment in drying equipment. A non-cascading system is economically feasible with the process of the invention because the steam being discharged from the dryer section is supplied to the evaporator 6 and used as a heat source for the evaporation of the liquid effluent from the clarifier. The evaporated residue or crystals from the evaporator 6, having a solids content generally of about 40% to 60% by weight, can be landfilled or incinerated, or as shown in Fig. 1, can be discharged to the solid waste dewatering unit 5, and combined with the sludge from the clarifier. In the dewatering unit 5, the solid waste is dewatered by mechanical equipment, such as a compactor, screw press, or belt press and the small amount of liquid removed from the solid waste can be returned to the clarifier. The dewatered sludge having a consistency generally in the range of about 35% to 50% by weight solids, can then either be landfilled or incinerated. With proper design of the dewatering unit 5, the colloidal material will be entrapped by the filter cake and the ionic solution in the filter cake increases as the lower ionic solution is displaced. The incinera- tion of the dewatered residue can be accomplished either in a coal or oil fired boiler. The dewatered residue is high in fuel value and also contains sulfur capturing sodium hydroxide and calcium carbonate. Applying the residue to coal as a dust control has a positive impact on sulfur dioxide emissions from the furnace or boiler. The dewatered residue can also be used for dust control of fly ash. Fly ash from coal burning operations is normally acidic, since the coal will contain high levels of sulfur. By utilizing the residue for dust control, the pH can be maintained closer to neutral. As shown in the flow diagram the pulp slurry after the cleaning operation and having a solids content of about 0.4% to 2.0% by weight of solids, is pumped to pulp washer 8, in which the dissolved solids contained in the fiber supply, or generated through the pulping operation, are washed from the pulp. When dealing with recycled pulp, the washing operation can also remove dirt, fillers, or suspended solids, such as clay and calcium carbonate. The pulp washing can be carried out by a method as disclosed in copending United States patent application Serial No. , filed , which is incorporated herein by reference. As disclosed in that patent application, a very thin mat of pulp is supported between a pair of porous endless belts and passed in a sinuous path over a series of rolls. Wash water is impinged against opposite faces of the mat and the tension in the belts as they pass over the rolls creates a dewatering action, so that the pulp is alternately showered with water and then dewatered by the belt tension, thereby removing fillers and dissolved solids from the pulp mat. If virgin pulp is used in the papermaking process, the washed pulp can then be delivered directly to the papermaking machine 8 to form paper or paperboard through conventional techniques. However, if the pulp is produced from recycled material which contains ink, deinking and ink removal operations are required. The deinking can be accomplish¬ ed by pulping the recycled material with dispersant chemicals, such as a surfactant, that act to dissociate the ink from the fibers and disperse the ink particles in the aqueous pulp. During the pulping operation, depend¬ ing upon the nature of the ink, sodium silicate can also be incorporated with the surfactant during the pulping. The sodium silicate provides alkalinity and aids in releasing and dispersing the ink particles. In addition, hydrogen peroxide and chelating agents can be utilized during pulping, which aid in solubilizing certain oils in the ink, act as a brightening agent, and permit highly alkaline operations without color reversion. Through this treatment during pulping, the ink is dissociated from the cellulosic fibers. Following the washing operation, the recycled pulp can then be subjected to an ink removal operation. Ink removal can be achieved either by froth floatation or dilution washing, which can include a side hill screen washer, a gravity decker, a vacuum filter, an inclined screw extractor, or other types of washing. The publica¬ tion "Beloit Corporation Deinking Manual " 2nd Ed., 1979, describes conventional ink removal processes. After deinking the recycled pulp may have a dingy color due to a small portion of residual ink, and thus the pulp is normally subjected to bleaching. In the bleaching operation, the pulp is thickened to a consis- tency of about 15% solids, and bleached by adding a material, such as hydrogen peroxide, ozone, or oxygen. The pulp is thickened in order to reduce the amount of bleaching chemicals that are required. The pulp then undergoes stock preparation, which normally consists of refining and dilution to provide the pulp in the headbox of the papermaking machine 9, with a consistency of about 0.2% to 1.2% by weight solids. In the papermaking process, the pulp as a thin web or layer is conveyed through the forming, press and dryer sections of the papermaking machine 9 in a conventional manner to form the paper sheet. In the papermaking operation, relatively pure water, having a minimum mineral content is required for certain equipment, such as the showers, and vacuum pump sealing water. In accordance with the invention, the condensate from storage tank 7 is used in the papermaking operation, as shown in the flow diagram. Depending on the water balance, make-up can also be added to storage tank 7. The makeup water would normally be municipal water, and if the makeup water has a high mineral content, the makeup water can be added to the liquid effluent flowing between the clarifier 4 and the evaporator 6, so that the makeup water is then subjected to the evaporation process. Water recovered from the papermaking operation, which can consist of water recovered from the showers and pump seal water, as well as water extracted from the wet paper web, is then recycled to the pulp washer 5 and used as the wash water for washing the pulp. The water recovered from the pulp washing operation, which consists of residual wash water, as well as water recovered by virtue of the increase in consistency of the pulp as it passes through the washing process, is then recycled to the pulper 1 for use in producing the pulp slurry. In addition, a portion of the recirculated water as shown in the flow diagram, can be recycled to the pulp cleaner 2. The process of the invention provides a paper¬ making operation which has zero water discharge and the solids discharged from the process have a consistency such that they can be either landfilled or incinerated. The process also provides a higher fiber yield, and as there is no fiber loss in a water discharge as in conventional processes. In many conventional papermaking operations, a substantial portion of the small fibers or fines are lost in the liquid discharge of the operation. As a further advantage, low pressure steam discharged from the dryer section of the papermaking machine is utilized as the heat source to evaporate the liquid effluent from the clarifier, and the condensate from the evaporation process serves as a heat source for the incoming water to the papermaking machine. Thus, it is not necessary to directly heat the incoming water as is required in a conventional papermaking operation. The process of the invention also enables brackish water having a high mineral content to be employed as make-up water by introducing the makeup water ahead of the evaporator, so that the makeup water is also vaporized. As the process has zero liquid discharge, the process utilizes substantially smaller quantities of water than a conventional papermaking operation, and this has distinct advantages in arid regions of the country where water is at a premium.

Claims: C AIMS I claim: 1. A method of papermaking having zero liquid discharge, comprising the steps of pulping a cellulosic material to provide a pulp slurry, cleaning the pulp slurry to remove suspended particulate material and produce a liquid residue, washing the pulp after cleaning with wash water to provide a washed pulp, utilizing the washed pulp in a papermaking process to produce a paper sheet, evaporating the liquid residue to provide vapor and an evaporated residue, condensing the vapor to provide a first condensate, utilizing the condensate in said papermaking process, utilizing water recovered from the papermaking process to wash said pulp, and utilizing water recovered from the washing operation in the pulping of said cellulosic material. 2. The method of claim 1, and including the steps of supplying high pressure steam from a steam generating source to a dryer section of the papermaking process, discharging lower pressure steam from said dryer section, and utilizing said lower pressure steam to evaporate said liquid residue. 3. The method of claim 1, and including the steps of condensing said lower pressure steam during the evaporation of said liquid residue to provide a second condensate. 4. The method of claim 3, and including the step of mixing said second condensate with said first condensate to provide a mixed condensate and utilizing said mixed condensate in the papermaking process. 5. The method of claim 3, and including the step of returning said second condensate to said steam generating source. 6. The method of claim 1, and including the step of combining fresh water with said first condensate to provide a combined supply, and utilizing said combined supply in said papermaking process. 7. The method of claim 1, and including the step of clarifying the liquid residue prior to evapora¬ tion by subjecting the liquid residue to floatation clarification to provide an upper layer of light weight solids and a lower layer of said liquid residue. 8. The method of claim 7, and including the step of combining the solids with said evaporated residue to provide a combined residue. 9. The method of claim 8, and including the step of subjecting said combined residue to mechanical dewatering to reduce the water content of said combined residue. 10. The method of claim 9, and including the step of discharging the dewatered combined residue to a landfill. 11. The method of claim 9, and including the step of incinerating the dewatered combined residue. 12. The method of claim 1, wherein said cellulosic material comprises recycled wastepaper containing ink and said method includes the step of removing the ink from the pulp after washing. 13. The method of claim 12, and including the step of bleaching the pulp after removal of said ink and prior to utilizing the pulp in said papermaking process. 1 . In a method of papermaking having zero liquid discharge, the steps comprising pulping a cellulosic material to provide a pulp, cleaning the pulp to remove suspended solids and provide a cleaned pulp along with a solid residue and a separate liquid residue, washing the cleaned pulp with wash water to remove dissolved solids from said pulp, utilizing the washed pulp in a papermaking machine to provide a paper sheet, supplying high pressure steam from a steam generating source to a dryer section of said papermaking machine to dry said paper sheet, discharging lower pressure steam from said dryer section, utilizing said lower pressure steam to evaporate said liquid residue and provide an evaporated residue and a vapor condensate, and supplying the vapor condensate to the papermaking machine for use in the papermaking process. 15. the method claim 14, and including the steps of recycling water recovered from the papermaking machine to wash said pulp, and recycling water recovered from washing of the pulp to said pulping operation. 16. The method of claim 14, and including the step of condensing said lower pressure steam during the evaporation of said liquid residue to provide a steam condensate. 17. The method of claim 16, and including the step of mixing said steam condensate with said vapor condensate to provide a mixed condensate, and supplying said mixed condensate to said papermaking machine for use in the papermaking process. 18. The method of claim 17, and including the step of combining fresh water with said mixed condensate to provide a combined water supply, and supplying said combined water supply to said papermaking machine for use in said papermaking process. 19. The method of claim 15, and including the step of utilizing a portion of the water recovered from said washing operation to clean said pulp. 20. The method of claim 14, and including the step of combining said solid residue and said evaporated residue to provide a combined residue. 21. The method of claim 20, and including the step of subjecting the combined residue to a mechanical dewatering operation to reduce the water content of said combined residue. 22. The method of claim 14, and including the step of transferring the pulp after pulping to a dump chest, and thereafter continuously flowing said pulp from said dump chest to said cleaning operation. 23. The method of claim 11, and including the step of combining a sufficient quantity of said combined condensate with said fresh water to heat said combined water supply to a temperature of 120°F to 160°F.

Inventors: HOFFMAN ROGER P, HOFFMAN, ROGER, P.
Applicants: HOFFMAN ENVIRONMENTAL SYSTEMS, HOFFMAN ENVIRONMENTAL SYSTEMS, INC.
Application year: 1995
Main classification: D21F1
IPC codes: D21B1, D21C5, D21C9, D21C11, D21F1