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All about paper making process

The document provides information about the paper making process at Ballarpur Industries Limited Unit - Shree Gopal. It details the raw materials used, flow diagram of the paper mill, pulp making process, recovery process, paper machines, effluent treatment plant, and stock preparation processes for different paper machines. Key aspects covered include types of raw materials, major unit operations from pulping to paper making, specifications of equipment used, and environmental compliance data.

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BALLARPUR INDUSTRIES LIMITED UNIT – SHREE GOPAL Paper Making Process
PAPER MAKING PROCESS
RAW MATERIALS USED Veneer : 40-45% Bamboo : 15-18% Consumption 325 TPD Consumption 90 TPD Euca. Wood : 35-40% Consumption 175 TPD
FLOW DIAGRAM OF PAPER MILL Raw Pulp Paper Paper MSD Chipper Mill Machine Finishing Godown Material Chemical Dispatch Recovery Chemical Complex Effluent Costing Engg Water Power QC/ Purchase Treatment HR & Maintenance Supply Plant R&D & Store Plant Finance
PULP MAKING PROCESS Steam for Power White Liquor
PULP MILL Chipper House Chipper Make Capacity Raw mat. no. (MT/h) handling 1 Vecoplan No. 1 25 Woodlogs/ Bamboo 2 Vecoplan No. 2 15 Veneer waste Chipper Digester House Kraft/Sulphate pulping process No of Digester : 3 of 120 m3 each Type : Vertical stationary of indirect heating Cooking Time : 260 minutes Pulp/cook : 12.0 MT Digester
PULP MILL Wash Plant Rotary Drum Vacuum Washer: : 4 Stages Capacity :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
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 BLD PULP EO FROM B/W D2 Bleach towers W/P DI C/D B/W NaOH B/W D1 B/W D2 M/C EO D2 No.4 H/W B/W H2O2 H/W B/W D1 B/W B/W DECKER B/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
RECOVERY Evaporator 1 Type : Short tube vertical (STVE) and free flow falling film No of effects : STVE-5 , FFFFE-4 Handling of thin BL : 72 m3/hr Steam Economy : 4.5 Concentration of BL : 62-64 % Evaporator 2 Type : Short tube vertical (STVE) No of effects : STVE-6 Handling of thin BL : 20 m3/hr Steam Economy : 3.0 Concentration of BL : 60-62 % Evaporator Recovery Boiler No of Boiler : 2 - JMW - ABL Total capacity : 315 TPD solids
RECOVERY Causticizing Section Capacity : 70 TPD, active alkali as Na2O Slaker : Stationary Lime mud washing : 2 Streets Lime Kiln Year of installation : 2005 Capacity : 60 TPD Lime kiln
PROCESS OF PAPER MAKING – STOCK PREPARATION Optical Whitener Fiber Sizing Chemicals Recovery Tinting Dyes System Power Broke Filler HD tower Pulp Functional Approach Pulp Paper Bleached Receiving Additives flow Refining Machine pulp Chest addition system
PAPER MACHINES Machine Type Make Deckle Speed GSM Production Paper grades No. 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 Cross All machines are equipped with size press.
PAPER CONVERSION Reel Orders Sheet Orders
PROCESS PAPER CONVERSION & FINISHING REWINDER PM-1 Jag PM-2 Jag PM-4, Beloit PM-4, Masson Rewinder Rewinder Rewinder Scott Max reel capacity 5 5 5 5 Speed in mpm 400 400 600 500 Beloit Rewinder Masson Scott Rewinder
PROCESS PAPER CONVERSION & FINISHING REWINDER PM-5, Servall PM-7, Jagenberg Max reel capacity 4 4 Speed in mpm 800 600 Servall Winder Jagenberg Winder
EFFLUENT TREATMENT PLANT Three stage Effluent Treatment Plant Installed and 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
PAPER MAKING PROCESS • Pulp Supply System • Stock refining • System cleaning • Approach Flow system • Paper making- MF
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 Chest Tinting 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
PULP SUPPLY SYSTEM (PM 1,2 & 4) 1000 m3 Bleached Thickener Machine back water (Krofta/Disc filter Pulp filtrate) for bottom dilution Buffer Chest To Refiners of PM 1, 2 & 4
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 Chest Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 13-16 kg/MT Pulp 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
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 Chest Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 10 kg/MT Pulp 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
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
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 Chest Refined pulp °SR: 28-30 Tinting Dye: PAC : 25 kg/MT Pulp 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
STOCK PREPARATION: PULP REFINING – PM-4 DDR-1 Measuring Mixing/ SR Box Virgin Pulp Tank Machine Chest Buffer Refined Chest Pulp Chest Broke Broke Chest
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-2 PAC: 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
PULP SUPPLY SYSTEM: PM- 5&7 500 m3 Bleached Pulp Machine back water for bottom dilution To PM-5 & 7 Stock Prep.
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 Chest Refined pulp °SR:27 Rosin: 22-25 kg/T PAC : Cato Starch: 3kg/T Pulp 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
STOCK PREPARATION: PULP REFINING – PM-5 Coated Broke Virgin 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
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/T Refined pulp °SR: 26 Filler : 225-235 kg/MT Cato Starch:5-63kg/T PAC : 34 kg/T Pulp 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
STOCK PREPARATION: PULP REFINING – PM-7 Wood Pulp Wood Pulper CONFLOW Virgin Pulp REFINER New Mixing Circulation Chest Chest SR Box Machine Machine Mixing Refiner Chest Chest Broke Broke Chest Pulper
STOCK PREPARATION: REFINER DATA Motor No Load Running Net load SEL M/C Refiner /Type drive, Power load (A) KWHr Wsec/m kw KwHr 3 x 3.5 x 12 250 180 60 120 M/C 1 TDR-21" Bar angle = 10 1.17 deg 2.8*3.3*8 350 320 140 180 M/C 2 TDR-24" Bar angle = 10 0.79 deg DDR-24" 2 x 3.2 x 6.3 300 300 110 190 M/C 4 0.78 Bar angle = 0SDM 10deg DDR-24" 4 x 8 x 8 x 30 250 200 120 80 0.6 M/C 5 TDR-21" 3 x 3.5 x 12 x 10 200 180 60 120 1.17 M/C 7 CONFLO 3.5 x 5 x 9 x 18 225 162 60 102 1.42
MF Paper Machines PM-1,2,4,5 & 7
PROCESS PAPERMAKING : MF PAPER MACHINE Dry Broke for cleaning & reuse Wet Broke for reuse Starch + Size Press Additives Back water to fiber recovery Steam Steam
PROCESS OF PAPERMAKING: MF PAPER MACHINE Machine PM-1 PM-2 PM-4 PM-5 PM-7 Make Charles Charles Escher Alsthrom, Karhula Walsmey Walsmey Wyss Germanny Year 1936 1936 1960 1984 1984 Renovated in 2004 Speed, mpm 100 110 340 260 120 Deckle width, 3.12 3.12 3.12 2.24 2.73 meter Production, 30-35 20-50 68-100 55-60 28 MT/day GSM 70-95 58-190 54-149 80-185 70-100
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 at Vibratory Screen Screening at Pressure Screen Cleaning at Head Box Quaternary Centricleaner To Drain ( fiber-mizer ) To Maloney filter
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 Reject Screening at Vibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
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 at Vibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
PROCESS OF PAPERMAKING Centricleaner: 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 1 Pressure 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
PROCESS OF PAPER MAKING: HEAD BOX Machine 1 2 4 5 7 Closed Closed Head Box type Open Open Air Open Pressurized Cushioned Simple Simple Tapered Tapered Tapered Distributors Manifold Manifold Flow Manifold Manifold Consistency 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 40-42 Slice opening, 10 10 15 12-14 13 mm Slice width, mm 3350 3350 3400 2450 3000 No of slices 25 25 28 22 24
PROCESS OF PAPER MAKING: WIRE PART Machine 1 2 4 5 7 Breast roll diameter, 406 600 550 500 500 mm No of table Rolls 16 12 - - 4 No of Hydrofoils - - 17 50 9 Wet vacuum Boxes 2 2 2 - - Dry vacuum Boxes 3 3 6 8 7 Vacuum Applied , mm 350 100-200 200-220 200 200 of Hg Couch roll Vacuum, 350 350 440-480 400-450 280-300 mm of Hg Couch roll Dia mm 762 762 762 650 618
PROCESS OF PAPER MAKING: PRESS PART Machine 1 2 4 5 7 1st Press Type Plain Plain Suction Suction Suction Top roll Granite Granite Dyna rock Micro rock Granite Bottom roll Rubber Rubber Rubber Rubber Rubber 2nd Press Type Plain Plain Plain Plain Plain Top roll Granite Granite Dyna Rock Micro rock Micro rock Bottom roll Rubber Rubber Rubber Rubber Rubber 3rd Press Type Offset Offset Reverse Offset Offset Top roll Granite Granite Dyna rock Micro mate Miicro mate Bottom roll Rubber Rubber Rubber Microrock Brass
PROCESS OF PAPER MAKING: DRYER SECTION Machine 1 2 4 5 7 No of dryers 27 27 36 28 16 No of dryer 4 4 5 4 3 groups No of felt 65 65 118 70 48 rolls Condensate Bucket Bucket Bucket Siphon Bucket Removal type type type type type sissies Syphon type Stationary Stationary Stationary Stationary Stationary Semi Semi Semi Semi Semi Hood closed closed closed closed closed
PROCESS OF PAPER MAKING: CALENDER & SIZE PRESS Machine 1 2 4 5 7 Calendar No of stacks 1 1 1 1 1 No of rolls 2 2 4 2 2 Size Press Type Inclined Inclined Horizontal Horizontal Inclined Movable roll Micro Micro Micro Micro Micro material Rock Rock Mate Mate Mate Fixed roll Micro Micro Micro Micro Micro material Mate Mate Rock Rock Rock Loading Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Paper Rope Rope Rope Rope Rope feeding carrier carrier carrier carrier carrier
PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METER Machine 1 2 4 5 7 Machine Wire 19.81 x 3.45 19.81 x 3.45 28.06 x 3.55 22.3 x 2.62 20.26 x 3.13 Pick 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 3.10 Second 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 3.10 Third 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 3.10 First bottom Dryer Screen 25.30 x 3.55 25.30 x 3.55 - 27.0 x 2.65 16.0 x 3.10 Second 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 3.10 Second 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 3.10 Third 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 3.10 Third 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 3.10 Fourth 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
Thanks
PROCESS OF PAPER MAKING: PAPER MACHINE Details M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7 Make Charles Wamsley Charles Wamsley Esser Wyss Alstom Karhula Karhula Year Of Installation 1926 1926 1983 1983 1983 Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st Floor Production (Tpd) 30 40 75 47 1.8 27 Machine Speed(Mpm) 100 110 350 270 60 115 Machine Deckle(C.M) 314 314 311 223 210 272 Draw Open Open Open Open Oen Open Approach Flow System Machine Refiner Type TDR/21” TDR/24” DDR/24” DDR/24”&TDR/21” Conical,Beater Conflo Pressure Screens No. 1 1 2 1 0 1 Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25 Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1 No.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 1 Head Box Closed air Closed Type Open Open Coushioned Pressurized Open open Dandy Roll Yes Yes Yes Yes No Yes Dia.of Dandy (mm) 330 330 1000 800 500 Press Part Ist Press Type Solid Solid Suction Suction Solid Suction 2nd Press Type Solid Solid Solid Solid Solid Solid 3rd Press Type Reverse Reverse Reverse Smoothening Smoothening Dryer Section Total No. of Dryer Cylinders 27 27 36 28 10 16 Dryer Groups (Steam Wise) 4 4 6 4 3 3 No. of D/Cy.In Pre Dryer 19 19 24 20 10 No. of D/Cy. In Post Dryer 8 8 12 8 6 Cooling Cylinders No No Yes No No No No. of Cooling Cylinders 2 Size Press Type Inclind Inclind Horizontal Puddle type Puddle type Steam System Conventional Conventional Conventional Conventional Conventional Conventional Condensate Removal System Bucket Bucket Bucket Siphon Bucket Bucket Type of Calender Kuster Kuster Kuster Kuster Kuster Pope Reel Inclined Inclined Horizontal Horizontal Horizontal

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All about paper making process

  • 1.
    BALLARPUR INDUSTRIES LIMITED UNIT – SHREE GOPAL Paper Making Process
  • 2.
  • 3.
    RAW MATERIALS USED Veneer: 40-45% Bamboo : 15-18% Consumption 325 TPD Consumption 90 TPD Euca. Wood : 35-40% Consumption 175 TPD
  • 4.
    FLOW DIAGRAM OFPAPER MILL Raw Pulp Paper Paper MSD Chipper Mill Machine Finishing Godown Material Chemical Dispatch Recovery Chemical Complex Effluent Costing Engg Water Power QC/ Purchase Treatment HR & Maintenance Supply Plant R&D & Store Plant Finance
  • 5.
    PULP MAKING PROCESS Steam for Power White Liquor
  • 6.
    PULP MILL Chipper House Chipper Make Capacity Raw mat. no. (MT/h) handling 1 Vecoplan No. 1 25 Woodlogs/ Bamboo 2 Vecoplan No. 2 15 Veneer waste Chipper Digester House Kraft/Sulphate pulping process No of Digester : 3 of 120 m3 each Type : Vertical stationary of indirect heating Cooking Time : 260 minutes Pulp/cook : 12.0 MT Digester
  • 7.
    PULP MILL Wash Plant RotaryDrum Vacuum Washer: : 4 Stages Capacity :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.
    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 BLD PULP EO FROM B/W D2 Bleach towers W/P DI C/D B/W NaOH B/W D1 B/W D2 M/C EO D2 No.4 H/W B/W H2O2 H/W B/W D1 B/W B/W DECKER B/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.
    RECOVERY Evaporator 1 Type : Short tube vertical (STVE) and free flow falling film No of effects : STVE-5 , FFFFE-4 Handling of thin BL : 72 m3/hr Steam Economy : 4.5 Concentration of BL : 62-64 % Evaporator 2 Type : Short tube vertical (STVE) No of effects : STVE-6 Handling of thin BL : 20 m3/hr Steam Economy : 3.0 Concentration of BL : 60-62 % Evaporator Recovery Boiler No of Boiler : 2 - JMW - ABL Total capacity : 315 TPD solids
  • 10.
    RECOVERY Causticizing Section Capacity : 70 TPD, active alkali as Na2O Slaker : Stationary Lime mud washing : 2 Streets Lime Kiln Year of installation : 2005 Capacity : 60 TPD Lime kiln
  • 11.
    PROCESS OF PAPERMAKING – STOCK PREPARATION Optical Whitener Fiber Sizing Chemicals Recovery Tinting Dyes System Power Broke Filler HD tower Pulp Functional Approach Pulp Paper Bleached Receiving Additives flow Refining Machine pulp Chest addition system
  • 12.
    PAPER MACHINES Machine TypeMake Deckle Speed GSM Production Paper grades No. 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 Cross All machines are equipped with size press.
  • 13.
  • 14.
    PROCESS PAPER CONVERSION& FINISHING REWINDER PM-1 Jag PM-2 Jag PM-4, Beloit PM-4, Masson Rewinder Rewinder Rewinder Scott Max reel capacity 5 5 5 5 Speed in mpm 400 400 600 500 Beloit Rewinder Masson Scott Rewinder
  • 15.
    PROCESS PAPER CONVERSION& FINISHING REWINDER PM-5, Servall PM-7, Jagenberg Max reel capacity 4 4 Speed in mpm 800 600 Servall Winder Jagenberg Winder
  • 16.
    EFFLUENT TREATMENT PLANT Threestage Effluent Treatment Plant Installed and 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.
    PAPER MAKING PROCESS • Pulp Supply System • Stock refining • System cleaning • Approach Flow system • Paper making- MF
  • 18.
    PROCESS FLOW: STOCKPREPARATION (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 Chest Tinting 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.
    PULP SUPPLY SYSTEM(PM 1,2 & 4) 1000 m3 Bleached Thickener Machine back water (Krofta/Disc filter Pulp filtrate) for bottom dilution Buffer Chest To Refiners of PM 1, 2 & 4
  • 20.
    STOCK PREPARATION: PAPERMACHINE-1 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest PAC Filler Mixing Machine Refiner SR Box Fan Pump Chest Chest Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 13-16 kg/MT Pulp 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.
    STOCK PREPARATION: PAPERMACHINE-2 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest PAC Filler Mixing Machine Refiner SR Box Fan Pump Chest Chest Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 10 kg/MT Pulp 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.
    STOCK PREPARATION: PULPREFINING – 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.
    STOCK PREPARATION: PAPERMACHINE– 4 Pulp from Buffer Dispersed Rosin Tinting Dye Fill Plus Chest Filler OBA PAC Mixing Machine Refiner SR Box Fan Pump Chest Chest Refined pulp °SR: 28-30 Tinting Dye: PAC : 25 kg/MT Pulp 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.
    STOCK PREPARATION: PULPREFINING – PM-4 DDR-1 Measuring Mixing/ SR Box Virgin Pulp Tank Machine Chest Buffer Refined Chest Pulp Chest Broke Broke Chest
  • 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-2 PAC: 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.
    PULP SUPPLY SYSTEM:PM- 5&7 500 m3 Bleached Pulp Machine back water for bottom dilution To PM-5 & 7 Stock Prep.
  • 27.
    STOCK PREPARATION: PAPERMACHINE– 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 Chest Refined pulp °SR:27 Rosin: 22-25 kg/T PAC : Cato Starch: 3kg/T Pulp 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.
    STOCK PREPARATION: PULPREFINING – PM-5 Coated Broke Virgin 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.
    STOCK PREPARATION: PAPERMACHINE– 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/T Refined pulp °SR: 26 Filler : 225-235 kg/MT Cato Starch:5-63kg/T PAC : 34 kg/T Pulp 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.
    STOCK PREPARATION: PULPREFINING – PM-7 Wood Pulp Wood Pulper CONFLOW Virgin Pulp REFINER New Mixing Circulation Chest Chest SR Box Machine Machine Mixing Refiner Chest Chest Broke Broke Chest Pulper
  • 31.
    STOCK PREPARATION: REFINERDATA Motor No Load Running Net load SEL M/C Refiner /Type drive, Power load (A) KWHr Wsec/m kw KwHr 3 x 3.5 x 12 250 180 60 120 M/C 1 TDR-21" Bar angle = 10 1.17 deg 2.8*3.3*8 350 320 140 180 M/C 2 TDR-24" Bar angle = 10 0.79 deg DDR-24" 2 x 3.2 x 6.3 300 300 110 190 M/C 4 0.78 Bar angle = 0SDM 10deg DDR-24" 4 x 8 x 8 x 30 250 200 120 80 0.6 M/C 5 TDR-21" 3 x 3.5 x 12 x 10 200 180 60 120 1.17 M/C 7 CONFLO 3.5 x 5 x 9 x 18 225 162 60 102 1.42
  • 32.
    MF Paper MachinesPM-1,2,4,5 & 7
  • 33.
    PROCESS PAPERMAKING :MF PAPER MACHINE Dry Broke for cleaning & reuse Wet Broke for reuse Starch + Size Press Additives Back water to fiber recovery Steam Steam
  • 34.
    PROCESS OF PAPERMAKING:MF PAPER MACHINE Machine PM-1 PM-2 PM-4 PM-5 PM-7 Make Charles Charles Escher Alsthrom, Karhula Walsmey Walsmey Wyss Germanny Year 1936 1936 1960 1984 1984 Renovated in 2004 Speed, mpm 100 110 340 260 120 Deckle width, 3.12 3.12 3.12 2.24 2.73 meter Production, 30-35 20-50 68-100 55-60 28 MT/day GSM 70-95 58-190 54-149 80-185 70-100
  • 35.
    PROCESS OF STOCKCLEANING: 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 at Vibratory Screen Screening at Pressure Screen Cleaning at Head Box Quaternary Centricleaner To Drain ( fiber-mizer ) To Maloney filter
  • 36.
    PROCESS OF STOCKCLEANING: 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 Reject Screening at Vibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
  • 37.
    PROCESS OF STOCKCLEANING: 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 at Vibratory Screen Screening at Pressure Screen Screening at Pope Reel Fibermiser To Drain To Drain
  • 38.
    PROCESS OF PAPERMAKING Centricleaner: 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 1 Pressure 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.
    PROCESS OF PAPERMAKING: HEAD BOX Machine 1 2 4 5 7 Closed Closed Head Box type Open Open Air Open Pressurized Cushioned Simple Simple Tapered Tapered Tapered Distributors Manifold Manifold Flow Manifold Manifold Consistency 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 40-42 Slice opening, 10 10 15 12-14 13 mm Slice width, mm 3350 3350 3400 2450 3000 No of slices 25 25 28 22 24
  • 40.
    PROCESS OF PAPERMAKING: WIRE PART Machine 1 2 4 5 7 Breast roll diameter, 406 600 550 500 500 mm No of table Rolls 16 12 - - 4 No of Hydrofoils - - 17 50 9 Wet vacuum Boxes 2 2 2 - - Dry vacuum Boxes 3 3 6 8 7 Vacuum Applied , mm 350 100-200 200-220 200 200 of Hg Couch roll Vacuum, 350 350 440-480 400-450 280-300 mm of Hg Couch roll Dia mm 762 762 762 650 618
  • 41.
    PROCESS OF PAPERMAKING: PRESS PART Machine 1 2 4 5 7 1st Press Type Plain Plain Suction Suction Suction Top roll Granite Granite Dyna rock Micro rock Granite Bottom roll Rubber Rubber Rubber Rubber Rubber 2nd Press Type Plain Plain Plain Plain Plain Top roll Granite Granite Dyna Rock Micro rock Micro rock Bottom roll Rubber Rubber Rubber Rubber Rubber 3rd Press Type Offset Offset Reverse Offset Offset Top roll Granite Granite Dyna rock Micro mate Miicro mate Bottom roll Rubber Rubber Rubber Microrock Brass
  • 42.
    PROCESS OF PAPERMAKING: DRYER SECTION Machine 1 2 4 5 7 No of dryers 27 27 36 28 16 No of dryer 4 4 5 4 3 groups No of felt 65 65 118 70 48 rolls Condensate Bucket Bucket Bucket Siphon Bucket Removal type type type type type sissies Syphon type Stationary Stationary Stationary Stationary Stationary Semi Semi Semi Semi Semi Hood closed closed closed closed closed
  • 43.
    PROCESS OF PAPERMAKING: CALENDER & SIZE PRESS Machine 1 2 4 5 7 Calendar No of stacks 1 1 1 1 1 No of rolls 2 2 4 2 2 Size Press Type Inclined Inclined Horizontal Horizontal Inclined Movable roll Micro Micro Micro Micro Micro material Rock Rock Mate Mate Mate Fixed roll Micro Micro Micro Micro Micro material Mate Mate Rock Rock Rock Loading Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic Paper Rope Rope Rope Rope Rope feeding carrier carrier carrier carrier carrier
  • 44.
    PROCESS OF PAPERMAKING: MACHINE CLOTHING SIZES, METER Machine 1 2 4 5 7 Machine Wire 19.81 x 3.45 19.81 x 3.45 28.06 x 3.55 22.3 x 2.62 20.26 x 3.13 Pick 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 3.10 Second 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 3.10 Third 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 3.10 First bottom Dryer Screen 25.30 x 3.55 25.30 x 3.55 - 27.0 x 2.65 16.0 x 3.10 Second 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 3.10 Second 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 3.10 Third 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 3.10 Third 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 3.10 Fourth 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.
  • 46.
    PROCESS OF PAPERMAKING: PAPER MACHINE Details M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7 Make Charles Wamsley Charles Wamsley Esser Wyss Alstom Karhula Karhula Year Of Installation 1926 1926 1983 1983 1983 Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st Floor Production (Tpd) 30 40 75 47 1.8 27 Machine Speed(Mpm) 100 110 350 270 60 115 Machine Deckle(C.M) 314 314 311 223 210 272 Draw Open Open Open Open Oen Open Approach Flow System Machine Refiner Type TDR/21” TDR/24” DDR/24” DDR/24”&TDR/21” Conical,Beater Conflo Pressure Screens No. 1 1 2 1 0 1 Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25 Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1 No.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 1 Head Box Closed air Closed Type Open Open Coushioned Pressurized Open open Dandy Roll Yes Yes Yes Yes No Yes Dia.of Dandy (mm) 330 330 1000 800 500 Press Part Ist Press Type Solid Solid Suction Suction Solid Suction 2nd Press Type Solid Solid Solid Solid Solid Solid 3rd Press Type Reverse Reverse Reverse Smoothening Smoothening Dryer Section Total No. of Dryer Cylinders 27 27 36 28 10 16 Dryer Groups (Steam Wise) 4 4 6 4 3 3 No. of D/Cy.In Pre Dryer 19 19 24 20 10 No. of D/Cy. In Post Dryer 8 8 12 8 6 Cooling Cylinders No No Yes No No No No. of Cooling Cylinders 2 Size Press Type Inclind Inclind Horizontal Puddle type Puddle type Steam System Conventional Conventional Conventional Conventional Conventional Conventional Condensate Removal System Bucket Bucket Bucket Siphon Bucket Bucket Type of Calender Kuster Kuster Kuster Kuster Kuster Pope Reel Inclined Inclined Horizontal Horizontal Horizontal