MECHANICAL PUMPING
The nature of
the mechanical
pulping process
BY D. MCDONALD, K. MILES, AND R. AMIRI
Abstract: Three independent properties must be optimized simultaneously for lightweight
mechanical printing papers: scattering coefficient which is required for opacity, fibre length for
strength, and density for printability. For a given wood species, there is a single relationship
between scattering coefficient and fibre length, from groundwood to refiner pulps to kraft. Greater
development of long fibres with less cutting, as measured by density, can be achieved by lowering
the refining intensity or increasing either the chemical treatment or temperature.
he quality of mechanical pulp has
T improved steadily over the last few
decades. Shortly after the introduc-
tion of thermomechanical pulp
(TMP) it became the preferred fur-
nish for newsprint and in recent years has
become a substantial component of supercalen-
dered and lightweight coated grades. With fur-
ther improvement in fibre and pulp quality, by
optimizing refiner operation and fractionation
strategies, TMP could conceivably become the
sole pulp in many high quality mechanical print-
ing grades.
Extensive research has been done to deter-
mine parameters influencing mechanical pulp
properties. Almost 30 years ago, Forgacs suggest-
ed that mechanical pulp could be characterized
by two factors, one related to fibre length and the
other to specific surface [32]. He proposed a
groundwood control scheme based on on-line
measuring of shives, fibre length and freeness.
However, this control concept predated suitable
on-line sensors. Since then a significant amount
of work has been done to better understand
mechanical pulps and in particular the effect of
operating parameters such as specific energy,
consistency and raw material on fibre and pulp
properties [5,6,9,12,17,19,26,33].
The wide particle size distribution in mechan-
ical pulps contributes to improved optical and
surface properties [3,7,15,23,30] making them
suitable for low-cost, lightweight papers. Further
cost saving could be achieved if minimum
strength and opacity specifications could be met
with fewer fibres per unit area of printing surface.
Another opportunity would be to capitalize on
either the inherent fibre properties of different
wood species or employ fractionation strategies to
tailor products for specific markets [1,2,11,12].
Even within species, variations offer significant
options for cost reductions or quality improve-
ment [4]. However, current refiner operating
conditions limit this approach.
Mechanical pulping has been studied at Papri-
can for many years [14,18,24,25,29]. Work on stone
groundwood, refiner mechanical and thermome-
chanical pulps has reflected the industry’s adoption
of the processes [8,10]. Both fundamental and
Pulp & Paper Canada T 181
practical approaches have addressed the potential
to develop high-quality mechanical pulp and to
reduce specific energy consumption [5,18,21,24].
The two key operating factors in refining are
the specific energy and the intensity [18,24],
defined as the specific energy per bar impact.
Manipulating the refining intensity can have an
effect on both energy consumption and pulp
quality [8]. Increasing the refining intensity by
either increasing the rotational speed of the
refiner [27] or lowering the consistency [5] low-
ers the energy required to reach a given freeness
but often reduces average fibre length and tear
strength. The optimization of refining intensity to
different wood species and wood of varying qual-
ity could lead to significant improvements in
refiner operation and pulp quality.
This report discusses the factors that deter-
mine the energy/quality relationships in mechan-
ical pulping. This understanding could unlock
the potential value of each wood species, reduce
process variability, and show how to make a
mechanical pulp with optimized properties.
BACKGROUND
The basic concepts of mechanical pulping are evi-
dent in the evolution of the process. The first
mechanical pulp was groundwood, which is char-
acterized by low energy but low strength proper-
ties, Fig. 1. Groundwood must be mixed with
chemical pulp to achieve adequate strength
D. MCDONALD
properties. With the introduction of refiners,
Paprican
mechanical pulps were stronger, but the addition
Pointe-Claire, QC
of chemical pulp was still necessary for grades
e-mail: dmcdonald@paprican.ca
such as newsprint. Increasing the refining tem-
perature by operating at higher casing pressure
was expected to reduce energy consumption. In
fact, thermomechanical pulp required more
energy but produced a high-quality pulp that
could be used as a single furnish for grades such
as newsprint. The highest quality mechanical
printing papers, lightweight-coated (LWC) and
supercalendered (SC), now contain a large pro-
portion of mechanical pulp but still require kraft
for runnability. History suggests making these K. MILES
grades entirely from mechanical pulp would be Paprican
the most cost-effective method. However, with Pointe-Claire,
current technology, sufficient energy cannot be QC
105:8 (2004) ❘❘❘ 27
 MECHANICAL PUMPING

FIG. 1. Better fibre development occurs with processes FIG. 2. Value-added papers need collapsed fibres to give a
that can apply more energy. dense sheet with a uniform printing surface.

FIG. 3. Higher density on handsheets made with long FIG. 4. Density of handsheets made with long fibres
fibres is achieved through higher fibre flexibility. increases with decreasing fibre coarseness.

applied to the fibres to develop pulp properties.

Although there has been significant research effort world-
wide to reduce energy consumption in mechanical pulping,
experience has shown that the key to a longer, more developed
fibre is being able to put more energy into the pulp. This can be
done by softening the fibre by heat or chemicals, or by reducing
the refining intensity. [Fig. 1]
Cross-sections of lightweight coated and supercalendered
sheets provide an illustration of the type of fibres that are
required for high value mechanical printing papers. [Fig. 2] The
individual fibres are collapsed, giving a highly densified struc-
ture which provides a uniform printing surface. Density is a
macroscopic indicator of the fibre characteristics such as flexi-
bility [28], (Fig. 3), coarseness, (Fig. 4), and collapse [16].
Although calendering provides much of the densification, the
pulp must respond to these forces. There must also be sufficient
long fibre to maintain strength under this mechanical action
and with the addition of fillers, which are required for opacity.
Three independent pulp properties need to be optimized for FIG. 5. For lightweight papers, scattering coefficient, fibre
lightweight papers: scattering coefficient, which is required for length, and density must be optimized.
opacity, fibre length for strength, and density for printability,
(Fig. 5). Mechanical pulps are particularly suited for lightweight Pilot Plant Trials
grades because of the inherent scattering by fines. This permits A considerable quantity of such data was obtained when repeat
a reduction in basis weight without compromising opacity and trials were carried out on black spruce and balsam fir as part of
showthrough. To maintain strength, the fibres must be devel- a study of seasonal quality variations. Pulp from each species was
oped without losing length. Flexible, conformable and collapsed produced on Paprican’s Bauer 36 in. double disc atmospheric
fibres, which promote better printability, are characterized by a refiner under the following conditions:
higher density. Examining pulp data plotted on these three axes • RMP (1200 rpm, no chip pre-steaming)
can provide insight into the limits of mechanical pulping and • Low intensity RMP (900 rpm)
the opportunities. • Low intensity ‘TMP’ (900 rpm, 10 min. of chip pre-steaming at 138°C).

28 ❘❘❘ 105:8 (2004) T 182 Pulp & Paper Canada


FIG. 6. Regardless of the refining process, the scattering
coefficient is a well definied function of the fibre length.
At a given fibre length fir always yields higher scattering
than spruce.
FIG. 7. Adding additional data to the plot of Fig. 6 shows
that the relationshop between scattering coeffieicnt and
fibre length extends all the way from stone groundwood
to softwoodkraft.
FIG. 8. For a given species scattering coefficient depends
on the quantity of fines and is independent of the process.
The wood was carefully selected so that universal relation-
ships could be developed. A common problem with many TMP
studies noted by Corson [4] is that the relationships developed
with small sample sites are overwhelmed by the inherent varia-
tions in the wood. In this case, trees of equal age were selected
Pulp & Paper Canada T 183
MECHANICAL PUMPING
FIG. 9. For a given species the energy needed for a given scat-
tering coefficient is extremely dependent upon the process.
and chipping was carried out on a whole tree at a time. The
large number of repeat trials done for this study also greatly
enabled any variations to be smoothed by averaging.
Scattering Coefficient and Fibre Length
Averaging of the results over the nine trials produced the rather
striking trend shown in Fig. 6. It is evident that the scattering
coefficient is a well-defined function of the fibre length,
expressed as the ‘L’ factor of the pulp and is completely inde-
pendent of the process used to make it. Equally apparent is that
the relationship is highly dependent on the species, with fir
always yielding higher scattering coefficient than spruce at a giv-
en fibre length.
Adding data from trials for other processes suggests that the
link between scattering and fibre length may be of a general
105:8 (2004) ❘❘❘ 29
 MECHANICAL PUMPING
FIG. 10. For a given speices the position on the scattering
coefficient/long fibre line is determined by specific energy,
refining intensity, temperature, and chemical treatment.
FIG. 12. Processes with higher specific energy require-
ments have more long fibre at a given density.
nature, (Fig. 7). Clearly, a convincing trend between scattering
coefficient and fibre length extends all the way from stone
groundwood to kraft. The implication is that the material need-
ed to produce scattering is derived from the reduction of long
fibre mass and the cutting of fibres during mechanical treat-
ment. Therefore, a compromise must always be struck between
the long fibre content required for strength and the cut materi-
al required for optical properties. As the plot of Fig. 8 shows, for
a given species, scattering coefficient is a function of the quan-
tity of fines and is independent of the process. However, for a
given species, the energy input needed to achieve a certain scat-
tering value is extremely dependent upon the process, as evident
in Fig. 9, where the effects are shown for spruce and fir inde-
pendently and also in combination. The difference arises
because both pre-steaming and reduced refining intensity pro-
mote long fibre development with minimal cutting. This extends
the specific energy which must be applied before a given fines
content is reached.
Four operating parameters determine the position of the
scattering coefficient/long fibre line for a specific wood species:
specific energy, refining intensity, temperature and chemical
treatment, (Fig. 10). The characteristics of the wood and physics
dictate the relationship between scattering coefficient and long
fibre but there are many different ways to move along this line.
For instance, mixtures of kraft and groundwood lie on the same
operating line, (Fig. 11). This was the traditional method of
30 ❘❘❘ 105:8 (2004)
FIG. 11. Mixtures of kraft and groundwood lie along the
same scattering coefficient/long fibre line.
FIG. 13. There is a direct correlation between the long fibre
content at a given freeness and the energy needed to
reach that freeness.
meeting chosen performance targets. In a refiner, changing the
specific energy, refining intensity, temperature or chemical treat-
ment will also change the position on the scattering coeffi-
cient/long fibre operating line. But none of these operating
changes are able to move off this line. Electrical, equipment and
chemical costs will determine the best set of operating parame-
ters to achieve the required properties.
Sheet Density and Fibre Length
A common goal of most mechanical pulping studies has been the
reduction of specific energy consumption. However, accom-
plishing this without compromising pulp quality has proven to be
elusive. The challenge is demonstrated in the plot of handsheet
density against long fibre content, (Fig. 12). In order to achieve
good strength characteristics, the long fibres must be retained as
the sheet surface is improved by increasing density. But, as Fig. 12
shows, this is a process-dependent condition. Moreover, the high-
est long fibre content at a given density is associated with the pro-
cesses having the highest specific energy consumption. Tradi-
tionally, mechanical printing papers were made by combining
groundwood with kraft. Refiner mechanical pulp provides a
longer fibre but increasing the specific energy increases density
at the expense of fibre length. Softening the pulp thermally or
chemically increases the fibre length and increases the potential
for density development in effect by operating on a different
long fibre-density line. This operating line can also be changed
T 184 Pulp & Paper Canada

FIG. 14. A whole diversity of fibre dimensions exists
amongst the various wood species.
by modifying the refining intensity. This suggests that lower refin-
ing intensities, perhaps combined with higher temperatures and
chemical treatment, could produce a high-yield pulp with prop-
erties approaching those of kraft.
IMPLICATIONS
The foregoing observations strongly suggest that the specific
energy needs for mechanical pulp depend to a large degree on
both the quantity of long fibre and the extent to which it is
developed. In fact, additional support for this was obtained
recently in pilot plant trials carried out on a monthly basis using
a Member Company’s wood supply. Each month’s trial included
conventional as well as low-intensity refining and the results were
interpolated to yield both the quantity of long fibre at 100 mL
CSF and the specific energy needed to obtain that freeness. The
plot, (Fig. 13), then shows very clearly the relationship between
long fibre content and specific energy consumption. Moreover,
low-intensity refining does not depart from the trend set by the
conventional process, but merely extends the line towards more
long fibre retention for a given freeness at a correspondingly
higher energy demand. This is in marked contrast to the lower
energy requirements at lower fibre lengths where the freeness is
easily reached by fibre cutting.
The potential to obtain particular pulp properties is deter-
mined by the intrinsic characteristics of the wood fibres
[1,2,5,11]: fibre length, diameter and cell wall thickness. The
scattering of light by an individual fibre is related to the diame-
ter of the lumen and thickness of the cell wall, when the fibre is
collapsed [20,22,31]. For a given species, mature wood will tend
to give longer fibres with thicker walls [13]. Juvenile wood,
which has thinner cell walls, would be more appropriate for
papers that require opacity but are not limited by strength. The
age of the tree is an obvious factor, however any tree has a dis-
tribution of both juvenile and mature wood located at specific
locations in the log [13]. For example, saw mill residuals tend to
contain a higher proportion of the mature wood. This indicates
that for optimizing the properties of a particular grade it is nec-
essary to account for the source of material whether it be in the
form of chips or roundwood or from old or new growth.
Plotting the diverse fibre dimensions of different wood
species gives some insights into their best product applications,
(Fig. 14). At one extreme are the short, thin-walled fibres of
hardwoods such as maple and aspen. At the other extreme we
have the pines and western firs with long, thick fibres.
The thin-walled fibres have the greatest potential to make an
opaque sheet assuming the fibres can be sufficiently collapsed by
either chemical or mechanical action. The short fibres and frag-
ile walls of the hardwoods are best suited to filler grades intend-
ed to raise opacity and perhaps brightness. Aspen CTMP might
Pulp & Paper Canada T 185
MECHANICAL PUMPING
FIG. 15. Low-intensity refining can even out the energy
variations to a given freeness for balsam fir by minimizing
the fibre cutting encountered at conventional refining
intensity.
FIG. 16. Low-intensity refining can improve fibre develop-
ment of more difficult species such as jack pine.
have a niche as a filler pulp in high-quality newsprint, uncoated
specialty ground-wood sheets, or as a supplement to coated
wood-free sheets. Some under-utilized species could give pulps
with greater strength assuming the fibres can be developed with-
out breakage. If for example, we tailor the refining conditions to
the characteristics of the wood, species like Douglas fir and
southern pine probably have greater potential for strength
development than at present. This is something that is not real-
ized under conventional refining conditions. However, a large
amount of energy would be required to reach this potential
which could make this approach impractical.
Of more immediate interest would be balsam fir, which has
relatively long fibres but thinner cell walls than jack pine and
black spruce. This wood, although traditionally less valued than
black spruce, has the potential to make a strong opaque pulp
because of its thin-walled fibres. At the same long fibre content,
balsam fir has a higher scattering coefficient than black spruce,
(Fig. 6). This means that under the right refining conditions bal-
sam fir could provide a more opaque sheet than black spruce at
the same strength. Thus, there would be the potential to make
a sheet of lower basis weight with balsam fir.
The quality of pulp made from balsam fir tends to be more
variable than that from black spruce. In the plot of Fig. 15, the
specific energy required to reach a freeness of 150 mL is shown
for a series of pilot plant refining trials over a two-year period.
The trials with lower energy are not a real energy saving but indi-
cate the fibre has been cut leading to poorer strength proper-
ties. By lowering the refining intensity it is possible to put more
energy into the pulp which can reduce this variation. Although
105:8 (2004) ❘❘❘ 31
 MECHANICAL PUMPING
jack pine has a reasonable fibre length the
pulp does not develop well under con-
ventional refining conditions. With low-
intensity refining, it is possible to make
jack pine look like black spruce pulp,
(Fig. 16). This demonstrates the potential
to make mechanical pulp from wood
species that have been under-utilized
because of quality considerations.
SUMMARY
Examination of an extensive amount of
data gathered from various mechanical
pulping trials has identified the following
two key features which all of these pulps
appear to have in common:
1. For a given species, scattering coeffi-
cient is a well defined function of fibre
length and can only be increased by fibre
length reduction.
2. For a given process, density increases as
fibre length decreases. The higher the fibre
length at a given density, the higher the spe-
cific energy consumption of the process.
When these features are combined
with the fibre characteristics of the wood
species, a more optimal use of our wood
resources should result.
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Résumé: Trois propriétés indépendantes doivent être optimisées simultanément pour les
papiers impression mécaniques légers : le coefficient de dispersion pour l’opacité, la longueur des
fibres pour la résistance, et la densité pour l’imprimabilité. Pour une essence de bois donnée, il y
a une seule relation entre le coefficient de dispersion et la longueur des fibres, des pâtes
mécaniques aux pâtes raffinées aux pâtes kraft. On peut obtenir un meilleur développement des
fibres longues avec moins de coupures, en mesurant la densité, en réduisant l’intensité de raffi-
nage, ou en accroissant le traitement ou chimique ou la température.
Reference: MCDONALD, D., MILES, K., AMIRI, R. The nature of the mechanical pulping
process. Pulp & Paper Canada 105(8): T181-186 (August 2004). Paper presented at the 2003 Intl.
Mechanical Pulping Conference in Quebec City, QC, June 2-4, 2003. Not to be reproduced with-
out permission of PAPTAC. Manuscript received September 29, 2003. Revised manuscript
approved for publication by the Review Panel on December 19, 2003.
Keywords: MECHANICAL PULPING, LIGHT WEIGHT PAPERS, PRINTING PAPERS, OPAC-
ITY, STRENGTH PROPERTIES, PRINTABILITY, REFINERS, VALUE ADDED PRODUCT
T 186 Pulp & Paper Canada