You are on page 1of 35

SPB¶S APPROACH ON WATER

CONSERVATION IN PAPER
MACHINE ± A CASE STUDY

BARATHI G
SRIRAM S
M/s Seshasayee Paper & Boards Limited,
ERODE 638 007

c
à  

   
÷hough the total amount of water on this planet has never
changed, the nature of that water is changing.

Water supply affecting factors:


‡ Immigration
‡ Population growth
‡ Climate change

In 2050, World·s Population expected: P  billion


Water will be world·s scarcest and most valuable commodities
Water is not just a societal issue ² affects BUSINESS also.

]
à  

   
‡ 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.
<
Ô Ô

‡ United Nation has recognized access to


water as a BASIC HUMAN RIGH÷.
‡ Water is not merely an economic
commodity, it is a SOCIAL and
CUL÷URAL good.
‡ Water has been recognized universally
as an invaluable resource.

g
Ô Ô
‡ 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
g
  bginning n   n To    i I Vill
gi V  Vi o pi ² Rl ion 21:6
‡ In ISLAM, the   law in Koran literally translates
to l V of  ing V 

ž
à   Ô  

INDIAN PAPER
INDUS÷RIES
Consumption 905.8 Reuse
million m3 210.1 million m3
(23.2 %)

Effluent discharge
695.7 million m3 (76.8
%)

%
à   Ô  

‡ Global Standard of Specific Average


Water Consumption is 28.66 m3/t in
Large Scale Wood Based Pulp & Paper
Mills.

‡ In India, is around 100 m3/t of paper.


à   Ô  

‡ ÷he Higher Consumption in India, due


to

² Lack of ÷echnology adaptation


² Poor equipment efficiency
² Poor Water Management Practices

S
à     
Ô Ô  
©IG 2 - W  Con
pion P n in Ini


g

g 

g

Cl l P p
ill Ini l P p
ill

Spi li P p


ill NVpin
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 ????

c
à       
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.

cc
à       
‡ 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.

c]
SPB¶S APPROACH on
Water Conservation in
Paper Machine Complex

c<
   

‡ 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.

cg
à   

 

 

300 tpd Pulp from RDH @ 160 tpd Pulp to PM(1-4) @


4% Cy. 3.5% Cy.
P p M  in # 5

7500 m3/day 4600 m3/day

140 tpd Pulp to PM#5 @


4% Cy. 3500 m3/day


à  
 


 
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

÷o E÷P 2000 m3/day &


Evaporation 200
m3/day

c%
à 
 


 
m 
 
 mm   m 
Compressor


Dec. Vac. P/p


Deculato To Head
Deculator Box
r
Dec. Cleaning
Seal Group
Pit

Vac. Vacuum
Pump pumps Poly Disc Save-
all Vacuum
Sump

Head box O/F


White Warm Showe
Water water r Silo
O/F
÷ower tank water P/U Tray
To Pulp tank Save-all water
Clear Press tray
mill ] Bar < Bar feed tank
Filtrat water
< Bar c] Bar Wire Pit
e tank
g Bar showers
Surface  Bar
To Pulper Dilution, Cy. Dilution, Thick stock condenser showers Fresh Water
screen dilution, Cleaning Group Dilution, line
System cleaning, Vacuum pump Cooling
Tower Makeup


à      
    
     
BACK WATER ©RESH WATER BE©ORE (
  A©TER (
 

All Pulper Dilution Compressor Makeup 200 m3/day 200 m3/day

Consistency Dilution Warm Water tank makeup 60 m3/day 60 m3/day

Shower Water ÷ank Surface Condenser 1580 m3/day 1580 m3/day

÷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

Chemicals Preparation 200 m3/day 200 m3/day

Others 50 m3/day 50 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

3 Bar for Wire showers 3 Bar for Felt roll showers

40 Bar for High Pressure showers


in clothing

70 Bar for High Pressure showers


in roll cleaning

cP
à       
  
‡ 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.
]

     
   
÷o E÷P
Fresh Water
Makeup

Vacuum Pumps

Vacuum
Vacuum pump Sump
Cooling ÷ower

Reuse to vacuum pumps (50%)

]c
à       
  
‡ Aion T n:

3 Vacuum Pump cooling tower makeup water was


replaced with Clear filtrate (60 ppm) from Poly
Disc save-all to replace Fresh water makeup.

3 Vacuum sump water was diverted to Poly Disc


save-all and the excess clear water of 60 ppm
from White water tower is supplied to Pulp mill
for Bleached ÷ower pump consistency control.

]]

      
  
Clear Filtrate Water
from White water
tower

Vacuum Pumps

Vacuum
Vacuum Pump Sump
Cooling ÷ower

Excess water to Pulp mill ÷o Poly Disc Save-all

]<
à       
  
‡ Bnfi  i:

3 E÷P load reduced


3 Fresh water replaced with Clear filtrate from
Save-all
3 Back water (clear water) used in Pulp mill helps
to maintain final pulp Brightness (since Back
water contains OBA)
3 Fines recovered in Poly Disc Save-all

]g
à       
  !
‡ I:
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.



       
   
Fresh Water
© " 
Makeup  

Deculator Vacuum
   
pumps sealing 

Deculator
Overflow to
Cooling WW 2
÷ower

Seal Pit
"  #
 

]%
à       
  !
‡ 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.



       
   
Deculator    

Vacuum
pumps
Overflow to Deculator cooling tower sealing

Deculator
Cooling Seal Pit "  #
 
÷ower

© " 


 

]S
à       
  !
‡ Bnfi  i:

Deculator Cooling tower make up with


Fresh water eliminated

Deculator Vacuum pump sealing water


o
temperature (30 C) achieved by passing
through cooling tower.
]P
à      $ 
Ô  
à 
   

 

] 



]
]


]  
Water Consumption cum

]

]



]


]
] 


]
]

]]
Before Implementation After Implementation

<
à      ©
%$ 
‡ 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.

<c
 %Ô
‡ 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.

<]
% &
à ‡
© 

<<
ACKNOWLEDGEMENT

‡ ÷hanks to

a ÷he management of M SESHASAYEE


PAPER & BOARDS LIMITED for co-
operation and guidance extended.
a IPPTA for providing this opportunity.
a AUDIENCE for sharing the valuable time.

<g
THANK
YOU

You might also like