Paper Mill READY

Bachelor of Science in Mechanical Engineering
College of Engineering and Technology

Golden Gate Colleges
Batangas City
Paper Mill Based Waste Paper Plant

Research in Industrial Plant Engineering
Submitted By:
Malicse, Angelica Mae D.
BSME 5th year
Submitted to:
Engr. Reynald Ilagan
IPE Instructor
January 25,2021
Golden Gate Colleges- BSME
Table of Contents
Chapter 1
Introduction………………………………………1
Brief description of the research……………….2
Chapter 2
Product Description and Application………….….3
The Production Process of Paper…………….….3
Raw Material Section………………………….……5
Papier Mache Preparation Section…………….….5
Paper Machine Section…………………….……….6
Paper Mill Glossary……………………………….….7
Chapter 3
Plant Location………………………………….…….28
Site and Plant Layout…………………………….….34
Plant Operation and Control…………………….…...35
Utilities…………………………………………….…….36
Storage………………………………………………….38
Waste Disposal………………………………………….39
ii
Health and Safety Program……………………….……...42
Material Handling…………………………………….…….47
Equipment Specifications……………………………….…48
Fire Protection………………………………………………57
Fire Extinguisher Layout………………………………...…62
Air Pollution Control System………………………….…...63
Heating and Cooling Calculation………………………....64
Waste water Treatment Layout…………………………...70
Chapter 4
Market Analysis……………………………………………….72
Production Schedule………………………………………….73
Capacity……………………………………………………….73
Paper Mill Organization Chart……………………………….74
Estimated Project Cost………………………………………75
Planning Schedule……………………………………………75
Reference………………………………………………………………..76
iii
List of Figures
Figure 2.1. The Flow of Paper Produced from Waste Paper
Figure 3.1 Plant Location in Brgy. Wawa Taguig near Pumping Station
Figure 3.2 Climatic Conditions in Taguig
Figure 3.3 Average Temperature in Taguig
Figure 3.4 Average Humidity in Taguig
Figure 3.5 Land Utilization Summary
Figure 3.6 Plant layout for Paper Mill
Figure 3.7 Operation of Pulp Mill (Continuous Flow System)
Figure 3.8 Operation Pulp Mill and Paper Machine Equipment
Figure 3.9 Process flow of Effluent Treatment Plant for Paper Mill
Figure 3.10 Fire Extinguisher Mounting Height
Figure 3.11 Fire Extinguisher Layout
Figure 3.12 Air Pollutant Types From Paper Mill
Figure 3.13 Effluent Waste Water Treatment Layout
Figure 4.1 Organization Chart
Figure 4.2 Estimated project cost
Figure 4.3 Planning Schedule (Gantt Chart
iv
CHAPTER I
Introduction
Paper has become an important necessity of our day-to-day life. Modern life
depends on paper and millions of tons of it are made and used each year. In present
time, writing paper demand is increasing day by day in our country and other region.
The range of possible uses of paper is limitless and new ways of using it are being
devised daily.
Paper is a uniform, felted sheet, composed of fibrous and non-fibrous additives,
which has been formed on a fine screen from a water suspension and, subsequently,
pressed, dried, and calendared. The sheet may also be sized and/or coated depending
on its intended use. Paper is produced by mechanically and/or chemically processing
cellulose fibers derived from wood, rags, grasses or other vegetable sources in water,
draining the water through fine mesh leaving the fiber evenly distributed on the surface,
followed by pressing and drying which is made from trees mostly grown on working
forests and from recovered paper.
The production and use of paper have a number of adverse effects on the
environment. Worldwide consumption of paper has risen by 400% in the past 40 years
leading to increase in deforestation, with 35% of harvested trees being used for paper
manufacture. Most paper companies also plant trees to help regrow forests. Logging of
old growth forests accounts for less than 10% of wood pulp, but is one of the most
controversial issues. Some manufacturers have started using a new and improve,
significantly more efficient way of producing paper. Recycling has always been a part of
1
papermaking. Thus, recycled paper was used in new paper products, reducing the
number of trees that need to be harvested to make paper.
Brief description of the research
The research is all about manufacturing and process of a Paper Mill producing
A4 Typewriting Paper, capacity 40 TPD OR 12000 TPA. The proposed paper mill will
generate pulp from recycling of waste paper as raw material and subsequently pulp
obtained from recycling of waste paper will be utilized for production of writing paper.
The paper mill is located at Circumferential Rd. 6, Brgy. Wawa, Taguig, Metro Manila
near Taguig Pumping Station 15 kms from the city of Manila and 29 kms from the waste
paper supplier.
2
Chapter II
PRODUCTION PROCESS
Product Description and Application
The paper mill will produce an A4 writing paper made of waste recycled papers
that is also biodegradable in nature to conserve the environment by saving trees. A4
paper is the size most used in the world. It is used as the classic paper sheet in all
industrialized countries. Today, it is used for all printing documents, letters, magazines,
forms, bit notice, posters, catalogues, magazines. In Engineering A4 size paper is the
mostly used as hard copy of drawing or document in a handy way. A4 measures 210 ×
297 millimeters or 8.27 × 11.69 inches, As per the paper thickness, 50-80 GSM will be
produced that gives appropriate level of brightness in addition to ensures proper print.
The production will be helpful to save the environment and conserve natural resources
by use of waste paper instead of cutting of trees for making pulp and paper.
THE PRODUCTION PROCESS OF PAPER
Operation steps in recycling of paper products in different qualities can vary
according to the means of the facility and desired paper class. Process variables that
are used in recycling are studied under 5 groups, even though some discrepancies may
occur (Şahin, 2011):
 Pulper
 Sieving and cleaning
 Dispersion
3
 Ink removal (for some special paper products)
 Whitening (for some special paper products)
Figure 2.1. The Flow of Paper Produced from Waste Paper
4
A. Raw Material Section
 Waste paper Stocking

Conservation and protection of purchased raw material. It is also important to
keep the paper out of rain and sunlight, because exposure to the elements
makes it harder to remove the ink from the paper.
 Waste Sorting Unit
Sorting of mixed raw material according to their types such as plastics, glass,
iron, etc. You can help by presorting your household waste, by separating
newspapers, for example, from magazines. One of the most expensive parts of
recycling is the collection, sorting, baling, and transportation of waste paper.
B. Papier Mache Preparation Section
 Raw Material Feeding Unit- waste paper is put on production line.

 Spread the Papier Mache (Pulper) Unit – turning waste paper into Papier
Mache in pulper.
 Rough Sieving Shelling Unit- remove Papier Mache from sand, metal and
plastics.
 Fine Sieving Shelling Unit- remove the Papier machine from fine.
 Reject Evacuation Unit- Evacuating foreign particles that are cleaned out from
the sieving system.
 Fine sand Separating Unit- remove the sand, soil etc. which are found in Papier
Mache.
 Density Unit- increase the rate of papier Mache’s dry matter from 1-1.5% to 9-
10%
 Chemical and Milling unit- to add paper chemicals to Papier Mache whose
density is high and re-milling.
5
C. Paper Machine Section
 Bute unit of Machine- Filling of production ready papier-mâché to the bute
(stocking) of machine.
 Head Box Unit- To turn Papier-Mache to lamina form and transfer to sieve.
 Sieve Unit for Purification from Water- To increase the rate of paper lamina’s
dry matter from 1-1,5% to 16-20% with the use of.
 Press Unit - To increase the rate of paper lamina’s dry matter from 16% to 48-
51% with the use of press and vacuums.
 Drying Unit- To dry lamina in drying cylinders up to 7,5% humidity.
 Quality Control System- To measure the produced paper’s values such as
gram, humidity, quality etc.
 Stuff Wrapper- To wrap the paper in production line into the buffer.
D. Paper Cut Section
 Manufactured Paper Cutting Dimensioning Unit- To cut the bobbins and cut
according to dimension of paper demand clients.
 Manufactured Paper Packing Unit- To store cut papers to the product
warehouse after weighing and packing them.
6
Paper Mill Glossary
ABRASION RESISTANCE
Ability of paper product to withstand abrasion. Measured by determining degree and
rate that a sample loses weight under specific rubbing action of an abrading substance,
such as an eraser.
ABSORBENCY
Property of pulp, paper, and its constituents and products that permits the entrainment
and retention of other materials it contacts, such as liquid, gaseous and solid
substances.
ACCEPTS
Stock after it has been subjected to some cleaning processes.
AFTER DRYERS
The bank of dryers positioned after intermediate or sizing rolls.
AGITATOR
(1) Propeller or agitating shaft for stirring the pulp suspension in a chest or tank. (2) A
rotating device for mixing fluids and fluid suspension in a tank or chest.
AIR DRY (a.d.)
7
Weight of moisture-free pulp or paper plus a nominal 10% moisture based on traditional
assumption that this amount of moisture exists when they come into equilibrium with the
atmosphere.
AIR DRYING
A method of drying the paper web on the paper machine by blowing air along the
direction of the web.
APPARENT DENSITY
Weight (mass) per unit volume of a sheet of paper obtained by dividing the basis weight
(or grammage) by the caliper (thickness).
BACKWATER
Water used in the papermaking process, recycled to reduce the wastage of fresh water,
and normally contains residual amounts of fibres and chemicals.
BACKS
The waste paper stock used to make the bottom ply of a sheet of board.
BAFFLE
A device which obstructs the flow of fluid, whether to aid mixing or restrict the flow rate.
BALE
Solid, compressed stack of pulp or paper sheets.
BASESTOCK
8
Paper or board to be further treated in various ways.
BASIS WEIGHT
Weight in pounds of a ream of paper, usually consisting of 480, 500, or 1000 sheets of a
specified size, according to grade. In countries using the metric system, more
commonly referred to as grammage and expressed as g/m 2.
BEATER
Large, longitudinally partitioned, oval tub used to mix and mechanically “work” pulp with
other ingredients to make paper.
BEATING
Mechanical treatment of fibres to improve fibre bonding. See Refining
BINDERS BOARD
Grey coloured, glazed board often used in the binding of hardcover books.
BISULPHITE PULP
Pulp made by the bisulphite cooking process using bisulphite cooking liquor.
BLEACHING
Chemical treatment to whiten, purify and stabilize the pulp normally carried out in
several stages.
BLENDING
Blending of different pulps in a chest to determine the quality of the final product.
9
BOGUS
Product that has been made from wastepaper or other inferior materials to imitate
higher-quality grades.
BOND
Class of printing/writing papers made from bleached chemical woodpulps and cotton
fibres.
BONDING STRENGTH
lntralayer binding force in a multi-ply paperboard or laminate. Also refers to the degree
of adherence of coating and film on a sheet and to the inter-fibre binding force within a
sheet.
BREAKS
When the paper being made on the paper making machine ruptures while passing
through the machine.
BREAKING
Process of returning sheets to liquid form.
BRIGHTNESS
Measure of the degree of reflectivity of a sheet of pulp or paper for blue light measure
under specified standard conditions. (Also, though incorrectly, called whiteness).
BRISTOLS or BRISTOL BOARDS
10
Heavy graded papers possessing higher than average quality characteristics. Rigid
enough to be used for announcements, invitations, postcards etc.
BROKE
(1) Paper trimmings or damaged paper due to breaks on paper machine and in finishing
operations.
(2) Paper which has been discarded during any stage in its manufacture; represents
loss in time, money and effort.
BROKE PIT
A pit below the machine into which broke is disposed from the machine floor.
BULK
Compactness property of a sheet in relation to its weight (whose value decreases as
compactness increases). Bulk is calculated as caliper divided by grammage.
CALENDER / CALENDERS
Piece of processing equipment located at dry end of paper machine, consisting of a set
of smooth faced rolls through which paper sheet is passed for smoothing, levelling,
polishing and gloss improvement. The rollers may be of polished metal (hard), or
composite material (soft); the hardness of the material affects the degree to which the
paper or board is crushed. Furthermore, the equipment could be placed in-line at the
end of the paper machine just before reel-up, or done as an off-machine process (see
supercalender).
11
CALENDER FINISHED
Paper and paperboard passed through a calender to improve surface characteristics by
application of pressure, friction or moisture.
CALIPER
Thickness of a sheet of paper or paperboard, measured under certain specifically stated
conditions, expressed in units of thousandths of an inch (called “mils” when referring to
paper, and “points” when referring to paperboard). In regions using metric
measurement, usually measured in millionths of a metre (microns or µm). Also called
thickness.
CAMBER
Greater diameter in the centre of a papermaking roll, compared to the ends; this
compensates for roll weight.
CAPSTAN
Machine to wind cable or rope.
CARBONIZING PAPER
Lightweight, uncoated paper made from unbleached chemical and/or mechanical pulps
and surface coated with a carbon solvent or wax so that it takes up carbon inks and
releases them under pressure, thereby duplicating the inked areas being printed.
CARBONLESS PAPER
12
Copying paper that is treated or coated so it can be used without needing carbon
coating or interleaved carbon paper.
CARLOAD
Quantity of paper shipped from mill in or on a freight car. Must exceed a freight
classification zone minimum weight to qualify for carload freight rate.
CAST COATED PAPER
Very high gloss coated paper and paperboard with surface characteristics produced by
allowing applied coating to harden while in contact with surface of steam heated, highly
polished, chrome plated drum.
CHEMICAL PULP
Mass of fibres resulting from reduction of wood or other fibrous raw material into
component parts during cooking phases with various chemical liquors in processes
such as sulphate, sulphite, soda and neutral sulphite semi-chemical process (NSCC).
CHEMICAL PULPING
Process of dissolving and extracting the lignin in wood by chemical means.
CHIPPER
A machine that chips logs after de-barking.
CLARIFIERS
Storage tanks in which suspended solids are allowed to settle and be removed from
green and white liquors in the causticising areas of a pulp mill.

13
COATED
Papers and paperboards that contain a layer of coating material, such as clay or
pigment, in combination with an adhesive.
COATING
Process by which paper or board is coated with an agent to improve its brightness
and/or printing properties.
COIL
A wound length of paper board in which the diameter is much greater than the width.
COMBINATION BOARD
Multi layered, cylinder made paperboard having outer and inner layers made from
different pulp stocks.
COMBINED BOARD
Multi layered board made by uniting a number of boards with proper adhesives.
CONSISTENCY REGULATOR
A device for diluting pulp stuff to a steady, preset solids content.
CYLINDER MACHINE
Machine primarily used to make paperboards. The forming cylinders are covered with
wire, so that, as they turn within a vat filled with stock solution, fibres are picked up to
form a web on the surface with water draining through and passing out at the ends. The
14
wet sheet is then transferred off the cylinder onto a felt for possible combining with other
sheets (multiple cylinders on same machine) and subsequent pressing and drying.
DANDY ROLL OR WIRE ROLL
A hollow roll with varied coverings, usually metal, that compacts the fibres and applies
finish characteristics e.g. a watermark.
DEBARKING DRUM
A cylindrical hollow tube (drum) through which logs are fed.
DECKLE
The width of the paper being produced on a paper or board making machine.
DEFIBRATION
Separation of wood fibres by mechanical and/or chemical means.
DEFIBERING
Term for pulping processes i.e. separating the fibres of pulp bales, broke or waste
paper, in water by mechanical action.
DEINKING
(1) Removal or printing ink and impurities from recovered paper; to produce recycled
fibre pulp with maximum whiteness by a floatation or washing process.
15
(2) Removal of ink and other undesirable materials from wastepaper by mechanical
disintegration, chemical treatment, washing and bleaching before reusing as a source of
papermaking fibre.
DEINKING CELL
Vessel in which glues and inks can be removed from post consumer or recycled waste.
DIE CUT
Paper and paperboard products cut by a metallic die to specified dimensions or form.
DIGESTER
Pressure vessel used to chemically treat chips and other cellulosic fibrous materials
such as straw, bagasse, rags etc, under elevated temperature and pressure in order to
separate fibres and produce pulp.
DRY END
Portion of a paper machine where sheet moisture is removed by evaporation. Consists
of several dryer sections or air dryers, depending on type and size of the machine. The
end of the papermaking machine where the wet paper is dried, maybe calendered, and
reeled up.
DRYER FABRIC
Fabric woven from high temperature resistant synthetic materials to support and provide
contact for the damp paper web with the hot dryer cylinders, at the dry end of the
papermaking machine.
16
DRYERS
(1) The steam heated cylinders on the papermaking machine over which the wet paper
passes and is dried.
(2) Portion of a paper machine where water is removed from wet paper by passing it
over rotating, steam heated, cylindrical, metal drums or by running it through a hot air
stream.
EFFLUENT
Waste backwater and rejects from which fibre is recovered prior to discharge from the
mill.
ELECTROSTATIC COPY PAPER
Smooth finished, stable, medium weight bond paper made from chemical pulps.
Generally treated with a zinc oxide coating material and used on dry type office copying
machines.
ELMENDORF TEST
Test commonly used in paper mill laboratories to determine tear resistant property of
paper. Also called tear test
ELONGATION
Physical property of a paper sheet that allows it to experience a certain degree of
stretching.
EMBOSSED
17
Paper finish obtained by mechanically impressing a design on the dry sheet or web with
engraved metallic rolls or plates.
ENAMEL
Clay coating on coated paper.
FINES
Small fibres that pass through the wire of the papermaking machine.
FINE PAPERS
High quality printing/writing and cover papers having excellent surface characteristics
for pen and ink writing.
FINISH
Surface characteristics of sheet of paper, such as smoothness, appearance and gloss,
as determined visually.
FINISHING
Processing of paper after completion of papermaking operations, including
supercalendering, slitting, rewinding, trimming, sorting, counting and packaging, prior to
shipment from mill.
FLEXOGRAPHIC PRINTING
Rotary letterpress printing process using liquid ink. Solvent-based formulations made of
aniline dyes and pigments (mixed with a binder) dry primarily by evaporation due to the
solvent vehicle; water-based formulations have now become more common and are
18
force-dried either by heat or irradiation (if the ink contains monomers that can be
polymerised by UV-irradiation). Sometimes called aniline printing.
FLUORESCENT PAPER
White paper made with synthetic dyes that produce a brighter appearance when
irradiation by some light. Primarily these materials absorb radiation in the UV region and
re-emit in the visible, tending to give the paper a bluish tinge. Alternatively, this
describes paper that is surface coated with coloured, light emitting dyestuff materials
(which reflect white light as colour).
FORMATION
The manner in which paper fibres are mixed in a sheet of paper. Physical distribution
and orientation of fibres and other solid constituents in the structure of a sheet of paper
that affects its appearance and other physical properties.
FOURDRINIER
The name of the brothers who developed the first process for making paper on a
continuous wire belt. Paper machines incorporating this principle are Fourdrinier
machines, and are still the most common form of paper machine in use today.
FOURDRINIER WIRE
Continuously travelling, endless, woven, metallic or plastic screen belt located in wet
end section of fourdrinier paper machine. Pulpstock is fed onto wire so that water is
drained from it as fibres oriented to form a continuous web.
GRINDER
19
A machine in which logs are defibered (or defibrated) against a revolving grindstone
GROUNDWOOD PAPER
Paper that is made from a furnish containing a large percentage of groundwood pulp.
HEAD BOX
Device for applying and distributing stock onto the wire that keeps fibres from clogging
together so that a consistent formulation can be achieved. Also known as a breast box
or flow box.
HYDRAPULPER
A metal tank fitted with an agitator rotor for disintegrating pulp and broke in water.
INDUSTRIAL PAPERS
Paper made for purposes such as industrial packaging, tissues, wrappings,
impregnating, insulating etc.
LINER
A term in board-making used to denote the top ply, usually of better quality, in a sheet of
cardboard.
MACHINE COATED
Paper and paperboard that have surface coating of adhesives and minerals applied
while being made on the paper machine, as an integral part of the papermaking
operation.
20
MACHINE DIRECTION (MD)
Direction from the wet end to the dry end of a paper machine or to a paper sheet
parallel to its forward movement on a paper machine.
MACHINE FINISH (MF)
Surface finish produced on an uncoated sheet of paper as it is being made on the paper
machine, and usually accomplished with limited calendering on the machine calender
stacks.
MACHINE FINISHED OR MF
Smooth paper calendered on the machine.
MACHINE GLAZED (MG)
High gloss surface finish produced on the wire side of a sheet by passing it over a large
diameter, highly polished, steam-heated roll as used on Yankee type paper machine
dryers.
MANIFOLD PAPER
Very thin regular bond paper with glazed or unglazed finish used to make carbon copies
of letters.
MATTE
Paper and surface finishes with very low gloss or lustre.
MEASURING UNIT OR SCANNER
21
Cross machine unit using ionising radiation source to gauge web characteristics such as
weight.
MECHANICAL PULP
Pulp produced by reducing pulpwood logs and chips into their fibre components by the
use or mechanical energy, via grinding stones, refiners etc. Grinding and screening of
chips to separate the fibres without removal of lignin.
MECHANICAL WOODPULP
Pulp made by grinding coniferous logs, which have had the bark removed.
MOISTURE CONTENT (MC)
Percent of water by its weight in paper, pulp, paperboard, chips etc., which will vary
according to atmospheric conditions because of the ability of these types of materials to
absorb or emit moisture.
MOISTURE PROOF
Ability of paper and paperboard to resist the penetration of water vapour.
MOISTURE VAPOUR TRANSMISSION RATE (MVTR)
Ease or rate of water vapour permeation through a sheet of paper.
MULTI-PLY
Paper or paperboard sheet made up of two or more layers.
NEWSPRINT
22
Grade of paper, combining high percentages of groundwood pulp, made especially for
use in the printing of newspapers.
OFFSET PRINTING
Process of indirect printing in which an impression of type or a design on a flat plate or
cylinder is transferred to a rubber blanketed cylinder from which it is impressed (“offset”)
upon the surface to be printed.
PACKAGING PAPER
Collective term for papers of different pulp composition and properties, sharing only the
application.
PAPER
Homogeneous sheet of felted cellulose fibres, bound together by overlapping and by
self-bonding (“hydrogen bonding”) or by the use of bonding agents, and made in a
variety of types.
PAPER STOCK
Water slurry of various pulp fibres, dyes, additives and chemicals that is pumped to the
paper machine for forming into a sheet.
PICK UP ROLL
Roll, which lifts the wet paper or board off the wire before the drying section.
PIGMENT
23
An insoluble mineral or organic powder used as a dye to colour paper and as an
additive to impart specific properties, such as bulk, porosity and opacity to the sheet.
PULP
Fibrous material produced by mechanically or chemically reducing plants into their
component parts from which pulp, paper and paperboard sheets are formed after proper
slushing treatment. Also used for dissolving purposes (dissolving pulp or chemical
cellulose) to make rayon (or viscose) and other synthetic products.
PULPER
Machine that disintegrates fibrous raw material using water and mechanical agitation.
PULPING
Separation of the fibres in the raw material that permits individual cellulose fibres to
form a free suspension in water.
RECOVERED PAPER
Paper recovered for recycling into new paper products.
RECYCLED FIBRE
Fibre obtained from recovered paper; also called secondary fibre, or Paper for
Recycling (PfR).
REEL
A term given to a wound length of paper or board in which the diameter is approximately
equal to the width.

24
REELER
A machine for rewinding reels or webs, slitting them to narrower width or widths and
trimming off the deckle edges.
REEL UP
The part of the dry end of a paper machine which winds up the paper web into a reel.
REFINER MECHANICAL PULP (RMP)
Pulp made by processing untreated woodchips in mechanical atmospheric refiners.
REFINING
Pulp and paper mill operations conducted of fibre suspensions to rub, brush, crush, fray
or cut fibres as desired. Imparts such characteristics as increased capacity to absorb
water and improved sheet formation.
REGISTER PAPER
Lightweight writing grade made from chemical pulp and possessing good tensile and
tearing strength. Comes in rolls especially for automatic register machines and in flat,
folded, snip apart packages for computer printouts and other copying purposes.
SLURRY
Liquid mixture consisting of suspended fibres, fillers, coating pigments and other solid
material in water or adhesive, used in the papermaking process.
SULPHATE PROCESS
25
An alkaline pulp manufacturing process in which the active components of the liquor
used to cook chips in a pressurised vessel are primarily sodium sulphide and sodium
hydroxide, with sodium sulphate and lime being used to replenish these chemicals in
recovery operations. Also called kraft process.
SULPHITE PROCESS
An acid pulp manufacturing process in which chips are reduced to their component
parts by cooking in a pressurized vessel using a liquor composed of calcium, sodium,
magnesium, or ammonia salts of sulphureous acid.
TRANSPARENCY
Ability of paper to allow light rays to pass through it in such a manner that objects
behind it can be clearly seen.
TRIM
(1) Dimension of the widest sheet of paper that can be made on a paper machine, not
including the edges (which are normally cut off).
(2) Part of the web trimmed off with the rough deckle edge on a reeler.
TURBINE
Rotative device for converting boiler house high pressure steam to kinetic energy, and
coupled to a generator, produces electricity.
WET END
26
(1) Section of the head end of a paper machine, which includes the head box, wire and
wet press sections. Where the sheet is formed from the stock furnish and where most of
the water is removed before entering the dryer section. Also called wire end.
(2) The first part of the paper machine up to the drying section.
WET MACHINE
Paper machine consisting essentially of a wire covered cylinder rotating in a vat of pulp
stock on which a mat of varying thickness is formed by drainage. These mats are
removed either intermittently in thick sheets called laps, or continuously.
WET STRENGTH PAPER
Paper in which the fibre constituents and/or the sheet are chemically treated to enhance
resistance to tear, rupture or disintegration after becoming saturated with liquids.
WHITE PAPER
(1) Any paper made from pulp stock who’s natural color has been corrected by the
addition of blue, yellow and red dyestuff.
(2) To a printer, any paper sheet that is devoid of printing material.
WARP
The thread running parallel to the length of a woven textile or wire fabric.
YANKEE CYLINDER
Cast iron cylinder, 8-18 feet in diameter and designed to handle steam pressures of up
to 160 psi. Functions as a press roll and surface for creping.

27
YANKEE DRYER
Type of steam heated paper dryer consisting of a large, revolving drum equipped with a
felt to held the sheet in contact with its highly polished surface. Commonly used for
drying tissue type papers.
CHAPTER III
General Consideration
I. Location
The paper mill is going to be established in a 5-hectare lot located near the road of
Circumferential Rd. 6, Brgy. Wawa, Taguig, Metro Manila. The mill is located near
Taguig Pumping Station beside Taguig River, C-6 road near H3 Concrete Builders
Incorporated in Brgy. Wawa having Latitude 14 o 31’07.72” N & Longitude 121 o04’52.04”
E. It is about 15 kms from the city of Manila and 29 kms from the waste paper supplier.
Project Location Map
28
Proposed
Plant Site
29
Figure 3.1 Plant Location in Brgy. Wawa Taguig near Pumping Station
Considering a good location has a big factor in many aspects of how the business
operates and how it becomes successful, such as its accessibility, the competition day
to-day operating expenses. Considerations why the location was chosen are as follows:
Marketing Area
The paper mill will produce bulk quantities for primary markets such as supermarkets,
school facilities and offices that frequently needs the product.
Raw Materials
30
Waste papers are mainly coming from CARPEL Environment Corporation in
Novaliches. Location is accessible and it is near the road, so the delivery would be
easier. The paper mill project will use 100% waste papers.
Transportation
Since the plant location is near the highway, the delivery would be speedy and
convenient from raw materials up to shipping to customers.
Community and labor attitudes
Availability of men power of requisite skill is also a factor. The residents in the barangay
are very hospitable. Workers are hardworking, skilled labor and very sociable.
Community infrastructure and amenities
The community is accessible and is near the ports. It is having enough power lines and
supply of electricity. The site location is also near the community service facilities.
Climatic Conditions: Geologic & Climatic Conditions
RAINFALL GRAPH // WEATHER BY MONTH
Figure 3.2 Climatic Conditions in Taguig
31
Months with the largest precipitation are August, July, September with 1083 mm
precipitation. Most precipitation occurs in August with an average precipitation 419 mm.
The annual amount of precipitation in Taguig is 1922 mm. The average annual
temperature is 31℃ in Taguig. The warmest month of the year is April, with an average
temperature: 34℃. Usually, January is the coldest month in Taguig, with average
temperature 30℃. The difference between the hottest month: April and the coldest
month: January is: 4℃. The difference between the highest precipitation (August) and
the lowest precipitation (February) is 399mm.
TEMPERATURE GRAPH // WEATHER AVERAGES
Figure 3.3 Average Temperature in Taguig
32
The hot season lasts for 1.5 months, from April 6 to May 22, with an average daily high
temperature above 92°F. The hottest day of the year is April 30, with an average high of
94°F and low of 79°F. The cool season lasts for 2.6 months, from November 23 to
February 13, with an average daily high temperature below 87°F. The coldest day of the
year is January 21, with an average low of 73°F and high of 86°F.
Average humidity over the year
The perceived humidity level in Taguig, as measured by the percentage of time in which
the humidity comfort level is muggy, oppressive, or miserable, does not vary
significantly over the course of the year, staying within 4% of 96% throughout.
Figure 3.4 Average Humidity in Taguig
33
Figure 3.5 Land Utilization Summary
II. Site and Plant layout
14 000 m
5300 m
Scale 1:1000cm
Legend:
1. Waste Paper Area (Conveyor on
ground)
2. Rotary Drum Pulper
3. Caustic Storage
4. Pulping
5. Paper Machine
6. Storage
7. Office
8. Parking
9. Boiler
10. Cogeneration Plant
11. Crude Oil Storage
12. Incinerator
13. Raw Water
14. Electrical Substation
15. Sludge Building
16. Control Room
17. Gas Holder
18. Aeration
19. Primary Clarifier
20. Sludge Tank
21. Ammonia Storage Tank
34 22. Storage Tank Sodium
23. Gap Storage Tank
24. Granulated Storage Tank
25. Anaerobic Digestion
26. Pulping Loading Area
Figure 3.6 Plant layout for Paper Mill
III. Plant Operation and Control
Figure 3.7 Operation of Pulp Mill (Continuous Flow System
35
Figure 3.8 Operation Pulp Mill and Paper Machine Equipment
IV. Utilities
o Power Requirement & Supply/Source
2500 KVA of power will be sourced through Masinloc Power for meeting the
electricity requirement of the project.
o Water Supply for the Plant Process
The location was near the surface water and it requires a treatment to remove
particulate impurities and color before their distribution to the plant process in
order to comply with the quality standards of the product. The water straight from
the surface will use coagulation and flocculation to condition impurities,
especially non-settleable solids and color, for removal from the water being
treated.
o Fuel
8 TPH boiler based on rice husk (6 Ton/Ton of Paper) as fuel will be installed for
meeting the steam requirement of the project. Boiler will be equipped with bag
filters with dust collectors for controlling air pollution and 30 M. height stack for
wider dispersion of pollutants.
o Steam
36
6 Tons of Paper as fuel will be installed for meeting the steam requirement. By
using paper to supplement coal or wood waste, the process produces a cleaner-
burning fuel and may be less expensive than traditional methods.
o Air Compressor
The plant will use oil-free compressors to produce the highest quality paper
possible, free of contamination, or fast and reliable compressed air to operate
plants at maximum efficiency. These compressors are used for roller adjustment,
feeding paper presses, agitating solution and spraying protective coatings on the
paper. In addition, they are used throughout the cutting and pressing system
process.
o Back Up Generator
A large power generator can decrease the plant interruption during a power
outage. An outage of power can occur due to weather, natural disaster or faulty
equipment. A critical element of being prepared for a disaster or power outage is
having a backup industrial generator.
Raw Material Requirement
37
V. Storage
Tanks for a particular fluid are chosen according to the flashpoint of that substance.
Blow Tank
The blow tanks are usually made of carbon steel and the
inner layer requires antiseptic treatment. The insulation is
done on the outside of blow tank, in order to keep the pulp at
a certain temperature in the blow tank. The flat-bottomed
blow tank will be use that has several advantages, such as
simple dasher, convenient maintenance, low cost, easy
installation and have less space occupied. the top of blow
tank is the gas-liquid separator. There are a number of
nozzles on the ring pipe of cone bottom for diluted pulp. The
screw-type dasher is installed on the bottom part of cone
bottom, and its rotation rate is 110r/min. The pulp passes
38
through the blowpipe, along with the tangential direction enter into the blow tank from
the inlet. The waste gas separated from the pulp is usually cleared out of exhaust steam
pipe, and sent to the heat recovery system. The pulp is out from the discharge pipe. The
concentration of pulp storage is about 11-14%.
VI. Waste Disposal
The major sources of pollution are particulate & gaseous emission from stacks of boiler
and Waste water generated due to various activities of proposed paper mill project.
Other sources of pollution are solid waste & noise.
WASTE WATER TREATMENT TYPE:
Approx. 780 KLD of waste water will be generated. An effluent treatment plant based on
Activated Sludge Principle (ASP) will be installed for treatment of generated waste
water of paper mill. Treated waste water will be 70% recycle and reuse in process and
other activities inside the plant and the other 30% treated water will be discharge to
environment.
The combined waste water generated from different process is collected and treated for
using ASP based effluent treatment plant capacity. The equalization tank is provided
with air supply for pre aeration and uniform mixing. From equalization tank, the waste
water is clarified in a primary clarifier for removal of suspended fibres. The clarified
39
waste water is treated by activated sludge process. The aeration tank is provided with
diffused aerators to maintain the dissolved oxygen level required to maintain the proper
metabolic activity of microbial culture. The overflow of aeration tank is further treated
through secondary clarifier for removal of suspended active biomass. After secondary
clarification, a part of the effluent is treated through pressure sand filter for further
recycle and reuse in the pulp mill and the rest is drained out into the local drain. A part
of secondary clarifier underflow is recycled to the aeration tank to maintain desired level
of active biomass and the rest are disposed off in sludge drying beds.
40
Figure 3.9 Process flow of Effluent Treatment Plant for Paper Mill
AIR POLLUTION:
An 8 TPH boiler (6 Ton/Ton of Paper) as fuel will be installed for meeting the steam
requirement of the plant. Boiler will be equipped with bag filters with dust collectors for
controlling air pollution and 30 M. height stack for wider dispersion of pollutants.
SOLID WASTE MANAGEMENT:
All these waste paper sheets will be recycled and reuse inside the premises in
manufacturing process. The boiler ash will be generated due to burning of rice husk as
boiler fuel. This boiler ash will be sold to vendors for filling activities. Sludge from ETP
will be used and sold as manure.
41
VII. Health and Safety Program
In order to create a safe and effective work environment, employees must be able to
identify the occupational hazards that lurk around every corner. According to OSH, Pulp
and paper manufacturing can be very hazardous due to massive weights and falling,
rolling, and/or sliding pulpwood loads. Workers may be struck or crushed by loads or
suffer lacerations from the misuse of equipment, particularly when machines are used
improperly or without proper safeguards.
Injury Statistics, Hazards and Regulations
Having and properly using the correct PPE is a critical aspect of your safety program.
Regulations like OSHA 29 CFR 1910, ASTM F739-12 for Permeation of Liquids and
Gases and NFPA 2112-Standard on FR Garments, equipment improvements, and the
proper use of PPE have resulted in the decline the numbers of fatalities and injuries
over the years. But even one injury is too many. The safety engineer must navigate the
regulations to ensure the workers get home safely.
42
This section highlights the hazards, controls, and safe work practices inside the plant.
1. It is common practice to install single point or barrier guarding, or other
engineering measures to prevent pinch point injuries. Identifying, proper
reporting, and resolution of potential dangers should be an ongoing effort for all
employees.
2. If an object were to enter an ingoing nip, it would be accelerated to the speed of
the paper machine and become a dangerous projectile when it exits.
3. Be cautious of sharp surfaces when:
o Working with your hands. Hand injuries are the most common injuries
associated with sharp surfaces.
o Using tools that are sharp by design, like saws and knives. For
example, when using a utility knife, always cut away from your body.
o Working around moving fabrics on paper machines. Bumping up
against the edge of a moving fabric will cause a very serious cut.
o Handling doctor blades and worn creping blades. Always follow
established procedures and wear all required PPE for your location.
o Performing new or unfamiliar tasks. Be alert for metal burrs, protruding
bolts, and sharp or rough edges.
4. Be aware that hot surfaces may sometimes remain hot for minutes, or even
hours, after a machine has been turned off. If you are unfamiliar with a machine,
don’t touch its surface unless you are sure it is safe.
5. Slips, trips, and falls are responsible for many industrial facility injuries, and
they’re a serious concern at paper manufacturing facilities as well. Injuries

43
ranging from cuts and bruises to broken bones, paralysis, and even death can
result from falls at ground-level or from only a few feet.
6. Maintenance and operations personnel should regularly use pressurized air to
perform “blowdowns” to remove dust from equipment surfaces and keep it from
accumulating. However, blowdowns temporarily increase the amount of dust in
the air, causing a respiratory hazard. This hazard can be reduced by using dust
masks or other forms of respiratory protection.
7. Workers should wear ear protection, like ear plugs and ear muffs, when working
in known and designated loud areas.
8. It is important that all substances are properly labeled to ensure proper
procedures are followed in the event of an incident. When working with
chemicals, always refer to the Safety Data Sheet, formerly called the Material
Safety Data Sheet. This document gives all of the known hazards and safety
precautions for that substance.
9. Always wear all required personal protective equipment when working with
chemicals. Know the location of all showers and eyewash stations in your work
area. If you get chemicals in your eyes or on your skin, flush with water
immediately to dilute the chemical and wash it away. Seek immediate medical
attention. If you inhale chemical fumes and you are not certain of their hazard
level, you should also seek immediate medical attention.
10. A confined space, as defined by OSHA, is a space that:
o Is large enough that a person can work in it
o Has limited or restricted means for entry or exit
44
o Is not designed for continuous employee presence
Because confined spaces are mostly closed-off spaces, it is possible for
hazardous gases to collect in them. Confined spaces can also lead to oxygen
deficiency, which can lead to light-headedness and loss of consciousness.
Due to the high risks and dangers associated with confined spaces, all
persons must be trained prior to participating in a confined space entry. An
official checklist and procedure from the facility is required to show that the
work in a confined space is safe and authorized. This form is called the
Confined Space Work Permit.
11. Hoses that are not properly stored can cause trip hazards, therefore, they should
be coiled when not in use.
12. Airborne dust is a fire hazard and an explosion hazard, so it is important that dust
is cleaned up and removed often. Even when dust control equipment is present,
dust can accumulate on surfaces such as the upper surfaces of equipment, on
building columns, and on roof trusses.
13. Keeping your paper machine and converting equipment clean and well-
maintained is the most effective thing you can do to prevent fires.
14. To work correctly, PPE must be comfortable and fit correctly. All PPE should be
inspected for damages or defects before use. Do not use defective PPE and
dispose of it properly.
15. Lockout/tagout refers to a set of procedures designed to protect workers from the
unexpected startup of machinery and equipment or the release of hazardous
45
energy during service or maintenance activities. It involves shutting off electrical
energy controls, draining lines, opening some valves and closing others, and
other isolation activities. These settings should be verified, and locks or tags
should then be used to ensure that these items do not re-energize or revert.
Everyone performing work on a system must provide their own locks. This
ensures that the system will not be re-energized until after all work is finished and
all locks have been removed. If a system does not accommodate locks, a tag can
be placed on the energy control stating that the device must not be operated.
16. E-Stops should only be used in case of imminent or actual danger to personnel
or equipment. In all other cases, the normal stop button or switch should be
used.
17. Housekeeping includes two basic activities: cleaning and organizing. A clean,
organized facility will provide a more efficient and safer work environment for its
employees. Poor housekeeping practices lead to messy, disorganize b d work
areas, and also increase the number of workplace hazards.
46
VIII. Material Handling
Warehouse:
A warehouse is a building for storing finished papers that has loading docks to load and
unload goods from trucks. It has cranes and forklifts for moving the stock papers, and
also for picking, checking, labelling and packing of papers for export.
Conveyors:
The conveyors are design to help transport bulk paper into pulp and also to stack out,
all the way to the digesters to produce a fine pulp and paper. A chain conveyor system
will be use powered by a continuous chain which are primarily utilized to transport these
raw materials.
Cranes:
47
Cranes for material handling systems will use for all lifting applications in the pulp and
paper industry, such as process duty cranes, maintenance cranes, parent roll handling
cranes, paper roll storage systems, workshop cranes as well as maintenance services.
Forklifts:
Forklifts provide operators and warehouse workers to move and sort the packages of
finished papers continuously in organizing, and improving the safety of workers inside
the industry.
Equipment and Specifications:
Rotary drum pulper

Xuridong
Model: XZG-200
Equipment Diameter: 200mm
Capacity: 30-50T/D
Motor Power: 55kw
Working Temperature: 40-900C
Consistency: 14-18%
Speed: 11-17 rpm
48
High Density Cleaner

Leizhan
Type: ZSC2
Nominal Size: 1000
Concentration of input pulp: 2-5%
Pressure input: 0.15-0.35mpa
Pressure output: 0.1-0.25mpa
Pressure Backwash Water:
pressure of input pulp +0.02mpa
Flow: 650-850 l/min
Forward Cleaner
Tianrun
Model: YF250
Single by volume: 252L / min
out of the plasma pressure
difference: 0.15-0.18MPa
Into the plasma concentration:
0.3-0.9%
49
into the plasma pressure: 0.28-0.4Mpa
Light Weight Cleaners

Leizhan
Pressure Screen
ShengFeng
Type: ZNS22
Rotor Circumference speed: 10-30rpm
Flow: 1000-6000 LPM
Inlet Consistency: 1.0-4.0
Production Capacity: 40-80 TPD (Hole)
40-80 TPD (slot)
Coarse Holes: 2.7mm
Fine Slots: 0.152mm
50
Inlet Pressure: 0.2-0.4 mpa

Motor Power: 22-55 kw
Voltage: 380v
Flotator
Leizhan
Type: ZFM 2
Throughout Capacity: 400 m3/h
Layers: 3-5
Consistency: 1.1±0.1%
Consistency of Ink: 2-3%
Production Capacity: 85-100
Voltage: 380v
Pulp Pump
Guang Mao
51
Pulp Propeller Agitator
Aotian
pulp chest volume: 40-60 m³
Pulp density: ≤5%
Impeller diameter: φ700mm
Impeller rotation speed: 240r/min
Motor power: 11kw
Motor rotation speed: 970r/min
Weight: 820kg
High speed pulp washing machine
Leizhan
52
A4 PAPER MAKING MACHINE
Leizhan
Operation Speed: 200-1200m/min

Power: 500KW
Trimmed width: 1880-3750mm
Dimension(L*W*H): 2300X1150X1600mm
Machine Parts:
Drying Cylinder Press Part Head Box Rewinder
High Quality Double Disc Mechanical Refiner Machine
Dingchen
53
Inner rotary pulp consistency transmitter
EASTTAI
54
Pulping equipment chain conveyor
ANDE
Model: BFW1600
Effective Width: 1600mm
Capacity: 95-400
Speed: 1.2-1m/min
Incline: <300
Maximum Size of Raw Material:
1400mm
Screw press washer
Leizhan
Type: ZNJ12
Control: PLC
Material: Stainless Steel
Standard of screw: Φ400
Concentration of Input pulp: 10-14%
Concentration of Output pulp: 25-35%
55
Production capacity: 40-50t/d

Motor Power: 30kw
Heat Dispersion Kneader
Xuzhou
Type: SHD2
Capacity of Production: 30-
45t/d
Power of Motor: 110kw
Norminal diameter: 500mm
Treating Consistency: >28%
Treating temperature: 40-100 C
Retention Time: 10-60 seconds
Speed: 100-900 rpm
Gap between bars:10-40 mm (compare to dispersion at 1 mm gap)
High Density Bleaching Tower

Andritz
Model: ZPT50
Metric Volume: 50m3
Stock Consistency: 25-30%
Bleaching Temperature: 60-70oC
Bleaching Time: 60-90min
56
Motor Power: 300kW
Steam Boiler Set

Zhengzou
IX. Fire protection Layout
Paper Mill Fire Hazards
o Combustible Dust
One form of a combustible dust exposure is the accumulation of paper dust within the
paper machine enclosure. This enclosure, normally referred to as the paper machine
hood, accumulates paper dust which is exposed to moisture from the heated steam
drums steam system and the oil residual from the minor oil system leaks. If this paper
57
dust is allowed to accumulate in the hood, a fire involving this residue can quickly
spread outpacing the operation of installed sprinkler systems. The installation of
automatic sprinklers throughout the paper machine hood along with a good
housekeeping and continued maintenance are the primary protection and fire
prevention measures in addressing this exposure.
o Heat Transfer Hot Oil Roll Systems
Depending on the paper being made, the surface of the paper may be enhanced by
using heated press rolls to give the paper a specific finish. In general, automatic
sprinkler systems should be provided over the entire system including distribution piping
and heater system and on the operating floor around the heated roll but not directly over
the heated roll. The system equipment should be provided with automatic shutdown
interlocks and the heating system should be provided with temperature controls
arranged to shut the system down upon an overheating condition.
o Hydraulic systems
Those hydraulic systems that are used as hydraulic equipment drives, which are usually
located in the wood yard and pulp mill, and the hydraulic units that operate systems on
the paper machine. These hydraulic systems usually have a larger fluid capacity and
are located in close proximity and sometimes within the confines of the equipment
enclosures. General fire protection includes the installation of automatic fire sprinkler
systems, hydraulic system automatic shutdowns and physical separation of the
hydraulic reservoir and pumping system from surrounding areas.
58
o Lubrication Systems
A paper machine will generally have multiple lubrication systems each with a tank
capacity about 5,000 to 8,000 gallons (about 18,900 to 30,300 liters). The tanks and
pumps are generally located on the building grade level within the building adjacent to
the paper machine. Due to the many heated surfaces and other ignition sources, an oil
leak can easily be ignited and can expose the entire machine to severe damage and
extended downtime. General fire protection includes the installation of automatic fire
sprinkler systems, tank and pumping system spill containment and fire detection
systems to alert operators of a possible fire near the tanks and pumping systems. Good
housekeeping and system maintenance are needed to prevent system leakage or to
reduce the amount of leakage accumulation until the system can be repaired during
paper machine outages.
o Ignitable Liquids and Other Chemicals
Bulk storage and handling of ignitable liquids must be done in accordance with codes
and standards and include storage tank space separation with spill containment, along
with automatic and manual firefighting capabilities. Decanting and distillation structures
must be provided with adequate space separation and automatic fire sprinkler or similar
systems installed throughout the process structures along with proper spill containment.
Other chemicals used in the paper and pulp making process include (this list is not all
inclusive) acids, caustics, oxygen, ozone, chlorine dioxide, hydrogen peroxide, sodium
chlorate, sodium hypo-chlorite and sulfur. All these chemicals include different and
59
specific types of hazards and exposures and each must be evaluated and provided with
proper protection safeguards.
o Storage
In-process storage of concern is at the exit end of the paper machine where the
continuous paper sheet is wound into large paper rolls called “Parent Rolls.” These rolls
weigh about 20 tons and are stored on horizontally on stands or on the floor waiting to
be cut into smaller rolls. Fires have occurred on these rolls and can be very difficult to
control since roof level sprinkler protection is normally about 30 to 50 ft. (9 to 15 meters)
above the rolls. Manual firefighting is the primary method of fire control in these
instances. Finished products are primarily roll paper storage and storage of paper
products in corrugated cartons. Roll paper presents one of the most challenging type
fires with automatic fire sprinkler protection being the primary method of protection for
this storage. Sprinkler system design is based the base weight and coating of the paper,
storage configuration, storage height and other variables. These sprinkler systems
require large water discharge capabilities at relatively high operating pressures.
Classification of Hazards: HIGH HAZARD
Extra hazard occupancies are locations where the total amount of Class A combustibles
and Class B flammables present, in storage, production, use, finished product, or
combination thereof, is over and above those expected in occupancies classed as
60
ordinary (moderate) hazard. These occupancies could consist of woodworking, vehicle
repair, aircraft and boat servicing, cooking areas, individual product display showrooms,
product convention center displays, and storage and manufacturing processes such as
painting, dipping, and coating, including flammable liquid handling. Also included is
warehousing of or in-process storage of other than Class I and Class II commodities.
Selection of Fire Extinguishers
a. Fire extinguishers shall be selected for the Classes of hazards to be
protected.
i. Fire extinguishers for protecting Class A hazards shall be selected from the
following:
1) Water type
2) Multipurpose dry chemical type
3) Wet chemical type
ii. Fire extinguishers for protection of Class B hazard shall be selected from the
following:
1) Aqueous film-forming foam (AFFF)
2) Film-forming fluoroprotein foam (FFFP)
3) Carbon dioxide
4) Dry chemical type
iii. Fire extinguishers for protection of Class C hazard shall be selected from types that
are specifically listed for use on Class C hazards.
61
Size and Placement Distribution of Fire Extinguishers
Class C Hazards
Fire extinguishers with Class C ratings shall be required where energized electrical
equipment can be encountered that would require a nonconducting extinguishing
medium. This requirement includes situations where fire either directly involves or
surrounds electrical equipment. Since the fire itself is a Class A or Class B hazard, the
fire extinguishers shall be sized and located on the basis of the anticipated Class A or
class B hazard.
62
Figure 3.10 Fire Extinguisher Mounting Height
X. Air Pollution Control Systems
Figure 3.11 Fire Extinguisher Layout
X. Air Pollution Control System
63
Figure 3.12 Air Pollutant Types From Paper Mill
Air pollution control at pulp and paper mills has been important concern in the recent
years. Especially VOCs produced form pulp and bleaching steps and steam are
conventionally treated by physico-chemical methods such as adsorption to activated
coal filters, absorption, thermal oxidation, catalytic oxidation, and condensation (Eweis
et al., 1998). More innovative approach to solve this problem is biofilters and
bioscrubbers that have three steps to remove pollutants from gaseous phase; The
transfer of pollutants from air to liquid phase, the transfer of pollutants from liquid phase
to biofilm phase where microorganisms are located, and Mineralization of pollutants by
microorganisms.
Heating and Cooling Load Calculation
Design Outdoor Condition: 360C Dry Bulb & 280C Wet Bulb
Daily Range: 90C
64
Room to be Maintained @ 230C & 50% Relative Humidity

Height: 6m
For Windows
Single placing
Double panel 0.9m wide and 1.5m High
Roller shade: dark
U=5.9 W/m2-k
For Walls
U=1.959 W/m2-k
Type G: Permanent Medium Color
Partition Wall: CR @ 290C
U=2.5 W/m2-k
For Doors
Regular Doors 1m x 2.5m
CR Partition Door: 1m x 2.5m
For Roof
Type 4 w/ Suspended Ceilings
U=2.5 W/m2-k
For Lightning
Fixture Y
25 W/m2
No. of occupants = 10
Wall
Area of External Wall
N= 10 (6) = 60m2
65
S= 10(6) - 2(0.9 x 1.5) = 57.3m2

E= 20(6) – 4(0.9 x 1.5) - 2(1 x 2.5) = 109.6m2
W= 20(6) – 4(0.9 x 1.5) = 114.6 m2
Cooling Load Temperature Differenceadj of the Wall
N= (15-0.55) (0.75) + (25-23) + (31.5-29) = 15.338
S= (26-3.33) (0.75) + (25-23) + (31.5-29) =21.503
E= (31-0.55) (0.75) + (25-23) + (31.5-29) = 27.338
W= (40-0.55) (0.75) + (25-23) + (31.5-29) = 34.088
Qs= UACLTDadj
N= (1.959) (60) (15.338) = 1802.829W
S= (1.959) (57.3) (21.503) = 2413.727W
E= (1.959) (109.6) (27.338) = 5869.644W
W= (1.959) (114.6) (34.088) = 7652.804W
Total Qs = 17739.004W
Roof
Area= (10) (20) – 12 = 188m2
66
Qs = UACLTDadj = (2.5 W/m2) (188m2) (25.875) = 12161.25W
Window
Area
N=0
S= 2 (0.9) (1.5) = 2.7m2
E= 4 (0.9) (1.5) = 5.4m2
W= 4 (0.9) (1.5) = 5.4m2
Qs= (SHGF) (SC) (A) (CLF)
N=0
S= (355) (0.59) (2.7) (0.83) = 469.377W
E= (700) (0.59) (5.4) (0.80) = 1784.16W
W= (700) (0.59) (5.4) (0.82) = 1828.764W
Lightning Load
Qs= (lamp rating) (Fu) (Fb) (CLF) = (25 W/m2) (4) (5x5) (0.95) (1.2) (1) = 2850W
Occupant Load
67
Qs= (gain per person) (sensible heat gain) (no. of people) (CLF) = (150) (0.55)
(10) (0.84) = 693W
QL= (gain per person) (latent heat) (no. of people) (CLF) = 150(1-0.55) (10) (0.84)
= 567W
Partition Load
Area= (4x6) (2) + (3x6) – 2.5 = 63.5m2
Qs= UA (to-ti) = 2.5 (63.5) (6) = 952.5W
Door
Qs = (2.5) (2.5) (29-23) = 37.5W
Infiltration
Number of air changes = a +bV + c (to-ti)
= 0.250 + 0.020 (2.5) + (0.022) (36-23) = 0.586
Q= number of air changes x volume of condition space
= 0.586 (188) (6) = 661.008
Qs= 1.23Q (to-ti) = 1.23 (661.008) (36-23) = 1056.5W
QL= 3000Q (Wo-Wi) = 3000 (661.008) (0.02422-0.0088) = 30578.23008W
68
Ventilation
Q= floor area (occupancy rate) (ventilation rate) = 188m 2 (7/100) (2.5L/person)
= 32.9 L\sec
Qs= 1.23Q (to-ti) = 1.23 (32.9) (36-23) = 526.07 W
QL= 3000Q (Wo-Wi) = 3000 (32.9) (0.02422-0.0088) = 1521.954 W
Qs
Wall 17739.004W
Lightning 2850W
Window 4082.301W
Occupants 693W
TOTAL 25364.305W
Qs total= Qs total x 1.5 = 38046.4575W
QL total= QL Occupants x 1.5 = 1039.5W
QS C (T −T )
= P C i
QS +Q L H C −H i
38046.4575 1(36−23)
=
38046.4575+ 1039.5 50.31−H i
H C =42.091425
ℜ=[ m recirculating air ( H C −H i ) ]+(m outside air H 1 )
69
14.5
[
ℜ= (
0.858
60 ]
)(50.31−42.091425) + (
0.1
0.887
x 81.75)
11.531327 kw
ℜ= =3.2797 TR
3.516
XI. Waste Water Treatment Layout
70
Figure 3.13 Effluent Waste Water Treatment Layout
Plant Design Layout Outline
A. Water intake and water treatment facilities
71
1) Raw water intake
a. Intake weir or bank: 1unit
b. Intake pump: Flow rate – 0.72m3/sec x head 50m x motor capacity 475kW x 3
units (one standby unit)
c. Pipeline: Inner diameter 1000mm x 1500mL (flow rate – 2m/sec)
2) Water treatment plant
a. Grid chamber: 10m (W) x 80m(L) x 5.5m(D) x 2 units
b. Mixing tank: 6m(W) x 6m(L) x 4.5m(D) x 2 units
c. Coagulation tank: 22m(W) x 15m(L) x 4.0m(D) x 2 units
d. Settlement tank: 22m(W) x 56m(L) x 5.0m(D) x 2 units (2 sludge scrapers/unit)
e. Chemical charger: 1 set
f. Rapid sand filtration system: 8m(W) x 25m(L) x 5.0m(D) x 2 units
3) Mill water supply system
a. Water tank: 30m(W) x 60m(L) x 4.0m(D) x 1 unit
b. Pump: Flow rate – 0.72m3/sec x head 35m x motor capacity 320kW x 3 units
(one standby unit)
c. Piping: One set
CHAPTER IV
MARKET ANALYSIS
72
Current Situation of the Business
The paper industry in the Philippines comprises 39 local recycling paper mills, 6
abaca pulp mills and 1 integrated paper mill situated in the province of Surigao that has
a tree plantation and supplies its own requirement for pulp to produce paper, or a total
of 46 industry players. The Philippine paper industry seeks to attain the capability to
serve all major pulp and paper requirements of the country and develop high-value and
quality pulp and paper products in the long-term, in a manner that is internationally
competitive and environmentally-sustainable.
The demand for paper and paperboard is greatly influenced by economic growth,
increases in school population, and population growth. Reports show that the annual
per capita consumption of paper in the Philippines is 13 kg as opposed to the world’s
per capita consumption of 43 kg. In the country, Laguna and other urbanized areas
show the highest density in paper consumption (DBP 2005). Seeing such huge growth
potential of the paper industry, it comes as no surprise to start a paper manufacturing.
Pricing and Distribution
As a new entrant to the market, the paper mill will have an advantage of using
latest technology which will enable to produce at a lesser cost maintenance and better
quality. The product can be distributed by establishing own distribution outlets in
strategic towns or by using hired or commissioned agents. Wholesaler: A merchant
intermediary who sells chiefly to retailers, other merchants, or industrial, institutional,
and commercial users mainly for resale or business use. Wholesalers typically sell in
large quantities. This will be the large supermarkets in Laguna City. Retailer: A
73
merchant intermediary who sells direct to the public. This will be the small stores or
minimarts in Laguna.
Production Schedule
Day to day manufacturing operations are the activities that a plant and its employees
engage in on a daily basis for the purpose of generating a profit and increasing the
inherent value as a going concern.
Capacity
Production capacity is based on a schedule of 300 working days per annum and 3 shifts
of eight hours per day. The operational workforce of the plant is quite uniform and
simple to follow.
From the technical point of view, a small-scale paper mill is one, which has a capacity of
40 tonnes per day. Accordingly, considering the demand projections worked out in the
market study section, it is proposed that a plant with a daily capacity of 40 per day is
recommended. This is equivalent to 12000 tonnes per year.
Paper Mill Organization Chart
74
Figure 4.1 Organization Chart
The organization is headed by the General Manger, assisted by Deputy General
Managers. Paper Mill is functionally divided mainly into two parts i.e., production and
services including maintenance (Engineering), and other supporting departments.
These departments are headed by Manager ranked officers. Sub sections of these main
departments are headed by Deputy Managers, Assistant managers and Technical
Officers. Man power in the plant is broadly divided into sections namely raw material,
pulping section, paper section and packaging section. During the partial modernization
of the Mill working strength was slightly increased to meet the additional requirement.
About 100 working employees including industrial workmen, staff and officers join their
hands together for operating the paper mill on all seven days of a week and 24 hours of
the day in round the clock pattern
Figure 4.2 Estimated project cost
75
Description Cost in Pesos

Land for Plant Php 300,800,000
Building Php 65,000
Plant Machinery Php 2,000,000.00
Operative Cost Php 50,000.00
Transportation Php 50,000.00
Waste Water System Php 20,042,250.00
TOTAL 323,007,250
Figure 4.3 Planning Schedule (Gantt Chart)
References:
76
3 Accessory Equipment for Pulp Digester | Blow Tank, Heat Exchanger. (2018). Retrieved
December 22, 2020, from Paperpulpingmachine.com website:
http://www.paperpulpingmachine.com/3-accessory-equipment-pulp-digester/
Air Systems for paper production | Voith. (2021). Retrieved January 22, 2021, from Voith.com
website: https://voith.com/uk-en/papermaking/air-systems.html
ASSESSMENT METHODOLOGY GUIDE. (2015). Retrieved from
https://www.mpac.ca/sites/default/files/docs/pdf/PulpPaperMills.pdf
Crowder College. (2016a, October 20). Ch06 standpipe and hose systems. Retrieved January 22,
2021, from Slideshare.net website: https://www.slideshare.net/debgoodlett/ch06-
standpipe-and-hose-systems
Crowder College. (2016b, October 20). Ch07 automatic fire sprinkler systems. Retrieved January
3, 2021, from Slideshare.net website: https://www.slideshare.net/debgoodlett/ch07-
automatic-fire-sprinkler-systems
Ekbåge, D. (n.d.). Process modelling in pulp and paper manufacture Application studies with
aspects of energy efficiency and product quality Environmental and Energy Systems.
Retrieved from https://www.diva-portal.org/smash/get/diva2:1427921/FULLTEXT02.pdf
Fire Protection and Prevention. (n.d.). Retrieved from
https://www.osha.gov/sites/default/files/2019-03/fireprotection.pdf
Holmes, R. (2017, July 11). PACKAGING MATERIALS AND CONTAINERS 单元二包装材
料及容器. Retrieved January 22, 2021, from Slideplayer.com website:
https://slideplayer.com/slide/6300198/
Organization Structure. (2019). Retrieved January 22, 2021, from Spmcil.com website:
https://spmhoshangabad.spmcil.com/Interface/OrgStructure.aspx
77
Paper Making Fire Hazards- Loss Prevention - Risk Logic. (2020, December). Retrieved January
3, 2021, from Risk Logic website: https://risklogic.com/paper-making-fire-hazards/
Paper Manufacturing Hazards & Safety Tips | Convergence Training. (2017, July 7). Retrieved
December 21, 2020, from Convergence Training Blog website:
https://www.convergencetraining.com/blog/paper-manufacturing-safety-tips
PROJECT DESCRIPTION FOR SCOPING. (n.d.). Retrieved from http://eia.emb.gov.ph/wp-
content/uploads/2018/09/PDS_Bataan2020-Proposed-Paper-Mill-Plant-Expansion-
Project.pdf
Pulp, Paper, and Paperboard Mills - Hazards and Solutions | Occupational Safety and Health
Administration. (2020). Retrieved December 21, 2020, from Osha.gov website:
https://www.osha.gov/pulp-paper/hazards-solutions
sinoart. (2020). Paper mill cranes and material handling system. Retrieved December 22, 2020,
from Hy-cranes.com website: http://hy-cranes.com/Industries/Paper-mill-cranes-and-
material-handling-system.html
Solid Wastes 3.1 Solid waste conditions. (n.d.). Retrieved from https://emb.gov.ph/wp-
content/uploads/2018/09/3-Solid-Waste-1.8.pdf
TABLE OF CONTENTS RULE 1. INTERPRETATION ...................................................................
1 RULE 2. COVERAGE .......................................................................... 1 RULE 3.
DEFINITION OF TERMS .......................................................... 2 RULE 4. AUTHORITY
OF THE CHIEF, BUREAU OF FIRE
PROTECTION....................................................................... 21. (n.d.-a). Retrieved from
https://bfp.gov.ph/wp-content/uploads/2013/12/Fire-Code-of-the-Philippines-2008-
IRR.pdf
78
TABLE OF CONTENTS RULE 1. INTERPRETATION ...................................................................
1 RULE 2. COVERAGE .......................................................................... 1 RULE 3.
DEFINITION OF TERMS .......................................................... 2 RULE 4. AUTHORITY
OF THE CHIEF, BUREAU OF FIRE
PROTECTION....................................................................... 21. (n.d.-b). Retrieved from
https://bfp.gov.ph/wp-content/uploads/2013/12/Fire-Code-of-the-Philippines-2008-
IRR.pdf
Types of Fire Sprinkler Systems and Their Applications | Kinetix Fire. (2019, March 28).
Retrieved January 3, 2021, from Kinetix Fire website: https://kinetixfire.com/types-of-
fire-sprinkler-systems-applications/
Types of Industrial Conveyors used in Pulp and Paper Industry. (2019, July 23). Retrieved
December 22, 2020, from Pulpandpaper-technology.com website:
https://www.pulpandpaper-technology.com/articles/types-of-industrial-conveyors-used-
in-pulp-and-paper-industry
unknown. (2009, September 8). Fig. 3. The desiccant dehumidification process The desiccant...
Retrieved January 22, 2021, from ResearchGate website:
https://www.researchgate.net/figure/The-desiccant-dehumidification-process-The-
desiccant-dehumidification-process-operates-as_fig3_265206545
WATER TREATMENT MANUALS COAGULATION, FLOCCULATION & CLARIFICATION.
(n.d.). Retrieved from
https://www.epa.ie/pubs/advice/drinkingwater/EPA_water_treatment_mgt_coag_flocc_cl
ar2.pdf
79
What is a Deluge Fire System? | Western States Fire Protection. (2018, December 10). Retrieved
January 3, 2021, from Western States Fire Protection Blog website:
https://www.wsfp.com/blog/deluge-fire-system-defined/
Wikipedia Contributors. (2021, January 12). Demographics of the Philippines. Retrieved January
12, 2021, from Wikipedia website:
https://en.wikipedia.org/wiki/Demographics_of_the_Philippines
90. (2012). 90. PROFILE ON SMALL SCALE PAPER MAKING - PDF Free Download.
Retrieved January 22, 2021, from Docplayer.net website: https://docplayer.net/20740848-
90-profile-on-small-scale-paper-making.html
Auditor, J. (2020a). Licensed Abaca Processors. Retrieved January 22, 2021, from Da.gov.ph
website: http://www.philfida.da.gov.ph/index.php/12-licensed/22-licensed-abaca-
processors
Auditor, J. (2020b). Licensed Abaca Processors. Retrieved January 22, 2021, from Da.gov.ph
website: http://www.philfida.da.gov.ph/index.php/12-licensed/22-licensed-abaca-
processors
Entre Pinoys. (2014, January 11). The Paper Making Process, Part 6: Equipment and Machinery
- Entrepinoys Atbp. Business Ideas Philippines. Retrieved January 22, 2021, from
Entrepinoys Atbp. Business Ideas Philippines website: https://ep.franphil.com/the-paper-
making-process-part-6-equipment-and-machinery/
Holmes, R. (2017, July 11). PACKAGING MATERIALS AND CONTAINERS 单元二包装材
料及容器. Retrieved January 22, 2021, from Slideplayer.com website:
https://slideplayer.com/slide/6300198/
80
Paper mill factory final project. (2014, June 21). Retrieved January 22, 2021, from Slideshare.net
website: https://www.slideshare.net/cordobo007/paper-mill-factory-idea
Papermaking - Fibre sources | Britannica. (2021). In Encyclopædia Britannica. Retrieved from
https://www.britannica.com/technology/papermaking/Fibre-sources
Papermaking OVERVIEW AND INTRODUCTION. (n.d.). Retrieved from
https://www.fibrelab.ubc.ca/files/2013/01/Topic-11-Papermaking-Introduction-text.pdf
unknown. (2012). Table 1 . Pollution sources in producing pulp and paper. Retrieved January 22,
2021, from ResearchGate website: https://www.researchgate.net/figure/Pollution-
sources-in-producing-pulp-and-paper_tbl1_281761323
81

Paper Mill READY

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

Paper Mill READY

Uploaded by

Copyright:

Available Formats

Bachelor of Science in Mechanical Engineering

College of Engineering and Technology

Paper Mill Based Waste Paper Plant

Malicse, Angelica Mae D.

BSME 5th year

Engr. Reynald Ilagan

Brief description of the research……………….2

Product Description and Application………….….3

The Production Process of Paper…………….….3

Raw Material Section………………………….……5

Papier Mache Preparation Section…………….….5

Paper Machine Section…………………….……….6

Paper Mill Glossary……………………………….….7

Site and Plant Layout…………………………….….34

Plant Operation and Control…………………….…...35

Health and Safety Program……………………….……...42

Fire Extinguisher Layout………………………………...…62

Air Pollution Control System………………………….…...63

Heating and Cooling Calculation………………………....64

Waste water Treatment Layout…………………………...70

Paper Mill Organization Chart……………………………….74

Estimated Project Cost………………………………………75

Figure 2.1. The Flow of Paper Produced from Waste Paper

Figure 3.2 Climatic Conditions in Taguig

Figure 3.3 Average Temperature in Taguig

Figure 3.4 Average Humidity in Taguig

Figure 3.5 Land Utilization Summary

Figure 3.6 Plant layout for Paper Mill

Figure 3.7 Operation of Pulp Mill (Continuous Flow System)

Figure 3.8 Operation Pulp Mill and Paper Machine Equipment

Figure 3.10 Fire Extinguisher Mounting Height

Figure 3.11 Fire Extinguisher Layout

Figure 3.12 Air Pollutant Types From Paper Mill

Figure 3.13 Effluent Waste Water Treatment Layout

Figure 4.1 Organization Chart

Figure 4.2 Estimated project cost

Figure 4.3 Planning Schedule (Gantt Chart

Paper is a uniform, felted sheet, composed of fibrous and non-fibrous additives,

on its intended use. Paper is produced by mechanically and/or chemically processing

forests and from recovered paper.

number of trees that need to be harvested to make paper.

Brief description of the research

Product Description and Application

that is also biodegradable in nature to conserve the environment by saving trees. A4

THE PRODUCTION PROCESS OF PAPER

Operation steps in recycling of paper products in different qualities can vary

occur (Şahin, 2011):

 Sieving and cleaning

 Ink removal (for some special paper products)

 Whitening (for some special paper products)

Figure 2.1. The Flow of Paper Produced from Waste Paper

A. Raw Material Section

 Waste paper Stocking

B. Papier Mache Preparation Section

 Raw Material Feeding Unit- waste paper is put on production line.

C. Paper Machine Section

 Bute unit of Machine- Filling of production ready papier-mâché to the bute

dry matter from 1-1,5% to 16-20% with the use of.

51% with the use of press and vacuums.

 Drying Unit- To dry lamina in drying cylinders up to 7,5% humidity.

 Quality Control System- To measure the produced paper’s values such as

gram, humidity, quality etc.

D. Paper Cut Section

according to dimension of paper demand clients.