Filler Recovery Process to Recover Raw Material in the Paper Mill Mineral Loaded Rejects ppt

Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 1
Title of Technology:

Filler Recovery Process to Recover Raw Material in the
Paper Mill Mineral Loaded Rejects
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage
Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
The FilRec™ process recovers the useful filler, which is the raw material in the paper making
stage and alters them to the paper furnish quality. The process starts with the fractionation
stage using pressure screen or bow screens, which separates out the coarse rejects (stiff
fibers, shives and other coarse solids like dirt) and the fine fractions, containing minerals and
water. The fine fractions from the fractionation stage are sent to the filler recovery stage,
which is a special type centrifugal cleaner separating out the mineral solids based on the
particle size. Fine fillers with water are sent back to the papermaking stage and the coarse
solids are sent to the mineral dispersion stage after concentrating them to 30 – 50% solids. In
the mineral dispersion stage, the coarse minerals are broken down with the help of a heavy-
duty dispersion machine. In this continuously circulated dispersion loop comprising of the filler
recovery and mineral dispersion stage, fine filler is recovered. The coarse fraction from the

fractionation stage is classified in the final rejects stage. The reusable fibers and fine fillers
are returned to the paper machine. The final rejects are sent for final disposal.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
65% fibre recovery
Reduction in Chemicals Requirement
80% fillers are saved based on broke quality
and make up
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)

•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in solids in the effluent
Equipment /Process Modifications
This is an add-on system to the paper mills with requirements of minor rerouting of piping
network.
Costing Details
Capital Cost: US $
300,000 to 400,000
Operating Costs US $ per year
Pumping and refining cost
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Recovered filler cost
Payback Period
Less than one year
Contacts of Successful User Contacts of Equipment Supplier
Name
Enso Fine Papers Oy

Name
Ahlstrom Machinery
Corporation
Address
Oulu Tehtaat PL 196
90101 Oulu
Finland
Address
Sentnerikuja 2
PO Box 5,
Helsinki 00441
Finland
Telephone
358-02046124
Telephone
(35) 89 503 9211
Telefax
358-0204633120
Telefax
(35) 89 562 4085
E-mail E-mail
www.ahlstrom.com/machinery
Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 2
Title of Technology

:
Wet Washing of Raw Material for Chloride Removal
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
The presence of chlorides affects any combustion technology and affects combustion in
fluidized bed recovery systems. However, the chlorides present in non wood raw materials
are washable and can be reduced to an acceptable level by means of suitably designed
washing systems consisting of equipment for submergence, washing draining and passing
through a screw press to an acceptable uniform level of moisture. The washing also helps
improve the pulp characteristics.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in water pollution load
Equipment /Process Modifications
The implementation of this technology requires installation of paddle washers, rotary drum
drain and screw press.
Costing Details
Capital Cost: US $
200,000
Operating Costs US $ per year

50,000
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
2 years
Contacts of Successful User Contacts of Equipment Supplier
Name
Shreyans Industries Limited
Name
Agro Pulping Machinery Pvt
Ltd.
Address
Ahmedgarh,
Dist. Sangrur
Punjab,
India
Address
Krishnan Complex, 4
th
Floor,
39-B, Chevalier Sivaji Ganesan
Road, T.Nagar,
Chennai – 600 017
India
Telephone
(91) 1675 40 347/40 349
Telephone

(91) 44 434 0698/ 434 4491
Telefax
(91) 1675 40 512
Telefax
(91) 44 434 5578
E-mail

snl.net.in
E-mail


Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 3
Title of Technology:

Hydrodynamic Separator for Raw Material Recovery
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load
Others

Process/Technology Description:
This technology is applied in the papermaking section to recover raw material and reduce
pollution loads. A new design of storage tank, “the hydrodynamic separator”, is installed
above the pulper on the paper making machines, which replaces the conventional white water
tanks. White water is pumped directly from the paper machine wire pit and press section to
the hydrodynamic separator. The white water enters the separator at an angle designed to
induce a cyclonic flow, which holds the solids in suspension towards the inner shell of the
vessel. Clear water separates and flows inwards below the annular baffle, overflowing the
central circular weir when the separator is full. The solids are concentrated at the bottom of
the separator, ready for the next pulper recharge. The conical base of the hydrodynamic
separator is shaped to release solids, reducing the number of blockages and therefore cutting
maintenance requirements.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in solids drain loss from 3.4% to
1.2%
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Solids removal by 42 to 96.5 %
Equipment /Process Modifications
In case of mills having white water tanks, retrofitting of the existing tanks and piping network
will be required. In case of mills not having white water tanks, installation of the entire system
is required.
Costing Details
Capital Cost: US $
102,000 for a 10,000 tons/ annum capacity mill
Operating Costs US $ per year
Savings : US $ per year
Power:

Chemicals:
Treatment costs:
Manpower:
Approx. 80,000
Payback Period
13 – 19 months
Contacts of Successful User Contacts of Equipment Supplier
Name
Arjo Wiggins Fine Papers Ltd.
Name
Indigenous Development
Address
Stowford Mill,
Ivybridge, Devon,
PL21 0AA
United Kingdom
Address
Telephone
(44) 1752 612 138
Telephone
Telefax
(44) 1752 612 103
Telefax
E-mail E-mail
Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand

Fact Sheet No: 4
Title of Technology:

Dry and Wet Cleaning of Straw
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
This technology is applicable in the agro-based mills, where the raw material poses a problem
due to higher amount of contaminants. This technology uses washers to wash the straw and
to remove unwanted part of the straw by use of a dregs remover. This kind of dry-wet straw
material preparation can remove mud, sand, grains, leaves and nodes, which can not turn
into fibres but consume chemicals in the course of digesting and bleaching. This process
improves pulp quality and reduces the quantity of pollutants generated in black liquor. Mud,
sand and grains removal upto 0.3 to 0.7 %, leaves and nodes removal upto 5 to 6 % are
achievable with this technology. Reduction in the hybrid cell content in the pulp is upto 4 %. In
addition, silica content of black liquor is reduced from 4.14 g/L to 3.59 g/L, which is favorable
for alkali recovery.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Optimum utilization of raw material
Reduction in Chemicals Requirement
Savings in chemicals by 2%
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)

Reduction in water pollution
Equipment /Process Modifications
For implementation of this technology, the feeding mouth of the four roller feeder needs to be
reduced and the hoppers also need to be modified. An additional screw conveyor to transfer
the raw material is required and the dregs remover needs to be replaced by dehydroextractor.
Costing Details
Capital Cost: US $
Operating Costs US $ per year
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Contacts of Successful User Contacts of Equipment Supplier
Name
Western Machinery Supplier
Address
Zhenjiang Light Ind. Machinery
Plant
Jiangsu Province
PR China
Telephone
Telefax
Widely used in China. For specific application,
please contact equipment supplier.
E-mail
Block Diagram of Adopted CP Technology:
4 # BELT
CONVEYOR

WASHNG
MASHINE
2# BELT
CONVEYOR
DEHYDROETRACTY
OR
SCREW
1# METERING
DEVICE
1# BELT
CONVEYOR
DIGESTER
RAW STRAW SHED

FOUR ROLLER
FEEDER
5 # BELT
CONVEYOR
2 #
METERING
DEVICE
6 # BELT
CONVEYOR
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 5
Title of Technology:

Application of Four Stage Counter-Current Vacuum Drum
Washers System for Extraction of Black Liquor
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
Four countercurrent vacuum washers are used in this system. The suction of the four vacuum
washers is maintained at 0.02 mPa. The temperature of the black liquor entering the washers
is maintained at 60
o
C and the residual alkali value after washing is achieved at a
concentration of less than 0.28 g/L. The requirement of the baume degree of the black liquor
before extraction is 6
o
Baume. According to the washing performance of straw pulp, in order
to keep a certain suction of the vacuum washers, lower pulp level, low rotation revolving of
drum and high thickness black liquor in operation are adopted. The operation requires one-
third wash drum to be immersed in pulp in order to keep the operation at low pulp level.
According to the diversities of raw material and their filterability, different thickness of feed
pulp are chosen to raise the dryness of the pulp after washing. In the equipment operation, it
is important to avoid the black liquor flow back to the vacuum washing system to influence the
steady state of suction. After going through the pulp washing system, the black liquor
extraction ratio reaches 80 to 85 % level. The higher concentration of the black liquor benefits
the alkali recovery.

Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in water consumption by 80%
Equipment /Process Modifications
This technology requires addition of four stage countercurrent vacuum washers system as an
add-on equipment with minor modifications in the existing system.
Costing Details
Capital Cost: US $
240,000
Operating Costs US $ per year
42,000
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Contacts of Successful User Contacts of Equipment Supplier
Name
Zhejiang Minfeng Group
Corporation
Name
Xi’an Paper-making Machinery
Plant
Address
70 # Luli Street, Jiaxing
Zhejiang Province

PR China
Address
Shannxi Province
PR China
Telephone Telephone
Telefax Telefax
E-mail E-mail
Block Diagram of Adopted CP Technology:
BLOW
TANK
1st
VACUUM
WASHER
2nd
VACUUM
WASHER
3rd
VACUUM
WASHER
4th
VACUUM
WASHER
FIBRE TRAP
BLACK
LIQUOR
BLACK
LIQUIOR
1# BLACK
LIQUIOR
STORAGE

TANK
2# BLACK
LIQUIOR
STORAGE
TANK
3# BLACK
LIQUIOR
STORAGE
TANK
4# BLACK
LIQUIOR
STORAGE
TANK
BLACK
LIQUIOR
BLACK
LIQUIOR
BLACK
LIQUIOR
CRUDE
PULP
ALKALI
RECOVERY
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 6
Title of Technology:

Solid State Chemical Recovery
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
There are a lot of wastes, both solid and liquid, which can be treated economically in
biological treatment by converting the waste first into a semi solid by mixing them with readily
available biomass and then subjecting the mixture to further biological and chemical
treatment. Strong wastewater like black liquor is extracted using special presses, and mixed
with easily available biomass and put into a solid state fermenter known as “Tuner Reactor”.
The mass dries up radially through thermofilic bio-fermentation and is then led to provide
heat. Extra heat is available for other uses. The ash is put through smelt dissolving and
further passed through recovery section for chemical recovery.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam Requirement (t/h)
Reduction in steam consumption
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
No secondary effluent streams
Equipment /Process Modifications
This technology implementation requires changing of black liquor washing system. New
equipment for solid state fermentation, pyrolysis and causticization need to be installed.
Costing Details

Capital Cost: US $
300,000
Operating Costs US $ per year
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Contacts of Successful User Contacts of Equipment Supplier
Name
Innovative Steels Pvt.
Limited
Name
Dewan Kraft Systems Pvt. Ltd.
Address
B-41, Sector 57, Noida
Uttar Pradesh
India
Address
No-127, Greater Kailash 1
New Delhi 110 048
India
Telephone Telephone
(91) 11 647 0215
Telefax Telefax
(91) 11 647 4646
E-mail E-mail

Website

/>Block Diagram of Adopted CP Technology:

Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 7
Title of Technology:

Twin Wire Filter Press
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
This process involves squeezing of pulp, sludges and biomass to extract water held inter-
statially, thus making them thicker. This technology finds application at all places where pulp,
sludges and biomass need to be treated as in case of deinking plants, effluent treatment
plants and dewatering in the pulp mills. This process is very useful in thickening of dilute
suspensions, thickening of pulp or any other dewatering requirements. The dilute suspension
of sludges is introduced through a headbox between a sandwich of two moving filter cloths
(wires). The wires move through a number of special rollers in a number of “S” formations to
squeeze out inter-statial water by gradually increasing shear forces. Hydraulic or pneumatic
presses are introduced as per the application demand.
Benefits and Investments Required:

Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in fuel, power requirement which
would be required for incinerating the waste.
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in water pollution
Avoids air pollution
Equipment /Process Modifications
Any existing system needs to be replaced by this equipment. The equipment requires
foundations and electrical connections.
Costing Details
Capital cost: US $
300,000 to 500,000
Operating costs US $ per year
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
2 years or less
Contacts of Successful User Contacts of Equipment Supplier
Name
UP Straw and Agro Pulp Mill Ltd.
Name
Dewan Kraft Systems Pvt. Ltd.
Address
New Delhi
India

Address
No-127, Greater Kailash 1
New Delhi 110 048
India
Telephone Telephone
(91) 11 647 0215
Telefax Telefax
(91) 11 647 4646
E-mail E-mail

Website
/>an
Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 8
Title of Technology
:
Sealed Water Recovery
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others

Process/Technology Description:
In the pulp and paper industry, water is used in different application areas like, process,
cooling, equipment jacketing etc. The water when used in a single pass system is wasted,
thus increasing the water requirements in the plant and increasing the requirements of
wastewater treatment. By making changes in the water loops and piping network, the sealed
water can be used in the system again. Since the water, which is used in the equipment
sealing needs to be clear of any impurities, such recovery system would require installation of
filters to purify water. The pressure requirements of the sealed water units and the drop in the
pipeline pressure needs to be matched in the system design.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Considerable reduction in the water

requirements
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in water pollution
Equipment /Process Modifications
The existing piping network needs to be modified for the re-routing of the water flow.
Additional equipment like small water tanks, filters etc. need to be installed.
Costing Details
Capital Cost: US $
Operating Costs US $ per year
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
2 years or less

Contacts of Successful User Contacts of Equipment Supplier
Name
Thai Kraft Paper Industry Co. Ltd.
Name
Indigenous Development
Address
99 Moo 6, Saeng Xuto Road,
Wangsala
Tha Muang, Kanchanaburi 71130
Thailand
Address
Telephone
(66) 34 561 440/561 191
Telephone
Telefax
(66) 34 561 199
Telefax
E-mail E-mail
Block Diagram of Adopted CP Technology:
ME 597 MOTOR
11 kW / 3 phase
380 V / 50 Hz
(in case of pressure failure, this
valve will be actuated to open
and mill water at constant 7 bar
will supersede sealed water)
Storage Tank
Main Filter
Recovery
Water

To Seal
Pump
WP#5
PIC
Booster Pump
(Standby)
ME
553
LIC
Mill Water
For make up tank
(in case of
insufficient
recovery water or
plugging in main
filter)
Pump
TDH = 60 M
Q = 30
m
3
/min
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 9
Title of Technology
:

Fluidized Bed Recovery System for Sodium Carbonate
Pellets
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
This technology involves treatment of undesired discharges from the pulp and paper industry
and recovery of bi-products from the same. The spent liquor from the pulp mill is concentrated
to a solid level of 20% in multiple effect evaporators. It is further concentrated to 40% solids
level at the venturi scrubber using the flue gases from Fluidized Bed Reactor (FBR). This
concentrated liquor is fired to the FBR with air/steam in the free board area. The organic part
of the black liquor burns and the inorganic salts form sodium carbonate pellets. This is a low
cost technology, which is within the reach of agro-based paper mills and also a low
temperature system capable of operating with higher silica black liquors. The particulate
emission is very low (150mg/m
3
). The mills adopting this technology have an option of selling
soda ash as a by-product. The system has an advantage of non-smelt residues, since the bed
media is a resourceful by-product. The process can be operated as a clean process, with the
addition of appropriate air pollution control equipment.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description

Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)

Reduction in water pollution
Equipment /Process Modifications
Add-on technology to the existing operating plants.
Costing Details
Capital Cost: US $
2,500,000
Operating Costs US $ per year
700,000
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
5 years
Contacts of Successful User Contacts of Equipment Supplier
Name
Shreyans Industries Limited
Name
Agro Pulping Machinery Pvt.
Ltd.
Address
Ahmedgarh, Dist. Sangru
Panjab
India
Address
Krishnan Complex, 4
th
Floor
39-B, Chevaliar Sivaji Ganesan

Road, T. Nagar
Chennai 600 017
India
Telephone
(91) 1675 40 347/ 40 349
Telephone
(91) 44 434 0698/ 434 4491
Telefax
(91) 1675 40 512
Telefax
(91) 44 434 5578
E-mail

vsnl.net.in
E-mail

Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 10
Title of Technology:

Dust Removal System in the Paper Cutting Operation
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage

Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
This technology finds application in the paper cutting operation, where a lot of dust is
produced affecting the work environment. This technology uses the controlled plant air to
suppress the small paper particles, which escape to the plant atmosphere. The air streams
build shield around the machine where the cutting operation takes place. This process not
only reduces the air pollution in the plant room, but also improves the working conditions in
the plant, as per the norms stipulated by the local authorities.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam Requirement (t/h)
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in particulates in the plant room.
Equipment /Process Modifications
The implementation of this technology requires installation of dust control equipment like air
ducts, solids collection system etc.
Costing Details
Capital Cost: US $
Operating Costs US $ per year
Savings : US $ per year
Steam:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Contacts of Successful User Contacts of Equipment Supplier

Name
Valmet Machinery
Address
9
th
Floor, Home Place Building
Sukhumvit Soi 55
Bangkok 10110
Thailand
Telephone
(66) 2 712 7241/ 712 7246
Telefax
(66) 2 712 7240
Please contact equipment supplier for specific
details.
E-mail

Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 11
Title of Technology
:
Depithing of Bagasse
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage

Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
Bagasse has been used as a principal agro-residue raw material both in small scale and
medium scale pulp and paper mills - as a substitute for wood. Bagasse contains 30-32% of
non-cellulosic material in addition to sand and fines. Cooking of bagasse without pith removal
consumes higher chemicals, energy and generates high pollution load. By installation of
depither 20-26% of pith can be removed resulting into reduced chemical, energy
consumption, increased yield and reduced pollution load. Separated pith can be used as a
fuel in steam generating boiler, thus reducing the problems that would be posed by solid
waste pollution. Depithing of bagasse in sugar mill is recommended to reduce transportation
costs and proper use of pith as fuel. After implementation of this technology, the pulping
capacity is expected to be increased by about 20 %.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Energy 10 – 15 % (for pulping)
Reduction in steam consumption
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in pollution load by 20- 25 %
Equipment /Process Modifications
The implementation of this technology requires installation of bagasse conveyor, bale
breaker, depither and pith conveyor/ blower.
Costing Details
Capital Cost: US $
20,000

Operating Costs US $ per year
10,000
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Less than 6 months
Contacts of Successful User Contacts of Equipment Supplier
Name
Bindla Duplex
Name
Chellam Projects Consultancy
and Technical Services Limited
Address
85 Km Stone, Bhpoa Road
Muzaffarnagar, Uttar Pradesh
India
Address
Krishnan Complex 4
th
Floor 39-
B, South Boag Road, T. Nagar
Chennai 600 017
India
Telephone
(91) 132 402 519/ 401 419
Telephone
(91) 44 434 0698/ 434 4491

Telefax
(91) 132 401 619
Telefax
(91) 44 434 5578
E-mail E-mail

Block Diagram of Adopted CP Technology:
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 12
Title of Technology:
Process Control : Stock Consistency Measurement and
Control Using Light Sensor
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage
Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
The light sensor consistency of transmitter has several advantages:-
1. No moving parts in the pipeline
2. Could handle high velocity
3. Not sensitive to velocity
4. It can be maintained without causing show down

5. Could be used for wide range of consistencies
6. Easy to calibrate
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m
3
)
•

Steam requirement (t/h)
Reduction in Chemicals Requirement
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)

•

Air emissions (Flow/SO
x,
NO
x
)
Equipment /Process Modifications
Costing Details
Capital Cost: US $
US $ 35, 000 each unit
Operating Costs US $ per year
Negligible as part of operating cost
Savings : US $ per year
Power:
Chemicals:
Treatment costs:
Manpower:
Payback Period
Contacts of Successful User Contacts of Equipment Supplier
Name
BTG KALLE
Address
Box 6062
SAFFLE 661 29
SWEDEN
Telephone
(46) 5334 2742
Telefax
(46) 5334 2608

Widely applied all over the world in
modern mills.
E-mail
Block Diagram of Adopted CP Technology:
Flo
Flow
2
I
I
I
D
1
3
Remarks:
1. Regulates light intensity
2. Consistency meausrement
3. Primary light beam
Technology Fact Sheet for Cleaner
Production in Pulp and Paper Industry
Network for Industrial School of Environment, Resources and Development
Environmental Management Asian Institute of Technology
UNEP – ROAP, Bangkok, Thailand Bangkok, Thailand
Fact Sheet No: 13
Title of Technology:

Fibre Recovery by Dissolved Air Floatation
Technology Applied in
:
Raw Material Preparation Stage Pulping Stage
Bleaching Stage Chemical Recovery Stage

Recycled Fiber Technology Stock Preparation Stage
Paper Making Stage Utilities/ Effluent Treatment
Technology Implementation Results in Reduction of:
Energy Consumption Pollution Volume/ Load Others
Process/Technology Description:
In pulp and paper units, lot of short fibres and fillers escape with water through the paper
machine wire, thickeners etc. This loss can be upto 7-8% of net production. In addition to
this, due to scarcity of natural resources viz. water and need to minimize the load of pollution
from paper industries, the concept of closed water system emerged. Dissolved Air Floatation
(DAF) is one of the alternatives to capture the fibres, reduce the pollution load and recycle the
water for process. Floating sludge separated in the DAF units is with high solid consistency
(2.3%) and can be directly recycled to machine chest. High molecular weight polyelectrolyte
ensures flocculation of smallest colloid and also help as retention aid on machine wire. This
technology requires higher operating costs due to high pressure requirements and also works
at higher chemical costs due to the requirements of the treatment chemicals.
Benefits and Investments Required:
Expected Benefits
(In absolute figures or % )

Description
Reduction in Utilities Requirement
•

Electricity consumption (kWh)
•

Wood/Fibre consumption (t/d)
•

Water consumption (m

3
)
•

Steam requirement (t/h)
Reduction in raw material requirements
Reduction in water requirement
Reduction in Chemicals Requirement
Reduction in treatment chemicals
Reduction in Pollution Generation
•

Water (BOD/COD/volume/toxicity)
•

Solid waste (kg/day)
•

Air emissions (Flow/SO
x,
NO
x
)
Reduction in water pollution
Equipment /Process Modifications
The implementation of this technology requires installation of surge tanks, scraping devices
for floating matter and pumps for feed water and recovered fibre.