Application of Water Pinch Analysis for Water Conservation in Indian Pulp and Paper Industry

B. P. Thapliyal, R. M. Mathur, Alok Goel

Central Pulp And Paper Research Institute P.O.Box. 174, Saharanpur

Central Pulp & Paper Research Institute, Saharanpur

Pinch Analysis
The term introduced by Linhoff & Vredeveld. Represents a set of thermodynamically based methods. A systematic methodology to identify and overcome the performance limiting constraints (or pinch) in any process

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Objective
To achieve financial savings by better process heat integration (maximizing process-to-process heat recovery and reducing the external utility loads). Systematically designing an optimal scheme of utility exchange between producers and consumers.

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Key Principles Pinch Analysis looks at the whole process instead of looking at the individual components. After understanding the overall process, it is easier to identify the opportunities for

improvement.

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Basic Concept
Pinch is viewed as the weakest link in a chain.

All systems have at least one Pinch. Some may have multiple pinches. When one pinch is relieved some other factor will cause a new pinch. There will always be a pinch. The technique consists of identifying the pinch, and then taking appropriate corrective action.
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Types of Optimisation
Structural:- Concerns with the selection of

appropriate process configuration or topology, e.g. sequence of streams selected. Parametric:- This concerns the numerical values of the process parameters such as flow, temperature, pressure, etc.
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Contd.

In existing processes, the process topology is already determined, therefore all that remains is to optimize the parametric values. But, it is a challenge to find out that a chosen process topology is the best one? This is where we apply Pinch Analysis

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Structural & Parametric Optimization by Pinch

Typical gains in Energy Efficiency by; Structural Optimization 15 to 35% Parametric optimization 3 to 7% Structural used. Pinch analysis offers benefits of both approaches.
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and

Parametric

optimizations

are

complementary and for best results both should be

Classic Applications
Energy Pinch optimization for process heat recovery Total plant energy analysis Power conservation and recovery opportunities through integrated CHP designs. Water Pinch for optimum water reuse / recycle.
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Pinch Analysis in Pulp and Paper Industry

After its introduction in 1984, Pinch Analysis has been applied in a number of mills. Documented results reported in the literature have shown; Energy cost reduction by 15-40%. Capacity de-bottlenecking by 5-15% for retrofits. Capital cost reduction by 5-10% for new design. Improved operational flexibility. CPPRI has taken the lead in bringing Pinch Technology to Indian Paper Industry.
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Water Consumption Trend in Indian Pulp & Paper Industries

Raw Material:100% bamboo Product:100% bleached
RMH 3% Pwr.House 4% Ch.Rec 5% Others 9% Stock 2% Chem.Plant 1%

Raw Material: Wood(63%), bamboo (34%) Product: 100% bleached

Stock 4% Others 4% ClO2Plant 3% Bleaching 40%

P.M/c 34%

Pulping 6% Pwr.House 6%

Pulping 14% Bleaching 28%

Ch.Rec 12%

P.M/c 25%

Water cons =118.43 m3/t

Water cons =123.9 m3/t

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Contd.. Raw Material: Wood & bamboo Raw Material: Wood, bamboo, RCF, Bagasse Product: Bleached & Unbleached Product:Newsprint
Pulping 5% Pwr.House 9% Others 3% ClO2Plant 1% Bleaching 28%

Chemi-Mech. Pulping 10%

RMH 3% Pwr.House 29%

Chem.Pulping 11%

Stk & P.M/c 27%

Ch.Rec 27%

Ch.Rec 19%

Stk & P.M/c 28%

Water cons =143.0 m3/t

Water cons =73.6 m3/t

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Contd.. Raw Material: Agro Residues(98), RCF(1), MP(1) Product: Bleached

Power House 7% Chemical Recovery 8%

Stock 4%

Others 3%

Paper Machine 52%

Bleaching 26%
Water cons =118.0 m3/t

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Contd.. Raw Material: Recycled Fibre(100) Product: Newsprint & Bleached

Others 3% Pwr.Hous e 11% Washing D.I. Plant 6%

Raw Material: Market Pulp(100) Product: Speciality Paper

Power

Flotation D.I. Plant 12%

Pur cha sed Pul p Pr ocesi ng 4%

House 3%

Stock 3%

Paper

Stk & P.M/c 68%

Machi ne 90%

Water cons =35.0 m3/t

Water cons =93.3 m3/t

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Application of Water Pinch Analysis in Pulp & Paper Industries

Huge potential for water conservation in paper mills. Help the mills in achieving their targets by exploring the possibilities of water conservation through reuse and recycling of waste water streams. By understanding the utilization pattern, to get an idea about the contaminants limit in various inlet and outlet streams in processes and its amalgamation with pinch concept provides a new insight on utilization of various waste water streams for accessing the water conservation potential. The case study presented in this article shows the potential of water conservation in Indian Paper industry and Highlights the reuse and recycle options of water in one wood based paper mill
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Water Pinch Composite Curves

Each water related Purity process operation can be considered as having input and output water streams and composite of water demand (Input) and water sources (Output) can be constructed.
Concentration

Fresh Water
Water Sources

Water Pinch graph depicts the water sources and demands in a process on purity vs. flow axes. Identify the optimum distributed effluent treatment design.

Water Demands

Water Pinch
Waste water

Water Flow

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Water Pinch Typical Results

Company
Bayer, Germany Cerestar, UK Gulf Oil, UK Monsanto, UK Monsanto, IL Parenco, Neth Rayonier, US SASOL, Africa Tyson Foods, Ga US Air Force, Ok Confidential, Al

Industry
Chemicals Food Proc. Oil refining Chemicals Chemicals Pulp & Paper Pulp & Paper Oal chem. Food Proc. Military Synthetic fibres

% Waste Water saving

25 25 30 40 28 30 58 50 20 40 22

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Steps for the methodology for practical application of Water Pinch Analysis
Flowsheet: Develop a simple flowsheet model of the water system, showing where water is used and where water (waste) is generated, i.e. determine water sources and sinks. Contaminant Data: Select key contaminants e.g. COD, salts, suspended solids. A key contaminant is defined as any property that prevents the direct re-use of the waste water stream, this might includes temperature and/ or acidity. Choose design concentrations which are maximum allowable for the sinks and the minimum practical for the sources.
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Contd..

Software Implementation:- Create the simulation model of the flowsheet. Perform the multidimensional water pinch analysis to determine optimum matches between the sources and the sinks. The first solution obtained is probably not the best solution since it is unconstrained. Review Design:- Examine the resulting network design and identify the pinches for the selected contaminants. It is usually necessary at this point to assess the design and determine which additional contaminants should be considered; which matches should be forbidden, and which matches should be forced (if any). This way we impose constraints on the network design. One can refer this step as an optimisation scheme. This procedure might also include process modifications and regeneration options that would result in lower targets.
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Case Study Paper Mill : Wood based

Average production Installed capacity Main raw material Product Digesters = 75,000 tpa. = 53,000 tpa. =Hard wood: Bamboo = 84:16 = Writing Printing paper of different grades & quality = 3 stationary batch digesters

No. of paper machines = Six. Brown stock washing section Bleaching sequence = (CDEoD1D2) Boilers Turbines 1. 2. = 5 power boilers (3 running) = Two = 1235 = 145

The present energy consumption of the mill is given below Electrical energy consumption, kWh/t of paper Fresh water consumption, m3/t of paper
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Water minimization study was conducted in the above mill based on limiting profile diagram, which indicates the minimum water requirement within the selected unit.

The study focused on single contaminant in the pulp mill section for reuse & recycle options within the mill.

A complete water balance of the pulp mill was prepared using online and portable flow meter and same is shown in fig -1.

The water samples from various streams were characterized with respect to their pollution load.

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PULP MILL SECTION RECYCLING PRACTICES FOLLOWED BY MILL

2.3 Hot water 30 m3/h Foul condensate 50m3/h 30 40 35 chemical BSW-4 Pulp washing 13 46.85 2.3 C/D Washer 10.50 59.7 2.30 Eop Washer Calculated DF=1.4 1.5 55 50 6 12 2.30 51.33 25 D1 Washer 53.9 11.5 7.6 70 70 10.0 72 50 1.29

5 2.30 D2 Washer 59.7 10.5 0.9 DECKER WASHER 10.0

120 7

63.0 3.7 25

Black liquor to chemical recovery 73.15

37 Conveyerdilut. 37 m3/h (back water) Paper M/c -4+sealing water 178.50

21

20

150 560+70+150

211

215

218

560

40 2.2 3228 1472 270 5.907 178 7.1 3050 960 365 3.917 272

129.18

79.01

50 3.3 3025 800 965 3.99 290

29.48

70 3 2495 816 812 3.487 308

70 2.7 2378 595 800 3.777 780

Total= 272 m3/h effluent to ETP

pH TS COD Hardness Conductivity Flow mg/l mg/l mg/l ms/cm m3/hr 2 3328 1240 1350 7.647 163.3

Fig. 1 Water Balance Flow Diagram

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Flow rate, m3/hr COD, mg/l

120 23800

BSW-4 Pulp washing 73.15 70000

46.85 1120

367.35

D1

1213.426 406.75

CD Pulp washing EOP Pulp washing

367.35 1472 406.75 960 371.74 800 365.26 816 837.26 595

S1

D2

862.1315 371.74

S2

D3

846.3722 365.26

D1 Pulp washing

S3

D4

787.127 837.26

D2 Pulp washing

S4

D5

574.5816

Decker Pulp washing

S5

Fig. 2 Extracted Flow Diagram

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Table 1, Data Extraction for water Pinch Analysis for Pulp Mill Section Source Flow rate, Concentration, m3/hr S1 S2 S3 S4 S5 367 407 372 313 837 mg/l 1472 960 800 816 595 D1 D2 D3 D4 D5 Demand Flow rate, m3/hr 367 407 372 313 837 Concentration, mg/l 1213 862 846 787 575

The data extracted from the water balance of the pulp mill section

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Approach for Limiting Profile Calculation

Arrange concentrations in ascending order. Calculate sum of flow for a given concentration Flow = FlowDemand - FlowDemand Refer Table 1 for above calculations. Calculate Net Mass Load (kg/hr) Net Mass load e.g. = Flow x ( C2 C1) / 1000 = 313 x (787-595) / 1000 = 60

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Table 2, Calculation for limiting profile diagram and minimum water requirement Sum(F) = Cum Mass Cum mass Load / Concentration SumF(Demand) Net Mass Load Load Conc SumF(Source)
595 787 800 816 846 862 960 1213 1472 0 313 -59 -372 0 407 0 367 0 0 60 -1 -6 0 6 0 93 0 0 60 59 53 53 60 60 153 153 0 76 74 65 63 69 62 126 104

The table also shows the analysis of the extracted data from water balance carried out to identify the minimum fresh water requirement for pulp mill section and also calculation for limiting profile diagram and minimum water requirement.
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1600 1400 Concentration, mg/l 1200 1000 800 600 400 200 0 0 20 40 60 80 100 CUM Mass Load
Fig. 3 - Limiting Profile Diagram

Limiting profile diagram between concentration & cumulative mass load is plotted. The inverse of the slope of tangential line shows the minimum fresh water requirement in case of a selected contaminant i.e chemical oxygen demand for pulp mill section.
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Approach for Water minimisation Networking

Arrange Source and Demand flow concentration as shown in Table-3. Calculate Water Balance. For S.No.5 (Demand) = (575 x 837) = 808 m3/hr 595 Balance available for next stage recycling = 837 808 = 29 m3/hr For S.No.4 (Demand) Water recycle potential Water recycle potential = (787x313 595x29) = 280 m3/hr 816 Balance available for next stage recycling = 313 280 = 33 m3/hr
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Table 3, Water minimization analysis

Fresh Water Supply, m3/hr S. No. Concentration, mg/l Demand, m3/hr Source , m3/hr 367 407 372 313 837 1213 862 846 787 575 118 47 1 40 2 3 3 4 29 5

1 2 3 4 5

1472 960 800 816 595

367 407 372 313 837

269.16 51

355.45 12

360 33

0.74 280 29

808

The above analysis shows that the minimum fresh water requirement in the pulp mill section is 118 m3/hr where as the actual consumption is 187 m3/hr. Thus there is a scope of improvement in utilization of fresh water consumption in the mill.
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Benefits from a Plant wide application of Pinch (Thermal and water) Analysis
Meaningful energy / water targets.

Feasible projects with real savings.

Essential

insights

into

Energy

Water

flows,

distributions, benchmarks, scope.

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Conclusions
The study conducted in selected mill in the pulp mill section shows that water pinch analysis can be used as a valuable tool for water conservation. Study in other section of the mill is under progress and substantial saving can be achieved by proper

implementation of water pinch analysis results. CPPRI is actively engaged in activity for Thermal & Water Pinch Analysis in Indian paper industry and looking into the requirement of the industry.
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Central Pulp & Paper Research Institute, Saharanpur