All about paper making process

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All about paer making process at India's no 1 Paper making company Balla

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All about paper making process

  1. 1. BALLARPUR INDUSTRIES LIMITED UNIT – SHREE GOPAL Paper Making Process
  2. 2. PAPER MAKING PROCESS
  3. 3. RAW MATERIALS USEDVeneer : 40-45% Bamboo : 15-18%Consumption 325 TPD Consumption 90 TPD Euca. Wood : 35-40% Consumption 175 TPD
  4. 4. FLOW DIAGRAM OF PAPER MILL Raw Pulp Paper Paper MSD Chipper Mill Machine Finishing GodownMaterial Chemical Dispatch Recovery Chemical Complex Effluent Costing Engg Water Power QC/ Purchase Treatment HR &Maintenance Supply Plant R&D & Store Plant Finance
  5. 5. PULP MAKING PROCESS Steam for Power White Liquor
  6. 6. PULP MILLChipper HouseChipper Make Capacity Raw mat. no. (MT/h) handling 1 Vecoplan No. 1 25 Woodlogs/ Bamboo 2 Vecoplan No. 2 15 Veneer waste ChipperDigester HouseKraft/Sulphate pulping processNo of Digester : 3 of 120 m3 eachType : Vertical stationary of indirect heatingCooking Time : 260 minutesPulp/cook : 12.0 MT Digester
  7. 7. PULP MILLWash PlantRotary Drum Vacuum Washer: : 4 StagesCapacity :195 BD Pulp per day Hot Water & Foul Washer Condensate Washer Defoamer dosing at inlet line of BSW-1 Filtrate Filtrate Filtrate Weak Black Liquor to Recovery Unbleached Pulp Drum Washer Filtrate
  8. 8. PULP MILL Bleach Plant Conventional bleaching process Capacity : 180 BD pulp per day Bleaching sequence : CDEOPD1D2 Centricleaner : 4 stage Pulp brightness(ISO) : 89-90 %UN BLDPULP EOFROM B/W D2 Bleach towersW/P DI C/D B/W NaOH B/W D1 B/W D2M/C EO D2No.4 H/W B/W H2O2 H/W B/W D1 B/W B/W DECKERB/W B/W B/W DECKER UN H/W EO B/W BLD 58 Eop LP LP M3 PRE LP C/D TUBE STEAM 400 M STEAM D1 STEAM 3 80M3 CD 156 EO D2 D2 D1 M3 250 250 CENTRI - CLEANING M3 M3 MILL H.MIXER WATER H.MIXER H.MIXER C/DMC EO MC MIXER FILT MIXER FILT. D1 MC D2 MC TANK TANK MIXER FILT. FILT. MILL O2 MIXER TANK TANK WATER C/D MC EO MC PUMP EO EO STOCK PUMP PUMP DI MC DEC B/W PUMP D2 MC PUMP KER Cl2 ClO2 ClO2 ClO2 Storage FILT. TANK DECKER tower MC PUMP To ETP To ETP Paper m/c
  9. 9. RECOVERYEvaporator 1Type : Short tube vertical (STVE) and free flow falling filmNo of effects : STVE-5 , FFFFE-4Handling of thin BL : 72 m3/hrSteam Economy : 4.5Concentration of BL : 62-64 %Evaporator 2Type : Short tube vertical (STVE)No of effects : STVE-6Handling of thin BL : 20 m3/hrSteam Economy : 3.0Concentration of BL : 60-62 % EvaporatorRecovery Boiler No of Boiler : 2 - JMW - ABL Total capacity : 315 TPD solids
  10. 10. RECOVERYCausticizing SectionCapacity : 70 TPD, active alkali as Na2OSlaker : StationaryLime mud washing : 2 StreetsLime KilnYear of installation : 2005Capacity : 60 TPD Lime kiln
  11. 11. PROCESS OF PAPER MAKING – STOCK PREPARATION Optical Whitener Fiber Sizing Chemicals Recovery Tinting Dyes System Power Broke FillerHD tower Pulp Functional Approach Pulp PaperBleached Receiving Additives flow Refining Machinepulp Chest addition system
  12. 12. PAPER MACHINESMachine Type Make Deckle Speed GSM Production Paper gradesNo. cm m/min. range TPD REB Charles 1 MF 314 100 60-90 30 Super Printing Wamsely Lky Parchment S/L Bond Charles 58- Super Printing 2 MF 314 115 40 Wamsely 190 Super Cartridge Bilt Classic Esser 54- S/L Offset 4 MF 311 350 75 Wyss 149 S/L Cartridge 60- MMPP 5 MF Alstom 223 270 50 124 BCB Base REB Normal 70- 7 MF Karhula 272 120 27 REB Colored 100 Criss CrossAll machines are equipped with size press.
  13. 13. PAPER CONVERSION ReelOrdersSheetOrders
  14. 14. PROCESS PAPER CONVERSION & FINISHING REWINDER PM-1 Jag PM-2 Jag PM-4, Beloit PM-4, Masson Rewinder Rewinder Rewinder ScottMax reel capacity 5 5 5 5Speed in mpm 400 400 600 500 Beloit Rewinder Masson Scott Rewinder
  15. 15. PROCESS PAPER CONVERSION & FINISHING REWINDER PM-5, Servall PM-7, JagenbergMax reel capacity 4 4Speed in mpm 800 600 Servall Winder Jagenberg Winder
  16. 16. EFFLUENT TREATMENT PLANTThree stage Effluent Treatment Plant Installedand Commissioned in 1987-Activated sludge process-Design Capacity: 54000 m3/day-Operating Capacity: 28000 m3/day Data showing the compliance to environmental norms PARTICULARS UNIT INFLUENT HSPCB TREATED NORMS WATER EFFLUENT EFFLUENT as on Nov-09 pH NA 7-8 7.0-8.5 7.2 – 7.8 BOD PPM 280-350 30 18-25 COD PPM 700-900 350 150-180 SUSPENDED SOLIDS PPM 700-900 50 25-35 AOX KG/T Paper 1.2-1.6 <1.0 0.6 -0.8
  17. 17. PAPER MAKING PROCESS• Pulp Supply System• Stock refining• System cleaning• Approach Flow system• Paper making- MF
  18. 18. PROCESS FLOW: STOCK PREPARATION (PM 1,2 & 4) Pulp from Bleached Dry broke Stock Chest through pulper Buffer Chest Broke Storage Refining of Stock through Broke Cleaning System Refiners in Refined ChestTinting dyes/ pigment preparation Optical whitener preparation Mixing Chest Cleaned Broke Tower PAC: Poly Aluminum Chloride Wet Broke from Filler/Dispersed Rosin/ Fill Plus Machine Chest respective M/C SR Box Fan Pump Centricleaner Filler Slurry Percol-47 Preparation system Pressure Screen Hydrocol- RK2 Preparation system Head Box
  19. 19. PULP SUPPLY SYSTEM (PM 1,2 & 4) 1000 m3 Bleached ThickenerMachine back water(Krofta/Disc filter Pulpfiltrate) for bottomdilution Buffer Chest To Refiners of PM 1, 2 & 4
  20. 20. STOCK PREPARATION: PAPER MACHINE-1 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest PAC Filler Mixing Machine Refiner SR Box Fan Pump Chest ChestRefined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 13-16 kg/MTPulp Consistency:-4.0% Violet PAC : 17 kg/MT Filler: Finex/CaCO3 Defoamer Biocide Pressure Wire Part Head Box Centricleaner Screen Defoamer Afranil ST – 0.5 kg/MT
  21. 21. STOCK PREPARATION: PAPER MACHINE-2 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest PAC Filler Mixing Machine Refiner SR Box Fan Pump Chest ChestRefined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 10 kg/MTPulp Consistency: 4.0% Violet PAC : 17 kg/MT Filler: Finex/ Defoamer Biocide Pressure Wire Part Head Box Centricleaner Screen Defoamer Afranil ST – 0.5 kg/MT
  22. 22. STOCK PREPARATION: PULP REFINING – PM-1&2 TDR 21” & NPM Pulp DDR 20” Machine Refiner Mixing Machine SR Box Chest Chest Buffer Chest Not in operation Paper Machine-1 TDR 24”NPM Pulp Machine Refiner Mixing Machine Chest SR Box Chest Buffer Not in operation Chest Paper Machine-2
  23. 23. STOCK PREPARATION: PAPER MACHINE– 4 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest Filler OBA PAC Mixing Machine Refiner SR Box Fan Pump Chest ChestRefined pulp °SR: 28-30 Tinting Dye: PAC : 25 kg/MTPulp Consistency: 4.0 As per Quality Fill Plus: 2.3 kg/MT OBA: 2.5 kg/MT Rosin: 10 kg/MT Pressure Wire Part Head Box Centricleaner Screen Defoamer Afranil ST 0.5 kg/MT
  24. 24. STOCK PREPARATION: PULP REFINING – PM-4 DDR-1 Measuring Mixing/ SR BoxVirgin Pulp Tank Machine Chest Buffer Refined Chest Pulp Chest Broke Broke Chest
  25. 25. PROCESS FLOW : STOCK PREPARATION – PM-5&7 Pulp from Pulp Mill Dry broke through pulper Tinting dyes/ pigment New Mixing Chest Broke Chest-1 Optical whitener Refining of Stock through Refiners Broke Chest-2PAC: Poly Aluminum Chloride Mixing Chest Dispersed Rosin Filler Slurry Machine Chest Cationic tarch SR Box Wet Broke from respective M/C Fan Pump Centricleaner Pressure Screen Head Box
  26. 26. PULP SUPPLY SYSTEM: PM- 5&7 500 m3 Bleached PulpMachine back waterfor bottom dilution To PM-5 & 7 Stock Prep.
  27. 27. STOCK PREPARATION: PAPER MACHINE– 5 Tinting Dye & OBA Coated broke Own Pulp Circulation Dump New Chest Chest Rag Chest Mixing Tinting dye: Irgalite/Methyl Dispered OBA : 2-2.5 kg/T Cationic Rosin Starch Broke Filler PAC Refiner Mixing Machine SR Box Fan Pump Chest ChestRefined pulp °SR:27 Rosin: 22-25 kg/T PAC : Cato Starch: 3kg/TPulp Cy :3.7% 32 kg/T Filler : 110-250 kg/T Defoamer Biocide Pressure Wire Part Head Box Centricleaner Screen Defoamer Antimusol- BPI Liq: 1-1.2 kg/MT
  28. 28. STOCK PREPARATION: PULP REFINING – PM-5 Coated BrokeVirgin Pulp DDR TDR Rag New Chest Mixing Dump Circulation To be Use as per Chest Chest Chest requirement SR Box Machine Mixing Chest Chest Broke Broke Chest- Broke Chest- Pulper 1 2
  29. 29. STOCK PREPARATION: PAPER MACHINE– 7 Tinting Dye Hydrex-P Imported Pulp Own Pulp New Hydra Cir. Chest Mixing Pulper chest Hydrex-P : 15-17kg/MT Rosin+PAC Dispered Tinting Dye ; Irg. voilet Cationic Starch Broke Filler OBA Refiner Mixing Machine SR Box Fan Pump Chest Chest Rosin: 32 kg/TRefined pulp °SR: 26 Filler : 225-235 kg/MT Cato Starch:5-63kg/T PAC : 34 kg/TPulp Cy :3.7% OBA : 8-9kg/T Defoamer Biocide Pressure Wire Part Head Box Centricleaner Screen Defoamer Antimusol- BPI Liq: 2-2.5 kg/MT
  30. 30. STOCK PREPARATION: PULP REFINING – PM-7 Wood Pulp Wood Pulper CONFLOWVirgin Pulp REFINER New Mixing Circulation Chest Chest SR Box Machine Machine Mixing Refiner Chest Chest Broke Broke Chest Pulper
  31. 31. STOCK PREPARATION: REFINER DATA Motor No Load Running Net load SELM/C Refiner /Type drive, Power load (A) KWHr Wsec/m kw KwHr 3 x 3.5 x 12 250 180 60 120M/C 1 TDR-21" Bar angle = 10 1.17 deg 2.8*3.3*8 350 320 140 180M/C 2 TDR-24" Bar angle = 10 0.79 deg DDR-24" 2 x 3.2 x 6.3 300 300 110 190M/C 4 0.78 Bar angle = 0SDM 10deg DDR-24" 4 x 8 x 8 x 30 250 200 120 80 0.6M/C 5 TDR-21" 3 x 3.5 x 12 x 10 200 180 60 120 1.17M/C 7 CONFLO 3.5 x 5 x 9 x 18 225 162 60 102 1.42
  32. 32. MF Paper Machines PM-1,2,4,5 & 7
  33. 33. PROCESS PAPERMAKING : MF PAPER MACHINE Dry Broke for cleaning & reuseWet Broke for reuse Starch + Size Press AdditivesBack water tofiber recovery Steam Steam
  34. 34. PROCESS OF PAPERMAKING: MF PAPER MACHINEMachine PM-1 PM-2 PM-4 PM-5 PM-7Make Charles Charles Escher Alsthrom, Karhula Walsmey Walsmey Wyss GermannyYear 1936 1936 1960 1984 1984 Renovated in 2004Speed, mpm 100 110 340 260 120Deckle width, 3.12 3.12 3.12 2.24 2.73meterProduction, 30-35 20-50 68-100 55-60 28MT/dayGSM 70-95 58-190 54-149 80-185 70-100
  35. 35. PROCESS OF STOCK CLEANING: PM-4 Stock at Stuff box from Machine chest Dilution of stock with back water in Back Water Primary Fan Pump Accept to Reject Cleaning at Primary Cleaning at Primary Centricleaner Secondary Fan Centricleaner Couch pit Pump Suction Dilution of stock with back water in Fan Pump Cleaning at Tertiary Reject Centricleaner Screening atVibratory Screen Screening at Pressure Screen Cleaning at Head Box Quaternary Centricleaner To Drain ( fiber-mizer ) To Maloney filter
  36. 36. PROCESS OF STOCK CLEANING: PM-5 Stock at Stuff box from Machine chest Dilution of stock with back water in Back Water Primary centriclener Accept to PCC Reject Screening at Pump Screening at Primary Centricleaner Secondary Suction Centricleaner Dilution of stock with back water in Screening at Fan pump Tertiary Centricleaner RejectScreening atVibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
  37. 37. PROCESS OF STOCK CLEANING: PM-7 Stock at Stuff box from Machine chest Dilution of stock with back water in Back Water Primary centriclener Reject Screening at Accept to Screening at Primary Centricleaner Secondary PCC Suction Centricleaner Screening at Tertiary Centricleaner Reject Screening atVibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
  38. 38. PROCESS OF PAPERMAKINGCentricleaner: Paper M/c 1 2 4 5 7 Primary 8 8 24 22 15 Secondary 3 3 8 7 5 Tertiary 1 1 4 1 1 Quaternary 1 1 1 1 1Pressure Screen: Paper M/c 1 2 4 5 7 Type Slotted Slotted Slotted Slotted Slotted Slot Size 0.30 0.30 0.30 0.30 0.25 Pressure Screen
  39. 39. PROCESS OF PAPER MAKING: HEAD BOXMachine 1 2 4 5 7 Closed ClosedHead Box type Open Open Air Open Pressurized Cushioned Simple Simple Tapered Tapered TaperedDistributors Manifold Manifold Flow Manifold ManifoldConsistency 0.5-1.0 % 0.6-1.2 % 0.6-1.0 % 0.8-1.0 % 0.7-0.9 %Freeness, °SR 40-42 40-42 40-42 34-36 40-42Slice opening, 10 10 15 12-14 13mmSlice width, mm 3350 3350 3400 2450 3000No of slices 25 25 28 22 24
  40. 40. PROCESS OF PAPER MAKING: WIRE PARTMachine 1 2 4 5 7Breast roll diameter, 406 600 550 500 500mmNo of table Rolls 16 12 - - 4No of Hydrofoils - - 17 50 9Wet vacuum Boxes 2 2 2 - -Dry vacuum Boxes 3 3 6 8 7Vacuum Applied , mm 350 100-200 200-220 200 200of HgCouch roll Vacuum, 350 350 440-480 400-450 280-300mm of HgCouch roll Dia mm 762 762 762 650 618
  41. 41. PROCESS OF PAPER MAKING: PRESS PARTMachine 1 2 4 5 71st PressType Plain Plain Suction Suction SuctionTop roll Granite Granite Dyna rock Micro rock GraniteBottom roll Rubber Rubber Rubber Rubber Rubber2nd PressType Plain Plain Plain Plain PlainTop roll Granite Granite Dyna Rock Micro rock Micro rockBottom roll Rubber Rubber Rubber Rubber Rubber3rd PressType Offset Offset Reverse Offset OffsetTop roll Granite Granite Dyna rock Micro mate Miicro mateBottom roll Rubber Rubber Rubber Microrock Brass
  42. 42. PROCESS OF PAPER MAKING: DRYER SECTIONMachine 1 2 4 5 7No of dryers 27 27 36 28 16No of dryer 4 4 5 4 3groupsNo of felt 65 65 118 70 48rollsCondensate Bucket Bucket Bucket Siphon BucketRemoval type type type type typesissiesSyphon type Stationary Stationary Stationary Stationary Stationary Semi Semi Semi Semi SemiHood closed closed closed closed closed
  43. 43. PROCESS OF PAPER MAKING: CALENDER & SIZE PRESSMachine 1 2 4 5 7CalendarNo of stacks 1 1 1 1 1No of rolls 2 2 4 2 2Size PressType Inclined Inclined Horizontal Horizontal InclinedMovable roll Micro Micro Micro Micro Micromaterial Rock Rock Mate Mate MateFixed roll Micro Micro Micro Micro Micromaterial Mate Mate Rock Rock RockLoading Hydraulic Hydraulic Hydraulic Hydraulic HydraulicPaper Rope Rope Rope Rope Ropefeeding carrier carrier carrier carrier carrier
  44. 44. PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METERMachine 1 2 4 5 7Machine Wire 19.81 x 3.45 19.81 x 3.45 28.06 x 3.55 22.3 x 2.62 20.26 x 3.13Pick Felt/ First Press Felt 10.36 x 3.55 10.36 x 3.55 16.50 x 3.65 10.5 x 2.65 12.0 x 3.10Second Press Felt 10.36 x 3.55 10.36 x 3.55 16.50 x 3.65 11.2 x 2.65 12.0 x 3.10Third Press Felt - - 16.50 x 3.65 - -First top Dryer Screen 25.30 x 3.55 25.30 x 3.55 43.00x 3.55 27.0 x 2.65 16.0 x 3.10First bottom Dryer Screen 25.30 x 3.55 25.30 x 3.55 - 27.0 x 2.65 16.0 x 3.10Second top dryer screen 25.30 x 3.55 25.30 x 3.55 27.80 x 3.60 21.5 x 2.65 20.0 x 3.10Second bottom dryer screen 25.30 x 3.55 25.30 x 3.55 27.80 x 3.60 21.5 x 2.65 20.0 x 3.10Third top dryer screen 12.50 x 3.55 12.50 x 3.55 21.80 x 3.60 21.5 x 2.65 16.0 x 3.10Third bottom dryer screen 7.00 x 3.55 7.00 x 3.55 21.80 x 3.60 21.5 x 2.65 16.0 x 3.10Fourth top dryer screen 23.30x3.55 23.30 x 3.55 30.00 x 3.55 21.5 x 2.65 -Fourth bottom dryer screen 23.30x3.55 23.30 x 3.90 32.00 x 3.60 21.5 x 2.65 -Sixth top dryer screen - 35.00 x 3.90 29.90x3.60 - -Sixth bottom dryer screen - 39.80 x 3.90 29.90x3.60 - -Cooling Top Dryer Screen - - 12.50x3.60 - -Cooling Bottom Dryer Screen - - 14.50x3.60 - -Last dryer screen - - - 7.5 x 2.65 7.5 x 3.10
  45. 45. Thanks
  46. 46. PROCESS OF PAPER MAKING: PAPER MACHINEDetails M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7Make Charles Wamsley Charles Wamsley Esser Wyss Alstom Karhula KarhulaYear Of Installation 1926 1926 1983 1983 1983Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st FloorProduction (Tpd) 30 40 75 47 1.8 27Machine Speed(Mpm) 100 110 350 270 60 115Machine Deckle(C.M) 314 314 311 223 210 272Draw Open Open Open Open Oen OpenApproach Flow SystemMachine Refiner Type TDR/21” TDR/24” DDR/24” DDR/24”&TDR/21” Conical,Beater ConfloPressure Screens No. 1 1 2 1 0 1Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1No.of Bottles in1st Stage 8 8 24 22 3 15 In 2nd Stage 3 3 8 7 5 In 3rd Stage 1 1 4 1 1 In 4th Stage 1 1 1 1 1Head Box Closed air ClosedType Open Open Coushioned Pressurized Open openDandy Roll Yes Yes Yes Yes No YesDia.of Dandy (mm) 330 330 1000 800 500Press PartIst Press Type Solid Solid Suction Suction Solid Suction2nd Press Type Solid Solid Solid Solid Solid Solid3rd Press Type Reverse Reverse Reverse Smoothening SmootheningDryer SectionTotal No. of Dryer Cylinders 27 27 36 28 10 16Dryer Groups (Steam Wise) 4 4 6 4 3 3No. of D/Cy.In Pre Dryer 19 19 24 20 10No. of D/Cy. In Post Dryer 8 8 12 8 6Cooling Cylinders No No Yes No No NoNo. of Cooling Cylinders 2Size PressType Inclind Inclind Horizontal Puddle type Puddle typeSteam System Conventional Conventional Conventional Conventional Conventional ConventionalCondensate Removal System Bucket Bucket Bucket Siphon Bucket BucketType of Calender Kuster Kuster Kuster Kuster KusterPope Reel Inclined Inclined Horizontal Horizontal Horizontal

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