Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: Title of Technology: Filler Recovery Process to Recover Raw Material in the Paper Mill Mineral Loaded Rejects Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage ' Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others ' Process/Technology Description: The FilRec™ process recovers the useful filler, which is the raw material in the paper making stage and alters them to the paper furnish quality The process starts with the fractionation stage using pressure screen or bow screens, which separates out the coarse rejects (stiff fibers, shives and other coarse solids like dirt) and the fine fractions, containing minerals and water The fine fractions from the fractionation stage are sent to the filler recovery stage, which is a special type centrifugal cleaner separating out the mineral solids based on the particle size Fine fillers with water are sent back to the papermaking stage and the coarse solids are sent to the mineral dispersion stage after concentrating them to 30 – 50% solids In the mineral dispersion stage, the coarse minerals are broken down with the help of a heavyduty dispersion machine In this continuously circulated dispersion loop comprising of the filler recovery and mineral dispersion stage, fine filler is recovered The coarse fraction from the fractionation stage is classified in the final rejects stage The reusable fibers and fine fillers are returned to the paper machine The final rejects are sent for final disposal Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Description 65% fibre recovery 80% fillers are saved based on broke quality and make up Reduction in solids in the effluent • Equipment /Process Modifications This is an add-on system to the paper mills with requirements of minor rerouting of piping network Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period 300,000 to 400,000 Pumping and refining cost Recovered filler cost Contacts of Successful User Contacts of Equipment Supplier Less than one year Name Enso Fine Papers Oy Name Address Oulu Tehtaat PL 196 90101 Oulu Finland Address Telephone Telefax E-mail 358-02046124 358-0204633120 Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Ahlstrom Machinery Corporation Sentnerikuja PO Box 5, Helsinki 00441 Finland (35) 89 503 9211 (35) 89 562 4085 www.ahlstrom.com/machinery Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: Title of Technology: Wet Washing of Raw Material for Chloride Removal Technology Applied in: ' Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: The presence of chlorides affects any combustion technology and affects combustion in fluidized bed recovery systems However, the chlorides present in non wood raw materials are washable and can be reduced to an acceptable level by means of suitably designed washing systems consisting of equipment for submergence, washing draining and passing through a screw press to an acceptable uniform level of moisture The washing also helps improve the pulp characteristics Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Description Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Reduction in water pollution load Equipment /Process Modifications The implementation of this technology requires installation of paddle washers, rotary drum drain and screw press Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User 200,000 50,000 years Contacts of Equipment Supplier Name Shreyans Industries Limited Name Address Ahmedgarh, Dist Sangrur Punjab, India Address Telephone Telefax E-mail (91) 1675 40 347/40 349 (91) 1675 40 512 shreyans.ed@smx.sprintrpg.ems.v snl.net.in Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Agro Pulping Machinery Pvt Ltd th Krishnan Complex, Floor, 39-B, Chevalier Sivaji Ganesan Road, T.Nagar, Chennai – 600 017 India (91) 44 434 0698/ 434 4491 (91) 44 434 5578 chellam@giasmd01.vsnl.net.in chellam@vsnl.com Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: Title of Technology: Hydrodynamic Separator for Raw Material Recovery Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage ' Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: This technology is applied in the papermaking section to recover raw material and reduce pollution loads A new design of storage tank, “the hydrodynamic separator”, is installed above the pulper on the paper making machines, which replaces the conventional white water tanks White water is pumped directly from the paper machine wire pit and press section to the hydrodynamic separator The white water enters the separator at an angle designed to induce a cyclonic flow, which holds the solids in suspension towards the inner shell of the vessel Clear water separates and flows inwards below the annular baffle, overflowing the central circular weir when the separator is full The solids are concentrated at the bottom of the separator, ready for the next pulper recharge The conical base of the hydrodynamic separator is shaped to release solids, reducing the number of blockages and therefore cutting maintenance requirements Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Description Reduction in solids drain loss from 3.4% to 1.2% Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Solids removal by 42 to 96.5 % Equipment /Process Modifications In case of mills having white water tanks, retrofitting of the existing tanks and piping network will be required In case of mills not having white water tanks, installation of the entire system is required Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period 102,000 for a 10,000 tons/ annum capacity mill Contacts of Successful User Contacts of Equipment Supplier Name Address Telephone Telefax E-mail Arjo Wiggins Fine Papers Ltd Stowford Mill, Ivybridge, Devon, PL21 0AA United Kingdom (44) 1752 612 138 (44) 1752 612 103 Approx 80,000 13 – 19 months Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Indigenous Development Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: Title of Technology: Dry and Wet Cleaning of Straw Technology Applied in: ' Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: This technology is applicable in the agro-based mills, where the raw material poses a problem due to higher amount of contaminants This technology uses washers to wash the straw and to remove unwanted part of the straw by use of a dregs remover This kind of dry-wet straw material preparation can remove mud, sand, grains, leaves and nodes, which can not turn into fibres but consume chemicals in the course of digesting and bleaching This process improves pulp quality and reduces the quantity of pollutants generated in black liquor Mud, sand and grains removal upto 0.3 to 0.7 %, leaves and nodes removal upto to % are achievable with this technology Reduction in the hybrid cell content in the pulp is upto % In addition, silica content of black liquor is reduced from 4.14 g/L to 3.59 g/L, which is favorable for alkali recovery Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Description Optimum utilization of raw material Savings in chemicals by 2% Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Reduction in water pollution Equipment /Process Modifications For implementation of this technology, the feeding mouth of the four roller feeder needs to be reduced and the hoppers also need to be modified An additional screw conveyor to transfer the raw material is required and the dregs remover needs to be replaced by dehydroextractor Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Contacts of Equipment Supplier Widely used in China For specific application, please contact equipment supplier Name Western Machinery Supplier Zhenjiang Light Ind Machinery Plant Jiangsu Province PR China Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: RAW STRAW SHED FOUR ROLLER FEEDER # BELT CONVEYOR # BELT CONVEYOR WASHNG MASHINE 1# METERING DEVICE 2# METERING DEVICE DEHYDROETRACTY OR SCREW 1# BELT CONVEYOR # BELT CONVEYOR 2# BELT CONVEYOR DIGESTER Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: Title of Technology: Application of Four Stage Counter-Current Vacuum Drum Washers System for Extraction of Black Liquor Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: Four countercurrent vacuum washers are used in this system The suction of the four vacuum washers is maintained at 0.02 mPa The temperature of the black liquor entering the washers o is maintained at 60 C and the residual alkali value after washing is achieved at a concentration of less than 0.28 g/L The requirement of the baume degree of the black liquor o before extraction is Baume According to the washing performance of straw pulp, in order to keep a certain suction of the vacuum washers, lower pulp level, low rotation revolving of drum and high thickness black liquor in operation are adopted The operation requires onethird wash drum to be immersed in pulp in order to keep the operation at low pulp level According to the diversities of raw material and their filterability, different thickness of feed pulp are chosen to raise the dryness of the pulp after washing In the equipment operation, it is important to avoid the black liquor flow back to the vacuum washing system to influence the steady state of suction After going through the pulp washing system, the black liquor extraction ratio reaches 80 to 85 % level The higher concentration of the black liquor benefits the alkali recovery Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Description Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Reduction in water consumption by 80% Equipment /Process Modifications This technology requires addition of four stage countercurrent vacuum washers system as an add-on equipment with minor modifications in the existing system Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period 240,000 Contacts of Successful User Contacts of Equipment Supplier Name Address 42,000 Zhejiang Minfeng Group Corporation 70 # Luli Street, Jiaxing Zhejiang Province PR China Xi’an Paper-making Machinery Plant Shannxi Province Name Address PR China Telephone Telefax E-mail Telephone Telefax E-mail Block Diagram of Adopted CP Technology: 1st VACUUM WASHER 2nd VACUUM WASHER 3rd VACUUM WASHER 4th VACUUM WASHER CRUDE PULP BLOW TANK BLACK LIQUIOR FIBRE TRAP BLACK LIQUIOR BLACK LIQUIOR BLACK LIQUIOR BLACK LIQUOR ALKALI RECOVERY 1# BLACK LIQUIOR STORAGE TANK 2# BLACK LIQUIOR STORAGE TANK 3# BLACK LIQUIOR STORAGE TANK 4# BLACK LIQUIOR STORAGE TANK Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Name Address Telephone Telefax E-mail Star Paper Mills Ltd Saharanpur Uttar Pradesh India (91) 132 727 520/ 727 531 (91) 132 726 283 20,000 3,000 Contacts of Equipment Supplier Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Praneet Enviroquips Pvt Ltd 91, Industrial Area Phase II Chandigarh 160 002 India (91) 172 652 138/ 652 753 (91) 172 547 187 Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 14 Title of Technology: Extraction of Black Liquor Using Screw Press Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: For agro-residue based mills, having no chemical recovery system in place, extraction of black liquor using screw press before pulp washing will reduce the water and time requirement for lignin removal The extracted black liquor having high solid content can be reused as secondary fuel after solar evaporation and mixing with agro washes viz straw screenings, pith etc In addition to this, part of the recovered black liquor can be reused for impregnation to utilize residual cooking chemical and heat For black liquor extraction, one of the low cost option is the installation of screw press in between blow tank and pulp washer Part of black liquor is used for pulp dilution and part for treatment and disposal This system reduces the washing time by 50 % Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Description Reduced energy for pulp washing Reduction fibre loss at washing stage Reduction in water requirement (50%) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Equipment /Process Modifications Implementation of this technology requires screw press, high pressure and high solids handling pump and black liquor collection tank for recycle/ reuse Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Name Address Telephone Telefax E-mail Bindlas Duplex 85 Km Stone, Bhopa Road Muzaffarnagar,Uttar Pradesh India (91) 132 402 519/ 401 419 (91) 132 401 619 5,000 3,000 Less than a year Contacts of Equipment Supplier Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Risha Industries 3E-110, Nehru Nagar Gaziabad, Uttar Pradesh India (91) 575 872 0842/ 865 2753 (91) 575 870 2007 Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 15 Title of Technology: Disc Cutter for Removal of Non-Cellulosic Material from Straws Technology Applied in: ' Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: For removal of non-cellulosic material like leaf, fines and dust from straws having moisture less than 15%, disc cutter alongwith air blower and cyclone can be employed in the raw material preparation stage Removed material can be used as fuel after briquetting or mixing with concentrated black liquor In addition to reduction in consumption of chemicals, energy, this process also increases the production capacity and reduces the pollution load This process also reduces the silica content in the black liquor thereby enabling the chemical recovery Implementation of this technology increased the pulping capacity by 28% and reduced the screw rejects by 20 to 25%.This process is highly suitable for small scale pulp mills This system has been installed at a 10 TPD plant at Central Pulp and Paper Research Institute, India Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Description Reduced electricity consumption (15-20%) Reduction in cooking chemicals (20%) Reduction in water pollution load (20-25%) Equipment /Process Modifications The implementation of this technology requires additional equipment like air blower, screw conveyor, disc mill, cyclone, collection chute and briquetting machine Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Name Address Central Pulp and Paper Research Institute Post Box 174, Saharanpur Uttar Pradesh 247 001 India Telephone Telefax E-mail 60,000 10,000 Less than years Contacts of Equipment Supplier Indigenous Development Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Screw Feeder Magnetic Separator Disc Mill Cyclone Separator Universal Separator Blower Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 16 Title of Technology: Raw Material Impregnation with Recycled Black Liquor for Unbleached Grade Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: In small pulp and paper mills having no chemical recovery of black liquor, residual alkali and heat is discharged into drain Discharged black liquor generates high pollution load to be treated in the effluent treatment plant and this process leads to non-utilization of valuable resources In small pulp and paper mills principally manufacturing unbleached paper grade, black liquor can be used for impregnation of raw material before pulping Proper impregnation not only utilizes the residual resources but also ensures uniform wetting and pulping In addition to this, for light raw material like straw, packing density of digester is also improved after impregnation, resulting into increased pulping capacity (as high as to 10 %) The low bath ratio cooking leads to reduced water requirements Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Description Reduction in steam requirement by to 8% Reduction in pulping chemicals by to % Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Equipment /Process Modifications The implementation of this technology requires additional equipment like belt conveyor, liquid feed tank, showers/ nozzles, black liquor tank and paddle mixer Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Name Address Telephone Telefax E-mail Raval Paper Limited A-6-7, Industrial Area Raibareli India (91) 535 803 3169 5,000 to 7,000 2,000 to 3,000 Less than years Contacts of Equipment Supplier Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Risha Industries E-110, Nehru Nagar Ghaziabad, Uttar Pradesh India (91) 575 872 0842/ 865 2753 (91) 575 870 2007 Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 17 Title of Technology: Process Control Using Freeness Measurement Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage ' Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: This instrument is used for measuring the freeness intermittently and could be used to control refining process Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Equipment /Process Modifications Description Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period US $ 15, 000 per unit (USA made) Negligible on overall operating cost Contacts of Successful User Contacts of Equipment Supplier Name Address Weyhaeuser Plymouth Mill North Carolina USA Name Address Telephone Telefax E-mail Block Diagram of Adopted CP Technology: HONEYWELL Black Cannyon Hwy 85 023 – 3099 Phoenix ARIZONA, USA (1) 603 313 5846 (1) 603 313 4696 Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 18 Title of Technology: Oxygen Delignification for Agro-based Pulp Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: Bleaching of pulp in the paper mill is carried out in multi-stages using various bleaching chemicals such as chlorine, hypochlorite and chlorine dioxide to achieve brightness of pulp Chlorine compounds in bleaching generate toxic effluents having poor degradability Chlorinated compounds are replaced by oxygen, ozone or hydrogen peroxide bleaching mainly for wood pulp bleaching and has not been applied for non-wood fibres so far As per experience from wood pulp, pre-bleaching with oxygen reduces the lignin content by almost 50% With this, requirement of bleaching chemicals has reduced drastically Oxygen delignification at alkali extraction stage reduces the AOX (toxicity) level considerably and increases the delignification degree Oxygen can be applied on pre-bleaching stage to reduce kappa number This is a well applied technology for wood based mills Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Description Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Reduction in BOD, COD values by 60 %, reduction in color by 80 % Equipment /Process Modifications The implementation of this technology requires additional equipment like oxygen generator, mixers, agitators and metering pumps Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Name Address Telephone Telefax E-mail Phoenix Pulp & Paper Public Co.Ltd 99 Moo 3, Tambol Kudnarnsai Amphur Nampong, Khon Kaen THAILAND (66) 4343 1504 – 6/ 4337 3406 - (66) 4337 3406/ 4337 3412 Phoenix@khonkaen.a-net.net.th 150,000 20,000 Contacts of Equipment Supplier Name Sund Defibrator AB Address SE 851 94 Sundsvall,Sweden Telephone Telefax E-mail (46) 60 155500/165151 (46) 60 165500 Block Diagram of Adopted CP Technology: Goran.rydin@sundsdefibrator.com Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 19 Title of Technology: Defibrisation of Agro-based Pulp as Alkaline Hot Stock Refining Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment ' Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: Refining requirements vary according to raw material used and final product quality However, refining requirements for agro-based pulp having short fibres are bare minimum and the process is actually defibrisation rather than refining Conventionally, refining is done after pulp washing i.e in cold and neutral pH Due to morphology of agro based pulp having short fibre length (like straws), during refining, there is more possibility of breaking fibres into smaller fibres (fragments), which generate higher pollution load Hot stock refining before washing pulp in alkaline medium avoids over refining due to its slippery action and energy requirements are also reduced considerably Hot stock refining has been adopted successfully in few mills using straw as raw material This technology also results in reduction in screening rejects percentage and improved runability of machine due to lesser percentage of fine fibres Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Description Reduction in fibre losses Reduction in water pollution load Equipment /Process Modifications The implementation of this technology requires altering of sequence of washing and refining In mills operating without a blow tank, installation of blow tank is necessary Costing Details Capital Cost: US $ Operating Costs US $ per year Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User 3,000 to 7,000 Nil Less than months Contacts of Equipment Supplier Name Address Ashoka Pulp and Paper Mills 2, Jawahar Nagar, Loni Road, Shahdara 110 032 New Delhi India Name Address Telephone Telefax E-mail (91) 11 228 3660 (91) 11 229 3660 Telephone Telefax E-mail Block Diagram of Adopted CP Technology: Vaishnav Steel Pvt Ltd 27-B, Industrial Estate, Merut Road, Muzaffarnagar 251 002 Uttar Pradesh India (91) 131 408 650/ 404 020 (91) 131 405 956 Technology Fact Sheet for Cleaner Production in Pulp and Paper Industry + ' / Network for Industrial Environmental Management UNEP – ROAP, Bangkok, Thailand School of Environment, Resources and Development Asian Institute of Technology Bangkok, Thailand Fact Sheet No: 20 Title of Technology: Secondary Fiber Technology for DI : Dispersion System Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage ' Pulping Stage Chemical Recovery Stage Stock Preparation Stage Utilities/ Effluent Treatment Technology Implementation Results in Reduction of: Energy Consumption Pollution Volume/ Load ' Others Process/Technology Description: The objective of dispersion of deinked pulp after the flotation process in deinking is to reduce the visible particles to a size it becomes invisible to the eye The system is essentially made up of : (1) Screw press to raise consistency from 6% to 28% o (2) Preheater with steam supply to raise the temperature to 105 C at atmospheric temperature (3) Disc disperser to work at consistencies of 25-35%, to reduce the visible particles so that it could not be detected by the eye The power requirement is 190 – 200 kW for the disc disperser alone Benefits and Investments Required: Expected Benefits (In absolute figures or % ) Reduction in Utilities Requirement • • • • Electricity consumption (kWh) Wood/Fibre consumption (t/d) Water consumption (m3) Steam requirement (t/h) Reduction in Chemicals Requirement Reduction in Pollution Generation • • • Water (BOD/COD/volume/toxicity) Solid waste (kg/day) Air emissions (Flow/SOx,NOx) Equipment /Process Modifications Description Costing Details Capital Cost: US $ Operating Costs US $ per year The total cost for the screw press , preheater screw for shredding , conveying , mixing and the disc disperser is US $ 900 000 (German made) To work the full dispersion system the power requirement would be about 300 kW for 100 tons per day deinked pulp Calculate the energy cost based on local cost Savings : US $ per year Power: Chemicals: Treatment costs: Manpower: Payback Period Contacts of Successful User Contacts of Equipment Supplier As this unit has to be engineered based on local conditions and quality of waste paper used, write to the equipment supplier for specific details Name Address J.M VOITH Postfach 1940 D7920 Heidonheim GERMANY Name Address BELOIT ITALIA Via Porro 11 S Pietro V.L Torine 1- 10060 ITALY (39) 12 123 1402 (39) 12 139 7637 Telephone Telefax Block Diagram of Adopted CP Technology: ... Separator for Raw Material Recovery Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage '' Pulping Stage Chemical Recovery Stage Stock... thus increasing the water requirements in the plant and increasing the requirements of wastewater treatment By making changes in the water loops and piping network, the sealed water can be used in. .. System in the Paper Cutting Operation Technology Applied in: Raw Material Preparation Stage Bleaching Stage Recycled Fiber Technology Paper Making Stage '' Pulping Stage Chemical Recovery Stage Stock