Aqueous ammonia mixed with caustic potash as wheat straw pulping liquor was investigated. The caustic potash did not only reduce the NH3 usage and cooking time, but also provided a potassium source as a fertilizer in the black liquor. Excess NH3 in the black liquor was recovered and reused by batch distillation with a 98% recovery rate of free NH3. The black liquor was further treated for reuse by coagulation under alkaline conditions. The effects of different flocculation conditions, such as the dosage of 10% aluminium polychloride, the dosage of 0.1% polyacrylamide, the reaction temperature and the pH of the black liquor on the flocculating process were studied. The supernatant was recycled as cooking liquor by adding extra NH4OH and KOH. The amount of delignification and the pulp yield for the process remained steady at 82-85% and 48-50%, respectively, when reusing the supernatant four times. The coagulated residues could be further processed as solid fertilizers. This study provided a new pulping process for wheat straw to reduce problems of discharge black liquor. (C) 2006 Elsevier Ltd. All rights reserved.