presentation in pt toba pulp lestari,tbk
TRANSCRIPT
By :By :Nurmay Siska R Siallagan/ 10022336Nurmay Siska R Siallagan/ 10022336
GT Environmental DepartmentGT Environmental Department
Dr. Raghunath Varanasi & Jekson Dr. Raghunath Varanasi & Jekson Sinurat, STSinurat, ST
Join Date at May 7 2010Join Date at May 7 2010
15 Oktober 2010 15 Oktober 2010
Table of Content :Table of Content :
1. Overview Wood Preparation2. Overview Fiber Line3. Overview Recovery Boiler, Evaporator, Multi Fuel
Boiler and Water Treatment Plant4. Analysis Water (Waste Water, River Water/ Bore
well) and Emission5. Regulation and License6. Solid Waste Management7. Symbol and Label B3 (Material and Waste)
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Introduction
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Process Area
1. Wood Preparation Plant
2. Fiber Line Plant
3. Chemical Plant
4. Recaustisizing and Lime Kiln Plant
5. Coal Gasifier Plant and Energy Plant
6. Effluent Treatment Plant
Fiber Line Plant
Digester
Washing and Screening
Bleaching
Pulp Machine
Technical Department
Quality Control/ Assurance (QC/QA)
Environment
Quality and Environment Management System (QEMS)
Energy
Evaporator
Recovery Boiler
Multi Fuel Boiler
Water Treatment Plant
Wood PreparationWood Preparation
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DebarkingDrum
DebarkingDrum
WashingStation
WashingStation ChipperChipper ScreeningScreening Chip PileChip Pile
To Digester
Wood yardWood yard
Barks to Pallman Chipper as Fuel to MFB
Oversize Chips
Source waste that Impact to environmental such:1. Waste water from washing and Drain Chip Pile.2.Solid waste from Debarking drum (barks),Chipper(dust) and Screening (undersize chips).
Digester PlantDigester Plant
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DKP Process DKP Process ::
BKP Process BKP Process ::
The main chemical reactions in the cooking process can be The main chemical reactions in the cooking process can be described as :described as :(NaOH,Na(NaOH,Na22S) + Chips (wood) S) + Chips (wood) → → Na-org + S-org + NaHSNa-org + S-org + NaHS
Chip FillingChip Filling
Prehydrolisisramp
Prehydrolisisramp
Prehydrolisiscook
Prehydrolisiscook
Prehydrolisisrelief
Prehydrolisisrelief
LiquidFillingLiquidFilling
KraftRampKraftRamp
KraftcookKraftcookBlowingBlowing
Chip FillingChip Filling
Liquid FillingLiquid Filling
KraftRampKraftRamp
Kraftcooking
Kraftcooking BlowingBlowing
PulpStock
Pulp Stock
30 min 70 min 90 min 20 min 30 min 40 min
70 min20 min
30 min 30 min 70 min 90 min 20 min
Cooking process for DKP = 370 minCooking process for BKP = 240 min
Block diagram process digester Block diagram process digester plantplant
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Source of waste from digester :Source of waste from digester :- Liquid from over flow accumulator tank.- Liquid from over flow accumulator tank.- Gas :NCG from air evacuation, relief, foam tank and WL - Gas :NCG from air evacuation, relief, foam tank and WL tank, vapor tank, vapor blow tank.blow tank.
Contaminated condensateTo stripper condensate
CondensateTo Effluent
NCG toincinerator
Liquor HeaterLiquor Heater
Digester Digester
AccumulatorAccumulator
Blow TankBlow Tank
MPSteam
WL
WL
Chips
LPSteam
Pulp DigestingBrown Stock Pulp to BSW
Condensate toBFW
Washing and ScreeningWashing and Screening
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Brown StockPulp From Digester
Source of waste from washing :Source of waste from washing :DNCG from washer hood 1,2,3,4.DNCG from washer hood 1,2,3,4.Solid from screening system as Shive.Solid from screening system as Shive.
Combine condensateHot Water
Radi ScreenRadi
ScreenWasher
#1Washer
#1Washer
#2Washer
#2Washer
#3Washer
#3Wash StockWash Stock
Washer #4
Washer #4
High Density Storage
High Density Storage
ScreeningSystem
ScreeningSystem
FiltrateTank #4FiltrateTank #4
FiltrateTank #3FiltrateTank #3
FiltrateTank #2FiltrateTank #2
FiltrateTank #1FiltrateTank #1
Screw Press
Screw Press
KnotsRe-cookedTo Digester
WBL toEvaporator
Unbleached PulpTo Bleaching Plant
Fiber Reject asSolid fuel to boiler
DNCG toIncinerator
Bleaching PlantBleaching Plant
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Unbleached PulpFrom BSW
Bleached PulpTo Pulp Machine
Bleached HD TowerBleached HD Tower
Do Stage andWasher
Do Stage andWasher
EOP Stage and Washer EOP Stage
and Washer D1 Stage and
Washer D1 Stage and
Washer D2 Stage and
Washer D2 Stage and
Washer
Filtrate Tank #DoFiltrate
Tank #DoFiltrate
Tank #EOPFiltrate
Tank #EOPFiltrate
Tank #D1Filtrate
Tank #D1Filtrate
Tank #D2Filtrate
Tank #D2
ClO2H2O2O2NaOH
ClO2 ClO2
ShowerWasher
ShowerWasher
ShowerWasher
Waste Water toAlkali Sewer
Waste Water toAcid Sewer
NCG toFlue gas
NCG toScrubbing Bleach
Plant
Source waste from bleaching plant are:- Acid liquid from filtrate tank Do, D1 and D2.- Alkali liquid from filtrate tank EOP.- Gas from washer hoods, Filtrate tank and Tower.
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SO2
Scrubbing Bleach Plant System
Scrubber
EO Filtrasi
Gas from Washer hoods and Tower
Gas from Filtrate Tank
Stack
to Sewer
Flue gas
Pulp MachinePulp Machine
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Source waste from pulp machine is over flow white water Source waste from pulp machine is over flow white water tank and reject pulp sewer.tank and reject pulp sewer.
Bleach pulpFrom Bleaching
StorageChest
StorageChest
PressureScreen
PressureScreen RadicloneRadiclone Double
ThickenerDouble
ThickenerStock ChestStock Chest
Machine Chest
Machine Chest
Head BoxHead BoxFourdrinierFourdrinierPress PartPress PartFlaktDryerFlaktDryer
Cutter &Layboy
Cutter &Layboy
Bailing line
Bailing line
Vacuum Vacuum White WaterSteam Condensate
To BFWDry Pulp toWare House
Steam
Reject Pulp toVibrating Screen
Reject PulpTo Sewer
EvaporatorEvaporator
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WBL fromBSW
WBL StorageTank
WBL StorageTank
Effect VEffect V Effect IVEffect IV Effect IIIEffect III Effect II ABEffect II AB
SurfaceCondenser
SurfaceCondenser
StripperColumnStripperColumn
ContaminatedCondensate
Tank
ContaminatedCondensate
Tank
StripperCondenser
StripperCondenser
IBLTankIBL
TankCombineCondensate
Tank
CombineCondensate
Tank
Effect I A,B,C,D
Concentrator
HBLTankHBLTank
Mill Water
CNCG to Incinerator
Warm Water toFiber Line &
Return to WTP
CombineCondensate to
Process
LP Steam
Pure CondensateBFW
HBL to Recovery
Foul CondensateFrom Digester &
Evaporator
Stripper CondensateTo Effluent
LP SteamCNCG toIncinerator
Line steam and gasLine liquidSource of waste from Evaporator is CNCG Source of waste from Evaporator is CNCG
and condensate from stripper column.and condensate from stripper column.
Recovery BoilerRecovery Boiler
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Dissolve Tank
Heavy Black LiquorFrom Evaporator
Make upSalt cake
Steam
Smelt
Green LiquorTo Causticization
Weak Wash From Recausticizing
FurnaceChamber
Primary Air
Secondary Air
Tertiary Air
ESP
Dust Recycle
Flue Gas
Flue Gas
Multi Fuel BoilerMulti Fuel Boiler
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Flue Gas
Steam Drum ECONOMIZER
HP Steam to TurbineGenerator
Boiler FeedWater
Sand
SH1
SH2
SH3
BoilerBlowdown
Air
Solid Fuel(barks, peat,
palm shell, wood chip)
ESP #2
ESP #1
Ash Silo
Ash Dump
Stack
Fly Ash
Fly Ash
Source of waste from multi fuel boiler is flue gas and Source of waste from multi fuel boiler is flue gas and ash.ash.
IncineratorIncineratorComponent NCG are :1. H2S (Hydrogen Sulfite).
2. CH3SH (Methyl Mercaptan).
3. (CH3)2S (Dimethyl Sulfide).
4. (CH3)2S (DiMethyl Disulfide).Process in incinerator is oxidation process from gases which sulfur contents to be gases which SO2, H2O, CO2 contents.This incinerator operated at temperature 850 – 1050 0C. And reaction is :H2S + ½ O2 → H2O + SO2
CH3S + O2 → H2O + SO2 + CO2
SO2 from the reaction will be absorption in SO2 scrubber with use caustic solution. The reaction is :SO2 + 2NaOH → Na2SO3 + H2O.
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Water Treatment PlantWater Treatment Plant
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AsahanRiver
F
Gravity Filter
Filter WaterReservoir
Clarifier WaterReservoir
Mill Process Water
RapidMixing Slow
Mixing
SettlingBasin
F
F
CoolingTower
Cooling Water Recycling
Waste WaterTo Effluent
Cooling Water Drain toEffluent
Sludge to river
Regulation And LicenseRegulation And License
A. Regulation.- UU RI No. 32 Tahun 2009 “Perlindungan dan
Pengelolaan Lingkungan Hidup”.- UU RI No. 18 Tahun 2008 “Pengelolaan Sampah”.- PP RI No.18 Tahun 1999 jo 85 Tahun 1999
“Pengelolaan Limbah Bahan Berbahaya dan Beracun”.
- PP RI No. 41 Tahun 1999 “Pengendalian Pencemaran Udara”.
- PP RI No. 82 Tahun 2001 “Pengelolaan Kualitas Air dan Pengendalian Pencemaran Air”.
- PP RI No. 85 Tahun 1999 “Perubahan Atas PP No.18/1999 Tentang Pengelolaan Limbah Bahan Berbahaya dan Beracun.
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Regulation and LicenseRegulation and License
- KepMenLH No. 13 Tahun 1995 “Baku Mutu Emisi Sumber Tidak Bergerak”.
- KepMenLH No. 48 Tahun 1996 “Baku Mutu Tingkat Kebisingan”.
- KepMenLH No. 50 Tahun 1996 “Baku Mutu Tingkat Kebauan”.
- KepMenLH No. 51 Tahun 1995 “Baku Mutu Limbah Cair Bagi Kegiatan Industri”.
- PerMenLH No. 02 Tahun 2008 “Pemanfaatan Limbah Bahan Berbahaya dan Beracun”.
- PerMenLH No. 03 Tahun 2008 “Tata Cara Pemberian Simbol dan Label Bahan Berbahaya dan Beracun”.
- KepBapedalda No. 05 Tahun 1995 “Simbol dan Label Bahan Berbahaya dan Beracun”.
- KepBapedalda No. 691 Tahun 2006 “Rekomendasi Persyaratan Kualitas Air Limbah Kegiatan PT. Toba Pulp Lestari, Tbk.
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Regulation and LicenseRegulation and License
B. License- KepMenLH No. 207 Tahun 2008 “Izin Penyimpanan
Limbah Bahan Berbahaya dan Beracun di HTI”.- KepMenLH No. 351 Tahun 2008 “Izin Pemanfaatan
Limbah Bahan Berbahaya dan Beracun Untuk Stabilisasi Slab di Lokasi Log Yard dan Pengerasan Jalan di HTI Serta Bahan Pengoreksi pH.
- KepMenLH No. 435 Tahun 2006 “Izin Penyimpanan Limbah Bahan Berbahaya dan Beracun Kepada PT. Toba Pulp Lestari, Tbk”.
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Analysis Water (Waste Analysis Water (Waste Water/River Water) and Water/River Water) and
Emission.Emission.Analysis Waste Watera. BOD (According to government
requirement)
b. COD(According to government requirement)
c. Color(According to government requirement)
d. Total Solid Suspended (TSS) (According to government requirement)
e. pH(According to government requirement)
f. Temperature (Monitoring)
g. Conductivity (Monitoring)
h. S2- (Monitoring)
i. NH3 (Monitoring)Apr 18, 2023 Nurmay Siska Rosilawati Siallagan 19
j. PO4 (Monitoring)
k. NO3 (Monitoring)
l. NO2 (Monitoring)
m. MLSS (Monitoring)
n. Cl2 (Monitoring)
o. SVI (Suspended Volume Index) (Monitoring)
p. N-Tot (Monitoring)
q. Na (Monitoring)
r. Ca (Monitoring)
s. Cl- (Monitoring)
t. SO4 (Monitoring)
Analysis River Water/ Bore Well
• PO4
• Mn • Fe • Na• Ba • Ca2+
• NO3
• NO2
• NH3
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l. pHm. Temperaturen. CODo. BODp. Colorq. TSSr. Zn s. Cl-
t. Cl2u. Turbidity
Analysis Emission
• Particulate
• Total reduce sulfur (TRS)
• Chlorine (Cl2)
• Chlorine dioxide (ClO2)
• Sulfur dioxide (SO2)
• Nitrogen dioxide (NO2)
• Opacity
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Symbol And Label B3Symbol And Label B3
Regulation be related about B3 waste :1. PP No. 18/1999 about B3 waste treatment.2. Permen LH No. 03/2008 about arrangement to give
symbol and label B3.3. Keputusan Menteri Perindustrian No. 148/1985 about
safety of dangerous and poison material in industry company.
4. Keputusan Menteri Tenaga Kerja No. 187/1999 about controlled dangerous chemical material in job area.
5. Undang-Undang No.32/2009 about environmental management and protection.
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Definition of B3:Hazardous is material which because characteristic and/or it concentration and/or it amount, as well as direct will to indirect, can pollution and/or damage environmental, and/or can danger of environmental, healthy, humanity live, and other live of creature .(Permen LH No. 03/2008 about arrangement to give symbol and label B3)
Criteria of B3 waste (PP. No.18/1999):- Easy to explode.- Easy to burner.- Reactive.- Toxic.- Infeksius.- Corrosive.
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Easy to Explode Oxidation Flammable Poison Dangerous
X
Irritation
Hazardous to
EnvironmentCorrosive Pressure
GasKarsigonic,Tert
agonic, and Mutagenic
Label Identify of B3:Label Identify of B3:
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Name B3/ name of Name B3/ name of tradetrade
Information handle of Information handle of action.action.
Additional information
Identity of pemasokIdentity of pemasok
Name B3Name B3
(Composition, No. (Composition, No. CAS/No. UN) CAS/No. UN) ProdusenProdusen-Danger declaration :Danger declaration :Classification of B3Classification of B3Fisik, health and Fisik, health and environmental.environmental.
Example of label identify
Label of placement (Kepmennaker No. 187/1999) : Put the label in place which easy to know by employee
and matters pertaining to manpower supervisor employee.
Drum to liquid and solid waste:
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coverRubber (packing)Ring key
Label
Symbol
Limbah Cair Limbah Padat
Solid Waste Management
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Solid Waste
Mill :Barks, under size chips, dust, dregs, grits, lime mud, sludge, ash boiler, mercury lamp, wet cell, COD bottle,
etc
Office :Toner catridge, paper,
pens, and other biodegradable waste
Clinic and Town Site :Infuse bottle, gauze, household waste, etc
Characteristic of B3?
-Sorting Plant: segregation in organic (sold) and organic to be compost.-- used concrete road, stabilization.-- Landfill or Dumpsite.
NO
Send to B3 house
Send to Authorized
YES
finish
Can be manage of
B3?
NO
3R (Reuse, Recycle, Recovery)
YES
Proposed ImprovementProposed Improvement
Problem statement: If sludge from secondary treatment burnt in boiler that ash from boiler can’t send to HTI before treatment to fertilizer in plantation. According to regulation government ministry letter that sludge and ash must treatment previously and then send to HTI as fertilizer in plantation.
Target improvement :Composting sludge and ash as fertilizer in plantation.
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Input – Process – Output
If sludge burnt in boiler that ash can’t send to sector
PT. Toba Pulp Lestari,Tbk
utilization sludge and ash as compost Compost
Scope of Process
Process description :Utilization sludge and ash as compost, start with determine location and people to do this process, determine method of composting, serve instrument, make standard operation procedure (SOP) compost, serve microorganism, Implementation to fertilizer in plantation.
Data BeforeData Before
No Description Unit
1 Total of effluent sludge / months Ton
2 Method of sending to Multi Fuel Boiler every day
3 Ash boiler to sector (mix with effluent sludge) every day
Ton
4 Ash boiler to sector (without mix with effluent sludge) every day
Ton
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LiteratureGraydon. A. R. H, “Composting Of Pulp and Paper
Mill Power Boiler Fly Ash with Wastewater Treatment Sludge”, Thesis, 1998
Process Analysis
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Problem identified during process :1. Extension license from government
environmental ministry to send ash boiler in sector.
2. If sludge burnt in MFB, so ash from MFBcan’t send to sector direct.
3. More many ash still there in the sector landfill in comparison with using as fertilizer.
4. Ash and sludge using as fertilizer is little.5. Not take care environmental as well as
to care environmental.
Agree from government
Sludge storage
by periodic at 15 days
sludge burnt in MFB
Ash send to sector
Ash as fertilizer in plantation
A
A
Checking of using ash as fertilizer
Finish
Composting
The method of compost making process is windrow.
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1 m2 m 1 m
2 m 1 m2 m
2m
10-15
m
* Assumption Sludge generate = 700 Ton/Month (MC= 70%)* For 40 % MC of sludge = 350 Ton/Month.* Total composting = 0,6x350 = 210 Ton/Month = 7 m3/Day.* Conduct of composting every three days with pile measure 2x15x1 = 30 m3.* Pile size is 4x16 = 64 m2, with assumption 3 months composting time.* The area will be need are: 30 x 64 = 1920 m2, above 2000 m2 (100m x 20m).* The are use concrete floor with leachate collection system.* Create SOP of composting.
Detail Of Buildings
Price Of Building
s
COMPOSTING PROCESS
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What is the decomposer for
composting process?
What is the decomposer for
composting process?
From literature that available nutrients in the compost shown in below:
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Component Soil targets Final compost with turned windrow
PhosphorousPotassium
CalciumMagnesium
CopperZinc Iron
Manganase Boron
Sulfate-sulfurSodium
AluminumTotal nitrogenOrganic matter
Total sulfur
150250
20002501025
150501
255010
0.55010
0.05
119970
30005500.6
16.23
3154.2
12.613001500.6357.80.32
Data from literature and data ash and sludge TPL
From literature that initial and final pH, moisture content, % N of compost :
Compost Ash only Sludge only S:A 2:1 S:A 1:1
pH
Initial Final
9.279.32
9.238.68
8.858.22
8.858.37
MC
Initial Final
40.2736.98
71.5460.25
54.7353.92
56.2448.83
%N
Final 0.15 2.14 1.16 0.59
Implementation1. Manage solid waste such ash boiler and sludge to be compost.2. To change using chemical fertilizer with using compost in plantation.
3. Reduce negative impact environmental in surrounding mill area.
Cost AnalysisBenefit of compost to get good image that our company care with environmental.
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Total Cost of Composting
Conclusion
1. Every process generate waste include waste water, solid waste and emission.
2. Every waste generated must be control correct to Government Requirements.