waste and energy audit in a paper mill

7/25/2019 Waste and Energy Audit in a Paper Mill

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WASTE AND ENERGY AUDIT IN A PAPER MILL

byPerera, L.A.K.A thesis submitted in partial fulfillment of the requirements for the degree of Master ofEngineering.Examination Committee : r. C. !is"anathan #Chairman$: r. Lars %aet& 'euterg(rdh: r. ). KumarPerera, L.A.K.*ationality : )ri Lan+anPre"ious egree : %.). Eng. #Ci"il Engineering$-ni"ersity of MoratuaMoratua, )ri Lan+a.)holarship donor : )edish /o"ernment 0hrough )edish1nternational e"elopment Cooperation Ageny#)ida$Asian 1nstitute of 0ehnology%ang+o+, 0hailandAugust, 2334Comment:

iiACKNOWLEDGMENT

0he author ishes to express his sinere gratitude to the folloing persons, ho in oneay or another, ha"e rendered their assistane for the aomplishment of this piee of or+.r. C. !is"anathan, my thesis ad"iser for his stimulating guidane and onstruti"eritiisms throughout the study.r. Lars %aet& 'euterg(rdh and r. ). Kumar for their illingness to ser"e as ommitteemembers for the examining ommittee and for their ad"ie and suggestions.)edish 1nternational e"elopment Cooperation Ageny #)ida$ for the sholarshipgranted to the author through the ourtesy of A10.Khun )ihapol 0hiramanus, the managing diretor, and Khun 5orraphat Poonsiri, the

prodution manager, and all their staff of 0eppattana Paper Mill for ooperati"e responsesthroughout my researh.Khun )uat, Khun )alaya, Khun Peter and all staff of EE program for theirooperati"eness and +ind support.r. )utat 5eesa+ul and his staff members at hydrauli lab and Mr. 'em 6ensen atphysial plant for pro"iding "aluable equipment ithout any hesitation.r. Mar+ 'ad+a of -*EP for pro"iding neessary information and sharing hisexperiene.Mr. 7onathan )ha of CLE0 and my unle 'an8i, for their support to produe this thesis.0o the author9s olleagues in A10 ho shoed true onern and the true meaning offriendship during his stay at the institute.

And most of all, my belo"ed parents, my brother and my sister for their ne"er endingenouragement and are.inally, 1 ould li+e to humbly dediate this piee of or+ to my belo"ed parents.ABSTRACT

0eppattana Paper Mill, a small non;integrated paper mill hih manufaturespaper and board as seleted as the study ob8et in this researh study. 0he study mainlyfoused to trap potential aste minimi&ation options in the mill. 1t mainly targetedtoards ra ater onser"ation, proess modifiations, impro"ement to the effluent


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treatment plant, energy onser"ation and to find possibilities for &ero disharge.0he study indiated that the ra ater onsumption is 3< m=>ton of paper hihis ? times higher than the standard norms and dissol"ed solids in ra ater is @ timeshigher than the aepted "alues. 0he suspended solid omponent lea"ing themanufaturing proess is 3 +g>ton of paper. 0he o"erall steam energy and eletrial

energy onsumption of the mill is found to be B tons>ton of paper and 4=2 +5h>ton ofpaper respeti"ely.Approximately B redution in ra ater onsumption of the mill and @Bredution in suspended solids to the primary larifier is en"isaged upon implementaion ofaste redution measures suh as ater reuse and asteater segregation.0he study onludes ith the proposals to redue the asteater disharge to theri"er by almost 2


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B.D Energy -tili&ation in Paper 1ndustry 2BB.3 Cleaner Prodution in the Paper 1ndustry 2=CHAPTER TITLE PAGE"

111 %ACK/'-* 1*'MA01* 06E 'E)EA'C6 )10E 2=.2 /eneral 1nformation 2=.B Prodution Proess 2?=.= Existing 5ater )upply )ystem 2?=.@ Existing 5asteater )treams B2=. Existing Effluent 0reatment Plant B2=.4 5asteater Charateristis B2=.? Energy Consumption B! ME06L/F [email protected] )tudy Program [email protected] ata Colletion B?@.= 1nplant Monitoring B?@.@ Material and Energy %alane B?@. 0otal 5ater %alane [email protected] 5ater Consumption Measurement [email protected] 5asteater lo Measurement [email protected] Chemial Analysis [email protected] )ampling [email protected] 5ater and 5asteater Charateristis =@@.? Effluent 0reatment Plant Audit =@! 'E)-L0) A* 1)C-))1* =.2 %enh Mar+s for 0eppattana Paper Mill =.2.2 'a 5ater -sed in Paper Mill =4.2.B 5asteater from Prodution Proess =4.2.= Energy Consumption of the Paper Mill =?.B 5aste Auditing of the Mill =?.B.2 1nput Material and its Cost Analysis @@.B.B 'eording for 5ater -sage @D.B.= Aounting for 0otal 5asteater 5 %a+ 5ater5 eatered PulpE0P Effluent 0reatment Plant iltered Cg /ram/AC /ranular Ati"ated Carbong>mB /rammage/1 /lass 1nterlea"ing Paper/5 /round 5ater/7>ton /iga 7oules per tonh 6our6'0 6ydrauli 'etention 0ime6t. 6eight+g Kilogram+Pa Kilo Pasal+5 Kiloatt+5h Kiloatt hourL>se Liters per seondmB )quare meterm= Cubi meterm=>day Cubi meters per daymg Milligrammg>L Milligram per Literm>min Meters minutemin. Minutemm MillimeterP J 5 Printing and 5riting PaperPM Paper Mahine )etionPM 1 Paper Mahine 1


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PM 11 Paper Mahine 11PM 111 Paper Mahine 111xiiP!A Poly !inyl AloholGty. Guantity

'>5 'a 5ater)% )ludge rying %eds)P )to+ Preparation)P 1 )to+ Preparation 1)P 11 )to+ Preparation 11)P 111 )to+ Preparation 111)>P )reened Pulp)) )uspended )olids)>' )reen 'e8et)5 )olid 5aste0emp. 0emperature

tonne Metri tonne0) 0otal )olids0)) 0otal )uspended )olids- -tility )etion-*EP -nited *ations En"ironment Program!P !irgin Pulp!ol. !olume5>M 5ire Mesh5P 5aste Paper55 5asteater -) ollars2

CHAPTER IINTRODUCTION

1.1 General Bac!r"#n$

0he paper industry is +non to be an intensi"e industry in e"ery sense of the ord: it is ramaterial intensi"e, apital intensi"e, energy intensi"e, ater intensi"e and also pollution intensi"e.0herefore, no more than e"er before, there is a ompelling urgeny to ontrol the pollution ausedby the paper industry.0he basi paper ma+ing proess has not hanged for the last B


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ponds or ati"ated sludge systems and physial>hemial treatment suh as filtration and hemiallyassisted larifiation.1n the early 23?


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board ill exeed =2< million tonnes in the year B


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here the furnish #or pulp mixture$ is e"enly distributed onto the ire sreen mesh. 0he aterolleted from the ire mesh is ontinuously reyled to dilute the pulp fed into the papermahine.%./.1.1 Screen)n! an$ Clean)n!

0he ob8eti"e of pulp leaning and sreening is to remo"e dirt and foreign matter suh as

sli"ers, grit, bar+, sand, stones, metal piees, plasti, lips et. 0he operating prinipal ofsreening depends on the si&e hereas the lean is based on differene in speifi gra"ity. 1nmodern aste paper based sto+ preparation, the sreen reei"es the sto+ at around @onsisteny #)1E5E'0, 233$ hereas KL1*E #2332$ and *A01*AL P'-C01!10FC-*C1L #2334$ says that this onsisteny should be less than 2.

F)!. %.1 S("c Pre0ara()"n Pr"ce 3McCUBBIN4 156+7

Coarse )reen0his is to remo"e o"ersi&e material suh as +nots, sli"ers and ungrounded piees of ood.0he sreens usually ha"e openings of ;2< mm in si&e and may be "ibratory, mehanial, openrotary, and entrifugal rotary #MC-%%1*, 23D=$.ine )reenine sreen is to remo"e fibre bundles and partiles that are @ to B< times larger thana"erage #MC-%%1*, 23D=$. 0he si&e of the opening ill normally "ary from B to B. mm#KL1*E, 2332$. 1n early stages open sreens ere applied. 0hey are "ibrating sreens and openentrifugal sreens. 1n modern mills losed sreen tehnology is used. 0his operates underpressure ith no free liquid surfae.CleaningCentrifugal leaning is the most ommon de"ie used in pulp leaning to remo"e bar+,sand, grit and other small partiles. 6ere dilute pulp #2 onsisteny$ is fed tangentially in aonial separator body ausing rapid spinning of the pulp and a donard mo"ement in theone.)mall surfae area partiles and high speifi gra"ity partiles ill mo"e donard and lighterand lean fibres arried upard to the aepted disharge #MC-%%1*, 23D= and KL1*E,2332$.)tuff %ox0o Paper MahinePump Pumplo Control!al"elo Metersand ControlMixing 6opper !al"esMixing Chest 6olding

ChestMahineChestColor,)i&e,illerAlumA % C %ro+e


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)lush %ro+efrom )ame 'unConsisteny 'egulator)lush Pulps7ordon 'efiners4

%./.1.% S("c Re*)n)n!

0his is a mehanial proess hih ats on fibres to gi"e them inreased surfae area,greater flexibility and smooth surfaes. 0he onsisteny norm for the refiner is in the range of@to @.. 0he speifi onsumption of energy for different types of refiners are gi"en in 0able B.2.#E*E'/F MA*A/EME*0 CE*0E', 233 $. KL1*E #2332$ says that the onsisteny normfor onial refiners is in the range of B;2


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ourdriner0he pulp suspension enters the head box at around min #MC-%%1*, 23D=$. KL1*E #2332$ says thisspeed is normally around 2B< m>min and ill "ary aording to the grammage of paper.

0in 5ire Paper Mahine6ere the sto+ is direted through no&&les o"er the full idth of the mahine beteen toourdriner type ires. )CAC61*// et al. #2332$ desribed the basi design for tin ire pressproess for sheet drying appliations. 0his paper says that the energy required for tin irepapermahine is D less than that ith ourdriner mahines. 6oe"er it is not used sine the yield isless.Cylinder MahinesCylinder mahines are used primarily for the prodution of hea"y grades of paper orboard and may use one or multiple ylinders to form the eb depending on the produt. 0hemahine operates at @< m>min on a"erage #MC-%%1*, 23D=$. 6ere also the onsisteny of the

sto+ arri"ing at the paper mahine is around


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%.8 S"#rce "* P"ll#()"n an$ )( C9arac(er)()c

%.8.1 S("c Pre0ara()"n

Cleaner and sreen re8ets an be upto fe perent of total prodution, normally under2 #MC-%%1*, 23D=$. 1t is not possible to define an aeptable rate of suspended solidsdisharge sine it depends on produt speifiation and leanliness of ra materials. 0he % of

disharge is generally negligible unless there are signifiant starh lea+s or other losses due toequipment ea+nesses. 0here is no signifiant atmospheri emission or solid aste from sto+preparation department.%.8.% Pa0er Mac9)ne S(e'

)to+s generally arri"e at the paper mahine area at a onsisteny of beteen = to 2Bonsisteny. 0he final produt is about 3tonne of paperprodued. MF'EE* #233@$ onfirms it by indiating the fresh ater onsumption in a paper and

board mill "aries beteen B to B< m=per tonne of paper produed depending on the graderequired. 1t also indiates that ater disharged in ubi meters per tonne of paper produed asfollos:*es Print : ;2

Light eight paper : 2B;Btonne. LKE#233@$ expresses that the yield of reyled paper may "ary from 4


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temperature an reah


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PondsAeratedlagoons0ri+ling ilters Chemialfloulation2B

Area requirement% Loading range #+g>m=$% redution Equali&ation requirementEquali&ation apaity)ho+ resistane"ery large


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per hour. 0he maximum steam pressure rating is 2< +g>mB. 0he proess steam onsumption is Btonnes per tonne of paper produed at a pressure of @ +g>mB in the paper mahine #C6A*AKet al. 233 and *A01*AL P'-C01!10F C-*C1L, 2334$. 0his is onfirmed byE*E'/F MA*A/EME*0 CE*0E' #233$ here it is stated that the figure "aries form 2.3;B.< tonnes per tonne of paper. 6oe"er 'A/A* #233


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CLEA*E' P'-C01* P01*); Prodution esign; Management 1mpro"ement; /ood 6ouse Keeping; )ubstitution of 0oxi Chemials

; Proess Modifiation; 1nternal 'euse*E5 CLEA*E' 0EC6*L/FE* P1PE 0EC6*L/FLead to better planning for5hih leads to inreaseeffiieny and reduedependeny onCLEA*E' P'-C01*2

CHAPTER III

BACKGROUND INFORMATION OF THE RESEARCH SITE

+.1 General In*"r'a()"n

0eppattana Paper Mill Co., Ltd. is a small paper mill loated at BB2, )aiat+o+e 'oad,Amphur Muang, Pathumthani. 0he loation map of the mill is shon in ig. =.2. 0he layout ofthemill is presented in ig. =.B.0he paper mill as established in 23?< ith a registered apital of .B million ollars. 0hetotal number of employees are [email protected] fatory has three prodution lines namely PM 1, PM 11 and PM 111 to manufature threeproduts namely duplex board, printing and riting paper and glass interlea"ing paperrespeti"elyith daily manufaturing apaities of =< tonnes, 2@ tonnes and 4 tonnes respeti"ely. 0he atualmanufaturing quantity ill depend on the demand for eah produt. uring high demandperiods forglass interlea"ing paper, the PM 11 is designed to on"ert for glass interlea"ing paper ith somemodifiations. 0he total prodution is onsumed in 0hailand and disussions are in the progresstoexport printing and riting paper to 1ndia.F)!. +.1 L"ca()"n Ma0 "* Te00a((ana Pa0er M)ll0o Lat Lum Kea Muniipal CounilPoliePost0o PathumthaniPathum!ili )hool

Chao Phraya 'i"er%angbon 0emple0o 5ine atory0o %anglain 0o %angbuthong0o 'angsit 0o )ri *a+arin 'oadPathumthani %ridge%ang )ai 'oad0o Pa+et

*ontha %uri %ridge%ang+o+ Pathumthani 'oad0eppattanaPaper Mill


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0emple Coa Cola atoryPathumthani Mar+et0ehno Pathumthani0hi"anon 'oad)aiat+o+e 'oad

*ot 0o )ale24

+.% Pr"$#c()"n Pr"ce2?

0he ra material used for different produts are desribed belo.uplex %oard : A mixture of @= aste maga&ines, @= ard board boxes and 2@ hite paperare added separately to the hydra pulper. 0hese are not mixed in the sto+ preparation proess buton"eyed separately to the et end of the paper mahine. *o de;in+ing of aste paper is done inthisoperation. 0he a"erage grammage of paper is found to be =2< g>mB on a"erage.Printing and 5riting Paper : A mixture of hite paper 4mB.Chemials suh as alum, resins and hite lay are added to the abo"e mentioned proessesdepending on final produt. etail list of ra material for eah produt are gi"en in detail in0ables. to .D.0he ra materials are first hand sorted for impurities and then fed to the hydra pulper hereater is added to arri"e at the required onsisteny through the experiene of the or+ers. Afterthis,unanted material suh as pins, lips, sand et. are separated by means of high density leaner,rifflerand fine sreening. 'a ater as ell as hite ater is added in the proess to get a ontiguousflo of the sto+. 0he sto+ is then fed to a de+er here exess ater is remo"ed and stored inhests. 0his ater #hite ater or ba+ ater$ hih is rih in fibre is stored for reyling.5hile adding the required quantity of ater to the sto+s, it is pumped to the paper mahineflo box hih transmits the sto+ to the ylinder mahine or to the belt in the fourdrinermahinehere it is e"enly distributed on the surfae of the mesh or belt. 5ater is remo"ed initially bygra"itydraining, folloed by sution, pressing and then drying by steam. 0he final produt is rolled intoareel hih is transferred to the utting setion here quality ontrolling, utting to the requiredsi&eand pa+ing ill ta+e plae. 0he flo diagrams for the eah of the prodution lines are gi"en inigs.=.= to =..+.+ E=)()n! Wa(er S#00l S(e'

/round ater is the main soure of ater. 0here are three deep ells to pump B3day.0he ground ater is used for ire mesh and belt leaning, as seal ater in sution pumps, feedaterto the softener, flo leaning ater and for human onsumption in the fatory as ell as in staff


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housing. Part of softener ater is sent through a ultra "iolet light before using it for drin+ingpurposes. Although the sto+ preparation is designed to use hite ater from the proess, thereareinstanes hen ground ater is used. Apart from this, treated ater from the effluent treatment2D23

BL to 42< mg>L. 0hisis inontraditory sine there is no ay of reduing dissol"ed solids from the existing treatmentsystem.BB


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B=B@

Ta&le +.1 Wa(e2a(er C9arac(er)()c "* (9e Te00a((ana Pa0er M)ll

Parameter 1nfluent Effluent0emperature #L$) #mg>L$ #mg>L$% #mg>L$=@?.B=

waste and energy audit in a paper mill

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