CHAPTER IV

MATERIAL BALANCE

The raw materials to be utilized in this study are the fiber found in the rice straw. The assumptions of the amounts of the substances entering in some of the equipment are based on data gathered by the researchers wherein actual experiments were conducted.

Table 4.1 Chemical Composition of Rice Straw Cellulose (w%) Rice Straw 41% Hemicellulose (w%) 33% Lignin (w%) 12% Ash (w%) 14%

Source: Bledzki and Gassan 1999; Bledzki et al. 2002; Lu et al. 2006; Marti-Ferrer et al. 2006;

I.

Material Balance around the Shredder Forty tons of rice straws are feed in the shredder for size reduction to turn the raw material

into segments about 1-2 inches.

Mass Balance

40 tons Raw Material

SHREDDER

40 tons Raw Material

Input = Output 40 tons Raw Material = 40 tons Raw Material

II.

Mass Balance around the Cooker The fibers are cooked at 80oC for 120 minutes where lignocellulosic materials are

treated with an 80% aqueous solution of acetic acid and 0.6% HCl. (Jahan, M., Lee, Z., Jin, Y., 2005).

Basis: 40 tons dry fiber Mass Balance

AcOH

HCl

40 tons Fiber

COOKER

35.0128 tons cooked fiber

+ 204.9872 tons Black Liquor

 Assumptions: i. ii. mass liquor = 5 (Haas and Lang, 1971) mass fiber Kappa # = 45.8 = % lignin left after 120 minutes cooking (Jahan, M., Lee, Z., Jin, Y., 2005) iii. iv. v. 57.4% of the ash is retained in the cooking (source) 80% of the total liquor is CH3COOH (Jahan, M., Lee, Z., Jin, Y., 2005) 0.6% of the total Liquor is HCl (Jahan, M., Lee, Z., Jin, Y., 2005)

Amount of lignin in the fiber = 40 tons fibers X 0.12 lignin = 4.8 tons lignin Amount of Lignin left in the cooked fiber = amount of lignin in the fiber X kappa # = 4.8 tons lignin X 0.458 = 2.1984 tons lignin Amount of Lignin removed = 4.8 tons 2.1984 tons = 2.6016 tons lignin

Amount of ash in the fiber = 40 tons fibers X 0.14 ash = 5.6 tons ash 57.4% of ash is retained in the cooking 5.6 tons Ash X 0.574 = 3.2144 tons Ash Amount of Ash removed = amount of ash in the fiber amount of ash retained = 5.6 tons 3.2144 tons = 2.3856 tons Ash

 Input: Tons of fiber = 40 tons Mass of Liquor = 5 (40 tons) = 200 tons Tons of CH3COOH = 200 tons X 0.80 = 160 tons CH3COOH Tons of HCl = 200 tons X 0.006 = 1.2 tons HCl Tons of H2O = mass liquor tons CH3COOH tons HCl Tons of H2O = 200 tons - 160 tons 1.2 tons = 38.8 tons H2O

 Output: Fibers = feed Fiber extracted Lignin extracted Ash Fibers = 40 tons 2.6016 tons 2.3856 tons = 35.0128 tons of cooked fiber Black Liquor = 200 tons + 2.6016 tons + 2.3856 tons = 204.9872 tons black liquor

 Overall Material Balance: Fiber + Liquor = cooked Fiber + Black Liquor 40 tons + 200 tons = 35.0128 tons + 204.9872 tons

III.

Mass Balance around Filter The pulp slurry from the cooking process will pass through a filter wherein the liquor is

separated from the pulp.

240 tons slurry

35.0128 tons cooked fiber

204.9872 tons black liquor

Mass Balance Input = Output 240 tons pulp slurry = 35.0128 tons cooked fiber + 204.9872 tons black liquor

IV.

Mass Balance around the Washer The fibers are washed with 80% acetic acid and with large quantities of water.

Mass Balance

Acetic Acid and Water

35.0128 tons cooked fiber

35.0128 tons cooked fiber

Washing

Input = Output 35.0128 tons impregnated fiber = 35.0128 tons impregnated fiber

V.

Mass Balance around the Extractor It is known that organic acid pulping gives rigid and brittle fibers and this pulp has lower

strength properties. In order to improve the strength properties of organic acid treated pulp by alkali. It is known that the following 3 reactions take place with alkali treatment: 1) solubilization of hemicellulose and residual lignin in pulp, 2) deacetylation of pulp, and 3) solubilization of residual silica (ash) in pulp.

70.0256 tons Liquor

35.0128 tons Cooked fiber

27.5449904 tons pulp

77.4934096 tons extracted Solution Mass Balance: Input = Output

 Assumption: i.

mass liquor =2 mass pulp

(Jahan, M., Lee, Z., Jin, Y., 2005)

ii. iii. iv.

Kappa # = 32.7 = % Lignin left (Jahan, M., Lee, Z., Jin, Y., 2005) 30% of Hemicellulose is desired to be dissolved. 36.9% of the original Ash content (5.6 tons) is retained in the pulp (Pan, Xue-Jun, et. al., 1999)

v.

10 % NaOH (Jahan, M., Lee, Z., Jin, Y., 2005)

Input:

Amount of liquor = 2 x 35.0128 tons pulp = 70.0256 tons Liquor Amount of NaOH = 70.0256 tons pulp x 0.10 = 7.00256 tons NaOH Amount of H2O = 70.0256 7.00256 = 63.02304 tons H2O Amount of Lignin left in the pulp = amount of lignin(left after cooking) X kappa # = 2.1984 tons lignin X 0.327 = 0.7188768 tons lignin Amount Lignin dissolved = amount of lignin(left after cooking) - amount of Lignin left in the pulp = 2.1984 tons lignin - 0.7188768 tons lignin = 1.4795232 tons lignin

Amount of Hemicellulose (from Raw material) = Mass of Raw material X % hemicellulose of the Raw material Amount of Hemicellulose(from Raw material) = 40 tons x 0.33 = 13.2 tons Hemicellulose Desired Hemicellulose to Dissolved = Amount of Hemicellulose(from Raw Materials) X % desired to be dissolved. Desired Hemicellulose to Dissolved = 13.2 tons x 0.3 = 3.96 tons Hemicellulose Ash Retained = 3.2144 tons ash x 0.369 ash Retained = 1.1861136 tons Ash Ash Removed = 3.2144 tons ash(left after cooking) 1.1861136 tons ash = 2.0282864 tons Ash Output: Tons of pulp = Feed (amount lignin dissolved + desired hemicellulose to dissolved + Ash removed) = 35.0128 tons (1.4795232 tons + 3.96 tons + 2.0282864 tons) = 27.5449904 tons pulp Overall Material Balance: 35.0128tons pulp + 70.0256 tons NaOH sol n = extracted mat ls + 27.5449904 tons pulp Extracted material = 77.4934096 tons

VI.

Mass Balance around Filter The pulp slurry coming from the extractor will enter the filter to collect the solid materials

and separate the solution containing the dissolved lignin, hemicellulose and ash content.

77.4934096 tons extracted mat l + 27.5449904 tons pulp 27.5449904 tons pulp

77.4934096 tons Extracted mat ls

Mass Balance

Input = Output Extracted mat ls + 27.5449904 tons pulp = Extracted mat ls + 27.5449904 tons pulp

VII.

Mass Balance around Screener

The reject fiber and dirt from the pulp are removed. 8% of reject materials will be separated from the pulp. The separation mechanism of the equipment is through the vibrating action of the screen. Basis: 27.5449904 tons pulp 27.5449904 tons pulp

2.203599232 tons reject fiber and dirt 25.34139117 tons pulp

Mass Balance Input = output

Input = 27.5449904 tons pulp Reject: 27.5449904 tons (0.08) = 2.203599232 tons reject fibers and dirt Output = 27.5449904 tons 2.203599232 tons = 25.34139117 tons pulp

VIII.

Mass balance around Refiner

This is where the cellulose fibers pass through a refining process which is vital in the art of papermaking. Before refining, the fibers are stiff, inflexible and form few bonds. The stock is pumped through a conical machine which consists of a series of revolving discs. The violent abrasive and bruising action has the effect of cutting, opening up and declustering the fibers and making the ends divide.

25.34139117 tons pulp

25.34139117 tons pulp

Mass Balance

Input = Output 25.34139117 tons pulp = 25.34139117 tons pulp

IX.

Material Balance around Paper Machine

The bleached pulp is prepared for paper making with a standard consistency of 0.5 % pulp for

thin sheets paper. The sheet of paper will be formed on a travelling wire or cylinder dewatered under rollers, dried by heated rolls, and finished by calendar rolls. The machine is expected to produce paperboards with a GMS of 200 g/m2 which is based on the specification of the equipment.

25.34139117 tons pulp(0.5% pulp) + 5042.936843 tons H2O 26.95892678 tons per roll of paper

5041.41636 tons H2O

Mass Balance Input = Output

 Assumption: i. ii. 0.5% bone dry pulp (http://www.Paper_machine.htm) 6% moisture in the produced paper

(http://www.Paper_machine.htm)

Input: Feed = 25.34139117 / 0.005 = 5068.278234 tons pulp slurry Mass of added water =5068.278234 25.34139117 = 5042.936843 tons water Output: 25.34139117 tons pulp / 0.94 = 26.95892678 tons per roll of paper Rejected H2O = 5042.936843 (25.34139117 x 0.06) = 5041.41636 tons H2O