Patent Description:
Recycling is a major factor in the modern green economy and is particularly significant in the paper industry's goal to become more efficient and environmentally sustainable. Use of recycled pulp in paper and packaging manufacturing, however, presents several obstacles to achieving high-quality product. Recycled pulp, for example, derived from old corrugated cardboard, writing/printing grades sized or coated with starch, contain starch, usually at high levels, and are beneficial to making recycled paper/paperboard. The grades of paper/cardboard to be recycled also have beneficial levels of CaCO<NUM>. Unfortunately, this starch content can become substantially degraded during manufacturing as can supplemental starch added during the manufacturing. Less starch in the resulting product means a loss of or lower mechanical properties in the paper/paperboard product made from the pulp. Further, the calcium found in pulp, such as pulp from recycled sources, can cause calcium precipitation, scaling or fouling in the post treatment of process water that occurs after pulp removal.

More specifically, in the past, numerous papermaking plants (especially those using recycled paper) have experienced numerous problems that may have been related to bacterial problems. However, when the standard approach to combating bacteria was attempted, no success was achieved. Biocides typically used in the papermaking industry and/or typical biocide treatments did not solve the following problems that were being seen in many machines making packaging papers. Those in the industry could not understand what was the exact problem and could not determine a solution to the problem. The present inventor however, determined that a particular microbial activity initiated the following sequence:.

At this point, the problems only get worse: (<NUM>) increased growth of fermenting bacteria results in increased production of extracellular amylases; (<NUM>) any starch added for strength in the wet end (between mixing chest and head box) is degraded; (<NUM>) the glucose oligomers encourage even more growth of microorganisms and so increase slime and/or other bacteria problems; (<NUM>) VFAs are a cause of serious odor problems in the paper as well as in the production environment and/or in the surroundings, potentially including habitation areas; (<NUM>) when calcium carbonate is dissolved and stabilized by VFAs, filler (e.g., from waste paper) is lost, essentially a loss of raw material; and/or (<NUM>) dissolved calcium can cause deposit or scaling problems.

In mills utilizing anaerobic digesters for waste water treatment, another related problem can develop, as follows:.

In mills utilizing aerobic digesters or ponds for waste water treatment, alone or in combination with anaerobic digesters, problems with CaCO<NUM> fall-out can develop, as follows:.

The present inventor was the first to understand the root of the problem and how to prevent and/or control this problem. The approach used by the present inventor, as described herein, is to reduce or prevent the breakdown of starch by microbiological activity in the paper mill. The root causes of the problem are in summary:.

Thus, the present inventor determined that the best way to solve this problem was to get ahead of the problem and stop the chain of events that are detailed above.

<CIT> discloses synergistic mixtures of haloamines and their use to control the growth of microorganisms in aqueous systems. <CIT> discloses synergistic mixtures of haloamines and non-oxidizing biocides and their use to control the growth of microorganisms in aqueous systems.

The present invention is directed to a method to control or prevent calcium precipitation and/or scaling, characterized by (i) in an aerobic or anaerobic digester that processes process water used in papermaking and containing calcium from pulp being processed, said method comprising in a papermaking process, continuously treating the process water containing said pulp with chloramine comprising monochloramine such that said process water when said pulp is present has a residual chloramine amount of from <NUM> ppm to <NUM> ppm, wherein calcium is present in said pulp, and then forming paper or paperboard from said pulp, and processing said process water, after pulp removal, to one or more digesters; or (ii) in a biological oxygen demand reduction system that processes process water used in papermaking and containing calcium from pulp being processed, said method comprising in a papermaking process, continuously treating the process water containing said pulp with chloramine comprising monochloramine such that said process water when said pulp is present has a residual chloramine amount of from <NUM> ppm to <NUM> ppm, wherein calcium is present in said pulp, and then forming paper or paperboard from said pulp, and processing said process water, after pulp removal, to said biological oxygen demand reduction system to reduce biological oxygen demands.

Additional features and advantages of the present invention will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned by practice of the present invention. The objectives and other advantages of the present invention will be realized and attained by means of the elements and combinations particularly pointed out in the description and appended claims.

The methods of the present invention can result in maintaining or increasing filler and/or ash content in the sheet product. For instance, solid calcium that would have been dissolved in conventional systems, is instead retained in the sheet as a raw material. Lower calcium ion concentrations (lower precipitated calcium levels) lead to increased uptake of starch into sheets including binding of starch to filler particles. Reduction in chemistry usage is also realized in multiple contexts including in the paper machine and subsequently in a biological waste water plant. Increased machine output due to reduction in size press starch solids and the option to transition from size press to wet end starch addition are also made possible. Also, with the present invention, a drying energy reduction can be achieved by the elimination of (<NUM> or <NUM> sides of <NUM>-sided) size press. Reduction in the amount of sludge to be landfilled and reduction in effluent plant polymer treatment are further made possible by the methods of the present invention.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide a further explanation of the present invention, as claimed.

The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate some of the features of the present invention and together with the description, serve to explain the principles of the present invention.

The present invention may be more fully understood with reference to the accompanying figures. The figures are intended to illustrate exemplary features of the present invention without limiting the scope of the invention.

A key point in achieving effective control of the problems detailed above is using the correct biocidal treatment, and this involves using the correct biocide, the correct dosage, the correct application point(s), maintaining the correct residual biocidal levels, and to keep doing this over an extended period of time. It was determined that high levels of one or more chloramines must be maintained to control the problems detailed above. Essentially, the present inventor determined that a very aggressive and persistent treatment schedule is needed as detailed herein.

Process water used in papermaking and containing calcium from pulp being processed is continuously treated with chloramine comprising monochloramine. The process water can be treated with one or more chloramines, for example monochloramine (MCA) or a combination of monochloramine (MCA) and dichloramine (DCA). A majority (by weight) of the chloramine can be MCA (such as at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>%, at least <NUM>% or <NUM>% by weight of the chloramine present). The treatment can be performed in any suitable manner. The treatment is continuous. The treatment can be performed at one or more stages or locations in a papermaking system. For example, the treatment can be performed in a vessel such as a head box, treating pulper, pulper fill water or dump chest, or any combinations thereof. The treatment(s) occurs where the pulp is present with the process water.

The pulp used in the present invention can be any suitable variety of pulp or combination of pulps. The pulp can be derived from hardwood, softwood, or a combination thereof. The pulp can be virgin, recycled, or a combination thereof. The pulp can be obtained from one or more sources such as broke, recycled packaging, old corrugated containers (OCC), mixed office waste (MOW), coated fine paper, baled mixed paper, sorted office paper, deinking grade newsprint, news blank, boxboard, boxboard with polymer, waxed boxboard, boxboard with foil, baled corrugated cardboard, waxed corrugated cardboard, beer carton waste, double lined kraft, bleached kraft, lightly printed bleached kraft, printed bleached kraft, colored kraft, brown kraft, kraft multiwall bag waste, kraft multiwall polybag waste, carrier stock, mixed envelope (new), white envelope, plastic windowed white envelope, colored envelope, plastic windowed colored envelope, kraft envelope, plastic windowed kraft envelope, printed kraft envelope, plastic windowed printed kraft envelope, white ledger, manifold white ledger, laser printed white ledger, colored ledger, manifold colored ledger, super ledger, carbon interleafed ledger, carbonless thermal ledger paper, hard white, mixed tab cards, manila tab cards, colored tab cards, manila file folder stock, soft white, ground wood fiber, magazines, magazines with hot melt, books, book stock, waxed cup stock, glassine, aseptic packaging, solid fiber containers, or any combination thereof. Starch can be present in recycled papers, such as broke, recycled packaging, old corrugated containers (OCC), mixed office waste (MOW), coated fine papers or other printing papers, or other indicated recycled papers, and in general all recycled cellulosic materials containing starch. The pulp can contain at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, at least about <NUM> wt % post-consumer content, or <NUM> wt % post-consumer content based on the total weight of dried pulp.

The pulp source and/or pulp can contain any desired amount of starch. For example, the pulp source and/or pulp can contain starch in an amount of at least <NUM>/Tonne (<NUM> Tonne, is a metric tonne = <NUM> lbs. ), at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, at least about <NUM>/tonne, greater than about <NUM>/tonne, or a range including one or more of such amounts. The starch can be present in the pulp at a desired amount based on the total weight of dried pulp fiber. For example, the starch can be present in the pulp in an amount of at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt %, at least about <NUM> wt% based on the total weight of dried pulp fiber, or a range including one or more of such amounts. For example, the starch content can be at least about <NUM> wt% including from about <NUM> wt % to about <NUM> % wet end cationic starch, from about <NUM> wt % to about <NUM> wt % size double sided stock, and from about <NUM>% to about <NUM>% starch from glue based on the total weight of dried pulp fiber. The starch that is present in the pulp and/or process water can be a result of the starch present in the pulp (such as starch that is from recycled sources such as packaging and/or paperboard) and/or can be a result of additional starch added to the pulp and/or process water.

Starch can be measured, before, after, and/or during treatment of the pulp using any suitable or desired method. Starch molecular weight (MW) distribution can be measured, for example, through size exclusion chromatography. The methods of the present invention can enable an increased quantity and average molecular weight of starch recovered from recycled fiber as well as broke in the context of virgin fiber packaging mills. Increased MW of starch helps achieve improved mechanical properties. The average MW in Daltons of amylose, amylopectin, and/or total starch in the pulp can be at least <NUM>. 0x10<NUM> D, at least <NUM>. 0x10<NUM> D, at least <NUM>. 0x10<NUM> D, at least <NUM>. 0x10<NUM> D, at least <NUM>. 0x10<NUM> D, at least <NUM>. 5x10<NUM> D, at least <NUM>. 0x10<NUM> D, at least <NUM>. 5x10<NUM> D, or at least <NUM>. 0x10<NUM> D.

The starch can be endogenous and/or exogenous to the pulp source and/or pulp. The pulp can be supplemented with additional starch at any desired time point, location, or rate. The starch can be obtained from any source or combination of sources. Any kind of starch or combination of starches can be used. The starch can have any desirable amounts and/or relative amounts of amylose and amylopectin. For example, the starch can contain from about <NUM> wt % to about <NUM> wt % amylose and from about <NUM> wt % to about <NUM> wt % amylopectin, from about <NUM> wt % to about <NUM> wt % amylose and from about <NUM> wt % to about <NUM> wt % amylopectin, or from about <NUM> wt % to about <NUM> wt % amylose and from about <NUM> wt % to about <NUM> wt % amylopectin based on the total weight of the starch. The starch can contain cationic starch, anionic starch, or a combination thereof. The starch can be modified, unmodified, or a combination thereof. Modified starch can include, for example, one or more of hydroxyethyl starch, carboxymethylated starch, dextrin, acid-treated starch, alkaline-treated starch, bleached starch, oxidized starch, enzyme-treated starch, monostarch phosphate, distarch phosphate, phosphated distarch phosphate, acetylated distarch phosphate, starch acetate, acetylated distarch adipate, hydroxypropyl starch, hydroxypropyl distarch phosphate, hydroxypropyl distarch glycerol, starch sodium octenyl succinate, an acetylated oxidized starch, or any combinations thereof.

The process water containing the pulp may have very low amylolytic bacteria counts and/or other bacteria. The amylolytic bacteria can be present at less than about <NUM> colony forming units (cfu) per gram of pulp dry weight (d. ), less than about <NUM> cfu/g pulp d. , less than about <NUM>,<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. , less than about <NUM>. 0x10<NUM> cfu/g pulp d. The amylolytic bacteria may be controlled such that the bacteria cause no significant breakdown of the starch in the pulp. For instance, the amount of starch originally present (when added to the process water) may not be reduced by more than <NUM>% by weight once in the paper made from the pulp. Put another way, at least <NUM>% by weight of the starting amount of starch in the starting pulp can make its way into the paper resulting from the pulp and this can be at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, at least <NUM> wt%, such as from <NUM> wt% to <NUM> wt%.

Any suitable chloramine or combination of chloramine can be used in the methods of the present invention. The chloramine contains monochloramine. The chloramine can be obtained from any suitable source. For example, BUSPERSE <NUM> product, BUSAN <NUM> product, and BUCKMAN <NUM> product, available from Buckman Laboratories International, Inc. , Memphis, Tennessee, can be used as precursors (<NUM>:<NUM> molar ratio to NaOCl in bleach) to form chloramine. The chloramine can be prepared accordingly to any suitable method. For example, chloramine can be produced by one or more technique described in <CIT>, <CIT>, <CIT>,<CIT>, and <CIT>. The chloramine can be formed as a stock solution that can be introduced to the process water. The chloramine can be formed in-situ in the process water. The chloramine can be formed by reacting at least one ammonium salt with at least one chlorine-containing oxidant. The chloramine can be formed by reacting at least one ammonium salt with sodium hypochlorite or calcium hypochlorite or both. For example, the ammonium salt can be ammonium bromide, ammonium sulfate, ammonium hydroxide, ammonium chloride, or a combination thereof. Monochloramine can be produced by reacting <NUM> to <NUM> molar ratio of the ammonium salt and chlorine.

Any suitable oxidant or combination of oxidants can be used in dual treatment methods as the oxidant used to reduce or eliminate starch-degrading enzymes, such as amylase. Oxidants can be used in the dual treatment method that are incompatible or compatible with monochloramine. As indicated, NaOCl is incompatible with monochloramine, wherein NaOCl releases free chlorine that reacts with the monochloramine and thus eliminates it. Other oxidants which are incompatible with chloramine which can be used are hypohalite compounds (e.g., OBr-), halogen oxidants added through halogen stabilisers such as halogenated hydantoins (e.g., bromochloro-<NUM>,<NUM>-dimethylhydantoin or BCDMH), DMH with bleach, urea with bleach, and the like. For example, though NaOCl is illustrated herein, other alkali metal hypohalites or alkaline earth metal hypohalites can be used, including any combinations thereof. Hypohalite salts may be added to process water in liquid or solid particulate forms, depending on the specific material. Oxidants which are effective to reduce or eliminate starch-degrading enzymes that are compatible with monochloramine can be used. Compatible oxidants do not release free halogen that reacts with the monochloramine. The oxidants which can be compatible with monochloramine can be chlorine dioxide (ClO<NUM>), peroxides such as hydrogen peroxide (H<NUM>O<NUM>), peracetic acid (PAA), perfluoric acid (PFA), or others, and in any combinations thereof.

<FIG> shows a method, indicated as process <NUM> comprising steps <NUM>-<NUM>, for the treatment of process water that contains pulp with chloramine. The treatment can be performed at one or more stages or locations in a papermaking system. For example, the treatment can be performed in a vessel such as a head box. The treating can occur at a head box, upstream of a head box, downstream of a head box, or any combination thereof. Multiple addition points per location can be interchangeable. In a system with a single water loop shared between pulper to machine, examples of addition points can include one or more of the following: pulper(s), pulper fill water, a dump chest, a mixing or machine chest, a head box, and/or white water. In a system with two water loops defining a stock preparation part and a machine part, examples of addition points can include one or more of the following: stock preparation, pulper(s), pulper fill water, a dump chest, stock chest(s), stock loop process water, a paper machine, a mixing or machine chest, a head box, broke, and white water. Stored broke can receive adequate treatment. If multiple lines (short/long) are employed, treatment can be maintained in at least one line, in more than one line, or in all lines.

The amount of chloramine and/or precursors used for treating the pulp can be constant or variable. A target residual chloramine value or range can be achieved by the treatment. The process water has a residual chloramine amount of from <NUM> ppm to <NUM> ppm, from about <NUM> ppm to about <NUM> ppm, from about <NUM> ppm to about <NUM> ppm, from about <NUM> ppm to about <NUM> ppm, from about <NUM> to about <NUM> ppm, from about <NUM> to about <NUM> ppm in the process water containing the pulp. As stated, this amount can be considered a chlorine equivalent. This would also be applicable for white waters, and/or various filtrates - superclear, clear and cloudy. This residual chloramine amount can be an average chloramine amount based on a <NUM>-hour period. The level of chloramine to pulp can be at least about <NUM> of chloramine per tonne (<NUM> tonne = <NUM> lbs. ) of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, at least about <NUM> of chloramine per tonne of dry pulp, or at least about <NUM> of chloramine per tonne of dry pulp.

The treatment of the pulp with chloramine is continuous. Treatment can be repeated any desired number of times and treatments can be separated by constant or variable time periods. The addition of chloramine and/or precursors to the pulp is continuous. The rate of addition of chloramine and/or precursors can be constant or variable. Chloramine, and/or precursors thereof, can be added in any manner to the process water, for example, by pouring, by nozzle, by spraying, by misting, by curtain, by weir, by fountain, by percolation, by mixing, by injection, or by any combination thereof. The process water can be treated for any period of time, on a continuous basis, such as at least about <NUM> hours, at least about <NUM> hours, at least about <NUM> hours, at least about <NUM> hours, or at least about at least <NUM> days, at least <NUM> weeks, at least <NUM> month, at least <NUM> months, at least <NUM> months, from <NUM> day to <NUM> months, from <NUM> day to <NUM> months or more. The amount of chloramine added can be varied based on any one or combination of different factors, for example, starch concentration, amylase concentration, microbial concentration, conductivity, redox potential, turbidity, amount of pulp, cation concentration, anion concentration, calcium ion concentration, volatile fatty acid (VFA) concentration, and pH.

The process water can have a constant or variable pH during the treatment of the pulp with chloramine. The pH can be at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM>. The process water can have a constant or variable temperature during the treatment of the pulp with chloramine. For example, the temperature can be at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, at least about <NUM>, or at least about <NUM>.

In the present invention, the minimizing of calcium ion formation in the process water is achieved. This prevents fouling of one or more components of the papermaking process and/or tanks/reactors. More importantly, by minimizing the calcium ion formation, this means that the calcium (e.g., calcium carbonate) stays with the pulp and eventually is present in the resulting paper product, and further this means that the calcium ion concentration in the process water (after pulp removal) is low thus resulting in controlled (or prevention of) calcium precipitation and/or scaling in the waste water treatment part of the process (such as the digesters and/or BOD systems). "Precipitation" can refer to settling or fall out of solids or insolubility, and "scaling" can refer to a specific process that forms deposits. For example, Ca<NUM>+ ion levels in the process water can be less than <NUM> ppm, less than about <NUM> ppm, less than about <NUM> ppm, less than <NUM> ppm, less than about <NUM> ppm, less than <NUM> ppm, less than about <NUM> ppm, or less than about <NUM> ppm, such as from <NUM> ppm to <NUM> ppm, from <NUM> ppm to <NUM>,<NUM> ppm, from <NUM> ppm to <NUM>,<NUM> ppm. This is especially the case once the pulp is substantially or entirely removed from the process water and this calcium concentration would be right before entering the waste water treatment part, such as right before entering the digester (s) or other BOD treatment equipment.

The methods of the present invention may be used to formpackaging sheets/boards. Such packaging sheets/boards can have any desirable starch content. For example, packaging sheets/boards can have a starch content of at least about <NUM>/ton (<NUM> ton = <NUM> lbs. ), at least about <NUM>/ton, at least about <NUM>/ton, or at least about <NUM>/ton of packaging sheets/boards. Strength of packaging sheets/boards and other paper products can be measured using any suitable technique, for example, the span compression test (SCT), the burst test, and/or the ring crush/Concora test. The methods described herein can be performed in aerobic systems, anaerobic systems, or any combination thereof.

As indicated above, chloramine and sodium hypochlorite can be used in a coordinated manner in the same process. Chloramine (e.g., monochloramine) can provide excellent performance for cost in high demand systems as a biocide enabling the rigorous level of infection control that is required to keep amylase levels very low. In direct tests, chloramine as an oxidizing agent shows virtually no activity to inactivate amylases specifically, although it can be active with respect to other enzymes. NaOCl is an inefficient biocide in high demand systems, even at very high treatment rate. In direct tests, NaOCl is very efficient at inactivating amylases (and enzymes in general).

To provide these coordinated effects, chloramines can be added in the indicated dosages herein, and the oxidant (such as NaOCl) used to control starch-degrading enzymes can be added in dosages at from about <NUM> wt% to about <NUM> wt%, or from about <NUM> wt% to about <NUM> wt%, or from about <NUM> wt% to about <NUM> wt%, or from about <NUM> wt% to about <NUM> wt%, of the actual chlorine demand in the treated solution. The "chlorine demand" can be the total amount of chlorine which would be used up in reactions with all chlorine-reactable compounds in the process solution and without leaving residual chlorine therein. The indicated dosages herein for the chloramine and oxidant (e.g., NaOCl) can be the amount of the respective active added to the process solution that is not reacted with the other indicated double treatment active in the process solution, and thus available to treat the process solution. The oxidant sodium hypochlorite (NaOCl) can be added in an aqueous form. NaOCl can be used in the methods herein in dilute aqueous forms, such as aqueous forms which can contain up to about <NUM> wt% chlorine (e.g., from about <NUM> wt% to about <NUM> wt% NaOCl), or other concentrations.

As shown by experimental results in an example herein, it has been demonstrated in laboratory tests that the addition of NaOCl at from <NUM>% to <NUM>% of the actual chlorine demand in high demand solutions containing amylases was enough to reduce or eliminate the amylase activity. As indicated, a double treatment strategy can be provided wherein NaOCl is used to eliminate amylase from the process, and chloramine is used to eliminate infection and prevent amylase production in the process. The combination of both treatments in a process results in a much more efficient treatment wherein a synergy between both treatments is obtained. Chloramine reduces and keeps infection and amylases low, and NaOCl eliminates whatever amylases still exist, such as α-amylases, thereby prevents starch degradation and reduces nutrient availability for the infection. Amylases can come in with poor quality old papers (wet, infected, moulded). Chloramine does not usually have any impact on the incoming amylases. NaOCl also inactivates external amylases that come into the process. Other sources of external amylases could be process waters imported from untreated paper machines, reused (partially) treated effluents that replace fresh water. Another source of amylases can be recycled fiber stock chests, deinking fiber stock chests or broke chests that have (occasional) very long residence time which renders any infection control, also with monochloramine, problematic; NaOCl can be used to eliminate amylase from the stock used from such chests and such prevent further contamination of process waters with amylases.

<FIG> shows a method, indicated as process <NUM> comprising steps <NUM>-<NUM>, for the indicated double treatment of process water that contains pulp with native starch with chloramine and sodium hypochlorite. As indicated, in a method of treating process water with chloramine and an incompatible oxidant such as NaOCl or other free halogen-releasing oxidant, chloramine and free chlorine from NaOCl, and/or other incompatible oxidant, preferably are not present together in the process water because the chloramine reacts with the free chlorine resulting in destruction of the two actives. Therefore, both actives preferably are kept separated (or substantially separated) from each other in the process water undergoing processing. This separation of chloramine and NaOCl (or other incompatible oxidant), where used as the oxidant, in the process water can be achieved in different ways. NaOCl (or other incompatible oxidant) and chloramine can be added at different positions in the process and as both actives are consumed as they move further through the process this will prevent them from mixing. NaOCl (or other incompatible oxidant) and chloramine can be sequentially added from the same position with a time delay between their respective additions. If chloramine is added to the process water before NaOCl (or other incompatible oxidant) addition, the delay of the addition of the NaOCl (or other incompatible oxidant) can be controlled to allow for the level of previously added chloramine to be below about <NUM> ppm, or below <NUM> ppm, or below detectible limits. By properly controlling chloramine addition upstream from the positions where NaOCl (or other incompatible oxidant) is added, the presence of chloramine at these positions can be prevented. In recycled fibre systems, typically residuals of chloramine are very low. After the chloramine treatment is stopped, if a chloramine residual is present it quickly disappears. After an appropriate (adjustable) delay after chloramine addition is stopped, NaOCl (or other incompatible oxidant) can be dosed. As indicated, NaOCl (or other incompatible oxidant) can be added in sub-demand concentrations, wherein free chlorine does not move forward from its position of addition before chloramine is added (or re-added). Places for adding the NaOCl (or other incompatible oxidant) in a papermaking process can be the pulper and high density chests, or other locations. After the NaOCl (or other incompatible oxidant) dosing is stopped, because a sub-demand treatment can be applied and no residual is present, chloramine dosing can resume, such as resume immediately. The resumed addition of chloramine after NaOCl (or other incompatible oxidant) addition can be optional, such as depending on the needs of the process system being treated. Both spatial and temporal separation of chloramine and NaOCl have been successfully used in tests done on industrial systems, whereby no mutual negative impact of the actives was detected. Experimental industrial results have shown that better efficacy of overall treatment can be obtained with lower chloramine addition rates, a lower overall cost of treatment, better strength characteristics of the new sheet, or combinations of these can be obtained. Experimental industrial results show that the method provides not only the efficient biocide/chloramine treatment, but it adds a specific double treatment approach with NaOCl that specifically targets the amylase in the process.

As indicated above, the present invention relates to a method to control or prevent calcium precipitation and/or scaling in an aerobic or anaerobic digester(s) that processes process water used in papermaking and that contained calcium from pulp being process, the method comprising in a papermaking process, continuously treating process water containing said pulp with chloramine comprising monochloramine such that said process water, when said pulp is present, has a residual chloramine amount from <NUM> ppm to <NUM> ppm (or the other residual amounts mentioned earlier), wherein calcium is present in said pulp, and then forming paper/paperboard from said pulp, and processing said process water, after pulp removal, to one or more digesters.

The present invention also relates to a method to control or prevent calcium precipitation and/or scaling in a biological oxygen demand reduction (BOD) system that processes process water used in papermaking and that contained calcium from pulp being processed, said method comprising in a papermaking process, continuously treating process water containing said pulp with chloramine comprising monochloramine such that said process water, when said pulp is present, has a residual chloramine amount of from <NUM> ppm to <NUM> ppm (or the other residual amounts mentioned earlier), wherein calcium is present in said pulp, and then forming paper/paperboard from said pulp, and processing said process water, after pulp removal, to said BOD system to reduce BODs.

In the methods above, involving the digesters and/or BOD systems, the calcium ion amount present in the process water after pulp removal can be <NUM> ppm or less, <NUM> ppm or less, <NUM> ppm or less, <NUM> ppm or less, or from <NUM> ppm to <NUM> ppm (based on the process water that reaches the digester or BOD system equipment).

In addition or in the alternative, the chemical oxygen demand (COD) can be measured and controlled by the present invention. The COD is a faster test method to determine or predict what the BOD is for the system. BOD testing can take days whereas COD testing can be minutes to hours to determine. One COD test procedure that can be used is the test described in <NPL>, where the Chemical Oxygen Demand (5220B)/Open Reflux Method. Thus with the present invention, COD demand can be controlled or reduced using the methods of the present invention. Essentially the nutrients that bacteria can feed on, like starch or the breakdown of starch can be reduced using the methods of the present invention, since the starch is retained in the pulp and eventually in the paper using the processes of the present invention.

The residual chloramine concentration of the process water, when entering the digester or BOD system equipment can be much lower, such as below <NUM> ppm (e.g., <NUM> ppm or less, <NUM> ppm, <NUM> ppm or less, <NUM> ppm or less, <NUM> ppm or less) and the like.

With the present invention, the starting starch levels found in the pulp with process water (at the start of the papermaking process) compared to the starch levels in the pulp and process water (right before the separation of the pulp from the process water - e.g., right before the pulp is placed on the screen) is within <NUM>% by weight, within <NUM>% by weight, within <NUM>% by weight, within <NUM>% by weight, within <NUM>% by weight, within <NUM>% by weight, or within <NUM>% by weight. In other words, with the present invention, the starch levels are preserved through the process and are not degraded or broken down by bacteria.

With the present invention, the difference between the ppm levels of the starting calcium levels (e.g. dissolved calcium, Ca<NUM>+ ) found in the pulp with process water (at the start of the papermaking process) compared to the calcium levels of the process water after the pulp is removed is at most an increase of <NUM> ppm (+<NUM> ppm or less), such as at most an increase of <NUM> ppm (+<NUM> ppm or less), at most an increase of <NUM> ppm (+<NUM> ppm or less), at most an increase of <NUM> ppm (+<NUM> ppm or less), and more preferably, a decrease in the calcium levels, such as a decrease of at least <NUM> ppm (- <NUM> ppm or more), a decrease of at least <NUM> ppm (- <NUM> ppm or more), a decrease of at least <NUM> ppm (- <NUM> ppm or more), a decrease of at least <NUM> ppm (- <NUM> ppm or more), a decrease of at least <NUM> ppm (-<NUM> ppm or more), a decrease of at least <NUM> ppm (- <NUM> ppm or more), a decrease of at least <NUM> ppm (- <NUM> ppm or more), with respect to starting versus final calcium levels in the process water as described above.

The following examples are given to illustrate the nature of the invention. It should be understood, however, that the present invention is not to be limited to the specific conditions or details set forth in these examples. Unless stated otherwise, in the Examples, the reference to "tonne" is a metric tonne and is based on "per tonne" of dry pulp.

This example demonstrates one or more of the superior benefits of the present invention. A new anaerobic digester was being used at an effluent plant that received waste water from papermaking (after pulp removal). Prior to the present invention, the plant reported loss of performance of the anaerobic digester from calcium precipitation and/or scaling and also reported blocking of the digester from precipitation and/or scaling. The plant had to shut down the digester to clean the digester (scale removal) This resulted in significant down time for the plant and unscheduled expenses to clean the digester. The plant operators did not understand the cause of the problem or a solution. The present inventor offered an experimental trial to see if the present invention would work in the field. The process water that became the waste water that entered the digester was treated. In particular, the process water (which contained pulp) was treated with chloroamines (primarily monochloramine) in an amount of <NUM>/tonne at the pulpers of the papermill and also at the top ply whitewater (WW) silo. This was done on a continuous basis. The amount of calcium ion concentration (dissolved in water) in the process water at the start of the pulp process (before the headbox) was measured and also the amount of calcium concentration right before entering the digester was measured and the difference in calcium was determined. Prior to using the present invention, the calcium ion concentration increased <NUM> ppm. This was a very negative, undesired occurrence. Once the present invention's method was used for <NUM> to <NUM> days (continuously), the difference in calcium concentration was determined again, and the change in calcium concentration had eventually gone to a minus <NUM>,<NUM> ppm. In other words, the amount of dissolved calcium at the digester was lowered by over <NUM>,<NUM> ppm compared to the amount of calcium at the start of the pulping at the papermill. This was an incredible turn around, which prevented the fouling of the digesters. Also, due to reducing the calcium content, the resulting sludge can be considered anaerobic sludge and not chemical disposal.

Further, in the pulp mill where the process water (waste water) came from, the pulp was recycled pulp (including recycled packaging) and had a high starch content. Prior to the use of the present invention, as described above, the initial starch content at the time of mixing with water went down significantly during the processing of the pulp, such that the wet sheets formed from the pulp had a significantly reduced starch content. It was discovered, by the present inventor, that the starch was being broke down by amylolytic bacteria. By using the methods of the present invention, besides achieving control of the calcium precipitation and/or scaling, the present invention also controlled the consumption of starch by controlling the bacteria. As a result, significant levels of the starting amount of starch were preserved and incorporated into the paper formed from the pulp.

This example also demonstrates one or more of the superior benefits of the present invention. An anaerobic digester was being used at different effluent plant that received waste water from papermaking (after pulp removal). Prior to the present invention, the plant reported loss of performance of the anaerobic digester from calcium precipitation and/or scaling and also reported blocking of the digester from precipitation and/or scaling. The plant had to shut down the digester to clean the digester (scale removal). This resulted in significant down time for the plant and unscheduled expenses to clean the digester. The plant operators did not understand the cause of the problem or a solution. The present inventor offered an experimental trial to see if the present invention would work in the field. The process water that became the waste water that entered the digester was treated. In particular, the process water (which contained pulp) was treated with chloroamines (primarily monochloramine) in an amount of <NUM>/tonne to <NUM>/tonne at the pulper dilution water of the papermill and also at the thick stock-before fractionation in an amount of <NUM> to <NUM>/tonne, and at the whitewater (WW) flume in an amount of <NUM> to <NUM>/tonne. This was done on a continuous basis. The amount of calcium ion concentration (dissolved in water) in the process water at the start of the pulp process (before the headbox) was measured and also the amount of calcium concentration right before entering the digester was measured and the difference in calcium was determined. Prior to using the present invention, the calcium ion concentration increased <NUM> ppm. This was a very negative, undesired occurrence. Once the present invention's method was used for <NUM> to <NUM> days (continuously), the difference in calcium concentration was determined again, and the change in calcium concentration had eventually gone to a minus <NUM> ppm. In other words, the amount of calcium at the digester was lowered by over <NUM> ppm compared to the amount of calcium at the start of the pulping at the papermill. This was an incredible turn around, which prevented the fouling of the digesters. Also, due to reducing the calcium content, the resulting sludge can be considered anaerobic sludge and not chemical disposal.

Claim 1:
A method to control or prevent calcium precipitation and/or scaling, characterized by
(i) in an aerobic or anaerobic digester that processes process water used in papermaking and containing calcium from pulp being processed, said method comprising in a papermaking process, continuously treating the process water containing said pulp with chloramine comprising monochloramine such that said process water when said pulp is present has a residual chloramine amount of from <NUM> ppm to <NUM> ppm, wherein calcium is present in said pulp, and then forming paper or paperboard from said pulp, and processing said process water, after pulp removal, to one or more digesters; or
(ii) in a biological oxygen demand reduction system that processes process water used in papermaking and containing calcium from pulp being processed, said method comprising in a papermaking process, continuously treating the process water containing said pulp with chloramine comprising monochloramine such that said process water when said pulp is present has a residual chloramine amount of from <NUM> ppm to <NUM> ppm, wherein calcium is present in said pulp, and then forming paper or paperboard from said pulp, and processing said process water, after pulp removal, to said biological oxygen demand reduction system to reduce biological oxygen demands.