REPULPING AND CLEANING OF RECOVERED PAPER: UNDELIVERABLE AND DISCARDED MAIL. David W. Bormett Supv. Res. Chem. Eng. Said Abubakr

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1 REPULPING AND CLEANING OF RECOVERED PAPER: UNDELIVERABLE AND DISCARDED MAIL Said Abubakr David W. Bormett Supv. Res. Chem. Eng. Chemical Engineer Marguerite S. Sykes John Klungness Forest Prod. Technol. Chemical Engineer Nancy Ross Sutherland General Engineer USDA Forest Service USDA Forest Service Forest Products Laboratory Forest Products Laboratory Madison, WI Madison, WI Alim Fatah Rajendra Kunar Materials Engineer Materials Engineer Charles Vidich Joe Peng Environ. Coordinator Program Manager U.S. Postal Service U.S. Postal Service 475 L Entant Plaza, SW 475 L Entant Plaza, SW Washington, DC Washington, DC ABSTRACT The USDA Forest Service, Forest Products Laboratory (FPL), has done substantial research in the area of recovered paper processing and contaminant separation. The U.S. Postal Service has a history of leadership in recycling efforts and an interest in purchasing recyclable postal materials that reduce environmental impact. The U.S. Postal Service and FPL are cooperating to evaluate the recyclability of paper products that end up in post offices. This study was conducted to explore the recyclability of Undeliverable Bulk Business Mail (UBBM) and Discarded Lobby Mail (DLM) to determine the level of contamination affecting the overall quality of the final pulp obtained from these materials. This, in turn, will give direction to the approach that should be taken in minimizing the negative effects of UBBM for recycling. In addition, results of this study will provide an idea of the type of processing needed for pulping UBBM material and its various end uses. Six trials were performed: three on each material. Feed stock was UBBM:photocopy paper or DLM:photocopy paper in ratios of 30:70 and 50:50. The Forest Products Laboratory is maintained in cooperation with the University of Wisconsin. This article was written and prepared by U.S. Government employees on official time, and it is therefore in the public domain and not subject to copyright. The use of trade or firm names in this publication is for reader information and does not imply endorsement by the U.S. Department of Agriculture of any product or service. A pilot-scale separation sequence was used to assess the removal of contaminants from the feed stock. The sequence involved high consistency pulping, screening, forward and reverse cleaning, and washing and flotation deinking. TAPPI standard dirt count was made on handsheets from pulp samples after each stage. Results showed that the dirt count for the UBBM and DLM was not reduced to the level of the control photocopy paper. However, results did suggest that with further processing, dilution with virgin pulp, or both, satisfactory low levels of dirt can be achieved. The flotation deinking process was especially effective in lowering dirt count. INTRODUCTION Despite the advances made during the last few years (l-5), contaminants from stickies remain a problem during both processing of recovered paper and the papermaking operation. Stickies are an undesirable recovered paper component that come from pitch, ink, plastic films, converting aids, paper coating, and adhesives (6,7). Adhesives are either hot melt or pressure sensitive. Hot-melt adhesives come from book and magazine binding, box glues, and other converting aids. Pressure sensitive adhesives come from some labels and postage stamps. A mixture of these stickies may be found at U.S. Postal Service offices in Undeliverable Bulk Business Mail (UBBM) and Discarded Lobby Mail (DLM). The UBBM is second- and third-class business mail that cannot be delivered or does not reach its destination because of outdated mailing lists and no forwarding guarantee. Forty million people change their address every year. The UBBM includes magazines, pamphlets, flyers, catalogues, advertising brochures, and nonprofit mail. Typical composition of UBBM and DLM includes about 25% old newspapers (ONP), 35% old magazines (OMG), and the balance is mixed. About two billion pieces of UBBM, which amounts to 440,000 tons per year, are not able to be delivered by the U.S. Postal Service. The work reported here is a part of an initial study to evaluate the recycling potential of UBBM and DLM. This information will help develop a strategy to remove contaminants from the pulp during deinking operations. The materials in UBBM and DLM have already been utilized in papermaking; therefore, it is important to ensure that the pulp produced from them has qualities similar to market recycled pulp. 410/ TAPPI Proceedings

2 EXPERIMENTAL PROCEDURE Six trials were performed, each consisting of a series of processing steps. For trials 1-3, these steps were high consistency pulping, screening through 0.3-mm slots to remove large particles, 76-mm forward cleaning to remove high density particles, and two stages in series of throughflow cleaning to remove low density particles. Samples from each stage were deinked by flotation in a 90-L laboratory-sized cell to remove residual ink and other debris and then washed using a 70-mesh, 60degree sidehill screen to remove ash and very small particulates. For trials 4-6, the same process steps were employed with one exception. To increase the removal of heavy ink particles, a 150-mm forward cleaner was added between the screening and the 76-mm forward cleaning. This gave two forward cleaning stages in the series. Table I lists the equipment for this process; Table II lists the feedstock composition. All photocopy paper was shredded into 6.4 mm-wide strips using a heavy-duty paper shredder. The UBBM and DLM supplied by the U.S. Postal Service was similarly shredded. Pulping Six batches of UBBM per trial were repulped at 15% consistency to provide sufficient material for the subsequent steps. In each trial, the six pulped batches were subsequently blended thoroughly before screening. Table III gives a sample of the pulping conditions used. Screening Blended slurry from the pulping was diluted to about 3% consistency for pumping purposes. After thoroughly mixing, a sample of the unscreened stock was saved for handsheet preparation. The slurry was then pumped to the flatscreen where it was further diluted using about 49 C water. Accepts passing through the 0.3-mm slots were pumped to a stock tank and diluted to about 0.70%-0.75% consistency at about 49 C. Rejects from the screening were bagged and saved. A 10-L sample of the screened accepts was saved for handsheets. Centrifugal Cleaning The 0.70%-0.75% target consistency stock was pumped through the forward cleaners. For the DLM stocks (trials 4-6), a 150-mm cleaner was first used, followed in series by the 76-mm cleaners. For the UBBM stocks, only the 75-mm cleaners were used. The intent was to determine whether more ink could be removed using two stages of forward cleaning. For the 150-mm cleaner, the operating pressures were 140-kPa feed pressure and 47-kPa back pressure. For the 75-mm cleaners, the feed pressure was 276 kpa, and the back pressure was 93 kpa. Three of the small cleaners were run in parallel. Rejects (3.2-mm-diameter tip opening) were collected and drained in a screen cart. Accepts from the 150-mm cleaner passed to a 600-L surge tank and were then pumped through the smaller cleaners to a similar tank. These accepts then were pumped through a throughflow cleaner (feed pressure 207 kpa, back pressure 69 kpa). Rejects (16-mm core diameter) were collected and drained in a screen cart. Accepts were pumped to an 8,000-L glass-lined stock tank where the entire batch was thoroughly blended. A 10-L sample of the blended stock was saved for handsheets. A second pass through the throughflow cleaner was done to reduce lightweight contaminants in the accepts to an acceptable level. A IO-L sample of accepts for handsheets was collected after each pass Pulping Conference /411

3 Flotation and Washing When the accepts from the first pass through the throughflow cleaner were completely mixed, a 70-L sample of the stock was transferred to the laboratory flotation unit. A flotation aid was added (Highpoint DI-600: 1.05 g = 0.2% of fiber weight) and thoroughly mixed. During aeration, foam was removed at first by simple overflow and then manually using a scraper blade. Air was shut off after 10 min, and while mixing, a 10-L sample was removed from the bottom of the unit. The remaining stock was allowed to slowly flow by gravity from the same bottom drain to a 70-mesh, 60-degree laboratory sidehill screen where free drainage removed water and small particulates. Sidehill accepts were saved. Particle Count Ten 1.2-g handsheets were prepared from each sample according to TAPPI T-205 om 88. Sheets were not stained due to the high residual ink count. After air drying, the sheets were read for number of particles and area of particles using the Optomax Speckcheck analyzer that was linked to a Hewlett Packard Scanjet 11C scanner. Detection level was 130; shade compensation was turned off. Tables IV and V contain the data for this phase of the study. Bleaching Conventional laboratory oxidative and reductive bleaching experiments were carried out on each of the deinked and cleaned pulps: sample 15 of trials 1-3 (UBBM) and sample 11 of trials 4-6 (DLM). Hydrogen peroxide and formamidine sulfinic acid (FAS) were applied according to the following conditions: Hydrogen peroxide: 1.0% H 2 O 2 When 2% and 3% H 2 O 2 were used, 1.2% 0.8% NaOH and 2% NaOH, respectively, were required. 3.0% Na 2 SiO 3 Other bleach chemicals remained constant. 0.05% MgSO 4 Conditions: Formamidine sulfinic acid: 1.0% FAS 0.6% NaOH Conditions: 15% consistency, 75 C -80 C, 90 min Residual peroxide was neutralized with sodium bisulfite to ph 6. 12% consistency, 80 C, 45 min Residual chemicals were removed by thorough washing. Handsheets were made from the bleached pulps according to TAPPI method T-205 using a 3. O-g basis weight rather than a 1.2-g basis weight. Brightness and CIE L*a*b* color were measured following TAPPI T-525 om-92 using a stack of three handsheets. A Technidyne Brightness Micro S-5 unit was used for the measurements. Physical Testing Handsheets (60 g/m 2 ) were prepared according to TAPPI T- 205 om-88. All physical testing was done according to TAPPI T-220 om-88, with the noted exception of "Internal Tear Resistance Of Paper" in which a single-ply tear test was done with 10 readings using a Thwing-Albert 200-g capacity Elmendorf tear tester. Taber stiffness was determined following TAPPI T-489 om-9. Optical properties were evaluated on a Techidyne photometer using TAPPI T-452 om-92 for 412/ TAPPI Proceedings

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5 brightness, TAPPI 524 om-94 for color, and TAPPI T-425 om-91 for opacity. Freeness of the pulps was determined according to TAPPI T-227 om-94. Fiber length was determined on a Kaajani FS-100 Fiber Length Analyzer following manufacturer s operating procedures. RESULTS AND DISCUSSION Pulping There was a considerable amount of plastic film in both stocks. Much of the film was found to be wrapped around the agitator as an aggregate. There was very little size reduction of the plastics in this pulper. Downstream of the pulper we found a significant amount of the plastic wadded in the piping and pumps. The flatscreen also had large amounts of plastic. The most serious potential problem with both stocks seemed to be the film packaging that is typically found on magazines. Products with this film would normally be fed intact to the pulper, where the film would prevent water from wetting and dispersing the contents. Screening The particle counts for the screening accepts for the UBBM reflect the values of the prescreened samples, indicating that the screening only removed the very large material. A smaller screen opening may be more efficient in removing stickies (4). The screen reject analysis is given in Table VI. Forward Cleaning The effectiveness of the 75-mm forward cleaners for removing UBBM contaminates can be shown by comparing sample point 3 with sample point 2. Approximately two-thirds of the particles were removed when the DLM loading was 50% or less. For the 100% loading, only about 20% of the particles were removed. In the DLM trials, we evaluated using two forward cleanings in a series. For the 30% and 100% loading trials, the 150-mm cleaner removed about 20% of the particles, the same as the 100% UBBM loading. The 50% DLM loading showed no removal (sample point 4). The 75- mm cleaners appeared to have removed a greater percentage of the particles (sample point 5 compared with sample point 4,). Comparing the results for UBBM and DLM, the use of two banks of 75-mm cleaners in a series may be more effective than using the 150-mm cleaner followed by the 75-mm cleaners. This technique change should be considered for future trial work. Throughflow Cleaning Throughflow cleaning for the UBBM gave mixed results (sample points 5 and 11). The small changes indicate that very little lightweight material was removed. The ink, being heavy, is not removed in this stage; the ash tended to be removed. The effect of this stage for the DLM was similar (sample points 6 and 10), and the conclusions were the same. The residual ink with adhesives remained with the pulp while the ash was removed. Flotation and Washing Flotation was very effective at removing the remaining removable contaminants (sample points 7 and 13; sample points 7 and 11). Although the actual particle counts for the UBBM stock were still too high to be a usable pulp, the material removed in this stage was significant. For the DLM stock, the pulp after flotation was very clean for the 30% and 50% loading levels. The 100% loading level pulp showed significant improvement but was still too contaminated for use. The washing stage was ineffective at removing additional contaminants in these size ranges (sample points 9 and 15; sample points 8 and 12). Bleaching Both furnishes were responsive to either oxidative or reductive bleaching when evaluating the brightness and reduction of b* values (yellowness). Bleaching results are summarized in Table VII. However, neither bleach sequences addressed the hard-to-bleach contaminants in the deinked pulps. Although mixtures with photocopy paper enabled high brightness and excellent b* values to be achieved, these values are deceptive because the mottled sheet appearance is unacceptable for printing and writing paper. This should not discourage efforts to recycle large quantities of waste paper from the U.S. Postal Service. Several alternatives are available. One alternative would be to segregate newspapers, unbleached kraft, or brightly colored paper. Newsprint has markets available, and the remaining paper can be upgraded relatively easily by deinking, cleaning, and bleaching. Another alternative would be to use a bleaching sequence that can selectively target contaminant fibers, e.g., pressurized peroxide or oxygen. A new deinking mill, American Fiber Resources in Sanford, West Virginia, uses these alternatives (8). Using a low grade, post-consumer furnish, this mill produces a high quality market pulp. With the increased demand for recycled fiber, it appears inevitable that future recycling mills will be designed to accommodate waste paper similar to that collected in post office lobbies throughout the United States. 414/ TAPPI Proceedings

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7 Physical Testing Tables VIII to X give the physical testing results of the handsheets made from the washing accepts from the sidehill screen the final stage of the cleaning process. These results show how the handsheet strength varied with the addition of photocopy paper to UBBM and DLM. The addition of photocopy paper to both UBBM and DLM caused an increase in freeness (Table VIII), a decrease in opacity (Table IX), and a decrease in fines content (Table X). The changes in the freeness and opacity were probably due to the change in fines content which, in turn, was probably attributable to the amount of mechanical fiber present. For future studies, a fiber analysis should be included. This analysis should provide data on mechanical compared with chemical pulp and hardwood compared with softwood fiber. The UBBM-containing furnishes increased in strength as the percentage of photocopy paper increased. The 100% DLM furnish had about the same strength levels as the 100% UBBM furnish, reflecting the similarity of the UBBM and DLM stock compositions. wraps, and (3) conduct a more involved bleaching program to determine whether new technologies will increase the effectiveness of the bleaching. It is also important to conduct contaminant source identification, develop a baseline model, and evaluate the chemical composition of stickies redeposited on simulated papermachine felt and wire. This can be accomplished using advanced analytical chemistry techniques combined with PIRA redeposition analysis (9). Similar work conducted by PAPRICAN researchers on various recovered paper grades showed that about 20% of the deposit is derived from various adhesives, 30% from inorganic, 20% consists of resin and fatty acids, 5%-10% of hydrocarbons, and 3%-8% of aluminum and calcium soaps (10). ACKNOWLEDGMENT We thank Pat LeBow, Charles Hillary, Robert Kelley, Richard Shilts, and Sara Spielvogel for their technical assistance in conducting this study. Their contributions are greatly appreciated. LITERATURE CITED CONCLUDING REMARKS This study established pilot-scale separation sequences for assessing the recyclability of UBBM and DLM. Some significant results and suggestions include the following: UBBM and DLM are both recyclable, but the plastic wrappers on some components may be troublesome. Both sources require extensive multistage cleaning to produce a pulp of acceptable quality. Yield needs to be taken into account with multiple stage processing. Bleaching was effective for fiber color removal. Residual black ink particles not removed by the cleaning process were apparently unaffected by bleaching. Strength loss using these stocks may be a problem, probably traceable to the percentage of mechanical pulp in the feedstocks. Presorting to remove the sources of high mechanical pulp (newspapers) would probably be the most beneficial in minimizing strength loss. New adhesive formulations need to have a density less than 0.95 or greater than 1.05 to have high removal efficiency in the centrifugal cleaning step. New adhesive formulations need to be such that they form large particles that are removable in the screening stage. To take advantage of the tackiness of stickies and to increase the efficiency of their removal, we suggest performing one flotation stage right after the pulping. This preliminary investigation indicates the need for future studies. We suggest repeating this work (1) using a largescale pulper to determine whether the plastic-encased materials will be pulpable, (2) consider eliminating the plastic 416/ TAPPI Proceedings

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