Abstract: The present invention provides a core for receiving a wound product wherein the core is made of a waste sludge produced in a papermaking process. The process for making the core includes the steps of mixing the sludge with a binder material, which may be either a wet strength or a dry strength agent, and then compressing the mixture into a core through a process such as extrusion or molding. Optionally, the sludge may be dried prior to mixing with the binder material.

Abstract: A method of treating solid-containing material contained in or produced from an effluent or waste from a process for the treating of waste paper. The solid-containing material includes constituents of the waste paper and organic material including cellulose fibers and inorganic particulate material including calcium carbonate and other inorganic particulate material included in the waste paper. The solid-containing material is subjected to a heat treatment that incinerates the organic material present and forms from the inorganic particulate material present a calcined product including calcium oxide from thermal decomposition of calcium carbonate. The calcined product is formed into an aqueous suspension wherein calcium oxide is converted to calcium hydroxide.

Abstract: A method for burning secondary sludge in a recovery boiler, in which method secondary sludge is mixed with black liquor. According to the method, an alkali is added to the secondary sludge so as to obtain a mixture having a pH of over 7, whereafter the mixture of alkali and secondary sludge is heated to a temperature of over 80.degree. C. and kept at this temperature for over 30 minutes. Thereafter the heat treated mixture of alkali and secondary sludge is supplied to the thick end of a black liquor evaporation plant.

Abstract: Paper mill sludge is reclaimed and useful products produced therefrom. A predetermined amount of paper mill sludge is continuously discharged from a storage reservoir onto a mixer/conveyor to create a first reactant stream. A predetermined amount of calcium oxide is input into the first reactant stream from a calcium oxide reservoir. The calcium oxide and paper mill sludge are mixed as they travel along the mixer/conveyor to form a first intermediate mixture. After a time period sufficient to allow for the reaction of the calcium oxide and paper mill sludge, a predetermined amount of diatomite is added to the reactant stream from a diatomite storage reservoir. The first reactant stream, now comprising the first intermediate mixture of paper mill sludge and calcium oxide combined with diatomite, forms a useful, environmentally safe product.

Abstract: A method for processing recycling mill sludge into pulp, and cellulosic products made from such pulp, is described. The method for forming cellulosic pulp comprises first forming an aqueous composition in a pulper comprising recycling mill sludge, caustic agent, bleaching agent and a chelating agent. The aqueous composition also preferably includes a deinking agent and sodium silicate. The composition is then processed in the pulper for a period of time sufficient to form pulp from recycling mill sludge. The disclosure also describes a method for forming cellulosic products. The method comprises forming a cellulosic pulp from recycling mill sludge, and thereafter forming cellulosic products from the pulp. The method for forming cellulosic products may further comprise forming a pulp mixture comprising from about 1 to about 40 percent pulp from recycled materials and recycling mill sludge, and from about 99 to about 60 percent virgin pulp.

Abstract: The invention described in the specification relates to a process and apparatus for the reduction of adsorbable organic halide (AOX), chemical oxygen demand (COD) and color bodies from the filtrates generated in a chlorine compound-containing pulp bleaching sequence. The method involves vigorously and intensely mixing certain pulp bleaching filtrates in order to lower the AOX content of the filtrate and the use of a peroxy compound and a ferrous salt catalyst to treat a combined filtrate streams thereby significantly reducing the level of AOX, COD and color in the effluent leaving the pulp bleaching plant.

Abstract: The specification discloses an unorthodox system for manufacturing strong, light-weight and weather-resistant cellulosic composite materials from discarded paper and newsprint, and papermill sludge--and from an unlimited variety of particulated fibrous lignocellulosics--without the use of an extrinsic adhesive. Both the matrix-forming resin and the fiber-substrate, which comprise the entire composite, are spontaneously created in situ at ambient conditions by the ammoniation of a mixture of a protein-containing material and a particulated cellulosic. Heating an article shaped from such a mixture to above 175.degree. C. polymerizes the resin and bonds the fiber-substrate into a cellulosic composite product. Also disclosed is a process for manufacturing reinforced and laminated composites as well as a composition which simplifies the production of both cellulosic composites and all-biomass thermosetting resins.

Abstract: A process and an apparatus for recovering clay and fiber from papermaking sludge. The sludge is dried, milled, and separated into distinct clay and fiber components. The fiber component of the sludge is then used as an alternative fuel source. The clay component can be used as recycle into the papermaking process, a masonry additive, or for any other suitable purpose.

Abstract: Provided are methods of dry recovering useable fiber from paper making sludge. In the methods, paper making sludge is dewatered and dried. The dewatered and dried sludge is then fiberized using a dry fiberizing machine into a fibrous material consisting of fibers and other material including fiber fines, clay, filler material and the like. The fibers in the fibrous material are then separated out in a sifting process. The separated fibers are then ready for use in paper making without further processing. The fiber fines and filler material separated from the fibers is also collected and can be used as filler material in other composite material applications.

Abstract: A continuous flow process for treating waste cellulosic fiber or paper mill sludge wherein calcium oxide, silica and water are blended with waste cellulosic fiber or paper mill sludge such that a pH is reached of between 10.5 and 12 to provide a treated mixture. The mixture is agitated such that it is dried and fluffed for use as an environmentally safe filler material.

Abstract: Deinking by-product from wastepaper recycling operations and pulp mill clarifier sludge are incorporated into drywall or other gypsum-based building products, such as building blocks. The deinking by-product or pulp mill clarifier sludge is diluted and mixed with stucco (calcium sulfate hemihydrate). The resulting slurry preferably is subjected to an initial dewatering, following the on-set of hardening of the gypsum, and drywall or other building product is formed from the dewatered material. A significant loading of fibrous material in the drywall sheet or other gypsum product is achieved using the procedure, imparting improved flexural strength to the product. The preferred procedure also may be used to incorporate virgin or recycled wood pulp into the building product.

Abstract: In a process for the recovery and re-use of raw materials from paper mill waste sludge, the sludge is subjected to a preliminary cleaning treatment at a relatively low consistency, thickened to a consistency of 10 to 30%, heated to at least 100.degree. C. and then passed through a disperser in the thickened heated state before being passed to a papermachine for re-use. Papermaking fibre from at least one other source is mixed with the sludge before and/or after treatment as just described, so that the final paper product typically contains up to 30% of raw materials recovered from sludge. The action of the disperser is to break up dirt and other debris, and as a result, the recovered raw materials can be re-used in the manufacture of high quality fine papers.

Abstract: The invention relates to a process for controlling the deposition of stickies from paper stock suspensions in papermaking. According to the invention, the deposition of stickies is controlled by addition of an effective quantity of a degradation product of native starch to the paper stock suspension.

Abstract: A system for recovering fiber from sludge by-products generated in a pulp and paper mill. Initially, heavy materials are separated from a sludge flow, with the flow thereafter separated into first and second components. High grade fiber is recovered from the first component by centrifugal cleaners and also by optional fine pressure screens. The second component is forwarded to a refiner which breaks-down the second component to form a low grade pulp. In addition, after removal of the high grade fiber, remnants from the first component flow are forwarded to an additional separator such as a liquid cyclone, which removes sand, grit and ash, and thereafter the remnants of the first component can be sent to the refiner for forming a low grade pulp. Thus, the sludge is essentially separated into four components including: (1) high grade pulp; (2) low grade pulp; (3) heavy materials; and (4) sand, grit and ash.

Abstract: A method of treating an aqueous system is disclosed. The method may be used to treat sewage streams as well as aqueous streams in pulp and paper mill processing. The method includes the steps of adding a polymeric composition to an aqueous stream. The composition is an anionically modified acrylamide polymer in an aqueous medium. The polymer is formed by reacting an acrylamide polymer with phosphorous acid, and has at least 5 mole percent phosphonate groups based on the acrylamide content of the polymer, and has a molecular weight of at least about 40,000. the pH of the composition is adjusted to at least about 7.7.

Abstract: Degradable particulate absorbent materials and processes for manufacture, wherein the absorbent materials have: i) in most forms of the invention, on the order of not more than 10% by weight inorganic solids or "fillers" and in all cases less than 30% inorganic solids by weight; ii) an open, porous, shot-like fiber structure with low bulk density on the order of not more than 30 lbs./ft..sup.3 and, preferably, in the range of 15 to 18 lbs./ft..sup.3.

Abstract: A process for the production of a papermaking filler product from the fiber fines/clay fraction of a pulp, paper, paperboard, or deinking mill waste solids such process comprising the reaction of said solids with sufficient acid to lower and maintain a pH of less than 5.0. Such process yields improvement in the drainage characteristics of the material. Bleach can be added or the pH raised back to neutral to further improve the specific resistance and/or brightness of the material.

Abstract: A method for producing a low-structure magnesium silicate SLR product useful to lower the strike through of low brightness paper products comprises adding a raw mineral source of soluble magnesium ions and sulfuric acid in a proportion and under conditions effective to form a slurry comprising soluble magnesium sulfate and a silica leach residue (SLR), and adding to the slurry a solution of an alkali metal silicate in a molar equivalent proportion of MgO:SiO.sub.2 of 1:2.0-4.0 under conditions effective to precipitate the magnesium ions and form a product comprising a low-structure magnesium silicate and SLR having a proportion of SiO.sub.2 MgO:SLR of 50-75%:5-12%:10-50% by weight of the product.A low-structure magnesium silicate SLR filler comprises 50 to 75 wt % SiO.sub.2, 5 to 12 wt % MgO, 10 to 50 wt % SLR, 0 to 6 wt % Fe.sub.2 O.sub.3, and 0 to 7 wt % Al.sub.2 O.sub.3, wherein the proportion MgO:SiO.sub.2 is 1:2.0-4.0.A paper product comprises at least an amount of the filler of the invention.

Abstract: A method and apparatus for making productive use of waste products such as spoiled, waste, or surplus paint and ink and waste slurry from pulp products manufacturing includes dewatering the waste slurry to obtain fiber from the slurry, drying the fiber in bulk, and combining the fiber with a mixture of paint and/or ink to create a moldable mixture. The mixture is formed into a utilitarian shape and cured or dried to form a solid object. In another aspect, there is provided a portable, self-contained apparatus for receiving waste and surplus paint and/or waste and surplus ink and fiber waste, and producing molded products using the method described above. The portable apparatus may be located temporarily at a site where such wastes are generated to avoid the transportation of wastes that is made expensive by mandated transportation safety regulations. A further aspect of the invention comprises useful article fabricated from waste materials using the method described above.

Abstract: A process for the production of papermaking fiber or pulp from waste solids emanating from pulp and paper mills, particularly waste solids in process water streams containing fibrous solids that cannot be directly recycled by paper mill "saveall" devices, from pulp and paper mill process water streams conveyed by the sewerage system to wastewater treatment plant facilities, and from "sludge" emanating from the underflow of a primary clarifier or sedimentation basin at pulp and paper mill wastewater treatment facilities either before or after the "sludge" is thickened and dewatered.

Abstract: A process for the production of papermaking fiber or pulp from waste solids emanating from pulp and paper mills, particularly waste solids in process water streams containing fibrous solids that cannot be directly recycled by paper mill "saveall" devices, from pulp and paper mill process water streams conveyed by the sewerage system to wastewater treatment plant facilities, and from "sludge" emanating from the underflow of a primary clarifier or sedimentation basin at pulp and paper mill wastewater treatment facilities either before or after the "sludge" is thickened and dewatered.

Abstract: Degradable particulate absorbent materials, together with processes for manufacture thereof, wherein the absorbent materials: (i) have, in most forms of the invention, only on the order of 0% to 10%, by weight, of inorganic solids or "fillers", and in all forms have less than 30% inorganic solids by weight; (ii) are not in pellet form; (iii) are characterized by an open porous fiber structure having relatively low bulk densities on the order of not more than 13 lbs./ft..sup.3 and preferably only from about 6 to about 10 lbs./ft..sup.

Abstract: An oil and grease absorbent material formed from treated paper sludge or other fibrous slurries and a method of treating the slurry to form the material which includes the physical properties of clay absorbents. The method involves the addition of materials to the shredded slurry to control color, bacteria, fungi, and density. A quantity of lipophyllic ray cells are added to the slurry to increase oil absorbency. The slurry is then formed into granules and dried before packaging.

Abstract: A method of making agglomerated cellulosic particles, particularly useful as a cat litter, comprises agglomerating a moist blend of fibers, aggregates of fibers, and/or fiber-sized pieces of a fibrous cellulosic material in a substantially horizontal rotating drum to form agglomerated particles; compacting surfaces of the particles; and drying the particles.

Abstract: A material for scavenging oil slick and/or oleaginous fluids comprising paper-machine sludge combined in the presence of water with a hydraulic cement and dried.

Abstract: A method for recovery of wastewater residues containing the activated sludge biomass, fibre and bark comprising the steps of treating these with alkali solution having a concentration of 5-80 g/l on the Na.sub.2 O basis at a temperature of 20.degree.-70.degree. C. and dewatering the reaction mixture obtained, the alkali filtrate decanted containing the activated sludge alkali hydrolysis products being used to dissolve the melt in the course of preparing the alkali pulping liquor, and the dewatered alkali mass being added, in an amount of up to 40 percent by mass, to the fibred mass composition for the manufacture of cardboard and wood-fibre board.

Abstract: A soft fluffy light weight substance comprising cellulose fibers and clay suitable as a filler and insulatng material, which is dispersible and absorbent in oil but which is not dispersible or absorbable in water, is made from paper making sludge by heating the sludge with mechanical agitation at about 350.degree. F. to evaporate all water therefrom and convert the product to lipophilic granules which are then milled in a hammer mill and forced through a screen of 3/64-5/64 inch mesh.

Abstract: An incombustible material containing at least one mineral substance, and including a first ingredient composed of a plurality of pieces constituted by fibers of cellulose and/or chips of wood shavings, with the pieces forming a network, a mass of thermosetting synthetic resin gluing the pieces of the first ingredient together, and particles of calcium sulfate, boric acid and an at least partially glass or ceramic forming mineral adhering to the fibers and/or chips.

Abstract: An article, such as a pallet having a substantially flat deck member and a plurality of hollow legs projecting from the deck member, is molded as a one-piece unit from a papermill sludge. Dried, comminuted papermill sludge is blended with a fibrous reinforcing material, preferably a cellulosic material such as fibrous bark particles, and a resinous particle board binder, the resulting mixture of furnish is formed into a loosely fitted mat, and the mat is placed between dyes of a mold and press and compressed to substantially the desired shape under temperature and pressure conditions sufficient to bond the sludge and bark particles together.

Abstract: A solar chemical process for converting sewer sludge from a gelatinous mass into a manageable product suitable for fertilizer includes the manufacture of a carbonaceous product by treating cellulose waste such as newspaper with sulfuric acid and heating the mixture until the cellulose product becomes substantially black. The black product is mixed with sludge in a ratio to produce a grainy product that can be chlorinated for sterility and spread as fertilizer. In a modified version of the process, coal ash is added to the sludge with the carbonaceous product for its nutrient value, and sand may be added with the coal ash to aid in aeration of the soil.

Abstract: An improved method for producing acoustical fiberboard, which method comprises adding agglomerate articles formed from an aqueous composition comprising fiberboard dust, a glactomannan gum or glactomannan gum derivative, and a crosslinking agent to an aqueous fiberboard slurry, is disclosed. The resulting acoustical fiberboard exhibits excellent sound absorption.

Abstract: A method for producing shaped bodies of fibrous materials using mineral fibers, cellulosic fibers, and zero fibers. The zero fibers are extremely thin and short cellulosic fibers produced either synthetically or from natural by-products from the cellulose industry. These bodies can be used as substitutes for asbestos fiber products, and display physical properties, such as resistance and rigidity, comparable to the asbestos products. The fibrous materials are produced using an aqueous dispersion of the mineral fibers, cellulose fibers, and zero fibers, whereafter the dispersion is de-watered, shaped and dried.

Abstract: A process for the disposal of paper pulp mill sludge by incorporating the sludge in the digestion step of a wood pulping operation without detrimental effects on the quality of the pulp obtained. In one aspect, the sludge is surplus sludge which is obtained from a system which microbiologically purifies spent wood pulping liquor by aeration and sedimentation.