tamil nadu newsprint and papers ltd. tamil nadu newsprint and papers ltd. green manufacturing...

Tamil Nadu Newsprint and Papers Ltd.

Green Manufacturing Practices: TNPL Case Study on Value Addition to Waste Author :S. Chinnaraj,

Co-authors :T. Vijayakumar, M.Senthil Kumar and S. V. Subrahmanyam

Research and Development Division, Tamil Nadu Newsprint and Papers Ltd. Kagithapuram, Karur Dt, Tamil Nadu -639136INDIA


Introduction

1. TNPL – Briefly…2. Value Addition to Bagasse as

Paper Making Raw-material

3. Value Addition to Solid Waste 4. Value Addition to Liquid

Waste


1. TNPL – Briefly…


TNPL – Briefly… Promoted by Govt. of Tamil Nadu in early 80’s World’s largest bagasse based paper plant at single location Presently produces 4,00,000 MT of PWP annually, Largest

exporter of PWP from the country ISO 14001:2004, ISO 9001:2008 and FSC FM/COC & CW/COC

Certified Uses one million MT of Bagasse every year and Installed Wind

Power Capacity 35.5 MW Treated effluent water is pumped to TEWLIS consisting 430

farmers with 1660 acres. 25,000 m3/day biogas generated from bagasse wash water

and used in Lime kiln resulting 15 KL F. Oil saving 1.00 Lakh acres Pulp wood plantation since 2004 involving

more than 17,000 farmers Four registered CDM project reduces 2.1 Lakh MT CO2

emission


TNPL – Briefly…

Installed 600 TPD mini cement plant under Lime Sludge and Fly Ash management

Commissioned 3 loop 2 disperser 300 TPD deinked plant to conserve fiber

Revamping steam and power system (RSPS) to augment in-house power generation from 81.12 MW to 103.62 and to reduce CO2 emission of 50,000 TPA

200 TPD Precipitated Calcium Carbonate (PCC) Plant and 120 TPD Wet Ground Calcium Carbonate (WGCC) Plant

Largest exporter of PWP in the country 2.00 lakh per annum green field project : TNPL UNIT II

to produce multilayer paper board


2. Value Addition to Bagasse as Paper Making Raw-material


1. TNPL is credited with unique innovation of waste to wealth.

2. TNPL uses about one million tones of bagasse every year instead of wood thereby avoiding felling of tress around 52,000 acres of forest land every year.

3. Value addition to sugarcane waste (bagasse) through pulp & paper production and effective utilization of biomass waste viz. residual sugars, bagasse pith and Black liquor, for bio-energy generation.

Value addition to Bagasse


Moisture52%

Moisture52%

Dry Weight48%

Dry Weight48%

3%3%

Fibre31%

Fibre31%

14%14%

4%4%

13%13%

14%14%

Residual sugar-Biogas

Residual sugar-Biogas

Pith- BiofuelPith- Biofuel

LossLoss

Black liquor solids- bio fuel

Black liquor solids- bio fuel

Bleached Pulp - Paper

Bleached Pulp - Paper

Bagasse

Value Addition to Bagasse


Wood Saved by Usage of Bagasse

Year Bagasse Pulp Produced in MT

Equivalent Wood Conserved in MT

2011-12 1,65,914 7,30,056

2012-13 1,70,632 7,09,786

2013-14 1,57,898 6,78,909


3. Value Addition to Solid Waste


Quantity of In-organics Solid Wastes Generation

S. No Parameter Unit 2011-12 2012-13 2013-14

1 Fly ash MT 45,806 36,618 43,205

2 Wet ash MT 19,824 11,522 14,356

3 Lime sludge MT 2,91,645 2,94,587 3,02,644

4 Lime grits MT 4,204 3,973 3,834


Quantity of Organics Solid Wastes Generation


1 Bagasse pith from Pulp Mill MT 98,036 82,816 87,053

2 Dust from Chipper House MT 2,257 9,129 9,078

3 ETP Primary Sludge MT 70,686 68,241 53,362

4 ETP Secondary sludge MT 3,755 4,817 5,501


Properties of solid wastes

S. No Description Major constituents (on OD basis)

1 Fly Ash Ash: 88 - 92%, LOI: 8 to 12%

2 Wet Ash Ash : 90-95 % , LOI : 3 to 5%

3Lime Sludge (Moisture:45 to 50%)

Acid insolubles: 6-7%, Silica as SiO2: 6% Mixed Oxides (R2O3): 1% Calcium as CaCO3: 88 - 90% Magnesium as MgCO3:1 – 1.5% Free CaO: 0.8 , Sodium as Na2O: 18%



S. No Description Major constituents (on OD basis)

4Lime grits (Moisture: 25 to 30%)

Acid in-solubles: 6- 7% , Silica as SiO2: 6-7% Mixed Oxides (R2O3): 3.1% Calcium as CaCO3: 85 - 88% Magnesium as MgCO3:3% Free CaO: 1.% , Sodium as Na2O: 1.8%

5Bagasse Pith (Moisture:45-50%)

GCV: 4000 -4200 Kcal/kg , Ash: 9% Volatile matter: 72% , Fixed carbon:13%



S. No Description Major constituents (on OD

basis)

6 Dust from Chipper house (Moisture: 25-30%)

GCV: 4000-4600 Kcal/kg, Ash: 2.4% Volatile matter: 72% , Fixed carbon:19%

7 ETP primary sludge (Moisture:75-80%)

GCV: 2300-2700 Kcal/kg Organics: 60-70% , Inorganics:30-40%

8 ETP Secondary sludge (Moisture: 83-85%)

GCV: 2500-3000 Kcal/kg Organics: 60-70% , Inorganics:30-40%


Quantity of Solid Wastes Recycled or used

S. No Parameter Unit 2011-

12 2012-13 2013-14

1 Lime sludge: re-burnt in lime kiln MT 1,80,173 1,82,571 1,82,810

2 Chipper dust used as fuel in boiler MT 2,257 9,129 9,078

3 Bagasse pith used as fuel in boiler MT 98,036 82,816 87,053


GHG Emission Reduction Due to Lime Sludge Re-burning In 2013-14

S. No Parameter Unit Value

1 Burnt Lime production MT 1,01,351 2 Reuse of Lime sludge MT 1,82,810 3 Lime Stone Conserved MT 1,69,340 4 GHG emission reduction due to logistic

reduction of lime sludge t CO2 e 1,371

5 GHG emission reduction due to burning of Lime Sludge in kilns

t CO2 e 80,436

6 Total GHG emission reduction t CO2 e 81,807


LSFM : Cement plant

Lime sludge from SRP 200 T/day

Fly Ash from Energy

boilers 100 T/day

Capital Outlay Rs 100 Cr

Capacity : 600 Tons/ day

Lime stone

On going Expansion Capacity : 900 Tons/ day


Environmental benefits of Lime Sludge & Fly ash Management (LSFM) system

Parameter Unit Value

Pozzalana Portland Cement MT 1,13,904Solid waste elimination due to reuse of Lime sludge MT 62,631Solid waste elimination due to reuse of Fly ash MT 17,010Lime Stone Conserved MT 73,487GHG emission reduction due to lime stone conservation MT 32,334GHG emission reduction due to logistic reduction of lime

sludgetCO2 e 470

GHG emission reduction due to logistic reduction of fly ash tCO2 e 156

Total GHG emission reduction due to LSFM tCO2 e 32,960


Inorganic Solid Waste Used MT/annum for Production of Cement

Lime sludge Lime grits Fly ash0

10000

20000

30000

40000

50000

60000

70000

2012-13 2013-14


Reduction In Quantity of Solid Wastes Disposed MT/annum

Lime sludge Lime grits Fly ash0

20000

40000

60000

80000

100000

120000

2011-12 2012-13 2013-14


GHG Emission Reduction Due to CO2 Sequestration Through PCC

S. No Parameter Unit Value1 Precipitated Calcium

Carbonate per annumMT 50,000

2 GHG emission reduction per annum

t CO2 e 22,000


Organic Waste Utilization


Energy Generation and GHG Emission Redun. by Utilization of Organic Waste as Fuel


1 Chipper dust MT 2,257 9,129 9,078

2 Bagasse Pith MT 98,036 82,816 87,053

3 Thermal energy generated GJ 7,53,910 6,86,727 7,18,284

4GHG emission reduction

t CO2 e 73,849 67,248 70,359


Economical and Environmental Benefits of Kitchen Waste Biogas Plant.

S. No Parameter Unit Value

1 Organic solid waste utilized from canteen /day Kg 160

2 Organic solid waste utilized from guest house /day kg 60

3 Total organic solid waste utilized from tnpl per day kg 220

4 Emission reduction /annum by avoidance of CH4 t CO2e 7.6

5 Volume of biogas used in the heating equipment / day

m3 20

6 Emissions reduction by fossil fuel displaced /annum

t CO2e 10.4

7 Emission reduction /annum t CO2e 18.0

8 Savings /annum Rs in lakh 2.0


Quantity of Wastes Disposed to Other Industries


1 Lime sludge MT 1,11,472 82,180 57,203

2 Lime grits MT 4204 3973 0

3 Fly ash MT 45,806 35,028 26,195

4 Wet ash MT 19,824 11,522 14,356


4. Value Addition to Liquid Waste


Properties Of Wastewater Generated

S. No Parameter Unit High BOD Stream

Low BOD Stream

1 pH 4.5 7.0

2 BOD5 ppm 4000(max) 600(max)

3 COD ppm 6000(max) 1200(max)

4 Total Suspended Solids ppm 7000(max) 1000(max)

5 Total Dissolved Solids ppm 3500(max) 1800(max)

6 Color, Pt. Co units ppm 300 350


Sold for Secondary use:Moulded- fibre products,

Fibre-boards, etc.

Wastewater fromPulp Mills & Paper

Machines

On-Land Discharge(for Irrigation)

Cooling Tower

Manual Bar Screen

Activated Sludge Basin

Primary Clarifier

Sludge Thickener

Secondary Clarifier

Ozone Treatment

DecanterSun Drying

Burnt in Mill Boilers(mixed with pith)

Wastewater fromBagasse storage,

Reclaim & Washing

Anaerobic

LagoonUASB

ReactorBuffer Tank

Neutralisation Tank

EqualisationTank

Bagasse Clarifier

Mechanical Bar Screen

Vac. Belt Filters

Vac. Belt Filters

Sun DryingMill Boilers

Tertiary Treatment

Liquid Waste Management


Bio-methanation Plant Concept


Bio-methanation: Environmental and Economic Benefits

Particulars Units 2011-12 2012-13 2013-14

COD Treated MT / Yr 22,127 24,443 21,577COD Reduced MT / Yr 18,847 21,008 18,917Biogas generation MM3 / Yr 8.73 101.33 9.66Furnace oil saving KL / Yr 5,241 6,080 5,798GHG reduction from CH4 avoidance MT CO2e 98,023 1,13,710 1,08,888GHG reduction from Furnace Oil saving MT CO2e 17,016 19,740 19,039

Total GHG reduction MT CO2e 1,15,039 1,33,450 1,27,928Revenue from Furnace Oil Saving

Rs. (in Million) 181.8 241.9 265.9


Properties Of Treated Wastewater

S. No Parameter UnitTNPCB Norms

TNPL Results

1. pH No. 5.5 – 9.0 7.5 – 8.02. BOD5 ppm 30 10-133. COD ppm 250 150 - 2004. Total Suspended Solids ppm 100 45 - 50

5. Total Dissolved Solids (in organics) ppm 2,100 1,400-1,600

6. Color, Pt.co units ppm - 230-2607. AOX Kg/T 1.0 <0.1


Pollution Load per DayAp

r-07

Jul-0

7O

ct-0

7Ja

n-08

Apr-

08Ju

l-08

Oct

-08

Jan-

09Ap

r-09

Jul-0

9O

ct-0

9Ja

n-10

Apr-

10Ju

l-10

Oct

-10

Jan-

11Ap

r-11

Jul-1

1O

ct-1

1Ja

n-12

Apr-

12Ju

l-12

Oct

-12

Jan-

13Ap

r-13

Jul-1

3O

ct-1

3Ja

n-14

Apr-

14Ju

l-14

Oct

-14

Jan-

15

0

2

4

6

8

10

12

14 11.9

5.2

0.2 0.4

2.71.0

COD BOD SS

MT

per D

ay


Specific Pollution Load per MT of Paper

Apr-

07Ju

l-07

Oct

-07

Jan-

08Ap

r-08

Jul-0

8O

ct-0

8Ja

n-09

Apr-

09Ju

l-09

Oct

-09

Jan-

10Ap

r-10

Jul-1

0O

ct-1

0Ja

n-11

Apr-

11Ju

l-11

Oct

-11

Jan-

12Ap

r-12

Jul-1

2O

ct-1

2Ja

n-13

Apr-

13Ju

l-13

Oct

-13

Jan-

14Ap

r-14

Jul-1

4O

ct-1

4Ja

n-15

02468

101214161820

17.5

4.54.0

0.90.77 0.10

COD BOD SS AOX

Kg/M

T of

Pap

er


Recycling Paper Machine Effluent After Clarification

Parameter Unit Paper machine effluent

Colour Pt Co 100- 120 Total Solids ppm 1000-1200 Total Dissolved Solids ppm 700 - 900 COD ppm 221 Chlorides as Cl ppm 200


Recycling Paper Machine Effluent After Clarification

Fresh water

Paper machine wastewater

ETP

Legend: Before Project After Project

Fresh water saving : 3000m3/day

Clarifier

Bagasse storage & washing

ETP


Recycling of Eop Filtrate in Chemical Bagasse Bleaching

Parameter Unit ValueReduction water consumption m3/day 1300

Reduction in effluent discharge volume m3/day 1300

Reduction of solids to effluent MT/day 3.25

Reduction of sodium discharge to Effluent Treatment Plant

MT/day 3

Reduction in hydraulic load m3/day 1300

LP steam reduction MT/day 45

Emission reduction per annum t CO2e 4182

Savings per annum due to Energy conservation

Rs in lakh 118

Fibre recovered per annum MT 1072

Savings per annum due to Fibre recovery Rs in lakh 250

Total Savings per annum Rs in lakh 368


Liquid Waste ManagementUtilization of Treated Wastewater For Irrigation

Prior to TEWLIS Irrigation Treated Effluent Discharge

Water Cisterns provided in TEWLIS Irrigated Land

View of TEWLIS Irrigated Lands


Impact of Wastewater Irrigation

Wastewater irrigated area (monitored by

TNAU)

Dry lands Non -irrigated area

TNPL

River bed area


Thanking you

Any Questions !

Thanking you

Any Questions !

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