Chapter 3

Among the cooks made for run No. 142 are Nos. 312 and 313, in which the concentration of the caustic soda was raised to 113 and 116 grams per liter and the percentage employed was also increased. In spite of these increases the stock from these two cooks did not show any appreciable improvement when dumped from the rotary. Stock from cooks Nos. 310, 311, and 312 was given a medium brush and washing of one hour, bleached with 10.95 per cent of bleach, made into a furnish consisting of 15.2 per cent of sulphite and 84.8 per cent of hurd stock, loaded with 15.2 per cent of clay, sized with 1.28 per cent of resin size, given a medium brush for one hour, tinted, and pumped to the stock chest. Stock from cooks Nos. 313 and 314 was treated in exactly the same manner, except that 11.4 per cent of bleach was used. It was pumped to the stock chest and mixed with the furnished stock from cooks Nos. 310, 311, and 312. A medium Jordan brush was given the stock and it acted well on the paper machine, which was speeded to 75 feet per minute. There seems to be a tendency in the hurd stock to crush a little at the "dandy roll," and although the marks are not removed by the calender stack which was employed in those tests it was found that one "nip" on the supercalenders renders them practically imperceptible and it is believed that the proper size and weight of calender stack would entirely remove these marks. All of the papers produced up to this point are somewhat lacking in the bulk desired in a book paper; therefore, in the two following runs soda-poplar stock was included in the furnishes.

In run No. 143 stock from cooks Nos. 315 and 316 was given a medium brush and washing for one hour and was medium brushed for one hour more, bleached with 11.3 per cent of bleach assisted with one-half pint of oil of vitriol, made into a furnish of 16.5 per cent of sulphite, 22.3 per cent of soda poplar, and 61.2 per cent of hurd stock, loaded with 22 per cent of clay, sized with 1.38 per cent of resin size, given a hard brush for one hour, tinted very strongly, and pumped to the stock chest. This stock was beaten to a greater extent than in previous runs. The stock was run on the paper machine at a speed of 75 feet per minute, using a medium Jordan brush, and no trouble whatsoever was experienced. Not over 2 pounds of "broke" was produced during the whole run, and that was in the "threading" of the machine. The color of the sheet is entirely satisfactory for many uses. The wood shives apparently were reduced to a satisfactory degree. Experienced paper makers commented very favorably on the running of this furnish and the quality of the paper produced.

Run No. 144 was intended as a duplicate of run No. 143. Stock from cooks Nos. 317 and 318 was given a medium brush and washing for one hour and a further medium brush of one hour, bleached with 11.4 per cent of bleach, and made into a furnish composed of 15.5 per cent of sulphite, 23.5 per cent of soda poplar, and 61 per cent of hurd stock, loaded with 21.4 per cent of clay, sized with 1.17 per cent of resin size, hard brushed for one hour, tinted by the expert colorer of the company, and pumped to the stock chest. Stock from cooks Nos. 319 and 320 was treated in exactly the same manner except that the stock was bleached with 12.1 per cent of bleach and pumped to the stock chest to mix with the former furnish. The stock acted very well on the machine, which was speeded to 75 feet per minute, with the Jordan refiner set at a medium brush. The sheet is as good, if not better, than that of run No. 143, and it is also a good illustration of the extent to which proper tinting will enhance the general appearance of a paper. The poor appearance of the samples of previous runs is due largely to lack of proper tinting. Various degrees of whiteness, however, are demanded by the trade.

=COMPARISON OF THE TESTS AND COMMERCIAL PRACTICE.=

In work of this nature and on this scale it is practically impossible to arrive at a cost figure which would be susceptible of commercial interpretation, and in this preliminary publication nothing will be attempted beyond a comparison of the process used with the hurds with that process commercially applied to poplar wood. The process last used with the hurds should not be regarded as final, satisfactory, or most suitable, as it has been shown that progress was being made up to the conclusion of the work.

In comparing the method of using hurds with the method of handling poplar wood, a difference is apparent on the delivery of raw material at the mill. Ordinarily, poplar is received at the mill in the form of logs about 4 feet in length, which may be stored in piles in the open. Hurds very likely would be received baled, and it would seem advisable to store them under cover for the following reasons: (_a_) Baled hurds would probably absorb and retain more water during wet weather than logs of wood, thereby causing excessive dilution of the caustic liquor; (_b_) prolonged excessive dampness might create heating and deterioration unless the hemp were properly retted; (_c_) wet hurds could not be sieved free from sand and chaff. Should further work show that the first two reasons need not be taken into consideration, the third objection might be overcome by sieving the hurds before baling. Even then, it is probable that baled hurds stored in the open would accumulate and retain considerable dirt from factory chimneys, locomotives, and wind. Checked pulp wood exposed in the open invariably suffers from these causes.

In the preparation of the raw material for the digesters there is likewise considerable difference between hurds and poplar wood. The former apparently requires only a moderate sieving to remove sand and chaff, which operation doubtless would require only a small amount of labor and the installation of some simple machinery of low power consumption. In preparing poplar for digestion, the 4-foot logs are chipped by a heavy, comparatively expensive chipper of high power consumption, after which the chips are sorted by sieving, the large pieces being rechipped. There would be a noteworthy difference in the installation, operating, and depreciation costs of the two equipments, and this difference would counterbalance to a considerable extent the difference in cost of raw material storage.

It is possible that in the use of the chip loft more care would have to be exercised in using hurds because of the tendency of the bast fiber to cause lodgments, but this should not be considered a serious difficulty.

The weight of hurds which are capable of being charged into a rotary is a decidedly unfavorable factor. The weight of a cubic foot of hurds varies somewhat with the proportion of bast fiber, but averages about 5.4 pounds, which, compared with a cubic foot of poplar chips at 8.93 pounds, represents a digester charge of 60.5 per cent of the weight of a poplar-wood charge, or, in terms of fiber capacity, the hurds charge would yield 38.6 per cent as much fiber as the wood charge. The hurds upon being baled for transportation may be broken and crushed to such a degree that the weight of the charge may be increased, and it might be found possible to increase the charge weight by steaming or by the employment of tamping devices. This small weight of charge constitutes one of the most serious objections to the use of hurds in paper manufacture.

In those tests in which the most satisfactory results were obtained, the cooking conditions were 29.5 per cent of caustic soda at a concentration of 107 grams per liter and a causticity of 84.0 per cent acting at a temperature of 170° C. for five hours, or a total time of seven hours. The steam condensation in the rotary used for these tests was abnormally high, due to the fact that the steam supply pipe was uncovered for a considerable distance and the rotary was entirely uncovered. It is believed, therefore, that a larger amount of caustic was necessary than would otherwise have been the case. This belief is strengthened by the quality of the waste liquor from one of the later cooks, which gave on analysis 16.85 grams per liter of free caustic soda and showed a causticity of 27.75 per cent. These data show that only 67.3 per cent of the total caustic employed was actually consumed in the cooking operation, which percentage is lower than obtains in practice. The stock from this cook was bleached with 11.5 per cent of bleach. But even as the figures stand, the comparison with poplar cooking practice is as follows: 29.5 per cent caustic soda used as against 22 to 25 per cent; 107 grams per liter as against 100 to 110; 84 per cent causticity is little different than obtains in practice; 170° C. is about commercial practice; five hours at pressure as against four to six hours; seven hours' total time as against possibly six to eight hours; 11.5 per cent bleach as against 8 to 10 per cent. Thus, it is evident that the cooking conditions employed were slightly more severe and expensive than those in commercial use with poplar wood.

The yield of total fiber obtained from the hurds may be placed at 35 per cent of bone-dry fiber calculated on the bone-dry weight of hurds used, or 33.1 per cent of air-dry fiber calculated on air-dry hurds. The yield of bleached fiber was not determined in this preliminary work, but may be safely estimated as 30 per cent, which is low when compared with a yield of about 47 per cent of bone-dry bleached fiber from bone-dry poplar wood. It is believed quite possible that satisfactory cooking conditions may be found which will give a higher yield than was obtained during these tests. The stock should be classed as easy bleaching, and 11.4 per cent of bleach is a satisfactory figure, although a little high.

As to beating cost, in the last two and most satisfactory tests the total washing and beating time was three hours, which may be about an hour more than ordinarily is used in making papers of this grade, although the practice varies to a considerable extent.

In regard to furnish, there is such a diversity of practice that it is difficult to make a comparison, but if the hurd stock can be produced as cheaply as soda-poplar stock, the furnish used in these last two tests should be regarded as satisfactory to the book and printing paper manufacturer.

The finish of the paper was not all that might be desired, but that was due almost entirely to the calender stack available for the work, which was composed of nine light rolls, many of which were about 6 inches in diameter and which had not been reground for some time. From a small test on a large calender stack it was readily shown that the paper produced is capable of taking a satisfactory finish.

This comparison, satisfactory in many respects, develops two factors which are decidedly unfavorable to hemp hurds, namely, raw-material storage and digester capacity, and they must be taken into full account in considering the paper-making value of this material, although it should be recognized that investigation may result in the material improvement of these conditions. Moreover, it is not at all improbable that further investigation would develop more satisfactory treating conditions and more suitable furnish compositions, and the belief in this possibility is strengthened by the fact that material progress was being made at the conclusion of this preliminary work.

Calculations on the raw material and acreage for a permanent supply for a pulp mill producing 25 tons of fiber a day for 300 days per annum, or 7,500 tons per annum, give the comparison between hurds and wood shown in Table II.

TABLE II.--_Comparison between wood and hemp hurds._

+-------------+--------------+-----------+-------------------- | | | | Acres required for | | | | sustained supply. | | | |---------+---------- | | Raw material | Annual | | Material. | Pulp yield. | required per | growth | For | For 1 ton | | year. | per acre. | 25-ton | of fiber | | | | mill. | per year. -----------+-------------+--------------+-----------+---------+---------- Wood | Two cords | 15,000 cords | 0.37 cord | 40,500 | 5.4 | yield 1 ton | | (about | | | of fiber. | | 0.55 ton).| | | | | | | Hemp hurds | One ton | 25,000 tons | 2.5 tons | 10,000 | 1.33 | yields 600 | | | | | pounds | | | | | of fiber. | | | | -----------+-------------+--------------+-----------+---------+----------

The most important point derived from this calculation is in regard to areas required for a sustained supply, which are in the ratio of 4 to 1. Every tract of 10,000 acres which is devoted to hemp raising year by year is equivalent to a sustained pulp-producing capacity of 40,500 acres of average pulp-wood lands. In other words, in order to secure additional raw material for the production of 25 tons of fiber per day there exists the possibility of utilizing the agricultural waste already produced on 10,000 acres of hemp lands instead of securing, holding, reforesting, and protecting 40,500 acres of pulp-wood land.

The annual growth per acre, although decidedly in favor of hurds, has little bearing on the project, because the utilization of the hurds is subordinate to the raising of hemp, and the paper manufacturer probably could afford to use only hurds resulting from the hemp industry.

=PHYSICAL TESTS OF THE PAPERS PRODUCED.=

Samples of paper produced in the seven tests were submitted to the Leather and Paper Laboratory of the Bureau of Chemistry. The report of that bureau on its tests is given in Table III.

TABLE III.--_Report of the Leather and Paper Laboratory of the Bureau of Chemistry on papers manufactured from hemp hurds._

+-----+------+-------------------+----------+ | | | Weight of 500 | | Laboratory | Run | | sheets. |Thickness,| No. | No. | Ash. +---------+---------+ 1/10000. | | | | | | | | | |25 by 38.|25 by 40.| | | | | | | | -----------+-----+------+---------+---------+----------+ | |_Per | | | | | | ct._ |_Pounds._|_Pounds._| | 31570 | 144 | 13.9 | 48 | 50-1/2 | 33 | 31571 | 143 | 14.5 | 49 | 51-1/2 | 35 | 31572 | 142 | 9.5 | 49-1/2 | 52 | 33 | 31573 | 141 | 10.9 | 48 | 50-1/2 | 38 | 31574 | 140 | 11.4 | 42 | 44 | 30 |[Transcriber's 31575 | 139 | 13.4 | 55 | 58 | 40 | note: Table III 31576 | 138 | 10.4 | 56 | 59 | 40 | continues below] -----------+-----+------+---------+---------+----------+

+--------------------------+----------+------------------------- | Strength (Mullen). | | Folding endurance. Laboratory | | Strength | No. +--------+--------+--------+ factor +-------------+----------- | | | |(25 by 40,| | |Average.|Maximum.|Minimum.| 500). |Longitudinal.|Transverse. | | | | | | -----------+--------+--------+--------+----------+-------------+----------- | | | | | | | | | | | | 31570 | 15.0 | 17.0 | 11.0 | 0.30 | 5 | 3 31571 | 14.0 | 14.0 | 13.0 | .28 | 4 | 4 31572 | 19.0 | 20.0 | 19.0 | .37 | 8 | 6 31573 | 16.5 | 18.0 | 11.0 | .33 | 10 | 8 31574 | 14.5 | 16.0 | 13.0 | .33 | 7 | 6 31575 | 19.5 | 20.0 | 17.0 | .34 | 8 | 5 31576 | 20.0 | 20.0 | 19.0 | .34 | 23 | 15 -----------+--------+--------+--------+----------+-------------+-----------

There is no system of numerically recording the general appearance and "look through" of a paper, but it can be stated that only papers Nos. 143 and 144 are satisfactory in these respects, the other samples being more or less thickly specked with shives. The general character and tests of these papers correspond very closely with No. 1 machine-finish printing paper, according to the specifications of the United States Government Printing Office, which call for a sheet not exceeding 0.0035 inch in thickness, strength not less than 12 points, free from unbleached or ground wood pulp, and ash not over 10 per cent. The strength factor of such papers is about 0.28. The ash should not be over 10 per cent for this grade of paper, but in spite of the larger amount used the physical tests are sufficiently high. It is to be noted that the physical tests of samples Nos. 138 to 142, inclusive, are higher than in Nos. 143 and 144, in which 23 per cent of soda poplar was used, which shows clearly that hemp-hurd stock imparts strength and folding endurance to a greater extent than does soda-poplar stock. From these preliminary tests it would be concluded, therefore, that hemp-hurd stock acts similarly to soda-poplar stock, but will produce a somewhat harsher and stronger sheet and one of higher folding endurance. Undoubtedly, there is more dirt in the samples than would be tolerated by the trade, but this was to be expected, since in this preliminary work the raw material was sieved by hand screens instead of by automatic machines which would sieve more thoroughly.

=CONCLUSIONS.=

There appears to be little doubt that under the present system of forest use and consumption the present supply can not withstand the demands placed upon it. By the time improved methods of forestry have established an equilibrium between production and consumption, the price of pulp wood may be such that a knowledge of other available raw materials may be imperative.

Semicommercial paper-making tests were conducted, therefore, on hemp hurds, in cooperation with a paper manufacturer. After several trials, under conditions of treatment and manufacture which are regarded as favorable in comparison with those used with pulp wood, paper was produced which received very favorable comment both from investigators and from the trade and which according to official tests would be classed as a No. 1 machine-finish printing paper.