1. pulp & paper industries

Gujarat Cleaner Production Centre

CLEANER PRODUCTION

OPPURTUNITIES

PULP &PAPER SECTOR

Gujarat Cleaner Production Centre - ENVIS Centre

CLEANER PRODUCTION

OPPURTUNITIES

IN

PULP &PAPER SECTOR

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CLEANER PRODUCTION

PULP &PAPER SECTOR


INTRODUCTION

1.1 Pulp and Paper

(Ref. EIA Guideline, Nov2011report)

Pulp and paper are manufactured from raw

include wood, recycled paper, and agricultu

production to make different streng

from using cotton rags for paper production and wood

fibre. The global pulp and paper industry consists of

and an equal number of very small companies.

other materials, such as rags, wastepaper

are engaged in manufacturing

products. Indian paper mills can be categorized based on raw

mills, agro-based mills and wastepaper based mills. The major products from these mills are

paper, paper boards and newsprints.

development, while it is associate

footprints on environmental resources.

of its development. The need for documentation of knowledge and record keeping has long been

perceived to be linked to the intellectual prowess of a nation. The tradition of use

patra” – or the bark of the “Bhoj” Tree for documentation of our

world over. Such recording pre-

substances. As time progressed, the

by civilizations. It was here that the Chinese made their first attempt to manufacture paper from

plant resources. Historians believe tha

makers - the kagzi’s- in the country as they expanded their

the first modern paper mill was set up in Sreerampur, West

process for paper making developed in the

paper in India has seen over a century and a half pass by.

very little soft wood for the manufacture of

wood, there was a problem in using them for harder indigenous raw materials. In the year 1914, a

process was developed to use bamboo for paper making. This provided the


(Ref. EIA Guideline, Nov2011report)

Pulp and paper are manufactured from raw materials containing cellulose fibres, which

include wood, recycled paper, and agricultural residues. There are several methods of pulp

production to make different strengths and grades of paper. In the 1800s, there was a shift away

s for paper production and wood became the most important source of

and paper industry consists of about 5000 industrial pulp and paper mills

number of very small companies. Pulp mills separate the fibres from wo

rials, such as rags, wastepaper or straw in order to create pulp. Paper mills primarily

cturing paper from pulp and may also manufacture converted pap

can be categorized based on raw materials viz. wood/fores

and wastepaper based mills. The major products from these mills are

, paper boards and newsprints. Pulp and Paper industry plays a vital role in socio

associated with significant environmental concerns

environmental resources. The use of paper by a society is often taken as a yardstick

The need for documentation of knowledge and record keeping has long been

ived to be linked to the intellectual prowess of a nation. The tradition of use

or the bark of the “Bhoj” Tree for documentation of our scriptures is acknowledged the

-dates most of the earliest known documentation on paper like

substances. As time progressed, the need for cheaper means of documentation of records was felt

was here that the Chinese made their first attempt to manufacture paper from

plant resources. Historians believe that it was the Moghals, who introduced the

in the country as they expanded their empire in India. It was in 1832 that

the first modern paper mill was set up in Sreerampur, West Bengal, using the mechanized

paper making developed in the western world. Thus the journey of machine made

a century and a half pass by. Unlike the West, however, India ha

manufacture of paper. Since machines were designed to

problem in using them for harder indigenous raw materials. In the year 1914, a

process was developed to use bamboo for paper making. This provided the requi

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taining cellulose fibres, which generally

methods of pulp

1800s, there was a shift away

became the most important source of

about 5000 industrial pulp and paper mills

Pulp mills separate the fibres from wood or from

or straw in order to create pulp. Paper mills primarily

paper from pulp and may also manufacture converted paper

materials viz. wood/forest based

and wastepaper based mills. The major products from these mills are

Pulp and Paper industry plays a vital role in socio-economic

due to its large

he use of paper by a society is often taken as a yardstick

The need for documentation of knowledge and record keeping has long been

ived to be linked to the intellectual prowess of a nation. The tradition of use of ‘bhoj –

scriptures is acknowledged the

entation on paper like

need for cheaper means of documentation of records was felt

was here that the Chinese made their first attempt to manufacture paper from

traditional paper

It was in 1832 that

Bengal, using the mechanized

western world. Thus the journey of machine made

Unlike the West, however, India had

paper. Since machines were designed to process soft

problem in using them for harder indigenous raw materials. In the year 1914, a

required impetus to


the paper making operations in the country.

the fortunes of the paper industry in its

scenario.

Figure 1 : Road Map Of Indian Paper Industries

1.2 GROWTH OF INDIAN

Figure 2 : Growth Of Indian Paper Industries


operations in the country. Figure 1 shows some of the major eve

the paper industry in its journey from a single unit in 1832, to the present day

Figure 1 : Road Map Of Indian Paper Industries

1.2 GROWTH OF INDIAN PAPER INDUSTRY

Of Indian Paper Industries

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some of the major events that shaped

journey from a single unit in 1832, to the present day


1.3 Classification of Papers

(Ref : EIA Report)

In India, paper and board types produced (Table 2

categories on the basis of intended use:

1. Printing and writing (graphic) papers

Printing and writing papers comprise one of the larges

include copier paper, stationery, computer printout, offset paper, and notepads.

broadly classified into those containin

mainly used in mass-produced p

applications. Each category can again be either coated

2. Industrial papers

Industrial paper is a term used to describe p

paper, therefore, includes building papers, insu

etc. Packaging paper may include high

some cases surface treated, multi

made from fresh unbleached pulp or recycled

quality, also accounts for a portion of

3. Special papers

These cover a wide range of paper types which cannot be specifically allocated to the two

product groups described above,

� papers for hygiene applications (tissues, kitchen rolls, toilet paper)

� filter papers for use in industry, t

� transparent papers for drawing

� photographic papers

� base paper for parchment, vulcanized fibre

� cigarette paper

� capacitor paper, etc.


1.3 Classification of Papers

In India, paper and board types produced (Table 2.1) are classified into the following broad

categories on the basis of intended use:

1. Printing and writing (graphic) papers

Printing and writing papers comprise one of the largest categories of paper products.

include copier paper, stationery, computer printout, offset paper, and notepads.

broadly classified into those containing wood and those not containing wood pulp. The former is

produced papers, while the latter is used for high quality and special

applications. Each category can again be either coated or uncoated.

Industrial paper is a term used to describe paper manufactured for industrial uses.

paper, therefore, includes building papers, insulating papers, wrapping papers, packaging papers,

. Packaging paper may include high-quality packaging materials for food and luxury goods, in

ulti-layer or coated for costly print processes. Corrugated board,

esh unbleached pulp or recycled corrugated board (a rising trend) depending on

also accounts for a portion of industrial papers in quantity terms.


product groups described above, e.g.:

papers for hygiene applications (tissues, kitchen rolls, toilet paper)

filter papers for use in industry, the home, the laboratory etc.

transparent papers for drawing

base paper for parchment, vulcanized fibre

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classified into the following broad

t categories of paper products. Examples

include copier paper, stationery, computer printout, offset paper, and notepads. This paper is

wood pulp. The former is

for high quality and special

nufactured for industrial uses. Industrial

packaging papers,

food and luxury goods, in

print processes. Corrugated board,

corrugated board (a rising trend) depending on



Table 1.1: Consumption Pattern of Paper and Paper Boards in India

Type of Paper

Cultural paper

Industrial paper

Specialty paper

Newsprint

1.4 Size of the Industry

(Ref : EIA Report)

In India, the industry is classified into following categories based on its production

1. Large scale : Greater than 33,000 tonnes per annum (TPA) of production

2 Medium scale : between 10,000 and 33,000 TPA

3 Small scale : Less than 10,000 TPA

1.5 Structure of Indian Paper Industry

(Ref : CPPRI Benchmarking Report)


: Consumption Pattern of Paper and Paper Boards in India

Main Varieties % of Total

Consumptions

Cream woven, maplitho, bond

paper, Chromo paper

41%

Kraft paper, paper board –

paper board – single layer

board, multilayer board,

duplex board

43%

Security paper, grease proof

paper, electrical grades

of paper

Glazed, non-glazed 12%

In India, the industry is classified into following categories based on its production

Greater than 33,000 tonnes per annum (TPA) of production

2 Medium scale : between 10,000 and 33,000 TPA

3 Small scale : Less than 10,000 TPA

Structure of Indian Paper Industry

(Ref : CPPRI Benchmarking Report)

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: Consumption Pattern of Paper and Paper Boards in India

% of Total

Consumptions

41%

43%

4%

12%

In India, the industry is classified into following categories based on its production capacity:


Figure 3 :

1.6 Scenario of Export/Import of paper/paper board and newsprint(Ref Nov 2011)

Particulars 2001

- 02

2002

-

Paper /

Paper

Board

Export 0.180 0.220

Newsprint Export 0.001 0.006

Total

Export

0.181 0.226

Paper /

Paper

Board

Import 0.11 0.15

Newsprint Import 0.45 0.54

Total

Import

0.56 0.69


: Structure of Indian Paper Industry

Scenario of Export/Import of paper/paper board and newsprint

2002

- 03

2003

- 04

2004

- 05

2005

- 06

2006

- 07

2007

- 08

2008

-

0.220 0.230 0.280 0.304 0.339 0.325 0.334

0.006 0.003 0.005 0.008 0.004 0.004 0.006

0.226 0.233 0.285 0.312 0.343 0.329 0.340

0.15 0.240 0.19 0.291 0.348 0.451 0.437

0.54 0.77 0.68 0.69 0.79 0.89 0.97

0.69 1.01 0.87 0.981 1.138 1.341 1.407

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Scenario of Export/Import of paper/paper board and newsprint

2008

09

2009

- 10

2011

- 12

0.334 0.389 0.518

0.006 0.013 0.009

0.340 0.382 0.527

0.437 0.614 0.632

0.97 0.85 0.95

1.407 1.464 1.582


1.7 Geographical distribution of Pulp and Paper Industry In India

1.8 PRESENT SCENARIO

Raw Material Consumption Pattern

Year

1970

2000


Geographical distribution of Pulp and Paper Industry In India

PRESENT SCENARIO 2013

Raw Material Consumption Pattern

% Share

Wood Agro Residue

84 9

39 31

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Geographical distribution of Pulp and Paper Industry In India

Waste Paper

7

30


2012

Comparision of Waste Paper Recovery Rate In India With Developed Countries

Comparision of Per Capita Consumption of Paper In India With Global

0

20

40

60

80

% Recovery of Waste Paper

0

100

200

300

400

USA

Fin

lan

d

Be

lgiu

m

Jap

an

Ca

na

da

Taiw

an

Avg Kg Per Capita Consumption of Paper


31 22


Capita Consumption of Paper In India With Global

% Recovery of Waste Paper

German

Swedan

Japan

Western Europe

USA

Italy

India

Taiw

an

Sin

ga

po

re

Sw

itze

rla

nd

De

nm

ark

Ne

wZ

ea

lan

d

Sw

ed

en

Ho

lla

nd

UK

Ge

rma

ny

Ch

ina

Ind

on

esi

a

Ma

laysi

a

Ind

ia

Per Capita Consumption of Paper

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47


German

Swedan

Japan

Western Europe

USA

Italy

India

USA

Finland

Belgium

Japan

Canada

Taiwan

Singapore

Switzerland

Denmark

NewZealand

Sweden

Holland

UK

Germany

China


1.9 General Steps For Manufacturing Process Of Waste Paper Industries

(1) Collection Of Waste Paper

Industrial waste paper is collected mainly from different sources such as publisher, printing

house, converters & departmental stores, super markets and mostly dealers of industrial waste.

Old newspaper, magazines and other wastepaper is collected by door

source of collection.

(2) WASTE PAPER PROCESSING

The 2 key goals of waste paper recycling operations are defibration and contaminant removal.

Now a days the process generally include pulping, screening, cleaning and deinking by

combination of soaking, flotation and washing depending upon the input raw material and final

product.

(3) PULPING

Pulping is the first unit operation in the recycling and deinking process. The pulping process is to

facilitate the separation of the non

contaminants in subsequent processes.

4) SCREENING & CLEANING

The objective of both screening and cleaning is the removal of non

minimal losses of useful fibre. Separation depends on physical differences, for example, in

screening size and shape are most important whilst in centrifugal cleaning

important difference. The low consistency equipment is operated after high consistency to avoid

the costs of consistency changes. The sequence used is also in the order of decreasing

contaminant size.

(5) Pressure screens

In this a wooden scraper or non contacting foil is used to provide the pressure pulse and to keep

the face of the screen clear. A mat forms readily on the face of the screen since water passes

through the screen plate orifices more easily than fibres. Fines perforatio

0.15mm can now be machined with accuracy in screen basket with advent of Laser rays. Screen

control system is very complex has supervisory & regulatory loops for each screen.



Collection Of Waste Paper



Old newspaper, magazines and other wastepaper is collected by door-to-door basis, is another

(2) WASTE PAPER PROCESSING



ombination of soaking, flotation and washing depending upon the input raw material and final


facilitate the separation of the non-fibrous material from the fibres and to remove the

contaminants in subsequent processes.

4) SCREENING & CLEANING

objective of both screening and cleaning is the removal of non-fibrous contaminants, with


screening size and shape are most important whilst in centrifugal cleaning density is the most



oden scraper or non contacting foil is used to provide the pressure pulse and to keep


through the screen plate orifices more easily than fibres. Fines perforations down to the size of



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door basis, is another



ombination of soaking, flotation and washing depending upon the input raw material and final


fibrous material from the fibres and to remove the

fibrous contaminants, with


density is the most



oden scraper or non contacting foil is used to provide the pressure pulse and to keep


ns down to the size of




(6) Centrifugal cleaning

It is useful for removal of high and low density contaminants.

cleaners remove medium size contaminants with a high specific gravity such as paper clips,

glass, grit, etc. It is the first cleaners after the pulping system and

operates more accurately at medium consistency between 2.5 to 5%.

(7) Dispersion and Kneading

The emergence of polymeric inks used in laser printers and copier papers necessitated usage of

dispersion and kneading equipment

efficient ink removal from the fibre. Dispersion also replaces deinking

removed so that there is no specky appearance. Temperature up to 150oC helps to melt the

stickies and reduce biological activity. Only disadvantage is high energy cost.

They are usually known as kneaders

shearing with a twisting & compressive action on fibres with no cutt

interactions forces are generated similar to high consistency pulper. If required steam is added,

exit temperature can be quite high (70

is effective for deinking when large spe

coated, offset, etc. A slow speed single shaft kneader reduces ink speck size successfully.

Brightness fell very slightly and is a indicator that ink has dispersed. Smaller ink specks have a

greater surface area and so absorb more light which results in a lower brightness. Kneading

reduces the long fibre content and create some fines and results in small change in freeness.

High-speed units:- They are known as

refiners with two plates one fixed & the other rotating at high speed. The reduction in brightness

shows effective ink removal with no change in fibre length and no fines creation as in slow speed

kneading, though freeness fell significant

of a waste paper processing line. In this location they are very successful in contaminants

dispersion, which substantially improves paper machine operation due to less deposition

problems with stickies.Visual quality is improved due to speck size reduction. Some installation

have high speed dispersion units following pulping in high quality printing & writing as well as

OCC recycling.


It is useful for removal of high and low density contaminants. High density high consistency

remove medium size contaminants with a high specific gravity such as paper clips,

glass, grit, etc. It is the first cleaners after the pulping system and operates at high consistency. It

operates more accurately at medium consistency between 2.5 to 5%.


dispersion and kneading equipment. It breakdowns large ink flakes to a size, which helps more

efficient ink removal from the fibre. Dispersion also replaces deinking – ink is dispersed but not


s and reduce biological activity. Only disadvantage is high energy cost. Low

kneaders and have single, double or triple shaft. The action is gentle

shearing with a twisting & compressive action on fibres with no cutting since inter


exit temperature can be quite high (70-80oC) due to the friction forces generated. The approach

is effective for deinking when large specks are created for eg. Laser printed, xerographics, UV



urface area and so absorb more light which results in a lower brightness. Kneading


They are known as dispersers or dispergers and have single s



kneading, though freeness fell significantly. High speed dispersion units are installed at the end



ies.Visual quality is improved due to speck size reduction. Some installation


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High density high consistency

remove medium size contaminants with a high specific gravity such as paper clips,

operates at high consistency. It


. It breakdowns large ink flakes to a size, which helps more

ink is dispersed but not


Low-speed units:-

and have single, double or triple shaft. The action is gentle

ing since inter-fibre


80oC) due to the friction forces generated. The approach

cks are created for eg. Laser printed, xerographics, UV



urface area and so absorb more light which results in a lower brightness. Kneading


or dispergers and have single shafts similar to



ly. High speed dispersion units are installed at the end



ies.Visual quality is improved due to speck size reduction. Some installation



(8) Deinking

Generally ink constitute 0.5 to2% of the mass of the waste paper. Deinking can be done by two

methods, washing and flotation depending upon the requirement. The washing deinking is less

effective in the removal of large ink specks >20 microns where as flot

effective in removal of small ink specks <20 microns. Though smaller particles can be removed

by flotation if they are agglomerated to form large particles. Better results are achieved by

combination system of the above two methods.

as centrifugal cleaners. Most ink is removed by either or both flotation and washing.

(I) WASHING DEINKING

Ink is broken up on pulping and some of these ink particles are removed by subsequent wash

stages with the washer filtrate. This is very effective even without pulping aids or without the use

of chemicals such as caustic, sodium silicate, dispersant and H2O2 in pulper. Methods for wash

deinking are thickening processes using a mechanical separation proc

separated from fibres by a separating element frequently a synthetic wire. The efficiency of wash

deinking is determined by the speed of mat formation & the thickness or basis weight of the mat.

Washing efficiency is also affected by

before the washing stage usually during pulping. Screw presses have been used for many years in

deinking both as wash units and thickeners. Drum washers or gravity deckers have become less

popular with the introduction of belt washers. Disc & vacuum filters are used as thickeners rather

than washers but with the same concept. The water ink emulsion is washed from the pulp and the

ink is removed from the wash water by flocculation or flotation using suit

clarified water may be reused in the system. The counter current washing is common in washing

deinking.

(II) FLOTATION DEINKING

Flotation is a process that separates materials based on the property of wettability. With the

exception of water based inks, ink particles are more hydrophobic than paper fibres which is the

basis of separation by flotation. Some fibre can be hydrophobic & some inks can be hydrophilic.

Chemicals are added to increase this difference between fiber and inks. Hydr

are able to adhere to the air bubbles and rise to the surface, the process is carried out in flotation.




effective in the removal of large ink specks >20 microns where as flotation deinking is less



combination system of the above two methods. Although some ink is removed by screens as well



ith the washer filtrate. This is very effective even without pulping aids or without the use


deinking are thickening processes using a mechanical separation process. Ink particles are



Washing efficiency is also affected by variables such as pH, temperature and treatment given



the introduction of belt washers. Disc & vacuum filters are used as thickeners rather


ink is removed from the wash water by flocculation or flotation using suitable chemicals. The


FLOTATION DEINKING


water based inks, ink particles are more hydrophobic than paper fibres which is the


Chemicals are added to increase this difference between fiber and inks. Hydrophobic materials


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ation deinking is less



Although some ink is removed by screens as well



ith the washer filtrate. This is very effective even without pulping aids or without the use


ess. Ink particles are



variables such as pH, temperature and treatment given



the introduction of belt washers. Disc & vacuum filters are used as thickeners rather


able chemicals. The



water based inks, ink particles are more hydrophobic than paper fibres which is the


ophobic materials



Large ink particles size 10-50 micron can agglomerate and skimmed out from the slurry. The

system efficiency depends upon the various

chemicals, water hardness, ink particle size, air bubble diameter, air to stock ratio and foam

removal system. Ink removal efficiency is better at the lower consistency. At a temperature range

of 40-45oC and pH of 6-9 the best brightness are obtained.

1.10 CORE ENVIRONMENTAL ISSUES

� Plastic waste is generated after screening in poire. It is hazardous material as per

GPCB norms. Normally Paper industries send the plastic waste to the cement

industries and do not apply any method for further reuse

� Fly ash is generated from boiler in very high amount. But the industry sold it

to the brick industry. They do not apply any new technology for further

� De inking sludge is generated due to chemical addition in the

board and printing press paper

to the CETP (Common Effluent Treatment Plant) for landfilling. But in fu

land available for landfilling if do not find technological option for reuse, recycle or

reduction etc.

� Pulp goes to effluent from diabole equipment and centricleaner about 500

� Steam losses from open drying system is about 15% to 2

has been applied.

� Equipment modifications are required for better process control, reduce water

consumption and also energy consumption.

� Loss of fibers from centricleaner and paper M/C head box due to poor

Maintainance and handling operations.

� In duplex board, newsprint and printing press industries, are using alum as a

sizing agent which reduce drainability, fiber retention and disables manufacturing

of high grammage paper. It also increases total suspended particles in effluent.

� Consistency indicator and regulator do not install for better quality of paper.

� Lower consistency pulper is used for pulp preparation which consumes large

Quantity of water . The number of dryers are increased for removal of water or

moisture from paper for better quality of it which consumes large quantity of

energy.


50 micron can agglomerate and skimmed out from the slurry. The

system efficiency depends upon the various factors like stock consistency, temp, pH, collector



9 the best brightness are obtained.

CORE ENVIRONMENTAL ISSUES

Plastic waste is generated after screening in poire. It is hazardous material as per


industries and do not apply any method for further reuse/recovery/recycle/reduce

Fly ash is generated from boiler in very high amount. But the industry sold it

to the brick industry. They do not apply any new technology for further reuse.

De inking sludge is generated due to chemical addition in the news print, duplex

paper industry. This type of solid waste is directly goes

to the CETP (Common Effluent Treatment Plant) for landfilling. But in fu


Pulp goes to effluent from diabole equipment and centricleaner about 500

Steam losses from open drying system is about 15% to 20 %.No steam recovery

Equipment modifications are required for better process control, reduce water

consumption and also energy consumption.

Loss of fibers from centricleaner and paper M/C head box due to poor

Maintainance and handling operations.

In duplex board, newsprint and printing press industries, are using alum as a


paper. It also increases total suspended particles in effluent.

Consistency indicator and regulator do not install for better quality of paper.

Lower consistency pulper is used for pulp preparation which consumes large

number of dryers are increased for removal of water or


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50 micron can agglomerate and skimmed out from the slurry. The

factors like stock consistency, temp, pH, collector



Plastic waste is generated after screening in poire. It is hazardous material as per


/recovery/recycle/reduce.

Fly ash is generated from boiler in very high amount. But the industry sold it

reuse.

news print, duplex

industry. This type of solid waste is directly goes

to the CETP (Common Effluent Treatment Plant) for landfilling. But in future there is no


Pulp goes to effluent from diabole equipment and centricleaner about 500 kg/day.

0 %.No steam recovery

Equipment modifications are required for better process control, reduce water

In duplex board, newsprint and printing press industries, are using alum as a


paper. It also increases total suspended particles in effluent.

Consistency indicator and regulator do not install for better quality of paper.

Lower consistency pulper is used for pulp preparation which consumes large

number of dryers are increased for removal of water or



Solid By Streams From Paper Industries

Solid By-

Streams

Dry

solid

(%)

Primary

Sludge

50

Secondary

(Biological)

Sludge

40-50

Deinking

Sludge

56

Coarse

Rejects

(Plastic)

55

Screen

Rejects

(Stickies)

55

1.11 Cleaner Production Inventory Of Application Technologies For Waste

Stream

(1) Use of By-Streams as Such

Land management options

(land spreading, land

restoration)

Absorbent, animal bedding


Solid By Streams From Paper Industries

Organic

matter

(%)

Mineral

matter

(%)

Energy

content

(MJ/tonwet)

Dry Matter

Contents

40 60 2690 Fibres, fillers,

coating clay, calcium

carbonate

50 50 4000-5000 Calcium carbonate,

cupper, micro

organisms,

fibres, proteins.

50 50 3000 Cellulose fibres,

calcium carbonate,

kaolin, ink

92 8 12000 Recyclable fibres,

wet strength fibres,

plastics,

wood, metal, others

90 10 8000 Cellulose, plastics,

hair, stickies

Cleaner Production Inventory Of Application Technologies For Waste

Streams as Such

On-site or

external

Deinking Effluent

sludge

Land management options N/A

N/A

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Dry Matter

Contents

Fibres, fillers,

coating clay, calcium

carbonate

Calcium carbonate,

cupper, micro

organisms,

fibres, proteins.

Cellulose fibres,

calcium carbonate,

kaolin, ink

Recyclable fibres,

wet strength fibres,

plastics,

wood, metal, others

Cellulose, plastics,

hair, stickies

Cleaner Production Inventory Of Application Technologies For Waste

Coarse

rejects

Screen

rejects


Anti-dust

(2) Conversion To Product

Feedstock for other paper grades,

softboard production and cement

bonded sludge board

production

Pyrolysis (chemicals)

For use in cement/asphalt/etc.

production

Synthetic Calcium Carbonate

CDEM

(3) Conversion To Energy

Gasification

Supercritical gasification

Combustion


N/A

On-site

or

external

Deinking Effluent

sludge

Coarse

rejects

Feedstock for other paper grades,

softboard production and cement

External

Onsite

For use in cement/asphalt/etc. External

Both

Both

On-site or

external

Deinking Effluent

sludge

Coarse

rejects

Both

Unknown

Both

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Coarse

rejects

Screen

rejects

Coarse

rejects

Screen

rejects


1.11.1 Eco-Friendly Clean Emerging Techniques

(1) Plastic Waste To :

� Cement Industry By Co

� Fuel/Energy By Plasma Pyrolysis

� Feed Stock For Bituminous Road Construction

� Eco-Friendly Crude Oil By Agilyx Process

(2) De-Inking Sludge To “Topcrete” Substitute Of Cement By

(3) “Das” (Dipolar Aromatic Solvent) Technique For Zero Rejects

(4) New Ecofriendly Technique For Removal Bod,Cod And Colour From Paper Mill Effluent

For Zero Discharge

(5) Reduction Of Tds (Total Dissolved Solid) In Kraft Paper Mill By Surface Sizing And New

Sizing Agent

(6) New Drying Technology For Reduction In Energy

Consumption

� Condebelt Drying Technology

� Boost Dryi

1.11.2 General CP Guidelines for Pulp and Paper Industry

1. Cleaner production measures Raw materials:

� Maintaining moisture content of the raw materials constant all year around.

� Keeping chemical inventory to a minimum and buying small

used materials.

� Steam explosion can be applied as the raw material pretreatment before the digestion step

to reduce the NaOH consumption

2. Cleaner production measures Wood

� Pulp mills integrated with lumbering facilities: a

during debarking; residual or waste wood from lumber processing is returned to the

chipping process; in-house lumbering rejects can be a significant source of wood furnish.


Friendly Clean Emerging Techniques

Cement Industry By Co-Processing

Fuel/Energy By Plasma Pyrolysis

Feed Stock For Bituminous Road Construction

Friendly Crude Oil By Agilyx Process

Inking Sludge To “Topcrete” Substitute Of Cement By CDEM Technology

(3) “Das” (Dipolar Aromatic Solvent) Technique For Zero Rejects



(6) New Drying Technology For Reduction In Energy

Condebelt Drying Technology

Boost Drying Technology

General CP Guidelines for Pulp and Paper Industry

Cleaner production measures Raw materials:

Maintaining moisture content of the raw materials constant all year around.

Keeping chemical inventory to a minimum and buying small containers of infrequently

Steam explosion can be applied as the raw material pretreatment before the digestion step

to reduce the NaOH consumption

Cleaner production measures Wood-yard:

Pulp mills integrated with lumbering facilities: acceptable lumber wood is removed


house lumbering rejects can be a significant source of wood furnish.

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Technology



Maintaining moisture content of the raw materials constant all year around.

containers of infrequently

Steam explosion can be applied as the raw material pretreatment before the digestion step

cceptable lumber wood is removed


house lumbering rejects can be a significant source of wood furnish.


� Avoiding hydraulic debarking

wastewater amount.

� Reusing leachate water.

� Co-production from bark: mulch, ground cover, charcoal.

� Burning bark from debarking and small chips from chipping for energy production

(depends on the moisture content).

� Dry de-dusting of straw for removal of fines and dust / Dry depithing of Bagasse / Dry

debarking of Wood

� The indirect steam digesters are used instead of current direct steam digester for a better

heat contribution. This modification will improve the consistency of cook

3. Cleaner production measures Pulp production:

� Increasing brown stock washing efficiency. Any remaining cooking liquor will increase

the chemical consumption in subsequent stages.

� The quality of bark must be consistent in one cook to obtain the h

cooked pulp.

� Counter current pulp wash is recommended in the washing step instead of batch washing

to save water. The applications of air bubbling and ultrasonic techniques are also of

interest to increase the efficiency of rinsing.

� Water reuse from evaporators. The evaporation plant is always one of the largest steam

consumers in the mill. Condensate might be used instead of fresh water in the mill.

� Repulping the rejects from screening rather than putting them into the landfill.

� Using pulp centrifuging to remove any remaining impurities.

� Sludge utilization by means of land

of concern, as sludge constituents are not well identified.


Avoiding hydraulic debarking – saving energy and water consumption, reducing

production from bark: mulch, ground cover, charcoal.

Burning bark from debarking and small chips from chipping for energy production

(depends on the moisture content).

of straw for removal of fines and dust / Dry depithing of Bagasse / Dry

The indirect steam digesters are used instead of current direct steam digester for a better

heat contribution. This modification will improve the consistency of cook

Cleaner production measures Pulp production:

Increasing brown stock washing efficiency. Any remaining cooking liquor will increase

the chemical consumption in subsequent stages.

The quality of bark must be consistent in one cook to obtain the homogeneity of the

Counter current pulp wash is recommended in the washing step instead of batch washing


interest to increase the efficiency of rinsing.

r reuse from evaporators. The evaporation plant is always one of the largest steam


Repulping the rejects from screening rather than putting them into the landfill.

lp centrifuging to remove any remaining impurities.

Sludge utilization by means of land-spreading. This method of sludge disposal is an area

of concern, as sludge constituents are not well identified.

16 | P a g e

ater consumption, reducing

Burning bark from debarking and small chips from chipping for energy production

of straw for removal of fines and dust / Dry depithing of Bagasse / Dry

The indirect steam digesters are used instead of current direct steam digester for a better

heat contribution. This modification will improve the consistency of cooked bark.

Increasing brown stock washing efficiency. Any remaining cooking liquor will increase

omogeneity of the

Counter current pulp wash is recommended in the washing step instead of batch washing


r reuse from evaporators. The evaporation plant is always one of the largest steam


Repulping the rejects from screening rather than putting them into the landfill.

spreading. This method of sludge disposal is an area


4. Cleaner production measures Chemicals

� Using of new technologies (CHP, BLG, heat transfer, heat exchanger).

� Improvements technical parameters of recovery boiler or furnace (geometrical shape

etc.).

� Using light gas strippers and gas collection systems which will remove hazardous and

foul smelling pollution from the air and increase workplace safety.

� Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.

5. Cleaner production measures Bleaching:

� Avoiding chlorine bleaching.

� Continuing research on biotechnological

� Oxygen and ozone with and without hydrogen peroxide can b

step.

6. Cleaner production measures Paper production:

� Cleaning the roll in the paper machines to avoid broken paper line.

� Adjustment of edge cutter to reduce side trimming loss.

� Use of soft water as a boiler feed water.

� Recycling water evaporated from drying process by condensing.

� Optimizing the thermal effects on water used in the paper machine and stock preparation

area.

� Providing disk save-all for paper machine.

� Repulping rejected paper in a closed loop manner.

7. Cleaner production measures Products processes and recycling, reduce:

� Increasing recycling rates. Recycling reduces energy consumption, decreases combustion

and landfill emissions, and decreases the amount of carbon dioxide in the atmosphere.

This process also saves money.

� Possibility for easy packaging recycling.

� Water from the washing step is encouraged for reuse in soaking step.


Cleaner production measures Chemicals recovery:

Using of new technologies (CHP, BLG, heat transfer, heat exchanger).

Improvements technical parameters of recovery boiler or furnace (geometrical shape

Using light gas strippers and gas collection systems which will remove hazardous and

ul smelling pollution from the air and increase workplace safety.

Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.

Cleaner production measures Bleaching:

Avoiding chlorine bleaching.

Continuing research on biotechnological bleaching and electrochemical bleaching.

Oxygen and ozone with and without hydrogen peroxide can be utilized in the bleaching

Cleaner production measures Paper production:

Cleaning the roll in the paper machines to avoid broken paper line.

ustment of edge cutter to reduce side trimming loss.

Use of soft water as a boiler feed water.

Recycling water evaporated from drying process by condensing.

Optimizing the thermal effects on water used in the paper machine and stock preparation

all for paper machine.

Repulping rejected paper in a closed loop manner.

Cleaner production measures Products processes and recycling, reduce:

Increasing recycling rates. Recycling reduces energy consumption, decreases combustion


This process also saves money.

Possibility for easy packaging recycling.

m the washing step is encouraged for reuse in soaking step.

17 | P a g e

Improvements technical parameters of recovery boiler or furnace (geometrical shape

Using light gas strippers and gas collection systems which will remove hazardous and

Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.

bleaching and electrochemical bleaching.

e utilized in the bleaching

Optimizing the thermal effects on water used in the paper machine and stock preparation

Cleaner production measures Products processes and recycling, reduce:

Increasing recycling rates. Recycling reduces energy consumption, decreases combustion



� Turning or mixing is recommended to reduce time of soaking, digestion, and washing.

� Waste water in each step should be separated and treated separately. Extra treatment need

to be considered for waste water from the pulping step which contains long molecules of

lignin and tannin.

� Recycling piping system need to be installed at the washing and soaking steps.

Installation of Indirect & More Efficient Heat Transfer System for Blow Heat Recovery in

Digester Section: This avoids generation of contaminated wastewater (in direct heat transfer,

waste gases are directly injected to water) and enables reuse of cooling wastewater.


Turning or mixing is recommended to reduce time of soaking, digestion, and washing.

Waste water in each step should be separated and treated separately. Extra treatment need

waste water from the pulping step which contains long molecules of

Recycling piping system need to be installed at the washing and soaking steps.


gester Section: This avoids generation of contaminated wastewater (in direct heat transfer,


18 | P a g e

Turning or mixing is recommended to reduce time of soaking, digestion, and washing.

Waste water in each step should be separated and treated separately. Extra treatment need

waste water from the pulping step which contains long molecules of

Recycling piping system need to be installed at the washing and soaking steps.


gester Section: This avoids generation of contaminated wastewater (in direct heat transfer,


1. pulp & paper industries

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