Manufacturing, Engineering and Technology Manufacturing and Assembly

Chemical Pulping Principles Processes And Variables Training

SAQA US 114263 | NQF 4 | Credits 12 | Duration 9 Days
From $1,798 per delegate

Description

This course equips learners with a comprehensive understanding of chemical pulping principles, processes, and variables essential for the pulp and paper industry. Participants will gain the knowledge to optimize pulping operations, troubleshoot process issues, and ensure quality and efficiency in chemical pulping.

Learning Outcomes

  • Apply the fundamental principles of chemical pulping, including the chemistry of delignification and fiber liberation.
  • Analyze the key process variables in chemical pulping, such as temperature, pressure, chemical concentration, and time.
  • Evaluate the impact of different pulping conditions on pulp yield, quality, and environmental factors.
  • Demonstrate the ability to monitor and control pulping processes to achieve desired pulp properties.
  • Implement troubleshooting techniques to address common process deviations and equipment issues.

Target Audience

This course is designed for process operators, technicians, and production supervisors in the pulp and paper industry who are involved in or responsible for chemical pulping operations.

Prerequisites

None — open enrollment

Course Outline

Day 1: Introduction to Chemical Pulping

Objectives:
• Understand the role of chemical pulping in the paper industry
• Identify key differences between chemical and mechanical pulping
• Recognize the main chemical pulping processes
• Describe the basic principles of lignin removal

Topics:
• Overview of pulp and paper industry
• Types of pulping: mechanical, chemical, hybrid
• Chemical pulping processes: kraft, sulfite, soda
• Basic chemistry of lignin and cellulose
• Environmental and economic importance of chemical pulping

Day 2: Kraft Pulping Process Fundamentals

Objectives:
• Explain the kraft pulping process flow
• Describe the role of white liquor
• Understand the impact of temperature and pressure
• Identify key reactions in the digester

Topics:
• Kraft process overview: from wood to pulp
• Composition of white liquor (NaOH, Na2S)
• Cooking parameters: temperature, pressure, time
• Delignification reactions and kinetics
• Batch vs. continuous digesters

Day 3: Sulfite Pulping Process

Objectives:
• Compare sulfite pulping with kraft pulping
• Understand the chemistry of sulfite cooking liquors
• Identify process variables affecting sulfite pulping
• Describe the impact on pulp quality

Topics:
• Sulfite pulping process overview
• Cooking liquor preparation (acid, bisulfite, neutral)
• pH and temperature effects
• Delignification and carbohydrate degradation
• Advantages and limitations of sulfite pulping

Day 4: Soda and Other Alkaline Pulping

Objectives:
• Explain the soda pulping process
• Understand the use of anthraquinone (AQ) as an additive
• Compare soda-AQ with kraft and sulfite
• Identify applications of soda pulping

Topics:
• Soda pulping chemistry and process
• Anthraquinone (AQ) catalyzed pulping
• Comparison of alkaline processes
• Non-wood fiber pulping (bagasse, straw)
• Environmental aspects of soda pulping

Day 5: Key Process Variables and Their Control

Objectives:
• Identify critical variables in chemical pulping
• Understand how variables affect pulp yield and quality
• Describe control strategies for digesters
• Analyze the impact of wood species and chip quality

Topics:
• Variables: temperature, time, chemical concentration, liquor-to-wood ratio
• Effect on kappa number, viscosity, and yield
• Control loops in batch and continuous digesters
• Wood chip properties: size, moisture, species
• Process optimization for target pulp quality

Day 6: Chemical Recovery and Recycling

Objectives:
• Explain the chemical recovery cycle in kraft pulping
• Describe the role of the recovery boiler and causticizing
• Understand energy generation from black liquor
• Identify environmental benefits of recovery

Topics:
• Black liquor evaporation and combustion
• Recovery boiler operation and safety
• Smelt dissolving and green liquor
• Causticizing process and lime kiln
• Energy efficiency and emission control

Day 7: Pulp Washing, Screening, and Bleaching

Objectives:
• Describe brown stock washing systems
• Understand screening and cleaning principles
• Explain the basics of bleaching sequences
• Identify quality parameters after washing and screening

Topics:
• Washing: drum, diffuser, press washers
• Screening: pressure screens, centrifugal cleaners
• Bleaching overview: ECF and TCF sequences
• Bleaching chemicals: ClO2, O2, H2O2
• Pulp quality testing: brightness, dirt count

Day 8: Troubleshooting and Process Optimization

Objectives:
• Identify common process problems in chemical pulping
• Apply systematic troubleshooting approaches
• Optimize process variables for improved efficiency
• Understand the impact on pulp quality and cost

Topics:
• Common issues: high rejects, low yield, poor strength
• Troubleshooting methodology: data analysis, root cause
• Optimization of cooking cycles
• Energy and chemical savings strategies
• Case studies from industry

Day 9: Integration, Safety, and Future Trends

Objectives:
• Integrate knowledge from all days into a holistic view
• Recognize safety hazards in chemical pulping
• Discuss emerging technologies and sustainability
• Prepare for unit standard assessment

Topics:
• Process integration: from wood handling to pulp storage
• Safety: chemical handling, high pressure, hot surfaces
• Environmental regulations and compliance
• Emerging trends: biorefinery, lignin valorization
• Review and assessment preparation

Practicals

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

Practical sessions are essential for learners to apply theoretical knowledge to real equipment. Learners will operate a pilot-scale digester, perform cooking trials, analyze pulp properties, and troubleshoot process variables under supervision.

Practical Activities
  • Digester Operation and Cooking Trial — Learners prepare wood chips, load the digester, set cooking parameters (temperature, time, chemical charge), and execute a kraft cook. (8h)
  • Pulp Washing and Screening — Learners wash the cooked pulp using a laboratory washer, screen the pulp to remove rejects, and measure washing efficiency. (8h)
  • Kappa Number and Viscosity Testing — Learners conduct Kappa number and viscosity tests on pulp samples to assess delignification and cellulose degradation. (8h)
  • Troubleshooting Process Variables — Learners are given a simulated process upset (e.g., high rejects, low yield) and must identify the cause, adjust variables, and re-cook to achieve target pulp quality. (8h)

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.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
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Mon 07 Sep 2026 Thu 17 Sep 2026 Virtual Spring 2026 $1,798 Register
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On-Campus training — face-to-face sessions at our training venues across Africa and beyond.
Showing all 498 sessions across 26 venues
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In-House training — we bring the trainer to your organisation, tailored to your team.
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Tue 15 Sep 2026 Fri 25 Sep 2026 Your Premises Spring 2026 $2,338 Register
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Thu 17 Jun 2027 Tue 29 Jun 2027 Your Premises Winter 2027 $2,338 Register
Wed 07 Jul 2027 Mon 19 Jul 2027 Your Premises Winter 2027 $2,338 Register
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Thu 28 Oct 2027 Tue 09 Nov 2027 Your Premises Spring 2027 $2,338 Register
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Thu 06 Jan 2028 Tue 18 Jan 2028 Your Premises Summer 2027 $2,338 Register
Wed 26 Jan 2028 Mon 07 Feb 2028 Your Premises Summer 2027 $2,338 Register
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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