BALLARPUR INDUSTRIES LIMITED

UNIT SHREE GOPAL

Paper Making Process

PAPER MAKING PROCESS

RAW MATERIALS USED

Veneer : 40-45%
Consumption 325 TPD

Bamboo : 15-18%
Consumption 90 TPD

Euca. Wood : 35-40%

Consumption 175 TPD

FLOW DIAGRAM OF PAPER MILL

Raw
Material

Pulp
Mill

Chipper

Paper
Machine

Paper
Finishing

Chemical
Recovery

MSD
Godown

Dispatch

Chemical
Complex

Engg
Water
Maintenance Supply

Power
Plant

Effluent
Treatment
Plant

HR

Costing
&
Finance

QC/
R&D

Purchase
& Store

PULP MAKING PROCESS

Steam for Power

White Liquor

PULP MILL

Chipper House
Chipper
no.

Make

Capacity
(MT/h)

Raw mat.
handling

Vecoplan No. 1

25

Woodlogs/
Bamboo

Vecoplan No. 2

15

Veneer waste
Chipper

Digester House
Kraft/Sulphate pulping process
No of Digester

: 3 of 120 m3 each

Type

: Vertical stationary of indirect heating

Cooking Time

: 260 minutes

Pulp/cook

: 12.0 MT

Digester

PULP MILL

Wash Plant
Rotary Drum Vacuum Washer: : 4 Stages
Capacity

:195 BD Pulp per day

Hot Water & Foul

Condensate

Washer

Washer

Defoamer
dosing at
inlet line of
BSW-1

Filtrate

Filtrate

Weak Black
Liquor to
Recovery

Unbleached Pulp
Drum Washer Filtrate

Filtrate

PULP MILL

Bleach Plant
Conventional bleaching process
Capacity
: 180 BD pulp per day
Bleaching sequence
: CDEOPD1D2
Centricleaner
Pulp brightness(ISO)
UN BLD
PULP
FROM
W/P

: 4 stage
: 89-90 %

EO
B/W
C/D B/W

NaOH
EO
H/W B/W

M/C
No.4
B/W

UN
BLD
400 M

C/D
80M3

C/DMC
MIXER
C/D MC
PUMP

CD

H/W
LP
STEAM

H.MIXER
FILT
TANK

D1
H/W B/W

H2O2

EO

58
PRE
M3
TUBE

DI
B/W

156
M3

EO

EO MC PUMP

EO
B/W

EO STOCK
PUMP

Cl2

D1

To ETP

To ETP

LP
STEAM
D1

D2

D2

250
M3

CENTRI CLEANING

H.MIXER
D1 MC
MIXER

D2 MC
MIXER

FILT.
TANK

DI MC
PUMP
ClO2

ClO2

DECKER
B/W
DECKER
B/W

FILT.
TANK

O2

Bleach towers

D2
B/W

250
M3

H.MIXER
EO MC
MIXER

D2
B/W

D1
B/W

LP
STEAM

Eop

D2
B/W

FILT.
TANK

MILL
WATER
MILL
WATER

DEC
KER

D2 MC PUMP
ClO2

FILT.
TANK

Storage
tower
Paper m/c

DECKER
MC PUMP

RECOVERY
Evaporator 1
Type
No of effects

: Short tube vertical (STVE) and free flow falling film

: STVE-5 , FFFFE-4

Handling of thin BL : 72 m3/hr

Steam Economy

: 4.5

Concentration of BL : 62-64 %
Evaporator 2
Type
No of effects

: Short tube vertical (STVE)

: STVE-6

Handling of thin BL : 20 m3/hr

Steam Economy

: 3.0

Concentration of BL : 60-62 %
Recovery Boiler
No of Boiler : 2
- JMW
- ABL
Total capacity

: 315 TPD solids

Evaporator

RECOVERY
Causticizing Section
Capacity

70 TPD, active alkali as Na2O

Slaker

Stationary

Lime mud washing

2 Streets

Lime Kiln
Year of installation

2005

Capacity

60 TPD

Lime kiln

HD towerPulp
Pulp
BleachedReceiving
Refining
pulp
Chest

Broke
Tinting
Dyes
Optical
Whitener
Sizing
Chemicals
Filler

Fiber
Recovery
System

Power

PROCESS OF PAPER MAKING STOCK PREPARATION

Functional
Additives
addition

Approach
Paper
flow
Machine
system

PAPER MACHINES
Machine Type Make
No.
1

MF

MF

Charles
Wamsely
Charles
Wamsely

Deckle
cm
314

314

Speed GSM
m/min. range
100

115

60-90

58190

Production Paper grades

TPD
30

REB
Super Printing
Lky Parchment

40

S/L Bond
Super Printing
Super
Cartridge

MF

Esser
Wyss

311

350

54149

75

Bilt Classic
S/L Offset
S/L
Cartridge

MF

Alstom

223

270

60124

50

MMPP
BCB Base

120

70100

27

REB Normal
REB Colored
Criss Cross

MF

Karhula

272

All machines are equipped with size press.

PAPER CONVERSION

Reel
Orders

Sheet
Orders

PROCESS PAPER CONVERSION & FINISHING REWINDER

Max reel capacity

Speed in mpm

PM-1 Jag
Rewinder

PM-2 Jag
Rewinder

PM-4, Beloit
Rewinder

PM-4, Masson
Scott

400

400

600

500

Beloit Rewinder

Masson Scott
Rewinder

PROCESS PAPER CONVERSION & FINISHING REWINDER

Max reel capacity

Speed in mpm

Servall
Winder

PM-5, Servall

PM-7, Jagenberg

800

600

Jagenberg
Winder

EFFLUENT TREATMENT PLANT

Three stage Effluent Treatment Plant

Installed and Commissioned in 1987
-Activated sludge process
-Design Capacity: 54000 m3/day
-Operating Capacity: 28000 m3/day

Data showing the compliance to environmental norms

PARTICULARS

UNIT

INFLUENT

HSPCB
NORMS
EFFLUENT

TREATED
WATER
EFFLUENT
as on Nov09

7-8

7.0-8.5

7.2 7.8

pH

NA

BOD

PPM

280-350

30

18-25

COD

PPM

700-900

350

150-180

SUSPENDED SOLIDS

PPM

700-900

50

25-35

AOX

KG/T Paper

1.2-1.6

<1.0

0.6 -0.8

PAPER MAKING PROCESS

Pulp Supply
System
Stock refining
System cleaning
Approach Flow
system
Paper making- MF

PROCESS FLOW: STOCK PREPARATION (PM 1,2 & 4)

Tinting dyes/ pigment

preparation
Optical whitener
preparation
PAC: Poly Aluminum
Chloride
Filler/Dispersed Rosin/
Fill Plus

Pulp from
Bleached
Stock Chest

Dry broke
through
pulper

Buffer Chest

Broke Storage

Refining of Stock
through Refiners in
Refined Chest

Broke Cleaning
System

Mixing Chest

Cleaned Broke
Tower

Machine Chest
SR Box
Fan Pump

Filler Slurry
Percol-47 Preparation
system
Hydrocol- RK2
Preparation system

Centricleaner
Pressure Screen
Head Box

Wet Broke from

respective M/C

PULP SUPPLY SYSTEM (PM 1,2 & 4)

Machine back
water
(Krofta/Disc filter
filtrate) for
bottom dilution

1000 m3
Bleached
Pulp

Thickener

Buffer
Chest

To Refiners of PM 1, 2 & 4

Fill Plus
PAC
Dispersed
Rosin
Filler

Tinting
Dye

Pulp from
Buffer Chest

STOCK PREPARATION: PAPER MACHINE-1

Refiner

Mixing
Chest

Machine
Chest

Refined pulp SR: Tinting Dye:

28-30
Iraglite Violet
Pulp Consistency:4.0%

SR Box

Fill Plus: 1.0 kg/T

PAC : 17 kg/MT

Fan Pump

Rosin: 13-16
kg/MT
Filler:
Finex/CaCO3

Defoamer Biocide

Wire Part
Defoamer
Afranil ST 0.5 kg/MT

Head Box

Pressure
Screen

Centricleaner

Fill Plus
PAC
Dispersed
Rosin
Filler

Tinting
Dye

Pulp from
Buffer Chest

STOCK PREPARATION: PAPER MACHINE-2

Mixing
Chest

Refiner
Refined pulp SR:
28-30
Pulp Consistency:
4.0%

Machine
Chest

Tinting Dye:
Iraglite Violet

SR Box

Fill Plus: 1.0 kg/T

PAC : 17 kg/MT

Fan Pump

Rosin: 10 kg/MT
Filler: Finex/

Defoamer Biocide

Wire Part
Defoamer
Afranil ST 0.5 kg/MT

Head Box

Pressure
Screen

Centricleaner

STOCK PREPARATION: PULP REFINING PM-1&2

NPM Pulp

TDR
21 &
DDR
20

Buffer
Chest

Mixin
g
Chest

Machine
Chest

Machine
Refiner

SR
Box

Not in
operation

Paper
Machine-1

NPM Pulp

Buffer
Chest

TDR
24

Mixin
g
Chest

Machine
Chest

Machine
Refiner
Not in
operation

Paper

SR
Box

Mixing
Chest

Refiner
Refined pulp SR:
28-30
Pulp Consistency:
4.0

Defoamer
Afranil ST 0.5 kg/MT

Dispersed
Rosin

Filler

Machine
Chest

Tinting Dye:
As per Quality
OBA: 2.5 kg/MT
Rosin: 10 kg/MT

Wire Part

PAC
Fill Plus

Tinting
Dye

OBA

Pulp from
Buffer Chest

STOCK PREPARATION: PAPER MACHINE 4

SR Box

Fan Pump

PAC : 25 kg/MT
Fill Plus: 2.3
kg/MT

Head Box

Pressure
Screen

Centricleaner

STOCK PREPARATION: PULP REFINING PM-4

DDR-1

Measuring
Tank

Virgin Pulp

Buffer
Chest

Broke

Broke
Chest

Refined
Pulp
Chest

Mixing/
Machine
Chest

SR
Box

PROCESS FLOW : STOCK PREPARATION PM-5&7

Tinting dyes/ pigment

Pulp from
Pulp Mill

Dry broke through

pulper

New Mixing Chest

Broke Chest-1
Optical whitener
PAC: Poly Aluminum
Chloride

Refining of Stock
through Refiners

Broke Chest-2

Mixing Chest

Dispersed Rosin
Filler Slurry

Machine Chest

Cationic tarch

SR Box
Fan Pump
Centricleaner
Pressure Screen
Head Box

Wet Broke from

respective M/C

PULP SUPPLY SYSTEM: PM- 5&7

Machine back
water for bottom
dilution

500 m3
Bleached
Pulp

To PM-5 & 7
Stock Prep.

STOCK PREPARATION: PAPER MACHINE 5

Tinting Dye
& OBA
Coated
broke

Wire Part
Defoamer
Antimusol- BPI Liq: 1-1.2
kg/MT

Filler

Machine
Chest

Rosin: 22-25 kg/T

PAC : 32 kg/T

DefoamerBiocide

Rag Chest

Tinting dye:
Irgalite/Methyl
OBA : 2-2.5 kg/T

Cationic
Starch

PAC

New
Mixing

Mixing
Chest

Refiner
Refined pulp
SR:27
Pulp Cy
:3.7%

Dispered
Rosin

Dump
Chest

Broke

Circulation
Chest

Own Pulp

SR Box

Fan Pump

Cato Starch: 3kg/T

Filler : 110-250
kg/T

Head Box

Pressure
Screen

Centricleaner

STOCK PREPARATION: PULP REFINING PM-5

Coated
Broke
Virgin Pulp

Rag
Chest

DDR

New
Mixing
Chest

Dump
Chest

SR
Box

Circulation
Chest

Machine
Chest

Broke
Pulper

Broke
Chest-1

TDR

To be Use as per
requirement

Mixin
g
Chest

Broke
Chest-2

STOCK PREPARATION: PAPER MACHINE 7

Tinting Dye
Hydrex-P
Own Pulp

Mixing
Chest

Refiner
Refined pulp SR:
26
Pulp Cy :3.7%

Hydra
Pulper

New
Mixing
chest
Cationic
Starch

Hydrex-P : 1517kg/MT
Tinting Dye ; Irg.
voilet

Filler

Dispered
Rosin+PA
C
OBA

Broke

Cir. Chest

Machine
Chest

Rosin: 32 kg/T
PAC : 34 kg/T
OBA : 8-9kg/T

Imported
Pulp

SR Box

Filler : 225-235
kg/MT

Fan Pump

Cato Starch:563kg/T

DefoamerBiocide

Wire Part
Defoamer
Antimusol- BPI Liq: 2-2.5
kg/MT

Head Box

Pressure
Screen

Centricleaner

STOCK PREPARATION: PULP REFINING PM-7

Wood Pulp

Wood
Pulper

CONFLOW
REFINER

Virgin Pulp

New
Mixing
Chest

SR
Box

Circulation
Chest

Machine
Refiner

Machine
Chest

Broke
Pulper

Mixin
g
Chest

Broke
Chest

STOCK PREPARATION: REFINER DATA

M/C

Refiner /Type

M/C 1 TDR-21"

M/C 2 TDR-24"

M/C 4

Motor
drive,
kw
3 x 3.5 x 12

250

Running
load (A)
180

No Load
Net load SEL
Power
KWHr Wsec/m
KwHr
60

120
1.17

Bar angle = 10
deg
2.8*3.3*8

350

320

140

180
0.79

Bar angle = 10
deg

DDR-24"

2 x 3.2 x 6.3

0SDM

Bar angle =
10deg

300

300

110

190
0.78

DDR-24"

4 x 8 x 8 x 30

250

200

120

80

0.6

TDR-21"

3 x 3.5 x 12 x 10

200

180

60

120

1.17

M/C 7 CONFLO

3.5 x 5 x 9 x 18

225

162

60

102

1.42

M/C 5

MF Paper Machines PM1,2,4,5 & 7

PROCESS PAPERMAKING : MF PAPER MACHINE

Dry Broke for cleaning & reuse

Wet Broke for
reuse
Back water
to fiber
recovery

Starch + Size
Press Additives
Steam

Steam

PROCESS OF PAPERMAKING: MF PAPER MACHINE

Machine

PM-1

PM-2

PM-4

PM-5

PM-7

Make

Charles
Walsmey

Charles
Walsmey

Escher
Wyss

Alsthrom,
Germanny

Karhula

Year

1936

1936

1960
Renovated
in 2004

1984

1984

Speed, mpm

100

110

340

260

120

Deckle width,
meter
Production,
MT/day
GSM

3.12

3.12

3.12

2.24

2.73

30-35

20-50

68-100

55-60

28

70-95

58-190

54-149

80-185

70-100

PROCESS OF STOCK CLEANING: PM-4

Stock at Stuff
box from
Machine chest
Dilution of stock with back
water in Primary Fan Pump

Back
Water

Cleaning at Primary
Centricleaner

Couch pit

Dilution of stock with back

water in Fan Pump
Reject

Screening at
Vibratory
Screen

Screening at Pressure
Screen
Head Box

To
Drain

Reje
ct

Cleaning
at
Secondar
y
Centriclea
ner

Accep
t to
Prima
ry
Fan
Pump
Sucti
on

Cleaning
at
Tertiary
Centriclea
ner
Cleaning
at
Quaternar
y
Centriclea
ner
( fibermizer )

To Maloney
filter

PROCESS OF STOCK CLEANING: PM-5

Stock at Stuff
box from
Machine chest
Dilution of stock with back
water in Primary
centriclener

Back
Water

Screening at Primary
Centricleaner

Dilution of stock with back

water in Fan pump
Screening at
Vibratory
Screen

Reject

Screening at
Tertiary
Centricleane
r

Screening at Pressure
Screen
Pope Reel

To
Drain

Reject Screening
at
Secondary
Centriclean
er

Screening
at
Fibermise
r
To Drain

Accept
to PCC
Pump
Suctio
n

PROCESS OF STOCK CLEANING: PM-7

Stock at Stuff
box from
Machine chest
Dilution of stock with back
water in Primary
centriclener

Back
Water

Screening at Primary
Centricleaner

Screening at
Vibratory
Screen

Screening at
Tertiary
Centricleane
r

Reject

Screening at Pressure
Screen
Pope Reel

To
Drain

Reject Screening
at
Secondary
Centriclean
er

Screening
at
Fibermise
r
To Drain

Accept to
PCC
Suction

PROCESS OF PAPERMAKING
Centricleaner:
Paper M/c

Primary

24

22

15

Secondary

Tertiary

Quaternary

Pressure Screen:
Paper M/c
Type
Slot Size

Slotted

Slotted

Slotted

Slotted

Slotted

0.30

0.30

0.30

0.30

0.25

Pressure Screen

PROCESS OF PAPER MAKING: HEAD BOX

Machine
Head Box type

Closed
Closed
Air
Pressurized
Cushioned

Open

Open

Distributors

Simple
Manifold

Simple
Manifold

Tapered
Flow

Tapered
Manifold

Tapered
Manifold

Consistency

0.5-1.0 %

0.6-1.2 %

0.6-1.0 %

0.8-1.0 %

0.7-0.9 %

Freeness, SR

40-42

40-42

40-42

34-36

40-42

Slice opening,
mm

10

10

15

12-14

13

3350

3350

3400

2450

3000

25

25

28

22

24

Slice width, mm
No of slices

Open

PROCESS OF PAPER MAKING: WIRE PART

Machine

406

600

550

500

500

No of table Rolls

16

12

No of Hydrofoils

17

50

Breast roll diameter,

mm

Wet vacuum Boxes

Dry vacuum Boxes

350

100-200

200-220

200

200

350

350

440-480

400-450

280-300

762

762

762

650

618

Vacuum Applied , mm
of Hg
Couch roll Vacuum,
mm of Hg
Couch roll Dia mm

PROCESS OF PAPER MAKING: PRESS PART

Machine

Plain

Plain

Suction

Suction

Suction

Top roll

Granite

Granite

Dyna rock

Micro rock

Granite

Bottom roll

Rubber

Rubber

Rubber

Rubber

Rubber

Plain

Plain

Plain

Plain

Plain

Top roll

Granite

Granite

Bottom roll

Rubber

Rubber

Rubber

Rubber

Rubber

Offset

Offset

Reverse

Offset

Offset

Top roll

Granite

Granite

Bottom roll

Rubber

Rubber

1st Press
Type

2nd Press
Type

Dyna Rock Micro rock

Micro rock

3rd Press
Type

Dyna rock Micro mate Miicro mate

Rubber

Microrock

Brass

PROCESS OF PAPER MAKING: DRYER SECTION

Machine

No of dryers

27

27

36

28

16

65

65

118

70

48

Bucket
type

Bucket
type

Bucket
type

Siphon
type

Bucket
type

Stationary

Stationary

Semi
closed

Semi
closed

No of dryer
groups
No of felt
rolls
Condensate
Removal
sissies
Syphon type
Hood

Stationary Stationary Stationary

Semi
closed

Semi
closed

Semi
closed

PROCESS OF PAPER MAKING: CALENDER & SIZE PRESS

Machine

No of stacks

No of rolls

Inclined
Micro
Rock
Micro
Mate

Inclined
Micro
Rock
Micro
Mate

Calendar

Size Press
Type
Movable roll
material
Fixed roll
material
Loading
Paper
feeding

Hydraulic Hydraulic
Rope
Rope
carrier
carrier

Horizontal Horizontal
Micro
Micro
Mate
Mate
Micro
Micro
Rock
Rock
Hydraulic
Rope
carrier

Inclined
Micro
Mate
Micro
Rock

Hydraulic Hydraulic
Rope
carrier

Rope
carrier

PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METER

Machine
Machine Wire
Pick Felt/ First Press
Felt
Second Press Felt
Third Press Felt
First top Dryer
Screen
First bottom Dryer
Screen
Second top dryer
screen
Second bottom dryer
screen
Third top dryer
screen
Third bottom dryer
screen
Fourth top dryer
screen
Fourth bottom dryer
screen
Sixth top dryer
screen
Sixth bottom dryer
screen

1
19.81 x
3.45
10.36 x
3.55
10.36 x
3.55

2
19.81 x
3.45
10.36 x
3.55
10.36 x
3.55

25.30 x
3.55
25.30 x
3.55
25.30 x
3.55
25.30 x
3.55
12.50 x
3.55
7.00 x
3.55
23.30x3.5
5
23.30x3.5
5
-

25.30 x
3.55
25.30 x
3.55
25.30 x
3.55
25.30 x
3.55
12.50 x
3.55
7.00 x
3.55
23.30 x
3.55
23.30 x
3.90
35.00 x
3.90
39.80 x
3.90

4
28.06 x
3.55
16.50 x
3.65
16.50 x
3.65
16.50 x
3.65
43.00x
3.55
27.80 x
3.60
27.80 x
3.60
21.80 x
3.60
21.80 x
3.60
30.00 x
3.55
32.00 x
3.60
29.90x3.6
0
29.90x3.6
0

22.3 x 2.62

20.26 x 3.13

10.5 x 2.65

12.0 x 3.10

11.2 x 2.65

12.0 x 3.10

27.0 x 2.65

16.0 x 3.10

27.0 x 2.65

16.0 x 3.10

21.5 x 2.65
21.5 x 2.65
21.5 x 2.65

20.0 x 3.10
20.0 x 3.10
16.0 x 3.10

21.5 x 2.65

16.0 x 3.10

21.5 x 2.65

21.5 x 2.65

Thanks

PROCESS OF PAPER MAKING: PAPER MACHINE

Details
M/C 1
Make
Charles Wamsley
Year Of Installation
1926
Machine Floor
Ground Floor
Production (Tpd)
30
Machine Speed(Mpm)
100
Machine Deckle(C.M)
314
Draw
Open
Approach Flow System
Machine Refiner Type
TDR/21
Pressure Screens No.
1
Type of Pressure Screen/Size
Slot/0.3
Centricleaners Stages
3+1
No.of Bottles in1st Stage
8
In 2nd Stage
3
In 3rd Stage
1
In 4th Stage
1
Head Box
Type
Dandy Roll
Dia.of Dandy (mm)
Press Part
Ist Press Type
2nd Press Type
3rd Press Type
Dryer Section
Total No. of Dryer Cylinders
Dryer Groups (Steam Wise)
No. of D/Cy.In Pre Dryer
No. of D/Cy. In Post Dryer
Cooling Cylinders
No. of Cooling Cylinders
Size Press
Type
Steam System
Condensate Removal System
Type of Calender
Pope Reel

M/C 2
Charles Wamsley
1926
Ground Floor
40
110
314
Open

M/C 4
Esser Wyss

TDR/24
1
Slot/0.3
3+1
8
3
1
1

DDR/24
2
Slot/0.3
3+1
24
8
4
1

Open

Open

Closed air
Coushioned

Closed
Pressurized

Yes
330

Yes
330

Yes
1000

Solid
Solid
Reverse

Solid
Solid
Reverse

27
4
19
8
No

Inclind
Conventional
Bucket
Kuster
Inclined

1st Floor
75
350
311
Open

M/C 5
Alstom
1983
1st Floor
47
270
223
Open

M/C 6
Karhula
1983
1st Floor
1.8
60
210
Oen

DDR/24&TDR/21 Conical,Beater
1
0
Slot/0.3
3+1
1
22
3
7
1
1

M/C 7
Karhula
1983
1st Floor
27
115
272
Open
Conflo
1
Slot/0.25
3+1
15
5
1
1

Open

open

Yes
800

No

Yes
500

Suction
Solid
Reverse

Suction
Solid
Smoothening

Solid
Solid

Suction
Solid
Smoothening

27
4
19
8
No

36
6
24
12
Yes
2

28
4
20
8
No

10
3

16
3
10
6
No

Inclind
Conventional
Bucket
Kuster
Inclined

Horizontal
Conventional
Bucket
Kuster
Horizontal

Puddle type
Conventional
Siphon
Kuster
Horizontal

No

Conventional
Bucket

Puddle type
Conventional
Bucket
Kuster
Horizontal