A

PROJECT REPORT
ON
INDUSTRIAL TRAINING
AT
HINDUSTAN PAPER CORPORATION LIMITED
[A GOVT. OF INDIA ENTERPRISE]
NAGAON PAPER MILL,
KAGAJNAGAR, ASSAM

A Project Report Submitted in Partial Fulfilment of the requirement for the

Degree of Bachelor of Technology (B.Tech) of
KIIT UNIVERSITY, Bhubaneswar

Submitted by:
TANMAY JYOTI DEKA
University Roll No: 1202373, 5th Semester
School of Mechanical Engineering

KALINGA INSTITUTE OF INDUSTRIAL TECHNOLOGY,

BHUBANESWAR-24, ODISHA
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2014
 CHAPTER 1

1.1 INTRODUCTION
a) Basic overview of the Industry-
Nagaon Paper Mill (NPM) is a unit of HINDUSTAN PAPER CORPORATION
LIMITED. It is an integrated pulp and paper making industry. The mill is located at Jagirod in the
district of Morigaon, Assam at a distance of about 70 km. from Guwahati. The mill site was
basically selected by a group of experts on techno-economic grounds to boost the economy of the
region and to use the abundant bamboo crop of the North Eastern forests. The NPM occupies a total
land area of 650 acres with a plant area of 200 acres. The mill is well connected by National
Highway 37 and Broad gauge (Guwahati Lumding route) of North Eastern Railways.
The mill was commissioned in October, 1985. It is a public sector undertaking under The
Ministry of Heavy Industry, GOVT OF INDIA. At the time of commissioning, it was India’s
largest paper mill. NPM was originally a 400 crore project with a capacity of producing 300 MT of
finished paper per day. NPM produces an average of 1, 00,000 MT finished paper per year.
NPM has two paper machines-
 JESSOP, commissioned on 27.3.1985
 UTMAL, commissioned on 26.4.1986

b) Production and managing staff-

NPM is an integrated pulp and paper manufacturing unit with captive caustic soda/chlorine
di-oxide plants. It also has a captive power generation unit in the same premises. The installed
capacities of the units are given below:
PRODUCT/BY-PRODUCT INSTALLLED CAPACITY
Writing & printing paper 1,00,000 MT per annum
Caustic soda lye 60 MT per day
Chlorine 52 MT per day
Chlorine di-oxide 1.65 MT per day
Power generation (coal based) 15 MW & 15 MW

As of 2007-2008, the annual production of NPM was 1, 17,623 MT. In 2009-2010 it was 1,
10,008 MT. The production in last year i.e. 2013-2014 was 80,230 MT. These papers produced in
NPM are transported by means of Trains, trucks or air to different distributors in different parts in
India. NPM has around 940 regular employees as well as many contractual workers. Non-stop
work i.e., paper production goes on here with these hardworking and sincere employees. Moreover
1340 contractors are in business with NPM who supplies different requirements in the industry.
There are mainly 3 shifts in NPM. Shift A, B & C, another General Shift is also there. The
workers and employees in Shift A works between (6 am- 2 pm), Shift B works between (2 pm-10
pm) and Shift C employees have their duty between (10 pm- 6 am). The General shift workers have
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their duty between (8 am- 5pm) with a 1 hour lunch break between (12:30 pm- 1:30 pm).
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c) 3 Certificates of NPM-
 ISO 9001 QMS (Quality Management System)
 ISO 14001 EMS (Environment Management System)
 OHSAS 18001 OHS ( Occupational Health System)

d) Raw Materials -
1. Bamboo: NPM uses Bamboo as its main raw material for the paper production. For the
production on 1MT of paper, 2 MT of bamboo are required. The bamboo is supplied to the mill
from different parts of Assam.
2. Water and Power: Huge quantity of water and power is required every day for the process. 152
m3 of water and 1402 KW power is required to produce 1 Mt of paper. It is the 2 nd largest
component for paper production. As per national standards, the cost of power takes up almost 30%
of the total production cost.
3. Coal: Around 2 lakh ton of coal is required per annum for production of paper. The coal comes
from Meghalaya and different parts of Assam.
4. Other Chemicals: Various chemicals like Hipo chloride, Sodium hydroxide, Chlorine dioxide,
Sodium sulphide, Chlorine and others are required to carry out the entire paper production process.

1.2 DIFFERENT DEPARTMENTS OF NPM

NPM is a union of different departments. However, the main sections of NPM are
Chipper house, Pulp mill, Paper Machine, Utility, Caustic & Chlorine Plant and Water
treatment Plant.

a) Chipper House: In this department, the raw material (bamboo) is converted into small
pieces known as chips.

b) Pulp Mill: The chips are cooked here after mixing with chemicals in the digester tank. Then,
these cooked chips bleached to form the products known as pulp.

c) Paper Machine: In the paper machine, resin, alum, talcum powder and colours are mixed
with the pulp for smooth, bright and coloured paper. Then the pulp is mixed with water finally the
mixture is dried by different machines and makes a roll of paper.

d) Utility: The utility department supplies water, compressed air, steam and power to all the
other sections of the industry. Steam is produced in the coal fired boilers which is used in the
system of steam turbine generator to produce power. Water and compressed air are also supplied by
utility departments for various uses.

e) Caustic and chlorine plant: The plant is set up to fulfil the requirements of chemicals
such as Chlorine, Chlorine di-oxide, Sodium Hydroxide etc.

f) Water treatment plant: The mill requires a large quantity of water for the various
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processes. This plant is set up to supply the water continuously to different departments of the mill.
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The plant filters water coming from the rivet “KAPILI” flowing nearby.
 CHAPTER 2

Mechanical Workshop

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MECHANICAL WORKSHOP AT HPCL, NPM

 Nagaon paper mill has a fully equipped mechanical workshop. The main objective of the
workshop is to provide various services to the other departments such as repairing and designing of
machinery parts. The workshop with modern machines and dedicated operators is capable of
operating the requirements of all other departments. Workshop has several machines namely Lathe
machine, Shaping machine, Slotting machine, Drilling machine, Boring machine, Grinding
machine etc. It also have Welding and Cutting equipment. Moreover, the workshop offer services to
automobiles and locomotives through its garage.
The principal machines in the workshop are briefly described in the following section:

2.1. LATHE MACHINE

Lathe is the most commonly used machine of workshop. A lathe is a machine tool which
rotates the work piece on its axis to perform various operations such as cutting, turning, threading,
grooving, knurling, drilling, boring, chamfering, facing with tools that are applied to the work piece
to create an object which has symmetry about an axis of rotation.
Lathes are used in woodcutting, metalworking, metal spinning, and glass working. Most
suitably equipped metalworking lathes can also be used to produce most solids of revolution, plane
surfaces and screw threads or helices.
Moreover, eccentric jobs can be performed in this lathe machines. Shafts of
different sizes with varying cross section can be machined with the help of a lathe machine.
For improving accuracy and ease of machining some accessories and attachments
are 1. Live centre 2. Dead centre 3. Steady rest
used - 4. Lathe centre 5. Indexing apparatus 6. Tapper attachments
,

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2.2 SHAPER MACHINE

 A Shaper is a type of machine tool that uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear tool path. It can cut curves, angles and
many other shapes. It is analogous to that of a lathe, except that is (archetypally) linear instead of
helical.
Shapers are mainly classified as standard, draw cut, horizontal, universal, vertical,
geared, crank, hydraulic, contour and travelling head. The horizontal arrangement is the most
common. Vertical shapers are generally fitted with a rotary table to enable curved surfaces to be
machined.
The main uses of a shaper machine are:
 Key cutting
 Keyways cutting
 Surfacing
 Splines cutting
 Dovetail cutting
 Contour surfaces
Clapper box block Tool slide

Ram
Tool post

Table
Frame

Base

Cross rail
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2.3 SLOTTING MACHINE
Slotting machines are similar to those of Shaper machine with the difference that the
ram holding the toll in slotting machine reciprocates in vertical direction. The cutting action of the
tool is only during the downward stroke.
The slotting machine can be considered as a vertical shaper and its
main parts are:
 Base, column and table
 Ram and tool head assembly
 Saddle and cross slide
 Ram drive mechanism and feed mechanism

The slotting machine is used for cutting grooves,

keys and slots of various shapes making regular and irregular
surfaces both internal and external cuttings, internal and external
gears and profiles. The slotter machine can be used on any type of
work where vertical tool movement is considered essential and
advantageous.

WORKING MECHANISM OF SHAPER AND SLOTTING MACHINE

The job is rigidly fixed on the machine table. The single point cutting tool held
properly in the tool post is mounted on a reciprocating ram. The reciprocating motion of the ram is
obtained by a quick return mechanism. As the ram reciprocates, the tool cuts the material during its
forward stoke. During return stoke there is no cutting action and the stroke is called the idle stroke.
The forward and return stroke constitute one operating cycle of the shaper. The quick return
mechanism is understood with the help of the following diagram.

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 This mechanism is made of a diving crank and of a driven slider crank. In the
considered configuration, the fixed pivot of the driven crank is located on the outside of the circle
on which the end of driving crank moves. The leads to an alternated motion of the slider crank. The
angular speed of the driven crank is variable. The duration of the motion for its part corresponding
to the blue arc (AB clockwise) is shorter than the one related to the red arc (AB anticlockwise). This
is why this device is named as Quick Return Mechanism, which was used in crank shapers, with the
slow part or the stroke being used for the working time of the tool and the quick part for the non-
productive time.

2.4 MILLING MACHINE

Milling is a machining operation in which a rotating cutter cuts the job when the job is
feeding in a direction at an angle with the axis of the tool. With various attachments milling
machine can be used for boring, slotting, circular milling, dividing and drilling. This machine can
also be used for cutting keyways, racks and gears and for fluting taps and reamers.
Milling operates on the principle of rotary motion. A milling cutter is spun about an axis
while a work piece is advanced through it in such a way that the blades of the cutter are able to
shave chips of material with each pass. Milling processes are designed such that the cutter makes
many individual cuts on the material in a single run, this may be accomplished by using a cutter
with many teeth, spinning the cutter at high speed, or advancing the material through the cutter
slowly. Most often it is some combination of the three. The speed at which the piece advances
through the cutter is called feed rate, or just feed; it is most often measured in length of material per
full revolution of the cutter.

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2.5 DRILLING MACHINE
Drilling is a operation of producing circular hole in the workpiece by using a rotating
cutter called drill. Holes of different diameters can be produced using drills of different sizes. A
drilling machine, called a drill press, is used to cut holes into or through metal, wood, or other
materials. Drilling machines use a drilling tool that has cutting edges at its point. This cutting tool is
held in the drill press by a chuck or Morse taper and is rotated and fed into the work at variable
speeds. Drilling machines may be used to perform other operations like countersinking, boring,
counter boring, spot facing, reaming and tapping.
All drilling machines have following construction characteristics-
 Spindle,
 Sleeve or quill,
 Column, head,
 Worktable and
 Base.
Main types of Drilling Machines are-
 Radial Drilling Machine
 Portable Drilling Machine
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 Sensitive Drilling Machine

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 Upright Drilling Machine

 Special Purpose Drilling Machine
 Gang Drilling Machine
 Multi-spindle Drilling Machine
 Special purpose drilling machine

2.6 BORING MACHINE

Boring is the process of enlarging a hole that has already been drilled, by means of
single point cutting tool. A horizontal boring machine is a machine tool which bore holes in a
horizontal direction. Horizontal boring machines are often heavy-duty industrial machines used for
roughing out large components but there are high precision models too. Boring is used to achieve a
greater accuracy of the diameter of a hole, and can be used to cut a tapered hole. Boring can be
viewed as an internal diameter counterpart to turning, which cuts internal diameters.
There are three types of horizontal boring machine:
 Table type
 Planer type
 Floor type
The table type is the most common and most versatile. So it is known as the
universal type boring machine.

Some important point about boring machine are:

 Vertical movement of the spindle head is possible.
 The table can have rotary motion.
 Both hand and power feed are available.
 Robust jobs can be machined.
 Main applications are- boring, drilling and facing

Power feed

Transmission shaft
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Boring bar
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table
gear box

Feed levers
Reverse lever

2.7 WELDING SECTION

Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a
filler material to form a pool of molten material (the weld pool) that cools to become a strong joint,
with pressure sometimes used in conjunction with heat, or by itself, to produce the weld. This is in
contrast with soldering and brazing, which involve melting a lower melting point material between
the work pieces to form a bond between them, without melting the work pieces.
There are mainly two processes of welding- Arc Welding and Gas Welding

ARC WELDING

NAME N AWS Characteristics Applications

Atomic hydrogen 149 AHW Two metal electrodes in Historical

Welding Hydrogen atmosphere

Bare metal arc 113 BMAW Consumable electrode, no Historical

Welding Flux or shielding gas
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Carbon arc 181 CAW Carbon electrode Historical, copper repair

Welding
Flux cored arc 136- FCAW Continuous consumable Industry, Construction
welding 137 Electrode filled with flux

Gas metal arc 131- GMAW Continuous consumable Industry

welding 135 electrode & shielding gas

Gas tungsten arc 141 GTAW Non consumable electrode, Aerospace, tool & die,
Welding slow, high quality welds Construction(piping)

Plasma arc 115 PAW Non consumable electrode, Tubing, instrumentation

Welding Constricted arc
Consumable electrode covered
Shielded metal 111 SMAW in flux , can weld any metal Construction, outdoors,
Arc welding Maintenance

Submerged arc 121 SAW Automatic, arc submerged in

welding granular flux

Magnetically 185 MIAB Both tube ends are electrodes, Pipelines and Tubes
impelled arc butt no protection gas, arc rotates
fast along edge by applied
magnetic field

OXY FUEL GAS WELDING

NAME N AWS Characteristics Applications

Air acetylene Chemical welding process, not Limited

Welding 321 AAW popular

Oxyacetylene 311 OAW Combustion of acetylene with Maintenance,

Welding oxygen produces high temperature Repair
flame, inexpensive equipment

Oxygen/ Propane 312 Gas welding with Oxygen or

Welding Propane flame

Oxy hydrogen 313 OHW Combustion of hydrogen with Limited

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welding oxygen produces flame

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Pressure gas PGW Gas flames heat surfaces and Pipe, railway
welding pressure produces the weld Tracks(limited)

CHAPTER 3

PAPER MACHINE
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3.1 INTRODUCTION
Paper is one of the most important products ever made by man and the paper machine
is the machine to produce it. Most of the modern paper making machines are based on the principle
of the Fourdrinier Machines. It has been used in some variation since its inspection. The
Fourdrinier uses a specially woven plastic fabric mesh conveyor belt, known as wire as it was once
woven from bronze, in the wet end to create a continuous paper web transforming a source of wood
pulp into a final paper product. The original fourdrinier forming section used a horizontal drainage
area, referred to as the drainage table.
NPM is having modern paper machines supplied by UTMAL-VOITH (West
Germany) and JESSOP-BELOIT (United Kingdom). These are FOURDRINIER MACHINES
designed for operational speed of 600m/min. Both the machines are provided with hydraulic head
box, foils (instead of conventional table rolls), suction boxes, suction couch roll and a series of
drier calendars. In one machine there is size press also for on line surface sizing mainly used for
manufacturing value added paper grades viz. Map litho and Xerox grade papers.
These machines have cleaners and screens to clean the low consistency stock before it
goes to Head Box and is made into paper. The cleaner removes the high density foreign material
like sand, metal fillings, stones etc. While the cover size material like pieces of wood, dirt, lumps,
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silver, pipe scales etc. are removed by screens.

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3.2 STOCK PREPARATION

 The stock is prepared and maintained here. Certain amount of stock is always
maintained in case any scarcity occurs. Also the high consistency pulp is converted into low
consistency by adding water. Chemicals are also added here. There are separate stock preparation
sections for both the machines.
From the BHD tower, the high consistency pulp is pumped to the LD (low density)
chest & back water is also added on its way to become low consistency (dilute) pulp. From LD
chest, these are then pumped to the DDRs (Double disc refiner). There are five nos. of DDRs. At a
time, only2 or 3 DDRs run. In the DDR, the fibre of the pulp is get pressed between both the
rotating discs. The fibre is made up of cellulose & hemi-cellulose. So, after pressing by DDRs, the
surface area of pulp i.e. fibre increases. So the water holding capacity also increases. Therefore, in
DDR, cutting or grinding of long fibre into short fibre takes place. The pulp then goes to the refined
stock chest then is pumped to the Sample Trough. The pulp is known as VIRGIN PULP. In the
sample trough, the virgin pulp & more pulp are also added i.e. recover fibre pulp & broke pulp.
These 3 pulps get mixed in the sample trough. Then paper which has some defects or not used for
production, which is again reused by repulping into broke. The pulp is blue in colour as dye (methyl
violet) is mixed with it. The pulp is known as BROKE PULP. The short fibre which flows with the
water in the wire part, is not wasted. With the short fibre long fibre is also mixed to form proper
pulp i.e. the RECOVER FIBRE PULP.
The defective paper goes to the broke chest where water is also added with it to make it
pulp. Then, the pulp goes to the HD cleaner where some impurities are ejected out. After that, it
goes to the deflecker no.1 & 2 where the pulp is cut into small fibres, these the goes to the deflecker
broke chest through which then goes to the sample trough (broke pulp).
In sample trough, dye is also added with the 3 pulp. These goes to the blending chest
for proper mixing of the 3 pulps, these are pumped to the machine chest & again pumped to the
brush refinery 1 & 2 where the pulp are cut into small fibres. Then is pumped to the stuff box or
constant level box. Valves are there to regulate the flow. The level is always maintained in the stuff
box so that no scarcity will occur. The extra pulp goes to the silo where the consistency of pulp is
very less i.e. around 0.6-0.8 & the rest is water. The silo is deep & is filled up with more amount of
water & very little amount of pulp in in. Through the primary fan pump, these goes to the primary
centri-cleaners. There are 63 nos. of PCC. The PCC work on the principle that there should be low
consistency. The pulp+ water circulates like cyclone inside the PCC. Due to this, the light particles
goes up & the heavy particles goes down.
The light particles from the PCC goes to the deculator. There are 2 sections in the
deculator. Here, air is removed, so, vacuum is created. At 450C, the water starts boiling. The accept
through deculator is pumped by the secondary fan pump to the pressure screens where the unwanted
particles are removed under certain pressure. The accept goes to the head box finally, which is used
for paper making. Only the pulp+water from PCC is used for paper production not the secondary,
tertiary & quaternary centri-cleaners.
The heavy particles from the PCC (rejects) goes to SCC. There are 7 nos. of it. Water
is added with the heavy particles. After the same described process in the centri-cleaners, the accept
goes to the SILO & the rejects goes to the TCC. There are 4 nos. of TCC, the accept goes to the
SCC & the reject goes to the QCC. There is only 2 nos. of QCC. These goes to the fibre saver.
From this, the accept goes to the secondary and tertiary centri-cleaners & reject goes to a bin &
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after screening, the mud & fibres are separated and sold. The SCC, TCC & the QCC are mainly for
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cleaning purpose.
3.3 CHEMICALS USED IN PAPER MAKING-
Dyes For good appeal & uniform shade of paper.

Alkaline sizing (alkaline ketone dimer- AKD) For making the paper water resistant.

Talcum powder To save costly fibres & helping in maintaining

a uniform paper surface.
Starch For coating the paper surface for better
smoothness & good printability.

3.4 PAPER MACHINE:

Paper machine have four distinct operational sections:
 The FORMING SECTION, commonly called the WET END, is where the slurry of fibres
is filtered out on a continuous fabric loop to form a wet web of fibre.
 The PRESS SECTION where the wet fibre web passes between large rolls loaded under
high pressure to squeeze out as much water as possible.
 The DRYING SECTION, where the pressed sheet passes partly around, in a serpentine
manner, a series of steam heated drying cylinders.
 The CALENDAR SECTION where heavy steel rolls smooth the dried paper.

Fig. Paper Machine

a) FORMING SECTION or WET SECTION

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The pulp which comes from the pulp mill has 95% pulp and 5% water but in paper machines, for
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paper production 95%water and 5% pulp is needed. The pulp+water which comes in the headbox
are spread uniformly through slices on the wire part. There are 38 nos. of slices (nozzles) which can
be manually or automatically controlled. The consistency &the pressure is the main factor & if the
proportion of any factor changes, the quantity of paper will also change. In the wire part, maximum
proportion of the water is drained out by gravity & vacuum as the wire is porous in nature. On the
wire part is the dandy roll over which the logo of the HPC NPM is fixed. It rotates & moves along
with the wire. It gives the symbol on the fibrous web & also touches it gently, as if it combs the
fibre. Then, the fibrous web goes over the vacuum boxes. There are 5 nos. of these. As there is
vacuum inside the vacuum boxes, it sucks the water from the fibrous web. After that, it goes over
the couch roll. It is the exit point of the fibrous sheet from the couch roll & carries it to the press
section. Dryness of paper after wire part is 60%.

Some important factors-

 GSM (gram/sq. meter) In gram
 Moisture content In %
 Calliper (thickness) In µ
 Ash (to increase weigh & In %
fill up the holes)
 Quantity In MT

With the change of any one of these factors, we can change the quantity of paper. There are 107
different quantities of paper. And also there are 27 different properties on the basis of which paper
is tested.

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b) PRESS SECTION
Here in the press section, high pressure about 40 kg/cm2 is given at 3 different presses (trinip press)
to remove the water as much as possible from the fibrous web.
The 1st press is between suction press roll & bottom kuster roll. In suction press, vacuum is created
to suck the water & in bottom kuster roll, oil pressure is there, in between these rolls, there are 2
felts, felt no.1 coming from up & the other felt no.2 coming from down. These two always
circulates in its position. The fibrous web goes between suction press roll & granite roll. The paper
along with the felt no.1 from 1 st press is then again got pressed here. The water is soaked by the felt
& as there is there is vacuum inside the suction press roll, so, it sucks the water from the felt. Then,
the paper goes over the surface of the granite roll & enters the nip of the third press. The third press
is between the granite roll & the top kuster roll. In top kuster roll also, there is oil pressure, actually,
both top & bottom kuster roll’s oil presuure is connected through a pipe. Here, also felt no.3 is
circulating between the rolls. The paper gets pressed here & the water is soaked by the felt. The
paper moves along with the felt forward to the next section i.e. the dryer section. Dryness of paper
after press section is 40%.
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c) DRYING SECTION
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In this section, the paper is dried by applying steam in rotating cylinders called dryers by increasing
temperature in a controlled manner. The pressure of the steam helps the vapour to condensate after
heat exchange & is collected in the collection tank which is further used by the boiler. There are 3
groups of dryers. Each group contains 10 cylinders over which the paper is carried over. There are
30 cylinders & out of 30, 29 are for drying purpose & 1 is for cooling purpose. Temperature of the
steam increases slowly from 100-1600C. For every 1 ton paper, 3 tons of steam is needed for drying.
Dryness of paper after dryer section is 92-94%.

d) SIZE PRESS SECTION

Up to here the process is same in both the machine i.e. JESSOP & UTMAL. But there is slight
change in the UTMAL machine. As it produces good quality and expensive paper. So, there is a
size press & 3 more groups of dryers after the size press. In the size press, starch is added to
produce smooth, glossy quality paper used in magazines etc. for better printability. A coating of
starch is given on the paper for better printability and for smoothening of paper. But before adding
starch, the paper should be that much dried that after adding starch it does not become too wet &
can move over on the dryers easily. The function of the dryers are same after the size press as the
dryers before the size press i.e. to dry the paper. This is the only difference between these two
machines. Before & after this part, the process is same in both the machines.

e) CALENDAR SECTION
At last the calendar section comes. It consists of a King Roll (big) & a Queen Roll (Small). The
paper passes between these 2 rolls & get pressed. This done for polishing & finishing of the paper.
It produces spark due to the heart & also produces statistical electricity due to the positive &
negative charges on the fibres. After that, the paper is scanned by the scanner to give the detailed
quality & quantity of the paper on the monitor.
After calendaring, the web has a moisture content of about 6% (depending on the furnish). It is
wound onto a roll called a tambour or reel, and stored for final cutting and shipping. A roll of 14-16
tons of paper is winded on the pope reel. After completion of the winding, with the help of EOT
(electrical overhead travelling) crane it is lifted up & kept it on the spool stand. These are called
paper rolls.
Again with the help of crane, these rolls are taken to the rewinder where the paper is cut into the
required size & rewinded into small reels.

f) FINISHING HOUSE-
In the finishing part, these reels are packed & are delivered according to the orders. Here A$ sheets
are also made with the help of cutters.
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Production/ day 300 MT(metric ton) minimum

1 ton paper costs (varies from quality to 40,000 rupees minimum
quality)
1 minute production loss Lose 400 rupees
Production / annum 1,00,000 MT minimum
Highest production till date 1,15,000 MT

Fig. Reels of paper

CHAPTER 4

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 Utility department

4.1 INTRODUCTION
The utility section is one of the most important sections in this premiere paper
manufacturing enterprise. Utility ia that section of an industrial plant which generates required
power for the plant by using natural, mechanical and human resources. It is the section by which
water, power, pressurized air and steam supply is made available to the various sections of the plant
as per required quantity and physical state. All the combustion and power generation takes place in
this section.
The main input of this plant are coal and raw water. As output this plant provides the
following services:
 WATER: Mill water, make up water, drinking water
 STEAM: H.P. Steam, M.P. Steam and L.P. Steam
 COMPRESSED AIR: Mill air and instrument air
 POWER
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The utility department of NPM supplies the necessary power for its own consumption
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and the pulp mill, paper machine, the river intake pump, the residential colony etc. Power is said to
be the 2nd largest cost component for the paper production. The plant has a capacity of 30 MW.
There are two turbine generators of 15 MW each.

4.2 DIFFERENT SECTIONS OF UTILITY, NPM

1. River intake pump house
2. Water treatment plant
3. Demineralization plant
4. Air compressor
5. Boiler feed pump
6. Boilers
7. Coal handling plant
8. Ash handling plant
9. Steam turbine and generator
10. Cooling tower

4.2.1 RIVER INTAKE PUMP HOUSE

HPCL uses the water resources of the river KAPILI. The pipe distance travelled by the river water
to reach its required place in the plant is about 7.5 KM. There are four pumps each running by 355
KW power motor. They are connected to the river by sumps so that purest water may be taken
inside the sumps of the pump.
When the river is flooded the pump at higher level sump runs and when it reaches the normal
condition the lower level pump runs. At one time only one pump runs and the other is put on
standby. The water taken from the river generally contains mud, metal ions and oxides and soluble
gases.

Water treatment plant and DM plant

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4.2.2 WATER TREATMENT PLANT
The raw water coming from river cannot be used in the application of mill directly. So to meet the
need of pure water as per required, Water treatment plant is introduced.
According to the characteristics of raw water following types of treatment of water have been
adopted-
 Aeration of raw water in cascade aerator
 Sedimentation in settling basin
 Treatment with lime solution
 Treatment with alum solution for coagulation
 Rapid mixing of chemicals with raw water in flush mixture
 Flocculation and clarification of chemically mixed raw water in clariflocculator
 Filtration of portion of clarified water in rapid gravity filters followed by chlorination for
sterilisation of drinking water
Description of the water treatment plant devices and flow pattern-
a) CASCADE AERATOR
Aeration of raw water provides oxygen from atmosphere to effect beneficial changes in
it. It also increases the rate of liberation of undesirable gases like carbon dioxide, hydrogen
sulphide, ammonia etc. to increase the effective water surface by changing it into water droplets.
It is a cheap and valuable mean of controlling taste, odour and corrosion property but it
is not always the same achievement. The aerator has a diameter of 11 m and has 5 no’s of steps
when the water passes through its inlet pipes with high speed. It changes water into droplets which
is collected in an open channel of 1800 mm width which is delivered by a channel of width 1200
mm.
Raw water is first introduced to aerator during treatment process where mainly
liberation of gasses and oxides of metal takes place without precipitation.
b) SETTLING BASIN
Two RCC basins which have slops in their lower surfaces and dimensions 45m x 15m
are used as settling basins. Its side water depth is 2.5 m with a minimum depth of 5m, 15 m away
from its inlet side. Its volume is approximately 2530 m 3. Reiteration of each tank is approximately
80 minutes and as each tank treats 1875 m3 of water per hour.
It has two inlet channels of width 750 mm with insulating shutters. Its settling sledge is
discharged through CI pipes of diameter 200 mm and valves.
Between settling basins a 1800 m wide RCC channel is provided with isolation to
bypass the settling basin.
c) FLUSH MIXER
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It’s an RCC structure which receives raw water mixed with chemicals. It mixes water with
chemicals. For mixing purpose compressed air is used to meet the required mixing process.
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d) CLARIFLOCCULATOR
It is a circular RCC construction. At centre, a RCC centre column is constructed surrounded by
another wall and the space between two is called FLOCCULATOR ZONE and the space between
flocculator zone and outer wall is called CLEANIFIER ZONE. The slope in each zone towards the
centre. The column is surrounded by a pit which collects all sludge for disposal. It has a rotary
bridge having arrangements to collect mud produced and pushing it towards centre when the bridge
is rotated. In the centre of the flocculator, an inlet pipe is introduced which provides the way to the
mud to escape. Its output is stored in the reservoir and required water is pumped by the pump house.

4.2.3 DEMINERALISATION PLANT

The mill water from the water treatment plant has some salts in aqueous state. Hence if
it is used directly in the boiler operation, salts may be deposited on the wall of the boiler and its
circulation line. Hence to overcome this problem, the mill water is again purified to meet the
desired purity of water for successful boiler operation. Demineralisation plant is the solution to this
problem. It uses ION-EXCHANGE process.
It has following parts-
 Pressure sand filter
 Cation exchanger
 Degasser sump
 Anion exchanger
 Demineralisation tank
 Mixed bed exchanger
 Polished demineralisation tank
 Deaerator
a) PRESSURE SAND FILTER (PSF)
Mill water from water treatment plant is pumped with high pressure enters the sand
filter where it is filtered in respect of small particles. In this, sand is used as purifying layer. There
are 3 nos. of sand filter in the DM plant of NPM.
b) CATION EXCHANGER (CE)
Water output from PSF is passed in a tank which has acidic resin, which is activated by
the treatment of resin with acid (Conc. HCL), as a working material which acts with the cation part
(Na2+, Ca2+ etc.) dissolved in water and hence catching the cations is called CATION
EXCHANGER. The ion exchange resins used is actually a small polystyrene bead. The pH of the
water at the outlet of CE is 3.5.
There are 3 nos. of cation exchangers in the DM plant of NPM. The resin capacity of
cation exchanger is 2160 cubic meter of water, this means once this amount of water passes through
the resin, it needs to be changed for regeneration. The regeneration is done by passing conc.HCL
through this bed.
c) DEGASSER PUMP (DS)
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Water output from CE is pumped from upper part of a vessel, where high pressure air
blows from lower side blower which changes into droplets. This give away the way to carbon
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dioxide to escape. Now this water is collected in the lower part of the DS.
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d) ANION EXCHANGER (AE)
Water output from DS is pumped through the anion exchanger, which contains basic
resins which is made by action of base on resin. It catches the anions (Cl -, SO42- etc.) in water by
reacting with water and the outlet water is anion free. This vessel is termed as ANION
EXCHANGER. The pH of the water at the outlet of AE is 8.5.
There are 3 nos. of AE in the DM plant of NPM. The resin capacity of this basic resin
is same as that of the cation exchanger equal to 2160 cubic meter of water and once this amount of
water passes through the resin, it needs to be changed for regeneration by NaOH dosing.
e) DEMINERALISATION TANK (DMT)
Now the water output is stored in the DM tank. It stores water till the pumping of water
to the mixed bed exchanger.
f) MIXED BED EXCHANGER (MBE)
It has both types of resin beds within a single vessel, so it is called MIXED BED
EXCHANGER. It catches the missing salts that could not be caught by CE and AE.
There are 3 nos. of MBE in NPM. Its capacity is higher than that of the CE and AE
which is equal to 26600 cubic meter of water.
Resins are regenerated by opposite processes occurring in the vessel. Cation
exchanging resin is first treated with acid (HCL) and anion exchanging resin is treated with base
(NaOH) to restore and reuse the resulting salt is sent to drain pipes. The pH of water at the outlet of
MBE is between 6.8-7.2.
g) POLISHED DEMINERALISATION TANK (PDMT)
It is the reservoir where output water from the MBE is stored. It has only role to store
the water in such a manner that it may not be further polluted by any impurities during storage.
Amine dosing is done in this tank to make the pH of water equal to 9.0
h) DEAEATOR
Water stored in the PDMT is first passed through the deaerator for the extraction of air
before it is pumped to the boiler by boiler feed pump.

4.2.4 AIR COMPRESSOR

Air compressor is the key device of getting compressed air which has wide application
range. Compressed air is used in cleaning purpose of various machine parts across the plant and in
the paper plant in handling and cutting tools.
There are two types of compressors in NPM-
a) RECIPROCATING COMPRESSOR b) CENTRIFUGAL AIR COMPRESSOR
The air compressor is fitted with a suction by which it takes the air input from the
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atmosphere. It is arranged in such a way that air received by the compressor should be as dry as
possible. Also the suspended particles are separated from air. It’s a rotary type air compressor.
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Fig. CENTRIFUGAL AIR COMPRESSOR
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 The compressed air is stored in two vessels known as Mill Air Vessel and Instrument
Air Vessel. As per names, 1st supplies air to the different process need of mill while other supplies it
to its instrumental uses. The compressed air requirement of the company is approximately 137000
normal cubic meter per day in which mill air is approximately 41000 normal cubic meter with
pressure range of 6 kg per square cm and instrumental air is 96000 normal cubic meter per day with
pressure range 3kg.

4.2.5 BOILER FEED PUMP

It is a high capacity pumping machine which pumps required amount of water at
required pressure range to the boiler during its light up and operation.
It supplies water with pressure approximately 67 kg per cubic cm which is numerically
5 units more than boiler pressure. It is used to maintain the required level in boiler estimating the
evaporation rate not allowing water level to drop very low for the safety of the boiler and its
operators.
It works continuously with the operation of boiler and evaporation of water. Its motor
driving capacity is 750 KW. Its pumping capacity is 210 cubic meter per hour.
There are 3 boiler feed pumps. One runs at a time while other two remains in standby
condition. There is also a TURBO FEED PUMP in NPM which works under the action of steam.

4.2.6 BOILERS
Boilers are steam generator and it is a closed vessel which generates steam at a desired
temperature and pressure. Boilers are those in which fuel is burned to get heat energy and is then
transferred to the fluid which is water in this case to boil and finally evaporate in desired
temperature and pressure to drive required operations.
There are 3 types of boilers at HPCL (NPM)-
a) SPREADER STROKER TYPE COAL FIRED BOILER - commissioned on 31/05/1984
b) ATMOSPHERIC FLUIDISED BED COMBUSTION
COAL FIRED BOILER (AFBC Boiler) – commissioned on 12/09/1984
c) RECOVERY BOILER. – commissioned on 26/06/1985
First two are COAL FIRED BOILER while the last is BLACK LIQUOR FIRED
BOILER. It means first two generates heat and steam using coal while last uses black liquor, output
from the pulp mill to generate heat and steam.
In the HPCL, NPM there are 5 boilers of 3 different types as there of them are
SPREADER STROKER TYPE COAL FIRED BOILERS, one AFBC and ONE RECOVERY
BOILER.
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The capacity of first type boiler is 80 ton per hour while that of AFBC boiler is 50 ton
per hour but that of recovery boiler is 90 ton per hour.
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AFBC BOILER:
It is the most modern coal fired boiler working in the HPCL, NPM. It is most efficient,
less polluting and easily controlled boiler. Its capacity is 50 ton/ hr. it coal consumption is approx.
7ton.hr to meet its yield of 50 ton/hr in normal condition. It uses powdered coal as well as fly ash
from the spreader stroker type coal fired boilers. Due to this its running is cheaper than that of other
ones. In normal condition its smoke cannot be seen, it is due to combustion of coal and fly ash.
It has three chambers and three main fuel feeders, which are again divided into three
sub fuel feeders. Three fly ash feeders are connected into three main feeders. There are also three
lime stone feeders, connected to the main feeders.
One FD fan is used to blow air as per requirement of complete combustion, one
primary air fan used to carry the combustible material fluidising them into the furnace. Before
lighting up the boiler all air vents, silencer vents are opened and all drains should be in closed
position.

RECOVERY BOILER:
It is the boiler which uses the black liquor produced by the pulp mill as its fuel and
generates heat and resulting generation of steam, but the main useful application of this boiler is
that by using it, blue liquor may be recovered as by-product which is further reacted to produce
white liquor. It is more important than steam generation by the recovery boiler. Hence it is a very
important part in case of a paper mill.
The RECOVERY BOILER of the HPCL, NPM working now have specifications as follows-
 It is a BHEL production
 It was modified by ENMAS PROCESS TECHNOLOGIES LIMITED in 1994
 Its capacity is 500 TDS per day
 Its steam generation capacity is 65.230 ton per hour
 Its superheater outlet temperature is 4000C
 Its total combustible air required is 103.910 ton per hour
 Excess air supplied to the boiler is 16.7 % more than theoretical requirement
 Free oxygen in flue gas is 3%
 The combustion of salt cake is 31.1 ton per hour
 It recovers 92% of the liquor available in the black liquor form.

4.2.6.1 VARIOUS BOILER PLANT CIRCUITS

 Feed water and steam system
 Pressure port circuit
 Boiler steam circuits
 Blower blow down circuits

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Sample cooler
 Chemical dosing system
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 Combustor/furnace
  Combustion air/one fuel air system
 Fuel handling/storage and fuel feed system
 Fuel gas circuit
 Bed ash/fly ash handling system
 Refectory and insulation
 Electrical and instrumentation
 Electrostatic precipitator
 Chimney

4.2.6.2 DIFFERENT PARTS OF A BOILER

 Economiser
 Steam drum
 Down course tube
 Furnace
 RH and LH bed evaporator
 Furnace membrane water walls
 Riser tubes
 Saturated steam support tube
 Superheater
 Attemperator

4.2.7 COAL HANDLING PLANT

In NPM, HPCL coal is mainly supplied from Meghalaya, the neighbouring state of
Assam. The company uses huge amount of coal and it depends upon the calorific value of the coal.
In this plant supplied coal from the mines is grinded to its required shape and size and it is run over
V-shaped conveyer belts moving on pulley driven by motor.to reach the coal bunker of the boilers.
Magnetic separators are applied at many places in the belt paths of the coal for
separating magnetic materials, such as iron, which is naturally available in the coal. Generally
bunkered coal move downward under the force of gravity but it is pulled inside the boiler using
motor rotating belts.

4.2.8 ASH HANDLING PLANT

During operation of spreader stroker type coal fired boiler, due to incomplete
combustion black smoke comes out. This is due to suspended coal particles which are black in
colour. It pollutes the environment as well as increases the cost for running the boilers. To
overcome this problem in the path of flue gases certain type of ash separators are introduced. It is
introduced below the economiser for most effective operation.
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In the NPM (HPCL) ash handling plant ash is separated by gravity separator which
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falls in ash hoppers installed at the lower part of the economiser. When the hopper is full of ash the
power cylinder operated gate is closed and air at 5 kg per sq. cm is introduced and delivery valve is
opened. Air containing ash is delivered out and when the hopper becomes vacant both the valves
are closed and gate is opened. The output ash is conveyed to the ash feeder of the AFBC boiler and
lastly burner instead of coal.

4.2.9 STEAM TURBINE AND GENERATOR

The superheated high pressure steam output from the superheater (approx. 400 0C) and
pressure approximately 60 kg per sq. cm is given to the turbine. Turbine has a moving part called
blades. They rotate under the action of pressurized steam and also provide space for the expansion
of high pressure. High temperature steam results the drop in pressure and temperature. The shafts
connected with blades receives mechanical works in the form of rotation.
This mechanical work is being used in power generation attaching with certain
coupling devices to an electric generator to fulfil the power needs of the plant in the case of HPCL.
This set is called TURBO GENERATOR which is the most used turbo generator in the world.
There are following specifications in the steam generation plant-
 Two sets of TURBO GENERATOR
 Power generating capacity = 15 MW each
 Total power generation capacity = 30 MW
 Temperature of input steam = 4000C
 Rated speed of the turbine blades= 6500 RPM
 Rated speed delivered to the generator = 3000 RPM
 Intermediate pressure output from turbine = 11 kg/sq.cm
 Lower pressure output from turbine = 4.5 kg/sq.cm

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4.2.10 COOLING TOWER
Cooling tower is theoretically a cross flow heat exchanger where heat is exchanged
between hot water and atmosphere. It the part of the utility section which controls the temperature
of water which is being processed by it. The hot water output from various parts of the plant is
pumped to the cooling tower for necessary cooling.
Water flow in the tower is arranged in such a way that it breaks into small droplets
increasing the surface area of hot water to increase the rate of evaporation and effectiveness of the
cooling tower.
The cooling tower works on the principle of CROSS FLOW HEAT EXCHANGE
principle, hot water droplets falling down from a certain height are exposed to the naturally glowing
atmospheric air. Some of high energy particles receiving energy from both air and their surrounding
get evaporated. Since they carry energy from the hot water hence temperature of hot water
decreases. This produces cooling effect in the remaining hot water. This process continues till the
droplets reach the lower level and become output water. This water attends lower temperature and
pumped back to its concerned places and hot water from those places reaches the cooling tower.
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 CHAPTER 5

CONCLUSION

The training I got in HINDUSTAN PAPER CO.LTD. , NAGAON PAPER MILL

was of immense help for me and I was fortunate to be guided by experienced operators and
engineers.
My training was allotted in three departments- Mechanical Workshop, Paper
Machine & Utility Department.
Beginning with the Mechanical Workshop Department I came to know a lot about
how different machinery parts are repaired and manufactured according to the requirements.
The visit to the Paper machine and finishing house were very informative in letting
me know about how raw materials is processed and made ready to prepare paper from it.
At the final stage it was my turn to know about the boiler, turbine and the power
generator in the Utility department. I even got the chance to study different parts of boilers,
turbines, compressed air cycle, centrifugal pump, Coal treatment plant, cooling tower etc. I then
visited the control room and the power house of the plant and was ably guided and apprised about
the operational parameters of the utilities…
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 All in all the training at HPCL (NPM) was a lifetime experience which lend me the
opportunity to get an on hand experience of how this govt. of India enterprise works for producing
best quality of papers…

FINAL COMMENTS-
The training was overall very informative and the operation of the plant speaks
volumes of how good the enterprise is in its working. The industry is a great example in the field of
paper production in ASIA & especially in INDIA.
At last I want to convey my thanks and gratitude to all the training guides,
supervisors, workers and the administrative authority of the HPCL, NPM.

…....

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