“Production of Paper from Non-wood Resources”

Name of the Student Registration No.

Aakash Batra 179101001
Akshay Dhiman 179101002
Arshan Khan 179101034
Shivam Kumar Yadav 179101025

Mentored by: Dr. Gaurav kataria

Introduction
• Paper demand in India is increasing nearly 8% annually and supply has not been able to
keep pace.
• Even when the world is moving towards digitalization, the global demand of paper is
increasing while its production capacity is not increasing at the same pace.
• Wood is a key raw material for paper making and India is a wood deficient nation. Landed
cost of wood has risen sharply in last few years.
• Substituting wood with any other raw material which is renewable will help save trees and
in return save our environment.
• The aim of this project is to study different types of paper production methods and produce
different raw material other than wood.
 Types of Pulping Process

S.No. Chemical pulping Chemicals used Properties of pulp isolated Common uses of isolated pulp
Methods
1 Sulphite Sulphurous acid/ sodium High flexibility and requires very little Used in making paper for special
sulphite bleaching purposes
2 Kraft/ Sulphate Combination sodium Strong, low brightness (dark brown) Making boxes, paper bags and
hydroxide and sodium wrapping paper. Can also be used for
sulphide writing paper
and paperboard when bleached

3 Alkaline Sodium hydroxide and Have properties like those of Ideal for all paper uses
anthraquinone sulphite.
4 Organosolv Organic solvents e.g. Ethanol Much of the properties are still being Preliminary results suggest possible
tested and evaluated application in all aspects of paper uses.

5 Bio-pulping Involves the use of Increased tear index, low kappa number Results suggests possible uses in all
white fungus K14 and other properties are still under aspects of paper.
investigations

** Zenat A. N., Sakhawy M. E. and El-Sayed E. S. A. , Hydrogen peroxide alkaline pulping of bagasse. in IPPTA:
Quarterly Journal of Indian Pulp and Paper Technical Association, July 2000.
Alkaline Pulping
• Most chemical pulping processes employee high concentrations of sodium hydroxide
(NaOH) and temperatures that are well above the boiling point of the solvent, water.
• However, its main role is to promote acid/base reactions that facilitate lignin breakdown
and dissolution of the lignin fragments.
• Some aliphatic hydroxyl groups will be ionized by the NaOH and become better
nucleophiles in reactions that follow.
• For many lignin degradation reactions, terminal phenolic groups need to be ionized; the
NaOH in the system does this.
• In addition, smaller phenolic lignin pieces, which are converted to phenolate ions by
NaOH, become solubilized.
Process Flow Diagram
Separation of Bagasse
Bagasse was extracted with a methanol-benzene (1:1) mixture for 8 hours. The material
was left to dry at room temperature, conditioned and the moisture content was
estimated.

Grinding
• The Rag Chopper is suitable to chop the Bagasse into small pieces to
feed the Digester / Beater.

• The Motorized Unit consists of Special Knives Blades and a loading

weight to chop the required size material. Feeding must be done
manually.

• Capacity – 80 to 100 Kg. /Hr. Power Connection Required – 3 Phase.

Pulping process

• The oven dries of depithed bagasse and the cooking liquor were mixed in the reactor at
ambient temperature.
• The cooking liquor consisted of a mixture of 16% sodium hydroxide, 0.1% anthraquinone,
and dose of hydrogen peroxide 3% based on oven dry bagasse basis. Also, small quantities
of chelating agent (EDTA) were used as a carbohydrate degradation inhibitor.
• The liquor to bagasse ratio was 6:1, the degree of temperature was 140℃ and 160℃ for
30-60 minutes. All these data mentioned before specified to produce peroxide-alkaline
bagasse pulps.
• The cooking time in the reactor should be between 30-60 minutes depending upon the
quantity of raw material.
• This process gives the yield of 55.7 %.
Digester blow
tank
• The tank is a large cylindrical
vessel which functions as
intermediate storage of the
cooked pulp, and from which the
pulp is discharged in an even
flow to a washing process.
Effect of Temperature

The influence of cooking temperature on alkali peroxide pulp properties has been studied at
two different temperature 140 and 160℃, on hydrogen peroxide concentration (3% H2O2).It is
observed that increasing the cooking temperature, had a negative effect on both the pulp yield
and alkali resistance of different pulps, this may be due to accelerate the decomposition
hydrogen peroxide by action of high temperature. On the other hand, increasing the cooking
temperature is accompanied by a pronounced increase in the delignification selectivity.

Addition of EDTA as a chelating agent

It has been found that increasing the percentage of EDTA in cooking liquor from 0.1 to 0.3% is
accompanied by a pronounced decrease in kappa number from 13.9 to 9.4 improvement in the
delignification process. Further increase in EDTA percent decreases the pulping selectivity, the
kappa number slightly increase to reach 10.9 at 0.5% EDTA concentration. Therefore, it can be
said that the best delignification is achieved at 0.3% EDTA.
Washing of the pulp

• Vacuum drum washer is a

common pulp washing equipment
for bleaching workshop and
extraction of pulp like wood
pulp, straw pulp and other types
of pulp.
• Vacuum drum washer is the key
technological equipment for
paper industry to solve the
problem of wastewater
pollution and implement alkali
recovery project. Vacuum drum
Screening of the pulp

• Paper pulp manufactured from Bagasse by any of the several

chemical processes contains chips and knots. Such chips and
knots are removed by various types of screens and so-called
knotters.
• Most chemical pulps, such as those of the soda and sulphate
types, as they come from the digesters, contain a foam producing
liquor.
• It would be desirable, therefore, to wash the pulp free of such
liquor before it is screened or knotted in-order to prevent the
occurrence of foam in the knotter because such foam is often so
troublesome that the operation of the knotter is difficult, if not
impossible.
Bleaching of the pulp
Bleaching of Bagasse pulp is the chemical
processing of bagasse pulp to lighten its color
and whiten the pulp. The TCF (OP)Q(PO)
sequence and the ECF (OP)D(EOP) sequence
can be employed in the production-scale bleach
plant, where the Q stage can be switched to a D
stage and the (PO) stage can be operated as an
(EOP) stage; the only difference is the
chemicals added into the system.
Beating of the pulp
A Hollander beater is a machine developed by the
Dutch in 1680 to produce paper pulp from cellulose
containing plant fibres. The objective of using a beater
is to create longer, hydrated, fibrillated fibres.
Grinding of fibres is not desirable. Therefore, the
"blades" are not what might be thought of as
"sharpened", and well-designed beaters make it
possible to minimize the shear action of the rotating
blades against the bottom of the water raceway.
Hollander beater 
Calendaring machine
The purpose of this machine is to
press the pulp together to make
thin sheets into rolls.
Cutting machine
As the suggests this type of machine is used for
cutting paper according to the requirement of the
customer. The machine changes depending on what
type of production are we doing like for A4 or
handmade paper.
 MACHINES QTY RATED COST
Economic balance   POWER
Capital Investment: RAG CHOPPER 1 3 kW 3,00,000/-
(Production
 
capacity 350-500
Kg/hr)  
• The rent for industrial land in Manesar
of 450 sq meter is around ₨. 1 VACUUM 1 2.2 kW 7,00,000/-
lakh/month. DRUM WASHER
(capacity 100to
• Machinery: 500kg)
Economic balance of 5 years. HOLLANDER 1 2 kW 1,50,000/-
BATTER
CALENDARING 1 4 kW 9,00,000/-
MACHINE
CUTTING 1 4 kW 1,00,000/-
MACHINE
DG SETS 1   2,80,000
TOTAL     24,30,000/-
 Cost of raw Material
Material Cost(rupees) Source

Bagasse 2/kg Naraingarh sugar mills Ltd

NaOH industrial grade 33/kg Joyce lub and chem Llp

Anthraquinone (94% purity) 100/kg National Analytical Corporation

H2O2 (50% purity) 43/kg Surya Min Chemicals

EDTA (99% purity) 140/kg Maya Chemtech India Pvt Ltd

Methanol 32/kg Gayatri Industries

Benzene 58/kg PS polychem

Cost of Paper
Total power consumed
Machine rated power (kW) time (min) time (hrs) power (kWh)
rag chopper 3 15 0.25 0.75
drum washer 2.2 30 0.5 1.1
hollander beater 2 30 0.5 1
callendaring 4 75 1.25 5
cutting 4 45 0.75 3
total 10.85

Rate of electricity in Manesar= ₨. 2.50/kwh

Total cost = 2.50* 10.85 = ₨. 27.125
Assuming Miscellaneous and labor cost 2 cycle per hour = ₨. 40
Total working hours in one day =12
Total = ₨. 507.125
Number of cycles per day= 2
Total number of working days= 300
Machinery cost=(507.125*2*300*5)/24,30,000 = Rs. 0.626
Total = Rs. 507.75
 Costing for raw material
Raw material Cost (Rs/kg) Quantity (kg) Costing(₨)
Bagasse 2 500 1000
NaOH 33 80 2640
Anthraquinone 100 0.5 50
H2O2 43 15 645
EDTA 140 1.5 210
Methanol 32 1 32
Benzene 58 1 58
Total 4635

 Total raw material cost for 2 cycle =2 * 4635 =Rs. 9270

Total cost = 9270 + 507.75 = ₨. 9777.75
Production of paper per day = 0.557 * 500 *2 = 557 kg
Cost 1 kg of paper = = ₨. 17.55/kg (approximately)
Total paper produced in a year= 557*300 = 167100 kg
Total cost of paper yearly = 167100 * 17.55 = Rs. 29,33,325.324
Yearly labour and miscellaneous cost= 40*300*12= Rs. 1,44,000
Total = Rs. 30,77,325.324
The yearly investment of the business is Rs. 30,77,325.324
Assuming the selling price of paper is Rs. 21.935 by keeping 25% profit margin
Total selling price = 21.935 * 167100 = Rs.36,65,756.25
Profit = Rs. 5,88,430.926
 • Paper can be produced from many different resources other than
wood; Bagasse is one them.
• The reason for choosing Bagasse was because the amount of
cellulose present in it. However, the substitute of Bagasse is
Hemp leaf as it has the same process.
Conclusion • The cost of producing 1 kg of paper of 100 GSM from Bagasse
is ₨. 17.55/kg (approximately) and the cost of 1 kg of paper of
100 GSM from wood is ₨.25/kg (average figure). Therefore,
the production of Bagasse is more economical.