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UNIVERSITI MALAYSIA PAHANG BOR JUDUL : OIL PALM FROND (OPF) AS AN ALTERNATIVE SOURCE OF PULP & PAPER PRODUCTION MATERIAL SESI PENGAJIAN: 2007/2008 Saya MOHAMMAD IZZUDDIN BIN YAKARI___________________ (HURUF BES mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di Perpustakaan Universiti Malaysia Pahang dengan syarat-syarat kegunaan seperti berikut: Tesis adalah hakmilik Universiti Malaysia Pahang. Perpustakaan Universiti Malaysia Pahang dibenarkan membuat salinan untuk tujuan pengajian sahaja. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. **Sila tandakan ( SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh _______________________ _________________________ (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: B-916, KG. SEB. TUAN CHIK HAJI Tn. Haji Mohd Noor bin Nawi 21200 K. TRG, TERENGGANU. Tarikh:_ 16 th May 2008 ___________ 16 th May 2008 _____ CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). Wood fibers are the main raw material uswood pulp production amounted to 166.3 million tonnes in 2001 as compared to recovered fiber pulp of 19.8 million tonnes. The recovered fiber is obtained from waste and fibers are from vegetable materials such as straw, bamboo, bagagrasses, cotton linters, flax hemp, rags, or other textile waste of the total other fiber pulp production, the main producer country in 2001 In Malaysia, there are 20 paper establishments of these, 10 mills are operating based on recycled papers, while only one mill is using mixed tropical softwoods for its paper production from this mill reached 123,000 tonnes in 2001.R&D on pulp and paper has been initiated by FRIM long time ago focusing on the evaluation of the suitability of raw material for pulping and papermaking. One of the R&D findings is the suitability of oil palm frond (OPF) as raw material for pulping. The potential of this finding can be viewed from the facts that there are about 26.2 million tonnes of OPF readily available from the palm oil industry and nd difficult to dispose. This paper examines the technical feasibind paper production and attempt to make an economic analysis on producing pulp and paper from OPF in Malaysia. 1.2 Objectives To utilize Oil Palm Frond (OPF) as almaterial to produce pulp and paper. To determine the effect of beating on the properties of oil palm frond (OPF) 1.2 Scopes The scopes of this study consist of: The effect of beating on fiber morphology The effect of beating on drainage time 3. The effect of beating on content stock freeness (CSF) 4. The effect of beating on paper strength. The optimum condition of b 1.3 Problem statement A lot of biomass waste not being utproduct. The Oil Palm Frond alternatives sources of imported fresh pulp. The wood based paper production faced with environmental drawback where sulphur emitted contained CHAPTER 2 LITERATURE REVIEW 2.1 PULP AND PAPER BACKGROUND Malaysia is net importer of most paper product except for toproduced about 5,000 tonnes (Kuusisto 1997). The imported paper and paper product have resulted in a lost in foreign exchage, which can be reduced by utilizing the local lignocellulosic materials in residues is the palm oil frond (OPF). Malaysia’s 351 palm oil mills produce 26.2 million tones of OPF per annum in the year 2000. Mo After the pulping operation, the pulp isness of 60-65% (Biermann 1996, Wan Daud . 1998). Bleaching makes pulp whiter and brighter to the eye. Bleaching is the chemical process applied to the pulp to through lignin removal. Pulp brightness is one of the parameters used in monitoring bleaching progress. An unbleached pulp is colored due to the absorbance of visible light by the presence of residual lignin, highly colored substances. There are more than ten types of bleaching chemicals. Lignin removal is achieved using chemicals, stages and sequences are used in producing different degree of pulp brightness and will affect the ong components are compensated by using the LWFL. As a comparison, the data from Canadian aspen (included. Although the average length is abou Smook, 2002 .) of 0.96 mm ( Law and Jiang, 2001 ), Maple of 0.92 ( Law et al., 1986 ), bagasse (0.5–3.75 mm) and wheat straw (0.7–3.1 mm). The bagasse and wheat straw ar Patel et al. (1987) and Atchinson (1989) ong as those of oil palm empty fruit bunch (EFB) fibers ( Wan Rosli et al., 1998 ). However, the coarseness of the oil palm fibers is low (0.097 mg/m), which is slightly halved than that of spruce and significantly lower than of aspen Fig. 1 fibers (fines) with further evidence coming from the Bauer–McNett classification which Table 2.2). One particular morphological have a much thicker wall when compared with e inverse of collapsibility of fibers) is based on the assumption that fibers act like a thin-wall cylinder whose collapse pressure Akamatsu et al., 1987 is diameter. With thick cell wall ( Fig. 2 sheet making, hence giving a sheet of hipotential in comparison with curve of oil palm frond fibers SEM of oil palm frond (A) and softhave relatively thick cell walls, which do not collapse as readily as the softwood spruce 2.1.3 Chemical composition of OPF Chemically, the frond strands are rich in-cellulose (49.8%) as illustrated in 2 , both of which are important parameters in determining the suitability of a raw material for papermaking ( Ona et al., 2000 comparison, the data from Canadian aspen ((20.5%) is lower than normally found in common hardwood, for example aspen of Law and Jiang, 2001 ) and eucalyptus of 22% ( Alcaide et al., 1990 are non-woody and the requirement for structural support associated with mechanical support for plant Boudet, 2000 and Douglas, 1996 ), its lacking will no longer allow plants to be upright ( Zhong et al., 1997 that they will be much easier to be chemically pulped. The frond strands are comparatively less resi like other non-wood fibers, contain comparatively high ash content. This characteristic might contribute to an abnormal mechanical wear of processing equipments. Thsilica in the black liquor recovery system mightping of this material. The monomer composition of polysaccharides shows almost only glucose and xylose, with the other monosaccharides representing less than 6%, which is in broad similarity with Timmell, 1967 and Wallis et al., 1996 ). Chemical composition of oil palm frond (OPF), Empty Fruit Bunches (EFB) and Hardwoods and Softwood. Component Oil Palm Fronds EFB Hardwood Softwood Lignin (%) 20.5 17.2 25.2 21-37 Holocellulose 83.5 70 72.4 60-80 -Cellulose 49.8 42.7 44.7 31-60 extractives (%) 1.4 Ash (%) 0.7 Alkali solubes 17.2 13.6 Pentosans (%) 27.3 12.9 Polysaccharide composition (%) Family Name Composition (%) Arabinose 1.5 Mannose 2.2 Galactose 0.9 Glucose 66.6 Xylose 28.9 3.3.2 Pulping Process Five hundred grams (oven dry) of OPF anthraquinone (soda-AQ) process using a 4 employed were maximum cooking temperature is 170 °C, time to maximum temperature is 90 minutes, time at maximum temperature is 90 minutes, OPF to liquor ratio is 1:8, amount of anthraquinone is 0.1% of OPF dron a screen and screened by a fractionator (Somerville type) with a screen plate of 0.20 mm slits to remove black liquor. M.K Digester Somerville type Figure 3.3.2 (c): OPF pulp fore paper making process and easily to form the sheet on fine mesh wire screen. At the end of digestion, the softened OPF was disintegrated for five minutndard Disintegrator 3000rpm. Figure 3.3.2 (c): Soaking OPF pulp Figure 3.3.2 (d): Standard Disintegrator Figure 3.3.5 (b): Burst Tester easured according to TAPPI T 220 om-88 APPI 1994) in a controlled temperature and humidity environment as stipulated in TAPPI 402 om-93 “Standard conditioning and p handsheets and related products” (TAPPI Tear Tester CHAPTER 4 RESULT AND DISCUSSION 4.1 INTRODUCTION Production paper must consider the quality and strength of the paper. The raw material selection is important as a result ofThe chemical composition in oil palm frond has higher cellulose contain that give the The silica content must be considered in the raw material selection caused by chemical reaction on the metal equipmhigher silica content as a result of higher maintenance of equipment. This alternatives way to overcome the problem by changes the hardwood to oil palm frond (OPF). RESULT AND DISCUSSION The sample of OPF chips was beating with P.F.I Mill with the degree of beating (15, 30, 45, 60 and 90 minutes). Drainage time was measured simply by draining a very dilute suspension fiber on a fine-mesh wire screen in a handsheet machine. Pulp freeness was measured by ISO 5267/1 – 1979 (E) “Pulps – Determination of drainability – Part 2: Canadian Standard freeness method” (CSF) (ISO 1998).The strength properties of the pulps were analyzed in terms of 4.2.1 Drainage Time and Stock Freeness The drainage time of pulp increase in drainage time. Draimainly by the resistance of the forming mat to the flow of water. There are eight factors in determining how much resistance a forming fiber mat will present to drainage: the temperature of the stock, the ount of air entrained in the stock, ash or filler content, the freeness of the stock on the wire, the fiber surface chemistry, the presence and degree of flocculation by chemical and the fines content (Unbehend 1992). Since the temperature was constant and no chemicals were added into the stocks, only three factors determined how much resistance a forming fiber will present to drainage: the freeness, the surface chemistry and the fines content. The CSF, a pulp freeness measurement, d beating shown in Figure 4.2.1 k is a function of the amount of free water and imbibed water in the sheet and associated with the fi 020406080100Beating (min)Drainage (s) Drainage (s) Figure 4.2.1 (a): The effect of beating on stock drainage 020406080100Beating (min)CSF (mL ) CSF (mL) The effect of beating on the stock freeness The effect of beating on fiber length 0.420.10.20.30.40.50.60.70.80.9020406080100Beating (min)Fibre Length (mm ) Fiber Length (mm) e pulps were analyzed in terms of tensile and burst F c), and they had a large surface area per unit weight. In general, the specific surface area of fines is 5-8 times that of fibers (Unbehend 1992). Fines major influenced on drainage performance. This is mainly due toswell considerably in water. Fines retain two to three times more water than fibers and behave much like a gel 4 , evaluated and presented in Figure strength improved tremendously with beating. The comparison was made by observing the decrease in freeness associated with beating in the P.F.I Mill. Different between the freeness of the two were small, with th 46.18020406080100Beating (min)Tensile Index (N.m/g) Tensile Index (N.m/g) Figure 4.2.2 (a): The effect of beating on tensile indices 13.12020406080100Beating (min)Burst Index (kPa.m Burst Index (kPa.m2/g) The paper strength, with randomly oriented fiber is dependent on the strength of ual strength and number of bonds between them. The number of bonds is influenced by fibered flexibility. A flexibility fiber will have more surface area for bonding. Fiber flexibility and bonding potential can be determined from the paper apparent density (Law & Jiang 2001). 0.728530.10.20.30.40.50.60.70.8020406080100Beating (min)Tear Index (mN.m/g) Tear Index (mN.m2/g) The effect of beating on tear indices Figure 4.2.2 (he burst and tensile d) shows that as the apparent density were increased, t indices were also increased. It can be seen that the burst and tensile indices for bleached pulp were higher than those for unbleached pulp. These differences were consistent over most of the apparent densittensile indices in bleached pulp. 0.40.450.50.550.60.650.70.750.8Apparent density (g/cm3)Tensile Index (kPa.m/g) Since the bleached pulp has a higher st soda-AQ pulps. e apparent density of unbleached pulp. The removal of lignin during bleaching and hemicelluloses. Cellulose and hemicelluloses contain hydroxyloptimum condition is at 60 minutes cause of ile, tear and burst CHAPTER 5 CONCLUSION & RECOMMENDATION CONCLUSION Oil Palm Frond (OPF) produced pulp with different drainage, strength and paper properties. The following conclusion may be freeness also gives the effect which is decrbeating. Fine and shortened fiber has increased the surface area to absorb water. The strength of paper was analyzed in term of tensile, burst and tearproduction of OPF pulp is at 60 minutes 46.18 N.m/g, burst index is 13.12 kPa.m 2 index is 0.72853 mN.m 2 /g. 5 As a recommendation for further study on paper production, continue with right leachi b ng stage and analyzed the effect of paper strength and properties. Other sources of raw material such as Oil Palm Trunk (OPTThe effect of temperature and chemical concentration of sodium paper production. The paper from OPF can be the wood base production. The wood base of paper production give the environmental drawback of sulphur contain emitted by the ng process. Economically, the productions of the potential market value. REFERENCES . Tuthill, Nickel Development Institute, Personal Communication, August 2000. kamatsu et al., 1987 I. Akamatsu, Y. Kobayashi, H. Kamishima, K. Hassan, M.N. R. Alen, Basic chemistry of wood de A A dustrial utilization of oil palm by-products. II: thermomechanical puCellul. Chem. 21 (1987), pp. 191–197. A Spanish agricultural residues with a view in obtaining cellulose pulp, Tappi J. 73 (1990) (8), pp. 173–177. A Papermaking Science and Technology Series vol. 3 , Fapet, Helsinki (2000), pp. 58– A Pulp and Paper Manufacture vol. III , Joint Textbook Committee of Paper Industry, Tappi Press, Atlanta (1989), pp. 58–60. Mohd Yusof, 1997 M.N. Mohd Yusof, High yield pulping of oil palm frond fibers in Malaysia, Proceedings of the Nanjing International Symposium on High Yield Niskanen, 2000 K. Niskanen, Paper physics, Papermaking Science and Technology Series vol. 16 , Fapet, Helsinki (2000). Ona et al., 2000 T. Ona, T. Sonoda, K. Ito, M. Shibata, Y. Tamai and Y. Kojima, Rapid ourier transform Raman spectroscopy, J. Pulp 26 (2000), pp. 43–47. View Record in Scopus | Cited By in Scopus (6) Patel et al., 1987 Y.S. Rao, Nonwood fiber plants for papermaking, , Tappi Press (1987) (Progress Report November 1998, pp. 109–115. Timmell, 1967 T.E. Timmell, Recent progress in the chemistry of wood hemicelluloses, Wood Sci. Technol. 36 (1967) (1), pp. 45–70. Smook, 2002 G.A. Smook, Handbook for Pulp and Paper Technologists (3rd ed.), Angus Wilde Publications, Vancouver (2002). Paper from OPF Beating Equipment (P.F.I Mill) UNIVERSITI MALAYSIA PAHANG BOR JUDUL : OIL PALM FROND (OPF) AS AN ALTERNATIVE SOURCE OF PULP & PAPER PRODUCTION MATERIAL SESI PENGAJIAN: 2007/2008 Saya MOHAMMAD IZZUDDIN BIN YAKARI___________________ (HURUF BES mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah)* ini disimpan di Perpustakaan Universiti Malaysia Pahang dengan syarat-syarat kegunaan seperti berikut: Tesis adalah hakmilik Universiti Malaysia Pahang. Perpustakaan Universiti Malaysia Pahang dibenarkan membuat salinan untuk tujuan pengajian sahaja. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. **Sila tandakan ( SULIT (Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysia seperti yang termaktub di dalam AKTA RAHSIA RASMI 1972) TERHAD (Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan) TIDAK TERHAD Disahkan oleh _______________________ _________________________ (TANDATANGAN PENULIS) (TANDATANGAN PENYELIA) Alamat Tetap: B-916, KG. SEB. TUAN CHIK HAJI Tn. Haji Mohd Noor bin Nawi 21200 K. TRG, TERENGGANU. Tarikh:_ 16 th May 2008 ___________ 16 th May 2008 _____ CATATAN: * Potong yang tidak berkenaan. ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD. Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertai bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ““I/We* hereby declare that I/we* have read this thesis and in fficient in terms of scope and quality for the award of the degree of Bachelor of Chemical Engineering” Signature : .................................................... Supervisor : Tn. Haji Mohd Noor bin Nawi Date : .................................................... PRODUCTION MATERIAL MOHAMMAD IZZUDDIN BIN YAKARI A thesis submitted in fulfillment of the requirements for the award of the degree of Bachelor of Chemical Engineering Faculty of Chemical & Natural Resources Engineering Universiti Malaysia Pahang MAY, 2008 DECLARATION I declare that this thesis entitled “OIL PALM FROND (OPF) AS AN ALTERNATIVE SOURCE OF PULP & PAPER PRODUCTION MATERIAL” is the result of my own research except as cited in references. The thesis has not been accepted for any degree and is not concurrently submitted in candidature of any other Signature :………………………………………. Name of Candidate : Mohammad Izzuddin bin Yakari Date : May 16 th , 2006 OIL PALM FROND (OPF) AS AN ALTERNATIVE SOURCE OF PULP & PAPER PRODUCTION MATERIAL MOHAMMAD IZZUDDIN BIN YAKARI UNIVERSITI MALAYSIA PAHANG DEDICTION father (Yakari), for their love and And, Special Thanks to my friends, my fellow course mate and all faculty members. ll your C Sincerely, Mohammad Izzuddin bin Yakari CKNOWLEDGEMENTS First and foremost, I would like to express my sincere appreciation to my r constantly guiding and encouraging me throughout this study. Thanks a lot for giving me a professional training, advice and oject to its final form. I am very thankful to Mr. Amran bin Shafie and Mrs. Mazlin binti Kusin the Department, Universiti TeIn preparing this project, I was in contact with many people, researches, academicians In particular, my sincere thankful is also extends to all my colleagues and others who have provided assistance at various occasions. Their views and tips are useful possible to list all of them in this limited space. And last, rents and other family members for their continuous support while completing this project.