Effects of D0-stage temperature, pH, and kappa factor on chlorine dioxide decomposition and D0-(EP)-D1 bleaching performance for eucalypt pulps

Mills have largely used chlorine dioxide (ClO2) for eucalyptus kraft pulp bleaching. Different mills have observed significant variation in ClO2 demand to reach full brightness (≥90 ISO). These large differences in ClO2 consumption derive from many factors. The most significant include differences in carryover loads and hexenuronic acid (HexA) contents and the level of chlorate formation across bleaching. Handling of pulp with high HexA content and ClO2 losses to chlorate can be minimized by proper operation of the ClO2 stages across the bleach plant. An oxygen delignified eucalyptus kraft pulp with a kappa of 10-12 units contains only 4-6 units actually derived from lignin. This scarce amount of lignin (0.6%-0.9%) is not able to consume high ClO2 doses and, as a consequence, the excess ClO2 applied can end up being converted into chlorate. Hence, proper optimization of ClO2 bleaching stages can save significant amounts of this oxidant. This study focused on optimizing ClO2 bleaching for a typical oxygen delignified eucalyptus kraft pulp of kappa number 11.7. Elemental chlorine free bleaching was carried out with the D0-(EP)-D1 sequence. The following conditions were varied in the D0 stage: temperature, end pH, and kappa factor. The results indicated that maximum ClO2 bleaching efficiency is achieved when minimum chlorate is formed, especially when ClO2 bleaching is adjusted in such a way that residual active chlorine is maintained to a minimum. The most significant variable affecting chlorate formation is pH; however, ClO2 doses (ClO2 concentration) also play a very important role. Chlorate formation is more intense in the D1 stage in relation to the D0 stage. Optimum conditions to run the D0 stage were 90°C, 3.5 pH, and 0.22 kappa factor.