SPB implemented several water conservation measures at its paper machine that reduced fresh water usage. They included recycling vacuum pump cooling water back to the pumps instead of sending it to the ETP. They also reused deculator vacuum pump sealing water by routing it through a cooling tower instead of to the white water tank. These changes eliminated fresh water makeup for the vacuum systems and reduced the overall fresh water usage.

1. 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

2. 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.

3. Why we need water conservation??? Though the total amount of water on this planet has never changed, the nature of that water is changing. Water supply affecting factors: Immigration Population growth Climate change In 2050, World’s Population expected: 9.4 billion Water will be world’s scarcest and most valuable commodities Water is not just a societal issue – affects BUSINESS also.

4. Why we need water conservation??? Increasing awareness that water resources, renewable natural resources, exist in limited quantities. The continuous and indefinite expansion of water uses is not possible. Situation of stability in the use of the water that is currently available must be sought. This should be one of the main strategic goals of a long-term water management policy. There is an urgent need to find ways of saving, reusing and recycling water and to develop methodologies to improve water resource management.

5. INTRODUCTION United Nation has recognized access to water as a BASIC HUMAN RIGHT. Water is not merely an economic commodity, it is a SOCIAL and CULTURAL good. Water has been recognized universally as an invaluable resource.

6. INTRODUCTION 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.

7. 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 %)

8. Water Usage in Paper Industry Global Standard of Specific Average Water Consumption is 28.66 m 3 /t in Large Scale Wood Based Pulp & Paper Mills. In India, is around 100 m 3 /t of paper.

9. Water Usage in Paper Industry The Higher Consumption in India, due to Lack of Technology adaptation Poor equipment efficiency Poor Water Management Practices

10. Water Consumption Pattern in Indian Paper Industries FIG.2 - Water Consumption Pattern in India 41% 43% 4% 12% Cultural Paper mills Industrial Paper mills Speciality Paper mills Newsprint mills

11. Global Standard Bench Mark for Water Consumption ???? INDIA 30 Spain 40 Finland 67 Canada 40 Europe 28.66 Australia 64 United States SPECIFIC WATER CONSUMPTION m 3 /Ton of Paper COUNTRY

12. Water Conservation Measures Equipment Modification : Recycling – Using water in the same process Reusing – Using water in some other process Reclamation – Collecting the waste water and use for some process Behavioural Modification: By stopping misuse of water for cleaning, etc. Turn-off water when not using it like in hose, tap, etc. Process Modification: Optimal usage of Cooling water – collecting and resue Collection and recycling of clean water from vacuum pumps Use of Seal-less pumps. This is used in most of the chemical industry. Monitoring the Showers in Paper machines and increase the usage of back water .

13. Water Conservation Measures Water Conservations also through: House keeping measures (Low cost measures) like leak identifications and arresting Production scheduling (to avoid unwanted draining the system) Automation like Level controller, Pressure controller Better Raw material utilization to avoid excess water usage in bleaching operation.

14. SPB’S APPROACH on Water Conservation in Paper Machine Complex

15. Brief on Paper Machine # 5 Make : VOITH Head Box : Hydraulic W type Wire Part : Duoformer F Press Part : Duo-centri II with Suction Pickup, Suction Press, PU covered CC rolls in I and III nip position Dryer Part : I & II groups are Unirun and III,IV,V and VI groups are conventional dryers Speed sizer : Voith Film Press Calender : Single stack with single nip CI rolls Automation : ABB – DCS – Advant station 500 series QCS – Accuray 1190 version GSM Range : 45 to 140 GSM Machine Speed : 400 to 950 mpm Average Production : 180 tpd Furnish : 70 – 80 % Captive Bleached Hardwood Pulp (ECF Bleached) 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.

16. 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

17. 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

18. 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

19. 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

20. 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 Forming roll, 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

21. Water Conservation Methods in SPB – Case 1 Issue: In Vacuum pump cooling tower, fresh water was added and return water sent to Effluent due to Fines content is more in return water Temperature is more i.e. around 50 o C Cooling tower fins are getting choked with fines settlement.

22. Vacuum Cooling Tower system before implementation Vacuum Pumps Vacuum Sump Fresh Water Makeup To ETP Reuse to vacuum pumps (50%) Vacuum pump Cooling Tower

23. Water Conservation Methods in SPB – Case 1 Action Taken: Vacuum Pump cooling tower makeup water was replaced with Clear filtrate (60 ppm) from Poly Disc save-all to replace Fresh water makeup. Vacuum sump water was diverted to Poly Disc save-all and the excess clear water of 60 ppm from White water tower is supplied to Pulp mill for Bleached Tower pump consistency control.

24. Vacuum Cooling Tower system after implementation Vacuum Pumps Vacuum Sump Clear Filtrate Water from White water tower To Poly Disc Save-all Excess water to Pulp mill Vacuum Pump Cooling Tower

25. Water Conservation Methods in SPB – Case 1 Benefits achieved: ETP load reduced Fresh water replaced with Clear filtrate from Save-all Back water (clear water) used in Pulp mill helps to maintain final pulp Brightness (since Back water contains OBA) Fines recovered in Poly Disc Save-all

26. Water Conservation Methods in SPB – Case 2 Issue: 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.

27. 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

28. Water Conservation Methods in SPB – Case 2 Action Taken: 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.

29. 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

30. Water Conservation Methods in SPB – Case 2 Benefits achieved: Deculator Cooling tower make up with Fresh water eliminated Deculator Vacuum pump sealing water temperature (30 o C) achieved by passing through cooling tower.

31. Water Conservation Before & After Implementation

32. Water Conservation – FUTURE PLANS From all pumps, sealing water will be collected in a sump and will be reused. Thus 250 m3/day can be saved. By using efficient filters, we proposed to substitute fresh water with backwater, wherever possible. Thus we are targeting for water consumption – 10 m 3 /t of Machine Production.

33. CONCLUSION By Process Modifications and using available automation, Water consumption reduced by around 400 m3 per day in Paper Machine # 5 Clear water sent to Pulp mill thus saving the costly chemicals like OBA. Recovered costly fibers and fillers from Vacuum pump sealing water, thus disturbance in wet end chemistry like Charge Demand, etc avoided. By closing the water loop in the Paper machine complex, wet end chemical consumption is optimized. ETP load reduced by close water loop.

34. LET’S NOT STOP; WE NEED TO GO FURTHER

35. ACKNOWLEDGEMENT Thanks to The management of M/s SESHASAYEE PAPER & BOARDS LIMITED for co-operation and guidance extended. IPPTA for providing this opportunity. AUDIENCE for sharing the valuable time.

36. THANK YOU