Papertech Manual 2012 Vol 5

About us
The Confederation of Indian Industry (CII) works to create and The Centre is housed in a Green Building which received the
sustain an environment conducive to the growth of industry in
India, partnering industry and government alike through
prestigious LEED (Leadership in Energy and Environmental
Design) Platinum Rating in 2003. This was the first Platinum
Best Practices Manual
Pulp & Paper industry
advisory and consultative processes. rated Green Building outside of U.S.A and the third in the world.
The Centre was inaugurated by H.E Dr A P J Abdul Kalam, the
CII is a non-government, not-for-profit, industry led and then President of India, on July 14, 2004.
industry managed organisation, playing a proactive role in
India's development process. Founded over 117 years ago, it is Volume 5
India's premier business association, with a direct membership
of over 6600 organisations from the private as well as public
sectors, including SMEs and MNCs, and an indirect membership
of over 90,000 companies from around 250 national and
regional sectoral associations.
With 63 offices including 10 Centres of Excellence in India, and 7

overseas offices in Australia, China, France, Singapore, South
Africa, UK, and USA, as well as institutional partnerships with About IPMA
223 counterpart organisations in 90 countries, CII serves as a
reference point for Indian industry and the international Indian Paper Manufacturers Association (IPMA) has emerged as
business community. a national level organisation and is an apex Association provides
a broad based common platform to project Industry's view and
CII – Sohrabji Godrej Green Business Centre (CII – Godrej GBC) is to articulate its strategy to cater to the growing need and global
one of the 10 Centres of Excellences of the Confederation of vision of the Paper Industry. Large Paper Mills from private and
Indian Industry (CII). public sector with a product mix of all varieties of Paper
(Writing, Printing, Packaging, Speciality, Paper boards and
CII-Sohrabji Godrej Green Business Centre offers advisory Newsprint) located in all regions and using conventional fibre
services to the industry in the areas of Green buildings, energy such as wood and bamboo and also unconventional raw
efficiency, water management, environmental management, materials like bagasse, recycled paper, etc. Comprise the
renewable energy, Green business incubation and climate Membership of IPMA in broad spectrum. The Association is
change activities. registered with the Registrar of Societies, Government of NCT of
Delhi.
The Centre sensitises key stakeholders to embrace Green
practices and facilitates market transformation, paving way for IPMA strives to promote, protect and improve trade, commerce
India to become one of the global leaders in Green businesses and Industry in general, with a focus on Industry connected with
by 2015. Paper in particular.
For further details, please contact:
Mahesh Puranam
Survey No 64, Kothaguda
Near HITEC City, Hyderabad - 500 084 mahesh.puranam@cii.in
Tel: +91 40 44185 101 +91 40 44185146
Fax: +91 40 23112837
www.greenbusinesscentre.com
Volume 5
1
Confederation of Indian Industry
CII-Sohrabji Godrej Green Business Centre
Disclaimer
© 2012,
All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in
any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior written
permission from CII- Sohrabji Godrej Green Business Centre, Hyderabad.
While every care has been taken in compiling this Manual, neither CII-Godrej-GBC nor Indian Paper Manufactures
Association (IPMA) accepts any claim for compensation, if any entry is wrong, abbreviated, omitted or inserted
incorrectly either as to the wording space or position in the manual.
The Manual is only an attempt to create awareness on Energy, Water and Environmental management and sharing
of best practices being adopted in Indian Paper industry and the international cleaner production technologies.
Published by Confederation of Indian Industry
CII – Sohrabji Godrej Green Business Centre,
Survey # 64, Kothaguda Post,
R R District, Hyderabad –500 032
India.
2
Best Practices Manual - Pulp & Paper Industry
Foreword
The Indian paper industry is growing at a fast clip and, given that the Indian
economy is expected to continue to grow at the present rate (or higher) for the next
20 years with a corresponding increase in literacy rate and affluence, the demand
for paper will only continue to grow. The Indian paper industry, with a long legacy
of over a century and a mix of large and small firms using old and new technology,
is building up capacity to cater to this increasing demand. A large number of the
units are embracing newer, more energy efficient technologies and ecologically
sustainable practices, and are showing increasing awareness of the environmental
problems facing the world today.
CII – Sohrabji Godrej Green Business Centre has the vision of making India a global
leader in green business by 2015, and one of its focus sectors is the Indian pulp and
paper sector. As a means of achieving this vision, the Centre facilitates industries
in adopting best available technologies and best operating practices, thus enabling them to become world class
energy efficient units.
To take this idea forward, the Indian consortium of CII – Sohrabji Godrej Green Business Centre and Indian Paper
Manufacturers Association (IPMA) are presently involved in a two year project with IVL and Innventia, both Swedish
research institutes with extensive experience in the paper sector, to identify the needs of the Indian pulp and paper
sector and to develop a roadmap for implementation of clean technologies. This activity is funded by the Swedish
International Development Agency (SIDA).
The key objectives of the project are:
Transfer and exchange of know-how and experiences, increase awareness and capacity to protect
the environment and manage climate change; thus contribute towards socially, economically and
environmentally sustainable development in India.
Broaden and deepen bilateral collaboration between Sweden and India for improving the environment
performance by introduction of cleaner technologies in Indian pulp and paper sector
The expected outcomes of the project are knowledge sharing/ transfer in pulp and paper sector and introduction of
new cleaner production technologies best suited to the Indian context.
The annual event ‘Papertech’ and this manual on Cleaner Production Technologies & Best practices are also efforts
that enable stakeholders to interact with others and learn from them.
I would like to express my gratitude to all the CEOs of the various pulp & paper mills in the country for their
contributions, guidance and support in shaping this initiative.
I would also like to thank Mr Pradeep Dhobale, Executive Director, ITC Ltd for his continued support for all our
initiatives related to making Indian Pulp & paper Industry world class.
My congratulations to Mr K S Kasi Viswanathan, Chairman, Paper Tech 2012 and all the members of the core working
group for their efforts and contributions.
I am sure that this manual would go a long way in facilitating quicker adoption of best practices in Indian pulp and
paper industry.
Dr Naushad Forbes
Chairman
Energy Efficiency Council, CII-Godrej GBC &
Director, Forbes Marshall
3
Preface
The year 2011 was an eventful year for the Indian pulp and paper Industry. Many
large capacity, high speed, state of the art paper machines have been commissioned
during this year. Quality of paper manufactured in the country has jumped. The
utilization of secondary fiber has also shown a significant jump.
With increasing pressures on availability and cost of input materials , cost of
manufacturing paper has become the real focal point. Energy is simply not available
and it’s price is going up by the day. This will continue. Needles to mention, same is
the case with water. Stakeholders are becoming more environmentally conscious
and the corporate social responsibility & “Environment friendliness” of a company is
increasingly used as a measure to assess a company’s performance. The industry has
proactively reacted to these challenges, addressing the Energy and Environmental
concerns at all levels of manufacturing.
Meantime, Government of India has also provided an impetus for Energy efficiency
by introducing the Perform, Achieve and Trade (PAT) scheme under the “National Mission for Enhanced Energy
Efficiency (NMEEE)”. The PAT scheme has been notified to the Designated Consumers (DCs) on March 30th, 2012.
Under the scheme, the DCs in the pulp and paper sector are required to reduce their specific energy consumption
within a specified time frame. Companies meeting the Target SEC will be benefitted, while companies not meeting
will be penalized. However the scheme provides a great opportunity for the paper sector to explore new ideas and
technologies to reduce energy , become green and also reduce their cost of production.
When CII – Sohrabji Godrej Green Business Centre, on it’s part, embarked upon its journey to “Make Indian Pulp and
Paper Industry World Class” in the year 2008, it was our vision that the Indian paper industry should improve it’s
performance particularly relating to Energy, Environment and water and be a leader for the world. Over the last four
years, this journey has been extremely rewarding and the Indian paper industry has certainly gone from strength to
strength.
For us, developing a “Best Practices Manual” for the sector every year, has been a small way to help stakeholders
to continue with their good work in this initiative. Earlier versions received encouraging response by the sector,
buoyed by which, we present to you this latest edition of the best practices manual. In this manual, apart from the
best practices identified from various plants in India by a core expert group, we have also included a few cleaner
production technologies identified from Sweden.
This manual has been prepared with extreme care, and the case studies presented here have good potential for
replication and adoption. I am confident that this manual will enable wider adoption of environmentally sound work
practices and technologies in our paper industry.
I invite all stakeholders to make the best use of this manual as well as other similar publications brought out by the
CII Sohrabji Godrej Green Business Centre, on their path to becoming world class performers.
I wholeheartedly appreciate all the support and cooperation extended to the working group in creating this manual
on best practices in the pulp and paper sector. I thank all those who were part of this initiative for sparing their
valuable time in preparing this manual.
K S Kasi Viswanathan
Chairman
Paper Tech 2012
& Deputy Managing Director,
Seshasayee Paper & Boards Limited
5
Acknowledgement
It is our privilege to express our sincerest regards to Mr. Pradeep Dhobale, Past Chairman – Energy Efficiency Council,
CII – Godrej GBC and Mr. K S Kasi Viswanathan, Chairman – PAPERTECH 2012 & Working group on “Make Indian Pulp
& Paper Industry World Class” for their invaluable contribution by leading the initiative from the front. We thankfully
acknowledge the contributions by Dr Naushad Forbes, Chairman – Energy Efficiency Council, CII – Godrej GBC in
providing valuable suggestions to guide us.
We also thank the following friends for working in a team and organizing a visit of an Indian and a Thai delegation to
Sweden during April 15 – 19, 2012. We are grateful to each and every one of them for their meticulous planning to
showcase Swedish services and technologies for cleaner production in the Pulp & Paper sector. The list of members
in the Indian delegation is attached as Annexure A.
1. Ms. Arati Davis, National Advisor - Energy and Environment, Environment Office, Embassy of Sweden
2. Ms. Anjali Bhola, Program Oifficer, Export Radet,
3. Mr. Ulf Frölander, President, Swedish Pulp and Paper Technology group of Sweden
4. Ms. Marita Erikson Wernius, Swedish Pulp & Paper Technology Group
5. Mr. Jonas Rottorp, Department Manger, IVL – Swedish Environmental Research Institute
6. Dr. Richard Holm, Business Development Manager, Innventia
7. Mr. Mattias Drotz, Senior Consultant, Innventia,
8. Mr. Narayan Moorthy, Secretary General, IPMA.
We deeply express our sincere thanks to the managements of the host mills, especially the West Coast Paper
Mills limited, for openly sharing the technical information with the working group and also for providing the local
hospitality and support to the visiting working group members. Also, the write ups provided for the identified best
practices deserve a special mention.
We take this opportunity to thank all the working group members who, inspite of their busy schedules, have visited
the identified mills and with great zeal contributed in identification of the best practices. The list of working group
members who visited West Coast Paper Mills Limited is attached as Annexure B. We are thankful for the management
of the companies to nominate them to participate in the working group visits.
6
Contents
S.No. Description Page Number
1 Executive Summary 9
2 How to use this Manual 11
3 Part 1: Facilitation of Implementation of Cleaner Production Technologies in Indian 15
Pulp & Paper Industry
4 Part 2: Best Practices Identified by CII - Working Group in Indian Pulp and Paper 145
Industry
5 Action Plan & Conclusion 231
6 Annexures
A: Indian Delegation attended the workshop in Sweden during 15 - 19 April, 2012 233
B: Attendees of the CII - Working group visit to West Coast Paper Mills, Dandeli during 235
8th and 9th May 2012
List of Swedish Companies included

S.No. Company
1 ÅF
2 AkzoNobel
3 Alfa Laval
4 Andritz
5 Aqua-Q
6 Cellwood Machinery
7 Chemrec
8 Cortus
9 Elof Hansson
10 Entrans group
11 GL&V Sweden
12 Innventia
13 IVL
14 Kemira
15 Lorentzen & Wettre
16 Meva Innovation
17 MoRe Research
18 NOSS
19 Promt and Frontway
20 Purac
21 SOMAS
22 SootTech
23 Swedish Exergy
24 UMV Coating Systems
7
8
CII’s efforts in Promoting World Class Energy Efficiency in Pulp & Paper Industry
EXECUTIVE SUMMARY
Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million
people and contributes Rs 25 billion to the government’s revenue. The government regards the paper industry as
one of the 35 high priority industries of the country.
In 1951, there were 17 paper mills, and today there are about 515 units engaged in the manufacture of paper and
paperboards and newsprint in India.
Growth of paper industry in India has been constrained due to high cost of production caused by inadequate
availability and high cost of raw materials, power cost and concentration of mills in one particular area. Government
has taken several policy measures to remove the bottlenecks of availability of raw materials and infrastructure
development. The higher production cost needs to be tackled by the sector as a whole by increased cooperation in
terms of sharing of best practices and moving towards cleaner production.
The CII-Sohrabji Godrej Green Business Center (CII-Godrej GBC) under the leadership of Mr. Jamshyd Godrej,
Chairman, CII Godrej GBC and Managing Director, Godrej & Boyce has adopted the vision of “Facilitating India to
become a global leader in green business (environment) by 2015”.
Towards this objective, the Energy Efficiency Council of CII-Godrej GBC under the chairmanship of Dr Naushad
Forbes, Director, Forbes Marshall has undertaken the development of “World Class Energy Efficient Units” in energy
intensive sectors, such as Cement, Power Plant and Pulp & Paper Industry.
The Paper sector initiative through a project titled “Make Indian Pulp & Paper Industry world class” is guided by a
working group chaired by Mr. K S Kasi Viswanathan, Deputy Managing Director, Seshasayee Paper & Boards Limited
(SPB), Pallipalayam.
The activities were initiated in a CEO meet organized in conjunction with Paper Tech 2007 at Hyderabad, a national
conference jointly done by CII-Godrej GBC and Indian Paper Manufactures Association (IPMA). The CEO’s meet was
attended by 19 CEO’s representing all the major Pulp and Paper Manufactures in the country.
Core working group:

A core working group was formulated with participation for Paper Mills, consultants and equipment suppliers. The
Paper Industry is sub divided into three groups namely Wood, Agro and Recycled fibre group. These groups visited
different paper mills, perceived to be doing well in terms of energy, water and environmental management, and
identified best practices followed in those mills.
The working group visited various Indian Pulp and Paper Industries in order to identify the best practices.
The out come of the working group plant visits is identification of 37 best practices from the Indian Pulp and Paper
Industry and released as the first edition of the National Best Practices Manual.
Subsequently the CEO's have been meeting every year (2008, 2009, 2010 & 2011) on the previous night of the
Papertech conference. The objective of the CEO meet is to review the activities of the previous year and chalkout the
plan fot the subsequent year.
Facilitator – Pulp and Paper Cleantech Project

As part of the world class initiatives CII partnered with IPMA, IVL and Innventia to initiate a project for bringing in
latest cleaner production technologies from Sweden to India.
“Facilitator – Pulp and Paper Cleantech Project” is a two year programme for the exchange of knowledge and
experiences for the dissemination of environmental friendly clean technologies to the Indian industrial sector with
special emphasis on the pulp and paper industry. This project is funded by the Swedish International Development
Agency.
9
As a first step CII and IPMA took a delegation to Sweden to attend a 5 day workshop on cleaner production
technologies with regards to the pulp and paper industry. The delegation also visited 2 Paper mills during the event.
The workshops and plant visits were organised by the Pulp & Paper Technology Group of Sweden. (PPT of Sweden)
and IVL.
Development of “Best Practices Manual – Pulp & paper Industry, Volume 5”

This volume of the best practices manual, namely “Best Practices manual – Pulp & Paper Industry”, contains two parts.
The first part was developed based on the interactions and learning that happened during the workshop conducted
by Pulp and Paper Technology group of Sweden and IVL / Innventia in coordination with IPMA and CII. (The list of
Indian participants to the workshop is attached as annexure A.
The second part of the manual was developed based on the learning from the working group visit to The West
Coast Paper Mills at Dandeli, Karnataka. The information collected was collated together with the best practices
implemented in ITC – PSPD Bhadrachalam unit, J K Paper Mills, Rayagada, Seshasayee Paper & Boards Ltd and
TamilNadu Newsprint and Papers Limited into a document which could be widely circulated through out Indian
Pulp and Paper Industry.
The fifth volume in the series compiled the best practices implemented in the visited mills and the best practices of
the other mills and contains their operational experiences latest as on May 31 2012.
During Papertech 2012, this volume of the “Best Practices Manual – Pulp & paper Industry” was released on June 7,
2012 at Hyderabad.
10
How To Use This Manual
The objective of this manual is to act as a catalyst to promote activities in Indian Pulp & Paper Plants towards
continuously improving the performance of individual units and there by achieving world class levels (with thrust on
energy, water & environmental management).
To set a clear goal for improving the performance and move towards the world class standards, the best
practices adopted in some Indian Pulp & Paper Plants & Latest Cleaner Production Technologies and Services
from Swedish Companies have been included in this manual as part of “Best practices Manual Pulp & Paper
Industry”.
The description of the best practices identified during the paper mill visit to The West Coast Paper Mills
Ltd., Dandeli, Karnataka by the working group forms a part of this manual. The details of the best practices
implemented by some other paper mills (ITC – PSPD Bhadrachalam unit, J K Paper Mills, Rayagada, Seshasayee
Paper & Boards Limited and TNPL) have also been included.
These best practices may be considered for implementation after suitably fine tuning to meet the
requirements of individual units.
Suitable latest technologies may be considered for implementation in existing and future Pulp & Paper
Plants for achieving the world class energy efficiency. Further investigation needs to done for the suitability
of these technologies for individual plant conditions.
The collated best operating parameters and the best practices identified from various plants need not
necessarily be the ultimate solution. It is possible to achieve even better energy efficiency and develop
better operation and maintenance practices.
Therefore, Indian Pulp & Paper Plants should view this manual positively and utilize the opportunity to
improve the performance and “Make Indian Pulp and Paper Industry World Class”.
11
12
PART 1
Facilitator - Pulp and Paper Cleantech Project
“Facilitator – Pulp and Paper Cleantech Project” is a two year programme for the exchange of knowledge and
experiences for the dissemination of environmental friendly clean technolgoies to the Indian industrial sector with
special emphasis on the pulp and paper industry. This project is funded by the Swedish International Development
Agency, and is for a period of two years.
The project partners are

India: CII – Sohrabji Godrej Green Business Centre (CII –Godrej GBC) and Indian Paper Manufacturers
Association (IPMA)
Sweden: IVL – Swedish Environmental Research Institute and Innventia, the Swedish pulp and paper
research institute
Background
In 2009 a Memorandum of Understanding was signed between India and Sweden, where clean technology was
highlighted as one of the main areas for partnership. This was reinforced during the first Joint Working group on
Environment, held on December 1, 2010 where clean technology and pulp and paper were selected as areas for
immediate action.
Sweden is understood to be one of the world’s leaders in paper production and technology solutions. Indian paper
mills have been in discussion with Sweden for some time. SIDA supported a partnership project in 2008 on clean
technology development, and the strongest interest for future business partnership opportunities came out from
the pulp and paper sector. SIDA, therefore, decided to commission a facilitator for industrial clean-tech focusing on
pulp and paper for India. The facilitator will focus on inclusive project goals, and the introduction of a broad range of
relevant sector actors in both India and Sweden.
The project was inaugurated during the “Nobel Week” in India during October 2011.
Project Objectives and Outcomes

The key objectives of the project are:
Transfer and exchange of know-how and experiences, increase awareness and capacity to protect
the environment and manage climate change; thus contribute towards socially, economically and
environmentally sustainable development in India.
Broaden and deepen bilateral collaboration between Sweden and India for improving the environment
performance by introduction of cleaner technologies in Indian pulp and paper sector
The expected outcomes of the project are knowledge sharing/ transfer in pulp and paper sector and introduction of
new technologies best suited for Indian context.
Project Progress
Kick off meeting by SIDA (Swedish International Development Cooperation Agency) amongst the project
consortium partners (IVL, Innventia, CII and IPMA) during the Nobel week.
Four paper mills in India were visited by a team comprising of experts from CII - GBC and Sweden to identify
key areas of concern and subsequent intervention. CII, IVL and Innventia participated in PAPEREX 2011 to
meet the various stakeholders of the Indian pulp & paper industry.
A 7-member IPMA delegation visited Sweden at the invitation of The Swedish Pulp & Paper Technology
Group and The Swedish Trade Council in April 2012 and gained exposure to new generation products and
15
technologies in the pulp and paper segment. A few representatives from the Agro and Newsprint segments,
besides CII – GBC, also joined the delegation. The specific areas of interest evinced by Indian delegation
during the visit were environmental technology solutions, energy efficiency measures, water conservation,
mitigation of carbon footprint, recycling fibre and enhancement of production efficiencies. On the last two
days of the visit, the delegation exclusively interacted with IVL and Innventia.
The suppliers of Swedish technologies identified to be of immediate relevance to the Indian pulp & paper
sector were invited to participate at PAPERTECH 2012. The consortium will be monitoring the progress of
interactions between the Swedish technology / equipment suppliers / service providers with the stake
holders of the Indian pulp & paper industry.
This section of the manual enlists the profile and technologies / services offered by the Swedish companies
that participated in the above said workshops.
16
ÅF
1. Introduction to ÅF
The ÅF Group is a leader in technical consulting, with expertise founded on more than a century of experience. They
offer highly qualified services and solutions for industrial processes, infrastructure projects and the development of
products and IT systems. They are specialists in effluent treatment in the pulp and paper industry.
2. Profile of the company: Areas of expertise

ÅF is the Northern Europe's leading industrial consultant and the largest independent consultant. They offer a
portfolio of services for all types of industrial production companies that covers the entire chain from initial idea
through feasibility studies, process analyses, calculation and project engineering to the construction, programming
and commissioning of plant. The ÅF consultants can work either as an integral part of the client's own organization,
or assume total responsibility for the delivery of an entire project or a specific function.
ÅF's core values are Great people, Teamwork
Indisputable independence
Services offered:
Consulting services - where technology and economy go hand in hand
Strategic planning, investments and environmental permits
Process and technical expertise in:
¾¾ Wood handling
¾¾ Chemical, mechanical and waste paper pulp
¾¾ Bleaching
¾¾ Chemical recovery
¾¾ Paper manufacturing and finishing
¾¾ Coatings and additives
¾¾ Conversion and logistics
¾¾ Steam and power generation
¾¾ Systems power supply and heat recovery
¾¾ Water and water purification technology
Biorefinery
Energy audits and energy optimisation
Environmental services
Materials technology
Inspections and guarantee inspections
Project management
Plant design - all aspects
17
Ongoing Assignments in Pulp & Paper sector:
Specialist Services
BAT Mechanical Pulping, Mid Sweden University
Digester Yield, Portucel Setubal
Support in moving equipment from Pulp Mill in Finland to India, Metso
Projects
Basic Design New Bleaching Plant, Stora Enso Skutskär (Sweden)
Basic Design New Line, Arauco (Chile)
Implementation New Power Unit, Bomhus Energi – EPCM
Implementation New Fibre Line + Rebuild Fibre Line, Sappi Ngodwana (South Africa)
Contact Details
ÅF-Industry AB
SE-169 99 Stockholm, Sweden
+46 10 505 00 00
Fax: +46 (0)10 505 00 10
Email: info@afconsult.com
Website: http://www.afconsult.com
India Office
1. AF-Mercados EMI
122001 New Delhi, India
Ph:+91 124 4241750
Fax:+91 124 4241751
Email: ade@mercadosemi.es
B - 206 Millennium Plaza,
Sector - 27, Gurgaon, Haryana
New Delhi
3. AF-Consult India Pvt. Ltd.
201301 Noida,
India
A-152, Sector 63
Noida
Ph: +91 0120 30961 31 / 45
Fax: +91 0120 30961 50
Email: afconsultindia@afconsult.com
18
AkzoNobel
1. Introduction to AkzoNobel
AkzoNobel is the largest global paints and Coatings Company and a major producer of specialty chemicals. They supply
industries and consumers worldwide with innovative products and are passionate about developing sustainable
answers for their customers. Their portfolio includes well known brands such as Dulux, Sikkens, International and
Eka.
Eka is one of the world's leading manufacturers of bleaching and performance chemicals for the pulp and paper
industry. Their long experience gives them a result-oriented approach to pulp and paper chemicals and their use.

The areas of expertise of the company are Paper chemicals, Pulp chemicals, Water treatment, Microbiological control
and Plant, Equipment & Industrial IT (Eka Engineering & Industrial IT).
3. About the latest services on the offering

a. Pulp Chemicals
Eka Chemicals is one of the world’s leading manufacturers of chemicals for the pulp industry. They have a vast
experience and competence in the supply and operation of plants and equipment for the processing of pulp
chemicals. This includes vendor managed inventory (VMI) and onsite production.
(i) Bleaching Chemicals:

Eka Chemicals is the largest producer of sodium chlorate worldwide and one of the largest suppliers of hydrogen
peroxide to the pulp and paper industry.
The combination of sodium chlorate, hydrogen peroxide and chlorine dioxide technologies makes Eka a unique
supplier of bleaching chemistry to pulp bleaching plants.
Over the last few years, they have developed their product offers to include:
Eka SC - Sodium Chlorate: Delivered as crystals by truck or rail. Eka SC is converted to chlorine dioxide, which
is used for ECF (Elementally Chlorine Free) bleaching of chemical pulp.
Eka HP - Hydrogen Peroxide: Eka HP is delivered as a 19 % – 70 % ready-to-use solution by truck or by rail.
Eka HP is primarily used for bleaching of chemical pulp, mechanical pulp and recycled fiber. Eka HP can also
be used for various special applications outside the pulp and paper industry.
Eka ClO2 - Chlorine dioxide : This concept is the most efficient method for large-scale conversion of Eka SC to
chlorine dioxide. Eka Chemicals owns and operates the onsite generator. Eka SC, Eka HP or another reducing
agent, together with sulphuric acid, are used as raw materials. Optimal operating conditions, highest safety
standards and cost efficient operation are ensured via remote supervision or control of the onsite generator.
Eka ClO2 generators can be supervised from one control room, around the clock, by highly skilled operators.
This ensures the highest availability and makes it easy to implement process improvements.
Eka Purate® : Eka Purate is a patented concept for onsite small-scale generation of chlorine dioxide, up to
4 MT/day. Used for chemical pulp bleaching in special pulp grades or when some additional capacity is
required in large scale operations.
19
(ii) Chelating Agents
Eka’s Dissolvine® chelating agents are used to remove unwanted metal ions and de-activate any remaining
ones. By combining amine and carboxylic acid chemistry in one molecule, this powerful chemical bond yields
aminopolycarboxylates, which form more highly stable chelates with metal ions than other types of chelating
agents.
Dissolvine chelates are used for production of mechanical pulps using hydrogen peroxide as bleaching agent in
BCTMP and bleached TMP pulp. Also for TCF (Totally Chlorine Free) kraft and sulphite pulp.
(iii) De-inking Chemicals

With the numerous chemistries used at a deinking mill, one of the main difficulties is controlling interactions. Eka
Chemicals total-system approach ensures that chemistry used for one particular purpose will not cause problems in
some other area of the deinking plant or paper machine.
Mill specific solutions: Eka Chemicals focuses on providing the best solution possible for customers’ de-inking mill.
They combine industry-leading services, such as FreeInk (a comprehensive study of ink removal parameters in North
America), EVOP (Evolutionary Optimization - software for optimizing the use of chemical additives) and mill surveys
with the widest array of de-inking and bleaching chemistry. The result is a mill-specific solution matching the best
chemical technology with customers’ water, furnish mix, flow sheet and performance targets.
Eka RF Series - A range of chemicals for flotation deinking processes.
Eka RF 4000 Series Soaps
Eka RF 4200 Series Surfactants
Eka RF 4400 Series Emulsions
Eka RF 4600 Series Blends
S-Quad™ - A deinking system, which lowers chemical costs while improving stickies removal by enabling the flotation
deinking process to operate at a neutral pH.
(iv) Non-Wood Bleaching

Bleaching of non-wood pulps: In regions where there is a lack of wood sources non-wood material is very often used
for pulp, paper and board production. Non-wood fibers are fibers from agricultural residues such as wheat straw and
sugar cane bagasse but also bamboo, reed, flax, kenaf, cotton linters.
The lignin and morphological structure of non-wood fibers make them easier to pulp compared to wood fibers.
However, during bleaching, substantial amounts of bleaching chemicals are consumed. The most common
chemicals used for bleaching of non-wood pulps still are chlorine and hypochlorite. These create pollution problems.
Eka has developed more modern bleaching technology based on chlorine dioxide and hydrogen peroxide for non-
wood pulps. The results are higher pulp brightness, better pulp strength, higher pulp yield and significantly lower
environmental impact.
Eka Purate® technology is ideal for small, non-wood pulp mills, which typically have a daily requirement of 5 ton
ClO2, or less. Eka Purate technology is supported globally via strategic manufacturing and distribution sites.
(v) Fluff Pulp Additives:
Eka Chemicals' fluff pulp additives help customers manufacture pulp with low burst strength and low required
defibration energy without deteriorating the absorbent properties of the fluff.
These fluff pulp debonders are responding and even anticipating present and future regulatory demands.
Eka Soft F 587K and 639 -Formulated cationic surfactants of quarternary ammonium compound type. Used
as debonders in fluff pulp manufacture. Note that these Eka Soft F products are formulated so that the
wetting characteristics are only marginally affected.
20
Eka Soft F60 Series - Designed for the latest European legislation with a very high efficiency
b. Paper Chemicals
Paper has all kinds of properties; whiteness, strength, bulk - it even rustles and sounds. Eka Chemicals helps customers
use the most cost-efficient chemistry in the most effective way. Their aim is to improve the performance, productivity
and profitability of customers business by optimizing your use of chemicals. As a global supplier of advanced
bleaching, papermaking, and coating chemistries, Eka Chemicals focuses on intelligent and interactive chemistry.
Eka makes high-performance chemicals work synergistically so that customers can take control of all their processes
and actually reduce the amount of chemicals in their system.
(i) Retention, dewatering, dry strength

Eka’s Compozil® systems are the most advanced and flexible retention, dewatering and dry strength systems available.
They offer custom designed systems to meet the challenges of any paper machine application.
Retention impacts efficiency in at least three ways. It cuts down on solids losses, decreases downtime, and reduces
the frequency of web breaks. Effective retention is the key to optimized runnability and reduced furnish costs.
Their Compozil® retention systems are based on a wide range of engineered colloidal silica nanoparticles or polymers
that together with other components can be used for virtually all types of paper grades. One of their latest innovations
is the Compozil Fx systems, suitable for very fast paper machines.
System components:
Eka NP Series - Nine distinct colloidal silica nanoparticle products, whose properties allow maximum
performance and efficiency in polymer or starch-based retention systems, acid or alkaline pH, and with any
grade.
Eka PL Series - A complete line of polyacrylamides available as powder, emulsion or dispersion, in a wide
range of charge densities and molecular weights. Includes unique products developed for specialized
performance and specifically for enhanced interaction with Eka NP in Compozil systems.
Eka ATC Series - Anionic trash catchers (Fixatives), organic or inorganic, for charge control and fixation. In
addition, a variety of new products and chemistries provide enhanced colloidal retention, improved wood
pitch, white pitch and stickies control, and better ash retention.
Eka CS Series - Cationic starch products. Include all common starch varieties, at a wide range of cationicity
levels.
Eka DS Series - A broad range of dry strength polymers used to develop strength properties in paper and
board.
(ii) Sizing Products

Eka Chemicals sizing products significantly increase customers’ efficiency and profitability. Offering both internal and
surface-sizing products, they enable customers to find the perfect combination to achieve targeted paper properties,
cut costs and improving runnability.
Internal sizing - for increased sizing control: Eka Chemicals offers rosin emulsions as well as synthetic sizing agents to
suit all internal sizing needs in paper and board production:
Eka CR Series - Cationic rosin dispersions
Eka DR Series - Alkylketene dimer (AKD) dispersions
Eka SA Series - Alkenyl succinic anhydride (ASA)
21
Surface sizing - for excellent printability: Surface size protects the base paper from excessive wetting, enhances
surface strength and reduces linting and dusting, which, in turn, improves paper printability.
Eka Chemicals advanced surface sizing products help customers enhance quality without increasing cost.
Eka SP Series - Anionic, cationic and amphoteric size press products
(iii) Coating Products

Innovative coating : Eka always look at the big picture to ensure customers coated grades are optimized. The
formulation of high-performance paper coatings is complex and requires advanced rheological characteristics
for a first class finished sheet. The importance of premium rheology and superior water retention is a priority for
runnability and exceptional finished sheet quality.
Innovative thinking: Eka have an in-depth understanding of the dynamic relationship between the fiber and furnish
which makes up the base. Couple that with the pigment and binder package that makes up the coating formulation,
which results in a complex system that is a finished product. Eka’s coating product line gives the formulator the tools
needed for optimum runnability and the best possible finished sheet properties.
Eka Flow L Series – Rheology Modifiers: Acrylic based thickeners to improve water retention and coating
rheology for optimum machine runnability.
Eka AZC/PZC Series - Crosslinkers & insolubilizers: Ammonium or potassium-based zirconium crosslinkers.
The crosslinker of choice for coated paper and board. They also help reduce linting and dusting when used
in uncoated papers.
Eka RC Series – Insolubilizer: Glyoxal-based resins for starch based coating and size press applications
Eka Sperse Series – Dispersants: Acrylic based dispersants to improve paper coating performance.
Eka LC Series - Lubricants: Calcium stearate and polyethylene lubricants that offer superior lubrication,
release properties, and surface texture.
Eka Structurecote – Starch based, green, renewable chemistry to replace protein, improve coating structure,
and improve surface properties.
Eka DC Series – Defoamers: Highly efficient for use in coating and size press applications.
Eka CC Series - Rheology aid & dispersant: Specialty products that include a multi-purpose rheology aid that
can reduce the viscosity of coating formulations to allow for higher solids. Also included in this range are
products such as coating dispersants.
Eka Stat Series – Anti static products: SSMA and MA chemistry used to reduce and neutralize static electricity
in paper and paperboard applications.
With Eka’s approach and utilizing a specialized, technical, paper sales force and listening to customers requirements
and understanding your needs, Eka Chemicals has become the industry leader in coating additives.
Through decades of research, applications support, and production, they have developed a wide range of multi-
functional products and performance options that are optimized for customers’ formulations, equipment, and
product requirements. Whether product is either coated board or ultra lightweight coated paper, Eka can develop a
cost-effective solution to meet customers’ needs anywhere in the world.
(iv) Wet Strength Products

Eka Chemicals has extensive knowledge about manufacturing paper products for use under wet conditions. They have
designed wet-strength products for all applications including liquid packaging board, kraft packaging, linerboard,
tissue and specialty grades.
These wet strength resins have been developed with two main targets: purity and efficiency.
22
Eka WS X14 and WS X0: Wet strength resins with extremely low CPD and DCP content. They respond to the
most demanding AOX targets in the effluent and OX in the paper. These are unique characteristics on the
market. Note that the Eka WS X14 provides the highest wet/dry ratio available on the market.
Eka WS 325 and Eka WS 505: Strong and stronger, with an efficiency uncommon in second generation
technologies. Used in a wide range of applications from board and label, to the top premium tissue
grades.
(v) Tissue Additives

Strong yet soft tissue products: Eka Chemicals is a complete supplier of first-class ingredients for demanding tissue
makers. They offer customers the best chemicals, combined with extensive know-how and application equipment.
A complete portfolio now available covering a wide array of applications:
Eka Soft T Series: Eka’s most advanced softeners and debonders provide bulk and surface softness. Applied
to the stock or sprayed on the sheet surface.
Eka Soft S Series: The latest softener designed to respond to the most stringent regulatory challenges. Very
efficient and allows to reach new level of softness.
Eka Soft B, M, R: For a very efficient Yankee surface protection - a full range of creping adhesives, coating
modifiers and release agents, with chemistries to respond to bulk and surface enhancement as well as
performance. Tailor-made products for customers’ particular demands.
c. Water Treatment
Maintaining and improving water quality: Today, papermaking involves increased process temperatures, greater
recycled raw material content, and higher rates of re-used water along with increased productivity demands. These
have made microbial fouling a more important factor to paper machine economy and performance efficiency.
With effective anti-fouling tools, machine productivity is improved by an increased effective run time and a decreased
number of breaks. Good water quality leads to increased production and improved quality, especially under alkaline
conditions.
For a sustainable environment: Pulp and paper mills also pollute water, which must be cleaned before it is released into
the environment. The composition of paper production pollutants in waste water depends on the paper produced
as well as on fillers and chemicals used. The pulp production and bleaching process generate other effluents and
require different treatment. Strict environmental regulations and demands to improve process efficiency make
water treatment and effluent control a daily challenge for Eka as chemicals supplier – customers’ partner in water
chemistry.
Eka Pam: Polyacrylamides for efficient flocculation in water treatment and sludge dewatering applications.
Eka WT: Polyaluminium chlorides for internal and external water treatment applications.
Eka Purate: Solution for small scale water treatment applications in a pulp and paper mill sites.
Contact Details
Lene Schack,
Manager Business Intelligence,
T: +46 31 58 74 79; F: +46 31 58 77 45
Email: lene.schack@akzonobel.com
Eka Chemicals AB
SE-445 80 Bohus, Sweden
T +46 31 587000
Website: akzonobel.com/eka
23
Alfa Laval AB
1. Introduction to the Company

Alfa Laval focuses on energy optimization, environmental protection and food production through their technological
leadership in heat transfer, separation and fluid handling. With more than 300 patents, they cover globe with
worldwide solutions to areas vital to society.

Added value for customers
Over the years, Alfa Laval has built up a reputation primarily on the strength of supplying high-quality products. This
is still valid, but they also want to provide value for their customers. This value is summarized in their mission: “To
optimize the performance of our customers’ processes. Time and time again.”
Key technologies
Alfa Laval is the global leader in its three key technologies
Heat transfer
Separation
Fluid handling
3. About the latest technology on the offering

Compact Heat Exchangers - Uniquely Efficient for Energy Recovery
Save money by maximizing heat recovery
Save cooling water by perfecting temperature approach
Compact Heat Exchangers - Dealing with fibrous fluids

Perfect fit for each duties
Accessibility on both sides
Minimum maintenance costs
Self-cleaning effect
24
Heat Exchangers for P&P industry
Plate Heat Exchagers
Alfa Laval is the world’s leading supplier of plate heat exchangers, all characterized by their compact design and high
thermal efficiency. The product portfolio includes various types of plate heat exchangers such as:
gasketed
semi-welded and fully welded
brazed
fusion-bonded
Plate heat exchangers are made up of a series of assembled, corrugated plates. Between the plates there are two
channels with a cold and a warm medium. These pass on each side of the plates and in opposite direction to each
other.
Gasketed plate heat exchangers, which are used for a large number of applications, are sealed with rubber gaskets.
Brazed plate heat exchangers have been developed to cope with higher pressures and temperatures. Welded plate
heat exchangers are used to handle even higher pressures and temperatures. Fusion-bonded plate heat exchangers
made of 100% stainless steel open possibilities in new areas and applications.
25
Spiral Heat Exchangers
The Compabloc is a breakthrough plate heat exchanger design that combines a whole range of technological
advantages into one compact unit. The all-welded plate pack does away with all gaskets between plates, and makes
it possible to operate with a wide range of aggressive media and at high temperatures and pressures.
Corrugated plate patterns generate high turbulence that results in overall heat transfer coefficients three to five
times greater than a shell-and-tube heat exchanger. In addition to minimizing fouling, this makes it financially viable
to use corrosion-resistant exotic metals.
This makes the Compabloc perfect for heat recovery in corrosive operating environments and for handling aggressive,
high-temperature fluids of all kinds. The compactness of this all-welded unit means it can be installed virtually
anywhere – as a condenser or reboiler for distillation and stripping columns, as a condenser on top of reactors and in
a wide range of other heat exchanger applications.
Spiral Heat Exchangers

Spiral heat exchangers exhibit ideal heat transfer and fluid handling characteristics for a wide range of rough industrial
applications.
These heat exchangers are suitable for viscous products and products with particles that could cause severe fouling
or corrosion in other types of heat exchangers.
26
Selection of product range
Separation – chemical recovery Extract and Purify by-products from process

Comprehensive range of technologies
More efficient extraction
Fully automated operation
Alfa Laval centrifuges will save money for
Installation cost
Solids disposal cost
Maintenance cost
Water consumption
Chemicals cost (due to higher chemical recovery)
P2 Decanter
Together with their other decanter ranges SG2 and STNX, the P2 range of decanter centrifuges is specially designed
for handling aggressive slurries and sludges in process industries. Alfa Laval decanters are the perfect choice for
separation duties in steelmaking, mining, industrial fermentation, production of pulp, paper, coke, chemicals,
petrochemicals, polymers, ethanol, starch, biodiesel and sugar processing.
Lowest power consumption on the market, minimum lifecycle costs
High performance and reliability
Dryer cake and reduced disposal costs compared to other technologies
Easy access and low noise levels
2Touch automatic control system guarantees continuously optimized operation
Easy cleaning using automatic Cleaning-in-Place (CIP) programs
Many upgrades and service possibilities available, such as videoscopy and online monitoring
Available in 2-phase and 3-phase versions, and in ATEX-compliant configurations. Special sealed and purged
versions are available for processing flammable feeds
27
Fluid handling
Applications
Digester
Black liquor
Recovery boiler
Bleaching
By-products
Paper machine
Power Plant
Mechanical pulping (TMP)
Waste Water Treatment
The use of inexpensive cooling water has become a widely accepted and successful solution to cooling problems in
pulp & paper industry, ships, power plants and district heating & cooling systems.
As the availability of cooling water quality has declined, the need for cost-effective solutions to eliminate clogging
and biological body and corrosion become apparent.
In a refrigeration system containing a heat exchanger and an Alfa Laval Filter, contaminated or corrosive water can
now cool even the most sensitive process equipment.
28
ALF FILTER
Alfa Laval's filter, ALF, is used as an integral part of a cooling system to remove dirt and debris that can cause clogging
or biological body in a plate heat exchanger or a condenser. Alfa Laval's filter is also suitable for many process fluids
where filtering is required. Despite effective grating or coarse filtration at the water intake, mussels and other marine
small animals get into the heat exchanger and being caught the heat transfer surface. Such environments are ideal
for this type of marine life, and they multiply rapidly, resulting in reduced heat transfer and even failure of the heat
exchanger.
Measures such as back flushing of the heat exchanger or chlorination is not always enough if the blockage is severe
and in some cases prohibited chlorination by environmental laws.
Alfa Laval's filter protects the heat exchanger from clogging and biological body and also protects against blocking
or clogging of the cooling system. The filter is normally installed near heat exchanger inlet, removes dirt and debris,
and marine animals and backwash automatically at regular intervals.
Dynamic Spray Devices - Industrial Rotary Jet Heads

Cost -effective cleaning
Toftejorg rotary jet heads provide high cleaning efficiency at significantly reduced cycle times to meet the tank-
cleaning requirements of various process industries – from the pulp and paper and chemical processing industries to
the bioethanol and starch industries. Toftejorg rotary jet heads also provide measurable savings by cutting energy,
chemicals and water consumption for virtually any tank size and configuration.
To achieve the best cleaning results, Toftejorg rotary jet heads use an optimized jet impact pattern to ensure efficient
distribution of rinse water to all inner tank surfaces. The high-impact dense spray pattern removes any residue after
the production cycle more quickly and effectively than the much more expensive and time-consuming cleaning
methods of soaking in chemicals or manual cleaning. Self-draining and self-cleaning, inside and out, all Toftejorg
rotary spray head devices comply with Good Manufacturing Practice. The Alfa Laval Rotacheck system verifies every
cleaning cycle to ensure compliance with today’s strict hygiene standards.
Performance reliability and long service life

Capable of operating at pressures of less than 0.3 bar, Toftejorg rotary jet heads offer very low inner resistance.
However, for optimal cleaning performance, the recommended operating pressure is between 5 and 12 bar. For
over half a century, rotary jet head and rotary spray head technology has proven successful in providing reliable and
repeatable cleaning performance and a long service life.
29
Cost-effective maintenance with minimal downtime
Proper maintenance is critical to optimizing any tank cleaning system, improving performance and extending
nozzle life. Spare part service kits are available with full parts traceability to facilitate parts replacement and provide
customers with complete documentation. Upon request, a video clip of maintenance procedures can be supplied.
High product integrity

To ensure product integrity and extend equipment service lifetime, all Toftejorg rotary spray head devices are made
of safe and non-reactive hygienic materials. Upon request, 3.1.B certificates to show conformance with EN 10204 and
ATEX category 1 certificates for to show conformance with the Atex 94/0/EC Machinery Directive can be supplied.
Documentation
All Toftejorg rotary jet heads are supplied with operator’s manual, CAS selection criteria (CAS is Alfa Laval´s design and
selection tool) and appropriate certificates, such as 3.1B or ATEX certificates. To determine the right parameters for
a specific tank, optional TRAX software may be used to simulate actual cleaning performance of a specific Toftejorg
rotary jet head configuration – prior to finalizing specifications and before installation.
Supply and delivery

Available in wide range of sizes and configurations, Toftejorg rotary jet heads provide coverage for virtually any
tank size. All standard components are kept in stock to shorten lead times and prevent unplanned downtime. Most
standard configurations can be supplied within a few days.
Part of a broad range of tank cleaning devices

Alfa Laval offers a comprehensive range of portable and fixed tank cleaning devices for use in the process industries.
These include:
Toftejorg Rotary Spray Heads (Dynamic tank cleaning devices)
Toftejorg Rotary Jet Heads (Dynamic tank cleaning devices)
Toftejorg Static Spray Balls (Static tank cleaning devices)
To meet the specific and varied requirements of the process industries, Alfa Laval can customize tank cleaning
equipment solutions based on their extensive product range, which has proven successful for the marine, sanitary
and pharmaceutical industries.
30
Contact details
Main office
Alfa Laval Lund AB, P.O. Box 74
SE-221 00 Lund Sweden
Indian office
Alfa Laval (India) Limited
|Head Office Country, Manufacturing Unit
Mumbai-Pune Road, Dapodi,
Pune - 411 012
India
Phone: + 91 202 710 71 00
Fax: + 91 202 714 77 11
E-mail: india.info@alfalaval.com
Web page: www.alfalaval.com
31
ANDRITZ
1. Introduction to Andritz Pulp & Paper

Andritz is reliable and committed technology and service provider for the production of pulp, paper, tissue, board,
fiberboard and power generation products.
Their range of technologies includes full lines for the processing of logs and annual fibers; production of chemical,
mechanical, and recycled fiber pulps; recovery and reuse of chemicals in the pulping process; generation of energy
from biomass and other fuels; stock preparation; paper, board and tissue machine approach flow; production of
paper, tissue, and board; coating and finishing; and handling of reject materials and sludge.

Andritz services include complete mill maintenance, equipment optimizations, upgrades and rebuilds, engineered
wear products, replacement parts, and technical field support.
Every industrial process occasionally encounters disturbances, obstacles, or bottlenecks. Andritz have a world of
experience, hundreds of installations and a long track record of success.
The challenge
The major challenge facing pulp producers is to achieve steady-state production of uniform pulp quality with the
highest yield and lowest possible consumption of chemicals and water regardless of the fiber source. And all this
within ever-tightening environmental regulations.
The solution
ANDRITZ is one of the few technology suppliers to deliver a complete chemical pulp mill and to have it perform with
world-renowned environmental excellence. Andtitz technologies for mechanical pulp production and recycled fiber
processing are among the best available.
Andritz technology portfolio for pulp production comprises equipment for every process in the modern pulp mill:
wood processing, fiberline, bleaching, deinking, chemical recovery, and pulp drying/baling.
Every component is designed to work independently in a rebuild or modernization application, or perfectly integrates
with other ANDRITZ systems in a complete line for new installations.
Experienced ANDRITZ project teams gives support during engineering, planning, erection, and start-up of mills.
Technical and service support is at-the-ready throughout the life of the equipment.
Special focus 1: ANDRITZ technologies for dissolving pulp production

Demands for environmentally friendly fiber sources have dramatically increased the interest in utilizing dissolving
pulp, particularly in textile processes. ANDRITZ has a cost-effective approach to dissolving pulp production that
includes a new continuous pre-hydrolysis kraft cooking process coupled with efficient washers and other proven
downstream pulp processing equipment.
32
Fig: Dissolving Cooking Fiberline
The challenge
The key challenges are maintaining high yield and productivity while ensuring consistent pulp quality.
The solution
ANDRITZ technology for the production of dissolving pulp is based on many years of experience with chemical
pulp fiberlines and intensive R&D on high alpha-cellulose dissolving pulp grades. Their experience with biofuels
has further led them to design the system with special features considering the optimal methods for by-product
recovery and reutilization.
Many of the existing ANDRITZ process technologies used in chemical pulping are already suitable for dissolving pulp
production. For this reason, existing chemical pulp lines can easily be converted to the production of dissolving pulp
with only minor modifications to the existing wood processing equipment, fiberline, drying plant, and evaporators.
ANDRITZ has experience integrating all of the existing process areas with this new technology specifically for dissolving
pulp production. Experienced ANDRITZ project teams gives support during engineering, planning, erection, and
start-up of dissolving pulp production line. Global and local technical and service support is at-the-ready throughout
the life of the equipment.
Special Focus 2: ANDRITZ LimeLine White Liquor Plant - Ecologically sound, economically efficient
ANDRITZ PULP & PAPER continues to develop technologies which minimize environmental impact by recycling and
reusing process streams inside a mill, rather than relying on end-of-pipe removal. This is particularly true in the
white liquor plant, where the conversion of green liquor into high quality cooking liquors is performed with great
efficiency.
The Challenges:
The major challenge in the white liquor plant is turning green liquor (the smelt from a recovery boiler) into pure
white liquor that can be reused in the pulping process – with minimal energy consumption and environmental
impact. Critical factors such as air emissions, energy efficiency, solid waste (dregs), and white liquor purity must be
considered when selecting the equipment for the white liquor plant.
33
The Solutions:
ANDRITZ has been an innovator for decades in recausticizing and lime reburning, and auxiliary processes and offers a
strong portfolio of LimeLine components for each process stage and support operation. The scope includes process
solutions for chemical conversion and filtration, equipment for the various steps in preparing cooking liquors, and on-
going services. The product portfolio includes not only traditional white liquor production, but also other modified
delignification liquors for kraft pulping. With 70+ new recausticizing plants, 200+ plant modernizations, 100+ new
lime reburning kilns, 30+ kiln modernizations, and several plants for white liquor oxidation or modified white liquors
– ANDRITZ has the experience to handle any project around the world.
LimeLine components are designed to excel as standalone unit processes, and offer truly superior performance when
integrated into a modern, energy-efficient, and environmentally safe production line. The results are reduced and
cleaner air emissions, excellent energy efficiency, reduced loads to the landfill, and very high white liquor quality –
even with the closed-cycle process loops.
ANDRITZ capabilities for paper production

Andritz provides all the paper technology and services such as from individual components for paper mill up to
complete production lines.
The challenge
The major challenge facing paper producers is to improve margins for commodity and specialty grades through
steady-state production of on-spec paper at the highest efficiencies with the lowest possible consumption of
chemicals and energy.
The solution
ANDRITZ delivers complete paper/board/tissue production lines for new installations and individual machine
components – from stock preparation to winders – for rebuild and modernization projects.
Andritz’s paper technology portfolio comprises well-proven equipment and innovative solutions for stock preparation,
paper/board/tissue production, paper finishing, coating, and winding, including automation systems.
Every component is designed to work independently in a rebuild or modernization application, or integrated into a
complete line for new installations.
34
a. Recausticizing
ANDRITZ LimeLine technology for recausticizing is the result of high expertise, long experience and innovative
process solutions.
LimeGreen - falling film cross-flow green liquor filter
Efficient separation of even small impurities
High availability
Less make-up lime required
No need for lime mud precoat
Long filter cloth life
Stable operation
LimeFree - lime mud free dregs handling
No lime mud needed – minimizes the amount of waste to landfill
Optimized lime purging
Small footprint required for installation
Green Liquor Cooler - efficient and trouble-free
Less over-liming and over-boiling
No cleaning required
Less acid washing shutdowns in white liquor filtration
Easier causticizing control
Efficient droplet separation
LimeSlake - multi-compartment lime slaker
Big lime mud particles
Improved separation of white liquor – alkali savings
Improved filtration of lime mud – alkali savings
Higher dry solids in lime mud
Self-cleaning
Effective scrubber
Clean working environment
LimeMilk – one- to-three compartment causticizer
Optimal sizing due to compartment flexibility
Carefully agitated
No lubrication water
No bottom bearing
LimeWhite - white liquor filter
Continuous operation
Clean and hot white liquor
35
Fully automated
Higher white liquor yield
Reduces water circulation
Less white liquor dilution
LimeDry - lime mud washing and dewatering
High capacity in a single unit
CPR – Continuous Precoat Renewal
Reliable, continuous feed to kiln
Continuously high dry solids
Filter cloth washing during operation
Energy savings and less ring formation in kiln
Less TRS emissions
Totally closed design - dust proof, clean working environment
b. Lime reburning
The modern and proven ANDRITZ lime reburning solution consists of a LimeKiln reburning kiln, a flash dryer, a
LimeCool cooler and a LimeFire burner.
LimeKiln - efficient and reliable lime reburning
Low fuel consumption with two-layer brick lining
Low emissions
Highly reliable carrying and thrust rollers
Low NOx Technology
Precise control of flue gas temperature
Easy and fast start-up
No internals needed
Integrated with LimeCool cooler and LimeFire burner
LimeCool - compact lime handling, cooling, and primary air heating
Low heat loss
Optimum cooling of lime
High capacity with efficient use of space
Internal dam
Clean working environment
No burner tunnel
Less overhanging weight
c. White liquor modification

StiroX - pressurized white and green liquor oxidation with oxygen gas
White liquor with low residual sulfide content for oxygen delignification
Oxidized white liquor helps to control mill sodium and sulfur balances
36
Excessive heat energy from exothermic oxidation reactions is recovered as hot water
Less emissions
MOXY - white liquor sulfide-to-polysulfide conversion
Polysulfide cooking offers a way to increase cooking yield
Optimal conditions for polysulfide reaction are achieved by blowing air and white liquor through a catalyst
bed with activated carbon
Strong presence in India

From mill wide systems to the largest drum pulper — latest ANDRITZ references on the Indian market:
1. JK Paper Ltd., Rayagada, ordered woodyard equipment, including the first HHQ-Chipper in India, as well as
a complete fiberline, recausticizing and lime kiln – the largest mill-wide scope of equipment from ANDRITZ
in India
2. To ITC Ltd., ANDRITZ delivers a FibreFlow drum pulper and dispersion system. This will be the largest drum
pulper in India!
3. Three-loop ANDRITZ deinking plant for Tamil Nadu Newsprint & Papers Ltd. — the first of this kind to be
commissioned in India!
Contact Details
Sweden Address
ANDRITZ AB
P.O. Box 126
Tynäsgatan 14
SE-651 04 Karlstad
Sweden
Phone +46 (54) 77145 00
pulpandpaper.se@andritz.com
Gopalan Sridhar
General Manager ( Chennai Facility)
ANDRITZ Technologies Pvt. Ltd.,
The Lords, Block II, Plot No. 1&2 (NP), III Floor,
Thiru Vi-Ka Industrial Estate, Jawaharlal Nehru Road,
Ekkatuthangal, Guindy
Chennai 600032. India.
Tel: +91 44 4293 9351
Mob: +91 97890 59351
Email: chennai.facility@andritz.com
Website: www.andritz.com
37
AQUA – Q
1. Introduction to Aqua-Q
Aqua-Q is a Swedish cleantech company focused on applied research and provides innovative cost effective solutions
for safe and clean water. The company develops and market/sale real time online microbial monitoring and sampling
system for drinking water and quality control of recycled water as well as related services like consulting and water
analysis.

Clean and safe water is of fundamental importance for human life, health care, industrial process, irrigation and so
on. Access to water of good quality is a scarce commodity. Its requirement is growing twice the rate of population
growth while the water resources are dwindling and rapidly depleted. Contaminated water is a concern.
Aqua-Q provides innovative environmental friendly and sustainable technological solutions to remove the
contamination in water and assuring the quality in real time.

Aqua-Q’ offers real time monitoring system which keeps an eye on produced water quality 24/7 at public/ industrial
water plant. When the system observes abnormal level of bio/micro contamination as they occur in real time it
immediately alerts the authorities so that the management of the water plant can take proper and quick action and
save money.
Aqua-Q’s system not only alerts the authority but grabs automatically relevant water sample for analysis which
even serves as evidence. Depending upon the nature of the contaminants Aqua-Q software can actuate disinfection
system or can execute other pre-programmed action plans. This not only protects the citizens’ agony by being sick,
it also saves millions of dollars.
Background
Drinking water is our most common and valuable commodity. Globally more than 2.2 million people die by drinking
unsafe contaminated water, distributed not only in developing countries but also in the most technologically
advanced countries. This is because the management of the drinking water plants is much too often not aware when
contamination occurs.
At current water consumption rate it is estimated by United Nations Population Fund that by 2025 there will be
over 60% of world population will live in areas where safe water is scarce. And the need for re-use of water will be of
utmost importance. These are incredible numbers which demonstrate the growing need to develop sustainable and
environmental technologies which are robust, accurate and cost effective for drinking water quality monitoring and
water resources.
Today most water works check the quality of the water they supply by taking several random samples. Even if
those samples are taken fairly often they do not give any information about the current level of contamination as
analysis result take 3-4 days. Aqua-Q, offers a more cost effective and safer alternative: real time monitoring by laser
technology and automatically capturing a sample when there is threat for contamination with time and date.
During 2010 and 2011 outbreaks of Cryptosporidium Parvum infection occurred in two municipalities in northern
Sweden causing disease in thousands of individuals and disrupting everyday life as water had to be boiled before
being used. Many hospitals in Sweden are very much concerned about the water quality. Several county council
plans to have their own water reservoirs so that they can manage at least 2 days.
38
Aqua-Q’s real time monitoring system is optimized among other features to give immediate alarm when surface
water or sewage water accidentally or by reason enters the drinking water pipeline creating risk for Cryptosporidium
Parvum infection.
In paper industry slime in water is a problem and a concern. Slime can be controlled by knowing the water quality
and with advanced disinfection system (ozone).
Principle of operation
Based upon the previous research and field experience the product WQM-100 was developed (Early Warning System).
The principle of the operations of WQM-100 is optical laser scanning on a partial flow 24/7.
The product is a modular based real time monitor to detect the possible microbial contamination in both source
water and in drinking water. The system comes with laser sensor, software with mathematical algorithm to cluster
the contaminants, monitor and automatic sampler.
Aqua-Q’s early warning system, WQM-100, detects immediately the abnormal level of micro contaminants as they
occur in real time and alert the plant management and responsible caretaker of apartments, offices and important
buildings wherever the WQM-100 is placed.
To be able to capture relevant water samples a modular hygienic sampler AQS is developed. The sampler can be
placed at different locations and be controlled by the software.
User friendly software was developed for collection of data, visualize on a monitor and real time evaluation of the
fingerprinting of the water. All data from the sensors are saved and traceable.
Ozone Application
Besides real time monitoring of drinking/recycled water and sampling the founders of Aqua-Q have practical
experience (consulting) of the use of ozone. Ozone is a strong oxidizing agent and used in various water treatment
processes. Aqua-Q has patent for disinfection of Legionella and some innovative applications.
Potential benefits
The potential benefits of WQM-100 is an early warning system which gives immediate information to plant operation
for a potential microbial threat and gives continuous information, in real time, of the water quality and the possibility
of the growth of biofilm inside the pipe line and its loosening. This is an ideal equipment to avoid slime problems and
maintain the level of biofilm. By knowing the optimization of the process the biofilm can be controlled.
39
Case studies
Ongoing case studies:
1. Hammarby Sjöstadsverk (research test bed) in Stockholm. This research test bed is owned by IVL (Swedish
Environmental Institute) and KTH (Royal Institute of Technology). WQM-100 is integrated on a treated waste
water treatment line to show the variations of the treated waste water.
2. WQM-100 is also installed at the biggest water plant in Sweden, Norrvatten. The equipment monitors the
source water intake from the lake Mälaren, just outside Stockholm.
So far the case studies are very promising.
Other benefits
Other benefits that can be obtained is the optimization of the process i.e. dosing of the chemicals for the treatment
of water, filter backwash, filter break through, quality control of boiler feed water and water for membrane
application.
Approximate Investment at Present Value

The investment cost for one system is about 600-800000 SEK depending upon the configuration.
Payback period
WQM-100 can be considered as an insurance against unwanted events. The maintenance cost is low and Aqua-Q
considers payback time to be very short, it all depends on the costs of the incidents. If the water in the boiler is
contaminated the cost is very high and the payback time is negligible. Prevention is better.
Sources of further information

For further information, please visit http://www.aqua-q.se/
Contact Details
Main Office
Aqua-Q AB,
Vidjavägen 53, S-123 52 Farsta, Sweden
Phone: +46 (0)73-6870306 / +46 (0)73-6781425
India Representatives
Mahant Advisory Services
Website: http://www.mahantadvisory.com/
40
Cellwood Machinery AB
1. Introduction to the company

Cellwood Machinery’s concept is to develop, design, manufacture and market high-tech machinery and complete
systems adapted to suit the needs of customers in the pulp and paper industry across the world for the environmentally
friendly processing of pulp and the recycling of waste paper, and manage after sales including training, start up,
service and spare parts supply.
Now they have over 500 systems in operation. The total quantity of waste paper pulp processed through all Krima
Disperging Systems world wide is over 90 000 tons per day.

Cellwood Machinery’s business concept is to provide energy-efficient machinery and services for disintegration and
grinding of recycled paper and other fibres in large volumes.
They customise their standard machines. Their equipment is unique and is based on the needs of the customer. They
provide in-depth technical solutions, extensive experience and creative ideas for the best possible solutions.
3. About the Latest technology on the offering

a. Pulper Rotor type G
Grubbens rotors are specially designed to operate at high consistency with baled pulp or broke. Regardless of whether
it is bales, paper machine web or guillotine broke, high consistency is essential for achieving optimum results.
The rotor design is the main reason for the pulpers being able to operate at a high consistency and low power
demand. The consistency range in the pulpers varies between 3 – 9%, depending on the material and whether the
pulpers are operating continuously or batchwise. The primary breaking up of paper and pulp is made by the friction
in the pulp stream at high consistency. It is therefore important to have good circulation also with high consistency.
b. Pulper Rotor type S

Grubbens new rotor type S is a further development from the well proven SRM-rotor. The rotor Type S was specially
developed for breaking up wet strength and other difficult paper qualities. The rotor Type S can be equipped with
counter knives in exactly the same way as the rotor Type SRM.
41
Advantages with the rotor Type S:
The rotor combines hydrodynamic and mechanical breaking of the pulp
The design of the vane at the rotor prevents plugging of the strainer holes
The rotor can break up tough paper qualities, especially wet strength qualities
The rotor allows higher pulp consistency through the strainer holes
The rotor gives a higher flow of the pulp over the strainer plate
The rotor assists emptying of the pulper because it normally gives an overpressure on the suction side
Rotor Type S fits on the existing bearing unit for Type SRM without modifications
c. Grubbens Stock Pump

Grubbens centrifugal pumps are specially designed for transportation of liquids with variable consistency, or liquids
containing air bubbles and lumps. Stock concentration of up to 8% can be pumped without in-feed pressure. With
in-feed pressure it can even manage to pump up to 12%
The self-ventilating rotor has no constrictions and therefore minimises the risk of blocking.
42
The pump characteristics can be adjusted by changing the pump speed, which, in the case of V-belt drive, is easily
done by changing the pulleys. When the power transmission is by V-belt drive the motor can be placed above the
pump, if so desired, so that drenching of the motor is avoided. The alternative to V-belt drive is a motor with frequency
converter.
d. High Density Cleaner

Grubbens High Density Cleaner takes care of unwanted particles and removes them from the suspension using the
vortex separation principle. Parts that have a higher density than the pulp, such as screws, nails, staples, steel parts,
stones and pebbles are effectively removed and gathered in the reject chamber.
When installed in an existing plant the cleaner comes with separate rotor, which allows it to operate without any
pressure drop. When the cleaner is installed in a new system the capacity of the pump will determine the pressure
in the cleaner.
e. Deflaker
Grubbens Deflaker is used for the separation of fibres in broke systems, virgin pulp systems and waste handling. Even
wet strength paper qualities can be deflaked
In the Grubbens Deflaker the pulp passes through eight vibration zones under continuous flow reversals and is
therefore well processed without fibre boundless in spite of the low peripheral speed.
43
The design of the deflaking discs allows compensation of wear trough axial movement of the rotor disc. The discs
are made of hardened, acid-resistant steel with Brinell hardness of about 400 HB. High corrosion resistance ensures
negligible abrasive wear.
Grubbens Deflaker types GLD 200 and 360 have fixed axial rotor discs. On type GLD 360 HW the rotor disc is axially
adjustable. The disc gap can easily be adjusted using a hand wheel which will enhance the performance of the
deflaker.
f. Dewaterer
Dewaterer type SD
Practically all fibre suspensions can be treated with the Krima Screw Dewaterer, normally within the consistency
range of 3–20%. The Krima Screw Dewaterer can, for example, be used for dewatering of: Screen reject, Knots, Waste
paper fibre, Cleaner reject, Semi-chemical pulp, Chemi-mechanical pulp, High-yield pulp
Basically, all Krima screw dewaterers comprise a rotating screw in a perforated basket. Dewaterers should always be
inclined. Type SD has a straight cylindrical core. The design is used for the simplest form of dewatering, i.e. material
which is easily dewatered, for example, knots before refining and long-fibre materials.
Dewaterer type SDC

Type SDC has a cone-shaped screw core. The cone-shaped core gives a radial compression which increases the outlet
consistency up to 8-12% at an inlet consistency of 3%. This type can, for example, be used as pre-thickener before the
Krima screw press in a waste paper system.
Dewaterer Screw type SDPP

Type SDPP is the most advanced type of screw dewaterer. The SDPP unit has both a conical screw core and
pneumatically controlled counter-pressure cone. The counter-pressure cone enables hydraulic pressure to build up
in the dewaterer and this ensures that the holes in the screen basket are kept clean. The SDPP unit is recommended
when the in-feed volume and/or freeness vary considerably and is therefore particularly suitable in waste paper
plants. This unit can thicken up to an outlet consistency of 20%.
44
g. Screw Press
Screw Press type KSR
Screw press type KSR for an inlet consistency of 3%. The screw press gives excellent results on recycled paper as well
as virgin pulp.
Advantages with the Krima screw press type KSR:

Good dewatering due to thin pulp cake.
Blockage free discharge due to pneumatic backpressure cone.
Low wear due to low operation speed.
Good accessibility during maintenance due to horizontally split screen baskets and a screw with dismountable
shafts.
The screen baskets of the press have good accessibility for inspection and cleaning due to the external
hoops which can be dismantled easily by hand.
Screw Press type RR

Screw press type RR for an inlet consistency of 8%. The screw press gives excellent results on recycled paper as well
as virgin pulp
45
h. Disperging system
Disperging system
Krima Disperging System is exclusively designed for disperging waxes, hot melts, bitumen, stickies, laser ink as well as
heavy colours. The Krima Disperging system is the most advanced system. Apart from producing the best disperging
result for all kind of dispergible contaminates in waste paper, this is also the most flexible disperging system.
The discharge side of the screw press does not need to be pressurized as the following plug screw is designed to seal
the system against the atmosphere. This design allows existing dewatering system to be used.
Shear forces introduced to the stock by the plug screw create a pre-disperging effect and at the same time an excellent
distribution of bleach chemicals when so required.
Retention time of the pulp in the standard design pre-heater is 2 min. which is enough for reductive bleaching with
FAS and a reduction of bacteria and spores in the stock.
Compact Disperging system

The Krima Compact Disperging System includes the Krima screw press type KSR with pressurized discharge outlet
chamber. Automatic torque control on the screw press drive ensures constant outlet consistency. Retention time for
the pulp in the steam heater is between 15 and 20 seconds.
46
Ultra Compact Disperging system
The Krima Ultra Compact Disperging System consists of only three machines. Krima screw press type KSR with
automatic torque control and as option equipped with a pressurized discharge outlet chamber. Existing dewatering
equipment can also be used.
An in-feed steam heater for introduction of shear forces to the pulp to create pre-disperging effect. Retention time
for the pulp in the heating zone is between 5-10 seconds. This system can for example be used to avoid yellowing of
mechanical fibres.
i. Bleaching System
In the Krima sequence Bleaching System the pulp will be continuously bleached under pressure at high pulp
consistency. The bleaching system is installed directly in connection with the Krima Disperging System. Because of
this it is possible to both pre-bleach and post-bleach with different chemicals.
The advantages with Krima Bleaching System:

High temperature is utilised in the bleaching process
Less energy consumption
Less chemical consumption
Minimum dilution effect on bleaching chemicals due to high pulp consistency
47
Different temperatures during pre-bleaching and post-bleaching
Different pulp consistency during pre-bleaching and post-bleaching
Different bleaching chemicals during pre-bleaching and post-bleaching
Possibility to make fast changes to conditions for bleaching efficiency
j. Refiner
The Krima refiner is designed for high consistency fibre treatment. The best results are reached when the inlet
consistency is between 20 and 30%. One of the most significant features of the unit is the patented and technically
superior in-feed zone, which allows treatment of all types of fibres without the risk of blocking.
The in-feed zone also contributes to the very low energy consumption. The power consumption varies according to
the type of refining discs. The refiner provides a high pumping effect which feeds the pulp directly to the required
station, i.e. machine vat or storage tower. The rotor can be equipped with special pump flights to achieve the
maximum pumping effect.
Contact Details
For further details: www.cellwood.se
Sweden Office
Box 65
SE-571 21 Nässjö
Sweden
Tel: + 46 (0)380 76000
Fax: + 46 (0)380 14123
e-mail: sales@cellwood.se
India Office
Eintec
G#17, Sreevatsa Square
7/31-A, Mettupalayam Road
Coimbatore, India 641 034
Telephone: +91- 422 264 5815
E-mail ID: meyappan@eintec.in
48
CHEMREC
1. Introduction to Chemrec
CHEMREC helps pulp and paper mills dramatically increase their cash flow and profitability by enabling them to
become Biorefineries. Application of its unique, proprietary black liquor gasification technology opens up new
markets for mills, producing sustainable, low-carbon chemicals and fuels.
Low carbon footprint

A recent CONCAWE/EUCAR study reviewed the carbon footprint of a variety of bio- and fossil fuels. Chemrec’s biofuels
clearly stand out in the study, with all of the various potential fuel products reducing overall footprint by greater than
90 percent. With the additional benefit of not competing for food or agricultural land, Chemrec biofuels are a true
leader in the move to sustainable mobility
Fig: Carbon footprint of various fuels
Intellectual Property
Chemrec has a broad patent portfolio protecting their technology globally. They hold more than a hundred patents
across 26 patent families covering gasification, gas cleaning and pulp mill integration aspects. They innovate and
constantly strive to add patents protecting a wide range of aspects of their technology.

Chemrec has some 20 years of experience in the field of black liquor gasification technology. During these years,
they have developed iterations of the technology in demonstration plants. The technology has now matured into a
proven concept which they offer on commercial terms to mills looking to expand their operations and enter the new
pulp mill paradigm – the Biorefinery.
Gasifier products
A300 Booster
The 150-300 tons/day atmospheric air-blown unit increases pulp production through improved black liquor recovery
capacity and flexibility in chemical recovery. The A300 Booster can be installed in parallel with the mill’s existing
49
recovery boiler. A significant benefit of this system is that it can be installed while the recovery boiler continues to
operate, thus avoiding down time and lost production.
OX450 Booster
The OX450 atmospheric oxygen-blown Booster with capacities up to 450 tons/day not only increases the black liquor
recovery capacity but also produces a fuel gas suitable as lime kiln fuel. In this way lime kiln fuel costs and the mill
carbon footprint can be significantly reduced.
P500 Expansion Unit

The 500-550 tons/day pressurized oxygen-blown unit offers mills additional capacity and increased yield, while
producing significant volumes of sustainable, low-carbon biofuels or high heating value fuel gas.
P2000 Replacement Unit

The 1000-4000 tons/day pressurized oxygen-blown unit replaces recovery boilers entirely, granting improved pulp
yield, while producing significant volumes of sustainable, low-carbon biofuels.
X2000 Combined Cycle Unit

The 1000-4000 ton/day pressurized unit oxygen-blown replaces recovery boilers entirely, granting improved pulp
yield, while doubling “green" power production.

a. Chemrec - a gasification technology inherently more efficient
Low-cost feedstock, very high conversion efficiency and inherently lower investment cost are features of the Chemrec
process that makes production of lower cost biofuels possible.
Building on existing industrial infrastructure Chemrec transforms pulp and paper mills into biorefineries with its
proprietary black liquor gasification technology. The excellent quality syngas that is produced can be converted into
sustainable, low-carbon fuels and chemicals such as:
Dimethyl ether
Methanol
Synthetic diesel
Synthetic gasoline
The Chemrec process has been shown to be very close to carbon dioxide neutral with a reduction of fossil CO2
emissions of 95%. The technology has potential to globally provide motor fuels equivalent to over 45 billion litres or
12 billion gallons per year of gasoline.
Gasification – gas quality, energy efficiency and integration

Gasification is already a large and mature component of the existing fossil petrochemical industry. The use of green
feedstock for gasification is however attracting more and more attention around the world. For the outsider it can
be difficult to distinguish between different types of gasification. Here follows a short guide to what distinguishes
the gasification process used by Chemrec as opposed to others with focus on gas quality, energy efficiency and
integration benefits.
50
Fuel gas, syngas and syngas quality
First, gasification processes can be divided into processes producing synthesis gas, sometimes abbreviated as syngas,
and processes producing fuel gas.
As syngas must consist essentially completely of carbon monoxide and hydrogen, gasification processes that produce
syngas must not let nitrogen from the air enter the process. This means that a gasification process that is to produce
syngas must either be fed only pure oxygen as oxidant or be indirectly heated. If air is used as the oxidizing agent
only fuel gas can be produced.
Syngas must for most synthesis processes be free from particulates and tar compounds and must hold only low
concentrations of methane.
So-called low temperature processes whether indirectly heated or oxygen-blown will form substantial amounts of
tars and methane. If the feedstock is Municipal Solid Waste (MSW), wood or agricultural residues the gas will also
include substantial amounts of particulates.
For raw syngas from a low temperature process to be acceptable for synthesis gas, upgrading it must, therefore, first
be treated to remove particulates and tars and catalytically treated to transform the major part of the methane to
carbon monoxide and hydrogen.
The Chemrec process in contrast is operated in the entrained-flow high temperature mode. This has the advantage of
suppressing methane formation and almost completely eliminating the formation of tars. The process also gives very
high carbon conversion so almost no char is formed. As a wet quench method and counter-current condensation
under pressure is used in the Chemrec process the particulate removal is very efficient, giving only parts per billion
of particulates in the cooled gas. The host pulp mill is already equipped with a system to separate particulates from
the excess quench liquid as this liquid will also contain the recovered cooking chemicals which are reused in the pulp
mill.
Fig: Schematic of a Chemrec gasifier with gas cooler steam

generator
Energy efficiency through heat generation

A gasification process and a fuel synthesis plant will always generate heat as a by-product. Some of this heat can be
recovered internally, how much depends on temperature levels of producers and consumers within the plant and on
51
how much heat recovery equipment such as heat exchangers are installed in the plant.
For energy efficiency it is essential that the heat generated as a by-product of the gasification process is re-used. It
can be used internally, in the gasification plant and the pulp mill, but can also be integrated with a districy heating
system. Övik energi, Örnsköldsvik, Sweden, distributes heat generated at the biorefinery Domsjö Fabriker, to the
industrial areas in the surroundings.
Nevertheless a substantial amount of heat will have to be removed from the plant. This can either be done through
the application of cooling systems from which the heat is dissipated to the air or water bodies around the plant or it
can be exported as useful heat from the plant to for example a neighboring industry with need of lower level heat or
a district heating network heating buildings around the plant. Stand-alone plants without possibility to export heat
will invariably have lower effective energy efficiency than plants that are externally heat integrated.
Case studies
1. The New Bern Booster gasifier, > 47000 h of full-scale operation
Commercial atmospheric, air-blown gasifier to boost recovery capacity
Capacity 300 t BLS/d, about 15% of total mill recovery capacity
Installed in 1996, operated >47 000 h until October 2008
Reached 95% annual availability and 2 years refractory life
Of great importance for development of refractory system and other components
2. Oxygen-blown high pressure gasifier consistently produces high quality syngas and green liquor
Located at the Smurfit Kappa mill in Piteå, Sweden
Used for development and technical demonstration
Oxygen-blown and operated at 30 bar(g)
Capacity 20 t BLS/d (3 MWth), >13 000 operating hours
Provides BioDME plant with syngas
52
Other benefits
The practical implications of black liquor and Chemrec technology are a simpler plant using fewer and commercial
processes
Fig: Schematic of Chemrec and conventional gasification processes
Chemrec plants are always heat integrated with the host pulp mill. As the Chemrec process is also energy efficient
it can deliver substantial amounts of process steam back to the pulp mill. This reduces the net amount of external
energy needed for the combined pulp mill and Chemrec plant.
Integration benefits
Integration with existing activities along the value chain is crucial for second generation biomass-based biofuels
production to be competitive. Moving through the value chain such integration can include:
Using the waste product of another value chain as the feedstock can substantially reduce feedstock cost.
In the Chemrec case, they use forest harvest residues, essentially tops and branches left from the timber
harvesting, as make-up energy feedstock for the host pulp mill. As gasification feedstock they use black
liquor, a pulp mill waste stream left over from the production of cellulose.
Providing by-products or services in addition to the primary product. In the corn ethanol industry this is key
to profitability; in addition to the ethanol also protein-rich livestock fodder in the form of distillers grain is
produced. In the case of the Chemrec process it provides two utilities to the pulp mill; it recovers and returns
for reuse hundreds of tons per day of spent cooking chemicals dissolved in the black liquor and it produces
process steam for use in the pulp mill.
53
Being located where logistics systems for the raw material and product is already in place. Being in a location
where infrastructure costs are high adds to investment and operating cost. A Chemrec plant is always
located directly at an operating pulp mill where thousands of tons of woody biomass is already brought
in and processed every day. The Chemrec biofuels plant simply receives the already prepared and uniform
feedstock black liquor.
Using the product to enhance the associated value chains. In the BioDME demonstration project already
fuelling trucks bringing logs into the mill and paper from the mill with high performance fuel produced in
the mill. The pulp and paper industry could thus not only be fossil fuel independent for their production
processes but also for a large part of their transport needs.
Black liquor -Liquid biomass with properties uniquely suitable for gasification for biofuels production
Single-step gasification without tar or methane reforming to high-quality syngas and green liquor
Gasification in an entrained flow high-temperature mode gives
Full carbon conversion
No tar formation
Low methane formation
Small reactor volume (~25 m3/1000 t BLS/d)
Simple gas clean-up
The technology has intrinsically lower investment and operating cost.
Installation on existing industrial size with shared services and utilities
Feedstock already prepared and
Feedstock is liquid and highly reactive
Two services in one unit –produces syngas and recycles valuable cooking chemicals
Heat integration with pulp mill provides outlet for surplus LP steam and increases net conversion
efficiency
Low quality make-up energy source –forest harvest residues or natural gas
Highest Efficiency and lowest emissions are possible with DME and syndiesel gasified from Blackliqor.
Chemrec is well within commercial fossil gasification parameters such as energy flow / gasifier size, gasifier type,
pressure and temperature.
54
PerstorpOXO BASF Germany Eastman Uba Ammonia Domsjö Sweden
Sweden Chemicals USA Japan
Feedstock Oil/ Nat. gas HVR HS Coal HS Coal/ Petcock Thick Liquor
Start up year 1980 Before 1970 1983 1984 2014
Gasifier size/ # of > 100 MW/1x 150 MW? / 4 x 33% 300 MW / 2x 100% 150 MW / 4 x 33% 100 MW/ 3 x 50%
trains 100%
Pressure bar 30 30 65 40 30
Temp., deg C 1300 1300 ~ 1400 1450 ~1000
Products Oxo chemicals Petrochemicals Photo chemicals Ammonia DME/ Methanol
3x50% gasification trains ensure 100% capacity always available
Fig: Gasification Trains
Thermal efficiency of gassifier: 92%
(LHV) MWth
BL feed (500 TPD BLS @ 73% concentration) 75 MW (input)
LP steam generation 23 MW
Feed Water heating 2 MW
Syn Gas 44 MW
Total useful Output 69 MW
b. Chemrec Boosters-Technology for recovery capacity increase and fuel cost reduction
Chemrec Boosters, purpose and profile:
Chemrec Boosters is proven technology that provides solution to increase pulp capacity even with the customer has
severe recovery boiler limitations.
The advantages are:

No recovery boiler rebuild shutdown is required
The investment is moderate
Easy to operate
55
Can produce fuel gas for lime kiln, natural gas or fuel oil replacement
Reduced fuel costs
Reduced carbon footprint
The boosters come in two versions: A300 and P500.

A300
Atmospheric, air-blown unit
Standard size is of 300 t BLS/d
Produces gas for steam generation
Well-proven with 47000 hours of operation
Low cost, high profitability when the recovery boiler is the mill bottle-neck
P500
Pressurized, oxygen-blown unit
Size up to 550 t BLS/d
Produces high value fuel gas for lime kiln firing
High thermal efficiency, produces fuel gas and LP steam
Typical cost economics for an Indian integrated pulp & paper mill (May vary from case to case)
Description Quantity / rate In rupees

Basis 100 TPD of BLS
Present Scenario : Black liquor HP Steam generation from 100 TPD 350 TPD
fired in the soda recovery boiler of BLS that now has to be generated
to generate steam by coal fired boilers
Cost of steam generation by coal Rs. 1000 / Ton
Total value of output Rs. 0.35 million /day
Using booster type BL gassifier Replaced Furnace oil from lime kiln 18 kL /day (Refer to above Rs. 0.81 million / day
to replace Furnace Oil in lime table)
kiln Cost of FO Rs. 45000 / kL
Quantity of LP steam generated 5.8 TPH
Cost of LP steam Rs. 500 / Ton (assumed) Rs. 0.07 million / day
Total value of output Rs. 0.88 million / day
Nett additional benefit of by booster type gassifier Rs. 0.53 million/day
Investment Rs. 350 million
Simple payback period 2.2 years
Maintenance cost of booster
Inspection to be carried out once every 6 months
Nozzles have to be regularly cleaned
Refractory life is 2 years (cost of refractory for a 550 TPD system is Rs. 25 million)
Entrained flow high temperature gasification

Combustion oxygen is mixed with atomized liquor to form hot flame at 1700-1800°C / 3100-3300°F. The result is low
tar and methane formation.
Secondary gasification reactions outside flame consumes residual char and lowers gas temperature to about 950°C /
1750°F. It results in a very low green liquor char content and moderate temperatures at reactor lining surface.
56
Case Studies
(i) A300 BOOSTER –INCREASED BLACK LIQUOR RECOVERY CAPACITY AT MODERATE INVESTMENt
COST
The New Bern Booster gasifier

Commercial atmospheric, air-blown gasifier to boost recovery capacity
Capacity 300 t BLS/d, about 15% of total mill recovery capacity
Installed in 1996, operated for more than 47000 hours until Oct 2008
Of great importance for development of refractory system and other components
Reached 95% annual availability and 2 years+ refractory life
Fig: CHEMREC® New Bern A300 Booster
ii) P500 BOOSTER -INCREASEDBLACK LIQUOR AND LIME RECOVERYCAPACITY
Improved Booster Concept

Chemrec’s revised Booster concept using their pressurized P500 gasifier provides the following benefits:
Gas cooling produces steam improving total heat economy
Fuel gas replaces natural gas or fuel oil in lime kiln
Higher lime kiln capacity than on natural gas or oil
Very low gas sulfur content
Attractive operating cost
P 500 Gasifier- Merits
It is the standard Chemrec unit for syngas generation for motor fuels production
The system can be pressurized to 30 bar (g)
57
It is Oxygen-blown
Standard size 500 ton black liquor DS/d
Very good overall thermal efficiency -syngas cooler steam generator recovers sensible and condensing heat
of gas
Suitable to feed acid gas removal system
Thermal efficiency of P500 unit (typical)
Fig: P500 Booster system solution
The gas treatment unit

An amine wash unit has been selected
Same principle as for the Chemrec BioDME plant amine wash
Removes sulfur and carbon dioxide from the syngas, 0.1 % H2S, 2% CO2 residual selected
Skid-mounted unit
Gives two gas streams
Sweet syngas
Odorous gas to incineration
58
Fig: Gas treatment unit
Fig: Amine Wash Unit under construction in Munich for Chemrec

BioDME
Total space requirement (preliminary) for gasifier unit is 20 m x 40 m, for gas treatment unit is 20 m x 8 m and for
oxygen plant is 20 m x 35 m besides location for flare.
Fuel gas gives higher lime kiln capacity

The upgraded syngas has a capacity advantage over natural gas and fuel oil due to
Higher flame temperature
Lower combustion air volume gives lower load on lime cooler
Lower flue gas volume gives lower load on kiln, flash dryer, electrostatic precipitator and ID fan
59
Example at 500 t black liquor DS/d with 73% DS, 35.6 MWLHV kiln heat input:
Natural gas Upgraded syngas Difference

Combustion air flow Nm3/s 10.02 7.93 -21%
Flue gas flow Nm3/s 11.03 9.48 -14%
Adiabatic flame oC 1971 2191 +220
temperature
Key stream data

Typical key utilities production / consumption at 500t DS/d and 73 % DS content
Net steam generation ~15 t/h
Net power consumption including oxygen plant ~5.6 MW
Oxygen demand 1.71 kg/s
Gas energy content: 35.6 MW (lower heating value)
Contact Details
Patrik Löwnertz
VP Marketing & Sales
Chemrec AB
Floragatan 10B
SE-114 31 Stockholm, Sweden
Ph:+46 8 440 40 67
Fax: +46-8-440 4066
Email: patrik.lownertz@chemrec.se
Website: www.chemrec.se
60
CORTUS
1. Introduction to Cortus
Cortus aims to be the leading provider of clean energy to customers in the Process, Power, Transport and Waste
Management industries.
Potential markets are forest rich countries in the Nordic region, the European Union and North America. Their
expansion phase will penetrate into emerging markets like Brazil, China, South Africa and India.

Mission Statement
Cortus AB aims to become an international leader in supply of clean renewable energy gas to high temperature
combustion in process and power industries based upon high thermal efficiency and cost effective gasification of
biomass.
Carbon and Climate Change

Carbon emissions are the leading cause of global warming and climate change. A primary source of carbon emissions
are fossil fuels. Realising the turn of environmental issues that could occur in the future if carbon emissions are
not controlled, The Kyoto Protocol was introduced to provide businesses with economic opportunities to be more
energy efficient by reducing emissions.
Cortus sees this as a great economic opportunity by supplying affordable, clean and renewable Synthesis Gas
generated from gasification of biomass, as a way to replace fossil fuels.
Green Power for Process & Power Industries

Cortus is building the future of innovative and sustainable energy supply for the process and power industries. High
temperature combustion in process and power industries demands high calorific and clean fuels. Cortus is now
introducing Green Power based upon their new biomass gasification technology - WoodRoll®.
WoodRoll® is Cortus way of solving global and environmental issues by providing sustainability. They replace fossil
fuels with green gas generated from biomass.
WoodRoll® has the unique ability of being able to accept a huge variety of feedstock while maintaining a high thermal
efficiency of up to 80%. In addition, their patented indirect heating technique produces a cleaner green gas than
conventional gasification methods, hence translating into better cost savings for their customers.
WoodRoll® will help to reduce millions of tons of carbon released while at the same time, providing their customers
with cost savings in millions of dollars through the circumvention of emission permits.
Cortus Advantage
The clean high calorific Syngas produced can substitute fossil fuel in any process. Cortus’ process is built upon
subsystems proven in other industrial processes but put together in a new fashion.
Cortus' WoodRoll® thermal efficient gasification technology and fuel flexibility makes it feasible and profitable to
build on-site plants that process locally available biofuels into clean energy.
Besides, the WoodRoll® produced Syngas has high purity as it is an indirectly heated process. Syngas is not diluted
with nitrogen from the air or polluting elements, hence eliminating the need to include an additional filtration system
which translates to additional cost savings for their customers.
61
3. About the latest technology on the offering - WoodRoll®
What is Biomass?
Biomass refers to any living or dead biological material that can be used as fuel or production. Second generation
biomass (non-food based products) like wood waste and industrial sludge is slowly gaining popularity as use of first
generation biomass (sugar, starch and vegetable oil) have been questioned over issues of increasing price of food
and the relatively low energy density of crops.
Currently, such second generation waste biomasses are normally incinerated or landfilled. Both have been heavily
criticized: in landfilling, escape of methane is 25 times more potent than carbon dioxide; incineration produces toxic
byproducts which need to be further processed. Gasification would be an important future waste management
technology.
What is Gasification?
Gasification is a process that converts carbon materials, such as coal, petroleum or biomass, into carbon monoxide
and hydrogen (synthesis gas). This is done by reacting the raw material at high temperatures with carefully controlled
amount of oxygen or steam. The synthesis gas is often used as intermediate raw material or as a fuel, depending on
its purity.
Gasification is an efficient method for extracting energy from different sources of organic materials, and also
considered as a clean waste disposal technique. Biomass gasification is much cleaner and more efficient than direct
combustion of biomass.
Gasification of Biomass
In general, gasification of biomass generally consists of 3 major processes:
Drying
Pyrolysis
Gasification
The drying step is usually the first step in any biomass gasification process. The drying step removes moisture from
biomass.
Pyrolysis is the chemical decomposition of carbonaceous material that produces char at elevated temperatures.
Pyrolysis produces combustible components, a variety of condensable organic compounds referred to collectively
as tar. Several non-combustible gases are also released, primarily N2, CO2, and water vapor.
Gasification process occurs as the char reacts with steam to produce carbon monoxide and hydrogen (Syngas) in the
reaction.
In conventional gasification processes, the 3 processes are combined into one gasifier. Cortus innovates this further
through the WoodRoll® gasification process, where these 3 processes are separated into 3 separate systems, resulting
in a much cleaner syngas that is undiluted with nitrogen.
Principles of WoodRoll® Technology

The core technology has three parts: drying, pyrolysis and gasification each of which are very well established
industrial components - with the arrangement of the components unique to Cortus.
Cortus’s first patent was granted in December 2008. They now have 3 granted patents and 2 more have been filed
and pending approval.
62
A Cleaner SynGas
A distinctive element of the WoodRoll® process is that the produced char is gasified with steam in an indirectly
heated reactor to produce synthesis gas.
The char and steam are thus not mixed with the exhaust from combustion or nitrogen from the air. This produces
a clean synthesis gas which is free from condensable tar residues and nitrogen aggregates compared to existing
conventional gasifier reactors.
The cleaner syngas produced via WoodRoll® eliminates further downstream filtering or purification processes to
remove unwanted substances within the gas stream. This translates to additional savings for their clients.
Typical composition of the dry Syn gas would be 60% Hydrogen, 30% Carbon monoxide and 10% Carbon dioxide
and is likely to have calorific equal to or more than that of Natural gas. The uniqueness of this biomass gasification
technology is the use of steam (H2O), and not air, as a source of oxygen.
Feedstock Flexibility
Over 100 different types of feedstock have been tested and analyzed by Cortus using the WoodRoll® process. They
have good knowledge of characteristics and reactivity of different fuels ranging from wood, bark, microalgae to
sludge.
This essential experience of conducting multiple tests adds innovation to WoodRoll® process, such that the system
could accept and process a large variety of feedstock.
High Thermal Efficiency

The creative usage of heat exchangers to conserve heat energy translates to 80% overall thermal efficiency for
WoodRoll® process with 20% moisture in biomass. However, the thermal efficiencies can be lower with higher
moisture in the feedstock.
One ton of dry biomass equals 5 MWth of input fuel.
Quantity of dry biomass needed to give 5 MWth of output Syn gas is 1.25 Tons. This will need about 600 kg/hr of
steam as input.
Cortus Next Step

Cortus is ramping up to the next phase which is 5MW demonstration plant which will be ready by 2011.
In August 2010, Cortus AB and Nordkalk AB signed a 12-year contract for supply of biogas to the Nordkalk factory in
Köping, Sweden. Cortus will supply biogas to Nordkalk corresponding to a reduction in carbon emission by 70000
tons annually in maximum capacity.
After 2 years, the plan is to expand the facility to 25MW thus becoming the dominant energy source for the Köping
factory.
Laboratory Testing
Cortus has done extensive testing on over 100 fuels and feed stocks in their laboratories. TGA has been used to
identify various characteristics of fuels such as gasification/pyrolysis temperature and mass/heat flow attributes.
These critical experiments in the laboratory help Cortus to calibrate their parameters before moving on towards
larger pilot scale testing. Moreover, it also gives them technological validation and helps them decide on feasibility
of fuels.
63
Fig: Laboratory testing
Pilot Plant Testing

Fuel that passes their laboratory tests are further tested in their pilot gasification reactor. The tests allow them to
optimize various parameters at an industrial level. They have learnt much from those campaigns which will crucially
aid in the design of their demonstration plant.
Fig: Pilot plant testing
Engineering Design
At Cortus, people are working to improve their engineering design based on the results of their extensive laboratory
and pilot testing. Their partners and suppliers are also experts in their respective components of the demonstration
plant.
64
Contact Details
Sweden Office
Rolf Ljunggren,
CEO,
Email: rolf.ljunggren@cortus.se
Ram Alzuheri,
Project Engineer,
Email: ram.alzuheri@cortus.se
Address
CORTUS AB,
Skalholtsgatan 2,
164 40 Kista, Stockholm,
Sweden
Office: +46 (0)8 5888 6630
Fax : +46 (0)8 752 8105
Website: www.cortus.se
65
ELOF HANSSON
1. Introduction to Elof Hansson

Elof Hansson International
Elof Hansson International supplies equipment and components, machinery and complete plants and process
segments to the pulp and paper, corrugating, converting, printing, packaging and sugar industries. Elof Hansson
International also plays a leading role in major projects such as new plants and renovation of existing facilities, as well
as all kinds of projects utilizing concession loans.

For more than five decades Elof Hansson has been successfully associated with the pulp, paper and converting
industries in India. They are actively engaged in the marketing and supply of pulp, paper and secondary fiber,
machinery and technical services, consumables and specialty chemicals.
Elof Hansson India’s head office is located in Chennai in the southeast of India. To cover the entire Indian market as
well as Sri Lanka, Pakistan, Bangladesh and Nepal they also have branch offices in Hyderabad, Mumbai, Delhi and
Kolkata.
The products and services of Elof Hansson are Pulp, paper and secondary fiber; Chemicals; Machinery, components
and spares; Process and quality control instruments; and Services and engineering.
3. About the latest services on the offering

a. Chemicals
Elof Hansson India offers chemicals for the following applications:
Water & Waste Water Treatment

Boiler feed water treatment
Single product, all organic filming & neutralizing amines based ELOGUARD® program.
Phosphate free program eliminates HP dosing, requires LP dosing only.
Superior and comprehensive protection against corrosion to pre boiler, boiler & condensate system.
Over 170 customers in industries like paper, oil refinery, sugar, textile, steel, power etc., with steam pressures
ranging from 8 Bar to 100 Bar rely on ELOGUARD.
In addition to above, Elof Hansson in cooperation with BKG Water Solutions, Germany offers comprehensive solutions
for the following:
Cooling Water treatment - Antiscalants, Corrosion inhibitors, Dispersants and Biocides.
Raw Water Pretreatment - Flocculants and Co aggulants.
RO Membrane Treatment - Antiscalants, Prereservation, CIP cleaning chemicals and programs.
Waste Water Treatment - Flocculants and Co-aggulants, Defoamers, Color removal, Odour control and Water
reuse / Recycle programs.
Selective process additives for Refinery / Petrochemical, Sugar mills, Paper mills, Paper mills and Food
industry.
66
Complete water treatment package, with control equipment for dosing, monitoring, control and Onsite
Service and Support.
For more information on BKG Water Solutions, please visit their website www.bkgwater.com
Corrosion Inhibition in Refinery Overhead systems
Filming and neutralizing amines based corrosion inhibitor, ELOGUARD P 86 for protection against corrosion
& scaling in overhead systems of crude/atmospheric distillation units, vacuum distillation units, delayed
coker unit (DCU) etc.
Paper/Board making
Fine and ultrafine high brightness kaolin clays from Thiele Kaolin, Georgia, USA.
b. Machinery, components and spares

Elof Hansson India offers the following products:
Stock and liquor pumps, energy efficient agitators
NCG, white liquor oxidation system
Blow heat recovery system
Rex technology and evaporator retrofitting
Dynablade for blade coaters and tissue creeping
Pulp Screening Components and Systems
Compact Wet End Systems
Low Consistency refining components
Water treatment plants, microfilters for solutions to recycle water in paper mills
Handling and wrapping systems for paper rolls and pallets
c. Process and quality control instruments

Elof Hansson India offers for the following products:
Lab instruments for paper testing and process optimization
Lab instruments for fiber rising, hygroexpansitivty, dynamic absorption
Lab reactors for pulping and bleaching, lab digesters
Consistency transmitters, on line analyzer, basis weight valves
Instruments for packages testing
On line gloss meter for paper and paper boards
PTS Domas formation, dirt, specs, sticky wire and felt mark modules and paper bale sensors for portable
measurements
Wet end charge analyzer, polymer control systems, lab charge analyzer, turbidimeter
BASIS weight valves
Optical consistency transmitter, paper machine retention monitoring and controls
67
d. Services and engineering
Elof Hansson India offers:
Systems for white liquor oxidation, non-condensable gases incineration
Steam and condensate system optimization
Instrument calibration and troubleshooting
Case studies
1. Undertake projects on EPS basis wherein EHI is the face to the customer.
2. Executed 60 TPD Deinking line in Vietnam for a Tissue Mill
3. Executed a 400TPD Pulp mill in Vietnam
4. Executed few White Liquor oxidation Plants and NCG plants with Know How from Lundberg of USA in
India
Contact Details
Sweden Office
Tomas Hultgren,
Vice President,
Direct Ph: +46 31 85 62 35
Fax: +46 31 85 68 54
Email: tomas.hultgren@elofhansson.com
Web : www.elofhansson.com
Address
Elof Hansson International AB
Elof Hansson Industry
SE-41380 GÖTEBORG,
Sweden.
Visiting adress:
Första Långgatan 17
Tel +46 31 85 60 00
Fax +46 31 12 67 35
E-mail info@elofhansson.com
India Office
Manos Mukherjee,
President
Elof Hansson (India) Pvt Ltd
New no. 149, Chamiers Road
R. A. Puram
Chennai 600 028
Tel: +91 44 2431 5110
Fax: +91 44 2431 5116
E-mail: manos.mukherjee@in.elofhansson.com
Or office.chennai@in.elofhansson.com
Website: www.elofhansson.com/india
68
ENTRANS GROUP

Focused on heat recovery with ORC technology, the Entrans team has rich experience in the energy and process
industry, especially in large heat pump and chiller systems, foundries, sawmills and paper industry.
Entrans is highly experienced in optimizing heat and cooling production within energy industry, identifying synergies
that can be reached by optimizing and integrating new systems into existing processes within process and energy
industry and in maintenance and overhaul of large heat pumps and chillers.

FlexiGen is the product from Entrans group for optimizing the efficiency of industrial processes, marine vessels
and geothermal sources by harnessing excess heat and achieving maximum performance from current available
resources and equipment.
The Organic Rankine Cycle (ORC) enables FlexiGen to generate electricity or mechanical power from low temperature
heat with a conversion efficiency of 5-20%.
FlexiGen is able to operate with temperatures as low as 50oC (up to a maximum of 220oC), maximising the use of all
heat sources available.
Heat can be converted to electricity as it is harnessed by FlexiGen from various sources. Every MWh of electricity
produced by FlexiGen translates to cost savings in producing or buying one MWh of electricity.
FlexiGen is self contained, with no gaseous emissions or any other associated environmental pollutants.
Every FlexiGen unit is designed using FlexiGen EOS™, a system configuration tool developed by the Entrans team
over more than 10 years, customizing each FlexiGen unit to the target system.
All components used in FlexiGen are obtained only from large and respected ISO 9001 certified vendors.

With a wide operating temperature range, FlexiGen is able to make use of many different heat sources across various
industries.
a. Industrial Applications
FlexiGen eliminates the problem of excess heat wasted in industrial processes such as those in cement plants and
steel mills. Facilities such as biofuel and waste incineration plants can make use of FlexiGen’s ability to generate
electricity to maximize the efficiency of current equipment. This can be done without risk of disruption to original
operations.
69
*When used in district heating systems, the district heating return flow can be used as a heat sink.
b. Geothermal Energy
Geothermal wells of “low-value heat” and the return flow of existing geothermal plants can utilize FlexiGen to achieve
a high conversion efficiency of heat to electricity due to its use of the Organic Rankine Cycle and optimized custom
design to each well/plant.
FlexiGen’s ability to utilize excess heat at low temperatures is due to the Organic Rankine Cycle (ORC). The ORC is a
thermodynamic cycle that uses an organic working fluid that has a lower boiling temperature as compared to water,
70
such that the operating temperature of the system is lower. This cycle is best explained using the pressure-enthalpy
graph of R134a, one of the refrigerants which are used in FlexiGen, as seen below.
1-2 Compression
The working fluid is first pressurized in liquid phase, using a pump.
2-3 Preheating
Heat transfer occurs from the heat source to the working fluid in the preheater, raising its temperature. The working
fluid is still in liquid phase here.
3-4 Evaporation
Heat transfer occurs from the heat source to the working fluid in the evaporator. The working fluid undergoes a
phase change here to become gas.
4-5 Expansion
The vapor is allowed to expand in the expander and is connected to a generator. This step produces electrical
energy.
5-1 Condensation
The remaining heat is removed from the working fluid in a condenser, where heat is transferred from the vapor to a
cooling source. The working fluid is now a low pressure liquid once again.
71
Generated power depends on the amount of released heat energy and the efficiency. Higher efficiency is achieved
with higher ΔT. Entrans helps to find the optimum configuration of efficiency and generated power for FlexiGen
which fulfils operating constraints and achieves customer-specific objectives.
Product Specifications
Electrical Output 25-70 kWel 70-150 kWel 150-300 kWel

Weight (tons) 3 4 7
Dimensions (hxwxl; m) 2 x 1.6 x 3 2.2 x 2.2 x 4 2.4 x 2.2 x 6
Note: FlexiGen P refers to the product line FlexiGen P50, FlexiGen P100, FlexiGen P250 with power drive only and are
available worldwide.
The product line FlexiGen 50, FlexiGen 100, FlexiGen 250 with power drive, heat pump and chiller mode. They are
available in the EU, US and Japan only.

Further information is available at the website: www.entransgroup.com or can be obtained from the email info@
entransgroup.com.
Contact Details
Main Office
Entrans AB,
Hammarby Fabriksväg 23,
120 33 Stockholm,
Sweden
Local Partner (India)

Nordic Cleantech Pvt.Ltd,
20/20 CDS Evergeen Enclave,
Velacherry, Chennai-42,
Ph - +91-9840933237
72
GL&V Sweden AB

GLV Inc. is a leading global provider of technological solutions used in water treatment as well as in pulp and paper
production. The Corporation operates in some 30 countries and has approximately 2,300 employees (as at December
31, 2010).
The Pulp and Paper Group designs and globally markets equipment used in various stages of paper production, from
pulp preparation to sheet formation and finishing. It also serves the global market with rebuilding, upgrading and
optimization services for existing equipment, as well as the sale of replacement parts. It ensures that its portfolio
consists of innovative products and technologies that bring added value to the customer, such as lower energy
consumption.

GLV’s main goal is to continue to strengthen its business groups’ position as leading global providers of water and
wastewater treatment and pulp and paper technological solutions to the market. In line with this, GLV will continue
to implement the Water Treatment and Pulp and Paper Groups’ business strategy.
3. About the Latest technology on the offering

a. Pulp & Paper Group
The Pulp and Paper Group of GLV is one of the largest suppliers of pulp and paper production equipment and a world
leader in existing equipment rebuilds, upgrades and optimization.
Key Strengths
The Pulp and Paper Group is a world leader in the sale of spare parts, in existing equipment rebuilds, upgrades and
optimization, as well as in the supply of new equipment.
The Pulp and Paper Group is recognized worldwide for its selection of fibre processing and pulp preparation
equipment. Many of its products are industry standards, such as Compact Press®, DUFLO® pumps, DUALOX®
mixers, SuperBatch® cooking process, Celleco™ pulp cleaners and disc filters, Beloit screening, washing and refining
technologies and IMPCO™ oxygen delignification systems. Among its innovative new products, the new DD®6000
refiner can improve fibre quality while reducing energy consumption and maintenance costs. Another leading
technology, the BTF™ automatic dilution system for paper machine headboxes, is the most efficient technology on
the market for improving sheet uniformity and operational flexibility. The Pulp and Paper Group also offers advanced
sheet formation technologies for improving stock drainage and sheet formation using an adjustable system. Finally,
it should be noted that some of the group’s equipment is recognized for its energy-efficient performance.
The Water Treatment Group (Ovivo) has a portfolio of technologies that include Moving Bed Bio-Reactors (“MBBR”)
and Submerged Aerated Filters (“SAF”) used by industrial and municipal systems for biological wastewater treatment.
Other products include Brackett Green’s technology for the screening of high-volume seawater and river water
intakes for power stations, refineries and desalination plants, which incorporate devices to protect marine life, as well
as a range of complementary technologies, notably for the washing and evacuation of wastewater. Furthermore,
clarifiers are on the list of the portfolio components most often targeted by the contracts awarded to the Group.
73
With the recent acquisition of CWT, the scope of its portfolio has expanded with additional technologies for seawater
desalination as well as water purification and ultrapurification. These are used in applications where obtaining a high
degree of purity is a critical factor, notably for the manufacture of components used in microelectronics.
Contact Details
Sweden Office
GL&V Pulp and Paper - an office of Groupe Laperrière & Verreault

Sweden AB.
Unit 7, 53 Gateway Boulevard / PO Box 1090
Epping VIC 3076
India Office
GL&V India Pvt Limited

Survey No 162/4A 5A,
Plot No 2 C, Off D P Road,
Opposite Tangent Furniture Showroom,
Aundh, Pune – 411007
Phone: +91 20 25800000
Fax: +91 20 25800213
Email : info.pune@glv.com
Website: glv.com
74
INNVENTIA
1. Introduction to Innventia
Innventia AB is a world leader in research and development relating to pulp, paper, graphic media, packaging and
biorefining. They generate, interpret and apply research results to create innovative products and processes. Their
science-based way of working allows them, in cooperation with their customers, to enhance all or any of the stages
in the innovation chain, from conception to final product, service or process. They contribute thereby to their
customers’ value creation. They call their approach boosting business with science. In April 2009 they changed their
name from STFI-Packforsk to Innventia.
2. Profile of the company: Areas of Expertise

Innventia is one of the world’s leading R&D companies with customers world-wide in the pulp and paper industry,
the packaging industry, the chemical industry, and the graphics business .
Innventia holds a unique position

the link between academic research and industrial applications, developing demonstrators and implementing
results
an international company, serving customers from almost every part of the world and co-ordinating
extensive networks
covers a large number of different fields, such as pulp, paper, packaging, graphics media, new materials and
biorefining
Industry-owned to a large extent:
The organization covering the whole value chain from material science to consumer value, from idéa to implementation
with 270 employees and Turnover of EURO 37 million (2010). They are industry-owned by 71%. The Group includes
PFI in Trondheim, Norway, LignoBoost Demo in Bäckhammar and Innventia UK Ltd. (Edge).
Sustainability
Research and development of efficient new processes and materials, especially products made from
renewable raw materials
Services aimed at improving sustainability performance and reducing environmental impact
Innventia services
Life cycle assessment (LCA)
75
Carbon footprint
Environmental indicators
Implementing corporate social responsibility (CSR)
Legislation and standardisation
Benefit from collaborative research
i. Cluster Research Programme

Several projects on different common themes run for 2 to 4 years
Companies minimise their risks by sharing investment costs in R&D
Partners benefit from joint results which can serve as platforms for further development and new business
opportunities
ii. Trade and Industry Groups

A number of companies work jointly to solve trade-specific issues and problems linked together by Innventia
researchers
Innventia is the co-ordinator of European research
Some examples:
SUSTAINCOMP: New advanced nanostructured wood-based biocomposites (€9.5 million, 17 partners)
BoostEff: Boosting raw material and energy efficiency using advanced sheet structure design and fibre
modifications (€11.7 million, 11 partners)
The ”EU Support Office” – an initiative that helps all Swedish actors in the Forest-based Sector to be successful in
European research.

a. LignoBoost – boosting pulp mills’ profitability
From fundamental research to industrial reality in less than 10 years
76
the LignoBoost process is a commercial and patented technique
extracts lignin from black liquor, a by-product from wood in the production of chemical pulp
increase the production of a normal pulp mill
LignoBoost Demo
Fig: Innventia demonstration plant in Bäckhammar, Sweden
Lignin as bio-fuel
lignin gives valuable income for example as a bio-fuel, replacing coal and oil
binding agent in biomass fuel pellet production to enhance the mechanical durability of the pellet
77
Carbon fibres and Activated carbon from Lignin
activated carbon is a valuable product that has been made from lignin
spinning threads of lignin for subsequent carbonation to carbon fibres
have a potential of replacing carbon fibres from fossil oil in different high value applications
b. Mechano-active materials
They respond to various stimuli as heat or electrical current. A variety of mechano-active papers are capable of
moving in exciting ways. They have a self-opening package. This package was designed in a cooperation with the
Swedish University College of Arts, Crafts and Design. It opens up when exposed to the heat in a kitchen oven.
78
c. Opto-active materials
Alter their appearance in response to changes in humidity, temperature, electrical current, etc. A thin paper coating
based on renewable materials that reacts to the moisture in exhaled breath
d. Nanocellulose
Nanocellulose is made from cellulosic fibres and forms viscous gel at low concentrations. It has many potential
applications, for e.g., as reinforcement in renewable composite materials, barriers for packages and viscosity improver
in food. New Pilot Plant at Innventia 2010.
79
Fig: Transparent film made from
nanocellulose manufactured at
Innventia.
e. Saliva detection paper

Saliva detection paper for Magle Life Sciences
New production technique to produce a paper which can trace the presence of saliva
Chemically modified starch on a filter paper surface for use in forensic laboratories worldwide
<1 year from concept to placing a finished product on the market
f. SOFA – Online Forming Analyzer

A tool for papermakers to monitor and control the web structure
First on-line measurement equipment in the wet end of the paper machine
Can be used in both single-wire and twin-wire paper machines
80
Fig: The SOFA System installed at the Korsnäs
Board Mill in Frövi
g. Stratified forming
Stratified forming
1. Reduces energy consumption and improves product properties
2. Paper grades with different properties and furnishes in the different layers
3. To be demonstrated in the BoostEff project
i. Parupu
Parupu
a new composite material based on cellulose and biodegradable PLA
by Södra Cell, architect and design firm Claesson Koivisto Rune and Innventia
On display at the Milan Furniture Fair 2009
Contact Details
Postal address
Innventia AB
81
Box 5604
SE-114 86 Stockholm
Sweden
Visiting address
Drottning Kristinas väg 61, Stockholm
Delivery address
Drottning Kristinas väg 61 B, 114 28 Stockholm
Phone: +46 8 676 70 00
Telefax: +46 8 411 55 18
E-mail: info@innventia.com
Website: www.innventia.com
82
IVL
1. Introduction to IVL Swedish Environmental Research Institute
IVL Swedish Environmental Research Institute is an independent, non-profit research institute, owned by a foundation
jointly established by the Swedish Government and Swedish industry.
IVL Swedish Environmental Research Institute was established in 1966 and has since then been involved in the
development of solutions to environmental problems, at national and international level. They work with applied
research and contract assignments for an ecologically, economically, and socially sustainable growth within business
and society at large.
The institute employs around 190 experts, which makes IVL a leading institute for applied environmental research
and consultancy services. They undertake research projects and contract assignments in the entire environmental
field. The activities include, for example, climate issues, environmental technology, indoor environment, waste
management, working environment, environmental measurements, and environmental quality evaluation.
2. Profile of the Institute: Areas of Expertise

IVL performs studies of the environmental effects in air, water, and soil, and the institute has its own accredited
laboratories for analysis. All activities are linked to six major theme areas: Climate and energy, Sustainable building,
Air and transport, Sustainable production, Resource-efficient products and waste, and Water.
The broad scope of IVL's activities, combined with its multidisciplinary approach, enables IVL to offer its customers
holistic solutions, as well as answers to highly specific problems.
IVL contributes with knowledge and tools for more environmentally-friendly products and processes in industry.
With the help of effective environmental management, social responsibility and sustainable working life, IVL offers
businesses and other organisations support in their work on sustainable development. Through a combination of
a system perspective and tailor-made environmental technologies in industrial processes, the most cost-effective
measures in from a life-cycle perspective and at plant level are identified.
With internationally renowned expertise in life-cycle assessment (LCA), carbon footprints and other tools, they identify
possibilities for improvements, environmentally-friendly product concepts, and environmental communication.
They perform modeling and process optimisation in collaboration with the industry to combine high-quality
products with reduced environmental impact. In their test laboratories, they adjust technical solutions for improved
energy efficiency and minimal environmental impact. They also contribute to organizational development through
improved methods of improving the physical working environment, improve operational management, enhance
comfort and improve the working climate.
Contact Details
IVL Swedish Environmental Research Institute Ltd.
P.O. Box 210 60
SE-100 31 Stockholm
The Stockholm office
Visiting/delivery address:
Valhallavägen 81
SE-114 27 Stockholm
83
Tel. +46 (0) 8 598 563 00 (switchboard)
Fax +46 (0) 8 598 563 90
E-mail: info@ivl.se
Website: www.ivl.se
84
KEMIRA
1. Introduction to Kemira
Kemira is a global over two billion euro water chemistry company that is focused on serving customers in water-
intensive industries. The company offers water quality and quantity management that improves customers’ energy,
water, and raw material efficiency. Kemira’s vision is to be a leading water chemistry company.
Kemira’s Strategy
Kemira focuses on water chemistry. Their core business consists of three customer-oriented businesses, Paper,
Municipal & Industrial, and Oil & Mining, which are extensively utilizing a shared product portfolio as well as their
know-how in water chemistry and product applications. They implement strategy through an integrated structure
and uniform processes and procedures.

Paper segment offers chemical products and integrated systems that help customers in the water intensive pulp
and paper industry to improve their profitability as well as their water, raw material and energy efficiency. Kemira’s
solutions support sustainable development. The business is divided according to the following customer segments:
Pulp, Printing & Writing, Packaging & Board and Tissue & Specialties.
Maximizing efficient use of water
Mission of Kemira is Efficient use and reuse of water. Vision of Kemira is a leading water chemistry company.
Offering
Competitive chemical products with reliable delivery.
Tailored chemistry and Monitoring, control and dosing support
Application expertise and support
Water chemistry technology
Production and logistics efficiency

Kidney technologies for Process water treatment. Chemical kidneys can be applied for
Recycling of coating colours
Treatment of highly polluted effluents
Bleach plant closure
85
Improvement of product quality
Examples of kidney technology in pulp mills:
Removal of extractives in Mechanical pulp production e.g. PGW/CTMP and Chemical Sulphite/dissolving
pulp production.
Removal of NPE (Non Process Elements) and recycling of chelating agents (EDTA) in Kraft mills. Closed-loop
bleach plant operation can be an alternative to effluent treatment. Reduction of Water usage with improved
or maintained Pulp quality. For example: Bleach Plant Effluent reduced to 3-4 m3/t pulp and COD < 10 kg/t
pulp
After the bleach plant in the Post screening/Pulp dryer area
Effluent treatment: Removal of organic pollutants by oxidation and coagulation, especially:
Low molecular mass compounds
Chelating agents (EDTA, DTPA)
Recalcitrant COD
AOX, Chlorophenols
Colour
Removal efficiencies are normally 80-90%. See the following graph for % removal of organic pollutants.
Fig: % Removal of organic pollutants by Oxidation and Coagulation
Global product portfolio

Coagulants, Polymers, Sizing agents, Dispersants, Defoamers, Biocides, Colorants, Specialties and related on-site
chemical preparation, dosing, control and monitoring tools.
For pulp production: Caustic, Acids, Chlorate, Chlorine dioxide, Peroxygens and Reductive bleaching agents. Some
of the products will be available from production sites in India during 2012.
Contact Details
Main office
86
Kemira Oyj
Porkkalankatu 3
P.O. Box 330
FI-00101 Helsinki, Finland
|Tel +358 10 8611
www.kemira.com
India Office
Kemira Chemicals India Pvt Limited
2nd Floor GHB House
Plot No 264/a/2, Road No 10, Jubilee Hills
Hyderabad – 5000033 AP India
Tel +91 040 2355 7082 / 83
Fax +91 040 2355 7081
87
LORENTZEN & WETTRE
1. Introduction to Lorentzen & Wettre
Lorentzen & Wettre is the leading manufacturer of equipment for quality control and process optimization for the
pulp and paper industry worldwide.
Facts about L & W

The company is founded in 1895 and have representation in 50 countries. The company is AAA-rated for more than
15 consecutive years. It is a member of the ABB group since September 2011.
In India they are represented by Elof Hansson International AB, until September 12, 2012. New organization for service
and support will be built up through their owner, ABB.

Lorentzen & Wettre is to provide the world's pulp and paper industry with advanced equipment for quality control
and process optimization from a position as the market and quality leader.
They shall analyse customers’ needs and recommend solutions that contribute to their profitability. They do this by
initiating lasting improvements within quality control and process optimization.
They have about 25 instruments in portfolio. All are known for high precision and reliability, easy to use, uniform
operator interface and are according to standardized industry testing methods.
L&W Autoline 400 is a 4th generation system which measures according to standards. It verifies quality/optimize
paper machine and has fast feed back to production. It is operator independent.
They have about 20 instruments in portfolio which minimize variations, improve quality and increase production.
Lorentzen & Wettre’s products contribute to improving paper quality, reducing manufacturing costs, and reducing
the consumption of raw materials and energy.
Their solutions range from automated fibre and pulp analysis, consistency transmitters, moisture sensors, all kinds
of laboratory paper testing instruments, automated paper testing system, to different kinds of service agreements.
Products from Lorentzen & Wettre are a safe investment, and provide pulp and paper mills with satisfied customers
and greater profitability, all over the world.

Paper Testing
The need for superior quality paper grades that are both versatile and consistent has never been greater. Therefore,
today’s papermaker relies upon many sources of information and measurement tools to assist in producing a product
that meets or exceeds these demands. Although there are many and varied online sensors, these are not enough
to present a total and clear picture of the paper machine’s performance. Quality testing data from an off machine
source is required.
Pulp Testing
The fibre language gives you new possibilities. Modern optical technique makes it possible to analyze fibre properties
88
statistically and in detail. Since the measurements are automatic with good repeatability they are suitable for online
measurements. For example paper strength properties can be predicted quite well from the fibre properties including
coarseness.
Runnability problems in the paper machine and paper quality deviations can be created from different types of fines,
shives or vessel cells in the pulp. The problems can also be a result of unknown variations in fibre mix, fibre quality or
refining. If appropriate pulp quality properties are measured continuously in the process it is easy to see correlations
with other things happening in the process and this enables taking correct actions and strategies based on measured
facts. Early detection of deviations in quality makes early corrective actions possible. A uniform pulp quality creates
the best situation for optimization of the paper machine, which is the base for a uniform paper quality, and is the
most important quality property in itself.
Paper Machine Optimization

Paper manufacturing is one of the most complex industrial processes in the world today. It is, of course, impossible
to manually control all the settings of a modern paper machine. The speed of the manufacturing process and the
quality requirements of the finished product are such that it is only by using modern measurement and control
techniques that it is possible to achieve quality targets.
Lorentzen & Wettre’s moisture sensors are used throughout the entire paper manufacturing process; in the forming,
pressing, coating and drying sections and are finally applied to the finished paper.
The most common measurements carried out by Lorentzen & Wettre’s handheld portable meters are moisture
content and felt permeability in the press section. Requirements for measurements of new properties in the process
are continually on the increase.
Service and Support

Lorentzen & Wettre offer preventive maintenance, service and calibration worldwide. To ensure customer’s access to
support and service, they offer a unique network with global coverage.
Their service and support covers everything from the basic service contract where they visit their customers regularly
to perform preventive maintenance and calibration of the instruments, to the complete full service contract that
comprises several planned visits per year and all necessary consumables.
Some of the instruments that are provided by Lorentzen & Wettre are given below:
1. L&W Moisture Tester

L&W Moisture Tester is the ultimate offline moisture measurement solution for paper, paperboard, corrugated board,
dry pulp, and other fibre materials. It measures moisture content at all stages of the process chain. Thanks to the
quick measurement procedure, L&W Moisture Tester can also be used for product checking when online moisture
sensors indicate out of specifications.
89
Benefits
Time saving (replaces the gravimetric method), the measurement takes only a few seconds
Measurement results are not affected by curled materials, uneven surfaces or multilayer structures.
Well proven micro wave measurement method
Suitable for trouble shooting
Back-up for online moisture sensors
2. L&W Compressive Strength Tester STFI

L&W Compressive Strength Tester STFI measures the compression strength of liner and fluting. Compressive strength
determines the stacking ability of corrugated boxes. The aim is to produce strong boxes, and at the same time use a
minimum of raw material.
Benefits
Proven measurement technology, SCT is the best method for optimization of compressive strength
Strip feeder for fast and easy testing
The built-in moisture sensor corrects all measurement values to give strength at standardized moisture
content
3. L&W PPS Tester

L&W PPS Tester measures the surface roughness of coated and calendered printing and writing paper. The method
is also used for measuring the surface roughness of newsprint. The instrument estimates the air leakage between the
paper surface and a thin metal band under conditions that simulates the printing process. The result is a significant
factor in determining the printability of paper and paperboard.
90
Benefits
L&W PPS Master Kit included. Paper samples and backing traceable back to L&W PPS reference instrument
Auto-start, a photocell detects the presence of a sample and automatically initiates a measurement sequence,
thus allowing hands-free operation
Auto-cycling function that permits the continuous cycling of the upper pressure foot to facilitate
representative and continuous measurements
Integrated check function for air pressures, three air flows and three clamping pressures for reliable
readings
4. L&W Bending Tester

L&W Bending Tester measures a material’s resistance to bending. This can be done either by measuring the force
needed to bend a test piece to a predetermined angle or by measuring and determining the bending stiffness,
which is an elastic property of the material. Bending resistance and stiffness affects the product performance in many
converting operations and is important in handling and protection purposes of packaging products.
Benefits
Pneumatic clamping of the test piece for repeatable measurements
Test piece support for correct clamping
Auto-touch function of the load cell against the test piece gives relaxed and operator independent test
results
Creaseability evaluation used for prediction of converting performance included
91
5. L&W Crush Tester
L&W Crush Tester tests corrugated board, liner and fluting as well as performing compression tests on small boxes.
The instrument measures new crush properties such as flat crush hardness and the total energy absorbed during a
FCT measurement. A built-in plate distance sensor can also be used to measure the corrugated board thickness.
Benefits
Easy to use with pre-programmed start position and evaluation of measurements, all for easy shift between
measurements such as RCT and ECT
Robust construction for reliable measurement results, especially important when measuring FCT so that the
test piece does not shear and cause “leaning” flutes
Gives automatically correct FCT value – Manual settings for each flute type is not needed
Measures new crush properties such as flat Crush Hardness, flat crush energy and flat crush stiffness
6. L&W Gloss Tester

L&W Gloss Tester measures gloss, which is an important property in the production of paper of high print quality. A
paper with high gloss gives good print quality and contrast, but too high paper gloss can reduce readability because
of reflection. To achieve a good compromise the paper’s gloss must be optimized.
92
Benefits
Suction plate with firm holding of sample, keeping the sample flat during measurement
Inspection hatch with light source for measuring a selected spot
Sturdy design for data confidence, the optical system has standardized sample backing
Check and calibration standards are easy to access meaning no specific operator skills needed. The standards
are also well protected from damage and contamination.
Immediate report of instrument check, calibration and measurements
Automatic start of measurement with sample sensor
Easy to replace lamp
7. L&W Bursting Strength Tester

L&W Bursting Strength Tester measures (according to Mullen) bursting strength of paper, paper board, and
corrugated board. Furthermore it also measures bursting energy absorption (BEA) and diaphragm-compensated
bursting strength. Bursting strength is a traditional measure of paper strength and it is also a test requirement for
corrugated board.
Benefits
Very fast testing cycle gives fast feedback to the production
Auto-start, a photocell detects the presence of a sample and automatically initiates a measurement sequence,
thus allowing hands-free operation
Auto-cycling function permits the continuous cycling of the upper pressure foot to facilitate representative
and continuous measurements
Available with automatic test strip feeder
8. L&W Autoline 400

L&W Autoline 400 is the fastest and most accurate automatic system for paper testing on the market. More than 50
properties can be measured and calculated within a few minutes. Short feedback time is a very important part of the
process control. Everything from newsprint to heavy linerboard and cardboard can be measured by L&W Autoline
400.
93
Benefits
Measures and calculates more than 50 different properties, most of them according to international
standards
Warning alert if the measurement results are outside specified targets and limits
Fast – about 8 minutes to measure a profile at 20 positions
Results are easily accessible via the mill’s local area network
Several pre-programmed testing sequences available
Remote viewing station provides real time data
9. L&W Felt Moisture Meter

L&W Felt Moisture Meter measures moisture in both machine direction (MD) and cross direction (CD) up to 3000 gH2O/
m². The instrument can also measure felt length as well as giving measurement positions. Regular measurements
with L&W Felt Moisture Meter are the key to optimal dewatering in the press section and lead to fewer problems
with machine disturbances and downtime – which in turn means substantial cost savings. Effective dewatering in
the press section can reduce energy consumption in the drying section and increase production considerably; a 1%
increase of the dry content in the press section gives 4% reduction in energy use in the dryer section.
94
Benefits
1% increase of the dry content in the press section = 4% reduction in energy use in the dryer section
Pinpoints any problems in the press felt
Access to comprehensive data
Control felt quality and reduce production costs
Enables you to take the right action in time
10. L&W Felt Permeability Meter

L&W Felt Permeability Meter measures water permeability of the press felts. The instrument also measures felt
length as well as giving measurements positions in relation to the machine width. It can be used for optimizing the
conditioning system as well as for quick trouble shooting. By measuring the water permeability, clogging and wear
are easily discovered, and the potential to optimize the pressing with regards to paper quality and dewatering is
made possible. L&W Felt Permeability Meter provides you with the best possible knowledge about the condition of
the press felts. This enables you to optimize dewatering and reduce costs significantly.
95
Benefits
Reduce energy consumption
Balance chemical usage
Reduce emissions
Reduce wear and maintenance requirements
11. L&W Fiber Tester

L&W Fiber Tester measures fibre quality quickly and easily and is at the same time an instrument for advanced analysis
of fibre dimensions. The measurement technology is automated, which enables frequent analysis of pulp quality.
The instrument is intended and optimized for laboratories and has a compact design.
Benefits
Fast classification of pulp quality
Early detection of deviations in pulp quality
New properties to define pulp quality
Compact design
Sample feeder
Proven measurement methodology
Self cleaning measurement cell
12. L&W Pulp Disintegrator

L&W Pulp Disintegrator conforms to industry standards for pulp disintegration. The pulp container is made of
stainless steel for durability and ease of cleaning, and the ergonomic design ensures that the instrument is easy and
safe to use.
96
Benefits
Ergonomic – electrical lift
Double interlock system ensures safe operation
Direct drive – less parts and less noise
Spill proof opening
Waterproof controls, sealed bearings and enclosed motor
Conforms to industry standards
Minimum of maintenance
13. L&W Pulp Tester

L&W Pulp Tester is a reliable, repeatable and cost-effective online system for process and laboratory control of pulp.
No matter what pulp is produced, it is important to fully understand the process and have reliable data. L&W Pulp
Tester measurements conform to established standards and together with the latest and fastest technique it is a
major help in achieving uniform paper quality and stable runnability.
Benefits
Automatic and online
Measurements according to standards
Quantitative measurements in one system
Minimize web breaks and optimize production
Increase mill productivity and profitability
Optimize usage of raw material
Control grade changes
14. KC/3 Blade Consistency Transmitter

KC/3 Blade Consistency Transmitter is a reliable and maintenance free transmitter. Its patented, shock resistant seal-
less transfer mechanism with unbreakable diaphragm makes it the only transmitter in the market with no moving
parts or o-rings seals in the transfer mechanism, making it impossible for process liquid to leak inside sensor. All
wetted parts are constructed of titanium. It is a 2-wire transmitter with modern Hart technology, and no external AC
power supply is needed.
97
Benefits
Installation to Sandvik NS70 Saddle
Fits to standard process coupling of Valmet Pulp-EL and Smart-Pulp, BTG MBT and SBT.
All parts easy to replace in the mill with standard shop tools
Gap measurement probe and electronics can be changed and tuned without taking transmitter off from
process
Quick-Cal procedure: Automatic calibration parameter tuning and position adjustment when laboratory
consistency value is entered
Low installation and lifetime costs
15. KC/5 Rotary Consistency Transmitter

With its wide range sensor, KC/5 Rotary Consistency Transmitter is applicable to all consistencies between 1.5–16%
With the patented built-in gate valve assembly, the transmitter can be installed and removed while the process is
running and with the revolutionary direct-drive servo motor KC/5 requires no maintenance, since there is no belt to
change.
Benefits
No wearable drive belt (direct-drive servo motor)
No wearable motor parts- no bearings- no brushes
Removable without process shutdown- field repairable by normal hand-tools - remote display included
Wide-range measurement sensor, applicable to all consistencies between 1.5–16%
Automatic maintenance like powerful self diagnostics includes friction measurement, reverse direction
rotation to check zero point and automatically loosen foreign objects.
16. L & W Consistency Meter

L&W Consistency Meter measures the amount of water at various stages after the forming section. Measurement
results make it possible to see if all dewatering elements are correctly adjusted in relation to the product that is
currently being produced. It is designed to analyse, and optimize dewatering in paper, board, and pulp machinery.
With L&W Consistency Meter one can gain control of drainage at the forming section so that such things as fibre
orientation, formation, and the distribution of fine particles are correct.
98
Benefits
Reduced energy consumption
Balanced chemical usage
Reduced emissions
Reduced wear and maintenance requirements
No radioactivity (High frequency technology)
17. KB² Fibre-Optic Sheet Break Detector

KB2 Fibre-Optic Sheet Break Detector is the new generation sheet break detector that with the latest RGB technology
enables 50 % more light with effective power LED. This allows longer measurement distances and operation in
high ambient light condition. KB2 is the perfect choice for installations in unclean, steamy and high temperature
environments or where the space is limited.
Benefits
Non-contact optical sensor
Reliable in harsh environments
Air purge system
99
Not affected by dirt, steam or high temperatures
Fast break detection
Handles all paper and board grades and applications regardless of colours
Detects breaks even against a cylinder
Easy to setup
Large graphical display and logical user interface
Proven with hundreds of installations worldwide
18. KPM Pulp Samplers

KPM Pulp Samplers provide representative sampling from the process line safely and diminishes errors by the
operator. The sampler breaks through the water layer inside the pipe, eliminating dewatering from the sampling
process.
Benefits
Screened and unscreened pulp with knots, shives and trash allowed
Cutting edge in piston
Pneumatic operation
Adjustable stroke length and piston orientation
Flushing water connection
Switch included to operate pneumatic sampler
Material SS 316L, Titanium available on request
Contact Details
Head Office
Mikael Nilsson,
Area Sales Manager,
Email: mikael.nilsson@l-w.com
100
Address
AB Lorentzen & Wettre
Box 4
SE 164 93 KISTA
SWEDEN
Visitors: Viderögatan 2
Phone: +46 8 477 90 00
Fax: +46 8 477 91 99 Sales
+46 8 477 90 25 Service
+46 8 477 90 10 Accounts
Email: info@l-w.com
101
MEVA INNOVATION AB

MEVA Innovation AB is a part of MEVA group. MEVA group of companies is working in the energy sector and that
purposefully maintains a high level of development in their respective technical areas.

Meva Innovation AB is a company focused on research, development and commercialization of small-scale
technology for high-efficiency cogeneration gasification of biomass. The company, with very large internal and
external expertise, developed VIPP - Vortex Intensive Power Process and found sustainable technical solutions to
previously less-efficient technologies and can now present a highly reliable and cost concepts.
3. About the Latest technology on the offering - VIPP - Vortex Power Process Intensive
Background
Department of Energy Engineering at Luleå University of Technology (LTU) began in the mid 90s to develop cyclone
gasification technology in cooperation with national and international partners. The former prototype of cyclone
gasifier basis was developed and built at the Energy Technology Centre in Piteå (ETC).
Meva Innovation AB has acquired the rights to the technology and further develop this in collaboration with the ETC.
A complete pilot plant has been built where further research and development of technology in collaboration with
the ETC.
VIPP-concept based on the gasification of biomass in a very carefully designed cyclone reactor after which cools and
purifies the gas in a multistep process. The result is a high grade fuel gas to drive an ideal gas engine or gas turbine
to generate electricity. In addition, heat is recovered from the whole system to such use in a district heating or for
local heating. Other applications include combustion of fuel gas in conventional Mesa boilers or furnaces. More
applications are, after further conditioning of fuel gas producing automotive fuels.
Potential benefits
Economy:
Then VIPP system has a high overall efficiency and significantly fewer installed components compared to other more
conventional cogeneration system, the total investment cost be kept low and therefore also reduces the production
cost per kilowatt hour.
102
Biomass as a fuel in turn means big savings in operating costs compared to fossil fuels when you can exercise the
right to electricity certificates.
Environment:
The outside world increasingly demanding low emissions is VIPP system with biomass as fuel and with its high
efficiency is a natural choice of small-scale CHP technology.
Development and production of VIPP system permeates large environmental thinking. All components and systems
that are built into the system pass their internal environmental audit on the material content and design.
Gas Cleaning System

VIPP ECP is ideally suited for purification to obtain the producer gas required to be used in the present application.
Since the pure fuel gas can be used to power gas turbines, it contain only very low levels of tar and particulates.
In other bio-gasification project has often overlooked this and therefore have Meva Innovation developed VIPP-ECP
to ensure long-term and continuous operation of the system.

For further information please visit the website:
ww.mevainnovation.se
Contact Details
Mr. Hakan Holmberg
Brogatan, S-931 62 Skelleftea
Sverige
Tel: 091020 01 90
Email: hakan.holmberg@mevagroup.se
103
MoRe RESEARCH
MoRe Research has been active in research, development and improving process efficiency for more than 100 years.
Once, part of the MoDo Group, MoRe Research is now an independent research and development company. They
offer production-related services and modern process optimisation, increasing the profitability of pulp, paper and
biorefinery operations.
The best results are achieved by working closely with the customers. MoRe Research works on a project basis with
mill-based development groups, from project specification to implementation and follow-up. The customers always
own the results and information produced, and non-disclosure agreements for strategically sensitive projects can be
signed.

Focus areas of MoRe Research are Hela vägen® (“All the way”), Analytical Services, Biorefinery, Education and Process
Emergency. MoRe Research is organised in two departments; Process Technology and Analytical Techniques.
Hela vägen®
MoRe Research’s concept, Hela vägen® (All the way) of studying and optimising every stage of the production process,
has been at the heart of MoRe Research’s methodology for many years. It is a holistic, intellectual approach with an
understanding of how all process steps affect each other and the end product. The methodology always keeps cost
effectiveness and the quality of the end product in focus.
Hela vägen® brings together the expertise, methods, testing equipment and laboratory resources at MoRe Research
and concentrates on an affordable, high-quality end product. This approach provides unique opportunities to
implement rapid and economical optimisation measures in the process. Whether an entire production line or just
a single process step is studied, MoRe Research has the knowledge and the understanding to manage the whole
process.
Biorefinery
In order to replace fossil materials as energy sources or as raw materials, biorefinery technologies are developing
rapidly all over the world. MoRe Research is at the forefront of this development. A strong driving force to this is the
determination to maximise the usage of wood raw material.
MoRe Research has the competence and the special pilot testing equipment needed for successful developments
in biorefinery technologies. The set of digesters, ultra filtering and reactor equipment, combined with their analysis
methods, support the customers’ biorefinery development. It is self-evident that the work carried out to create value
from the by-products of the pulp process must be done without disturbing normal production or impairing the end
products.
Analytical services
Analyses are an important basis for critical decisions in production, marketing and research. The analytical services are
built on an advanced laboratory infrastructure, a comprehensive range of advanced analytical equipment, expertise
104
in many areas, extensive experience and good process knowledge.
Picture 1: MoRe Research has an array of

advanced analytical equipments to conduct
almost any analysis for the customers
MoRe Research is a powerful resource for chemical, physical and graphical analysis. Customers make good use of
the services and look to MoRe for problem-solving techniques and suggestions. Irrespectively if it is a question
about routine analyses or special analyses, MoRe Research acts as a central laboratory or as an integrated part of the
customer’s own resources.
Process emergencyTM
ProcessakutenTM (process emergency) is a new tool available to solve mills’ urgent process problems. With short
notice, a hands-on team is ready to solve the problems by combining process data analysis, information from the
mill’s own staff, special analyses and studies in laboratory or pilot scale.
Education
MoRe Research has extensive competence about the pulp process chemistry and related analysis. Since ten years
MoRe Research cooperates with the training company P&L in (e.g.) certifying process workers within pulp cooking and
bleaching as well as for laboratory workers. Customised educations for any need within pulp, paper and biorefinery
areas can be organised.
3. About the latest services on the offering - The pilot machines optimise customer profitability
in a cost-efficient way
MoRe Research has a pilot plant and laboratory resources covering the whole process, from raw material to pulp,
paper and biorefinery products. In the pilot tests, realistic studies can be performed and mill trials designed in an
economical and technically productive way. The pilot machines are the same scale as each other, supporting the
Hela vägen® approach without bottlenecks, and all resources are located at the same premises.
Along each step of the process MoRe Research can conduct comprehensive analyses of wood, pulp, paper and
process liquids using advanced analytical resources.
Digester
The flexible pilot digester, which is unique in the world, offers tremendous opportunities for both pulp cooking and
biorefinery studies.
105
Picture 2: MoRe Research has a purpose built
pilot digester, unique in the world, for sulphite
and sulphate cooking methods for pulp mills and
biorefineries
Ultrafiltration
Using various kinds of membranes, valuable components are filtered out of process liquids and effluents.
Oxygen delignification and bleaching

All stages from oxygen delignification until final bleaching can be performed in the bleaching pilot plants.
Viscose pilot plant
All manufacturing stages from dried specialty cellulose until finished viscose solution can be simulated.
Dynamic sheet former

The dynamic sheet former, the Formette, can be used to manufacture paper from 30 GSM to cardboard in several
layers up to 280 GSM with the product properties achieved on a large paper machine.
Experimental paper machine

A unique paper machine that can produce paper in grammages between 30 and 200 GSM. Fitted with a Yankee
cylinder for tissue manufacture, the lowest grammage limit of is 15 GSM.
Coater
For conventional coating and surface sizing.
Troubleshooting
Various microscope techniques and chemical analyses are used to solve problems in connection with operational
disruption and end products.
106
Picture 3: The experimental paper machine is
very flexible and can produce tissue and paper in
grammages between 15 and 300 g/m2
Picture 4: By combining the analysis results from

microscopy and analytical methods, troubleshooting is
done in a very efficient way

MoRe Research is based in Örnsköldsvik in Sweden but is active in many countries, also in India and Thailand and has
hence routines for getting samples for analysis from far away.
More information can be obtained via direct contact and/or by visiting the web site www.more.se.
Contact Details
1. Stefan Svensson, MD, MoRe Research AB
Tel. +46 660 750 35, mobile +46 70 234 83 00,
email: stefan.svensson@more.se
2. Magnus Edblad, Process Consultant, MoRe Research
Tel. +46 660 750 23, mobile +46 70 204 98 85,
email: magnus.edblad@more.se
Address
MoRe Research AB,
Box 70, SE-891 22 Örnsköldsvik, Sweden
107
NOSS
1. Introduction to NOSS
Advanced fiber development systems
Noss is a Swedish company group serving customers in the pulp and paper industry around the world. They supply
advanced Fiber Development Systems comprising equipment for hydrocycloning, screening, thickening, fiber
fractionation, deaeration, refining and bleaching.

Noss’s extensive technological and human resources enable them to provide complete system deliveries comprising
everything from a single machine to turn-key installations.
Noss focuses on customer-oriented solutions in order to enhance process performance and to achieve the fiber and
paper characteristics demanded by the end-user.
Noss provides
Feasibility studies
Project management
Process engineering
Mechanical engineering
Procurement of auxiliary equipment
Construction management
Turn-key Installations
Noss undertakes the supply of complete turn-key installations including the procurement of suitable auxiliary
equipment, which enables them to take full responsibility of the installation.
Detailed Engineering
Noss provides detailed engineering for all disciplines such as mechanical automation, electrification, piping etc.
Noss’s highly skilled professional engineers combine their experience and know-how with the latest CAD system in
order to meet today’s and the future’s rigorous demands.
108
3D model of a Noss installation
RADICLONE
Hydrocycloning Systems for high quality pulp, paper and board
RADICLONE AM80: Efficient fiber development process for heavyweight
contaminant removal and fractionation
RADICLONE BM80: Efficient fiber development process for separation of
lightweight contaminants and thickening
RADISCREEN
Pressurized screens for knotter, fine, coarse and machine screening
RADISCREEN-K is a Knotter Screen. RADISCREEN-F is a Fine Screen.
RADISCREEN-C is a Coarse Screen. RADISCREEN-M is a Machine Screen.
PERISCREEN
PERISCREEN-M is a Machine Screen for all stock types and applications
Low energy consumption
Reliable operation
Low pulse
PERISCREEN-F is a Fine Screen for all pulp types and applications
High and low consistency applications
Low energy consumption
Slotted or perforated screen baskets
109
PERIVAC
Perivac is a Space-saving Deaerator for efficient air removal
High production
Low power consumption
Reliable operation
The PERIVAC deaerator is designed for most efficient removal of both free
and dissolved air as well as other gases from paper stock suspensions.
RADITRIM
Raditrim is a Secondary Knotter Screen and Tailing Fine Screen
RADITRIM-K is most efficient, totally enclosed secondary knotter screen
for high yield at low energy consumption.
RADITRIM-F is a completely enclosed Tailing Fine Screen combining shive
separation and thickening with effective fiber recovery
PERICLONE
PERICLONE Hydrocycloning Systems for all stock types
Reliable operation
Innovative design
Easy maintenance
PERICLONE A125 is a pressurized hydrocyclone bank system used for
different cleaning purposes in the pulp and paper industry, such as paper
machine approach flow systems, recycled fiber systems etc.
Fig: Board Machine Approach System
Laboratories and Pilot Plant : Customer-oriented Research & Development
110
Development of new processes and equipment
Noss puts high emphasis on the continuous development of new processes for the pulp and paper industry. In close
cooperation with their customers Noss meets the challenge of finding solutions to future problems and requirements,
taking into account customers' own experience and specific knowledge.
The activities at their Research and Development Department constitute the basis for the implementation of new
systems and machinery.
Fiber related studies and research

In the well-equipped laboratories of Noss, they can carry out virtually any kind of fiber related study. They undertake
analyses and investigations of paper characteristics, fiber properties, impurities and printability as well as dynamic
flow processes.
Fig: Microscopic analysis at Noss Laboratories
Fig: Advanced analysis methods are the basis for

continuous research
111
Fig: Noss full-scale pilot plant is adapted to perform reality-based
trials for a variety of processes
Customer trials
Noss perform customer trials both at their pilot plant in Norrköping and on site with mobile equipment. These
experiments, carried out with the collaboration of customers, are of vital importance in the constant quest of finding
optimal process solutions. The pilot plant includes equipment for screening, cycloning, fractionation and selective
treatment, such as beating and refining.
Contact Details
Main Office:
Noss AB,
Box 20, SE-601 02 Norrköping,
SWEDEN
Telephone: +46 11 23 15 00
Telefax: +46 11 13 59 23
E-mail : info@noss.se | www.noss.se
India Office:
1. eintec
Vijay Singhal
A-30 Upkar Apartments, Mayur Vihar, Phase-1
Delhi - 110 091, INDIA
Telephone: +91 11 2271 5075
Telefax : +91 11 2271 5098
Mobile: +91 99 1010 6568
E-mail: vijay@eintec.in
2. eintec
L.S. Meyappan
GF#17 Sreevatsa Square, 7/31-A. Metupalayam Road, Thudiyalur Post,
Coimbatore - 641 034, INDIA
Telephone: +91 422 264 5815
Telefax : +91 422 264 5814
Mobile: +91 999 429 8526
E-mail: meyappan@eintec.in
112
PROMT AND FRONTWAY
1. Introduction to PROMT and FrontWay
1.1 PROMT
PROMT is an independent design and trading company, based in Sweden and committed to be their customer’s
partner for complete projects and for contract management.
They offer qualified services and a broad international network of experienced partners in the field of plant design,
relocation- and upgrading of entire industries, chosen parts of machinery or in the matter of finding/ installing the
suitable equipment.
1.2 Frontway
FrontWay delivers front end simulation products, services and system solutions to the pulp and paper industry. The
focus on energy savings is high. FrontWay is situated in Norrköping, privately owned and has been in operation since
2004.
FrontWay is participating in several research projects and makes unique solutions on standard platforms. The
combination of research, practical skills and former management experiences from the Pulp and Paper Industry, is
unique in the way of delivering a system solution. FrontWay sells “system solutions” that works!

2.1 PROMT
The business idea of PROMT:
PROMT is a Swedish company which relocates, upgrades and optimizes process plants for the industry and, by their
unique competence, design and deliver flexible, tailor-made solutions to their customers worldwide.
Their main business areas are
Plant relocation
Plant engineering
Energy optimization
2.2 Frontway
The business idea of FrontWay:
"Deliver Products and consultant services for energy savings and CO2-minimization"
FrontWay have software that supports its customers’ needs and demands. The software are named PaperFront,
BalanceFront and BenchFront. The main uses are within pulp- and paper industry. The e-sim concept, is utilizing the
benefits from the software above.
3. About the latest technology on the offering - Efficient Simulation and Implementation
Method
In joint cooperation FrontWay and PROMT has developed the energy optimization concept e-SIM, efficient Simulation
and Implementation Method.
113
Background
The background for this concept is the growing need of effective and profitable solutions of energy savings within
the process industry of which both PROMT and FrontWay has the competence to provide. The concept covers
process systems close to the production units, e.g. stock preparation systems, WW systems, spray water systems,
vacuum systems etc, etc. But is not limited to only the Pulp & Paper processes but all kind of processes where a media
is transported.
The e-SIM concept is based upon a systematic approach, minimizing the time to find the most effective and profitable
energy savings either for a complete plant or for a system. The steps are following:
1. Selection of a process section
2. Collection of data and build a model in PaperFront®
3. Simulation of all operation modes, products and recipes in PaperFront®
4. Evaluate and select sections with high potential for savings
5. Detailed, on-site mapping of the selected sections
6. Calculation and simulation of efficient alternatives
7. Analysis, report and proposal for changes or rebuild
8. Investment ecalculation and quotation for a rebuild
9. Implement the changes
Potential benefits
Using the e-SIM concept will result in, after only a few weeks work, that the customer will get:
Potential energy savings of 15-25 %
Identified energy efficient investments with a pay-off < 2 year
LCC savings 10 times the investment
A qualified analysis of the complete process system(s)
Identification of the most profitable actions
Investment estimate
Updated process plant documentation
114
A tool for continuous optimization and planning
Improved process knowledge for the customers O&M staff
Case study
As an example, e-SIM were used for a large pulp & board plant in Sweden. During 2 months the following were
done:
1. Simulation covered 130 pumps, 19 production recipes, 100 settings / scenario
2. Screening (OK pumps, intermittent operation, emergency operation etc.).
3. 6 pump sections were selected
4. Mill mapping on site were made in two days
5. Detail simulation – Comparison with alternative solutions done by engineers
6. Evaluation – change of pumps, speed control, change of control philosophy
7. FrontWay made the programming and simulation
8. PROMT made all detail mapping, analysis and proposal for changes
9. PROMT offered the whole rebuild/modification project
Results:
6 pumps identified for large savings potential
Savings potential = approximately 12,00,000 kWh/annum
Reduced CO2 - emission = approx 200 MT/a
With an energy price of 0.06 €/kWh savings were 78 000 €/annum
In principle 3 solutions for changes :
• Speed control
• Change of pump wheel
• Change of pump
The customer got a State-of-the-art control over the process with the PaperFront® tool
Other benefits
All modes of operation are simulated, also the complex ones
Clear and overall picture over the entire process and its bottle necks
Improved energy efficiency = increased availability (Inefficiency = heat + friction = wear)
Customer key persons are involved
The most profitable investments are identified
Improved process knowledge for the staff
New products and modes of operation can be studied and simulated
Approximate Investment and pay back period at Present Value

The e-SIM concept is a flexible method, ranging from part of processes up to entire plant systems, hence the
investment will be dependant upon such factors as complexity, availability of technical data, extent of the systems,
availability of the customers own operative staff etc. As an indication, the investment in the e-SIM concept will result
in pay-back time of less than one year, if the proposed actions for energy savings are implemented.
115
Sources of further Information
Please refer the following websites for further information:
PROMT : http://www.promt.se
FrontWay : http://www.frontway.se
Contact Details
PROMT
PROMT International AB,
Drottninggatan 40,
SE-652 25 KARLSTAD,
Sweden,
www.promt.se
Telephone: +46 (0)54-241 00 00
Telefax: +46 (0)54-241 00 10
FRONTWAY
Office: +46(0)8 559 221 48
Cellphone: +46(0)708 15 58 12
E-mail: General Information: info@frontway.se
Office Address
Post Address: FrontWay AB, SE-601 86 Norrköping
Visiting Address: S:t Persgatan 19, Norrköping
Website: www.frontway.se
4. Conclusion
The e-SIM concept is a unique method to rapidly and cost-efficient trace and find the most energy effective solutions
in complex process systems, taking into consideration all different modes of current – and future – operations as well
as extreme situations, e.g. shut-downs, sheet-breaks, catch-up operation etc. The customer will take the advantage
of the latest simulation technology and experienced experts for analyzing his specific production plant, finding the
most profitable changes in order to have an energy efficient and sound production. The concept is not only limited
to Pulp & Paper industry but for all other types of process industry.
116
PURAC
1. Introduction to Purac
Purac is a part of Läckeby Water Group, an independent, privately-owned Swedish Group, which offers contracting,
products, and servicing for water treatment and biogas production.

Purac offers contracting for customers worldwide. They design and build treatment plants for wastewater, drinking
water and process water, as well as plants for biogas production and gas treatment. To date, they have completed
more than 4,000 contracts in 70 countries worldwide, primarily in Europe and Asia.
The contracting business unifies their know-how on processes, design and contracting with their internally-developed
and licensed technologies for increased efficiency and more economical operation. There are, for example, methods
that make it possible to reduce floor-space needs and operating costs by up to 50 per cent.
Purac Key Technologies

Separation technologies
• DAF (Dissolved Air Flotation)
• FlofilterTM
• GEWETM Lamella sedimentation
• Membranes, MF/UF/NF/RO
Biological Aerobic effluent treatmen
• MBBR (Moving Bed Biofilm Reactor)
• MBR (Membrane Bio Reactor)
• BAS (Biofilm Activated Sludge) concept for P&P wastewater treatment
• SELAC (Selector Activated Sludge)
Biological Anaerobic effluent treatment
• ANAMET® (Anaerobi – Aearobi – Methane production)
• UASB (Upflow Anaerobic Sludge Blanket)
• EGSB (Expanded Granular Sludge Blanket)
3. About the latest technology on the offering - DAF and Flofilter - Superior separation of
suspended solids
Superior separation of suspended solids
Developed and refined since 1950s, the Purac Dissolved Air Flotation technique is an effective and rapid method for
separation of particles from water and wastewater.
Guaranteed performance
Low investment
Compact design
a. Dissolved Air Flotation (DAF)

Water flowing into the DAF tank is injected with a high-pressure air/water solution, derived from recycling some 10%
of the plant flow through an air/water saturation system. Regulation of pressure release valves causes the pressure
117
of the recycled water to suddenly drop. This pressure change creates micro-bubbles that attach to the flocculated
material and rapidly carry it to the surface, forming a stable floating sludge.
Sludge Removal
Surface sludge is removed by a chain-driven flight scraper into a trough from where it is transported to storage.
Fig: Chain-driven flight scraper for surface sludge

removal
Fig: PURAC DAF CLASSIC
Applications
Purac DAF Classic system is a widely used particle separation solution in waterworks, industrial and municipal
wastewater treatment, for sludge thickening, as well as for treatment of industrial effluents in the food, pulp, and
paper industries.
Other benefits
Effective
Removal of suspended solids is excellent, typically >95%.
Compact
A hydraulic load of up to 15 m/h can be processed in environments with space limitations.
Robust
118
Wide variations in flow and solid loadings can be easily handled.
Low Sludge Volume
The floating sludge has high dry solids content (3-6%). There is no need for further sludge thickening.
b. Purac Flofilter™
Combined flotation and filtration
After flocculation/DAF, the water gravitates through the filter bed, which removes the remaining contaminants to
the required level.
The Purac Flofilter is an established, well-proven technique for treatment of surface waters, operating as a constant
level filter with an outlet-modulating valve during this phase.
Flofilter is a compact and efficient plant as it combines flotation and filtration in one treatment basin. In addition
to this two-stage processing, Flofilter offers other major advantages: rapid start-up, shut down and response; low
volume output of sludge; excellent algae removal; and low backwash consumption (2–3%) of feed flow rate based
on one wash per day.
Filter backwashing can be initiated by a timer or loss of head. Conventional air scour water wash techniques are
employed for filter washing.
Fig: PURAC FLOFILTER

The numbers indicated in the above schematic are: 1. Inlet 2. Flocculation 3. Distribution and reaction chamber 4.
Saturation unit 5. Floated sludge scraper 6. Sludge trough 7. Filter media 8. Filter bottom with nozzles 9. Clear water
outlet 10. Backwash water inlet 11. Dirty backwash water channel 12. Dirty backwash water outlet 13. Backwash air
inlet.
Flootek DAF units

Under the brand Flootek, Purac undertakes delivery of ready-made skid mounted DAF units of stainless/acid-proof
steel that are prepared for swift and simple plug-in installation. The units are widely used for wastewater treatment,
mainly within the food industry, oil refineries, pulp and paper mills, and metal finishing.
119
Case studies
1. Fors Mill, Stora Enso Fors, Sweden - Upgrading of Effluent treatment

The plant has combined CTMP and FBB capacity of 400,000 t/y.
Upgrading of Effluent Treatment
Increased production + higher requirements
Qmax = 18,000 m3/d
CODinlet = 28,000 kg/day
TSSinlet = 3,000 kg/d
Contract – Q2 2010
Commissioning – Q2 2011
Taking over – Q1 2012
Effluent treatment – Process solution
Fig: Schematic of the BAS (Biofilm Activated Sludge)

concept for P&P wastewater treatment
With the new effluent treatment system, the parameters are as below:
CODoutlet= 10,000 kg/d
TSSoutlet= 500 kg/d
120
P-totoutlet= 4,4 kg/d
N-totoutlet= 110 kg/d
2. Iggesund Mill, Holmen-Iggesund Paperboard, Sweden

Holmen – Iggesund Paperboard has a Pulp & Paperboard production capacity of 330,000 t/y.
Effluent treatment
Higher requirements COD and TSS
Tertiary treatment
Q=75,000 m3/d
Dissolved Air Flotation, DAF
CODfeed 300 mg/l --> CODoutlet < 100 mg/l
Turn-key contract - Q2 2008
Commissioning - Q3 2009
Tertiary treatment, capacity 75,000 m3/d
Fig: Schematic of the tertiary treatment process
3. Mondi Swiecie Mill, Mondi Swiecie A.S., Poland

Upgrading of Effluent Treatment
New paper machine based on recycle paper
Products are Container board & Sack Paper Kraft
Existing ETP is not having enough capacity
121
Results achieved
Operational costs are considerably lower
Investment cost gets minimized – no need for additional aeration volumes
Less sludge handling for dewatering and disposal
Production of biogas 23 000 m3/d can be used as fuel for boilers
Replaces 15 ton oil equivalents per day
Contact Details
Head office
Purac
Emdalavägen 10
SE 223 69 Lund
P.O. Box 1146
SE 221 05 Lund,
Sweden
Phone +46 46 19 19 00
Fax +46 46 19 19 19
info@purac.se
www.lackebywatergroup.com
122
SOMAS
1. Introduction to Somas
Somas - The market leaders in control valve R&D
SOMAS Instrument AB develops, produces and markets control- och on/off-valves made from high-grade, acid-proof
stainless steel.

New or reconditioned replacement valves with full warranty means security and economy. For customers this is
the key to cost reduction by minimizing spare part inventory size, lower replacement costs and shorter intervals of
suspension of operation.

Paper & pulp industry product line
In the paper & pulp industry, the valves most commonly used are actuated and manual cutoff valves. SOMAS ball
segment valves are the most commonly used control valves, while butterfly valves and ball valves are usually to be
found in cutoff applications.
SOMAS valves are made from stainless material. They also supply valves made from titanium or nickel-rich alloys.
Meeting the existing control objectives is a matter of course at SOMAS. Their actuators are made from surface treated
Aluminium and stainless steel. In this way SOMAS meets the paper & pulp industry’s control objectives. The safety
requirements are easily met since the actuator exerts its maximum torque at the fully open or closed position.
a. Ball segment valves

High capacity, excellent tightness and free flow: These words aptly describe some of the superior properties of the
ball segment valve. SOMAS ball segment valves have been designed to fulfill the strictest requirements of the process
industry on the control valves used. Due to its free flow and choice of different materials for housing and seat, the ball
segment valve is usually the best choice for the industry.
Design of the ball segment valve

The ball segment valves high capacity results from the design of its seat and ball segment. Compared to other valve
designs it is often possible to use smaller and more economical valve sizes. What puts SOMAS ball segment valves
apart from many other suppliers is that the free flow part minimises the risk of clogging.
123
The valve/actuator unit
The ball segment valve is first and foremost a control valve offering excellent tightness in the closed position. The
properties of this valve make it useful for most applications. In combination with SOMAS pneumatic actuators and
positioners the result is a flexible unit with a wide control range.
Product Line
SOMAS ball segment valves offers the following:

Dimensions in the range DN25/2 - DN700.
Pressure classes PN10 - PN100.
Good tightness in IEC 534-4 class V as standard with stellite seat and IEC 534-4 class VI with PTFE seat.
Ball segment and shaft as a one-piece design gives backlash-free operation and accurate control.
Double trunnion supported segment gives high durability and low torque requirement.
Body design makes maintenance easy. Seat can be exchanged or replaced without removing the actuator
or dismantling the valve.
Body for centrally mounted ball segment with continuous seat-trim contact to eliminate potential problems
with dirt build-up and fluid crystallisation.
Body option for eccentrically mounted ball segment for clean hot media like steam and gas at high
temperatures - maximum 550°C.
Trim options available as options to solve problems with noise and cavitations.
References
The excellent properties of the ball segment valve are most obvious when it is put to use as a control valve. This
means that it can be used in more or less all industries - chemical, petrochemical, pharmaceutical industry and paper
& pulp industry to name but a few.
The ball segment valve is suitable for all media, gaseous and liquid. Even in the case of wood pulp, the ball segment
valve is at an advantage due to its free flow. Adaptions of the ball segment valve makes it able to deal with MC-
applications (Medium Consistency).
Since Somas ball segment valves can be supplied with different choices of material for the seat, they are able to
adapt them to a wide range of operating temperatures ranging from the extremely cold (cryogenic) to the extremely
hot (superheated stem and engine exhaust gasses). SOMAS ball segment valves can handle it.
124
b. Butterfly valves
SOMAS butterfly valves helps to adjust flow, be it steam, gas, water or other fluids. SOMAS butterfly valves can handle
it. Their butterfly valves are made from high-grade stainless steel with a homogenous metal seat as standard. They
can be installed by mounting between flanges, with or without lugs. The valves are also available with flanges.
SOMAS metal-seated butterfly valves of type VSS and MTV bears a historical relationship to the very first valves
manufactured by them. Both valves have an advanced triple-eccentric design. The design of the seat and the unique
construction of the disc provides for excellent shut-off and more or less eliminate the need for maintenance. The
high surface pressure between seat and disc makes the valve useful for pulp applications where the fibers are easily
cut. The MTV butterfly valve is the most cost-efficient choice for control- and on/off-applications.
All their valves are tested for leakage and meets the requirements of IEC 534-4 Class V for valves with SS 2377-seat
(Class VI for valves with PTFE-seat).
The universal design allows for a choice of many different materials in valve manufacture. This broadens the field of
application. The metal seat ensures that high-velocity flow will have no effect on the valves tight shut-off ability and
allows for many years of operation.
Dimensions up to DN 1200, pressure classes PN 10-50 and the universal design allows for manufacture in many
different materials and enables Somas to cover most applications in the process industry.
The butterfly valve is useful for clean as well as contaminated media; fluids, gasses and steam. For control installations
the valve is fitted with SOMAS pneumatic actuator and positioner.
Product Line
SOMAS butterfly valves are used in hundreds of thousands of installations in a variety of applications.
SOMAS butterfly valves have many advantages. They offer the following:
Made of stainless steel
Dimensions DN80 - DN1200
Pressure classes PN10 - PN50
Mounting between flanges, with lugs or flanged
Stainless steel seat is not affected by high flow rates replaceable seat in alternative materials
Unique disc geometry which in combination with the homogenous seat acheives tightness to IEC 534-4
Class V as standard
Advanced triple eccentric design acheieves excellent tightness
125
References
Maintenance-free valve is a good match for the shipping industry. One of the major advantages of SOMAS butterfly
valves is that they are almost maintenance-free. This is an important feature for the shipping industry, where these
valves are used as cargo valves on product tankers.
The absolute strength of the butterfly valve: The strength of the butterfly valve stems from the design of its component
parts. On the surface the valve appears to be of simple construction, but this is the very reason why it can cope so
easily with tough applications in extreme conditions.
The metal seat allows the valve to operate at very high temperatures, waste gate valve applications in exhaust gas
turbines being one example. The seat is exposed to high surface pressure, making it possible to use the valve with
pulp suspensions in concentrations up to 4%. Special materials allow the valve to operate in extremely demanding
applications such as steam turbines, with high pressures, high temperatures and rapid shut-off time requirements.
c. Ball Valves
SOMAS ball valve is designed to take care of any leakage of gas or liquid. The valve is a full bore, flanged ball valve
with cylindrical bore made in dimensions from DN 25 to DN 400. The valve is made from stainless steel with spring
loaded seats for good tightness, even at low differential pressure.
The valve ball is hard chromed as standard, but can also be supplied with Hi-Co coating. The valve can be supplied
with actuator and accessories for manual operation, on/off or control applications.
SOMAS 3-piece full-bore ball valves are mainly intended for use as manually operated valves or remotely actuated
on/off valves. The ball valve meets ISO standards.
The valve is available with threaded ends, welding ends or flanges. It is also possible to combine different types of
ends.
SOMAS 3-piece full-bore ball valves are equipped with seats of two materials. Fibreglass-reinforced PTFE as standard,
or carbon-filled PTFE adapted for steam.
Product Line
SOMAS offers two types of ball valves, SKV and S36. Below are their respective specifications.
Type SKV
Pressure classes PN10 - 25 (DN80 - 400) PN10 - 50 (DN25 - 50)
Full cylindrical bore for maximum capacity
Hard chrome plated ball as standard. HiCo-coated as an option
Seats in PTFE 53 or HiCo (High Cobolt alloy)
Spring loaded seats for good tightness at low differential pressure
Complete range of actuators and accessories for manual operation, on/off or control applications.
Type S36
Pressure class PN50
Full cylindrical bore for maximum capacity
Two alternative seat materials: fibreglass reinforced PTFE or carbon filled PTFE
126
ISO connection flange for actuators
Three alternative pipe connections. Threaded, weld ends or flanged
References
The ball valve is used in the paper and pulp industry , mainly as a remotely or manually actuated on/off valve, but also
as a control valve. The ball valves double seats makes it suitable if the direction of flow and pressure may shift. One
example is around the digester in batch digester applications. The ball valves floating ball allows for pressure on the
seat to be achieved by the differential pressure in either direction.
Ball valves with fully cylindrical bore: SOMAS ball valves have a fully cylindrical bore , which allows for minimal flow
resistance in the fully open position. The fully cylindrical bore also provides advantages when dealing with abrasive
media, since no part of the valve protrudes into the flow and no irregularities create turbulence. These conditions
occur mainly in the chemical industry, the mineral industry and in the paper and pulp industry.
Contact Details
For more information about the company, products or services, please contact the following:
Joakim Johannesson
Sales & Marketing Director
SOMAS Instrument AB,
Box 107
SE-661 23 SÄFFLE
Sweden
Email: joakim.johannesson@somas.se
Phone: +46 (0)533 16700\
Fax: +46 (0)533 14136\
E-mail: sales@somas.se
Visit- and delivery address
Norrlandsvägen 26 - 28
SE-661 40 SÄFFLE
Sweden
Website: www.somas.se
127
SootTech AB

CleanTech Company SootTech started in 2007 based on innovation HISS sweep the Chalmers Innovation and industry
innovator Erik Dahlen. Supported by the Energy Agency installed a first pilot system at Nordic Paper's recovery boiler
in Bäckhammar, Sweden.
2. Latest technology on the offering - High Impact Soot System (HISS)

Background
Steam soot blowing is effective, but provide greater amount of flue gases. Many boilers have to lower the load during
the sweep to meet the increased flue gas quantity. Sweeping then leads a double cost of both lost production and
soot blowing steam.
In conventional soot blowing, soot blowers run continuously in sequence cleaning in forward and reverse direction.
50% of the steam (during reverse direction) is of no use. Sequence of cleaning is almost twice as long as it needs to
be.
More than 90% cleaning is 1st stroke Time hardens ash to concrete
SootTech High Impact Soot System (HISS) uses steam only in forward direction. Since there is no steam during the
reverse direction, HISS requires 50% less steam as compared with conventional soot blowing system.
128
Operation of soot blowers is sequential. Operation of soot blowers is overlapping.
Steam is utilized in forward and reverse Steam is not utilized in reversed direction.
direction
Potential benefits
Main purpose of a soot blowing system is to remove soot deposited in the boiler effectively. Photographs below
shows result of High Impact Soot System v/s conventional soot blowing system. HISS is much efficient in removing
soot due to overlapping operation.
Result of conventional soot blowing system Result of high impact soot system (HISS)

In terms of energy saving, it utilizes steam only in forward direction, hence consumes 50% less steam as compared
with traditional soot blowing system.
Case study
Rebuilt recovery boilers are normally run well over design data which often results in a low thermal efficiency of the
heating surfaces is too small. High load means that it quickly built ash layers on the heat surfaces inside boilers, which
reduces boiler efficiency. The efficiency is especially sensitive to ash in the boiler colder parts (economizer).
To determine whether a more efficient sweeping of an individual panndel may increase efficiency, experiments
were performed on Bäckhammar’s recovery boiler that is equipped with SootTech’s patented LIFT-fouling systems.
The experiment involved a study of the difference in steam production per unit of fuel with sweep of the boiler’s
129
economizer area performed and with the conventional cleaning techniques, and partly with SootTech’s patented
HISS-cleaning technology.
Results showed an increase in boiler efficiency with HISS technology in just over 3%, reflecting an increase in steam
production of about 80 tons of steam / day during normal operation.
"Raising boiler efficiency by 3% is sensational. This outcome strengthens the technology and making it far more
interesting both for power boilers and recovery boilers. For Indian pulp & paper industry, this means that there is an
inherent energy reserve that can be easily realized with improved cleaning "says CEO, Erik Dahlen.
In general, by installing SootTech High Impact Soot System (HISS) on a recovery boiler (without advanced soot
blowing systems) the energy saving can be in the range of 30 – 40% of soot blowing steam and / or increased
productivity of recovery boiler by 3 – 8% (due to increased thermal efficiency). Since the benefits can vary from case
to case, it is advised to conduct a preliminary study by SootTech before taking a decision.
Sources of further Information

Further information is available in the website: www.soottech.com
Contact details
Mr. Erik Dahlen
CEO
Erik.dahlen@soottech.com
SootTech AB
Stena Center 1
412 92 Goteborg
130
SWEDISH EXERGY AB
EXERGY STEAM DRYING FOR PULP AND PAPER MILLS
Prem Verma1, Claes Münter1; Staffan Bauman1 and TS Venkataraman2
ABSTRACT: Exergy Steam Drying technology has existed for past three decades or so and many new applications have
been developed during this period. But during past few years the real benefits have been exploited in connection
with bio-fuel production and energy integration. The steam dryer consists of a closed loop system, where the product
is conveyed by superheated and pressurised carrier steam. The carrier steam is generated by the water vapours from
the product being dried, and is indirectly superheated by another higher temperature energy source such as steam,
flue gas, thermal oil etc. Besides the superior heat transfer advantages of using pressurised steam as a drying medium,
the energy recovery is efficient and simple as the recovered energy (70-90%) is available in the form of steam. In some
applications the product quality is significantly improved. Pulp and Paper industry uses enormous amount of water
and hence thermal energy used for water removal should be reusable to some extent as heat source. The Exergy
steam drying technology matches the advances made in evaporation. Lime mud will be a new area of application
for Exergy Drying. Repalcing fossil fuel in Lime kiln with Biomass gasification will lead to” Green Lime”
Keywords; Exergy, bio-fuel, bio-mass, pellets, Bed drying, steam drying, lime mud drying, gasification.
1. INTRODUCTION
The Exergy steam dryer was developed in the late 70's for energy efficient drying of paper pulp. Since then a number
of different applications have been developed, however the main benefits has recently evolved by the different
processes for bio fuel production.
Superheated steam as a drying medium brings a number of advantages; high heat transfer rate, high energy recovery,
no emissions to atmosphere, no risk for fire or explosion during operation, minimal product degradation and short
residence time. The dryer contains very little product to be dried. The Exergy Steam Dryer provides significant savings
both for the producer and also the environment.
The initial investment for the plant is comparable to conventional drying system requiring post treatment systems
like thermal oxidation for the exhaust gases. Operating costs for the Exergy Steam Dryer are only about 20% of the
conventional dryers.
2. STEAM DRYING TECHNOLOGY

2.1 Process description
Exergy Steam drying technology is based on the drying capacity of pressurised superheated steam. Moisture from
product is vaporised by the driving force as super heated steam moves towards saturation curve.
At atmospheric pressure, the heat transfer rate of steam is slightly less than hot air, but by pressurising the steam the
heat transfer rate increases rapidly, See table I.
1 Swedish Exergy, Gothenburg, Sweden,

Email:prem.verma@swedishexergy.com
2 Esvin Advanced Technologies, Chennai, India
Email: tsvenkat @eth.net
131
Media Pressure Temp Relative h
bar (a) C kW/m2,K
Air 1 100 1,3
Steam 1 100 1
Steam 2 120 1,7
Steam 5 150 3,4
Table I: Relative heat transfer capacity between air and steam
For products, such as sawdust, peat or milled wood, the residence time required is only 5-10 seconds for drying from
50% product moisture to less than 10% in the Exergy Steam Dryer.
The Exergy Steam Dryer consists of a pressurised closed loop, where the carrier steam is circulated by a fan. The
carrier steam is super heated above the saturation temperature in a super-heater. The heat is indirectly transferred
via a shell and tube heat exchanger (super heater) from any high-grade heat source such as medium pressure steam,
flue gases, thermal oil or hot water, see figure 1.
Figure 1: Principle of Exergy Steam Dryer

The product is introduced into the high velocity steam flow via a pressure lock, i.e. a rotary valve or feed screw. The
product is conveyed and simultaneously dried in the drying ducts, and separated in a cyclone.
The product is discharged via another pressure lock, whereas the carrier steam, still above the saturation temperature,
is recirculated through the system. However, the evaporated water from the product is now increasing the amount
of carrier steam, and to maintain a constant system pressure, excess carrier steam must be bled-off through a control
valve. This bled-off steam is now available for energy recovery; directly or as clean steam after a steam re-boiler.
2.2 Main features

Superheated steam in a closed loop system provides following main features:
High-energy recovery is possible, available as pressurised steam.
132
No emissions or steam plume to the atmosphere, all volatiles are contained.
No risk for fire or explosion during operation as no oxygen is present.
Only a small amount of product is in the system at any given time.
Complete sterilisation of contaminated products such as bacteria in municipal sludge.
Less product degradation even at higher temperature as no oxygen is present and residence time is
extremely short.
Installation takes little floor space.
2.3 Gross Energy consumption

The gross heat energy consumption is in the range of 750 kWh heat per ton water evaporated from the product. In
addition, 40-60 kWh electrical power per ton water evaporated is required for conveyors, rotary valves and circulation
fan.
3. ENERGY INTEGRATION & RECOVERY

There are a number of possible ways of utilising the energy of the carrier steam, some examples are mentioned
below.
3.1 Direct vapour usage

The easiest way is of course if the carrier steam can be utilised directly for another purpose; district heating, evaporator
system, direct steam-injection for process heating etc. In this way, 90-95% of the energy input to the dryer is available
for recovery.
3.2 Low pressure steam production

In many cases the product steam contains volatiles from the product, as well as fine particles not separated in the
cyclone. The vapours can then be converted to low pressure clean steam in a re-boiler, and utilised in other processes.
A typical heat- and mass balance is shown in Table II.
In to dryer Flow, ton,/hr Heat flux, kW

Wet biomass 20 158
Heating steam, 14 bare 12,5 6763
Electrical energy 600
Out from dryer Flow, ton/hr Heat flux, kW

Dry biomass, 100 ºC 11,1 574
Generated steam, 3 bare 8,9 6787
Heat losses 150
Table II: Heat- and mass balance for an Exergy Dryer drying 10 ton dry
solids/hour from 50% moisture down to 10% moisture.
3.3 Power production

The clean steam produced can also be used for power production in a condensing steam turbine.
133
3.4 Pre-drying
The product steam can also be used directly in a pre-dryer. The steam is condensed in an air heater, and the air is used
for conventional air drying of the product before entering the steam dryer. The total energy required for a specific
drying duty can be reduced by about 50%.
A simple, robust but very efficient pre-dryer is the Exergy Bed dryer; see fig. 2, suitable for drying biomass products
like wood chips, bark, bagasse, coal peat etc.
A fan pushes ambient air through a heat exchanger and blows the heated air through a bed of the wet product. The
bed is moved by hydraulic stokers. Air leaves the bed saturated with moisture from drying the product during 1-2
hours. The bed dryer can be part of the fuel storage before the boiler fuel feeding system.
Figure 2: The principle of Exergy Bed dryer.
3.5 Mechanical Vapour Recompression

When there is no external usage for the excess steam, it can be compressed with turbo or screw compressors and used
for heating the dryer itself. No external heat source is required, only electrical power for the compressor. Electrical
power consumption is in the range of 150-200 kWh per ton water evaporation.
Table III: Energy consumption comparing different ways of heat recovery with conventional open air dryer.
4 APPLICATIONS FOR EXERGY DRYER

4.1 Wood based bio-fuels
The increased usage of wood based bio fuels is also raising demands for efficient energy production. To incinerate
wet wood is the most inefficient energy production process, therefore energy efficient drying is essential for the
future sustainability.
134
By using energy efficient drying system the emission of green-house gases, carbon dioxide and water vapour can be
reduced, see Fig. 3.
Higher fuel heat value after drying and therefore also higher boiler efficiency means that less fuel needs to be burnt.
Us the Exergy Steam dryer means that fuel moisture will be leaving the plant as condensate and not as vapour from
the boiler stack.
Figure 3: Emissions of carbon dioxide and water

vapour as a function of moisture content in the fuel.
By integrating pellet production with heat and power production, the drying process can “borrow” the energy as
medium pressure (MP) steam, and give it back as low pressure LP steam. In some cases (Skellefteå Kraft and Energi E2)
the LP steam is used for power production. Net energy consumption for drying is only 150 kWh per ton evaporated
water.
A flow diagram of such process is shown in Fig. 4.

Wood chips with about 50% moisture are first milled to particle size suitable for pelletizing after drying. The Exergy
Steam dryer uses steam from HP-turbine and produces steam for the LP-turbine. Steam is produced in the boiler by
using fuel wood dust as reject from the pelletizing process.
Remaining low grade heat can be used for pre-drying of the raw material or for district heating.
135
Figure 4: Flow diagram for a Bio-combine pellet
plant.
Figure 5: Exergy Steam Dryer at DONG Energy pellet

mill, Koege, Denmark (50 ton/h)
4.4 Industrial and municipal sludge

Sludge has become a critical issue for both municipalities and industries (mainly pulp & paper) as a waste handling
problem. Sludge is a bio-fuel and can contribute to the “green” heat and power production. The heat value of
sludge, even if digested for bio-gas production, has enough combustion value for both steam drying and substantial
production of heat.
By integrating the drying and incineration of the sludge, the excess heat produced in the boiler and the carrier steam
from the dryer can be utilised for electrical power production and/or district heating. The available heat value of one
ton wet digested municipal sludge at 25% dry solids is in the range of 0,5-1 MWh depending upon ash content. After
drying to 90% d.s. the heat value is 2-4 MWh/ton dry solids.
In fig, 7 a flow diagram is showing a plant for energy production from municipal sludge. The pasty, sticky dewatered
sludge is first mixed with dry sludge in a mixer to a friable feed to the dryer. After drying is the sludge immediately
sent to the boiler for steam production. Steam is used for producing both electrical energy and district heat. About
80% of the fuel value can be used for power and/or heat production.
136
Figure 6: Plant for production of energy from
sewage sludge.
Figure 7: Sludge dried in the Exergy Steam Dryer.
5.0 Future applications:

5.1 Drying of Lime mud
In the Paper industry large pulp mill together with the chemical recovery island were able to initially achieve self
sufficiency in energy using the energy from Black liquor. This was also achieved largely due to better Evaporation
technology that could ensure high steam economy. The energy deficit has arisen ever since lime mud reburning
became mandatory for the Indian Mills about a decade ago. Since Furnace oil (FO) is used as fuel in India in the Rotary
Lime Kiln (RLK), Mills not only had to pay heavy energy penalty but also had no cost control due to the volatility of
global oil prices.
Mills partly offset this cost by adopting coal based Gasifier to supplement FO but this had limitations up to 50 % in
RLK due to enhanced flue gas volume.
Big Mills that use only wood as raw material have improved the Lime mud washing to get lower moisture levels. Some
big Indian mills have achieved already dryness of 75% in Lime mud compared to others (who are constrained by high
silica in their Raw material) at 55%. This means 60% reduction in water removal but problems of resultant high flue
gas temperature that may affect ESP and ID fan are being addressed by diluting the flue gas- load on ID fan
137
ENERGY BALANCE Energy Heat rate %
MJ/ADt MJ/kg of CaO
Energy for calcinations 786 3.18 51
Energy for drying 350 1.41 23
Energy in Flue gases @200 Deg.C 237 0.96 15
Heat in lime mud @60Deg.C &75% dry -54 -0.22 -4
Heat in lime @200 C. 39 0.16 3
Shell heat losses 185 0.75 12
Total 1543 6.24 100
Table IV : Energy balance in a Rotary Lime Kiln
5.2 Cost benefits analysis:

As can be seen from the above the second highest energy used is for the drying- so there is ample scope to improve
that. If the moisture is as high as 45% instead of 25 % as above, the energy consumption would go up by nearly 1.4
MJ/kg i.e nearly 35 kgs of oil per t of CaO. In other words the FO consumption will be 190 kgs/t of lime as against
standard 155 kgs/t. This means for a 260 tpd Lime production, the annual savings in FO would be about 3000t.
Typical input- output is furnished in for a lime mud being fed at 47% dryness.
Table V: Mass and Heat balance
Figure 8: Elevation of a Swedish Exergy steam dryer
138
The installed cost of such a system as above would be in the range of $ 4. 0 million, with a simple pay back period of
less than three years. Most of the parts, other than some critical component would be manufactured in India and
engineering carried out at the Indian branch office at New Delhi.
6.0 The emergence of GREEN LIME

The next logical step is to integrate the Exergy Dryer with Biomass Gasifier to produce “Green Lime”. Till a decade
ago Mills were inadvertently emitting GH gases by purchasing fresh lime. It may be noted that for every tonne of lime
produced nearly 0.8 t of Co2 is released in Air. The Industry has now avoided 75% of that by reburning lime mud but
curiously, so far no carbon credit has been claimed by the Industry. However, the Industry has got a chance now to
claim, may be retrospectively, the carbon credit if it can replace at least 50 % of the fossil fuel used in the RLK with
introduction of Biomass.
Biomass cannot be just burnt directly in the Lime Kiln as the salts in the Biomass impact the quality of lime and also
add to the dead load in the liquor cycle. So gasification of the Biomass that enables you to remove the salts during
the gas clean up system is the best option. Paper Mills have readily available Biomass source such as Bark, Chipper
dust, effluent sludge (Primary) etc.
Gasification is an endothermic process and the Moisture in Biomass burdens the heat load further- so Exergy steam
drying complements it by recovering the steam which can be reused in gasification even if it is dirty. Further the
Synergy comes from the lime kiln which gives hotter flue gas which can be used in the Exergy dryer.
We are developing engineering design for pre drying system for lime mud using flue gas heat in Exergy dryer and
pilot test runs are being planned at our facility near New Delhi. Commercial systems will be available soon for new
RLK or may be a fluid bed calciner that will be suitably designed to take care of the shorter drying zone and higher
flue gas exit temperature. Exergy dryer is better than flash dryer because the LP steam we produce can be used in
causticizing.
7.0 Conclusion
1. With the global focus on Biomass energy, drying assumes greater significance than ever before as
transportation cost is a major component of biomass price. Biomass pellets is lucrative business. Here Exergy
dryer with steam recovery and lower emissions scores over other forms of drying.
2. Paper Industry has two major raw materials Biomass and Lime mud, both have great potential to reduce
GHGs and earn carbon credits.
3. Flash dried pulp will be the thing of the past, since Exergy steam drying has proved more cost effective for
India to produce pulp in Assam or abroad or even import from wood -rich countries.
4. RLK to reduce moisture from 45% to 25%
Contact Details
Offices Sales Agents in India
Sweden Exergy Dryers Pvt Ltd. 1. IBI Chematur
Swedish Exergy AB (Engineering & Consultancy) Limited
Gamla Rambersgvägen 34 Andheri Kurla Road
SE-417 01 Gothenburg Marol Naka, Andheri (East)
Sweden Mumbai - 400 059
Phone: +46 (0)31 51 39 90 Phone: +91 (0) 22 2850 5152
Fax: +46 (0)31 51 79 60 Mobile +91 94226 15598
E-mail: info@swedishexergy.com email jm.pavgi@ibichematur.com
Website: www.swedishexergy.com Web: www.ibichematur.com
139
India Offices
S-86, IBI House, Chimatpada 2. Esvin Advanced Technologies Limited
A-274 Beta-1, Greater Noida Esvin House, Perungudi
Distt- Gautambudh, 201308 (U.P), India Chennai - 600 096
Phone: +91 9818904912 Phone: +91 (0) 44 392 79 356
Fax: +91 9310826712 Mobile +91 98 40 02 5414
E-mail: info@swedishexergy.in email tsvenkat@eth.net
Web: www.swedishexergy.in Web: www.esvintech.in
140
UMV COATING SYSTEMS
UMV Coating Systems – Customized coating solutions
UMV Coating Systems AB is a member of the Mattsson Group. With roots in BTG and UMV Machinery, UMV Coating
Systems AB has become a world-leading developer and supplier of innovative surface treatment technology to the
coated paper and board industry, for new machine installations and rebuilds.

Apart from advanced equipment for single or double-sided surface sizing, pigmenting and coating, UMV Coating
Systems AB takes responsibility for complete coating sections, including pre-study, design, manufacture, installation
supervision, training and startup.
INVO® Tip is the latest of many unique products from UMV.
3. About the latest technology on the offering – INVO® Tip

UMV has developed a new innovative, energy saving and quality enhancing metering element. The new product,
INVO® Tip, gives excellent fibre coverage. Pilot trials and commercial mill trials shows that it is possible to reduce the
amount of coat weight by 20 – 35% depending on the coating colour mix and still maintain the same print quality!
Many mills are today using conventional techniques, such as airknife, for achieving good fibre coverage. The new
INVO® Tip gives a possibility to replace the airknife and reduce the energy consumption by increasing the solid
content from 40 to 65%, and increase the production output by 20 – 40% depending on existing drying capacity or
other existing equipment limitations.
Additional cost advantage is that it is possible to utilize a cheaper coating colour mix and still maintain the same
paper quality.
The new coating metering element gives also a possibility for easy and stable coat weight control and it is possible
to maintain the coat weight through out the life time of the metering element.
The INVO® Tip can easily be connected to the web break sensor and make sure that the metering element is turned
away immediately during a web break. This will improve the life time of the INVO® Tip.
Potential Benefits
In a board machine INVO Tip can lead to reduced thickness of top layer and reduce cost of production. This is one
of the big advantages to reduce or in some cases also eliminate this fibre layer. One board producer in Europe has
in pilot trials at UMV proved that it is possible to produce coated board without the bleached fibre layer, this would
result in a cost saving of approximate EUR 5-6 million.
Case Study - Perfomance improvement, cost reduction and R.O.I. with INVO Tip on a Board
Machine
The Board Mill situation is like this. It is a three coating station i.e., with bent blade, air knife and bent blade. The
production was limited by the pre drying section (under sized) and the post drying section after coating (low solids
colour with air knife). Bad offset print quality such as mottling, uneven surface coverage etc.
The decision is to stop the air knife and use Invo Tip on station 1 and 3, keeping the same CW (28 to 30 GSM total).
The expected benefits are:
141
Production increase by transfer of 4 drying cylinder from post to pre drying part
Decrease steam consumption cost
Improvement of print quality and access to new market
Reduction of specific energy consumption: T.steam / T. paper (higher colour solids: 65 % solids with INVO
Tip instead of 45 % with Air Knife ).
Production increase by transfer of 4 drying cyl. from post to pre drying section
Additional benefit such as print quality improvement
Production data with Air Knife:
Production data with INVO tip:
142
Savings on production increase: Economical data
With Air Knife With INVO Tip

Fixed cost € /H 4 500 € 4 500 €
Fixed cost € /T 168 € 157 €
Prod time H./year 8500 8500
Gross prod. /year 227052 243270
Net prod. /year 204347 218943
Broke rate 10%
Savings on fixed costs 11 €/T or 2458929
€/year
Savings on specific consumption reduction: T. steam / T. paper
Savings in drying
Reduction in water to evaporate (kg/h) 575
Reduction in steam consumption (2 kg /kg water) 1150
Savings €uro / h.(@18 € / T.steam) 21
€uro/annum ( 8500 h/annum) 175950
Invo Tip: Pay back period

The savings that are obtained with Invo Tip are:
Steam saving: 0.18 M€
Prod.increase: 2.46 M€
Total Savings are 2.64 M €. Investment cost for Invo Tip adaptation is 0.09 M€ and Relocation of cyl. (Optional) is 0.5
M€. So, the total investment is 0.59 M €. The ROI is less than 3 months.
Other Benefits
The patented INVO® Tip gives
Excellent fibre coverage
Improved print quality
Increasing production
Energy savings
Cost reduction due to cheaper raw material
Excellent life time easy control of the coat weight
Fits all of the existing coaters on the market
It is possible to maintain the coat weight through out the life time of the metering element. If the coating colour
solids is stable there is no need to adjust the INVO Tip angle to maintain the coat weight, there is no wearing effect
on the soft metering tip. Also the repeatability in settings are excellent when changing INVO Tips since introduction
of the new generation of diameter 14 mm INVO Tip.
143
Conclusion from case study
INVO Tip to replace Air Knife is the best investment on a Board Machine with fast payback:
Steam consumption decrease
Production increase
Huge Print quality improvement
Opening to new grades, new market
Investment details for a typical INVO Tip

The installation drawing for 2 motion drives + couplings and shafts and Control & pneumatic cabinets + 1 control
panel is given below:
Recurring expenditure for metering element is 1000 – 1200 SEK/m (110 – 130 EUR/m) depending on ordered quantity.
Installation time is approximately 8 – 12 hours.Estimated / typical Life of an INVO Tip element is 1 – 2 days normally.
Sources for further information

Further information is available at the website:
http://www.umv.com/umv/about.html
Contact Details
Main Office
UMV Coating Systems,
Industrigatan 7,
PO Box 162,
SE-661 24 SAFFLE, Sweden
Phone: +46 522 982 80
Fax: +46 522 983 23
E-mail- General: info@umv.com
E-mail- Sales: sales@umv.com
India Representative
Pepco Machinery Private Ltd
Prabhat Battishmira
Cell: +91 98 300 59390
E-mail: info@pepco.co.in
144
Part II
Best Practices Identified by CII - Working
Group in Indian Pulp and Paper Industry
146
West Coast Paper Mills Ltd.
Best Practices
1. Fly Ash Sold To Cement Plants Or For Brick Manufacturing.
2. Online Quality Monitoring Of Effluent Discharged To The River
3. Low Colour In Effluent (<70 Co-Pt Colour Units)
4. Low Stack Emissions From All Chimneys (70 + 10 Mg/Nm3).
5. Hot Screening Of Unbleached Pulp With Four Stage Screening
6. Reduction In Clo2 Consumption By 3 kg/Ton Of Pulp As Active Chlorine And Increased Brightness > 90% Due To Use Of Bleach Sequence
Of Dhot-Eop-Dd
7. Low Specific Energy Consumption Of Fiberline And Paper Machine.
10. Online Kappa Monitoring And Control At Multiple Locations.
11. Installation Of Tandem Shoe Press Resulting In High Dryness Of 50-53% And Retaining Of Bulk (Increased Filler Addition From 12% To
18%).
12. Stricter Monitoring Of Paper Properties By Tighter Control Of Parameters Through Autoline 400 And The Tso Module In It Measures
The Fiber Orientation.
13. Installation Of Clari Disc Filter For Lime Mud With Low Chemical Losses. CD Filter Also Installed For White Liquor.
14. Energy Management In Air HandlIng Dryer –Hood Section Of Paper Machine
147
148
About West Coast Paper Mills Ltd.
WCPM enjoys a pedigree of standing over the past 50 years. The company’s vision in constant up gradation of its
process and technology to offer uniform quality of customized products, the “wood to paper” process mastery and
product research have enabled the mill to produce a wide portfolio of wood free papers and boards of highest
quality.
The product-line features well-established brands of commercial to premium grades of paper and boards ranging
from 54 to 600 GSM catered to across six different product segment namely; Writing, Printing, Business stationery,
specialty, industrial and packaging.
The company operates six versatile machines with an installed capacity of 3,20,000 TPA. With the latest addition of
500 TPD State of Art Voith Paper Machine, the quality standards have risen to international standards.
With the installation of world’s most renowned “Bielomatik” online cut-pack converting line ,the quality standards of
copier papers have been elevated to international standards. The overwhelming success of is Copier grades namely
B2B, Copy Gold and Copy Plus have created a revolution in the market for cut size papers in a record short time.
As an ISO 9001:2008 company, WCPM has been consistently striving to improve its quality benchmarks. At the heart
of WCPM’s success is its strong customer focused research initiative backed by a sophisticated research center and a
team of qualified professionals who have translated into a high degree of customer satisfaction, reflected in its loyal
off take.
Technology
WCPM has been constantly upgrading its technology to offer uniform quality of customized products. The “wood
to paper” process mastery and product research have enabled the mill to produce wide portfolio of wood free
papers and boards of highest quality. The ECF Bleached, Alkaline sized papers are processed through online process
and quality control systems to facilitate excellent physical, surface and optical properties to papers that meets
international quality standards.
SALIENT POINTS OF EXPANSION PROJECT AT WCPM:

The Company was incorporated on March 25, 1955 and started Commercial Production on 16.05.1959 with an
initial capacity of 18,000 TPA which has been increased over the period by way of regular expansion/modernization
programme to 1,80,000 TPA.
Once again, the expansion programme was undertaken from July 2007 to increase the capacity from 1,80,000 TPA to
3.20,000 TPA and also to enhance power generation capacity from 40.3 MW to 70.3 MW. The expansion was carried
out with total investment of 1425 crores with 446.32 crores set exclusively for environmental management. The
project was completed on 10th May 10, 2010.
The major sections installed during expansion are;
Fiber Line
1. New Fiberline
2. Chemical Recovery Boiler
3. Causticizing Plant and Rotary Lime Kiln
Paper Line
4. Stock Preperation section 6
5. PAPER MACHINE 6
6. Autoline 400 for Quality control
149
Converting Equipment
7. Rewinder
8. Sheet cutters
9. Ream packing machine
10. A4/A3 copier cutter
11. Reel packing & conveying system
Utilities
12. Power plant – 34.5 MW
1. New Fiberline
The plant has taken proactive steps in installing a efficient new fibre line.The plant has installed 2 new chippers of
50TPH each supplied by Vecoplan, Germany.
A New ECF advanced Pulp mill of 725 TPD has been installed. The new process gives high brightness (89 +1%) & high
strength (7.5 -8.0 cps viscosity) pulp. The pulp mill was supplied by M/s. Metso of Sweden.
The mill has 4 super batch reactor based digesters of 400m3 each capable of 150 to 160 MT of wood chips having
40% moisture. The time taken for cooking is 275 to 285 mins (from chipping to discharge). The mill has ODL followed
by 4 stage bleaching (Dhot followed by EOP and DnD) with only 2 stage washing sequence. The mills is operated
completely using DCS having online Kappa Analyser at 3 points (Before and after ODL and After EOP) which has
resulted in better control and saving on chemical use. The new fiber line also has the advantage of significantly lower
water consumption at 20m3/ Ton of pulp.
LVHC (Low Volume High Concentration) non condensable gases collected from Digester and Evaporator plant are
incinerated in Rotary Lime Kiln
A new efficient Chlorine Di Oxide Plant of 11 TPD supplied by M/s. Uhde India has been installed along with O2
generation plant of 1 TPH supplied by MVS Engineering has also been installed.
Fiber line Process Flow Diagram
150
ECF Fibre Line
Chlorine Di Oxide Plant
Pulping Technology
In a business where it is essential to generate a part of our intermediate raw material needs, it is imperative to produce
superior quality pulp at the lowest cost, with least environmental impact. West Coast Paper has a credible record to
show in this regard.
West Coast Paper Mills adopted a Mega expansion Programme - New Fiberline with ECF bleaching sequence with
an object of
Improved Pulp quality.
Increased Energy efficiency.
Improved environmental performances.
Capacity enhancement.
The company’s investment in a brand new 725 TPD (Bleached Pulp) Metso fiber-line, has replaced the old unit with
eco friendly elemental chlorine–free (ECF) bleaching process. This has enabled to produce consistent quality of high-
bright and hi-strength pulp with improved cleanliness & also reduced load on effluent. The high degree of bleaching
has improved the optical properties of paper.
151
The areas covered for Capacity expansion in Fiberline are
Sl. No. Section Before expansion After Expansion (TPD)

(TPD)
1 Chipper House 1000 3000
2 Cooking 330 800
3 Washing & screening 330 800
4 Oxygen delignification ---- 800
5 Bleaching 330 725
6 ClO2 4 15
7 Oxygen ------ 24
Entire equipments of of Fiberline are supplied by M/S Metso Sweden.
Chippers and auxiliaries are supplied by Vecoplan, Germany.
ClO2 plant is supplied by M/S UHDE (India) with an integrated process for ClO2 generation.
Oxygen plant is supplied by M/S MVS Engineering New Delhi.
Super Batch cooking process in the new fibreline facilitate to produce superior pulp quality imparting extra strength
to the paper the much needed for functional superiority at the end user point. Keeping in view of the increasing
quality awareness among customers in the highly competitive market scenario the need for process optimization
was felt and the company’s prudent investment in modernizing the pulp mill and chemical recovery plants have
resulted in overall operational efficiency with improvement in quality parameters at reduced operational cost. This
was made possible through enhanced economies of operating scale and the reduction in consumption of utilities like
water, steam & power and the process chemicals. Following are the new installations those have enabled increase in
overall efficiency of the pulping and chemical recovery processes resulting in improved quality of Paper.
a) Drum chippers 2nos. with silo capacity 1200 T
b) Superbatch digesters 400 M3 x 4 nos.
Metso supplied Superbatch cooking technology with 4 x 400 m3 capacity digesters. In each batch 150 – 160 Tons of
chips at 38-45 % moisture is converted to 42 tons of unbleached pulp by consuming active alkali 450 kg/ton of pulp
~ 18 – 18 .5%.
c) 4 stages hot screening with two stage washing and Oxygen delignification.
d) Two stages of washing are achieved with Twin roll press leading to a soda loss of 20 – 22 kg/ton as Na2SO4
e) Bleach plant with Dhot-EOP-DnD sequence An online kappa analyzer (Kajaani brand) is installed with
sampling ports at three locations to control the chemical dosing and enable controlled bleaching with
lesser chemicals
f) 3 nos. of Twin wire roll presses in bleaching
g) A sophisticated causticizing plant for improved green and white liquor generation. Compact disc filter for
better white liquor clarification, &X filter for green liquor clarification
h) Higher capacity falling film evaporator of 230 Mt/hr
i) High-pressure boiler of 64 kg at 470ºC for higher steam and power generation, with a high-efficiency
electrostatic precipitator
152
Comparison between old and new Fiberline
Note: In new fiberline additional power required for ODL and Oxygen plant.
2. Chemical Recovery Boiler

A new chemical recovery boiler has been installed which has a capacity to handle 1100TDS/Day. This is a single drum
boiler designed to handle high solid concentration (75%) black liquor and produce high pressure steam (65 bar). The
boiler is installed with high performance MIGI® technology based ESP and is operated using Digital Control System
(DCS) with inbuilt safety features.
153
Chemical Recovery Boiler
3. Causticizing Plant and rotary lime kiln

The causticising plant of 3500m3 capacity has been installed. The plant is provided with a X– Filter for green liquor
filtration (< 20ppm clarity), a CD Filter for white liquor filtration (< 20ppm clarity) and a CD Filter for mud washing
minimizing chemical losses (0.2% to 0.3%) & solid dryness > 70%.
Also the plant has installed a 230 TPD rotary lime kiln.
Caustisizing plant and Rotary Lime Kiln
4. Stock Preperation section 6

The plant has installed advanced and efficient Stock preparation and approach flow equipments supplied by M/s.
Voith for new paper machine no. 6. The section is fully integrated DCS system based and has a highly efficient broke
cleaning system.
The section also has Colour kitchen and wet end chemical preparation equipments from M/s. ABB Cellier, France.
5. Paper Machine 6
The plant has installed one of the most efficient and advanced paper machines supplied by M/s. Voith during its
expansion. The machine is capable of producing 1, 50,000 TPA of high quality writing & printing paper and copier
paper. The paper can be produced in the basis weight range of 45 – 90 GSM of sized and unsized paper with 5,300
mm deckle. The machine has a high designed speed of 1200 m/min and an operating speed of 1000 m/min.
154
Paper Machine No. 6
The machine is provided with Masterjet Headbox with Dilution Control system for uniform basis weight profile, good
fiber dispersion, uniform CD profile and fiber orientation resulting in excellent sheet formation, improved strength
and dimensional stability.
Masterjet Headbox with Dilution Control
The machine is also provided with advanced wire section with DuoFormer which has advantage of excellent
formation, uniform drainage and Top former to improve formation and Surface smoothness.
Wire section with DuoFormer
The machine is provided with Tandem NipcoFlex Shoe Press which resulted in high bulk, higher dryness of sheet and
uniform sheet structure.
155
Tandem NipcoFlex Shoe Press
The machine’s drier section is provided with closed hood and Pocket ventilation system to improve the steam drying
performance.
Dryer section with Closed Hood & Pocket

ventilation system
The machine is also provided with SpeedFlow Film Size Press which is a pre-requisite for high speed machine to
provide uniform starch application on both sides of the paper, better printing properties, higher tensile strengths
and less sheet breaks.
SpeedFlow Film Size Press
The Machine is also provided with Soft Nip Calender and Pope Wheel. The primary purpose of soft nip calender is to
control uniformity, smoothness, bulk and finish of the paper by controlling:
Nip pressure
Roll surface temperature
156
Profiling
Minimum two sidedness
The pope wheel is Jumbo roll of 28 tonnes which results in jointless paper reels and Cobra auto reel change.
Soft Nip Calender
Pope Wheel
The new paper machine has Power consumption of 460 – 480 kWh/ tonne, Steam consumption of 1.9 tonne/ tonne
and water consumption 15-18 m3/tonne
6. Autoline 400 for Quality control

The plant has installed L&W Autoline 400 equipment supplied for better quality control. The equipment is capable
of measuring all Quality parameters in auto mode in 8-10 minutes for the Cross Direction strip of paper for each roll.
The machine can measure 7 quality parameters in a single go. The 7 parameters that can be measured using Autoline
400 are ;
a. Roughness
b. Thickness
c. colour, brightness, opacity and whiteness of paper using ELREPHO
d. Bending resistance
e. Tear/burst
f. Tensile strength and
g. Grammage
157
Autoline 400
7. Rewinder
The plant has installed a modern high speed rewinder supplied by M/s. Voith. It has a operating speed 2500 m/min
and has good reel building capability.
Rewinder
8. Sheet cutters
The plant has installed 3 advanced Sheet cutters, supplied by Milltex, Italy and Pizzolato, Italy. Each sheet cutter has
a capacity of 100 - 120 TPD and has been provided with paper counter and tab inserter.
Sheet Cutter
9. Ream packing machine

The plant has installed 3 automatic ream wrapping machines with labeling capability. Each machine has capacity to
produce 13-15 reams per min. These have been supplied by M/s. Marushi.
Ream packing machine

158
10. A4/A3 copier cutter
The plant has installed A4/A3 copier cutter with a capacity of 150-200 TPD. The machine has auto ream packing,
labeling, cartoning and strapping capability. The machine has beeb supplied by M/s. Bielomatik.
A4/A3 Copier Cutter
11. Reel packing & conveying system

The plant has installed a new reel packing and conveyer system as part of the expansion. The machine packs
the market reels in Kraft layer and stretch film layer and has automatic conveying. This has helped in achieving
International packing quality of reels. The reels are jointless with nil joint being consistently achieved in greater then
98% of the reels produced and 1 joint in less than 2% of the reels. The reels produced are very tight with no loose
winding and core collapsing problem.
Reel Packing and conveying system
12. Power plant – 34.5 MW

The plant has installed a new coal fired captive power to produce 34.5 MW. The plant has a turbo generator (TG)
supplied BHEL and AFBC (Atmospheric Fluidized Bed Combustion) boiler supplied by THERMAX. The plant has a
Maximum continuous rating of 125 TPH, working pressure of 65 kg/cm2, steam temperature of 480±5oC and an
operating efficiency of 86%.
Power Plant
159
Best Practice 1
Fly ash sold to cement plants or for brick manufacturing
a. Progressively lesser fly-ash being sent to land fills.
Coal is the chief source of energy in India and it will continue to do so in the near future. Indian coal having 20 – 40 %
ash is widely used in the Indian Pulp & Paper industries, so also in West Coast Paper Mills.
Electrostatic precipitation is the most popular and widely used method of emission control today which enables
collection of dry fly ash. The characteristics of coal contribute significantly to the characteristics of fly ash collection.
After arresting the fly ash in ESP, it is then transported to silos through suction or by pressurized air. When required,
this can be obtained in the container for further transportation directly from the silos through chutes at the bottom,
or to the delivery point by pipeline using vacuum suction or pressurized air.
Although accurate data about the influence of the polluted atmosphere on the state of health of persons inhabiting
the vicinity of the power station is not available, cases of pulmonary diseases, including asthma and silicosis are
found to be on the increase. In association with moisture in the atmosphere, fine particles of fly ash often form
aerosols which affect visibility around power stations, though to varying extent. Aerosols, being particles in colloidal
dispersion and of lower bulk density, take a long time to settle down as fine precipitation of dust. These can thus be
carried over considerable distances from the power station.
Utilizing Flyash as a resource:

Although the scope for use of ash in concrete, brick making, soil-stabilization treatment and other applications has
been well recognized, only a small quantity of the total ash produced in India is currently utilized in such applications.
Most of the ash generated from the captive power plants is disposed off in the vicinity of the plant as a waste material
covering several hectares of valuable land.
Utilization of fly ash can result not only in reducing the magnitude of the environmental problems, but it is also to
exploit fly ash as raw material for value added products (and conserve traditional materials), and for extraction of
valuable materials.
Amongst many uses that fly ash can be put to, that in building materials is particularly suitable. It is also anticipated,
that there would be considerable short-fall in production of various building materials. According to a study, there
would be a large short-fall in the production of bricks – to the tune of 25 billion bricks on an estimated demand of
100 billion bricks per year in India by the turn of the century.
Considerable work has been done in various research institutions in India for utilization of fly ash. In spite of the
recognition of the size of fly ash utilization / disposal problem and availability of technologies appropriate for Indian
fly ashes and applications, India utilizes hardly about 3% of the total fly ash generated.
Considering the colossal problem of disposal of fly ash, as well as the opportunities for conserving traditional resources
like clay, cement, etc., the manufacturing of fly ash bricks is very important from the nation’s environmental and
economic points of view.
A West Coast paper mill has been proactive in increased utilization as a resource in the form of raw material for
cement making and for utilizing them for brick manufacturing. The following table quantitatively summarizes the
efforts taken by WCPM towards reduction of flyash being sent to land fill.
160
For the year \ 2010- Percentage For the year 2011- Percentage
2011 On BD basis (%) 2012 On BD basis (%)
(@ 25% moisture) (@ 25% moisture)
Cement Industries
Katwa Cement 4,817 7.96 4336 7.10
Kanoria Cement 4,871 8.05 6065 9.93
Raghoji Cement Nil Nil Nil Nil
J K Cement,Muddapur Nil Nil 4123 6.75
Sub Total 9,689 16.00 14,524 23.78
Bricks / Blocks Manufacturing Industries
Hubli 7,881 13.02 12473 20.42
Kali Nirmiti Kendra, Dandeli Nil Nil Nil Nil
Halmaddi, Dandeli 680 1.12 11503 18.83
Others 12,906 21.32 14846 24.30
Sub Total 21,467 35.46 38,822 63.55
Land Filling
Within Mill area 594 0.98 177 0.29
Deserted mines 28,796 47.56 7564 12.38
Sub total 29,390 48.54 7,741 12.67
Grand Total 60,545 100.0 61,087 100.0
b. Research sponsored by WCPM for fly ash utilisation as manure.

WCPM has signed an MOU on August 5, 2010 with UNIVERSITY OF AGRICULTURE SCIENCE for a three year research
project on what effect fly ash has on crop production. The WCPM funded project, currently in its second year, aims to
establish flyash as a fertilizer source to the farmer community.
The initial feedback received from the scientists is given below:
1. They have involved 45 farmers for the demonstration on their lands and have used the fly ash from WCPM
in the ground nut crop.
2. No adverse effects on the quality of soil have been observed
3. The crop was green even during dry spells due to increase in moisture holding capacity of the soils.
4. 5 to 15% increase in the crop yield was observed.
Further work in this direction is in progress.
Utilization of flyash for cement manufacturing: Cement Industry Perspective

Reducing clinker factor in fly ash based Portland Pozzolona cement:
Current Status
The increased use of fly ash in Portland Pozzolona Cement (PPC) has direct impact on reduction in clinker factor (%
of clinker content by mass in cement) in cement thereby reducing the CO2 emission by reduced fuel combustion
and reduced limestone calcinations. Therefore exploring the newer technical avenues for maximizing the utilization
levels of fly ash are the biggest challenge.
161
In India, the estimated generation of fly ash is of the order of 190 million tonnes in the year 2010-11 which is expected
to increase to 450 million tonnes by the year 2020-21 and to 900 million tonnes by the year 2031-32 (Source-DST).
At present about 100 million tonnes of fly ash is being utilized in cement, construction and other building materials.
There are Indian standard specifications IS: 3812 (part 1) 2003 for quality of fly ash to be used as Pozzolona and IS:
3812 (part 2) 2003 for quality of burnt clay to be used as Pozzolona. The ASTM and EN standards for quality of fly ash
are C-618-08 and ENV: 197-1-1992 respectively. While fly ash is available in abundance in India and is used widely,
burnt clay Pozzolona is not much in use. Besides its use as Pozzolanic additions in manufacture of PPC, fly ash is used
in many other areas such as raw material component for the manufacture of Ordinary Portland Cement, sintered fly
ash light weight aggregates and concrete, cement- / silicate-bonded fly ash / clay fly ash building bricks, pre-cast
fly ash concrete building units, cellular concrete, bricks and blocks, lime and cement fly ash concrete, structural
fill for roads, construction sites, land reclamation etc., as a filler in mines, as a filler in bituminous concrete and
manufacture of insulating and semi-insulating bricks, as a plastisizer and a pumping aid, as a water reducer in
concrete, sulphate resisting concrete and as a filler in paints and pigments and so on. Fly ash use as Pozzolona in
PPC, however, remains the biggest user segment. PPC production reached more than 130 million tonnes during
2010-11, which amounted to around 60% of total cement production in India.
Fly ash conforming to IS: 3812 (1) 2003 can be used (up to 35% max) in the manufacture of Portland Pozzolona
Cement as per IS: 1489 (part 1) 1991. The role of fly ash in PPC is attributed to the Pozzolanic action leading to a
contribution towards strength development. Studies carried out on Indian fly ash samples have indicated that the
range of glass content varies between 15 and 45% and the Lime Reactivity (LR) between 2.0 and 7.0 MPa. The fine
fraction of fly ash below 45 micron is major portion, in general and contributes predominantly in the performance of
PPC. This particular aspect of fly ash is very important with a view to enhance the percentage of use of fly ash in PPC
and concrete and needs further thorough and systematic investigations to arrive at certain adoptable methodologies
of using finer fly ash at higher levels.
Studies have been undertaken with a view to improve the lime reactivity of dump ash / pond ash, and fly ash from
initial fields of ESP so that non conforming fly ash could be made reactive conforming to IS: 3812 (1) 2003 and could
gainfully be utilized. These studies have revealed that such fly ash could be utilized up to 25% on an average after
activation through mechanical, chemical and thermal routes. The studies on activation of conforming fly ash also
indicate that the utilization levels of fly ash could be increased by about 10–15% from the current levels, subject to
revision of national standards.
Anticipated benefits
Thermal savings: Saving potential: 180 – 235 kcal / kg cement PPC (27 – 35% fly ash replacement)
Electrical savings: Saving potential: 13 – 17 kWh / t PPC
CO2 reduction potential:
Direct:
Reduction of 220–280 kg CO2 / t PPC (for a cement with 27–35% by mass fly ash)
Indirect:
1 kWh reduction in specific power consumption reduces CO2 emission by 1kg hence, reduction in CO2 emission is
expected to be 13–17 kg/t PPC (for a cement with 27–35% by mass fly ash)
Note:
The above thermal / electrical savings are worked out considering OPC (95% clinker) as base level, 27% fly ash or current
national average in PPC, and 35% fly ash as achievable target in future.
162
Main influencing parameters:
The permitted level of fly ash in India is (15–35%) as compared to European standards (6–55% by weight for siliceous
fly ash (source: ECRA). The following are the technical reasons for lower utilization of fly ash in India:
Poor quality of Indian fly ash in terms of
• Low lime reactivity
• Low glass content
• High carbon content
• Varying fineness levels
Exploitation of only pozzolanicity of fly ash in cement and concrete
Fine powder effect is limited up to 5% in OPC (performance improver)
Cost estimation
Investment cost depends on size of silo at power plant complex, fleet size of tankers, type of handling equipment at
plant etc. The current estimated cost of fly ash collection systems at thermal power plant, handling and transportation
to cement plant in mill hopper etc. is in the range of INR 140–150 million for indigenous supplies.
Condition, barriers, constraints:

Utilization of fly ash in cement, concrete and building materials will largely depend upon the factors such as availability
of the fly ash in dry state, extent of variation in the quality of fly ash.
Technical:
I. Provision of transportation of dry fly ash in closed wagons because otherwise transit losses are high as it is
a fine powder.
ii. Since bulk of fly ash is being disposed off in wet state, arrangements have to be made for extraction and
supply of fly ash in dry state. Some plants have installed fly ash dryers at huge capex, to process wet fly ash
iii. Provision of marketing of standard quality fly ash in bags or any other packing such as drums, etc.
iv. Variation in the quality of fly ash is one of the major problems related to its bulk utilization. Efficient coal
blending systems and controlled coal combustion techniques will ensure good quality fly ash generation in
Indian thermal power plants.
v. Further research is required concerning the activation of non-conforming fly ash for their rational use
Policy:
i. Need for modifications of existing standards and codes consequent upon the acceptance of different uses
of fly ash and formulation of new standards whenever necessary
ii. Unawareness of consumers towards quality of fly ash based products along with confidence of builders in
the conventional building materials
Finance:
i. Tax relief and fly ash utilization subsidy will go a long way in promoting its larger utilization.
ii. Limitation in distance over which the fly ash can be commercially transported
163
Best Practice 2
Online quality monitoring of effluent discharged to the river
Maintaining effluent water quality is one of the major challenges facing the Indian Pulp and paper industry. As
regulation become more stringent with regard to quality of effluents discharged and also due to varying loads
on effluent treatment plants it is becoming ever so necessary to continuously monitor the quality of water being
discharged from the facilities and take necessary actions immediately incase of any deviations from stipulated
norms.
The main objectives of having a online monitoring system is to
Identification of state (concentration) and trends in water quality;
Identification of the mass flow (loads) in surface water and effluent;
Testing of compliance with the standards
Early warning and detection of deviations from the standards
West Coast Paper Mills is located in one of the more eco sensitive zones and its effluent is discharged into Kali River,
home to the famed crocodiles, through Halamaddi Nala. The facility has taken proactive steps in installing the online
monitoring station for continuously monitoring the quality of its combined effluent before it is discharged into
Halamaddi Nala. The online monitoring system is used to monitor water quality parameters like Dissolved Oxygen,
Temperature, pH and flow. The system is helping the facility in having a better control over effluent quality as well as
meets the regulatory requirements with reduced scrutiny by the environmental agencies. Through implementation
of On -line monitoring system, corrective action can be immediately initiated as & when any of the 4 selected
parameters tend to go beyond the limits specified. Corrections taken after the pollutant level in the river is noticed
later, because of continued high impurity level, would be a costly exercise as the damage had already been done.
Preventive action for course correction is the gain by this scheme. This fact had been corroborated by the thriving of
acqua-maritime beings.
Online Water quality Monitoring System
164
Best Practice 3
Low colour in Effluent (<70 Co-Pt colour units)
The pulp and paper industry uses large amounts of process water, despite significant conservation. Thousands of
gallons of water must be treated for every ton of pulp or paper produced. The industry has long dealt with the issues
of BOD and TSS, and more recently with issues such as Dioxins, Furans, and AOX. Many pulp and paper operations
already have permit limitations on color and others will likely follow.
Pulping and bleaching processes release colored compounds into the effluent stream. Most of the color comes from
removing lignin in the bleaching operation, particularly in the caustic extraction stage. The color exists in a range of
physical forms, from suspensions to true solutions. Colour being one of the most easily recognizable parameter to
detect the pollution levels in effluent with just visual inspection, it becomes ever so important to control the color of
the effluent and maintain it as clear as possible.
Alternate pulping and bleaching strategies such as extended delignification and oxygen delignification have reduced
pulp mill color significantly, and these load reduction strategies will continue to be a key part of any color control plan.
While in some cases process modifications may be adequate to meet local requirements, other circumstances may
dictate additional modifications in the effluent treatment plant like separate treating of various effluent streams.
West Coast Paper Mills has taken proactive steps to achieve better water quality in comparision to KSPCB norms,
especially in terms of color reduction. The plant has been able to achieve below 70 Co-Pt colour units. The water
quality parameters achieved against the KSPCB norms is as follows.
Sl. Main Parameter KSPCB stipulated std. Achieved range in our

No. effluent
1 pH 7.0 to 8.5 7.0 to 7.8
2 SS, ppm 50 (max) 35 to 45
3 DS, ppm 2,100 (max) 350 to 400
4 B.O.D., ppm 30 (max) 18 to 24
5 C.O.D., ppm 250 (max) 180 to 220
6 Chloride, ppm 350 (max) 150 to 190
7 Sulphate, ppm 1,000 (max) 70 to 90
8 AOX, kg/T of product Less than 1.0 0.2 to 0.25
9 Colour Co-Pt units 500 Co-pt Colour units (Removed Below 70 Co-Pt colour units.***
to the maximum extent)
The facility has been able to achieve these through
a. Better control on treatment through online monitoring and Bio assay tests
b. Treating the mill effluent in two separate streams; Pulp mill, Chemical recovery plant & Power house effluent
along with colony sewage is being treated in one stream and Paper machine effluent in another stream
c. Installation of New state of the art fiberline, ECF bleaching & Oxygen de-lignification system
a. Better control on treatment through online monitoring and Bioassay tests:

The plant has installed online monitoring system for combine effluent stream and also carries out bio assay test
regularly. The online monitoring system measures DO, pH, Temperature and flow. This helps the facility in continuos
monitoring of effluent quality and optimize the chemical use and aeration times.
Bioassay (commonly used shorthand for biological assay), is a type of scientific experiment typically conducted to
165
measure the effects of a substance on a living organism (mostly fish of certain species common to the effluent sink)
and are essential in monitoring environmental pollutants. This procedure helps in determining the potency or the
nature of an effluent is estimated by studying its effects on living matter and helps the facility to take immediate
steps to improve the quality of effluent if there is deviation.
Bioassay test chambers
b. Treating the mill effluent in two separate streams:

The plant treats the mill effluent in two separate streams; Pulp mill, Chemical recovery plant & Power house effluent
along with colony sewage is being treated in one stream and Paper machine effluent in another stream.
Pulp mill, Chemical recovery plant & Power house effluent along with colony sewage is being treated in one stream,
first in primary treatment followed by mist cooling system to bring down the effluent temperature from 60°C to 30°C.
It is then treated with Activated sludge with diffused aeration followed by secondary treatment to settle the sludge &
the clear over flow is discharged into polishing pond. While Paper machine effluent needs only a primary treatment
with the sludge settled in clarifier & the clear overflow flows in to polishing pond along with Pulp mill secondary
clarifier overflow for extra cushion to Dissolved oxygen with 4 nos of surface aerators & the clear overflow is being
discharged.
Effluent treatment plant layout
166
c. Installation of New state of the art fiberline, ECF bleaching & Oxygen de-lignification
system:
The facility has installed new state of the art fiber line, elemental chlorine free bleaching system and oxygen
delignification system which has reduced the color of the effluent from 150 to 200 Co-Pt units to below 70 Co-Pt
units.
Combined untreated effluent and treated

effluent
167
Best Practice 4
Low Stack emissions from all chimneys (70 + 10 mg/Nm3)
Pulp and paper mills generate a range of emissions of listed substances from pulping processes and power generation.
Major sources of emissions occur at the pulping and bleaching stages, and in energy generation. One of the major
component of stack emission is particulate matter. This is one of the major noticeable components of stacks and
leaves visual impression on the air pollution load as well as having a negative impact on health & surrounding
environment, so it is becoming more and more important to control the particulate and fly ash emissions from the
stacks. The most effect way of controlling these emissions is through installation of ESPs (Electrostatic Precipitators).
This aids in effective collection of fly ash and other particulate matter.
Particulate which accumulates on collecting electrode surfaces and on discharge electrodes must periodically be
dislodged by rapping the collecting plates and discharge electrodes. Rapping removes particulate to the hoppers
for disposal and maintains both the discharge and collecting electrodes in an "operationally" clean condition for
proper operation.
One of the ways of improving the ESP efficiency is through the use of MIGI® rapping technology. It offers the advantage
of
High collecting efficiency ( ≥99.9% )
Rapper is isolated from flue gas for minimizing required space, performing maintenance without shutdown
of ESP.
Vibration force transmits from top to bottom, which is in compliance with dust collection characteristics.
Minimize rapping unit to realize reasonable control for each rapping unit, and remove dust efficiently.
Small section power supply make parameters of power supply are more suitable for property of dust.
Improve liability and stability of equipment by effectively monitoring rapper system.
Insulation compartment with penthouse shape make easy protection, maintenance and management
available.
Prevent from leakage and dew by adopting purge air system.
Energized dura-trode discharge electrode with high rigidity.
For MIGI rapper, rapping strength can be adjusted easily
The MIGI® rapper is a simple electromagnetic coil that provides a controlled and adjustable lift for its one moving part,
a 20 pound plunger. Individual rapper operation is initiated by a controlled, short duration, low voltage (110 V d.c.)
pulse. This pulse energizes the coil, generating a magnetic field that lifts the plunger into the phenolic guide tube.
After the coil is de-energized, the plunger drops by gravity and impacts on a stationary rapper rod that transmits the
forces to the ESP collecting plates and discharge electrodes.
Unlike a tumbling hammer (European) design, the MIGI® rapper has no moving parts in the gas stream and is not
exposed to the erosive effects of the flue gas and particulate.
The roof mounted MIGI® design permits on-line inspection and servicing. And, as service conditions change, both
the frequency and the intensity of the rapping force can be easily changed from the rapper control panel.
West Coast Paper Mills has proactively installed MIGI® Rapping Technology in ESPs in all the stacks which are more
effective in reducing the particulate emissions much below the stipulated norms.
The emissions achieved with the use this technology by West Coast Paper Mills is as follows
Stack Monitoring data for the year 2011-12 at WCPM
168
Stacks attached to Stipulated STD Tested Values
CRP Boiler ( Old)
Flow,Nm3 /hr 125,000 115,074
SPM, mg/Nm3 150 71
H2S mg/Nm3 10 0.28
CRP Boiler ( New)
Flow,Nm3 /hr 225,720 191,814
SPM, mg/Nm3 150 82
H2S mg/Nm3 10 0.32
RLK (Old)
Flow,Nm3 /hr 20,000 16,694
SPM, mg/Nm3 150 66
RLK (New)
Flow,Nm3 /hr 39,600 26,723
SPM, mg/Nm3 150 65
FBC - 1
Flow,Nm3 /hr 92,000 74,949
SPM, mg/Nm3 150 85
SO2, mg/Nm3 - 774
FBC - 2
Flow,Nm3 /hr 1,23,912 99,063
SPM, mg/Nm3 150 78
SO2, mg/Nm3 - 717
FBC - 3
Flow,Nm3 /hr - 94,857
SPM, mg/Nm3 50 38
SO2, mg/Nm3 - 677
FBC - 4
Flow,Nm3 /hr 1,44,108 1,14,588
SPM, mg/Nm3 150 77
SO2, mg/Nm3 - 724
169
Best Practice 5
Hot screening of unbleached pulp with four stage screening
Metso has released a new type of com¬binated knotter and fine screen, des-ignated DeltaCombi™, which is based on
the successful DeltaScreen® and DeltaKnotter™ concept. This machine is intended for efficient separation of knots,
uncooked chips, junk (metal, stones etc.), shives and other undesirable de¬bris in the accepted pulp.
Design
The DeltaCombiTM consists of a vertical, Cylindrical housing with a top cover, designed as a pressure vessel. Inside
the housing, a rotat¬ing screen basket with holes, is mounted on a bearing unit, the same type as the one used in
DeltaScreen®. Additionally for fine screening a similar rotor and Nimega™ basket as in DeltaScreen® is mounted.
Working Principle
The working principle is the same as for a single knotter and as for a single fine screen.
The pulp is fed tangentially into the bottom part of the screen through the rotating screen basket from the outside to
the inside. The pulse gener¬ating stationary foils are located on the accept side of the screen basket. The coarse reject
is taken out from the bottom part. The accept which has passed the rotating screen basket is led up through the rotor
of the fine screen and downwards between the rotor and NImegaTM screen basket, as in an ordinary DeltaScreen®.
Features
High consistency and high capacity
Excellent knot and shive removal efficiency
Possible light weight removal
Unique stator design
Unique adjustable rotor-screen bottom seal
Same type of bearing unit as the one used in DeltaScreen®.
WCPM had hot screening in Old Pulp Mill

with Three stage screening
170
1. Delta-Combi- DC 8
Two functions are being carried out in the same screen.
a. Hole screen basket with 10 mm hole – Removes Knots from the cooked pulp.
b. Slot screen 0.25 mm – Removes fine rejects and acts as Primary stage.
2. Knots are taken to KFA-50 which separates knots from the fiber. Knots are recharged to Digester & accept fiber
goes back to Blow tank.
3. Delta screen FS-40 as secondary screen with 0.25 mm
4. Tertiary screen- FS-40 as tertiary screen This followed by screw press (Fan separator) which removes liquor
from Tertiary rejects and dispose rejects in solid form~ 35-40 % Cy.
In New fiberline WCPM opted for four stage screening with additional Delta Knotter screen to reduce the fiber loss
going with rejects.
1. Delta combi DC- 10.

a. Hole screen with 10 mm dia.
b. Slot screen with 0.3 mm slot
2. Delta knotter DK-4 with 10 mm hole basket- Purpose of delta knotter is to make Knots fiber free. Knots are
carried to KFA-50
3. Delta screen DC-4 as secondary screen with 0.3mm slot
4. Tertiary screen FS-40as tertiary screen with 0.3 mm slot basket
5. Rejects are taken to KFA -50 tail screen 3mm hole. –Rejects are passed through Screw press (Fan Separator) to
dispose rejects as solid (35 % Cy)
Main difference between hot screening of old Pulp Mill and New fiberline is
1. Increase capacity
2. Better fiber recovery from rejects
171
Best Practice 6
Reduction in ClO2 consumption by 3 kg/ton of pulp as active chlorine and increased brightness
> 90% due to use of Bleach sequence of Dhot-EOP-DnD
Chemical pulp, the raw material in paper, is not naturally white; its light color or pure whiteness is the result of a
multi-phased bleaching process. Bleaching means removing or altering the color substances in the pulp. It is done
in phases.
The darkness of chemical pulp is caused by lignin, the natural adhesive that binds wood fibers together. A key issue
in bleaching is how the lignin is processed, i.e. how much lignin is removed from the pulp. Typically, chemical pulp
is bleached by removing lignin and mechanical pulp by preserving it. If lignin is removed from the pulp, the pulp
remains brighter longer and yellows more slowly later.
The objectives of bleaching are usually to lighten the color of the pulp, preserve brightness, improve cleanliness, or
reduce pitch content.
Bleaching improves the cleanliness of the pulp. When the last of the lignin is removed from the pulp, the fibers of the
fiber bundles, i.e. the shives, are released and any remaining bark debris dissolves. The chemicals used in bleaching
also effectively dissolve any extractives contained in the pulp.
The chemical pulp stock is bleached in several separate phases. In between each phase it is washed. By alternating the
bleaching and washing phases, the pulp can be made very bright without compromising its structure and strength.
Bleaching chemical pulps

Chemical pulps, such as those from the kraft process or sulfite pulping, contain much less lignin than mechanical
pulps, (<5% compared to approximately 40%). The goal in bleaching chemical pulps is to remove essentially all of
the residual lignin, hence the process is often referred to as delignification. Sodium hypochlorite (household bleach)
was initially used to bleach chemical pulps, but was largely replaced in the 1930s by chlorine. Concerns about the
release of organochlorine compounds into the environment prompted the development of Elemental Chlorine Free
(ECF) and Totally Chlorine Free (TCF) bleaching processes.
Delignification of chemical pulps is rarely a single step process and is frequently composed of four or more discrete
steps. These steps are given a letter designation, and these are given in the following table:
Chemical or process used Letter

designation
Chlorine C
Sodium hypochlorite H
Chlorine dioxide D
Extraction with sodium hydroxide E
Oxygen O
Alkaline hydrogen peroxide P
Ozone Z
Chelation to remove metals Q
Enzymes (especially xylanase) X
Peracids (peroxy acids) Paa
Sodium dithionite (sodium hydrosulfite) Y
172
A bleaching sequence from the 1950s could look like: CEHEH. The pulp would have been exposed to chlorine, extracted
(washed) with a sodium hydroxide solution to remove lignin fragmented by the chlorination, treated with sodium
hypochlorite, washed with sodium hydroxide again and given a final treatment with hypochlorite. An example of a
modern totally chlorine-free (TCF) sequence is OZEPY where the pulp would be treated with oxygen, then ozone,
washed with sodium hydroxide then treated in sequence with alkaline peroxide and sodium dithionite.
The usual bleaching sequence encountered in an ECF bleaching sequence is D0 – EOP – D1. The functions of Chlorine
dioxide (D), Extraction or washing (E), Oxygen (O), Hydrogen peroxide (P) is described in brief.
Chlorine dioxide (D)

Chlorine dioxide, ClO2 is an unstable gas with moderate solubility in water. It is usually generated in an aqueous
solution and used immediately because it decomposes and is explosive in higher concentrations. It is produced by
reacting sodium chlorate with a reducing agent like sulfur dioxide.
2 NaClO3 + H2SO4 + SO2 --> 2 ClO2 + 2 NaHSO4
Chlorine dioxide is sometimes used in combination with chlorine, but it is used alone in ECF (elemental chlorine-
free) bleaching sequences. It is used at moderately acidic pH (3.5 to 6). The use of chlorine dioxide minimizes the
amount of organo-chlorine compounds produced. Chlorine dioxide (ECF technology) currently is the most important
bleaching method world wide. About 95% of all bleached Kraft pulp is made using chlorine dioxide in ECF bleaching
sequences.
Extraction or washing (E)

All bleaching agents used to delignify chemical pulp, with the exception of sodium dithionite, break lignin down into
smaller, oxygen-containing molecules. These breakdown products are generally soluble in water, especially if the pH
is greater than 7 (many of the products are carboxylic acids). These materials must be removed between bleaching
stages to avoid excessive use of bleaching chemicals since many of these smaller molecules are still susceptible to
oxidation. The need to minimize water use in modern pulp mills has driven the development of equipment and
techniques for the efficient use of available water.
Oxygen (O)
Oxygen exists as a ground state triplet state which is relatively unreactive and needs free radicals or very electron-
rich substrates such as deprotonated lignin phenolic groups. The production of these phenoxide groups requires
that delignification with oxygen be carried out under very basic conditions (pH >12). The reactions involved are
primarily single electron (radical) reactions. Oxygen opens rings and cleaves sidechains giving a complex mixture
of small oxygenated molecules. Transition metal compounds, particularly those of Iron, Manganese and Copper,
which have multiple oxidation states, facilitate many radical reactions and impact oxygen delignification. While the
radical reactions are largely responsible for delignification, they are detrimental to cellulose. Oxygen-based radicals,
especially hydroxyl radicals, HO•, can oxidize hydroxyl groups in the cellulose chains to ketones, and under the
strongly basic conditions used in oxygen delignification, these compounds undergo reverse aldol reactions leading
to cleavage of cellulose chains. Magnesium salts are added to oxygen delignification to help preserve the cellulose
chains, but mechanism of this protection has not been confirmed.
Hydrogen peroxide (P)

Using hydrogen peroxide to delignify chemical pulp requires more vigorous conditions than for brightening
mechanical pulp. Both pH and temperature are higher when treating chemical pulp. The chemistry is very similar to
that involved in oxygen delignification, in terms of the radical species involved and the products produced. Hydrogen
peroxide is sometimes used with oxygen in the same bleaching stage and this is given the letter designation Op in
bleaching sequences. Metal ions, particularly Manganese catalyze the decomposition of hydrogen peroxide, so some
improvement in the efficiency of peroxide bleaching can be achieved if the metal levels are controlled.
173
Bleaching sequence at West Coast Paper Mills
ECF Bleaching sequence Dhot-EOP-DnD was given by Metso to achieve target brightness of 90 degree. The advantage
of this sequence over Do-EOP-D are
1. Better retention time at three Dioxide stages than two Dioxide stage
2. Reduction chemical consumption due distribution of Chlorine dioxide which is the main bleaching chemical
in ECF sequence.
3. Better control over brightness at each stage.
Since WCPM has conventional bleaching sequence C/D-EOP-H-D where hypo was used No data is available to
compare with Dhot-EOP-D at WCPM. However as per information from M/S Metso, indicates ClO2 consumption is
more in Dhot-EOP-D sequence than Dhot-EOP-DnD. This is imperative because of the reasons mentioned above.
Source: Metso.
174
Best Practice 7
Low Specific Energy Consumption of Fiberline And Paper Machine
a. Fiberline 420 kWh/T, 1.4 T/Ton (MP + LP steam)
b. Paper machine 470 kWh/T and 1.9 T of steam per ton of paper with size press
Pulping Technology
In a business where it is essential to generate a part of our intermediate raw material needs, it is imperative to produce
superior quality pulp at the lowest cost, with least environmental impact. West Coast Paper has a credible record to
show in this regard.
New-Gen Fiberline with ECF bleaching sequence

The company’s investment in a brand new 750 TPD Metso fiber-line, replacing the old unit with environmentally
benign elemental chlorine–free (ECF) bleaching process in the in-house pulping street has enabled produce consistent
quality of high-bright and hi-strength pulp with improved cleanliness & lasting freshness with least pollution load.
The high degree of bleaching has improved the optical properties of paper.
The high capacity digesters of 400 m3 in the new fibreline facilitate produce superior pulp quality imparting extra
strength to the paper the much needed for functional superiority at the end user point.
Keeping in view of the increasing quality awareness among customers in the highly competitive market scenario
the need for process optimization was felt and the company’s prudent investment in modernizing the pulp mill and
chemical recovery plants have resulted in overall operational efficiency with improvement in quality parameters at
reduced operational cost. This was made possible through enhanced economies of operating scale and the reduction
in consumption of utilities like water, steam & power and the process chemicals.
The installation of high capacity digesters , high-speed chippers, X filter for green liquor clarification, Compact disc
filter for better white liquor clarification, Higher capacity falling film evaporator of 230 MT/hour , High-pressure
boiler of 63 kg at 470ºC for higher steam and power generation , a high-efficiency electrostatic precipitator with a
sophisticated causticising plant for improved green and white liquor generation etc have enabled increase in overall
efficiency of the pulping and chemical recovery processes resulting in improved quality of Paper.
175
Brief specifications of the new pulp mill at WCPM
The new pulp mill at WCPM is rated for 725 TPD of unbleached pulp and is operated upto 800 TPD of unbleached
pulp. The configuration of the system is as below.
1. Wood Yard: Two drum chippers of capacity 50 TPH each are installed for chipping and a silo of 1200 Tons
capacity is used for chip storage.
2. Cooking: Metso supplied Superbatch cooking technology with 4 x 400 m3 capacity digesters. In each batch
150 – 160 Tons of chips at 45 – 48% moisture is converted to 42 tons of unbleached pulp by consuming 450
kg/ton of pulp with active alkali of 17.5 – 18 %.
3. Screening and Washing: Metso supplied a four stage Hot stock screening system with Delta Combi (coarse
and fine) screen, Delta knotter, secondary and tertiary screen. Two stages of washing is achieved with press
type washers leading to a soda loss of 20 – 22 kg/ton as Na2SO4.
4. Oxygen Delignification and bleaching: Two stage ODL is installed with a bleaching sequence of Dhot – EOP
– DnD punctuated by press type washers delivering consistency of about 30%. An online kappa analyzer
(Kayaani brand) is installed with sampling ports at three locations to control the chemical dosing and enable
controlled bleaching with lesser chemicals.
Parameter Value
WBL 11 m /ton of pulp with 16 – 17% solids concentration at 85oC and 180 gpl
3
Yield 46.6 – 46.7 % unbleached yield and

43 – 43.2 % bleached yield
Washing loss 20 – 22 kg/ton as Na2SO4
Pulp viscosity 7.5 – 8 cp
Kappa 17 – 18 at cooking; 15 – 16 before ODL; 8 – 8.5 after ODL
Blow tank Cy 5–6%
Steam consumption MP (7 bar) steam at Digestors: 0.7 T/T pulp
LP (3 bar) steam at Digestors: 0.2 – 0.25 T/T
Bleaching: 0.5 T/T pulp
Power consumption 420 kWhr/ton of pulp (including ClO2 plant and chipper house)
225 kWhr/ton (Only ODL and fibreline)
Paper Making
WCPM company operates six versatile Paper Machines with an installed capacity of 3,20,000 TPA.
The varied functional characteristics of the Machines and the swing capacity have enabled the company to produce
a wide portfolio of paper and boards ranging from 54 to 600 GSM , catered to a diversified application segment
enabling the mill to sustain its share in a market sensitive to season and cycle.
Hi-tech Machines for New Generation Papers
With the latest addition of 500 TPD State of the Art Voith Paper Machine, the quality standards in WCPM have risen to
international standards. The Hi-tech machine operated at 1100 MPM , with a GSM ranging from 52 to 90 is rated the
best in the country and the latest of its kind in the world
Salient Feature:
New generation former that features a combination of Fourdrinier wire section with a top former that facilitate
uniform basis weight Profile and excellent sheet formation with least two-sidedness and MD/CD tensile ratio.
Speed flow size Press: Paper is processed through a metered size press to get the "extra finish" to impart the best
surface and optical properties.
176
Shoe press and soft-nip calendaring: facilitate achieving high bulk, good dimensional stability with low two-
sidedness.
The advanced on-line process and quality control system ensures consistency in quality in line with international
standards.
The sweeping success of the PM-6 made Copier papers namely B2B, Copy Gold and Copy Plus which have taken
the top slot in the market for cut size papers in a record short time, is the testimony of the customer acceptance on
account of functional superiority.
The Sudarshan brand Maplitho papers have been rated one of the best in the industry, duly acknowledged by reputed
print-houses and institutions.
Process Highlights
Paper made using 100% virgin Wood Fiber enables excellent physical properties to paper required for
strength and durability.
Wood Pulp is processed through ECF, Eco-friendly bleaching process that enables achieve high degree of
brightness while preserving the strength properties.
Paper made using alkaline sizing.
Usage of high grade fillers like PCC have enhanced the optical properties ensuring high brightness , opacity
and scatter values imparting the paper a lasting freshness with least abrasion factor.
Advanced Stock Preparation System enables maintain consistent quality through effective and online
process control measures.
Our new machine is fully integrated with the distributed control system, making it possible to control the entire
machine from a single location compared with our erstwhile practice of manual intervention at each stage.
WCPM believes in continuously upgrading the technology and process through its extensive R&D and adoption of
State of the Art technology prevalent in the global paper industry.
Paper Machine-VI
DECKLE-516-525
PRODUCTS GSM APPLICATION

Range
Sudarshan Classic / Ultra Shine 60 – 88 Printing & Publishing
Diaries, Calandrra, Annual Reports, leaflets, high quality textbooks
and notebooks
Sudarshan Deluxe Maplitho 54 – 88 Printing & Publishing
Diaries, Calandrra, Annual Reports, leaflets, high quality textbooks
and notebooks
Business Stationery / Photo 70 Photo copying,
Copy paper 1.B2B
Laser printing, Inkjet printing
Digital printing,
Copy Gold 75
Copy Plus 80
177
Brief specifications of the new paper machine at WCPM
The plant has installed one of the most efficient and advanced paper machines supplied by M/s. Voith during its
expansion. The machine is capable of producing 1, 50,000 TPA of high quality writing & printing paper and copier
paper. The paper can be produced in the basis weight range of 45 – 90 GSM of sized and unsized paper with 5,300
mm deckle. The machine has a high designed speed of 1200 m/min and an operating speed of 1000 m/min.
Paper Machine No. 6

Headbox: The machine is provided with Masterjet Headbox with Dilution Control system for uniform basis weight
profile, Good fiber dispersion, Uniform CD profile and fiber orientation resulting in excellent sheet formation,
improved strength and dimensional stability.
Wire part: The DuoFormer at the wire section gives the advantage of excellent formation, Uniform drainage while
Top former improves formation and Surface smoothness. Two-sidedness is also reduced.
Press part: The machine is provided with Tandem NipcoFlex Shoe Press which resulted in higher bulk, higher dryness
of sheet and uniform sheet structure.
Drying section: The machine’s drier section is provided with closed hood and Pocket ventilation system to improve
the steam drying performance.
Size Press: The machine is also provided with SpeedFlow Film Size Press which is a Pre-requisite for high speed
machine to provide uniform starch application on both sides of the paper, better printing properties, higher tensile
strengths and less sheet breaks.
Calendering: The Machine is also provided with Soft Nip Calender and Pope Wheel. The primary purpose of soft nip
calender is to control uniformity, smoothness, bulk and finish of the paper by controlling:
Nip pressure
Roll surface temperature
Profiling
Minimum two sidedness
The pope wheel is Jumbo roll of 28 tonnes which results in jointless paper reels and Cobra auto reel change.
178
The new paper machine (PM6) has Power consumption of 460 – 480 kWh/ tonne, with Steam consumption of 1.9
tonne/tonne (of paper) and water consumption 15-18 m3/tonne of paper.
Parameter Value
WBL 11 m /ton of pulp with 16 – 17% solids concentration at 85oC and 180 gpl
3
Yield 46.6 – 46.7 % unbleached yield and

43 – 43.2 % bleached yield
Washing loss 20 – 22 kg/ton as Na2SO4
Pulp viscosity 7.5 – 8 cp
Kappa 17 – 18 at cooking; 15 – 16 before ODL; 8 – 8.5 after ODL
Blow tank Cy 5–6%
Steam consumption MP (7 bar) steam at Digestors: 0.7 T/T pulp
LP (3 bar) steam at Digestors: 0.2 – 0.25 T/T
Bleaching: 0.5 T/T pulp
Power consumption 420 kWhr/ton of pulp (including ClO2 plant and chipper house)
225 kWhr/ton (Only ODL and fibreline)
179
Best Practice 8
Online kappa monitoring and control at multiple locations
Chemical pulping is a harsh process for cellulose fiber. The pulp maker’s challenge is to run the fiber line cost
effectively, preserving the virgin fiber quality properties for papermaking; the process management without online
analyzers and controls is quite difficult.
Laboratory analysis of Kappa has a disadvantage that it is based on chemical volumetric titration and gives only a
relative measure of lignin content. In comparision online kappa monitoring is based on UV absorption and also can
be used to measure absolute brightness. Online monitoring is more accurate compared manual laboratory analysis.
Also in comparison to earlier manual control based on lab measurement techniques auto control based on online
analyzers provided more accurate chemical dosing based on kappa of feed resulting in chemical savings as well as
achieving consistent brightness, viscosity and strength in pulp.
Comparison of Manual Control Based on Lab

Measurements and Auto Control based on
Online Analyzers
KAJAANI Kappa Q analyzer

The new Metso Kappa Analyzer (Metso Kappa Q) launches several new features and measurements to improve the
total pulp mill quality management. Metso Kappa Q is a new online analyzer for chemical pulp mills utilizing the
newest Metso analyzer platform technologies and measurement capabilities. Metso Kappa Q measures pulp lignin
content and brightness faster than ever before. The measurement capacity of Metso Kappa Q is easily expanded by
adding measurement modules and sampling points. Furthermore, Metso Kappa Q introduces a new measurement
capability - online fiber and shive analysis from cooking up to the finished pulp!
KAJAANI Kappa Q analyzer installed at WCPM

At WCPM, KAJAANI Kappa Q analayzer was installed to
Control alkali to wood ratio
Remove 95% lignin
Stabilize blowline kappa
Achieve quality targets like final brightness and dirt count
O2 stage control
¾¾ Calculate needed kappa reduction
¾¾ Tune alkali dosage by multiplying kappa reduction by a kappa factor to maintain stable alkalinity when
pre O2 kappa is changing
¾¾ Check operator bias based on post O2 kappa
180
¾¾ Tune O2 dosage by multiplying alkali dosage by oxygen to alkali ratio
¾¾ Decrease O2 to alkali ratio if there is foaming problem or pH is low post O2
The salient features of KAJAANI Kappa Q analyzer installed at WCPM are;
Unique new capability: fiber properties and shive measurement online from cooking up to finished pulp
Three sampling points with one analyzer to save cost. (models available upto six points)
The proven Kappa and brightness measurements online
Measurement capacity alternatives: 10, 20, 30 or 40 per hour
Compact size
Cost effective sampling arrangement
New interfacing for high availability
KAJAANI Kappa Q Analyzer Layout
Kappa Factor control at Oxygen delignification stage

The benefits achieved by WCPM for installing online kappa analyzer are as follows.
181
1. Chemical consumption reduction of 8% in ClO2 and 8% in H2O2.
a. 3 -4 kg/ton of ClO2 as active chlorine
b. 1.5 kg/ton of H2O2
c. 2 kg/ton of caustic
2. Reduction in cost of production of bleached pulp ~ Rs. 120 – 130 /Ton
Chemical consumption prior to Kappa analyzer control April’11-Aug’11
Chemical consumption after Kappa analyzer control Sept’11-March’12
Chemical savings
Note: ClO2 consumption is expressed as ClO2. Hence savings as active Cl2 ~ 4.0 - 4.4 Kg/Ton Bleached pulp
WCPM operational experience of Kappa Analyzer:
After putting Kappa control into operation the monitoring and control of chemical was much easier
Brightness control at each stage was better than earlier
Reduction in chemical has also resulted in improvement of pulp strength
Data on Performance
182
183
Best Practice 9
Installation of tandem shoe press resulting in high dryness of 50-53% and retaining of bulk
(increased filler addition from 12% to 18%)
Making paper or board

Making paper or board1 involves three clusters of activities; furnish preparation, the paper machine and finishing
operations. In the preparation of furnish, pulped wood and/or waste paper is processed and mixed with water, some
chemicals and other additives. This mixture is called furnish. The percentage of dry solids in the furnish, also called
the dryness of the paper sheet, is about 1%. Then, the furnish is fed into the paper or board machine. Water is
removed in three sections; dryness increases as the paper sheet moves along the paper machine:
Forming section: forming the paper sheet while draining and suctioning (1% to 20% dryness at couch)
Pressing section: mechanical dewatering by passing the paper sheet through a number of press nips (20%
to 45% dryness)
Drying section: evaporative drying of paper sheet (45% to 90-95% dryness)
Finally, finishing operations as e.g. calendaring, winding and cutting are needed to deliver the final product.
The paper machine’s drying section requires the largest amount of energy per kilogram water removed.
Improvements in the specific energy consumption of a ton of paper are therefore typically directed at reducing the
energy requirement of the drying section. This can be achieved by improving drying technologies. A second route is
to increase the amount of water removed in the pressing section. Shoe press technology does exactly that.
Shoe press technology is a paper-making technology that improves dewatering of the board or paper sheet in the
wet pressing section and, therefore, reduces the need for evaporating drying.
Shoe press technology is an exemplary technology of the second category; it improves the dewatering capacity of
the conventional pressing section by extending the time that the paper sheet remains in the press nip. This time
is also called the nip residence time. The amount of water removed in the pressing section is proportional to the
magnitude and the duration of the pressure applied to the paper sheet. The product of pressure and nip residence
time is called the ‘press impulse’.
In conventional roll presses both the pressure applied and the nip residence time were constrained. Pressure could
not be increased unlimited, because the paper sheet would be damaged (especially at higher machine speeds).
Nip residence time decreased with increasing machine speeds. The constrained press impulse of conventional roll
presses was overcome by shoe press technology.
Typical design difference of a roll press and shoe press
Design parameters Roll press Shoe press
Length of press or nip width (cm) 4–7 25 – 30
Linear load (kN/m) 150 – 450 1,000 – 1,500
Press impulse (kN*s/m2) 3.0 – 5.0 15 – 21
The major advantage of the shoe press is the higher dryness achieved at the exit of the pressing section. Depending
on the grade produced, the increase is about 5 to 10% compared to conventional pressing. This results in a better
runnability. The higher dryness leads to an increased production capacity (about 10 to 20%), when a shoe press is put
on an existing (dryer limited) paper or board machine. When a shoe press is implemented on a new paper machine,
the drying section can be shortened thus reducing capital expenditure.
A second advantage is the reduced demand for steam in the drying section. This may lead to an improvement
184
in energy efficiency in spite of the increased electricity consumption. Additional driving capacity and increased
pumping capacity for cleaning the felts are needed. If increased electricity consumption is not taken into account, a
shoe press may save 0.5 GJ to 2.0 GJ per ton paper (0.2 – 0.8 Tons of steam /ton of paper). Savings in energy costs are
of the order of Rs. 50 to Rs. 250 per ton paper. Energy cost savings make up 60 to 80% of the payback generated if
the machine’s speed is not increased. If a paper machine’s production speed is increased, energy cost savings make
up 10 to 20% of the payback per ton paper.
A third advantage is improved product characteristics. The pressing section is important for paper properties
because most physical and surface characteristics are in some way related to the density of the sheet. Pressing causes
densification. The effect of a shoe press on paper properties differs among the grades produced. Installing a shoe
press on a board machine induces a favorable increase in strength properties. This permits savings in refining, the
use of fewer strength additives, and the application of cheaper furnishes and /or increase in filler quantity in paper.
The installation of a shoe press on a paper machine leads to a higher dryness without reducing the thickness of the
sheet. This results in cost saving by reducing the amount of fibre needed.
With the Tandem shoe press installed in the new paper machine PM 6, the plant team is able to achieve an after
press dryness of 50 – 53% (depending on the grade). This also led to the retainment of bulk which thereby lead to
the increase in filler addition from 12% to 18%.
NEW PAPER MACHINE :
Steam - Specific steam consumption = 1.9Ton/ Ton of Paper
Power - Specific power consumption = 478kWh /Ton of Paper
185
Best Practice 10
Stricter monitoring of paper properties by tighter control of parameters through Autoline 400 and
the TSO module in it measures the fiber orientation
The L&W AutoLine 400 Profiler overcomes the challenge faced by mills around the world to measure the immense
information stream of a paper machine in an efficient and profitable way. It is designed to test paper in accordance
with industry standards, regardless of the manufactured grade. Samples are cut directly from the reel in a uniform
manner using the L&W Profile Sample Cutter. The sample’s identity controls the preset test sequence and report
format. Once the operator has confirmed the sample’s identity, the sample is fed into the system and test results
from each testing module are speedily available in real time.
The L&W AutoLine 400’s speed of testing (a complete CD-profile with 20 measuring points from an 8 meter wide
web takes approximately 8 minutes) combined with its transfer functions will enable the mill to integrate the quality
measurements directly into the mill network systems and thus optimise performance.
The return on investment for the AutoLine 400 is estimated at 1 to 2 years, with its modular design ensuring low
expenses for consumables, spare parts and maintenance.
L&W Autoline 400 is claimed to be the fastest and most accurate automatic system for paper testing on the market.
According to L & W, more than 50 properties can be measured and calculated within a few minutes. Short feedback
time is a very important part of the process control. Everything from newsprint to heavy linerboard and cardboard
can be measured by L&W Autoline 400.
Benefits
Measures and calculates more than 50 different properties, most of them according to international
standards
Warning alert if the measurement results are outside specified targets and limits
Fast – about 8 minutes to measure a profile at 20 positions
Results are easily accessible via the mill’s local area network
Several pre-programmed testing sequences available
Remote viewing station provides real time data
Reduced testing variation is the key

Reducing measurement uncertainty or test variability is at the heart of what L&W Autoline 400 provides the modern
paper mill. In today's competitive market place, costs have been cut to the bone. The largest potential for cost savings
now comes from incremental changes in the paper making process. To achieve these cost savings an accurate
measurement of the process is required.
It has long been recognized that the traditional system of manually gathering and testing paper samples can produce
unacceptable levels of measurement uncertainty. L&W Autoline users report significant reductions in test variation.
This reliability improvement, combined with quick access to test results, allow the paper maker to shift production
targets, and achieve more consistent performance. This is where the potential for savings can be found.
WCPM, by installing Autoline 400, has been able to greatly reduce or even eliminate traditional sources of variation
in paper testing, such as:
Operator and instrument variation. Unlike using individual bench top instruments for testing, an automated
paper testing system requires no operator involvement and no specialized skills. Thus, differences in lab
results related to tester changes or different operating techniques can be completely avoided. With the
automated paper testing system, the operator simply inserts the sample and is done. The sample strip is
186
automatically fed through the device and tested accordingly.
Sample Preparation. Sample preparation is one of the most important and often overlooked areas of testing
variation. Manually cutting samples from a jumbo reel is difficult to duplicate from reel to reel, much less
from operator to operator. Improperly cut samples from the reel can affect how the individual test pieces
are prepared as well as the orientation of the sample in the test instrument. When using a Profile Sample
Cutter, samples are collected the same way every time, ensuring consistency and less variability.
Testing in the true MD and CD direction. Manually cutting samples from the reel and again cutting the
individual test pieces presents another opportunity for variation. If samples are not cut straight, one cannot
test in the true MD and CD direction every time. Not testing in the true MD and CD direction will introduce
variations as well as lowering test results. With the Profile Sample Cutter, the samples are cut in the true CD
direction. Precise feeding of the sample ensures that the automated paper testing system will test in the
true MD and CD direction every time.
Same Position Testing. Not testing in the same position on the reel every time could simply be showing
position variations, rather than an actual quality problem. Contrarily, this fault could also be hiding existing
or developing problems. L&W Autoline 400 utilizes a precise feeding mechanism, to ensure it will measure
in exactly the same position every time. This also facilitates long-term comparisons of a particular cross
machine position in order to analyse MD variations.
Increasing the number of data points. Increasing the number of positions tested makes the average of
those measurements statistically more reliable. With automated paper testing systems testing volume is
dramatically increased compared to manual testing. It is possible to test every property, every reel, every
time. Other users of Autoline typically test 20 positions across the complete reel width.
Financial benefits
By allowing for tighter controls, optimizing testing procedures and lowering overall costs, L&W Autolines actually
make money for their owners.
Users of these systems have been able to benefit by optimizing process operating conditions, lowering customer
complaints and retaining or expanding market share. The speed, accuracy, and frequency of measurements allow the
papermaker to make short-term process improvements and long-term process changes in order to reduce variability
and produce a consistent, high quality product.
This type of automation also represents a fundamental change, or paradigm shift, in attitudes both towards the
work place and the role of employees. Highly skilled personnel no longer need to carry out repetitious and routine
functions. This type of work can now be performed more cost effectively by machines, leaving technicians more time
to concentrate on process and quality improvement, rather than measurement and data collection.
It has been observed that by increasing the reliability of the testing it is possible to shift the target and therefore
there is a huge potential to save money. Other possible benefits have been listed below:
Increased productivity results
Speed increase on dryer-limited grades
Weight decrease (when sold by area or strength)
Less downgraded product Reduced grade change losses
Reduced start up time
Reduced breaks
Improved quality
Improved market share
Reduced customer complaints
187
Preservation of existing market share
Reduced machine direction variability
Reduced cross-direction variability
Reduced costs
Reduced steam costs per ton
Reduced fibre usage
Total weight increase (when sold by weight)
Substitution of recycle for virgin fibre
Substitution of fillers for fibre
Decreased chemical additive costs
Reduced refining
Reduced freight costs
Manpower optimization
Quick analysis: From start to result in less than 10 minutes

Cut the sample
As it is important that the test samples are always precisely cut in a uniform manner, the use of L&W Profile Sample
Cutter (code 148) is highly recommended. The sample cutter cuts samples directly from the reel and is easily handled
by one operator. It also ensures that the paper samples are cut straight and perpendicular to the machine direction.
Furthermore, the sample strip is rolled up onto the cutter to prevent creases. The sample is cut to the correct width,
approximately 300 mm (about 12 in), to fit the feeding system of L&W Autoline 400 Profiler.
Identify the sample

There are two ways to register a paper sample with L&W Autoline 400:
Operator registration: The operator registers production information for test strips in L&W Autoline.
Automatic registration: L&W Autoline 400 carries out registration automatically, based on data from the
process computer. The operator needs only to confirm the proposed test identity and feed the sample
into L&W Autoline 400. A bar code enables the test strip to be recognized directly by L&W Autoline 400's
computer.
For automatic registration, with or without bar code, L&W Autoline's measuring program must be connected to the
mill's computer network.
Start the test
The sample's identity controls the pre-set test sequence and the report format. Once the operator confirms the
paper sample's identity the sample is simply fed into the system. L&W Autoline 400 software is based on Windows
operating system, which makes it easy to set up test sequences and other settings.
Different testing modes

The operator can choose between different pre-set testing sequences. It is the testing sequence that controls which
properties will be measured, the frequency and the step length between each measuring point. It also controls
which type of report is printed out and/or if the data should be transferred to the mill-system. There are two different
measurement options to choose from:
188
Position measurement – all measurements are performed in exactly the same positions. This mode is
recommended when the highest possible repeatability between different measurements is required.
Speed measurements – all measurements are carried out simultaneously, as long as there is paper under the
module. This mode ensures fast feedback time of the results.
L&W Autoline 400 can be configured with measurement modules that are independently selected and combined for
the desired measurements.
Available modules include Lorentzen & Wettre's unique formation measurement as well as dynamic absorption and
wettability. The majority of modules measure according to current industry standards. The most recent innovations
include L&W Autoline Compressive Strength STFI Module, L&W Autoline Stylus Roughness Module, L&W Autoline
Surface Formation and L&W Autoline Smoothness Oken.
Report formats
Three different types of reports can be generated:
Reel Report – A statistical summary of the sample with mean or median value, standard deviation or
coefficient of variation. The report also contains set target values and limits.
Profile Report – A cross profile of a property. This can either be a continuous curve, including the exact testing
points highlighted, or a Roll Position profile with calculation of mean/median value per roll position.
Values Report – All data points measured in one report. This is the main report that is sent to the mill
computer system.
Pre-set target and limit values

All reports can also include targets and limits. If the values are outside the limits, different colours highlight the
event.
A complete profile report in 8 minutes
The test results are ready in 5–10 minutes, depending on the test method, the number of properties tested and the
length of the sample. For example, an optimized testing program of an 8 metre wide web, in 20 positions, takes
approximately 8 minutes.
As soon as measuring is completed the results are displayed directly on the screen as cross-direction profile graphs
or in table form. Data from each reel of paper measured can be documented just as easily.
The results are used to verify paper quality and optimize the process. The fast feedback to production enables the
machine operator to correct any faults in the paper machine during operation, thereby preventing the next reel from
also being outside specifications.
Machine operators can follow the testing results and take action to optimize the production.
189
Best Practice 11
Installation of Clari Disc Filter for Lime Mud with low chemical losses. CD Filter also installed
for White liquor
Lime mud moisture maintained at less than 25% with stable operation of lime kiln and purity
unaffected ( > 85 %)
ClariDisc® Filter
The Lime Mud ClariDisc® uses the center barrel and sectors of the White Liquor ClariDisc® Filter but applies vacuum
just like the drum filter. The disc design allows a much greater filtration area in a smaller footprint with a lighter
floor load per unit area. Agitation is acheived by eductor, which allows lower vat solids that a mechanical agitator
can safely support. The lower solids, either by feed dilution or filtrate recirculation, improve the soda recovery and
discharge solids. Hard alloy scraper blades are used and the disc-type HiPAC® is standard.
Other information on the features of the Clari Disc Filter for Lime Mud; chemical losses associated with lime mud.
Sludge dryness in Lime Mud Clari Disc is 25 + or –> 5 % due to low silica in sludge.
Purity of lime is around 82-85% and oil consumption per ton of lime is reduced considerably due to above
reason.
Benefits for CD filter installed for white liquor

1. The sodium content in the sludge is less due to White Liquor CD filter being used in Causticiser for WL
filtration.
2. Dryness of sludge in White liquor CD filter is high due to low silica % in sludge
3. White Liquor CD filter performance is good as compared to conventional Clarifier w.r.t clarity.
4. White Liquor conversion from Green Liquor is 90-95%. Hence soda loss is less resulting in lime mud CD filter
to get good dry ness of filter cake.
5. The unit of CD filter is compact and requires very less space for installation
6. The entire operating system of White Liquor CD filter is fully automatic.
7. The clear and high quality White Liquor supply to PM gives lot of benefits like reduction of scale formation
and gives good quality of pulp.
190
Best Practice 13
Energy Management In Air Handling Dryer –Hood Section Of Paper Machine
Process Background
Cold Air from ambient (30 to 35°C) is being preheated in air to air heat exchanger , wherein the incoming air is heated
by hot humid air leaving the hood of the paper machine dryer. The warm fresh air is further heated using LP steam &
flash condensate to 95°C . The hot air is led to the dryer section using forced draught blower for removing the vapour
from PV sections. As it is a closed hood, there is very little chance of the hot humid air leaking out.
The warm humid air at around 75 to 80°C is drawn by blower to the heat exchanger. Heat is supplemented in the
air to air heater by turbo-air exhaust (at 130°C temperature). After transferring the otherwise wasted heat is led to
second heater in series wherein heat is further tapped for preheating ambient water. The cooled air is led through
the exhaust duct to the atmosphere.
Benefits
LP steam consumption reduction through maximization of heat recovery from all sources possible.
Uniqueness
Apart from the conventional waste heat recovery from the hood discharge hot humid air through air to air heat
exchanger, the following schemes are additional-
LP steam consumption reduction through
Hood entry air temperature optimized at 95 °C ( < 100 °C).
Utilization of heat in turbo-air for preheating fresh air
Low temperature heat recovery from exhaust humid air for hot water generation for process use.
Savings
LP steam consumption had reduced by approximately say 0.2 T/Tof product.
Issue
Condensation of humid air (50 °C) in the water heat exchanger need to be checked for fouling.
Replication
The above schemes can straight away be implemented in all other paper mills in their hood-air handling dryer
section
191
192
JK PAPER MILLS, Rayagada
Best Practices
1. Reduction In Furnace Oil Consumption In Lime Kiln By Using Coal Tar With Fo
2. Increase In Recovery Efficiency By Using Po Back Water In Dp-2
193
194
About JK Paper Ltd
JK Paper Limited is a flagship company of J.K.Organization. It has entered into paper manufacturing since 1938.
Currently it is India’s largest producer of branded papers and a leading player in the Fine Papers and Packaging Board
segments. It operates two integrated Pulp and Paper Mills in India, JK Paper Mills in Rayagada, Orissa, in eastern India
which manufactures coated, uncoated and market pulp and Central Pulp Mills in Songadh, Gujarat, in western India
manufacturing fine papers and packaging boards. JK Paper Ltd. has a combined manufacturing capacity of 2,90,000
tonnes per year, using contemporary technology. The company has taken up a large expansion program which
would result in capacity of 4,24,000 tonnes per annum or over 46% higher capacity than the current levels.
The products include a wide range of Coated and Uncoated Printing & Writing Papers and Packaging Boards. Both
the manufacturing units of the company are ISO 9001-2000,ISO-14001 and OSHAS complying. Additionally TPM is
also in advance stage of implementation. The company has received “ TPM Excellence as well as Consistency Award
‘’ and now proposing itself to challenge TPM Special Award.
JK Paper Mills pioneering initiatives in the Indian paper industry started as far as the mid 60’s. It was the first company
to manufacture surface sized printing & writing paper, followed by copier paper. The Company’s state-of-the-art
Packaging Board plant at Central Pulp Mills produces international quality virgin boards like FBB, SBS and Cup Stock,
in the brand names of “JK Tuffcote”, “JK Ultima” and “JK PureFil”, Nearly 95% of the Company’s product mix comprises
high value products, marketed under various popular brand names such as, ‘JK Copier’, ‘JK Bond’, ‘Cedar’, ‘JK Excel
Bond,’ ‘JK Cote,’ ‘JK Tuffcote’, ‘JK PureFil’ and ‘JK Pristine Cote’.
JK Paper passionately believes in Environment and Safety and has been introducing cleaner and environment-friendly
technologies. JK Paper Mill has been adjudged as the Greenest Paper Mills in India. Both the units of the Company are
ISO 14001 certified for their eco-friendly operations and OHSAS-180001 Certified for Health, Safety and Security.
The Company’s plantation, driven by in-house research programme, has coverage of more than 70,000 hectares
with 7,000 hectares of plantation being added every year. By providing farmers high quality plant species through
the Company’s plantations research centre, it helps farmers to improve their economic well being. A large number
of farmers in the state of Orissa, Andhra Pradesh, Chhattisgarh, West Bengal, Gujarat and Maharashtra are benefiting
form the programme. Theses plantations with their superior quality plants contribute towards a strong base for high
quality raw materials for the Company.
JK Paper is the first integrated Pulp and Paper Company in India conferred with TPM Excellence Award by Japan
Institute of Plant Maintenance, apart from various accolades received over the years.
The Company has an export footprint for high value branded products and Packaging Boards in the middle East,
South East Asia, SAARC and various African countries.
195
About J.K.Paper Mills, Rayagada
JK Paper Mills, a unit of JK Paper Ltd., is a premier integrated pulp and paper mill located at Jaykaypur, Dist. Rayagada,
Orissa. Since its inception, JK paper mills has strived for excellence and consistently set high standards in quality,
productivity, conservation of energy and water, industrial safety as well as pollution control and environment
protection which are indicated by achievements like :
Manufacture of surface sized Maplitho for the first time in the country with indigenous raw material
Capacity utilization of 120%
First paper mill in India to get ISO 9001 and ISO 14001.
Adjudged first greenest paper mill in India in 1999.
Most modern and largest paper mill in the country.
JKPM was commissioned in the year 1962 with an integrated pulp and paper plant with 18000 TPA installed capacity
for manufacturing high quality writing and printing papers. Over the years, the production capacity has been
enhanced to a level of 127,000 TPA with the addition of 4 more paper machines manufacturing diversified product
range from 29 GSM to 300 GSM of different grades of paper. In 2005, an offline coating machine has also been set up
to manufacture premium grades of coated papers.
The secret of success of the mill is attributed to its policy for sustained efforts for quality, new product development
and offering continuous value addition to customers.
196
Best practice 1
Reduction In Furnace Oil Consumption In Lime Kiln By Using Coal Tar With Furnace Oil
Furnace oil (FO) is one of the major consumables in the lime kiln. With ever increasing price of FO, which directly
results in increasing production costs, it is becoming necessary for plants to look into alternatives. One of the coast
effective alternatives available to reduce the cost of operation of lime kiln is substitution of FO with coal tar, produced
as a by product of producer gas production. Coal tar has similar calorific value as furnace oil but has high viscosity
compared to FO which makes it difficult to be used with FO.
JKPM has 3 producer gas production units. Producer gas along with FO is used for lime kiln for converting lime sludge
to lime. Coal tar is produced as a by product of producer gas production from coal using air & steam. Coal tar was
earlier sold outside. Now the plant has taken a noval step to utilize coal tar and reduce furnace oil consumption to
an extent of 20%.
The plant was able to successfully reduce the viscosity of coal tar by maintaining high temperature & by adding some
additives thus making it suitable to be used with FO. This is done as follows; coal tar from day tar tank is sent to tar
mixing tank where it is mixed with FO and Thermopol (additive) at 70oC using steam. The ratio of FO, coal tar and
additive is 4:1:0.005. This is then pumped to FO dry tank where it is further heated to reduce the viscosity. This filtered
and the pump to lime kiln for firing. This procedure has reduced the consumption of FO by as much as 20% FO or Rs.
139.29 lacs/annum savings in lime kiln fuel costs.
Producer Gas & Coaltar Generation
Process Flow diagram of Producer gas, Coal

tar and FO
197
Cost benefits analysis:
198
Saving
199
Best practice No. 2
Increase In Recovery Efficiency By Using Po Back Water In Dp-2
In Pulp Mill, from Discharge tank the cooked pulp is taken to Disc Knotter where knots chips are removed. The accepted
pulp from Disc Knotter is taken to Brown stock washer (BSW-1 & BSW-2) for washing purpose after processing on
both the washer, the washed pulp is subjected to three stage screening through primary (D8), secondary (D4) and
tertiary (D2) .
The accept from the primary Delta screen is sent to the Displacement Press No.1 (DP-1) where consistency of pulp
increases by removal of water & fed into ODL with Oxidized white liquor & Oxygen. Oxygen delignification is
carried out to control bleach chemicals requirement in further stage and to reduce pollution load. This oxidized and
delignified pulp is pumped to DP 2 where hot water is used for washer spray and pulp is squeezed to increase the
consistency about 30-35%. Through dilution screw conveyor pulp is sent to unbleached tower by adding reclaimed
water for dilution. After oxygen delignification pulp from unbleached pulp tower sent to post oxygen washer for
washing before pulp bleaching.
The plant is following the counter current washing from BSW-1 to DP-2. At DP-2 we add hot water in wash spray &
warm water in Screw dilution. In PO washer the plant uses machine back water & filtrate of this washer was being
drained. That was contributing around 300 kg/hr COD load & major color component to the effluent plant.
As Filtrate of PO washer was being drained causing Alkali loss of 180 kg/hr, contribution of COD load on ETP of around
300 Kg/hr. The plant is using this water partially in chips washing plant & from there it was going to ET plant. After
carrying out lab trials the plant started to take PO back water in DP-2 wash spray after providing a steam heating &
in DP-2 screw dilution.
Block Diagram of Washing
200
Before Implementation
After Implementation
201
Tangible & intangible benefits
202
Tamil Nadu Newsprint & Papers Ltd.
Best Practices
1. LP Steam savings Chemical Bagasse Pulping Line -3
2. LP Steam Savings in Hard Wood Fiber Line
3. Power Savings in Pulp Mill by replacing one 650 kW HT Motors with two 150 LT Motors:
4. Power savings by down sizing of Pump Impellers in Pulp Mill
6. Reduce Furnace oil consumption by 5 liters per Ton of Burnt Lime produced in Soda Recovery Section
6. Reduction in LP steam consumption by using segregated process condensate from Evaporator I and II in Soda Recovery Section
7. Other Best Practices incorporated at TNPL
203
204
About Tamil Nadu Newsprint & Papers Ltd:
Tamil Nadu Newsprint and Papers Limited (TNPL) was established by the Government of Tami Nadu during early
eighties to produce Newsprint and Printing & Writing Paper using bagasse, a sugarcane residue, as primary raw
material. The Company commenced production in the year 1984 with a initial capacity of 90,000 tonnes per annum
(TPDA). Over the years, the production capacity has been increased to 2,45,000 TPDA and the Company has emerged
as the largest bagasse based Paper Mill in the world consuming about one million tonnes of bagasse every year. The
Company completed a Mill Expansion Plan during December 2010 to increase the mill capacity to 4,00,000 TPDA
TNPL exports about 1/5th of its production to more than 30 countries. Manufacturing of quality paper for the past
two and half decades from bagasse is an index of the company’s technological competence. A strong record in
adopting minimum impact best process technology, responsible waste management, reduced pollution load and
commitment to the corporate social responsibility make the company one of the most environmentally compliant
paper mills in the world.
Technology
TNPL is an acknowledged leader in the technology of manufacture of paper from bagasse – the sugar cane residue.
Started with an initial capacity of 90,000 tonnes per annum (TPDA) on a single Paper Machine., the Mill doubled
the capacity to 180,000 tonnes per annum in the year 1995 by addition of one more Paper Machine. Under the Mill
Development Plan (MDP) completed during May 2008, the pulp production capacity has been increased from 520
TPDd to 720 TPDd. The pulp being produced by TNPL, in post-MDP is Elemental Chlorine Free (ECF). Along with this,
the upgrade of the Paper Machines has resulted in reaching the paper production capacity to 2,45,000 TPDA. TNPL
has completed the Mill Expansion Plan (MEP) in December 2010 to raise the mill capacity to 400,000 TPDA.
Mill Expansion Plan (MEP):

The implementation of Mill Expansion Plan (MEP) was completed and commercial production started on 25th January
2011. The state-of-the-art Paper Machine 3 (PM-3) supplied by Voith Paper, Germany has a capacity to produce
155,000 TPDA of Printing and Writing paper. The PM3 has a deckle width of 5.45 m and operating speed of 1100
m/m. As part of Mill Expansion Plan, Backward integration of Chemical Bagasse pulping line has been implemented
to have better pulp quality with reduction in water and bleach chemical consumption. The chemical bagasse pulp
line is capable of producing 500 TPD of pulp and is the world’s largest single line for bagasse.
OTHER KEY PROJECTS UNDER IMPLEMENTATION:

Revamping of Steam and Power system:
The Company has proposed to replace the 3 old low pressure Boilers of 60 TPH each installed during 1984 with a new
energy efficient and environmental friendly Circulation Fluidised Bed Combustion (CFBC) Boiler of 125 TPH steam
generation capacity of 105 ata pressure rating. In addition, the Company has proposed to replace the two old Turbo
Generator sets witha new TG set of 41 MW capacity to augment the in-house power generation for meeting the
205
additional power requirement. The total capital outlay is Rs 135 crore. The order for main plant and machinery has
been placed and civil works are in progress. The project is targeted to be completed by June 2012.
De-inking Plant:
To meet the additional pulp requirement in the post- MEP, the Company has initiated steps to install a state- of-the-
art Deinking plant of capacity 300 TPD, at an estimated capital outlay of Rs.174 Crore. The order for main plant and
machinery has been placed. The project is targeted to be completed during second quarter of 2012.
On-site Precipitated Calcium Carbonate (PCC) plant

Following the switching over to alkaline sizing in the Stock preparation, h the paper machines started using
Precipitated Calcium Carbonate (PCC) as the wet end filler. In view of the huge requirement of PCC ,the Company
has proposed to install an on-site PCC plant of 60,000 TPA capacity on Built, Own and Operate (BOO) basis in the Mill
premises. The plant will be established by OMYA International AG, Switzerland at a capital outlay of Rs.30 crore. The
project is under Environmental clearance and expected to be commissioned during next financial year.
On-site Wet Ground Calcium Carbonate (WGCC) plant

While the company continues to use PCC, trials were conducted for increasing the ash content in the pape. Towards
this, a combination of GCC and PCC was tried out, to improve the surface properties of paper in an economical
way. As the results are found encouraging the company has been using GCC, which is currently being purchased in
powder form. Considering the huge quantity of GCC requirement the company has initiated action for establishing
an on-site GCC plant, in the same lines of PCC plant.
Lime Sludge & Fly Ash Management (600 TPD Cement Plant)
The lime sludge generation from the Recovery Cycle and the Fly Ash generated from the power boilers are issues of
concern in solid waste management of the mill. An innovative solution of combining these two wastes and converting
them into high grade cement has been drawn through installation of a 600 TPD cement manufacturing plant abutting
the Mill premises. Environmental Clearance and the Consent to Establish were received from Department of MOEF
/ GoT and theTamil Nadu Pollution Control Board. This project is undertaken at a capital outlay of Rs.68 crores. The
civil works commenced during September 2010. This project is expected to be commissioned during first quarter of
2012.
206
Best Practice 1
LP Steam savings Chemical Bagasse Pulping Line -3
Recovery of heat from Weak Black Liquor before sending to Digester Discharger dilution and utilizing the heat for hot
water generation for use at Bagasse ECF Bleach Plant.
A set of 5 Heat Exchangers are installed in series and bring down the temperature of Weak Black Liquor (WBL) from
95°C to 50 – 55°C using shell and tube heat exchangers. The WBL is used for Chemical Bagasse 2 & 3 Digesters (totally
4 Digesters) Cold Blow system at their Dischargers before blowing the cooked pulp slurry into storage tank.
Around 80 m3/hr water used for oil cooling in Twin Roll Presses (8 Nos.) of CB Washing & ECF Bleaching areas is reused
along with 100 m3/hr fresh water to recover heat from the Heat Exchangers. The temperature raise in the water is
from 35°C to 75°C. The hot water is used for Bagasse ECF Bleaching plant, where the required temperature is 80°C.
Previously LP steam was used for hot water generation to the required temperature.
Generally there is problem with clogging which normally occurs once in a month. Clogging is identified by drop in
WBL outlet quantity and drop in Water outlet Temperature. Leak in Heat Exchanger tubes are identified by raise in
conductivity through conductivity meter fixed in the water outlet.
Cleaning and Tubes leak are attended, when changes observed in WBL Outlet quantity, Water outlet Temperature
and conductivity. Tubes cleaning are done with high pressure spiral jet nozzle.
MOC of heat exchangers:

4 Heat Exchangers: Shell – MS & Pipe – SS.
1 Heat Exchanger – Shell and Tubes are SS.
Benefits:
1. LP Steam 250 TPD is saved, a cost saving of
Rs. 630 Lakhs/annum
2. Flash Vapour release from storage tank through vent is controlled.
3. Odor in the environment is controlled.
207
Best Practice 2
LP Steam Savings in Hard Wood Fiber Line
Recovery of Heat from existing Heat Exchangers by effective utilization of heat transfer area in optimizing the water
outlet temperature in tune to the control of water inlet.
Water from the following Heat Exchangers are used in Hot Water tank for Hot Water generation to use in HW ECF
Bleach Plant.
1. LCHV Gas Heat Exchanger
2. HCLV Gas Heat Exchanger
3. Post Oxygen Washer Filtrate Heat Exchanger
4. Hot Black Liquor Heat Exchanger.
Hot water Temperature at Hot water tank was at 75°C with the water received from all the above 4 Heat Exchangers.
In order to increase hot water temperature to the required level of 80°C for HW ECF Bleaching Process, efforts are
made to fine tune the utilization of heat transfer area of the Heat Exchangers by controlling the inlet water flow
and optimizing the outlet temperature. After optimization, it is observed that Water inlet into Hot Water Tank got
reduced to 100 m3/hr. from 136 m3/hr. This has increased the compound temperature of Hot water tank from 75°C
from 80°C. Previously 1.10Tons of LP steam was used to raise the temperature to the required level. Now, use of LP
steam is stopped.
Tabulation shows Steam requirement to maintain 80°C at Hot Water Tank – Before & After fine tuning of Heat
Exchangers utilization
Heat LP Steam required to maintain 80°C in Hot Water Tank Net LPS
Exchanger Before fine tuning After fine tuning Savings
Water Outlet LPS reqd. Water Outlet LPS reqd. – Tons/hr
inlet m3/hr Temp °C Tons/hr inlet m3/hr Temp °C Tons/hr (S1-S2)
(Q1) (T1) (S1) (Q2) (T2) (S2)
1 10 55 0.38 5 67 0.10 0.28
2 18 65 0.41 10 70 0.15 0.26
3 23 60 0.70 20 65 0.46 0.24
4 85 83 -0.39 65 87 -0.70 0.31
Total 136 --- 1.10 100 --- 0.01 1.09
Net LP Steam Savings in Tons / day 26.16
Net LP Steam Savings in Tons / annum (for 330 days) 8632.8
Savings - INR / annum 69 Lakhs
Benefits:
1. LP Steam 26 TPD is saved, a cost saving of Rs. 69 Lakhs/annum.
2. Around 136 Cu.M hot water was generated earlier. Now this quantity got reduced to 100 Cu. M/hr resulting
in Fresh Water saving of 36 Cu.M/hr.
3. Effective utilization of Heat Exchangers is achieved.
208
Best Practice 3
Power Savings in Pulp Mill by replacing one 650 kW HT Motors with two 150 LT Motors
In Back Water Clarification area one 650 kW HT motor pump was running for both CBP-2 and CBP-3 plants for making
bagasse slurry and bagasse washing process. This pump had to run even only one of the plants is in running condition.
Instead of this single pump, two pumps of 150 kW each are installed exclusively as one of CBP-2 and other for CBP-3.
This has resulted in power savings of 140 kW.
Energy Savings by replacing High capacity Water pumps in Black Water Clarification Plant
Particulars HT Motor- LT Motor 150 LT Motor 150

600kW (A) kW – 1 (B) kW – 2 (C)
Design flow rate of pump 3400 Cu.M/hr. 1800 Cu.M/hr. 1800 Cu.M/hr.
Design head of pump 55 Mtrs. 33 Mtrs. 33 Mtrs.
Running Current 25 Amps 195 245
Power Factor 0.825 0.79 0.81
Voltage 11000 Volts 415 Volts 415 Volts
Power Consumption 392 kW 110 kW 142 kW
Power Savings: A – (B+C) = 392 – (110+142)) = 140 kW
Benefits:
140 Units/hrs. Power saved, amounting to Rs. 33.60 Lakhs/annum
(Considering Running Hours as 8000 hrs./annum)
209
Best Practice 4
Power savings by down sizing of Pump Impellers in Pulp Mill
In Chemical Bagasse Pulping Line – 3, Bagasse Reclaim chest pump and collection Tank pumps are with HT motor
and were running with frequent ON/OFF as per the levels of the chests. The impeller of these pumps are trimmed
suitably after which the pumps are run with less OFF position and longer run duration.
Before and after trimming, the operating hours is same. Before trimming, excess bagasse after feeding to Digesters
will return back to Bagasse Reclaim chest. Now the excess bagasse quantity returning to Bagasse Reclaim chest got
reduced considerably for the same operating hours. Since energy meters are installed before and after trimming the
resultant Total energy savings of around 175 kW.
Particulars Bagasse Reclaim chest pump Bagasse Collection Tank Pump

Before trimming After trimming Before trimming After trimming
Full Running Current 46 Amps 46 Amps 119 Amps 119 Amps
Running Current 44 Amps 29 Amps 101 Amps 69.4 Amps
Voltage 3300 Volts 3300 Volts 3300 Volts 3300 Volts
Power Consumption 190 kW 140 kW 451 kW 326 kW
Benefits :
Energy saved on account of Reclaim chest Pump : 190-140 = 50 Units
Annual Savings (50units x R.Hrs 3696 x Rs.3/unit) : Rs. 55 Lakhs (approx)
(considering R.Hrs 11hrs/day x 28 days x 12 months)
Energy saved on account of Collection Tank Pump : 451-326 = 125 kW
Annual Savings (125units x R.Hrs 7392 x Rs.3/unit) : Rs. 27 Lakhs (approx)
(considering R.Hrs 22hrs/day x 28 days x 12 months)
210
Best Practice 5
Reduce Furnace oil consumption by 5 liters per Ton of Burnt Lime produced in Soda Recovery
Section
The high calcium carbonate and low silica lime stone is imported and used as makeup lime stone in Limekiln. The
chemical properties viz calcium carbonate, silica, magnesium are control parameters in the specification of imported
limestone. How ever physical properties, density and porosity, of lime stone received from different origins are
varying. The lime stone having less porosity and high density is of hard burning nature and consume excess furnace
oil. The Lime stone of different origin was tested in Geological department of Anna University, Chennai for physical
properties. Based on the findings the porosity of lime stone is introduced as a control parameter in the specification
of limestone.
The density of lime stone at 0.57% porosity is 2.721 g/cm3.The density of lime stone at 4.79% porosity is 2.20g/cc.It
is observed that the porosity of material increases as density decreases. The material is softer at high porosity. Heat
penetration at softer material is higher than harder material. The temperature required for calcination is less for high
porosity and less density. This resulted in reduction in oil consumption.
Analysis of Limestone:
Moisture -3.97%
Calcium as caco3 -97.39%
Magnesium as MgCo3 -0.68%
Sio2% -0.32%
Stone size 10mm to 50mm -92.36%
Porosity -4.79%
Density -2.20 g/cm3
Testing method:
Testing is done as per IS13030:1991 Indian standard method for Laboratory determination of water content,
porosity, density and related properties of rock material.
Benefit:
Saving of 5 liters of furnace oil per ton of burnt lime produced.
Filtration in WLCD filter also increased.
211
Best Practice 6
Reduction in LP steam consumption by using segregated process condensate from Evaporator I
and II in Soda Recovery Section
Around 350 m3 per hour of process condensate is generated from Evaporater 1 and 2 in soda recovery plant. Out of
which around 100m3 per hour is used in soda recovery caustisizing plant for lime mud washing purpose and about
200 m3per hour was used for brown stock washing in pulp mill.
By providing a system the process condensate is segregated in to Low BOD and High BOD condensate. The low
BOD condensate is used in soda recovery plant for Lime mud washing purpose and high BOD condensate is used in
pulp mill for brown stock washing. The balance high BOD condensate is cooled in cooling tower and sent to Biogas
plant for biogas generation.
Characteristic properties of the water streams
Before segregation After Segregation

Evaporator foul Low BOD condensate High BOD condensate
Condensate
Location of extractionCommon foul condensate Foul condensate from 5th 7th effect and surface
from evaporator I & II effect condenser
Quantity& temperature 350 m /hr at 55°c
3
Quantityextracted100 m3/hr Balance250 m3/hr at55°c
at 75°C
Usage Lime mud washing BSW washing &
Biomethanation
100 m /hr for lime mud 100 m /hr for lime mud 250 m3/hr
3 3
washing (after heating to washing without heating

75oC) & 250 m3/hr for BSW
Benefits:
Earlier combined process condensate at 550C is heated using LP steam to 75 0C and used for Lime mud washing.
After implementation of scheme, Low BOD process Condensate at 750C from 5th effect is segregated and used for
Lime mud washing. By this scheme LP steam used for heating the combined process condensate is stopped.
Net saving of LP steam - 2 TPH
Saving realized per annum - Rs 32 lakhs.
212
Best Practice 7
Other Best Practices incorporated at TNPL
1. Reduction in power consumption by providing VFD for WLCD filter WL Separator tank
pump
The pump is used to run with control valve throttled condition. By providing VFD the pump can be run as per
requirement and energy can be saved. 55kW pump of WLCD filter WL separator tank is provided with VFD.
Benefit :
Power Savings realized - 23kWh
Annual Savings realized - Rs 3.67lakhs
2. LP Steam Savings in Paper Machine – 3

Paper Machine-3 is VOITH Machine. As per VOITH design, 4 Tons/hr. LP steam is used for Process Water and White
Water heating. It is a part of standard package of VOITH because the heating of process water and white water is
necessary at a Optimum Temperature (say 40oC) as the ambient climatic conditions are subject to variations. (40oC-
25oC). Hence it is necessary to heat the water (Process & White water). Normally this low temperature is rare in this
tropical climatic conditions. If, such a low temperature occurs, fines in White water shall develop latency leading to
clogging of Nozzles in showers.
As per our operating conditions, since the ambient temperature is always above 25°C (unlike in European countries),
the process and White Water does not require heating. Use of LP steam is stopped. The implementation of the
project was started in April-2012 and the performance is under observation.
Benefits:
LP Steam savings 4 Tons/hr, amounting to Rs. 3200 / hr.
Reduction in Chemical usage: Sand filtered Water is used in Paper Machines 1 & 2 (as in PM-3) in place of clarified
process water. Only Clarified Process water is being treated in Sand filter and supplied for PM#1, 2&3. The sand
filtered water is having lower TSS (Total suspended solids) <100ppm. It improves the process by the way of reduction
in chemical consumption.
Benefit:
Consumption of AKD, OBA & Dyes got reduced.
213
214
ITC Limited, PSPD
Unit-Bhadrachalam
Best Practice 1
1. Energy conservation in Boiler Feed Water Pumps
2. Reduction in fresh water consumption for pulp dilution at Pulp Mill
215
216
About ITC Limited, PSPD, Unit-Bhadrachalam
Company Profile
ITC Limited - Paperboards and Specialty Papers Division - Bhadrachalam unit has emerged as one of the most modern
and contemporary players in the business worldwide. Unit Bhadrachalam offers a vibrant product range for packaging
and graphic solutions such as Coated SBS Board (Pearl and Safire Graphic), Coated Folding Box Board (Cyber XL Pac),
Coated Board White Back, Coated Gravure Board, Coated Board Gray Back & many more. The Unit serves thousands
of customers in India and abroad & to a wide range of industries from foods to personal products, office stationers
to appliances and accessories. It makes the complete range of paperboards that today offer unparalleled choice for
FMCG packaging.
Energy & Water Management Practices

Water & energy utilization and its reduction has become a major focal point for pulp and paper mills around the world.
Concern for water & energy conservation, adoption of environmental laws and forced environmental conditions have
driven many pulp and paper mills in the country to reduce plant water & energy usage. Adoption of Best Available
Technology and Best Management Practices with more environment friendly process, viz. oxygen delignification
and elemental chlorine free (ECF)/Ozone bleaching coupled with complete recycling of white waters in paper
machines and adoption of energy efficient process, plant, and machinery resulted in energy & water conservation at
ITC-PSPD.
217
Best Practice No. 1
Energy conservation in Boiler Feed Water Pumps
1.1. Background
Unit Bhadrachalam has cogeneration plant with total power generation capacity of 84 MW. High Pressure steam is
generated through a combination of Soda Recovery & Coal Fired boilers & then passed through a set of Turbines to
generate power. As a typical installation in boilers two high pressure Boiler Feed water pump (one running and one
standby) were used to pump water to boiler. The feed water flow control used was step mode by using a control
valve with an average opening of 40 % of control valve. The feed water pump outlet pressure used to vary between
92 to 105 bar before control valve in accordance with the steam demand.
1.2. Objective
To reduce energy loss across control valve & achieve energy conservation.
1.3. Action taken

Looking at the pressure variation & higher pressure loss across control valve, optimization proposal was worked out.
Out of two pumps, one pump is fixed with VFD to maintain constant boiler feed water pump outlet pressure. The set
point was reduced in step manner till 80 bar reducing the loss across control valve. Thereby power consumption was
reduced by 80 kW.
.4. Achievements & Benefits

The power consumption is reduced by 80 kW from 390 kW to 310 kW for the pump for similar loads. This has resulted
in 20% energy saving as compared to original operating practice.
1.5. Additional Benefits

The pressure loss across the valve is reduced which in turn reduces wear & tear of valve. Also, pump life increased due
to smoothening of discharge pressure.
Boiler Feed Water Pump Variable Frequency driver
218
Trend of pressure before & after installation of VFD
1.5. Replication potential / Learning

All the boilers operated with flow control valve result in higher pressure drop across the valve. These can be considered
for future application of VFD. This will result in energy conservation by minimizing energy loss across control valve.
At Unit-Bhadrachalam, all Boilers’ Feed water pumps have been installed with VFD for flow control & saving of 20%
is achieved for Boiler Feed water pumping.
219
Best Practice No. 2
Reduction in fresh water consumption for pulp dilution at Pulp Mill
2.1. Background
Pulp is produced from wood through stages of chipping, cooking, screening & washing and finally bleaching. The
last stage of bleaching is DP, where, the pulp at 30% consistency is produced at the outlet of DP press. Process water
(fresh water) is used to dilute this pulp from 30% to 10% consistency which is then transferred to Bleached tower.
And finally the pulp is pumped to machines according to the demand. Thus the water added for dilution is sent to
paper machine along with pulp.
In process of papermaking the water is removed at various stages of paper machine. Partly it is recycled back for
bleached tower pulp dilution & remaining excess is drained to ETP.
2.2. Objective
To reduce fresh water consumption pulp mill process.
2.3. Action taken

A study was done to find ways of reducing fresh water consumption at pulp mill. It was identified that the back water
from paper machines can be utilized for DP press screw dilution, as this is the final stage & pulp is sent to paper
machines from here.
Storage tank for paper machine back water erected near Pulp mill to store the back water coming from paper
machines. Piping laid for back water receiving & pumping to Dp stage for pulp dilution. Controls provided in fresh
water line based on tank level & operating conditions.
2.4. Achievements & Benefits

Fresh water consumption reduced by 2000 kL/day for Pulp Mill. The resultant is approx 8% of saving in fresh water
consumption at Pulp Mill.
2.5. Additional Benefits

Load on ETP for additional effluent is reduced. The pumping power for fresh water is reduced to the extent of fresh
water saved. Chemicals consumption reduced at Paper Machine.
Proposal Schematic diagram
220
Buffer Tank for Back Water Pump
Machine Back water
2.6. Replication potential / Learning

Wherever pulp dilution is done by fresh water, this approach can be considered after a thorough study of the process.
Saving of 5-10% in fresh water consumption can be achieved by replacing it with machine back water at various
stages.
221
222
Seshasayee Paper and Boards Limited
Best Practice 1
1. Energy Management In Condenser Cooling Water Circuit Of 21 Mw Steam Turbine
223
224
About Seshasayee Paper and Boards Limited (SPB)
The Company
Seshasayee Paper and Boards Limited (SPB), the flagship company belonging to ‘ESVIN GROUP’, operates an
integrated pulp, paper and paper board Mill at Pallipalayam, Erode-638 007, District Namakkal, Tamilnadu, India.
SPB, incorporated in June 1960, was promoted by Seshasayee Brothers (Pvt) Limited in association with a foreign
collaborator M/s Parsons and Whittemore, South East Asia Inc., USA. After commencement of commercial
production, having fulfilled their performance guarantee obligations, the foreign collaborators withdrew in 1969.
Main promoters of the Company as on date are a group of companies belonging to the ESVIN group headed by Mr.
N Gopalaratnam.
SPB commenced commercial production in December 1962, on commissioning a 20000 tpa integrated facility,
comprising a Pulp Mill and two Paper Machines (PM-1 and PM-2), capable of producing, writing, printing, kraft and
poster varieties of paper.
The Plant capacity was expanded to 35000 tpa in 1967-68, by modification of PM-2 and addition of a third Paper
Machine (PM-3). The cost of the expansion scheme, at Rs 34 Millions, was part financed by All India Financial
Institutions (Rs 31 Millions).
In the second stage of expansion, undertaken in 1976, capacity was enhanced to 55000 tpa, through addition of a 60
tpd new Paper Machine (PM-4). Cost of the project, including cost of a Chemical Recovery Boiler and other facilities
for enhanced requirement of utilities, was estimated at Rs. 176 Millions. The same was part financed by term loans
from Institutions and Banks to the extent of Rs. 145 Millions and the balance out of internal generation.
SPB undertook various equipment balancing and modernisation programmes, since then, for improving its operating
efficiency, captive power generation capacity, etc., upto 1992-93.
Expansion / Modernisation Project

The Company embarked on an Expansion / Modernisation Project to enhance its production capacity from 60000
tonnes per annum, to 1,15,000 tonnes per annum and to upgrade some of the existing facilities, at an estimated cost
of Rs 1890 millions.
The said Expansion / Modernisation Project was completed in December 2000. After successful trials, the Commercial
Production out of the new Paper Machine commenced on July 1, 2000.
The current installed capacity of the Company stands at 1,15,000 tonnes per annum.
Raw Materials
The Company’s paper plant was originally designed for using bagasse, as the primary raw material mixed with 20%
bamboo fibre. Bagasse was being obtained from nearby sugar mill on substitution basis using oil fired boilers.
With sharp increase in oil prices in 1970-71, the Company shifted over to the use of hardwood, at the time of its
expansion undertaken in 1978. Raw material mix underwent a substantial change, with bamboo and hardwood
forming 60% and 40%, respectively, of its raw material consumption.
“National Best Practices - Pulp & Paper Industry”
Soon Company started apprehending difficulties in procurement of bamboo. In 1981, it added one more digester,
to increase the share of the hardwood in the furnish mix to 80% and restricting bamboo use to only 20%.
With the commissioning of more wood based industries in Tamilnadu, there was again an apprehension about
availability of hardwood.
225
s a long term strategy, the Company at this time decided on restructuring use of bagasse which was seen to be the
most reliable source of fibre for the entire Industry.
In 1984, the Company promoted Ponni Sugars and Chemicals Limited, as the captive source for bagasse supply. It
added bagasse handling systems and modernised PM-1 and PM-2, to shift over to the use of bagasse.
The furnish mix for the existing Paper Machines of the Company is 55% bagasse and 45% hardwood. The Company
has vast experience in handling bagasse and is expected to be one of the major strong points vis-à-vis its competitors
in India, as the Indian Paper Industry will continue to be bogged down by the problem of raw material availability.
For the new Paper Machine, the furnish is imported waste paper and imported pulp which are sourced from far east
countries, Europe and USA. A small quantity is supplemented out of captive pulp production.
Exports performance
SPB’s exports are nearly 20% of its production and is a significant exporter in the Indian Paper Industry. Due to its
excellent export performance, SPB has been awarded ‘Golden Export House’ status.
Awards
SPB is in receipt of various Awards awarded by Government of India, Government of Tamilnadu, Industry Associations,
etc.
Some of the Awards received by SPB in the past include:
Capacity Utilisation Award
Energy Conservation Award
Environmental Protection Award
Safety Award
Export Performance Award
Good Industrial Relations Award
TERI - Corporate Environmental Award
Environmental Protection
The Company attaches paramount importance to the conservation and improvement of the environment. In its
efforts to improve the environmental protection measures, the Company has installed:
Two Electro Static Precipitators for its Boilers to control dust emissions
An Anaerobic lagoon for high BOD liquid effluents
A Secondary Treatment System for liquid effluents and
An Electro Static Precipitator and Cascade Evaporator to the Recovery Boiler.
These facilities will ensure sustained compliance by the Company of the pollution control norms prescribed by the
Pollution Control Authorities.
ISO 9001/ IS0 14001 Accreditation
The Company’s quality systems continue to be covered by the “ISO 9001” accreditation awarded by Det Norske
Veritas, The Netherlands.
The Company has also been accredited with “ISO 14001” certification by Det Norske Veritas, The Netherlands, for its
Environmental Quality Systems.
226
Board Of Directors
The Company’s Board is broad based comprising 10 Directors:
Sri N Gopalaratnam, Chairman and Managing Director
Sri R V Gupta, I.A.S., (Retd.)
Dr S Narayan, I.A.S., (Retd.)
Sri Bimal Kumar Poddar
Sri Arun G Bijur
Sri V Sridar
Smt Sheela Rani Chunkath, I.A.S (Nominee of TIIC)
Sri Debendranath Sarangi, I.A.S (Nominee of Govt. of Tamilnadu)
Sri K S Kasi Viswanathan, Deputy Managing Director
Sri V Pichai, Director (Finance) & Secretary
They are ably assisted by a team of qualified and experienced professionals in operations, personnel, finance and
marketing disciplines.
227
Best Practice
Energy Management In Condenser Cooling Water Circuit Of 21 MW Steam Turbine
Objective
To achieve Condenser Vacuum improvement and performance enhancement of Condenser of Steam Turbine
Background
The Steam Turbo-generator related to CPP is one of Double Extraction Condensing type. Exhaust steam leaving the
turbine is at vacuum and is being condensed in the Condenser using cooling water in closed circulation. Steam is
condensed on the shell side with cooling water flows through the tubes in 2 pass arrangement.
Condenser with 2 pass cooling water

circuit.
Cooling water treated on a continuous basis after picking up heat from the waste exhaust steam is returned to the
cooling tower having 3 cells in place. Each of the cooling tower cell has got its own fan for cooling the incoming
warm water.
2of 3 cooling water pumps are

being used for circulating the
cooling water to the condenser
228
As the cooling water pumps were overdesigned and with throttling of outlet valve, the cooling water flow was being
maintained at around 2700 to 2800 m3/h at over 4 kscg pressure. Cooling water velocity in the condenser tubes
was at 1.8 m/s. The temperature rise across the condenser at rated condenser load was close to 8 Deg C. Condenser
vacuum hovered between 0.88 and 0.92 at.
Scheme
As there was no measurement of cooling water flow measurement in place, in order to estimate the exhaust steam
dryness, the flow and temperatures across the condenser were required. Hence it was decided to measure the cooling
water flow measurement using Ultra-sonic flow meter. Towards this , with joint coordination with MITCON –GEA ,
using Ultrasonic sensor , cooling water flow measurements were carried out. The pump throttling was removed with
the result the flow increased by around 25%.
The resultant gain was one of reduction in cooling water flow differential across the condenser.
Consequently the cooling water outlet temperature dropped by 1.5 to 20C.
Parameter Unit Before After

CWP Valve Throttling - Yes No
Exhaust steam flow to Condenser TPH 40 42
CW flow rate to Condenser m3/h 2700 3600
CW inlet temp. to condenser °C 34.1 34.1
CW outlet temp. from condenser °C 41.9 40.1
CW temp. diffl.at Condenser end °C 7.8 6.0
Condenser Vacuum atm 0.90 0.90
Exhaust steam /condensate temp. °C 45.5 46
CW Pump Pressure kg/cm2 4.0 -4.1 2.4 -2.6
Power Consumption –CW Pumps kW 173-176 173-175
Benefits
Increased LMTD and very small drop in condensing steam temperature and unnoticeable improvement in vacuum
is to be expected.
Increased cooling water velocity directly aids in increased heat transfer coefficient. The increased cooling water
velocity integrated with continuous sustained cooling water treatment ensures higher Cleanliness factor. With
Condenser area remaining same & the heat transfer coefficient going up, leverage on increased LMTD is on the
cards.
With all of the above, after the corrections as stated above, the condenser vacuum had certainly had not deteriorated
at any point of time-be it summer or high condenser steam loads as was the case the previous years. The condenser
vacuum ( even after correcting for site elevation) had been between 0.89 to 0.92 atm. ( Refer the Historic Operating
data summarised in Table -2.
Uniqueness
Through the measurements proposed in place, the dryness fraction of exhaust condensing steam leaving to the
condenser could be computed using the algorithm specially developed in place. This concept probably would be
first of its kind.
229
Savings
Coupled with sustained high quality cooling water treatment, the condenser vacuum had been improved, though
marginally. The resultant gain is one of 0.1 MW and some times even higher.
Issue
The issue of higher power consumption of cooling water pumps did not arise , as the pressure loss due to throttling
had been gainfully converted to advantage of higher cooling water flow and consequent condenser tube cleanliness
and marginal increase in vacuum.
Replication
Quality Cooling water treatment along with increased flow velocity would aid in increased cleanliness factor of
condenser tubes and is recommended for all the mills having condenser –water cooling scheme in place..
Consequent reduction in Cooling water outlet temperature needs to be assessed on case to case basis prior to
replication.
Condenser –Cooling Water Cycle –Historic Data
Parameter Unit 2005 2010 2012 2012

Date - 27-12 27-09 28-01 15-05
Condensing TPH 45-48 36-40 48-49 42-45
Vacuum atm 0.885 0.875 0.90 0.895
CW flow m /h
3
2800 2800 3600 3600
CW temp in °C 29 33 31 34
CW temp in °C 38.5 40 37.4 40
ΔTcw °C 9.5 7.5 6.4 6
CW Pump Pressure kg/cm2 (g) 4.1 4.0 2.4-2.6 2.3 -2.5
Power consumption kW 176 173 172 175
CT –All3 Fans running - Yes Yes Yes yes
230
Action Plan & Conclusion
Action Plan
The individual paper plants have to assess the present performance and should develop their own individual
target for improving parameters concerning energy, water and environmental performance.
Set and achieve voluntary target of at least 1 to 5% reduction in specific energy consumption every year.
The best practices and the performance improvement projects compiled in this manual may be considered
for implementation after suitably fine tuning to match the individual plant requirements.
If required, CII-Godrej GBC will help the individual units to improve the performance by providing energy
audit services and identifying performance improvement projects specific to individual units to achieve the
targets.
The present level of performance and the improvements made by the individual units have to be
monitored.
The performance improvement of these units will be reviewed in the “Papertech” every year and the
information will be disseminated among the Indian Pulp and Paper plants.
Conclusion
The objective of the project will be fulfilled only if the performance of all the pulp and paper units improves and
achieves world class standards.
We are sure that the Indian Pulp and Paper units will make use of this opportunity, improve their performance and
move towards the world class Energy Efficiency.
231
232
Annexure A
Indian Delegation attended the workshop in Sweden during 15 - 19 April, 2012
Sl.No. Name Company
1. Mr. Vijay Patharkar Bilt Graphic Paper Products Ltd
2. Ms Anjali Bhola Export Radet
3. Mr Vijay Kumar Indian Newsprint Manufacturers Association (INMA)
4. Mr. N. Moorthy Indian Pulp Manufacturers Association
5. Mr. A.L.N. Krisnamohan ITC Limited
6. Mr. Viswanathan Murali ITC Limited
7. Mr. Sajan Kumar Sriniwas Mishra Khanna Paper Mills Ltd
8. Mr. Anil Trakroo Khanna Paper Mills Ltd
9. Mr. P.K. Garg Mysore Paper Mills Ltd
10. Mr. B.N. Srinivasa Mysore Paper Mills Ltd
11. Mr. Pawan Aggarwal Naini Tissues Limited
12. Mr. Apurve Goel Rama Paper Mills Ltd
13. Mr. Kasi Vishwanathan Seshasayee Paper & Boards Ltd
14. Mr. Anil Kumar Shreyans Industries Limited
15. Mr. Siddha Jothykrishnan Varadarajan Tamil Nadu Newsprint
16. Mr. BH Rathi The West Coast Paper Mills Ltd.
17. Mr. Karthikeyan Sattanathan Confederation of Indian Industry
18. Mr. Mahesh Puranam Confederation of Indian Industry
233
234
Annexure B
Attendees of the CII - Working group visit to West Coast Paper Mills, Dandeli
during 8th and 9th May 2012
Sl.No. Name Designation Company
1 Dr T G Sunderraman GM (Energy & Climate Change) Seshasayee Paper & Boards Limited
2 Mr. I J Singh CGM Star Paper Mills Limited
3 Mr. B S Ravindra Engineer Andhra Pradesh Paper Mills Limited
4 Mr. G Nageswara Rao Sr Manager (paper) Mysore Paper Mills
5 Mr. Narayan Mutsaddi Manager (Energy & recovery) Mysore Paper Mills
6 Mr. Satish Sankhyan Deputy General Manager - Projects Metso
7 Mr. Sujay Majumdar Start-up Commissioning Manager Metso
8 Dr. S. Chinnaraj Sr. Manager (R & D) TamilNadu Newsprints & Papers Limited
9 Mr. S. Nagarajan Sr. Manager (Energy) TamilNadu Newsprints & Papers Limited
10 Mr.P Price Tholkappian Sr. Manager (Mech) TamilNadu Newsprints & Papers Limited
11 Mr. M. Shanmugam Sr. Manager (Paper) TamilNadu Newsprints & Papers Limited
12 Mr.Mahesh Puranam Counsellor Confederation of Indian Industry
13 Mr.Ajay Ranjith V Engineer Confederation of Indian Industry
14 Mr.Ravi Teja Engineer Confederation of Indian Industry
235
Notes
236
About us
The Confederation of Indian Industry (CII) works to create and The Centre is housed in a Green Building which received the
sustain an environment conducive to the growth of industry in
India, partnering industry and government alike through
prestigious LEED (Leadership in Energy and Environmental
Design) Platinum Rating in 2003. This was the first Platinum
advisory and consultative processes. rated Green Building outside of U.S.A and the third in the world.
The Centre was inaugurated by H.E Dr A P J Abdul Kalam, the
CII is a non-government, not-for-profit, industry led and then President of India, on July 14, 2004.
industry managed organisation, playing a proactive role in
India's development process. Founded over 117 years ago, it is Volume 5
India's premier business association, with a direct membership
of over 6600 organisations from the private as well as public
sectors, including SMEs and MNCs, and an indirect membership
of over 90,000 companies from around 250 national and
regional sectoral associations.
With 63 offices including 10 Centres of Excellence in India, and 7

overseas offices in Australia, China, France, Singapore, South
Africa, UK, and USA, as well as institutional partnerships with About IPMA
223 counterpart organisations in 90 countries, CII serves as a
reference point for Indian industry and the international Indian Paper Manufacturers Association (IPMA) has emerged as
business community. a national level organisation and is an apex Association provides
a broad based common platform to project Industry's view and
CII – Sohrabji Godrej Green Business Centre (CII – Godrej GBC) is to articulate its strategy to cater to the growing need and global
one of the 10 Centres of Excellences of the Confederation of vision of the Paper Industry. Large Paper Mills from private and
Indian Industry (CII). public sector with a product mix of all varieties of Paper
(Writing, Printing, Packaging, Speciality, Paper boards and
CII-Sohrabji Godrej Green Business Centre offers advisory Newsprint) located in all regions and using conventional fibre
services to the industry in the areas of Green buildings, energy such as wood and bamboo and also unconventional raw
efficiency, water management, environmental management, materials like bagasse, recycled paper, etc. Comprise the
renewable energy, Green business incubation and climate Membership of IPMA in broad spectrum. The Association is
change activities. registered with the Registrar of Societies, Government of NCT of
Delhi.
The Centre sensitises key stakeholders to embrace Green
practices and facilitates market transformation, paving way for IPMA strives to promote, protect and improve trade, commerce
India to become one of the global leaders in Green businesses and Industry in general, with a focus on Industry connected with
by 2015. Paper in particular.
For further details, please contact:
Mahesh Puranam
Survey No 64, Kothaguda
Near HITEC City, Hyderabad - 500 084 mahesh.puranam@cii.in
Tel: +91 40 44185 101 +91 40 44185146
Fax: +91 40 23112837
www.greenbusinesscentre.com

Papertech Manual 2012 Vol 5

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Papertech Manual 2012 Vol 5

Uploaded by

Copyright:

Available Formats

About us

With 63 offices including 10 Centres of Excellence in India, and 7

For further details, please contact:

List of Swedish Companies included

Core working group:

Facilitator – Pulp and Paper Cleantech Project

Development of “Best Practices Manual – Pulp & paper Industry, Volume 5”

The project partners are

Project Objectives and Outcomes

2. Profile of the company: Areas of expertise

2. Profile of the company: Areas of expertise

3. About the latest services on the offering

(i) Bleaching Chemicals:

(iii) De-inking Chemicals

(iv) Non-Wood Bleaching

(i) Retention, dewatering, dry strength

(ii) Sizing Products

(iii) Coating Products

(iv) Wet Strength Products

(v) Tissue Additives

1. Introduction to the Company

2. Profile of the company: Areas of expertise

3. About the latest technology on the offering

Compact Heat Exchangers - Dealing with fibrous fluids

Spiral Heat Exchangers

Separation – chemical recovery Extract and Purify by-products from process

Dynamic Spray Devices - Industrial Rotary Jet Heads

Performance reliability and long service life

High product integrity

Supply and delivery

Part of a broad range of tank cleaning devices

1. Introduction to Andritz Pulp & Paper

2. Profile of the company: Areas of expertise

Special focus 1: ANDRITZ technologies for dissolving pulp production

ANDRITZ capabilities for paper production

c. White liquor modification

Strong presence in India

2. Profile of the company: Areas of expertise

3. About the latest technology on the offering

Approximate Investment at Present Value

Sources of further information

1. Introduction to the company

2. Profile of the company: Areas of expertise

3. About the Latest technology on the offering

b. Pulper Rotor type S

c. Grubbens Stock Pump

d. High Density Cleaner

Dewaterer type SDC

Dewaterer Screw type SDPP

Advantages with the Krima screw press type KSR:

Screw Press type RR

Compact Disperging system

The advantages with Krima Bleaching System:

Low carbon footprint

Fig: Carbon footprint of various fuels

2. Profile of the company: Areas of expertise

P500 Expansion Unit

P2000 Replacement Unit

X2000 Combined Cycle Unit

3. About the latest technology on the offering

Gasification – gas quality, energy efficiency and integration

Fig: Schematic of a Chemrec gasifier with gas cooler steam

Energy efficiency through heat generation

Fig: Schematic of Chemrec and conventional gasification processes