Summary of Project Based on EnvironmEnt FriEndly technologies in PulP and PaPer Industry at Vapi

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1 Summary of Project Based on EnvironmEnt FriEndly technologies in PulP and PaPer Industry at Vapi

2 OBJECTIVE: The main objective of this study is to conduct a waste audit in a paper mill and develop new technological options in existing process. The specific objectives are: a) To carry out a material balance for each of the unit production processes; b) To determine the possibilities for closing the water cycles in order to reduce the discharges and emissions; c) To determine the possibilities of recovery and re-use of fibre from the waste streams; d) To implement cleaner production technologies; e) To improve its energy management strategies; f) To prepare a plan for unit to achieve zero liquid discharge. SCOPE AND LIMITATIONS: This study was carried out in the pulp and paper industries at vapi, which manufactures paper and board. The main focus of this research study is to find out how to reduce the Prevailing ground water extraction, minimize waste generation and utilization of wastes as a by-product to the extent possible i.e., Recycle, Recover, Reuse, Reduce, while keeping the production at the same quantity. The study will basically involve material balance, particularly the fibre and water balance. Consistency balance is another important parameter. However, this is difficult to measure in the absence of costly instrumentation. The results of this study will specifically be beneficial to Pulp and Paper Industries at Vapi. However, this research will be helpful to replicate other paper mills for cleaner production technologies.

3 METHODOLOGY OF INVESTIGATION: CURRENT STATUS OF WASTE PAPER UTILIZATION IN VAPI SECTOR: The RCF/ WP as a raw material is best suited for following end products Newsprint Duplex board Kraft paper/test liner

4 WASTE PAPER UTILISATION AND PRODUCTION IN VARIOUS INDUSTRIES AT VAPI: Name of the Industry Ruby Ltd. Macons Type of Raw Material Purchased Pulp from ind. And imported Name of Product Test Liner paper/ Kraft Paper (HSN Code 4805) Raw material Consumption in tonne / tonne of product Consistency & Types of Pulper Avg. Production Capacity (t/day) 1.1 tonne waste paper 1 % 250 tonne/day 90 % Yield Shah Pulp & Paper Mills Ltd. Indigenous imported paper & waste Newsprint & Writing paper 1.25 tonne waste paper 17 % Hydro Type tonne/day 85 % Rama Pulp and Paper Imported Kraft Paper, Waste & news paper waste OTC (One Time Carbon) (18 GSM, Micron Size) & A Grade Kraft Paper 150 GSM PM 1 : 44.2 tonne/day (1.052 tonne/tonne of product) PM 2 : tonne/day (1.041 tonne/tone of product) PM 1 : 2.5% (ATS Pulper) PM 2 : 6 % PM 1 : 42 tonne/day PM 2 : 16 tonne/day PM 1 : 95 % PM 2 : 96 % Rama NewsPrint ONP, OMG, White record, News &Pumps, share forms & Mix papers News print paper PM 1: tonne/tonne of product PM 2 : tonne/tonne of product PM 1 : 2.7 % PM 2 : 5.2 % 228 tonne/day PM 1 : 93 % PM 2 : 92% Gayatri Shakti P & B Ltd Indigenous waste paper Duplex Board (4 Layer) 1.1 tonne/tonne of product 4 % 14 tonne/day 91%

5 Kwality Pulp and Paper Mill Waste Paper M.G. Kraft Paper tonne/tonne of product 1-2 % 29 tonne/day % Craft Pulp and Paper Mill Waste Paper M.G. Kraft Paper tonne/tonne of product 1-2% 48 tonne/day % Damanganga Board Mills Pvt. Ltd. Waste Paper Kraft Board (4 layer) tonne/tone of product 2.5 % 52 tonne/day % R.A.Shaikh Paper Mills Pvt. Ltd. Waste Paper M.G. Kraft Paper tonne/tone of product % 80 tonne/day % Aryan Pulp and Paper Mill Imported Kraft paper Waste M.G. Kraft Paper (150 GSM) 1.11 tonne/tone of product 2.5 % 90 tonne/day 90 % Indian Kraft Paper Waste Old corrugated cartoon, New Kraft corrugated cutting, New corrugated cutting

6 Production Detail % Yield Avg. Production (t/d) Pulp and Paper Industries In Vapi Waste Paper Utilisation Waste Paper (t)/(t) of Product Pulp & Paper Industries In Vapi

7 WATER CONSUMPTION IN VARIOUS INDUSTRIES AT VAPI: Name of the Industry Water Usage in Process (m 3 /day) Total Water Consumption (m 3 /day) Total Waste Water Generated (m 3 /day) Shah Pulp & Paper Mills Ltd 540 (4.1 m 3 /tonne of product) (127 m 3 /day goes to CETP) Gayatri Shakti Paper & Board Ltd Damanganga Board Mills Pvt. Ltd. 30 (1.4 to 1.5 m 3 /tonne of product)) Ruby Macons Ltd (1.5 to 2 m 3 /tonne of product) [After treatment water is used for gardening] (Zero Discharge) Craft Corner Paper Mills Ltd. Kwality Pulp & Paper Mills Rama Pulp and Paper Ltd. (1.6 m 3 /tonne of product) 97 (Zero Discharge) (1.7 m 3 /tonne of product) 77 (Zero Discharge) (2.32 m 3 /tonne of product) 135 Zero Discharge Rama NewsPrint 6406 (29.6 m 3 /MT) 6945 (32 m 3 /MT) N.A.

8 Aryan Pulp and Paper Mill R.A.Shaikh Paper Mills Pvt. Ltd. (5.82 m 3 /tonne of product) 413 Zero Discharge 2.2 m 3 /tonne of product) m 3 /day goes to CETP

9 Water Consumption Gayatrishakti Rama Rama paper R.A.Shaikh Craft Kwality Aryan Damanganga Ruby Macons Shah Water Consumption (m3/tonne of product) Total Water Consumption Gayatrishakti Rama Rama paper R.A.Shaikh Craft Kwality Aryan Water Consumption (m3/day) Damanganga Ruby Macons Shah

10 ELECTRICITY/ENERGY CONSUMPTION IN VARIOUS INDUSTRIES AT VAPI: Name of the Industry Avg. Energy Consumption (KWH/MT of Product) Avg. Energy Consumption in process (KWH/month) Avg. Energy Consumption in ETP (KWH/month) Total Energy Consumption in Process + ETP (KWH/month) Remark Shah Pulp & Paper Mills Ltd Craft Corner Paper Mills Ltd. Kwality Pulp & Paper Mills Avg.Unit generated by turbine KWH/month and by G.G.Set KWH/month Rama Newsprint KWH/tonne consumed Rama Pulp & Paper Aryan Paper Mill

11 PROBLEM IDENTIFICATION IN VARIOUS PAPER INDUSTRIES: Plastic waste is generated after screening in poire. It is hazardous material as per GPCB norms. Normally Paper industries send the plastic waste to the cement Industries and do not apply any method for further reuse/recovery/recycle/reduce. Fly ash is generated from boiler in very high amount. But the industry sold it to the brick industry. They do not apply any new technology for further reuse. De inking sludge is generated due to chemical addition in the news print, duplex board and printing press paper industry. This type of solid waste is directly goes to the TSDF (Treated Solid Disposal Facility) for landfilling. But in future, there is no land available for landfilling if do not find technological option for reuse, recycle or reduction etc. Pulp goes to effluent from diabole equipment and centricleaner about 500 kg/day. Steam losses from open drying system is about 15% to 20 %.No steam recovery has been applied. Equipment modifications are required for better process control, reduce water consumption and also energy consumption. Loss of fibers from centricleaner and paper M/C head box due to poor Maintenance and handling operations. In duplex board, newsprint and printing press industries, are using alum as a sizing agent which reduce drainability, fiber retention and disables manufacturing of high grammage paper. It also increases total suspended particles in effluent. Consistency indicator and regulator do not install for better quality of paper. Lower consistency pulper is used for pulp preparation which consumes large Quantity of water. The number of dryers are increased for removal of water or Moisture from paper for better quality of it which consumes large quantity of energy.