ms-09-development of a paper recycling process

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DEVELOPMENT OF A PAPER RECYCLINGPROCESS

CONFERENCE PAPER FEBRUARY 2014

DOI: 10.13140/2.1.4078.8802

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Muhammed Kamrul Islam

Chittagong University of Engineering & Tech

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Retrieved on: 31 October 2015
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Proceedings of the 15thAnnual Paper Meet 07-08 February 2014Dhaka, Bangladesh

Mechanical Engineering Division The Institution of Engineers, Bangladesh

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DEVELOPMENT OF A PAPER RECYCLING PROCESS

1Dibakar Bhattacharjee,2Md. Kamrul Islam1Maintenance Engineer,BSRM steels Ltd E-mail

2Lecturer ,Atish Dipankar University of Science and [email protected],

[email protected]

ABSTRACT: Modern civilization cannot be imagined without the use of paper. Large amount of papers

are being used in everyday life; among them most of are treated as useless and they are thrown here and

there after using. Sometimes it causes environmental pollution. Today, 90% of paper pulp is made ofwood. Paper production accounts for about 35% of felled trees, and represents 1.2% of the world's total

economic output. Recycling one ton of newsprint saves about 1 ton of wood while recycling 1 ton of

printing or copier paper saves more than 2 tons of wood. So, it is the necessity of paper wastemanagement to save the environment from its annihilation and pollution. Newsprint papers, Printing

paper and tissue can be made by this recycling process that can be repeated at least 5 to seven times. The

ratio of waste paper and water is a vital factor in the paper recycling process. So the motive was to find

out the desirable waste paper and water ratio, analysis the quality and decide the usefulness of the

particular need. In this experiment the best pulp was obtained at a ratio of 100 gram paper and 4 liters ofwater. The grammage value of the paperboard was 315.58 gm/m2, bulk was 2.535x10-06m3/gm., moisture

content 16%, absorption time 5.4 second and tensile strength was 4.58 kPa. Though the recycled paper

from this paper recycling machine are not so smooth and thin as like the produced paper from mill bywood, they can be used for banner, title, poster cards; also for making box where numbering or leveling

is very easy. Automatic recycling machine will increase the turnover ratio significantly and the use of

plate heater will be an advantage to heat in wet condition.

Keywords: Paper pulp, Pulp machine, Grammage, Turnover ratio, Tensile Strength.

1. INTRODUCTION

Industrialized paper making has an effect on the environment both upstream, where raw materials are

acquired and processed and downstream .Today, 90% of paper pulp is made of wood. Paper production

accounts for about 35% of felled trees, and represents 1.2% of the world's total economic output.

Recycling one ton of newsprint saves about 1 ton of wood while recycling 1 ton of printing or copier

paper saves more than 2 tons of wood. So the designing and fabrication of waste paper recycling plant istherefore a welcome development as it will ensure that the source of raw material for paper production is

multiplied and also waste paper that could have constituted into wastes are recycled for various

productive purposes.

Papermaking and producing paper from recycled materials came to the United States simultaneously in

1690, when William Rittenhouse, who had learned to make paper in Germany, founded America's first

paper mill on Monoshone Creek near Germantown, which is now Philadelphia. Rittenhouse made hispaper from discarded rags of cotton and linen[1]. On April 28, 1800, an English papermaker named

Matthias Koops was granted the first patent for paper recycling-English patent no. 2392, titled Extracting

Ink from Paper and converting such Paper into Pulp. In his patent application, Koops described his

process as, "An invention made by me of extracting printing and writing ink from printed and written

paper, and converting the paper from which the ink is extracted into pulp, and making thereof paper fit

for writing, printing, and other purposes[2]."

In 1801, Koops opened a mill in England that was the first in the world to produce paper from materialother than cotton and linen rags-specifically from recycled paper. Two years later, the Koops mill

declared bankruptcy and closed, but Koops' patented paper-recycling process was later used by paper

mills all over the world. As early as 1921, Britain established the British Waste paper Association toencourage waste paper reuse. Recycling has become a major industry in the United States, employing

thousands of workers and saving energy, reducing land fill demand, and conserving valuable resources.

In 2010, 63.5 percent of the paper used in the United States was recovered for recycling [3,4].

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Proceedings of the 15thAnnual Paper Meet 06-07 December 2013Dhaka, Bangladesh


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Approximately 80 percent of U.S. paper mills use some recovered paper fiber to produce new paper and

paperboard products. The first Australian paper mill to use recycled material was built in 1815 - it used

recycled rags to make paper. Waste paper collections from households and factories started in Melbournein the 1920s.

In Bangladesh paper production mainly depends on pulp made from wood. But it is necessary to recycle

paper in Bangladesh to save the environment from pollution. Fransiab Limited Company, Habib Trading

Corporation, Holy Trading Corporation, the Angles Corporation, Prokiti Hardware Company are theleading companies who have started paper recycling. It is the first project on paper recycling at CUET.

Recently Eusufzai Z. (2012) has made the hand operated pulper machine to make pulp [5]. I have carried

out the other process of paper recycling and testing according to my project proposal submitted.

2. MODEL AND FRAMEWORK

Paper recycling generally involves the collecting of waste paper, sorting them by their types, processingthem into raw materials and manufacturing new products using these recycled raw materials. The whole

process is briefly described below. To start the paper recycling process, the waste paper needs to besorted such as by newsprint, computer paper, magazine paper etc, as different types of paper are treated

differently during the paper recycling process to make different types of recycled paper products. The

sorted paper is usually soaked in a pulper, which contain water and chemicals. The waste paper is shreds

into small pieces. Heating the mixture breaks the paper down more quickly into tiny strands of cellulose(organic plant material) called fibers. Eventually the old paper turns into a mushy mixture called pulp.

The pulp is forced through screens containing holes and slots of various shapes and sizes. The screen

removes small contaminants such as bits of plastic and globs of glue. This process is called screening. In

addition, the pulp may also be spun around in large cone-shaped cylinders. Heavy contaminants (e g.

Staples) are thrown out of the cone via centripetal forces, while lighter contaminants collect in the center

of the cone and are removed. This process is called cleaning. The next stage in the paper recyclingprocess involves deinking removing the ink from the paper fibers of the waste paper. Sticky materials

(referred to as stickies) like glue residue and adhesives are also removed at this stage.

During refining the pulp is beaten to make recycled fibers swell, making them ideal for paper making. If

the pulp contains any large bundles of fibers, refining separates them into individual fibers. If the

recovered paper is colored, color stripping chemicals remove the dyes from the paper. Then if white

recycled paper is being made, the pulp may need to be bleached with hydrogen peroxide, chlorine dioxide

or oxygen to make it whiter and brighter. If brown recycled paper is being made, such as that used for

industrial paper towels, the pulp does not need to be bleached.

Fig. 1 : Design of hand operated pulper

In the last stage of the paper recycling process, the cleaned up pulp is ready to be made into recycled

paper. The recycled fiber can be used alone, or blended with new wood fibers (i.e. virgin fibers) to give it

extra strength or smoothness. The pulp is mixed with water and chemicals, such that the pulp is 99.5%water. This watery pulp mixture then enters the head box of a paper making machine, and is sprayed in a

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continuous jet onto a huge wire mesh-like screen moving very quickly through the paper machine. On the

screen, water starts to drain from the pulp, and the recycled fibers begin to bond together to form a waterysheet. The sheet then moves rapidly through a series of felt-covered press rollers which squeeze out more

water from the pulp. In this way recycled paper is created. The following equipment is necessary for the

experimental setup of paper recycling process: Pulper, Screener, Roller.

3. SETUP AND PROCEDURE

In order to recycle paper the following equipment were made in CUET workshop. The hand

operated pulper machine was made by Eusufzai Z. (2012). The total height of the pulper is 13

inch. It has support at its middle to hold on pulp container. Screener was made with stainless steel

net and wooden frame as shown in figure 4.3. The stainless steel net has 80 holes per inch. After

making the pulp it was settled down on the screener. In order to make roller the followingmaterials were used.

>> Stainless Steel Pipe(Length - 1 feet; Outer Diameter 2 inch, Inner Diameter 1.5 inch)

>> Mild Steel Bar(Length - 1.5 feet, Diameter -0.75inch )>> Two Ball Bearings( Bearing no. 6904ZZ, Inner Diameter 20mm, Outer Diameter 37mm,

Width 9mm.)

Fig. 2: Pulper machine and screener

In recycling of waste paper mainly the following process were followed.

Pulping

Screening

Rolling

Drying

3.1 PulpingPulp was made by adding waste paper with water. After using various waste paper and water ratio the

best pulp was found at a ratio of 100gram paper and 4 litres of water. Pulp was made with the help of

hand operated pulp machine.

3.2 ScreeningAfter getting the pulp it was poured on the screener. As a result the pulp slurry was settled

downed on the screener.

3.3 RollingAfter screening the pulp, it was rolled with the help of the hand roller in order to remove extra water from

the pulp.



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Fig 3: Pulp making and screening

3.4 Drying and Paper Making

After rolling it was dried in the sunlight for about 2 hours. After drying it was pulled over the screener

carefully. The final recycled paper was as like as shown in the figure 4.

Fig 4: Rolling and recycled paper

4. PROPERTY ANALYSIS AND TESTS

The basis weight, substance or grammage is obviously most fundamental property of paper board. The

Basis weight of paper is the weight per unit area. This can be expressed as the weight in grams per squaremeter.

Length of paperboard 26cm

Width of paperboard 19.5cm

Area of paperboard 0.0507 m2

Weight of the paperboard 16gm

Grammage is 315.58 gm/m2Bulk is another very important parameter of paper particularly for printers. Bulk is a term used to

indicate volume or thickness in relation to weight. It is the reciprocal of density (weight per unit

volume). It is calculated from caliper and basis weight

Bulk = thickness/Grammage

Thickness of the paperboard 0.8 mm and Bulk is 2.535 x 10-06

gm

Almost all grade of paper has some percentage of moisture. Moisture in paper varies from 2 -

12% depending on relative humidity, type of pulp used, degree of refining and chemical used.



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Most physical properties of paper undergo change as a result of variations in moisture content.

Moisture control is significant economic aspect of paper making. Poor moisture control canadversely affect many paper properties. All strength properties are sensitive to moisture about

1% change in a samples moisture content changes the compression strength with an average of

8%.Weight of the paperboard before drying in a microwave oven 15 gm

Weight of the paperboard after drying in a microwave oven 12.6 gm

Moisture Content = (15-12.6)/15 =16%Water absorption is an important parameter for paper used for writing and also the paper used for

the manufacture of soft drink cups. Nowadays cobb absorption tester is used to measure water

absorption property of paper. Here water absorption property was measured manually. Average

absorption time T =5.4s.

The tensile force required to produce a rupture in a strip of paperboard. Tensile strength can beused as a potential indicator of resistance to web breaking during printing or converting.

Here , Length of the paper strip 120mm

Width of the paper strip 20mmThickness of the paper strip 0.8mm

Area of the paper strip 2.410-3m2

Fig. 5: Stress Strain curve

5. CONCLUSION AND FURTHER STUDY

The development of manually operated paper recycling process is much cheaper than the automated

paper production process. It can serve dual purposes, it can be manned permanently at a stationary

position or it could be shifted from one place to another as the case may be. One great advantage to be

derived from the use of this process is that the cost of running it is minimal compared to what it takes torun a full plant. The simplicity of operation of this machine ensures that no too much technical skill is

needed to operate it. In addition it is an environment friendly process.

As my recycling process is manual, so if it can be automatic electric motor operated then recycled paperwill more practical and turnover ratio will increase with a large amount. Then the recycle paper would be

perfect for writing. As sunlight is needed for heating purpose, in rainy season it will be difficult to heat.

So a plate heater can be used for heating purpose.

ACKNOWLEDGEMENTS

These should be brief and placed at the end of the text before the references.



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REFERENCES

[1] Counsell T.A.M and Allwood J.M (2005), Desktop Paper Recycling: A survey of novel technologiesthat might recycle office paper within the office, Journal of Materials Processing Technology 173 (2006)

111-123

[2] Kenneth W.B (1970), Handbook on Pulp and Paper Technology, 2ndedition, Van Nostrand Reinhold

Co. , New York.

[3] Perry R. H. (1984), Green D.W. , Perrys Chemical Engineers Handbook, 6th

edition, McGraw-Hill,USA.

[4] Sinnot R.K (1984), Coulsons and Richardsons Chemical Engineering , Volume 6, 3rdedition,

Butterworth-Heinemann, Woburn, U.K

[5] Eusufzai Z. (2012), Design and fabrication of Paper Recycling Machine, Chapter 4, Department of

Mechanical Engineering, Chittagong University of Engineering & Technology.

ms-09-development of a paper recycling process

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