WATER RECYCLING IN MANUFBEST PRACTICES IN WATER IN

A. N. BHATTACHARJEE & MANAS

KOLKATA 31ST AUGUST 2012KOLKATA, 31ST AUGUST. 2012

BALLAVPUR PAPER MFG. LTD..

A it f EMTAA unit of EMTA

FACTURINGNTENSIVE OPERATIONS

BOSE

CONTENTSCONTENTS

• WATER – A SCARCE RESOU

ECONOMISING PROCESS W• ECONOMISING PROCESS W

URCE

WATER IN PAPER INDUSTRYWATER IN PAPER INDUSTRY

GLOBAL WATER RESOURCECONTENTS

Itkmkmea

is estimated that between 12500 to 14000m3 is available for human consumptionm3 is available for human consumptionach year

STILL WE HAVE A SHORTAGECONTENTS

Many countries in Africa, the Msome Eastern European coun

quantities of fresh water resourc

Middle East, Western Asia and tries have lower than average

ces available to their populations

POPULATION PRESSURE ON RCONTENTS

Due to rapid population growth, wateper capita per year in 1970 to 9000Expected to drop to 5100 m3 by 2025

RESOURCES

er availability reduced from 12,900 m3

m3 in 1990 and < 7000 m3 in 2000.5.

TYPICAL WATER CYCLE

PAPER INDUSTRY IN INDIACONTENTS

Paper manufacturing in India mainly com

Paper manufactured can be of different gr) W iti P i ti b) N ia) Writing Printing paper b) Newspri

c) Duplex Board d) Industriae) Tissue

Paper could be made from virgin pulp froresidue like bagasse or wheat/ rice straw

Water is the most vital component used in

Check production capacity in India of var

prises of integrated Pulp and Paper mills.

rades liketnt

al packaging paper (KRAFT)

m bamboo, soft & hard wood, agricultural or recycled fibre (waste paper).

n the paper making process.

ious grades.

SCENARIO OF PAPER INDSOME USEFUL DATA

RAW MATERIAL WISE PAPER P

• W

R2025303540

Wood • R

• A05

1015

Wood AgriResidue

Recycle PaperAgri Residue

India Produces 11.37 Million West Bengal Produces 0.4 Mi

In India Specific water consump

I Gl b l b t S ifi W t CIn Global best Specific Water Consu

DUSTRY IN INDIA

PLANT IN INDIA

Wood :- 32 %

R l d P 38 %Recycled Paper :- 38 %

Agri Residue :- 30 %

tonnes of Paper Per Year llion Tonnes of Paper Per Year

ption :- 150M3/tonne of product

ti 29 M3/t f dumption :- 29 M3/tonnes of produc

PAPER MANUFACTURING PRO

STEP 1 PULP MAKINGCONTENTSSTEP 1 – PULP MAKING

MECHANICAMECHANICAPULPING PRO

+ CLEANING SCREENING + REF

Pulp is commercial cellulose fibers de

mechanical or chemical treatment to re

recycled it gets shorter which decreasesrecycled it gets shorter which decreases

OCESS

AL ENC

Y

HEAD BOXAL OCESS

+ FINING

PULP (3.5%)

8% C

ON

SIST

E HEAD BOX OF PAPER MACHINE

0.8

erived from wood, recycled paper etc by

elease fibers.For every time the Fibre are

s strength so it can be reused 5 to 7 timess strength, so it can be reused 5 to 7 times.

STEP 2 – PAPER MACHINECONTENTS

WIRE PARTWater is removed in this section bygravity and vacuum suction.gravity and vacuum suction.Resulting mixture has 25% solid. Ifproduction is at 6tons/hr then waterremoved will be 720 M3 / Hr

Water is removed in this section bypressing between rolls. Resultingmixture has 50% solid. If productionis at 6tons/hr then water removedwill be 6 M3 / Hr

PRESS PART

STEP 2 – PAPER MACHINECONTENTS

STEAM DRYER SECTION

Water is removed in thissection steam drying.

Resulting mixture has 94%Resulting mixture has 94%solid.

If production is at 6tons/hrthen ater remo ed at thisthen water removed at thisstage is tons 6 M3 /Hr

PAPER MAKING – A WATER INCONTENTS

The paper making process generates

Concerns for the environment has ledi i i t ti L dminimise water consumption. Less d

High cost of fresh water (eg. in statesdevelopment to re-use process waterdevelopment to re use process water

CURRENT TREND IN PULPCLOSE THE PROCE

NTENSIVE PROCESS

a great quantity of waste water.

d to development of procedures to di h !discharge!

s like Gujarat) has also spurred the to the maximum possible.to the maximum possible.

P & PAPER INDUSTRY IS TO ESS WATER SYSTEM

WATER FLOW IN CLOSED WATTYPICAL CLOSED WATER SYS

gh Pressure Shower

PAPER M/C

gake up water 0 m3/day

High press

Silo

White WaterTank

Wire Pit

KROFTAKROFTA

Regenerated Water (500 m3/day)

TER SYSTEMSTEM IN PAPER PLANT

PULP MILL

sure shower (regen. water)

dilu

tion

show

er

Regen. WaterTank

Back WaterTank

Regenerated Water (1500 m3/day)

Influent (520m3/day)

ETPInfluent (520m3/day)

Sludge BedGardening

WHITE WATER SYSTEM – PITFCLOSED WATER SYSTEM – PIT

1. Organic compounds accumulate in white micro-organism to grow on water surfaceweb. In subsequent drying process, the bproduct.

2. Water is exposed to atmosphere and absothis O and an environment without O suthis O2 and an environment without O2 suO2 is used up the micro-organisms start t(VFA) giving of unpleasant odour & increa

Use Biocides to control content of mdispersion agent, this dissolves t

FALLS & SOLUTIONSTFALLS & SOLUTIONS

water system. This acts as a substrate for e as a bio-film. This film enters the paper bio-film fragments damaging the quality of

orbs O2. Micro-organisms in water consumes uitable for anaerobes is produced Once theuitable for anaerobes is produced. Once the o ferment releasing some volatile fatty acids asing demand of retention aides.

icro-organics. Often combined with the cluster of micro-organisms.

WHITE WATER SYSTEM – PITFCLOSED WATER SYSTEM – PIT

Inorganic ions accumulate increasing temperature coupled with anionic ions

Different additives added in white wateDifferent additives added in white watepitch and anionic trash.

Cations in the white water (if present istrength by decreasing the number of

Use fixing agents to remove su

Adopt membrane filtration

FALLS & SOLUTIONSTFALLS & SOLUTIONS contd….

the temperature of white water. This high s creates corrosive conditions.

er affects process in the form of stickieser affects process in the form of stickies,

n high concentration) decrease the paper inter-fibre bonds.

bstances from the whitewater.

to reduce COD discharge

CUMULATIVE EFFECT OF CLOS

• TOTAL AND DISSOLVED ORGANIC CARTOTAL AND DISSOLVED ORGANIC CAR

t is the sum measure of the concen

.TOTAL SUSPENDED SOLIDS ( mg/lt) :-

Covalently bonded in the orga

It is a measure of the concentration o

to the amount of

.CHEMICAL OXYGEN DEMAND ( COD )( mg/lt

It is defined as the amount of dissolv

Stabilize organic and inorganicg g

SED WATER SYSTEM

RBON :-RBON :

ntration of all organic carbon atoms

anic molecules in waste water

of solids in suspension which correlat

treatment required.

t):-

ed oxygen required to oxidize and

c content of the waste water

WHITE WATER SYSTEM – PITFMAKE UP WATER IN CLOSED SPAPER MAKING – A HUGELY WMAKE UP WATER IN CLOSED S

REQUIREMENT OF MAKE UP WATER

1. Steam Dryer section –

2. High pressure shower in Press sec

POWER GENERATION

1. Mixed Cooling Water pond (natural evaporation)

2. Steam condensate loss in pulp & pa& Boiler continuous blow-down

3. Domestic Use

FALLS & SOLUTIONSSYSTEMWATER INTENSIVE PROCESSSYSTEM

R (FRESH WATER)

144 M3/day

ction - 80 M3/day

- 140 M3/day

aper m/c- 200 M3/day

- 10 M3/day

KROFTA - MECHANISM

ADVANTAGES of DISSOLVED

Low Reten

High specific clarification cap

Clarified water extracted containsClarified water extracted contains

D AIR FLOATATION METHOD:

ntion time

pacity (160 – 220lpm / sq mt.)

s < 150 ppm of suspended solids.s 150 ppm of suspended solids.

ACTIVATED CARBON FILTER

•Hi•Higc

1. Carbon is generally activated

To attract negatively c

2. It usually used to remove sedi

• PROPERTIES:-

h d f i it j t 1 f ti tgh degree of microporosity, just 1gm of activatecarbon has a surface area in excess 500 m2.

•It is usually derived from charcoal•It is usually derived from charcoal

BENEFITS :-BENEFITS :-

d with a positive charge and is designed

charged water contaminents.

ments and volatile organic compounds.

ETPETP – VARIOUS STEPS

TSS: 1800 to 3000 mg/ltMLSS: 3000 – 4000 mg/lt

COD: 3000 mg/ltpH: 5 to 6.5

HILL SCREEN

Process feed Sludge

TSS: 600 to 1000 mg/ltCOD 2500 mg/lt

SCREENg

PRIMARY COD 2500 mg/ltpH: 7.5 to 8 (lime addition)

TSS: 150 to 250 mg/lt

CLARIFIER

TSS: 150 to 250 mg/ltCOD: 1600 - 2000 mg/lt

pH :- 7.0

TSS: 150 to 250 mg/COD: < 100 mg/

e Removal

Remove organic particles bygravity with addition of polyg y p yelectrolyte as coagulant & forbetter sedimentation.

Micro- organisms + O2 usedAERATED LAGOON

Micro- organisms + O2 used to oxidise organic pollutants in water to separate waste sludge

S di t ti t kSECONDARY CLARIFIER

Sedimentation tank used to remove settleable solids in waste water

/lt/lt

FILTER

ETP

• TSS: 1800 to 3000 mg/lt• MLSS: 3000 – 4000 mg/ltMLSS: 3000 4000 mg/lt• COD: 3000 mg/lt• pH: 5 to 6.5

Process feedHILL

SCREENSludge

SCREEN

PRIMARY

g

TSS: 600 to 1000 mg/ltCOD 2500 mg/lt

CLARIFIERCOD 2500 mg/lt

pH: 75 to 8 (lime addition)

TSS: 150 to 250 mg/ltTSS: 150 to 250 mg/ltCOD: 1600 - 2000 mg/lt

TSS: 150 to 250 mg/COD: < 100 mg/

e Removal

Remove organic particles bygravity with addition of polyg y p yelectrolyte as coagulant & forbetter sedimentation.

Remove organic particles byAERATED LAGOON

g p ygravity with addition of polyelectrolyte as coagulant & forbetter sedimentation.

S di t ti t kSECONDARY CLARIFIER

Sedimentation tankused to remove settleable solids in waste water

/lt/lt

FILTERFILTER

TYPICAL WATER BALANCE IN KRAFWITH RECYCLED WASTE PAPER.COURTSEY :- BALLAVPUR PAPER M

• 150 TPD KRAFT LINER150 TPD KRAFT LINER

PAPER MACHINE

Biocide and

Membrane

filteration

White water tank

FT PAPER PLANT

MFG. LTD

PULP MILL

KROFTAKROFTA

ETP

SAVE WATER -- SAVE EARTHH