PulpandPaperReport FINAL PDF

State Level Workshop Report
Environment Friendly Techniques in Pulp & Paper Sector

26th April, 2013; Hotel Fortune, Vapi (Gujarat)
Foreword
Dr. Dieter Mutz

Director
Indo German Environment Partnership (IGEP) Programme
Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH
New Delhi
The Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH is providing technical
cooperation in the area of “Environment Friendly Techniques in Pulp & Paper Sector” under the
Sustainable Industrial Development component of the Indo German Environment Partnership (IGEP)
Programme under the Indo German Bilateral Development Cooperation. The IGEP Programme is
jointly implemented by the Ministry of Environment & Forests, GoI and GIZ (on behalf of the German
Federal Ministry for Economic Cooperation & Development).
As a part of the cooperation activity, a State level Workshop on “Environment Friendly Techniques in
Pulp & Paper Sector” was organised at Vapi on April 26, 2103, jointly with the Confederation of
Indian Industry (CII) and the Gujarat Cleaner Production Centre. The present workshop report is a
compilation of various presentation made, as well as issues and suggestions brought out by the
participants.
Your feedback, comments and suggestions on the report are welcome, which we are sure will be
very useful while preparing policy instruments by us in the coming year.
New Delhi (Dr. Dieter Mutz)

June 28, 2013 Director, GIZ-IGEP
Contents
1. Background .................................................................................................................. 2
2. Introduction .................................................................................................................. 2
3. Programme of the Workshop ...................................................................................... 3
4. Participants in the Workshop...................................................................................... 4
5. Inaugural Session of the Workshop ........................................................................... 4
6. Technical Sessions of the Workshop ......................................................................... 6
7. Concluding Session of the Workshop........................................................................ 8
8. Annexure I - Workshop Programme .......................................................................14

9. Annexure II - List of Participants .............................................................................16
10. Annexure III - Technical Presentations ....................................................................22
Note: The current report (along with technical and spotlight presentations) can also be
downloaded from : http://tinyurl.com/pulpgiz
Page | 1
1. Background
The on-going Indo German Development Cooperation has “urban and industrial
environmental policy & management” as one of priority areas of cooperation. The Indo
German Environment Partnership (IGEP) Programme forms a part of this priority area, under
which technical cooperation is being provided to the identified Indian partner organisations
by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ), on behalf of the
German Ministry for Economic Cooperation and Development (BMZ).
The IGEP Programme, which is implemented jointly by the Ministry of Environment and
Forests (MoEF) of the Government of India and GIZ has a thrust area on Sustainable
Industrial Development (SID). Under the SID component, the relevant activities for which the
advisory services are sought are related to the following core topics:
 “Environment Friendly Techniques in Identified Industry Sectors”

 “Planning of New Industrial Parks and Investment Zones”
 “Waste Water Management”
The overall objective of the technical cooperation on the core topic of “Environment Friendly
Techniques in Identified Industry Sectors” is to promote thee use of environment-friendly
technologies and techniques is in selected SME sectors”. The identified sector for this focus
activity are textiles and pulp & paper sectors in which following activities are envisaged:
 Baseline Surveys / Situation Analysis for the proposed industrial sectors in India and
assessment of core issues related to environment, resource efficiency and climate
change.
 Organisation of Regional/State/Local level workshops and consultations to exchange
information on potential solutions.
 Identification of volunteering industries for demonstration of viable environment friendly
techniques on pilot basis.
 Documentation and dissemination of pilot experiences/results Evolving supportive policy
documents/instruments for application of viable solutions across the pulp & paper
industry sector in the country.
2. Introduction
The environmental concerns are growing leading to higher environmental litigation risks for
the industries, particularly those from the SME sector. According to a World Bank study
(South Asia Environment and Social Development Unit), “India: Strengthening Institutions for
Sustainable Growth”, SME contributes to nearly 70% of industrial pollution load in India. The
major forms that have been highlighted include, air pollution, water pollution, soil
contamination, radioactive contamination, noise pollution, light pollution, visual pollution, and
thermal pollution. Also, a recent study by the Bureau of Energy Efficiency (BEE), which takes
into consideration the SME sector, revealed that the overall energy saving potential of the
clusters is about 72,432 TOE (tonnes of oil equivalents), which is 27.4% of the total energy
consumption in SMEs.
The Indian paper industry is one the largest and oldest sectors in the country and amongst
the most important in the economy in terms of output, investment and employment. The
paper manufacturing process, in general, is characterized by the high consumption of
resources like electricity, fuel, water and a variety of chemicals in a long process sequence
Page | 2
that generates a significant amount of waste and emissions. Hence, the paper sector can
benefit by making improvements targeting resource efficiency, process improvements,
energy efficiency and reduced negative environmental impacts. By employing appropriate
technologies, both environmental and economic gains can be achieved.
For referencing viable environment friendly techniques in pulp & paper sector, various
sources of information are available. For example, the BREF (Best Available Techniques
Reference Documents) from Germany and the Comprehensive Industrial Documents
(COINDS) of the Central Pollution Control Board provide useful information. Also, the
success stories of some of the champion pulp & paper industries of India who has
demonstrated pioneering efforts in technological innovation in terms of adopting cleaner
production techniques are a vital source of proven environmental friendly technology In
addition, there are also technology providers dealing with relevant technologies for the pulp
& paper sector, such as the insulation systems, low energy motors, online pollution
monitoring systems etc. Agencies such as the Gujarat Cleaner Production Centre have also
undertaken pilot studies in the pulp & paper industries.
There is a greater need to evolve a platform where such relevant resources can be
discussed and documented, so that the entrepreneurs can have a ready reference document
to understand and implement such technology.
Strategically, to gather information and to facilitate information exchange, under the IGEP
Programme, stakeholder consultations are being organised periodically. Such consultations
are organised at local, regional, state and national levels to facilitate identification of core
issues faced by the sector and to look out for viable technical solutions. The consultations
are organised through workshops, meetings and conferences.
Against this background, as a part of the Phase I activities, GIZ collaborated with the
Confederation of Indian Industry (CII) together with Gujarat Cleaner Production Center
(GCPC) and organized the 1-day State-level Workshop on “Environment Friendly
Techniques in Pulp & Paper Sector” on April 26, 2013 at the Hotel Fortune, Vapi (Gujarat).
The workshop was aimed to share knowledge, experiences and case examples. It was also
intended to provide a platform for discussion on the core issues related to policy/regulatory,
and technological and management aspects which are prime aspects to be addressed for
ensuring improved environmental performance by the pulp & papers sector in India.
3. Programme of the Workshop

The workshop focussed on the following aspects-:
 Issues and Challenges in Pulp & Paper sector of India relevant from the perspective
of improvement in the environmental performance; and
 Need for New Government Policies and supportive instruments towards
enhancement of environmental performance of Pulp & Paper industries of in India
 Scope of latest available technologies for the Pulp & Paper sector in India.
The workshop programme included:
 Inaugural session
 Technical Session I: Environmental Policies, Laws and Challenges
 Brainstorming Session on Core Issues
Page | 3
 Technical Session II: Technological Aspects for Improved Environmental
Performance in Pulp & Paper Sector
 Technical Session III: Environmental Management in Pulp & Paper Sector
 Concluding session
The programme details are given in Annexure I. The programme covered 12 technical
presentations covering various relevant topics and is provided in Annexure III.
4. Participants in the Workshop

The workshop had over 50 participants including representatives of government bodies,
industries, technology providers, infrastructure developers, investors and consultants. The
list of participants that have registered in the workshop is given at Annexure II.
Pic: Participants at the workshop
5. Inaugural Session of the Workshop

The workshop started with an inaugural session. Mr D P Chandrana
President-Technical, Anmol Polymers Pvt. Ltd. gave the welcome remarks and Mr. Lalit
Sharma, Senior Technical Expert, GIZ-IGEP presented the theme address, and set the
context for the workshop.
There were three special addresses from:
 Dr. K U Mistry, Chairman, Gujarat Pollution Control Board

 Mr Ashok Shukla, President, Vapi Industrial Association
 Mr. Bharat Jain, Member Secretary, Gujarat Cleaner Production Center
Page | 4
The inaugural session concluded with Mr. Dinesh Ghai, Sr Counsellor, Confederation of
Indian Industry delivering the concluding remarks and vote of thanks to all the participants,
speakers, project partner GIZ, press and media.
Pic: Dr. K.U. Mistry, Chairman, Gujarat Pollution Control Board

addressing the participants during the Inaugural Session of Workshop
Pic: Mr. Lalit Sharma Technical Advisor, GIZ - IGEP, Delhi moderating the workshop
Page | 5
6. Technical Sessions of the Workshop
In the technical sessions of the workshop, topics presented are given below.
Technical Session I: Environmental Policies, Laws and Challenges
 Environmental Policies, Standards and Regulatory Aspects in Pulp & Paper

Industries
 Environment and Energy related issues in Boiler
 Effluent Management in Paper Industry
Technical Session II: Technological Aspects for Improved Environmental

 Best Available Techniques in Europe for Pulp & Paper Sector / BREF EU Reference
Documents
 Advanced / Best Available Technologies for Small and Medium Paper Machine
 Steam Systems Optimization in Pulp & Paper sector
Technical Session III: Environmental Management in Pulp & Paper Sector
 Case Study of Cleaner Production in Vapi Paper Mills

 Zero Liquid Discharge Case Study
 Best Practices in Water Management in Pulp & Paper Industry
 Greenco Rating for Pulp & Paper Industries
Spotlights
 Innovative low life cycle cost pumps

 Solar Thermal Application in Industries – Case Example
 “CS/PTFE” Piping System Used In Paper & Pulp Mill
The presentations are attached at Annexure III. The presentations made by the speakers
and current report can also be downloaded from : http://tinyurl.com/pulpgiz
Page | 6
Pic: Dr. K U Mistry, Chairman, GPCB conducting Technical Session I of the Workshop
Pic: Dr. N J Rao, Vice Chancellor, Jaypee University of Engineering

and Technology conducting Technical Session II of the Workshop
Pic: Mr. Rajesh Doshi, Executive Director, VWEMCL conducting Technical Session III of the Workshop
Page | 7
Pic: Participants at the workshop
7. Concluding Session of the Workshop

The Concluding Session of the workshop focused on collecting inputs and suggestions from
the participants which was conducted as a brainstorming session after technical session I.
Three groups were formed to discuss on the topics and presentation were made by the
groups on the results from the discussions. Following are the topics covered by the groups:
 Group 1: Issues and Challenges in Pulp & Paper sector in India relevant to improved
environmental performance.
 Group 2: New Government Policies and supportive instruments required for

supporting Pulp & Paper sector in India.
 Group 3: Scope of latest available technologies for the Pulp & Paper sector in India.
Pic: Mr. Lalit Sharma Technical Advisor, GIZ - IGEP, Delhi moderating Brainstorming Session on Core Issues
Page | 8
Pic: Group 1 lead by Dr. N J Rao, discussing on Issues and Challenges in Pulp & Paper sector
in India relevant to improved environmental performance
Pic: Group 2 lead by Mr. Tushar Shah, discussing on New Government Policies and supportive
instruments required for supporting Pulp & Paper sector in India
Page | 9
Pic: Group 3 lead by MR. Bharat Jain discussing on Scope of latest available technologies
for the Pulp & Paper sector in India
The important points/suggestions that emerged from the group discussions are summarised
below.
Group 1: Issues and Challenges in Pulp & Paper sector in India relevant to improved
environmental performance
 One of the core issue in recycled pulp & paper industries is the generation of high
TDS effluent. The source of these high TDS in the effluent are due to the chemicals
used for sizing and are mixed with pulp to do internal sizing. Cost effective treatment
of high TDS effluent is the major challenge for the paper industries.
 One of the very critical issue related with the waste water from the paper industries is
the colour, which works as a constraint for the water recycling in the process and
thus leading to additional waste water generation.
 Presently the paper industries are generating solid waste in the form of deinking
sludge, sludge from ETP which contains organic solids resulting in high calorific
value. These wastes that are presently sent to landfills have potential for use at a
waste to energy generation plant.
 All the recycled paper industries are using almost same technologies and processes
but there are significant variations in water consumption. Identification and
elimination of the causes for such high water consumption is one of the biggest
challenges for evolving a benchmark for recycled paper industries.
Page | 10
 Plastic waste generated from the recycled paper industries is considered as
hazardous waste and thus disposal of the plastic waste is a major challenge for the
paper industries. In spite of its higher calorific value, the only option available for
disposal is co-processing in cement industries that too with their specific quality
requirement which needs pre-processing before being considered by cement
industries. The distance of the paper mill from the cement industry is another
important factor in these cases since these has significant bearing on the
transportation cost to see this work as an economically viable option.
Group 2: New Government Policies and supportive instruments required for

supporting Pulp & Paper sector in India
 The existing air quality norms are based on the requirements for residential areas,
while there is a need to have relaxed air quality norms for the industrial areas.
 There is a need for proper guidelines by the regulatory bodies for the reuse or
disposal of boiler fly ash generated in the industries.
 Need for additional finance mechanism, apart from MNRE subsidy, to support
implementation of renewable energy generation projects within the paper industries
(like thermal solar applications or solar photovoltaic).
 Support from government is needed for implementation of environment friendly

technologies. This may be in the form of soft loans or grants (up to 50 % at least), as
the new technologies implementation are cost intensive and there are risks
associated with the results after implementation.
 The pricing mechanism that is being followed by the CETP needs review since the
CETP charges to the industries are based on the consumption of water while it
should actually be on the basis of waste water quantity discharged. Guidelines
should be provided by SPCB’s on suitable pricing mechanism.
 Marine discharge norms for treated wastewater are similar to that of the land
discharge, although the investments for the onshore and offshore pipelines are
significant. Thus, CETPs have to invest more in treatment to achieve the norms for
marine disposal similar to that of land disposal. The marine disposal norms should be
kept 500 mg/l for COD.
Group 3: Scope of latest available technologies for the Pulp & Paper sector in India
 Although some of the industries have achieved zero discharge with repeated water
recycling and treatment, but after certain number of recycles the water needs to be
discharged for further treatment in an ETP due to increase in certain chemicals or
fine particles. There is a need of such technology which can address the above
limitation.
 There is scope for substitution of conventional chemicals with the eco-friendly

chemicals, as lot of chemicals based on enzymes are now in market. Various studies
that are currently on-going related to bio-deinking, bio-bleaching, bio-pulping etc., are
of interest to the industries so that they can have the access to those commercially
available probable substitution solutions.
Page | 11
 Technology options are need for avoiding SPM (suspended particulate matter)
generation as atmospheric emissions instead of presently putting control devices to
reduce the SPM emission.
 In recycled paper process, the fibre is recycled many times and thus the fibres break
and become non-usable after a point. There is a need for technology for
strengthening the fibre in spite of continuous recycling.
 For a cluster of paper mills, there is possibility to have individual ETP with bio-
methanation plant which will generate energy out of the organic load in the effluent
and the sludge of the ETP.
^^^
Page | 12
Annexures
Page | 13
Annexure I
Workshop Programme
One - Day Workshop on

February 27,2013; Centre Of Excellence, GIDC Industrial Estate, Vapi (Gujarat)
09:30 hrs Registration & Tea

1000 hrs – 1035 hrs : Inaugural Session
Mr D P Chandrana
1000 hrs Welcome Remarks President-Technical
Anmol Polymers Pvt Ltd.,
Mr Ashok Shukla
1010 hrs Address by President
Vapi Industrial Association
Mr Bharat Jain
1015 hrs Address by Member Secretary,
Gujarat Cleaner Production Center
Dr K U Mistry
1025 hrs Special Address by Chairman
Gujarat Pollution Control Board
Mr Dinesh Ghai
1035 hrs Concluding Remarks Sr Counsellor
Confederation of Indian Industry
1045 hrs Tea Break (15 min)
1100 hrs – 1205 hrs : Technical Session I: Environmental Policies, Laws and Challenges
Introductory Remarks by Dr K U Mistry
1100 – 1110 hrs
Session Chairman Chairman; Gujarat Pollution Control Board
Environmental Policies,
Mr Yunus Tai
Standards and Regulatory
1110 – 1125 hrs Environment Engineer; Gujarat Pollution
Aspects in Pulp & Paper
Control Board
Industries
Mr Vivek Taneja
Environment and Energy
1125 – 1140 hrs Head Business Development – Power
related issues in Boiler
Division; Thermax
Effluent Management in Mr N K Verma
1140 – 1155 hrs
Paper Industry GIZ Consultant
1155 – 1205 hrs Questions & Answers , Discussion
Brainstorming Session on Core Issues
Conducted by:
Mr. Tushar Shah (Director Daman Ganga Paper Mills, Vapi)
1205 – 1300 hrs
Dr. N J Rao (Vice Chancellor, Jaypee University of Engineering and
Technology)
Moderated by : Mr. Lalit Sharma (GIZ)
1300 – 1400 hrs Change Over & Lunch
1400 hrs – 1515 hrs : Technical Session II: Technological Aspects for Improved Environmental
Introductory Remarks by Mr N J Rao
1400 – 1405 hrs
Session Chairman Vice Chancellor, Jaypee University of
Page | 14
Engineering and Technology
Best Available Techniques Mr Lalit Sharma
in Europe for Pulp & Paper Senior Technical Expert,
1405 – 1415 hrs
Sector / BREF EU GIZ, Indo German Environment Partnership
Reference Documents Programme
Advanced / Best Available Mr N K Jain
1415 – 1425 hrs Technologies for Small and Director (Pulp, Paper & Power - India)
Medium Paper Machine Metso Paper India Pvt Ltd.,
Steam Systems
Dr Datta Kuvalekar
1425 – 1435 hrs Optimization in Pulp &
Forbes Marshall
Paper sector
Spotlights
Innovative low life cycle Mr Dhanraj Hathiwala
1435 – 1445 hrs
cost pumps Sr. Sales Engineer; Grundfos
Solar Thermal Application
Mr Abhishek D Bhatewara
1445 – 1455 hrs in Industries – Case
Director; Clique Solar
Example
“CS/PTFE” Piping System Mr Ajay Kotwal
1455 – 1505 hrs
Used In Paper & Pulp Mill Marketing Manager; Hi-Tech Applicator
1505 – 1515 hrs Q&A, Discussions (10 min)
1515 hrs – 1610 hrs : Technical Session III: Environmental Management in Pulp & Paper
Sector
Mr Rajesh Doshi
Introductory Remarks by
1515 – 1520 hrs Executive Director, Vapi Waste & Effluent
Session Chairman
Management Company Ltd.
Case Study of Cleaner
Dr. H. M. Bhatt
1520 – 1530 hrs Production in Vapi Paper
Industry Consultant
Mills
Mr P Vairaperumal
Zero Liquid Discharge
1530 – 1540 hrs Process Engineer; Tamilnadu Water
Case Study
Investment Company
Best Practices in Water Mr Pritesh Parekh
1540 – 1550 hrs Management in Pulp & Executive – Corporate Marketing Group
Paper Industry Ion Exchange
Mr Dinesh Ghai
Greenco Rating for Pulp &
1550 – 1600 hrs Senior Counsellor; Confederation of Indian
Paper Industries
Industry
1600 – 1610 hrs Questions & Answers , Discussion (10 min)
1610 hrs – 1650 hrs : Concluding Session and Way Forward (Moderated by GCPC and GIZ)
Concluding Remarks
 Issues and Challenges in Pulp & Paper sector in India relevant to
improved environmental performance
1610 – 1620 hrs  New Government Policies and supportive instruments required for
supporting Pulp & Paper sector in India
 Scope of latest available technologies for the Pulp & Paper sector in
India
 GIZ, Indo German Environment
Way Forward
1620 - 1700 Partnership Programme
 Confederation of Indian Industry
1700 End of Workshop
Page | 15
Annexure II
List of Participants
One - Day Workshop on
April 26, 2013; Hotel Fortune, Vapi (Gujarat)
S. No. Name Designation Name of the Company Telephone Mobile Email Id

Mr Pardeep Aker Powergas
1 Director (EPC) 022 66915502 9820078145 pardeep.dang@akersolutions.com
Dang Private Limited
Mr Suhas Aker Powergas
2 Senior GM 022 66915502 9820586721 suhas.upadhye@akersolutions.com
Upadhye Private Limited
Mr D P President- Anmol Polymers Pvt dpchandarana@gmail.com ;
3 9573598727
Chandarana Tech Ltd info@anmolpolymers.org
Mr Ramesh K Managing Best Paper Mills Pvt
4 9824149437 best.ashar@gmail.com
Shah Director Ltd.,
Best Paper Mills Pvt
5 Mr Nitin V Oza Director 9377315523 best.ashar@gmail.com
Ltd.,
Mr C S c.kashikar@bilt.com;
6 DGM, R & D BGPPL, Ballarpur 95610 88187
Kashikar cskashikar@rediffmail.com
CCI – Control
Mr Ashraf Exec. Manager
7 Component India Pvt. 120 4089579 ashrafj@ccivalve.com
Jamal - AE
Ltd
Mr. N. S. K.
8 GM, COE Centre Of Excellence
Srinivasan
9 Mr Ambuj Dixit Consultant Clique Solar ambuj@cliquesolar.com

Business
Mr Sameer
10 Development Clique Solar sns@cliquesolar.com
Satija
Executive
Page | 16
Mr Narendra Creative Papers
11 9769588989 creativepapersgroup@yahoo.in
Goyal Group
Daman Ganga Board
12 Mr R D Sharma GM 9825610006 info@damanganga.com
Mills P Ltd.
Daman Ganga Board
13 Mr R B Yadav Sr, SIC 9825610006 info@damanganga.com
Mills P Ltd.
Mr Chandrakant Sr Manager Deevya Shakti Paper
14 08548 255754 8008820909 c.mahale@deevyashakti.com
Mahale Environment Mills Ltd
Senior Design
Development
Mr Aritra Engineer,
15 Consultants Private 9831677183 aritra.bhowmick@in.dclgroup.com
Bhowmick Paper &
Limited
Process
DGM(Business Elof Hansson India
16 Mr N Ranjit 9840796309 n.ranjit@in.elofhansson.com
Development) Pvt Ltd
Mr Shrinivas Regional Elof Hansson India
17 9821313536 s.joshi@in.elofhansson.com
Joshi Manager Pvt Ltd
Mr Ramesh Emami Paper Mills
18 Sr.Manager 9437964505 khuntiar@emamipaper.in
Khuntia Ltd
Mr Jainath Research Forest Research
19 7520622575 jainathsah@gmail.com
Prasad Sah scholar Institute
Group Gayatrishakti Paper & 0260 2401560
20 Mr A.K. Bansal 9909300555 akbansal@gspbl.com
President Baords Ltd / 2400451
Mr Madhukar Gayatrishakti Paper & 261 2401560 /
21 Vice President 9824175615 joshua@gspbl.com
Joshua Baords Ltd 2400451
Mr S.R. Manager Pulp Gayatrishakti Paper & 262 2401560 /
22 9099960864 tondare@gspbl.com
Tondare Mill Baords Ltd 2400451
Gayatrishakti Paper &
Mr R. L. 263 2401560 /
23 G.M. (Q.C.) Baords Ltd 9099960865 -
Ekhande 2400451
Page | 17
Mr Rajendra Pulp Mill Gayatrishakti Paper & 264 2401560 /
24 9377021892 -
Choudhari Incharge Baords Ltd 2400451
Gayatrishakti Paper & 265 2401560 /
25 Mr K.P.Singh G.M. (Maint) 9925156397 kpsingh@gspbl.com
Baords Ltd 2400451
Mr Rajendra K. Manager Gayatrishakti Paper & 266 2401560 /
26 9099960869 shete@gspbl.com
Shete (Mech. & Dev.) Baords Ltd 2400451
Mr Manan Shah Grundfos Pumps (I)
27 Engineer 9558813510 manan@grundfos.com
Sales Pvt. Ltd
Gujarat Industrial
Superintending
28 Mr. A. K. Patel Development
Engineer
Corporation
Regional Gujarat Pollution
29 Mr G V Patel bmwuhgpcb@gmail.com
Officer Control Board
Deputy
Mr J D Gujarat Pollution
30 Environment bmwuhgpcb@gmail.com
Goswami Control Board
Engineer
(0261)
Regional Gujarat Pollution
31 Mr. A. G. Patel 2442696, gpcb-sur@gujarat.gov.in
Officer Control Board
2411192
Regional Gujarat Pollution 02637)
32 Mr H P Patel nav.ro.gpcb@gmail.com
Officer Control Board 280830
Mr Jitesh P hariind_ad190@dataone.in ;
33 Partner Hariram Industries 9427102885
Shah hariramind@gmail.com
Mr DIvyanshu
34 CEO Harsh Engineering 9825130242 divyanshu@harshindia.com
Patel
Marketing
35 Mr Ajay Kotwal Hi-Tech Applicator 9820385039 hitech.mum@ptfeindia.com
Manager
36 Mr Hardik Shah Director Hi-Tech Applicator 9879504425 hardik.shah@ptfeindia.com
Page | 18
Mr Suhash
37 Director Hi-Tech Applicator 9824014471 suhash.shah@ptfeindia.com
Shah
38 Mr Amar shah Proprietor JEW 2226853480 9322226290 jew@jewpump.com
Mr Pramod Manager – JK Paper Ltd. Unit: 02624 305 919328921158

39
Kumar Environment CPM 491 /+919879691817
Sr. Manager – JK Paper Ltd. Unit:
40 Mr A K Somani
P&D CPM
Mr Chinmay Trainee- (P& JK Paper Ltd. Unit:
41
Kulkarni D) CPM
Sr. Manager – JK Paper Ltd. Unit:
42 Mr Pankaj Inani
(Power Block) CPM
Mr Shailendra Dy. Manager – JK Paper Ltd. Unit:
43
Bagul (Pulp Mill) CPM
Dy, Manager –
Mr Rajesh JK Paper Ltd. Unit:
44 (Process
Pawar CPM
Board)
Chief Manager
Mr Ranjeet JK Paper Ltd. Unit:
45 - (Electrical
Bhavsar CPM
Board)
Mr Jarnail Sr Engineer JK Paper Ltd. Unit:
46
Chand Yadav (Electrical) CPM
Mr Girish Regional Sales
47 Kadant Johnson 9158889625 girish.shenai@kadant.com
Shenai Manager
0260-
48 Mr S K Rana Proprietor Microfab Industries 9824137706 microfabpaperind@gmail.com
2421056
Project Co- 0260-

49 Mr A K Kalra Microfab Industries 9898025795 akkalra_2000@yahoo.com
Ordinator 2421056
Page | 19
Neral Paper Mills P
50 Mr R P Gala W T Director 2602780196 9833109882 rpgneral@outlook.com
Ltd
Production Neral Paper Mills P

51 Mr S Patil 2602780196 9377069709
Manager Ltd
Mr Deepak K
52 Director Otr Papers Pvt Ltd 9810194800 deepdec31@Yahoo.com
Garg
Mr Bhooshan
53 Director Otr Papers Pvt Ltd
Chauhan
President – Rama Newsprint &
54 Mr R H K Sinha 9909240001 rhksinha@ramanewsprint.com
Works Papers Ltd
Rama Newsprint &
55 Mr A K Vishwal
Papers Ltd
REConnect in REC -
56 Mr Ram 9620221101 vishal.pandya@reconnectenergy.com
PAT
Mr Lon lon.rollinson@mwv.com ;
57 Ruby Macons Limited 260 3050000
Rollinson mk.kureshi@mwv.com
58 Ruby Macons Limited
59 Mr Rasik Bhatt Owner/CEO Selan Bioscience 9825843989 selan_India@yahoo.com
Dr Santosh Manager Env

60 SGS India Pvt Ltd 9825307128 santosh.zargar@sgs.com
Zargar Services
Mr Abhishek Executive
61 Siemens Ltd 9687668690 pandey.abhishek@siemens.com
Pandey Sales
Mr Mahadeo
62 Unade Manager Siemens Ltd 9833403501 mahadeo.unade@siemens.com
Page | 20
Dr Tatyasaheb General Tata Chemicals
63 8976000272 tpatil@tatachemicals.com
A Patil Manager Limited
Mr A Arivalagan Manager - TATA Consulting
64 9757287324 aarumugam@tce.co.in
General Projects Engineers
Manager - TATA Consulting
65 Mr A K Sharma 022-66472059 aksharma@tce.co.in
Process Engineers
TECSOL Engineers 080-23196054
66 Mr P R Raheja Director 9880044662 rahejap@tecsolengineers.com
Pvt.Ltd / 56
Mr A TECSOL Engineers
67 Director 9880044664 seshachalam@tecsolengineers.com
Seshachalam Pvt.Ltd
Mr. Kanu M. United Phosphorus
68
Desai Ltd
Mr Sureshbhai Vaibhav Paper Boards
69 M. Tech 93747 30994 suresh@vaibhavpaper.in
Desai G Pvt. Ltd.,
Mr Nimish J Vaibhav Paper Boards
70 Director 98980 13480 nimish@vaibhavpaper.in
Shah Pvt. Ltd.,
Mr. Ashok Vapi Industrial
71
Shukla President Association
Paper
72 Mr B C Adhyaru 9974422557 bcadhyaru@yahoo.co.in
Consultant
Mr Hemant
73 Alert Engg. 9377026080 patelhemantt@gmail.com
Patel
Page | 21
Annexure III
Presentations
Note: The current report (along with technical and spotlight presentations) can also be
downloaded from : http://tinyurl.com/pulpgiz
Page | 22
Paper Mill in Gujarat
Environmental Policies, Standards
and Small Medium Large Total
Regulatory Aspects
in
Pulp & Paper Industries 80 22 32 134
Except one paper Mill (wood base), all are recycle fiber
Yunus Tai based.
Gujarat Pollution Control Board
Page 1 Page 2
Standards Standards
Large Pulp & Paper-News Print/Rayon Grade (Capacity above 24,000 MT/Annum):
Effluents: Parameter Concentration
pH 7.0- 8.5
BOD 30 mg/l
Small Pulp & Paper Plant (Capacity up to 24,000 MT/Annum):
COD 350 mg/l Effluents:
S.S 500 mg/l
Absorbable Organic 1.0 kg/ton of product Flow (Total Waste water Discharge)
Halogens (AOX) in from 1/3/2008
i) Agro based: 200 cum/ton of paper produced
effluent discharge
ii) Waste Paper based:75 cum/ton of paper produced
Flow (Total Waste water Discharge)
i) Large Pulp & Paper 200 cum/ton of paper produced
ii) Large Rayon grade 150 cum/ton of paper produced
Page 3 Page 4
Environmental Issues contd……

 High volume of effluents  High level of Pollutant
COD 200-4000mg/l
Wood based mills:100-150 m3/t Paper
BOD 200-1000mg/l
Agro based mills:100-150 m3/t Paper
 Disposal of Solid Wastes ,t/t Paper
RCF based mills:40-100 m3/t Paper
Wood based mills: 0.8-1.0
 High color in effluents Agro based mills:0.5-1.0

RCF based mills:0.3-0.5
Wood based mills:300-800 PCU
 High energy consumption
Agro based mills:300-3500 PCU
Wood based mills: 1200-1500 KW hr/t Paper
RCF based mills:200-300 PCU Agro based mills: 900-1100 KW hr/t Paper
RCF based mills: 400-700 KW hr/t Paper
Control of NCG ( Odor ) emissions Page 5 Page 6
CREP
Past Scenario……
As per Corporate Responsibility for Environment Protection (CREP)-2002, following
water discharge standards have been agreed upon by different pulp and paper • Fresh water consumption by M. G. Craft paper mills in
manufacturing associations:
Vapi: 40-50 m3/t Paper in process
A. Large scale pulp and paper mills: • Recycling of waste water leads to make up of water
 Less than 140 cum/ton of paper within 2 years requirement including utility to 4-5 m3/t Paper
 Less than 120 cum/ton of paper in 4 years for mills installed before • Paper Mill claims almost zero discharge
 1992 • Cyclone/Multi cyclone+ Gravity settler as APCM in
 Less than 100 cum/ton of paper in 4 years for mills installed after Boiler
• Fiber sludge, either goes for sundry board making or landfill
 1992
• Plastic waste to scrap dealer
B. Small scale pulp and paper mills:
• Fly ash for land filling
 Less than 150 cum/ton of paper within 3 years
Page 7 Page 8
Environmental Compliance Contd……

• Policy decision by the Board to conduct joint study with Vapi • Fly ash partially used for brick manufacturing
Paper Mill Association about total recycling of waste water • Plastic waste for co-processing to Cement Industries, a
• Study reveals it further require secondary treatment beginning
• Joint decision by Board and Vapi Paper Mill Association to
provide secondary treatment and permit discharge of 1.0 m3/t
Paper produced
• Bag filters for Boilers up to 10 T
• ESP for Boilers > 10 T
Page 9 Page 10
Areas of concern Suggestion
 Process modification for conservation of water to  CPCB guideline for conservation of water to be
compete  reviewed
 with global player  Explore the possibility of using fiber sludge in
 Up gradation in environmental technology for recycling of  eco-friendly IDOL making
 waste water  Promote conversion of useful product from

 plastic waste and also for co-processing in
 Management & handling of de-inking sludge generated
 sponge iron plant
 from News print/writing paper
 Use of deinking sludge to be used as fuel
 Management & handling of fiber sludge
Page 11 Page 12
Contents
Energy Efficiency through Cogeneration
Options Macro view of Power / Energy scenario in India
Viability of Captive Power for Pulp & Paper
Paper Industry Cogeneration options
Fuel options
26th April 13
Business Model options
A word about us
Power Division Page 1 Page 2
INDIA’S GROWING ENERGY DEMAND

Factor Unit 2005 2030 2030
Reference Abatement Case ENERGY CONSUMPTION PATTERN
GDP growth % 7.5 7.5
Population Billion 1.10 1.47 1.47 Temperature
Losses Manipulation
Energy Demand Btoe 0.5 1.8 1.4 16% 37%
Power Demand TWh 700 3870 2910

Power Capacity GWs 150 760 640
GHG Emissions Bn Tons 1.6 5.0 – 6.5 2.8 – 3.6
of CO2
Source: McKinsey Analysis
Considering that 80 % of the India of 2030 is yet to be built, Electricity

16% Transportation
the country has a unique opportunity to pursue 20%
development while managing emissions growth, enhancing Source: Wikipedia
4
its energy security and creating a few world scale clean-
Page 3 Page 4
EMISSION BY GDP GROWTH RESOURCES AVAILABLE – HYDRO CARBON

Resources Reserve/Production (Years)
Current Projected *
Extractable Coal 89 45
and Lignite
Oil (2005) 24 -
Gas (2005) 34 -
* Assuming coal sector growth @ 5% per year. In
case of oil and gas, the period will be dependent on
Page 5
the new finds. Page 6
Source: McKinsey Analysis
Capacity scenario
Power scenario
 Installed Capacity 235000 MW * ( approx)
 (including Captive)
 Availability
 Current shortfall
 Quality
Base- 9%
Peak 11 %
 Affordability
 Reqd installed capacity by 2017 320000 MW
 Addition reqd per annum 20000 MW

Page 7 Page 8
Capacity scenario
Capacity scenario
 As per Mckinsey estimates, the gap would further increase due to:
 Growth in residential consumption @ 14%  Further, the peaking gap is set to double from present till 2017
 Electrification of rural India
 Realisation of latent demand  Currently no focus on peaking plants
 Manufacturing growth
 This gap will have to be met with costly power from DG sets/ traded
 Reqd capacity by ‘17 in high growth scenario 445000 MW power.
 Additional capacity reqd 225000 MW
 Addition reqd per annum 25 - 30000 MW

Page 9 Power Division Page 10
Are utility scale plants enough?

When will MPP’s / IPP’s come up?? Need to reduce carbon - PAT
 Long Gestation period upto 7 to 8 yrs for a 500 / 1000MW from
concept to commissioning.
 India has made a commitment to global community to be a responsible
 MPP’s lost in policy struggle none close to financial closure yet.
global citizen and reduce it carbon intensity.
 Large Water resources availability
 Land acquisition issues  BEE has instituted a Perform Achieve & Trade (PAT) scheme for
energy intensive industry
 Rehabilitation issues
 Transmission Corridors  Steel is identified as a main Designated Consumer (DC) to reduce
 Most are pit head based away from load centre carbon & energy intensity.
 Transmission network costs??  The industry now has obligation to reduce the energy intensity
 Open Access – right of way on Transmission lines

• NOC from SLDC’s
Page 11 Thermax Limited Page 12
Benefits of Dis- Gen
 Low gestation period

 20 to 100 MW unit in less than 2-3 years
 Local generation close to load centre
 No transmission losses
 No large investment in Transmission network
 Fastest way to get private investment in power
 Small scale – low concentration of pollution levels locally
 Not very demanding on Water – increasingly scarce resource/ ACC options
 Faster financial closure
 Planned approach can create smaller islanded grids
 Can be integrated to national grid
 Private investment in smaller power plants ( Industries)
 Even if their core business is not Power
 Additional Revenue source from sale of access power
Thermax Limited Page 13 Page 14
Typical Cogen - Advantages Typical Steam Turbine Cogen
 Back Pressure Turbine.

HEAT  Extraction - Condensing
Turbine.
STEAM
BOILE TURBIN  Extraction - Back Pressure
R Type.
E
Note:
CONDENS  Choice based on Heat-Power
ER balance, type of fuel and
• Overall Efficiency > 75% PUM pressure levels of the process
– Captive Power at lower • Quality Power at all times steam.
P
cost – Longer life of electrical  Largely used with solid fuels in
• Fuel Savings > 40~50% equipment India.
– Less fuel storage Page 15 Page 16
Viability …..1
Issues for pulp & paper industry
With Indian Coal ( non linkage/ e- auction/ open market)@ Rs 2800/ Ton.
Power to Steam ratio Cost of Power
 Viability
Zero process 3.95
 Fuel 1:2 3.09
1:6 1.41
 Water
With Indian Coal ( with linkage) @ Rs 1600/ Ton.
 Manpower availability Zero process 2.39
1:2 1.37
 Capacity constraints for raw material / equipment manufacturers
1:6 -1.67
 Increase in Capex costs With Imported Coal @ Rs 5000/ Ton.
Zero process 4.23
 Increase in completion time 1:2 3.39
1:6 2.1
Fuel Options
 Lignite
Viability conclusion
 Area specific in Gujarat / Rajasthan / Tamil Nadu
 Bio Mass
• Key Issues Affecting Viability
 Area specific
 Quantity Limitations – can be substitute
 Coal
• Power to steam ratio
 Imported ( viable option for units near ports)
• Cost of fuel
 Domestic
 Linkage
 E auction
 Blending
NON CONVENTIONAL FUELS

Biomass
PUNJAB -Rice Husk, Mustard
Stalk UP - Rice Husk , Bagasse,
Bagasse Pith
 Can be a viable option based on location and distance from
biomass availability NORTH
 Seasonal availability MAH - M.P - Mustard Rice Husk,

Bagasse, WEST Stalk, Rice
EAST Bagasse
 Storage issues GN Shell, Husk, De-
Rice Husk oiled Cake
 Boiler design issues SOUTH
Rice Husk, Bagasse, De Oiled

Bran, Coffee Husk, GN Shell,
Coconut Shell, Palm Waste
Power Division Page 21 Page 22
Combustion Technology options Pusher grate furnace arrangement

• Stoker
 Higher air temp possible in water-cooled
• Traditional method
• Fouling fuels can cause outages grate sections.
• FBC  Helps in high moisture fuels.
• Needs support fuels  Heat picked up by circulating water for
• Capex grate cooling can be recovered in heat
• Fuel sizing exchanger for combustion air heating.
• Trava Grate  Lower grate heat release rates as
• Fouling fuels a limitation at higher temp pressure cycles
compared to TG, thus higher grate area
• Pusher Grate
provided giving longer residence time for
• Takes care of fouling fuels
complete combustion.
• Sizing not an issue
• Can combust almost anything
Sale thru Power Exchange
Possible New Revenue Source
12000 12000
Amount of Power Traded Average MCP
10000 10000
Amount of Power Traded (in MWh)
Average MCP (in Rs/ MWh)

8000 8000
6000 6000
4000 4000
2000 2000
0 0
2 4 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 22
Date (July, 2008)
The manpower crunch

Water Availability
 Water availability / quality is going to deteriorate over years due  This is affecting all parts of the value chain- equipment suppliers,
increasing demand and inadequate infrastructure investment. consultants, contractors, end users etc.
 This will create hurdles for industry as a whole and industry will have to
respond with innovative solutions.  This is affecting completion schedule of most projects.
 For Power Plants, Air cooled condensers are now available and can be
used for CPP’s .  This is also affecting efficient operations of constructed assets.
 They bring down water requirement by 85%.
Page 27 Page 28
Outsourcing a possibility Pulp & Paper Case – Batan 2020

EPC + O&M = EPCOM
 Outsourcing of setting up as
well as operations and
maintenance
 EPC contractor bound with the

performance of the plant
 O&M guarantee on all vital

parameters like:
 Efficiency – heat rate
 Availability
 Gross Power
 Aux Consumption
Our Offerings in environment Our Offerings…
abatement …  Dedusting and Fume Extraction Systems
 Bag Filters & Bag Houses  Flue Gas Desulphurisation (FGD) Systems
 Gas Cleaning Plants for Metallurgical Applications
 Electrostatic Precipitators (ESP’s)  Coal & Pet coke Preparation Plants
 Coal Injection and Cast House Dedusting Systems for Blast Furnaces / Smelters
 Particulate & Gaseous Scrubbers
 Pushing Emission Control Systems for Coke Ovens
 Modular Gas Coolers / Heat  Ammonia Flue Gas Conditioning Systems
Exchangers  Services, Spares and Retrofit & Rebuild

 Air Purification Systems with chemical filters for removal of corrosive / toxic /
 Retrofits & Revamp of Existing odorous gases
Equipments
Page 31 Page 32
Profile of some of our Power Projects

Still Innovating with… Sree Metaliks (P) Ltd.
More than…
 4000 Multi cyclones & Cyclones
 600 High Efficiency Cyclones
 7000 Bag Filters
 130 Scrubbers
 1000 Electrostatic Precipitators
 200 Air Purification Systems
 150 Turnkey Projects
Highlights:
- 1x8 + 1x20MW Power Plant
- The 8 MW units was the first CPP in India to be set up in the sponge iron industry on EPC Basis. This is
based on recovery of waste heat from the sponge iron kilns
Page 33 Page 34
Madras Cement Limited JK Lakshmi
Highlights: Highlights:
- 36 MW CPP for their cement plant at Alathiyur, followed by another 36 MW CPP at Jayantipuram. - 36 MW CPP at Sirohi. Two repeat orders 18MW and 12MW Waste Heat recovery based.
- Thermax received a bonus of 1 Crore for early completion of the project. - Thermax won bullet bonus of 1.5 Crores for early completion of project.
- Thermax recently awarded another 40 MW Power Project for their upcoming cement plant at Ariyalur. - Thermax recently awarded 1 x12.1 MW Power Plant based on waste heat recovery from cement kilns.
Page 35 Page 36
A word about us
A word about us
 Over 1000 MW of EPC Contracts commissioned
We are leading solution provider in Captive Power  Over 1500MW under commissioning as of date
 Over 10000 GWh power generated from Commissioned plants on EPC
Boilers  Series of Bullet Bonuses won for early commissioning
ESP’s  Twenty plus plants under O&M Contracts
WTP’s  Over 1,000,000 hours of operational experience

 Solutions provided to diverse sectors using varied fuels
Chemicals
 Market Leaders in Vapour Absorption Machines
Turnkey power plants
 Boilers supplied produce steam equivalent to over 8000 MW worldwide
O&M for Power Plants
 Over 600 Environment abatement systems working
For More Details:
www.thermaxindia.com
Contact :
Vivek Taneja
Head of Business Development
Power Division
Sai Chambers, Wakdewadi
Pune – 411003
Ph: +91-20-25541010
Page 39
Issues concerning effluent management
Presentation
 Non-compliance of effluent standards (BOD, COD, TSS)
on particularly by small scale agro-based units.
 Non-achievement of water consumption norms.
“EFFLUENT MANAGEMENT IN  Difficulty in removal of colour in the effluent.
PAPER INDUSTRY”  Incorporation of measures to control AOx
 Adoption of measures to control pollution of receiving water
By body.
N.K. Verma  Requirement for compliance of norms (TDS, SAR) for disposal
Consultant, GIZ of effluent on land for irrigation.
1
Page 1 Page 2
Recommended measures to tackle

Problems faced by small agro-based pollution problem of small pulp & paper
pulp and paper units  Increased use of waste paper or imported pulp, to meet
effluent standards.
 Unable to comply standards for BOD, COD & TDS by
adopting conventional effluent treatment.  Upgradation of ETP where needed and its proper operation.
 Unable to afford chemical recovery unit for black liquor.  Adoption of lignin removal process for treatment of black
 Lack of control of AOx liquor recommended by CPPRI/CPCB.
 Inadequate washing of pulp to reduce kappa number, there
by lignin content.  Adequate washing of pulp before bleaching and switching
 Coloured effluent discharge makes receiving water body from use of elemental chlorine to total chlorine free
(rivers) unfit for bathing.
bleaching or chlorine dioxide to meet AOx standards (2kg /
Page 3
tonne of paper). Page 4
Recommended measures for waste Issues concerning large pulp & paper
paper based units units
 Not all mills have adequate system of pulp washing to achieve
 Effective removal of suspended solids and recovery of fiber. desired kappa number for reducing lignin content before
bleaching.
 Switching over to elemental chlorine free bleaching or total  Not all units have gone for elemental free chlorine bleaching of
chlorine free bleaching. pulp to control AOx in effluent to meet standards (1kg / per
tonne of paper).
 Management of solids (rejects & sludge) through energy  Water consumption norms not met by all units.
recovery.  Receiving water bodies do not meet standards, even mills
comply with standards of BOD, COD & TSS & TDS.
 Maximization of recycling of water.
 Need for adoption of suitable colour removal method.
Page 5 Page 6
Cleaner technology for AOx reduction
Need for control of AOx
 Technologies for kappa number reduction.
 Bleach plant effluents from pulp & paper industry exhibit
toxicity to aquatic life.  Extended delignification.
 Toxicity mainly due to halogenated organic compounds
formed during bleaching of pulp with chlorine or chlorine  Improved pulp washing.
based chemicals.
 Most of chlorinated organic compounds are carcinogenic  Oxygen delignification.
and requires control.
 Need to switch over from traditional bleaching sequence of  Chlorine dioxide substitution.
CEH by using oxygen as effective delignifying agent and
then use ClO2 and hypochlorite for brightening.
 Oxidative alkali extraction bleaching.
Page 7 Page 8
Charter on Corporate Responsibility for

Environmental Protection (CREP) Charter on Corporate Responsibility for
Environmental Protection (CREP)
 Waste water discharge (m3/t of paper).
continued ..
 Large pulp & paper industries = 120
 Small pulp & paper industries = 150  Utilization of treated effluent for irrigation, wherever
 Compliance of standards for BOD, COD and AOx by small
pulp & paper industries – upgradation of ETP. possible.
 Achievement of standards of AOx (1kg/ tonne of paper) by
large pulp & paper industries.  To take up project on colour removal with CPPRI by Indian
 Installation of chemical recovery plant or utilization of black Paper Manufacture Association.
liquor with no discharge from pulp mill or shift to waste
paper, by small pulp & paper industries.
Page 9 Page 10
THANKS
11
Page 11
• Legal background and History
“Best Available Techniques (BAT) Reference Document - BREF

April 25, 2013, Vapi • BREF reference document for - Textile Industry
Lalit Sharma lalit.sharma@giz.de
• COINS reference documents by CPCB - Textile Industry
• Conclusion and Way Forward
Presented by : Lalit Sharma GIZ-IGEP, New Delhi Page 1 Page 2
Legal Background:
The European ‘Industrial Emissions Directive’ (IED) 2010
EC: Joint Research Centre (JRC)
1. Legal background: The Institute for Prospective (1994 Seville, Spain).

Promotes & enables a
Technological Studies (IPTS)
European Industrial Emissions better understanding of
links between env’t
Sustainable Production and technology, economy
Directive (IED) from 2010 Consumption Unit
and society.
Mission : Provide
customer-driven support
to the EU policy-making
The European IPPC Bureau
Integrated Pollution Prevention and

Control’ Directive/Act (1996)
Industrial Emissions Directive (2010)

Presented by : Lalit Sharma GIZ-IGEP, New Delhi Page 3 Presented by : Lalit Sharma GIZ-IGEP, New Delhi Page 4
Definition of BAT according to Art. 3 para. 10 IED

The European IPPC Bureau (Integrated Pollution Prevention
and Control’ Directive/Act) is an output oriented team which
Best = most effective with respect to the prevention and –
produces reference Best Available
documents on where that is not practicable – the reduction of emissions
and the impact on the environment as a whole
Techniques REFerence documents, called BREFs
↘which are the main reference documents used by Available = developed on a scale which allows implementation in
the relevant industrial sector, under economically and
competent authorities in 27 Member States when issuing
technically viable conditions,
operating permits for the installations that represent a taking into consideration the costs and advantages,
significant pollution potential in Europe whether or not it is used in the respective Member State
↘~50,000 of these installations in Europe Technique = includes both the technology used and the way in
which the installation is designed, built, maintained,
operated and decommissioned
BAT: EU’s Contribution in international context 2. Best Available Techniques
European information exchange on BAT is considered to be an EU contribution to (BAT) reference document for the
the global process initiated in 2002 at the World Summit (Johannesburg) so that
non-EU countries can also reap the benefits of this ambitious work. Pulp & Paper Industry
↘ These documents BREF were vehicles through which BAT
and emerging techniques are determined in a transparent
manner, based on sound techno-economic information
↘ The BREFs inform the relevant decision makers about what
may be technically and economically available to industry in
order to improve their environmental performance and
consequently improve the whole environment.
Download of the BREF:
http://eippcb.jrc.es/reference/BREF/ppm_bref_1201.pdf
http://eippcb.jrc.es
http://eippcb.jrc.es
The content of BREFs and BAT Conclusions PROCESS DESCRIPTION, RISK TO THE ENVIRONMENT, & CONTROL
General outline of the BREFs: TECHNIQUES
 Description of Process
Preface, Scope  Risk to the Environment
1. General information about the sector concerned  Control Techniques
BAT FOR THE MANUFACTURE OF BOARD
2. Applied processes and techniques  Introduction
3. Current emission and consumption levels  BAT - General Preventative Measures & Prevention of Environmental Impact
 BAT - Minimisation of Environmental Impact
4. Techniques to consider in the determination of BAT  BAT - Management and Treatment of Residues
5. Best available techniques (BAT) conclusions  BAT ASSOCIATED EMISSION LEVELS
 Emission Levels for Discharges to Air
6. Emerging techniques
 Emission Levels for Discharges to Water
7. Concluding remarks and recommendations for future work  COMPLIANCE MONITORING
 Monitoring of Emissions to Air
References, Glossary of terms and abbreviations
 Monitoring of Aqueous Emissions
BREF’s  Monitoring of Emissions to Groundwater
 Monitoring of Solid Waste
04 06 20
In particular, this document covers the following processes and • Environmental issues
activities: • Wastewater
 chemical pulping: • Emission to air
 kraft (sulphate) pulping process
 sulphite pulping process • Energy consumption
 mechanical and chemi mechanical pulping • Solid and liquid waste
 recovered paper processing with and without deinking
 papermaking and related processes. • Hazardous material management
This document does not address the following activities:

 Production of pulp from non-wood fibrous raw material (e.g.
yearly plant pulp).
 Stationary internal combustion engines.
 Combustion plants of less than 5 MWth rated thermal input.
04 06 20
BAT as solution for environmental Problems ? 3. COmprehensive INdustry

• BREF Pulp & Paper industry includes description of around 100
documentS (COINS)
techniques in the chapter - 04 “Techniques to consider in the reference documents by CPCB for Pulp & Paper
determination of BAT”
• Generic BAT for whole textile industry
• Process-integrated BAT
• End of pipe techniques
• All main textile fibre types are included
• additional information on auxiliaries, dyes and pigments, textile machinery
and typical recipes
• BAT refer to industrial practice with valuable information for plants of
different size and structure (small plants as well as large plants)
• Application of BAT often results in cost savings, partly without great //cpcb.nic.in/Publications.php
expense
Contents of COINS: (2002)

- Overview, Production Process, Pollution, etc
- Chapter 05: In-plant Control Measures
Good Housekeeping,
Process & Equipment Modification
Recovery, Reuse, Conservation and //cpcb.nic.in/Publications.php
Innovative techniques
- Pollution Control and Cost Issues
- Monitoring Programme
- Standards and Guidelines
COINs – Large & Small Scale Industries

Conclusions (I)
4. Conclusion & Way Forward • BAT is a dynamic concept based on and promoting continuous
improvements in environmental performance
• As the outcome of the information exchange on BAT, the BREF

Outcomes to consider…! documents are a unique and valueable source of information for
applicable techniques and their associated emission and
consumption levels
• BAT is more than the application of specific technologies; good

housekeeping, maintenance, input control and a proper monitoring
system for the emissions are also relevant.
• COINS documents from CPCB is also a information bank
Conclusions (II) Further Steps: Scope of Cooperation

• As the structure of the European Pulp & Paper industry is different,
the BREF does not provide specific BAT conclusions for all Objective is to facilitate promotion of Best Available
processes used in India, but at least the general ones apply. Techniques without entailing excessive cost (BATNEEC) in
• Where processes currently applied in India are not covered in the the identified industry sectors in India.
PLAYERS
BREF, it might be beneficial to initiate an information exchange

process on BAT in your country, based on the same principles as
under the IED.
Use of BAT (BREF/COINS)

• Surely handy knowledge bank
PARTNERING
• Does not complies to follow but certainly has

beneficial techniques
• Solves main environmental issues (EU Context)
• Can result in cost savings
Additional information
Scope of Cooperation (Suggested Only) • Download of all BREF documents (EIPPCB Website)
http://eippcb.jrc.es/reference/
↘ Exchange of knowledge and experiences, including • Special link for the iron &steel BREF and related documents:
reference documents; http://eippcb.jrc.es/reference/i&s.html
• Industrial emissions website of the EU Commission
↘ Developing customised BREF documents for http://ec.europa.eu/environment/air/pollutants/stationary/index.htm
India/Improving existing COINS documents
• European Pollutant Release and Transfer Register (E-PRTR)
↘ Undertaking pilot measures on demonstration http://prtr.ec.europa.eu
purpose in identified industries/sectors; • Sustainable production website of the German Federal Environment Agency
http://www.umweltbundesamt.de/nachhaltige-produktion-
↘ Promoting dialogue among various stakeholders; anlagensicherheit-e/index.htm
↘ Training/capacity building of CPCB;
The environment is a growing
concern for everyone
New technologies enable
environmentally sound and
cost-effective processes
N.K.Jain, Director (Pulp, Paper & Power)

26.4.2013
Continuous development towards:

Sustainability – challenge & opportunity Improved
Safety Improved
Less raw
materials environmental
image
Lower energy
consumption Less
emissions
Improved Lower fresh
• Energy
• Better image efficiency water
• Raw materials consumption
• Water
ACTIONS • Improved profits
• Emissions • Social responsibility Compliance Less waste
with water
• Health & safety regulations
Less
Page 3
chemicals Page 4
Sustainability is an integral part of Metso’s

strategy Metso invests 130 M€ on R&D and focuses on
reducing costs and environmental impact
 We apply our know-how and
expertise to promote sustainability
of industry globally:
 Environmental technology and
services
 Research and product
development focusing on
environmental solutions
 Group-wide environmental
targets for own production
 Our values, our Code of Conduct Metso is supporting training project which aims
for helping teenagers from the poor
and the UN Global Compact neighbourhoods in Sorocaba, Brazil to get their
initiative we endorse, guide Metso first job.
employees to operate in a manner
In the picture: Douglas Freire de Lima, Luis Balsamo
consistent with sustainability. (Fishing Project teacher), Carolina da Silva Ferreira,
Rosangela Santos De Paula.
Page 5 Page 6
Sustainability in practical terms
Reduce... Reuse... Recycle... The Solver effect

...use of raw … water, ...in order to Examples of
material, power and raw safeguard environmentally sound results
energy and materials to natural
water make both resources, save
consumption is economical energy, lower
essential due to and pollution levels,
diminishing environmental and conserve
reserves and sense. landfill space.
increasing
costs.
Page 7
Reduce
Water consumption
In most process line cu.m/ton

60
deliveries, fresh water 50
consumption has been 40
30
reduced by 20 - 90% with 20
Fresh water
is one of the most critical
Metso solutions
• More closed and integrated
processes
• Wash press technology
10
0
1980s
500,000
1990s 2000s Future target
SOLVER EFFECT
Water savings in a
large mill,
• Non-chlorine bleaching
resources. compared to 1980s’
levels, correspond
to the average daily
water consumption
of 0.5 million
people.
Page 10
Reduce
Energy consumption
Double Disc and refiner Holmen Braviken,

Sweden produces
segment technology 780 t/day TMP pulp.
Metso helps the industry become more • Significant energy savings Electricity savings
= 400 kWh/t
in TMP production using compared to the
energy efficient Metso’s Double Disc and

latest refiner segment
technology
Lennart Nilsson,
Production Manager
mill’s earlier TMP
process.
SOLVER EFFECT
and less CO2 intensive. Over 10,000
electrically heated,
or cooled, homes
10,000 can be provided
with the amount of
electricity saved
annually at the
Braviken mill.
Page 12
Reduce Reuse
Energy consumption Process residuals for energy
PowerDry Plus Pulp mill produces bio- RECOX High Power boiler at
• 50% energy savings compared energy UPM Kuusankoski, Finland
with infrared drying • A pulp mill produces large

• Significant improvement in amounts of bio-energy from
product surface quality organic compounds
• Lower heat loads dissolved from wood in the
• Safer working environment cooking process and from
SOLVER EFFECT woodhandling residues SOLVER EFFECT
PowerDry Plus Additional electric
annually saves • Metso’s new RECOX High energy supply in a
8,900 MWh Power recovery boiler large mill is
17,000 electricity
(on an 8-m-wide increases a mill’s energy 150,000 equivalent to the
annual need of
paper machine). efficiency by up to 30% around 150,000
This would give electrically heated,
light to 17,000 60W or cooled, houses.
light bulbs for a
Page 13 Page 14
whole year!
CO2-neutral energy generation

World’s largest biomass boilers delivered by Metso
Since 2000, Metso has sold almost 5 GWe of boiler
capacity fuelled with renewables – equivalent to 6 average
nuclear reactors. Saving money and environment through
raw material efficiency

Solver effect Solver effect
Replaces over CO2 emissions equivalent to
140,000 rail car over 24 million cars are avoided
loads of coal annually.
annually.
Page 15
Reduce Reduce
Raw material consumption Chemicals consumption
ValZone metal belt OptiCell flotation unit
calender
• Less fiber raw material • Effective ink removal
needed in board making • High brightness increase
• Enables board machine
• Lowest chemical
production increase from 20
consumption
up to 40%
• Improves product quality SOLVER EFFECT • Consistent end product
SOLVER EFFECT
Over 700 million quality OptiCell helps
extra 1-liter milk
cartons can be reduce
produced from consumption of
700,000,000 fiber saved in a
board machine
-50% chemicals during
start-up by 50%
designed for 300 compared to earlier
kt/a and furnished technologies.
with ValZone.
Page 17 Page 18
Reduce
Raw material cost with OptilLayer curtain coater Tools to reduce environmental load
• Innovative products and
Before: Raw material cost 250 €/t After: Raw material cost 200 €/t
processes
Blade topcoating, 10 g/m2 300 €/t Blade topcoating, 10 g/m2 300 €/t
• Advanced automation
Blade middle coating, 10 g/m2 250 €/t Curtain toplayer for surface properties, 10 g/m2 320 €/t technology
Blade precoating, 10 g/m2 250 €/t Curtain bottom layer for opacity, 10 g/m2 700 €/t
Bleached hardwood and softwood fiber, 30 g/m2 500 €/t Mixed waste or OCC, 27 g/m2 • Life cycle services
Selected office waste, 30 g/m2 300 €/t
Old corrugated medium, 95 g/m2 150 €/t

Old corrugated medium, 95 g/m2 150 €/t
• Close co-operation with our
clients
Mixed waste or OCC, 28 g/m2
Starch, 5 g/m2 Starch, 5 g/m2
SOLVER EFFECT
Cost saving Curtain coating eliminates the need for white pulp in
coated white top linerboard production
50 €/t
Page 19 Page 20
Page 21
Steam Systems Optimisation in Pulp and paper
Industry Overview of session
- Observations on Specific Energy Consumption

- Importance of Steam as a Cost
-- Datta Kuvalekar , Forbes Marshall India - Factors affecting steam consumption
- Need for Automation
- New Developments
Page 1 Page 2
Need for Focus on Steam Systems optimisation
Steam
Accounts for
•The Need to Produce High Quality Paper
•The Need to run machines faster
70%
•The Need to minimise Cost of Manufacturing
•The need to jump productivity and Energy efficiency
All of these have forced mills to look at improving their systems
Energy Consumption
and Automation is one of the strategies. Most Indian mills also
have potential to reduce energy between 5-25 % using basic Energy
of a paper machine
efficient technologies and systems. Page 3 Page 4
25 % costs are decided here!
20% • Energy costs constitute 25 % of Manufacturing costs .

• 70 % of Energy Costs are mainly for Steam and balance for
Reduction in Steam Power on the Paper Machine.
Consumption • Avg 2.5 kg of Steam/kg of paper for the Paper m/c --the largest
for a 250 TPD plant steam guzzler . Hence focus on Steam
• Energy Audits for Paper mills that have uncovered Steam
saves $ 585000 wastage between 10- 25 % , with paybacks upto 1 year !
Equivalent to almost 1000 • Steam optimisation need not mean large investments - Even
Tonnes of Extra Paper small changes can lead to large savings . Harnessing Knowledge
is essential.
Produced !! • We are sure such opportunities to save energy exist in Indian
(Vapi) mills too !
Page 5 Page 6
Hierarchy of Approach
How does one measure
Specific Energy Consumption ?
-kg of fuel per kg of Paper

-kg of steam per tonne of Paper or kg of Steam/kg of water evaporated
-Kw-h / Tonne of Paper
-GJ/ t onne of water evaporated?
-Total equivalent Energy/ Tonne of Paper ? Gj/Tonne of Paper?
Page 7 Page 8
The Heat robbers !

3% distribution losses How does one Reduce
Specific Energy Consumption ?
77%
80% steam
Unburnt
Stack Process
Blowdown consumption 57% -Obviously minimise the Losses ( Boiler losses, Distribution losses)
- Enhance Condensate Return & Recover Flash Steam
- Improve the Process heat Utilisation ( Heat Transfer rate)
100% fuel
energy
(Condensate & Flash)
20%
Page 9 Page 10
A Study Conducted by Paprican-Recycled Mills A CII –Study Conducted by Forbes Marshall for
Indian Recycled Paper Mills
Steam GJ/Tonne Electrical Kw-h/Tonne Fuel (Coal) Steam

T/T of Paper T/ T of Paper
Best 6 425 Best 0.299 1.5
Average 11 875 Average 0.380 1.9
Specialist in process efficiency & energy conservation Specialist in process efficiency & energy conservation
Page 11 Page 12
Some Observations Basic Principles of reducing energy consumption
• Reduce Temperature of any exhausts in Boiler House

• Minimise Amount of water evaporated in drier section
• Minimise Steam condensed outside driers
Study indicates that :
• Wide variance for both steam and Electrical • Maximise Condensate return and pressure
•Technology and Age of Machines/mills makes a difference
• Type of raw material used for pulp makes a big difference
• Minimise Electrical consumption of drives/pumps
• Mill practice also plays a role in determining the level and its here that the steam system plays a vital role • Monitor and Manage Energy Consumption trends &
Specialist in process efficiency & energy conservation costs.
Page 13 Page 14
Steam Generation & Steam Turbines --
Steam Distribution – Minimising Losses

Some issues to be considered
•Low Pressure/load boiler operation

•Captive Power Boiler operation if present
• Desuperheating in case of turbine bypass
•Steam turbine load balancing for varying loads  Steam piping to take shortest route from boiler to Paper machine
•Multiple Boiler operation and load balancing  Delivering Steam at the Right Pressure and Temperature to Digesters &
 Paper machine is essential
 Steam should be Dry Saturated at Drier Inlets
 This means that Steam conditioning is essential
 Minimising Pressure Drops in lines
 Insulate Steam and Condensate and flash steam lines.
 Correct Drain Trapping is essential to prevent steam wastage.
Specialist in process efficiency & energy conservation

Page 15 Page 16
Specific Steam Consumption on Machines

The Link between Steam and Electricity !
• Which is more representative • Typical good values
?
• Newsprint 1.5- 1.6
• Wr/Pr (NS) 1.5-1.7
• Wr/Pr (SS) 1.8-2.0
kg of steam / kg of Finished
• Kraft 1.5- 1.9
production
• Paper Board 2.1-2.3
- Machines faring poorly on steam generally fare as bad on • Tissue 0.9-1.2
electricity too! OR
- A cascading effect.
- Link between condensate removal and Drive power • kg of steam/kg water = 1.3
kg of steam /kg of water
- Need to integrate energy management system that covers steam
and electricity in one system ! evaporated ?
Page 17 Page 18
Factors affecting Specific Steam consumption..1
Here is an Opportunity
• Furnish Type • No. of Driers /Material
To reduce Cost- • Design of steam and condensate system
• Stock Freeness
The Drying section • Dryness off Press • Condensate evacuation efficiency
• Stock Temperature • Extent of Flash steam recovery
• Felt tensions • Type of Siphon/clearances
• Paper breaks/idling • Presence of non condensibles/air
Page 19 Page 20
Factors affecting Specific Steam consumption….2

Steam Utilisation- Energy Efficiency of Paper Machine
 Drying Paper Uniformly at normal steam pressures

 Removing Condensate from Driers efficiently
 Returning Condensate to Boiler house
 Flash Steam Recovery
• Type of Hood and Controls  Steam Response to Final Moisture Value
• Hood doors open/closed
• Sizing of Thermocompressors
• Differential Pressures across Driers
• Number of driers connected to Condenser
• Finally the Degree of Automation
Specialist in process efficiency & energy conservation

Page 21 Page 22
Low pressure steam - Paper Industry

a source for energy conservation
MAKE UP • Yankee Dryers
H.P.ST LINE
 In a number of Paper mills low pressure EAMFCV
• Cascading
PC
steam is generated (from the process or systems
from a flash vessel) • Blow through
DRYING
 Most mills vent this low pressure steam THERMOCOMPRE CYLINDER
systems
SSOR
to the atmosphere Dryer pressure: 3 - 3.5
kg/cm2
 Use of this steam would result in a
CONDENSATE FLAS Flash steam : 0. 5
tremendous saving to the company in RETURN H kg/cm2
terms of fuel cost, water & water TAN
(Steam recirculation)
treatment costs Page 23 K Page 24
Hood & Pocket Ventilation-
Automation for Efficient operation
Needs for Efficient Steam and Condensate system
• Steam at the Right Pressure , Saturated and Dry Felt
• Correct syphon selection and clearance

• Adequate Differential Pressure PV Ventilation
• Venting of Non- condensibles/Air

• 100 % Recovery of Flash Steam/ Blow thru
• Minimising leakages thru rotary joints
• Adequate Thermal insulation
• Adequate Steam Trapping on distribution lines
Cylinder
Page 25 Roll Page 26
Hood & Pocket Ventilation- Application of Pinch Analysis

Controls Specially for Pulp mills with several Hot and Cold streams
Hood provides Consistent Drying 4.63 m3/h
environment 5 F (m3/h) Duty
Acid (MJ/h)
Hood also provides Energy efficiency 4 C 40oC 60 8715
Filtrate 3 [4221]
10-12 % saving in Steam is possible using PO(75
filtrate
oC)
1 80oC 56 2352
Closed Hoods (90oC)
Pocket Ventilators can increase OWL 2 88oC 35 1470
(110oC)
production by 5-8% Water 3 30oC 15 2352
Controls for : (67oC) [2352]
a) Pocket Ventilation Temperature Control ClO2 (82oC) 1 4 10oC 25 3024
[2352] 26oC [672]
b) Dew Point Control /Exhaust Humidity Water 3 30oC 10 1470
c) Zero Level Control for minimum (65oC) [1470]
leakage air. EOP filtrate H 78oC 30 1260
(88oC) [1260]
DHT filtrate 75oC 60 3276
H 2
(88oC) [1806] [1470]
O2 H 100oC 31 390.6
Specialist in process efficiency & energy conservation mixture [390.6]
Page 27 (103oC) Page 28
Where do we begin ?
The energy efficient Paper mill
First Start with installing accurate meters for Steam /condensate/electricity
 The Small Things

 Check for leaking traps and replace immediately
 Check Syphon tips and clearances
 Check for Rotary Joint seal failures /leakages
 Check for excessve DP set points
 Check for obvious leakages
 Check Excessive Steam pressure
 Install Airvents and sightglasses
 The Larger things Leading to Automation Automation pervades every aspect of Steam in a Paper Plant
 Control Exit moisture from Presses To operating Efficient Boilers
 Installing Thermocompressors To World Class Steam and Condensate systems of Paper machines
 Control Valve and DP automation To Energy Efficient Hoods and PV systems
 Changeover to correct syphons To Robust Quality Control systems integrated with Steam systems
 Install Drier Diagnostic systems
• Hood controls Specialist in process efficiency & energy conservation
Page 29 Page 30
Status of Pulp & Paper Mills in India Status of Pulp & Paper Mills in India
• Gujarat has the highest number (around 105) of Recycled
• Around 180 agro based & 420 recycled fiber based small
fiber based mills in India (around 420). Thus Gujrat has
& medium scale pulp and paper mills are estimated to
25% of the total RCF based mills in India.
exist in the country.
• After Gujarat, Maharashtra has good number of RCF
• It is also noticed that the maximum Agrobase mill are
based mill (Approx. 85 Nos, 20%). UP (Approx. 50 Nos,
situated in UP (about 28% of total).
12%) Punjab (Approx. 45 Nos, 11%) & Tamilnadu (Approx.
• After the UP majority of the agrobased mill are situated in 30 Nos, 7%) also has good numbers of RCF based Mills.
Maharshtra (16%), Punjab (About 12%) and in AP (10%).
• A unique feature of these categories of mills can be noticed
• All other states contribute around 5% or less in the total in all state that usually these mills are located or
number of Agrobased paper mills. established in cluster i.e on an average 3-5 mills are
• Gujarat contributes on 3-4% in total number of agrobased usually found in close vicinity of each other within a radius
mils. Most of the Mills in Gujarat is based on waste paper of few km. The major factors governing their location are
based or Recycled Fiber base mills. primarily the availability of resources such as water, raw
Page 1
material, etc. Page 2
Environmental Issues In Mills

Sources of Waste Water Discharge in Large Pulp & Paper
• The main issues in paper mills are use of water & Mills
Sources Discharge Intensity of pollution
Fibrous raw material Washing of raw materials. Small volume with least pollutants.
discharge of waste water. The following are the figures of washing
the wastewater disposal which need to be remembered Digester House Spills & leakages of black liquor & Small volume but high concentration of
gland cooling water pollutants
while discussing about the eco-friendly approach in pulp & Pulp washing The final wash often referred as Small volume and large quantity of
paper industry. brown stock wash or unbleached pollutant
wash
• Agro Based Mill: 200 (150) m3 wastewater / T of paper produced Centricleaners Rejects containing high Small quantity but high-suspended
concentration of fibres and girt or solids.
sand.
• Waste Paper Based Mill: 75 (50) m3 wastewater / T of paper Pulp bleaching Wastewater from chlorination stage Very large volume with high
produced having low pH and high concentration of pollutants. About 60-
chlorolignins, from caustic extraction 65% of wastewater is contributed from
stage with dark brown colour & high this section. The effluents contain toxic
pH as well as chlorolignins from chloro-organic compounds.
hypochlorite stage
• Also we need to see the source of wastewater. The major Paper machine Often referred to as white water. Volume depending upon the extent of
source of the wastewater generation is as on next slide. recycling. It contains maximum
suspended solids like fibers, fines and
small quantity of dissolved pollutants.
Page 3 Page 4
Eco-friendly Approach In Mills Eco-friendly Approach In Mills

After consideration of these main factors, we can go ahead to
Often the implementation of the eco-friendly approach is taken
plan for the eco-friendly approach. Here, we also need to keep
as individual target instead of making a combined target in line
in mind that each ton of paper produce in agro based paper
with the policies and regulatory provision. Minor change in the
mill requires 17 trees. These are the key field of development
policies and regulatory framework must be done to promote
of eco-friendly approaches for pulp & paper mills.
the eco-friendly approach.
• Now in line with the Environmental Policies as well as the
For example; as said earlier, there are many Agro-based mills
Regulatory provision, the approach of eco-friendly
which uses lot of natural resources especially the vegetation. If
techniques in pulp & paper mill, we need to focus on various
special benefits to the RCF based industries are offered under
factors like:
strategic operations & with a reframed regulatory provision for
• Legal Provisions of Waste management such special action, significant benefits to the nature & ecology
• Gap in outcome of practical approach and anticipated can be realised and the switching of Agro-based mill to RCF
outcome of theoretical concept based mill will be proven to be the best option towards eco-
friendly approach.
• Possibilities of R&D and implementation of the outcome
Page 5 Page 6
Further, taking the waste management as an example, More importantly, we need to notice that the main issues of the
significant benefits to mills and nature can also be realised if pollution due to the paper mill are due to the water
the regulatory provision is reframed for utilisation of wastes consumption & waste water disposal. In last few years lot of
generated by other. As it is very well know, all metro cities and works has been done in this field to reduce the water
big cities and even all rural area generates lot of paper wastes consumption & wastewater generation. Many mills have
per day. These wastes are being dumped in the switched to RCF based production and are performing well by
solid/hazardous waste disposal sites instead of reuse. reducing the stress on environmental aspects.
If the policies are reframed to give the special benefits to the By introducing the CREP authorities have achieved significant
industry engaged in utilisation of paper wastes segregated result in increasing numbers of RCF based mills and reducing
from the municipal/ domestic wastes. By doing so, two main the Agro based mills. That is factor which resulted the higher
issues can be solved: municipal solid waste management & number of RCF based mill in India.
stress on nature caused by agro based mills.
Page 7 Page 8

Dr.HKN1
As mention earlier the RCF based mills in India are about 70%
of total mills. Even after this, the goal of eco-friendly approach
in pulp & paper mill could not be achieved considerably We, the Precitech Laboratories, are in this field since ______. Some the
key descriptions of our efforts are presented here.
because of the insufficient availability of efficient &
economically feasible technology. Even the environmental Traditionally, paper mills have been considered as very high consumers of
policies and regulatory provisions also are the factor in lower water, since paper making is all about first converting bound fibers into free
fibers and then dewatering the free fibers to form paper again.
growth of eco-friendly approach.
However, this changed substantially due to high cost of water and its
treatment and advent of newer and better technology. With application of
the new found knowledge and some common sense, there developed many
The policies and regulatory provisions are prepared or enacted ways of reusing water in different ways in the paper mill. This was relatively
as same for normal practicing mills and the mills attempting easy to do in waste paper based paper mills, since the process did not have
eco-friendly approach. Here, it is required that authority gives any digestion or chemical treatments involved in paper making.
some special benefits and exemption to the mills introducing &
practicing eco-friendly approach in their production.
Page 9 Page 10

The primary concern of reuse of water was high suspended
solids. The TSS comprised of fibers, fines & fillers that created
So from 70 to 100 M3/t of paper, the water consumptions have havoc on showers and vacuum elements like boxes on wires,
dropped to as low as 3.5 M3/t and even lower of paper suction-cooch etc. This challenge was addressed by putting up
produced. This was a win-win situation for a developing Purgators or Dissolved Air Flotation [DAF] units, depending on
country like ours, whereby we saved precious forest resources the size of mill and the volume of the water circuit. These units
by re-cycling waste paper and conserving water also, while basically separate the suspended solids and water; send the
fulfilling the growing demand of paper. clean water back to Paper machine for reuse. This also
reduced the TCOD loads on the paper machine, keeping the
As the cliché goes, we save 17 trees when we make a ton of system much cleaner. The recovered solids can either be re-
paper from waste paper. used on the machine itself in stock preparation or be recycled
into making lower quality sun-dried boards etc. The exact flow-
rates of this loop would differ according to machine speeds /
Page 11
production rates & quality of paper produced. Page 12
However, this loop has brought about a great cost-advantage
to mill owners, since they stopped losing precious fiber and One of the ways this equilibrium is brought about is by the
substantially increased their yield [t of paper produced/ t of evaporation process of Paper machine itself. As mentioned
wastepaper]. earlier, paper making is all about dewatering and after Press
Section, the paper is dried with the help of steam-heated dryer
cylinders. This evaporation removes quite some water from the
A partial bleed from the primary loop after removal of TSS is
system, keeping it diluted to that extent. The steam for this
then used for removal of SCOD, bringing it down to acceptable
Drying process is received from the boiler, heats up the dryer
levels for partial reuse in the mill itself and/or discharge to a
cylinders and goes back as condensate water to the boiler.
common treatment facility. This treatment can be done
There are some losses of water involved in this steam-
anaerobically and/or aerobically, depending on what route
condensate circuit, based on individual mills’ condensate
individual mill choose to go. All this brings about equilibrium in
recovery.
the system and has made it possible for the mills to face the
challenges by these changes.
Page 13 Page 14
Eco-friendly Approach In Mills

The closure of water circuits, partial or complete, has been done, but not
without challenges. The major challenges faced are:
Paper mill is an ideal case of application for combined heat • The high levels of dissolved salts, especially chlorides results in faster wear and
and power system [CHP], whereby electrical power can be tear of machine itself. All wet section parts have been replaced by high grade
stainless steel, which too have much shorter life span in such extreme
generated at a lower cost as a by-product, while the complete
environment. This involves high capital costs
steam is used for Drying process. In remote locations, a full-
• Chemical costs have gone up, due to changed water chemistry and application
fledge CPP makes sense due to high T&D losses involved in of high end imported products for producing reasonable quality paper.
grid power and unreliable power supply, but water
• Clogging of low aperture parts on paper machine, like showers etc. is still a
consumption increases in such cases due to high evaporation menace, resulting in increased machine down times and lower productivity.
losses on condenser cooling towers. But it still makes sense
While working for many paper industries, we have noticed that the
since more than three quarters of steam is used as it is on industries are more or less focusing on the prime interest of their economy
paper machine for drying. and applicability of the provisions of policies & regulatory framework.
Page 15 Page 16

If special benefits to these units is given up on use of waste
Often, we have been noticed that the mills are not stepping ahead with the
innovative eco-friendly approach in their production because of absence of paper materials available in municipal waste as well as in
special benefits as well as applicability of the same regulatory provisions for some industrial waste. You might be knowing that many
all Mills. Some actions of eco-friendly approach has been taken by almost industrial wastes like packaging materials like
all mills, but the things can be improved more if some benefits under containers/boxes made up of paper material are treated as
provision of policies and regulatory framework is given specifically to the
Hazardous waste and must be disposed off through TSDF or
units adopting the innovative eco-friendly approaches in their routine.
Common Incineration facilities. By such disposal the valued
Here, for example, if we see that waste paper based mills are leading group material is being wasted & scope of innovative approach by
among the pulp & paper mills in India. However, we can see that they have
adopted only two major action towards the eco-friendly approach.
paper mills is being vanished. Authority can plan & introduce
some scheme of reuse of such industrial wastes for production
• Use of only specific type of waste paper as raw materials
of paper product for use in making packaging materials again.
• Use of treated wastewater Such scheme can be introduced with minor modification in
prevailing regulatory provisions & environmental policies.
Page 17 Page 18
Another such example is related with problem of disposal of As we have experienced there are lot of opportunities in R&D field to bring
isolated plastic waste from the recycled paper – the raw revolution in pulp & paper mill sector through the Eco-Friendly approach.
materials of RCF based mills. Almost all RCF based mills are We have noticed the following key possibilities which may help the mills in
facing this critical issue and so being restrictive in use of all complying with regulatory compliance as well as by financial & technical
feasibilities.
type of waste paper. If any specific provisions are made by
amendment in regulatory framework and by introducing some 1. Use of Advanced Chemicals to reduce the sludge waste & TDS level in
treated effluent.
scheme through updated environmental policies, lot of waste
papers from many sources can be reused by the RCF based 2. Use of Electro chemical process for treatment of waste
mills. As mention above, the plastic waste isolated from the 3. Application of innovative bleaching method for pulping and waste paper
waste paper is biggest challenge for the mills. If authority treatment.
makes and provision and arrangement of mandatory use of We are under progressive mode of the development of such chemicals &
these plastic wastes by the plastic industry the paper mills will technology and method. We are planning to get our work supported by
get benefited and they will step ahead for use of more waste. some industry & mill as well as govt. authorities.
Page 19 Page 20
As we have experienced there are lot of opportunities in R&D field to bring

revolution in pulp & paper mill sector through the Eco-Friendly approach.
We have noticed the following key possibilities which may help the mills in
complying with regulatory compliance as well as by financial & technical
feasibilities.
1. Use of Advanced Chemicals to reduce the sludge waste & TDS level in
treated effluent.
2. Use of Electro chemical process for treatment of waste
3. Application of innovative bleaching method for pulping and waste paper
treatment.
We are under progressive mode of the development of such chemicals &
technology and method. We are planning to get our work supported by
some industry & mill as well as govt. authorities.
Page 21
Your logo Your logo
CONTENTS
 Section A : Introduction to TWIC

Zero Liquid Discharge Facility for Pulp and
Paper Effluents - a Case Study
 Section B : Concept of ZLD
 Section C : Case Study of Pulp & Paper Wastewater

Presented by P.Vairaperumal on behalf of:
I. Sajid Hussain, Head O&M (Water Reuse)
Tamilnadu Water Investment Company Limited.
www.twic.co.in
sajidhussain@twic.co.in
26//04/2013 TWIC presentation 2013 Page 1 26/04/2013 TWIC presentation 2013 Page 2
Your logo Your logo
Genesis
TWIC was formed as the promoter holding company of NTADCL, in the

year 2000. A Rs.1000 Cr first PPP water project supplying water to Industry
and municipality.
Section A: Introduction to TWIC
Promoted by Infrastructure Leasing and Financial Services Limited
(IL&FS) [54%] and Government of Tamil Nadu (GoTN) [46%]
Over the last few years, TWIC has been in the forefront of a number of
initiatives both in the urban water space as well management of industrial
effluent
26/04/2013 TWIC presentation 2013 Page 3 26/04/2013 TWIC presentation 2013 Page 4
Your logo Your logo
Focus Areas
Water • Industrial Effluent

• Sewage Reuse Section B: Concept of ZLD
Reuse • Desalination
Urban • Treatment Plants

Water • Urban Water Distribution
26/042013/ TWIC presentation 2013 Page 5 26/04/2013 TWIC presentation 2013 Page 6
Your logo Your logo
Need for ZLD ..1

Concept of ZLD
 Most polluting industries such as Pharma, Pulp& Paper, Tanneries, Textile
 ZLD - stands for Zero Liquid Discharge – meaning zero discharge of Dyeing, Chemicals , Power Plants etc generate wastewater with high
wastewater from Industries. salinity/TDS.
 A ZLD system involves a range of advanced wastewater treatment  Conventional ‘Physico-chemical-biological’ treatment does not remove salinity
technologies to recycle, recovery and re-use of the ‘treated’ wastewater and in the treated effluent. The TDS content is well above the statutory limit of
thereby ensure there is no discharge of wastewater to the environment. 2100 mg/l.
 A typical ZLD system comprises of the following components:  By discharging saline treated wastewater pollutes ground and surface waters.
 Pre-treatment  Several states in India including Tamilnadu are water stressed. Competing
 Reverse Osmosis demands for water from agriculture and domestic use has limited industrial
growth.
 Evaporator & Crystallizer
Your logo Your logo
Need for ZLD .. 2 Benefits of ZLD

 To save costs and reduce the capacity needed.
 TN has taken a lead on ZLD due to absence of fully flowing perennial river.  High operating costs can be justified by high recovery of water (>90-95%) and
Other states such as Gujarat and Karnataka also are now are considering recovering of several by products from the salt.
ZLD.  Meeting most stringent regulatory norms.
 Location of industries in ‘Inland areas’ and issues related to sea discharge  Possibility of use of sewage for recovery of water, for Industrial and Municipal
use, using ZLD technologies.
of ‘treated’ wastewater.
 Reduction in water demand from the Industry & frees up water for Agriculture
 High cost of water (> Rs. 40) and statutory regulations are prime drivers for and Domestic demands.
ZLD.
Your logo Your logo

Challenges in ZLD
 ZLD results in generation of hazardous solid wastes creating disposal
challenges- need to think of Zero Waste Disposal (ZWD) Plants. Generate
products/ by-products out of the waste.
 Economic viability- cost and availability of water, regulatory pressure are the
real driving force.
Section C: Case Study of Pulp & Paper ETP
 High Carbon foot print- is this environmentally sustainable?
 High Operating cost and financial impact on the industry and its Regional/
National/Global competitiveness.
 Technology shortcomings.
26/04/2013 26/04/2013
TWIC presentation 2013 Page 11 TWIC presentation 2013 Page 12
Your logo Your logo
Techno - Commercial Feasibility for ZLD Project for Techno - Commercial Feasibility for ZLD Project for Pulp &
Pulp & Paper Mill ..1 Paper Mill ..2
 Project: This project is for a major paper and newsprint manufacturer in South India.
In order to meet its environmental obligations the mill has decided to implement a 10
MLD project for reuse of water.
 TWIC Role : Implementation and operation of the pilot plant and preparation of
technical and commercial feasibility report as a precursor to development, financing,
implementation and operation of Zero Liquid Discharge facility
Aeration Tank Ultra Filtration
 Benefits of this Project:
The project would enable the Pulp & Paper Mill reducing its water consumption and
further improve on the quality of treated wastewater used for irrigation.
 Current Status: 120 m3/day pilot plant has been successfully demonstrated. A full
scale plant is now proposed.
Nano Filtration Reverse Osmosis
26/04/2013 26/04/2013
TWIC presentation 2013 Page 13 TWIC presentation 2013 Page 14
Proposed Treatment Scheme for Bleaching

Your logo Effluent & Existing Pulp & Paper Mill ETP
River Water
Background of The Project

Water Treatment Plant
 The Pulp & Paper Mill entered into a contract with TWIC with a view to improve
RO permeate for reuse

the overall characteristics of the treated effluent being discharged. It also was
Wood based Paper Machine &
desirous of exploring the possibility of using treated water in the process Pulp Mill
Baggase based others after recycle
Pulp Mill & Evaporation
Fire Fighting & Coal
losses
 TWIC recommended the setting up of a pilot plant for this purpose in order to
Handling Area
ESP Filtrate
evaluate various options
TDS: 4500 -5000 mg/l
 The pilot plant was designed and commissioned in October 2011 and was Soda Recovery
Plant ( Sulphate Proposed Existing Effluent
stream for SRP) Treatment Plant treatment System
operated for a period of 8 months
Lime Sludge for Sodium Chloride
Cement industry Salt TDS: <1000 mg/l
Pulp Sludge Bio Sludge For Irrigation
Legends
Water / Recycle RO Permeate line
Reject / By products line
Effluent line
26/04/2013
TWIC presentation 2013 Page 15
Your logo Your logo

Simple Schematic of Proposed Process
Effluent characteristics of Bleach Liquor Raw collection
for Pulp & Paper Effluent
Sl.No Parameters Range Preliminary Treatment
1 pH 5.0 – 6.0 Primary Treatment Pulp Sludge

2 BOD 900-1100
3 COD 2000 - 3400 Secondary Treatment Bio sludge
4 TSS 450 - 1000
Tertiary Treatment Chemical Sludge for Cement Industry
5 TDS 4500 - 5800
6 Cl- 1500 - 2000 Quaternary Treatment NF reject ( Sulphate Stream) for SRP section
7 SO42- 500 - 600
8 Total Hardness 900 - 1200 Reverse Osmosis R.O Permeate ( Water for Reuse)
All values are expressed in mg/l except pH.

Brine for Evaporator
Dyeing Units Crystallizer
Your logo Your logo
Demonstration of Concept through a Pilot Plant Summary of recoveries and wastages
 Based on the schematic and discussions with client ,a detailed Effluent

Wastages 100% Recoveries
design & engineering was undertaken by TWIC
 The pilot plant was erected & commissioned in October 2011

Pulp and Lime Sludge
 Pilot plant performance were evaluated for 6 months with hard wood Chloride (0.42%)
Brine PROPOSED
(6.28%) Sodium Sulphate
bleach effluent ,further evaluations were carried out for another TREATMENT Liquor (13.16%)
PLANT
2months Bio Sludge Water (81%)
(0.04%)
 Data generated based on the piloting provided inputs for designing Total: 6.30%
Total: 93.70%
of full scale plant
Page 19 26/04/2013 TWIC presentation 2013 Page 20
Your logo Your logo

Pilot Plant Stage wise Samples Quality Of Various Recovered By-products
S. No Parameters units Recovered Sulphate Lime sludge for cement plant
Water stream
( RO ( NF Reject) Description Composition in %
Permeate) ( Dry wt basis)
CaCO3 75%
1 pH 6 7.1
MgCO3 12.6%
2 TSS mg/l 0 21
SiO2 0.7%
3 TDS mg/l 177 31328
Organic matter 9.15%
4 Turbidity NTU 0 8
Moisture 1.8%
5 COD mg/l 1 1587
6 BOD mg/l 1 3 Quality of Crystallized salt
7 Total mg/l 0 51 Parameters Purity in %

Hardness
NaCl 90% - 95%
8 NaCl mg/l 134.4 5286
Na2SO4 3 %- 4%
9 Total Silica mg/l 0 29
Inert 1%
Samples collected at different Point 10 Na2SO4 mg/l 0 16543
Your logo Your logo

Benefits of the Project
Robustness of the Technology  Reduced TDS load
TDS level of the treated discharge effluent will be reduced
 Production of high quality R.O Water
 During the piloting quality was changed due to change in the production
About 81 % of the effluent will be recovered as R.O permeate which saving water considerably
process from high acidic bleaching process to low acidic bleaching process,  Generation of useful by products
which again reversed after a short period and then again low acidic pulping By-products generated, such as, Sulphate and Lime sludge can be used within the paper mill.
process was established. The high quality brine generated can be sold off to other industries, such as, dyeing
industries or industrial salt manufacturers. For a 10 MLD plant 21.8 Tonnes/day of Na2SO4 and 36.3
 Parameters such as pH, sulphates, chlorides , hardness ,etc ,varied drastically
Tones/day of lime sludge is expected.
during this period.  Improving effluent Management Efficiency
 However the performance of the pilot was more or less stable which proves the
Due to segregation ,treatment & recycling of these waste streams, the pollution load on the
remaining composite effluent will be reduced. Therefore ,performance of the existing ETP will also
flexibility and robustness of the technology.
improve.
 Water Conservation
Due to recovery of about 81% of influent to ZLD plant, water consumption of the pulp mill will come
down from 50 m3/ MT to 43 m3/ MT .
Your logo Your logo
Estimated O&M Cost for 10 MLD ZLD Plant

S.No Description Operating Cost
I Variable Cost (Rs /m3)
Energy, Steam, Chemicals & Consumables 59.00
II Fixed Cost (Rs /m3)
Energy Cost, Manpower Cost, Lab Chemicals & Consumables,
28.00
Maintenance Cost, Replacement Cost for Resins & Membranes
Total Operating Cost ( Rs/m3) 87.00
III Recovery Cost ( Rs/m3)
1 Recovered Water 5.00
2 Pulp 0.40
3 Lime Sludge 2.16
4 Sodium Sulphate to Soda recovery 11.68
5 Chemical sludge to Cement Manufacturing 8.76
Recovery Cost (Rs /m3) 28.00
Net operating cost (Rs/m3) 59.00
Note: Depreciation and Financial costs not included. Cost of brine transportation extra.
NEEDS OF THE PULP AND PAPER INDUSTRY
Best Practices in Water
Management in Pulp & Paper
Industry  Huge volumes of water required in production processes
 Water treatment chemicals for boiler feed and cooling towers
By  Specialty process chemicals

Ion Exchange India Ltd
Workshop on "Environment Friendly Techniques -  Waste water treatment & Recycle
Pulp & Paper Sector”
26th April, 2013. Vapi, Gujarat.  Drying and incineration of wet paper sludge
Page 1 Page 2
TOTAL WATER MANAGEMENT IN PAPER INDUSTRY

RAW WATER POLYMERS
RO CHEMICALS /
RESINS
BOILER WATER
Sustainable Approach
TREATMENT &
CLARIFIER FILTER CHLORINATION RO/DM FIRESIDE
CHEMICALS
COOLING
CHEMICALS
STEAM BOILER
COOLING
TOWER
LIME KILN
TURBINE
A. Waste Water Recycle & Reuse
RECOVERY INDSIZE
PROCESS
CAUSTISIZER FIBER LINE PLANT
COOKING & STOCK HEAD BOX
DIGESTING PREPARATION
INDFELT
FABCLEAN
CHIPPER
BLEACHING
FOAMING
SECTION/ INDSIZE B. Use of Specialty Chemicals for Process Improvement
HOUSE WET-END
AGENTS
BLACK LIQUOR
PRESS
SECTION
POLY
MER DRYER
STORAGE S
INDSORB
HRSCC
INDFIX
CHEST WHITE WATER +
INDBRITE
TRACES OF BLACK LIQUOR PRODUCT
INDION DYNASAND
BIOCIDES /SLIMICIDES FILTER
LUCAS ANAEROBIC /AEROBIC SYSTEM

WHITE WATER RECYCLED FOR REUSE IN PAPER
MACHINES / PAPER MILL Page 3 Page 4
Recycle for Industry

Conventional treatment
Raw Water Treatment Treated Effluent Effluent Treatment Discharge
Water Plant Water
Process Plant
Source Modern Integrated Solutions Product

Reduction Recovery
Recovered Product
Partially
treated
Raw Water TreatmentTreated Effluent effluent
Process Product
Water Plant Water Recovery Plant
Recycled Water Water Recycle
Water Plant Waste
Reuse Minimisation
Page 5 Minimal Discharge Page 6
Recycling ? why ?
Technologies
for
 Raw water scarce
 Raw water cost high Recycle

of
Waste Water
 Strict discharge regulations
- both in terms of quantity and quality
 Zero discharge
Page 7 Page 8
Membrane Separation Process

• Ultrafiltration
•Reverse Osmosis
Page 9 Page 10
ULTRA FILTRATION
What Can Uf Remove?
What can UF reduce?
 Silicates Total Organic Carbon
 Colloids Color components
ULTRA  Particulate Matter
FILTRATION
 Algae
 Bacteria What can UF not remove?
 Coliform Salts
 Viruses Gasoline
 Giardia Sugars
Alcohols
 Cryprosporidium
Low Molecular
 Oils and Grease
Weight Molecules
 Proteins
Page 11 Page 12
Introduction Contd..
REVERSE
OSMOSIS  RO is a high pressure technology where salts
SYSTEM
are rejected by membranes
 Separation based On interaction Of ions In

water using polymer based membranes
 Continuous process
Page 13 Page 14
Membrane treatment? Continuous Sand Filter

• Handles 10 times more dirt
 Quick payback than conventional filters
 Simple to operate
 Rugged & Modular construction
• Continuous operation -
constant and low pressure drop
 Immediate results
 Consistent, high-quality effluent • Ideal for White water Recycle
in Paper Industry
 Positive barrier
Page 15 Page 16
Fluidised Media Reactor (FMR)

FLUIDISED MEDIA REACTOR
SINGLE TANK DESIGN UNIT
• Aeration tank
with patented media
• Lamella Settler
• Chlorine Contact Tank
Page 17 Page 18
KEY FEATURES
FLUIDESED MEDIA REACTOR
( FMR )
INLET
• Single Tank design
• 1/3 space requirement compared to conventional Plants RECYCLE SCHEME
• Low operating cost ( approx.Rs.8-10/m3)
• Uses High Porosity moving media for bacteria to grow OUTLET
• Useful for modification / capacity

extension of existing STP”S/ETP’s
Page 19 Page 20
Case Study- Paper Mill In East India

Wastewater treatment scheme
The Challenge:
selection • Used to Consume huge volumes of water in its production
processes ( Very high Cost of water Rs.40 /m3)
• Simultaneously used to generate huge quantities of waste

• Disposal (Under Pollution Control Board norms) water.
• Water scarcity as well as a problem with disposal of white water

• Water Scarcity (Need for Recycle)
effluent - the quality of white water was inconsistent and
unable to meet pollution discharge norms
• Zero Discharge Norms (Goverment Regulations)
The Solution:
• Common Effluent Treatment Plants The treatment recommended and implemented consisted of:
• Clarification
• Process products recovery
• Filtration
Page 21 Page 22
White water recycle in Paper industry

SOLID
CONTACT
FROM CLARIFIER
PAPER The Result:
MACHINE
& SAVEALL
CLARIFIED CONT •2.9 MGD (11000m3) water recycled and reused in
WATER SAND
HOLDING
SUMP FILTER
process
TANK
POLYMER
•Water recovery of 98% and fibre recovery of 99%
SUSPENDED SUSPENDED
SOLIDS DOSING SOLIDS - 20-50 PPM
150 -1400 PPM
•Capital investment payback period of less than 2 years
TO MIXING CHEST
SLUDGE
PIT
Water SUSPENDED TO PAPER MACHINE

Consumption- SOLIDS 3 - 5 PPM
11000m3/day
Page 23 Page 24
Utility Waste Recycle EFFLUENT TREATMENT & RECYCLE
SDI < 3 Digestion and
Turbidity < 0.1NTU Bleaching Effluent
Cooling Tower/ Boiler Boiler and CT
Bioorganics : nil 1.5
bleed
Water / DM 15
Urea + DAP
Paper
regeneration waste Machine Chlorination Filter and Clarifier
Ultrafiltration system Effluent Alum + Poly 5.6 effluent
140 Permeate
for
Reuse
Feed MGF RO Feed Tank Equalization
HRSCC FMR
Lamella
CCT
MGF
MGF ACF
UF feed UF UF
tank Clarifier Feed tank System Permeate/RO RO
tank Feed tank
ST Antiscalent
SMBS Air Sludge
Acid Air
Reverse Osmosis System Reject
CF
Backwash Pit
Excess Backwas
Sludge h
effluent RO reject
Management
Permeate Sludge Pit In Client
Scope
0.00 Sludge
Dewatering Sludge Cake for disposal
Filtrate
System
Water for Reject
Reuse Page 25 Note: Above mentioned figures indicate flow in m3/hr Page 26
B. Use of Process improvement chemicals Use of Process improvement chemicals
• Alkyl Ketene Dimer

• Deinking Additives Total Sizing Care
Pulp Care • Surface Sizing
• Pulp Mill Defoamer
• Whitening Agent
• Anionic trash controller • Pigment Dyes Total
TotalOptical
OpticalCare
Care
• Retention & Drainage Aid Performance & wet end care
• Dispersant
• Lubricant Total Coating care
• Wet & Dry Strength Resin TotalRunnability
Total RunnabilityCare
Care
• Cross Linking Agent
Page 27 Page 28
Benefits
Conclusion
1) Improves water repellent proportion
Factor for Effective water management:
2) Improves fiber retention
3) Control microbial growth • Regular Water Audits
4) Reduces foaming • Waste Water Recycle & Reuse

5) Enhances cooking rates
• Effective use of specialty chemicals for process improvement
6) Improves washing & bleaching efficiency
• Focus on Waste to energy concept
Many chemical formulations :
• Improve Process yields
• Reduces water consumption
Page 29 Page 30
CII – Sohrabji Godrej Green Business Centre
Hyderabad
Increasing
Unique activity of CII supported by the Government of Andhra Pradesh,
Competitiveness USAID and Pirojsha Godrej Foundation
through
Environmental
Sustainability
“How Green is your Company”

Environment Friendly Techniques in Pump and Paper Sector “Centre of Excellence” for Energy, Environment, Green Buildings, Renewable
Vapi : 26 April 2013 energy, Water & Climate change activities in India
© Confederation of Indian Industry © Confederation of Indian Industry
CII’s Strategy for Achieving World Class Energy Efficiency

Global Leadership Status
 Focus Areas that will be addressed
 Energy Efficiency
 Overall objective
 Green Buildings
 Facilitating continuous performance improvement
 Renewable energy
 Environment & Recycling and assist the Indian industry in achieving the
 Water Management
 Create Sector-wise leadership world class standards
 Initiatives taken in
 Cement
 Create a platform for close technical
 Power plants
interaction with special focus on Energy
 Pulp & Paper
 Now Sugar
Efficiency
Strategy : Create ‘Islands of Excellence’ & Expand  Involvement of all stake holders
CII Initiatives in Paper Sector Benefits to Paper Industry

 Activities Performed and Benefits Achieved
 20 cleaner production technologies were
 Cleaner production technologies were introduced with the help
identified and compiled in the form of Manual
of Swedish International Development Agency
 Introduction of latest trends & technologies
 Technical and project management were carried out by
Swedish companies IVL and Inventia  Visit to best operating plants
 Mission of Indian CEOs was taken to Sweden
 National & international units
 Copies of Manual were shared with all the stakeholders
 Training Programmes and Awareness Sessions
 Development & wide access to technical details
 5 Nos Best practices manuals
Introduction of Cleaner Production technologies in
 Manual on Cleaner Production technologies various units

GreenCo Rating System GreenCo Rating - Intent
 The system is a framework to :  Unit level
 Define and assess the performance on
 More Competitive
the green front
 How green is your company?  Green Image
 Monitor and sustain “Green” initiatives
 National level
 Guide phased growth
 Scope  India should be globally
 Manufacturing & Service Sector competitive

 Unit / Facility level rating
 Exporter of Green
First of its kind in the world Products and Services
Systems Greenco Rating System - Approach

: 300 Points GreenCo Rating System
Leadership
&
Strategies
People
& Systems
Partnerships
Actions
Results / Impacts
Higher focus for
: 700 Points
Performance
Impacts
Neither Tough, Nor Easy
Greenco Rating System -Weightages Companies Registered for Pilot Rating

Sl No. Name of the Organisation
S.No Parameters Weightages 1 Dr. Reddy’s Laboratory –FTO 3
(Points)
2 Dr. Reddy’s Laboratory –CTO 2
1 Energy Efficiency 150 3 Vasavadatta Cement, Sedam
2 Water Conservation 100 4 ITC-PSPD, Bhadrachalam
5 Bangalore International Airport Ltd

3 Renewable Energy 100
6 JCB India Ltd, Ballabgarh
4 GHG Reduction 100
7 Hindustan Unilever, Mysore Factory
5 Waste Management 100
8 J K Tyre Industries Ltd, Kankroli
6 Material Conservation, Recycling & Recyclables 100 9 J K Tyre Industries Ltd, Banmore
7 Green Supply Chain 100 10 Bosch , Jaipur
8 Product Stewardship 75 11 ACC Ltd, Thondebhavi

12 Brakes India Ltd, Sholingur
9 Life Cycle Assessment 75
13 ThyssenKrupp Electrical Steel India Ltd
10 Others (Ventilation, Site Selection & Innovation) 100 14 Vedanta Aluminum Limited, Lanjigarh
Total 1000 15 Mphasis Technologies, Bangaluru

16 HIL, Golan Unit, Gujarat
17 Sundaram Fasteners, Madurai
More than 50 Companies interested in Pilot Rating
GreenCo Rating System Driver for Excellence
World Class
 ITC Paperboards and Energy
Efficiency
Specialty Papers Division first
Recyclability Water
GreenCo rated Paper / product Positive
Stewardship
Company
 Gold Rating
Renewable GHG
 Bengaluru International Airport Energy Mitigation
Limited (BIAL) first GreenCo

rated company
Green Waste
Supply Minimization
 Silver Rating
Chain / Zero Waste
Assessment Report – Strategic suggestions to further Low Material

enhance the Environmental Sustainability Utilization
Environmental Sustainability at
ITC Limited Godrej & Boyce Group
 ‘Carbon Positive’ – 6 years in a row  Godrej Good & Green Vision – by 2020
 Sequestering/ storing twice the amount of CO2 ITC
emits  Ensuring Employability
 ‘Water Positive’ – 9 years in a row  Training 1 million rural & urban youths
 Creating two times more Rainwater Harvesting than  Creating Greener India
ITC’s net consumption
 Carbon Neutral, Zero waste, water positive& Energy efficient
 ‘Solid Waste Recycling Positive’ business
 Reusing/Recycling more solid waste than generated
 30% renewable energy source
 All Environment, Health and Safety Management
 Innovating for Good & Green Products
Systems
 Reduction in material, eliminating toxicity
 Sound business model – ‘Triple Bottom-line Approach’
 100% recycled or recyclable
World Class Energy Efficiency GHG Management
 Trend setter in Norms

 GHG Inventorisation
 Lowest in world
 Measure the emissions
 Continuously increasing the
threshold  Seek opportunities for mitigation
 ONGC
 Reliance Industries ,
Jamnagar  Carbon Neutral
 Long term Targets set
 2011-12: 53.68
MBTU/bbl/NRGF  Implemented Methane recovery
 All new buildings
(Nelson’s Refinery Gradient Factor –
complexity of refinery)  Platinum Rating under LEED rating
system
 One of the lowest SEC figure
in the world  100 MW wind farm
 Raising the barrier

Carbon Footprinting
 Carbon Label
 Future Trend Water Management -

 Commitment to reduce the
Beyond the Fence
environmental impact of its
cement Are we competing with the Society?

 Example : Carbon Trust, UK
 Excellent Potential for
companies to pursue
Water Management –Beyond the Fence Alternate Fuel and Raw Materials (AFR)
 Utilization of Alternate fuels
 BILT Bhigwan
 Managing the waste of others
 Water scarce area
 Alternatives to raw materials
 < 450 mm annual rainfall
 Currently 10% of the companies
 Water irrigation management have implemented it
System  1 % thermal substitution
 PPP Model  ACC

 2200 farmers (5400 Ha)  Co – Processing
 Benefits  Utilizing the waste of other

industries
 Agriculture Productivity
 Substantial reduction in coal
 20 % improvement
consumption
 Reduction in monoculture
 Industrial Waste : 12482 T
 Social Return on Investment Processed
(SROI)
Net Savings: Rs. 62 million
 1:1.97
Greenco Rating System -Benefits Greenco Rating System

 Resource Conservation
 More Information on
 Corporate Green Image
Greenco Rating
 Where it stands
www.greenco.in
 Transparency
 Soft copy of Abridged
 Meeting Future Reference Guide can be
Regulations downloaded
Driver for “Excellence in Environmental Sustainability”

Invite companies to register for the rating !!
Sum up
 Green Initiatives lead to
 Competitiveness & Global Excellence
Dinesh Ghai
 Some Immediate steps Senior Counsellor
Confederation of Indian Industry
 Resource Optimisation – Energy, water, material CII – Sohrabji Godrej Green Business Centre
Hyderabad
 GHG accounting and reduction
 Greening Supply Chain – Logistics, Purchase, etc.. E‐mail: dinesh.ghai@cii.in

www.greenco.in
 Pursuing GreenCo Rating www.greenbusinesscentre.com
 CII will be glad to support “Green is Competitive”
Green Makes Business Sense

Spotlights
PUMP AUDIT PUMP AUDIT
Wel-come to Seminar on Why save energy?
ENERGY CONSERVATION IN PUMPING
SYSTEM Nearly 20% of the world’s electrical
energy is used for pump systems
Dhanraj Hathiwala
Grundfos Pumps (I) Pvt. Ltd
Other use
Pump systems
30% to 50% of the energy consumed by

pump systems could be saved!

Reasons for Excess Power Consumption
Reasons for Excess Power Consumption in pumps
IMPROPER SELECTION
• Improper Selection
Correct Improper (Efficiency Drops by 8%)
• Over Design
• Old Inefficient Pumps
• Improper layout

Reasons for Excess Power Consumption Reasons for Excess Power Consumption
IMPROPER LAYOUT
OVER DESIGN
Peculiar site where the suction as well as the

delivery valves are throttled due to over
sizing at design stage
PUMP AUDIT LIFE CYCLE COSTS: PUMP AUDIT
Reasons for Excess Power Consumption
Over design
29%
Energy cost: 85%

Focus on Life Cycle
Cost
•Energy
Low ef f iciency
71% Maintenance cost:10%
Initial cost: 5%
Cost of Ownership is about thinking ahead and knowing PUMP AUDIT PUMP AUDIT
what is hidden under the iceberg
Purchase price
Maintenance cost
ENERGY SAVING TIPS IN
PUMPS
Energy cost
ENERGY SAVING TIPS PUMP AUDIT ENERGY SAVING TIPS PUMP AUDIT
Use two or more smaller pumps instead of one larger

pump so that excess pump capacity can be turned off.
Proper Selection of the Pumps

Two pumps can be operated in parallel
during peak demand periods, with one
Selecting a centrifugal pump can be pump operating by itself during lower
challenging because these pumps H BEP demand periods. Energy savings result
generate different amounts of flow at
different pressures. Each centrifugal from running each pump at a more
pump has a "best efficiency point" efficient operating point and avoiding the
(BEP). need to throttle a large pump during low
Q
demand. An alternative is to use one
 variable-speed pump and one constant-
speed pump.
Q
ENERGY SAVING TIPS PUMP AUDIT ENERGY SAVING TIPS PUMP AUDIT
•Use high efficiency EFF1 Class motors for pump drives Use variable-speed drives to avoid losses from throttle valves and
bypass lines, except when the system is designed with high static
heads.
Pump system efficiency
Variable Speed Control of Pumps pays !!!
can be improved directly
by increasing the
efficiency of the motor -
refer to the "High
Efficiency Motors"
section which provides
details of the benefits of
high efficiency motors.
ENERGY SAVING TIPS PUMP AUDIT PUMP AUDIT
REGULARLY MAINTAIN YOUR SYSTEM
Although centrifugal pumps are widely used due to their low

GRUNDFOS’ ROLE IN ENERGY
maintenance requirements, as with all machinery, they do require CONSERVATION
periodic maintenance.
Common maintenance tasks on centrifugal pumps include: “PUMP AUDITS”
Bearing lubrication and replacement.
Mechanical seal replacement.
Wear ring replacement.
Impeller replacement.
Pump/motor alignment.
Motor repair or replacement.
PUMP AUDIT DETAILED PUMP AUDIT

PRELIMINARY AUDIT: AUDIT:
Flow
measureme
Data
nt discussed
with
Short list customer
pumps for Power
study measuremen Calculating the
t pumping
system
efficiency
Preliminary Audit
Paramete
Pressure rs
measureme finalized
nt Data analysis and
recommendations
with or without
piping
modifications
Final
Report
Essar Steel Plant

SOLUTION
APPLICATION & Existing Pump details Installed New Pump model CR 90-5
Type of Application : Water Cross slush of 11 bar pressure Reduced Maintenance.
Less vibration
Existing Pump Model : RKB 65 Negligible greasing required
Existing Motor Rating : 55 Kw Easy installation, no alignment required
Existing Power consumption : 51 kw Higher Efficiency leading to Reduce Power Consumption.
37 Kw motors offered against existing 55 Kw motors.
Space Saving possible (Pumps are installed at Basement and Space is
very important)
PROBLEMS WITH EXISTING PUMP
Possible saving – 18 kwh * 4.5 Rs/kwh * 24 Hr * 320 day = Rs. 6.22
 Higher amount of gland leakages, frequent gland changing required L/Anum
 Less bearing life,
After successful performance of CR 90-5. Received order of CR 120-6 for
 Frequent greasing required same application with Higher flow requirements..
 Poor Efficiency Leading to High Power Consumption.
 Over all higher maintenance and manpower required to maintain pumps
CASE STUDIES 2: PUMP AUDIT PUMP AUDIT

INDUSTRY
Application : Coolant circulation pump
Old pump Power : 148 kW (Horizontal Split case pump)
New pump Power : 90 kW (Hydro 6 X CRN 90-4)
Power saving : 58 kW (Successfully implemented)
Thyssenkrupp Electrical Steel

Old System New System
Thank you
Solar Energy Conversion
Application of Solar Thermal
Systems for Paper & Pulp Solar
Photovoltaic
Electricity
Solar Energy
Industry Utilization Solar
Heat
Thermal
A SOLAR BOILER COMPANY
Page 1 Page 2
Solar Thermal Technology Classification Concentrating Optics
Parabolic
Focus
Reflector
Page 3 Page 4
Concentrators Concentrated Solar Thermal in IPH
PTC ARUN Scheffler CLFR

Parabolic rotational solids Extruded parabolic profiles • ARUN and Scheffler are the only proven technologies in
Concentrate the irradiance Concentrate the irradiance India
up to 2,000 times up to 200 times • ARUN is used for process heat applications from 80°C-250°C
• Scheffler is used for applications up to 120°C
• PTC & CLFR are mainly used in large scale power plants
5
internationally
Page 5 Page 6
Two variants of ARUN® technology ARUN® Performance – At a glance
ARUN®160 ARUN®100 Output per day, on a clear
sunny day
Application By 1 ARUN®160 By 1 ARUN®100
Dry Saturated Steam 1200 kg 700 kg
Hot Water 25,000 liters 15,000 liters
Cooling 25 TR for 8-10 hours 15 TR for 8-10 hours
Cooking 7,500 meals 4,500 meals
Milk Pasteurization 30,000 liters 18,000 liters
Effluent evaporation 2.5m3 1.5m3
Laundry 600 kg 350 kg
Page 7 Page 8
ARUN® Technology – How it works? ARUN® Technology –

Fresnel Mirror Arrangement
Concentrator Sun Tracker
2D fresnel parabola
Page 9 Page 10
ARUN® Technology – ARUN® Technology:

Fresnel Mirror Arrangement Automatic 2-axis tracking system
Aperture areas always faces the sun
DNI is captured in full (no cosine loss)
Absorber at
focal point
Reflected
Sun Rays
Sun rays
2D fresnel parabola
Page 11 Page 12
ARUN® Technology – Key Features
Integration with Existing System
• High Temperature & Pressure 4000C Oil / 25 bar
Steam
• Small Footprint Area 3m x 3m
Retrofit into existing process
• Written Performance Characteristics Guarantee

• Non-Solar Hours Operations when augmented with
a Heat Energy Storage Facility
• First IBR-Approved Solar Boiler in India
• High Wind Bearing Capacity, up to 45m/s or 150
Page 13 km/hr Page 14
Chitale Dairy
Applications Steam Generation for Milk Pasteurization

Location Sangli
Delivery 5 bar and 152˚C
Capacity 80 – 100 kW th per dish
Government of India,
Heavy Water Board Dish numbers 2 dishes
Commissioning October 2009
Saves 36000-40000 lit of FO

pa
Akshardham Temple
Page 15 Page 16
ARUN®100 makes its debut at

ITC Maurya Hotel, New Delhi
Akshardham Temple, New Delhi
Steam for Hospitality applications like Laundry, Cooking, Bathing
Steam Generation for community cooking
Location Delhi
Location New Delhi
Delivery 8 bar (g) and 175˚C
Capacity 80 – 100 kW th per dish Delivery 6 bar and 160˚C
Dish numbers 2 dishes Capacity 48 – 60 kWth per dish
Commissioning Nov 2009 Dish numbers 1 dish
Commissioning October 2012
Saves about 30,000 lit of PNG

pa
Saves about 10,000 kg of

Page 17 PNG pa Page 18
Mahanand Dairy Mahindra & Mahindra, TVS Group, Residential
(100% on ARUN, since 2006)
Pune Chennai Township
Pressurized Hot Water for Milk
Pasteurization with storage Pressurized Hot Water for Degreasing Process
Pressurized Hot Water for Hot water generation for
Comfort Cooling domestic purpose (under
construction)
Saves about 22,000 lit of Saves equivalent of 18,000 lit Saves about 35,000 lit of Equivalent to 100 ETC
FO pa of FO pa Page 19 diesel pa systems Page 20
Investment Economics
Radiation data for given site
• Financial Incentives
• MNRE Subsidy
• Tax benefit due to 80% accelerated depreciation
• Extra grants under UNDP-GEF project
• Project Payback
• Cooking (substituting LPG @ Rs90/kg): <2 years
• Process Heat
• Substituting Furnace Oil, Diesel, PNG @ Rs 45/lit: 2-3 years
• Substituting Coal, Biomass, Wood: ~5-7 years
• Cooling: 7-10 years
• BOOT model
Page 21 Page 22
Steam Output p.a. per ARUN160 Cash Flow Profile
Page 23 Page 24
Clique Solar Facts about Clique Solar
• We are active in the Solar Thermal segment • Working in the solar domain since 2004
• We are specifically focused on off-grid Concentrated Solar Thermal • MNRE channel partner since Aug 2011
(CST):
• Promoted by veteran IIT Bombay alumni
• Industrial Process Heating (IPH)
• Winner of ‘Best Project Award’ at Intersolar India
• Solar-assisted Cooling
• We are pioneers in the IPH market
• In top 3 in the world at the CSP Today Awards, Spain
in ‘Best Technology Supplier’ category
• First ARUN installation in Feb 2006
• Consortium member of one of India’s first CSP power
• Even today, the only commercially proven technology in the 120-
250°C plants coming up near New Delhi
Page 25 Page 26
Thank you!
• Website: www.cliquesolar.com
• Email: sales@cliquesolar.com
• Video: http://www.youtube.com/CliqueSolar
• Phone: +91 22 2860 9014
Page 27
Hi Tech Applicator India’s Pioneer
1102-B Phase III GIDC Vatva Ahmadabad 382445

Tel : 91 79 25833040 / 25891740
E mail : hitech@ptfeindia.com Fluro Polymer Processor
Page 1 Page 2
Corrosion Selection of correct PIPING
• Paper Industry is the most complex industry which is using air, • Since all the above chemicals are aggressive selection of piping
water and chemicals system is most important
• In Bleaching Chlorine is the most common used chemicals other • Here normal SS or Duplex piping do not give lease of life as
then Sodium Chlorate, and Sulphuric Acid desired
• Typically in India people use SS / Duplex or even PP/FRP lined
• All the above chemicals are highly aggressive pipes
• Here the pH ranges from less than “1” in sourcing acid tank to • Which is not correct in ENVIROMENTL POINT OF VIEW as
“13” in caustic storage leaky joints and pipes cause great concern
Page 3 Page 4
Typical aplication areas
• Although steel is commercially cheaper but it does not give the • Pulp Bleaching
lease of life as expected
• Sulphuric Acid Plant
• Thus because of maintenance every now and then plant looses
• Black liquor
money which is unaccountable
Page 5 Page 6
Thank You
• We are available on
• It had been proved world over CS/PTFE piping system are not
only cost effective but it gives lease of life to piping system of • Hitech.mum@ptfeindi
the plant
• This was general a.com
• This is reducing huge cost of the plant which is otherwise spent
on MAINTENANCE
presentation would be • OR
happy to meet you on • hitech@ptfeindia.com
• Moreover since it does not allow any leakage through piping
system it is greatly environment friendly case to case basis in
person • I am also available on
• 9820385039
Page 7 Page 8
Deutsche Gesellschaft für
Internationale Zusammenarbeit (GIZ) GmbH
Indo-German Environment Partnership (IGEP) Programme

B-5/2, Safdarjung Enclave
New Delhi 110029
Tel: +91 11 4949 5353
Fax: +91 11 4949 5391
E-mail: contact@igep.in
Websites: www.giz.de, www.igep.in

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State Level Workshop Report

Environment Friendly Techniques in Pulp & Paper Sector

Dr. Dieter Mutz

New Delhi (Dr. Dieter Mutz)

8. Annexure I - Workshop Programme .......................................................................14

 “Environment Friendly Techniques in Identified Industry Sectors”

3. Programme of the Workshop

The workshop programme included:

4. Participants in the Workshop

Pic: Participants at the workshop

5. Inaugural Session of the Workshop

There were three special addresses from:

 Dr. K U Mistry, Chairman, Gujarat Pollution Control Board

Pic: Dr. K.U. Mistry, Chairman, Gujarat Pollution Control Board

Technical Session I: Environmental Policies, Laws and Challenges

 Environmental Policies, Standards and Regulatory Aspects in Pulp & Paper

Technical Session II: Technological Aspects for Improved Environmental

Technical Session III: Environmental Management in Pulp & Paper Sector

 Case Study of Cleaner Production in Vapi Paper Mills

 Innovative low life cycle cost pumps

Pic: Dr. N J Rao, Vice Chancellor, Jaypee University of Engineering

7. Concluding Session of the Workshop

 Group 2: New Government Policies and supportive instruments required for

Group 2: New Government Policies and supportive instruments required for

 Support from government is needed for implementation of environment friendly

 There is scope for substitution of conventional chemicals with the eco-friendly

One - Day Workshop on

09:30 hrs Registration & Tea

S. No. Name Designation Name of the Company Telephone Mobile Email Id

9 Mr Ambuj Dixit Consultant Clique Solar ambuj@cliquesolar.com

36 Mr Hardik Shah Director Hi-Tech Applicator 9879504425 hardik.shah@ptfeindia.com

38 Mr Amar shah Proprietor JEW 2226853480 9322226290 jew@jewpump.com

Mr Pramod Manager – JK Paper Ltd. Unit: 02624 305 919328921158

Project Co- 0260-

Production Neral Paper Mills P

58 Ruby Macons Limited

59 Mr Rasik Bhatt Owner/CEO Selan Bioscience 9825843989 selan_India@yahoo.com

Dr Santosh Manager Env

Environmental Issues contd……

 High color in effluents Agro based mills:0.5-1.0

Environmental Compliance Contd……

Areas of concern Suggestion

 waste water  Promote conversion of useful product from

Power Division Page 1 Page 2

INDIA’S GROWING ENERGY DEMAND

Power Demand TWh 700 3870 2910

Considering that 80 % of the India of 2030 is yet to be built, Electricity

EMISSION BY GDP GROWTH RESOURCES AVAILABLE – HYDRO CARBON

 Reqd installed capacity by 2017 320000 MW

 Addition reqd per annum 20000 MW

 Addition reqd per annum 25 - 30000 MW

Are utility scale plants enough?

 Open Access – right of way on Transmission lines

 Low gestation period

Typical Cogen - Advantages Typical Steam Turbine Cogen

 Back Pressure Turbine.

NON CONVENTIONAL FUELS

 Seasonal availability MAH - M.P - Mustard Rice Husk,

Rice Husk, Bagasse, De Oiled

Combustion Technology options Pusher grate furnace arrangement

Amount of Power Traded Average MCP

Amount of Power Traded (in MWh)

Average MCP (in Rs/ MWh)