Wastewater management in pulp and paper industry

1. First Stage Presentation of M.Tech
Wastewater management in
pulp and paper industry
by
Daulat Ram Meena
(133180017)
Under the guidance of
Prof. Anurag Garg &
Prof. Santanu Bandyopadhyay
1
Centre for Environmental Science and Engineering,
Indian Institute of Technology, Bombay,
8th october, 2014
CESE

2. Outline
 Introduction
 Background and Motivation
 Objective of the Study
 Literature Review
 Methodology
 Results and Discussion
 Summary
 Future Work Plan
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3. Introduction
 Paper was invented by the Chinese Cai Lun in 105 A.D.
 In Indian history, First handmade paper was
manufactured in 1159 A.D.
 First paper manufacturing industry was established by
Spanish in 1144 A.D.
 First paper mill was set-up in 1812 at Serampur in West
Bengal.
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4. Background
 Pulp and paper industry is the core sector of the Indian
economy.
 Most inputs are water, energy, chemicals and fibers but input
consumption rate is very high compare to output products.
 The per capita consumption of paper shows the development of
the country.
 In India, per capita paper consumption is about 9.3 kg per annum
and it is about 2% of the global consumption.
 Every industry’s growth is depending on resources, capital, energy,
fillers, public perception and demand.
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Per capita per annum paper consumption of
different country (in kg)

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 Water consumption pattern in
pulp and paper industry
 Wastewater generation pattern
in pulp and paper industry

7. Objectives
 To study about the raw material used for paper making and its chemical
composition.
 Data collected from the different literature and review on water
consumption, wastewater generation, wastewater characteristics,
chemicals and energy consumption.
 To reduce consumption of fresh water in pulp and paper industry by
identification of re-use and recycle method of wastewater by using of
different water minimization tools.
 To design water distribution network for minimization of water
consumption and suggest measures to reduce of energy consumption
in pulp and paper industry
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8. Literature Review
Classification of pulp and paper industry:-
Based on the raw material utilization:-
1. Wood based pulp and paper industry (with share of 31%)
2. Agro-based pulp and paper industry (22%)
3. Waste paper based pulp and paper industry (47%)
Based on size of the mill:-
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S.No. Category Annual installed capacity (tonne/annum)
1. Large More than 33000
2. Medium Between 16500-33000
3. Small Less than 16500

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Major types of paper and their consumption pattern
Type of paper Main Varieties % of total consumption
Cultural paper Bond paper, cream woven,
maplitho, chromo paper
41%
Industrial paper Kraft paper, paper bond,
multilayer board, duplex
board
43%
Specialty paper Security paper, grease
proof paper, electrical
grades of paper
4%
Newsprint Glazed, non-glazed 4%

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Pulp
and
paper
making
process
Raw
Material
Water
Energy
Chemicals
Labour
Non fibrous
additives
Products- Wood
pulp, newsprint,
toilet paper,
corrugated
material,
paperboard for
packaging, printing,
writing etc
Waste
water
Solid waste
Air pollutant
Input and output of the pulp and paper industry

11. Raw material preparation
 Raw material is cut into small pieces and washed for removing soil
and dirt or prepared for pulping operation
 Raw material preparation process depends on the material which
is used such as debarking, chipping, screening for wood.
 Water is used for washing and cleaning of the raw material.
 The logs are chipped to suitable size and oversized chips are re-
chipped with the help of disc and drum chippers.
 This process requires little energy.
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12. Pulp making
Pulping is a process in which lignocellulosic fibrous material is
separated from cellulose fibers in wood, agro-residue and waste
paper.
There are four method for pulping process:
1. Chemical pulping
2. Semi-mechanical pulping
3. Chemical-mechanical pulping
4. Mechanical pulping
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Mechanical
Energy
Chemical
Energy

13. Bleaching
 Bleaching operation is used for removing the colouring matter of the
pulp or improve brightness and to make it appropriate for paper making
operations.
 Different types of bleaching agents are used to bleach the pulp like
chlorine, chlorine dioxide, oxygen, ozone, hydrogen peroxide through
elemental chlorine or total chlorine free bleaching processes.
 Oxygen and peroxide are used as bleaching agent for total chlorine
free (TCF) process for eliminating chlorinated pollutants in wastewater.
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14. Chemical Recovery
 Globally, 90% chemical pulping and 2/3rd total pulping is
done by kraft process. Chemical efficiency of the kraft
process is about 97%.
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15. Wastewater Generation
 The characteristics and amount of generated wastewater from
pulp and paper industry is depend on the type of
manufacturing process, raw materials, applied technology,
recovery process etc.
 This water is highly polluted and it contains high BOD, COD,
AOX (adsorbable organic halides), SS, lignin etc.
 More than 95% of the fillers and fibers are insoluble in paper
production..
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16. Contd…
16
Fundamental
process
Effluent generated Pollution load
Raw material
preparation
Barker bearing cooling water TSS
Pulping Spent liquor, Leakages from
pipelines, black liquor from
small agro-based mills without
chemical recovery
High BOD, COD, Colour, TDS, TSS, Toxicity
Washing & Cleaning Wash water Low BOD, COD, colour and toxicity
Bleaching Bleach plant wash water High BOD, COD, Dioxins, Toxicity, most of effluent colour, about
65% of total colour from bleaching of hard wood based mill,
about 95% of total colour from bleaching section of soft wood
based mill, Entire AOX from bleaching section
Stock preparation Clean up wastewater Low BOD, COD, colour
Paper machine White water Fiber fines and filler particles from wastewater from paper
machine area, BOD, COD from paper additives and colour from
dyes present in paper machine wastewater, Metal ion impurities
in chemicals and additives and corrosion products
Finishing Cleanup wastewater Low BOD, COD, colour

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Parameter Chipper
house
Digester
house
Pulp
washing
Pulp
bleaching
Paper
machine
Chemical
Recovery
Volume (m3/t
of paper)
20-60 5-10 20-40 140-180 40-90 -
Colour Muddy Dark
brown
Dark
brown
Brown Whitish Light brown
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 550-700 520-700 320-610
Characteristics of wastewater from different
process of paper mills

18. Energy Consumption
 In India, pulp and paper industry is an energy intensive industry
due to lack of technology.
 Indian pulp and paper industry consume about 3% of all the
country’s energy and 7% of total industrial sector’s energy.
 About 52 GJ energy consumed for one ton paper production.
 Energy consumption mostly depends on type of raw material and
the type of technology.
 In Indian pulp and paper industry mostly coal and electricity is
used for paper production.
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Cleaning & cutting
Digester
Evaporator
Washing & screening
Bleaching
Chemical recovery
Stack preparation
Paper machine
Deaerator
Utilities
Electricity
(in
kWh/ton of
paper)
12.5-18.8
11.5-18.5
1.6-1.8
2.3-5.1
13.8-18.5
3.7-5.5
112-128
58-62
145-155
88-92
170-190
275-286
465-475
248-252
2.7-3.9
2.5-4
0.35-0.4
0.5-1.1
3-4
0.8-1.2
Fuel
(in GJ/ton
of paper)
Steam(in
ton/ton
of paper
Energy consumption pattern in each process

20. Water Source Diagram
 Water source diagram method is used at different situations such as:
reuse, re-use with multiple water resources, re-use with water losses
along the process, recycling and re-use with flow rate constraints.
 The water source diagram is more flexible and dynamic for
management of water networks with reduction in total consumption.
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 Graphical method and mathematical programming method is mostly
used for the issue of systematic design water recovery network.
 The graphical method divides the design problem into a two-step
procedure, i.e., targeting and design. The main advantage of this
approach is that the minimum utility (water) consumption is targeted
before any network design.
 Mathematical programming is more complex and it can be used for
multiple contaminants problem.
 The traditional techniques for the minimization of the use of water with
multiple contaminants considered the contaminants individually.

22. Methodology
 There are basically two systematic approaches required for dealing
with waste minimization challenges namely:
• Heuristic algorithm procedures
• Mathematical programming procedures
 The algorithm procedures involve the use of graphical tools while
mathematical techniques use analytical modeling techniques which
have proved to very complex.
 The algorithm procedure adopted in this study is based on the use
water sources diagram.
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Procedure:
Step 1: The problem is divided into concentration interval based upon
limiting operation data and water is allowed to be reused between intervals.
Concentration limits of each interval are considered sources of water.
Step 2: The operations involved are to be represented arrows from
respective inlet to outlet concentrations. As soon as the arrows cross a
particular concentration line, the consequent effluent takes the value of the
concentration. Mass transfer of contaminant takes place at each interval
owing to concentration gradient.

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C1 C2 C3 C4 C5 C6 C7 C8
F1
F2
F3
F4
F5
Concentration interval (in ppm)
Where,
C1, C2, C3……..are the concentration of pollutants &
F1, F2, F3……..are the flow rate of the water for process 1,
process 2, process 3 respectively

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Step 3: The next step is to calculate the amount of contaminant transferred
in each operation by the following equation :
Δmkj=fLk×(Cfj−Cij)
Where,
Δmkj - represents the amount of contaminant to be transferred in a
particular operation k in the interval j ;
fLk - flowrate through operation k ;
Cfj - final (higher) concentration of interval j &
Cij - initial (lower) concentration in the interval j .

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Step 4: Synthesis of the mass-exchange network has to be done in this
step.
To fulfill the objective of minimization of waste water the following rules
has to be followed:
• Using external water sources only when any internal water source is
unavailable;
• Inside a concentration interval all possible amount of contaminant
must be transferred;

27. Result and discussion
• Water source diagram for COD
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Operation Inlet Flow Rate
(t/h)
Outlet flow
rate (t/h)
CODmax. (mg/l) Inlet CODmax (mg/l) Outlet ∆m (kg/h)
Raw material
operation
4 2 200 450 1
Pulping 27 22 150 2200 55.35
Pulp washing 14 12 150 1700 21.7
Pulp bleaching 14 20 100 800 9.8
Paper machine 54 31 75 600 28.35

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75 100 150 200 450 600 800 1700 2200
4
27
14
14
54
1
1.2 6.75 4.05 5.4 24.3 13.5
0.7 3.5 2.1 2.8 12.6
0.7 0.7 3.5 2.1 2.8
1.35 2.7 2.7 13.5 8.1
Concentration interval (in ppm)

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Operation Flow
Rate (t/h)
TSS (mg/l) Inlet TSS (mg/l)
Outlet
∆m (kg/h)
Raw
material
operation
4 150 1000 3.4
Pulping 27 100 1100 27
Pulp
washing
14 100 800 9.8
Pulp
bleaching
14 75 800 10.15
Paper
machine
54 50 2000 105.3
Water source diagram for TSS

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50 75 100 150 800 2000
4
27
14
14
54
1000 1100
2.6 0.8
1.35 17.5 5.4 2.7
0.7 9.1
0.35 0.7 9.1
1.35 1.35 2.7 35.1 10.8 5.4 48.6
Concentration interval (in ppm)

31. Summary
 Pulp and paper industry is highly consumptive of energy, raw material and
water. Pulp and paper industry generate highly polluted wastewater which
contains several organic and inorganic compounds. The water source
diagram was applied for single contaminant problem for COD and TSS.
 This report presents a heuristic algorithmic procedure for the design of
mass transfer networks. Water source diagram easy to apply and all
calculations can be done by hand.
 It minimizes external water source requirements by maximizing water re-
use. It is possible to work with multiple external water resources, flow rate
constraints, recycle rates and regeneration processes.
 This method give a flow sheet and a set of information that can be used
to estimate the cost of effluent distributed treatment systems.
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32. Future Work Plan
• Literature search on:-
- Pinch analysis
- Mathematical modelling
- Tool for minimization of water & energy consumption
- Water source diagram
• Pinch analysis and mathematical modelling for individual process of
pulp and paper industry.
• Overall water network design for multiple contaminants with the help of
water source diagram, pinch analysis and other tools.
• Cost analysis 30-10-2014 32

33. 30-10-2014 33
Activities Oct 2014 Nov. 2014 Dec. 2014 Jan. 2015 Feb 2015 Mar 2015
April
2015
May 2015
Literature
Review
Water source
diagram
Pinch analysis
Mathematical
modelling
Water
distribution
network
Report

34. References
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effluents: a review. Advances in Environmental Research, 5(2), 175-196.
 Bajpai, P. (2012). Brief description of the pulp and paper making process.
InBiotechnology for Pulp and Paper Processing (pp. 7-14). Springer US.
 Gomes, J. F., Queiroz, E. M., & Pessoa, F. L. (2007). Design procedure for
water/wastewater minimization: single contaminant. Journal of Cleaner
Production, 15(5), 474-485.
 Jomes, J. F., Mirre, R. C., Delgado, B. E., Queiroz, E. M., & Pessoa, F. L. (2013).
Water Sources Diagram in Multiple Contaminant Processes: Maximum
Reuse. Industrial & Engineering Chemistry Research, 52(4), 1667-1677.
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35. 30-10-2014 35
 Ince, B. K., Cetecioglu, Z., & Ince, O. (2011). Pollution prevention in the pulp and
paper industries.
 Karthik, M., Dhodapkar, R., Manekar, P., Aswale, P., & Nandy, T. (2011). Closing
water loop in a paper mill section for water conservation and
reuse.Desalination, 281, 172-178.
 Kumaraprasad, G., & Muthukumar, K. (2009). Design of mass exchange network
and effluent distribution system for effective water management. Journal of
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 Pokhrel, D., & Viraraghavan, T. (2004). Treatment of pulp and paper mill
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 Marques, S. V., Delgado, B. E. P. C., Pessoa, F. L. P., & Queiroz, E. M. (2008).
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Diagram As Tool. CHEMICAL ENGINEERING, 13, 399.
 Schumacher, K., & Sathaye, J. (1999). India’s pulp and paper industry: Productivity
and energy efficiency. LBNL-41843, Lawrence Berkeley National Laboratory.
Contd…

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Singh, P., & Thakur, I. S. (2006). Colour removal of anaerobically treated pulp and
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Wild Publications Inc.
 Tewari, P. K., Batra, V. S., & Balakrishnan, M. (2009). Efficient water use in
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Contd…

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