All about paer making process at India's no 1 Paper making company Balla

1. BALLARPUR INDUSTRIES LIMITED
UNIT – SHREE GOPAL
Paper Making Process

2. PAPER MAKING PROCESS

3. RAW MATERIALS USED
Veneer : 40-45% Bamboo : 15-18%
Consumption 325 TPD Consumption 90 TPD
Euca. Wood : 35-40%
Consumption 175 TPD

4. FLOW DIAGRAM OF PAPER MILL
Raw Pulp Paper Paper MSD
Chipper Mill Machine Finishing Godown
Material
Chemical Dispatch
Recovery
Chemical
Complex
Effluent Costing
Engg Water Power QC/ Purchase
Treatment HR &
Maintenance Supply Plant R&D & Store
Plant Finance

5. PULP MAKING PROCESS
Steam for Power
White Liquor

6. PULP MILL
Chipper House
Chipper Make Capacity Raw mat.
no. (MT/h) handling
1 Vecoplan No. 1 25 Woodlogs/
Bamboo
2 Vecoplan No. 2 15 Veneer waste
Chipper
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 Digester

7. PULP MILL
Wash Plant
Rotary Drum Vacuum Washer: : 4 Stages
Capacity :195 BD Pulp per day
Hot Water & Foul Washer
Condensate
Washer
Defoamer
dosing at
inlet line of
BSW-1 Filtrate Filtrate Filtrate
Weak Black
Liquor to
Recovery
Unbleached Pulp
Drum Washer Filtrate

8. PULP MILL
Bleach Plant
Conventional bleaching process
Capacity : 180 BD pulp per day
Bleaching sequence : CDEOPD1D2
Centricleaner : 4 stage
Pulp brightness(ISO) : 89-90 %
UN BLD
PULP EO
FROM B/W
D2
Bleach towers
W/P DI
C/D B/W NaOH B/W
D1 B/W D2
M/C EO D2
No.4 H/W B/W H2O2 H/W B/W D1 B/W B/W DECKER
B/W B/W B/W
DECKER
UN H/W EO B/W
BLD 58 Eop LP
LP M3 PRE LP
C/D TUBE STEAM
400 M STEAM D1 STEAM
3
80M3 CD 156 EO
D2 D2
D1
M3 250 250
CENTRI -
CLEANING
M3 M3 MILL
H.MIXER WATER
H.MIXER H.MIXER
C/DMC EO MC
MIXER FILT MIXER FILT. D1 MC D2 MC
TANK TANK MIXER FILT. FILT. MILL
O2 MIXER
TANK TANK WATER
C/D MC EO MC PUMP EO EO STOCK
PUMP PUMP DI MC DEC
B/W PUMP D2 MC PUMP
KER
Cl2 ClO2
ClO2
ClO2 Storage FILT.
TANK DECKER
tower MC PUMP
To ETP To ETP
Paper m/c

9. 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 %
Evaporator 2
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
Recovery Boiler
No of Boiler : 2
- JMW
- ABL
Total capacity : 315 TPD solids

10. 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

11. PROCESS OF PAPER MAKING – STOCK PREPARATION
Optical Whitener
Fiber
Sizing Chemicals
Recovery
Tinting Dyes
System
Power
Broke
Filler
HD tower Pulp Functional Approach
Pulp Paper
Bleached Receiving Additives flow
Refining Machine
pulp Chest addition system

12. PAPER MACHINES
Machine Type Make Deckle Speed GSM Production Paper grades
No. cm m/min. range TPD
REB
Charles
1 MF 314 100 60-90 30 Super Printing
Wamsely
Lky Parchment
S/L Bond
Charles 58- Super Printing
2 MF 314 115 40
Wamsely 190 Super
Cartridge
Bilt Classic
Esser 54- S/L Offset
4 MF 311 350 75
Wyss 149 S/L
Cartridge
60- MMPP
5 MF Alstom 223 270 50
124 BCB Base
REB Normal
70-
7 MF Karhula 272 120 27 REB Colored
100
Criss Cross
All machines are equipped with size press.

13. PAPER CONVERSION
Reel
Orders
Sheet
Orders

14. PROCESS PAPER CONVERSION & FINISHING REWINDER
PM-1 Jag PM-2 Jag PM-4, Beloit PM-4, Masson
Rewinder Rewinder Rewinder Scott
Max reel capacity 5 5 5 5
Speed in mpm 400 400 600 500
Beloit Rewinder Masson Scott Rewinder

15. 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

16. EFFLUENT TREATMENT PLANT
Three stage Effluent Treatment Plant Installed
and Commissioned in 1987
-Activated sludge process
-Design Capacity: 54000 m3/day
-Operating Capacity: 28000 m3/day
Data showing the compliance to environmental norms
PARTICULARS UNIT INFLUENT HSPCB TREATED
NORMS WATER
EFFLUENT 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

17. PAPER MAKING PROCESS
• Pulp Supply System
• Stock refining
• System cleaning
• Approach Flow system
• Paper making- MF

18. PROCESS FLOW: STOCK PREPARATION (PM 1,2 & 4)
Pulp from Bleached Dry broke
Stock Chest through pulper
Buffer Chest Broke Storage
Refining of Stock through
Broke Cleaning System
Refiners in Refined Chest
Tinting dyes/ pigment preparation
Optical whitener preparation Mixing Chest Cleaned Broke Tower
PAC: Poly Aluminum Chloride
Wet Broke from
Filler/Dispersed Rosin/ Fill Plus Machine Chest respective M/C
SR Box
Fan Pump
Centricleaner
Filler Slurry
Percol-47 Preparation system
Pressure Screen
Hydrocol- RK2 Preparation system
Head Box

19. PULP SUPPLY SYSTEM (PM 1,2 & 4)
1000 m3
Bleached Thickener
Machine back water
(Krofta/Disc filter Pulp
filtrate) for bottom
dilution
Buffer
Chest
To Refiners of PM 1, 2 & 4

20. STOCK PREPARATION: PAPER MACHINE-1
Pulp from Buffer
Dispersed Rosin
Tinting Dye
Fill Plus
Chest
PAC
Filler
Mixing Machine
Refiner SR Box Fan Pump
Chest Chest
Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 13-16 kg/MT
Pulp Consistency:-4.0% Violet PAC : 17 kg/MT Filler: Finex/CaCO3
Defoamer Biocide
Pressure
Wire Part Head Box Centricleaner
Screen
Defoamer
Afranil ST – 0.5 kg/MT

21. STOCK PREPARATION: PAPER MACHINE-2
Pulp from Buffer
Dispersed Rosin
Tinting Dye
Fill Plus
Chest
PAC
Filler
Mixing Machine
Refiner SR Box Fan Pump
Chest Chest
Refined pulp °SR: 28-30 Tinting Dye: Iraglite Fill Plus: 1.0 kg/T Rosin: 10 kg/MT
Pulp Consistency: 4.0% Violet PAC : 17 kg/MT Filler: Finex/
Defoamer Biocide
Pressure
Wire Part Head Box Centricleaner
Screen
Defoamer
Afranil ST – 0.5 kg/MT

22. STOCK PREPARATION: PULP REFINING – PM-1&2
TDR 21” &
NPM Pulp DDR 20”
Machine
Refiner
Mixing Machine SR Box
Chest Chest
Buffer
Chest Not in operation
Paper Machine-1
TDR 24”
NPM Pulp
Machine
Refiner
Mixing Machine Chest SR Box
Chest
Buffer
Not in operation
Chest
Paper Machine-2

23. STOCK PREPARATION: PAPER MACHINE– 4
Pulp from Buffer
Dispersed Rosin
Tinting Dye
Fill Plus
Chest
Filler
OBA
PAC
Mixing Machine
Refiner SR Box Fan Pump
Chest Chest
Refined pulp °SR: 28-30 Tinting Dye: PAC : 25 kg/MT
Pulp Consistency: 4.0 As per Quality Fill Plus: 2.3 kg/MT
OBA: 2.5 kg/MT
Rosin: 10 kg/MT
Pressure
Wire Part Head Box Centricleaner
Screen
Defoamer
Afranil ST 0.5 kg/MT

24. STOCK PREPARATION: PULP REFINING – PM-4
DDR-1
Measuring Mixing/ SR Box
Virgin Pulp
Tank Machine
Chest
Buffer Refined
Chest Pulp
Chest
Broke
Broke
Chest

25. PROCESS FLOW : STOCK PREPARATION – PM-5&7
Pulp from Pulp Mill Dry broke through
pulper
Tinting dyes/ pigment
New Mixing Chest
Broke Chest-1
Optical whitener
Refining of Stock through
Refiners Broke Chest-2
PAC: Poly Aluminum Chloride
Mixing Chest
Dispersed Rosin
Filler Slurry Machine Chest
Cationic tarch SR Box Wet Broke from
respective M/C
Fan Pump
Centricleaner
Pressure Screen
Head Box

26. PULP SUPPLY SYSTEM: PM- 5&7
500 m3
Bleached
Pulp
Machine back water
for bottom dilution To PM-5 & 7
Stock Prep.

27. STOCK PREPARATION: PAPER MACHINE– 5
Tinting Dye &
OBA Coated broke Own Pulp
Circulation Dump New
Chest Chest Rag Chest
Mixing
Tinting dye: Irgalite/Methyl
Dispered
OBA : 2-2.5 kg/T
Cationic
Rosin
Starch
Broke
Filler
PAC
Refiner Mixing Machine SR Box Fan Pump
Chest Chest
Refined pulp °SR:27 Rosin: 22-25 kg/T PAC : Cato Starch: 3kg/T
Pulp Cy :3.7% 32 kg/T Filler : 110-250 kg/T
Defoamer Biocide
Pressure
Wire Part Head Box Centricleaner
Screen
Defoamer
Antimusol- BPI Liq: 1-1.2 kg/MT

28. STOCK PREPARATION: PULP REFINING – PM-5
Coated Broke
Virgin Pulp DDR TDR
Rag New
Chest Mixing Dump Circulation To be Use as per
Chest Chest Chest
requirement
SR Box Machine Mixing
Chest Chest
Broke Broke Chest- Broke Chest-
Pulper 1 2

29. STOCK PREPARATION: PAPER MACHINE– 7
Tinting Dye
Hydrex-P Imported Pulp
Own Pulp
New Hydra
Cir. Chest Mixing Pulper
chest
Hydrex-P : 15-17kg/MT
Rosin+PAC
Dispered
Tinting Dye ; Irg. voilet
Cationic
Starch
Broke
Filler
OBA
Refiner Mixing Machine SR Box Fan Pump
Chest Chest
Rosin: 32 kg/T
Refined pulp °SR: 26 Filler : 225-235 kg/MT Cato Starch:5-63kg/T
PAC : 34 kg/T
Pulp Cy :3.7%
OBA : 8-9kg/T
Defoamer Biocide
Pressure
Wire Part Head Box Centricleaner
Screen
Defoamer
Antimusol- BPI Liq: 2-2.5 kg/MT

30. STOCK PREPARATION: PULP REFINING – PM-7
Wood Pulp
Wood
Pulper CONFLOW
Virgin Pulp REFINER
New
Mixing Circulation
Chest Chest
SR Box Machine Machine Mixing
Refiner Chest Chest
Broke Broke Chest
Pulper

31. STOCK PREPARATION: REFINER DATA
Motor No Load
Running Net load SEL
M/C Refiner /Type drive, Power
load (A) KWHr Wsec/m
kw KwHr
3 x 3.5 x 12 250 180 60 120
M/C 1 TDR-21"
Bar angle = 10 1.17
deg
2.8*3.3*8 350 320 140 180
M/C 2 TDR-24"
Bar angle = 10 0.79
deg
DDR-24" 2 x 3.2 x 6.3 300 300 110 190
M/C 4
0.78
Bar angle =
0SDM
10deg
DDR-24" 4 x 8 x 8 x 30 250 200 120 80 0.6
M/C 5
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

32. MF Paper Machines PM-1,2,4,5 & 7

33. PROCESS PAPERMAKING : MF PAPER MACHINE
Dry Broke for cleaning & reuse
Wet Broke for reuse Starch + Size Press
Additives
Back water to
fiber recovery
Steam Steam

34. PROCESS OF PAPERMAKING: MF PAPER MACHINE
Machine PM-1 PM-2 PM-4 PM-5 PM-7
Make Charles Charles Escher Alsthrom, Karhula
Walsmey Walsmey Wyss Germanny
Year 1936 1936 1960 1984 1984
Renovated
in 2004
Speed, mpm 100 110 340 260 120
Deckle width, 3.12 3.12 3.12 2.24 2.73
meter
Production, 30-35 20-50 68-100 55-60 28
MT/day
GSM 70-95 58-190 54-149 80-185 70-100

35. PROCESS OF STOCK CLEANING: PM-4
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Back Water Primary Fan Pump Accept
to
Reject Cleaning at
Primary
Cleaning at Primary Centricleaner Secondary
Fan
Centricleaner
Couch pit Pump
Suction
Dilution of stock with back water in
Fan Pump Cleaning at
Tertiary
Reject Centricleaner
Screening at
Vibratory Screen Screening at Pressure Screen
Cleaning at
Head Box
Quaternary
Centricleaner
To Drain
( fiber-mizer )
To Maloney filter

36. PROCESS OF STOCK CLEANING: PM-5
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Back Water Primary centriclener Accept to
PCC
Reject Screening at
Pump
Screening at Primary Centricleaner Secondary
Suction
Centricleaner
Dilution of stock with back water in Screening at
Fan pump Tertiary
Centricleaner
Reject
Screening at
Vibratory Screen Screening at Pressure Screen
Screening at
Pope Reel Fibermiser
To Drain
To Drain

37. PROCESS OF STOCK CLEANING: PM-7
Stock at Stuff box
from Machine chest
Dilution of stock with back water in
Back Water Primary centriclener
Reject Screening at Accept to
Screening at Primary Centricleaner Secondary PCC Suction
Centricleaner
Screening at
Tertiary
Centricleaner
Reject
Screening at
Vibratory Screen Screening at Pressure Screen
Screening at
Pope Reel Fibermiser
To Drain
To Drain

38. PROCESS OF PAPERMAKING
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

39. PROCESS OF PAPER MAKING: HEAD BOX
Machine 1 2 4 5 7
Closed
Closed
Head Box type Open Open Air Open
Pressurized
Cushioned
Simple Simple Tapered Tapered Tapered
Distributors
Manifold Manifold Flow Manifold 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,
10 10 15 12-14 13
mm
Slice width, mm 3350 3350 3400 2450 3000
No of slices 25 25 28 22 24

40. PROCESS OF PAPER MAKING: WIRE PART
Machine 1 2 4 5 7
Breast roll diameter,
406 600 550 500 500
mm
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
350 100-200 200-220 200 200
of Hg
Couch roll Vacuum,
350 350 440-480 400-450 280-300
mm of Hg
Couch roll Dia mm 762 762 762 650 618

41. PROCESS OF PAPER MAKING: PRESS PART
Machine 1 2 4 5 7
1st Press
Type 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 Press
Type Offset Offset Reverse Offset Offset
Top roll Granite Granite Dyna rock Micro mate Miicro mate
Bottom roll Rubber Rubber Rubber Microrock Brass

42. PROCESS OF PAPER MAKING: DRYER SECTION
Machine 1 2 4 5 7
No of dryers 27 27 36 28 16
No of dryer
4 4 5 4 3
groups
No of felt
65 65 118 70 48
rolls
Condensate
Bucket Bucket Bucket Siphon Bucket
Removal
type type type type type
sissies
Syphon type Stationary Stationary Stationary Stationary Stationary
Semi Semi Semi Semi Semi
Hood
closed closed closed closed closed

43. PROCESS OF PAPER MAKING: CALENDER & SIZE PRESS
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 Micro Micro Micro Micro Micro
material Rock Rock Mate Mate Mate
Fixed roll Micro Micro Micro Micro Micro
material Mate Mate Rock Rock Rock
Loading Hydraulic Hydraulic Hydraulic Hydraulic Hydraulic
Paper Rope Rope Rope Rope Rope
feeding carrier carrier carrier carrier carrier

44. PROCESS OF PAPER MAKING: MACHINE CLOTHING SIZES, METER
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

45. Thanks

46. PROCESS OF PAPER MAKING: PAPER MACHINE
Details M/C 1 M/C 2 M/C 4 M/C 5 M/C 6 M/C 7
Make Charles Wamsley Charles Wamsley Esser Wyss Alstom Karhula Karhula
Year Of Installation 1926 1926 1983 1983 1983
Machine Floor Ground Floor Ground Floor 1st Floor 1st Floor 1st Floor 1st Floor
Production (Tpd) 30 40 75 47 1.8 27
Machine Speed(Mpm) 100 110 350 270 60 115
Machine Deckle(C.M) 314 314 311 223 210 272
Draw Open Open Open Open Oen Open
Approach Flow System
Machine Refiner Type TDR/21” TDR/24” DDR/24” DDR/24”&TDR/21” Conical,Beater Conflo
Pressure Screens No. 1 1 2 1 0 1
Type of Pressure Screen/Size Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.3 Slot/0.25
Centricleaners Stages 3+1 3+1 3+1 3+1 1 3+1
No.of Bottles in1st Stage 8 8 24 22 3 15
In 2nd Stage 3 3 8 7 5
In 3rd Stage 1 1 4 1 1
In 4th Stage 1 1 1 1 1
Head Box
Closed air Closed
Type Open Open Coushioned Pressurized Open open
Dandy Roll Yes Yes Yes Yes No Yes
Dia.of Dandy (mm) 330 330 1000 800 500
Press Part
Ist Press Type Solid Solid Suction Suction Solid Suction
2nd Press Type Solid Solid Solid Solid Solid Solid
3rd Press Type Reverse Reverse Reverse Smoothening Smoothening
Dryer Section
Total No. of Dryer Cylinders 27 27 36 28 10 16
Dryer Groups (Steam Wise) 4 4 6 4 3 3
No. of D/Cy.In Pre Dryer 19 19 24 20 10
No. of D/Cy. In Post Dryer 8 8 12 8 6
Cooling Cylinders No No Yes No No No
No. of Cooling Cylinders 2
Size Press
Type Inclind Inclind Horizontal Puddle type Puddle type
Steam System Conventional Conventional Conventional Conventional Conventional Conventional
Condensate Removal System Bucket Bucket Bucket Siphon Bucket Bucket
Type of Calender Kuster Kuster Kuster Kuster Kuster
Pope Reel Inclined Inclined Horizontal Horizontal Horizontal