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SPB’S APPROACH ON WATER CONSERVATION IN PAPER MACHINE – A CASE STUDY BARATHI G SRIRAM S M/s Seshasayee Paper & Boards Limited, ERODE 638 007
G Barathi: A Pulp & Paper Technologist from IITR and MBA (Marketing). Having experience of nearly 18 years in Paper Making Process with good analytical skill and Trouble shooting skill. Having conversant with Writing & Printing Paper with Virgin fiber and Recycled Fiber, Multilayer Kraft machine. Experienced in Project commissioning.
Since ancient times, water has been recognized as an invaluable resource.
The Ramayana, Mahabharata & various other Vedic, Buddhist and Jain texts contain several references to water harvesting structures in existence and “ water being revered as a life giving and sustaining force”.
The BIBLE quotes, “I am the Alpha and the Omega, the beginning and the end. To the thirsty I will give water without price” – Revelation 21:6.
In ISLAM, the Sharia law in Koran literally translates to laws of sharing water.
Water Usage in Paper Industry INDIAN PAPER INDUSTRIES Consumption 905.8 million m 3 Effluent discharge 695.7 million m 3 (76.8 %) Reuse 210.1 million m 3 (23.2 %)
20 – 30 % Captive Chemical Bagasse Pulp (ECF Bleached)
Products : W F Printing & Writing paper, S S Maplitho, Pigment Coated Paper, Copier Grades, Coating Base Paper.
Water & Pulp Balance in Paper Machine # 5 complex Paper Machine # 5 300 tpd Pulp from RDH @ 4% Cy. 7500 m 3 /day 140 tpd Pulp to PM#5 @ 4% Cy. 160 tpd Pulp to PM(1-4) @ 3.5% Cy. 3500 m 3 /day 4600 m 3 /day
Water Balance in Paper Machine # 5 complex Paper Machine # 5 Fresh Water 2400 m 3 /day To PM(1-4) 4600 m 3 /day To ETP 2000 m 3 /day & Evaporation 200 m 3 /day To RDH 3100 m 3 /day From RDH 7500 m 3 /day
Water Circuit in Paper Machine # 5 complex White Water Tower Save-all feed tank Clear Filtrate tank Warm water tank Shower water tank Poly Disc Save-all Vacuum pumps Head box O/F Silo O/F Press tray water P/U Tray water Wire Pit 2 Bar 3 Bar 40 Bar 70 Bar showers 3 Bar 12 Bar showers Surface condenser Vac. Pump Deculator Compres sor Cooling Towers Vacuum Sump To Pulp mill Deculator Dec. Vac. P/p Dec. Seal Pit To Head Box Cleaning Group To Pulper Dilution, Cy. Dilution, Thick stock screen dilution, Cleaning Group Dilution, System cleaning, Vacuum pump Cooling Tower Makeup Fresh Water line WATER CIRCUIT IN PAPER MACHINE # 5
Water distribution before and after implementation of water conservation measures 2390 m 3 /day 2790 m 3 /day Total Consumption 50 m 3 /day 50 m 3 /day Others 200 m 3 /day 200 m 3 /day Chemicals Preparation 250 m 3 /day 250 m 3 /day Pump Sealing water NIL 300 m 3 /day Vacuum pump sealing water tank makeup Cleaner group tank makeup NIL 100 m 3 /day Deculator seal pit makeup Thick Stock Screen system dilution 1580 m 3 /day 1580 m 3 /day Surface Condenser Shower Water Tank 60 m 3 /day 60 m 3 /day Warm Water tank makeup Consistency Dilution 200 m 3 /day 200 m 3 /day Compressor Makeup All Pulper Dilution AFTER (m 3 /day) BEFORE (m 3 /day) FRESH WATER BACK WATER
Paper Machine Showers 70 Bar for High Pressure showers in roll cleaning 40 Bar for High Pressure showers in clothing 3 Bar for Felt roll showers 3 Bar for Wire showers 12 Bar for Sheet Knock Off shower and Edge Knock Off showers with ON/OFF valves
2 Bar Lubrication shower for
Suction Couch roll,
Suction Pick up roll,
Suction Press roll
Usage Points Barrel Filter (Duplex) -- Filter 60 – 70 10 – 20 ppm SHOWER WATER TANK WARM WATER TANK
Fresh water was added in Deculator Cooling Tower for make up as the Sealing water was going to Deculator seal pit and to White water tank because
High Temperature i.e. 40 o C
To maintain vacuum barometric leg.
Contamination of Deculator Vacuum pump sealing water with 4 th stage Centri-cleaner reject tank water.
Deculator Cooling Tower system Before implementation Deculator Vacuum pumps sealing Fresh Water Makeup Overflow to WW 2 Seal Pit Deculator Cooling Tower Feed to 4 th Stage Cleaner 4 th Stage Reject Tank Make up from Clear water
Deculator vacuum pump sealing water was diverted to Deculator Cooling tower for reuse through Overflow line without disturbing Vacuum barometric leg.
Deculator Vacuum pump sealing water (40 o C) is recycled through Cooling tower.
Increased the height of the wall between Deculator seal pit & 4 th Stage reject tank thus segregated vacuum pump sealing water from 4 th stage reject tank.
Deculator Cooling Tower system after implementation Deculator Vacuum pumps sealing Deculator Cooling Tower Seal Pit 4 th Stage Reject Tank Make up from Clear water Overflow to Deculator cooling tower Feed to 4 th Stage Cleaner