WO1998045102A1 - Method for modifying papermaking sludge and products made therefrom - Google Patents

Method for modifying papermaking sludge and products made therefrom Download PDF

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Publication number
WO1998045102A1
WO1998045102A1 PCT/US1998/006172 US9806172W WO9845102A1 WO 1998045102 A1 WO1998045102 A1 WO 1998045102A1 US 9806172 W US9806172 W US 9806172W WO 9845102 A1 WO9845102 A1 WO 9845102A1
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WO
WIPO (PCT)
Prior art keywords
dispersant
papermaking sludge
weight percent
sludge
sheet
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1998/006172
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English (en)
French (fr)
Inventor
James Jay Tanner
David Henry Hollenberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Original Assignee
Kimberly Clark Worldwide Inc
Kimberly Clark Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly Clark Worldwide Inc, Kimberly Clark Corp filed Critical Kimberly Clark Worldwide Inc
Priority to BR9814239A priority Critical patent/BR9814239A/pt
Priority to AU67849/98A priority patent/AU726654B2/en
Priority to JP54282898A priority patent/JP2001518853A/ja
Priority to CA 2284544 priority patent/CA2284544C/en
Priority to DE1998627272 priority patent/DE69827272T2/de
Priority to NZ500256A priority patent/NZ500256A/en
Priority to EP98913255A priority patent/EP1007310B1/en
Publication of WO1998045102A1 publication Critical patent/WO1998045102A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04Waste materials; Refuse
    • C04B18/18Waste materials; Refuse organic
    • C04B18/24Vegetable refuse, e.g. rice husks, maize-ear refuse; Cellulosic materials, e.g. paper, cork
    • C04B18/241Paper, e.g. waste paper; Paper pulp
    • C04B18/243Waste from paper processing or recycling paper, e.g. de-inking sludge
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/38Moulds or cores; Details thereof or accessories therefor characterised by the material or the manufacturing process
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/01Waste products, e.g. sludge
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H11/00Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
    • D21H11/14Secondary fibres
    • DTEXTILES; PAPER
    • D21PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21HPULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/06Paper forming aids
    • D21H21/08Dispersing agents for fibres
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02WCLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00Technologies for solid waste management
    • Y02W30/50Reuse, recycling or recovery technologies
    • Y02W30/91Use of waste materials as fillers for mortars or concrete

Definitions

  • this sludge While the composition of this sludge is variable, it generally consists of a mixture of wood pulp fibers and fines, and a combination of inorganic fillers that are used in some paper grades. These inorganic fillers are most often calcium carbonate and/or kaolin clays. It is possible that other clays can be present as well as amounts of titanium dioxide and other pigments and fillers and inks, but the major constituents are generally fiber/fines and the inorganic fillers calcium carbonate and clay.
  • sludges from deinking operations are dewatered prior to disposal because it reduces the weight of material going to the landfill and reduces the charges for landfill disposal because these are typically based on weight. Since the majority of the weight in the sludge comes from water, it behooves the sludge processor to remove as much water as possible. The resulting material typically is a crumbly, not very cohesive material that appears to be dry. At thirty percent consistency, most sludges are more like dry solids as opposed to a suspension or dispersion. Because of the non- cohesive character of sludge, the materials handling equipment for moving, storing and transporting are generally the same as for dry materials.
  • the prior art sets forth basically five different approaches for utilizing the sludge as a product: (1) Pelletizing the sludge using high pressure and binders where the sludge is dried before pelletizing.
  • the pellets can be used as absorbents or chemical carriers, e.g., fertilizer. Alternatively, large diameter pellets or cylinders are used as fuel.
  • the purpose for the added inorganic material is to provide superior opacity.
  • incorporation of clay as a coating or filler and calcium carbonate as a filler also provides improvements to the surface of the paper such that the quality of the printing is improved.
  • wood pulp even though it is a renewable resource, is becoming more expensive. The cost of wood pulp currently exceeds the cost of calcium carbonate or clay, and it therefore makes economic sense to include considerable amounts of these fillers in paper. All of these trends act together to provide increases in the amounts of waste materials in the form of sludge that will be generated in the future. Therefore there is a need for a commercially feasible method of utilizing papermaking sludge.
  • sludge from papermaking and/or paper recycling can be altered and controlled when mixed with a small amount of dispersant (hereinafter defined).
  • the cellulose fibers, cellulose fines, clays and fillers normally present in papermaking sludge have been agglomerated by the use of flocculants and dewatering polymers in the water treatment process that leads to the generation of papermaking sludge in a tissue mill.
  • papermaking sludge typically has a dry, crumbly texture even though it contains large amounts of water
  • the modified papermaking sludge of this invention has a consistency, appearance and feel (rheology) closely resembling modeling clay.
  • the modified sludge of this invention can be formed into a very thin cross section which has integrity and uniformity. This can be done by injection molding or profile or sheet extrusion in a manner similar to that used to form polymer or food products. Therefore, as a result of this invention, papermaking sludge can be modified and thereafter converted to a useful form of paper or other molded or extruded products.
  • the addition of the dispersant to the papermaking sludge acts as a deflocculant and effectively reverses the agglomeration of the cellulose fibers, fines, clays and fillers which took place in the tissue mill.
  • This desired reversal is not easily accomplished and is made more difficult by the minimal water level present in the papermaking sludge when deflocculation is initiated, therefore requiring high shear and mixing.
  • the initial distribution of water and particles is non uniform and the papermaking sludge is crumbly. After adding the dispersant and initial mixing of the crumbs, the loose agglomerates begin to grow.
  • the water and colloidal particles begin to redistribute and fill the interstices between the particles and to coat the exterior surfaces of crumbs with water films.
  • the crumbs grow by interaction and accretion and are increasingly worked or plastically deformed by the mixer.
  • the indicated viscosity rises irregularly.
  • the growing crumbs are gradually consolidated and there is increasing interchange among them by shear and tearing.
  • Large clumps form in the mixer that have a plastic character that exhibits a rather uniform viscosity within the clump.
  • the exterior surface condition of the large clumps allow them to be brought together where they readily cohere into larger clumps.
  • the desired condition to allow forming into a paper-like sheet is an empirical fine tuning between an insufficiently plastic mix which will tear or delaminate on passing through a die and a too compliant or incohesive mixture which will slump and not retain the extruded shape.
  • the quantity of dispersant added, moisture level of the sludge and mixing intensity/time and temperature are the controllable variables to obtain the fine tuning of the rheological properties.
  • the invention resides in a method of modifying papermaking sludge comprising adding from about 0.5 to about 20 dry weight percent of a dispersant to the papermaking sludge and mixing the dispersant and the papermaking sludge until the rheology of the mixture is substantially the same as that of modeling clay.
  • the modified sludge like modeling clay, exhibits changing rheological properties with temperature and liquid addition.
  • a rheology which is substantially the same as that of modeling clay is a rheology substantially the same as that of Roma Plastilina Grade No.1 gray/green modeling clay, commercially available from Sculpture House, 38 East 30 ,h Street, New York, New York, held at a temperature from 65° to 85°.
  • the papermaking sludge mixture behaves like modeling clay within this temperature range, it can be further processed into other products as described herein.
  • the invention resides in a modified papermaking sludge comprising from about 0.5 to about 20 dry weight percent of a dispersant, said modified sludge having a tensile strength (maximum stress at failure) of about 5 kilopascals or greater, more specifically about 10 kilopascals or greater, still more specifically from about 5 to about 70 kilospascals, and still more specifically from about 10 to about 35 kilopascals.
  • the modified sludge of this invention can also have a strain at failure of about 0.02 or greater millimeter per millimeter, more specifically about 0.03 or greater millimeter per millimeter, and still more specifically from about 0.02 to about 0.1 millimeter per millimeter.
  • a typical papermaking sludge has an estimated maximum stress at failure of only about 0.88 kilopascals.
  • the tensile test method and apparatus used to measure the tensile strength and strain are described in connection with Figures 5 and 6 herein.
  • the amount of dispersant added to the sludge can be from about 0.5 to about 20 weight percent or greater, more specifically from about 1 to about 12 weight percent, and still more specifically from about 2 to about 8 weight percent.
  • the invention resides in a method of making a paper sheet comprising: (a) combining papermaking sludge with a dispersant; (b) mixing the papermaking sludge and the dispersant; (c) forming the mixture into a sheet, such as by extruding and rolling the extruded material; and (d) drying the sheet.
  • the extrusion of the mixture and rolling the extrudate can be achieved using conventional extrusion and rolling equipment where the mass of malleable material is extruded into a uniform size continuous strand, ribbon or thick sheet.
  • the extrudate is passed through a nip or series of nips to further extrude it into a thin sheet.
  • the drying can be accomplished by using can dryers and passing the extruded sheet over the circumference of a series of heated rotating cans to vaporize the water. Drying of the sheet can be accelerated by impinging the sheet with high velocity hot air. Considerable shrinkage will occur during the drying and a calendering of the sheet may be needed to create a smooth sheet. The rate of water removal will be a function of the thickness of the sheet, the drying temperature and the adjacent air turbulence. Because of the unique form and composition of this production, other drying methods that would not be efficient for conventional paper, such as microwave drying, might find efficient application in the drying of products of the present invention.
  • the invention resides in a modified sludge composition
  • a modified sludge composition comprising from about 5 to about 60 weight percent cellulose fibers and fiber fragments (fines), from about 10 to about 50 weight percent inorganic material such as calcium carbonate and clays, from about 0.5 to about 20 weight percent dispersant, and from about 30 to about 70 weight percent water.
  • the invention resides in a dry (air dry) paper sheet comprising from about 5 to about 30 weight percent cellulose fibers of traditional papermaking length (greater than 1.0 millimeter), from about 1 to about 10 weight percent cellulose fiber fragments, from about 5 to about 30 weight percent calcium carbonate, from about 5 to about 30 weight percent clay, and from about 1 to about 30 weight percent dispersant.
  • the dry paper sheet of this invention is much weaker in tensile strength for comparable basis weight than conventional papers due to the absence of significantly high quantities of long cellulosic fibers. It also has lower stretch properties than normal paper stocks such as writing or copier paper. However the tensile properties are not directional.
  • the sludge paper surface is very tightly bonded and any inorganic materials are not free to shake loose, it readily accepts ink and provides a sharp edge to an ink line, which is needed for direct printing of complex graphics on paper or board stock.
  • the paper does not readily redisperse in water from its dry state. It is more brittle and less porous than conventional paper. The density is higher than typical paper and the bulk is lower.
  • the paper sheets of this invention can substitute for light or heavyweight printing papers, newsprint, linerboard, corrugating medium, S2S, clay coated board such as carton board and packaging materials. The paper sheet value exceeds the costs of processing and alternative disposal.
  • composition of the papermaking sludge there is an organic portion, an inorganic portion and water.
  • the amount of water in the sludge can be from about 30 to about 70 weight percent, more specifically from about 40 to about 60 weight percent.
  • the organic portion of the papermaking sludge comprises cellulose fibers and fines and can be from about 5 to about 40 weight percent, more specifically from about 10 to about 35 weight percent, and still more specifically from about 15 to about 30 weight percent of the papermaking sludge. From about 10 to about 70 weight percent of the organic portion can be fiber fragments or fines. From about 30 to about 90 weight percent can be whole fibers or fibers having an average length of about 1 millimeter or greater.
  • the inorganic portion of the papermaking sludge can be from about 10 to about 65 weight percent, more specifically from about 30 to about 50 weight percent. From about 10 to about 90 weight percent, more specifically from about 20 to about 80 weight percent, and still more specifically from about 40 to about 60 weight percent of the inorganic portion can be calcium carbonate. From about 10 to about 90 weight percent, more specifically from about 20 to about 80 weight percent, and still more specifically from about 40 to about 60 weight percent of the inorganic portion can be clay. Suitable clay materials include kaolin clay or any sedimentary clay of colloidal size that is iron-free and has an AI 2 O 3 : SiO 2 mole ratio of about 1:2; e.g. Dickite, Halloysite and Nacrite.
  • a "dispersant” is a material that helps maintain fine solid particles in a state of suspension and inhibit their agglomeration or settling in a fluid medium. With the help of mechanical agitation, dispersants can also break up agglomerates of particles to form particle suspensions. Overall, dispersants are useful in preventing settling, deposition, precipitation, agglomeration, flocculation, coagulation, adherence or caking of solid particles in a fluid medium.
  • Suitable dispersants include: organic polyeiectrolytes including polycarboxylates, poiysulfonates, polysulfates and polyphosphates; inorganic sulfonates, polyphosphates and silicates; and polymers containing polar groups such as polyacrylamides and polyols.
  • Suitable synthetic polymer dispersants are the co-polymers of ethylenically unsaturated monomers with mono-ethylenically unsaturated carboxylic acids or their partially neutralized salts.
  • the preferred, ⁇ , ⁇ -monounsaturated carboxylic acids include acrylic acid, methacrylic acid, maieic acid, maleic anhydride, itaconic acid, itaconic anhydride, fumaric acid, half esters or half amides of maleic, fumaric and itaconic acid, crotonic acids, alkyl acrylates and methacrylates containing 1- 18 carbon alkyl groups, vinyl esters, vinyl aromatic compounds, dienes, etc.
  • Homopolymers of monethylenically unsaturated carboxylic acids or mixtures of these monomers may also be used.
  • Examples include acrylic acid and methacrylic acid homopolymers and acrylic acid/methacrylic acid copolymers.
  • polyacrylamides of use include polyacrylamides and polymethracrylamides and their N and N,N dialkyl derivatives containing 1-18 carbon alkyl groups.
  • Exemplary of the sulfonic acid containing polymer dispersants are the homopolymers of monoethylenically unsaturated sulfonic acids (or salts thereof) and copolymers thereof with the aforementioned ethylenically unsaturated monomers.
  • Suitable sulfonated containing monomers include aromatic sulfonic acids (such as styrene sulfonic acids, 2-vinyl ethylbenzenesulfonic acid, 2-vinyl-3-bromobenzenesulfonic acid, 2-allylbenzenesulfonic acid, vinylphenyi methanesulfonic acid), heterocyclic sulfonic acids (such as 2-sulfo-4-vinyl-furane and 2-sulfo-5-allylfurane), and aliphatic sulfonic acids (such as ethylenesulfonic acid and 1-phenylethylene sulfonic acid).
  • aromatic sulfonic acids such as styrene sulfonic acids, 2-vinyl ethylbenzenesulfonic acid, 2-vinyl-3-bromobenzenesulfonic acid, 2-allylbenzenesulfonic acid, vinylphenyi methanesulfonic
  • sulfonated polymers that have been found to be of value in bringing about changes in the rheology of the mixtures of interest include calcium lignosulfonates, formaldehyde modified napthalene sulfonates, sulfonated melamine-formaldehyde polymers and other sulfonated polymers.
  • Exemplary of natural polymers and their derivatives that have been found to be useful as dispersants in the present invention include the carboxylated, sulfonated and phosphated derivatives of cellulose and starch such as carboxymethyl cellulose and carboxymethyl starch and neutralized or partially neutralized salts thereof.
  • Other water soluble derivatives of cellulose and starch such as the hydroxyethyl and ethoxyiated celluloses and starches are also of use in the present invention.
  • Carbohydrate based materials such as corn syrups, maltodextrins, as well as naturally occurring carbohydrates (alginic acids, carrageenen, and gums such as arabic, algin, agar, ghatti, karaya, acacia, xanthan and chemically modified derivatives thereof).
  • Other carboxylated polymers have also been found to be of value in modifying the rheology of the clay-carbonate-wood pulp blends.
  • inorganic dispersants and rheology modifiers such as the condensed phosphates, and the silicates that are commonly used to disperse particulates in the water treatment and ceramics industries. These include tetrasodium pyrophosphate, sodium hexametaphosphate, and sodium silicate.
  • Figure 1 is a schematic illustration of a method of making a sludge sheet using a roller.
  • Figure 2 is a schematic illustration of a laboratory method for drying a sludge sheet.
  • Figure 3 is a schematic illustration of a continuous method of producing sludge paper.
  • Figure 4 is a schematic illustration of core profile extrusion of sludge.
  • Figure 5 is a schematic illustration of how the "dog bone" shaped sludge samples are prepared for tensile testing.
  • Figure 6 is a further illustration of a single sample prepared for tensile testing.
  • Figure 1 illustrates a method of rolling a quantity of sludge modified in accordance with this invention into a flat sheet. Shown is a quantity of hand rolled modified sludge 1 sandwiched between a top plastic sheet 2 and a bottom plastic sheet 3 supported on a flat surface (not shown). The modified sludge is flattened into a wet sheet 4 using a brass roll 6. This method is further described in connection with Example 1.
  • Figure 2 illustrates an alternative method of drying a modified sludge sheet as more fully described in Example 2. Shown is a steam heated platen 21, a wet, flattened modified sludge sheet 4 such as that illustrated in Figure 1 , a bottom plastic sheet 3 and a canvas cover 22 which is adapted to overlay the modified sludge sheet and apply tension while the sheet is drying.
  • FIG. 3 is a schematic illustration of a continuous method of making modified sludge sheets. Shown is a hopper/mixer 31 in which the sludge and dispersant are received and mixed, an extruder 32 which continuously feeds the mixture through a shaping die to produce the appropriate shaped extrudate 33, a pair of rollers 34 and 35 which provide a nip through which the extrudate passes and is flattened into a wet modified sludge sheet 36, a carrier and drying fabric 37 which supports the modified sludge sheet and carries it through the process, and drier rolls 38 and 39 which dry the modified sludge sheet to the desired moisture level, which is typically from about 1 to about 10 weight percent.
  • the dried modified sludge sheet 40 is peeled away from the support fabric after the dryer roll 39.
  • FIG 4 is a schematic illustration of an alternative method of making a sludge product, in which the sludge product is profile extruded into a desired shape such as the tube shape shown. Shown is the hopper/mixer 31, the extruder 41, the drying chamber 42, and the profile extrudate 43. Such a process is useful for making roll cores for bath tissue and towels, in which the dried tube 44 is cut into appropriate lengths for producing rolls of bath tissue.
  • the extrudate can be L-shaped to be used as corner supports. It will be understood that the number of possible shapes is unlimited, depending only upon the desired end use of the sludge product.
  • Figure 5 illustrates preparing "dog bone"-shaped samples of sludge materials for tensile testing.
  • An amount of a sludge sample to be tested is placed between two sheets of polyethylene film 51.
  • the sample is then rolled with a 22 pound brass rolling pin having a diameter of 125 millimeters and a width of 175 millimeters. The rolling is stopped when the flattened sample 52 has been reduced in thickness to about 0.060 inch.
  • the top sheet of polyethylene is removed and dog bone shaped tensile test specimens 53 are cut out using a knife blade, similar to cutting out cookies from rolled dough.
  • the length of the samples is about 60millimeters.
  • the maximum width (at the ends) of the samples is about 24 millimeters.
  • the minimum width (at the center) is about 8.5 millimeters.
  • Multiple tensile test samples can be cut from the sludge sample to provide meaningful average tensile values.
  • a small piece of Saran® wrap 54 is placed over each end of the sample, as illustrated in Figure 6, in order to prevent the sample from sticking to the testing machine clamps.
  • sample specimens are tested at room temperature by placing them in the Model 2712-001 pneumatic grips of an Instron Model 55 tensile machine with a 500 Newton loadcell and a gage length of about 38 millimeters and a grip pressure of 15 psi.
  • the specimen elongation rate is set at 10 millimeters per minute. The maximum stress and strain are measured at the instant failure occurs. Examples Examplel .
  • Samples of the papermaking sludge were obtained from a deinking mill where paper to be recycled (mixed office waste) was processed to remove both ink and inorganic fillers and coatings to create a pulp fiber useful for making tissues.
  • the solid waste stream coming from this mill contained about 50% moisture.
  • the inorganic portion of the sludge constituted about 55-60 percent of the solids and was a function of the feed stock coming into the mill.
  • the inorganic portion of the sludge was approximately 50% clay commonly used for coating of papers (kaolin) and 50% filler commonly used for paper (calcium carbonate).
  • the organic portion of the solids contained about 8% long fiber useful for papermaking.
  • the balance of the organic portion was predominantly cellulosic fines (materials that can pass through a 200 mesh screen).
  • the samples were taken from the deinking mill at the discharge of the conveyor that transports sludge from the screw press to the accumulation container. The samples were collected in clean 5 gallon buckets. The samples were refrigerated at 30°F. prior to use.
  • a smaller sample (about 500 grams) of the sludge was taken from the container of sludge and allowed to warm to room temperature (72°F.). The warmed sample was placed into the stainless steel bowl of a model K45SS Kitchenaid Mixer (4 quart) and mixed at the "stir" speed using the pastry dough agitator. 7.5 grams of polyacrylamide anionic dispersant (Cyanamer A-370 from Cyanamid Corp.) was added by sprinkling on the mixing sludge mass. This sprinkling was completed over approximately 20 seconds trying to keep the dispersant on the sludge and off of the bottom of the bowl.
  • Adequate mixing was accomplished in approximately 5 minutes of agitation and could be observed as the mass of sludge changed from several small pieces and particles to a single clay like mass.
  • the sludge changed from a crumbly, particuiate mass to a moldabie, clay like single mass.
  • a 20 gram sample of the siudge/dispersant mixture was briefly worked by hand into an approximate cylindrical shape (like a pencil) about 1.5 cm in diameter. This small sample was placed between 2 sheets of 5 mil high density polyethylene (HDPE) bag material. A 43 pound brass rolling pin (5 inch dia. X 7 inch) was used to roll the sample into a thin sheet as shown in Figure 1.
  • HDPE high density polyethylene
  • the top sheet of HDPE was carefully removed to allow moisture to escape from the sludge sheet.
  • the sheet was allowed to dry by evaporation into the room at ambient conditions (72°F and 50 RH). This yielded a dry sheet of sludge paper but with considerable warpage.
  • a second sheet sample was dried by an alternate method using a steam-heated brass platen (Valley Laboratory Equipment by Voith Serial No. 119-434 & 77062) as illustrated in Figure 2.
  • This hot platen has a convex curvature of approximately 21.5 inch diameter which allows a canvas sheet to be applied over the vented side of the paper sheet which restrains it during drying and precludes warpage.
  • Tension can be applied to the canvas at a level of from 4.75 to 18 pounds over a 9.8 inch width to create a restraining pressure of from approximately 0.045 psi to 0.17 psi .
  • the temperature of the brass platen is set by a continuous flow of saturated steam at 3.5 psi which is approximately 215°F.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Civil Engineering (AREA)
  • Sustainable Development (AREA)
  • Environmental & Geological Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Paper (AREA)
  • Treatment Of Sludge (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
PCT/US1998/006172 1997-04-08 1998-03-27 Method for modifying papermaking sludge and products made therefrom Ceased WO1998045102A1 (en)

Priority Applications (7)

Application Number Priority Date Filing Date Title
BR9814239A BR9814239A (pt) 1997-04-08 1998-03-27 Método para modificadar borra de fabricação de papel e produtos feitos de borra modificada de fabricação de papel
AU67849/98A AU726654B2 (en) 1997-04-08 1998-03-27 Method for modifying papermaking sludge and products made therefrom
JP54282898A JP2001518853A (ja) 1997-04-08 1998-03-27 製紙用スラッジ改質方法及びこれから製造された製品
CA 2284544 CA2284544C (en) 1997-04-08 1998-03-27 Method for modifying papermaking sludge and products made therefrom
DE1998627272 DE69827272T2 (de) 1997-04-08 1998-03-27 Verfahren zur herstellung von papier oder anderen in form hergestellten oder extrudierten produkten und ein so hergestelltes trockenes papierblatt
NZ500256A NZ500256A (en) 1997-04-08 1998-03-27 Method for modifying papermaking sludge and products made therefrom
EP98913255A EP1007310B1 (en) 1997-04-08 1998-03-27 Method of making paper or other molded or extruded product and a dry paper sheet obtainable by the method

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US84196097A 1997-04-08 1997-04-08
US08/841,960 1997-04-08
US08/906,249 1997-08-05
US08/906,249 US5795377A (en) 1997-04-08 1997-08-05 Method for modifying papermaking sludge and products made from modified papermaking sludge

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WO1998045102A1 true WO1998045102A1 (en) 1998-10-15

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PCT/US1998/006172 Ceased WO1998045102A1 (en) 1997-04-08 1998-03-27 Method for modifying papermaking sludge and products made therefrom

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US (1) US5795377A (enExample)
EP (1) EP1007310B1 (enExample)
JP (1) JP2001518853A (enExample)
KR (1) KR20010006110A (enExample)
AU (1) AU726654B2 (enExample)
BR (1) BR9814239A (enExample)
CA (1) CA2284544C (enExample)
DE (1) DE69827272T2 (enExample)
ES (1) ES2227821T3 (enExample)
NZ (1) NZ500256A (enExample)
WO (1) WO1998045102A1 (enExample)

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US6146498A (en) * 1997-04-30 2000-11-14 Kimberly-Clark Worldwide, Inc. Wound product cores and processes for making them
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CA2284544A1 (en) 1998-10-15
DE69827272T2 (de) 2005-03-10
KR20010006110A (ko) 2001-01-26
BR9814239A (pt) 2000-10-03
DE69827272D1 (de) 2004-12-02
NZ500256A (en) 2002-06-28
AU6784998A (en) 1998-10-30
ES2227821T3 (es) 2005-04-01
US5795377A (en) 1998-08-18
EP1007310B1 (en) 2004-10-27
CA2284544C (en) 2005-06-21

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