Professional Documents
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CONSERVATION IN PAPER
MACHINE ± A CASE STUDY
BARATHI G
SRIRAM S
M/s Seshasayee Paper & Boards Limited,
ERODE 638 007
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÷hough the total amount of water on this planet has never
changed, the nature of that water is changing.
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Increasing awareness that water resources, renewable natural
resources, exist in limited quantities.
÷he continuous and indefinite expansion of water uses is not
possible.
Situation of stability in the use of the water that is currently
available must be sought.
÷his should be one of the main strategic goals of a long-term
water management policy.
÷here is an urgent need to find ways of saving,
reusing and recycling water and to develop
methodologies to improve water resource
management.
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Since ancient times, water has been recognized as
an invaluable resource.
÷he Ramayana, Mahabharata & various other Vedic,
Buddhist and Jain texts contain several references
to water harvesting structures in existence and
´V bing lif giing n
ining fo
÷he BIBLE quotes, I
Alp n O
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bginning n n To i
I Vill
gi V Vio pi ² Rl ion 21:6
In ISLAM, the law in Koran literally translates
to l V of ing V
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INDIAN PAPER
INDUS÷RIES
Consumption 905.8 Reuse
million m3 210.1 million m3
(23.2 %)
Effluent discharge
695.7 million m3 (76.8
%)
%
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©IG 2 - W Con
pion P n in Ini
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Cl l P p
ill Ini l P p
ill
P
à
COUNTRY SPECI©IC WATER
CONSUMPTION
Ton of P p
United States 64
Australia 28.66
Europe 40
Canada 67
Finland 40
Spain 30
INDIA ????
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Eqip
n Moifi ion:
Recycling ² Using water in the same process
Reusing ² Using water in some other process
Reclamation ² Collecting the waste water and use for some process
B io l Moifi ion:
By stopping misuse of water for cleaning, etc.
÷urn-off water when not using it like in hose, tap, etc.
Po Moifi ion:
Optimal usage of Cooling water ² collecting and resue
Collection and recycling of clean water from vacuum pumps
Use of Seal-less pumps. ÷his is used in most of the chemical
industry.
Monitoring the Showers in Paper machines and increase the usage
of back water.
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Water Conservations also through:
² House keeping measures (Low cost measures) like
leak identifications and arresting
² Production scheduling (to avoid unwanted
draining the system)
² Automation like Level controller, Pressure
controller
² Better Raw material utilization to avoid excess
water usage in bleaching operation.
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SPB¶S APPROACH on
Water Conservation in
Paper Machine Complex
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Make : VOI÷H
Head Box : Hydraulic W type
Wire Part : Duoformer F
Press Part : Duo-centri II with Suction Pickup, Suction Press, PU covered CC
rolls in I and III nip position
Dryer Part : I & II groups are Unirun and III,IV,V and VI groups are conventional
dryers
Speed sizer : Voith Film Press
Calender : Single stack with single nip CI rolls
Automation : ABB ² DCS ² Advant station 500 series
QCS ² Accuray 1190 version
GSM Range : 45 to 140 GSM
Machine Speed : 400 to 950 mpm
Average Production : 180 tpd
Furnish : 70 ² 80 % Captive Bleached Hardwood Pulp (ECF Bleached)
20 ² 30 % Captive Chemical Bagasse Pulp (ECF Bleached)
Products : W F Printing & Writing paper, S S Maplitho, Pigment Coated Paper,
Copier Grades, Coating Base Paper.
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Fresh Water 2400 From RDH 7500
m3/day m3/day
÷o PM(1-4) 4600
m3/day
P p M in #
5
÷o RDH 3100
m3/day
c%
à
m
mm
m
Compressor
Vac. Vacuum
Pump pumps Poly Disc Save-
all Vacuum
Sump
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BACK WATER ©RESH WATER BE©ORE (
A©TER (
÷hick Stock Screen Deculator seal pit makeup 100 m3/day NIL
system dilution
Cleaner group tank Vacuum pump sealing water 300 m3/day NIL
makeup tank makeup
Pump Sealing water 250 m3/day 250 m3/day
To l Con
pion 27P
2P
cS
WARM WATER TANK SHOWER WATER TANK
ppm 10 ² 20 60 ² 70
Filter -- Barrel Filter (Duplex)
Usage Points 2 Bar Lubrication shower for 12 Bar for Sheet Knock Off shower
(Forming roll, and Edge Knock Off showers with
(Suction Couch roll, ON/OFF valves
(Suction Pick up roll,
(Suction Press roll
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I:
In Vacuum pump cooling tower,
fresh water was added and return
water sent to Effluent due to
² Fines content is more in return water
² ÷emperature is more i.e. around 50o C
² Cooling tower fins are getting choked with
fines settlement.
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÷o E÷P
Fresh Water
Makeup
Vacuum Pumps
Vacuum
Vacuum pump Sump
Cooling ÷ower
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Aion T n:
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Clear Filtrate Water
from White water
tower
Vacuum Pumps
Vacuum
Vacuum Pump Sump
Cooling ÷ower
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Bnfi i:
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3 Fresh water was added in Deculator Cooling
÷ower for make up as the Sealing water was
going to Deculator seal pit and to White water
tank because
o
High ÷emperature i.e. 40 C
÷o maintain vacuum barometric leg.
Contamination of Deculator Vacuum pump sealing water
with 4th stage Centri-cleaner reject tank water.
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Fresh Water
©"
Makeup
Deculator Vacuum
pumps sealing
Deculator
Overflow to
Cooling WW 2
÷ower
Seal Pit
" #
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Aion T n:
Deculator vacuum pump sealing water was
diverted to Deculator Cooling tower for reuse
through Overflow line without disturbing Vacuum
barometric leg.
o
Deculator Vacuum pump sealing water (40 C) is
recycled through Cooling tower.
Increased the height of the wall between
Deculator seal pit & 4th Stage reject tank thus
segregated vacuum pump sealing water from 4th
stage reject tank.
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Deculator
Vacuum
pumps
Overflow to Deculator cooling tower sealing
Deculator
Cooling Seal Pit " #
÷ower
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Bnfi i:
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Water Consumption cum
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Before Implementation After Implementation
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©
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From all pumps, sealing water will be
collected in a sump and will be reused. ÷hus
250 m3/day can be saved.
By using efficient filters, we proposed to
substitute fresh water with backwater,
wherever possible. ÷hus we are targeting
for water consumption ² 10 m3/t of Machine
Production.
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By Process Modifications and using available automation,
Water consumption reduced by around 400 m3 per day in
Paper Machine # 5
Clear water sent to Pulp mill thus saving the costly
chemicals like OBA.
Recovered costly fibers and fillers from Vacuum pump
sealing water, thus disturbance in wet end chemistry like
Charge Demand, etc avoided.
By closing the water loop in the Paper machine complex,
wet end chemical consumption is optimized.
E÷P load reduced by close water loop.
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% &
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ACKNOWLEDGEMENT
÷hanks to
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THANK
YOU
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