WPS 522:

"Chemical Principles for the Papermaking Process Engineer"
(See Syllabus, next item below)


Fall 2007 Semester, WPS 522 Sec. 601

Instructor: Martin Hubbe, Professor
Phone: (919) 513-3022
E-mail: hubbe@ncsu.edu (best way to contact)
Office Hours: MWF 10:00 to 10:45 AM and by arrangement
Office: Biltmore 1206 (new section of building, Robertson wing, ground floor)
Syllabus: http://www4.ncsu.edu/~hubbe (Click on "WPS 522"); also in Course-Pack
Course-Pack (if you have trouble getting it from the WebCT system): You buy through instructor, approx. $24 to cover copying at local Sir Speedy and mailing

Online quizzes: http://webassign.ncsu.edu , then use your UNITY ID and password.

Course Calendar, Fall 2007

Week Dates

Assignment Due
Note: The online quiz cut-off is usually 11 PM of day before the chapter reading assignment is due (except for first two, etc.).

1 August 23-25 FIRST WEEK OF CLASS. Watch introductory video (marked "Ch. 1" or "Ch. 0"). Read Course-Pack (CP), Chapter 1: Papermaking process overview; Complete the first chapter online quiz BEFORE you watch the video for Chapter 1 (marked 1A).
2 August 28-Sept. 1 Read Appendix A of the course-pack carefully. The definitions will be on the first test and you will be asked about them on various quizzes. Watch the video for chapter 1 (marked 1A) and respond e-mail your answers to the lecture questions and the problems at the end of the chapter in the coursepack. Read CP Ch. 2: Aqueous chemistry basics for papermakers. Complete the Second chapter online quiz promptly before you watch the video. Then watch the video for chapter 2 and send an e-mail with your answers to the lecture questions.
3 Sept. 6-8

Read CP Ch. 3: Principles of soluble polymers and their use. Online quiz 3 due. Watch the video for chapter 3 and send an e-mail with your answers to the lecture questions.
Read CP Ch. 4: First-pass retention, formation, and related concepts. Online quiz 4 due. Then watch the video for chapter 4 and send an e-mail with your answers to the lecture questions.
DEADLINE TO SELECT GENERAL TOPIC AREA FOR YOUR TERM PAPER
Chapter homework due for Ch. 2 by end of week.

4 Sept. 11-15

Read CP Ch. 5: Surfaces of fibers, fines, and fillers. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 3 and Ch. 4 by end of week.

5 Sept. 18-22 Read CP Ch. 6: Introduction to colloids; what makes a suspension stable. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 5 and Ch. 6 by end of week.
6 Sept. 25-29

Read CP Ch. 7: Paper process additives, their chemistry & properties. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Read
CP Ch. 8: Strategies of chemical preparation, dilution, and use. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 7 by end of week.

7 Oct. 2-6

Read CP Ch. 9: Papermaking functional additives. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
DEADLINE TO PROVIDE A PARTIAL BIBLIOGRAPHY FOR YOUR TERM PAPER, FOLLOWING THE FORMAT PROVIDED
Chapter homework due for Ch. 8 and Ch. 9 by end of week.

8 Oct. 9

Schedule your Mid-Term Test this week with your Proctor.
Read
CP Ch. 10: Sizing and surface sizing, Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.

9 Oct. 16-20 Read CP Ch. 11: Starch, and dry strength. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Read CP Ch. 12: Wet-strength. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 10 and Ch. 11 by end of week.
10 Oct. 23-27 Read CP Ch. 13: Uses of dyes and fillers to control paper's appearance. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Read CP Ch. 14: Retention aids and their use.
Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 12 and Ch. 13 by end of week.
11 Oct. 30-Nov. 3 Read CP Ch. 15: Drainage and formation uniformity, Worksheet: Factors that hurt or help retention aid performance; Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 14 by end of week.
12 Nov. 6-10

Read CP Ch. 16: Substances that interfere with retention and drainage, Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Read CP Ch. 17: Applications of colloidal principles in deposit control, Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 15 and Ch. 16 by end of week.

13 Nov. 13-17 Read CP Ch. 18: Foam and defoamers. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Read CP Ch. 19: Applications of water chemistry in aqueous coatings. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 17 and Ch. 18 by end of week.
14 Nov. 20-22

Read CP Ch. 20: Applications of water chemistry in recycling; Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
DEADLINE FOR DRAFT* OF TERM PAPER, end of week.

Chapter homework due for Ch. 19 and Ch. 20 by end of week.

15 Nov. 27-Dec. 1 Read CP Ch. 21: Lab and on-line tests for slurries and suspensions. Do the corresponding online quiz promtly. Then watch the video for the chapter and send an e-mail with your answers to the lecture questions.
Chapter homework due for Ch. 21 by end of week.
16 Dec. 4-8 Read CP Ch. 22: Wastewater and the environment. (Review for final exam.)
DEADLINE FOR FINAL VERSION OF TERM PAPER (by end of week)
Final Dec. 8-15 Final test time (target 45-60 minutes; closed book) To be arranged with your proctor
Note (*): Those who submit a preliminary draft of their term paper by the end of week 14 ordinarily can expect suggestions for revision of form and content. Implementation of such suggestions will increase the grade of a typical paper by 5 to 10 points. The final term paper will be graded, without regards to the quality of the draft version.

 

SYLLABUS, WPS 522

A. Instructor:

Dr. Martin A. Hubbe
Biltmore Hall 1206
Telephone: (919) 513-3022
E-mail: hubbe@ncsu.edu
Website: http://www4.ncsu.edu/~hubbe/index.htm
Classes held: Fall semester, by distance education, see calendar.
Course delivery:
" Hard copy: Course-pack (see later)
" Web: Course calendar, course-pack, quizzes, readings, confidential grade record
" CD or DVD video of lecture sessions (usually 3 per week, 50 min. max.)
Office hours: Please send an e-mail or leave a phone message if you need to schedule an extended phone discussion. Students are welcome to call any time.

B. Course prerequisites and restrictions:

Students are expected to hold a Bachelor of Science or similar degree in a branch of engineering or science. The undergraduate experience should have included at least one year of chemistry courses. Experience related to manufacture of paper may be helpful, but not required, in order to take the course.

C. Student learning outcomes:

By the end of the course students will be able to do the following:
1. Identify technical terminology related to the chemistry, materials, and processes of paper manufacture.
2. Explain the functions and principles of engineering unit operations and equipment commonly used in papermaking, repulping, and wastewater remediation.
3. Explain the functions and engineering principles of using different chemicals that are added during papermaking.
4. Calculate first-pass retention, addition rates (employing conversion factors), and solve problems requiring a use of chemical engineering concepts.
5. Apply knowledge of polymers, including identification of polymers as random, block, or alternating, determination of charge equivalents, and anticipation of whether a polymer is likely to be soluble in water.
6. Correctly distinguish between related colloidal chemical concepts, such as zeta potential vs. charge demand.
7. Apply concepts of chemical interactions with surfaces and with each other.
8. Correctly identify the types of ethical principles being used in case-study examples (part of an effort to include such topics within departmental courses).
9. Synthesize course material, plus supplemental reading material into an original, clear, professional, and useful term paper.
Methods of Assessment

Student outcomes will be assessed in several different ways, as follows (see Section H for grading details):

D. Textbooks

Students are required to download or obtain a course-pack, which includes 22 chapters, 374 pages, 208 original figures, and an index. A hard copy of the course-pack is made available each fall semester for approximately $24 from Sir Speedy, which is located at 2526 Hillsborough ST, Raleigh, telephone 834-8128. Distance-education students should contact the instructor at hubbe@ncsu.edu or (919) 513-3022 to make arrangements to get their copy.

E. Course Organization and Scope

Main topics (approximate number of hours in parentheses):

1. Overview of paper manufacturing process relative to chemical use (3)
2. Aqueous solution chemistry related to papermaking applications (2)
3. Principles of soluble polymers and their use in papermaking (3)
4. The nature of surfaces fibers and fillers suspended in water (3)
5. Colloidal principles and applications: stable and unstable suspensions (3)
6. Chemistry and preparation of wet-end additives (4)
7. Effects of wet-end chemical additives on paper properties (6)
8. Effects of additives on retention, drainage, and formation (4)
9. Chemical and surface-chemical factors in recycling and secondary fibers (2)
10. Aqueous coatings: formulation and applications (2)
11. Applications of wet-end chemistry in improving paper machine performance (2)
12. Case studies related to paper machine operations, coatings, and product performance (3)
13. Wet-end chemistry monitoring and control (3)

F. Schedule of Reading Assignments

The schedule (see Calendar, above) is based on a typical schedule of lecture/discussions (3 credit hours. The schedule is slightly adjusted each year to conform to the academic calendar. Students will receive an up-to-date course calendar by e-mail, and it also will be posted on the course website at http://www4.ncsu.edu/~hubbe.

G. Projected Schedule of Homework Due Dates, Quizzes, and Tests

In addition to in-class tests and assigned homework, students are required to complete 21 on-line quizzes by means of NC State's WebAssign® system. The online quizzes are composed of ten questions each, all multiple-choice. The order of the possible answers is randomized for each student. Students are allowed to use their notes during these quizzes, though it is expected that some students will prefer to use the on-line quizzes as an opportunity for self-assessment. The overall score becomes available to each student upon completion of his or her test. Answer keys with several lines of supplementary explanation will become available after the final deadline for taking each quiz. The detailed schedule is adjusted each year to conform to the academic calendar (see Calendar, above).

H. Grading System

Course Component
Weighting
On-line quizzes:
15%
Chapter homework
15%
Special assignments
15%
Term Paper
15%
Mid-term test
20%
Final test
20%
TOTAL
100%


Each distance-education student is required to nominate a proctor, who is subject to approval by the instructor. Send the proctor's name, address, e-mail address, and phone number to hubbe@ncsu.edu. The proctor's main responsibility will be to administer the mid-term and final exams. Often the proctor is a boss or human resources manager or the student. All academic integrity rules are strictly enforced.

Online quizzes will use NC State University's own WebAssign® system. Though the students' first set of answers will count towards their score, the student immediately will have a chance to find out what questions they got wrong, and a chance to correct those answers. The main purposes of the quiz are (a) to provide an indication to the student as to whether they are reading the text with sufficient care, (b) to reinforce some correct information, and (c) to provide the professor with an early indication of problems in understanding. Because the on-line quizzes are not being used mainly for self-assessment, full credit will be given for on-time completion with at least seven out of ten of the answers correct on the first attempt.

Chapter homework will include a high proportion of problems that have numerical or short-answer solutions. Credit will be given based on the percentage of correct answer. Partial credit will be given in many cases, as long as the intermediate steps are shown legibly, with proper attention to unit labels.

Special assignments will consist mainly of (a) questions asked during the lecture segments which are marked with an e-mail icon, and (b) questions e-mailed to one or more students. The following rubric will be used to assess responses to such questions:
Question answered with reasonable promptness 50%
(including revised schedules worked out in advance
with the instructor)

Answer thoughtfully considers the question asked, 25%
and answers it in the context of concepts from either
the lecture or written sources

Answer is factually correct. 25%

The term paper will be assessed according to the following rubric:

20% Follows the format (based on an example provided to the student)
20% Tells and interesting story; makes a point; persuades the reader
20% Achieves a high level of factual accuracy
20% Makes use of published literature, including 4 or more accurate references
20% Adequately answers the question or questions assigned to the student

Each term paper will address a specific question, formulated by the instructor, and based on an assigned, recent research article in the field of papermaking chemistry.

Viewing of tests from previous years/semesters will not be tolerated, since the goal is a thorough reading of the whole text. Also, the questions and even the nature of the tests is subject to change without notice. Students should come prepared to take a closed-book exam, answering either multiple-choice, short-answer, or essay questions in any proportion. The best preparation is to thoughtfully read the course-pack.

I. Instructor's Policies on Incomplete Grades and Late Assignments

On-line quizzes (WebAssign®) must be completed by the electronically posted deadline in order to receive credit.

Students who expect to miss any of the deadlines given in the course calendar for their semester are required to contact the instructor at least weekly to give an update on their progress, until they catch up with the class. Special arrangements can be made in case of major travel, illness, etc.

Points with a maximum value of 10% of the assignment will be deducted from worksheet assignments and other written work that is late by one week or more in the absence of earlier communication with the instructor. Points with a maximum value of 20% will be deducted from an assignment that is late by more than two weeks. These penalties may be waived in cases where there is an excused absence.

J. Instructor's Policies on Absences and Scheduling Makeup Work

Students are expected to complete reading assignments, on-line quizzes, and homeworks by the deadlines posted on the calendar. Exceptions will be made in case of prior communication with the instructor, including a plan for when the work will be done.

On-line quiz homework can be done ahead of time, but it cannot be made up after the deadline of each particular assignment (due to posting of results). It is the responsibility of students who wish to make up for any lost points to obtain permission to do extra work to replace the value of any missed on-line (WebAssign®) quizzes.

K. Academic Integrity Statement

All academic integrity rules of the Department and University are strictly enforced. Students are free to discuss issues related to coursework with their peers, bosses, or friends, but the completed homework assignments and project work must be their own. No collaboration is permitted when completing quizzes, tests, and on-line quiz homework.

Students are expected to participate actively via e-mail (or possibly a chat room), especially when prompted to do so by requests that are made in the course of lectures. There is no penalty for a wrong answer during class discussions. Students are expected to take initiative in making sure that they understand the material and ask questions when they do not. Questions about the material are welcome at any time that the instructor is available by phone (919) 513-3022 or through e-mail, hubbe@ncsu.edu.

L. NC State Policy on Working with Students with Disabilities

Reasonable accommodations will be made for students with verifiable disabilities. In order to take advantage of available accommodations, students must register with Disability Services for Students at 1900 Student Health Center, Campus Box 7509, telephone 515-7653, http://www.ncsu.edu/provost/offices/affirm_action/dss/ .

N. Statement on "Pass-Through" Charges

Each student is responsible for purchase of a course-pack (see Section D above, Textbooks). Course-packs will be available for purchase from Sir Speedy, which is located at 2526 Hillsborough Street. The estimated total cost is $39.

O. Statement on Transportation

No field trips or other travel are included in WPS 522.


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