Industrial Waste Water or Effluent Treatment Systems – Chemical Methods

Effluent treatment chemicals are commonly used to clean industrial wastewater. One method of using effluent treatment chemicals is the biodegradation process. This process uses biological agents to break down the pollutants in the water.

Industrial water treatment

Industrial wastewater treatment describes the processes used for treating wastewater that is produced by industries as an undesirable by-product. After treatment, the treated industrial wastewater (or effluent) may be reused or released to a sanitary sewer or to a surface water in the environment.

Wastewater treatment

Wastewater treatment is a process that removes and eliminates contaminants from wastewater and converts this into an effluent that can be returned to the water cycle.

 

Industrial wastewater treatment describes the processes used for treating wastewater that is produced by industries as an undesirable by-product. After treatment, the treated industrial wastewater (or effluent) may be reused or released to a sanitary sewer or to a surface water in the environment.

Wastewater treatment

Wastewater treatment is a process that removes and eliminates contaminants from wastewater and converts this into an effluent that can be returned to the water cycle.

Effluent Treatment Processes

There are many effluent treatment process technologies available to industrial plants. Each technology has its own advantages and disadvantages. The most common effluent treatment technologies are listed below:

Chemical Method of Effluent Treatment

Precise calculations of Effluent load is an important factor to select the treatment chemicals

Effluent treatment refers to a system used to reduce the toxicity and harmful components of wastewater effluents. One common method for effluent treatment is chemical treatment, which involves the use of chemicals to decompose or destroy waste materials. Chemical treatments can be divided into three main categories: primary, secondary, and tertiary treatments. 

Primary treatment removes large particles from water by using physical filters such as settling tanks or cascades. Secondary treatment uses chemicals to oxidize pollutants so they cannot bioaccumulate in organic matter or dissolve into groundwater supplies. The tertiary treatment combines various forms of effluent treatment chemicals to break down the effluents and pollutants. The following are some of the most common types of effluent treatment chemicals: 

  • Activated carbon filters
  • Particulate interceptors
  • Ultraviolet radiation

Physical Method of Effluent Treatment

Physical methods, such as sedimentation and flocculation, can be used to remove suspended solids from effluent. These processes use energy to break down the particles into smaller pieces that are then removed from the water.

Physio-chemical Method of Effluent Treatment

Effluent treatment chemicals (ETCs) are used to treat wastewater and effluent in industrial processes. They are used to reduce or neutralize pollutants, including bacteria, metals, organic materials, and toxins.

Chemicals that have been used as ETCs include chlorine dioxide (ClO), ozone (O3), hydrogen peroxide (H2O2), particulate matter filters such as activated carbon (AC), and granular activated carbon with anthracite coal ash(GAC-A).

 

Biological Method of Effluent Treatment

One of the most effective ways to treat effluent is through biological means. Biological treatment converts organic materials into hydroxides and acidity levels that are less harmful to the environment. This process can be very efficient, with some systems able to remove 80-90% of pollutants from water. However, it is also more expensive than other effluent treatment methods and requires regular maintenance.

WATER SCARCITY

There is a water scarcity issue in many parts of the world, including India. This can affect the ability to treat effluent from industrial processes with chemicals.

 

WATER POLLUTION

Water pollution is the contamination of water bodies with substances that are hazardous or detrimental to human health and the environment. Sources of water pollution can include sewage treatment plants, agricultural runoff, chemical facilities, and automobiles.

Many pollutants originate from domestic effluents such as wastewater, cooking oil, and soap scum. Industrial effluents like production waste streams and acid rain come from manufacturing processes. Marine debris includes everything from fishing nets to derelict vessels that have sunk into coastal waters leaving behind materials such as plastics and paint which can harm marine life.

Water Discharge norms are at the most stringent stage and use of specialty chemicals has become mandatory to maintain the parameters.

WATER CYCLE AND THE CAUSES AND EFFECTS OF WATER POLLUTION

Water pollution is the result of activities that contaminate water with pollutants. The most common sources of water pollution are factories, sewage plants, and automobiles. Pollution can come from numerous sources including wastewater treatment plant effluent, agricultural runoff, oil spills, and manufacturing waste products.

Some pollutants in water can cause health problems such as skin rashes or respiratory illness. Water also contributes to climate change by serving as a carrier for toxins and carbon dioxide emissions. Proper management of resources like treated wastewater can help Reduce environmental impacts while ensuring safe drinking water supplies for communities.

Wastewater Treatment – Role of Sludge Conditioners

Adequate conditioning of sludge before removal is a mandatory step to ensure performance

The effluent treatment plant operator must be familiar with the role that sludge conditioners will play in wastewater treatment. Sludge conditioners are used to treat sewage and agricultural waste before it is discharged into waterways or landfills. 

Some common types of sludge conditioners include: 

  • Alkalizers – These devices make water more acidic by breaking down organic molecules into smaller pieces. This makes it easier for bacteria to convert these molecules into energy, which then helps break down pollutants in the sewage. 
  • Denitrifiers – De-nitrifiers take nitrogen out of the air

Tertiary Wastewater Treatment by Activated Carbon

Activated carbon is a natural material made of tiny pieces of charcoal. When water is passed over the activated carbon, it forms molecules called “carbon dioxide” and “oxygen”. This process helps to treat water with harmful contaminants.

Activated carbon filtration is a commonly used technology based on the adsorption of contaminants onto the surface of a filter. This method is effective in removing certain organics (such as unwanted taste and odors, micropollutants), chlorine, fluorine or radon from drinking water or wastewater. However, it is not effective for microbial contaminants, metals, nitrates, and other inorganic contaminants. The adsorption efficiency depends on the nature of the activated carbon used, the water composition, and operating parameters. There are many types of activated carbon filters that can be designed for household, community, and industry requirements. Activated carbon filters are relatively easy to install but require energy and skilled labour and can have high costs due to the regular replacement of the filter material.

Coagulation, Flocculation and Sedimentation

Effluents are used in the treatment of chemicals, water and soil. Flocculation and sedimentation can be used to separate contaminants from effluent.

Filtration

Effluent treatment chemicals are filtered through either a 0.22-micron filter or a more specific 0.1-micron filter in order to remove any large pieces of debris that may be left over from the effluent treatment process.

Particle filtration is a physical or mechanical process that separates solids from fluids. Particle filtration typically is defined as the filtration of particles larger than 1 micron and is used as one of the first filtration steps in industrial wastewater treatment. Common technologies that are used for fine-particle filtration include bag filters, cartridge filters, multimedia filters, and self-cleaning filters.

Because industrial wastewater characteristics can vary so dramatically, depending on the industry, it is common to use multiple technologies to process the water. The properties of the solids in the water, including particle size, shape, density, stickiness, and quantity, as well as other materials in the water such as oil, determine which filter technologies are used.

The water quality is described in terms of total suspended solids (TSS) in units of milligrams per litre (mg/l). The TSS level helps to determine which filtration technology to use. Additional information such as the particle size distribution and particle shape can help to identify the appropriate technology to use and the correct filter cut-off. For example, if the particle sizes range from 20 to 80 microns, then a 20-micron or lower filter cut-off would remove 100 percent of the particles.

Aeration

The effluents from commercial and industrial plants can contain high levels of solids, VOCs and other pollutants. The treatment of these effluents is an important step in reducing the environmental impact. One common method used to treat these effluents is aeration. Aeration breaks down suspended materials into smaller pieces that can be removed by the plant’s wastewater treatment system.

 

Industrial Wastewater Treatment

Effluent treatment chemicals are used in industrial wastewater treatment to remove pollutants. Waste effluent is treated with a combination of physical, chemical and biological processes to achieve compliance with environmental regulations.

 

Questions:

What chemicals are used in STP?

Effluent treatment chemicals include various solvents, desiccants and ultraviolet light.

· pH neutralization of water

To control better, the pH level of the wastewater, basic chemicals such as alkalis and other acidic acids can be added to the water.

· Use of chemical precipitation to remove heavy metals

Chemical precipitation is a method of removing heavy metals from wastewater. To avoid contamination, add the precipitation reagent to the water. To form solid particles, heavy metals are ionically bonded with the reagent. Filtration is then used to eliminate these solid particles from the water.

· Chemical coagulants

Chemical coagulants are chemicals based on aluminium or iron that aid in the removal of pathogens, fluoride, organic compounds, and other pollutants. They work to destabilize wastewater particles by presenting a positively charged coagulant that reduces the particles’ negative charge. Waste particles aggregate to form larger bodies that can be purified.

· Flocculation of wastewater/sewage

Through charge bridging and magnetic neutralization, flocculants aid in the removal of very fine particles from wastewater treatment plants. Waste particles are encouraged to form clumps or flocs that can settle out during the sedimentation process with the addition of flocculants.

· Removal of odor

Certain toxic contaminants frequently cause the water to smell bad. To keep the water scented fresh, effective wastewater treatment methods include the use of iron salts, biofiltration, oxidants, and other technologies.

· Cleaning and de-greasing chemicals

Water in a wastewater treatment plant includes oil and grease residue that must be processed before being released back into the environment. Solvent chemicals can aid in the breakdown of grease, making it easier to eliminate.

· Chemical oxidation process

Chemical oxidation is a process used in wastewater engineering to convert pollutants into less harmful compounds. This contributes to the purification of surface waters. To reduce the impact of hydrogen peroxide, chlorine antibiotics, and other compounds in the water, reducing agents such as sodium bisulfite, sodium hydrosulphite, and other chemicals are used.

· Use of de-foamer and anti-foamer for wastewater

A defoaming agent is a chemical preservative that aids in the reduction of trapped air and foam produced during the wastewater treatment process. Defoaming agents dissolve existing foam, while antifoaming agents prevent new foam from forming. The most common application of silicone is as a defoaming agent.

A well-planned layout helps in the conservation of energy and reduces chemical consumption

What are the effluent treatment systems? 

The effluent treatment systems are machines and processes used to remove pollutants from wastewater. The main types of effluent treatment systems are biological, chemical, and physical. Effluent treatment systems are used to clean water before it is discharged into the environment.

The effluent treatment facility is installed for the biological treatment of the effluents. The effluent bears large amounts of organic matter. The direct discharge of the effluent into the water bodies causes depletion of DO of the water. Hence, in order to meet the recommended standards of quality of the effluent, it is necessary to treat the effluent before it is finally disposed of. This treatment facility provides for the removal of major pollutants from the effluent.

People Also ASK

What are the primary purposes of wastewater treatment plants?

The primary purposes of wastewater treatment plants are to remove contaminants from water and to produce water that meets quality standards for the reuse of water in processes and operations.

Which chemicals are used in effluent treatment as coagulants?

General and 7 most used coagulants in the water treatment plant is under:

  1. Alum (aluminum sulfate), Al2(SO4)3. Still, the most common coagulant in the United States, it is often used in conjunction with cationic polymers.
  2. Poly aluminium chloride, Al(OH)x(C1)y. This is efficient in some waters, requiring less pH adjustment and producing less sludge. (simply called PAC)
  3. Ferric chloride, FeCl3. This may be more effective than alum in some applications.
  4. Ferric sulfate, Fe2(SO4)3. It is effective in some waters and more economical in some locations.
  5. Ferrous Sulfate, FeSO4. It costs a bit more compare with ferric chloride, but the result would be better than that
  6. Sodium Aluminate, Na2Al2O4
  7. Cationic polymers can be used alone as the primary coagulant or in conjunction with aluminum or iron coagulants.

Nowadays most of plants are using Cationic polymers, and the cost is high compared with inorganic coagulants. But it can be used with a wider pH range and produce less sludge.

The choice or selection of a coagulant chemical depends upon the nature of the suspended solid to be removed, the raw water conditions, the facility design, and the cost of the amount of chemical necessary to produce the desired result.

Which chemicals are used in effluent treatment as flocculants?

To select a flocculant, consider the following factors:

  1. Type of suspended particles: Different flocculants are effective for different types of particles, so it’s important to identify the composition of the particles to be treated.
  2. pH level: The pH level of the water or wastewater can impact the effectiveness of the flocculant, so it’s important to determine the pH level before selecting a flocculant.
  3. Dosage: The dosage of flocculant needed will depend on the concentration of suspended particles and the desired level of clarification. Lab testing should be conducted.
  4. Compatibility with other chemicals: If other chemicals are being used in the water or wastewater treatment process, it’s important to select a flocculant that is compatible with these chemicals to avoid any negative impacts.
  5. Cost: The cost of the flocculant is an important consideration, especially for large scale operations.
  6. Environmental impact: Consider the environmental impact of the flocculant, including any potential toxicity and biodegradability.

How Advance Chemicals can help in your quest to find the right Effluent Treatment chemicals or Waste Water Treatment Chemicals?

A variety of effluent treatment chemicals are available to help you manage wastewater and industrial effluents. These chemicals can be used alone or in combination, depending on the specific needs of your plant.

Some common types of effluent treatment chemicals include alkalinity adjusters, disinfectants, odour control agents, solvents, and flocculants. Depending on the type of pollutant being treated and the severity of the situation, a range of treatments may be necessary (from simple maintenance procedures to more extensive engineering solutions).

Our team of experts, who specialize in environmental protection, will analyse the wastewater streams both qualitatively and quantitatively. On basis of the analysis, we will recommend stage-wise chemical inputs and will ascertain the adequacy of the installed equipment as well. We will be able to predict the outcomes with up to 99% accuracy.

We boast of a vast research-based manufacturing unit and thus have a state-of-the-art laboratory facility. We can even customize chemicals to suit your best needs.

Reducing Fluff Generation on Paper Machines: The Benefits of Specialty Chemicals

Introduction

Advance Chemicals (AC) manufactures and supplies a wide range of paper machine chemicals that improve paper quality and machine efficiency. Our products include retention aids, drainage aids, and machine speed and quality improvers. 

In this blog post, we will focus on the benefits of using specialty chemicals to reduce fluff generation on paper machines. Fluff is a common problem on paper machines, and it can cause a number of issues, including decreased machine efficiency, paper quality problems, and process upsets. 

Using specialty chemicals is an effective way to reduce fluff generation and improve paper machine performance. AC’s retention aids and drainage aids improve paper quality and machine efficiency by reducing fluff generation. In addition, our machine speed and quality improvers help keep paper machines running at peak performance. 

If you are experiencing fluff problems on your paper machine, we invite you to contact us to learn more about our specialty chemicals and how they can help you improve paper machine performance. 

What is fluff and why is it a problem?

Fluff is a type of non-fibrous material that accumulates in paper machines due to the presence of deposits and waste material in the pulp. It is composed of fillers and other materials that are not picked up by the drainage wire but still manages to pass through the press section. Fluff is a major issue in papermaking, because it can reduce the efficiency of the paper machine and negatively impact the quality of the final product. Fluff can cause a number of problems, such as process upsets and decreased paper strength. It can also lead to paper quality problems, such as linting, streaks, and product defects. Additionally, fluff can lead to reduced machine efficiency, because it absorbs moisture and reduces the overall throughput of the machine.  

The benefits of specialty chemicals

 Specialty chemicals can reduce fluff generation on paper machines and improve paper quality and machine efficiency. These chemicals are designed to reduce retention and increase drainage in the papermaking process, which minimizes the amount of fluff that accumulates on the paper machine. Retention aids, used in conjunction with drainage aids, help improve formation of the paper sheet and decrease fluff accumulation. Retention aids help capture and retain fillers in the papermaking process, which reduces the amount of fluff that is generated. Drainage aids, on the other hand, help reduce the amount of fiber that is lost during the papermaking process, which also reduces fluff generation. In addition, AC’s Machine Speed and Quality improvers help minimize fluff generation by controlling the flow of fillers and other materials. These products help keep paper machines running at peak performance, while also minimizing fluff and improving paper quality. 

How to reduce fluff generation with specialty chemicals

 Reducing fluff generation on paper machines is a multi-faceted process. The first step is to identify the sources of the fluff. This can be done by analysing the pulp stream and making adjustments to the process accordingly. Once the source of the fluff has been identified, it is important to use suitable specialty chemicals to improve the drainage and retention on the paper machine. Retention aids should be used to capture and retain fillers in the papermaking process, while drainage aids should be used to reduce the amount of fibers lost to fluff. In addition, AC’s Machine Speed and Quality improvers can help minimize fluff generation by controlling the flow of fillers and other materials. 

Conclusion

Fluff can have a serious impact on paper machine efficiency and paper quality. Reducing fluff generation is essential for achieving optimal performance on paper machines, and this is where specialty chemicals come into play. APC manufactures a wide range of specialty chemicals that can reduce fluff generation and help improve paper quality and machine efficiency. Our products include retention aids, drainage aids, and machine speed and quality improvers. If you are experiencing fluff problems on your paper machine, we invite you to contact us to learn more about our products and how they can help you reduce fluff generation and improve your paper machine performance.

Paper Sizing Agents – Roles and Significance

Surface sizing agents are materials that are applied to the surface of paper to improve its strength and printability. These agents work by creating a barrier on the surface of the paper that helps to protect it from moisture and other environmental factors. This barrier also helps to improve the surface strength of the paper, making it more resistant to tearing and other forms of damage.

Additionally, surface sizing agents can improve the printability of paper by creating a smoother and more uniform surface that is better suited for printing.

There are several different types of surface sizing agents that are commonly used in papermaking. Some of the most common include:

  1. Starches: Starches are natural polysaccharides that are derived from plants. They are commonly used as surface sizing agents because they are readily available and relatively inexpensive. Starches are also biodegradable, making them an environmentally friendly choice.
  2. Synthetic polymers: Synthetic polymers such as polyvinyl alcohol (PVA) and polyacrylamide (PAM) are also commonly used as surface sizing agents. These materials are known for their superior strength and durability, making them a popular choice for high-performance paper applications.
  3. Rosin: Rosin is a natural resin that is derived from pine trees. It is commonly used as a surface sizing agent in papermaking due to its ability to improve the strength and printability of paper.
  4. Casein: Casein is a protein that is derived from milk. It is used as a surface sizing agent in papermaking due to its ability to improve the strength and printability of paper.
  5. Alkyl ketene dimer (AKD): AKD is a synthetic wax that is used as a surface sizing agent in papermaking. It improves the strength and printability of paper.

The choice of surface sizing agent will depend on the specific application and the desired properties of the end product. Some paper manufacturers may use a combination of different surface sizing agents to achieve the desired properties.

In conclusion, Surface sizing agents are materials that are applied to the surface of paper to improve its strength and printability by creating a barrier on the surface of the paper that helps to protect it from moisture and other environmental factors. Starches, Synthetic polymers, Rosin, Casein and Alkyl ketene dimer (AKD) are some of the common surface sizing agents used in papermaking. The choice of surface sizing agent will depend on the specific application and the desired properties of the end product.

At Advance Chemicals we offer Sizing agents covering Fortified Rosin, AKD, and both cationic and Anionic Version of Surface Size Agent.

Retention and Drainage Program in the Paper Industry: Advance Chemicals’ Solution

In the paper industry, the retention and drainage program is a critical aspect of the papermaking process. The goal is to maximize the retention of fibers and fillers, minimize the number of fines and debris, and improve the drainage rate of the paper machine. This results in a higher-quality paper with improved strength, brightness, and overall appearance.

Advance Chemicals is a leading provider of retention and drainage solutions for the paper industry. The company offers a comprehensive program designed to improve the efficiency of the papermaking process and produce high-quality paper.

The retention and drainage program by Advance Chemicals is based on a combination of advanced chemical technologies, process optimization, and expert application support. The program includes a range of products specifically designed for the paper industry, including retention aids, drainage aids, and coagulants.

Retention aids are chemicals that are added to the papermaking process to increase the retention of fibers and fillers. They help to prevent fines and debris from escaping the paper machine and promote the formation of a uniform sheet. Drainage aids are added to the process to improve the flow of water and reduce the formation of debris, resulting in a faster drainage rate and a cleaner sheet.

Coagulants are used to control the charge of the fibers and fillers in the papermaking process. They help to prevent the formation of flocs and promote a uniform sheet. The coagulants used in the retention and drainage program by Advance Chemicals are carefully selected to minimize any negative impact on the papermaking process and produce a high-quality product.

In addition to the chemical products, Advance Chemicals also provides expert application support. The company’s experienced technicians work with papermakers to optimize the process, providing advice on product selection, dosages, and application methods. This ensures that the retention and drainage program is tailored to the specific needs of each customer and produces the best results.

In conclusion, the retention and drainage program by Advance Chemicals is a comprehensive solution designed to improve the efficiency of the papermaking process and produce high-quality paper. The program combines advanced chemical technologies, process optimization, and expert application support to deliver the best results for papermakers.

Paper Strength

When it comes to increasing the strength of paper apart from changing fiber quality, there is no better solution than using resins. There are two main types of resins that are used to improve the strength of paper: wet strength and dry strength resins. They provide different benefits and can both be used to improve the strength of paper.

At Advance Chemicals, we specialize in providing strength resins that will improve the strength and durability of paper products. Our wet strength resin (ACCO 0917) are designed to increase the burst factor of paper, meaning that the paper will be able to withstand more pressure without bursting or tearing. This makes it ideal for paper products that may be exposed to moisture or other liquids.

Our dry strength resins (ACCO 0911, 0913, 0915) are designed to increase the burst and tear factor of paper. This makes paper products more resistant to tears and prevents paper from becoming too brittle. This makes it perfect for products that may be exposed to extreme temperatures or situations where the paper may be subjected to a lot of wear and tear.

No matter what your paper strength needs are, Advance Chemicals has the perfect strength resin for you. Our strength resins have been specifically designed to improve the strength of paper products so that they can handle any pressure or wear and tear that they may be subjected to. With our strength resins, you can be sure that you are getting the most out of your paper products.

So, if you are looking for a way to improve the strength of your paper products, look no further than Advance Chemicals. Our strength resins are designed to help you get the most out of your paper products. With our strength resins, you can be sure that your paper products will be able to withstand any pressure or wear and tear that they may be subjected to and will remain strong for a long time.

Alkyl ketene dimer – New Age Paper Sizing

Structure of the AKD derived from palmitic acid

Structure of the AKD derived from palmitic acid

Alkyl ketene dimers (AKDs) are a family of organic compounds based on the 4-membered ring system of oxetan-2-one, which is also the central structural element of propiolactone and diketene. Attached to the oxetane ring of technically relevant alkyl ketene dimers there is a C12 – C16 alkyl group in the 3-position and a C13 – C17 alkylidene group in the 4-position.

The main application of alkylated ketene dimer is in the sizing of paper and cardboard, as well as in thhydrophobization of cellulose fibers. The products thus modified are distinguished by higher mechanical strengths and less penetration of water, inks, or printing inks.[1]

AKD’s feature hydrophobic alkyl groups extending from a beta-propiolactone ring. A specific example is derived from the dimerization of the ketene of stearic acid. This ketene is generated by pyrolysis of stearoyl chloride.[2] AKD’s react with the hydroxyl groups on the cellulose via esterification reaction. The esterification is competitive with hydrolysis of the AKD. Prior to the development of AKD’s, hydrophobicity was imparted by incorporating rosin into the paper.

Related to AKDs, is alkenyl succinic anhydride which is another substitute used in sizing applications (ASA). As for AKDs, ASA reacts with hydroxy groups of the cellulose to form an ester, anchoring the hydrophobic group to the surface. ASA is prepared by thendne reaction of unsaturated hydrocarbons with maleic anhydride.

A continuous process in which long-chain carboxylic acid chloride and tertiary amine (e. g. dimethyl isopropylamine, dimethylcyclohexylamine or triethylamine) is supplied separately without solvents to a tube reactor, kneader or preferably a twin-screw extruder or planetary roller extruder and reacted at temperatures between 90 and 110 °C, delivers lactone contents of over 90% at short reaction times. Processing is carried out by phase separation or acidic extraction.[19]

 

Alkylated ketene dimers as paper sizing agents

The problems with the acidic (aluminum sulfate-mediated) mass sizing of paper with alkaline-digested colophony resins introduced since the early 19th century led beside the use of alkaline flocculants (such as chalk or calcium carbonate as the alkali reserve) to the search for alternative materials for sizing in a neutral or alkaline environment. In addition to the significantly more reactive alkenyl succinic anhydrides (which do also hydrolyze rapidly in the presence of water) alkylated ketene dimers were preferred surface and mass sizes in the paper industry from the 1960s onwards.

 

Industrially applied AKDs are derived from fatty acids with chain lengths between C14 (myristic acid) to C22 (behenic acid); palmityl (C16) diketene and stearyl (C18) ketene and mixtures thereof are preferably used, as well as fatty acid mixtures from the hydrolysis of animal and vegetable fats. Because of the chain length of the original fatty acids, AKD are waxy solids with melting points between 42oC and about 70 °C. Mixtures of alkylated ketene dimers and water are dispersions at temperatures below 40 °C or emulsions at temperatures above 45 °C. Liquid AKDs are widely used, they are based on unsaturated fatty acids like oleic acid or branched fatty acids, like iso-stearic acid.

Aqueous alkyl diketene dispersions generally contain 10-20 wt% of AKD, as well as active protective colloids (particularly polycations such as cationic starch, copolymers of N-vinylpyrrolidone and quaternized N-vinylimidazole, acylated polyethyleneimines or cationic high molecular weight polyacrylamides with an average molar mass up to 7 million g/mol) and other stabilizers (usually anionic surfactants, for example, lignin sulfonates or condensation products of naphthalene-sulfonic acid sodium salt and formaldehyde). Such stabilized AKD dispersions are active and stable at room temperature for up to three months and also tolerate the addition of different fillers for paper or cardboard (e.g. kaolin, chalk, talc, titanium dioxide, calcium sulfate, aluminum oxide, etc.) from 5 to 25%. The amounts of alkyl ketene dimers used for the sizing of paper and paper products are preferably in the range from 0.15 to 0.8 wt%, sometimes from 0.05 to 0.2 wt%, based on the dry paper stock.

 

Paper sizing with alkylated ketene dimers

For paper sizing with AKD, a three-step process was proposed which, despite controversial discussions in the 1990s, seems to describe the processes that are taking place. 

Decisive criteria for the quality of the hydrophobicity of papers are

  1. The retention of the AKD particles on the wet paper mass on the paper screen
  2. The spreading of the AKD particles on the surface and the penetration in the paper mass
  3. The chemical reaction of the hydroxyl groups of the cellulose (esterification) with the alkylated ketene dimers to form beta-ketocarboxylic esters.

The molecular structure (i.e., molar mass and cross-linking degree), the molar charge density of cationic groups, the exact dosage of the cationic polymer as a dispersion stabilizer and retention aid as well as keeping the other process parameters such as temperature, pH and residence times is crucial.

After removal of excess water – also to avoid hydrolysis of the AKD to the beta-keto acid and subsequent decarboxylation to the ketone –

follows the cracking of the stabilized AKD particles on the base paper mass, the melting of the solid AKD wax (at approx. 90 °C), the spreading of the liquid AKD wax by surface diffusion on the cellulose fibers, and the formation of closed hydrophobic layers. The thickness of the hydrophobic layers depends on the AKD concentration in the dispersion.

Ad 3. The hydrophobization of cellulose fibers with alkylated ketene dimers takes place most effectively in neutral or preferably weakly alkaline media (pH 7.5-9.0). The reaction temperature is generally 90-110 °C, with approximately 40% of the AKD used reacting with the cellulose. After the reaction contact angles of >100° are measured, indicating the hydrophobic character of the AKD-modified model surfaces. The esterification of hydroxyl groups of cellulose fibers was also demonstrated by comparison reactions with 14C-labeled AKD.

The sizing with AKD is suitable for the permanent hydrophobization of newsprint, printing and writing paper and cardboard used as a container for liquids (including foodstuffs such as milk), as well as for the improvement of shape stability and runnability.

Commercial Production

At Advance Chemicals, undergoing robust testing frequently, the production of AKD is strictly under defined and controlled conditions thus giving out world call AKD for application in various grades of paper making.

 

Advantages and Disadvantages of Silicone Defoamers

Industry production and defoaming processes are closely connected. Preventing or controlling is crucial when working in different industries involving aqueous solutions or adhesives. Foaming could influence the appearance and effectiveness of the product, coating weight, increase manufacturer times and expenses, diminish product quality, the flow speed of liquid, and many more other factors.

Advance Chemicals ACCO 0941 silicone-based defoamer is designed to knock down the foam and effectively control and minimize production applications, which could save processing time and money. Our Silicone Based Defoamers are suitable for application in food and beverage, chemical, plastics, pulp and paper, oil and gas, metalworking, construction, and others.

Defoaming agents can effectively remove and suppress the formation of foam. The Silicone-based defoamers are versatile, practical, and economical solutions for controlling foam.

Silicone-based defoamers are ingrained with silicon key ingredients that might be more effective than oil or water-based emulsion. Silicone antifoams are used in processes that involve liquid-gas contact and agitations with the end goal of optimizing manufacturing throughput and productivity.

 

Before you choose an Antifoaming Chemical, it is imperative to peek into its pros and cons.

Advantages of Silicone Based Defoamers

 

  • Wide applications

Due to the chemical structure of silicone oil, it is insoluble in various applications and can be used in myriad industrial uses. It can be blended in oil systems as well as defoaming water systems.

 

  • Lower surface tension

Lower surface tension translates to higher defoaming efficiency. The surface capacity of silicone oil is 20-21 dynes/cm, lower than that of water 72 dynes/cm.

 

  • Thermal stability

An ordinary dimethicone can resist about 150 degrees Celsius for a long time and 300 degree Celsius for a short time, and the Si-O bond does not deteriorate. The silicone defoamer can be used over a wide range of temperatures.

 

  • Good chemical stability

The chemical stability is high, and it’s gruelling to react with other substances. Silicone defoamers can be blended with acids, bases, and salts as their formulation is reasonable.

 

  • Physiologically inert

The properties of silicone oil are non-toxic to humans and animals when added with a semi-lethal dose of more than 349mg/kg of body weight. Therefore, silicone defoamers can be used in food, medical, pharma, cosmetic, and other industries.

 

  • Powerful defoaming

Silicone defoaming breaks the foam, significantly inhibits the foam, and avoids the formation. It is used in small amounts, one part per million of the weight of the foaming medium. It’s not only low cost but also does not pollute defoamed material.

 

Disadvantages of Silicone Based Defoamers

 

  • Poor durability

Silicone-based antifoam is relatively poor durability.

 

  • Oil-soluble

Silicone is oil soluble, and it reduces the defoaming effects in oil systems.

 

  • Temperature resistance

It is not ideal for long-term high-temperature resistance and strong alkali resistance.

 

High-grade silicone defoamer

Advance Chemicals is a defoamer chemical supplier; with unrivaled experience and unparalleled experience, our company has products suitable for all walks of life. We offer food-grade, tech-grade, and agriculture antifoams with various viscosities that are ready to use and concentrated ones.

 

Advance is synonymous with good service and punctual delivery. With a solid customer base, we are the leader in the market for water treatment chemicals as well.

We are renowned as one of the most reliable Pulp & Paper chemical suppliers in India, and offer a range of specialty chemicals.

 

 

Difficulties for persistent control of foam in pulp operations

 

Pulp and paper makers need to reduce excessive foam created in the pulping process, when extracting cellulose fibers from wood, and during the washing process when making products such as Kraft brown-stock. Also due to various contaminants, foam is a permanent trouble during recycling operations. To process, manufacturers use foam control formulations, ‘antifoams’ or ‘defoamers’. To be competitive, pulp manufacturers are constantly seeking to lower costs and to use less water, energy and chemicals. Also to minimize their impact on the environment.

In all these respects, silicone-based antifoam formulations outperform mineral-based products, being easier to use – and at lower dosage – to produce better quality pulp. Silicones provide both greater and more rapid knockdown, and more persistent control of foam, and are stable across the extreme pH and temperature conditions needed to make pulp.

 

A long experience in foam control agents

Advance Chemicals has been helping major clients in Asia for more than 15 years, by continuing to develop our full-range of cutting-edge ACCO range foam control agents, formulations and processing aids.

Our experts work closely with the Pulp and Paper Industry to provide them upstream support by advising on use of the right products in the most efficient way for cost-effective and environmentally safe processes.

 

ACCO​ foam control agents are a comprehensive and highly effective portfolio of products available in different forms, such as compounds and emulsions.

 

A persistent foam control agent

ACCO 0941 is an innovative foam control agent, based on a highly-active silicone compound. Advance Chemicals has specifically designed ACCO 0941 to be the foam control agent of choice for several industries. ACCO 0941 meets all essential criteria in terms of productivity, reliability and quality, to reduce total cost of operations. Benefits include:

  • Excellent foam knock-down
  • Persistent foam control
  • Lower dosage compared to mineral oil-based antifoams
  • Enhanced efficiency of pulp washing
  • Improved drainage of pulp
  • Ease of use
  • Reduced consumption of chemical additives

In case of any technical query related to foaming or related to Pulp & Paper Specialty Chemicals kindly drop us an email of info@advancechemicals.in or submit the form through www.advancechemicals.in

Difficulties for persistent control of foam in pulp operations

Pulp and paper makers need to reduce excessive foam created in the pulping process, when extracting cellulose fibers from wood, and during the washing process when making products such as Kraft brown-stock. Also due to various contaminants, foam is a permanent trouble during recycling operations. To process, manufacturers use foam control formulations, ‘antifoams’ or ‘defoamers’. To be competitive, pulp manufacturers are constantly seeking to lower costs and to use less water, energy and chemicals. Also to minimize their impact on the environment.

In all these respects, silicone-based antifoam formulations outperform mineral-based products, being easier to use – and at lower dosage – to produce better quality pulp. Silicones provide both greater and more rapid knockdown, and more persistent control of foam, and are stable across the extreme pH and temperature conditions needed to make pulp.

 

A long experience in foam control agents

Advance Chemicals has been helping major clients in Asia for more than 15 years, by continuing to develop our full-range of cutting-edge ACCO range foam control agents, formulations and processing aids.

Our experts work closely with the Pulp and Paper Industry to provide them upstream support by advising on use of the right products in the most efficient way for cost-effective and environmentally-safe processes.

 

ACCO foam control agents are a comprehensive and highly effective portfolio of products available in different forms, such as compounds and emulsions.

 

A persistent foam control agent

ACCO 0941 is an innovative foam control agent, based on a highly-active silicone compound. Advance Chemicals has specifically designed ACCO 0941 to be the foam control agent of choice for several industries. ACCO 0941 meets all essential criteria in terms of productivity, reliability and quality, to reduce total cost of operations. Benefits include:

  • Excellent foam knock-down
  • Persistent foam control
  • Lower dosage compared to mineral oil-based antifoams
  • Enhanced efficiency of pulp washing
  • Improved drainage of pulp
  • Ease of use
  • Reduced consumption of chemical additives

In case of any technical query related to foaming or related to Pulp & Paper Specialty Chemicals kindly drop us an email of info@advancechemicals.in or submit the form through www.advancechemicals.in

Paper Machine Runnability – Retention Aid

Retention Aid is the key to cost savings in a paper mill. Retention aids are used at the wet end of a paper mill to improve the retention of fine particles, fillers, additives & sizing agents during the formation of paper. Particularly retention aid is needed to be added in the alkaline paper-making process, but not in the acidic paper-making process because in this process alum helps in retention. Modern paper-making technology is an alkaline paper-making process. Moreover, modern mills operate high-speed paper machine with increased usage of recycled fibers. In this case, the task of retaining is more challenging and paper machine runnability will be troublesome. As a result, the papermaking process becomes less economical. Hence the demand for retention aid is increased to save costs.

The chemical most used as retention aids are polyacrylamide and polyethyleneimine.

Troubles of low retention:

Papermaking is in essence a filtration process. The paper machine wire cloth can be considered as a continuous filter; where a proportion of the solids in the stock is retained and some fine particles are drained through the wire cloth mesh with water and formed white water. The greater part of the white water is returned to the stock, with the result that the concentration of fines and fillers gradually increases. It should be retained otherwise following troubles arise:

  • Fine fiber particles and filler drainage
  • Higher additives and sizing cost
  • Increased deposits
  • Decreased runnability
  • More downtime for cleaning
  • Filling of wet-press felts
  • Bad paper sheet formation
  • Higher sewer losses

 

The function of retention aids

The best retention of fine particles and colloids in the papermaking process normally occurs when the zeta potential is near to zero and retention aid takes care of that. The main functions of retention aids are the following:-

  • Accelerate drainage, hence increasing machine speed
  • Improved retention of fines and fillers
  • Reduced wet-end additives and sizing usage
  • Reduced steam usage due to better surface contact
  • Reduce deposits
  • Reduce sheet breaks
  • Improves paper machine runnability
  • Improved paper sheet formation
  • Increased brightness
  • Cleaner white-water system
  • Reduce downtime for cleaning
    Overall, Increase the productivity

 

Disadvantages of retention aid

If retention aid is used in higher doses, as a result highly flocked sheet is formed. Also, observed are increased paper web break, two-sidedness, and decreased paper machine runnability. Hence to optimize runnability the dosing needs to be optimized.

Importance of Sizing Agents for Paper Making

Introduction

The papermaking process is highly cost-sensitive and the market is extremely competitive. Specialty chemicals have been developed and applied in to assure an efficient process and meet specific end-use paper requirements.

Paper can be classified according to different criteria, either by weight, color or raw material source. Here we talk about woodfree paper, which is a paper made from chemical pulp, without lignin. With woodfree paper, the final performance depends on the quality of the fibrous matrix and the properties of the surface. The surface characteristics are controlled by surface treatments which aim to give specific qualities to the paper, according to its purpose.
Surface treatments are divided into two types:

  1. Mechanical, like calendaring, or 
  2. Chemicals such as coating and surface sizing.

Calendaring and surface sizing are the treatments used while the coating is more common in magazine paper or photographic paper.

Why talk about sizing?
Existing studies on surface sizing focus on evaluating the surface quality of paper, after the application of different solutions, through surface characterization techniques such as contact angle measurement or inverse gas chromatography.

The lack of works exploring surface sizing in a more industrial context contributes to the importance and applicability of the present study. The complexity of the paper structure and the presence of various components make this system quite complex. Thus, to establish a possible process optimization and, consequently, a final improvement of paper characteristics, it is essential to understand the interactions between the various components present in this stage of production.

The Process

For surface sizing, a solution composed mainly of starch is applied to the surface of the paper sheet.

Regarding technology, film size press is the most used, in which a film of the solution is transported and applied to the paper surface by the applicator rollers. This technology allows an independent application of the solution to each side of the paper. Usually, solids content,  viscosity, and temperature are the process control parameters. The penetration of the solution into the paper structure and its uniform surface often determines the printing quality.

The behavior of a liquid on a surface is crucial for homogeneous film formation processes, where properties such as contact angle and surface tension play an important role. Thus, the present work intends to give a deeper understanding of the interactions between the surface sizing solution and the paper surface. More specifically, it aims to measure the contact angle and the surface tension of surface sizing solutions and to relate these properties to starch content and temperature.

What is Surface Sizing?

Surface sizing is a surface treatment whose main objective is to increase the bond between the fibers by filling the pores with a solution composed mainly of starch. This treatment is used to increase the surface resistance, stiffness, and printability, and to control the hydrophilic character of the fibers.

The surface sizing solution is composed typically of starch, sizing agent, optical brightening agents (OBAs), salt, and defoamers.

Starch is the main component of the solution and it acts as a binder to connect vessel segments and loose fibers at the surface. To be used properly, starch needs to be fully dissolved (cooked and disintegrated into amylose and amylopectin) through the process of cooking. Afterward, starch has to be modified to keep its rheological properties and to be protected against retrogradation. Enzymatic or thermal conversion is usually practiced to manipulate the viscosity of the starch solution. On the other hand, the introduction of other functional groups through chemical modifications such as oxidation, esterification, or nucleophilic substitution can give other properties to the starch.

Surface sizing agents are compounds containing hydrophobic groups that repel water molecules and prevent their absorption by the paper sheet. These agents, when combined with starch and applied to the paper surface, form a thin reticular film at the paper surface, impacting certain properties such as smoothness, surface resistance, and hydrophobicity.

For surface sizing, sizing agents can be cationic rosin, AKD, or synthetic polymer compounds like co-styrene maleic anhydride or co-styrene-acrylate. While cation rosin and AKD are preferably applied at the wet end, syntenic polymer compounds were specially designed for surface sizing. Compared to the other available sizing agents, polymer compounds are extremely versatile and compatible with all types of starch, and in some cases, do not need defoamers.

To improve the optical properties of the paper surface, like brightness and whiteness, optical brightening agents are usually applied in surface sizing. There are three types of OBAs used in the paper industry, all based on stilbene molecules. The difference between each one lies in the number of sulfonic substituents, which in turn affect their properties. In general, the whitening effect, solubility, and price increase with the number of sulfonic substitutes, while the affinity to the fibers decreases.

Due to the current high-speed rate of production, together with the heat and friction between the paper and the metal parts of the machine, a favorable environment is created for static electricity to accumulate in the materials. This has serious risks such as production downtime or equipment damage. To overcome the problem is usual to add mono or divalent salt to improve the paper surface conductivity. The addition of a divalent salt, such as calcium chloride, further improves printing quality by enhancing the sharpness of colors on paper.

Defoamers are usually present on surface sizing solutions as a process chemical rather than a functional chemical. Foam is associated with operational problems, reduced efficiency, and surface defects in surface treatments and must be controlled. Defoamers are sophisticated formulations made up of extremely water-insoluble surfactants with the ability to spread rapidly to gas/liquid interfaces, destabilizing the foam lamellae previously stabilized by other surfactants.

Surface sizing performance is affected by the properties of the applied aqueous solution such as composition, viscosity, or temperature, as well as the properties of the paper sheet such as weight, moisture content, porosity, and surface energy, among others. These properties should be adequately controlled to ensure the desired absorption of the aqueous solution into the sheet.

Our range of Sizing Agents be it AKD, Fortified Rosin, Cationic or Anionic Surface Sizing Agent are engineered to cater to all of the aspects mentioned above and ensure smooth runnability of paper machine.

The products codes are as below, and the codes are clickable so that you get the technical details of each product:

  1. ACCO – 0921 – Anionic Surface Size
  2. ACCO – 0922 – Cationic Surface Size
  3. ACCO – 0924 – AKD Emulsion
  4. ACCO – 0925 – Fortified Rosin