all about paper making process
DESCRIPTION
All about paer making process at India's no 1 Paper making company BallaTRANSCRIPT
BALLARPUR INDUSTRIES LIMITED
UNIT – SHREE GOPAL
Paper Making Process
PAPER MAKING PROCESS
Veneer : 40-45%Consumption 325 TPD
Bamboo : 15-18%Consumption 90 TPD
Euca. Wood : 35-40%Consumption 175 TPD
RAW MATERIALS USED
Raw Material
Raw Material ChipperChipper Pulp
MillPulp Mill
Paper Machine
Paper Machine
Paper Finishing
Paper Finishing
DispatchDispatchChemical RecoveryChemical Recovery
Chemical ComplexChemical Complex
Water Supply
Power Plant
Effluent Treatment
PlantHR
Costing &
Finance
QC/ R&D
Purchase & Store
Engg Maintenance
MSD Godown
MSD Godown
FLOW DIAGRAM OF PAPER MILL
Steam for Power
White Liquor
PULP MAKING PROCESS
Chipper House
Digester House
Kraft/Sulphate pulping process
No of Digester : 3 of 120 m3 each
Type : Vertical stationary of indirect heating
Cooking Time : 260 minutes
Pulp/cook : 12.0 MT
Chipper
Digester
Chipper no.
Make Capacity (MT/h)
Raw mat. handling
1 Vecoplan No. 1 25 Woodlogs/ Bamboo
2 Vecoplan No. 2 15 Veneer waste
PULP MILL
Wash Plant
Rotary Drum Vacuum Washer: : 4 Stages
Capacity :195 BD Pulp per day
Washer
Weak Black Liquor to Recovery
Hot Water & Foul Condensate
FiltrateFiltrateFiltrate
Unbleached Pulp
Drum Washer Filtrate
Defoamer dosing at
inlet line of BSW-1
Washer
PULP MILL
C/D B/W
FILTTANK
H.MIXER
C/D MC PUMP
C/DMC MIXER
EO MC PUMP
EopEOPRETUBE
DECKER MC PUMP
C/D80M3 D1
D1 MC MIXER
DI MC PUMP D2 MC PUMP
D2 MC MIXER
Cl2
CD
H/W
FILT.TANK
H/WEO B/W
O2
EO MCMIXER
EO B/W
EO STOCKPUMP
EO
D1 B/W
H.MIXER
LP STEAM
DI B/W
D1
D2 B/W
D2 B/W
ClO2
FILT. TANK
FILT.TANK
D2
DECKER B/W
FILT. TANK
ClO2
DECKER
MILL WATER
DECKER B/W
LP STEAM
H.MIXER
D2B/WD1
B/W
EOB/W
UN BLD PULP FROM W/P
NaOH
H2O2
M/C No.4B/W
LP STEAM
CENTRI - CLEANING
MILL WATER
58M3
156M3
250M3
250M3
UN BLD
400 M3
ClO2
Paper m/c
Storage tower
H/W
To ETPTo ETP
Bleach PlantConventional bleaching process
Capacity : 180 BD pulp per dayBleaching sequence : CDEOPD1D2
Centricleaner : 4 stage
Pulp brightness(ISO) : 89-90 %
D2
Bleach towers
PULP MILL
RECOVERY
Evaporator 1
Type : Short tube vertical (STVE) and free flow falling film
No of effects : STVE-5 , FFFFE-4
Handling of thin BL : 72 m3/hr
Steam Economy : 4.5
Concentration of BL : 62-64 %
Type : Short tube vertical (STVE)
No of effects : STVE-6
Handling of thin BL : 20 m3/hr
Steam Economy : 3.0
Concentration of BL : 60-62 %
Evaporator 2
Recovery Boiler
No of Boiler : 2
- JMW
- ABL
Total capacity : 315 TPD solids
Evaporator
RECOVERY
Causticizing Section
Capacity : 70 TPD, active alkali as Na2O
Slaker : Stationary
Lime mud washing : 2 Streets
Lime Kiln
Year of installation : 2005
Capacity : 60 TPD
Lime kiln
Tinti
ng D
yes
Opti
cal W
hite
ner
Sizi
ng C
hem
ical
s
Fille
r
Pow
er
Brok
e
HD tower Bleached pulp
Pulp Refining
FunctionalAdditivesaddition
Approach flowsystem
PaperMachine
Pulp ReceivingChest
Fiber RecoverySystem
PROCESS OF PAPER MAKING – STOCK PREPARATION
Machine No.
Type
Make Deckle
cm
Speed
m/min.
GSM range
Production TPD
Paper grades
1 MFCharles Wamsely
314 100 60-90 30REB Super Printing Lky Parchment
2 MFCharles Wamsely
314 11558-190
40
S/L Bond Super Printing Super Cartridge
4 MFEsser Wyss
311 35054-149
75
Bilt Classic S/L Offset S/L Cartridge
5 MF Alstom 223 27060-124
50MMPP BCB Base
7 MF Karhula 272 12070-100
27REB Normal REB Colored Criss Cross
All machines are equipped with size press.
PAPER MACHINES
Reel Orders
Sheet Orders
PAPER CONVERSION
PM-1 Jag Rewinder
PM-2 Jag Rewinder
PM-4, Beloit Rewinder
PM-4, Masson Scott
Max reel capacity 5 5 5 5
Speed in mpm 400 400 600 500
Beloit Rewinder Masson Scott Rewinder
PROCESS PAPER CONVERSION & FINISHING REWINDER
PM-5, Servall PM-7, Jagenberg
Max reel capacity 4 4
Speed in mpm 800 600
Servall Winder Jagenberg Winder
PROCESS PAPER CONVERSION & FINISHING REWINDER
Three stage Effluent Treatment Plant Installed and Commissioned in 1987-Activated sludge process-Design Capacity: 54000 m3/day-Operating Capacity: 28000 m3/day
PARTICULARS UNIT INFLUENT HSPCB NORMS
EFFLUENT
TREATED WATER
EFFLUENT as on Nov-
09
pH NA 7-8 7.0-8.5 7.2 – 7.8
BOD PPM 280-350 30 18-25
COD PPM 700-900 350 150-180
SUSPENDED SOLIDS PPM 700-900 50 25-35
AOX KG/T Paper 1.2-1.6 <1.0 0.6 -0.8
Data showing the compliance to environmental norms
EFFLUENT TREATMENT PLANT
• Pulp Supply System• Stock refining• System cleaning• Approach Flow system• Paper making- MF
PAPER MAKING PROCESS
Pulp from Bleached Stock Chest
Buffer Chest
Refining of Stock through Refiners in Refined Chest
Mixing Chest
Machine Chest
SR Box
Fan Pump
Centricleaner
Pressure Screen
Head Box
Dry broke through pulper
Broke Storage
Broke Cleaning System
Cleaned Broke Tower
Tinting dyes/ pigment preparation
Optical whitener preparation
PAC: Poly Aluminum Chloride
Filler/Dispersed Rosin/ Fill Plus
Filler Slurry
Percol-47 Preparation system
Hydrocol- RK2 Preparation system
Wet Broke from respective M/C
PROCESS FLOW: STOCK PREPARATION (PM 1,2 & 4)
Buffer Chest
1000 m3
Bleached Pulp
Machine back water (Krofta/Disc filter filtrate) for bottom dilution
To Refiners of PM 1, 2 & 4
Thickener
PULP SUPPLY SYSTEM (PM 1,2 & 4)
RefinerMixingChest
MachineChest
SR Box Fan Pump
CentricleanerPressure Screen
Head BoxWire Part
Tinti
ng D
ye
Fill
Plus
PA
CD
ispe
rsed
Ros
in
Fille
rDefoamer
Pulp
fro
m B
uffer
Ch
est
Refined pulp °SR: 28-30Pulp Consistency:-4.0%
Tinting Dye: Iraglite Violet
Fill Plus: 1.0 kg/TPAC : 17 kg/MT
Rosin: 13-16 kg/MTFiller: Finex/CaCO3
DefoamerAfranil ST – 0.5 kg/MT
Biocide
STOCK PREPARATION: PAPER MACHINE-1
RefinerMixingChest
MachineChest
SR Box Fan Pump
CentricleanerPressure Screen
Head BoxWire Part
Tinti
ng D
ye
Fill
Plus
PA
CD
ispe
rsed
Ros
in
Fille
rDefoamer
Pulp
fro
m B
uffer
Ch
est
Refined pulp °SR: 28-30 Pulp Consistency: 4.0%
Tinting Dye: Iraglite Violet
Fill Plus: 1.0 kg/TPAC : 17 kg/MT
Rosin: 10 kg/MTFiller: Finex/
DefoamerAfranil ST – 0.5 kg/MT
Biocide
STOCK PREPARATION: PAPER MACHINE-2
Buffer Chest
NPM PulpTDR 21” & DDR 20”
Mixing Chest
Machine Chest
SR Box
Buffer Chest
NPM PulpTDR 24”
Mixing Chest
Machine Chest SR BoxMachine Refiner
Paper Machine-2
Paper Machine-1
STOCK PREPARATION: PULP REFINING – PM-1&2
Machine Refiner
Not in operation
Not in operation
RefinerMixing Chest
MachineChest
SR Box Fan Pump
CentricleanerPressure Screen
Head BoxWire Part
Tinti
ng D
ye
PAC
Pulp
from
Buff
er
Ches
t
Refined pulp °SR: 28-30 Pulp Consistency: 4.0
Tinting Dye: As per QualityOBA: 2.5 kg/MTRosin: 10 kg/MT
PAC : 25 kg/MTFill Plus: 2.3 kg/MT
DefoamerAfranil ST 0.5 kg/MT
Fille
r
OBA
Fill
Plus
Dis
pers
ed R
osin
STOCK PREPARATION: PAPER MACHINE– 4
Buffer Chest
Virgin Pulp
DDR-1
Mixing/ Machine
Chest
SR Box
Refined Pulp Chest
Measuring Tank
Broke Chest
Broke
STOCK PREPARATION: PULP REFINING – PM-4
Pulp from Pulp Mill
New Mixing Chest
Refining of Stock through Refiners
Mixing Chest
Machine Chest
SR Box
Fan Pump
Centricleaner
Pressure Screen
Head Box
Dry broke through pulper
Broke Chest-1
Broke Chest-2
Tinting dyes/ pigment
Optical whitener
PAC: Poly Aluminum Chloride
Dispersed Rosin
Filler Slurry
Wet Broke from respective M/C
Cationic tarch
PROCESS FLOW : STOCK PREPARATION – PM-5&7
500 m3
Bleached Pulp
Machine back water for bottom dilution To PM-5 & 7
Stock Prep.
PULP SUPPLY SYSTEM: PM- 5&7
Refiner MixingChest
MachineChest
SR Box Fan Pump
CentricleanerPressure Screen
Head BoxWire Part
Dis
pere
d Ro
sin
Catio
nic
Star
ch
PAC
Fille
rDefoamer
Refined pulp °SR:27 Pulp Cy :3.7%
Rosin: 22-25 kg/T PAC : 32 kg/T
Cato Starch: 3kg/TFiller : 110-250 kg/T
DefoamerAntimusol- BPI Liq: 1-1.2 kg/MT
Biocide
Rag ChestNew Mixing
Own PulpCoated broke
DumpChest
Circulation Chest
Brok
e
Tinting Dye & OBA
Tinting dye: Irgalite/MethylOBA : 2-2.5 kg/T
STOCK PREPARATION: PAPER MACHINE– 5
Circulation Chest
Rag Chest
Coated Broke
Virgin Pulp DDR
Mixing Chest
Machine Chest
SR Box
NewMixing Chest
DumpChest
TDR
To be Use as per requirement
Broke Chest-1
Broke Pulper
Broke Chest-2
STOCK PREPARATION: PULP REFINING – PM-5
Refiner MixingChest
MachineChest
SR Box Fan Pump
CentricleanerPressure Screen
Head BoxWire Part
Dis
pere
d Ro
sin+
PAC
Catio
nic
Star
ch
OBA
Fille
rDefoamer
Refined pulp °SR: 26Pulp Cy :3.7%
Rosin: 32 kg/TPAC : 34 kg/TOBA : 8-9kg/T
Filler : 225-235 kg/MT
DefoamerAntimusol- BPI Liq: 2-2.5 kg/MT
Biocide
HydraPulper
Own Pulp
New Mixingchest
Cir. Chest
Cato Starch:5-63kg/T
Brok
e
Imported PulpHydrex-P
Hydrex-P : 15-17kg/MTTinting Dye ; Irg. voilet
Tinting Dye
STOCK PREPARATION: PAPER MACHINE– 7
Circulation Chest
Virgin PulpCONFLOWREFINER
Mixing Chest
Machine Chest
SR Box
NewMixing Chest
Machine Refiner
Wood Pulper
Wood Pulp
Broke ChestBroke Pulper
STOCK PREPARATION: PULP REFINING – PM-7
M/C Refiner /TypeMotor drive, kw
Running load (A)
No Load Power KwHr
Net load KWHr
SELWsec/m
M/C 1
TDR-21"
3 x 3.5 x 12 250 180 60 120
1.17Bar angle = 10 deg
M/C 2
TDR-24"
2.8*3.3*8 350 320 140 180
0.79Bar angle = 10 deg
M/C 4
DDR-24" 2 x 3.2 x 6.3 300 300 110 1900.78
0SDMBar angle =
10deg
M/C 5
DDR-24" 4 x 8 x 8 x 30 250 200 120 80 0.6
TDR-21" 3 x 3.5 x 12 x 10 200 180 60 120 1.17
M/C 7
CONFLO 3.5 x 5 x 9 x 18 225 162 60 102 1.42
STOCK PREPARATION: REFINER DATA
MF Paper Machines PM-1,2,4,5 & 7MF Paper Machines PM-1,2,4,5 & 7
Dry Broke for cleaning & reuse
Wet Broke for reuse
Back water to fiber recovery SteamSteam SteamSteam
Starch + Size Press Starch + Size Press AdditivesAdditives
PROCESS PAPERMAKING : MF PAPER MACHINE
PROCESS OF PAPERMAKING: MF PAPER MACHINE
Machine PM-1 PM-2 PM-4 PM-5 PM-7
Make Charles Walsmey
Charles Walsmey
Escher Wyss
Alsthrom, Germanny
Karhula
Year 1936 1936 1960Renovated
in 2004
1984 1984
Speed, mpm 100 110 340 260 120
Deckle width, meter
3.12 3.12 3.12 2.24 2.73
Production, MT/day
30-35 20-50 68-100 55-60 28
GSM 70-95 58-190 54-149 80-185 70-100
PROCESS OF STOCK CLEANING: PM-4
Stock at Stuff box from Machine chest
Dilution of stock with back water in Primary Fan Pump
Cleaning at Primary Centricleaner
Screening at Pressure ScreenScreening at
Vibratory Screen
Head Box
Back Water
Reject Cleaning at Secondary
Centricleaner
Accept to Primary Fan Pump Suction
Cleaning at Tertiary
Centricleaner
Cleaning at Quaternary
Centricleaner ( fiber-mizer )
To Maloney filter
Reject
To Drain
Dilution of stock with back water in Fan Pump
Couch pit
Stock at Stuff box from Machine chest
Dilution of stock with back water in Primary centriclener
Screening at Primary Centricleaner
Screening at Pressure ScreenScreening at Vibratory Screen
Pope Reel
Back Water
Reject Screening at Secondary
Centricleaner
Accept to PCC
Pump Suction
Screening at Tertiary
Centricleaner
Screening at Fibermiser
To Drain
Reject
To Drain
Dilution of stock with back water in Fan pump
PROCESS OF STOCK CLEANING: PM-5
Stock at Stuff box from Machine chest
Dilution of stock with back water in Primary centriclener
Screening at Primary Centricleaner
Screening at Pressure ScreenScreening at
Vibratory Screen
Pope Reel
Back Water
Reject Screening at Secondary
Centricleaner
Accept to PCC Suction
Screening at Tertiary
Centricleaner
Screening at Fibermiser
To Drain
Reject
To Drain
PROCESS OF STOCK CLEANING: PM-7
Centricleaner:
Paper M/c 1 2 4 5 7
Primary 8 8 24 22 15
Secondary 3 3 8 7 5
Tertiary 1 1 4 1 1
Quaternary 1 1 1 1 1
Pressure Screen:
Paper M/c 1 2 4 5 7
Type Slotted Slotted Slotted Slotted Slotted
Slot Size 0.30 0.30 0.30 0.30 0.25
Pressure Screen
PROCESS OF PAPERMAKING
Machine 1 2 4 5 7
Head Box type Open OpenClosed
Air Cushioned
Closed Pressurized
Open
DistributorsSimple
ManifoldSimple
ManifoldTapered
FlowTapered Manifold
Tapered Manifold
Consistency 0.5-1.0 % 0.6-1.2 % 0.6-1.0 % 0.8-1.0 % 0.7-0.9 %
Freeness, °SR 40-42 40-42 40-42 34-36 40-42
Slice opening, mm
10 10 15 12-14 13
Slice width, mm 3350 3350 3400 2450 3000
No of slices 25 25 28 22 24
PROCESS OF PAPER MAKING: HEAD BOX
Machine 1 2 4 5 7
Breast roll diameter, mm
406 600 550 500 500
No of table Rolls 16 12 - - 4
No of Hydrofoils - - 17 50 9
Wet vacuum Boxes 2 2 2 - -
Dry vacuum Boxes 3 3 6 8 7
Vacuum Applied , mm of Hg
350 100-200 200-220 200 200
Couch roll Vacuum, mm of Hg
350 350 440-480 400-450 280-300
Couch roll Dia mm 762 762 762 650 618
PROCESS OF PAPER MAKING: WIRE PART
Machine 1 2 4 5 7
1st PressType Plain Plain Suction Suction Suction
Top roll Granite Granite Dyna rock Micro rock Granite
Bottom roll Rubber Rubber Rubber Rubber Rubber
2nd Press
Type Plain Plain Plain Plain Plain
Top roll Granite Granite Dyna Rock Micro rock Micro rock
Bottom roll Rubber Rubber Rubber Rubber Rubber
3rd PressType Offset Offset Reverse Offset Offset
Top roll Granite Granite Dyna rock Micro mate Miicro mate
Bottom roll Rubber Rubber Rubber Microrock Brass
PROCESS OF PAPER MAKING: PRESS PART
Machine 1 2 4 5 7
No of dryers 27 27 36 28 16
No of dryer groups
4 4 5 4 3
No of felt rolls
65 65 118 70 48
CondensateRemoval sissies
Bucket type
Bucket type
Bucket type
Siphon type
Buckettype
Syphon type Stationary Stationary Stationary Stationary Stationary
Hood Semi
closed Semi
closedSemi
closedSemi
closed Semi
closed
PROCESS OF PAPER MAKING: DRYER SECTION
Machine 1 2 4 5 7
Calendar
No of stacks 1 1 1 1 1
No of rolls 2 2 4 2 2
Size Press
Type Inclined Inclined Horizontal Horizontal Inclined
Movable roll material
Micro Rock
Micro Rock
Micro Mate
Micro Mate
Micro Mate
Fixed roll material
Micro Mate
Micro Mate
Micro Rock
Micro Rock
Micro Rock
Loading Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic
Paper feeding
Rope carrier
Rope carrier
Rope carrier
Rope carrier
Rope carrier
PROCESS OF PAPER MAKING: CALENDER & SIZE PRESS
Machine 1 2 4 5 7
Machine Wire 19.81 x 3.45 19.81 x 3.45 28.06 x 3.55 22.3 x 2.62 20.26 x 3.13
Pick Felt/ First Press Felt 10.36 x 3.55 10.36 x 3.55 16.50 x 3.65 10.5 x 2.65 12.0 x 3.10
Second Press Felt 10.36 x 3.55 10.36 x 3.55 16.50 x 3.65 11.2 x 2.65 12.0 x 3.10
Third Press Felt - - 16.50 x 3.65 - -
First top Dryer Screen 25.30 x 3.55 25.30 x 3.55 43.00x 3.55 27.0 x 2.65 16.0 x 3.10
First bottom Dryer Screen 25.30 x 3.55 25.30 x 3.55 - 27.0 x 2.65 16.0 x 3.10
Second top dryer screen 25.30 x 3.55 25.30 x 3.55 27.80 x 3.60 21.5 x 2.65 20.0 x 3.10
Second bottom dryer screen 25.30 x 3.55 25.30 x 3.55 27.80 x 3.60 21.5 x 2.65 20.0 x 3.10
Third top dryer screen 12.50 x 3.55 12.50 x 3.55 21.80 x 3.60 21.5 x 2.65 16.0 x 3.10
Third bottom dryer screen 7.00 x 3.55 7.00 x 3.55 21.80 x 3.60 21.5 x 2.65 16.0 x 3.10
Fourth top dryer screen 23.30x3.55 23.30 x 3.55 30.00 x 3.55 21.5 x 2.65 -
Fourth bottom dryer screen 23.30x3.55 23.30 x 3.90 32.00 x 3.60 21.5 x 2.65 -
Sixth top dryer screen - 35.00 x 3.90 29.90x3.60 - -
Sixth bottom dryer screen - 39.80 x 3.90 29.90x3.60 - -
Cooling Top Dryer Screen - - 12.50x3.60 - -
Cooling Bottom Dryer Screen - - 14.50x3.60 - -
Last dryer screen - - - 7.5 x 2.65 7.5 x 3.10
PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METER
Thanks
PROCESS OF PAPER MAKING: PAPER MACHINE
Details M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7Make Charles Wamsley Charles Wamsley Esser Wyss Alstom Karhula KarhulaYear Of Installation 1926 1926 1983 1983 1983Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st FloorProduction (Tpd) 30 40 75 47 1.8 27Machine Speed(Mpm) 100 110 350 270 60 115Machine Deckle(C.M) 314 314 311 223 210 272Draw Open Open Open Open Oen OpenApproach Flow System Machine Refiner Type TDR/21” TDR/24” DDR/24” DDR/24”&TDR/21” Conical,Beater ConfloPressure Screens No. 1 1 2 1 0 1Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1No.of Bottles in1st Stage 8 8 24 22 3 15
In 2nd Stage 3 3 8 7 5In 3rd Stage 1 1 4 1 1In 4th Stage 1 1 1 1 1
Head Box
Type Open OpenClosed air
CoushionedClosed
Pressurized Open open Dandy Roll Yes Yes Yes Yes No YesDia.of Dandy (mm) 330 330 1000 800 500Press Part Ist Press Type Solid Solid Suction Suction Solid Suction2nd Press Type Solid Solid Solid Solid Solid Solid3rd Press Type Reverse Reverse Reverse Smoothening SmootheningDryer Section Total No. of Dryer Cylinders 27 27 36 28 10 16Dryer Groups (Steam Wise) 4 4 6 4 3 3No. of D/Cy.In Pre Dryer 19 19 24 20 10No. of D/Cy. In Post Dryer 8 8 12 8 6Cooling Cylinders No No Yes No No NoNo. of Cooling Cylinders 2 Size Press Type Inclind Inclind Horizontal Puddle type Puddle typeSteam System Conventional Conventional Conventional Conventional Conventional ConventionalCondensate Removal System Bucket Bucket Bucket Siphon Bucket BucketType of Calender Kuster Kuster Kuster Kuster KusterPope Reel Inclined Inclined Horizontal Horizontal Horizontal