Design and Management of water systems for pulp and paper mills

Thit k v qun l cc h thng nc trong nh my giy

Prepared by: Dr. Loi Kien Nguyen Translated by: Thu Ha

Typical components in effluent of pulp and paper mills

Thnh phn chnh ca nc thi t cc NMG v bt giy
Wood/fibres G/X si Process chemicals and reaction products Ha cht x l v sn phm ca cc phn ng ha hc Additives (fillers, retention aids etc) Cc cht ph gia (cht n, cht tr bo lu)

Methods of effluent treatment Cc PP x l nc thi

Primary-removal of solids Kiu Th I - Loi b cht rn Clarification Lm sch Flotation Tuyn ni Straining/filtration Lc Chemical coagulation/flocculation C c/Kt bng ha hc Secondary-Removal of BOD/COD Kiu Th II - Loi b BOD/COD Activated sludge Bn hot tnh Aerated lagoons H hiu kh Anaerated process X l k kh Tertiary Kiu Th III Activated carbon Dng cacbon hot tnh Evaporation Cho bay hi Lignin removal Loi b lignin Stripping Tch si Ion exchange Trao i ion Oxidation -xy ha Freezing Lm ng bng

Typical measurements Cc phng php o lng

BOD (BOD 5, BOD7, BOD 20-24) COD Suspended solids (>1.6 m) Cht rn l lng Phosphorus Nitrogen Adsorbable organic halogens (AOX Adsorption onto activated carbon) Cc halogen hu c d bm dnh (AOX-bm ln than hot tnh) Total organic chlorine (TOCl) Dioxin Extractable organic halogen (EOX Extracted by acetone) Cc halogen hu c d chit xut (EOX-chit xut bng axtn) Colour Toxicity Cht c

Effluent loads Finnish mills (90s)

Reduction of water consumption and waste water from pulp mills Gim thiu lng nc tiu th v thi ra NM bt giy

Closed = no discharge to receiving water Kn=khng c nc thi a vo dng nc cp

Reason 1 Nguyn do th nht

Harmful substances in wastewater Nhng cht c hi c trong nc thi Toxic substances (BOD, AOX) Cht c (BOD, AOX) Colour substances Cht to mu High temperature Nhit cao Nutrients Dng cht Variation in pH S thay i pH

Reason 2 Nguyn do th nh

Availability of fresh water Kh nng cung ng nc sch Availability of effluent discharge recipient Kh nng tip nhn nc thi

Reason 3 Nguyn do th ba

Lower capital with new technologies Vn u t thp hn vi cc Cng ngh mi Elimination of treatment cost Gim thiu chi ph x l Failure to meet environmental standards can cause production losses/costs Vic khng tha mn cc tiu chun mi trng c th gy tht that trong sn xut hoc khin chi ph SX tng.

Reason 4 Nguyn do th t

Consumers favour environmental friendly products nh gi cao ca ngi tiu dng i vi cc sn phm thn thin vi mi trng

Reason 5 Nguyn do th nm

International financial institutions demand strict adherance to environmental standards Yu cu kht khe ca cc nh ch ti chnh quc t v cc tiu chun mi trng

Closed integrated unbleached kraft pulp mill

Nh my bt giy kraft khng ty tch hp kn

Water for process

FreshW ater C hips 2.47 s/c 0.10 8.90 D iffuser W ashing 11.65 D .F2.50 s/c 0.12 7.25 10.00 5.77 0.09 Spill B liquor lack Evaporation A steamloss ctual Stripper steam 0.28 0.28 0.60 0.29 W w hite ater Evaporation %return 4.23 1.92 0.85 1.63 2.02 s/c 0.12 W ash 7.25 Filter s/c 0.40 1.48 Screwpress 2.0 s/c 0.50 0.99 PMD ryend s/c 0.91 0.10

D igester 7.88

PM W etend

7.93 balance C ondensate 2.76 3.14

R ecovery 0.60 R ecaust

W for processes ater

Total In=4.84 Total O =4.84 ut IN U =0.00 -O T

Excess condensate 0.11 2.66 C oolingtow er

Water for steam generation

SB 4.04 RECOVERY 2.17 0.32 8.00% 3.63 5.76 0.08 4.89 Turbine 0.98 5.40 Steamcondensate 3.56 0.80 Balance ROplant 1.02 0.22 0.86 Condensate loss 2.00% 0.08 3.92 Extraction loss 20% M steam ill Stripper loss% 3.92 1.87 1.32 100% 0.3 Evap. loss ratio= 1.0 0.86 W SAC Dem and 0.45

15.00% 0.86

BD 2.00% 0.08 2.12 BD 2.00% 0.04 6.20

Digester Evaporator Paper M achine Stripper

Power Boiler

W for steamgeneration ater

IN= OUT = IN-OUT = 1.09 1.09 0.00

Filtration 1.09 0.07

M ake-up water

Effluent

0.02 0.06 Excess evap. condensate RO blowdown Excess (-) or Make-up (+) fresh water 3.14 3.29 0.22 1.21 4.50 3.20 Cooling tower BD 6.00% Loss 1.03 (at WCAS+spill) Recrystalliser To services 0.04 0.27 TDS, ppm

Filtration plant blowdown WSAC blowdown Boiler BD Woodyard run off

0.07 0.08 0.12 0.14

0.42

0.55

Effluent

0.73

IN = OUT = IN-OUT =

4.98 4.98 0.00

Water balance
CONTROL PARAMETERS Fresh Water to PM Stripper steam loss Steam to WSAC Turbine extraction Cooling Tower tol. temperature, C Blow down from boiler Soot blower Condensate loss Cooling tower blow down Total fresh water make-up Actual Effluent TOTAL MILL BALANCE Water in chips Fresh water to PM Sub-total Fresh water for steam Sub-total Fresh water to cooling tower Run off from wood yard 2.00 100% 15% 20% 45.00 2% 8% 2% 6% 4.30 0.59 IN 2.47 2.00 4.47 1.09 5.56 1.21 0.14 SB Recovery Condesate loss Cooling tower Evap. loss at WSAC Loss in salt cake Effluent

Recaust Recovery In paper

OUT 0.11 0.60 0.99 1.70 0.32 0.08 2.10 3.20 0.86 0.02 0.73 6.91

IN-OUT

2.77

3.46

TOTAL

6.91

0.00

Water consumption and effluent from paper machines Tiu th nc v nc thi ca my xeo

Roles of water in paper making Vai tr ca nc trong qu trnh xeo giy

Fibre transportation Vn chuyn x si Dispersion of fibres, additives, filler etc.. Phn tn x si, cc ph gia, cht n Cleaning, cooling, sealing, lubrication etc..Ra sch, lm mt, hn gn, lm bng Development of hydrogen bonds in the drying process Pht trin cc lin kt hydro trong qu trnh sy kh

Stock after Concentrator/Press 7-50% Dilution

Stock to paper machine 0.5-1.0% Showers from draining and pressing

After press 40-50% Evaporation loss Cooling water for vacuum system After drying 92%

Typical white water system

Flow box
Showers

Broke Stock

Wire

Mixing Chest

Silo

Seal Pit

Machine Chest Dilution water White Water Tank Effluent Seal water from Dryer vacuum system

Principles for water closure Cc nguyn tc khp kn dng nc

Segregation Phn lp Fibre recovery Thu hi x si Fresh water substitution Thay th nc sch Fresh water reduction Gim lng nc sch

Potential reduction: from about 100m3/t to 6-25m3/t Kh nng gim: t khong 100 m3/tn xung cn 6-25 m3/tn

White water system with saveall unit

H thng nc trng vi b thit b thu hi
Showers

Broke Stock

Mixing Chest

Silo

Seal Pit Saveall

Machine Chest Dilution water White Water Tank

Seal water

Effluent

FRESH WATER CONSUMPTION OF PAPER MILLS GRADE Newsprint Fine paper Supercalendered papers Lightweight coated papers Tissues Linerboard Corrugating medium Multiply board

m3/t 6 to 12 5 to 10 10 to 15 10 to 20 10 to 15 2 to 10 2 to 10 8 to 15

Adverse effects from water closure Nhng hiu ng ngc do khp kn dng nc
Built-up of fines, TDS, colloidal solids, BOD Hnh thnh nhng ht mn, TDS, ht keo rn, BOD Increase in temperature Nhit gia tng Variation of chemical concentration Thay i tch t ha hc shower nozzles plugging Tc nghn cc ng phun xt scale, deposit Tch t cn Corrosion n mn bacterial growth Vi khun pht trin change of pulp freeness and retention Tnh bo lu v tnh t do ca bt thay i unstable wet end chemistry Ha tnh u t kh n nh

TREATMENT OF WHITE WATER FOR REUSE X L NC TRNG TI S DNG

A white water handling strategy is a compromise amongst the following functions: Mt chin lc kim sot nc trng phi bo m cc chc nng sau:
Retaining solids and heat Km gi c cc cht rn v nng Providing a source of lean white water for cleaning showers and chemical dilution Cung cp ngun nc trng sch lm sch cc vi phun v pha lang ha cht Providing make-up water for the pulp mill Cung cp nc b sung cho l hi ca nh my bt Providing a source of rich white water for pulp stock dilution Cung cp ngun nc trng di do pha long dung dch bt Retaining raw materials in thin-stock loop Lu gi nguyn liu th trong phu dung dch bt lang Purging thin-stock loop of TDS, colloidal materials Loi b c cc cht keo t, TDS khi phu dung dch bt long Providing surge capacity to allow stable operation following sheet break Cung cp ngun cho php duy tr vn hnh my sau khi b t giy Providing surge capacity to minimise the changes in thin-stock loop concentrations of TDS, colloidal solids, additives etc.. Cung cp ngun gim c ti a nhng thay i tch t TDS, keo t, ph gia trong phu dung dch bt lang

Characteristics of white water c im ca nc trng

Variation of stock consistencies- Fibres and fines Nng dung dch bt-cc x si v ht mn-thay i Variation of particle size distribution Fillers S phn b cc c ht cht n- thay i Presence of colloids Tn ti cc th keo t

SOLIDS IN WHITE WATER

Components Length, micron Width, micron Fibres 1000 to 3500 30 Fines <150 30 Fillers 1 to 5 1 to 5 Colloids <1 <1

Types of Saveall system Nhng kiu h thng thu hi nc trng

Filtration - large particles/sweetening
nhng ht ln / c pha thm bt x di needed Lc-cn c

Disk Drum

Flotation - 1-3% s/c, effective for removal of colloidal and filler

Tuyn ni 1-3% s/c, loi b hiu qu cc th keo t v cht n

Typical filtration saveall arrangement B tr thu hi nc trng kiu lc in hnh

Factors affecting filtration performance Cc yu t nh hng n quy trnh lc

Fines in sweetener stock characteristics c im thnh phn mn trong dung dch bt c pha thm bt x di White water ash content Hm lng tro nc trng Flow and stock consistency to the filter Dng lu chuyn v nng dung dch bt dn ti cc b lc

Rules for white water system engineering Nhng qui tc i vi cng ngh vn hnh h thng nc trng
Independent white water system for each PM Mi my xeo c mt h thng nc trng ring Circulation of rich white water Nc trng giu x si c cho tun hon Availability of stock for sweetening Lun c sn dung dch bt pha thm x si di Tight broke control Kim sot giy t cht ch Correct use of recovered stock from saveall S dng chnh xc dung dch bt c c t h thu hi nc trng Strict operating practice with adequate inventories for grade changes Thc hin nghim ngt quy trnh vn hnh vi lng d tr thch hp cho vic thay i chng loi giy

Stability of white water system Tnh n nh ca h nc trng

Sources of instability: Cc nguyn nhn gy bt n Operational upsets Sai st trong vn hnh Variations of stock flow and chemical composition Bin ng trong dng lu chuyn v thnh phn ha hc ca dung dch bt Variations in the nature and chemical composition of the make-up water Bin ng v bn cht v thnh phn ha hc ca nc b sung Solution Gii php Minimising variations Duy tr cc bin ng mc ti thiu Diverting out-of-specification stock Cho chuyn hng dng dung dch bt khng t cht lng Increasing fresh water Cho thm nc sch Providing adequate white water surge capacity Cung cp cng sut dng trn nc trng thch hp Providing adequate broke storage C kho tr giy t ph hp Increasing purge Tng cng ra sch

REPLACING FRESH WATER WITH RECYCLED WHITE WATER THAY TH NC SCH BNG NC TRNG TI S DNG

WATER DEMANDS Areas Forming section showers Press felt cleaning Grooved roll shower Gland sealing water Vacuum pump sealing water Cooling water Misc.

m3/t 13.4 - 14.9 9.0 - 10.0 1.2 - 1.3 3.6 - 4.0 5.5 - 6.0 14.3 - 15.7 4.5 - 5.0

Guides Hng dn
The spray nozzles must be effectively protected from plugging with fibres Cc vi phun xt phi c gi cho khng b nght v x si
Fibre length rather than s/c that determine the tendency for nozzles to plug Nu x si c chiu di ln hn s/c th cc vi phun s d b tc nghn Fibre longer than 0.3 mm are particularly troublesome. Loi x di hn 0.3mm s c bit gy kh.

The filter must be easy to maintain and clean B lc phi d bo tr v lm v sinh Piping should be sized for a flow velocity>3m/s Cc ng dn nn c kch c ph hp vi tc dng chy >3m/s

REDUCTION OR ELIMINATION OF FRESH WATER DEMAND GIM THIU NHU CU NC SCH

Typical practices Nhng cch thc in hnh

Re-use of vacuum pump seal water Dng li nc lm kn bm chn khng Replacing the vacuum pump with a centrifugal exhauster Thay bm chn khng bng loi bm ht kh ly tm Mechanical seal Hn kn c hc Air cooling Lm mt khng kh

Cascading vacuum pump seal water system H thng nc hn kn bm chn khng phn tng

Temperature control vacuum pump seal water system H thng nc hn kn bm chn khng kim sot nhit

Recirculating vacuum pump seal water system with cooling tower H thng nc hn kn bm chn khng tun hon vi thp lm mt

Counteracting the disadvantages of high degrees of system closure X l nhng bt li ca vic khp kn h thng mc cao

Adverse effects from water closure

Nhng hiu ng ngc ca vic khp kn dng nc
Degradation of paper quality (wet strength and optical properties) Lm gim cp cht lng giy ( bn t v cc c im quang hc) Deposit formation nh hnh giy b vt m do lng cn Biological growth Vi sinh pht trin Corrosion Gy n mn Retention aid consumption Tn nhiu cht tr bo lu Temperature and subsequent biological treatment of the effluent X l nc thi bng PP sinh hc thay th v nhit

Methods used to reduce the TDS concentration Cc PP thng dng lm gim s tch t cht rn ha tan
Effective pulp washing/Use of pulp press Ra bt hiu qu/S dng p bt Water management strategy based on counter current washing principle Chin lc qun l nc da trn nguyn tc dng ng h o dng ra Sewering white water from pulp mill instead of paper mill Cho tho nc trng t nh my bt thay v t nh my giy