PAPER MAKING PROCESS CHART

K.Grass – Kahi – Sabai

Grass Wheat Straw +
Baggase Rice Straw

Cooking

Washing

Screening + Cleaning

Bleaching

Stock Preparation

Finishing

Finished Paper

Despatch
 Pulp

Stock Preparation

Head Box

Wire Part

Press Part

Dryer Part

Calender

Pope Reel
Slice :- Uniformly Distributed the pulp

Slice

1. Top Slice 2. Bottom Slice

Lip :- Gap b/w Top and Bottom Slice.

PAPER MACHINE – 2

PARTS OF MACHINE
HEAD BOX
WIRE PART
PRESS PART
DRYER PART
CALENDER
POPE REEL

Parts are same as in paper machine – 1

 Head Box ( open type )

 It has 24 dryers.
 Diameter of dryer = 1500m.
 Roll is made up of cast iron.
 Width of paper roll is 2m.

Gear Box
To reduce and increase the speed.

Speed
225 MPM ( Meter Per Minute)

PAPER MACHINE – 3
PARTS OF MACHINE
HEAD BOX
WIRE PART
PRESS PART
DRYER PART
CALENDER
POPE REEL

Working of parts are same as in paper machine –

1.
Head Box ( closed type )

Speed
425 MPM ( Meter Per Minute )

These are three parts of press.

Pick up zone :- It is used for input
Retaining zone :- It is used for treatment.
Suction zone :- It is used for output.

 Width of wire part = 3.75m.

 Length of wire part = 33.15.
 It has 23 Dryer.

 7 – first group
 8 – second group
 8 – third group
Rolls are :- Breast Roll, Table Roll, Shake Roll, Auto guide Roll, Auto
Tension Roll, Return Roll, Wash Roll, Suction couch Roll, Pick up Roll,
Supports Roll, Guide Roll, BDR Roll.

Breast Roll :- It pick up the whole wire.

Table Roll :- Remove the water and push the wire.

FDR Roll :- Push the wire.

Wash Roll :- To clean the wire.

Tension Roll :- To tension the wire.

Return Roll :- To Return the wire.

Guide Roll :- To guide the wire.

Breast Roll SCR

Auto guide Roll FDR

Strecter Roll
Wash Roll

Wire returning Roll

Shake Roll
Auto Tension
BLOCK DIAGRAM OF PULP
PIN LONG BELT
FEEDER CONVEYOR

AQUA PULPER
SEPARATOR

CROSS EQUALIZIN
SCREW

DIGESTER SCREW
FEEDER

BLOW KNOTTER
TANK SCREEN
KNOTTER BSW – 1 HIGH
SCREEN BSW – 2 DENSITY
BSW - 3 TOWER

COWAN MIXING TRIPPLE

SCREEN TANK DISC
REFINER

NOZZLE DECKER DECKER

PIT WASHER TOWER

Cl2 WASHER CL2 DILUTION

TOWER BOX

AIKALINE ALKALI H1 TOWER

TOWER WASHER

H2 WASHER H2 TOWER H1 WASHER

 H2 WASHER

BLEACH
SCREEN

CENTRI
CLEANER

H3 TOWER
& H4
TOWER

STOCK
PREPARATION
 CUTTER UNIT

Before cutting the Sarkanda, wheat straw etc.

Dust is removed by de- duster having rotor. And it goes to pin feeder – 1 through belt
conveyor. After that cutting is done in P.F – 1.
And through conveyor belt wheat straw, Sarkanda goes to digester tank.

DIGESTER

After the feed is cut by cutter. It is put in digester. The temp. in the digester is 170
degree +7kg pressure and present feed + caustic soda.

FUNCTION OF NaoH

Function of NaoH to dissolve at high temp. To make cooking easy to remone all the
undissolve solid.
From digester pulp is sent to blow tank and it reaches the knotter screen by pump. It is
used to screen the rejected particles from the pulp.

SPECIFICATION OF FEED

1 ton feed + 3% H2O + 14-15% caustic

BROWN STOCK WASHER

After screening the pulp reaches BSW for washing its function is to remove the black
liquor from the pulp. Then BSW pulp goes to high density tower.
 TDR

The wash pulp passed through refiner for refining. Then it pass through the cowan
screen which remove the reject the pulp. Then the pulp sent to the decker washer.

DECKER WASHER

It is used for washing to make pulp more bright and clean.

CHLORINE TOWER

After this Cl2 is added to pulp by static mixture in Cl2 tower. Then excess of Cl2 is
removed from pulp with Chlorine washer.

H1 WASHER & H2 WASHER

Pulp of H1 tower is washes in the H1 washer & H2 here CaCoCl2 is added in the pulp
for brightness and with the help of screw elevator it goes to H 3 washer. And pulp is
goes bleach screen and then Centricleaner and then H3 washer.

HIGH DENSITY TOWER

From H3 washer pulp goes to HD tower i.e. final stock preparation.

 CHEMICAL RECOVERY PLANT

VIBRATING
WBL SCREEN

E V A P O R A T O R

1 2 3 4 5 6

BLACK LIQUOR

SBL RECOVERY SMELT

BOILER

WASHER CAUSTIZER GLC

WASHER 2 WASHER 1 DRUM

MST FILTER
BALL BEARING AND ROLLER BEARING
The ball and roller bearings substitute pure rolling motion for plain sliding motion.
Balls makes point contact where as rollers makes line contact their surface.
Advantages :-
Coefficient of friction is lower.
It can work at higher speeds.
Lesser wear.
Lesser lubricant consumption.

BALL BEARING

1. Journal Bearing
2. Thrust Bearing
The Roller Bearing can take from 50% to 70% more load that the ball bearing

ROLLER BEARING

Cylinder Roller Bearing

Tapered Roller Bearing
FULE AND AIR BOILER
FLUE GAS AND AIR

ESP
ECO.

AP
H

FD1 FAN

FD FAN

FD2 FAN

CHIMENY
 BOILER

S.NO. NO.OF BOILER CAPACITY TONES WORKING

PRESURE
1. John Thompson 26 34 kg/cm2
( England )
2. John Thompson 26 34 kg/cm2
( England )
3. CVL ( Chhithar Vessel
Ltd ) Cha 60 68 kg/cm2

Steam Boilers
A steam boiler or generator is usually, a closed vessel made of steel. Its function is
transfer the heat produced by the combustion of fuel (solid, liquid or gasenous) to
water and ultimately to generate steam.

Steam may be supplied to an external combustion engine.

i.e steam engine and turbines.

IMPORTANT TERMS FOR STEAM BOILER

Boiler shell, Combustion Chamber, Grate, Furnace, Heating Surface, Mountings,
Accessories.

BOILER SHELL
A Boiler shell should have sufficient capacity to contain water and steam. Is is made
up of steel plates bent into cylinder form.

COMBUSTION CHAMBER
It is generally below the boiler shell.
GRATE
It is a platform in the combustion chamber upon which fuel is burnt.

FURNACE
It is the space above the grate and below the boiler shell. It is also called fire box.

HEATING SURFACE
It is the part of boiler surface, which is exposed to the fire.

MOUNTINGS
These are fittings which are mounted on the for its proper functioning. They include
water level indicator, pressure gauge, safety valve etc.

ACCESSORIES
These are the devices, which form an integral part of boiler. But are not mounted on it.

They include Superheated, economizer, feed pump etc.

And help in running efficiently.

AIR PREHEATED
It is used to recover heat from the exhaust.
Flue gases. It is installed b/w the economizer and the chimney.

ADVANTAGES
There is an increase of about 2% in the boiler.
Efficiency for each 35-40 degree C rise in temp. of air.
 SCHEMATIC DIAGRAM OF A STEAM
ENGINE OR TURBINE

TURBINE
2

STEAM WORK
O/P

C/W
BOILER
CONDENSAR

HEAT SUPPLIED
HEAT
REJECTED 4
1

FEED PUMP
HOT WELL
 EXTRACTION
PUMP

TURBINE
There are four turbine produced electricity In ABC paper LTD.
Give below with details specification.

No. of Capacity Alternator Turbine Steam Steam

Turbine MW Speed Speed Pressure Temp. 0C
RPM RPM Kg/Cm2
1. 1.5 1500 6000 32 415
2. 5 3000 3000 32 415
3. 1.2 1500 6000 32 415
4. 10 1500 10,000 65 475

IMPULSE TURBINE
The steam flows through the nozzle and impinges on the moving Blades.
Blades are symmetrical.

STEAM TURBINE
A turbine is device which converts thermal energy of a flowing fluid (steam) into
useful work this o/p of
Turbine may be use to run a governor it produced electricity.

FEATURES
 Efficiency is higher.
 Its imp components are steam boiler and accessories.
 It requires more space for installation.
 Starting of steam turbine is difficult and takes long times.
Dry saturted steam

SUPERHEATED STEAM
When the dry saturated is further heated at a constants pressure thus raising its
temperature. Superheated steam is supplied to the turbine

COOLING TOWER
It is used in power plants and refrigeration plants. Its function is to cool the water from
the condenser by exposing it to the atom sphere. Air, so that the cold water may be
used again for circulation. It is a certain height (at about 9m from the ground level ).
The water falls down in radial sprays from a height and the atmosphere air enters from
the base of the tower.

CONDENSER
It is a closed vessel in which steam is condenser the steam gives up heat energy to
coolant ( which is water ) during the process the condenser.

GOVERNOR
It is enters the steam to the turbine. The function of Governor is to regulate the mean
speed of an engine. When there are variations in the load.

FIXED BLADE Through nozzles, pressure is put on the blades it rotates.

STATOR It is the outer cover of the turbine.

OIL PUMP It supply the oil in the turbine.

ROTOR Its rotates the turbine.

 BACK PRESSURE TURBINE
The back pressure turbine is also used in application where Combined power and heat
in steam for process work is required. In this process the steam leaves the turbine at a
higher pressure. Then in normal turbine and is generally superheated the superheated
steam is not suitable for process work due to the following reasond :-
 The control of its temp. is impossible.
 The rate of heat transfer from the super heated steam to the heating surface is
lower than that of saturated steam.
Thus, the exhaust is passed through a de super heater to make the steam saturated. The
saturated steam is then passed through a heater where it is fully condensed.

Saturated Steam

TURBINE

Boile
r

HEAT
I
NG

DE-SUPERHEATER
FEED PUMP

BACK PRESSURE TURBINE

 REASONS OF TRIPPING THE TURBINE

 Over current earth fault.

 Under load current
 High voltage
 High frequency
 Low frequency
 Over voltage
 More vibration turbine
 More bearing temp.
 More winding temp. of alternator
 Less steam pressure
 Less steam temp.
PROCESS CONTROL CHART
WATER TREATMENT PLANT ( BOILER HOUSE )
W RAW WATER PRESSURE
A
TANKS FILTER
T
E
R

F
R
O
M DE-GASSER CATION UNIT

T
/
W
E DM WATER
L ANION UNIT UNIT
L

BOILER FEED DE-ERATOR

PUMP TANK

PROCEDURE
 First of all water is coming from tube well and then water is stored in ram water
tank.
 Minerals are present in fresh water.
 With the help pump Raw water goes to multi Grade Filter (MGF) or Pressure
Filter. Water having two type of solid i.e. Suspended solid and TDS (Total
Dissolved Solid). Here sand, scale, fungi is filtrate from water. These are
suspended solid.
 Water goes to Ion exchange (only cation)
Minerals are :- Ca, Mg, Na, Hco3, Co3, Co2 and Sulphate.
These minerals are eliminated from water. In Ion exchange.
 Water goes to De-gasser. Here Co2 is removed from the water.
 In the next stage, water goes to Ion exchange (only anion).
These are also Minerals :- CaCl2, MgCl2, NaCl2 and silica are removed from
water.
 PH (%of H2) value of water is7. which is maintained by DM Plant.
 Now water is Dematerialized. It is used in boiler.
 LATHE
ENGINE LATHE
It is also called “centre lathe”. Because it has two centre b/w which the job can be held
and rotated.

MAIN PART OF CENTRE LATHE ARE

Bed, Head Stock, Tail Stock, Carriage.
BED
Bed is the base of the lathe. It is massive and rigid casting made in one piece to resist
reflection and vibration. It hold or support all other part. i.e. head stock, tail stock and
carriage.

HEAD STOCK
The head stock is permanently fastened to the left hand end of the lathe.

TAIL STOCK
Tail Stock is on the other end of the bed from the head stock. Its chief function is to
hold the dead centre. So that long work piece L/D>4 can be supported b/w center. It
can be moved by along the bed.

CARRIAGE
In b/w the head stock and the tail stock in the carriage. It is movable on the bed ways.
IT HAS FIVE MAJOR PARTS
Saddle
Cross slide
Compound rest
Tool post
Apron

SHAPER
SHAPER
A process for removing metal from surface in horizontal, vertical and angular planes
by the use of a single point cutting tools in a ram that reciprocates the tools in a linear
direction across the work piece on the table of the machine.
 SHAPER MACHINE

CONSTRUCTIONS
BASE
The bed takes up the total dead weight of the machine as well as the dynamic load
during machine operation. Its material a usually gray cast iron.

COLUMN
It is mounted on the base.
TABLE
It moves across the column rails to give the feed motion of the job. The cross rail a
part of the slide which can be moved up and down.

RAM
Ram carries the tool head at its front. The ram travels two times fasters on the return
strokes then on the forward strokes.

TOOL HEAD
It hold the cutting tools and is fastened to the front the ram.

GRINDING
Grinding is a material cutting operation perform by means of a rotating abrasive tool,
calling “grinding wheel”.
Grinding wheel abrasion by friction grinding wheel are made of fine grains of abrasive
material held together by a bonding material called a bond. Each individual and
irregularly shaped grain act at cutting element it is employed for finishing various
parts such as pinion engine and crank shaft.
Composition of grinding wheel
 Abrasive
 Bonding Material
 Grain Size
 Grain
 Structure
ABRASIVE
An abrasive is a hard material which can be used to cut of wear away other material
grinding wheel are made of abrasive particles bonding together by suitable bond.

ABRASIVE

Natural Artificial
Emery Aluminum oxide
Sand Store Silicon carbide
Corundum
BOND
A bond is a material that hold the abrasive grains together enabling the mixture to the
in desired shape.
 Rubber Bond
 Silicate Bond
 Resinoid Bond

GRAIN AND GIRT SIZE

The size of grain is generally specified by the girt size. Larger the size of grain more
will the material removal capacity.
The grain size is indicated by girt number as shown below.
Very fine grain = 220-800
Fine grain = 70-180
Medium grain = 30-60
Coarse grain = 4-24

GRADE
Grade of a wheel in a measure of how strongly the grains are held by the bond

The bonding material is a wheel surrounds the individual grains and links them
together.

FOR EX..
A to H-Soft
I to P-medium
Q to Z- Hard

STRUCTURE
The structure of grinding wheel refers to relationship of abrasive grains and bonding
material.

FOR EX..
1-6 = DENSE
9-16 = OPEN
FINISHING HOUSE
 BLOCK DIAGRAM

PARENT CUTTER
ROLL SIMPLEX
DUPLEX

WEIGHING REEL SIZE

CHECKING CHECKING CHECKING

STACKING
CHACKING
GODOW
N

BUNDLE FINISHIN
WEIGHIN G
G PACKING
 FINISHING HOUSE
FINISHING HOUSE IS THE LAST BUT MOST IMPORTANT SECTION OF
MILL. IN THIS SECTION THE PAPER FINISHING IS DONE BEFORE
PACKING OF PAPER. PARENT ROLL IS WINDED FROM MORE
SMOOTHNESS OF PAPER. THE QUALITY OF PAPER IS CHECKED
WEIGHED AND PACKING IS DONE AND IS THEN SENT TO GODOWN.
THE CUSTOMER MEMANDS SHEETS THEN REELS ARE CUT BY
CUTTERS PROFILE OF SHEETS IS CHECKED AND CHECKING QUALITY
WEIGHING AND PACKING IS DONE IN BUNDLES AND SENT TO
GODOWN FROM WHERE THESE BUNDLES ARE DISPATCHED.
 ACKNOWLEDGMENT

I am very thankful to Mr. M.R Yadav Who gives me the chance to do my training in
ABC Paper limited. It was a great experience to get 4 weeks training in ABC paper
limited, Saila Khurd. It was great to me Mr. U.C Mishra ( AGM) as my instructor in
training . Moreover, I am very thankful to Mr. R.S Yadav (Manager of Mechanical
Department) who gives me practical knowledge of industry and teaches me about
many mechanical components. Mr. Raman Verma Manager who teach mechanical part
tell me about basics of mechanical. I am thankful to all mechanical Engineers, who
help a lot in my training period. I get a best knowledge of industry while doing my
training in ABC paper limited.