2010,
FOREWORD
The paper industry in India is more than a century
old. At present there are over 500 paper mills in the
country manufacturing industrial grades, cultural
grades and other specialty papers.
The domestic paper sector has posted an impressive
growth figure of 5 8% in 2009 10, in spite of the
global demand for paper declined by 8 10%. The
total installed capacity in the country now stands at
9.3 Million Tons per annum with a production of 8 million tons per annum and we expect the demand to increase to 10 million tonnes by 2012.
. The current per capita consumption of Paper in India is 8 kg per person compared to the
global average of 56 kg per person. Increasing literacy levels, current lower per capita
consumption and increased exports all contribute to a healthy rate of the growth of the
sector for a long period.
The paper industry in India is witnessing major capacity expansions during which conscious efforts are made to adapt state-of-art technologies. This leads to lower production
costs as well as lesser environmental impacts. The industry is also fast adapting ecologically sustainable practices like ECF bleaching, extended delignification, high pressure
cogeneration systems etc.
Globally, there is a consensus that Climate change represents one of the greatest environmental, social and economic threats which the planet earth is facing. Our Industry
being directly dependent on natural resources for raw material needs to act responsibly
in combating climate change. At the national level, business and industry will need to play
a major role by adopting an aggressive carbon reduction strategy. Also emerging are
financial incentives for Indian Industry to adopt low carbon strategies. Growing environmental concerns of consumers and the greening of business by responsible corporations have also started to compel products and supply chains to become more carbonsensitive.
Confederation of Indian Industry, CII-Godrej GBC has a vision of making India a Global
Leader in Green Business by 2015. To fulfill the vision, the Centre has adopted several
focus areas viz. Green Buildings, Energy Efficiency, Renewable Energy, Environment &
Recycling, Water management and Climate change activities. The centre also woks on
programmatic initiatives like the Mission on Sustainable Growth with the purpose of
promoting and championing sustainable growth in Indian Industry, without compromising on high and accelerated growth. To advance energy efficiency in the industry, the
Centre through the exclusive Energy Efficiency Council facilitates industry adopt best
operational practices and thus become World Class Energy Efficient units.
We strongly believe that, to achieve the vision, it is necessary to demonstrate and achieve
leadership status in each sector, through creation of Islands of Excellence. The pulp and
paper sector was identified as a focus sector in the year 2007 and a road map was
adopted towards Making Indian Pulp and Paper Industry World Class. Significant improvement in the energy, water and environmental performance has been recorded by
some of the mills.
There is a pertinent need to have a neutral platform for sharing knowledge and skills
across the industry for the best practices. While the Papertech Conference series provide
this platform for face to face interactions the manuals on national and international best
practices serve as a ready reckoner for units towards achieving improved results. The
current manual is the third in this series.
I would like to express my gratitude to all the CEOs of the various Pulp & Paper mills in the
country for their contributions, guidance and support in shaping this initiative.
My congratulations to Mr K S Kasi Viswanathan, Chairman, Working group on Make
Indian Pulp & Paper Industry World Class and all the members of the core working group
for their efforts and contributions.
I am sure that this best practices manual would go a long way in facilitating quicker
adoption of best practices in the Indian Pulp and Paper industry
PREFACE
of experts visited ten select Indian paper mills and identified the best practices followed
there. These national best practices were documented in the first volume of this manual
series. The second volume contained the best practices identified/implemented in the
European paper mills, again by the same working group.
The next logical step is to see how far these identified Best Practices have been
put to use by select mills. In this connection the working group visited four mills namely
Andhra Pradesh Paper Mills, ITC Bhadrachalam, Seshasayee Paper & Boards Ltd and
Tamil Nadu Papers Ltd. This manual, the third volume of Best Practices Manual Pulp &
paper Industry contains the best practices identified in these units.
To take this initiative forward it is felt that a visit to well run paper mills in places
like China, Indonesia and Thailand will be of great help. Discussions are under way to
make these mill visits possible before the end of this year.
I take this opportunity to thank Mr Pradeep Dhobale, Chairman Energy Efficiency Council, CII - Godrej GBC for his unstinted support, CEOs of various Paper Mills for
their encouragement and the core working group members for their untiring efforts.
Acknowledgement
It is our privilege to express our sincerest regards to Mr. Pradeep dhobale, Chairman Energy Efficiency Council, CII Godrej GBC and Mr. K S Kasi Viswanathan,
Chairman working group on Make Indian Pulp & Paper Industry World Class for
their invaluable contribution by leading the initiative from the front.
We deeply express our sincere thanks to the managements of the host mills for
openly sharing the technical information with the working group and also for providing the local hospitality and support to the visiting working group members.
Also, the write ups provided for the identified best practices deserve a special
mention.
We take this opportunity to thank all the working group members who, inspite of
their bust schedules, have visited the four identified mills and with great zeal
identified the best practices. The list of working group members is attached as
annexure. We are thankful for the management of the companies to nominate
them to participate in the working group visits.
C O N T E N T
S.NO.
Chapter
Page No.
1.
Executive Summary
01
2.
08
3.
09
4.
26
4.1.
Pulp Mill
28
4.2.
61
4.3.
70
4.5.
98
5.
120
6.
Annexure
121
EXECUTIVE SUMMARY
Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million people and contributes Rs 25 billion to the governments revenue. The government regards the paper industry as one of the 35 high priority industries of the country.
In 1951, there were 17 paper mills, and today there are about 515 units engaged in the
manufacture of paper and paperboards and newsprint in India. The pulp & paper industries in India have been categorized into large-scale and small-scale. Those paper industries, which have capacity above 24,000 tonnes per annum are designated as large-scale
paper industries. India is self-sufficient in manufacture of most varieties of paper and
paperboards. Import is confined only to certain specialty papers. To meet part of its raw
material needs the industry has to rely on imported wood pulp and waste paper.
Growth of paper industry in India has been constrained due to high cost of production
caused by inadequate availability and high cost of raw materials, power cost and concentration of mills in one particular area. Government has taken several policy measures to
remove the bottlenecks of availability of raw materials and infrastructure development.
For example, to overcome short supply of raw materials, duty on pulp and waste paper
and wood logs/chips has been reduced. However, the aspect of higher production cost
needs to be tackled by the sector as a whole by increased cooperation in terms of sharing
of best practices and moving towards cleaner production.
The CII-Sohrabji Godrej Green Business Center (CII-Godrej GBC) under the
leadership of Mr. Jamshyd Godrej, Chairman, CII Godrej GBC and Managing
Director, Godrej & Boyce has adopted the vision of Facilitating India to become a global leader in green business (environment) by 2015.
Towards this objective, the Energy Efficiency Council of CII-Godrej GBC under
the chairmanship of Mr Pradeep Dhobale, Divisional Chief Executive, ITC Ltd,
PSPD has undertaken the development of World Class Energy Efficient Units
in energy intensive sectors, such as Cement, Power Plant and Pulp & Paper
Industry.
The Paper sector initiative through a project titled Make Indian Pulp & Paper
Industry world class is guided by a working group chaired by Mr. K S Kasi Viswanathan,
Deputy Managing Director, Seshasayee Paper & Boards Limited (SPB), Pallipalayam.
The activities were initiated in a CEO meet organized in conjunction with Paper Tech 2007
at Hyderabad, a national conference jointly done by CII-Godrej GBC and Indian Paper
Manufactures Association (IPMA). The CEOs meet is attended by 19 CEOs (details of the
CEOs are given in the annexure A) representing all the major Pulp and Paper Manufactures in the country.
The CEOs discussed and endorsed the following action plan to be taken up for developing
World Class Energy Efficient Paper plants in the country.
Inter plant visits for sharing and identify best practices (during August
2007 February 2009)
The working group visited some of the Indian Pulp and Paper Industries in order to
identify the best practices. The companies to be selected are identified based on a questionnaire circulated to the above mentioned companies.
The plants visited by the working group are:
1.
APPM, Rajahmundry
2.
3.
4.
5.
6.
JKPM, Rayagada
7.
8.
9.
Make at least three Indian paper mills world class in three years (by 2010)
With the help of technology suppliers Andritz, GL&V and Metso, the working group could
visit the following mills in the five working days between 13 17 October 2008.
CII thanks the host companies Andritz Oy, GL&V and Metso, for their excellent hospitality
provided to the European mission attendees. This European paper mill mission was conducted by CII, in association with IPMA (Indian Paper Manufacturers Association).
The visit to the Chinese paper mills was planned but the working group backed out citing
apprehensions inline with the recent trend of economic downturn.
Volume 2 of the best practices manual of the pulp & paper Industry was released on July
2, 2009 in the inaugural function of the seminar Papertech 2009 conducted jointly by CII
and IPMA at CII Sohrabji Godrej Green Business Centre, Hyderabad. In Papertech
2009, together with sharing of best practices from the Indian Pulp & Paper mills, bringing
in more international experiences in the form of case studies and technological advancements was the focus. Thus the occasion of release of the manual can be considered apt
with its intent of the manual.
Inter plant visits for further sharing and identify best practices (during
February 2010 May 2010)
Since the inception of the activities of Make Indian Pulp & Paper Industry World Class in
2007-08, some of the mills have done well to improve their energy, water and environmental management performances. Thus, the steering committee of the initiative guided
the working group to select the following four Pulp & Paper Mills to visit (or re-visit) and
identify the best practices implemented there.
1.
2.
3.
4.
The next steps in the process of Making Indian Pulp & Paper Industry
World Class were envisaged to be focused towards:
Continue to move towards the international standards in energy, water and environmental management.
The objective of this manual is to act as a catalyst to promote activities in Indian Pulp
& Paper Plants towards continuously improving the performance of individual units and
there by achieving world class levels (with thrust on energy, water & environmental
management).
To set a clear goal for improving the performance and move towards the world class
standards, the best practices adopted in some Indian Pulp & Paper Plants have been
included in this manual as part of Best practices from Indian Pulp & Paper Industry
The description of the best practices identified during the European paper mills visit
by the working group forms the first part of this manual. The details of the state of
the art technologies from the international paper plants have also been included
These best practices may be considered for implementation after suitably fine tuning to meet the requirements of individual units
The collated best operating parameters and the best practices identified from various plants need not necessarily be the ultimate solution. It is possible to achieve
even better energy efficiency and develop better operation and maintenance practices
Therefore, Indian Pulp & Paper Plants should view this manual positively and utilize
the opportunity to improve the performance and Make Indian Pulp and Paper Industry
World Class.
10
Installation of energy efficient high steam pressure and temperature coal-fired with
high thermal efficiency. Increases in specific steam generation from 3.7 T/T of coal to
11
3.9 T/T of coal. Increase in specific power generation from 90 kWh/t of steam to 130
kWh/t.
2.
Installation of cooling tower for water circulation and conservation in Paper Machines
No.2 and No.3 Reduction in water consumption is 50 M3/hr.
3.
Replacement of high pressure steam ejector with medium pressure steam ejector in
34 MW turbine resulted in increased power generation of 30 kW
4.
Rising of de-aerator water temperature of coal fired boiler No.6 resulted in increase
in HP steam generation. Resultant increase in power generation is 160 kW
5.
Use of warm water in place of fresh water in DM water plant, reduction soot blowing
steam pressure in recovery boiler and installation of vent condenser for de-aerator of
recovery boiler No.4 resulted in reduction of steam consumption by 13 TPD
6.
Installation of flash steam recovery system of CBD system of recovery boiler No. 4
resulted in steam saving of 5 TPD
7.
91
90
84
1252
1247
1261
12
ITC BHADRACHALAM
Company Profile
ITC Limited - Paperboards and Specialty Papers Division - Bhadrachalam unit has
emerged as one of the most modern and contemporary players in the business worldwide. Unit Bhadrachalam offers a vibrant product range for packaging and graphic solutions such as Coated SBS Board (Pearl and Safire Graphic), Coated Folding Box Board
(Cyber XL Pac), Coated Board White Back, Coated Gravure Board, Coated Board Gray
Back & many more. The Unit serves thousands of customers in India and abroad & to a
wide range of industries from foods to personal products, office stationers to appliances
and accessories. It makes the complete range of paperboards that today offer unparalleled choice for FMCG packaging. During 2009-10, Unit Bhadrachalam has achieved turnover of Rs. 1539 Crore with production of 4.65 Lac tons of Paper & paperboards.
Technology Adoption
ITC Limited, Paperboards & Specialty Papers Division, Unit: Bhadrachalam had implemented Cleaner Technology in August, 2002 by investing Rs.225 crores and introduced
Elemental Chlorine Free (ECF) pulp bleaching for the first time in India. The successful
implemental of the latest technology had given enough confidence to implement the
world class bleaching technology called Ozone Bleaching as a part of mill development programme. In the year 2007-08, Unit Bhadrachalam implemented cleaner technologies to improve the overall environment with an investment of Rs.235 crores includes
A state-of-the- art 800 BD TPD super batch cooking system which saves energy and
is even more environmentally friendly.
A 400 BD TPD new fiber line consisting of the brown stock washing, screening, oxygen delignification and bleach plant.
Adoption of latest Ozone bleaching technology in Fiber line. With this Unit Bhadrachalam
became First Paper mill in India and 11th mill in the world to have ozone bleaching.
13
Fuel switch from fossil fuel to biomass residues for power & process heat generation
by avoiding the non-renewable fuel consumption & helping for sustainability of environment.
Units operations are automated with DCS along with advanced process control enabling precise control on quality of product, consistent production and monitoring resource consumption on real-time basis. Investments were made continuously to improve
quality, productivity and reduce cost.
14
Environmental Performance
Lite ECF pulp mill with ozone and chlorine dioxide bleaching fiberline reduced AOX level in
waste water to less than 0.1 to kg/ton (i.e 0.0046 kg/ton in final treated effluent discharge) against the National norm of 1kg/ton with significant reduction in colour of effluent. The plant has achieved 100 % Solid Waste Utilization for the year 2009-10.
The odor control system is in existence since July 2008 by collecting high concentration
low volume (HCLV) NCG from areas like super batch digesters & evaporators and incinerating in lime kilns. ITC Bhadrachalam now going for Installation of HVLC (High Volume
Low Concentration) NCG System to further bring down the odor from present level with
process modifications.
In recognition of the commitment towards environment Unit Bhadrachalam was rated
with 5 STAR International rating in Environment by British Safety Council.
Awards
Unit has won numbers of awards in the field of environmental improvement, energy
conservation, safety and productivity improvement. Unit has won CII National award for
Excellence in Energy Management consistently for last nine years & Excellence in Water
Management for 2007, 08 & 09. Unit has been awarded by 5-Star Rating & Sword of
Honour in 2009 by BSC, Greentech Environment Excellent Gold Award 2007, 08& 09,
Bureau of International Recycling award for Wealth Out of Waste initiative.
15
16
: 285.99 acres
: 5.87 lakhs
ITC PSPD, Bhadrachalam unit is also a carbon positive company. The following table
shows the CO2 released and sequestered over the years.
Carbon Positive:
Unit
05-06
06-07
07-08
08-09
CO2 Released
Kilo tonnes
1202
1143
1352
1572
CO2 sequestered
Kilo tonnes
1244
2025
2638
3695
CO2 sequestered
Percent
104
177
195
235
17
Benchmark references
Specific Power Consumption & Specific Steam Consumption Benchmark
reference:
All About Paper, The life cycle of the Indian pulp and paper industry Green rating project,
Centre for Science and Environment, New Delhi.
18
The Company
Seshasayee Paper and Boards Limited (SPB), the flagship company belonging to ESVIN
GROUP, operates an integrated pulp, paper and paper board Mill at Pallipalayam, Erode638 007, District Namakkal, Tamilnadu, India.
SPB, incorporated in June 1960, was promoted by Seshasayee Brothers (Pvt) Limited in
association with a foreign collaborator M/s Parsons and Whittemore, South East Asia Inc.,
USA. After commencement of commercial production, having fulfilled their performance
guarantee obligations, the foreign collaborators withdrew in 1969. Main promoters of the
Company as on date are a group of companies belonging to the ESVIN group headed by
Mr. N Gopalaratnam.
SPB commenced commercial production in December 1962, on commissioning a 20000
tpa integrated facility, comprising a Pulp Mill and two Paper Machines (PM-1 and PM-2),
capable of producing, writing, printing, kraft and poster varieties of paper.
The Plant capacity was expanded to 35000 tpa in 1967-68, by modification of PM-2 and
addition of a third Paper Machine (PM-3). The cost of the expansion scheme, at Rs 34
Millions, was part financed by All India Financial Institutions (Rs 31 Millions).
In the second stage of expansion, undertaken in 1976, capacity was enhanced to 55000
tpa, through addition of a 60 tpd new Paper Machine (PM-4). Cost of the project, including cost of a Chemical Recovery Boiler and other facilities for enhanced requirement of
utilities, was estimated at Rs. 176 Millions. The same was part financed by term loans
from Institutions and Banks to the extent of Rs. 145 Millions and the balance out of
internal generation.
SPB undertook various equipment balancing and modernisation programmes, since then,
for improving its operating efficiency, captive power generation capacity, etc., upto 199293.
Expansion / Modernisation Project
The Company embarked on an Expansion / Modernisation Project to enhance its produc-
19
tion capacity from 60000 tonnes per annum, to 1,15,000 tonnes per annum and to upgrade some of the existing facilities, at an estimated cost of Rs 1890 millions.
The said Expansion / Modernisation Project was completed in December 2000. After
successful trials, the Commercial Production out of the new Paper Machine commenced
on July 1, 2000.
The current installed capacity of the Company stands at 1,15,000 tonnes per annum.
Raw Materials
The Companys paper plant was originally designed for using bagasse, as the primary
raw material mixed with 20% bamboo fibre. Bagasse was being obtained from nearby
sugar mill on substitution basis using oil fired boilers.
With sharp increase in oil prices in 1970-71, the Company shifted over to the use of
hardwood, at the time of its expansion undertaken in 1978. Raw material mix underwent
a substantial change, with bamboo and hardwood forming 60% and 40%, respectively,
of its raw material consumption.
Soon Company started apprehending difficulties in procurement of bamboo. In 1981, it
added one more digester, to increase the share of the hardwood in the furnish mix to
80% and restricting bamboo use to only 20%.
With the commissioning of more wood based industries in Tamilnadu, there was again an
apprehension about availability of hardwood.
As a long term strategy, the Company at this time decided on restructuring use of bagasse which was seen to be the most reliable source of fibre for the entire Industry.
In 1984, the Company promoted Ponni Sugars and Chemicals Limited, as the captive
source for bagasse supply. It added bagasse handling systems and modernised PM-1 and
PM-2, to shift over to the use of bagasse.
The furnish mix for the existing Paper Machines of the Company is 55% bagasse and 45%
hardwood. The Company has vast experience in handling bagasse and is expected to be
one of the major strong points vis--vis its competitors in India, as the Indian Paper
20
Industry will continue to be bogged down by the problem of raw material availability.
For the new Paper Machine, the furnish is imported waste paper and imported pulp which
are sourced from far east countries, Europe and USA. A small quantity is supplemented
out of captive pulp production.
Exports performance
SPBs exports are nearly 20% of its production and is a significant exporter in the Indian
Paper Industry. Due to its excellent export performance, SPB has been awarded Golden
Export House status.
Awards
SPB is in receipt of various Awards awarded by Government of India, Government of
Tamilnadu, Industry Associations, etc. Some of the Awards received by SPB in the past
include:
Safety Award
Environmental Protection
The Company attaches paramount importance to the conservation and improvement of
the environment. In its efforts to improve the environmental protection measures, the
Company has installed:
two Electro Static Precipitators for its Boilers to control dust emissions
21
These facilities will ensure sustained compliance by the Company of the pollution control
norms prescribed by the Pollution Control Authorities.
Board Of Directors
The Companys Board is broad based comprising 10 Directors:
Sri V Sridar
Organisation
The day to day affairs of the Company are looked after by the Chairman and Managing
Director and supported by :
Sri K S Kasi Viswanathan, Deputy Managing Director and
Sri V Pichai, Director (Finance) & Company Secretary.
They are ably assisted by a team of qualified and experienced professionals in operations,
personnel, finance and marketing disciplines. ef Profile of Participating Companies
22
23
PROCESS DESCRIPTION
PULP MILL
The paper production capacity of 2,45,000 tpa is supported by the following 3 pulp lines.
1.
2.
3.
The chemical baggasse pulping lines employs ECF bleaching with a capacity of 500 TPD.
During Mill Expansion Plan(MEP) both the baggasse pulping lines will be integrated and
total pulping capacity will be augmented to 500 TPD.
PAPER MACHINE
The mill has 2 nos. dual purpose paper machines capable of producing newsprint/writing
and printing paper. The Paper Machine #1 (PM1) has a trim width of 6.8 M at a continuous
operating maximum speed of 750 m/min, while the PM2 has a trim width of 6.6 M,
capable of operating at speed around 850 m/min. The machine also incorporated several
improved features to support higher percentage of weak bagasse pulp in the furnish.
The erection of Paper Machine # 3 with a capacity of 1,55,000 tpa is under progress and
is scheduled to be commissioned by October 2010
24
The Causticizing Plant has a capacity to produce 3600 m3/day of white liquor (NaOH +
Na2S).The recausticizing plant has a two stage slaking, which was introduced to overcome the problem of high silica bagasse liquor and a white Liquor Claridisc filter. The
smelt of inorganic from Recovery Boiler is dissolved in weak white liquor and causticized
with burnt lime to convert back to active alkali and the lime sludge generated from the
precoat filter. A new Lime mud claridisc filter has been installed to improve the dryness of
the mud which is fed to lime kiln. Two Lime mud reburning kilns each of 170 tpd capacity
, recycle lime sludge and re-generate burnt lime required for the causticizing process.
UTILITIES
The mill has five Service Boilers, four each of 60 T/hr steam generation capacity at 44 Kg/
cm2 and one 90 t/hr steam generation capacity at 64 Kg/cm. Erection of sixth Boiler
with capacity of 125 t/hr steam generation at 104 Kg/cm2 is under progress and is
expected to be completed by August 2010. The Mill has 5 turbines for captive power
generation of 81.12 MW.
A project to install a CFBC boiler with capacity of 125 t/hr steam generation at 104 Kg/
cm2 and a 41 MW turbine is under way and is scheduled to be completed by December
2012.
During 1993, TNPL has diversified into the field of Non-conventional energy sources, for
generation of electricity, mainly to reduce dependence on grid power. Under this programme
till date, the company has set up a 35 MW Wind Farm in Tamil nadu . The power generated from the wind farm is being sold to the TNEB.
The mill has a modern Effluent Treatment Plant designed to treat 20 MGD of effluent
generated from various sections of the mills. TNPL has Bio-methanation plants to treat
the high BOD/COD stream and generate biogas up to 40,000m3/day, which is utilised in
Lime Kiln, to partly substitute Furnace oil.
2005- 2006
2006-2007
2007-2008
2008-2009
2009-2010
Water in
kL/ton paper
Steam in
MT/ ton paper
Power in
kWh/ ton paper
104
109
108
91
67
6.72
6.69
6.47
7.65
7.84
1476
1461
1421
1518
1630
25
2.
3.
4.
5.
Spray switch from hot to ambient water for final bleached washer in fiberline (SPB)
6.
Energy management- heat recovery from EOP filtrate discharge effluent (SPB)
7.
9.
26
27
28
29
Installation cost
Installation cost of integrated plant is approximately 3 times more than the cost of
non integrated plant.
Operating cost
Operating costs of integrated and non integrated plants are about Rs.50/kg of ClO2 and
Rs. 75 per kg of ClO2 respectively. Operating cost of non integrated plant is mainly dictated by price of Sodium Chlorate which is imported overseas. Integrated plant is mainly
power intensive unit. As long as cost of power is low, integrated plant is economically
viable.
Operational Experience:
The operation of integrated plant is handled by two operators per shift. The operations of
the plant are carried out through scada system. Bearing little problems, the operation of
the plant is smooth and safe. Time requirement for resumption of production after shut is
about 5-6 hours. Periodical checking of oxygen and hydrogen content present in vent
gases of electrolysis unit is necessary.
Operation of non integrated plant is stable and easy. Plant is fully automated and is
operated through DCS. Plant can be switched over to production at desired concentration
of ClO2 within one hour. Plant efficiency is high and plant can be operated between 40%
-105%.
Factors to be considered while selecting the processes:
Installed cost
Operating cost
Environmental norms
30
Summary of comparison
Integrated process
Non-integrated process
Chemical Process
Munich Process
Capacity
3 TPD
10 TPD
Raw Material
Hydro-Chloric Acid
Power Consumption
Not significant
ClO2 concentration
7-8 gpl
10 gpl
Start up time
5 6 hrs
1 hr
Generation cost
Investment cost
31
15 kg AA /T of blown pulp
Cooking section
Lower AA consumption
More pulp/digester
Fiberline
More throughput
Less scaling
40-50% Improvement
Recovery Island
32
33
34
In order to increase the pulp temperature to 70oC, e-filtrate used for dilution is heated
using low pressure steam in a sparger connected to the dilution filtrate pipe.
35
Wash water is added to the press in accordance with the dilution factor and production rate. Excess filtrate is either drained or pumped to the filtrate tank of post oxygen
press depending on the calcium concentration in the system. About 50% kappa reduction
takes place in Ozone stage and brightness enhancement of 10-12% is achieved. 1 Kg of
ozone is practically found to replaces 4-5 kgs of ClO2 as active chlorine. 50% reduction of
ClO2 and peroxide consumption are achieved after ozone bleaching (refer table-2). A
significant improvement in strength properties is observed though viscosity is slightly on
lower side. Runnability and brightness stability on paper machines is also proven to be
improved.
36
Ozone Generation :
Ozone sometimes called activated Oxygen contains three atoms of oxygen and is the
second most powerful oxidizing agent next to fluorine. Technically production of Ozone is
through silent electric discharge of Oxygen rich feed gas using special generator. During
the ozone synthesis process oxygen molecules are initially split through the supply of
energy. The resulting oxygen atoms then react to create ozone with oxygen molecules
and release heat which must be dissipated by culling. Ozone formation takes place between two electrodes, which are isolated from each other by a dielectric made of glass or
ceramic and by a small gap. A high voltage, medium frequency, unilaterally grounded
alternating voltage is applied to the electrodes. The Oxygen gas flows through the gap,
resulting in ozone generation in the electric field.
The generator at ITC has a capacity to produce 200 kg/hr Ozone at 12% concentration and can reach upto 230 kg/hr at 10% concentration. The three pillars of Ozone
generation are Feed gas, power and cooling water. 1500 Nm3/hr oxygen compressors
supply 93% pure oxygen produced from onside VSA plant. Two chillers of 600 TR reach
serves the cooling water required. Specific power consumption per kg of ozone is 8-9 k
WHr.
37
Challenges :
The A stage press is prone to scaling if calcium content in the incoming pulp from PO
stage (Post Oxygen) is high. Calcium sulphate the oxalate scaling deposits on the low pH
38
loop which causes drop in press outlet consistency. Once the consistency drops below
35% from the A press going to Ozone reactor the efficiency of ozone reactivity drops
drastically increasing the consumption of ClO2 and H2O2 in later stages. Better washing
and pH control of A stage are very critical for avoiding scale formation in the system.
Calcium carbonate scale forms in the high pH loop of e stage if calcium content in the
incoming pulp is high. Though calcium carbonate scaling is easier to clean, it causes
reduction in dilution water flow due to deposits in backwater lines thereby reducing production rate. Use of anti-scaling chemicals prolongs the deposition rate but adds to the
production cost.
Due to the fact that calcium concentration is more in the backwater of e stage it
cannot be used for closure to PO stage thus increasing the water consumption in the
bleach plant and load on effluent. Continuous usage of 100% debarked raw material
been proven to give relief regarding calcium deposits.
Replication potential:
This project is replicable for expansion and modernization of large pulp and paper
mills to improve the environmental performance, energy conservation and operational
excellence.
39
40
Process description
The RDH (Rapid Displacement Heating) digester utilizes the liquor displacement operation to optimize the cooking process.
The operation is divided into five separate steps:
41
A. Chip filling
B. Warm black liquor impregnation
Using warm black liquor from the warm liquor tank with a high sulphidity, a low alkalinity
and a temperature below 100oC the chips are impregnated in order to preheat the chips
and help accelerate the delignification during the cook.
As the warm black liquor and the cooking liquor (a mixture of warm black liquor and hot
white liquor) are spent and subsequently displaced by the following liquid they are sent
either to the warm fill liquor or to the black liquor tank.
Heat exchangers are used to recover part of the energy used for heating the make-up
white liquor, and white liquor is being added to the hot black liquor to make up for
variation in the chemical loss.
Central to this scheme is a tight control of the chemical contents of the black and white
liquor. The RDH digester maintains a uniform distribution of chemicals during the cook,
but in order to determine the correct amount of white liquor to add it is necessary to
determine the alkali concentration of both the warm and hot black liquor as well as the
white liquor.
Without monitoring, the alkali changes can pass through and will cause considerable
variations in the Kappa number of the pulp, which can only be noticed once the cook is
42
finished and thus require additional bleaching chemicals or even be rejected. However if
the variation in alkali is detected, the addition of white liquor can be adjusted in order to
stabilize the situation.
43
In order to further enhance pulp strength as well as yield at Seshasayee Paper & Boards
Limited, it was decided to vary the cooking temperature in Rapid Displacement Heating
(RDH) process.
Objective:
The objective is to effect reduction in cooking temperature from 168oC to 158oC and
there by reduce steam consumption.
44
delignification temperature dependency. Even a difference of couple of degrees in cooking temperature can make a big difference in pulp quality. H-factor has been defined so
that 1 hour in 100 C is equivalent with H-factor of 1. While the delignification is assumed
to be one single reaction, the following equation describes the H-factor mathematically.
Proposal:
Maintaining ODL temperature at 93C (as against the earlier figure of 103C, it was
decided to reduce RDH cooking temperature from 168C by ~ 10C(Fig.1). Kappa number is maintained at 20+.
Benefits:
By decreasing the cooking temperature, the following benefits were accrued.
Issues :
Since the cooking temperature has been decreased, cooking time had been extended
by 45 minutes.
45
Replication :
This concept can be used based on the quality of wood being used in that particular
mill. Also, lowering the cooking temperature results in increased reaction time and there
by increases the overall cycle time per batch. Care needs to be taken to ensure that this
aspect does not result in productivity loss.
Futuristic scope:
It is to be seen as to what extent the cooking temperature can be further lowered
without any adverse impact on productivity or quality of the product.
46
RDH Digester 4 Nos followed by 5 accumulators viz., warm, hot and White Hot. And
Heat Exchangers 3 Nos with option of Double Displacement Technology.
Pressure Screening
Elemental Chlorine Free (ECF) bleaching with D0, EOP and D1 Sequence
47
Objective:
To effect reduction in Low pressure steam consumption, without affecting both the
beaching process and the chemical extraction in the washers.
Proposal:
Instead of hot water spray, it was decided to go in for cold ( ambient) water spray for
final bleached washer (Fig.1). However, it was not totally effective as the filtrate temperature had to be raised by using heat. Finally it was optimised at hot and cold water
mix ( in the proportion of 3:2 , for achieving the desired objective.
48
Benefits:
49
Spin-off gains:
Sizing problem minimised.
Issues:
None , as of date.
Replication:
This concept can be comfortably replicated in other pulp mills also.
Futuristic scope:
To be taken up by the Paper mill, on a case to case basis, after looking into the overall
pros and corns of the system in place.
50
Objective:
To effect reduction in temperature of EOP filtrate prior to discharge, thereby protecting environment with saving in valuable L.P. steam consumption on a sustained basis.
Besides scaling and fouling of heat exchanger have to be curtailed.
51
A special heat recovery unit in the style of Wide-gap Plate Heat Exchanger (supplied
by ALIL imported SS 316 plates) [Fig.2] was installed to cool the effluent leaving EOP
before discharging the same. The flow chart of the scheme in place is illustrated in Fig.3.
52
53
54
However, the scaling of the heat exchanger due to lowering of the fluid temperature
resulted in plugging and heat transfer impairment, alternate recourse for descaling was
resorted to. Dilute Sulphamic acid was added to the hot fluid before entry to the heat
exchanger and the treated effluent was circulated so as to minimise, if not avoid total
scaling of the heat exchanger.
Results
Through extraction of heat in otherwise waste hot effluent, the effluent temperature
is lowered from 75C to say 50C. the hot water generation for process use called for
lowered steam consumption requirement on a continuous basis.(Fig.4). The environmental gain in terms of lowered discharge effluent temperature did not call for dilution of
effluent with fresh water nor a separate cooling tower nor an elaborate neutralisation of
the same.
Benefits:
Spin-off gains:
The effluent being near neutral and not warm can now be discharged as such without
the need of dilution with freash water nor the requirement of elaborate neutralisation .
Issues:
Initial issue of opening up the plates of WGPHE (Wide Gap Plate Heat Exchanger)
because of pluggage & scaling had been resolved through circulation with sulphamic acid
addition to the hot effluent before leading it to the heat exchanger. Also, the following
points needs to be taken into consideration.
Selection of heat exchanger should be done with utmost care. Usual Shell and Tube heat
exchanger cannot be used as the filtrate would contain fibres and fines.
Wide Gap Plate Heat Exchangers are costlier than a typical Plate type heat exchanger
55
EOP filtrate tends to scale a lt and hence a de scaling chemical dosage can be considered
mandatory.
Replication:
This concept can be comfortably replicated in other pulp mills also.
Futuristic scope:
Discussions are on with the designer of the special heat exchanger for achieving the
rated design efficacy of the wide-gap heat exchanger, so as to achieve low effluent discharge temperature and higher thermal conversion.
56
57
Objective:
To effect reduction in ClO2 consumption in bleaching stage.
Proposal:
It is proposed to go in for addition of 0.8 % Hydrogen peroxide in Oxygen Delignification
stage (ODL). With 3.5 kg/cm2(g) pressure and temperature at 93 C, H2O2 reinforced
ODL is ensured (Fig.1).
Benefits:
58
Spin-Off Gains:
Attendant reduction in steam consumption related to reduction in ClO2 generation
(though marginal) is ensured.
Issues:
None faced, as of date.
Replication:
This concept can be comfortably replicated in other pulp mills also. Hydrogen peroxide, added before the first bleaching stage, acts as a delignifying agent under high temperature (>75"C) and alkaline conditions, reducing the amount of chlorine dioxide required in subsequent stages. Depending on chemical costs, delignification with hydrogen
peroxide in ODL can be more economical than chlorine dioxide substitution.
59
60
Objective
Productivity is maintained even with saving in fibre; through reducing the moisture
variation within 0.25 per cent point (5 %) from the set point.
61
62
Financials:
There had been practically no additional investment called for.
Benefits:
By fine tuning the controller in QCS and keeping the moisture content at 5 % -for a
60 gsm product- resulted in a saving of 0.4 to 0.45 TPD of finished paper. Financial gains
63
Spin-off gains:
Issues:
No issues, as of date.
Replication:
Certainly the concept of automation control raising the reel final moisture at a constant acceptable higher figure can be followed in other Paper mills.
Futuristic scope:
Though there is scope to affect further increase in Moisture in the reel, it had been
decided to stay put and try to stabilise the operation at 5 % moisture content in autosetting on a continuous basis.
64
Unit:
Background:
Energy costs have increased consistently over the past few years and show no sign of
settling in the coming decade. In the wake of the increasing trend of the energy costs, it
is crucial of the paper makers to manufacture paper in an energy efficient manner. A key
aspect of energy efficiency in a paper machine is its design configuration. This best practice reflects on TNPLs approach for energy conservation at design stage for their Paper
machine no. 3.
Project Profile:
TNPLS Capacity expansion plan envisaged an increase in Capacity from the previous level of 245,000 TPA to 400,000 TPA with the addition of the new paper machine (PM
#3). This machine will be dedicated for the manufacture of SS printing and Writing paper,
copier paper, pigmented paper with bleached chemical bagasse pulp constituting 60% of
the over furnish, the balance 40% being fully bleached chemical mixed tropical hard
wood pulp. The pulping is of ECF bleaching system.
The proposed PM #3 will be a VOITH Fourdrinier paper machine with a top-wire
former, incorporating specific features favouring production of superior quality surface
sized printing & writing papers, copier and pigmented paper, with pre-metered sized
press.
65
Stock Preparation:
The stock Preparation uses energy efficient low noise conical Metso refiners for refining hardwood and softwood pulps with automatic specific energy control mechanism and
on line vibration monitoring systems. Fiber recovery system uses a bag less poly disk
save-all with three filtrate zones generating cloudy, clear and super clear filtrates. These
filtrated will be entirely reused for pulp dilution, showers and for make-up thereby minimizing fresh water consumption. Broke handling systems are designed for handling both
regular broke and coated broke with extensive High density cleaners and screens before
being added along into the stock proportionating system in a constant ratio. The deaeration and cleaning system uses modern VOITH Vac de-aerator with high performance
4 stage centri-cleaners and slot pressure screens.
Head box:
PM #3 is equipped with a Dilution Head box Master jet F/B designed for achievement
of good fibre orientation profiles.
Wire section:
The wire section of the paper machine is a cantilevered type fourdrinier with duo
Former D supplied by VOITH, Germany.
Press section:
The press section is a bi nip Tandem Nipcoflex press with suction pick-up roll.
Vacuum section:
The vacuum systems employs Energy efficient Multistage and Single stage Vacuum
Turbo air blowers, extraction pumps and low vacuum fan.
Dry section:
The dry section of the machine has a Pre-dryer section with 6-dryer groups, first five
(5) dryer groups after press section with single tier group followed by one convectional
double tier arrangement.
66
After-dryer section has 2-dryer groups. The first dryer group after speed-sizer with
single tier group followed by one (1) convectional double tier arrangement
Size press:
Surface sizing (1.5-3.0 gsm/side)/pigmenting (4-6 gsm/side) and coating (future)
(up to 10 gsm/side) is done by a VOITH speed flow Metered Size press (SPEED SIZER AT)
Calendar:
Paper machine-3 is equipped with a two roll single nipped ECO-SOFT calendar.
The following Technical features are considered in regard of Green Technology while
selecting the machine
Heat recovery system in the dryer hood supply and return air. Future option for a Turbair
heat recovery system
No fresh water usage for Turbair plat compared to water ring pumps(closed loop)
Wet end chemical dilution with Super Clear Filtrate (SCF) for fresh water saving
SCF and CF showers at PM where ever feasible for fresh water saving
Oil detection system in the cooling back water tank which indicates an oil leakage at a
cooling water consumer, no oil polluted water will be pumped to the cooler plant or to
further application in the process
Warmed cooling water return will be used as feed water for the warm water system for
steam saving
Shower water from Heat recovery units will be used again for the former exhaust flushing
for fresh water saving
Motors Efficiency class 1 (EFF1 motors for 1-90 kW) for energy savings
67
VOITH Drives:
Hollow shaft with wide bore for material lead-through and mounting
Radial bearing
Encoder if required
Revolver
Incremental encoder
Absolute encoder
68
Other features:
Sealing
Painting
Encoder system
Energy cost approx, 10% lower than Water ring Vac pumps
Heat recovery Usable for heating process water /supply air to hood
69
70
the shafts channels into the filtrate vessel. Lime mud that it attached on the surface of
the filtering discs rotates with the discs. At certain point hot water showers will pre-wash
lime mud cake during the normal filtration. After that pre-washed lime mud is scraped
from the discs with scraper plates to lime mud chutes. Dilution water will be led into the
same chutes and lime mud is directly diluted to storage consistency of 30 - 35%. From
the chutes lime mud is led through collection pipe to the lime mud slurry vessel. Constant
circulation is kept between lime mud tank and collecting pipe for equalizing lime mud
consistency effectively. Homogenous lime mud slurry will be pumped from lime mud
slurry vessel to a lime mud washer.
Capacity of the Compact Disc-Filter is controlled by level changes in the Compact
Disc-filter vessel. When the level inside the vessel rises the rotation speed of the shaft
will be increased. At certain point, when maximum rotation speed of filter shaft is reached
(6 rpm), the Compact Disc-Filter will have scraper diving sequence.
In scraper diving the scraper blades will be transferred into in position so that the
outer section of the lime mud precoat will be removed, thus leading to better filterability
of the lime mud precoat. After scraper diving the scraper blades will be transferred back
to normal position and rotation speed of the discs will be dropped to the minimum. This
kind of a scraper diving will prolong the normal filtration sequence and ensure sufficient
capacity without the need of changing the whole lime mud precoat.
71
Maintenance kept in mind when designing the filter. Filtering sectors can be replaced
directly from the manholes
Non-plugging chute design to ensure problem-free removal of lime mud from the
Compact Disc-filter
Filtering discs are arranged in different sectors and these sectors can be replaced
through the manholes, which make replacement faster and more maintenance friendly
72
ing advantages like augmentation of production, improved white liquor strength and
better white liquor clarity.
Replicability :
Installation of compact disc filter is an attractive proposition with a simple pay back
period of at most 3 years. This best practice can be replicated in any integrated pulp and
paper mill.
73
74
with steam condensate. This results in an increase in firing solids or evaporator/concentrator capacity and allows recovery of the clean steam condensate. Finally, the absence of
direct contact minimizes the risk of diluting the black liquor below the safe firing concentration.
In some heating systems black liquor is circulated to maintain velocity within the
heater at varying boiler operating rates. Further, the location of the heater downstream
of the boiler nozzle feed pumps and the use of the recirculation pump does not necessitate any change to the nozzle feed pumps. The additional pressure drop of the heater is
taken up by the recirculation pump. This pressure drop is minimized by the use of flow
enhancers inside the tubes which promote turbulence, allowing the total amount of
recircultated flow to be reduced.
The unit may be installed in either a slightly inclined horizontal position or a vertical
position. The orientation and piping arrangement must facilitate the removal and drainage of wash condensate or weak liquor from the heater.
75
Benefits:
As a result of installing the indirect heating system, the mill may be able to reduce
capacity on an overloaded concentrator, or may increase steam production in the recovery boiler due to the higher heating value of the higher solids liquor. Furthermore, the
system provides less deviation from the temperature set point, providing a constant
viscosity to the liquor guns.
In the case of APPM, due to increase in black liquor concentration, the efficiency of
the recovery boiler has increased resulting in increased steam generation.
76
high black liquor viscosity which makes it difficult to concentrate the liquor
poor settling of lime mud and lower conversion of carbonate to sodium hydroxide in the
causticizing system
This project has been implemented in unit: CP of The Andhra Pradesh Paper Mills.
77
De-silication Technique:
APPM, Unit: CP, a rice straw based pulp mill intends to install chemical recovery.
Since rice straw black liquor is rich in silica, chemical recovery of this black liquor is not
feasible without de-silication.
Submersed Bubble Reactor technology adopted by CPPRI (Central Pulp & Paper Research
Institute) avoids localized carbonation and lower the pH in a controlled manner.
Weak Black Liquor (WBL) from Pulp Mill, is received at 6% solids & 70C in to the
WBL Tank. It is pumped to Submerse Reactor Tank 1. Flow of the liquor is controlled with
78
Flue Gas from Coal Fired Boiler is used as the source for the Carbon-di-oxide gas
required for de-silication. A Blower draws flue gas from the Chimney of Coal Fired Boiler
# 4. This gas is drawn before entering the Blower, through a seal tank where suspended
fine dust if any in the gas is scrubbed. The flue gas blower injects gas into the circulating
flow of black liquor of each SRT. Flow of the total flue gas is measured and controlled.
Foam Handling:
The foam generated in SRT 1, SRT 2, SRT 3 and HRT is routed to the Foam Tank.
Foam breaking steam nozzles, using Steam, have been provided. Foam breaker is mounted
on the top of the Foam Tank. A Transfer pump transfers the Black liquor collected at the
79
bottom of the Foam Tank. A Screw Pump delivers the under flow slurry from Clarifier, to
the Filter Press.
Provision is made to send little slurry when needed, to SRT 2, for seeding purpose.
This helps in increasing the particle size of the silica during under carbonation, in-turn
improving the Filter performance. Suspended silica in the de-silicated black liquor is separated and washed in the Filter Press. This Filter Press is a 60 chamber, polypropylene
recessed, closed delivery type press, having a pull back closing device with motorized
power pack.
This silica slurry from the Clarifier Underflow is fed to Filter. The black liquor gets
filtered across the poly propylene filter cloth covered over the chamber plates and comes
out of the filter outlet as mother filtrate. It is collected in the Mother Filtrate Tank. It is
pumped to Black Liquor Polishing Tank. Provision is given to further wash the silica cake
of its entrapped liquor.
After washing and drying of cake, inlet valves are closed and Filter Press is opened
with the help of closing device. Then the chambers are opened one by one and the silica
cake is dislodged into a receiver. The filter cloth cleaned.
Since the pH, RAA and total solid content are low, this black liquor is not suitable as
such for chemical recovery and de-silication. Pulping trials were carried out with
varying chemical charge, temperature and cooking cycle time.
80
It forms rock hard deposits on heat transfer surfaces; and beehives on Furnace Walls
during burning.
Presence of silica leads to Low dryness of mud in causticizers during mud washing.
Thermal analysis studies showed that silica forms a sheath over lime particles so that
CO2 cannot escape from CaCO3 molecules, making Lime mud difficult to burn.
81
In ceramic Industry
In lubricating grease
In cosmetics
Replication potential:
This best practice can reduce the silica content in the black liquor from about 8 gpl to
a level of 1.5 2 gpl. Reduction in silica from 1.5 gpl is not proven to be achieved by
this method.
This best practice is most applicable to a straw based small & medium scale pulp mill
with recovery section.
82
Unit:
Problem Statement:
Unable to reduce fluctuation of burning zone temperature due to long dead time associated
in the process between fuel oil flow and burning zone temperature.
Excess oxygen in flue gas being maintained on the higher side (> 5%)
Fuel oil flow affecting both burning zone temperature and excess oxygen in flue gas
which is a multivariable problem and same cannot be addressed by basic level controllers.
Disturbance in the unit demands for frequent changes in the operating parameters to
maintain the critical operating parameters with good judgment.
Long dead time process can be effectively handled by model based Advanced Process
Controller.
APC responds to disturbances in the plant and takes corrective action typically every
minute around the clock.
83
Maintaining primary, secondary and tertiary air ratios as well as excess oxygen in flue
gas which is a typical multi-variable problem.
Improve Steam per Ton of Black liquor solids by optimizing the overall boiler
operations
Frequent disturbances in the unit demands for frequent control actions to maintain
critical operating parameters.
APC addresses the multivariable control problem to maintain both air ratios and
excess oxygen in flue gas.
APC takes corrective actions every 30 seconds for disturbances in the unit to maintain
excess oxygen close to the minimum allowable limit.
Venting of steam due to frequent changes and mismatch in the supply and demand of
steam.
84
Frequent changes in supply and demand of steam demands for frequent control
actions. Loss of time to control result in loss of energy in terms of venting.
Any mismatch between supply and demand is taken care by changing load on CFB-6 &
CFB-7 by APC.
APC responds to supply/demand imbalance promptly and takes corrective action every
15 seconds round the clock.
Loading the most efficient TG to improve overall efficiency (Implementation going on)
Benefit:
Reduction in steam venting due to frequent and prompt corrective action by APC.
HP steam header pressure fluctuation has reduced which resulted in reduced HP steam
venting to a greater extent.
Optimized TGs operation which will result in reduced specific steam consumption per
MW of power.
85
Unit:
ITC, Limited
Background:
ITC PSPD Unit Bhadrchalam has series of coal fired boiler since inception. Unit was
retaining all the boilers in operation as plant expanded, keeping initial boilers as standby
boilers. Growing fiber requirement necessitated thought process backward integration
towards captive plantation through coloned varieties of select species of Eucalyptus and
subabul. Company has covered over 90,000 hectares of land for plantation to supply pulp
wood which can generate 10 Lac MT of wood annually.
Normally 20% of the plantation is the over ground biomass in the form of lops & tops,
bark and leaves. After the company stared using only debarked wood, farmers were
encouraged to debark the wood and transport debarked wood to the mill to avoid transportation of bark. Farmers in need of growing for next cycle of plantation has burnt all the
biomass generated.
Company has identified following opportunities on above back ground
The biomass left in the field has significant calorific value inspite of higher moisture
which can be used as fuel for boiler
awareness on GHG
emissions and opportunity to generate CERs, unit has conceptualized the idea of installing a bio fuel boiler called Green boiler.
This Green boiler is designed for 90 TPH steam generation, 64 kg/cm2 (g) pressure,
4805 deg C super heated steam output designed for firing with 100% F grade coal ,
86
70% Biomass + 30% Indian Coal. This boiler is a single drum design, natural circulation,
water tube, balanced draft, over bed cum under bed fuel feeding system, top supported
pressure parts and hopper bottom design.
Fuel combustion will be in an Atmospheric Bed Combustor (AFBC) fixed at the boiler
bottom. Fuel is stored in the bunker. Drag chain feeders are connected at the bottom of
surge hoppers. The fuel is fed by these feeders into the combustor by over bed feeding
system through coal spreaders. Also fuel is spread through under bed fuel feed pipes. For
biomass feeding pneumatic spreaders are provided.
The following are the various biomass which are being fired:
Wood bark
Chip dust
Lean wood
Wood slivers
This biomass first passed through shredders to reduce them to the required size. The
finished biomass is sent to the boiler and fired. This has helped in reducing the coal
consumption to an extent of fuel switch by biomass.
Has potential to generate good number of CERs per annum. A source of revenue.
The carbon foot print for manufacturing paper and paperboard reduces significantly to
the extent of substitution of coal by biomass
Opportunity to improve the efficiency of steam generation by not using old boilers
87
The H.P.steam requirement for the soot blowing application is derived from the main
steam header of the boiler. Balance 30 % low and medium pressure steam are used for
process other than utilities.
In the Vertical air system of ANDRITZ design of Chemical recovery boiler, combustion air
is split in three stages and the same are being admitted at 3 levels. Whereas the primary
and secondary air are heated, tertiary air admitted at the highest of the 3 levels is unheated. The primary and secondary air is heated to the temperature of 200oC. This has
been achieved in three stage heating using HP, MP & LP steam.
In chemical recovery boiler, reasonably good bed stabilisation can be achieved in the air
temperature range of 150-200oC. Preheating the air temperature to the tune of 200oC
with the support of HP steam leads to increased energy consumption. There is an opportunity for optimising the primary and secondary air temperature and minimise the steam
consumption.
88
Objective:
To optimise the primary and secondary combustion air temperature in the chemical recovery boiler and minimse the steam consumption for combustion air heating.
Proposal:
The primary air temperature is gradually reduced from the set point of 200oC which was
as per the original design. Presently the air temperature is maintained in the range of
175-180oC.
HP steam utilisation has been totally avoided to achieve the temperature of 175-180oC.
The MP steam consumption also has significantly reduced. This has been taken up without affecting any of the operating parameters of the Chemical recovery boiler.
Benefits:
Use of HP steam has been totally eliminated for the heating application and utilised for
additional power generation.
Marginal reduction in MP steam consumption , since the air heating is lowered by 20oC
Spin-off gains:
The reduction in combustion air temperature has resulted in reduction in exhaust flue gas
temperature of the chemical recovery boiler.
Issues:
The plant operating team has observed no issues till today due to the reduction in combustion air temperature.
Replication:
The concept can be replicated in other pulp mills where the primary and secondary air
temperature is heated around 200oC.
Futuristic scope:
Secondary air temperature can be lowered gradually through adoption of stacked air
89
system. This would ensure high reduction in L.P. and M.P. steam consumption.
90
91
Objective:
To achieve high cycle efficiency through lower specific steam consumption for unit power
generation.
Process:
In Seshasayee paper Boards Ltd the following measures have been taken up by design
for improving the cycle efficiency of the plant:
Steam- side pressure and temperature drop across the main steam pipeline is designed
low so as to achieve the maximum driving potential through the turbine.
Superheater heating surface is liberally designed right from Primary, secondary & tertiary
so as to ensure rated steam temperature on a continuous basis.
Designing and then operating at the highest main steaming conditions right from steam
water circulating tubes ( 74 to 75 kg/cm2) encompassing the combustion chamber and
then through the superheater coils right upto steam turbine inlet ( 64 kg/cm2 & 455C)
had ensured high cycle efficiency in terms of enhanced electrical power.
92
The concept of higher steaming conditions at the steam turbine inlet could be realised by
mixing the high temperature steam produced in coal fired boiler and comparitively low
temperature steam produced in the chemical recovery boiler but at the same operating
pressure. This can be achieved by mixing the steam in a common header.
Benefits:
Increased cycle efficiency due to higher temperature at the inlet of the turbine and hence
additional Power generation for the same heat input.
Issues:
There is no issue faced by the plant team as on date due to increase in steam temperature. The fear of high temperature corrosion had been negated through close to 2 years
of continuous operation of the boiler without attendant pressure part failure.
Replication:
This concept can be comfortably replicated in other pulp mills where the main temperature of
the chemical recovery boiler is lower. Increase the steam temperature of the coal fired boiler
operating at 64 kscg to say 485 490oC. Mix the steam generated at higher temperature in
coal fired boiler with the steam generated in Chemical recovery boiler.
Since the connecting header is common at the same main steam pressure, the resultant
mixed steam temperature can be raised to 460 to 465oC at turbine entry. The increased
steam temperature at the inlet of the steam turbine will increase the overall cycle efficiency.
The concept has also been successfully implemented in Andhrapradesh Paper Mills ltd. The
same concept can be extended to other mills who are having common steam pressure but
steam at lower temperature from chemical recovery boiler.
93
2.
Fume condensation
Physical carryover
This is material that has been entrained in the flue gas. It produces a hard, fused deposit,
usually in the front parts of the superheater. Chemically, its composition is similar to
smelt.
Fume condensation
This material forms when inorganic vapours are cooled to their condensation temperature. This results in a very fine, soft deposit, usually in the generating bank and economizer. In the back side of the superheater, the deposits can be a combination of carryover
and fume. It all depends on the temperature profile of the gas, and characteristics of the
dust.
The two most important factors that determine whether deposits over pressure parts
accumulates, are the quantity of particulates in the upper sections, and the stickiness of
the same.(Fig. 1).
94
Fig.1
A third factor, soot blower operation also affects the operation as shown in the next
diagram. (Fig.2). Particulate removal efficacy depends not only on the type , quality and
quantity of deposits over pressure part exterior, but also on the soot blowing effectiveness , location, duration and time gap .
Fig.2
Objective:
To optimise the operation of the soot blowers based on the requirement and minimise the
steam consumption in the soot blowers.
95
Process:
STAGGERING THROUGH INTELLIGENT SOOT BLOWING CLUSTERING
As per the usual industrial operating practice, all the 28 soot blowers in the chemical
recovery boiler is operated once in a shift and all the 3 shifts in a day. The soot blowing
stretches for a continuous time period of 21/4 hours. In this practice, the soot blower is
put in operation even if there is no deposit formation on the heating surface. Operating
the soot blower without deposit formation will result in
Based on the operational feed back, in order to improve the soot removal effectiveness, the blowing sequence was split into 2 clusters each of 14 No. of soot blowers. With
a time gap between the 2 clusters at 45 minutes, the soot blower operation from start of
the 1st unit to the end of the last (28th) unit extended to 3 hours. It was found that the
soot blowing efficacy in terms of removal of soot & stack clarity enhanced.
Without stopping at this, Seshasayee Paper operating personnel had gone one step
further in going in for further extending the soot blowing period by going in for Cluster of
4, with each cluster of 6 soot blowers, as detailed in Table -1.
Time gap between each of the Clusters of 45 minutes in between each of the cluster
affected a total time stretch of 4hrs 20 min.
Benefits:
The feed back is one of reduction in particulate emission through the stack. Longer
time stretch had enabled less solid particulate accumulation on the pressure part exterior. The improvement in soot blowing efficacy for particulate removal from pressure part
exterior could be accomplished purely based on operators feed-back and putting the
scheme in practice.
Issues:
No issues faced, as of date.
Replication:
Based on the operational success, other paper mills who had gone in for High Pressure
Chemical Recovery Boilers, can adopt similar technique as stated above in their units.
96
Fig.3
CHEMICAL RECOVERY BOILER # 11 - SOOT BLOWER LOCATION
TABLE - 2
97
Unit:
ITC, Limited
Background :
At ITC-PSPD all employees, including middle and top management, are fully involved
to give maximum thrust on water & resource conservation as it affects bottom line of the
main performance. In general, schemes with an investment up to 10 lakhs with a pay
back period of two years or less is implemented without loss of time and Unit Head is fully
empowered to take decision. Suitable rewards are given after the implementation and
displaying the envisaged savings. Water Conservation schemes implemented with the
ideas generated from external consultants are judiciously engineered and meticulously
executed. ITC-PSPD culture is to involve each and every engineer in every discipline as a
champion for faster execution of the job, thereby; the importance of Water & Resource
conservation is percolated to all workmen. Also, proposals are generated through employee involvement through suggestion scheme (TPM) which is linked with monetary
benefits.
As a result of consistent efforts for water conservation, Specific Water Consumption
has reduced by over 33% from 74 m3/T in 2004-05 to 50 m3/T in 2009-10.
98
Project Description
Water Saving
(m3/day)
10
11
1200
1200
1719
1000
1000
1540
500
All the hydra pulpers are provided with back waters from
machine 5 various layers at PM-5
500
500
500
200
99
12
13
14
15
16
17
18
400
350
648
350
240
338
100
100
101
Water collected from PM-1,2& 3 Hydraulic Stations reused for High pressure showers
Energy cell along with departments identify the opportunities to conserve water through
reduction, reuse and recycle opportunities.
Proposal identified by Energy cell and departments are raised as capital scheme for
value above Rs. 10 Lac 100 Lac
Proposals which are integrated with process and with investment more than Rs. 100 Lac
are taken through projects for initiation and implementation
Energy Cell prepares the concept note of the proposal identified with investment and
payback
Department approves the concept note agreeing for implementation of proposal and
budget requirements.
Energy Cell prepares the capital scheme based on concept note and submits to Divisional
Management Committee for approval of funds for implementation.
On implementation, Energy Cell monitors the savings achieved against the envisaged
savings and reports back to department.
To monitor sustainability of savings, Energy Cell monitors the savings on monthly basis
for one year to confirm the savings.
Apart from the above water consumption reduction initiatives, a project was taken up
for un-metered reduction throughout the plant. The project resulted in considerable fresh
water saving of 5300 m3/day which was going un-metered because of the water leaking
through underground old network of fresh water & fire hydrant pipelines.
102
Measurements were made from supply point to various end user points
Meters were installed at various places, where there was no sub-metering arrangement.
The metering system was integrated with the advanced IP-800 Dashboard system to
monitor the water consumption on real time basis.
The major reason was the water leaking through underground old pipelines. The seeping
water was going as un-metered.
Action taken:
The whole underground network of pipelines was eradicated & new overhead connections were provided for all the areas
103
Unit:
ITC, Limited
Background:
Effluent Treatment Plant upgraded with the new MBBR Technology in the year 200809.The overflow from Primary Clarifier (Coloured effluents) is led to MBBR tank to further
reduce soluble COD by 40-60%. The outlet of MBBR will move to Aeration tank and then
to Secondary Clarifier for further reduction of pollution loads. To reduce the Inlet temperature to MBBR Tank cooling Tower introduced in the month of April2010.
104
Due to increase in T, water quantity required at the process side is much less. MCS
requires water pressure equivalent to the height of cooling tower as shown in the following diagrams. Hence, considerable amount of energy is saved on circulation water pumping. Also, MCS does not require any fans for cooling. Thus, a huge amount of energy is
saved on circulation and cooling.
Mist Cooling System will supply cold water temperature with an approach of 0 to 1C
to WBT as against an approach of 4 to 6C in cooling tower. For plants with space constraints, a closed pond can be used. The approach to WBT increases to 2.5C with a
closed-pond design, but a closed pond is 30 to 35 percent smaller than an open pond.
Mist Cooling Systems can have chokeless design with the size of smallest opening in
MCS is more than one inch (25 mm) in diameter. Hence chances of particles choking the
system are low. Another benefit of mist cooling is reduced maintenance requirements.
While cooling towers use louvers, fan blades, clamps and other components that must be
replaced, mist cooling systems do not have any moving parts and therefore require little
maintenance. Shallow mist cooling ponds also are easier to clean than the deeper ponds
required for cooling towers, and ponds can be designed with two or three compartments
to provide additional maintenance flexibility.
Drift losses are 0.1% for normal conditions and 0.25% for Windy conditions. These
can be further reduced to 0.05% by adopting our closed pond design. Evaporation loss
will depend on the temperature drop obtained from the system.
Chemical dosing, makeup water and blowdown requirements are similar to what is
required with cooling towers. However, the atomization in mist cooling, along with the
related absorption and retention of air by the water particles, allows the water to have
better biochemical oxygen demand (BOD) and chemical oxygen demand (COD) values
than the water in cooling towers.
105
Replication potential:
Mist cooling systems have been installed in The West Coast Paper Mills, Dandeli and
more recently in Orient Paper Mills, Amlai.
106
Unit:
ITC, Limited
107
The process gave an opportunity for ITC PSPD employees to contribute through their
rich experience and innovative ideas and enabled others to be part of success as the
activities are carried out in the form of teams. This has created good team and healthy
competitive spirit. At the same time, it improved relationship between employees and
managers due to active cooperation and support in solving the problems.
108
109
Unit:
ITC, Limited
Background:
ITC as a part of their Corporate Social Responsibility Charter has taken up Wealth
Out of Waste (WOW) as a green initiative to protect environment and reduce global
warming. The effort is to create awareness among general public on the need for waste
avoidance, source segregation maximum recycling, minimizing landfill, to help improve
the environment and work towards a cleaner and greener societies. Against this backdrop, many schools, Corporate, residential locations, commercial complexes were been
approached in Hyderabad and the response, according to ITC, is quite encouraging.
Wow has been designed to manage waste from individual households as well as civic
bodies. It discourages recyclable waste from going into landfills or getting burntboth of
which damage the environment.
As a part of this programme awareness programme is being conducted to school
children and public on the benefits of the Reduce-Reuse-Recycle process.
being encouraged to segregate recyclable waste.
Public is
The WOW initiative has been acclaimed by Municipal Authorities, Environmental Agencies and other as a unique effort with multiple benefits to society. Apart from preserving
and protecting the environment, improving civic amenities, as well as public health and
hygiene, it also generates sustainable raw material for paper and other industries at
competitive prices, there by helping conserve scarce environmental resources.
As against 60-70 % of the waste being recycled in the West (the US and Europe),
only 14 % gets recycled in India. Even China and other Asian countries are better placed,
with 25-30 % recycling.
ITC is actively promoting the WOW (Wealth out of Waste) initiative in Hyderabad,
Bangalore, Chennai and Coimbatore to help increase the recovery of waste paper. The
company provides special bags to accumulate dry wastes such as paper, plastic and
metals and arranges periodic collection through outsourced agencies. The segregated
110
dry waste can save almost 40 per cent of municipal garbage handling costs, he pointed
out.
Environmental hazards:
Roughly, 60 per cent of the waste generated in households consists of paper and the
rest, metal, plastics and other things. ITC has been trying to educate the public about the
two-bin system segregation of waste into two categories (recyclable and the rest) at
source. We are implementing the programme in some of the cities and towns in Andhra
Pradesh. The response has been very good. Recycling of one tonne of waste paper saves
17 trees and 7,000 gallons of water. This is just an example of the benefits of recycling.
Generated quantity:
Every day about 4,200 tonnes of waste were being generated in Hyderabad, of which
1,200 tonnes could be recycled. Mumbai was generating 6,800 tonnes (2,000 tonnes);
Kolkata 5,500 tonnes (1,600); Chennai 4,500 tonnes (1,300); New Delhi 6,000 tonnes
(1,800) and Bangalore 4,000 tonnes (1,200).
Recyclable waste is collected from each house hold by paying Rs.5/- each kg of
waste. ITC - PSPD Company is set to increase waste paper collection for paper board
mills.
ITC has decided to step up its waste paper collection business under its WOW (Wealth
out of Waste) programme, to augment raw material supply for its paper board mills. ITC
uses about 1.8 lakh tonnes of imported waste paper annually at its mills in Coimbatore
and Bhadrachalam. The company needs about 3 lakh tonnes of waste paper annually.
The balance is sourced domestically.
Achievements:
The total wastepaper collected though this programme amounted to 6000 tonnes during
2008-09.
111
Total Waste paper recycled for operations is 40,194 tonnes during 2008-09.
112
Objective:
To achieve SPM content in flue gas leaving stack at 50 mg/Nm3.
Process:
After a detailed study and series of adjustments for uniform gas distribution it was
identified that there is a need for removal of ash from the last field of the ESP for minimising
the SPM emission level. For faster removal for ash from the last field, rapping mechanism
was installed.
113
The rapping mechanism ensured faster removal of ash from the field and hence
improved collection efficiency in the last field. This has resulted in reduction in SPM emission level below 50 mg/Nm3.
View of Boiler 11 Chemical Recovery Boiler -4 field ESP with inlet & outlet ducts
Benefits:
The SPM emission is reduced to the level 50 mg/Nm3. This requires only a marginal
investment for installing the rapping mechanism in the last field of the ESP.
Issues:
None reported.
Replication:
This concept can be comfortably replicated in other pulp mills having Recovery Boiler
aiming for low SPM emission. As a matter of fact, TNPL had adopted in a small way, the
deflector concept at ESP gas entry, for effecting reduction in SPM in flue gas leaving ESP
(of FLS design).
114
Objective
Reduce fresh water addition in vacuum pump cooling tower to lower temperature and also saving in fibre, all wet end chemicals and fines which is required for better
formation of sheet.
115
Vacuum Pump cooling tower makeup water was replaced with Clear Filtrate Water (60
ppm) from Poly disc save-all to replace Fresh water Make up.
Vacuum sump water was diverted to Poly Disc Save-all and the excess clear water of
60 ppm from White water tower was supplied to Pulp mill for Bleached Tower Pump
Consistency control.
116
Benefits:
By Process modifications and using the available automation, the following benefits are
being realised :
Fresh water (340 m3/day) is replaced with Clear filtrate from Save-all.(Fig.3)
Back water is used in Pulp mill helps to maintain final pulp Brightness (Since Back water
contains OBA)
Costly fibres and fillers are recovered from Vacuum pump sealing water, thus disturbance
in wet end chemistry like Charge Demand, etc are avoided.
By closing the water loop in the Paper Machine complex, wet end chemical consumption
is optimized.
117
Issues:
None, as of date.
118
Unit: TNPL
Water Management initiatives
The approach followed at TNPL to reduce water consumption is as follows.
Revise goals/targets
Different streams of water have been analyzed for possibilities of recycling after some
treatment. The following table gives some of the streams of return water being matched
with the recycling opportunity.
119
The individual paper plants have to assess the present performance and should
develop its own individual target for improving parameters concerning energy, water
and environmental performance
The best practices and the performance improvement projects compiled in this manual
may be considered for implementation after suitably fine tuning to match the individual
plant requirements
If required, CII-Godrej GBC will help the individual units to improve the performance
by providing energy audit services and identifying performance improvement projects
specific to individual units to achieve the targets
The present level of performance and the improvements made by the individual
units have to be monitored
Conclusion
The objective of the project will be fulfilled only if the performance of all the pulp and
paper units improves and achieves world class standards.
We are sure that the Indian Pulp and Paper units will make use of this opportunity,
improve their performance and move towards the world class Energy Efficiency.
120
ANNEXURE
LIST OF WORKING GROUP MEMBERS
S.No
Name
Designation
Company
Mr K M Kassetty
APPM
Mr. P V Raman
Manager - Recovery
APPM
Engineer - Energy
CII-Godrej GBC
Mr. S Karthikeyan
Counsellor
CII-Godrej GBC
Counsellor
CII-Godrej GBC
Mr. K Sivaram
Counsellor
CII-Godrej GBC
Mr. M B S Nair
President
Mr.N.Thirugnanam
Manager(Paper)
10
Mr. S K Jain
Vice President
11
Mr. A Das
General Manager
ITC Ltd
12
Mr A Padmanaban
General Manager
ITC Ltd
13
ITC Ltd
14
ITC Ltd
15
Mr. G. Manikanta
ITC Ltd
16
17
Mr. Srikrishna
18
Mr. B Pandey
19
20
Dr. Marimuthu
AGM ( R&D)
SPB
21
Dr. T G Sunderraman
Head (Energy)
SPB
22
Mr. Bharathi
[Paper Machine ]
SPB
23
[Project]
SPB
24
Mr. Sridhar
[Fiberline]
SPB
25
Mr. Asokan
Manager - Pulp
TNPL
26
Mr. K.Kuppuswamy
TNPL
27
Mr. Ranjith
28
Mr. D Ravichandran
TNPL
29
Mr. T Venugopal
Manager - Sales
Vacon Drives
APPM
Chief Engineer
ITC Ltd
ITC Ltd
General Manager
JKPM
Siemens
TNPL
121