INPLANT TRAINING

REPORT
In accordance with
15 days Training
At Ballarpur Industries Limited (BILT).

BILT Graphic Paper Products Limited,

BALLARPUR
From: 23thJULY to 06th August , 2024

SUBMITTED BY : MANISH KUMAR

FROM:

Panipat institute of engineering and technology.

(affiliated to Kurukshetra university)
Samalkha Panipat haryana

ACKNOWLEDGEMENT

We, the final year chemical technology students of University Department of

1
 Chemical Technology, Amravati, thanks Mr. C. S. Kashikar [Link]
Manager, Mr. Bhushan Awate (Manager R&D), Mr. Gajanan Rothe, Assistant
Manager- R & D for valuable guidance and kind assistance throughout our
training at BGPPL.

We are grateful to the staff and employees of all the departments, especially the
Research and Development section for making us acquainted with all the processes
carried out in the mill.

INDEX
 Introduction : 5

 Raw Material : 6

 Chipper House : 8

 Pulp Mill : 12
 Digester House : 13

 Screening Section : 18

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 Washing Section : 20

 ODL Plant : 23

 Bleaching Section : 25

 Stock Preparation : 29

 Machine House : 33

 Finishing House : 43

 Recovery Section : 45

 Effluent Treatment Plant : 56

 Water Treatment Plant : 60

 Research and Development

Section

Introduction

3
 BGPPL is one of the most largest paper manufacturing company in India .
The establishment of BGPPL, was took placed in the year 1952, when Lala
Karamchand Thapar acquired Shree Gopal Paper Mill Limited at Yamuna nagar.
BGPPL units account nearly 10-15% of country’s total paper production.
Ballarpur unit is an integrated pulp and paper mill with a capacity of 605000
MTPA (metric ton per annum,) of writing and printing papers manufactured from
bamboo and hard woods.
The raw materials come from AP, Karnataka, Maharashtra. It is an ISO- 14001,
ISO- 9001 and 5’S certified unit and OHSAS-18001. It manufactures various
varieties of writing and printing papers .

It has 7 machines . Highest paper production is occurred in PM-7 with the

capacity of 500 T/day .

For BGPPL, the past few years were full of modernisation, technology
upgradation, provisional or distributed control system and microprocessors based
on control system etc. Almost every section of the mill is modernised. The thrust
was on selection of appropriate technology and equipments from quality as well
as pollution control consideration. BGPPL has the largest Effluent Treatment
Plant having a capacity of 35,000 m3/day of effluent by Activated Sludge Process.

4
RAWMATERIAL
Raw Material

• Hardwood- Hardwoods consist of Eucalyptus, Casurina, Subabul and

Mixed fire wood.

• In addition to this, bamboo which is a grass is also used.

• Softwood – Softwood consists of imported pulp.

Feed composition- 90% hardwood and 10% bamboo is maintained here.

Softwoods yield stronger pulps than hardwoods and have long fibres, hence these
are preferred. Earlier the feed ratio was 60%hardwood and 40% softwood.
However due the growing scarcity of bamboo the current softwood utilisation is
reduced to 10% only. Fibre dimension- The optimum length of fibre is 25-35mm
while the desired fibre thickness is 6-8mm and width is 8-10mm.

• Material storage: material stored in the wood yard is highly inflammable

and hence needs to be protected against fire and decay.

• Fire protection measures:

 6 to 8 feet wide free space is left along each stack.

 Dry grasses and leaves are collected and disposed off.

 Fire hydrants are used.

 Arrangement of tower for continuous watching is done.

 Smoking is strictly prohibited in the yard.

 The employees are trained against fire fighting.

 Decay control measures:

 Unwanted materials like decayed wood are removed from the stack.

 Aluminium phosphide (celphos) tablets are used which evaporate and

prevent the decay of wood.

5
CHIPPERHOUSE
Chipper House

The objective of chipping house is to treat wood log in such a way that it meets
the regularities and standard. For efficient cooking and processing of chips, these
are reduced to usually 25-30 mm size. The raw material in the form of wood is
received through trucks from various parts of Andhra Pradesh, Karnataka and
Maharashtra. They are washed in the loaded position with treated water coming
from the effluent treatment plant for easy and efficient chipping.

Through the belt conveyors these washed logs of wood are fed to the chippers.
The chippers operate on the principle of a flat revolving disc with knives set
radially on the surface and projecting out from the plane of the disc. There are 4
fly knives, out of these 2 are dead knives which has 1130 mm total length, 200
mm breadth and 20mm thickness. The wetted logs of wood are fed horizontally to
the chippers and are chipped to the optimum size.

SCREENING:

Chips obtained from chippers vary largely in their size and hence are sent to
screeners. A stream of unclassified chips is fed to 4 vibratory screens that have
openings of decreasing size. The mesh sizes of screens are 50, 30, 5mm in
diameter respectively. Due to screenings the chips get separated into undersized,
desired size and oversized chips. The oversized chips are sent to rechippers which
are 2 in numbers and are rechip back, while undersized chips are blended with
saw dust pulp and are taken to the boiler house, as fuel for boilers. The required
size chips are transferred to the silo for storage through belt conveyors. Here the
silo is divided into 2 equal sections with each section further divided into 5
compartments, each having capacity of 45MT.

6
 PULP MILL
Digester House
Digester refers to that part of paper manufacturing where the raw material in the
form of chips are converted to pulp.`Pulp` can be commonly called as Cellulosic
fibres, which are separated from the wood chips after cooking.

Cooking carried out at high temperature and pressure leads to the rupturing of
bonds to break the wood structure into fibrous mass.

Digester operation-

The batch type stationary digesters are used for pulping operation for good yield.
Chips digester house operation is divided in 5 parts as below-

• Cooking.

• Blow heat recovery system operation.

• Condensate recovery system operation.

• Spill collection system operation.

• Non condensable gases recovery.

This operation is carried out in 7 sequential steps-

• Chip filling

• Liquor charging

• First stage steaming

• First stage cooking

• Second stage steaming

• Second stage cooking

Digestion operation

The primary objective of cooking operation is to separate the wood fibres, joined
to each other by lignin. Here, Kraft pulping process is employed for cooking in
which mainly NaOH+Na2S is used as cooking liquor or white liquor. In this
process, lignin gets dissolved in soda, and Na2S play an important role in
maintaining the strength of the NaOH in the cooking liquor for complete cooking.
White liquor is fed upto 3/4th of the digester along with black liquor which is

7
added for dilution. Steam is added with the help of steam valve. Blowing is done
from the bottom of the digester where blow valve is provided. The liquor is
continuously circulated from top to bottom through a circulation pump. During
circulation, the liquor is allowed to pass through preheater where its temperature
increases at the inlet to the digester, which is ultimately beneficial on account of
steam consumption.

Blowing:
After digestion, the digester contents are discharged into blow tank where the
softened chips are disintegrated into fibres. This is called Blowing. In the digester
the material is under high pressure. The cooked material is fed into the blow tank
from the top from high pressure to low pressure, where the cooked chips get
disintegrated into fibres along with the release of hot vapours called blow

Blow heat recovery system:

In this system the blow vapours from the blow tank are taken to the Voith cyclone
separators. Here the fibres separated are transferred to blow tank through dump
chest, while the vapours are sent to the spray condensers. At this stage, water is
added through nozzle at 500C with the help of primary pump, while hot water at
about 900C is recovered and taken to Voith PHE Feed Pump. The primary pump is
operated usually at lower temperature for efficient separation of vapours. Here
the efficiency of heat recovery is about 90%.

Condensate contamination:

The condensate gets contaminated due to mostly rupture of heat exchanger tube
or rarely due to suction of black liquor in steam line. Conductivity meter is used
to check the contamination of condensate whose reading can be seen on the
digester house control panel.

Main advantages of Alkaline Pulping:

• High strength pulp can be obtained.

• Different varieties of wood species can be

• Barks can also be tolerated.

• Efficient recovery of chemicals is possible.

8
Screening Section
In this operation, the pulp from the blow tank is first taken into junk traps. Here
the removal of heavy metal particles like iron takes place and the pulp is moved
onto pressure knotters where the knots are removed. There are two open vibratory
knotters provided. The screen plate has perforation of 3mm. The accepted stock
falls through the holes and is taken to the primary vertical screen.

At BGPPL, 3 stage screening is carried out. The perforation of the screen is 2mm.
The accepted is taken to the primary screen, while the rejected knots are taken to
the digester for cooking. The accepts from the primary vertical screen are taken
to brown stock washing, while the rejects are taken to knotters. The rejects from
the primary screen move to the secondary screen. The accepts from the secondary
screen are taken back to the primary screen, whereas the rejects from the
secondary screen are taken to tertiary screen. The accept from the tertiary screen
are again taken back to secondary screen , whereas the rejects move on to the
sand cleaner where the sand particles are removed from the pulp and send back to
primary screen. This is a continuous process. All the 3 screens are pressure
screens. The screening efficiency is around 90%.

Washing Section:

The objectives of washing are:

Remove of residual liquor that would contaminate the pulp during

subsequent processing steps.

Recovery of maximum amount of spent chemicals with minimum dilution.

Process description:

At the digester, chips are cooked and lignin dissolved in the cooking liquor
forming black liquor leaving behind the pulp. In the pulp screening plant, knots
and shives are removed. In the wash plant, pulp is washed in stages to render free
from black liquor.

The pulp mass coming as accept from primary screen is diluted further using
black liquor from the wash plant. The consistency is controlled to about 1% at
this stage. The stock is led to the wash plant, which consist of 4 rotary drum
vacuum filter arranged in series. The pulp is fed to the vat of first washer, where
from the pulp mat form on the first drum and subsequently falls into the
repulpervat of the next washer. Thus, the pulp moves from one vat to another and
finally emerges as the washed pulp at the 4th washer and discharges into high
density storage. However, wash water is added as drum shower on the 4thwasher.

9
The washer filtrate moves counter currently to the pulp and emerges as filtrate
from the first drum. This filtrate is known as thin black liquor. The thin black
liquor is used in the blow tank bottom case and for dilution purposes. The excess
of this black liquor from the sealed tank of first washer is screened on the Malone
filter to remove fibres present, if any. The screened black liquor is pumped to
chemical recovery section.

Oxygen delignification plant (ODL)

ODL is the process of further removal of lignin from the entering pulp with 5%
lignin content to near about 2-3%. It begins with a pulp of 10-12% consistency
being discharged from the last stage of unbleached pulp washing. White liquor is
added in conventional way, the pulp is then pumped through a high intensity
shear mixer where oxygen is added and dispersed. The oxygen reactor is an
upflow tower usually pressurised. The pulp is diluted at the top and blown to the
blow tank, where gases are separated from the suspension. From the blow tank
the pulp passes to one or more washing stages before passing into the
chlorination stage for bleaching.

In this unit there are two oxygen reaction towers with the capacity of 360m3 each.
Having two towers increases the capital cost but it prevents the fibre loss due to
over reaction of oxygen with the pulp.

Bleaching Section

In order to get the pulp of desired brightness and purity, bleaching operation is
carried out. In this process the brown coloured pulp obtained from digester is
converted to white pulp with the help of bleaching agents like chlorine, calcium
hypochlorite, etc. At Ballarpur, bleaching is done in 4 stages-

• CD (using Cl2 , ClO2)

• Eop (extraction with caustic)

• H (using CaCl(OCl))

• D (ClO2 )

CD stage:

10
In the bleaching process, unbleached pulp from the tower is fed to the
chlorination tower, it is also called CD tower. In the CD tower, the chemicals
used are chlorine gas and chlorine dioxide liquid and hence called CD tower. The
chlorine gas is injected into the pulp from the bottom of the tower, as it is used in
the gaseous form. The ClO2, which is used in the liquid form, is fed from the
top.ClO2 added serves to minimize degradation of cellulose, reduce colour of
effluent and provide better brightness stability. Here lignin reacts with Cl2 by
oxidation substitution reaction to form chloro lignin. Here, the unbleached pulp
comes from the 1000m3 storage tank and it enters the CD tower from the bottom.
The CD tower is called as upflow tower in which the feed enters from the bottom
and the overflow is taken out from the top. Thus, the overflow of pulp obtained
after addition of Cl2 and ClO2 is taken to the bleached plant washer-1(BPW-1).
The pulp taken to BPW-1 is slightly brighter than the original unbleached pulp.
The washed, extracted pulp moves to the next stage.

Eop stage:

In this stage the extraction of the pulp with caustic and O2 takes place. By using
alkali, the chlorolignin formed in the previous stage is dissolved and removal of
colour compound takes place. This tower is also an up-flow tower. The pulp
enters at the bottom and the over-flow moves on to the next operation. The main
chemicals used are O2 and H2O2. O2 is added to increase the strength of the pulp.
The retention time in this tower is 2.5 hrs. The Kappa number initially is 13 and it
is drastically reduced to 3-3.5 after this stage. The over-flow from this tower goes
to BPW-2. Mill water is added to BPW-2 from the top. The pulp from BPW-
moves for next operation to the hypo tower.

H stage:

The chlorination and alkaline extraction will not give commercially required
brightness to the pulp and hence oxidative bleaching stage, where the active
component is sodium or calcium hypochlorite in an alkaline medium. The
brightening is achieved by destructive oxidation of lignin and the continuous
presence of alkali leads to the solution of reaction products, thus opening deeper
layers of lignin in the fibre for further attack. Sulfamic acid is added to control
the viscosity of pulp. It is important to maintain the pH because below this Ph,
hypochlorite is in equilibrium with significant amounts of hypochlorous acid
which is a powerful oxidant of carbohydrates. Since the pH is high, the lignin is
continuously extracted as it is depolymerised. The rate and extent of hypochlorite
bleaching reactions depend on the nature of the pulp, bleach demand of the pulp,
chemical application, temperature, pH, retention time and consistency.

D stage:

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It is the final stage used in the bleaching sequence to obtain final brightness. The
ClO2 bleaching stage is an oxidative bleaching stage conducted under controlled
and optimised condition to promote its reactivity with lignin and other colour
constituents of the pulp with minimum carbohydrate degradation. The main
function of this stage is high selectivity in dissolving lignin without degrading
cellulose and hemi-cellulose, thus preserving the pulp strength and resulting in
high brightness. The rapid adoption of ClO2 for pulp bleaching can be attributed
to its high selectivity in destroying lignin without significantly degrading
cellulose or hemi-cellulose, thus preserving pulp strength while given high, stable
brightness. The high selectivity of ClO2 for lignin makes it useful for later
bleaching stages where lignin is present in very low concentrations. This stage
can also be considered to be very useful in reducing the shives content. ClO2 is
usually considered to have 2.5 times the oxidising power of Cl2 on a mole per
mole basis.

FLOW DIADRAM
OF
STOCK PREPARTION

12
 From Intermediate Decker Hw Hw lower Hw dilution
pulp mil tank thicknes tower drain pump chest
s

Hw closing
pump Refined chest Hw Hw Hw hc Hw refining
hw refiner 2 refiner1 cleaner pump

OBA
Dye 1
Chemi
Stocker mixer cal Dye 2
bright
ness Dye 3
agent

Machine Blocide
chest
Carbonic starch

Mixing
pump

Solo pit

blocide
White water 1st cleaning
feed pump

Ist Low consistency

Head Central Fan centricleaner 1st
1 stage Deculator
box header pump stage
screen

1st stage screen 2nd stage lc

ACCEPT

cleaner
REJECT

reject stand pipe

3rd stage lc
Second stage feed cleaner
pump
5th stage lc 4th stage lc
cleaner cleaner
2nd stage screen

Drain out

13
Pulp received from pulp mill is unsuitable for paper making, hence it is subjected
to various mechanical and chemical treatment to get the desired quality of paper.
This operation is carried out in stock preparation. The main objectives of stock
preparation is-

• Storage of the pulp obtained from the pulp mill

• Pulp refining

• Blending of pulp with necessary additives

• To supply stock to the paper machine as per requirement

• Pulp storage system:

• Both bleached and unbleached pulp obtained from pulp mill is stored in
the storage tower of capacity 100m3 each. Here the consistency of pulp is
maintained at 4-4.5% respectively.

Refining of stock:

It refers to the mechanical action on the fibre in water suspension to convert raw
fibre into a form suitable for the formation into a web of desired characteristics
on a paper machine.

There are three types of refiners namely-

• Conical refiner.

• Double disk refiner (DDR).

• Triple disk refiner (TDR).

The major effects of refining on fibre are-

• Swelling of fibre.

• Increase in fibre flexibility.

• Fibre shortening.

• External fibrillation of fibre.

• Breaking of the inner fibre bonds and replacement by water fibre bond.

• Increase in drainage resistance.

• Decrease in risk of flocculation

CHEMICAL ADDITIVES:

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Dyes:

Dyes are the colouring agents added to the stock to impart desired colour to the
final product. Dyes may be acidic, basic, direct and pigment dyes. Acid dyes
being negatively charged have low retention and have poor bonding with fibres,
whereas basic and direct dyes have great affinity for cellulose. Pigment dyes have
a low affinity for cellulose but they are resistant to light, air and water and have a
good appeal. However, these are comparatively costly than others. Basic dyes and
pigment dyes are more commonly used.

Optical Brightening Agent (OBA):

The optical brightening agents are added to increase the apparent brightness and
whiteness of paper. For example, Bluton-AS, Bluton-BA, Tinopal, etc. The OBA
addition takes place both at the stock preparation as well as at the dry end.

Sizing:

Sizing chemical is added to the stock in order to impart water repellent property
to the fibre (Cobb value). Sizing can be acidic, alkaline and neutral. In acidic
sizing, the paper becomes weak, dull and brittle on ageing. It causes reversion of
brightness, strength and colour. It is also corrosive, dirty and causes damage to
the machine parts. Alkaline sizing prevents reversion on aging. Hence, alkaline
sizing is preferred. Some sizing agents are Alkene succinic anhydride (ASA). The
alkaline sizing is accomplished by ASA. Rosin is used for neutral sizing but this
paper has low life and turns yellow on exposure to sunlight due to reversion of
cellulose. Cationic starch is added which forms an emulsion with ASA on
external sizing whereas internal sizing increases the strength of paper.

MACHINE
HOUSE
Machine House:
Paper machine is a device for continuously forming, dewatering, pressing and
drying a web of paper fibres. Until most recently, the most common type of wet
end was Fourdranier where a dilute suspension of fibres typically of 0.3-0.6%
consistency is applied to an endless wire screen or plastic fabric. Water is

15
removed by gravity or the pressure difference developed by table rolls, foil or
suction equipment and drilled couch. The web at this point is at 18-23%
consistency. More water is squeezed out in press section to a consistency of 35-
50%. Finally the sheet is dried with steam heating in the drier section.

Paper machine consists of-

• Forming section

• Draining section

• Pressing section

• Drying section

• Winding:

o In BGPPL, there are 7 paper machines 4 are MF and 3 are

MG.

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HEAD BOX:

The function of head box is to take the stock delivered by the fan pump and
transform the pipeline flow into an even, rectangular discharge, equal in width to
the paper machine and at uniform velocity in the machine reaction. The head box
lies between the distributer and slice.

In BGPPL, PM-I, II, V has open head box, PM-VI and VII has closed head box
and PM III and IV has pressurised head box in which pressure is regulated
through a compressor which either supplies air into and out of the head box to
maintain the definite head to bring down the rush to drag ratio to the desired set
point.

17
 Functions of head box:

• To spread the stock evenly across the wire part.

• To correct the inequalities in velocity of flow.

• To equalise the turbulences and cross flows created in the distributors.

• To create controlled turbulence to eliminate fibre flocking

Slice:

A slice is a rectangular orifice in front of head box it takes relatively slow moving
stock in head box at high speed and discharged it with a velocity close to wire
speed. At BGPPL projection and vertical slice are in operation.

WIRE PART:

The wire, also called the forming fabric, is a continuous loop or finely woven
screen made from wire or plastic (nylon). The wire is used to:

• Transport the fibre.

• Permit draining the sheet.

• Transmit power

Parameters PM-1 PM-2 PM-3 PM-4 PM-5 PM-6 PM-7

Consistency 0.4- 0.4- 0.4- 0.4- 0.5-0.7% 0.4- 0.6-0.8%

18
Breast Roll:

It supports the wire below the head box. It is made up of cast steel and is covered
with copper coating for corrosion protection. It is the turning roll for the wire at
the slice and is driven by wire. It also acts as suction former.

Forming Board:

It is mainly use for supporting work which is made from polyester monofilament
made endless by a seam to form a continuous belt. The mesh of fabric permits the
drainage of the retaining fibre by shaking action.

Hydrafoils:

Foil is a stationary blade held in contact with the wire at the front and

diverting from the wire at an angle of 1.5 to 2⁰. Foils are normally 2-8

m long. Foils have higher drainage and negligible fibre loss compared to table
rolls.

Table Rolls:

These are also used for water removal purpose. This must be straight, rigid and
dynamically balanced since the vibration will disrupt the formation of sheet on
the wire.

Wet and Dry Suction Boxes:

19
 These are placed before dandy roll or wet suction boxes and after dandy roll or
dry suction boxes. Suction boxes are used for removing water from the mat by
applying vacuum system in the range of 7.5-25 mm Hg.

Parameters PM-1 PM-2 PM-3 PM-4 PM-5 PM-6 PM-7

No. of suction 4 3 2 2 4 8 3

Boxes

Vacuum applied 180- 460- 100- 100- 180- 200 45 kPa

200 470 120 120 200
mmHg

No. of slots 50 50 9 9 20 4 4

Slot angle 60 0 60 0 60 0 60 0 60 0 60 0 60 0

Dandy Roll:

This is used to improve the finish and formation. It is also used to produce water
mark in paper.

Couch Roll:

This roll is usually the drive roll for the entire machine. It removes sufficient
amount of water so that the web leaving the wire part will have considerable
strength.

Lump Breaker Roll:

This roll is a solid roll with a suitable soft cover that is mounted over a couch roll
to assist the sheet by pressure.

Straight and Guide Rolls:

These are used automatically to maintain the correct tension on the wire.

Showers:

A series of showers are used to keep the wire clean.

PRESS SECTION

The primary function of the press is to remove water, impart favourable sheet
properties and impart higher wet web strength for good run ability in the drier

20
 section. The pressing operation may be considered as an extension of water
removal process by mechanical means. Here following types of presses are used-

Plain press- It is used to remove water mechanically without applying any

vacuum.

Suction press- In the suction press a rotating outer shell and a stationary suction
quadrant, the rotating one is drilled to allow air and water to be drawn into the
suction quadrant, the shell of the row is usually rubber covered to give it with
little softness and prevent the whole pattern from being transmitted to the web
through the felt.

Smoothening press- This type of press is used in MG or Yankee type of machine.

The sheet passes through first press and comes to smoothening press. Here the
roll is in contact with the surface of MG dryer. As the sheet passes through the
nip, water removal takes place.

Offset press- In this press the paper is passed between two metal rolls under
pressure, the sheet is pressed and passed to next section

Parameter PM-1 PM-2 PM-3 PM-4 PM-5 PM-6 PM-7

Top roll dia. 750 710 790 550 710 610 770

( mm )

Bottom roll 710 750 710 510 760 686 852

dia.

( mm )

Vacuum 525 460- 240- 300 460- 400 45 kPa

470 260 470
( mmHg )

Dryer section:

Drying is removal of moisture or water from the wet web leaving the press
mainly by evaporation throu7gh steam heated cylinders.
Parameters PM-1 PM-2 PM-3 PM-4 PM-5 PM-6 PM-7

21
Calendering:

The calendar stack is a series of solid rolls mounted horizontally and stacked
vertically. During machine calendering, the paper from dryer passes between the
rolls under pressure.

Functions of Calender:

To build even reels, it provides calliper control throughout the width of sheet.

• To produce smooth well finished sheet.

• Correct irregularity in the sheet formation.

• To improve surface flatness and density of the paper.

• To improve glaze of the paper sheet.

Technical Data:

Particulars PM-1 PM-3 PM-4 PM-6 PM-7

No. of 1 1 1 1 1
stacks

No. of rolls 2 2 2 2 2

Nip Self 110 60-100 110 30-

pressure loaded kg/cm 2 kg/cm 2 kg/cm 2 150 kg/cm 2

Surface Sizing:

Surface sizing refers to the application of dry and wet strength additives to the
paper usually at the size press.

Objectives of surface sizing:

• To improve water penetration resistance.

22
 • To obtain wet rub and wet pick resistance.

• To improve the surface and internal bond strength.

• To reduce the porosity.

• To improve the printing properties.

Technical Data:

Particulars PM-3 PM-4 PM-6

Type Horizontal Horizontal Horizontal

Movable roll Rubber Rubber Rubber material covered covered covered

Fixed roll Micro rock Micro rock Micro rock material

Loading Hydraulic Hydraulic Hydraulic

Paper feeding Rope carrier Rope carrier Rope carrier

Winding/Reeling:

The paper after calendaring is sent for winding where paper is bound over cast
iron roll. The paper is passed through tension roll so that the paper being wound
on core is under uniform tension across the width.
This is called pope reel. This is the last unit of paper machine.

23
 Common Flow Sheet of Paper Machine

Fibre Slurry

Head Box

Suction Wire Section Back Water

Press Section/Size Press

Suction Pressing Water

Dryers/MG Drying/Pre
Steam Condensate
Drying/Post Drying

Calendars

Pope Reel

Re-winders

24
FINISHING
HOUSE

25
Finishing House
The main function of the finishing house is to process the paper manufactured on
machines in wheel or in sheet form as per the requirement of the customer. The
paper finishing plant includes the following-

• Rewinder

• Cutter

• Counting

• Packaging

• Labelling

Rewinder:

The function of the rewinder is to rewind the paper manufactured on the pop reel
and also to remove the defective paper. The bigger sized reels are reduced to
smaller size of required width and diameter as per the customer demand. A
typical rewinder consists of parent reel, tension roll, camber roll, top and bottom
slitters, D bar, drum roll, core shaft, ejector and rider [Link] parent reel is the
reel to be rewound, hydraulic break is provided in the shaft of parent reel.
Tension and camber rolls are provided to give tension to the paper and thereby
avoid creeping. The shear force between slitter roll and slitter knives
accomplishes slitting and trimming of the sheet and it is wound on the core shaft.
Over this shaft a pneumatically operated rider roll is provided to ensure proper
reel building.

Cutter:

The function of the cutter is to cut the paper reel or rolls into sheets of required
dimensions. A typical cutter consists of a backward stand, cutting section and
delivering section. In the back stand the rolls are mounted, from this reels the
cutting section draws the paper. The incoming paper is slit width wise in the
slitters and lengthwise in the [Link] paper cutting, the sheets and reels are
sent to the finishing section where they are counted, packed and weighed. After
the completion of packaging checker count, the number of reams and finished
report is prepared. This contains information about lot number, quality, size,
weight, no. of reams. Then reel finishing and labelling is done. Wrapmatic
machine is provided which wraps the reams which are cut at the Pasaban
Cuttters. Finishing loss is around 10-11%.

26
RECOVERY
SECTION

27
Recovery Section:
Chemical recovery is the process of recovering pulping chemicals from the spent
liquor and reuse. The main objectives of chemical recovery are:

• To recover the cooking chemicals from the spent liquor.

• To generate large amount of heat by burning the organic material derived

from the wood present in the black liquor .

• To reconstitute these chemicals to form fresh cooking chemicals.

• To minimise air and water pollution.

Recovery process consists of 6 steps:

• The concentration of weak black liquor in multiple effect evaporators

from 15% TDS (total dissolved solids) to 50% TDS.

• Further concentration in forced circulation evaporator from 50% TDS to

65% TDS.

• The combustion of concentrated liquor in a suitably designed furnace for

burning matter from the sodium salts for reduction of sulphur containing
salts to sodium sulphide and for utilising the heat produced in the
generation of steam.

• Green liquor production and clarification.

• Causticising of green liquor, withdrawal of clarified and causticised

solution or white liquor used in another cycle.

• Burning of mud to recover lime.

The chemical recovery plant can be divided into 3 sections-

• Evaporation

• Recovery

• Causticising

Standard operating procedure for recovery department-

• To receive black liquor from pulp mill at 17 0Tw and minimum 780C
temp.

• To prepare semi concentrated thick black liquor in evaporator plant no. 1,

2, 3 and 4 and blending at FCE plant header.

28
 • Prepare thick black liquor of 68+ 20Tw in FCE plant and supply to
recovery boilers.

• Supply pure condensate to DM plant.

• Supply foul condensate to causticising plant.

• Receive and blend white and yellow salt cake in proper proportion.

• Feed salt cake to salt cake bins.

• Mix salt cake in thick black liquor in recovery boiler 1 and 2.

• Fire black liquor in RB-1 and RB-2 at 325-340 TPD and 220-240 TPD
dry black liquor solid respectively.

• Collect ash in recovery boilers ESP and reuse by mixing in thick black
liquor.

• Supply high pressure steam to high pressure header.

• Supply green liquor of 114gpl to causticising plant.

• Receive lime from various vendors and blend in proper proportions.

• Feed lime to lime bin by running lime crusher.

• Ensure continuous running of white liquor clarifier, dreg washer and lime
mud washer rake machine.

• Run causticising plant for supplying white liquor to pulp mill having
active alkali strength of 90+ 3gpl. In cake, active alkali goes below 87gpl
start caustic dosing at white liquor polisher outlet.

• Ensure continuous running of causticizers, lime mud slurry tank and drags
mixer agitator.

• Ensure white liquor, mud washer and filtrate clarity and strength.

• Supply weak white liquor to recovery boiler.

• Dispose grits and stones generated in slakers and rake clarifier.

• Wash and filter lime sludge produced from causticizing plant to get
filtrate strength of 4-5.5gpl in new mud filter and 6-8gpl in old mud filter.

• Dispose lime sludge through dumpers through DDC department.

Evaporators:

29
Cooking chemicals which are separated from pulp after screening in the Malone
filter in the pulp mill, along with wood residues is called as black liquor. This
black liquor having initial concentration of 16-17%, containing 0.110gpl of
constant suspended solids, 5.9gpl of free alkali, organic content 50.2% and
inorganic content 49.8% comes to the evaporation unit. The aim of evaporators is
to concentrate thin black liquor from 16-17% concentration to 60-65% solid
content. In BGPPL, 4 multiple effect evaporators (MEE) having long tube
vertical evaporators (rising film) are used which concentrate the thin black liquor
from 16% to 50% solids, while rest of the concentration is increased in forced
circulation plant having 3 vapour separators. The most important physical
properties of black liquor that affects the evaporation process are specific gravity,
viscosity, specific heat and boiling point characteristics.

Multiple Effect Evaporators:

MEE consists of series of evaporators with indirect heating for removal of water.

MEE-1: It is backward feed multiple effect evaporator having 4 effects. The

black liquor is fed at the fourth evaporator and it moves backwards, while the
steam is added at the first evaporator and it flows forward. The black liquor
coming out of the first street reaches a concentration of 25oTw. The steam used is
flash steam from vapour separator two (VS-2). Condensate collected from each
effect called as foul condensate is collected and sent to hot water tank. It is used
in causticizing section for mud washing.

Liquor Flow: IV-III-II-I

Steam Flow: I-II-III-IV

MEE-2: It is mixed feed multiple effect evaporator having 6 effects. The black
liquor is introduced at the 4 th effect from where it goes to 5th effect. From here, it
is taken to the 4th body internal heater, which is provided to facilitate higher
evaporation at lower steam cost. Then the liquor moves to the 2nd effect and then
to the 2nd. Later the liquor moves forward to the 1st effect B-section and A-section
and finally to 6th effect C, B and A sections. The vapours are condensed in the
surface condenser where the pressure is maintained at 2.1kg/cm 2.

Liquor Flow: IV B→ V B→ IV H→ III H→ III B→ II B→ I B→ I A→ VI B→

VI A

Steam Flow: IV→I→II→III→IV→V

MEE-3: It is a mixed feed multiple effect evaporator having 5 effects.

Here thin black liquor is fed to the 4 th effect from where it goes to the 5th effect
and then to the 3rd effect next to the 2nd effect B section, 2nd effect A section and
finally to 1st effect C, B and A section respectively. The black liquor
concentration obtained at the last effect of MEE-3 is about 38oTw. Here the water

30
evaporation capacity is 35.6 TPH. The number of tubes in each effect is 300 ,
diameter of the tube is 50.8 mm while the tube length is 7.927 m.

Liquor Flow: IV B→ V B→ III B→ III A→ II B→ II A

Steam Flow: I→II→III→IV→V

MEE-4: It is a mixed feed multiple effect evaporator having 6 effects. The thin
black liquor having 16-18% solid content is fed to the 4 th effect. The black liquor
is fed from bottom to the tube while steam is passed from shell. In the 4th effect,
the calendria pressure is maintained around 9 cm of Hg and ad 76oC. The final
black liquor concentration is 38oTw.

Liquor Flow: V B→ VI B→V H→ IV H→IV B→ III H→ III B→ II

H→ II B→ II A→I H→I B→I A

Steam Flow: I→II→III→IV→V→VI

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 temperat
ure

Forced circulation plant:

A forced circulation unit is mainly used to concentrate the black liquor of 48-
50oTw to the desired concentration of 70oTw. Here the liquid circulation takes
place continuously by mechanical means. Black liquor coming out of the
evaporators (MEE- II, III & IV) is collected in common header. Here the
concentration of the black liquor coming out of different evaporators is evenly
maintained at 45 oTw. The rapid circulation of liquor carries all resin, soap, pulp
and other suspended matter through the evaporator without fouling the tubes. The
vapours and the black liquor are separated in the vapour separators. The black
liquor is concentrated in successive stages of forced circulation plant while the
vapours are sent to the flash steam.

Technical data:

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 Number 3

Number of heaters 6

Number of tubes 232

BL feed concentration 44-48 o Tw

BL outlet concentration 70 o Tw

Steam pressure 4.5-5 kg/cm 2

BL from pulp mill 3200-3300 m 3 /day

BL to boiler section 1450 m 3 /day

Steam economy 4-4.5 TPD

Recovery Boilers:

The main function of the recovery boiler is to recover the inorganic pulping
chemicals by burning of the organic materials in the kraft liquor and to make use
of the heat energy generated for high pressure steam generation. The thick black
liquor coming from the evaporator plant and entering the recovery boiler consists
mainly of 62.2% of total solids, 52.15% organic matter, 47.85% inorganic matter.
It has a gross calorific value of 3222.50cal/gm, SVJ of 8.53ml/gm, viscosity of
308cp and free alkali of 5.80. The concentration of solid content at 90 oC is
71.75oTw.

The major operations carried out in recovery boilers are:

• Evaporation of the residual moisture from the liquor solids.

• Supply of heat for steam generation.

• Reduction of oxidised sulphur compounds to sulphite.

• Recovery of inorganic chemicals in molten form.

• Conditioning of the products of combustion to minimize chemical carry

over.

Process Description:

The thick black liquor coming from the evaporation plant is burnt in two
recovery boilers RB-1 and RB-2 respectively for the production of smelt and
steam generation. The black liquor leaves the forced circulation evaporators at

33
70oTw and is collected in a strong black liquor tank from where it is taken to the
salt cake mixing tank. The black liquor is taken to the primary heater where it is
heated from 110150oC. Then it is taken to secondary heater where it is heated to
120122oC. The remaining black liquor from the ring header is taken to the
electrostatic precipitator ash tank where it is mixed with ash generated at ESP.
From here, it is passed back to the salt cake mixing tank and finally the smelt
from the bottom section is dissolved in the tank to get green liquor. This green
liquor is then sent to causticising section.

Conversion of sodium salts:

2NaOH + CO2 Na2CO3 + H2O

Na2O + CO2 Na2CO3

Reduction of make-up chemicals:

Na2SO4 + 4C Na2S + 4CO

Na2SO4 + 2C Na2S + 2CO2

Preparation of Green Liquor:

The smelt from the recovery furnace is collected in dissolving tank. It is dissolved
with weak white liquor. The green liquor so formed contains suspended solids
called dregs which are present in the form of flocculants at high temperature and
settled to give clear green liquor solution. This clear solution of GL overflows out
of the clarifier and is stored in GL storage tank while the drags are sent to the
dreg washer to separate out carbonaceous material, silica, metal and sulphites.
These are used in recausticisers while the suspended dregs are disposed off.

Slaking and Causticising:

The clear green liquor from the clarifier is sent to the GL splitter box through the
heater to maintain high temperature of liquor. The splitter box is used to divide
the GL flow to the rotary slaker drum. A uniform flow rate is maintained to the
rotary drum slaker. In the slaking unit, the GL is mixed with lime from the lime
bin through a table feeder at a controlled rate. About 10-15% of the reaction takes
place here. The slaking unit consists of 2 sections:

• Slaker Section Compartment:

34
This compartment has large vent stack and separate lime feeding arrangement.
Lime is brought to an intimate contact with GL in the slaker. About 85-90%, the
action is completed in the slaker.

• Classifier:

Insoluble material present in the liquid mixture is kept in suspension by turbulent

intake and is classified into the classifier section where the conditions allows the
coarser material to settle and be scrapped up by the sloping bottom of the
classifier to discharge and remove from the system. Water sprays are provided to
separate soda from grits material.

White Liquor Clarification:

This unit is provided in order to remove substantially all of the suspended solids
to provide cooking liquor of adequate clarity. The over flow of the clarifier is sent
to the white liquor polishers which are used to remove most of the remaining
suspended solids. The clarified and polished WL is stored in the WL storage tank
from where it is supplied to pulp mill. The under flow of the black liquor clarifier
i.e. lime sludge is drawn from the bottom by means of ODS pump and is pumped
to the 2 streets of lime mud washers, each street having three mud washers.
White liquor characteristics :

Contents Concentration(gpl) as Na 2O

NaOH 70

Na2 S 22

Na2 CO3 18

Active Alkali 90-92

Total Alkali 110

Lime Mud Handling:

The lime from WL clarifier is collected in the recausticising tank and washed into
2 streets of mud washer by dividing the slurry through the splitter box. Washing
is done counter currently i.e. mud flows from LMW-1 to LMW-3 while the hot
water flows from LMW-3 to LMW-1. The under flow mud from the last washer
is taken to the lime mud agitator tank. The overflow of the mud washer is called
weak WL and is used in the dilution of smelt to convert it into green liquor. The
lime mud from agitator tank is finally filtered off over vacuum drum filter using
hot water. The filtrate from the vacuum drum filter is fed into the lime mud
washer, while the filter cake is disposed off.

35
 consistency 35-40%

Soda loss 0.9-1.6% Avg. CaO

0.1-0.6%

pH 12-12.6

Lime mud washer:

The weak white liquor from lime mud washer is then washed in washers (3 in
no.) in 3 stages counter currently. The lime mud is then washed on rotary drum
filter. BGPPL has 2 rotary drum filters. The drum comprises of 3 zones.

• Suction zone:

Here the lime mud along with washer forms sheet on drum surface by
vacuum.

• Filtrate zone:

Here the water present in the mud is removed along with caustic.

• Mud removing suction:

The mud is removed by scrapper and disposed off through trucks.

Strength of the caustic removed from mud is 4.2gpl, which is fed to the lime mud
washer 3A and 3B.

Lime kiln:

The open disposal of lime mud creates hazardous effects to land as well as human
life and hence recovery of lime mud is done to prevent pollution and to fulfil the
environmental legislation. Lime mud from the lime mud washers is taken to the
lime kiln for the recovery of lime. Here the lime mud along with some fresh
calcium stones is burnt in the huge rotary lime kiln at high temperature to get
back lime.

Technical data:
Capacity of lime kiln : 180 T/Day

Length of kiln : 82m

Diameter of kiln : 12.5m

Speed of rotation : 0.65-0.75rpm

Fuel consumption : 20kg/hr

36
EFFLUENT
TREATMENT
PLANT

37
Effluent Treatment Plant
The main objective of modern pulp and paper mill operation is to reduce the
losses from the process and to treat the effluent so that their impact on the
environment is minimized. It is an important to preserve environmental quality
for the benefit of present inhabitant and future generation.

The ET plant is economic as it helps in better control on fibre and chemical

losses of plant by selling the sludge generation in ET plant which contains nearly
50-55% organic content which otherwise was going waste in effluent. Here
activated sludge process is used to treat the effluent. Some portion of the clarified
effluent from ET plant is used in showers for washing bamboo to remove silica,
in Andritz filter press and for plantation purpose.

Process flow:

Mechanical bar screen:

The effluent from all sections comes to ET Plant through pipelines. The effluent
is passed through bar screen to remove big sized particles like stones, chips, rags,
plastics and other unwanted particles that could choke the feed lines of the pump.
The combined effluent is stored in the sump at a pH of 6.5 to 7.5. HCl is used to
maintain the pH.

Primary Clarifier:

Clarifier is a large tank with a rotating rake system. The mill effluent, which
consists of suspended solids, is taken in this clarifier and given a settling time of
6 to 8 hours to enable the solids to settle at the bottom. The overflow clear water
flows to aeration tank and the underflow or sludge goes to the thickener.
Defoamer is added to the primary clarifier in order to reduce any foam generation
from the effluent.

Sludge Treatment:

The sludge generated at the primary clarifier is sent to the thickener where it is
thickened upto 4 to 5% consistency. The thickener has a capacity of 800 m3.
Further it is sent to Andritz filter press where dewatering takes place and the
consistency of sludge is increased from 4 to 20%. Dorr Oliver filter, which is a
vacuum filter where the sludge consistency is increased from 2 to 14%. High
consistency sludge, which consists of about 50 to 55% organic content is sent to
the board making unit.

Areation tank:

The overflow from the primary clarifier comes to the aeration tank. This tank is
a large rectangular tank with a capacity of 13,500 m 3. It has 12 aerators which
are agitated to induce the necessary oxygen to meet the BOD. Here microbial floc

38
is suspended and waste water from primary clarifier is fed continuously. A
retention time of 4 to 5 hours is provided and the activated sludge solids multiply
as dissolved organic waste is metabolised. Chemicals like urea and diammonium
phosphate (DAP) are added to the aeration tank as nutrients to microorganisms.
The effluent is continuously drawn off the secondary clarifier.

Secondary Clarifier:

The effluent from the aeration tank comes to the secondary clarifier. Here
flocculants are added, which bind together the suspended particles. A retention
time of 5 to 6 hours is given. Whenever there are an uncontrollable amount of
microorganisms, addition of bleached liquor (hypo) is done which results in the
formation of dead mass. The addition takes place after the sludge has been sent
back to the aeration tank. About 50 to 85% of underflow sludge is sent back to
the aeration tank. The bleached liquor also helps in removing the slimy nature of
sludge. The remaining sludge is sent to the primary clarifier. The overflow, which
is treated effluent, is discharged to Wardha River and a part of it is used for mill
purpose and plantations.

Effluent Characteristics:

Parameters Untreated Treated MPCB

6.4 – 6.8 7.4 – 7.8 5.0 – 5.9

o
35 – 40 30 - 35 -

500 – 700 160 – 230 250

BOD 5 (ppm) 150 – 250 10 - 12 30

DO (ppm) 0.8 – 1.0 Nil 0.5 – 2.0

Sulphates as SO 4 (ppm) - 185 -

pH

Temp ( C)

COD (ppm)

39
(MPCB- Maharashtra Pollution Control Board)

Chemical dosage:
Urea : 590 kg/day

DAP : 285 kg/day

20 kg/day
Flocculant :

Sludge Characteristics:

Sludge generated : 150 TPD

Consistency : 20 – 25%

Organic Content : 50 – 55%

40
 WATER
TREATMENT
PLANT

41
 Water Treatment Plant:
Water is main necessity of BGPPL which gets fulfilled by its own well and from
river Wardha.

Water consumption:40-45cu.m/day.

The water is drawn through the pump to the mill site which have impurities like
suspended and floating impurities. Then the water is collected in receiving
channel in two line one for well another for river. In receiving channel the water
is treated with coagulating agents like polyammonium chloride and calciumhypo
chlorite to coagulate particle and kill bacteria respectively. Then the water is send
to clarifier where clear water overflows which is then supplied to different
sections of mill and colony. The another clarifier is also use for m/c back water
which after treatment send back to machine house.

RESEARCH
AND

DEVELOPMENT
Research and Development:
The R and D department consists of four branches viz.:

• QAS Input Lab

42
• QAS lab

• Environmental lab

• R and D lab

43
ENViRONMENTAL LAb:
The environment legislation has made it imperative for every pulp and paper
industry irrespective of scale of operation, to adopt environmental friendly and
cleaner technologies within stipulated time frame in order to ensure its substance.
It is in this perspective that the whole of R & D Environmental lab becomes
important and also in order to strengthen the indigenous capability for resolving
the environmental issues and challenges. In paper industry, the sources of waste
water are mainly from:

Fibrous raw material washing:

• Digester house

• Pulp washing

• Centri cleaners

• Pulp bleaching

• Paper machine

• Chemical recovery

Activities under Environmental Lab:

Characterization of mill effluents for various pollution parameters:

• To generate data based information on magnitude pollution load in paper

mills.

• Development of cost effective methods for treatment of liquid waste.

• Monitoring of ambient air quality, stack and fugitive air emissions.

• Meteorological testing.

Characterisation of solid wastes:

• Conversion of solid wastes to value added products.

Facilities available:

BGPPL has well equipped environmental lab with modern analytical

equipments for efficient environmental monitoring. These include- AOX
analyser, BOD track apparatus, Auto sampler, Turbidity meter, Respirable dust
sampler, Gas Tech apparatus, Noise meter, Spectrophotometer, etc.

44
Testings done:

• Analysis of effluents for various pollution parameters including

AOX.

• Evaluation of bio energy potential in pulp and paper mill effluents.

• Performance evaluation of effluent treatment system.

• Determination of AOX in paper products.

• Ambient air, stack and fugitive emission monitoring.

• Quantification of gaseous and particulate emissions.

• Analysis of gaseous pollutants including non-condensable gases.

• Efficiency evaluation and troubleshooting of effluent treatment plants and

other pollution control devices.

• Determination of COD and BOD in effluent water.

QAS LAb:
Quality Assurance System (QAS) refers to planned and systematic production
processes that provide confidence in product suitability for its intended purpose.
It is a set of activities intended to ensure that papers satisfy customer
requirements in a systematic and reliable fashion. However, QAS cannot
absolutely guarantee the production of quality products, but makes them more
likely.

Two key principle characteristics of QAS:

• To make the products fit for customer demands.

• To eliminate their mistakes occurred during paper manufacturing.

QAS Lab testing:

Different grades of paper require different properties depending upon their end
use. Hence, a paper maker has to make requisite adjustments so as to get desired
results without affecting the allied properties of paper to greater extent. Paper
properties can be broadly classified as:

• properties- Grammage, thickness, density, porosity, smoothness.

• Strength properties- Tensile strength, breaking length, burst strength.

• Optical properties- Colour, brightness, opacity, etc.

45
 These properties are checked in QAS lab. If all these properties meet the
customer demand then the products are packed and supplied, otherwise recycled
for paper formation. Thus the acceptance or rejection of paper is performed in
QAS lab.

QAS Input Lab:

In this lab, various chemicals like lime, PAC, NaOH, H 2SO4, fillers, pulp, coal,
water samples, starch, dyes, etc. are tested. These testings can be broadly
classified as:

• Dyes – Irgilite Violet, Rhodamine.

• Starches- Maize starch, Cationic starch, etc.

• Sizing agents- ASA (Alkene Succinic Anhydride), Rosin, AKD (Alkene

Ketene Dimer).

• Fillers- GCC, PCC, TiO2, soapstone.

• Coal analysis- Moisture content, volatile organic content, ash, fixed

carbon content, gross calorific value.

• Furnace Oil Analysis- GCV, viscosity, etc.

• Recovery Contents Analysis- Black liquor, White liquor, Green liquor.

• Sodium Sulphate Analysis- White, brown, yellow.

• Pulp Analysis- Optical properties, viscosity of pulp.

• Packing Material analysis- High density polyethylene (HDPE), Low

density polyethylene (LDPE), core pipe, mill board.

R & D LAb:
The Research and Development Lab is responsible for carrying out following
analysis:

• Pulping

• Bleaching

• Pulp Analysis

• Microbiological Experiments

• Evaluation of chemicals used in paper manufacturing, etc.

46
Working:

Chips from chipper section are brought in R & D lab for pulping analysis. These
are then air dried and tested for paper properties. Any new species of wood are
first analysed in R & D lab before it is used in plant. If its yield and allied
properties are good enough, then the species is selected, otherwise rejected for
drawbacks. If any problem regarding pulp bleaching, stock preparation, etc.
occurs in the plant, then the sample is sent to R & D lab to find out the problems
and the solution concerned. Chemicals like OBA, starch, dyes, sizing chemicals
and other new chemicals which can replace the earlier ones, are also sent to R &
D for its evaluation. If its performance is better than the routine chemical used,
then it is replaced. Various microbes develop in the stock sample and also in the
back water. To control them, biocides or slimicides are used. In addition, Bug
Count is carried out in R & D lab. The strength properties of the paper obtained
after refining, bleaching, etc. are also studied here.

THANK YOU

47