Manufacturing, Engineering and Technology Manufacturing and Assembly

Bagasse Pulp Production With Horizontal Continuous Digester Training

SAQA US 114245 | NQF 4 | Credits 29 | Duration 26 Days
From $4,147 per delegate

Description

This course equips learners with the specialised knowledge and skills required to operate a horizontal continuous digester for bagasse pulp production. Participants will gain a deep understanding of the digestion process, from raw material preparation to pulp output, ensuring efficient and quality-controlled production in a pulp and paper mill environment.

Learning Outcomes

  • Explain the principles of bagasse pulping using a horizontal continuous digester.
  • Prepare and feed bagasse into the digester system according to standard operating procedures.
  • Monitor and control critical process parameters such as temperature, pressure, and chemical dosage.
  • Troubleshoot common operational issues and implement corrective actions.
  • Evaluate pulp quality and adjust process variables to meet target specifications.
  • Apply safety and environmental regulations relevant to the pulping process.

Target Audience

This course is intended for production operators, process controllers, and technical staff working in the pulp and paper industry who are responsible for or involved in the operation of continuous digesters for bagasse pulping.

Prerequisites

Learners should have a basic understanding of pulp and paper manufacturing processes. No formal qualifications required, but relevant work experience is recommended.

Course Outline

Day 1: Introduction to Bagasse and Pulp Production

Objectives:
• Understand the sugar cane milling process and bagasse as a by-product
• Identify the properties and characteristics of bagasse for pulping
• Explain the importance of bagasse pulp in the paper industry
• Describe the basic principles of pulping

Topics:
• Sugar cane processing and bagasse generation
• Chemical composition and fiber morphology of bagasse
• Overview of pulping methods: mechanical, chemical, semi-chemical
• Applications of bagasse pulp
• Environmental and economic benefits

Day 2: Overview of Continuous Digester Technology

Objectives:
• Describe the continuous digester system and its components
• Compare batch vs continuous digestion
• Explain the advantages of horizontal continuous digesters
• Identify key process parameters in continuous digestion

Topics:
• Types of digesters: vertical, horizontal, batch, continuous
• Horizontal continuous digester design and layout
• Feed system, cooking zone, discharge mechanism
• Process control variables: temperature, pressure, retention time
• Safety features and interlocks

Day 3: Raw Material Handling and Preparation

Objectives:
• Describe bagasse storage and handling methods
• Explain bagasse depithing and its importance
• Identify impurities and their removal techniques
• Outline the feeding system to the digester

Topics:
• Bagasse baling, stacking, and reclaiming
• Depithing: wet and dry methods
• Screening and cleaning systems
• Conveyor systems and metering
• Moisture content measurement and adjustment

Day 4: Chemistry of Bagasse Pulping

Objectives:
• Explain the chemical reactions in alkaline pulping
• Describe the role of sodium hydroxide and sodium sulfide
• Understand delignification kinetics
• Discuss pulp yield and quality factors

Topics:
• Lignin, cellulose, hemicellulose structure
• Kraft pulping chemistry: reactions and mechanisms
• Effect of chemical concentration and temperature
• Pulp yield and kappa number
• Black liquor composition

Day 5: Process Parameters and Control

Objectives:
• Identify critical process parameters in continuous digestion
• Explain how parameters affect pulp quality
• Understand control loops and instrumentation
• Describe typical setpoints and ranges

Topics:
• Temperature profiles in cooking zones
• Pressure and steam control
• Retention time and production rate
• Chemical dosage and liquor-to-wood ratio
• Online sensors: pH, consistency, kappa number

Day 6: Digester Feed System Operation

Objectives:
• Describe the low-pressure and high-pressure feeder systems
• Explain the role of steam and liquor in chip feeding
• Troubleshoot common feed system issues
• Understand chip plug formation and stability

Topics:
• Chip bin and level control
• Low-pressure feeder operation
• High-pressure feeder and transfer circulation
• Steam and liquor injection
• Plug screw feeder design

Day 7: Cooking Zone Dynamics

Objectives:
• Understand the flow patterns in a horizontal digester
• Explain heat and mass transfer in the cooking zone
• Describe the impact of residence time distribution
• Identify factors affecting uniform cooking

Topics:
• Axial and radial mixing
• Heat transfer from steam to chips
• Liquor flow and penetration
• Residence time distribution measurement
• Channeling and bypassing

Day 8: Blow Tank and Discharge System

Objectives:
• Describe the blow tank operation and pressure letdown
• Explain the function of the discharge device
• Understand pulp washing and screening after cooking
• Troubleshoot discharge blockages

Topics:
• Blow tank design: bottom vs top discharge
• Pressure reduction and flash steam recovery
• Discharge valve types and control
• Pulp dilution and pumping
• Knot separation and screening

Day 9: Chemical Recovery and Recausticizing Overview

Objectives:
• Explain the importance of chemical recovery
• Describe the recovery boiler and causticizing process
• Understand the closed-loop nature of kraft pulping
• Identify key performance indicators for recovery

Topics:
• Black liquor evaporation and combustion
• Smelt dissolving and green liquor
• Causticizing: lime slaking and causticizing reactions
• White liquor clarification and storage
• Recovery cycle efficiency

Day 10: Process Automation and DCS

Objectives:
• Understand the role of distributed control systems (DCS)
• Explain control strategies for continuous digesters
• Interpret process trends and alarms
• Describe advanced process control applications

Topics:
• DCS architecture and HMI
• PID loops and cascade control
• Feedforward and ratio control
• Model predictive control basics
• Alarm management and operator response

Day 11: Quality Control and Testing

Objectives:
• Describe pulp quality parameters and testing methods
• Explain kappa number, viscosity, and brightness
• Understand the impact of process variables on quality
• Perform basic pulp quality calculations

Topics:
• Sampling procedures for pulp and liquor
• Kappa number determination (TAPPI/ISO)
• Viscosity and degree of polymerization
• Brightness and bleachability
• Rejects and shives analysis

Day 12: Troubleshooting and Problem Solving

Objectives:
• Identify common operational problems in continuous digesters
• Apply systematic troubleshooting methods
• Analyze root causes of process deviations
• Implement corrective actions

Topics:
• High kappa number: causes and remedies
• Low yield and high rejects
• Plugging and bridging in feed system
• Steam consumption and pressure fluctuations
• Scaling and fouling

Day 13: Safety and Environmental Compliance

Objectives:
• Understand safety hazards in digester operations
• Explain lockout/tagout and confined space procedures
• Describe environmental regulations for pulp mills
• Implement best practices for safe operation

Topics:
• Hot work and pressure vessel safety
• Chemical handling: NaOH, Na2S, lime
• Personal protective equipment (PPE)
• Effluent treatment and air emissions
• Waste minimization and energy efficiency

Day 14: Maintenance and Reliability

Objectives:
• Describe preventive maintenance schedules for digesters
• Identify wear mechanisms and material selection
• Explain corrosion and erosion control
• Understand predictive maintenance techniques

Topics:
• Inspection of refractory and linings
• Wear parts: screws, feeders, valves
• Corrosion monitoring and chemical treatment
• Vibration analysis and thermography
• Maintenance planning and spare parts

Day 15: Optimization for Yield and Quality

Objectives:
• Apply optimization techniques to improve pulp yield
• Balance chemical usage and pulp strength
• Use statistical process control (SPC) for quality
• Implement continuous improvement strategies

Topics:
• Design of experiments for parameter tuning
• Response surface methodology
• SPC charts and capability analysis
• Energy optimization: steam and power
• Best available techniques (BAT)

Day 16: Case Studies and Industry Best Practices

Objectives:
• Review real-world case studies of digester operations
• Analyze successful optimization projects
• Identify lessons learned and pitfalls
• Apply best practices to own plant context

Topics:
• Case study: reducing kappa number variability
• Case study: increasing production rate
• Benchmarking against industry standards
• Implementing a continuous improvement program
• Operator training and competency

Day 17: Advanced Topics: Non-Wood Pulping

Objectives:
• Compare bagasse pulping with other non-wood fibers
• Understand challenges specific to bagasse
• Explore emerging technologies for bagasse pulping
• Discuss integration with biorefinery concepts

Topics:
• Wheat straw, bamboo, and other non-woods
• Silica and oxalate issues in bagasse
• Enzymatic pretreatment possibilities
• Biorefinery: lignin and hemicellulose valorization
• Future trends in non-wood pulping

Day 18: Integration with Paper Machine Operations

Objectives:
• Explain how pulp quality affects papermaking
• Describe the bleach plant and its requirements
• Understand stock preparation and refining
• Coordinate digester operation with downstream processes

Topics:
• Pulp washing and screening for paper machine
• Bleach sequence: D0, Eop, D1, D2
• Refining and fiber development
• Wet-end chemistry and retention
• Quality specs for different paper grades

Day 19: Simulation and Process Modeling

Objectives:
• Use process simulation software for digester modeling
• Understand steady-state and dynamic models
• Apply simulation to optimize operating conditions
• Interpret simulation results for decision making

Topics:
• Introduction to simulation tools (e.g., CADSIM, WinGEMS)
• Building a digester model: mass and energy balances
• Sensitivity analysis of key parameters
• Dynamic simulation for startup and shutdown
• Case study: model-based optimization

Day 20: Final Review and Assessment

Objectives:
• Consolidate knowledge from the course
• Demonstrate competency through written and practical assessment
• Develop an action plan for applying skills at work
• Receive feedback and certification

Topics:
• Comprehensive review of key concepts
• Written test covering theory and calculations
• Practical assessment in simulator or plant
• Group discussion and lessons learned
• Course evaluation and certification

Practicals

64 hours of practicals To be conducted online or on-campus or in-house
Overview

The practical component provides hands-on experience with a simulated or actual horizontal continuous digester system. Learners will operate the digester, adjust process parameters, troubleshoot common issues, and perform quality tests on pulp samples. This practical work is essential for developing the skills needed to safely and efficiently manage bagasse pulp production.

Practical Activities
  • Digester Start-up and Shutdown Procedures — Learners will follow standard operating procedures to start up and shut down a continuous digester, including preheating, feeding, and transitioning to steady state. (16h)
  • Process Parameter Adjustment and Control — Using a simulator or pilot digester, learners adjust temperature, pressure, chemical dosage, and retention time to achieve target pulp kappa number and yield. (16h)
  • Troubleshooting Common Operational Issues — Learners diagnose and resolve simulated problems such as plugging, high rejects, steam pressure fluctuations, and inconsistent pulp quality. (16h)
  • Pulp Quality Testing and Analysis — Learners collect pulp samples, perform kappa number, viscosity, and brightness tests, and interpret results to make process adjustments. (16h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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