"

. DESIGN AND FABRICATION Of A US1:1> PAP1ER

RECYCLING PLA~t '

BY

SOBOWALE, JONATHAN OLUGBENGA 96/5323EH

A RESEARCH PROJECT SUBMITTED IN PARTIAL ~ i

, FULFILMENT OF

THE REQUIREMENT FOR THE AWARD OF BACHELOR.

OF ENGINEERING.(B.ENG.) OE.GREE IN THE

DEPARTMENT OF CHEMICAL ENGINEERING,

SCHOOL OF ENGINEERING AND ENGINEERING

TECHNOLOGY.

FEDERAL UNIVERSITY OF TECHNOLOGY, MINNA.

FEBRUARY,' 2002 .

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DECLARATION

hereby declare that this project work was designed and fabricated by me under

supervision of Engr M.A. Olutoye.

DATE SOBOWALE, J. O.

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CERTIFICATION

This is to certify that this project titled "DESIGN AND FABRICATION OF

ASTE PAPER RECYCLING PLANT " was carried out by JONATHAN

LUGBENGA SOBOWALE under the supervision of Engr. M.A. Olutoye and

to the Chemical Engineering Department, Federal University of

echnology, Minna in partial fultillment of the requirement for the award of

lor of Engineering (B. Eng) degree in chemical engineering.

Engr. M.A.Olutoye Project supervisor

Dr. J.O.Odigure

Head of department

External examiner

sign and date

sign and date

sign and date

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.' DEDICATION

I dedicate thi~ project to. my parents elder 'and deaconess B.a. Sobowale., for , . . ..•.. , ... ' " . , ..... .

their untiring coml11itmehtto ensure I am educated, despite all odds.

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ACKNOWLEDGEMENT

receive\l\any .... thing except it be given to him from above. I deeply

appreciate the grace mercy and goodness of God over my life. Every thing I am

today I became by his love, I appreciate him greatly.

I also, will acknowledge those whose contributions either morally and or

financially made my acad.emic journey a smooth one.

To my project supervisor Engr. M.A. Olutoye, your continuous attention to me I

despite your tight schedule made the job easier, I deeply appreciate you. To

Engr. Dr. K. R. Onifade, Engr. Lekan Adeniyi and all the other wonderful lecturers

in Chemical Engineering Department, your contribution to my life is

unquantifiable.

To my parents Elder and Deaconess B.D. Sobowale. Your love and support is

my strength. Also to my siblings, Grace, Sunday, Emmanuel, Dare and

Moyinoluwa, thanks for your love. To my covenant friend Femi Abifarin I deeply

value our relationship, we will meet at the top.

Also to my project partners, Ochor Spencer and Shittu Abolaji, and all the

graduating students of Chemical Engineering Department 2000/2001 session

(my class mates) I· love you all. Also to my allies Michael Joe, Tolu Ibitola,

Ndubuisi Nwiyi, Umar Dantala, Abimbola A.ro and all the others, too numerous to

mention, we will all meet at the top. To my Guardian Mrs.A.B. Adebayo, and the

children Lola, Seyi, Wumi and Ibukun ,i deeply appreciate you for all your

support.

To my Mosun Ajiboye, your unconditional love is deeply appreciated, you are a

gem among pearl.

Finally to everyone who's behind the scene contributions made the journey a

smooth one, the lord will reward you all abundantly.

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ABSTRACT

The research work "DESIGN AND FABRICATION OF WASTE PAPER

RECYCLING MACHINE" has been carried out. The fabricated plant consist of six

major component Units which include the disc refiner, the hydropulper, the head

box, the felt conveyor, the driers and the rollers.. From the results of

experimental analysis carried out on the study, it was discovered that for every

0.1 Kg. Of used paper fed into the refiner, about 7000mt (7 litres) of water is

required to defibre it, and about 0.2 kg. Of starch adhesive is required. The

calculated volume of the refiner, hydropulper and head box are 11795.62cm3,

62930.47cm3 and 60979.096cm3 respectively. The fabricated machine is

capable of producing 7.6 Kg of recycled paper from 10 kg of used paper.

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2.6.3 Washing

Dewatering and Thickening

Units and FUnction of The Recycling PI-ant

The Disc Refiner

The Hydropulper

The Head box

Ttle Press Section -

The Drying Section -

CHAPTER THREE

Methodolo~;!y and Design Calculation

Choice of Operating Method-

Description of The Recycling Plant Designed- -

3.2 Individual Unit Design

3.3.1 The Disc Refiner -

3.3.2 The Hydropulper- -

3.3.3 The Headbox

3.3.4 Felt Blanket Conveyor

3.3.5 The Dryers -

3.3.6 The Cylindrical Rolls Dimension-

3.4

3.6

Energy Requirement of the Plant

Efficiency of dryer-

Energy Balance Across the Roller

CHAPTER FOUR

4.2 Material Balance Across Designed Plant

4.2.1 Assumed Data and Flow Sheet for Tissue

Production -

4.2.2 Material Balance Around Refiner

4.2.3 Material Balance Around Hydropulper-

4.2.4 Material Balance Over Headbox

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Material Balance Over Felt Conveyor­

Material Balance Around Drier -

Material Balance Around Roller

CHAPTER FIVE

Material Selection and Cost Analysis -

Material Selection-

Cost Analysis

CHAPTER SIX

Conclusion and Recommendation

Conclusion -

Recommendations-

REFERENCES

APPENDIX A

APPENDIX B

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',CHAPTER ONE

INtRODUCTION

Eri~ineering ci~9Is. ,with how the properties of matter can be, made into '",

useful products toman, while the process of the production is undertaken via a

design work. ( Sinnott R.K,.1983). Paper, being one of the important products

ever' invented "by man, as its inventio~' means that more people would be

'~ducated' because more books' would be' printed and distributed, it is therefore " ,,' '~!:~":' ',' , . " ' expedient toensyre that its reduction is enhanced.

The primary source of raw material for production of paper is vegetable

, fibers, obtained mail1iyirom plants, To ensure thattheforest is not deplet~d of r ''; ,:" > . " ,.'>" ':- " " " :' , ,'; ,'ff:., «::

these woods, th~re is need to providealte'rnative source of raw materia:ls, this " ," , ,,', ' "' . ., ,

therefore leads to the invention of the process of recycling.

Recycling,' which is the extraction and.recovery of valuable;materials from

'scrap or other ditc~rd~19j materi:~ls, is employed to supplement the production of " ,'~-" . '~~,' "::?'l":I~ < ~I , .f \. ,

paper. The d~signing; ~nd fabri'cating of a used paper recycling plant is th~refore , '" ,r , '," ' /" ".,.< " . ',

, a welcome'develop'rnent as it will ensure that the source of raw material for paper

proSfuctioh is' mul\iplied and also waste paper that could have constituted into , : ~~"' "

wa~tes are r~cybledfor variousj:>roductive purposes.,

BACKGROUN[) RESEARCH

Papyrus, which was essentially u~das a' raw material i~ the ancient

'worid was made by the Egyptians In the third millennium B.Cand continu~d in

use in the' rvtediterrane'an region until about the 10th century A 0 after which it'

"was gradually displ~bed by parchment Paper was first made at about 1'800 . " ,'. "<:\"" " ,", ,,,;. .' , .

years ago in Chi~a.The first major improvement ever, Chinese manual paper",

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manufacture of pulp from wood. By the mid 20th century, however, over 90% of

.. all papermaking fibers were invented from wood pulp. I '> ' '

2.3 MANUFACTURING PROCESS

In the production of paper, there are four major steps. \l.f;r~l d:.L "" '1" ;!. t, :",

1. Fiber or stock preparation. " .' .. ? " .,\

2. Formation of the paper web on the paper-making machine. 'ft ~); '"; 1.; ~ 1 ' • " d ~ l t ,': :

3. Water removal.

4. Finishing the paper.

2.3.1 FIBER OR STOCK PREPARATION

Stock or fiber preparation involves the conversion of wood into its individual

fibers of cellulose. There are two-basis method of pulp preparation viz:

2.3.1.1 MECHANICAL PULP

In the mechanical pulp the reduction of wood fibers is essentially a physical

operation in which the fibers are actually pulled away from each other by the

a,8R!ipf!tiqriA?f\sqm~ type .of mechanical force. t - .' '"

rhe:t~t;J~mjcal pulp involves the cooking of the chips in a chemical solution under

pressure until the fibers are separated by dissolution of the lignin binder and fall

apart with very little or no mechanical action.

Before the woods are conveyed for pulping, it is first of all debarked by passing it

t~rough an hohzortal drum which rotates to remove the bark. The debarked log

is then fed to a chipper

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2.5 USED PAPER RECYCLING

In recent years, the recycle utilization of resources has been of great

importance as an effective measure for the solution of en~rgy, resources and

environmental pollution problems. Within this concept, the recovery and

utilization of waste paper have tended to increase in developed countries,

many studies have been published which have tried to explain why the

recovery of waste paper and its utilization have increased and why and by

how much it is expected to increase in the future.

Recovered waste paper has been found to be a very valuable raw material

for the paper and board industries, and is completely utilized for domestic

demand. The importance of domestic waste paper as a raw material is

growing through due to the soaring prices of virgin pulp and imported pulp ,'"

Wood.

2:6.0 USED PAPERHECYCLING PROCESS

In order to produce optimum quality paper from the recycling of used paper,

there are some basic processes, which the material has to pass through. The

process is slightly different from what is obtained in paper production from

. wood pulp.

2.6.1 PULPING AND DEFIBERING

This is the process of transforming long smooth secondary fibers into

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fibrillated more flexible fibers by a mechanical means.

2.6.2 CLEANING AND SCREENING

This process involves the use of centrifugal cleaners to separate on the

bases of particle weight unwanted material which main content include

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