Cleaner ProduCtion

In
Waste PaPer recycling industrial sector
1.

Background :

There is huge potential for conservation of natural resources and reduction in pollution by
increased recycling of secondary fibres. The waste paper recycling yields fibre at low
chemical and energy inputs thereby considerable cost reduction. The energy consumption
in waste paper based mills is 30-40% less than that of an integrated pulp & paper mill.
The effluent problem is also considerably less severe for waste paper based mill. A wide
range of boards, lower grade writing papers and tissue papers may be produced from
waste paper . Investment for processing equipment is lower as compared with chemical
pulping equipment . A large number of mills based on recycled fibres were set up in Late
70s to meet the paper demand in the country. Since 1990 these mills are growing and
expansion of capacities is a regular phenomenon. The Indian paper industry produces
10.11 million tons paper per annum, just 2.6% of the total world production of 394
million tons/annum of paper, paper board and newsprint. As compared to international
capacities, we lag far behind. Many of the Indian Paper mills are also working actively in
the areas of water and environmental management not only to better the statutory norms
but also in a proactively move closer to Cleaner Production.

2.

Present Scenario of Recycle Paper Industries:

There are 653 paper mills in India and installed capacity is about 9 million tonnes /
annum. Out of 653, As of date, about 550 mills in India use waste paper as primary fibre
source for paper, paperboard and newsprint production. This waste paper is sourced
indigenously as well as through imports. . There are 70 industries in Gujarat and all are
recycle paper mill. VAPI is the biggest Industrial Estate in Asia continent in and around

VAPI there are as good as 40 Small and Medium scale PAPER & PAPER BOARD
manufacturers. Indias paper manufacturing capacity is expected to grow at a
Compounded Annual Growth Rate (CAGR) of 7.4 percent from 8.4 million MT per
annum to 11.2 million MT per annum between 2008 and 2010. The per capita
consumption of India stands at only 9.3 kg as against 42 kg in China, 22 kg in Indonesia,
25 kg in Malaysia, 247 Kg in Japan and 312 kg in the US. The present recovery and
utilisation of waste paper by paper mills in India is 3.0 million tones annually, which
translates to recovery of 27% of the total paper and paperboard consumed. This recovery
rate is very low when compared to developed countries like Germany-73%, Sweden,
69%, Japan-60%, Western Europe-56%, USA-49% and Italy-45%. According to an
estimate, the import of waste paper has increased from 5.1 million USD in 1980 to one
billion USD in 2011. India imports around 4.0 million tonnes of recycled paper annually.
The Cost of import pulp is around $ 650-700/tonne due to poor recovery rate around only
27%.. As per IPMA (Indian Paper Mfg. Association), Indias demand is expected to
double to 20 million tonnes by 2020 where as mfg capacity at present 10 million tones.

3.

Core Environment Challenges And Generated CP Options :

SR.
No.

1.

2.

Problem
Recycle
Paper
industries are using
Alum & Rosin to
make the paper
hydrophobic, these
chemicals usually
increase the effluent
load and also the
yield
percentage
from the existing
process
is
low
which results in
fibre losses and
contribute to solid
waste as sludge
Some of the Paper
Mills are using

CP OPTIONS

Benefits

Enable high pulp yield

with zero pulp rejects,
increase productivity,
reduce water, energy
and chemical
System And Method For Repulping Of
consumption and less
Paper Products And Improvement Of
Water Quality With Dipolar Aprotic expensive when
compared with the total
Solvents And Recovery.
cost of chemicals that
are usually used in
conventional methods.

Technological Alternative By Electro Reduce colour agents,

Chemistry Method by Kakatiyo BOD, COD, TDS, TSS

3.

4.

5.

6.

conventional
process
of
manufacturing and
thus using ETPs to
treat the effluent
generated which is
having COD level
of 10000 and BOD
of 500-800 and thus
cannot be reused
after treatment
The
Alum
and
Rosin
used
by
industries is major
source of TDS in
the effluent water
and thus increases
the fresh water
consumption
and
treatment cost of the
Paper industries

Generation of deinking sludge,

rejects, which are
Hazardous and sent
to Landfills
presently

Electro Cluster Method.

and also a greater

potential and cost
effective method to treat
the pulp and paper mill
effluent.

Technological Alternative By use of

Starch Spraying as a sizing agent in
place of existing chemical additives like
as alum and rosin. This invention relates
to a new method of applying
Hydrophobic sizing directly on the
moving web in the drying section of
paper machine for the production of
paper board and packaging grades

It increases internal
bonding and plybond
strength, to improve
bulk and stiffeness and
to avoid de-lamination
of coatings and paper
layer.

Technological Alternative by CDEM

(Conversion of Deinking Sludge From
the Papermaking process into mineral
products).The mineral product named
Top Crete has very similar
properties to cement

It has similar properties

like as cement, then it is
used
in
different
building
applications
such
as
stabilize
terrains. In order to be
competitive, the price of
Top-Crete has to be
lower than cement.

BFCB
(Bubbling Fluedized bed
Combustion Boiler) can be used for
coarse rejects and sludge.
Technological Alternative by use of
pulverized coal fly ash addition as a wet
end filler in papermaking.

Useful
recovery.

Nano Insulation apply for improving

drying efficiency as well as operations,
reduce steam loss and also evaporation

Reduce energy
consumption.

Boiler fly ash

generated by the
industries are sent to
Technological alternative by utilization
landfills
of Fly Ash for removal of coloured
contents from effluent of paper industry
Energy Losses in
drying section

for

heat

It decrease production
cost and reduce disposal
and
environmental
problems.

loss.
To Modify Conventional Drying
Technology through Condebelt and
Boost Drying.
7.

Electricity
inefficiency

8.

Resource losses due

to material handling
practices and good
house keeping

9.

Utilize / Convert
Plastic waste into
useful By- product

Identification of the losses in electrical

energy consumption and
implementation of the measures
Cleaner production practices and
measures to be implemented

Reduce Energy
Consumption.
Reduce Electricity
consumption.
Improve Better process
control.

Utilize Plastic waste to the cement

industry through the co-processing.
Reduce environment
Convert Plastic Waste into Crude Oil.
problems.
Convert Plastic Waste into Fuel/Energy
through plasma pyrolysis.

Plastic Waste at VAPI

Case study through Co-Processing
1.

Background :
As we are all aware that VAPI is the biggest Industrial Estate in Asia Continent. In and
around VAPI there are as good as 40 Small and Medium scale PAPER & PAPER
BOARD Manufacturers. All of them are KRAFT PAPER, DUPLEX BOARD,
NEWSPRINT & WRITING PRINTING Manufacturers. All Companies are based on
100% waste paper recycling process and they are not using any wood, bamboo or any
other conventional raw-material for making the paper. Hence, such Industry is called as
eco-friendly Industry wherein they are helping to save the Environment by not using the
virgin pulp which is generated by processing wood. The waste paper is the paper which
is collected from different sources such as it may be collection of Offices, Household and
from the Paper & Board Converting Plants such as Printers, etc from India as well as
foreign countries.

2.

Plastic Waste :
The waste paper is in the form of different shape & sizes and of different qualities. In
this waste paper there are so many Paper & Board pieces & in Cartons which are poly
coated, plastic laminated or plastic coated. Apart from poly coated there may be some
other impurities like pins, staples & stone, etc. All these impurities are present in the
waste paper which is indigenous as well as imported. The waste paper of different type as
mentioned above is subjected for disintegration into the pulping unit which is called as
the pulper along with the water. During disintegration which is a continuous process poly
coating is separated from pulp and is removed as waste plastic. Pulp is used for paper
making. Plastic waste is then subjected for the bailing process. During bailing, the
squeezing again takes-place and whatever water is there gets squeezed out and once the

bale is properly squeezed and formed in the size, this is tied-up with the help of wire and
taken out with the help of Forklift. This is the final waste plastic which is in the bale
form and ready to dispatch to required destination.
Table 1: Composition Of Plastic Waste
Nature of Plastic Waste at source

3.

Ash
Carbon

-less than 10%

-75-85%

GCV
Hydrogen

6000-7500Kcal/Kg
-less than 3%

Moisture

-less than 2%

Nitrogen

-less than 0.2%

Sulphur

-less than 0.005%

Present Scenario Of Plastic Waste In Vapi :

Till Late September 2012, the plastic waste generated during the manufacturing was sent
to TSDF site of Vapi Waste & Effluent Management co. Ltd, vapi for land filling, until
Oct 2012 when Gujarat Pollution Control Board issued a note wherein it was instructed to
all paper industries to explore possibilities of co-processing or co-incinerating the plastic
waste in industries at high temperature. Because of the non-biodegradable and
impervious nature of plastic, if disposed in the soil, they could arrest the recharging of
ground water aquifers. As per time to time directives of GPCB the plastic waste being
generated by the member units of Gujarat Paper Mills Association (GPMA) to be
disposed off to:(1) TSDF Of Vapi Waste & Effluent Management Co.Ltd.
(2) In the premises of Vapi Paper Mills Ltd-VAPI.(for storing only)
(3) In the premises of Satyen Flourine Ind.VAPI. (for storing only)
(4) To any Cement Industry for incineration in their Kilns with proper authorization from

Gujarat Pollution Control Board.

Accordingly, till Nov 2012 the quantity of plastic waste stored at various sites on
temporary basis is as under. The generation of plastic waste of paper mills of vapi is
around 180-200 MT per day ie around 3500 4000 MT per month.(Shown In Table 2)

Table 2 : Waste Plastic Generation In Vapi

Sr No.

Name

Quantity MT

Vapi Waste & Effluent

Management Co. Ltd (TSDF
site):

11,073.00

Premises of Vapi Paper Mills

Ltd
Premises of Satyen Flourine
Industries

15,341.09

4.

29,534.14

Cleaner Production Prospective Through GPCB (Gujarat Pollution

Control Board)
On 6th April-2011 one MOU was executed between AMBUJA CEMENT LTD (ACL) &
GUJARAT PAPER MILLS ASSOCIATION (GPMA). The summary of the MOU was
long term understanding between the 2 parties that the total quantity of plastic waste
generated by the member units of GPMA will be consumed by ACL as a co-processing
(AFR) in their cement kilns. Accordingly, plastic waste is being regularly sent for coprocessing to the Kodinar unit of Ambuja Cements Ltd from all paper mills in vapi. Till
Nov 2012, 30873 MT of plastic waste is being sent from paper mills of vapi. A bar chart
(Shown In Figure 1) showing the dispatches made to Ambuja Cements Ltd, Kodinar
during the last twelve months from various paper mills is mentioned below herewith.
Regularly, there have been joint meetings of Cement manufacturers and paper mills in
the presence of Member Secretary, Mr. Hardik Shah to resolve all statutory issues and to
boost the co-processing of plastic waste to other cement plants. Moreover co-processing

of plastic waste has also been explored in the following cement plants in Gujarat and
Outstate.
(1) Ultratech Cement Ltd., Jafarabad unit (Gujarat).
(2) Ultratech Cement Ltd., Kovaya unit (Gujarat).
(3) Sidhee Cement Ltd., Sidheegram (Gujarat)
(4) Lafarge Cements Ltd., Sonadhi Plant, Chattisgarh.
(5) Lafarge Cements Ltd., Arasmeta Plant, Chattisgarh.
(6) Vikram Cement Works (Ultratech Cement Ltd), Madhya Pradesh.
(7) Aditya Cement Works,Unit-1 (Ultratech Cement Ltd), Rajasthan.

Figure 1 : Dispatch of Plastic Waste To Cement Industry

Benefit Through Co-Processing :

Through Coprocessing of Palstic Waste to Cement Industry, reduce environment
pollution load in all recycle paper industries in vapi. Cement Industry use Plastic Waste
as a fuel in the modify cement kilns under norms of Gujarat Pollution Control Board..