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					          West Coast Paper Mills
Welcome IPPTA Members in Annual Seminar at
                  Chennai
           on 7th & 8th March'13
         Green production technique
 As a responsible corporate, WCPM’s commitment to cleaner
 environment is reflected in its ‘minimum impact-best process’
 technology adopted across the mill operation. Green
 production, resource conservation, and a reduced pollution
 loads at every stage makes WCPM one of the most
 environmentally compliant paper mills in the country.
 Features Of ECF Fiberline
The company’s investment in a
brand new 725 TPD (Bleached
Pulp) Metso fiber-line, has
replaced the old unit with eco
friendly elemental chlorine–free
(ECF) bleaching process.

This has enabled to produce
consistent quality of high-bright
and hi-strength pulp with improved
cleanliness & also reduced load
on effluent.

The high degree of bleaching has
improved the optical properties of
paper.
      Capacity & Suppliers of Plant

                     a c i TD
                     p t
                    C ai yn P
               r xas
                e     o   o xas
                           s
               P epni n P tepni no
                   P
                  TD         TDP
h pr o e
  i
CpeH su            00
                  10          00
                             30
 o i
   on
C kg               3
                  30          0
                             80
 a i &c n
   sn    e n
W h g sr ei g      3
                  30          0
                             80
 x e dlgi ct n
   y   i f i
O gn e ni ao                  0
                             80
l ci
 e n
Bah g              3
                  30          2
                             75
lO
C2                 4          15
 x e
  y
O gn                          24

l n a ny
 a  c r
     h
P tM i a             u le
                      pi
                     Sp r
h e a ula
 i r d x i
 p          e
C ps na ii r s   MVoaG a
                 / e pn e n
                  S cl   m
                         r y
neqpes fo i r e / e ,S d
 t
 i  u n
Er e i mt o fFen MM o wa
              bl
               i    s
                  S t  en
l p t
 O a
C2l n            / H I i
                  S D na
                 MU E d
x nN e l t
 yg    to n a
O e&ir g pn      MM E i ei g ei
                 / V nn r ,D
                  S S g e n  lh
          Projects benefits Achieved

State of art Washing & screening
    Cleaner pulp
Reduction in
    Power consumption
    Alkali loss
    Black liquor evaporation load
    B.O.D. and C.O.D.
    Specific water consumption
    Less manpower
Oxygen delignification & ECF bleaching
   Improved pulp strength
   Environmentally free
   Reduced AOX to effluent
   Reduced bleach chemical consumption
 Journey through Fiberline at WCPM
                                      Paper
                                      machine




Wood
yard

                        Fiberline

            Cooking



                       Chipper house :
                       Wood handling
                       and chips preparation
    Pulping Raw Material at WCPM


WCPM is using Hard wood as Raw material

Varieties of Hard wood being used

 Eucalyptus
 Casurina
 Subabul
 Acacia
                       Chipper House




 Mechanized Feeding system by Grabber loader
 Log washing system
            LOG WASHING SYSTEM




                        Wash water

 To wash out impurities such as sand, mud and loosely
  adhered bark from logs to prevent erosion of
  equipment
 Reduce Non Process Element coming into system.
 To Improve pulp quality specially dirt due to external
  resin carried over with logs.
 Log Washing




             Loose Bark



Wash water
                          Vecoplan Chipper




 2 New Drum chippers with Auxiliaries Chip screen & rechipper, supplied by
  Vecoplan Germany.
 Each Chipper capacity 50 T/hr
         Vecoplan -Chips screen




Capacity – 50 T/hr
WOOD CHIPS
                     Chips Silo




                                   200 T     400 T

                      600 T




Chips storage/Silo            Total compartments -3 Nos.
Capacity- 1200 T
 Journey through Fiberline at WCPM
                                       Paper
                                       machine




Wood
yard

                           Fiberline




            Digester house :
            Super Batch cooking
Super Batch Cooking
       Combined Chip and Impregnation Liquor Filling




   Circular steam packing configuration to minimize void spaces
   Black liquor impregnation occurs at a temperature below 100 deg C.
   Low alkali - neutralizes wood acidity.
   Liquor has high sulfidity.
                      Hot Liquor Filling




 Hot black liquor displaces impregnation liquor, then hot white liquor
  is added
 Energy saved by conserving heat from previous cooks within hot
  black liquor
                   Heating and Cooking




 Liquor re-circulated for uniformity’s sake.
 White liquor may be added during cook to control alkalinity and final
  fiber quality.
                     Digester Displacement




 Used cooking liquor is displaced by wash liquor into accumulators
  for use in later cooks.
                          Discharge




“Gentle Blow”
 Pulp is well below 100 degrees C at this point.
 Digester is emptied with a centrifugal pump.
   Reduce strength loss
Chips Transportation to Super Batch Digesters




          Four sets of Chips extraction screws
          Each set consists of Two screws.
          Capacity of each set – 360 T/hr
Chips Transportation to Super Batch Digesters




              Chips conveyors
                Fiberline – Super Batch Cooking




 Metso supplied Super batch cooking technology with 4 x 400 m3
 capacity digesters.
 In each batch 150 – 160 Tons of chips at 38-45 % moisture is converted to
  42 tons of unbleached pulp
 Super Batch cooking process in the new fiberline facilitate to produce
  superior pulp quality imparting extra strength to the paper the much needed
  for functional superiority at the end user point.
Fiberline – Super Batch Cooking




      Auxiliary tanks required for Super Batch
      cooking Liquor control
 Journey through Fiberline at WCPM
                                           Paper
                                           machine




Wood
yard



       Cooking
                               Fiberline



                  Hot Screening
                  Washing &
                  Oxygen Delignification
Purpose of Screening of Pulp
         Screening Stages


 Coarse screening of pulp
 Fine screening of pulp
 Screening of reject
 Screening for separation of sand and
  Plastics
     WCP global deknotting and Screening system
                                                                                      TRPA-1540
                                   3ary knotter
                                   KFA-50




          Junk trap                                                                    Tail
                                                                                      screen
                                                                                      TS-50
                                                     D4 2ary   FS-40 3ary
                                                  fine screen fine screen
                                                                                               Screw
                                                                                               press




Pulp                                                           Sand
LC tank                                              Delta     cleaner           Liquor
                                                   thickener                         +
                                                                                  fibers




             DeltaCombi       K4 2ary knotter


                      Deknotting                                     Fine screening
SCREENING EQUIPMENT
Hot Screening at WCPM




 Four stage Hot Pressure screening
   with slotted basket 0.3 mm.
     Coarse Reject Handling




Coarse reject/knots are being stored in small bin
& fed back to digester at the time of chip charging
   Fine Reject Handling




Fine rejects +0.3 mm is being handled through
screw press to avoid Black liquor carry over
It is fed back to digester while chips charging
                     Washing & Oxytrac


      MP Steam
      Caustic                                          Hot water

TRPA-1540       TRPB-1532
                            OxyTracTM    TRPB Z-1532
                       Washing




 State of art New Brown stock washing with Press
  washers.
 Two stage washing with Twin roll press
 Reduction in Carry over of chemical
Oxygen Delignification

               Two stage Oxygen
               delignification has
               resulted 40 % reduction
               in Bleach chemical
               consumption.

               Reduction in color of
                effluent
 Journey through Fiberline at WCPM
                                         Paper
                                         machine
                             Fiberline




Wood
yard




                        Fiberline
            Cooking



                      Bleaching
         Bleaching general simplified flow diagram
O2                              DHT EOP (DnD)
H2O2
NaOH
 H2SO4
 ClO2

                   SO2                                   SO2

                                EOP              D   D
             DHT




                                                     Hot water
              Acid               Alkaline
              195 m3/h           133 m3/h            LP Steam
              84°C               84°C
              17,3 kg COD/adt    10 kg COD/odt
                         Fiberline-Bleaching




 Bleach plant with Dhot-EOP-DnD sequence
 An online kappa analyzer (Kajaani brand) is installed with sampling ports
  at three locations to control the chemical dosing and enable controlled
  bleaching with lesser chemicals
 3 nos. of Twin wire roll presses in bleaching
 89-90 O Brightness & +7.5 viscosity
            Features Of 4th Generation Press




Easy to operate and run
Can handle a large turn down ratio
A safe & reliable washer even under upset conditions
Ease of maintenance
Automatically adjusted process seals (water or air)
Low power consumption
Bright Pulp after ECF Bleaching
                          Fiberline Control Room




 Trained staff and operators to operate plant
 All process control is controlled & monitored from Control room.
                                  Best Practice -1
                               Hot liquor Impregnation
Schematic diagram for
Hot liquor impregnation for Dig.no. 3

                                                                             is la e e t
                                                                            D p c mn
                               la k u r o le
                              B c liq o c o r                                   Tnak

                                                   4 26
                                                  2 .1 1
                  400mm dia



                                                                    0 m
                                                                   3 0m
                                                                    no
                                                                   O - ff
                                                                    a e
                                                                   v lv




                                                       350mm dia
                                       T d .N.3
                                        o ig o
                                                                     9 - 20
                                                                      09 C
                                                                      la k u r
                                                                     B c liq o


                                         0 m ia
                                        4 0m d
                               no
                              O - ff
Ws P s 1
 a h re s                      a e
                              v lv
 ak a r
B c w te
    ak
   Tn
                                 2 26
                                3 .1 1
                                 = 2 m /h
                                Q 90 3 r
                                H=2 M5
        Chips Impregnation with Hot liquor impregnation



 Feed Temperature of B.L In normal process of impregnation is 83-84 OC.
  This was increased to 92-93. by doing line modification as shown in
  Schematic diagram.Trial of Hot Black liquor impregnation for Dig. No. 3
  was taken in July’12.
Followings are the observations and findings :
 During ILF temperature gain is about 8-10 degree C
 After Hot liquor fill equalization temperature is raised by 6-8 degree C
 Total cycle time is reduced by 8- 10 minutes
        Process parameters with Normal impregnation of Black liquor


                                                     HLF Equal. Heating         Cycle
       AD Chips                 Temperature
                                                    Volume Temp. Time           Time
Cook
                  Species                After 10
 No.                                                         o
        Tons                 After ILF   Minutes     M3          C   Minutes   Minutes
                                         Circuln.
  5      163        Mix         83          76       262    147       100       285
  9      162        Mix         84          76       265    149        93       281
 13      161        Mix         83          77       260    139       102       288
 17      164      Casurina      84         76        254    142       104       291
 21      181      Casurina      84         73        241    137       119       295
 25      168      Casurina      83         77        262    146       109       294
 29      164        Mix         84         75        235    138       110       304
 33      169        Mix         83         76        261    143        98       289
 37      171      Casurina      84         76        255    142       102       296
 41      172      Casurina      83         75        286    144        96       281
AVG     167.5                  83.5       75.7      258.1   142.7    103.3     290.4
            Process parameters with Hot impregnation of Black liquor



                                                    HLF     Equal.   Heating   Cycle
           AD Chips             Temperature
                                                   Volume   Temp.     Time     Time
Cook No.              Species
                                        After 10
                                After                        o
             Tons                       Minutes     M3           C   Minutes Minutes
                                 ILF
                                        Circuln.
  276        136       Mixed    95         87       234      152       31       278
  280        159      Casurina  92         85       288      154       24       272
  284        143       Mixed    91         88       236      147       48       281
  288        135       Mixed    92         87       241      150       33       275
  292        146       Mixed    94         91       255      149       35       278
  296        141       Mixed    94         88       290      151       23       265
  300        147       Mixed    94         88       290      149       38       274
  304        160       Mixed    94         83       241      146       44       297
  312        150       Mixed    92         85       240      152       35       300
  316        144       Mixed   94.84       85       237      154       26       281
  AVG       146.1              93.28     86.7      255.2    150.4     33.7     280.1


                                         75.7               142.7              290.4
                     Best Practice -2
               Specie wise separate cooking

 In most of the mills, wherever the raw material is more than one
  specie, it is normal practice to do mixed cooking.
 Every specie of wood has different characteristics. Hence cooking
  chemical requirement and yields are different.
 At WCPM also initially mixed cooking was started. Separate cooking
  was started by storing in three compartments of silo,
 On an average cooking was done in following pattern as below:


Clonal + Debark EC + Acacia ( Debark) ---- 55 % 10-11 Cooks/day
Casurina ---- Bark --------------------------------- 35 %      6-7 Cooks/day
Subabul--- Bark     ---------------------------------- 10 %   1-2 cooks/day
                               Data with Mixed cooking
 Process Parameters             Sep-11   Oct-11   Nov-11 Dec-11   Jan-12   Feb-12    Mar-12
 AA %                            21.22    21.29    21.59  22.13     20.9    21.02     21.14
 AA KG/TON ub pulp              459.49   454.84   467.01 474.57   449.52    450.5    454.16
 Raw Material/ Bleached pulp      3.99     3.88     3.98   4.03     3.68     3.92      3.94
 WBL solids                       2.19     2.19     2.27   2.24     2.19     2.18      2.17
 Discharges                       500      471      456    458      503      489       502
 Discharges/day                  16.67    15.19     15.2  14.77    16.23    16.86     16.19
 BL pulp                        19755    18644    18002 18091     19909    19320     19809
                               Data with Separate cooking
 Process Parameters               Apr-12    May-12 Jun-12     Jul-12   Aug-12       Sep-12
 AA %                              19.79     20.06  20.25     21.47     20.71        21.1
 AA KG/TON ub pulp                424.97    430.78 426.62     455.9    438.77       447.28
 Raw Material/ Bleached pulp        3.77      3.93  3.794     3.764     3.738         3.8
 WBL solids                          2.2      2.17   2.16      2.17      2.08        2.08
 Discharges                         362       535    495       498       500         492
 Discharges/day                    12.07     17.26   16.5     16.06     16.13        16.4
 BL pulp                          14331     21087 19998       20131    20206        19893
 Observations on separate cooking of species in April’12:
 Overall cooking chemical (Active .Alkali.) was reduced 1. -1.2 % on B.D.
  chips basis ~ 30 -40 Kg/Ton of Bleached pulp.
 Cooking was more uniform than earlier due to separate cooking % rejects have come
  down 31 Trips/day to 19 Trips/day ~ 35-40 % reduction.
 Raw material /ton of Pulp was reduced
 Because of A.A. charge reduction, Steam generation in soda recovery was improved.
                              Best Practice -3
                Reduction of fiber going with tertiary rejects
In the Screening system, fine rejects from tertiary screen is processed through tail
screen to recover the fiber and rejects are finally pressed in screw press and
collected in trolleys to feed back along with chips during chips charging. Due to
inadequate capacity of screen dilution pump, fiber going with the reject was as high
as 35-40 %. Separate pump was installed exclusively for coarse screen and tail
screen. This has reduced the fiber content to 19-20 %

                                                                        Screw Press
                                          Sl No    Particulars   Unit
                                                                           rejects

                                            1     Moisture        %        63.7
Screw press rejects analysis                2     Ash             %        14.4
before putting separate dilution pump       3     Fiber           %        37.7
                                            4     Rejects         %        37.4
                                            5     Silica          %         0.4


                                                                        Screw Press
                                          Sl No    Particulars   Unit
                                                                           rejects
 Screw press rejects analysis
                                            1     Moisture        %        69.5
 after putting separate dilution pump
                                            2     Ash             %         16
                                            3     Fiber           %        19.4
                                            4     Rejects         %        54.7
                                            5     Silica          %        0.1
                       Best Practice - 4
  Reduction of Fiber in Brown stock Press 1 back water tank


 In the original system, pulp leakage from longitudinal seals was going
  to BSW press 1 back water tank.
 In practice, vat pressure of BSW 1 press is always high than Press 2
  & 3 due to more solids. This caused more leakage of pulp from
  longitudinal seals and increased fiber content in Black liquor. This has
  also affected filtering capacity of Black liquor filters.
 This has increased load on Liquor filter. Line modification was carried
  out to take this fiber in to the Press 1 stand pipe. This has reduced the
  fiber content from 600 ppm to 200 ppm
   Best Practice -5
Feed forward screening
              Advantages of Feed Forward screening

 Conventionally screening system is supplied as cascade system where
  the accept of the forward stage is recycled back.
 Feed forward screening is the screen room configuration where accept
  from the secondary screen is combined with the accepts from primary
  screen, instead of cascaded.
Benefits of Feed Forward are :
 Rate of screening increases by 8 - 10 %
 Hydraulic load on Primary screen/delta reduces.
 Reduction in fiber going along with reject.
 Based on the envisaged benefits Rate of screening increased from 32 T
   to 34.5 T/hr
                          Best Practice -6
                       Online Kappa Analyzer

  Our requirement : Higher brightness with Stable pulp Quality

                                                        Simply apply
Achieving higher brightness is an easy task.            excess chemical


                                                    Easy bleachability



Alternatively maintain low Kappa.

                                                  Pulp viscosity & Pulp
                                                     Strength is low




 Solution                           “KAJAANI Kappa Q”
                                     New Kajaani On line Kappa Analyzer
Metso Kappa Q analzer installed at WCPM have the following highlights:


Three sampling points with one analyzer to save cost. (models available up
   to six points)
 The proven Kappa and brightness measurements online
 Measurement capacity alternatives: 10, 20, 30 or 40 per hour
 Compact size
 Cost effective sampling arrangement
 New interfacing for high availability
     Chemical consumption prior to Kappa analyzer control April’11-Aug’11
                                                              v e
                                                               e
                                                               r
                                                              Aga
lo
SN   hc
      e l
      m
     C ia           A1
                    pr
                     -1      a
                             M 1 J-
                              y
                              -
                              1   n
                                  1
                                 u1               ul1
                                                   -
                                                  J1       A1 A'1
                                                           u1 p -
                                                            g
                                                            -  r1
                                                               il
                                                              ug
                                                              A1'1
  hn i x
   lr D ie
   o
1 Ci e Od           10
                    96
                     .        9.
                               5
                              18        16
                                        88
                                         .        9.
                                                   6
                                                  14        18
                                                            95
                                                             .        9.
                                                                       4
                                                                      15
  a t e ig
   OBh
   H   c
2 N al an           13
                    58
                     .         6
                               13
                                .        1
                                         76
                                          .        7
                                                   13
                                                    .        1
                                                             51
                                                              .       6.
                                                                       4
                                                                      14
  S
3 H4
  2O                0.
                     5
                    23        27
                              0.
                               1        2.
                                        25
                                         7        9.
                                                   5
                                                  19        21
                                                            16
                                                             .        09
                                                                       .
                                                                      23
 O
4H
 22                 2.
                     5
                    15         9
                               9
                               .2       25
                                         .
                                        13        0.
                                                   4
                                                  13        12
                                                            06
                                                             .        12
                                                                       .
                                                                      11
 xe
 yg
5O n                7
                    26
                     .
                     8        8.
                               0
                              27         7
                                         2.
                                          9       8.
                                                   6
                                                  27        7
                                                            20
                                                             .
                                                             5        8.
                                                                       0
                                                                      20


     Chemical consumption after Kappa analyzer control Sept’11- March’12

                                v '1
                                 A -
                                 u
                                Ag 1
lo
N
S    Ci l
     hc
     ea
      m  e O
         p-1 t1N1 D1J1 F 2M
         S1 c -
              1 o
                v-  c
                  1 e1 a2 e
                     - n- b1 a
                           - -1
                             r2
                                a'2
                                 r
                                 c
                                M1h
 h eO
 lr Dd
  oi
1Cni x   8
      ie 18 1
          .
          1  78 14 17 16 11 1
              . 74
                 .  7
                    .5 .
                       7  .
                        7 78 7
                             .6  7
                                 .
                                147
 a t la
 OBh
  H c  n 4
2N ae ig 1.5 1
             34 18 18 14 13 18 13
              . 29
                 .  4
                    .4 .
                       3  .
                        9 40 5
                             .
                             5   .
                                 41
 S
3HO
 2 4     99 7
          .  .7 73
                 .  6
         13 18 18 12 19 18 19 15
                    .3 .
                       64 6
                          .6 8
                             9
                             .   .
                                 76
 O
4H
 22              .
                 0 0.
                    3 .
                0
                15 17 89  8 11 9
                        1 8
                          .  8 .
                             .
                           8 0     .
                                   9
                                8 15
                                 9 0                                   .
                                                                       998
 x
 yg
5One            4
                25 23 26 25 28 26 27
                 .
                 1 50
                    . 48
                       .  6
                          .1 .
                             0 7
                             7  2
                                .  6
                                   .
                                   2                                   5.
                                                                        8
                                                                       23
                        Benefits of Online Kappa Control


                                          v ae
                                           e
                                          A rg
                                                        v g1 a n
                                                         A' -  v s
                                                        A u1 S i g
   lN
   S o             Cml
                   h ia
                    e c                   pl1
                                           r  -
                                          Ai' 1
                                                         ah
                                                         r 1  go
                                                               / n
                                                        Mc' 2 KT
                                           u1
                                           g
                                          A'1
      1      h i D x
              l n
              o      i
                     d
             C r e iO e                   14
                                           95
                                            .               74
                                                             .
                                                            17            .7
                                                                          11

      2      a a l cn
              O   e h
             N HtBa i g                    14
                                           64
                                            .               43
                                                             .
                                                            11            .3
                                                                          21

      3      HO
             2S4                            .
                                           03
                                           29               75
                                                             .
                                                            16            .2
                                                                          38
      4      H2
             2O                             .
                                           11
                                           12               .9
                                                            98            .2
                                                                          13
      5      x e
              y n
             Og                            20
                                           80
                                            .               53
                                                             .
                                                            28            .1
                                                                          27
The benefits achieved by WCPM for installing online kappa analyzer are as follows :
Chemical consumption reduction of 8% in ClO2 and 8% in H2O2.
 3 -4 kg/ton of ClO2 as active chlorine
 1.5 kg/ton of H2O2
 2 kg/ton of caustic
 Reduction in cost of production of bleached pulp ~ Rs. 120 – 130 /Ton
Now we are all together in the same boat
THANKS FOR PATIENT HEARING

				
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