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4.1.1 Overview
Kraft pulping process involves cooking of prepared raw materials (wood chips, grasses,
wheat straw, bagasse, etc.) with cooking chemicals (pulping chemicals), and processing
(blowing, washing, screening and cleaning) the cooked material into unbleached pulp.
Blowing of cooked material involves release of hot vapours. Heat is recovered from these
vapours through using a blow heat recovery system. Washing of the cooked material
(blown pulp) generates black liquor, which contains spent cooking chemicals and
solubilized constituents (mostly non-cellulosic organic constituents) of the raw material
being cooked. Cooking chemicals and energy are recovered through concentrating and
burning the liquor and causticizing resultant smelt (green liquor), in a chemical recovery
plant. Recovered cooked chemicals are used in pulping in the form of white liquor.
Storage, handling and preparation of raw materials, despite being same for different pulping
processes, has also been included under the Kraft pulping process for convenience. Overall
Kraft pulping process, including storage, handling and preparation of raw materials, and
Kraft liquor cycle, is schematically shown in Figure-4.1.1.
Three of the five mills analyzed (Alpha Pulp Mill, Beta Pulp and Paper Mill and Gamma
Pulp and Paper Mill) are employing the Kraft pulping process. All the three mills have
chemical recovery plants. Kraft pulping process of the Alpha Pulp Mill includes a pre-
hydrolysis step for facilitating manufacture of rayon grade pulp.
4.1.2.2 Storage
Raw material is usually stored in open space. Ground barrier of concrete or asphalt is often
provided underneath the stored raw material for reducing dirt contamination and/or
inhibiting attack by termites and other ground organisms. Storage is associated with fire
hazard. About 1% of the wood stored is usually lost in storage per month to respiration,
thermal degradation, chemical reactions and microbial activity. For minimizing the storage
losses, chemical sprays (chip preservative treatment) are often used. Depending on the raw
material stored and chemical sprays used, drainage water from the raw-material storage
yard may require treatment. Bulky raw materials, such as bagasse (which contain residual
sugars), are often stored under water. Such storage may generate wastewater, which may
require treatment prior to disposal. Raw materials (specially wood chips) are often stored in
enclosed or built areas, and storage bins and silos.
4.1.2.3 Debarking
Debarking is required when wood is used as raw material. Either a wet operation, or a dry
operation, may be employed for wood debarking. This operation produces bark as solid
waste (4 to 5% of the wood debarked). Wet debarking involves use of water and generation
of wastewater. Mechanical debarking involves use of electrical energy. Dry debarking can
cause air pollution and noise pollution problems. Debarking operation may not always be
carried out within the mill premises.
4.1.3.1 Pulping
Kraft pulping, in addition to the above-mentioned activities and operations, also includes a
blow heat recovery system, which produces hot water from the blow tank vapours. All the
three mills analyzed are employing batch Kraft pulping process. Except in the old pulp unit
of the Beta Pulp and Paper Mill, pulping is done through indirect heating of the digester
contents in an external pre-heater with saturated medium pressure steam. Direct steam
injection pulping is practiced only in the old pulp unit of the Beta Pulp and Paper Mill.
4.1.3.1.1Digester loading
Loading refers to the packing of the digester with the prepared raw material (often with the
help of steam), while purging out air and other non-condensable gases, the addition of
cooking chemicals (sodium hydroxide and sodium sulfide) in the form of white liquor, and
the adjustment of wood to liquor ratio in the digester (usually with weak black liquor,
WBL).
If cooking involves a pre-hydrolysis step, then loading of white liquor is delayed till pre-
hydrolysis is over. Loading of the digester for pre-hydrolysis may in fact include loading of
the prepared raw material and hot water or hot foul condensate.
4.1.3.1.2Pre-hydrolysis
Pre-hydrolysis is an optional operation. It is usually employed when rayon grade pulp is
produced and/or when pentasons removal is desired. Pre-hydrolysis involves cooking of
raw material in water (cooking medium) at elevated temperature (155 to 170°C) and
draining out the cooking medium as pre-hydrolysate liquor (PH liquor). After loading, the
digester contents are heated (by circulating the cooking medium through an external heat
exchanger, pre-heater, wherein it is indirectly heated by MP steam) to gradually increase
temperature to desired level and maintained at that temperature for a fixed duration. Steam
condensate is generated at the pre-heater and it can still be used for low temperature heating
purposes. Further, this condensate, if not contaminated, can be recycled and reused as
boiler feed water. For avoiding build up of false pressure, non-condensable gases
accumulated in the digester are vented into the atmosphere continuously and/or
intermittently. These vented gases may be rich in volatile organic compounds.
For draining out the cooking medium, supply of MP steam to the pre-heater and circulation
of the medium through the pre-heater are stopped, and the digester vent is opened for
allowing escape of relief gases and drop of digester content’s pressure to a desired value.
After this, the medium is drained out as PH liquor through a screen plate. Frequently, pre-
hydrolysed material of the digester is washed in hot water and the wash water is drained out
as pre-hydrolysate wash liquor (PH wash liquor). PH liquor is acidic and hot, and it is rich
in organic matter. Characteristics of PH liquor sampled from Alpha Pulp Mill are given in
Table-4.1.1. PH liquor has a tendency to clog pipelines through crust formation.
4.1.3.1.3 Cooking
If the loaded raw-material is pre-hydrolyzed first, after draining out the PH liquor, the
digester contents are added with white liquor and wood to liquor ratio is suitably adjusted,
usually, with weak black liquor (WBL), which is obtained from brown stock washing of the
pulp processing section. Cooking involves raising the temperature of digester contents to
155-170°C by circulating the cooking medium through pre-heater and indirectly heating it
with MP steam. Steam condensate generated at the pre-heater has recycling and reuse
potential both as a low temperature heating medium and as boiler feed water. During
cooking, in order to avoid development of false pressure, the accumulated non-condensable
gases are vented out continuously and/or intermittently. Such vented gases may be rich in
reduced organic sulfur compounds. Anthraquinone is often added to the digester during
cooking, may be for catalyzing or accelerating fragmentation of lignin and for rendering it
vulnerable to attack and dissolution by cooking chemicals.
In the Beta mill, instead of using a pre-heater, direct steam injection cooking is practiced.
4.1.3.1.4Blowing
Preparation for blowing includes stopping circulation of the cooking medium through the
pre-heater and brining down digester pressure to the desired level through venting. Once
pressure is dropped to the desired level, digester contents (cooked material along with the
cooking medium) are blown under pressure into a blow tank. Blowing leads to drop in the
temperature of the blown material to under 100ºC. Excess heat of the blown material is lost
in the form of blow vapours from the blow tank. Sometimes blow may not be complete and
some of the cooked material may still be left in the digester. In such cases, the digester is
added with the black liquor (obtained from pulp washing), pressurized with steam and then
the digester contents are re-blown. Heat is recovered from the blow vapours through a blow
heat recovery system.
In one of the pulping units of Beta Pulp and Paper Mill, where grasses, straw and bagasse
are used as raw-material, cooking liquor is blown separate from the cooked material. After
blowing the liquor, the cooked material is drained out from the digester as slurry with the
help of water jets. Generalized batch Kraft pulping process is schematically shown in
Figures-4.1.3 & 4.1.4.
4.1.3.2.1Screening
Pulp from the blow tank is usually screened in a pressure screen or a vibratory screen or a
gravity centrifugal screen (and sometimes defiberized in a disc refiner), prior to its
washing. Because of high rejection rates, rejects of pressure screens are usually further
screened in a secondary pressure screen and/or a vibratory screen for recovering useful
fiber from the rejects. Pressure screens may also separate tramp material from the pulp. Use
of vibratory screens is associated with foaming and liquor spatter problem. Foaming
problem is relatively less (when compared with vibratory screens) in case of gravity and
centrifugal screens. Rejects generated from screening (known as knots) are either discarded
as waste (through burning, land filling, etc.) or loaded back to the digester either along with
fresh chips or as a separate batch. Dripping of cooking liquor is common in the knots
handling area. See Figure-4.1.5 for a flow diagram of screening in a pulp processing unit of
the Beta Pulp and Paper Mill.
In the old pulp unit of Beta Pulp and Paper Mill, where cooking medium is blown separate
from the cooked material, the blown medium is screened separately, and the fibrous mass
recovered from such screening is added to the pulp slurry prior to its screening, cleaning
and washing.
4.1.3.2.3Pulp cleaning
Pulp cleaning is meant for the removal of sand, dirt and other dense particles from the pulp.
High density cleaners (HD cleaners) and/or multi-stage centri-cleaners are used for cleaning
the pulp. In the Beta Pulp and Paper Mill, a reiffler, wherein heavier particles are allowed
to settle under gravity, is used for pulp cleaning.
HD cleaners are employed for cleaning the pulp prior to brown stock washing. These can
tolerate higher pulp consistencies (3-4%), and are appropriate for removing relatively larger
size heavier particles. These cleaners have stock savers attached to them for re-suspending
the rejects and recovering good fiber. This re-suspension and recovery of fiber involves use
of elutriation fluid.
Centri-cleaners are usually used for cleaning the washed pulp of around 1% consistency.
These cleaners prove very appropriate for the removal of heavier but small size particles
like grit and sand. Usually multistage centri-cleaners (three or more) are used. This
cleaning process involves separation of the input pulp stream into an “accepts” stream and a
“rejects” stream. Rejects stream of one stage of centri-cleaning is cleaned in the next stage
of centri-cleaning in order to recover good fiber and concentrate the rejects. Accepts stream
of a centri-cleaner stage is passed through the earlier centri-cleaner stage as input pulp. A
fiber-miser is used for the final processing of rejects and recovery of good fiber. Typical
flow sequence of a multi stage centri-cleaning process is shown in Figure-4.1.7.
4.1.4.2.7Soot blowing
Solids entrained in the flue gases usually settle on the water tubes (of the furnace, super
heater, boiler tube bank and economizer sections) and adversely affect the heat exchange
process. Soot blowing is practiced, specially for cleaning the tubes free of soot and ensuring
efficient heat exchange. High pressure superheated steam, extracted from the steam header
of the recovery boiler, prior to its connection to the turbine header, is used for blowing the
soot. The blown soot partially gets collected into the bottom hopers and, partially, gets
carried along with the flue gases. Soot blowing usually increases load on ESP and release
of SPM in the exhaust.
4.1.4.3.4Dregs washing
Green liquor clarification leads to the generation of dregs. These dregs are mixed with hot
water in a dregs mixer tank and washed in a dregs wash tank. Wash water generated from
such washing is recausticized in a recausticizer tank through adding underflows of white
liquor clarifier and hot water. Recausticized slurry is taken to the lime mud washers.
Washed dregs, which are rich in carbon and inorganic impurities, such as calcium and iron
compounds, are disposed as solid waste. In the Alpha Pulp Mill, where limekiln is used for
the calcination of lime mud, scrubbing wastewater generated from the limekiln exhaust is
also used for recausticizing the dregs wash water.
foul vent
condensate gases
white liquor
screenings (knots)
saturated & rejects (grit)
PH liquor
steam
boiler
feed water lime
weak white liquor
flue
gases
rejects
LP/MP
steam
Dust Condensate
hopper pots
Figure-4.1.2: Process flow diagram of a wood based Pulping unit of the Beta Pulp and
Paper Mill
A. prepared B. vent gases
purged gas raw material saturated
liquor MP steam
steam
Blower liquor
heater
Digester
Pre-
Pre-heater
Liquid
separator Digester
steam
liquor condensate
liquor liquor
white liquor
WBL and/or water
vent gases saturated
white liquor liquor MP steam
C.
& WBL D.
vent hot water
gases liquor
heater
digester
Pre-
heater
Digester
Pre-
steam
liquor condensate
A. Prehydrolysis
B. PH liquor draining
liquor C. Sulfate cooking
PH liquor & D. Digester loading
PH wash liquor
heater
vent of non- Blow tank Digester
Pre-
Primary
condensibles
condensor
BL leaks WBL
from BSW
BL from
spill sumps
Figure-4.1.5: Process flow diagram for pulp screening in a pulp processing unit of the Beta
Pulp and Paper Mill
hot process water
blown washed
pulp BSW-1 BSW -2 BSW -3 BSW -4 pulp
foam foam
2 1 foam
vent gases
Filtered WBL for
BL tank sealing purposes
Figure-4.1.6: Schematic process flow diagram for multistage counter-current brown stock
washing
water
Primary accepts
Pulp centricleaner Primary centricleaned pulp
Feed tank centricleaners
water rejects
Secondary
accepts Centricleaner
Feed tank
Secondary
centricleaners
Tertiary
Centricleaner
Feed tank
water
accepts
Fiber
? mizer
accepts
Stone Spill tank Quart.
traps cleaner
unbleached
pulp
accepts
accepts
Pressure rejects Vibratory H2SO4
knotter screen tower
UBDK water
Sec. Centri-
vent cleaner H2SO4
accepts knots Dosing tank mill water
hotwater/
UBDK water
accepts
screen
Vacuum UBDK
pump water rejects 1. WBL to
Seal pot Vibratory chemical recovery plant
screen blow tank, digester,
? knots pressure knotter, etc.
flashed
vapours*3
Flashing
section condensate from
non-condensable other effects
gases*4
heating Heater
medium*2 section Condensate Condensate
leg pot
condensate*5
black concentrated
liquor black liquor*1
MP steam
water Precooler
non-conden. Primary
gases Steam ejector
MP steam Sondary
After cooler
foul condensate Steam ejector
condensate
to TBL
storage tank
steam cond. black liquor steam cond. black liquor steam cond.
semi-conc.
black liquor
MP steam Super
heater Economizer ESP
Air pre-
heater
tert. hopper ash
cond. Mud drum
sec.. ESP ash
Furnace
prim. hopper WWL
smelt ash
MP steam
TBL
BL pre- WWL steam Ash
heater Wood & vent tnak
furnace oil
cond. TBL Smelt
TBL Dissolving
tank to WBL
Mixing storage tank
tank ESP ash
green liquor
salt cake
TBL
Figure-4.1.12: Process flow diagram for one of the recovery boilers of Gamma Pulp and
Paper Mill
air
air Cyclone
separator
compressed air
for screen plate
Cleaning !
filtrate
dewatered air vent
lime mud
ID fan
reburnt lime
primary air for causticizing
Electrostatic
precipitator
process water
Primary Calcinated for roller cooling ESP
air blowe lime hopper
dust
4.2.3 Wood pulp bleach plant of the Beta Pulp and Paper Mill
Schematic process and material flow diagram of the new bleach plant of Beta Pulp and
Paper Mill is shown in Figures-4.2.3a & 4.2.3b. Various operations and activities of this
plant include:
• Chlorine-chlorine dioxide bleaching (Cl2-ClO2 bleach stage)
• Oxidative alkali extraction stage
• Chlorine dioxide bleaching –1 (ClO2-1 bleach stage)
• Chlorine dioxide bleaching –2 (ClO2-2 bleaching)
• Centri-cleaning
• Thickening and washing
• Handling of fumes, vent gases and foam
4.2.4.2 Hypochlorite
Hypochlorite is unstable and looses its strength on standing. At higher temperatures
(>50ºC) or in the absence of excess alkali, it decomposes and forms chlorate. Hence,
hypochlorite is produced on-site through reacting chlorine with 5% caustic solution or milk
of lime.
In the Beta Pulp and Paper Mill, calcium hypo is produced through reacting sniff gases and
chlorine line purgings of the on-site chlor-alkali plant with milk of lime. Process and
material flow diagram of the hypo unit is shown in Figure-4.2.5a. Milk of lime of desired
strength is prepared through slaking lime in a lime slacker in hot water and cleaning the
resultant slurry in a classifier and a grit-settling tank. Two hypo towers connected in series
are used for counter-current scrubbing of the sniff gases and chlorine line purgings with
milk of lime. During such scrubbing, chlorine of the sniff gases and purgings reacts with
lime and produces hypo. Once strength of the produced hypo (scrubbing solution) reaches
the desired level, it is drained out as hypo solution, stored in a hypo storage tank and
supplied to the bleach plant.
In the Alpha Pulp Mill, which produces rayon grade pulp, sodium hypo is used in the
bleach plant. This hypo is produced through reacting 5% caustic solution with chlorine.
Process and material flow diagram of the hypochlorite unit is shown in Figure-4.2.5b. In
this unit liquid chlorine supplied in bullets is evaporated in chlorine evaporator and used in
the hypo tower for reacting with caustic. Heat energy required for such evaporation is
supplied through jacket heating by steam. 50% strength caustic is diluted to 5% strength
with process water in an alkali tank and used in the hypo tower. Sodium hypochlorite
produced is stored in a hypo storage tank and supplied to the bleach plant.
4.2.4.4 Oxygen
Absorption based separation systems are used for on-site production of oxygen from
atmospheric air. It is an energy intensive dry process. It requires almost no material inputs
except atmospheric air. And, it has no significant air pollution impacts. Process flow
diagram of an on-site oxygen production unit of Beta Pulp and Paper Mill is shown in
Figure-4.2.7. Atmospheric air is first compressed and treated for the removal of water.
There may be inter-cooler and after-cooler for ensuring the water removal. Then dry air is
passed through a molecular sieve adsorbent at high pressure. At this pressure, nitrogen and
other impurities of the air are picked up by the adsorbent, while oxygen comes out
unaffected from the adsorption system. This oxygen is further pressurized, stored and
supplied to the bleach plant. Once saturated with nitrogen and other impurities, the
molecular sieve is regenerated through lowering the pressure, where the adsorbed nitrogen
escapes into the atmosphere.
Bleaching chemicals
3.
MC mixer Bleaching
tower Back water from
next bleaching stage
1. 4.
2.
Blower
SO2
Seal pit
Overflows
Effluent to drain to drain
oxygen
Pulp from
Bleached
ClO2-1 tower* ClO2 MC mixer BD filtrate HD tower
D2 filtrate Process water
Hot water
Stand pipe 3-step cent. Stand pipe
rejects
& pump cleaning & pump
fumes fumes
BD fumes
air air pulp
filtrate
ClO2-1 ClO2-2 Bleach
Heater mixer Stock chest
washer washer decker
filtrate foam filtrate foam BD filtrate filtrate
for vat dil. steam for vat dil. for vat dil.
NaOH
ClO2-1filtrate ClO2-2filtrate Hot water Filtrate
seal tank seal tank seal tank
D1 filtrate D2 filtrate BD filtrate
Backwater Backwater process water
SO2 SO2 OH tank
to drain to drain
BD filtrate for
D1 filtrate D2 filtrate centricleaning BD filtrate
overflows
H2SO4 H2SO4 dilution
tank filter water
ClO2 solution
Chlorite to bleaching Seal pit
off gases
Filter OH tank
Generator
hotwater LP steam reboiler
overflows condensate
Heating for dissolving filter
tank chlorite vent gases
hotwater process Air ejector
water water system white WL
Methanol liquor (WL) scrubber
Dissolving
tank stor. tank
ejected water and slurry to
non-condensable recovery
sodium chlorite gases methanol
Figure-4.2.4: On-site chlorine dioxide production unit of Beta Pulp and Paper Mill
lime condensates
circulation
circulation
hot water grit grit
Hypo Hypo Hypo
sump-2 sump-1 stor. tank
MOL
a. Calcium hypo plant of Beta Pulp and Paper Mill Hypo to
bleaching
Seam for
Jacket heating
Liquid Chlorine
Chlorine evaporator
bullet
Hypo
Steam cond. tower
Process water
Caustic to
bleaching
b. Sodium hypo plant of Alpha Pulp Mill
Sulfur
LP steam melting tank
cooling
water liquid condensate
sulfur
SO2 abs.
tower
SO2 Storage
tank
SO2 solution
to bleaching
Figure-4.2.6: Process and material flow diagram of sulfur dioxide production unit of Alpha
Pulp Mill
atmospheric air
Air
compressor
Air receiver
pressurized
air
Oxygen
compressor
Oxygen
storage tank
oxygen
to bleaching
4.3.1 Overview
Pulping is concerned with the disintegration of waste paper and/or paper board into fiber
mass or pulp stock. Processing of the pulp stock is concerned with removal of contaminants
and print, and with bleaching and colour stripping. Processing results in the production of
furnish that is used in the stock preparation for paper making. Processes involved in the
pulping and pulp processing are
1. Hydrapulping
2. Contaminants removal
3. Deinking
4. Bleaching and colour stripping
Process flow schemes employed by the two secondary fiber based paper mills analysed
(Epsilon paper Mill and Delta Paper Mill) are shown in Figure-4.3.1. Examination of these
process flow schemes indicate that the operations/activities listed below are typically
employed in the pulping and processing of secondary fiber:
a. Hydrapulping f. Refining
b. Screening g. Flotation
c. Cleaning h. Washing and thickening
d. Fractionation i. Bleaching and colour
e. Dispersion and kneading stripping
4.3.2 Hydrapulping
Hydrapulping is meant for processing the raw-material (waste paper) into defibered stock
and supplying to the subsequent operations. Further, pulping is supposed to facilitate
separation/removal of contaminants, such as adhesives, inks, laminated materials, etc., from
the stock in the subsequent operations. High consistency (>12%) batch pulpers are usually
preferred for hydrapulping. In both the waste paper based mills analysed, high consistency
batch pulpers are used. Lower level of contaminant degradation, better contaminant
removal, lower energy requirements and saving of chemicals (such as deinking chemicals)
are the main advantages reported with these pulpers.
The waste paper in the hydra-pulper is slushed and the slushed fiber mass or pulp stock is
extracted through an extraction screen plate. For facilitating discharge through this
extraction screen plate, the stock is diluted to 3 to 5% consistency, prior to extraction.
Unslushed material and contaminants that can not pass through the extraction screen plate
are left behind as rejects in the pulper. In certain cases, slushed material is transferred in
total into a detrashing screen, rather than extracting through the screen plate. This screen
allows only accepts to pass through to the subsequent operations, while accumulating
rejects within. Rejects accumulated in the pulper or in the detrashing screen are removed at
regular intervals and discharged, as rejects, after washing for recovering the residual useful
fiber.
Water is consumed in the hydrapulping process for the following purposes:
• diluting the stock and adjusting its consistency to the desired level (backwater of
pulp processing, rather than process water, is mostly used for this purpose)
• washing the rejects and recovering useful fiber in the screens
• rotor gland cooling and sealing purposes (in fact, usually, circulating oil cooling
system is used for this purposes, and process water is used for cooling this circulating
oil)
Higher pH and temperature substantially reduce pulping time (result in better
defiberization) and energy requirements of pulping. Further, they significantly affect
separation and dispersion of ink and other contaminants. For ensuring high pulping
temperatures hot water is used and direct steam injection into the pulper is practiced. For
raising pH to the desired level, caustic is usually added into the pulper. The caustic, in
addition to ensuring better defibering, limits attrition of contaminants. Hydrogen peroxide
is often added to the pulper along with sodium silicate and other chemicals, usually, for
preventing alkali darkening of fiber and/or facilitating print separation.
Surfactants are often added to the pulper for facilitating dispersion removal of wax, which
is a common additive in the corrugated grades of waste paper. Low temperature pulping
(>50°C) is often preferred over high temperature pulping, specially, for preventing melting
and dispersal of contaminants like wax that cause stickies problem, and facilitating their
easy removal during cleaning operations. When deinking is desired, pulper is added with
deinking chemicals, such as hydrogen peroxide, peroxide stabilizing chemicals, etc. If the
waste paper contains wet strength resins, appropriate chemicals are added to the pulper for
breaking these resins.
Filtrate generated from the screening of rejects is rich in useful fiber, and mostly reused in
the hydra-pulper for stock consistency adjustment.
4.3.3.2 Deinking
Deinking is concerned with the removal of print without loosing useful fiber. For deinking
to occur, ink particles should not be bound to fibers or trapped in the fibrillar areas. Further,
these should not be present in the bound water layers of individual fibers.
Hydrapulping leads to the breakdown of print into ink particles of a wide size range.
Dispersion/kneading also helps in the deinking process through breaking down larger ink
particles into smaller ones, which in turn can be removed by wash deinking. Either flotation
deinking, or wash deinking, or both, are used for removing ink particles from the repulped
stock. The latter is effective in removing smaller size ink particles (1 to 10 micron size
particles), while the former for removal of larger ink particles (10 to 150 micron size
particles).
Use of caustic during pulping helps in breaking down the print, through weakening bonds
between the fibers and the print, and the ester bonds of the print vehicle network (the
network that holds ink particles together). However, use of caustic can darken the recycled
fiber, specially mechanical fiber. For preventing this, hydrogen peroxide is used along with
caustic in the pulping process. For preventing decomposition of the added hydrogen
peroxide, sodium silicate and chelating agents, such as diethylene triamine penta acetic acid
(DTPA), are also used in the pulping process. Sodium silicate, in addition protecting the
hydrogen peroxide, assists deinking process through – buffering the system and supporting
the peroxide activity, acting as a dispersing agent for the print particles, and reacting with
calcium and forming precipitate that helps in the agglomeration of print particles. Sodium
silicate is also reported to reduce loss of fiber during flotation deinking.
Soaps, surfactants, talc, etc. are also used in the deinking process. Soaps are added either to
the pulper or to the flotation cell. These assist in the flotation removal of ink particles, by
enhancing their hydrophobic nature, and agglomerating them. Efficient performance of
soaps require presence of sufficient concentration of calcium ions. Hence, frequently,
calcium salts, such as, calcium chloride and calcium hydroxide, are also added to the
flotation deinking systems. In some cases, instead of soaps, fatty acids are added to the
pulper. These acids in turn create soap in situ. Displectors (fatty acid alkoxylates), which
assist both in detaching print from the fiber and collecting the detached print particles into
agglomerates with hydrophobic surface, are also sometimes used in the deinking systems.
Talc is also added to the flotation deinking systems mainly for pacifying the stickies and
reducing foam levels.
Proprietary mixtures of surfactants and solvents (usually known as ink collector chemicals)
are used in the wash deinking systems. These chemicals do not require calcium ions. Here,
the surfactant molecules keep ink particles in suspension, till they are removed by wash
deinking systems, through adhering to the latter and making them hydrophilic. Further, the
surfactants are believed to wet the print and allow the applied deinking chemicals to
penetrate into its micro cracks. Use of cyclohexyle pyrrolidone, as two phase mixture with
water for removing the print, is also reported.
For efficient removal of UV cured inks, which are used in printing and photocopying,
solvents (such as paraffin, terpentine) and surfactants, or solid thermoplastics, are added to
the pulper, and pulping is carried out at elevated temperature. High temperature pulping
results in the flowing of print into spheres. As the stock cools, these spheres get hardened,
and such hardened spheres are then removed either through screening (in slotted pressure
screens) or through centri-cleaning. Enzymes are also commonly used for deinking. The
added enzymes detach print from fiber through degrading cellulose and hydrolyzing ester
bonds of the print vehicle network. Enzyme deinking can eliminate use of sodium
hydroxide, sodium silicate, hydrogen peroxide, etc., in the deinking systems.
Use of surfactants in wash deinking can affect coagulation, flocculation and separation
treatment of backwater. Similarly, use of flocculants in the treatment of backwater, when
the latter is reused in the deinking process, can affect performance of the surfactants in the
wash deinking process. Deinking is associated with the loss of fiber, fines and fillers from
the stock.
Delta Paper Mill is using a two stage flotation deinking system. Schematic diagram of this
is shown in Figure-4.3.3.
4.3.3.3.3Hypochlorite bleaching
Sodium hypochlorite is a color stripping chemical. It discharges dyes from recycled fiber
rather than bleach the latter. Hypochlorite is preferred specially for discharging red and
yellow colors, for which hydrosulfite and hydrogen peroxide are ineffective. If the fraction
of high yield pulp is greater than 10 to 15% in the stock, hypo bleaching may prove
ineffective. Hypo bleaching can impart yellow color, specially, to the mechanical fiber of
the stock. Optimal conditions for the hypo bleaching are – pulp consistencyof 10 to 15%,
pH around 10, temperature about 40° C, and retention time upto 2 hours. Stock coming out
from the hypo bleaching tower is usually ensured to contain residual hypochlorite in order
to prevent coloring of the stock. Hypochlorite bleaching generates chlorinated derivatives
(chloroform in the emissions and chlorinated organic compounds in the effluent).
4.3.4.1.1HD cleaners
HD cleaners are used for removing high density materials, such as, staples, grit, fragments
of bale wire, nuts, bolts, etc., from relatively high consistency (2.5% or more) stock. These
cleaners are very much similar to centri-cleaners, but have an electrically powered impeller
for imparting centrifugal force to the pulp. High density materials are removed from the
stock and get collected into a dirt tank provided at the rejects discharge end of the cleaner.
Useful fiber present in this dirt tank (along with the rejects) is recovered through use of
elutrition water. This water is introduced into the dirt tank for maintaining certain minimum
upflow velocity, which is sufficient for re-suspending the fiber and carrying it back into the
body of the cleaner. Rejects accumulated in the dirt tank are drained out at regular intervals.
In the Epsilon Paper Mill, these rejects are screened over a side hill screen for draining out
water prior to disposal.
4.3.4.1.2Centri-cleaners
Centrifugal cleaners are used for the removal of heavier particles (sand, grit, clay, etc.),
abrasive contaminants and lighter particles (waxes, polyethylene film, polystyrene, etc.
provided they are not stably dispersed) from the stock. Three types of centri-cleaners –
forward flow cleaner, reverse flow cleaners and thru flow cleaner – are, usually, used.
Forward flow centri-cleaners are meant for the removal of heavier particles and the other
two types are for the removal of lighter particles. Stock is diluted to 0.7 to 1.2%
consistency and then passed through the centri-cleaners. Centri-cleaning leads to the
division of the feed stock into “lights” stream and “heavies” stream, or into “accepts”
stream and “rejects” stream.
Rejects stream is usually about 10% of the feedstock. This stream still has high
concentration of useful fiber. For recovering this fiber, the rejects stream is further cleaned
in a series of centri-cleaners. In the Epsilon Paper Mill, a three stage centri-cleaning system
of forward flow centri-cleaners is used. In the Delta Paper Mill, a five stage centri-cleaning
system is used. Rejects stream of one stage of centri-cleaning is fed as input to the next
stage of centri-cleaning. Accepts stream of one stage of centri-cleaning is fed to the
previous stage of centri-cleaning through mixing with its input stream. Consistency of
rejects stream is higher than that of input stream and accepts stream. Hence, before feeding
to the next stage of centri-cleaning, consistency of the rejects stream is reduced to the
desired level through adding water.
Schematic diagram of a three stage centri-cleaning system employed in the Epsilon Paper
Mill is shown in Figure-4.3.4. Rejects from the last stage of centri-cleaning are passed
through a side hill screen for draining out water prior to disposal.
4.3.4.3 Flotation
Flotation has two applications, namely, deinking flotation and dissolved air flotation.
Deinking flotation is used for removing ink particles and other smaller size
contaminants (samller in size than the fines and fiber) from the stock. Dissolved air
flotation is used for the recovery of fines and fiber from backwater.
For the flotation removal, contaminant particles should be hydrophobic and their size
should be in the range of 10 to 150 microns. Further, the particles should be in suspension.
Flotation is mostly carried out on cleaned and screened pulp stocks of 0.6 to 1.2%
consistency, under alkaline conditions at 40 to 45° C. Flotation may involve use of soap
and deinking agents (ink collector chemicals), talc, etc. Salts like calcium chloride are also
added to the stock for ensuring requisite hardness. Hydraulic retention time for flotation
deinking units is usually around 20 minutes.
Flotation is an energy intensive operation. Usually 4:1 or 10:1 air to stock ratio is
employed. Air bubble size is maintained in the range of 0.3 to 0.5 mm. Smaller bubble size
increases loss of fiber, while larger bubble size reduces deinking efficiency. Flotation
generates waste in the form of froth or scum. This froth is usually removed as overflow, or
through a vacuum system. The froth removed usually contains useful fiber and for
recovering this fiber, the froth is defoamed and again subjected to flotation (secondary
flotation). Flotation requires dilution water and elutrition water, for adjusting and
maintaining stock consistencies, and generates significant quantities of effluent.
Delta Paper Mill uses altogether three flotation cells (primary flotation cell; post-flotation
cell and secondary flotation cell) for flotation deinking purpose. Process and material flow
diagram of flotation cells of the Delta Paper Mill is shown in Figure-4.3.3. This mill uses
the primary flotation cell for contaminants removal from screened stock at 1.2%
consistency. Post flotation cell is used for contaminants removal after oxidative bleaching
of the stock, again at 1.2% consistency. Froth generated by both primary and post-flotation
cells is collected into a foam tank, defoamed and then processed in the third flotation cell
(secondary flotation cell).
Dissolved air flotation systems are usually employed for efficiently recovering fines and
fiber from (machine) backwater. In these systems, part of the clarified output of the
flotation unit is super-saturated with compressed air in a pressurized mixing chamber. This
super-saturated water is then introduced, along with the backwater, from which fines and
fiber are to be recovered, into a non-pressurized flotation unit. In this unit, additional air of
the water is released in the form of very fine microscopic air bubbles. These bubbles get
attached to the fines and fiber of the backwater, reducing their density, and causes them to
float to the surface. Through removing this floating layer, the fines and fiber are recovered
and the backwater is clarified. Epsilon Paper Mill is using dissolved air flotation system for
recovering fiber and fines from the machine backwater. Schematic diagram of the system
employed by this mill is shown in Figure-4.3.6.
4.3.4.6 Refining
Refining is used less frequently in the secondary fiber processing. When used high
consistency refiners are employed. Purpose of such refining is for imparting certain special
properties, like, stretchability. Refining is an energy intensive activity and refiners are
associated with noise and vibration problems. Circulating oil cooling systems are usually
associated with these refiners, and temperature of the circulating oil regulated through
cooling with water. Epsilon paper Mill, which produces industrial paper for the
manufacture of cement sacks, is employing a double disc refiner for refining its dewatered
stock at 28% consistency.
High consistency pulping
Flotation
Coarse pressure screening
Centricleaning
Fine pressure screening
Fine pressure screening
Centricleaning
Thickening & dewatering
Thickening & dewatering
Dispersion & oxidative bleaching
High consistency refining
Flotation
Thickening
Reductive bleaching
cooling water
* Continued in Figure-4.3.3b
accepts
LR HR Clrf. Clrf. Clrf. LR HR
accepts
accepts
rejects from
flotation-2 Clrf.
HR
Clrf. LR Centricleaning Verticle screen
Foam tank
Stage-3 (secondary)
accepts
Clrf.
accepts
Clrf. Clrf.
Clrf. LR HR
Flotation-1 Centricleaning
Rejects tank
(secondary) Stage-4
accepts
Clrf. Clrf.
effluent
to sewer Centricleaning
Cldf. – cloudy filtrate from disc filter-1 Rejects stream Minisorter
Stage-5
Clrf. – clear filtrate from disc filter-1
HR – heavier rejects Rejects stream
LR – lighter rejects
steam
FW – freshwater
Hot water to warm water tank Cldf.-1 – cloudy filtrate from DF-1
tank of the pulper Clrf.-1 – clear filtrate from DF-1
Cldf.-2 – cloudy filtrate from DF-2
Clrf.-2 – clear filtrate from DF-2
DF-1 – disc filter-1
DF-2 – disc filter-2
to start/stop chest
Clear filtr. Cloudy filtr.
tank tank stock
Pri. centri-
cleaner overflows to
feed Tank Stock silo
filtrate from
gravity thickener
filtrate
rejects
accepts
stock silo water
(backwater)
rejects to
tridyne pulper
flocculating agent
Flotation
unit
relief gases vent gases
Pressurized
Scum tank
mix chamber
compressed recovered
air fiber & fines
clarified
backwater
machine
backwater
4.4.1 Overview
Paper making involves processing of fiber mass or pulp for improving its paper formation
properties, and adding different additives and process control chemicals to it for preparing
paper furnish. Diluted paper furnish is transformed into a pulp mat or paper web by
spreading it as a thin layer and dewatering on a paper former. Dewatered paper web is dried
to reduce moisture content to acceptable level through energy intensive drying operations.
Dried paper is further processed for obtaining the final paper for shipment. Papermaking
can be considered to include the following activities:
a) Stock preparation
b) Approach system to the paper machine
c) Wet-end operations and activities
d) Dry-end operations and activities
e) Off-machine operations and activities
4.4.2.1.1Hydrapulping
Hydrapulping is an important operation in the mills that use pulps (dewatered pulps and dry
pulp sheets) sourced from other mills. It is also an important operation in the broke system
of a paper mill (broke system is meant for collecting, pulping, processing, and reusing
paper machine broke). However, in case of an integrated mill, since pulp is supplied as
high-density stock by the mill’s pulp unit(s), hydrapulping is not an important operation.
Hydrapulping is concerned with adding water and slushing the received pulps into a stock
of desired consistency. Mostly, backwater is used in the hydrapulping.
4.4.2.1.2Fractionation
Fractionation is an enrichment process involving division of a low consistency fed stock
into two or more classes on the basis of fiber length. Multistage pressurized fractionators
with either holes or slots are used for this purpose. Beta Pulp and Paper mill is fractionating
unbleached virgin bamboo pulp in a 3-stage fractionation unit for separating long fiber
fraction. The separated long fiber fraction is dewatered in a screw press and supplied to a
paper mill, which is manufacturing cement sacks, for blending with the secondary fiber.
Fractionation contributes no rejects. However, water is consumed for consistency
adjustments and backwater is generated from the dewatering of fractionated pulp.
4.4.2.1.4Blending
Blending is concerned with mixing of different stocks (mechanical fiber, chemical fiber,
recycled fiber, broke, etc.) in desired proportions and addition of different non-fibrous
components (additives and process control chemicals) to the blended stock.
Additives may include the following:
• Wet-end sizing chemicals such as modified rosin, IVAX (commercial name for
dispersed rosin formulation for internal sizing), wax emulsions, synthetic sizing agents,
etc.
• Dry strength additives such as natural and modified starches, gums and non-
synthetic polymers, and polyacrylamides – starches and gums are added as cooked low
concentration solutions.
• Wet strength additives such as urea-formaldehyde, melamine-formaldehyde,
polyamide resins, etc.
• Fillers such as clay (kaolin, bentonite), calcium carbonate, titanium oxide, talc
(magnesium silicate), etc.
• Dyes, pigments and optical brighteners
Process control chemicals added may include
• Alum or polyaluminum chloride
• Drainage and retention aids
• Pitch dispersants like talc
• Defoamers and slimicides
• Silicates
• Acids and alkalies (for adjusting pH)
• Corrosion inhibitors
Depending on the fiber stock used, and on the product manufactured, chemicals and
additives used may vary. Stuff boxes are usually used for metering and accurate
proportioning of different pulps. Accurate dosing of additives and chemicals is achieved
through preparing solutions or suspensions of known concentration and regulating their
flow rates.
Blending is performed in a chest. But, for simple paper machine furnish, an independent
blending chest may not be used. Instead blending is performed within the machine chest.
Some of the additives and process control chemicals may not be added to furnish in the
blending chest. Instead, they may be added to the furnish, prior to loading into the head
box, or to the white water, which is used for diluting the furnish, prior to its loading into the
head box. In the Epsilon Paper Mill, while drainage and retention aids are added to the
furnish prior to its loading to the head box, defoamers and slimicides are added to the
white-water.
4.4.5.1.1Cylinder Drying
Drying section comprises of a series of large diameter, rotating cylinders filled with steam.
Paper web, coming out from the press section, is passed over a series of cylinder dryers for
evaporation dewatering. A synthetic permeable fabric (known as dryer felt) is used for
tightly holding the web against cylinder dryer surface and facilitating better heat transfer. A
dryer section may have 3 to 5 pairs of dryer felts. Each of these pairs includes a top felt and
a bottom felt. In certain cases, where sheet fluttering and subsequent breaking is a problem,
instead of using paired dryer felts, serpentine felts are preferred for continuously supporting
the moving web. For tightly holding the web against cylinder dryer, these felts are
controlled by tensioning and positioning rolls.
Saturated steam is injected, into each of the cylinder dryers, as a source of heat.
Condensation of the injected steam on the inner surface of the cylinder releases heat, which
is picked by the web, which is in contact with the cylinder on the outer side. Absorbed heat
is used for the evaporation removal of water while the web is transferred from one cylinder
to the next. Steam condensate formed inside the dryer cylinder is continuously siphoned out
with the help of a specially designed siphon assembly. For ensuring proper siphoning,
pressure differential is maintained between the steam inlet line and the condensate outlet
line of the cylinder. For avoiding accumulation of non-condensable gases, while siphoning
out the condensate, 15 to 20% of the steam applied is also siphoned out as entrained steam.
For better control over the pressure of the applied steam, dryer cylinders, of a dryer section,
are usually divided into 3 to 5 groups, and each group is provided with independent steam
pressure control and application system. Condensate, along with the entrained steam, drawn
out from one group of dryer cylinders is taken into a separator tank for separating the
entrained steam. Entrained steam thus separated is recycled and reused in either of the
following two ways:
a) Directly using it as input steam in some other group of dryers, which require relatively
lower pressure steam
b) Passing the steam through a thermo-compressor, where it is mixed with high pressure
super heated steam, and reusing the resultant steam in the same group of dryers as input
steam
Condensate of the separator tanks of all the groups of dryer cylinders is collected and
pumped to the boiler house for reuse as boiler feed water, provided it satisfies quality
requirements. Otherwise the condensate is drained out as effluent.
Entrained steam from that group of cylinders, which is operated at the lowest steam
pressure, is separated and passed through a surface condenser, or through a direct contact
condenser, for condensation. Non-condensable gases accumulating in this condenser are
sucked out and vented out with the help of a blower. Schematic diagram of
steam/condensate flow sequence for the dryer section of the Epsilon Paper Mill is shown in
Figure-4.4.7. The Mill uses a direct contact condenser. Condensate, together with the
process water used for condensing, is collected here into a warm water tank for reuse.
Warm water that cannot be reused is drained out as effluent.
4.4.5.4 Calendaring
Calendaring involves pressing the paper web in one or more roll nips. Objectives behind
such pressing are to obtain a smooth surface, to achieve compaction of the web, to improve
cross-direction uniformity, etc. Calendaring is performed on a dried paper web (at 3 to 4%
moisture level) or sometimes on partially dried paper. Prior to calendaring, for ensuring
enough moisture, the web is passed over a cooled sweat roll (having condensed moisture),
or a steam shower, or moist shower is applied over the web, or moisture may be added to
the web surface by means of water boxes.
Calendaring is done in a calendar stack. Within this stack, there can be one or two heat
transfer rolls. Through these rolls hot water is usually circulated. Calendaring can be either
an on-machine activity or an off-machine activity. On-machine calendaring is performed on
the paper web usually after drying. However, in certain mills, it is carried out in the
calendar nips provided between the last two groups of cylinder dryers.
4.4.5.5 Reeling
Paper product is collected on a drum reel (also known as collecting roll). A reel, known as
pope reel, is provided ahead of the drum reel but after the calendar stack, for applying
adequate tension on the sheet being collected. Cooling water is usually circulated through
the pope reel for cooling the paper web prior to its reeling.
4.4.6.3 Rewinding
Purpose of rewinding is to cut and wind the full width large diameter paper reel into
suitable size rolls. Winding involves trimming off of the two edges of the roll. Trims
generated are pneumatically conveyed to the UTM pulper as dry broke. This activity
involves consumption of paper board cores.
Recovered
Couch pit UTM Pulper
fiber chest
fiber draining
& overflowing water
into the sewer filtrate to Gravity
backwater thickener
tank
Broke Dump
Chest
stock silo
water pulp draining
into sewer
rejects
from dirt tank
Partially processed
HD cleaner secondary fiber Shark pulper
Blending
Prepared stock
to the machine
Dye holding
tank
overflows
Vibratory
screen
furnish to
accepts to rejects Head box fourdrinier
whitewater
overflows
to whitewater
dragouts of knocked
down web & trims
wetting HP & chem.
showers ** showers
pressure
screen accepts defoamer
process water Returning
for foam breaking wire zone
showers for reuse
edge Bleedings
Wire Pit Clarified
water Tank
to fan pump Whitewater pickup roll
for furnish dil. silo tray water process water
over overflows
process water flows Backwater
during startup Krofta Unit to sewer
tank
recovered
to DDR overflows compressed fiber & fines
feed chest to Sewer air
X Connected to the vacuum system * Water from Twin compartment boxes and from the Dandy Roll tray s
** Seal pit-1 overflows are collected into the backwater tank
tray water
to wire pit
Uhle Box
mill water Collect.
showers tray
in the roll process water
HP shower
chemical to sewer
shower
Pickup/ Bipin Press 3rd Press paper web to
paper web suction Roll drier section
chemical chemical
shower shower
X process water
process water HP shower
HP shower Collect.
Collect. tray
Uhle Boxes tray to sewer Uhle Box
(2 numbers)
to sewer
to sewer
Press Felt
Vacuum
pumps vacuum pump
discharge trench
Seal pi-1
suction boxes of
couch rolls overflows vent
Sump of
Cyclone vacuum
suction boxes of separators plume
suction rolls of presses
overflows
Dryers area
Blower steam
Heater
Heater
Heater
Heater
cond. Blower
hot air
Starch starch
service tank screen
Starch
steam process water
cooking
maize starch
Utilities and services of a pulp and paper mill is considered to include the following:
I. Extraction, treatment and supply of water
II. Generation and supply of steam
III. Generation/extraction and supply of electrical energy`
IV. Production and supply of instrumental air and plant air
V. Maintenance activities of the mill
VI. Other utilities and services
4.5.1.9 Backwaters
Limits prescribed for water consumption and wastewater generation have been mostly
responsible for the collection and extensive reuse of backwater in place of the process
water. Major sources of backwater in a pulp and paper mill include the following:
• Backwater generated at unbleached decker from thickening of washed brown stock
• Backwaters generated during washing of pulp at different bleach stages and at bleach
decker
• Backwater generated at the washing/thickening and/or dewatering operations of
secondary fiber processing and stock preparation
• Machine backwater getting collected in the second compartment of the machine
backwater tank
In addition to the above, backwater is generated at the flotation cells, screens, and cleaning
units as “rejects” streams.
All the mills analyzed are reusing these backwaters to different degrees. Backwaters of
unbleached decker and bleached decker are, mostly, reused for upstream pulp consistency
adjustments (required for the pulp cleaning and screening). Backwater of one stage of
bleaching is reused in another (provided that the reuse is compatible) in the displacement
showers of the associated rotary vacuum drum washers. Backwater generated from the
washing/thickening and dewatering is used in the hydrapulping and in the stock dilution
(required for stock cleaning, screening, deinking, etc., purposes) on the upstream side.
Machine backwater is reused, both directly, and after clarification, in the save all units on
the paper machine in different showers, in the couch pit and UTM pulper. None of the mills
analyzed is reusing backwater from flotation cells, cleaning and screening units.
4.5.2.2 Overview
Boiler house is one of the important utilities of a pulp & paper mill. It supports the mill
through supplying medium-pressure (MP) and low-pressure (LP) saturated steam for
utilization as heating medium. Four of the five mills analyzed have cogeneration units
(cogeneration of heat energy and electrical power). In these mills, boiler house is concerned
with the supply of high-pressure super-heated steam to the turbine generator. Extraction
type turbines are used in these mills. MP and LP steam are extracted from these turbines
and supplied to the mill for use as heating medium. Exhaust steam of the turbine is
condensed, in a turbine condenser, and supplied back to the boiler as boiler feed water.
Epsilon Paper Mill is not having a cogeneration unit. In case of Delta Paper Mill only one
type of steam is extracted from the turbine.
Boiler houses of three of the five mills analyzed (Alpha Pulp Mill; Beta Pulp and Paper
Mill; and Gamma Pulp and Paper Mill) include mainly two types of boilers: coal fired
boilers and chemical recovery boilers (use heavy black liquor, HBL, as fuel). The other
two mills depend, totally on coal-fired boilers. Four of the mills analyzed have one or more
of other types of boilers, which use bark, wood dust, ETP sludge, rejects generated from the
secondary fiber processing, etc., as fuels.
Water required for steam generation (boiler feed water) is obtained from the following
three sources:
a) Steam condensate generated at the condenser of the turbine
b) Steam condensate collected and returned from different points of the mill to the boiler
house for reuse as boiler feed water
c) Demineralized water (usually for use as make up boiler feed water)
Epsilon Paper Mill, which is not having a turbine generators does not produce high pressure
(HP) steam, and hence, the boiler is not having super heaters.
Water tube/drum type boilers are mostly used for generating steam. In the Delta Paper Mill
there is one fire tube/submerged tube boiler. The mills are having fluidized bed boiler
furnace for burning pulverized coal as fuel. Delta Paper Mill is meeting its fuel requirement
partially through burning petroleum coal (which is rich in sulfur, but has higher calorific
value and is cheaper). The boilers used are having either a single drum (steam drum) or a
two drum (steam drum and mud drum) natural circulation steam generators. These have bed
tubes, water walls, super heaters, boiler tube bank, economizer, etc.
Activities and operations associated with steam generation and supply are:
a) Reception, storage, preparation, conveyance and loading of coal to the boiler furnace
b) Pre-heating and supply of combustion air to the boiler furnace
c) Handling and disposal of flue gases
d) Handling and disposal of bottom ash and flyash
e) Conditioning, pre-heating and loading of boiler feed water
f) Fate of boiler feed water in the boiler
g) Handling and management of steam
h) Distribution of steam and collection of steam condensate
A schematic diagram showing flow of fuel, combustion air and of flue gases in the boiler of
the Delta Paper Mill is given in Figure-4.5.5. Figure-4.5.6 shows movement of boiler feed
water, steam and cooling water in the cogeneration unit of the Delta Paper Mill.
4.5.3.2 Power from SEB grid and electrical energy system of the
mill
Because of the cost factor, and other reasons, pulp and paper mills make efforts to depend
least on the SEB grid power. Mills have to pay for the power extracted from the grid, and
power tariff may even vary within a day, with time (tariffs may be higher during peak hours
of the day). Grid power is available as AC current at higher voltage (as high as 115 kV),
while voltage requirements of the motors used in the pulp and paper mills vary widely
(from 13 kV to below 550 V). Power generated by the captive power generation units has
relatively low voltage. Some of the devices/machinery (such as electrostatic precipitators)
used in the mills require DC current. Extraction and use of grid power, and use of electrical
energy generated on-site internally, thus necessitate creation and maintenance of a variety
of facilities, specially for metering, for stepping-up or stepping-down voltage, and for
converting AC to DC. Further, facilities are also required for ensuring protection and
safety, and for integrating internally generated electrical energy with that extracted from the
grid. A mill’s electrical energy system, in addition to the captive power generation units
(cogeneration unit and diesel generation sets), includes transformers, rectifiers, electrical
meters and monitoring devices, relay and circuit breakers, etc., as integral parts.
4.5.3.2.1Transformers
Transformer core, along with the insulated coils, is submerged in transformer oil. Due to
multitude of reasons, some fraction of the electrical energy flowing through is lost and
emitted as waste heat in the transformers. Transformer oil picks up this heat and gets heated
up. This heat is then pumped out and dissipated into the surrounding atmosphere through
the following mechanisms:
• Natural circulation of the transformer oil through external air-cooled tubes
• Communication of the air present, in contact with the transformer oil, in the transformer
with the external atmosphere through the air breather
When the transformer is loaded, due to elevated temperatures, inside air expands and leaves
the transformer through the breather. Insulation leaks may lead to generation of hot gases
and these gases also find their way into the atmosphere through the breather. When the
transformer is not loaded, due to cooling of the interior, cool atmospheric air moves in
through the breather. This air can bring in moisture and contaminate the transformer oil.
For avoiding this problem, moisture adsorbing substances, like silica gel, are used in the
breather.
At regular intervals, the transformer oil is tested for a number of parameters and, depending
on the requirements, the oil is conditioned (once a year or two) usually through filtration
and vacuum dehydration. Aging can lead to loss of properties and make the transformer oil
unfit for use. This necessitates replacement of old oil with fresh transformer oil. Discarded
transformer oil is disposed off as hazardous waste. Due to leaks, transformer oil may be lost
from the transformer, and for maintaining the oil at the desired level, fresh transformer oil
is added at regular intervals as make-up oil.
Overloading of transformers, contamination of transformer oil (specially with water),
obstructions to the natural circulation, and cooling of the warm oil, etc., can lead to
accidents that involve pressure build-up and explosion of the transformer, spillage of oil,
and fire. Transformer oil contains paraphenic, naphthanic, and aromatic compounds (like
polychlorinated biphenyls), and, hence, it is highly toxic. Explosions and fire are usually
associated with emission of toxic fumes and smoke.
4.5.3.2.2Rectifiers
Rectifiers are mostly associated with the electrostatic precipitators (ESP) used for the
treatment of flue gases from boilers. These are used for converting AC to high voltage DC
and supplying it to the ESP. All components of the rectifier are built into a sturdy metal
frame and the frame in turn is immersed in a transformer oil tank. Energy losses occurring
in the rectifier heat up the oil, and thermal energy of the hot oil is dissipated to the
surrounding air.
Similar to that of transformers, transformer oil of the rectifiers requires regular conditioning
and aged transformer oil requires replacement by fresh oil. Rectifiers also have accident
potential.
4.5.5.3 Lubrication
Within a pulp and paper mill, many machines require lubrication. A few machines require
cooling by circulating cooling oil systems. Mills employ specialized oilmen for ensuring
lubrication (and maintenance of oil levels through lubrication and addition of fresh oils) of
all such machines according to a pre-decided schedule. Further, at regular intervals, but
relatively less frequently, lubricating oils and circulating cooling oils of different machines
are examined for their properties, and in all such cases where properties are lost, aged oils,
which are in use, are discarded and replaced by fresh oils. Discarded lube oils and cooling
oils are hazardous. These are collected and temporarily stored (in stores) till their disposal
(through sale to outside parties). For ensuring availability, inventory of lubricating oils and
cooling oils is maintained in the mill’s stores and issued as and when required for use.
4.5.5.4 Housekeeping
All those operations and activities that can be improved through simple, practicable and
common sense measures can be considered as subjects for housekeeping. A good
housekeeping is supposed to minimize loss of materials, conserve water and energy
(electricity), improve working conditions and worker safety, minimize environmental
impacts, improve productivity, reduce production costs, etc. Bad housekeeping in the pulp
and paper mills analyzed can be exemplified by the following:
• Leakages in pipes and equipment, spillages, and unintended overflows of tanks/chests
• Wasteful and unnecessary use of water or running of taps, and not properly metering
water
• Unnecessary running of pumps, and other equipment and machinery
• Hot and cold pipes with poor or damaged insulation
• Excessive dependence on corrective maintenance and not having documented
procedures or manuals for maintenance
• Unorganized stores and scrap yards, and disposal of empty cans, packaging material,
discarded insulation material, scrap and other wastes in unintended areas
• Unsorted wastes affecting their proper handling and disposal (including their recycling
and reuse, and resource recovery)
4.5.5.5 Stores
Stores procure materials required by the mill, stock them within and issue for use as and
when required. If the received materials are not properly inspected, the mill may end up
receiving damaged materials, materials with missing components and materials not
satisfying the specifications and quality requirements. If the received materials are not
stocked as per the stocking conditions recommended by suppliers, if due consideration is
not given to the non-compatibilities and dangerous nature of materials, and if safety
measures and appropriate equipment are not used while handling the materials (receiving,
transferring, stocking and issuing), the material may be damaged, accidents may occur and
workers may be exposed to dangerous materials. Overstocking of materials, non-
verification of expiration dates, and non-application of first-in first-out principle for
managing the stock, makes wastage of materials imminent.
4.5.6.4 Canteen
All the mills analyzed have canteens within the premises for preparing and serving food to
the mill workers. Canteens are supplied with groceries, cooking fuel and drinking water.
Preparation and serving of food is associated with the generation of wastewater (which is
usually rich in vegetable oils) and solid waste (which is rich in putrefiable organic matter).
The wastewater generated is usually mixed with the other domestic sewage of the mill for
treatment and disposal.
Lime
Alum tank grit
dosing tank
Flash
mixing tank
underflow Clari-
sludge flocculator
Rapid sand
chlorine in filter
storage bullet for
back backwash water
wash
Treat. water
Chlorinator reservoir
seepage
drinking water losses
process water
soft water
Pressure Backwash
backwash water
filter water A
backwash Act. carbon
water column Backwash water
SAC regeneration
HCl Resin bed wastewater caustic & Mixed
resin bed Regeneration waste
solution HCl solns
rinse
wastewater Rinse wastewater
air & stripped
Blower Degassifier carbon dioxide Plate heat DI water
exchanger tank steam cond. from
surface condenser
regeneration of turbine generator
air waste
WBA
Resin bed backwash water Return Boiler feed Condensate
cond. tank water tank tank
rinse wastewater
regeneration
solution backwash water
cond. returned
SBA from mill Boiler feed water
caustic Resin bed regeneration waste
solution
rinse wastewater
A
lithium bromide
condensed water Flashed Dehydrated
Vapour Bromide
condenser MP steam cooler
rejects
flue gases
PA fan to chimney
combustion air
sec. air
ID fan
Steam
drum
Super Air
Furnace Economizer ESP
heater Pre-heater
Mud
drum
bed material
bed material boiler FD fan
& bottom ash feed water
superheated
steam
flyash flyash flyash flyash flyash
combustion air
boiler hydragine
Steam jet NCG Inter feed water pH booster
air ejector cooler vent SSB
Vent of
NCG cooling cond.
water Deaerator Economizer
Steam jet
After air ejector NCG
cooler
condensate LP steam
cond. MP steam
regeneration CBD
wastewater Cooling Condensor Pri. super Steam
tower heater drum
Bearings
AOP
cooling
Lube oil
MOP
tank Gear box
cooling
EOP
10µ oil
Alt. Brgs. filter
cooling
LP servo LP Oil
CPC filter
After-
Separator After-
cooler
air filter
cooling
inlet air cooling water
filter water
Inter-
cooler Plant Pre-filter
Receiver Dryer
air Dryer
tank (regen.)
cooling cond. tanks
vent
water