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Report
PM-6 LINE
(OCC-PLANT, CTMP PLANT, Chemical Section and PM-6)
Submitted By
Acknowledgement
ountless thanks to ALLAH Almighty for giving me such extraordinary abilities and making me privileged enough to take part in such activities and all respects and regards to Holy Prophet Hazrat Muhammad (PBUH) for giving me the faith paving me on the right path with the essence of faith in ALLAH. I would like to express my heartiest gratitude to: Rana Javed Bahir, Mill Manager (BSPM), Packages Limited. Dr. Baber Ali, PM-6 Line Manager, Packages Limited. Engr. Khalid Mahmood, PM-6 Manager, Packages Limited. Engr. Adnan Yousaf, Manager OCC and CTMP Plant, Packages Limited. Engr.M. Waseem, Development Engineer PM-6, Packages Limited. Engr. Qaiser Iqbal, Process Engineer Chemical Section, Packages Limited. Engr. Sharjil Naushad, Shift Executive PM-6, Packages Limited. Engr. M. Ammar Malik, Shift Executive PM-6, Packages Limited. M. Khalil (APS-OCC), Packages Limited. I would also like to thank my Supervisor Dr. Baber Ali, Engr. Khalid Mahmood and Engr. Saqib Arif for their cooperation and help. They fully supported me throughout my work. I express my heartiest gratitude to them. Their cooperation made this project a lot much easier. Bundle of thanks to my parents, who were and are very supportive and cooperative at every time and always there by my side to guide me and gave me the courage that I can do the best in my life and taught me the differ between the good and the evil, for this be my guide in my life.
CONTENTS
Page No. Acknowledgement ..02 Contents ..03 Executive Summary 04 Introduction .05 History of Paper ..06 Producing Paper Today ...07 Making Pulp from Wood ....08 Making Pulp from Waste 10 Manufacturing Paper from Pulp .11 Full Paper Making Process .13 Paper Making Machine ...17 Paper Manufacturing in Pakistan 19 Paper Manufacturing in Packages Limited (Pakistan) 24 Company Profile and History .24 Products ...26 BULLEH SHAH PAPER MILLS ...28 The Bulleh Shah Project ..28 Paper and Board Manufacturing in BSPM ..29 OCC-PLANT ...29 Raw Materials of OCC-PLANT ..29 Stages in OCC-PLANT 29 Block Diagrams ....30 CTMP-PLANT .33 Raw Material of CTMP-PLANT ..33 Stages in CTMP-PLANT ..33 Block Diagram ..33 Chemical Section ..34 Pulp Section Chemicals 34 Types of Chemicals ..35 Paper Manufacturing Process at PM-6 Line .36 Block Diagrams of Approach Flow System of PM-6 Line ..............36 Block Diagram of Broke System of PM-6 ...37 Block Diagram of Paper Manufacturing Process at PM-6 ... 37 Stages in Paper Manufacturing Process at PM-6 ..38 Conclusions and Problems 42 Recommendations .42 References .42
Executive Summary
y learning Experience with Packages Limited begins with my joining from 0107-2010 which has completed now. My internship report contains all the information about my work experience with the Packages Limited, which was established in 1956 as a joint venture between the Ali Group of Pakistan and Akerlund & Rausing of Sweden to convert paper and paperboard into packaging for the consumer industry and commissioned its own paper mill with a production capacity of 24,000 tones in 1968. With growing demand the capacity was increased periodically and in 2003 was nearly 100,000 tones per year and production capacity is increasing day by day. As a Internee I spent good time in learning and was rewarded for my best efforts, learnt to deal with different situations, had experience of industrys working environment which effects an engineer performance and attitude towards work and had good time in learning and performing as a trainee engineer in the PM-6 but also experienced the turbulence of the trouble times while PM-6 was going through one of its major transition phase. Confidence, on time decision making, consistency, hard work, team work, seeking success out of dark, innovation, creativity, problems handling or solving techniques and customer handling techniques are the key learnings out of my job and I would like to say it will be one of my best skill that would remain with me and help me in the coming life which offer many challenges. In short I would like to highlight this, that my working experience with Packages Limited was very memorable and full of learning, where I found a lot of positive changes in my life, attitude, behavior learning and problem solving skills and behavior.
-Introduction:
The Paper Industry plays a very prominent role in the world economy. The Industry is largely based on a raw material that is derived from forest crops with harvest rotations that can approach 100 years in length. The sheer volume of timber required for the industry's production processes is staggering. Since timber is their largest single production cost, paper firms historically have devoted enormous amounts of capital to the ownership and management of secure timber resources.
Especially since the end of World War II, the Paper Industry has experienced a massive wave of technological change that has transformed its basic operating and process management and control systems. Where earlier production processes relied on the craft knowledge of skilled operators and superintendents, newer production processes incorporate sophisticated sensors, information systems, and software-based process controls. This shift, which began in the 1970s, has had far-reaching effects on the industry's fundamental operations. Today, new paper machines are nearly 40 feet wide, hundreds of feet long, and over two stories high. The Industry's capital-intensive pulping and papermaking facilities, which can cost up to 1.5 billion dollars, are designed as high tech computer-based operating systems with paper machines that run at speeds exceeding 60 miles per hour with production outputs of up to 500,000 tons per year. This significant technological advancement in the Paper Industry has required investments of hundreds of billions of dollars. In fact, the annual capital investment in the US Paper Industry has ranged from 8 to 15 billion dollars per year over the last two decades. This has required firms to develop and manage increasingly complex relationships with external and internal suppliers of ever more complex production equipment (including software controls). Automated process control systems also have introduced far-reaching changes into the types of skills needed by production crews, requiring firms to make substantial investments in the training of hourly workers and supervisors, growing numbers of process engineers, and new organizational systems for operations management.
-History of Paper:
Papyrus paper is the first paper in history. Found in the tombs and temples of Ancient Egyptians as far back as 2700 B.C. It was made by Ancient Egyptians from papyrus plant. The amazing part about papyrus paper is that it's very strong, durable, and elastic and is made naturally. The process of making this paper was rediscovered just about 15 years ago. These pictures are 100% hand painted by artists in Egypt today on papyrus paper; a reflection of the great civilization of Ancient Egypt. New evidence shows that the Chinese used old chopped-up fishing nets to make the world's very first paper. Three hundred years later, around 100 A.D., a Chinese scholar and government official named Ts'ai Lun made paper out of tree bark and scraps of linen and hemp. Even though archaeological evidence shows that paper may have been made even a little earlier, Ts'ai Lun was the first to have his efforts recorded. Like many inventors through the centuries, he built upon the work of others. Because he documented his invention, Ts'ai Lun is generally known as the man who "invented" paper. The art of papermaking was kept a secret in China for centuries. It was not until 793 A.D. that paper was made outside the Orient. The process slowly spread through Africa and Europe in the 10th century, and finally reached England around 1494, two years after Columbus sailed to America. Finally, in 1690 the first U.S. paper mill was built at Germantown, Pennsylvania by William Rittenhouse. The Rittenhouse mill made about 100 pounds of paper per day. At this time, paper was made by hand from old cotton and linen rags, which was a very slow and labor-intensive process. As the demand for paper grew, it became harder and harder to find enough old rags to meet the demand. It wasn't until the late 1860s that Americans first began making paper from wood. The table shows the dates of the earliest mills in various countries:
Year (AD) Spain (Xativa) France (Herault) Italy (Fabriano) Germany (Nuremberg) Switzerland (Marry) Belgium 1150 1189 1260 1389 1400 1407 Holland (Gennep) UK (Hertfordshire) Sweden (Motala) Denmark Russia (Moscow) USA (Germanstown, Pa.) Year (AD) 1428 1488 1532 1540 1690 1690
More than 5,000 products are made from paper and papermaking by-products. In the U.S, most paper is made from trees because wood is a renewable resource which is wisely managed by U.S. timber companies. Paper products are categorized into five main categories: 9 9 9 9 9 Newsprint and magazine papers Printing and writing papers Sanitary and household Paper-based packaging materials and products Other - Specialized paper
Internship Report Abd u Slam (CIIT/SP08-BEC-003/LHR) -Making Pulp from Wood: Wood pulp currently represents 44% on average of the fiber used to manufacture paper and board worldwide, of which 11% is home produced. None of these mills uses mature fully grown trees, but rather small dimension timber, (which is no use to other commercial users such as furniture makers and builders), saw mill waste and forest thinning. In the past the industry used softwoods such as spruce, pine, fir, larch and cedar almost exclusively, but hardwoods such as birch and aspen are gaining in popularity. Fast growing eucalyptuses have been successfully cultivated in Northern Spain, Portugal and Brazil and provide the papermaker with very high quality pulp. Softwoods provide long strong cellulose fibers and are used to produce papers where strength is a requirement, for example, packaging papers. The shorter hardwood fibers provide bulk, smoothness and opacity and are used to produce fluting medium and printings and writings. Trees vary enormously in the time they take to reach full size. Much depends on climate and the soil, but these figures give a rough comparison:
Tree Type
Willow Sitka spruce Douglas fir Scots pine Norway spruce Oak
When a tree trunk or thick branch is cut across, a series of dark rings can be seen. These are annual rings which result for the seasonal growth. Each ring represents one year's growth. The grain in timber is caused by the annual rings which show when a log is cut. Teak, mahogany, oak, beech and elm have attractive grain and are used for furniture making (rather than papermaking). Wood pulp comes from trees from managed forests where more trees are planted than harvested to ensure that demand for timber products will never outstrip supply. The forest industry has become more aware over recent years that it has a responsibility, not only to ensure the economic viability of its operations, but also to ensure that the requirements of local communities are catered for. Greater care is taken to ensure that logged areas blend in more readily with the landscape. Certain pulp characteristics depend on the process used to reduce the wood to its component fibers. There are three main ones: 9 Mechanical or ground wood 9 Chemical 9 Combination
-Mechanical Pulp:
This is a very cost effective but energy intensive process. Because the entire log apart from the bark is used. The log is put through a grinding or refining process to separate the fibers. Chemicals are not used, but there is a high energy use which can only partly be offset by using the bark as fuel. Mechanical pulp retains all the natural tree substances sap, sulphur compounds, sugar and a lignin which binds the fibers together. Because lignin reacts with ultra violet light, papers made from mechanical pulp tend to 'yellow' when exposed to light. Mechanical pulps are used to manufacture newsprint and some packaging boards.
-Chemical Pulp:
Most chemical wood pulp is made by the sulphite process. Chips from de-barked logs are dissolved in caustic soda and sulphur by heat and pressure leaving a strong brown pulp, colored by the effect of the chemicals on the lignin and wood sap. The pulp is commonly known as Kraft - the German word for strong. About 20% of chemical pulp is made by the sulphite process. Chemical pulping uses less energy than mechanical pulping. In modern mills, recovery boiler operations and the controlled burning of bark and other residues make the chemical pulp mill a net energy producer which can often supply power to the grid, or steam to local domestic heating plants. Chemical pulp, however, produces a strong liquid effluent that needs to be treated. The term "wood free" is often used in the trade to signify that the chemical pulping process has been used. It is not meant to be misleading and has been used for decades to mean "free from mechanical wood" (or "ground wood free").
-Combination Pulp:
Thermo-Mechanical-Pulp (TMP) and Chemi-Thermo-Mechanical-Pulp (CTMP) are a combination of the mechanical and chemical processes. De-barked logs are chipped in both, and then heated to extreme temperatures to soften them before passing through grindstones for mechanical reduction to fibers. The difference is that chemicals are sprayed onto the chips in the CTMP process to reduce the undesirable effects of the retained natural wood substances. The main disadvantage of this form of pulping is the high energy demand. The consumer often requires high quality papers which retain strength, do not discolour during storage or go yellow when exposed to light. One of the most effective ways of achieving all three is bleaching which has the added advantages of improving absorption capacity and getting rid of small residues of bark or wood, as well as giving a high level of purity, particularly important when the paper is being used for hygiene, medical or certain food packaging purposes.
Internship Report Abd u Slam (CIIT/SP08-BEC-003/LHR) For many years chlorine was used because of its efficiency. In recent years however it has been discovered that alternative bleaches such as chlorine dioxide or oxygen have a lower impact on the environment and they are now increasingly being used throughout the industry.
10
Much of the paper sent to the mill will contain contraries and must be processed to remove all unwanted materials (such as pins, staples, and adhesive tape) the paper will have to be cleaned and contaminates disposed of. Depending on the final intended use, inks will be dispersed or removed by de-inking. Uses for the contraries or 'sludge' are being developed by waste paper using mills; some use de-inked sludge to generate energy, others are developing uses such as composting and brick-making thus reducing disposal to landfill.
11
If the pulp mill is close to the paper mill, i.e. it is part of an integrated mill; the liquid pulp is pumped direct to the paper mill. Otherwise, after straining, the pulp is dried and packed into bales. The trees used in papermaking are mainly grown in Scandinavia, North America and Canada. They are cone-bearing for example, spruce, pine or fir (softwoods), and leaf-bearing trees such as birch, beech or eucalyptus (hardwoods). Waste paper is a very important source of fiber for the papermaking industry. It is called secondary fiber to distinguish it from the fiber obtained directly from wood (sometimes called primary fiber). Before waste paper can be turned into pulp it must be collected, sorted, graded and baled. It is then transported to the mills where further processes are carried out to remove unsuitable materials (contraries) e.g. Paperclips, staples and plastic. It is then broken down into pulp and sometimes printing ink is removed from the slurry (see de-inking). The wire can travel at speeds of up to 2000m/minute. By the time it reaches the end of this section the fibers have become a sheet of paper, though very moist and having little strength. It then passes to the press section. This consists of a number of sets of heavy rollers through which the moist paper is conveyed, on thick felts. Even at this stage the paper 'web' is still weak and moist. It then passes to the dry end which consists of a large number of steam heated drying cylinders, up to 100 or more on large paper machines. Part of the way down the bank of drying cylinders is the size press. It is here that a solution of water and starch can be added to the sheet in order to further improve the surface. Beyond the drying cylinders comes the calender, which consists of a stack of polished iron rollers mounted one on top of the other. Its function is to polish or glaze the surface of the paper as it passes between the rollers. Still traveling at up to 2000m/minute the paper now comes off the machine ready for winding into large reels, each of which may contain up to 20 tones of paper. These reels are later either cut into sheets or slit into smaller reels according to the type of paper and the customer's requirements. A separate process is the coating of the paper with china clay and then polishing it through the calender. This makes 'art' paper, the glossy kind used for pictures. There are 3 main kinds of modern coating processes; blade coating, air knife coating and roll coating. Blade coating is often done `off' the paper machine, as is air knife coating. But roll coating is done 'on' the paper machine and can either be a complete coating or a first coat followed by 'off-machine' coating by the blade or air knife process.
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9 9 9 9 9 9 9 9 9 9 9 9 9
Timber De-Barker Chipping Machine Chemical Pulping Process Mechanical Pulping Process Hydrapulper Blend Chest Waste Paper De-inking Refining Screening and Cleaning Papermaking Machine Conversion and Printing
13
-Timber:
Timber used for papermaking comes from well managed forests where more trees are planted than harvested to ensure sustainable growth. Papermakers usually use only the parts of the tree that other commercial industries don't want - such as saw mill waste and forest thinning.
-De-Barker:
Bark is stripped from the logs by knife, drum, abrasion, or hydraulic barker. The stripped bark is then used for fuel or as soil enrichment.
-Chipping Machine:
Stripped logs are chipped into small pieces by knives mounted in massive steel wheels (used in chemical pulping process). The chips pass through vibrating screens, whereby undersized chips, dust etc and oversized chips are rejected. Accepted chips are then stored in huge bins ready for the next process.
14
-Hydrapulper:
When the bales of wood pulp or waste paper arrive at the paper mill they are loaded onto a conveyor and passed into a circular tank containing water. This has a very powerful agitator at the bottom which breaks up the bales into small pieces. The pulp mass created begins to look like thick porridge. This machine is known as a Hydrapulper. It operates automatically and when the disintegrating process is complete it discharges the pulp into large storage tanks.Hydrapulpers used mainly for handling waste paper are fitted with special devices for removing unwanted contraries such as wire, plastic, paper clips, staples etc.
-Blend Chest:
The stock passes to a blend chest where numerous chemicals can be added to obtain the required characteristics to the finished paper. Dyes are also added, as necessary, to color the paper. Dyes fix themselves to the cellulose fibers and are fast to light and water. Each grade of paper and board requires a very accurate blend of pulps and additives and the properties of the paper are continually monitored by computers during manufacture.
-Waste Paper:
Waste paper is collected from Waste Paper Banks and Commercial collections. When you deposit your used papers into a waste paper bank, you are sorting the paper into grades before the merchant collects it. This is why you can only put certain papers into a particular bank. Many offices have in place an office recycling scheme. Again the waste paper is usually segregated ready to be collected. Waste paper currently represents 67% of the raw material used in the UK to make paper and board. The waste paper merchant collects the used paper which is then sorted by hand into different grades. Paper not suitable for recycling is removed. The waste paper merchant will then bale the waste paper ready to be taken to the paper mill.
-De-inking:
Before printed paper, such as office waste and newspapers, can be recycled into high quality paper products the ink needs to be removed, otherwise it will be dispersed into the pulp and a dull grey paper will result. There are two main processes for de-inking waste paper known as washing and flotation.
15
1. Washing
The waste paper is put into a pulper with a large quantity of water and broken down into slurry. Contaminants or 'contraries' such as staples and plastic are removed by wire mesh machines and a mechanical action. Most of the water containing dispersed ink is drained off from the pulp through slots or screens that allow small particles through, but not the pulp. Water can be added to rinse the fibers and drained to remove more of the ink. Adhesive particles known as 'stickies' are removed by fine screening. About 80% of the original fiber is recovered by this process (though it will depend on the type of washing equipment being used) with the remaining 20% of ink, clay, filler, plastics etc. left behind. De-inking by washing has been used with great success on 'wood free' waste grades to produce pulp for writing papers and tissue; and on old newspapers to produce a stock for newsprint manufacture. It is more effective than the flotation process at removing smaller ink particles.
2. Flotation
Again the waste paper is made into slurry and the contaminants are removed. Then special surfactant chemicals are added which makes a sticky froth on the top of the pulp. Air bubbles are blown through the pulp and these carry the ink to the surface. As the bubbles reach the top foam layer is formed that traps the ink. The foam must be removed before the bubbles break or the ink will go back into the pulp. Because the ink is removed from the flotation machine in a concentrated form, the flotation system does not require a large water treatment plant. When the flotation method is used to de-ink old newspapers, around 30% used magazines are usually added. The clay present in coated papers can improve de-inking efficiency as the ink attaches itself to the clay particles before floating to the surface. The flotation method is more able, than the washing method, to remove larger ink particles. Yields from flotation de-inking are quoted as 90 - 95% but filler is not removed to the same extent as in the washing process. Once the pulp has been de-inked it is ready to be made into paper. The most common performance measurements of the de-inking process are paper brightness (measured by a brightness meter) and the number of ink specks on a sheet surface (measured by visual inspection using a magnifying lens). However, the mechanical properties of the paper, such as tear strength, also need to be determined. Paper recycling is increasing, there are approximately 420 de-inking mills world-wide (120 having been completed in the past 4 years). Newsprint, writing and office papers, and tissue are made from de-inked recycled paper and research is continuing to further improve the de-inking process.
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-Refining:
The cellulose fibers pass through a refining process which is vital in the art of papermaking. Before refining, the fibers are stiff, inflexible and form few bonds. The stock is pumped through a conical machine which consists of a series of revolving discs. The violent abrasive and bruising action has the effect of cutting, opening up and declustering the fibers and making the ends divide. This is called fibrillation. In this state, the fibers are pliable and have greater surface area, which significantly improves the fiber bonding. The properties of the paper are directly related to the refining process. Refining used to be called beating.
-Papermaking Machine:
DRYER FELT APRON/ SLICE HEAD BOX COUCH ROLL DANDY ROLL TABLE ROLLS
STEAM EXHAUST
BREAST ROLL FOILS FORMING WIRE FOURDINIER (WET END) SUCTION BOXES SUCTION ROLLS WET PRESSES DRYERS (DRY END)
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The Paper Machine is a very large piece of machinery. A typical machine is about the length of two football pitches and around 4 meters wide. It can run up to speeds of 2000m/minute or 60miles/hour. The machine itself consists of 7 distinct sections. The flow box, wire, press section, drier section, size press, calendar and reeling up. The first section of the machine is called the 'Wet End'. This is where the diluted stock first comes into contact with the paper machine. It is poured onto the machine by the flow box which is a collecting box for the dilute paper stock. A narrow aperture running across the width of the box allows the stock to flow onto the wire with the fibers distributed evenly over the whole width of the paper machine. The machine is operated by computer control. The computer will monitor the paper for moisture content, weight etc and computer screens will show pictures of the process and should any adjustments need to be made, an alarm will sound.
Machine
Flow Box
Control Room
-History:
Paper board manufacturing unit all demands were met through imports. The first paper making industry in the sub-continent was set up in Delhi and Lahore in 1956. Lahore at that time had a production capacity of 500 tons per annum. Due to ill planned growth; many of the units were closed in the 80s and 90s.
-Types of Paper:
9 9 9 9 9 9 9 9 Writing and printing paper Corrugated Paper (Fluting) Test Liner Kraft and Water proof liner White duplex coated Uncoated board Tissue paper Chip board
-Paper manufacturing:
Raw materials are 9 9 9 9 65% local grass and wheat straw. 25% based on waste paper. 10% imported pulp. Other raw materials include bagasse, rice straw and cotton waste.
-Pulp manufacturing:
This includes a mild chemical pretreatment of wheat straw in slightly alkaline sodium sulphite liquor at temperature ranging from 160 to 190 degree Celsius. After this cooked pulp is washed thoroughly to get rid of the sodium sulphite.
-Bleaching:
The bleaching process is used to improve the pulp brightness. Chlorine, Sodium Hypochlorite and Chlorine Dioxide are used as a bleaching agent.
-Paper manufacturing:
For the conversion of pulp into a continuous sheet of paper, the bleached blended pulp together with the filling materials is passed over a wire with a series of presses and driers.
-Corrugated Packaging:
Corrugated packaging is a rigid sort of packaging that is used generally in our daily lives named CARTONS.
-Environmental Impact:
Pulp and paper industry of Pakistan is considered to be one of the most polluting industries because of Waste water, air emissions, and solid waste and other health risks.
-Cost of Production:
C ost of Production
In 1996, a joint venture agreement was signed with Printcare (Ceylon) Limited for the production of flexible packaging materials in Sri Lanka. Packages Lanka (Private) Limited commenced production in 1998. Packages Limited now owns 79% of this company. In 1999-2000, Packages Limited successfully completed the expansion of the flexible packaging line by installing a new rotogravure printing machine and expanded the carton line by adding a new Lemanic rotogravure inline printing and cutting creasing machine. A new 8-color Flexographic printing machine was also installed in the Flexible Business Unit in 2001. Packages Limited has also started producing corrugated boxes from its plant in Karachi from 2002. In 2003, Packages entered into an agreement with Vimpex of Austria to provide management and technical assistance to help in the operation, production optimization and capacity expansion of a paperboard mill in Syria. A team from Packages is currently providing these services and is close to optimizing mill production. Over the years, Packages has continued to enhance its facilities to meet the growing demand of packaging products.
PACKAGES LIMITED
TOTAL SALES 2005
TISSUE PAPER 12% Rs 953 MILLION PAPER & BOARD AND PRE-PRESS 19% Rs 1,513 MILLION
PACKAGES LIMITE D
I N V E S T M E N T 1994 - 2004
E N V IR O N M E N T 14 %
TECHNO L OG Y 34 %
CA P A C I TY 52 %
TOTAL INVESTMENT = US $
140 M
-Products:
9 9 9 9 9 Paper & Board Carton Business Unit Corruwal Business Unit Flexible Business Unit Consumer Products
Paper quality and weight is determined by the client's specific requirements and Packages ensures this is carried out to the exact specifications provided. Paper is available in the following weights: Type of Paper Test liner Corrugated medium Paper/Fluting Wrapping Paper High gloss writing paper Poster Paper Weight (g/m2) 110-200 100-175 70-90 58-68 40-90
-Board:
Packages manufacture several types of board. Food Board, a basic raw material in liquid food packaging, is being manufactured since 1979 for Tetra Pak Pakistan Limited. This material is used in making aseptic packaging for milk, cream, oil, fruit juices and other perishable food items. Some board products are: 9 9 9 9 9 9 liquid packaging board food grade board duplex board / chipboard bleached board tobacco board and cardboard liner board
Board is available in the following weights: Type of White Board Bleached Board Duplex Board Cardboard Liquid Packaging Board Weight (g/m2) 195 - 205 150 - 450 160 - 250 150 - 290
BULLEH SHAH PAPER MILLS The Bulleh Shah Project: In 2005, Packages Limited started a new pulp and paper mill project in Kasur located 50 km south of Lahore. The greenfield site spread on 42 hectares is known as Bulleh Shah Paper Mill coined after a famous Pakistani poet from this region.
B U L L EH
S HA H CT L L
P A P E R M
I L LS
P RO J E
O VE R A O BJ E C T I V E
T o I n c r e a s e o u r P r o d u c ti o n C a p a c i t y to M e e t F u tu r e M arket D em an d
T o ta l P r o je c t C o s t U S D 0 M
The greenfield site comprises of two modern paper machines PM6 and PM7 that will enable us to increase our paper and paperboard production from 100,000 to 300,000 tones per year. PM6 already in operation since 2007 manufactures container board.
PM-6 LINE
O C C -P L A N T
C T M P -P L A N T
P M -6 / P M -7
P A P ER
&
B OA R D
C HE M IC A L S
-OCC-PLANT:
OCC (Old Corrugated Container) is a plant in which pulp is produced from waste paper and board.
-Stages in OCC-PLANT:
There are six stages in OCC-PLANT 1. 2. 3. 4. 5. 6. Slushing Coarse Screening Centri Cleaning Fine Screening Thickening Reject Handling
Slushing
Accept from Drum Screen Drum Screen
Reject
Chute Drain
Pulper
Pulper Screen
Reject
Junk Trap
Accept Pulper Pum p M Gear Box HD Cleaner No.1 (Rufclone) A HD Cleaner No.2 (Rufclone) A
Dump Tank
C o a rse Sc ree n in g
Dum p Tank
Pum p
Pum p
Ac cept
Reject
Reject
Rejec t
Centri Cleaning
Accept from Primary Cleaner Accept from Secondary Cleaner Accept from Tertiary Cleaner
Pump
Primary Cleaner
Secondary Cleaner
Tertiary Cleaner
Reject
Reject
Reject
Quaternary Cleaner Primary Cleaner Accepts Primary Fine Screen Stand Pipe Reject To Reject Tank ( DAF )
F in e S c ree n ing
Accept Prim ary Fine Screen Stand Pipe Prim ary Fine Screen Ligh t Reject Short Fiber Disc Filter
Pum p
Heavy Reject Accept Accept Secondary Fine Screen Ligh t Reject Heavy Reject Pulp Fine Screens Rejects Thickener Dew atering W ater Rem ove Cloud y Chest (W ater) Reje ct Tank (DAF) Long Fiber Disc Filter
Tertiary Fine Screen Pulp Hydraflaker Feed Che st Pum p Hydraflaker Tertiary Fine Accept Screen Feed Che st Pum p
T hickening
Primary Fine Screen Accept Chest OCC Short Fraction from Disc Filter Main Drive Screw Motor Water Cloudy Filtrate Chest Water Clear Filtrate Chest Shower Motor Pulp Short Fiber MC Standpipe
Pump
Secondary Fine OCC Long Fraction from Disc Filter Screen Accept Chest
Shower Motor Main Drive Screw Motor Water Water Clear Filtrate Chest Pulp
Pump
Reject Handling
Pump
Accept
Reject
Reject
KUFFRATH PRESS
-CTMP-PLANT:
CTMP (Chemi-Thermo Mechanical Pulp) is a plant in which pulp is produced from the straw with the help of combination of the mechanical operations and chemical processes. CTMP is a branch of mechanical pulp. Yield of pulp is about 80%.
Overflow Straw Unit Dry Cleaning Accept Belt Dry Silo Store M Feed Hydropulpe r Straw+Water M Mixing Tank (Agitator)
Pump
Pressed StrawBin
By Pass Screw
Screw Drainer
Water Drain
Liquor Remove
Screen 0.3mm
Accept
-Chemicals Section:
Different chemicals are used in paper manufacturing process.
Chemical Name
High Phase Size Top Sizer Dipole L125 Delta Size Rosin FFSOREZE
Form
Liquid Liquid Liquid Paste Paste Solid( Powder)
Nature
Acidic Basic Basic Basic Acidic & Alkaline Basic
PH
2 3 10 10 10 3 3.5 & 10 11 11
-Dyes:
Dyes are used for shading of paper and depend on the customer requirement. Dyes are introduces in machine/blend chest and also increase printing ability. For white & printing paper Violet Dye is used. Example: Indosole brown, Bismark brown and Carta brown
-Fillers:
9 9 9 9 Fillers are used as filling agent (To fill the very small pores of paper). Increase the weight of paper. Increase whiteness, smoothness and brightness of paper. Increase the opacity of paper.
-Polymers:
9 9 9 9 Polymers are long chain molecules. Polymers used as retentionate. Polymers increase the head box consistency and reduce wire water consistency. Retain the pulp (very fine fibers).
-Bio sides:
9 Bio-Sides are used to control the growth of bacteria and slime. 9 Bio-Sides are used as anti-scaling agent (to control scaling).
-Sulphuric Acid:
9 Sulphuric acid is used to control the PH of pulp.
Anti-Foamers:
9 Anti-foamers are used to reduce foam particles formation in white water.
Pum p
Pum p
Pum p
Pum p
Refiner
Pum p
Pum p
Pum p
Pump
Pump
SILO (Back)
SILO (Top)
Pump
L.R H.R
L.R
Pump
Back Layer Primary Screen 0.25 mm ( Slots) Accept Pulse Elimination Tank (Back)
H.R
Pump
Pump
Accept
Tertiary Screen
Broke System of PM -6
Broke T owers
Blend Chest
Blend Chest
HD Cleaner
Deflaker
Pulp Towers
PM-6 Line
2:Silo
4:Head Box
5:Wires Section
7:Dryers
6:Press Section
10:Calendering Section
12:Rewinder Section
Market
-Silo: In this section, tower containing water are available which are used to dilute the
pulp from 2.5% - 3.5% to < or equal 1%.
-High Pressure Screen: In this section high pressure screen are used to final
removal of all unwanted material. Usually slots type screen are used of 0.25mm slot size.
-Head Box:
After screening the stock arrives at the head box. The purpose of the head box is to deliver a uniform suspension of unformulated fibers across the width of the machine. The head box is the receptacle on the wet end of the paper machine in which the pulp, or stock, is evenly distributed onto the wire which looks like a sheet or web.
-Wire Section: In this Section water is removed (dewatering) and in wire section 20%
dryness is achieved. There are four parts of wire. 9 9 9 9 Forming Board Hydrofoils Vacuum foils Suction Boxes
Forming board:
Forming board is a part of wire at which evenly distributed pulp falls on wire.
Hydrofoils:
A hydrofoil blade for use in a paper making machine wherein a plurality of variously angulated surfaces is provided for producing turbulence having controllable scale and intensity while independently controlling the rate of dewatering.
Vacuum Foils:
A type of ving under the wire in the wire section of a paper machine creating a vacuum pulse to eliminate water from the stock (fiber/water slurry).
Suction Boxes:
Suction boxes located beneath an endless forming wire in a papermaking machine are mounted on resilient supports, and are coupled to vibrators which impart movement to the suction boxes with components in the longitudinal direction of the forming wire and in the vertical direction, and of such resultant direction and amplitude that the suctionboxes at least in their highest position contact the underside of, and move in the same direction as, the forming wire.
FO RM I N G W I RE
FO I L BL A D E
FO I L
FO R M E D FI BE R M A T
ST O C K FR E E S U SP E N S I ON
CE R A M I C BL A D E
FO RM I N G WIR E
LO W P R E SS U R E
R E M OVED W A TE R RE SI N BO D Y
SU P PO R T
-Press Section:
After the paper web is produced, the water must be removed from it by pressing the sheet removes the water by force. Once the water is forced from the sheet, felt (not to be confused with the traditional felt) is used to collect the water. When making paper by hand, a blotter sheet is used. In this section water is further removed (dewatering) by pressing the web. Web is passed between two moving press rolls and web is press between them. Then water is extracted with the help oh high vacuum. In the press section 45% dryness is achieved.
-Dryer Section:
In this section drying of web is done to our requirement usually 92% dryness is achieved in dryer section. Drying involves using air and or heat to remove water from the paper sheet. In the earliest days of papermaking this was done by hanging the paper sheets like laundry. In more modern times, various forms of heated drying mechanisms are used. On the paper machine, the most common is the steam-heated can dryer. These dryers can heat to temperatures above 200F (93C) and are used in long sequences of more than 40 cans. The heat produced by these can easily dry the paper to less than 7% moisture when the paper sheet enters the paper machine Dryer Section; it is about 50% water. It must be dried to less than 10% water for a finished product. The most common Dryer Sections include Steam Cylinders and Air Dyers. Infrared Dryers are most commonly used on coating lines.
HOO D
S TE A M FI L L ED D R Y E R CAN S
AIR BL O W E RS
DR Y E R FE L TS
PA P E R W E B D R Y E R SEC T I O
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-Calendering Section:
A calender consists of a number of rolls, where pressure and heat is applied to the passing paper. Calenders are used to make the paper surface extra smooth and glossy. It also gives it a more uniform thickness. The pressure applied to the web by the rollers determines the finish of the paper.A calender refers to the use of two rolls, or calenders, that squeeze paper in order to smooth the surface. Often a sheet/web is run between a series of calenders that squeeze the sheet in several directions, smoothing the surface in every possible direction.
-Pope Section:
A paper machine pope section refers to the roll on to which the paper is wound when it comes off the last dryer of the paper machine. In this section Winding of web or sheet of dry paper made on machine.
-Rewinder Section:
Rewinders rewind the roll off the original winder. Because it is difficult to retain perfect consistency of thickness and grain when the sheet is being wound on directly off the machine onto the first winder, rewinding the sheet can help even out stretches and crooked sheets and other imperfections.
-Problems:
9 9 9 9 9 9 Lack of competitive Infrastructure and technological base. Economies of Scale Non-availability of raw and auxiliary materials at the competitive prices. Restrictive local demand and competitive factors for export market. Tariff and local duties irregularity. Dumping of cheap products.
-Recommendations:
9 The government should enhance competitiveness by bringing the prices low down to international prices. 9 Duty should be reduced on the imported raw material (including wood pulp, chemicals, waste paper, plant and machinery). 9 Development institutions should be made at macro levels for the pulp and paper industry. 9 An incentive package should be introduced to revitalize the projects in difficulties. .
-References: 9 Paper and Pulp By CASEY 9 Paper and Pulp Technology By BERRT
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