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Deinking chemistry performance: from laboratory flotation tests to the
simulation of an industrial pre-flotation lineD. Beneventi, B. Carré, T. Hannuksela and S. Rosencrance
Air Air Air Air Air Air
Air Air
Froth 1ry stage
Froth 2ry stage
Cell 1
Cell 2
Cell 3
Cell 4
Cell 5
Cell 6
Cell 1
Cell 2
Floated pulp
Pulp feed
2ry stage
1ry stage
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2DB– September, 2007
Guideline
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests• Process simulation
Conclusions
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3DB– September, 2007
Extrapolation of laboratory flotation tests to the industrial scale difficult/misleading
Absence of a laboratory test/data analysis procedure to interpret and simulate the action of deinking chemicals at lab and industrial scale
Motivations and objectives
To develop a lab test procedure and a simulation tool to predict the influence of process chemistry on deinking selectivity in industrial lines
Lab benchmark test
Data analysis and process simulation
Selectivity in industrial lines
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4DB– September, 2007
Guideline
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests• Process simulation
Conclusions
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5DB– September, 2007
Materials and methodsLaboratory flotation test procedure
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
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6DB– September, 2007
Materials and methodsLaboratory flotation test procedure
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Re-pulping chemistry NaOH (%) Silicate (%) Peroxide (%) Collector (%) Soap, 2% silicate 0.7 2 0.7 0.45 Soap, 1% silicate 0.7 1 0.7 0.45 Blend, 2% silicate 0.7 2 0.7 0.15 Blend, 1% silicate 0.7 1 0.7 0.15
Re-pulping chemistries tested in this study Re-pulping chemistry NaOH (%) Silicate (%) Peroxide (%) Collector (%) Soap, 2% silicate 0.7 2 0.7 0.45 Soap, 1% silicate 0.7 1 0.7 0.45 Blend, 2% silicate 0.7 2 0.7 0.15 Blend, 1% silicate 0.7 1 0.7 0.15
Re-pulping chemistries tested in this study
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7DB– September, 2007
Materials and methodsLaboratory flotation test procedure
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotation• Consistency: 0.8% • Temperature: ~40°C• Ca2+: 150 mg/L
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8DB– September, 2007
Materials and methodsLaboratory flotation test procedure
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotation• Consistency: 0.8% • Temperature: ~40°C• Ca2+: 150 mg/L
• Pulp feed flow: 2 L/min
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9DB– September, 2007
Materials and methodsLaboratory flotation test procedure
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotation• Consistency: 0.8% • Temperature: ~40°C• Ca2+: 150 mg/L
• Pulp feed flow: 2 L/min • Air flow: 4 L/min
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10DB– September, 2007
Materials and methodsLaboratory flotation test procedure
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotation• Consistency: 0.8% • Temperature: ~40°C• Ca2+: 150 mg/L
• Pulp feed flow: 2 L/min • Air flow: 4 L/min• Cell volume: 14.5 L
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
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11DB– September, 2007
Materials and methodsLaboratory flotation test procedure
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotation• Consistency: 0.8% • Temperature: ~40°C• Ca2+: 150 mg/L
• Pulp feed flow: 2 L/min
• Froth removal thickness: 1, 2, 3, 5 cm
• Air flow: 4 L/min• Cell volume: 14.5 L
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
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12DB– September, 2007
Materials and methodsLaboratory flotation test procedure
High consistencypulping
• Furnish:50% OMG/50%ONP
• Consistency: 13%
• Temperature: 45°C
• Pulping time: 15 min
• Ca2+: 150 mg/L
Laboratory continuous flotationPulp characterization• ERIC, Brightness• Ash content (475°C), fibre content• Mass flow
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
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13DB– September, 2007
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests • Process simulation
Conclusions
Guideline
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14DB– September, 2007
Materials and methodsData analysis and process simulation
Flotation de-inking modelling
ngnn c
SQK
dtdc α
−=
SQK
k gnn
α⋅=
Air
Pulp chest
d
Adjustable froth removal
Pulp aeration line
S cell cross sectionQg air flowcn particle concentrationKn experimental flotation rate
Flotation
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15DB– September, 2007
Materials and methodsData analysis and process simulation
nfn c
VQ
dtdc 0⋅
−=φ
Air
Pulp chest
d
Adjustable froth removal
Pulp aeration line
V cell volumeQf
0 water upstream flowcn particle concentrationφ entrainment coefficient
Flotation de-inking modelling
Entrainment
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16DB– September, 2007
Materials and methodsData analysis and process simulation
gf
f
QQQ+
=ε
FRTLde ⋅−⋅= 0εεAir
Pulp chest
d
Adjustable froth removal
Pulp aeration line
Flotation de-inking modelling
Frothing
ε water holdupε0 water holdup at the froth/pulp interfaceQf water upstream flowQg gas flowFRT froth retention timeLd water drainage coefficient
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17DB– September, 2007
Materials and methodsData analysis and process simulation
dnff Qc
dtdM
⋅⋅−= δ
Air
Pulp chest
d
Adjustable froth removal
Pulp aeration line
Flotation de-inking modelling
Drainage
dMf /dt particle drainage rateδ particle drainage coefficientcnf particle concentration in the frothQd water drainage flow
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18DB– September, 2007
Materials and methodsData analysis and process simulation
Air
Pulp chest
d
Adjustable froth removal
Pulp aeration line
Flotation de-inking modelling
Laboratoryflotation tests
Experimentaldata fitting with
model equations
Extraction of transport
coefficients
Process scale-up and design usingmodel equations
Industrial line simulation
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19DB– September, 2007
Materials and methodsData analysis and process simulation
Industrial pre-flotation line
Cell volume (L)
Cell cross section area (m2)
Pre-flotation feed flow (L/min)
Cell nominal flow (L/min)
Gas flow (L/min)
Number of 1ry cells
Number of 2ry cells
Recirculation rate on 2ry cells (%)
24000 12 30000 40000 20000 6 2 71
Parameters used to simulate an industrial pre-flotation unit
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20DB– September, 2007
Materials and methodsData analysis and process simulation
Industrial pre-flotation line
Air Air Air Air Air Air
Air Air
Froth 1ry stage
Froth 2ry stage
Cell 1
Cell 2
Cell 3
Cell 4
Cell 5
Cell 6
Cell 1
Cell 2
Floated pulp
Pulp feed
2ry stage
1ry stage
Cell volume (L)
Cell cross section area (m2)
Pre-flotation feed flow (L/min)
Cell nominal flow (L/min)
Gas flow (L/min)
Number of 1ry cells
Number of 2ry cells
Recirculation rate on 2ry cells (%)
24000 12 30000 40000 20000 6 2 71
Parameters used to simulate an industrial pre-flotation unit
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21DB– September, 2007
Guideline
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests• Process simulation
Conclusions
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22DB– September, 2007
Comparison of fatty acid soap and fatty acid-surfactant blend
100
200
300
400
500
600
700
800
900
1000
0 10 20 30 40 50
Time (min)
ERIC
(ppm
)
Soap, 1% silicate
Blend, 1% silicate
2 cm 1cm 3 cm 5 cm
b)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
0 10 20 30 40 50Time (min)
Fibr
e co
nsis
tenc
y (g
/L)
Soap, 1% silicate
Blend, 1% silicate
2 cm 1cm 3 cm 5 cm
ERIC of floated pulp Fibre consistency in the froth
ResultsLaboratory flotation tests
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23DB– September, 2007
)
0
1
2
3
4
5
6
7
8
9
0 10 20 30 40 50Time (min)
Ash
con
sist
ency
(g/L
)
Soap, 1% silicate
Blend, 1% silicate
2 cm 1cm 3 cm 5 cm
b)
0.0
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
0 10 20 30 40 50
Time (min)
Fine
s co
nsis
tenc
y (g
/L)
Soap, 1% silicate
Blend, 1% silicate
2 cm 1cm 3 cm 5 cm
Comparison of fatty acid soap and fatty acid-surfactant blend
Fines consistency in the frothAsh consistency in the froth
ResultsLaboratory flotation tests
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24DB– September, 2007
0
5
10
15
20
25
30
35
0 1 2 3 4 5 6
Froth thickness (cm)
Wat
er lo
ss (%
)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
b)
0
0.02
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0 2 4 6 8 10 12 14 16 18
Retention time (s)
Wat
er h
oldu
p (%
)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
Comparison of fatty acid soap and fatty acid-surfactant blend
Water loss vs. froth removal thickness Water holdup in the froth vs. FRT
ResultsLaboratory flotation tests
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25DB– September, 2007
Flotation yield of tested deinking chemicals
a)
0
5
10
15
20
25
0 1 2 3 4 5 6
Froth thickness (cm)
Fibr
e lo
ss (%
)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
b)
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5 6
Froth thickness (cm)
Fine
s lo
ss (%
)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
c)
0
10
20
30
40
50
60
70
0 1 2 3 4 5 6
Froth thickness (cm)
Ash
loss
(%)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
d)
0
5
10
15
20
25
30
35
40
0 1 2 3 4 5 6
Froth thickness (cm)
Tota
l los
s (%
)
Soap, 2% Silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
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26DB– September, 2007
Ink removal efficiency
62
64
66
68
70
72
74
76
78
0 1 2 3 4 5 6Froth thickness (cm)
Ink
rem
oval
(%)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicate
ResultsLaboratory flotation tests
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27DB– September, 2007
Guideline
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests• Process simulation
Conclusions
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28DB– September, 2007
Process yield
ResultsProcess simulation
Air Air Air Air Air Air
Air Air
Froth 1ry stage
Froth 2ry stage
Cell 1
Cell 2
Cell 3
Cell 4
Cell 5
Cell 6
Cell 1
Cell 2
Floated pulp
Pulp feed
2ry stage
1ry stage
36.4
44.3
33.8
41.4
7.8
13.1
7.6
12.2
2.64.2
1.1
15.2
35.6
20.3
36.3
5.9 5.85.5 5.46.6
3.23.1
7.52.9
0
5
10
15
20
25
30
35
40
45
50
Soap, 2% silicate Soap, 1% silicate Blend, 2% silicate Blend, 1% silicate
Loss
(%)
Total loss 1ry
Total loss 2ry
Fibre loss
Ash loss
Fines loss
Water loss
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29DB– September, 2007
Laboratory and pre-flotation line flotationselectivity
ResultsProcess simulation
60
63
66
69
72
75
78
81
84
87
5 10 15 20 25 30 35
Total loss (%)
Ink
rem
oval
(%)
Soap, 2% silicate
Soap, 1% silicate
Blend, 2% silicate
Blend, 1% silicateSoap, 2% silicate
Soap, 1% silicate
Blend, 1% silicate
Blend, 2% silicate
Air Air Air Air Air Air
Air Air
Froth 1ry stage
Froth 2ry stage
Cell 1
Cell 2
Cell 3
Cell 4
Cell 5
Cell 6
Cell 1
Cell 2
Floated pulp
Pulp feed
2ry stage
1ry stage
Air
Pulp chest
d
Adjustable froth removal
Pulp aeration line
Lab flotation column
Industrial pre-flotation line
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30DB– September, 2007
Guideline
Motivations and objectivesMaterials and methods
• Laboratory flotation test procedure• Data analysis and process simulation
Results• Laboratory flotation tests• Process simulation
Conclusions
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31DB– September, 2007
ConclusionsLaboratory flotation tests
Silicate decreases fibre loss by depressing fibre entrainment and promoting fibre drainage in the froth
A decrease in ink removal due to more intense ink drainage in the froth was also observed when increasing silicate dosage from 1 to 2%.
The fatty acid-surfactant blend gave a higher ink removal selectivity than that obtained with fatty acid soap
Air
Pulp chest
Floated pulp
Froth collection
To vacuum pump
Adjustable froth removal
Pulp aeration line
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32DB– September, 2007
ConclusionsProcess simulation
The performance scale determined during laboratory trials was respected and further emphasized by the layout of the simulated line
The presence of a secondary stage in modern deinking lines boosts the ink removal selectivity
The fatty acid-surfactant blend used with 2% silicate demonstrated the most favourable deinkingperformance
Air Air Air Air Air Air
Air Air
Froth 1ry stage
Froth 2ry stage
Cell 1
Cell 2
Cell 3
Cell 4
Cell 5
Cell 6
Cell 1
Cell 2
Floated pulp
Pulp feed
2ry stage
1ry stage