THE LIBRARY OF THE UNIVERSITY OF CALIFORNIA LOS ANGELES ■3 'ft//, NOTES ON THE MANUFACTURE OF WOOD PULP AND WOOD-PULP PAPERS. NOTES ON THE MANUFACTURE OF WOOD PULP AND WOOD-PULP PAPERS. By JAMES DUNBAR, Author of "The Practical Papermaker." Price, 2s.; hy Post, 2s. od. PRINTED for the AUTHOR BY MACKENZIE & STORRIE, 35 SHORE, LEITH. MDCCCXCIV. T5 PREFACE. 1)11 /v TN my previous efforts to put before the paper trade a reliable Guide to the Manufacture of Paper, based upon my own practical experience, I confined myself to the raw material best known to me at that time. But since the issue of the last edition of my book a decade in papennaking seems to have passed over us ; and, with the advent of a popular and comparatively new material, which is better known on the Continent of Europe than with us, and which is fast coming to the front, I con- sider the present a fit opportunity to put my experience of wood fibre manipulation on the Continent before the trade. The result I leave to practical men. If I am enabled to add a little to the knowledge of those en- gaged in the papennaking industry (especially the rising and younger portion), it will be a pleasure to me to know that I have thus been of some help to them. I have endeavoured to confine myself to what I consider up-to-date information relating to Wood Pulp and Wood-Pulp Papers, and the application of the latest ideas to machinery used in their manufacture, with suggested improvements which have for their object the saving of time and consequent cheapening of produc- tion. In this I am much indebted to Bertrams Limited, St Katherine's Works, Sciennes, Edinburgh, who have 852010 VI PREFACE. kindly sui)plied the illusti'ations, which will, I am confident, be found useful for reference, and an aid to what is meant by the various suggestions as to improvements. I assure my readers that the details here given have all come under mv own immediate observation — nothing; having been added to nor taken from them. In short, they are precisely what I have seen put into practice day after day, with the most satisfactory results as to economy and efficiency. JAilES DUNBAR. NoTE.^ — The matter contained in this book is entirely distinct from that appearing in "The Pkactical Papermaker," which may still be had from Mackenzie &, Storrie, 35 Shore, Leith. 1 N DEX. PAGE Sulphite Pulp .... 1 Sulphate of Soda Cellulose . 7 Hand-Barking 9 Boiling Department 11 Draining Tanks . 12 "Washing Department . 13 Straining Department . 13 Bleaching Department 14 Cellulose Drying Machine . 15 Sorting Department . 16 Packing Department . 16 Soda Recovery Department 16 Sulphate of Soda Pulp : its '. Manufacture int< 3 Pap er 17 Treatment in the Beater 18 Esparto Papers . 26 Spanish Esparto . 27 African Esparto . 27 Tripoli Esparto . 27 Cleansing Esparto 28 Esparto Boiling . 28 Washing and Bleaching 29 Half-Stuflf Machine . 30 Mechanical Department . 35 Conical Engines . 35 Paper Machine . 37 Water-Power ; 40 Chemical Department 42 Tub-Sizing 42 Bleach Test 43 Phlorogusine 43 China-Clay . 44 Vlll INDEX. Possible Improvements . . . . Couch-Roll Brackets .... " Doctors " on Cylinders and Calenders Remarks High-Class Duplex Paper Finishing Paper Web (Calendering Department Friction Calenders . . , . Pearson and Bertram's Refining Engine Paper-Machine AVire . . . . Conclusion ...... I'ACiK 48 50 50 55 63 65 66 70 73 75 82 Wood Pulp and Wood-Pulp Papers. > •<- SULPHITE PULP. OULPHITE PULP is one of the strongest of tlie O wood-pulp family ; it is also one of the best brands, and ought to be ranked as a perfect fibre. The process of manufacture being protected by patents, I have no right to enter into details on that subject, but mil confine myself to a description of the manufactured article. The best brands are clean, of a slightly rose tint, of a fine silky fibre, and pleasant to the feel and the eyes. One will say. What has the feel of a fibre to do with its value as a papermaking material ? I must say it has much to do with it, as a hard harsh material will not make a kindly-feeling paper, which is so much desired 1)y the printer, but will produce a paper which does not take kindly to the type, the result being an imperfectly printed sheet, — which is a source of much annoyance to the workman, and the cause of blame being thrown upon the shoulders of the person who is neither respon- sible for nor able to bear it. This pulp, if properly treated, may enter into the composition of a comparatively fine paper, with the best results. But the extraordinary care Avhich must be exercised in its preparation, to pre- vent its tendency to flake or cloud, has been the means of giving it a bad reputation as a material for the pro- duction of fine papers. This tendency can be avoided :2 NOTES ON THE MANUFACTURE OF if the material gets full justice. It can be, and is, successfully manufactured into cartridges, manillas, engine- and tub-sized writings, and fine printings, if used either alone or with rags, both of which sj'stems are practised on the Continent. In the production of news and other common papers with Sulphite and Mechanical Pulp the result is most satisfactory. This, of course, means the use of the common brands of Sulphite Pulp. Although not per- fect in cleanness, it is strong, and well fitted, as far as strength and cleanness are concerned, to compete most favourably with the common iil:)res used for the same puri)ose, economically and otherwise. To compare Sulphite Pulp with rags, as an economical fibre and a fibre which will produce an equal paper when the cost of production is taken into consideration, is entering upon debatable ground, as every papermaker's facilities are not alike for economical production ; and it is a well-known fact that the same paper is not produced in diff'erent mills from exactly the same material, the reason being best known to the papermakers themselves, and possibly in a great measure attributable to the local surroundings and the available facilities for producing an up-to-date and first-class article. But I must say that the very best brands of bleached Sulphite Pulp, in my opinion, are more valuable and cheaper as a paper- making material than many of the grades of rags used for papers for which Sulphite is best adapted. Sulphite Pulp is cleaner, stronger, and keeps the mill clean, which is a very important consideration indeed. There is no dirt or dust blowing about the mill, no boiling, no washing and bleaching — that is, if the pulp is purchased in a bleached condition. In fact, there is a total absence of all the dirty processes which have been the bone of contention between the paper manufacturer and either the landed proprietor or tht; sanitary authorities — and WOOD PULP AND WOOD-PULP PAPERS. ^ which have cost the former so much money, and given him so much trouble — as to the pollution of streams which never were clean. To treat Sulphite Pulp as is done on the Continent of Europe for a fine printing or engine-sized writing paper, the beater roll should never be put down heavily upon it. The fibre is an exceedingly fine one, although of great length, and is best treated with the drawing- out process, which has the tendency not only of clearing- out but of finely separating the fibres, both in length and in diameter, to the desired uniformity for the various papers for which this pulp is suited. And, by giving the stuffs a firm hard brush at the end of the beating, a finished pulp will be produced, capable of making a close and uniform sheet of paper, which will not flake or cloud, or take the appearance of a wood paper, but will feel and look more like a hard rag paper, made from a much more expensive material than Sul- phite Pulp. I Avill now try to describe the action of Sulphite Pulp on the paper machine. We will conclude that the beaterman has done the best he can in his department, which, 1 must say, is the vital part of papermaking. If the stuff has been prepared for a fine printing paper, the shake motion must not have a high speed, but a reasonably long throw. This treatment will avoid the flaking, and a close uniform sheet will result. On the other hand, if an antique or cartridge paper is desired (which means in most cases a hard rattling paper, to take the character of a hand-made paper), it must be shaken on the machine at a high speed with a compara- tively short throw. Under no circumstances should an exceedingly long shake be given to wood papers, as it is this, and this alone, which facilitates the flaking, and makes the paper look like a rope-brown — wild, cloudy, and marley. A few experiments with the shake motion 4 NOTES ON THE MANUFACTURE OF are of more value than any written instructions, especially when applied to the manufacture of tine printings — this not applying so much to antiques and cartridges. A most important item in the management of wood papers on the machine is the drying of them. This amounts to a tine-art in the manufacture of wood papers, and it takes a highly proficient machineman to carry the process through in a thoroughly satisfactory manner. Paper machines have been built in this country and in Germany specially for the manufacture of wood papers, with the most satisfactory results — particularly so with our own make of machine, which I will describe at some length, showing where we produce a perfect machine, and where the German errs. It is well known to papermakers that wood papers are most difficult to dry, under ordinary conditions ; but with a properly-constructed machine the result is most satisfactory. One of the largest engineering liouses in Scotland has built a machine which meets all the re- quirements of the paper manufacturer in this respect, by the introduction of the three-sets-of-press-roU system. The origin of this system is undoubtedly German ; but the German counteracted the benefit of three presses by reducing the number of drying cylinders. Hence the desired efi'ect was not obtained by him. Our engi- neers at once grasped the situation, and introduced a machine which fulfilled all their expectations by pro- ducing the desired paper. This three-sets-of-press-roll system not yet being adopted to any great extent, re- quires from me some explanation, which I will try to give in as intelligible a manner as possible. The first idea of introducing three sets of press-rolls was economy of fuel ; but, at the same time, it accom- plished another and very important change in the working of the paper machine. The German, as he WOOD PULP AND WOOD-PULP PAPERS. 5 added presses, reduced the number of cylinders, con- sequently destroying the first efi'ect ; Avhereas our engineers have been rather inclined to add to the number of drying cylinders along with the additional sets of press-rolls. And rightly too in practice, for the reason that, by the use of three sets of press-rolls, the paper is made comparatively dry while not yet having been subjected to artificial heat. As a natural conse- quence (a lower temperature being required on the cylinders), the paper passes on to the reel without being subjected to that roasting process which is common on many of our ordinary machines. But the German, by reducing the number of the drying cylinders, had still to keep up a high temperature, which roasted the paper, and, in the case of wood papers, produced them brittle and unsatisfactory. Of course, paper manufacturers naturally ask, What about the bulk of the paper under the pressure of three sets of press-rolls? I maintain that the bulk is not injured in the slightest degree. The idea (held by myself as well as others) that hard pressing injured the bulk of the paper, is now exploded. Paper pressed between felts will not get thinner. 1 have had it tested upon many difierently-composed papers, with the result that there was no material diiference. The smoothers and the calenders do thin the paper in a small degree. But I do not call even that a thinning process ; it is rather a very necessary levelling and smoothing operation. When the stationer cries out about bulk, believe me, it is not the press-rolls which are at fault; and if he wants an 18 lb. demy to feel like a 20 lb. demy, the best way is to tell him that it cannot be done. The excessive use of china-clay will, to a certain ex- tent, injure the bulk of the paper and make it feel thin for its demy weight. But such paper would feel thin if you should pass the press-rolls altogether; and I am 6 NOTES ON THE MANUFACTURE OF pleased to say that such paper is never put on the market by the British paper manufacturer. I strongly advocate the three-sets-of-press-roll system, and consider it one of the best additions to the paper machine for the rational manufacture of paper from any fibre, but especially wood fibre. I have met men in my wanderings who, if they could, would dispense Avith press-rolls altogether, with a view to save felts — a very laudable object certainly, if it could be accomplished. As I understand the manufacture of paper, press-rolls do more than lead the paper and press out a certain amount of water from it. They solidify it, level and smooth it, and render it fit to be handled in leading it through the cylinders. The advocates of dispensing with the press- rolls overlook or forget these facts, while every in- telligent papermaker will, I am sure, agree that I am right in this matter. I Avill now try to describe the manufacture of Sul- phate of Soda Cellulose ; and, as there is no fear of meddling with other people's private affairs, I will begin at the foundation, and finish with the manufactured paper. IMPROVED WET END Section No. 1 of Paper-making Machine. Section No 2 of Paper making Machine. Section No. 3 of Paper-making Machine. WOOD PULP AND WOOD-PULP PAPERS. SULPHATE OF SODA CELLULOSE. The wood is conveyed to the mill by sea and rail. It is a mistake to imagine that wood-pulp mills are planted down in the midst of an inexhaustible forest, where the wood supply is ample for all time coming. This is not the case. The pulp manufticturer must go many miles for his supply of raw material, and this at considerable cost. Swedish wood for consignment to Norway is, as a rule, carried by rail, and most of the Norwegian wood by sea, or by small Craft which ply on the fjords. When the wood arrives at the mill, each lot is piled up in the mill-yard separately, and allowed to remain there until it is examined and the management satisfied that the various consignments are according to contract, and fit to be manufactured into the best brands of pulp. They are then passed over to the bark-removing de- partment, which is the first cleansing process to which they are subjected. This bark-removing process was, in the early history of pulp manufacture, done by hand ; but of late years several sorts of machines have been introduced for the purpose, but with indifi*erent success where economy of wood was a consideration. The machine for bark-removing which is considered the best will remove the bark quickly and economically if the wood is perfectly straight and round; but if it is otherwise, there is so much of the good wood removed before all the bark is off, that it comes to be a very expensive operation. Consequently, many of the mills which had adopted these machines have abandoned them and gone back to the old system of hand- barking, which is cheaper and more economically done, especially when you take into consideration the probable 8 NOTES ON THE MANUFACTURE OF percentage of crooked and uneven wood to be found in a consignment of, say, five or six cubic fathoms given out to each man, from a consignment of 800 to 1000 cubic fathoms received at the mill. However, a description of the barking machine will not be out of place, as it might be a very valuable machine to have where there is a possibility of trouble with the workmen, which is not at all a rare occurrence in nearly every trade. The machine consists of a strong cast-iron V-shaped trunk, cast in one piece. Across the top is a malleable- iron shaft, 4 in. in diameter, and extending over each side of the frame, on which are keyed two cast-iron circular plates, one on each end of the shaft. Into each of these plates are four openings for receiving the tools which remove the bark. These tools are fixed in the plates at an angle exactly the same as in a joiner's plane. Speed is a very important item in working this machine satisfactorily. If too slow, it jams itself, and will not remove the bark ; and the speed must not be under 1500 revolutions per minute to enable the machine to do its work satisfactorily. Facing the plates there is a lifting apparatus, which enables the man in charge to keep the wood close up to the cutting tools. At the same time, by means of rotary toothed gear, the wood is kept revolving in front of the barking tools, the rotary motion being supplied by the main shaft of the machine and operated in connection with the lifting gear. Two men can work at this machine — one at each side ; and, if the wood is piled beside them, they can remove the bark from an enormous quantity in one day. The machine absorbs from 18 to 20 horse-power, and is capable of cleaning wood for ten tons of finished cellulose per day. It is an admirable piece of mechanism, and in many respects does its work cleverly. But, for economy of wood, the hand-barking is preferable. WOOD PULP AND WOOD-PULP PAPERS. V Hand-Barking. Scandinavian pulp manufacturers are not behind the times or indisposed to adopt the most modern tools in the market, nor are they slow in finding out if these tools meet their requirements as far as efficiency and economy are concerned. Hence the adoption of mechanical means in removing the bark, and its subsequent abandonment and falling back upon the old and better system of hand- barking. In the process of hand-barking, the workman is provided with a stool or trace, about 10 feet long, and sufficiently high to enable him to work comfortably. At one end of this stool is a hollow piece of wood, and at the other a spike or spur, which holds the log in position while the workman removes the bark. When it is necessary to turn the log, the workman lifts the end where the spike is, and turns the log with ease — this turning process being continued until all the bark is removed. The first operation in hand-barking is the removal of any projecting knots or inequalities with a hatchet, and then with a draw-knife the bark is removed in a very cleanly manner — the bark being, as a rule, taken off by beginning at the root-end and finishing at the crop-end. The reason for so doing is the easier removal of the bark, and the operation is performed quicker and cleaner. A good workman will earn as much as three or four shillings per day of ten hours, which is very good pay for this class of work in Norway. It must be distinctly understood that hand-barking does not only mean the removal of the outer bark, but also the inner bark, which is of a yellow colour, and full of minute grey specks, which, if left, it would be impossible to remove by any subsequent cleansing pro- cess through which the boiled material passes. The wood, being thoroughly cleaned of its bark, is now passed 10 NOTES ON THE MANUFACTURE OF over to the examiner, whose duty it is to reject any por- tion of it wliich does not come up to his standard of cleanness — the perfect being passed over to the chop- ping- department, which is the first process of disinteo^ra- tion which the wood passes through. Before entering upon the chopping process, I may mention that all the wood is thoroughl}^ examined, and any log showing the slightest indication of being imper- fectly cleaned is at once sent back to the " barker " to be done over again. The cleaned wood which has passed the examiner is now sawn into lengths convenient for the man at the chopper to handle. The chopper consists of a cast-iron circular plate, about 4 feet in diameter by 2| inches thick. There are three recesses in the plate —two for the cutting knives, and one for the ri[)per. The ripper cuts deep enough into the wood to disintegrate suf- ficient material for the two chopping knives to remove. This divides the wood into small pieces, which facilitates the sorting and the l)oiling. The wood is not cut off square at the end, but at an angle, which takes less power, and is more expeditiously done. The cut Avood falls from the chopper into a pit, where a belt elevator is working for the purpose of raising the wood up to the sortino; screen. This sortino- screen consists of a wooden frame with a wirecloth bottom, all of l^-inch mesh, except a small part of the screen at the end where the cut wood enters, which is covered with a much finer wirecloth, that carries off any sand or sawdust before it enters the screen proper. This sorting screen has a sharp shaking motion, which enables the good wood to pass through the meshes of the wirecloth, and the large knotty pieces to fall over the end of the screen, where it is collected and conveyed and mixed with the bark in the soda recovery department as fuel. The sorted wood Avhich passes through the wirecloth WOOD PULP AND WOOD-PULP PAPERS. 11 now coines in contact with a Ian, which blows itthrongh an 8-inch pipe up to the boiling department. This is an admirable system of conveying material from one depart- ment to another. And when one begins to think over such a mode of conveying raw material in a cleanly manner, there is practically no end to the uses to which it can be applied. Cut straw, cut wood, and cut rags could be blown any reasonable distance with such a fan. I cannot say how it would behave with esparto, not having tried it. The system is perfectly cleanly, and the material can be blown directly into the boiler — thereby saving manual labour, and rendering any waste of fibre absolutely impossible. Boiling Department. In this department (like the boiling department of a paper mill) is carried on the most important operation through which the raw material passes for the production of a thoroughly reliable and satisfactory cellulose. Any blundering in this operation cannot be rectified in any of the subsequent processes through Avhich the puljj passes, but will have to pass through the mill as defec- tive pulp, and be sold as such, not for papermaking purposes, but as a lining which is put between the wall and the sheathing of wooden houses, no defective pulp being allowed by the pulp manufacturers to leave the country. The form of boiler used is the upright stationary boiler, made of steel, and capable of withstanding a pressure of 200 lbs. per square inch. Attached to each boiler is a square cast-iron box, into which (by means of a pipe attached to the boiler) can be blown a small por- tion of the boiled wood, to enable the man in charge to determine whether it is sufficiently cooked. The quan- tity of cut wood contained in the ordinary-sized boiler is 1 7 cubic metres. 12 NOTES ON THE :\rANUEArTrRE OF When the filUng-in of the boiler is comj^leted, the steam is turned on, and the average time from the turning-on of the steam until it indicates 120 lbs. of pressure on the boiler gauge is about 2^ hours. The wood is then allowed to boil at that pressure for 3 hours, after which the steam is shut off; and from the time of shutting-ofF the steam until it comes down in pressure on the boiler to 45 lbs. about an hour is occupied. The pressure being down to 45 lbs., the boiled pulp can with perfect safety be blown over to the draining tanks. The boiler contains in all 29 cubic metres — 17 cubic metres of wood and 12 cubic metres of lye (7'4 cubic metres of lye at 17° Beaunne, and 4*6 cubic metres of spent lye blown from the adjoining boiler) — which com- plete the boiling contents. The most important feature in the economical manu- facture of cellulose, and one which the Scandinavian has ^carried through in a most perfect manner, is the economy of manual labour, the conveyance of the materials from one department to another being almost entirely auto- matic, and wholly done by mechanical means. Draining Tanks. The draining tanks are close vessels, connected with the boiler by the blow-off pipe, and having a steam- escape pipe on the top for the escape of the steam blown over with the pulp. Inside these tanks is arranged a false bottom, for the purpose of draining the pulp of its lye, which is collected, and is subsequently conveyed in pipes to the soda recovery department. The draining tanks are each capable of holding the contents of one boiler, and will thoroughly drain and partially wash the contents in a very short time, the pulp being now in a lit condition to be run to the washing department. WOOD PULP xVND WOOD-PULP PAPERS. 13 Washing Department. The pulp enters this department in a dirty brown state, containing much matter which must be washed out. Hence the importance of having a plentiful supply of clean water for this purpose, as, if the washing is con- ducted in an efficient and cleanly manner, a correspond- ing amount of chlorine will be saved in the subsequent bleaching process, and a better-coloured pulp produced. The pulp coming from the draining tanks is passed over a series of sand-traps, with skimmers, which catch a considerable amount of impurities of a light and float- ing character. It then falls into the washing tanks, which is the first real washing process, the previous one being simply draining and flushing. Into these washing tanks is arranged a series of drum washers, which, with the addition of an unlimited supply of clean water, change the pulp from its pi'cvious dirty brown colour to a pleasant golden brown, indicating that the washing has been sufficiently done and the pulp is in a fit state to be conveyed to the straining department. Straining Department. There are various types of strainers used for strain- ing wood pulp — from the old jog strainer to the latest im- provements in strainers, into the merits or demerits of PATENT SELF-CLEANSING STRAINER. BERTRAMS LIMITED, SCIENNES, EDINBURGH. 14 NOTES ON THE MANUFACTURE OF Avliich it is unnecessary to enter. Suffice it to say, that in any case the pulp must be reduced to the thinnest possible consistency before you attempt to strain it, if you desire to make it perfectly (;lean. I may here men- tion, that possibly, if we acted upon this system in straining (jur half-stuff at our presse-pate machines, we would immediately obtain a much cleaner material, and with less waste. By this diluting process the good pulp is thoroughly separated from the impurities (the form(T floating and the latter sinking), which are conveyed to an auxiliary strainer, where any good pulp passes through the plates to the original supply, and the im- purities remain, and are periodically removed and cast into the refuse heap. The strained pulp from the strainers keeps continually passing through a conical washer, where its density is increased sufficiently to be lifted up in a comparatively thick mass from the well into which it is collected. The belt elevator, which lifts the pulp, discharges it direct into the bleaching en seine. Bleaching Department. The bleaching engines, which are made of wood, are lined inside with cement to the thickness of about 1| inch. This is done in a very ingenious manner, as follows : — The sides of the engine (not the bottom) are fllled with scupper or claut nails — that is, nails about 2 inches long, Avith large heads left projecting about 1 inch. The cement is laid on this, and the nails hold it in position ; and I have been infonxied that an engine lined in this way will last for many years. When the desired quantity of pulp is in the engine, it is first washed with warm water for about an hour. The pulp is then washed down until there is sufficient WOOD PULP AND WOOD-PULP PAPERS. 15 room for the bleaching liquor ; it is then bleached in the ordinary way. The quantity of bleaching poAvder necessary to bleach 10 tons of Sulphate of Soda Cellulose is 2000 kilogs., or 4375 lbs. — that is, when the pulp is brought up to the standard colour suitable for the English market. The bleaching being finished, the pulp is again washed with a plenti- ful supply of clean water until it shows no traces of chlorine. It is then emptied down to the cellulose dry- ing machine. Cellulose Drying Machine. This machine, commonly called a drying machine, is practically an ordinary Four- drinier machine, the only difference being that there is no shake motion on the wire, and no felts on the cylinders. The web of pulp is run on this machine as thick as it can be dried. It is led direct off the machine through the cutting machine, where it is cut into sheets, which are conveyed to the sorting department. W ^ 0) 00 •-' ,_ . ■^ ;, 53 c3 .ti a> tj t^ eg !jf) cc ^ 01 S