tSz g
SCmFPSo Raw
MaterialpwPBBmF
ChipperTkoBg
Poo
Pulp
MillTSBmFg
SHwPdm
Paper
MachineTSBmFg
uPdPRwPdf
Paper
FinishingrPRBSCHw
DispatchpwmAPHSog
tmHvMmFb Chemical
Recovery pwmAPHSog
pvABomJ
Chemical
Complex
Water
Supply
Power
Plant
Effluent
Treatment
Plant
HR
Costing
&
Finance
QC/
R&D
Purchase
& Store
Engg
Maintenance crg
sv7vz d
MSD
Godown
FLOW DIAGRAM OF PAPER MILL
Steam for Power
White Liquor
PULP MAKING PROCESS
Chipper House
Digester House
Kraft/Sulphate pulping process
No of Digester : 3 of 120 m3 each
Type : Vertical stationary of indirect heating
Cooking Time : 260 minutes
Pulp/cook : 12.0 MT
Chipper
Digester
Chipper
no.
Make Capacity
(MT/h)
Raw mat.
handling
1 Vecoplan No. 1 25 Woodlogs/
Bamboo
2 Vecoplan No. 2 15 Veneer waste
PULP MILL
Wash Plant
Rotary Drum Vacuum Washer: : 4 Stages
Capacity :195 BD Pulp per day
Washer
Weak Black
Liquor to
Recovery
Hot Water & Foul
Condensate
FiltrateFiltrateFiltrate
Unbleached Pulp
Drum Washer Filtrate
Defoamer
dosing at
inlet line of
BSW-1
Washer
PULP MILL
C/D B/W
FILT
TANK
H.MIXER
C/D MC
PUMP
C/DMC
MIXER
EO MC PUMP
Eop
EO
PRE
TUBE
DECKER
MC PUMP
C/D
80M
3 D1
D1 MC
MIXER
DI MC
PUMP
D2 MC PUMP
D2 MC
MIXER
Cl2
CD
H/W
FILT.
TANK
H/W
EO
B/W
O2
EO MC
MIXER
EO
B/W
EO STOCK
PUMP
EO
D1
B/W
H.MIXER
LP
STEAM
DI
B/W
D1
D2
B/W
D2
B/W
ClO2
FILT.
TANK
FILT.
TANK
D2
DECKER
B/W
FILT.
TANK
ClO2
DEC
KER
MILL
WATER
DECKER
B/W
LP
STEAM
H.MIXER
D2
B/WD1
B/W
EO
B/W
UN BLD
PULP
FROM
W/P
NaOH
H
2
O
2
M/C
No.4
B/W
LP
STEAM
CENTRI -
CLEANING
MILL
WATER
58
M
3
156
M
3
250
M
3
250
M
3
UN
BLD
400 M
3
ClO2
Paper m/c
Storage
tower
H/W
To ETPTo ETP
Bleach Plant
Conventional bleaching process
Capacity : 180 BD pulp per day
Bleaching sequence : C
D
E
OPD1D2
Centricleaner : 4 stage
Pulp brightness(ISO) : 89-90 %
D2
Bleach towers
PULP MILL
RECOVERY
Evaporator 1
Type : Short tube vertical (STVE) and free flow falling film
No of effects : STVE-5 , FFFFE-4
Handling of thin BL : 72 m
3
/hr
Steam Economy : 4.5
Concentration of BL : 62-64 %
Type : Short tube vertical (STVE)
No of effects : STVE-6
Handling of thin BL : 20 m
3
/hr
Steam Economy : 3.0
Concentration of BL : 60-62 %
Evaporator 2
Recovery Boiler
No of Boiler : 2
- JMW
- ABL
Total capacity: 315 TPD solids
Evaporator
RECOVERY
Causticizing Section
Capacity : 70 TPD, active alkali as Na
2
O
Slaker : Stationary
Lime mud washing : 2 Streets
Lime Kiln
Year of installation : 2005
Capacity : 60 TPD
Lime kiln
T
in
t
in
g
D
y
e
s
O
p
t
ic
a
l W
h
it
e
n
e
r
S
iz
in
g
C
h
e
m
ic
a
ls
F
ille
r
P
o
w
e
r
B
r
o
k
e
HD tower
Bleached
pulp
Pulp
Refining
Functional
Additives
addition
Approach
flow
system
Paper
Machine
Pulp
Receiving
Chest
Fiber
Recovery
System
PROCESS OF PAPER MAKING – STOCK PREPARATION
Machine
No.
TypeMake Deckle
cm
Speed
m/min.
GSM
range
Production
TPD
Paper grades
1 MF
Charles
Wamsely
314 10060-90 30
REB
Super Printing
Lky Parchment
2 MF
Charles
Wamsely
314 115
58-
190
40
S/L Bond
Super Printing
Super
Cartridge
4 MF
Esser
Wyss
311 350
54-
149
75
Bilt Classic
S/L Offset
S/L
Cartridge
5 MFAlstom 223 270
60-
124
50
MMPP
BCB Base
7 MFKarhula 272 120
70-
100
27
REB Normal
REB Colored
Criss Cross
All machines are equipped with size press.
PAPER MACHINES
Reel
Orders
Sheet
Orders
PAPER CONVERSION
PM-1 Jag
Rewinder
PM-2 Jag
Rewinder
PM-4, Beloit
Rewinder
PM-4, Masson
Scott
Max reel capacity 5 5 5 5
Speed in mpm 400 400 600 500
Beloit Rewinder Masson Scott Rewinder
PROCESS PAPER CONVERSION & FINISHING REWINDER
PM-5, Servall PM-7, Jagenberg
Max reel capacity 4 4
Speed in mpm 800 600
Servall Winder
Jagenberg Winder
PROCESS PAPER CONVERSION & FINISHING REWINDER
Three stage Effluent Treatment Plant Installed
and Commissioned in 1987
-Activated sludge process
-Design Capacity: 54000 m
3
/day
-Operating Capacity: 28000 m
3
/day
PARTICULARS UNIT INFLUENT HSPCB
NORMS
EFFLUENT
TREATED
WATER
EFFLUENT as
on Nov-09
pH NA 7-8 7.0-8.5 7.2 – 7.8
BOD PPM 280-350 30 18-25
COD PPM 700-900 350 150-180
SUSPENDED SOLIDS PPM 700-900 50 25-35
AOX KG/T Paper 1.2-1.6 <1.0 0.6 -0.8
Data showing the compliance to environmental norms
EFFLUENT TREATMENT PLANT
•Pulp Supply System
•Stock refining
•System cleaning
•Approach Flow system
•Paper making- MF
PAPER MAKING PROCESS
Pulp from Bleached
Stock Chest
Buffer Chest
Refining of Stock through
Refiners in Refined Chest
Mixing Chest
Machine Chest
SR Box
Fan Pump
Centricleaner
Pressure Screen
Head Box
Dry broke
through pulper
Broke Storage
Broke Cleaning System
Cleaned Broke Tower
Tinting dyes/ pigment preparation
Optical whitener preparation
PAC: Poly Aluminum Chloride
Filler/Dispersed Rosin/ Fill Plus
Filler Slurry
Percol-47 Preparation system
Hydrocol- RK2 Preparation system
Wet Broke from
respective M/C
PROCESS FLOW: STOCK PREPARATION (PM 1,2 & 4)
Buffer
Chest
1000 m
3
Bleached
Pulp
Machine back water
(Krofta/Disc filter
filtrate) for bottom
dilution
To Refiners of PM 1, 2 & 4
Thickener
PULP SUPPLY SYSTEM (PM 1,2 & 4)
Refiner
Mixing
Chest
Machine
Chest
SR Box Fan Pump
Centricleaner
Pressure
Screen
Head BoxWire Part
T
in
t
in
g
D
y
e
F
ill P
lu
s
P
A
C
D
is
p
e
r
s
e
d
R
o
s
in
F
ille
r
Defoamer
P
u
lp
f
r
o
m
B
u
f
f
e
r
C
h
e
s
t
Refined pulp °SR: 28-30
Pulp Consistency:-4.0%
Tinting Dye: Iraglite
Violet
Fill Plus: 1.0 kg/T
PAC : 17 kg/MT
Rosin: 13-16 kg/MT
Filler: Finex/CaCO3
Defoamer
Afranil ST – 0.5 kg/MT
Biocide
STOCK PREPARATION: PAPER MACHINE-1
Refiner
Mixing
Chest
Machine
Chest
SR Box Fan Pump
Centricleaner
Pressure
Screen
Head BoxWire Part
T
in
t
in
g
D
y
e
F
ill P
lu
s
P
A
C
D
is
p
e
r
s
e
d
R
o
s
in
F
ille
r
Defoamer
P
u
lp
f
r
o
m
B
u
f
f
e
r
C
h
e
s
t
Refined pulp °SR: 28-30
Pulp Consistency: 4.0%
Tinting Dye: Iraglite
Violet
Fill Plus: 1.0 kg/T
PAC : 17 kg/MT
Rosin: 10 kg/MT
Filler: Finex/
Defoamer
Afranil ST – 0.5 kg/MT
Biocide
STOCK PREPARATION: PAPER MACHINE-2
Buffer
Chest
NPM Pulp
TDR 21” &
DDR 20”
Mixing
Chest
Machine
Chest
SR Box
Buffer
Chest
NPM Pulp
TDR 24”
Mixing
Chest
Machine Chest SR Box
M
a
c
h
in
e
R
e
f
i
n
e
r
Paper Machine-2
Paper Machine-1
STOCK PREPARATION: PULP REFINING – PM-1&2
M
a
c
h
in
e
R
e
f
i
n
e
r
Not in operation
Not in operation
Refiner
Mixing
Chest
Machine
Chest
SR Box Fan Pump
Centricleaner
Pressure
Screen
Head BoxWire Part
T
in
t
in
g
D
y
e
P
A
C
P
u
lp
f
r
o
m
B
u
f
f
e
r
C
h
e
s
t
Refined pulp °SR: 28-30
Pulp Consistency: 4.0
Tinting Dye:
As per Quality
OBA: 2.5 kg/MT
Rosin: 10 kg/MT
PAC : 25 kg/MT
Fill Plus: 2.3 kg/MT
Defoamer
Afranil ST 0.5 kg/MT
F
ille
r
O
B
A
F
ill P
lu
s
D
is
p
e
r
s
e
d
R
o
s
in
STOCK PREPARATION: PAPER MACHINE– 4
Pulp from Pulp Mill
New Mixing Chest
Refining of Stock through
Refiners
Mixing Chest
Machine Chest
SR Box
Fan Pump
Centricleaner
Pressure Screen
Head Box
Dry broke through
pulper
Broke Chest-1
Broke Chest-2
Tinting dyes/ pigment
Optical whitener
PAC: Poly Aluminum Chloride
Dispersed Rosin
Filler Slurry
Wet Broke from
respective M/C
Cationic tarch
PROCESS FLOW : STOCK PREPARATION – PM-5&7
500 m
3
Bleached
Pulp
Machine back water
for bottom dilution To PM-5 & 7
Stock Prep.
PULP SUPPLY SYSTEM: PM- 5&7
Refiner Mixing
Chest
Machine
Chest
SR Box Fan Pump
Centricleaner
Pressure
Screen
Head BoxWire Part
D
is
p
e
r
e
d
R
o
s
in
C
a
t
io
n
ic
S
t
a
r
c
h
P
A
C
F
ille
r
Defoamer
Refined pulp °SR:27
Pulp Cy :3.7%
Rosin: 22-25 kg/T PAC :
32 kg/T
Cato Starch: 3kg/T
Filler : 110-250 kg/T
Defoamer
Antimusol- BPI Liq: 1-1.2 kg/MT
Biocide
Rag Chest
New
Mixing
Own PulpCoated broke
Dump
Chest
Circulation
Chest
B
r
o
k
e
Tinting Dye &
OBA
Tinting dye: Irgalite/Methyl
OBA : 2-2.5 kg/T
STOCK PREPARATION: PAPER MACHINE– 5
Circulation
Chest
Rag
Chest
Coated Broke
Virgin Pulp DDR
Mixing
Chest
Machine
Chest
SR Box
New
Mixing
Chest
Dump
Chest
TDR
To be Use as per
requirement
Broke Chest-
1
Broke
Pulper
Broke Chest-
2
STOCK PREPARATION: PULP REFINING – PM-5
Refiner Mixing
Chest
Machine
Chest
SR Box Fan Pump
Centricleaner
Pressure
Screen
Head BoxWire Part
D
is
p
e
r
e
d
R
o
s
in
+
P
A
C
C
a
t
io
n
ic
S
t
a
r
c
h
O
B
A
F
ille
r
Defoamer
Refined pulp °SR: 26
Pulp Cy :3.7%
Rosin: 32 kg/T
PAC : 34 kg/T
OBA : 8-9kg/T
Filler : 225-235 kg/MT
Defoamer
Antimusol- BPI Liq: 2-2.5 kg/MT
Biocide
Hydra
Pulper
Own Pulp
New
Mixing
chest
Cir. Chest
Cato Starch:5-63kg/T
B
r
o
k
e
Imported PulpHydrex-P
Hydrex-P : 15-17kg/MT
Tinting Dye ; Irg. voilet
Tinting Dye
STOCK PREPARATION: PAPER MACHINE– 7
DDR-24" 2 x 3.2 x 6.3 300 300 110 190
0.78
0SDM
Bar angle =
10deg
M/C 5
DDR-24" 4 x 8 x 8 x 30250 200 120 80 0.6
TDR-21" 3 x 3.5 x 12 x 10200 180 60 120 1.17
M/C 7
CONFLO 3.5 x 5 x 9 x 18225 162 60 102 1.42
STOCK PREPARATION: REFINER DATA
MF Paper Machines PM-1,2,4,5 & 7MF Paper Machines PM-1,2,4,5 & 7
Dry Broke for cleaning & reuse
Wet Broke for reuse
Back water to
fiber recovery
SteamSteam SteamSteam
Starch + Size Press Starch + Size Press
AdditivesAdditives
PROCESS PAPERMAKING : MF PAPER MACHINE
PROCESS OF PAPERMAKING: MF PAPER MACHINE
Machine PM-1 PM-2 PM-4 PM-5 PM-7
Make Charles
Walsmey
Charles
Walsmey
Escher
Wyss
Alsthrom,
Germanny
Karhula
Year 1936 1936 1960
Renovated
in 2004
1984 1984
Speed, mpm 100 110 340 260 120
Deckle width,
meter
3.12 3.12 3.12 2.24 2.73
Production,
MT/day
30-35 20-50 68-100 55-60 28
GSM 70-95 58-190 54-149 80-185 70-100
PROCESS OF STOCK CLEANING: PM-4
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Primary Fan Pump
Cleaning at Primary Centricleaner
Screening at Pressure Screen
Screening at
Vibratory Screen
Head Box
Back Water
RejectCleaning at
Secondary
Centricleaner
Accept
to
Primary
Fan
Pump
Suction
Cleaning at
Tertiary
Centricleaner
Cleaning at
Quaternary
Centricleaner
( fiber-mizer )
To Maloney filter
Reject
To Drain
Dilution of stock with back water in
Fan Pump
Couch pit
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Primary centriclener
Screening at Primary Centricleaner
Screening at Pressure Screen
Screening at
Vibratory Screen
Pope Reel
Back Water
RejectScreening at
Secondary
Centricleaner
Accept to
PCC
Pump
Suction
Screening at
Tertiary
Centricleaner
Screening at
Fibermiser
To Drain
Reject
To Drain
Dilution of stock with back water in
Fan pump
PROCESS OF STOCK CLEANING: PM-5
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Primary centriclener
Screening at Primary Centricleaner
Screening at Pressure Screen
Screening at
Vibratory Screen
Pope Reel
Back Water
RejectScreening at
Secondary
Centricleaner
Accept to
PCC Suction
Screening at
Tertiary
Centricleaner
Screening at
Fibermiser
To Drain
Reject
To Drain
PROCESS OF STOCK CLEANING: PM-7
Machine 1 2 4 5 7
Head Box type Open Open
Closed
Air
Cushioned
Closed
Pressurized
Open
Distributors
Simple
Manifold
Simple
Manifold
Tapered
Flow
Tapered
Manifold
Tapered
Manifold
Consistency 0.5-1.0 % 0.6-1.2 % 0.6-1.0 %0.8-1.0 % 0.7-0.9 %
Freeness, °SR 40-42 40-42 40-42 34-36 40-42
Slice opening,
mm
10 10 15 12-14 13
Slice width, mm 3350 3350 3400 2450 3000
No of slices 25 25 28 22 24
PROCESS OF PAPER MAKING: HEAD BOX
Machine 1 2 4 5 7
Breast roll diameter,
mm
406 600 550 500 500
No of table Rolls 16 12 - - 4
No of Hydrofoils - - 17 50 9
Wet vacuum Boxes 2 2 2 - -
Dry vacuum Boxes 3 3 6 8 7
Vacuum Applied , mm
of Hg
350 100-200 200-220 200 200
Couch roll Vacuum,
mm of Hg
350 350 440-480 400-450 280-300
Couch roll Dia mm 762 762 762 650 618
PROCESS OF PAPER MAKING: WIRE PART
Machine 1 2 4 5 7
1
st
Press
Type Plain Plain Suction Suction Suction
Top roll Granite GraniteDyna rockMicro rockGranite
Bottom roll Rubber Rubber Rubber Rubber Rubber
2
nd
Press
Type Plain Plain Plain Plain Plain
Top roll Granite GraniteDyna RockMicro rockMicro rock
Bottom roll Rubber Rubber Rubber Rubber Rubber
3
rd
Press
Type Offset Offset Reverse Offset Offset
Top roll Granite GraniteDyna rockMicro mateMiicro mate
Bottom roll Rubber Rubber Rubber Microrock Brass
PROCESS OF PAPER MAKING: PRESS PART
Machine 1 2 4 5 7
No of dryers 27 27 36 28 16
No of dryer
groups
4 4 5 4 3
No of felt
rolls
65 65 118 70 48
Condensate
Removal
sissies
Bucket
type
Bucket
type
Bucket
type
Siphon
type
Bucket
type
Syphon typeStationaryStationaryStationaryStationaryStationary
Hood
Semi
closed
Semi
closed
Semi
closed
Semi
closed
Semi
closed
PROCESS OF PAPER MAKING: DRYER SECTION
Machine 1 2 4 5 7
Calendar
No of stacks 1 1 1 1 1
No of rolls 2 2 4 2 2
Size Press
Type InclinedInclinedHorizontalHorizontalInclined
Movable roll
material
Micro
Rock
Micro
Rock
Micro
Mate
Micro
Mate
Micro
Mate
Fixed roll
material
Micro
Mate
Micro
Mate
Micro
Rock
Micro
Rock
Micro
Rock
Loading HydraulicHydraulic HydraulicHydraulicHydraulic
Paper
feeding
Rope
carrier
Rope
carrier
Rope
carrier
Rope
carrier
Rope
carrier
PROCESS OF PAPER MAKING: CALENDER & SIZE PRESS
Machine 1 2 4 5 7
Machine Wire 19.81 x 3.4519.81 x 3.4528.06 x 3.5522.3 x 2.62 20.26 x 3.13
Pick Felt/ First Press Felt10.36 x 3.5510.36 x 3.5516.50 x 3.6510.5 x 2.65 12.0 x 3.10
Second Press Felt 10.36 x 3.5510.36 x 3.5516.50 x 3.6511.2 x 2.65 12.0 x 3.10
Third Press Felt - - 16.50 x 3.65 - -
First top Dryer Screen 25.30 x 3.5525.30 x 3.5543.00x 3.5527.0 x 2.65 16.0 x 3.10
First bottom Dryer Screen25.30 x 3.5525.30 x 3.55 - 27.0 x 2.65 16.0 x 3.10
Second top dryer screen25.30 x 3.5525.30 x 3.5527.80 x 3.60 21.5 x 2.65 20.0 x 3.10
Second bottom dryer screen25.30 x 3.5525.30 x 3.5527.80 x 3.6021.5 x 2.65 20.0 x 3.10
Third top dryer screen 12.50 x 3.5512.50 x 3.5521.80 x 3.60 21.5 x 2.65 16.0 x 3.10
Third bottom dryer screen7.00 x 3.557.00 x 3.5521.80 x 3.6021.5 x 2.65 16.0 x 3.10
Fourth top dryer screen 23.30x3.5523.30 x 3.5530.00 x 3.5521.5 x 2.65 -
Fourth bottom dryer screen23.30x3.5523.30 x 3.9032.00 x 3.6021.5 x 2.65 -
Sixth top dryer screen - 35.00 x 3.9029.90x3.60 - -
Sixth bottom dryer screen - 39.80 x 3.9029.90x3.60 - -
Cooling Top Dryer Screen - - 12.50x3.60 - -
Cooling Bottom Dryer Screen - - 14.50x3.60 - -
Last dryer screen - - - 7.5 x 2.65 7.5 x 3.10
PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METER
Thanks
PROCESS OF PAPER MAKING: PAPER MACHINE
Details M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7
Make Charles WamsleyCharles WamsleyEsser Wyss Alstom Karhula Karhula
Year Of Installation 1926 1926 1983 1983 1983
Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st Floor
Production (Tpd) 30 40 75 47 1.8 27
Machine Speed(Mpm) 100 110 350 270 60 115
Machine Deckle(C.M) 314 314 311 223 210 272
Draw Open Open Open Open Oen Open
Approach Flow System
Machine Refiner Type TDR/21” TDR/24” DDR/24”DDR/24”&TDR/21”Conical,Beater Conflo
Pressure Screens No. 1 1 2 1 0 1
Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25
Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1
No.of Bottles in1st Stage 8 8 24 22 3 15
In 2nd Stage 3 3 8 7 5
In 3rd Stage 1 1 4 1 1
In 4th Stage 1 1 1 1 1
Head Box
Type Open Open
Closed air
Coushioned
Closed
Pressurized Open open
Dandy Roll Yes Yes Yes Yes No Yes
Dia.of Dandy (mm) 330 330 1000 800 500
Press Part
Ist Press Type Solid Solid Suction Suction Solid Suction
2nd Press Type Solid Solid Solid Solid Solid Solid
3rd Press Type Reverse Reverse Reverse Smoothening Smoothening
Dryer Section
Total No. of Dryer Cylinders 27 27 36 28 10 16
Dryer Groups (Steam Wise) 4 4 6 4 3 3
No. of D/Cy.In Pre Dryer 19 19 24 20 10
No. of D/Cy. In Post Dryer 8 8 12 8 6
Cooling Cylinders No No Yes No No No
No. of Cooling Cylinders 2
Size Press
Type Inclind Inclind Horizontal Puddle type Puddle type
Steam System Conventional ConventionalConventionalConventional ConventionalConventional
Condensate Removal System Bucket Bucket Bucket Siphon Bucket Bucket
Type of Calender Kuster Kuster Kuster Kuster Kuster
Pope Reel Inclined Inclined Horizontal Horizontal Horizontal