Workshop Report - Knowledge Platform for … Report Environment Friendly Techniques in Pulp & Paper Sector 27th February, 2013 Center of Excellence (COE), GIDC Industrial Estate, Vapi

Workshop Report

Environment Friendly Techniques in Pulp & Paper Sector

27th February, 2013 Center of Excellence (COE), GIDC Industrial Estate, Vapi (Gujarat)

Contents

1. Background .................................................................................................................. 3

2. Introduction .................................................................................................................. 3

3. Programme of the Workshop ...................................................................................... 4

4. Participants in the Workshop ...................................................................................... 5

5. Inaugural Session of the Workshop ........................................................................... 5

6. Technical Sessions of the Workshop ......................................................................... 6

7. Concluding Session of the Workshop ........................................................................ 8

1. Background The on-going Indo German Development Cooperation has “urban and industrial environmental policy & management” as one of priority areas of cooperation. The Indo German Environment Partnership (IGEP) Programme forms a part of this priority area, under which technical cooperation is being provided to the identified Indian partner organisations by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ), on behalf of the German Ministry for Economic Cooperation and Development (BMZ). The IGEP Programme, which is implemented jointly by the Ministry of Environment and Forests (MoEF) of the Government of India and GIZ has a thrust area on Sustainable Industrial Development (SID). Under the SID component, the relevant activities for which the advisory services are sought are related to the following core topics: “Environment Friendly Techniques in Identified Industry Sectors” “Planning of New Industrial Parks and Investment Zones” “Waste Water Management” The overall objective of the technical cooperation on the core topic of “Environment Friendly Techniques in Identified Industry Sectors” is, “The use of environment-friendly technologies and techniques is promoted in selected SME sectors”. This core topic has focus on textiles and pulp & paper sectors with following activities: Baseline Surveys / Situation Analysis is to be undertaken for the Textile and Pulp &

Paper industries in India and core issues related to environment, resource efficiency and climate change are assessed.

Regional/State/Local level workshops and consultations will be organised to exchange information on potential solutions.

Volunteering industries will be identified for demonstration of viable environment friendly techniques on pilot basis.

Pilot experiences/results will be documented and disseminated. Supportive policy documents/instruments will be worked put for application of viable

solutions across the pulp & paper industry sector in the country.

2. Introduction The environmental concerns are growing leading to higher environmental litigation risks for the industries, particularly those from the SME sector. According to a World Bank study “India: Strengthening Institutions for Sustainable Growth”, South Asia Environment and Social Development Unit, SME contributes to nearly 70% of industrial pollution load in India. The major forms that have been highlighted include, air pollution, water pollution, soil contamination, radioactive contamination, noise pollution, light pollution, visual pollution, and thermal pollution. Also, a recent study by the Bureau of Energy Efficiency (BEE), which takes into consideration the SME sector, revealed that the overall energy saving potential of the clusters is about 72,432 TOE (tonnes of oil equivalents), which is 27.4% of the total energy consumption in SMEs.

The Indian paper industry is one the largest and oldest sectors in the country and amongst the most important in the economy in terms of output, investment and employment. The paper manufacturing process, in general, is characterized by the high consumption of resources like electricity, fuel, water and a variety of chemicals in a long process sequence

that generates a significant amount of waste and emissions. Hence, the paper sector can benefit by making improvements targeting resource efficiency, process improvements, energy efficiency and reduced negative environmental impacts. By employing appropriate technologies, both environmental and economic gains can be achieved. For referencing viable environment friendly techniques in pulp & paper sector, various sources of information are available. For example, the BREF (Best Available Techniques Reference Documents) from Germany and the Comprehensive Industrial Documents (COINDS) of the Central Pollution Control Board provide useful information. Also, possibly some of the pulp & paper industries in Indi might have championed in pioneering efforts in technological innovation. In addition, there also technology providers dealing with relevant technologies for the pulp & paper sector, such as the insulation systems, low energy motors, online pollution monitoring systems etc. Agencies such as the Gujarat Cleaner Production Centre have undertaken pilot studies in the pulp & paper industries. To gather information and to facilitate information exchange, under the IGEP Programme, strategically stakeholder consultation are being organised periodically. Such consultations are organised at local, regional, state and national levels to facilitate identification of core issues faced by the sector and to look out for viable technical solutions. The consultations are organised through workshops, meetings and conferences. Against this background, as a part of the Phase I activities, GIZ collaborated with the Gujarat Cleaner Production Center (GCPC) and organized the 1-day Regional Workshop on “Environment Friendly Techniques in Pulp & Paper Sector” on February 27, 2013 at the Centre of Excellence, GIDC Industrial Estate, Vapi (Gujarat). The workshop was aimed to share knowledge, experiences and case examples and to discuss on the core issues, including policy and regulatory related, and technological and management related aspects that need to be addressed for ensuring improved environmental performance by the pulp & papers sector in India.

3. Programme of the Workshop The workshop focused on:

Policy/Legal/Regulatory Aspects – Challenges and Opportunities Technological aspects – Challenges and Opportunities Roles of Key Stakeholders (industries, industrial associations, government,

regulatory bodies) – innovative approaches/actions, capacity building requirement The workshop programme included:

Inaugural session. Technical Session 1: Environmental Policies, Laws and Challenges Technical Session 2: Technological Aspects for Improved Environmental

Performance in Pulp & Paper Sector Concluding session.

The programme details are given in Annexure I. The programme covered 12 technical presentations covering various relevant topics.

4. Participants in the Workshop The workshop had over 80 participants including representatives of government bodies, industries, technology providers, infrastructure developers, investors and consultants. The list of participants that have registered is given at Annexure II.

Pic: Participants at the workshop

5. Inaugural Session of the Workshop

The workshop started with an inaugural session. Mr. Raghu Babu Nukala, Senior Technical Advisor and Programme Coordinator, GIZ-IGEP presented the welcome and theme address, and set the context for the workshop.

There were three special addresses from:

Dr. K U Mistry, Chairman, Gujarat Pollution Control Board.

Mr. M. M. Jivani, Chief Engineer, Gujarat Industrial Development Corporation.

Mr. Ashok Shukla, President, Vapi Industries Association.

The inaugural session concluded with Mr. Bharat Jain, Member Secretary, Gujarat Cleaner Production Center (GCPC), Gandhinagar delivering the concluding remarks and thanking all the participants, speakers, project partner GIZ, press and media. The media coverage reflecting the Inaugural Session is given at Annexure III.

Pic: Dr. K.U. Mistry, Chairman, Gujarat Pollution Control Board

addressing the participants during the Inaugural Session of Regional Workshop

6. Technical Sessions of the Workshop

In the technical sessions of the workshop, topics presented are given below. Technical Session I: Environmental Policies, Laws and Challenges

Pulp & Paper Industry – Regulatory Overview

Effluent & Solid Waste Treatment Systems for Pulp & Paper Industries at VWEMCL

Environment Related Issues for Pulp & Paper Sector

The Paper Recycling Industry of Vapi – an Environmental Perspective

Opportunity to Utilize Centre of Excellence, Vapi for Research / Analytical Solutions / Pilot Project by Pulp & Paper Industries

Technical Session II: Technological Aspects for Improved Environmental Performance in Pulp & Paper Sector

Best Available Techniques Reference Document for Pulp & Paper Sector Energy Conservation Opportunities in Pulp & Paper Sector Core Issues in Recycle Paper Industries and Technological Solution in Vapi Electro Chemistry- A New Eco-Friendly Method for Effluent Treatment Energy-Efficiency - Moving India's SMEs Towards a Sustainable Future

Quick BOD Measuring System The presentations are attached at Annexure IV. The presentations made by the speakers are uploaded in the GIZ website on www.ecoindustrialparks.net.

http://www.ecoindustrialparks.net/

Pic: Mr. Raghu Babu Nukala, GIZ conducting Technical Session I of the Workshop

Pic: Mr. Bharat Jain, GCPC conducting Technical Session II of the Workshop

Pic: Participants at the workshop

7. Concluding Session of the Workshop

The Concluding Session of the workshop focused on collecting inputs and suggestions from the participants. Three groups were formed to discuss on the topics and to make presentation on the results from discussions. The topics covered by the groups included:

Group 1: Policy/Legal/Regulatory Aspects – Challenges and Opportunities.

Group 2: Technological aspects – Challenges and Opportunities.

Group 3: Roles of Key Stakeholders (industries, industrial associations, government,

regulatory bodies) – innovative approaches/actions, capacity building requirement.

Pic: Group 1 discussing on Policy/Legal/Regulatory Aspects - Challenges and Opportunities

Pic: Group 2 discussing on Technological aspects – Challenges and Opportunities

Pic: Group 3 discussing on Roles of Key Stakeholders (industries, industrial associations, government, regulatory bodies) – innovative approaches/actions, capacity building requirement

The important points that emerged from the group discussions are summarised below.

Group 1: Policy/Legal/Regulatory Aspects – Challenges and Opportunities

Presently, there is no comprehensive reference document on the Pulp & Paper industries that reflects the technological, availability, management and other relevant aspects, which can be used as a reference document/guide for selecting and implementing Environment Friendly Techniques (both techniques & technologies). Preparation of such a comprehensive document should be taken up. The format of BREF documents from Europe could be considered.

The COINDS documents (of CPCB) are very old and not being updated according to

the advancement in technologies available now days also they do not include the cost benefit analysis since it is one of the major criterions for selecting and implementing new techniques/technologies.

Pilot projects should be undertaken in pulp & paper industries and case examples

documented and used while preparing reference documents for the pulp & paper sector. There is a need for including guidelines in the document which will be helpful for selecting and implementation of the environment friendly techniques.

Effluent discharge standards should be developed on the basis of receiving water

bodies. Also, the standards should be different based on the product type and industry’s size (large/medium/small). Presently, the standards are same for virgin paper production units and recycled paper units while there is huge difference in resource consumption and pollution generation. Also, separate standards may be set up for existing and new plants, taking into consideration the constraints in retrofitting of the technologies in existing plants and the scope and technological advancements in the case of new plants.

Presently, due to cost differences between natural gas and coal, it does not make it

financially viable to use natural gas. Similarly, there is no motivation for industries to

recycle/reuse water. There should be provisions in the policy for encouraging recycle/reuse of water from different processes and also for usage of clean fuel (e.g., natural gas).

The technology/techniques that will be propagated for the pulp & paper sector may

have large impact financial implications on the industry, particularly on product pricing if not uniformly applied across the country. This aspect should be taken into consideration.

There should be a monitoring system for pollution parameters, which can provide online/real time feedback so that immediate actions can be taken by the industry to prevent pollution generation. For example, through online BOD monitors, instead of waiting for 3 days or 5 days, actions can be initiated right away if there are real-time online monitors. However, SMEs cannot put up costly instrumentation for such monitoring systems. If there are centralised facilities and monitoring systems, pollution parameters can be controlled in time, by disseminating information to industries about their emissions/discharges and various options for abating/controlling the same.

Implementation strategy for labelling programme like “Ecomark” is available but not

practiced by industries as they do not have regulatory mandate and associated incentives.

Group 2: Technological aspects – Challenges and Opportunities

Recovered energy in Indian pulp & paper mills meets only 45% of energy requirements of pulp and recovery section (in good global mills there is energy excess).

Freshwater consumption is high, current average is 57 m3/tonne for virgin paper

industries (European average 10 m3/tonne for the virgin paper). However, in the recycled paper industries, as claimed by the industry the consumption is much lesser than even the European average.

Use of chemicals (e.g., Alum & Rosin) to make the paper hydrophobic reduces yield

percentage, which results in fibre losses and increase in fresh water consumption.

Energy Losses in drying section are significant due to non-availability of the side insulations for dryer due to constant dynamic motion.

Electrical equipment inefficiency due to improper sizing and designing of the equipments and auxiliaries and less knowledge on the efficiency part of the equipments.

Resource losses due to material handling practices and lack of good housekeeping.

Weak instrumentation & process control. This results in wide variations in quality of sectional outputs.

Conventional process of manufacturing generates effluent with COD level of 10,000

mg/l and BOD of 500-800 mg/l, which cannot be reused after treatment.

Generation of de-inking sludge and rejects, which are hazardous are sent to landfills presently. However, alternatives of using it as fuel is possible, which needs to be checked and approved by SPCBs.

Boiler fly ash generated by the industries is sent to landfills, although some industries are also sending it to brick manufacturers, However, it is not commercially done till now.

Plastic waste generation from recycled paper industries could be co-processed in cement industries. This is being practiced (limited to certain quality of plastic) by a few industries. One of the industries in Vapi has made a briquette out of the waste mixture containing plastic without PVC and fibre sludge from the ETP, and are seeking SPCB permission to commercialize and use it in boilers.

The Environment Friendly Techniques available in BREF documents could be selected and tried/tested for the pilot work in selected industries, and also used for creating database for applicable techniques in the sector.

Group 3: Roles of Key Stakeholders (industries, industrial associations, government, regulatory bodies) – innovative approaches/actions, capacity building requirement

Training to Industries on resource efficiency and cleaner production is required as the

SMEs do not have resources to get the experts to train and increase knowledge of their workforce.

Knowledge sharing platform should be created on the available feasible (technological, available, economical) techniques. Industries in clusters should also work together to have collective impact on decreasing pollution load.

R & D activities should be taken up, for example in cooperation with industries and the Centre of Excellence at Vapi Industrial Estate, to improve the product and the associated manufacturing processes.

^^^

Annexures

Annexure 1

Workshop Programme

One - Day Workshop on Environment Friendly Techniques in Pulp & Paper Sector

February 27,2013; Centre Of Excellence, GIDC Industrial Estate, Vapi (Gujarat)

09:30 hrs Registration& Tea

Inaugural Session

10:00 hrs Welcome &Theme Address by

Mr. N. Raghu Babu GIZ, Indo German Environment Partnership Programme

10:15 hrs Address by Mr. Ashok Shukla President, VIA

10:25 hrs Address by Mr. M. M. Jivani CE, GIDC

10:35 hrs Address by Dr. K.U. Mistry Chairman, Gujarat Pollution Control Board

10:45 hrs Vote of Thanks by

Mr. Bharat Jain Member Secretary, Gujarat Cleaner Production Center

Technical Session I: Environmental Policies, Laws and Challenges

10:50 hrs Introductory remarks Mr. N. Raghu Babu GIZ, Indo German Environment Partnership Programme

10:55 hrs Environmental Policies, Standards and Regulatory Aspects in Pulp & Paper Industries

Dr. B. R. Naidu Zonal Officer, Central Pollution Control Board

11:10 hrs Issues in Effluent & Solid Waste Treatment Systems for Pulp & Paper Industries

Mr. Rajesh Doshi ED, VWEMCL (Vapi Waste & Effluent Management Company Ltd.)

11:25 hrs Environment related issues for Pulp & Paper Sector

Mr. G. V. Patel RO, Gujarat Pollution Control Board

11:40 hrs Environmental Challenges & Opportunities in Pulp & Paper Sector – Industry’s Perspective

Mr. Vijay Madnaik President, GPMA (Gujarat Paper Mill Association)

11:55 hrs Opportunity to Utilize COE for Research / Analytical Solutions / Pilot Project by Pulp & Paper Industries

Mr. N. S. K. Srinivasan GM-Tech., COE (Centre Of Excellence), Vapi

12:10 hrs Q&A, Discussions (30 min)

Lunch 12:40 – 13:30 hrs

Technical Session – II : Technological Aspects for Improved Environmental Performance in Pulp & Paper Sector

13:30 hrs Introductory remarks Mr. Bharat Jain Member Secretary, Gujarat Cleaner Production Center

13:35 hrs Best Available Techniques in Europe for Pulp & Paper Sector – EU Reference Documents

Mr. Nitesh Patel GIZ, Indo German Environment Partnership Programme

13:50 hrs Environmental Performance of Recycled Paper Industries in Vapi, Gujarat

Mr. Tushar Shah Director, Damanganga Paper Mills

14:05 hrs Energy Conservation Opportunities in Pulp & Paper Sector

Mr. Nitesh Patel GIZ, Indo German Environment Partnership Programme

14:20 hrs

Core Environmental Issues (Technological) in Pulp & Paper Industries

Mr. Gopal Chaudhari Assistant Project Engineer, Gujarat Cleaner Production Center

Spotlights

14:35 hrs Fuel Saving Opportunity in Boilers Mr. Shyam Gupta CMD, Global Energy Technologies Pvt. Ltd.

14:40 hrs Electro Chemistry – Effluent Treatment in Paper Mills

Dr. Ramu G. Research Scientist

14:45 hrs Energy-Efficiency - moving India's SMEs towards a sustainable future

Mr. Yogesh S Pandey KAEFER

14:50 hrs Quick BOD measuring technique Mr. Vaibhav Savji Forbes Marshall

14:55 hrs Q&A, Discussions (25 min)

Concluding Session and Way Forward (Moderated by GCPC and GIZ)

15:20 hrs

Group Discussions & Presentations

Policy/Legal/Regulatory Aspects – Challenges and Opportunities Technological aspects – Challenges and Opportunities Roles of Key Stakeholders (industries, industrial associations, government,

regulatory bodies) – innovative approaches/actions, capacity building requirement

17:00 hrs Concluding Remarks

GIZ, Indo German Environment Partnership Programme

Gujarat Cleaner Production Center Gujarat Pollution Control Board

17:30 hrs High Tea & End of Workshop

^^^

Annexure II

One - Day Workshop on

Environment Friendly Techniques in Pulp & Paper Sector February 27,2013; Centre Of Excellence, GIDC Industrial Estate, Vapi (Gujarat)

S. No. Company Name Participants Name Designation E mail address

1. Gujarat Pollution Control Mr. J. D. Goswami DEE [email protected]

2. Shri Gajanan Paper & Board Pvt. Ltd.

Mr. R. U. Dalta Manager [email protected]

3. Ramji Board & Paper Mills Pvt. Ltd.

Mr. S. P. Garg Chairman [email protected]

4. Ramji Board & Paper Mills Pvt. Ltd.

Mr. Pramod Singh Manager [email protected]

5. Rama Pulp & Paper Ltd. Mr. V. K. Varshney General Manager [email protected]

6. Kherani Paper Mills Pvt. Ltd.

Mr. N. S. Rao Vice President [email protected]

7. Ratna Paper Mill Mr. R. G. Desai Production Manager

-

8. Shah Pulp & Paper Mill Ltd. Mr. Amrish ETP Manager [email protected]

9. R. A. Shaikh Paper Mills Pvt. Ltd.

Mr. S. K. Shaikh Director [email protected]

10. Saiyed Paper Mills Ltd. Mr. R. R. Patil Manager [email protected]

11. Aryan Paper Mills Pvt. Ltd. Mr. Sunil K. Shah Director -

12. Aryan Paper Mills Pvt. Ltd. Mr. N. D. Patil Manager [email protected]

13. N. R. Agarwal Industries Ltd.

Mr. Ranjit Patel Incharge [email protected]

14. Apna Paper Mills Pvt. Ltd. Mr. Jagdish Patel Supervisor -

List of Participants

mailto:[email protected]











15. Jay Chemicals Mr. M. R. Prakash Director -

16. Super Deluxe Paper Mills Mr. Rajender - -

17. Sarigam Ind. Association Mr. Uday Marballi President -

18. Damanganga Board Mills Ltd.

Mr. D. P. Joshi Administration Manager

-

19. Damanganga Board Mills Ltd.

Mr. R. B. Yadav Production Manager

-

20. Ramji Board & Paper Mill Pvt. Ltd.

Mr. S. P. Garg Chairman [email protected]

21. Forbes Marshall Mr. Vaibhav Savji Marketing Manager [email protected]

22. Shah Paper Mills Ltd. Mr. B. M. Tyagi General Manager [email protected]

23. Vaibhav Paper Boards Pvt. Ltd.

Mr. Nimish J. Shah Director [email protected]

24. Devana Paper Mills Pvt. Ltd.

Mr. R. R. Vyas General Manager [email protected]

25. Devana Paper Mills Pvt. Ltd.

Mr. Dinesh Garg Vice President [email protected]

26. Vaibhav Paper Pvt. Ltd. Mr. Omvilash Yadav Electrical Incharge -

27. Shree Ajit Pulp & Paper Ltd. Mr. Gautam Shah Managing Director [email protected]

28. Saiyed Paper Mills Ltd. Mr. Deepak D. Chemist [email protected]

29. Remco Paper & Board Industries Pvt. Ltd.

Mr. Girish Patel Mechanical Engineer

[email protected]

30. Vapi Waste & Effluent Management Company Ltd.

Mr. K. R. Dave Deputy General Manager

[email protected]


Mr. Ishan Shah Assistant Manager [email protected]

32. Vapi Industries Association Mr. Somabhai Patel - [email protected]

33. N. R. Agarwal Industries Ltd.

Mr. Amrish Singh Arya E. S. O. [email protected]

34. Kwality Pulp & Paper Mills Ltd.

Mr. Rajkumar Production Manager

[email protected]















35. Craft Corner Paper Mills Ltd.

Mr. Mahavir Production Manager

-

36. Center Of Excellence Mr. N. S. K. Srinivasan General Manager [email protected]

37. Garnett Specialty Paper Mr. Din Dayal Senior Chemist -

38. KAEFER Mr. Yogesh S. Pandey Deputy General Manager

[email protected]

39. Nueon Technical Solutions Mr. Dhaval Contractor Chief Executive Officer

[email protected]

40. Individual Mr. Ramu Gundu Research Associate

-

41. Clean Environment Construction Project Company

Mr. N. C. Patel CMD -

42. Ruby Macons Limited Mr. S. B. Nandi Senior Manager [email protected]

43. Garnett Specialty Paper Mr. Fatim Ahmed Assistant General Manager

-

44. Best Paper Mills Pvt. Ltd. Mr. Ramesh Shah Director [email protected]

45. N. R. Agarwal Industries Ltd. Unit III & IV

Mr. Lalan Sharma Senior Manager [email protected]

46. N. R. Agarwal Industries Ltd. Unit III & IV

Mr. Satendra Mishra Mill Incharge [email protected]

47. IOCL Mr. V. C. Mirani Managing Director -

48. GPMA Mr. S. B. Jani - -

49. Gayatrishakti Paper & Boards Ltd.

Mr. Joshua Vice President [email protected]


Mr. S. R. Tondave Mill Incharge [email protected]


Mr. E. K. Hande General Manager -

52. Bhagwati Paper Mills Mr. Surjit Mill Incharge [email protected]

53. Best Paper Mills Pvt. Ltd. Mr. D. B. Ashar Director [email protected]












54. N. R. Agarwal Industries Ltd. Unit I

Mr. S. K. Pathak Manager [email protected]

55. N. R. Agarwal Industries Ltd. Unit I

Mr. S. G. Dutta Assistant Laboratory Incharge

[email protected]

56. Shah Paper Mills Ltd. Mr. B. P. Singh Director [email protected]


Mr. Pranav Pathak Vigilance Incharge [email protected]

58. GIZ (IGEP) Mr Raghu Babu Nuakala Sr. tech. Advisor & Programme Coordinator

[email protected]

59. GIZ (IGEP) Mr. Nitesh Patel Junior Advisor [email protected]

60. GCPC Mr Bharat Jain Member Secretary [email protected]

61. GCPC Ms. Chinkal Patel Project Engineer [email protected]

62. GCPC Mr. Punam Rathod Project Engineer [email protected]

63. GCPC Mr. Hiren Bhendwal Project Engineer [email protected]

64. GCPC

Mr. Gopal Chaudhari Assistant Project Engineer

[email protected]

65. GCPC Ms. Aagnya Pandit Project Engineer [email protected]













Annexure III Presentations

1

Page 112/03/2013

Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH

A public-benefit enterprise of the German Government [German Federal Ministry for Economic Cooperation and Development]

Supports the German Government in the field of international cooperation for sustainable development.

GIZ is also engaged in international education work around the globe.

GIZ currently operates in more than 130 countries worldwide and has over 16,000 staff.

Page 212/03/2013

GIZ in India

Germany has been cooperating with India by providing expertise through GIZ for more than 50 years.

Focus on the following areas:

» Energy - Renewable Energy and Energy Efficiency

»Sustainable Urban and Industrial Development

» Natural Resource Management

» Private Sector Development

» Social Protection

» Financial Systems Development

Page 312/03/2013

Indo German Environment Partnership (IGEP) Programme

Thrust Area: Sustainable Industrial Development

Planning of New Industrial

Parks & Investment Zones

Waste Water Management

Environment Friendly

Techniques(Pulp & Paper,

Textiles)

Page 412/03/2013

Cooperation Activities in Gujarat

Planning of new industrial parks – co-operation with GIDB, GIDC

Waste water management – cooperation with VWEMCL

Environment friendly techniques in pulp & paper sector and textiles sector – cooperation with industries and industries associations

Capacity building of GPCB to promote state-of-the-art environmental management and pollution control in the state of Gujarat – cooperation with GPCB

Cooperation with GCPC

Page 512/03/2013

Cooperation Activities in Vapi

Capping and closure of TSDF

Improvement of CETP and up-gradation

Pulp & paper sector

Page 612/03/2013

Pulp & Paper Sector

Identify the environmental issues related to pulp & paper sector(perspectives of the industry, regulatory agencies, people, government...)

Highlight the immediate need of the sector in order to do their business in sustainable manner

Identify best available environment-friendly technologies and techniques (most effective – e.g. reduces pollution, allows implementation - technically feasible, economically)

Demonstrate the use in selected pulp & paper industries

Develop an up-scaling strategy and supportive policy documents/instruments

2

Page 7company presentation 201212/03/2013 Page 812/03/2013

Pulp & Paper Sector Optimising freshwater consumption (e.g., average 57 m3/tonne; European

average 10 m3/tonne).

Resource losses due to material handling practices and lack of good housekeeping

Energy efficiency (e.g., energy losses in drying section )

Discharge of black liquor - contains highly polluting constituents lignin andcooking chemicals; difficult to treat in effluent treatment plants as lignin is noteasily bio-degradable

High TDS in the waste water (e.g. use of alum, rosin)

Wastes generated

Fuels used in boilers

Compliances with environmental standards and other legal requirements

Efficiencies, reliable operations, overall control

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Pulp and Paper Industry

REGULATORY OVERVIEW

B. R. NaiduAdditional Director &

Zonal Officer (West)

Central Pollution Control Board

Fact file…

– Paper manufacturing is a highly capital, energy and water intensive industry.

– In India, around 905.8 million m3 of water is consumed and around 695.7 million m3 of wastewater is discharged annually by this sector.

– The global best specific water consumption is 28.66 m3/tonne for large scale wood based pulp and paper mill far better than India’s average fresh water consumption in pulp and paper sector, which is ~60‐70 m3/tonne of product.

Major categories of the paper mills in India

-- The major categories of the mills for which norms have been set up are

- Wood based mills producing - Bleached varieties - Unbleached varieties - Newsprint - Rayon grade pulp

- Agricultural residue based mill producing - Bleached varieties with & without recovery system - Unbleached varieties without recovery system

- Recycled fiber and Market Pulp based mills producing - Writing & Printing varieties with & without deinking - Newsprint with & without deinking - Unbleached Kraft - Board

REGULATORY PROVISIONS

• ‘Environment’ is defined as the sum total of water, air and landand the inter relationships which exists among and betweenwater, air and land, and human beings, other living creatures,plants, micro-organisms and property.

• Any solid, liquid or gaseous substance present in suchconcentration as may be or tend to be injurious to environmentis called an environmental pollutant [EP, Act, 1986]

• India, being a signatory to the United Nations Conference onthe human Environment held in Stockholm in 1972 and othersubsequent Conferences aimed at arresting the degradation ofenvironment and conserving it, is committed to takeappropriate and adequate steps for the preservation of naturalresources of the earth and for the protection and improvementof human environment.

• Among the seventeen most polluting industries identified byMinistry of Environment & Forests (MoEF), paper industryis one amongst them.

• In order to conserve and maintain the environmentalquality, the Govt. of India, (Ministry of Environmental &Forests and Central Pollution Control Board) have formulatedand notified discharge quality standards for wastewater andwaste gases and also the total quantity permitted to bedischarged depending upon, the raw materials used, thetechnology adopted and the year of establishment of theindustry. For the paper and pulp mills, the minimalnational standards (MINAS) for wastewater andwaste gases are given.

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Typical Emissions from Pulp & Paper Industry

Water PollutionThe set of indicators measure pollutants released to a papermill’s receiving waters—typically, rivers or streams. The resultingenvironmental impact depends on local factors such as thevolume and composition of pollutants released, and the volumeand flow of the receiving waters. These indicators are

• Effluent Flow

• Biochemical Oxygen Demand (BOD)

• Chemical Oxygen demand (COD)

• Color

• Total suspended solids (TSS)

• Dioxins and dioxin-like compounds

• AOX

• EOX

Fundamental process Effluent generated Pollution load

Raw Material preparation Barker bearing cooling water TSS

Pulping Spent liquor, Leakages frompipelines, pump glands and overflows of storage chests, blow pitspill over, black liquor from smallagricultural residue based millswithout chemical recovery

High BOD, COD, Color, TDS,TSS and Toxicity

Screening Weak liquor Low BOD, COD, TSS

Washing & Cleaning Wash water Low BOD, COD, color and even toxicity, Low level of metal ions, Fiber fines which pass through filter cloth in washing units, Sand and clay particularly in bamboo and straws, Fiber fines

Source Points of liquid Effluent Fundamentalprocess

Effluent generated Pollution load

Bleaching Bleach plant wash water High BOD, COD, Dioxins(formed in Cstage and removed from the pulp in E-stage filtrate),Toxicity, even mutagenicand carcinogenic character, Most ofeffluent color , About 65% of total colorfrom bleaching section of hard wood basedmill, About 95% of total color frombleaching section of soft wood based mill,Entire AOX from bleaching section

Stock preparation Clean up wastewater Low BOD, COD, color

Paper machine White water Fiber fines and filler particles from wastewater from paper machine area, BOD,COD from paper additives and color fromdyes present in paper machine wastewater,Metal ion impurities in chemicals andadditives and corrosion products,Slimicides and biocides used for slimecontrol

Finishing Cleanup wastewater Low BOD, COD, color

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Characteristics of waste water from different sections of paper mills

Parameter Chipperhouse

DigesterHouse

Pulpwashing

PulpBleaching

PaperMachine

ChemicalRecovery

Volume (m3/t paper)

20-60 5-10 20-40 140-180 40-90 -

Color Muddy Darkbrown

Darkbrown

Brown Whitish Lightbrown

pH 6.4-8.0 9.0-10.0 8.5-9.6 6.0-9.6 5.3-8.1 7.0-9.0

Total solids (mg/l)

540-900 1000-2500

1400-2500

2100-2700

850-1250 1270-2800

Suspended solids (mg/l)

240-520 140-190 350-1000 140-220 490-900 400-760

BOD(mg/l)

30-50 300-360 230-480 125-155 100-160 90-180

COD(mg/l)

175-450 1850-2200

900-1700 550-700 520-780 320-610

Pollution loads from combined Waste waters in Indian Paper Mills

Parameter Large papermills

Small paper mills based on

Agro-residue Wastepaper

Flow, m3/t paper 100-200 150-200 50–100

pH 6-9 6 – 8.5 6 - 8.5

Suspended solids, kg/t 100-150 90-240 50 -80

BOD kg/t 35 - 50 85- 370 10 - 40

COD, kg/t 150 500 - 1100 50 - 90

Air Pollution• For gaseous emissions, the particulate matter and hydrogen sulfide

are the most important parameters. Since some pulp and paper millsuse lime-kilns and all the mills operate boilers for steam generationfor meeting their process heat and power requirements, they burncoal/fuel & furnace oil/agricultural wastes or a combination of them(i.e. multifuel boilers), and emit SO2, PM, HC and CO into theatmosphere.

• Integrated mills emit fine particulates, which escape theirelectrostatic precipitators via their recovery furnace stacks and boilerstacks.

• Respirable particulate fraction has two sub categories-

(i) Coarse particulate fraction (size 10 <dp <2.5 micrometer) and (ii)fine particulate fraction (dp < 2.5 micrometer).

• Since the emission standards are to be accepted only when theambient air standards are met, a very heavy responsibility rests withthe occupiers of paper mills to meet the fines standards

Air Pollution

Greenhouse gas emissionsThe pulp and paper industry is the fourth largest emitter ofgreenhouse gases among manufacturing industries, andcontributes 9 percent of total manufacturing carbon dioxideemissions (U.S. Energy Information Administration 2002; Martinet al.).

Nitrogen oxidesNitrogen oxides (NOx, which include NO and NO2) are products of thecombustion of fuels in boilers.

Volatile organic compoundsVolatile organic compounds (VOCs) are a broad class of organiccompounds that are gases at room temperature, such as vapors fromsolvents. VOCs react with nitrogen oxides (NOx) to form ground‐levelozone, the major component of smog and a severe lung irritant. Thepulp and paper industry is the fourth highest contributor of VOCemissions to the atmosphere by industry sector (U.S. EPA 2002).

Total reduced sulfurTotal reduced sulfur compounds cause the distinct odor associatedwith kraft pulp mills.

Air Emissions from the Pulp and Paper Industry

Pollutant Effects Source

Carbon dioxide greenhouse gas fuel combustion

Hydrogen sulphide rotten egg smell Kraft process

Sulphur dioxide acid rain fuel combustion and pulping process. (Kraft 1-3 kg SO2/tonne) , sulphite 5kg SO2/tonne )

Volatile organics some toxic effects and precursors to the formation of ozone

various

Chloroform toxic, possible carcinogen

chlorine bleaching

Other organo-chlorines some highly toxic chlorine bleaching

Main emission of reduced sulphur compounds from sulphate pulping

Emission source Emission rate kg S/t90

H2S CH3SH CH3SCH CH3SSCH3

Digester batch 0-0.15 0-1.3 0.05-3.3 0.05-2.0

Digester continuous 0-0.1 0.5-1.0 0.05-0.5 0.05-0.4

Evaporation (indirect) 0-0. 0.05-1.0 0.1-1.0 0.1-0.8

Recovery furnace (withdirect contact evaporation)

0.05-1.5 0.05-0.8 0.05-1.0 0.05-1.0

Smelt dissolving tank 0-25 0-2 0-1 0-0.3

Lime kiln 0-1 0.01 0.01 0.01

Settling basin 0-0.5 0-0.2 0.01 0-0.02

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Absolute odor threshold values for reduced sulphur compounds from kraft pulping

Compound Odour threshold (ppb)

Hydrogen sulphide H2S 0.2-4.7

Methyl mercaptan CH3SH 0.8-2.1

Dimethyl sulphide CH3SCH 1.0-3.9

Dimethyl disulphide CH3SSCH3 5.6

Solid waste generated in large paper mills

Section Large paper mills Small paper mills

Raw material handling/preparation

45 kg/t paper 210 (straws)550 (bagasse)

Hypo preparation (Grit) 20 kg/t

Recausticising lime mud 593 kg/t

Power plant/Boiler ash 656 kg/t 1300

Primary sludge 84 kg/t 116

Secondary sludge 16 kg/t 105

Total 1507 kg/t 1731 (2071)

Environmental concerns…

Some of the current environmental issues faced by Indian paper industry and being addressed under corporate responsibility for environmental protection (CREP) are given below:

• Minimization and elimination of color and AOX in the effluent through innovative non‐chlorine bleaching practices.

• The management and disposal of lime sludge from chemical recovery.

• Minimization of fresh water consumption.

• Minimization of emission of odor.

• Maximization of energy efficiency.

• Enhancement in the waste paper recycling as a raw material.

• Establishment of chemical recovery unit in agro‐based raw materials from pulp and paper industry.

Charter on CREP in Pulp & Paper Industry

Large Pulp and Paper Implementation Schedule

Discharge of AOX kg/tonne of paper

AOX 1.5 kg/tonne of paper within 2 years

AOX 1.0 kg / tonne of paper in 5 years

Installation of lime kiln Within 4 years

Wastewater discharge cum / tonne of paper

Less than 140 cum/tonne of paper within 2 years Less than 120 cum / tonne in 4years for units installed before 1992 Less than 100 m3 / tonne of paper per units installed after 1992.

Odour control by burning the reduced sulfur emissions in the boiler/lime-kiln

Installation of odour control system within 4 years.

Utilization of treated effluent for irrigation

Utilization of treated effluent for irrigation wherever possible

Colour removal from the effluent

Indian Paper Manufacturers Association to take up project with Central Pulp & Paper Research Institute

Small Pulp and Paper Implementation Schedule

Compliance of standard of BOD, COD & AOX

Recovery of chemicals by installation of Chemical recovery plant or utilization of black liquor with no discharge from pulp mill within 3 years OR Shift to waste paper

Upgradation of ETPs so as to meet discharge standards

ETPs to be upgraded within 1 year so as to meet discharge standards.

Waste water discharge/ tonne of paper

Less than 150 cum/tonne of paper within 3 years

Utilization of treated effluent for irrigation

Utilization of treated effluent for irrigation wherever possible

Colour removal from the effluent

Indian Agro and Recycled Paper Manufacturers Association to take up project with CPPRI.

Note: Non-complying units not meeting notified standards under Environment (Protection) Act, 1986 will submit action plan with PERT Chart along with bank guarantee to SPCBs by June 30, 2003.

ENVIRONMENTAL ISSUES IN PULP AND PAPER INDUSTRY

• Discharge and emission norms for pulp and paper industryhas been formulated in early nineties based on thetechnological and environmental scenario existing then.

• Over these years large scale pulp and paper mills haveundergone significant increase in scale of operation as well aschange in technological level and environmental status.

• New issues related to Water & Energy Conservation, Controlof Absorbable Organic Halides (AOX), Color of Effluents, NonCondensable Gases, Solid Wastes and Product

• Moreover developments like Kyoto Protocol & WTO entry haveput further pressure on achievement of environmentalprotection norms matching global standards.

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Some pollution prevention advances that have beenimplemented within the pulp and paper industry world wide:

Chemical recovery systems

Prevention of chlorinated compounds

Secondary fiber substitution

Extended Delignification

Oxygen Delignification

Ozone Delignification

Anthraquinone Catalysis

Black Liquor Spill Control and Prevention

Enzyme Treatment of Pulp

Improved Brownstock and Bleaching Stage Washing

Improved Chemical Controls and Mixing

The Ecomark Criteria for Paper:

The Ecomark Criteria for Paper:

• Eco-labelling of a product is a means to improve the environment.

• This relies on the concept of “from cradle to grave’.

• The BIS, in 1992, has notified the requirements which shall be met bythe paper manufacturers while applying for ECOMARK on their products.

•These requirements are product-specific.

• The paper and paper boards manufactured out of pulp containing notless than 60 percent by weight of pulp made from materials other thanbamboo, hardwoods, softwoods and Reeds.

• Recycled paper and paper boards must be made from 100% wastepaper. The hand made paper is 100% eco-friendly.

• Paper and paper boards used for packaging of food materialsshall be manufactured from virgin pulp and shall be free fromdioxins.

• Printed surfaces of the paper shall not come into contact withthe food and the maximum amounts of contaminants in paperintended to come into contact with food shall not exceed theprescribed limits.

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1

Page 1company presentation 201212/03/2013

Effluent & Solid Waste Treatment Systems for Pulp & Paper Industries

at VWEMCL


• Quality & Quantity of Effluent Generation from Pulp & Paper Sector.

• Treatment Systems for the Effluent from Pulp & Paper Sector.

• Major Problems & Potential Solutions in Waste Treatment of Pulp & Paper Sector.


WASTEWATER PRODUCING STEPS FROM PULP & PAPER MILL

Wood Preparation for Pulping Solid, BOD, Color

Pulping wastepaper digester and Liquor Evaporator/Condensator

High strength BOD, reduced sulfur compounds, AOX, VOCs

Post pulping Process/washingHigh strength BOD, reduced sulfur compounds, AOX, VOCs

Bleaching BOD, Color, Chlorinated Compounds, AOX, VOCs

Paper Making Solid, BOD, Color


• Approx effluent generation 70 – 80 % of water consumption.

• Average Flow to CETP : 55 MLD

• Pulp & Paper industries contribute ~ 15-20% of Effluent to CETP

• CETP receives wastewater from pulp & paper industries mainly through direct underground pipeline/chamber & Pumping stations to CETP

Number of Pulp & Paper Industries in vapiGIDC in operation &Member of CETP

Description KraftPaper

Duplex/New Printing Paper/Board

Total

Pulp & Paper Industry 22 10 32

Base Volume (Approx) –Water consumption (MLD)

2.8 10.8 13.6


WASTEWATER CHARTERIZATION

Category of Pulp & Paper Industry

Water requirement (cubic Meter/Ton of Paper Produced) approx

Total Wastewater discharge (cum/Ton of

Paper Produced) approxAgrobased 300 - 350 200

Waste Paper Based 100-150 75

Parameters

CPCB Standard Discharge Limit

pH 7 -8.5BOD (3 days at 27oc) 30

COD 250


• The paper mill wastewater characteristically contains darkbrown colour, very high level of Biochemical Oxygen Demand(BOD), Chemical Oxygen Demand (COD), due to presence oflignin and its derivatives from the raw cellulosic materials,chlorinated compounds, suspended solids (mainly fibres), fattyacids, tannins, resin acids, sulphur and sulphur compounds,adsorbable organic halide (AOX), pollutants.

• Theoretical wastewater are high organic content around 20 -110kg COD /air dried ton paper

QUALITY OF WASTE WATER

2


• Total average COD loading : 22925.6 kg/day

• Total average TSS loading: 8664.5 kg/day

Observation: Wastewater characteristics effluent flow, COD and TSSloading in the treated effluent are statistically lower for KraftManufacturing Industries then Dulex/Newsprinting manufacturingunits.

Monitoring results of Pulp & Paper Industries From January 2012 – to Dec – 2012


• Impact on CETP performance:

• Chlorinated organic compounds

• Limited nutrients (N & P) present in the wastewater- reason for the growth of filamentous micro organisms & sludge bulking problem.

• Lignin compound found in wastewater which is difficult to degrade biologically.

IMPACT ON CETP TREATMENT PERFORMANCE


- Physical Methods

• Sedimentation and Floatation

- Physico – Chemical Methods

• Chemical flocculation

• Activated Carbon Adsorption

• Chemical Precipitation to remove colloids and color

TREATMENT OF PULP AND PAPER INDUSTRIESWASTWATER


- Biological Treatment Methods

• Anaerobic Lagoons

• Stabilization Ponds

• Aerated Lagoons

• Activated Sludge Process

• Plastic Media Tricking Filters

• Rotating Biological Contractor

• Anaerobic Contact Filter

TREATMENT OF PULP AND PAPER INDUSTRIESWASTWATER


INNOVATIVE TECHNOLOGY:• Advance flocculation

• Ozone/AOP technology

• Membrane Technologies (Ultra Filtration, NF)

• Reverse Osmosis

• Chemical Oxidation

• Electrodialysis


• POLYMER INDUCED FLOCULATION Treatment of Pulp and Paper Mill Wastewater by Polyacrylamide (PAM) in Polymer Induced Flocculation. Cationic polyacrlyamide Organopol with very high molecular weight and low charge density is found to give the highest flocculation efficiency in the treatment of the paper mill wastewater.

• Ozonation is widely used chemical oxidation method to eliminate or reduce pollution caused by the effluents of the pulp and paper industry. It can achieve 95% of turbidity reduction, 98% of TSS removal, 93% of COD reduction

INNOVATIVE TECHNOLOGY:

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Page 13

SOLID WASTE PERSPECTIVE


RAW MATERIALS USED FOR MANUFACTURING OF PAPER

‐Core Pipe‐Kraft Waste‐Paper Tube Waste‐Plain Waste‐P.O.Y. Waste‐Press Kraft Waste‐P.T.C. Waste‐Pulping Waste‐Super Plain Waste‐Soft Wood Pulp,‐Hard Wood Pulp‐Waste Paper, ‐Poly Aluminium Chloride


‐ Absorbent Kraft ‐ Cream Wove ‐ One Time Carbon‐ Thermal Paper‐ Kraft Paper‐ Tissue Paper ‐M.G./M.F. White & Colour

Paper‐M.G. Kraft Paper‐ Laminated Paper‐ Coated Paper‐ Embossed Paper

LIST OF PRODUCTS MANUFACTURED IN PAPER INDUSTRY


CONTRIBUTION OF PAPER INDUSTRY IN TOTAL WASTE QUANTITY

• VWEMCL receives approx. 8000-10000 MT ofwaste every year

• It is around 8-10 % of total wastes received bythe company


QUALITY OF PAPER WASTE IN SOLID WASTE PERSPECTIVE

• The waste from paper industry containsmoisture in the range 35-70 %

• The Calorific Value of 1500-2400 cal/gm

• The organic content is slightly higher in paperIndustry


MAJOR PROBLEMS IN PULP AND PAPER MILL SOLID WASTE DISPOSAL TO LANDFILL

• The paper industry waste takes time for drying henceoperational problems in waste dumping and spreadingin landfilling operations occurs as wheels oftransporting vehicles skid while dumping

• The waste contains colour and fiber clay includingslowly bio -degradable organic such as cellulose,wood fibers and lignin

4


ALTERNATIVE SOLUTIONS FOR SOLID WASTE PRE-TREATMENTS BEFORE LANDFILLING

• Effective drying mechanisms can be adopted formoisture reductions

• The waste can be used for co-processing with cementindustry after mixing or blending with relatively highCV wastes

• Treatment systems can be enhanced for the reductionof solid waste quantity at source


• Due to high CV contents briquettes can be preparedand used for further treatments

• Plastic waste generation is a major of the industrywhich can be used as an alternative fuel for cement orother kilns

ALTERNATIVE SOLUTIONS FOR SOLID WASTEPRE-TREATMENTS BEFORE LANDFILLING


THANK YOU

12-03-2013

1

G. V. Patel

REGIONAL OFFICER

Gujarat Pollution Control Board

Total Number of Pulp & Paper Industries in India : 672

Total Production : 8.0 Million Tons

Large / Medium Scale :

Total Number of Industries covered by this typeis 90%

Small Scale :

Total Number of Industries covered by this typeis 10%

TYPES OF PAPER MILLS ENV. ISSUES IN DIFFERENT SECTORS High volume of effluents

- Wood based mills:100-150 m3/t Paper- Agro based mills:100-150 m3/t Paper - RCF based mills:40-100 m3/t P aper

High color in effluents - Wood based mills:300-800 PCU- Agro based mills:300-3500 PCU- RCF based mills:200-300 PCU

High energy consumption- Wood based mills: 1200-1500 KW hr/t Paper- Agro based mills: 900-1100 KW hr/t Paper - RCF based mills: 400-700 KW hr/t Paper

High level of Pollutant

- COD 200-4000mg/l, Discharge Limit (CPCB) : 250mg/l- BOD 20-1000mg/l Discharge Limit (CPCB) : 30mg/l (in land), 100mg/l (on

land)

Discharge of AOX related compounds (1.0-3.0kg/t Paper) Effective Management of Black Liquor in Agro based Mills Control of NCG ( Odorous ) emissions Disposal of Solid Wastes ,t/t Paper

- Wood based mills: 0.8-1.0- Agro based mills:0.5-1.0- RCF based mills:0.3-0.5

REQUIREMENT FOR ENVIRONMENTAL COMPLIANCE

Wood Based Mills

Modified Technology for Pulping & Bleaching

Improved Pulp Washing

Efficient use of Water, reuse & recycling

Installation of Odour Control Technology

Solid Waste Management & its disposal

Up-gradation of ETP & optimal use


Agro Based Mills

Installation of Chemical Recovery or alternateoption

Improved Pulp Washing

Oxidative Bleaching

Reduced Water Consumption

Other Solid Waste Management


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Recycled Fiber Based Mills

Reduced Water consumption through closed waterloops

Waste Management


ENVIRONMENTAL ISSUES

Water Pollution

Waste water generation during paper makingprocess.

Air Pollution

Flue gases emissions from fuel burnt out in theboiler.

Hazardous Waste

Hazardous waste generation from the contaminatesreceived along with waste paper and operation of

Waste water discharged from a pulp and paper millcontains solids, nutrients and dissolved organic matter. Italso contains alcohols and chelating agents andinorganic materials like chlorates and metal compounds.Organic matter dissolved in fresh water is measuredby Biological Oxygen Demand (BOD) which changes theecological characteristics.

Recycling the effluent and using bioremediation pondsand employing less damaging agents in the pulping andbleaching processes can help reduce water pollution.

Discharges can also discolour the water leading toreduced aesthetics.

WATER POLLUTIONWater pollution can be curtailed using various methods asmentioned here:

Primary Collection water recycling

Screening and removal of Fines

Using environment friendly dyes

Maximizing closed loop water recycling

Good Housekeeping to ensure that grease and oil is notcontaminating waste water

WATER POLLUTION - TREATMENT

SPM, Nitrogen dioxide (NO2),Sulfur dioxide (SO2)

and Carbon dioxide (CO2) are all emitted during paper

manufacturing. Common chemicals that constitute SPM are

nickel, arsenic and lead. When these particles are inhaled,

they tend to accumulate in the lungs and cause respiratory

problems and lung damage. Nitrogen dioxide and Sulfur

dioxide are major contributors of acid rain, whereas CO2 is

a greenhouse gas responsible for climate change.

AIR POLLUTIONAir pollution can be curtailed using various methods asmentioned here:

Wet Scrubbers

Bag Filters

ESP

Use of good quality of fuel

Boiler efficiencies should be at very high levels to reducepollution

AIR POLLUTION CONTROL MEASURES

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Paper waste accounts for nearly over 25% of total waste

and Paper waste like other wastes faces the additional

hazard of toxic inks, dyes and polymers that could be

potentially carcinogenic when incinerated or mixed with

groundwater via traditional burial methods such as modern

landfills.

Paper recycling mitigates this impact, but not the

environmental and economic impact of the energy

consumed by manufacturing, transporting and burying and

or reprocessing paper products.

SOLID WASTESolid waste can be curtailed using various methods asmentioned here:

Pre- Checks on the quality of raw material

Recover and re-use of fibre from ETP

Choosing correct chemicals and avoiding overuse

Maintaining clean and good house keeping

Upkeep of all equipment to ensure maximum efficiency

SOLID WASTE & ITS MANAGEMENT

SOLID WASTE & ITS MANAGEMENT SOLID WASTE & ITS MANAGEMENT

The paper demand increases every day as a result ofdeveloped population and industrialization. Water andenergy utilization and in particularly waste generation arebecoming more important concern ever worldwide.

A major goal is to decrease damage to environment bywaste minimization, reuse and recycle. To use bestavailable techniques and innovative methods is becomingmore an issue. However, end-of-pipe treatment is still themajor approach to minimize the risk. To evaluatepollutants and to develop treatment technologies need aholistic approach.

NEED OF THE HOUR

The best available treatment technology for all threewaste phases depends on the production processes,raw materials and the regulations, which the industrieshave to obey.

All paper mills should re-check their mass balance andensure corrective measure to set their records right.

Group discussions and sharing of information is veryimportant to ensure sustainability of the industry as a whole.

Good House keeping and proper maintaining of all records isa pre-requisite to ensuring cleaner production processes.

MOST IMPORTANT

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1

Page 1

Your logo

Opportunity to Utilize

Centre of Excellence,Vapi

for Research / Analytical Solutions /

Pilot Project by

Pulp & Paper Industries

Opportunity to Utilize

Centre of Excellence,Vapi

for Research / Analytical Solutions /

Pilot Project by

Pulp & Paper Industries

Page 2

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Areas Covered in Presentations

Existing Facilities in COE.

Proposed Research / Analytical Solution for Pulp &

Paper Sector.

Requirement of Policy to Utilize the COE Facilities

for R & D and Solving Environmental Issues.

Page 3

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Centre of Excellence, (COE) Vapi

A Division of Vapi Waste & Effluent Management

Company Limited, Vapi (VWEMCL).

Established under the Industrial Infrastructure

Development Scheme (IIDS) of the Ministry of

Commerce and Industry, Government of India.

Page 4

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Existing Facilities in COE

LABORATORY -ANALYTICAL & COLOUR

INFORMATION TECHNOLOGY -VIDEO CONFERENCE FACILITY &

CONVENTION CENTRE

PILOT PLANT

Page 5

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CENTRE OF EXCELLENCE

An ISO-9001:2008 Accredited Organization

World Class Analytical & Product Development

Facility Available At Vapi, Under One Roof Within

Reach At Affordable Price

In the process of getting, FDA (Food and Drugs

control Administration), and NABL (National

Accreditation Board for testing & calibration

Laboratories)Page 6

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CENTRE OF EXCELLENCE

Focusing Knowledge Sharing And Case Studies For

Sustainable Growth and Continual Innovation

Our Assets - System and Experience In Analytical

Services

Near Term Initiatives - Environmental Solutions ,

Analytical Application Research ,MOU with Gujarat

Cleaner Production Centre

2

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Analytical Laboratory

A state of the Art Laboratory having Modern Sophisticated Instruments such as NMR, GC-MS, ICP, Particle Size Analyzer, GC and HPLC as well as DSC and TGA.

The Laboratory has capability of analyzingsamples as per various Customer Requirements

Page 8

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Services ProvidedMaterials Analysis; Problem Solving;

Method Development & Validation;

Contaminant Determination;

Third Party Inspection;

Training and Consulting etc

Page 9

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Analytical Equipments at COE

Spectroscopy,Molecular Identification

and Analysis

FTIR - FOURIER TRANSFORM INFRARED SPECTROMETER

PERKINELMER

SpectroscopyMolecular Identification

and Analysis

UV- VISIBLE SPECTROPHOTOMETERSHIMADZU


and Analysis

NMR - NUCLEAR MAGNATICRESONANCE SPECTROMETER

VARIAN - 400 MHz


and Analysis

ICP - OES - INDUCTIVE COUPLED PLASMA - OPTICLE EMMISION

SPECTROSCOPY,PERKINELMER

Page 10

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Chromatography IC - ION CHROMATOGRAPHY,METROHM

ChromatographyGC-MS (GAS CHROMATOGRAPH - MASS

SPECTROMETER),PERKINELMER

ChromatographyGC - GAS CHROMATOGRPHY

(WITH FID,FPD & ECD,NPD),PERKINELMER

ChromatographyHPLC - HIGH PERFORMANCE

LIQUID CHROMATOGRAPHY,SHIMADZU

ChromatographyHPTLC - HIGH PERFORMANCE THIN LAYER

CHROMATOGRAPH,CAMAG

Page 11

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Physical and Thermal Analysis

DSC - DIFFERENTIAL SCANNING CALOROMETER

PERKINELMER

Physical and Thermal Analysis

TGA - THERMOGRAVIMETRIC ANALYZER, PERKINELMER

Analysis of Total Organic Carbon

TOC - TOTAL ORGANICCARBON ANALYZERTELYDEN TEKMAR

PARTICLE SIZE ANALYZER

PARTICLE SIZE ANALYZERMALVERN

Page 12

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KARL FISCHER TITRATOR LAB-INDIA

PH-METER LAB-INDIA

TCLP MILLIPORE

BOMB CALORIMETER RICO SCIENTIFIC

VISCOMETER BROOKFIELD

3

Page 13

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A Versatile Scale-Up Solutions

Pilot Plant for Scale-up Activity

Very Good Infrastructure - SS Reactors; Glass Lined Reactors;

Hydrogenation Reactors with Multi Service Facilities and Utilities

Examples of possible Chemical Reactions

Catalytic Hydrogenation, Nitration, Sulphonation,

Acylation, Esterification, Condensation, Hydrolysis,

Reduction, Soponification, Formulation etc.

Services - Used for Process Optimization, Yield Material Balance

and Other Activities By Customers

Page 14

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Pilot PlantDesigned to test Customer unique process

and production requirements in an accurate,

small- scale simulation.

Effective Logistical Considerations

and Extensive Storage Space.

Uninterrupted Power Supply.

Page 15

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State of Art Information & Communication Technology Centre

VIDEO CONFERENCE ROOM - Video

Conferencing Facilities for our centre

it connect with ISDN Line. And also available in Projector.

Convention Centre for Seminars & Conferences

150 Seating Capacities, Fully Air-Conditioned,

Very Good Sound System and Projector.

Page 16

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Analytical SolutionsIt covers

Materials Analysis and Characterization,

Problem Solving, Contaminant Determination,

Method Development & Validation,

Training and Consulting, Complaint Handling,

Litigation

Page 17

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Analytical SolutionsIt covers

Awareness, Third Party Inspection,

Contract Research, Methodology for fast response to highly complex challenges,

Theory and Practice of Modern and Ultra

Modern Equipments.

Page 18

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Analytical Solutions

Instrumental & Other Analytical Tests

Water Analysis

Comprehensive Analysis – ETP Sludge - 61Parameters - Soil, Sludge & Sediments

Instrumental Analysis

Waste Water Analysis - Treatability Study of Effluent Samples

4

Page 19

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Analytical Application Research

Determination of Heavy and Toxic Metals using Inductively Coupled Plasma Optical Emission Spectrometer (ICP-OES) in Paper.

Analysis of Contaminants on Paper (FTIR)

Migration studies from recycled paper packaging materials - Analytical method for rapid testing

Page 20

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Analytical Solutions - Requirement of Policy –Thinking Aloud Exercise

Testing of Raw Materials, In process and Finished Product +

Customer Satisfaction And Customer Feedback Handling +

Product Development and Quality Up gradation + Solving

Environmental Issues.

Analytical Solutions for the above areas using both

Instrumental Techniques + Analytical Wet Chemistry

Could be provided as a team efforts involving GCPC + giz +

VWEMCL /COE + Paper Customer + Chemical , Auxiliary and

Colour Manufacturers + Concerned Experts

Page 21

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Requirement of Policy –Thinking Aloud Exercise

Getting a branch of IIP( Indian Institute of Packaging , Mumbai ) to COE – UN Number Related Activities

Testing, Analytical & Product Development services for the paper industry including Packaging Testing Facility + Product Application Laboratory for Pulp and Paper Industry

Page 22

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THANK YOU

1

Page 1Presented by : Nitesh Patel GIZ-IGEP, Gandhinagar

“Best Available Techniques Reference Document for Pulp & Paper Sector”

February 27, 2013


1. The definition and thedetermination of BAT


Definition of BAT according to Art. 3 para. 10 IED

Best = most effective with respect to the prevention and –where that is not practicable – the reduction of emissionsand the impact on the environment as a whole

Available = developed on a scale which allows implementation inthe relevant industrial sector, under economically andtechnically viable conditions,taking into consideration the costs and advantages,whether or not it is used in the respective Member State

Technique = includes both the technology used and the way inwhich the installation is designed, built, maintained,operated and decommissioned


What is BAT for a particular industrial sector?

BAT for a particular industrial sector is identified by an information exchangeprocess for each sector between

• EU Member States

• Industry concerned

• Environmental NGOs

• EU Commission

BAT Reference Documents for the sector (BREF)

Outcome of the

information

exchange

process

BAT conclusions


2. The content of BAT Reference Documents


The content of BREFsGeneral outline of the BREFs:

Preface, Scope

1. General information about the sector concerned

2. Applied processes and techniques

3. Current emission and consumption levels

4. Techniques to consider in the determination of BAT

5. Best available techniques (BAT) conclusions

6. Emerging techniques

7. Concluding remarks and recommendations for future work

References, Glossary of terms and abbreviations

Annexes (dependent upon relevance and availability of information)

2

Page 7Presented by : Nitesh Patel GIZ-IGEP, Gandhinagar12.03.2013

PROCESS DESCRIPTION, RISK TO THE ENVIRONMENT, & CONTROL TECHNIQUES Description of Process Risk to the Environment Control TechniquesBAT FOR THE MANUFACTURE OF BOARD Introduction BAT - General Preventative Measures & Prevention of Environmental Impact BAT - Minimisation of Environmental Impact BAT - Management and Treatment of Residues BAT ASSOCIATED EMISSION LEVELS Emission Levels for Discharges to Air Emission Levels for Discharges to Water COMPLIANCE MONITORING Monitoring of Emissions to Air Monitoring of Aqueous Emissions Monitoring of Emissions to Groundwater Monitoring of Solid Waste


In particular, this document covers the following processes and activities:

chemical pulping: kraft (sulphate) pulping process sulphite pulping process mechanical and chemi mechanical pulping recovered paper processing with and without deinking papermaking and related processes.

This document does not address the following activities:

Production of pulp from non-wood fibrous raw material (e.g. yearly plant pulp).

Stationary internal combustion engines. Combustion plants of less than 5 MWth rated thermal input.


Reference document Subject

Industrial Cooling Systems (ICS) Industrial cooling systems, e.g. cooling towers, plate heat exchangers

Economics(ECM) and Cross-Media Effects Economics and cross-media effects of techniques

Emissions from Storage (EFS) Emissions from tanks, pipework and stored chemicals

Energy Efficiency (ENE)General energy efficiency

Generation of steam and electricity in pulp and paper

Large Combustion Plants (LCP) mills by combustion plants with a rated thermal input of ≥ 50 MWth

General Principles of Monitoring (MON)

Emissions and consumption monitoring

Waste Incineration (WI) Waste Incineration Waste Treatments Industries (WT) Waste Treatment


There are also a number of environmentally relevantprocesses and operations, which do not specifically relate tothe pulp and paper production and so will only be mentionedbriefly in this document. These include:

occupational safety and hazard risk storage and handling of chemicals raw water treatment cooling and vacuum systems monitoring of emissions


Good housekeeping in recovered paper handling and storage

Description

Unloading and storage of loose recovered paper in an enclosed facility with a roof

Outdoor storage of recovered paper with concrete paving

Recovered paper storage in bales under roof


Achieved environmental benefit

Good housekeeping of recovered paper handling and storage does not havesignificant negative impacts on environment, safety and public health.

Cross-media effects

The sorting on site will create additional residues the mill has to take care of,a residue that otherwise accumulates at the offsite collection yards.

Operational data

Sorted bales mostly stored in the open air, in some cases under a roof. Recovered paper stored should be placed on a concrete-paved area with

rainwater drainage and/or containment for contaminated flows. The contaminated rainwater is preferably collected and treated in a waste

water treatment plant; uncontaminated rainwater, e.g. from roofs can be discharged separately.

3


Applicability

Measures/techniques can be applied in new and existing mills.

Economics

No information submitted.

Driving force for implementation

Requirements from competent authorities and permits.

Example plants

At the UPM Steyrermühl paper mill, AT, mixed recovered paper is storedunder a roof. Most mills in Germany place recovered paper stored in theopen air on a concrete-paved area with rainwater drainage. Collectedcontaminated rainwater run-off is treated in the biological waste watertreatment plant.


3. Further Steps: Scope of Cooperation


• Pulp & Paper sector one of the priority sectors where the technicalcooperation could focus on. To understand need for environmentalimprovement in Pulp & Paper sector, strategic actions to be plannedhence the overall scope of cooperation can be :

↘ Exchange of knowledge and experiences, including reference documents;

↘ Developing customised BREF documents for India;

↘ Undertaking pilot measures on demonstration purpose in identifiedindustries/sectors;

↘ Promoting dialogue among various stakeholders;

↘ Training/capacity building of PCBs;

↘ Facilitate technology transfer to industries as per requirements.

12.03.2013

Scope of Cooperation


7. Further information• Download of all BREF documents (EIPPCB Website)

http://eippcb.jrc.es/reference/

• Special link for the iron &steel BREF and related documents:http://eippcb.jrc.es/reference/i&s.html

• Industrial emissions website of the EU Commissionhttp://ec.europa.eu/environment/air/pollutants/stationary/index.htm

• European Pollutant Release and Transfer Register (E-PRTR) http://prtr.ec.europa.eu

• Sustainable production website of the German Federal Environment Agency http://www.umweltbundesamt.de/nachhaltige-produktion-anlagensicherheit-e/index.htm

1

Page 1

Presentation on

“Energy Conservation Opportunities in Pulp & Paper Sector”

Mr. Nitesh PatelGIZ, Indo German Environment Partnership Programme

Gandhinagar

12/03/2013 Page 212/03/2013

Stock Preparation

Forming

Pressing

Drying

Steam

Electricity

Electricity

Paper making

Steam

Electricity

Steam

Electricity

Paper

Energy Requirement of the Pulp and Paper Industry

Page 312/03/2013

Energy efficiency is not a question of latest technology!

Page 4

Everything counts ….. Its boiler

Page 5

Steam leaks

Page 6

1.4 bar

6.9 bar41.4 bar

25.4 mm2.54 mm1 Btu ~ 1 kJ

Steam Leakages

2

Page 7

Better maintenance of insulation

Page 8

Bad insulation on valves

Energy Savings* from Installing Removable Insulated Valve Covers, Btu/hr

Operating Temperature, °F

Valve Size, inches

3 4 6 8 10 12

200 800 1,090 1,560 2,200 2,900 3,300

300 1,710 2,300 3,300 4,800 6,200 7,200

400 2,900 3,400 5,800 8,300 10,800 12,500

500 4,500 6,200 9,000 13,000 16,900 19,700

600 6,700 9,100 13,300 19,200 25,200 29,300

Page 9

Energy Conservation Tips

Use removable insulations at valves as theyresult in significant energy losses

Carry out losses using charts in thepresentation and reference material

Condensate recovery line should be insulatedproperly

Page 10

Combustion

0

5

10

15

20

25

30

0 1 2 3 4 5 6 7 8 9 10

residual oxygen [%]

add

itio

nal

loss

es [

%] additional losses basis stoichiometric

additional losses basis 3% residual oxygen

additional losses basis 5% residual oxygen

compared to 3% residual-O212,5% higher losses

Page 11

Efficiencies in the steam system

85 – 98 %Heat exchange

75 – 90 %Steam transportation

(70-) 82 – 95 %Steam boiler

EfficiencyPart of the steam system

Page 12

Economizer

Install a stack economizer to pre-heat boiler, make-up water or produce high temperature hot water for some other concurrent

5% of boiler input capacity can be recovered

3

Page 13

Exhaust gas losses of an oil boiler

Page 14

Flash steam losses from open condensate tank

Page 15

Condensate losses

Page 16

Boiler surface losses

Page 17

Air to fuel control?

Page 18

Fouling and scaling

4

Page 19

Steam system

Reduce leaks

Improve operation of steam traps

Increase condensate recovery

Increase flash steam recovery

Use lower steam pressure if possible

Improve insulation

Clean boiler to minimze stack gas losses

Control air/fuel ratio (check every month)

Use excel sheet to mointor boiler efficiency (direct method and indirect method)

Page 20

Big Motors

Page 21

Lifetime costs of a motor

maintenance

original costs

Energy costs

96% of the global cost is energy 2.5% of the global cost is buying 1.5% of the cost is for maintenance

Page 22

Motor efficiency class

European Standard:

• EFF1: High efficiency motors

• EFF2: Standard efficiency motors

• EFF3: Poor efficiency motors

Power (kW)

Eff

icie

ncy

(%)

Page 23

Motor sizing

Oversizing a motor too much:

increases the capital cost

decreases the functional motorefficiency as shown in figure

can increase the motor’s operatingspeed if there is no regulation.

decreases the power factor whichmean an increase of the reactivepower (direct kVA losses) & increasein I2R losses

Page 24

Star - Delta conversion

PStar = 1/√3 x PDelta

… for motor load under 40 %

5

Page 25

Energy saving potential

energy saving measure saving

Energy efficient motors 2 - 8%

Correct dimension 1 - 3%

Motors with adjustable speed drives 10 - 50%

Different gears 2 – 10%

Quality of the power supply 0.5 – 3%

fine tuning, lubrication 1 – 5%

Page 26

Increasing speed

This could lead to a significant change in imposed

load and annual energy consumption. For

example, for a fan and a pump, a small increase in

the motor speed (ex.: 1440 rpm to 1460 rpm, only

1.4%) can result in a 4% increase in the load and

in the energy consumption. …….. In same ways

savings in reverse

Page 27

Pumps

Page 28

Overall cost of a Pump

Page 29

M M

FIC

M

FIC

FC

Flow / Head Control Methods

Page 30

valve

energy saving

FC

delivery head in %

mot

or p

ower

in k

W

Comparision of Flow / Head Control Methods

Page 1

CORE ISSUES IN RECYCLE PAPER INDUSTRIES AND TECHNOLOGICAL

SOLUTION IN VAPI

company presentation 201215/01/2014

By GUIDED By

Gopal H Chaudhari Bharat Jain

Assistant Project Engineer Member Secretary

Gujarat Cleaner Production Centre

Page 2

CONTENTS


INTRODUCTION

PRESENT SCENARIO IN VAPI PAPER MILL

CORE ISSUES AND FUTURE

INVENTORY OF APPLICATION TECHNOLOGIES FOR WASTE STREAM (SLUDGE, PLASTIC AND REJESTS)

ECO-FRIENDLY EMERGING TECHNIQUES

Page 3

INTRODUCTION


There are 653 paper mills in India.

Out of 653, As of date, about 550 mills in India use waste paper as primary fibresource for paper, paperboard and newsprint production.

VAPI is the biggest Industrial Estate in Asia Continent.

There are 70 industries in Gujarat and all are recycle paper mill.

In and around VAPI there are as good as 40 Small and Medium scale PAPER & PAPER BOARD Manufacturers.

India’s paper manufacturing capacity is expected to grow at a Compounded Annual Growth Rate (CAGR) of 7.4 percent from 8.4 million MT per annum to 11.2 million MT per annum between 2008 and 2010.

The per capita consumption of India stands at only 9.3 kg as against 42 kg in

China, 22 kg in Indonesia, 25 kg in Malaysia, 247 Kg in Japan and 312 kg in the

US.Page 4

PRESENT SCENARIO 2013


Raw Material Consumption Pattern

Year % Share

Wood Agro Residue Waste Paper

1970 84 9 7

2000 39 31 30

2012 31 22 47

Page 5



Comparision of Waste Paper Recovery Rate In India With Developed Countries

01020304050607080

% Recovery of Waste Paper

German

Swedan

Japan

Western Europe

USA

Italy

India

Page 6



Comparision of Per Capita Consumption of Paper In India With Global

050

100150200250300350400

US

AF

inla

ndB

elgi

um

Jap

an

Ca

na

da

Tai

wan

Sin

gapo

reS

witz

erla

nd

De

nm

ark

Ne

wZ

eal

and

Sw

ed

en

Ho

llan

dU

KG

erm

an

yC

hin

aIn

done

sia

Mal

aysi

aIn

dia

Avg Kg Per Capita Consumption of Paper USAFinlandBelgiumJapanCanadaTaiwanSingaporeSwitzerlandDenmarkNewZealandSwedenHollandUKGermanyChinaIndonesiaMalaysiaIndia

Page 7

CORE ISSUES


Plastic waste

De - inking sludge

ETP sludge (after primary and secondary treatment of effluent)

Conventional Drying System consumes large amount of energy.

Steam losses from open drying system is about 15% to 20 % due to poor

insulation.

Page 8

CORE ISSUES


Fly Ash

High TDS in paper mill effluent due to use of internal sizing agent like as alum,

PAC and rosin.

High BOD and COD in paper mill effluent, increases production cost due to high

conventional treatment cost.

Water and Energy Consumption in Conventional Paper making process is very

high.

Quality of product in conventional paper making process is very poor.

Page 9

SOLID BY STREAMS FROM PAPER INDUSTRIES


Solid By-Streams

Dry solid (%)

Organic matter (%)

Mineral matter (%)

Energy content

(MJ/tonwet)

Dry Matter Contents

Primary Sludge

50 40 60 2690 Fibres, fillers, coating clay, calcium carbonate

Secondary (Biological) Sludge

40-50 50 50 4000-5000 Calcium carbonate, cupper, micro organisms,fibres, proteins.

Deinking Sludge

56 50 50 3000 Cellulose fibres, calcium carbonate, kaolin, ink

Coarse Rejects (Plastic)

55 92 8 12000 Recyclable fibres, wet strength fibres, plastics,wood, metal, others

Screen Rejects (Stickies)

55 90 10 8000 Cellulose, plastics, hair, stickies

Page 10

FUTURE


PRESENT MODIFY

Page 11

INVENTORY OF APPLICATION TECHNOLOGIES FOR WASTE STREAM


(1) Use of By-Streams as Such

On-site orexternal

Deinking Effluentsludge

Coarserejects

Screenrejects

Land management options (land spreading, landrestoration)

N/A

Absorbent, animal bedding N/A

Anti-dust N/A

Page 12



(2) Conversion To Product

On-site orexternal


Coarserejects

Screenrejects

Feedstock for other paper grades, softboard production and cement bonded sludge boardproduction

External

Pyrolysis (chemicals) Onsite

For use in cement/asphalt/etc. production

External

Synthetic Calcium Carbonate Both

CDEM Both

Page 13



(3) Conversion To Energy

On-site orexternal


Coarserejects

Screenrejects

Gasification Both

Supercritical gasification Unknown

Combustion Both

Page 14



(1) PLASTIC WASTE TO :

CEMENT INDUSTRY BY CO-PROCESSING

FUEL/ENERGY BY PLASMA PYROLYSIS

FEED STOCK FOR BITUMINOUS ROAD CONSTRUCTION

ECO-FRIENDLY CRUDE OIL BY AGILYX PROCESS

Page 15



(2) DE-INKING SLUDGE TO “TOPCRETE” SUBSTITUTE OF

CEMENT BY CDEM TECHNOLOGY

(3) “DAS” (DIPOLAR AROMATIC SOLVENT) TECHNIQUE FOR

ZERO REJECTS

(4) NEW ECOFRIENDLY TECHNIQUE FOR REMOVAL BOD,COD

AND COLOUR FROM PAPER MILL EFFLUENT FOR ZERO

DISCHARGE

Page 16



(5) REDUCTION OF TDS (TOTAL DISSOLVED SOLID) IN KRAFT

PAPER MILL BY SURFACE SIZING AND NEW SIZING AGENT

(6) NEW DRYING TECHNOLOGY FOR REDUCTION IN ENERGY

CONSUMPTION

CONDEBELT DRYING TECHNOLOGY

BOOST DRYING TECHNOLOGY

Page 17

CORRE ISSUE ON PLASTIC WASTE


Accordingly till November 2012 the quantity of plastic waste stores at various sites on

temporary basis is as under :

The generation of plastic waste of paper mills of Vapi is around 180-200 MT/Day i.e.

around 3500-4000 MT/Day

Sr.No.

Name Quantity (MT)

1. Vapi Waste & Effluent Management Co. Ltd (TSDF Site)

11,073.00

2. Premises of Vapi Paper Mills Ltd 15,341.09

3. Premises of Satyen Fluorine Industries 29,534.14

Total 55948.23

Page 18

CORRE ISSUE ON PLASTIC WASTE


Nature of Plastic Waste At Source :

Ash < 10 %

Carbon 75 – 80 %

GCV (Gross Calorific Value) 6000 – 7500 Kcal/Kg

Hydrogen < 3 %

Moisture < 2%

Nitrogen < 0.2 %

Sulphur < 0.005%

Total Halogen < 0.5%

Page 19

CO-PROCESSING OF PLASTIC WASTE


Co-Processing of Plastic Waste has been explored in the following Cement Plants in

Gujarat and other states.

Ambuja Cement Ltd (Gujarat)

Ultratech Cement Ltd., Jafarabad Unit (Gujarat)

Ultratech Cement Ltd., Kovaya Unit (Gujarat)

Sidhee Cement Ltd., Sidheegram (Gujarat)

Lafarge Cements Ltd., Sonadhi Plant (Chhattisgrah)

Lafarge Cements Ltd., Arasmeta Plant (Chhattisgrah)

Vikram Cement Works (Ultratech Cement Ltd), (Madhya Pradesh)

Aditya Cement Works, Unit – 1 (Ultratech Cement Ltd), (Rajasthan)

Page 20

PLASTIC WASTE IN BITUMINOUS ROAD CONSTRUCTION


Page 21

PLASTIC WASTE TO FUEL/ENERGY BY PLASMA

PYROLYSIS

company presentation 201215/01/2014 Page 22

Plasma Technology

•Pyrolysis – oxygen starved

•Mass-less heat created from plasma torch – heat value of waste is irrelevant to the process

•Uniform, reactor temperatures above 1,500°C (plasma “plume” temperature > 6,000 deg. C); Controlled processing atmosphere

•Lower volume of off gas

•Depending on waste composition treated, PTDR generates 2 to 4 times the thermal energy that it consumes

•No bottom or fly ashes generated

•Production of dioxins or furans is IMPOSSIBLE

•No secondary wastes, Recovers valuable products

•Combustion –excess air required

•Heat value of waste required to maintain combustion reaction or supplementary fossil fuels required

•Operating temperatures around 1,000 °C

•Large volumes of off-gas generated

•“Cold” spots plus excess oxygen inside incineration chamber can result in Dioxins and furans

•Fly and bottom ash treatment and landfill disposal needed

Incineration Technology

Page 23

PLASTIC WASTE TO SYNTHETIC CRUDE OIL


“An Environmentally Responsible, Anaerobic Thermal Reclamation Process”

Page 24

PLASTIC WASTE TO SYNTHETIC CRUDE OIL


Page 25

PLASTIC WASTE TO SYNTHETIC CRUDE OILBY AGILYX


Comaparision of Crude Oil Sourcing

Page 26



Comparison of Plastics End-of-Life Options

Page 27



Comparison of Plastics End-of-Life Options

Page 28



Agilyx Crude Production Versus Incineration of Plastics - Grams CO2e/MJ

Page 29



Outputs:

Crude Oil – C5 to C80

80 %

Non-Condensable Gas

– C1 to C4

10 %

Solid Carbon Residual (CHAR)

9 %

Inorganic Acids (Cl, Br, etc.)

> 1 %

Characteristics Test Method

Typical Value

API Gravity D-1298 40 – 45

Sulfur D-4294 0.08 – 0.12

Total Acid Number D-664 0.07 – 0.10

Karl Fisher Water E-203 0.5 – 1.0

Heavy Metals*: AA <5.0

Pour Point D-97 24 – 30

Page 30



ECONOMICS :

Page 31

DE-INKING SLUDGE TO TOP-CRETE BY CDEM

company presentation 201215/01/2014 Page 32



CDEM converts the input – deinking sludge,consisting of:

in-organics (kaolin and calcium carbonate), organics (cellulose, additives, latex), Water

By means of an exothermic reaction at 800oC into: meta-kaolin, calcium carbonate, calcium oxide, heat, CO2, vapour.

Page 33



COMPARISION BETWEEN TOPCRETE AND CEMENT

Component Cement (%) Top-crete (%)

CaO 63 57

SiO2 20 22

Al2O3 5 15

MgO 1 2

TiO2 2 1

Fe2O3 3 0.7

SO3 3 < 1

K2O 0.8 < 1

Na2O < 1 < 1

Page 34



COMPARISION BETWEEN TOPCRETE AND CEMENT

Component Cement (%) Top-crete (%)

CuO ? < 1

ZrO2 ? < 1

SrO ? < 1

ZnO ? < 1

Bao ? < 0.1

Fineness (M2/Kg) 400 - 4000 13,000 – 15,000

Page 35

DAS TECHNOLOGY


Reference: Pulp & Paper International (February 2012) & DAS technology is aninvention of the inventor (Dr. Salah Awadel-Karim, Director of Sanatatechnologies Inc., Vancouver, Canada. DAS technology has been filedinternationally (PTC/CA2007/002289) and published by WIPO (WO/2009/073948)in June 2009

DAS stands for Dipolar Aprotic Solvents family. This family includesDimethylformamide (DMF), Dimethylactamide (DMA), Dimethylsulfoxide(DMSO), Hexamethylphosphorc triamide (HMPT), acetone, and pyridine. Thesecompounds have noticeable effect on hydrogen bonding.

This method addresses two parts:

(1) With respect to the Repulping of Cellulosic Material (2) With respect to the Water Quality Improvement.

Page 36

DAS TECHNOLOGY


(1) BENEFITS With Respect To The Repulping Of Cellulosic Material

High yield of recovered pulp fibers with considerable fiber flexibility

Ease of defibrillation and recovery of fibers with attenuated H-bonds

Fibers can be recycled continuously due to open hydrogen bond packing

Dissolution-hydration of hemicellulose (e.g. surface adsorbed xylans) and better degree of hemicellulose retention

Ease of detachment of additives, adhesives, and ink particles due to greater specific molecular surface area exposure to de-additive, de-adhesive, deinking reactions.

Energy savings by reduction in other operations (e.g., kneading, soaking, deinking)

Ease of bleaching, i.e., greater exposed surface area of fibers for reaction

Page 37

DAS TECHNOLOGY


(1) Benefits With Respect To The Repulping Of Cellulosic Material

Better sheet strength properties

Enhanced paper machine operation

Enhanced paper machine operation

Ease of draining; less fines for blocking screens

Smoother paper sheets from re-pulpled material due to fibers being flexible and comfortably in pressed position; no fluffiness on sheets due to no stiff fibers sticking out

Environmentally benign.

Page 38

DAS TECHNOLOGY


(2) Benefits With Respect To The Water Quality Improvement

Better interfiber bonding.

Ease of detachment of adhesives, additives and ink particles due to high dissolving power quality of dipolar aprotic solvent treated water (i.E., Dissolution of extraneous substances).

Improved fibrous mass transfer due to high dissolving quality and greater carrying efficacy of aprotic solvent-water system.

Lesser sludge load due to microbiological stability of water, i.E., Highly tetrahedral lattice water and small water clusters with no free oxygen for bacteria and enzymes to grow and proliferate.

Limitation in the use of sheet strength and sizing agents.

Reduce water, electrical and chemical consumption.

Page 39

DAS TECHNOLOGY


(3) Benefits Concerning To The Improvement In Mill Prodcution

High Productivity

Low Production Cost

Better Paper Quality

A Benign Environment

Page 40

DAS TECHNOLOGY


(3) Benefits Includes Reduction of Carbon Footprint Through :

Forest conservation

Reduction of emission

Provision of reactive water

Reduction of chemical use

Reduces energy consumption

Reduces greenhouse gas (GHG) emissions more than conventional recycling.

Page 41

DAS TECHNOLOGY


A Comparison Between Conventional And New Technology Production Cost

Description Existing %

DAS%

Cost India

CostDAS

Raw material $ 155.00 $ 155.00

Chemicals 100 33 $ 20.00 $ 6.60

Water /cubic meter per ton 100 85 $ 80.00 $ 68.00

Power consumption 100 90 $ 45.00 $ 40.50

Productivity increase by fiber savings

56 75 - -29

Productivity increse by machine runnability

0 8 - -12

Labor 100 90 $ 60.00 $ 54.00

Total Cost Comparision

Page 42

DAS TECHNOLOGY


A Comparison Between Conventional And New Technology Production Cost

Description Existing %

DAS%

Cost India

CostDAS

Maintenance 100 75 $ 40.00 $ 30.00

Total Cost $ 400.00 $ 313.1

Net Saving Percentage 22 %

Total Cost Comparision

Page 43

DAS TECHNOLOGY


A Comparison Of Physical Properties For Newsprint And Writing/Printing Paper Industry From Conventional And DAS

Analysis Units Writing/PrintingIn Vapi

NewsPrintIn Vapi

NewsPrintIn Surat

DAS(New

Solvent)

Freeness CSF N.A. N.A. N.A. 151

Basis Weight,

Conditioned

g/m2 50-80 45 46 65. 62

Bulk cc/g 1.30 1.65 1.50 1.95

Burst Index Kpa.m2/g 1.20 1.3 1.59 2.18

Tear Index mN.m2/g 4.2/5.0 4.5/5.3 4.1/6.0 8

Final Pulp

Page 44

DAS TECHNOLOGY


A Comparison Of Physical Properties For Newsprint And Writing/Printing Paper Industry From Conventional And DAS

Analysis Units Writing/PrintingIn Vapi

NewsPrintIn Vapi

NewsPrintIn Surat

DAS(New Solvent)

Tensile Index N.mg 32/20.5 40/22 N.A. 38.6

Stretch % 1.8 1.9 1.4/3.2 2.03

Tensile Energy

Absorption

J/m2 N.A. N.A. 34.6

Brightness ISO, Top

% 70-80(Final Paper)

56-60(Final Paper)

50-57(Final Paper)

48.3 (After Pulping)

Brightness ISO, Bottom

% N.A. N.A. 46.8(After Pulping)

Final Pulp


1

Page 1

Your logo

ELECTRO CHEMISTRY- A NEW ECO-FRIEDLY METHOD FOR EFFLUENT TREATMENT


By

Dr RAMU GUNDU

Page 2

Your logo

INTRODUCTION


• This method is mainly aimed to reduce color load of effluents

• Color persists due to the presence of lignin content

• When electricity is passed through a solution, ions are liberated

• Oxygen ions are liberated at anode (+)

Page 3

Your logo

INTRODUCTION


• Hydrogen ions are liberated at cathode (-)

• High molecular weight compounds of

• Effluents get converted into low molecular weight compounds

• Low M.W ions get themselves associated with H+

• The H+ will be moved to the surface and thus the effluents get decolorised

Page 4

Your logo

BASIC LABORATORY DESIGN OF THE DEVICE


Page 5

Your logo

TREATMENT PROCESS


• Effluents were sent into the reactor through inlet pipe

• Then the electrodes are charged with the direct current

• should allow to get the reaction to occur for 5mnts

• after 5mnts the uncolored effluents starts flow out from out

let

Page 6

Your logo

HOW IT IS ECO-FRIENDLY


Parameters (in ppm)

Before treatment

After KEC treatment

Colour

(Pt.Co)2100±50 63±2

COD 850±10 15±2

BOD 250±10 NIL

TDS 2200±10 100±5

TSS 200±5 2±0.05

TS 2400±10 102±5

2

Page 7

Your logo

ENERGY UTILIZATION


• Solution Volume 2 liters

• Lignin content 400ppm

• Current Passed 5.0amps

• Voltage of Sol. 11 Volts

• Time required for 5 mnts

reaction

• Color reduction 97%

Page 8

Your logo

COST BENEFIT ANALYSIS


• This will applicable for 22,000 gallons per day

• current required 0.745 killo amperes

• electrolyte sol 11 volts

• total power required 11 x 0.745

» = 8.195 KWH

» = 8.195 Units

• total power required per day=8.195x24

= 196.68 units/day

Page 9

Your logo


COST BENEFIT ANALYSIS

• Power charges per unit = 5 rupees

• For 22,000 gallons = Rs. 983.4/-

• Amount saved by the recycling of raw water= Rs. 400/-

• Effective cost of electro chemistry method

= 983.4 – 400 = 583.4/-

Page 10

Your logo


CONCLUSION

• This process is Zero discharge

• EC process residue can use in land irrigation

• EC process is an environmental friendly

• By this we can fight against water crisis

• EC is cost effective method

• By using this method we can meet pollution control board standards

Page 11

Your logo


1

Page 112/03/2013

KAEFER GIZ Private Public Partnership

Energy-Efficiency - moving India's SMEs towards a sustainable future

Yogesh S Pandey

Page 2

Introduction

12/03/2013

• Small and Medium Enterprises contribute to 95 % of all industry establishments

• 40 % of domestic exports and industry output and 45 % of the manufacturing sector.

• Estimated to employ about 59 million persons in over 26 million units throughout the country

Page 3

Paper Industry Overview

12/03/2013

• Paper industry has poised growth and touch 11.5 million tons in 2011-12 from 9.18 million tons in 2009-10

• Indian Paper industry accounts for 1.6% of world’s production

• Provides employment to 0.50 million people

• Highly energy intensive, the share of energy cost in total manufacturing cost is 25-30%

17%

22%

4%27%

30%Chemicals

Labour

Water & Utilities

Raw Material

Energy

Page 4

Energy Consumption in Indian Paper Mills

12/03/2013

Page 5

Specific energy consumption of paper industry in India

12/03/2013 Page 6

Objectives & Partners

12/03/2013

Main objectives are to provide industrial SME access to:

• Advisory service and training

• Financial products that enable them to implement energy efficient insulation

• Awareness raising of the SME’s on the competitive advantages of integrating sustainable measures into their operations

Main partners:

• KAEFER Punj Lloyd Ltd. (KPLL) India

• German International Cooperation

• Bureau of Energy Efficiency (BEE)

2

Page 7

Project Overview

12/03/2013

Identify and prioritize target SME sectors in India

Install insulation on two pilot plants in SMEs

• Easily replicable results

• Quantifiable payback

• Owner consent for a brief plant shutdown needed

Set CSR measures

Awareness raising campaign through:

• Training, energy bus

• Seminars, associations

Make financial products available

Page 8

Selection of industries & difficulties

MovIEE presentation 201212/03/2013

Visited industries:

• Industrial furnaces

• Several process plants

Problems faced during plant visits:

• No significant energy savings recognized

• Plant shut down very difficult

• Multiplier effect limited

Page 9

Final selection of pilot plant

12/03/2013

Pulp & Paper industry

• Paper machine: Drying process

Selected as pilot project because:

• Significant energy saving

• Cost savings very attractive and quantifiable

• Only short plant shut down for insulation implementation necessary

• Very high replication potential

Page 10

The drying process

12/03/2013

Page 11

Challenges and solutions in the drying process

12/03/2013

Challenges:

• Rotating at 50-60 rpm

• Normally industries insulate with glass/mineral wool

• Water resistance very low

• Insulation peel off within 2-3 month

• Promote corrosion

Page 12

Challenges and solutions in the drying process

12/03/2013

Solution:

• Resin bounded mineral wool slabs

• Water vapor resistance factor: 1

• Chemically neutral, neither cause nor promote corrosion

3

Page 13

Economic savings and payback time

12/03/2013

Drying Drums, Nos 38, Ø1.5m, No 1, Ø 4.5m

Total not insulated area: 128 m2

Temperature: 120°C

What is the impact if this drums were insulated up to the latest standards:

Investment: Rs. 500,000

Cost Savings: Rs. 1,200,000/ Year

Payback time: 5 Month

Earnings (5 yr): Rs. 55 lakhs

Page 14

Further advantages

12/03/2013

• Enhancing paper machine production capacity (5-10%)

• Improve paper output quality

• Improved personal protection for workers

• Reduce ambient temperature in the workshop

• Easily replicable for other paper mills

Page 15

Further plan

12/03/2013

Energy Bus

• Provide in-situ training on industrial insulation in SME clusters

• Advisory service and technical assistance

• Training for local banks on loans for energy efficient measures for SMEs

Conduct workshop and training with

• Industry associations

• Research institutes

• Universities, etc.

• Project up scaling through SDAs

Page 16

Thank you

12/03/2013

Yogesh S Pandey

12-03-2013

1

Energy Conservation Environment Process Efficiency Energy Conservation Environment Process Efficiency

What is BOD?

• Amount of dissolved oxygen consumed by microorganisms for the biochemical oxidation of carbonaceous and inorganic matter.

• Determination of the relative oxygen requirements of waste-waters, effluents and polluted waters.

Energy Conservation Environment Process Efficiency

Why to Monitor?

• It gives an idea of the biodegradable fraction of the organic matter present in any effluent.

• Measuring the waste loadings to treatment plants and in evaluating the BOD removal efficacy of such treatment systems.

• Can detect possible unrest/leakage in process.


Current methods of BOD measurement

• BOD 3

• BOD 5

Energy Conservation Environment Process Efficiency Energy Conservation Environment Process Efficiency

12-03-2013

2


Membrane

Measuring Unit

Control Unit


Benefits of BioSens

• Reduction in measuring time from 3/5 days to 40 minutes.

• No need of additional instruments like Incubator/Titration.

• Can arrest any disturbance in manufacturing process with quick BOD measurement of influent.


Industries tested

• Sewage treatment plants

• Paper

• Dairy/Food products

• Beverage

• Pharmaceutical


Percentage deviation of BioSens vs BOD5 (Beverage Inlet)

-0.6%

-0.8%+2.5%

-2.6%

+1.1%

+7.7%-1.0%

+1.9% -0.6%-0.8%

0

500

1000

1500

2000

2500

1 2 3 4 5 6 7 8 9 10

Sample Number

BO

D m

g/l

BOD5 mg/l

BOD biosensor mg/l

*Percentage deviation with respect to BOD5 mg/l

RANGE BOD5 mg/l BOD biosensor mg/l

Inlet: 610 mg/l – 2081 mg/l 605 mg/l - 2105 mg/l


Percentage deviation of BioSens vs BOD5 (Beverage Outlet)

*Percentage Deviation with respect to BOD5 mg/l

RANGE BOD5 mg/l BOD biosensor mg/l

Outlet: 27 mg/l - 69 mg/l 28 mg/l - 69 mg/l

+6.2%

+3.5%

+6.4%

+4%-5.8%

0.0%

+8.3%+4.7%

+3.0%

+6%

010203040

50607080

1 2 3 4 5 6 7 8 9 10

Sample Number

BO

D m

g/l

BOD5 mg/l

BOD biosensor mg/l


Supporting Document

• MOM for BioSensdemonstration at BILT, Bhigwan.

12-03-2013

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Supporting Document

• MOM for BioSensdemonstration at International Paper (APPM), Rajahmundry


Key Features• Eco friendly

• Fast response time

• No use of hazardous chemicals/reagents

• Get rid of incubation, titration & calculations

• Reduced electrical consumption

• Avoid use of number of glass wares

• Graphical representation of Time v/s DO consumption

• Direct reading in PPM


Go Green With BioSens...!!!