Gujarat Cleaner Production Centre
CLEANER PRODUCTION
OPPURTUNITIES
PULP &PAPER SECTOR
Gujarat Cleaner Production Centre - ENVIS Centre
CLEANER PRODUCTION
OPPURTUNITIES
IN
PULP &PAPER SECTOR
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CLEANER PRODUCTION
PULP &PAPER SECTOR
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INTRODUCTION
1.1 Pulp and Paper
(Ref. EIA Guideline, Nov2011report)
Pulp and paper are manufactured from raw
include wood, recycled paper, and agricultu
production to make different streng
from using cotton rags for paper production and wood
fibre. The global pulp and paper industry consists of
and an equal number of very small companies.
other materials, such as rags, wastepaper
are engaged in manufacturing
products. Indian paper mills can be categorized based on raw
mills, agro-based mills and wastepaper based mills. The major products from these mills are
paper, paper boards and newsprints.
development, while it is associate
footprints on environmental resources.
of its development. The need for documentation of knowledge and record keeping has long been
perceived to be linked to the intellectual prowess of a nation. The tradition of use
patra” – or the bark of the “Bhoj” Tree for documentation of our
world over. Such recording pre-
substances. As time progressed, the
by civilizations. It was here that the Chinese made their first attempt to manufacture paper from
plant resources. Historians believe tha
makers - the kagzi’s- in the country as they expanded their
the first modern paper mill was set up in Sreerampur, West
process for paper making developed in the
paper in India has seen over a century and a half pass by.
very little soft wood for the manufacture of
wood, there was a problem in using them for harder indigenous raw materials. In the year 1914, a
process was developed to use bamboo for paper making. This provided the
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(Ref. EIA Guideline, Nov2011report)
Pulp and paper are manufactured from raw materials containing cellulose fibres, which
include wood, recycled paper, and agricultural residues. There are several methods of pulp
production to make different strengths and grades of paper. In the 1800s, there was a shift away
s for paper production and wood became the most important source of
and paper industry consists of about 5000 industrial pulp and paper mills
number of very small companies. Pulp mills separate the fibres from wo
rials, such as rags, wastepaper or straw in order to create pulp. Paper mills primarily
cturing paper from pulp and may also manufacture converted pap
can be categorized based on raw materials viz. wood/fores
and wastepaper based mills. The major products from these mills are
, paper boards and newsprints. Pulp and Paper industry plays a vital role in socio
associated with significant environmental concerns
environmental resources. The use of paper by a society is often taken as a yardstick
The need for documentation of knowledge and record keeping has long been
ived to be linked to the intellectual prowess of a nation. The tradition of use
or the bark of the “Bhoj” Tree for documentation of our scriptures is acknowledged the
-dates most of the earliest known documentation on paper like
substances. As time progressed, the need for cheaper means of documentation of records was felt
was here that the Chinese made their first attempt to manufacture paper from
plant resources. Historians believe that it was the Moghals, who introduced the
in the country as they expanded their empire in India. It was in 1832 that
the first modern paper mill was set up in Sreerampur, West Bengal, using the mechanized
paper making developed in the western world. Thus the journey of machine made
a century and a half pass by. Unlike the West, however, India ha
manufacture of paper. Since machines were designed to
problem in using them for harder indigenous raw materials. In the year 1914, a
process was developed to use bamboo for paper making. This provided the requi
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taining cellulose fibres, which generally
methods of pulp
1800s, there was a shift away
became the most important source of
about 5000 industrial pulp and paper mills
Pulp mills separate the fibres from wood or from
or straw in order to create pulp. Paper mills primarily
paper from pulp and may also manufacture converted paper
materials viz. wood/forest based
and wastepaper based mills. The major products from these mills are
Pulp and Paper industry plays a vital role in socio-economic
due to its large
he use of paper by a society is often taken as a yardstick
The need for documentation of knowledge and record keeping has long been
ived to be linked to the intellectual prowess of a nation. The tradition of use of ‘bhoj –
scriptures is acknowledged the
entation on paper like
need for cheaper means of documentation of records was felt
was here that the Chinese made their first attempt to manufacture paper from
traditional paper
It was in 1832 that
Bengal, using the mechanized
western world. Thus the journey of machine made
Unlike the West, however, India had
paper. Since machines were designed to process soft
problem in using them for harder indigenous raw materials. In the year 1914, a
required impetus to
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the paper making operations in the country.
the fortunes of the paper industry in its
scenario.
Figure 1 : Road Map Of Indian Paper Industries
1.2 GROWTH OF INDIAN
Figure 2 : Growth Of Indian Paper Industries
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operations in the country. Figure 1 shows some of the major eve
the paper industry in its journey from a single unit in 1832, to the present day
Figure 1 : Road Map Of Indian Paper Industries
1.2 GROWTH OF INDIAN PAPER INDUSTRY
Of Indian Paper Industries
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some of the major events that shaped
journey from a single unit in 1832, to the present day
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1.3 Classification of Papers
(Ref : EIA Report)
In India, paper and board types produced (Table 2
categories on the basis of intended use:
1. Printing and writing (graphic) papers
Printing and writing papers comprise one of the larges
include copier paper, stationery, computer printout, offset paper, and notepads.
broadly classified into those containin
mainly used in mass-produced p
applications. Each category can again be either coated
2. Industrial papers
Industrial paper is a term used to describe p
paper, therefore, includes building papers, insu
etc. Packaging paper may include high
some cases surface treated, multi
made from fresh unbleached pulp or recycled
quality, also accounts for a portion of
3. Special papers
These cover a wide range of paper types which cannot be specifically allocated to the two
product groups described above,
� papers for hygiene applications (tissues, kitchen rolls, toilet paper)
� filter papers for use in industry, t
� transparent papers for drawing
� photographic papers
� base paper for parchment, vulcanized fibre
� cigarette paper
� capacitor paper, etc.
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1.3 Classification of Papers
In India, paper and board types produced (Table 2.1) are classified into the following broad
categories on the basis of intended use:
1. Printing and writing (graphic) papers
Printing and writing papers comprise one of the largest categories of paper products.
include copier paper, stationery, computer printout, offset paper, and notepads.
broadly classified into those containing wood and those not containing wood pulp. The former is
produced papers, while the latter is used for high quality and special
applications. Each category can again be either coated or uncoated.
Industrial paper is a term used to describe paper manufactured for industrial uses.
paper, therefore, includes building papers, insulating papers, wrapping papers, packaging papers,
. Packaging paper may include high-quality packaging materials for food and luxury goods, in
ulti-layer or coated for costly print processes. Corrugated board,
esh unbleached pulp or recycled corrugated board (a rising trend) depending on
also accounts for a portion of industrial papers in quantity terms.
These cover a wide range of paper types which cannot be specifically allocated to the two
product groups described above, e.g.:
papers for hygiene applications (tissues, kitchen rolls, toilet paper)
filter papers for use in industry, the home, the laboratory etc.
transparent papers for drawing
base paper for parchment, vulcanized fibre
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classified into the following broad
t categories of paper products. Examples
include copier paper, stationery, computer printout, offset paper, and notepads. This paper is
wood pulp. The former is
for high quality and special
nufactured for industrial uses. Industrial
packaging papers,
food and luxury goods, in
print processes. Corrugated board,
corrugated board (a rising trend) depending on
These cover a wide range of paper types which cannot be specifically allocated to the two
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Table 1.1: Consumption Pattern of Paper and Paper Boards in India
Type of Paper
Cultural paper
Industrial paper
Specialty paper
Newsprint
1.4 Size of the Industry
(Ref : EIA Report)
In India, the industry is classified into following categories based on its production
1. Large scale : Greater than 33,000 tonnes per annum (TPA) of production
2 Medium scale : between 10,000 and 33,000 TPA
3 Small scale : Less than 10,000 TPA
1.5 Structure of Indian Paper Industry
(Ref : CPPRI Benchmarking Report)
Gujarat Cleaner Production Centre - ENVIS Centre
: Consumption Pattern of Paper and Paper Boards in India
Main Varieties % of Total
Consumptions
Cream woven, maplitho, bond
paper, Chromo paper
41%
Kraft paper, paper board –
paper board – single layer
board, multilayer board,
duplex board
43%
Security paper, grease proof
paper, electrical grades
of paper
Glazed, non-glazed 12%
In India, the industry is classified into following categories based on its production
Greater than 33,000 tonnes per annum (TPA) of production
2 Medium scale : between 10,000 and 33,000 TPA
3 Small scale : Less than 10,000 TPA
Structure of Indian Paper Industry
(Ref : CPPRI Benchmarking Report)
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: Consumption Pattern of Paper and Paper Boards in India
% of Total
Consumptions
41%
43%
4%
12%
In India, the industry is classified into following categories based on its production capacity:
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Figure 3 :
1.6 Scenario of Export/Import of paper/paper board and newsprint(Ref Nov 2011)
Particulars 2001
- 02
2002
-
Paper /
Paper
Board
Export 0.180 0.220
Newsprint Export 0.001 0.006
Total
Export
0.181 0.226
Paper /
Paper
Board
Import 0.11 0.15
Newsprint Import 0.45 0.54
Total
Import
0.56 0.69
Gujarat Cleaner Production Centre - ENVIS Centre
: Structure of Indian Paper Industry
Scenario of Export/Import of paper/paper board and newsprint
2002
- 03
2003
- 04
2004
- 05
2005
- 06
2006
- 07
2007
- 08
2008
-
0.220 0.230 0.280 0.304 0.339 0.325 0.334
0.006 0.003 0.005 0.008 0.004 0.004 0.006
0.226 0.233 0.285 0.312 0.343 0.329 0.340
0.15 0.240 0.19 0.291 0.348 0.451 0.437
0.54 0.77 0.68 0.69 0.79 0.89 0.97
0.69 1.01 0.87 0.981 1.138 1.341 1.407
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Scenario of Export/Import of paper/paper board and newsprint
2008
09
2009
- 10
2011
- 12
0.334 0.389 0.518
0.006 0.013 0.009
0.340 0.382 0.527
0.437 0.614 0.632
0.97 0.85 0.95
1.407 1.464 1.582
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1.7 Geographical distribution of Pulp and Paper Industry In India
1.8 PRESENT SCENARIO
Raw Material Consumption Pattern
Year
1970
2000
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Geographical distribution of Pulp and Paper Industry In India
PRESENT SCENARIO 2013
Raw Material Consumption Pattern
% Share
Wood Agro Residue
84 9
39 31
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Geographical distribution of Pulp and Paper Industry In India
Waste Paper
7
30
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2012
Comparision of Waste Paper Recovery Rate In India With Developed Countries
Comparision of Per Capita Consumption of Paper In India With Global
0
20
40
60
80
% Recovery of Waste Paper
0
100
200
300
400
USA
Fin
lan
d
Be
lgiu
m
Jap
an
Ca
na
da
Taiw
an
Avg Kg Per Capita Consumption of Paper
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31 22
Comparision of Waste Paper Recovery Rate In India With Developed Countries
Capita Consumption of Paper In India With Global
% Recovery of Waste Paper
German
Swedan
Japan
Western Europe
USA
Italy
India
Taiw
an
Sin
ga
po
re
Sw
itze
rla
nd
De
nm
ark
Ne
wZ
ea
lan
d
Sw
ed
en
Ho
lla
nd
UK
Ge
rma
ny
Ch
ina
Ind
on
esi
a
Ma
laysi
a
Ind
ia
Per Capita Consumption of Paper
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47
Comparision of Waste Paper Recovery Rate In India With Developed Countries
German
Swedan
Japan
Western Europe
USA
Italy
India
USA
Finland
Belgium
Japan
Canada
Taiwan
Singapore
Switzerland
Denmark
NewZealand
Sweden
Holland
UK
Germany
China
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1.9 General Steps For Manufacturing Process Of Waste Paper Industries
(1) Collection Of Waste Paper
Industrial waste paper is collected mainly from different sources such as publisher, printing
house, converters & departmental stores, super markets and mostly dealers of industrial waste.
Old newspaper, magazines and other wastepaper is collected by door
source of collection.
(2) WASTE PAPER PROCESSING
The 2 key goals of waste paper recycling operations are defibration and contaminant removal.
Now a days the process generally include pulping, screening, cleaning and deinking by
combination of soaking, flotation and washing depending upon the input raw material and final
product.
(3) PULPING
Pulping is the first unit operation in the recycling and deinking process. The pulping process is to
facilitate the separation of the non
contaminants in subsequent processes.
4) SCREENING & CLEANING
The objective of both screening and cleaning is the removal of non
minimal losses of useful fibre. Separation depends on physical differences, for example, in
screening size and shape are most important whilst in centrifugal cleaning
important difference. The low consistency equipment is operated after high consistency to avoid
the costs of consistency changes. The sequence used is also in the order of decreasing
contaminant size.
(5) Pressure screens
In this a wooden scraper or non contacting foil is used to provide the pressure pulse and to keep
the face of the screen clear. A mat forms readily on the face of the screen since water passes
through the screen plate orifices more easily than fibres. Fines perforatio
0.15mm can now be machined with accuracy in screen basket with advent of Laser rays. Screen
control system is very complex has supervisory & regulatory loops for each screen.
Gujarat Cleaner Production Centre - ENVIS Centre
1.9 General Steps For Manufacturing Process Of Waste Paper Industries
Collection Of Waste Paper
Industrial waste paper is collected mainly from different sources such as publisher, printing
house, converters & departmental stores, super markets and mostly dealers of industrial waste.
Old newspaper, magazines and other wastepaper is collected by door-to-door basis, is another
(2) WASTE PAPER PROCESSING
The 2 key goals of waste paper recycling operations are defibration and contaminant removal.
Now a days the process generally include pulping, screening, cleaning and deinking by
ombination of soaking, flotation and washing depending upon the input raw material and final
Pulping is the first unit operation in the recycling and deinking process. The pulping process is to
facilitate the separation of the non-fibrous material from the fibres and to remove the
contaminants in subsequent processes.
4) SCREENING & CLEANING
objective of both screening and cleaning is the removal of non-fibrous contaminants, with
minimal losses of useful fibre. Separation depends on physical differences, for example, in
screening size and shape are most important whilst in centrifugal cleaning density is the most
important difference. The low consistency equipment is operated after high consistency to avoid
the costs of consistency changes. The sequence used is also in the order of decreasing
oden scraper or non contacting foil is used to provide the pressure pulse and to keep
the face of the screen clear. A mat forms readily on the face of the screen since water passes
through the screen plate orifices more easily than fibres. Fines perforations down to the size of
0.15mm can now be machined with accuracy in screen basket with advent of Laser rays. Screen
control system is very complex has supervisory & regulatory loops for each screen.
9 | P a g e
1.9 General Steps For Manufacturing Process Of Waste Paper Industries
Industrial waste paper is collected mainly from different sources such as publisher, printing
house, converters & departmental stores, super markets and mostly dealers of industrial waste.
door basis, is another
The 2 key goals of waste paper recycling operations are defibration and contaminant removal.
Now a days the process generally include pulping, screening, cleaning and deinking by
ombination of soaking, flotation and washing depending upon the input raw material and final
Pulping is the first unit operation in the recycling and deinking process. The pulping process is to
fibrous material from the fibres and to remove the
fibrous contaminants, with
minimal losses of useful fibre. Separation depends on physical differences, for example, in
density is the most
important difference. The low consistency equipment is operated after high consistency to avoid
the costs of consistency changes. The sequence used is also in the order of decreasing
oden scraper or non contacting foil is used to provide the pressure pulse and to keep
the face of the screen clear. A mat forms readily on the face of the screen since water passes
ns down to the size of
0.15mm can now be machined with accuracy in screen basket with advent of Laser rays. Screen
control system is very complex has supervisory & regulatory loops for each screen.
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(6) Centrifugal cleaning
It is useful for removal of high and low density contaminants.
cleaners remove medium size contaminants with a high specific gravity such as paper clips,
glass, grit, etc. It is the first cleaners after the pulping system and
operates more accurately at medium consistency between 2.5 to 5%.
(7) Dispersion and Kneading
The emergence of polymeric inks used in laser printers and copier papers necessitated usage of
dispersion and kneading equipment
efficient ink removal from the fibre. Dispersion also replaces deinking
removed so that there is no specky appearance. Temperature up to 150oC helps to melt the
stickies and reduce biological activity. Only disadvantage is high energy cost.
They are usually known as kneaders
shearing with a twisting & compressive action on fibres with no cutt
interactions forces are generated similar to high consistency pulper. If required steam is added,
exit temperature can be quite high (70
is effective for deinking when large spe
coated, offset, etc. A slow speed single shaft kneader reduces ink speck size successfully.
Brightness fell very slightly and is a indicator that ink has dispersed. Smaller ink specks have a
greater surface area and so absorb more light which results in a lower brightness. Kneading
reduces the long fibre content and create some fines and results in small change in freeness.
High-speed units:- They are known as
refiners with two plates one fixed & the other rotating at high speed. The reduction in brightness
shows effective ink removal with no change in fibre length and no fines creation as in slow speed
kneading, though freeness fell significant
of a waste paper processing line. In this location they are very successful in contaminants
dispersion, which substantially improves paper machine operation due to less deposition
problems with stickies.Visual quality is improved due to speck size reduction. Some installation
have high speed dispersion units following pulping in high quality printing & writing as well as
OCC recycling.
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It is useful for removal of high and low density contaminants. High density high consistency
remove medium size contaminants with a high specific gravity such as paper clips,
glass, grit, etc. It is the first cleaners after the pulping system and operates at high consistency. It
operates more accurately at medium consistency between 2.5 to 5%.
The emergence of polymeric inks used in laser printers and copier papers necessitated usage of
dispersion and kneading equipment. It breakdowns large ink flakes to a size, which helps more
efficient ink removal from the fibre. Dispersion also replaces deinking – ink is dispersed but not
removed so that there is no specky appearance. Temperature up to 150oC helps to melt the
s and reduce biological activity. Only disadvantage is high energy cost. Low
kneaders and have single, double or triple shaft. The action is gentle
shearing with a twisting & compressive action on fibres with no cutting since inter
interactions forces are generated similar to high consistency pulper. If required steam is added,
exit temperature can be quite high (70-80oC) due to the friction forces generated. The approach
is effective for deinking when large specks are created for eg. Laser printed, xerographics, UV
coated, offset, etc. A slow speed single shaft kneader reduces ink speck size successfully.
Brightness fell very slightly and is a indicator that ink has dispersed. Smaller ink specks have a
urface area and so absorb more light which results in a lower brightness. Kneading
reduces the long fibre content and create some fines and results in small change in freeness.
They are known as dispersers or dispergers and have single s
refiners with two plates one fixed & the other rotating at high speed. The reduction in brightness
shows effective ink removal with no change in fibre length and no fines creation as in slow speed
kneading, though freeness fell significantly. High speed dispersion units are installed at the end
of a waste paper processing line. In this location they are very successful in contaminants
dispersion, which substantially improves paper machine operation due to less deposition
ies.Visual quality is improved due to speck size reduction. Some installation
have high speed dispersion units following pulping in high quality printing & writing as well as
10 | P a g e
High density high consistency
remove medium size contaminants with a high specific gravity such as paper clips,
operates at high consistency. It
The emergence of polymeric inks used in laser printers and copier papers necessitated usage of
. It breakdowns large ink flakes to a size, which helps more
ink is dispersed but not
removed so that there is no specky appearance. Temperature up to 150oC helps to melt the
Low-speed units:-
and have single, double or triple shaft. The action is gentle
ing since inter-fibre
interactions forces are generated similar to high consistency pulper. If required steam is added,
80oC) due to the friction forces generated. The approach
cks are created for eg. Laser printed, xerographics, UV
coated, offset, etc. A slow speed single shaft kneader reduces ink speck size successfully.
Brightness fell very slightly and is a indicator that ink has dispersed. Smaller ink specks have a
urface area and so absorb more light which results in a lower brightness. Kneading
reduces the long fibre content and create some fines and results in small change in freeness.
or dispergers and have single shafts similar to
refiners with two plates one fixed & the other rotating at high speed. The reduction in brightness
shows effective ink removal with no change in fibre length and no fines creation as in slow speed
ly. High speed dispersion units are installed at the end
of a waste paper processing line. In this location they are very successful in contaminants
dispersion, which substantially improves paper machine operation due to less deposition
ies.Visual quality is improved due to speck size reduction. Some installation
have high speed dispersion units following pulping in high quality printing & writing as well as
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(8) Deinking
Generally ink constitute 0.5 to2% of the mass of the waste paper. Deinking can be done by two
methods, washing and flotation depending upon the requirement. The washing deinking is less
effective in the removal of large ink specks >20 microns where as flot
effective in removal of small ink specks <20 microns. Though smaller particles can be removed
by flotation if they are agglomerated to form large particles. Better results are achieved by
combination system of the above two methods.
as centrifugal cleaners. Most ink is removed by either or both flotation and washing.
(I) WASHING DEINKING
Ink is broken up on pulping and some of these ink particles are removed by subsequent wash
stages with the washer filtrate. This is very effective even without pulping aids or without the use
of chemicals such as caustic, sodium silicate, dispersant and H2O2 in pulper. Methods for wash
deinking are thickening processes using a mechanical separation proc
separated from fibres by a separating element frequently a synthetic wire. The efficiency of wash
deinking is determined by the speed of mat formation & the thickness or basis weight of the mat.
Washing efficiency is also affected by
before the washing stage usually during pulping. Screw presses have been used for many years in
deinking both as wash units and thickeners. Drum washers or gravity deckers have become less
popular with the introduction of belt washers. Disc & vacuum filters are used as thickeners rather
than washers but with the same concept. The water ink emulsion is washed from the pulp and the
ink is removed from the wash water by flocculation or flotation using suit
clarified water may be reused in the system. The counter current washing is common in washing
deinking.
(II) FLOTATION DEINKING
Flotation is a process that separates materials based on the property of wettability. With the
exception of water based inks, ink particles are more hydrophobic than paper fibres which is the
basis of separation by flotation. Some fibre can be hydrophobic & some inks can be hydrophilic.
Chemicals are added to increase this difference between fiber and inks. Hydr
are able to adhere to the air bubbles and rise to the surface, the process is carried out in flotation.
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Generally ink constitute 0.5 to2% of the mass of the waste paper. Deinking can be done by two
methods, washing and flotation depending upon the requirement. The washing deinking is less
effective in the removal of large ink specks >20 microns where as flotation deinking is less
effective in removal of small ink specks <20 microns. Though smaller particles can be removed
by flotation if they are agglomerated to form large particles. Better results are achieved by
combination system of the above two methods. Although some ink is removed by screens as well
as centrifugal cleaners. Most ink is removed by either or both flotation and washing.
Ink is broken up on pulping and some of these ink particles are removed by subsequent wash
ith the washer filtrate. This is very effective even without pulping aids or without the use
of chemicals such as caustic, sodium silicate, dispersant and H2O2 in pulper. Methods for wash
deinking are thickening processes using a mechanical separation process. Ink particles are
separated from fibres by a separating element frequently a synthetic wire. The efficiency of wash
deinking is determined by the speed of mat formation & the thickness or basis weight of the mat.
Washing efficiency is also affected by variables such as pH, temperature and treatment given
before the washing stage usually during pulping. Screw presses have been used for many years in
deinking both as wash units and thickeners. Drum washers or gravity deckers have become less
the introduction of belt washers. Disc & vacuum filters are used as thickeners rather
than washers but with the same concept. The water ink emulsion is washed from the pulp and the
ink is removed from the wash water by flocculation or flotation using suitable chemicals. The
clarified water may be reused in the system. The counter current washing is common in washing
FLOTATION DEINKING
Flotation is a process that separates materials based on the property of wettability. With the
water based inks, ink particles are more hydrophobic than paper fibres which is the
basis of separation by flotation. Some fibre can be hydrophobic & some inks can be hydrophilic.
Chemicals are added to increase this difference between fiber and inks. Hydrophobic materials
are able to adhere to the air bubbles and rise to the surface, the process is carried out in flotation.
11 | P a g e
Generally ink constitute 0.5 to2% of the mass of the waste paper. Deinking can be done by two
methods, washing and flotation depending upon the requirement. The washing deinking is less
ation deinking is less
effective in removal of small ink specks <20 microns. Though smaller particles can be removed
by flotation if they are agglomerated to form large particles. Better results are achieved by
Although some ink is removed by screens as well
as centrifugal cleaners. Most ink is removed by either or both flotation and washing.
Ink is broken up on pulping and some of these ink particles are removed by subsequent wash
ith the washer filtrate. This is very effective even without pulping aids or without the use
of chemicals such as caustic, sodium silicate, dispersant and H2O2 in pulper. Methods for wash
ess. Ink particles are
separated from fibres by a separating element frequently a synthetic wire. The efficiency of wash
deinking is determined by the speed of mat formation & the thickness or basis weight of the mat.
variables such as pH, temperature and treatment given
before the washing stage usually during pulping. Screw presses have been used for many years in
deinking both as wash units and thickeners. Drum washers or gravity deckers have become less
the introduction of belt washers. Disc & vacuum filters are used as thickeners rather
than washers but with the same concept. The water ink emulsion is washed from the pulp and the
able chemicals. The
clarified water may be reused in the system. The counter current washing is common in washing
Flotation is a process that separates materials based on the property of wettability. With the
water based inks, ink particles are more hydrophobic than paper fibres which is the
basis of separation by flotation. Some fibre can be hydrophobic & some inks can be hydrophilic.
ophobic materials
are able to adhere to the air bubbles and rise to the surface, the process is carried out in flotation.
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Large ink particles size 10-50 micron can agglomerate and skimmed out from the slurry. The
system efficiency depends upon the various
chemicals, water hardness, ink particle size, air bubble diameter, air to stock ratio and foam
removal system. Ink removal efficiency is better at the lower consistency. At a temperature range
of 40-45oC and pH of 6-9 the best brightness are obtained.
1.10 CORE ENVIRONMENTAL ISSUES
� Plastic waste is generated after screening in poire. It is hazardous material as per
GPCB norms. Normally Paper industries send the plastic waste to the cement
industries and do not apply any method for further reuse
� Fly ash is generated from boiler in very high amount. But the industry sold it
to the brick industry. They do not apply any new technology for further
� De inking sludge is generated due to chemical addition in the
board and printing press paper
to the CETP (Common Effluent Treatment Plant) for landfilling. But in fu
land available for landfilling if do not find technological option for reuse, recycle or
reduction etc.
� Pulp goes to effluent from diabole equipment and centricleaner about 500
� Steam losses from open drying system is about 15% to 2
has been applied.
� Equipment modifications are required for better process control, reduce water
consumption and also energy consumption.
� Loss of fibers from centricleaner and paper M/C head box due to poor
Maintainance and handling operations.
� In duplex board, newsprint and printing press industries, are using alum as a
sizing agent which reduce drainability, fiber retention and disables manufacturing
of high grammage paper. It also increases total suspended particles in effluent.
� Consistency indicator and regulator do not install for better quality of paper.
� Lower consistency pulper is used for pulp preparation which consumes large
Quantity of water . The number of dryers are increased for removal of water or
moisture from paper for better quality of it which consumes large quantity of
energy.
Gujarat Cleaner Production Centre - ENVIS Centre
50 micron can agglomerate and skimmed out from the slurry. The
system efficiency depends upon the various factors like stock consistency, temp, pH, collector
chemicals, water hardness, ink particle size, air bubble diameter, air to stock ratio and foam
removal system. Ink removal efficiency is better at the lower consistency. At a temperature range
9 the best brightness are obtained.
CORE ENVIRONMENTAL ISSUES
Plastic waste is generated after screening in poire. It is hazardous material as per
GPCB norms. Normally Paper industries send the plastic waste to the cement
industries and do not apply any method for further reuse/recovery/recycle/reduce
Fly ash is generated from boiler in very high amount. But the industry sold it
to the brick industry. They do not apply any new technology for further reuse.
De inking sludge is generated due to chemical addition in the news print, duplex
paper industry. This type of solid waste is directly goes
to the CETP (Common Effluent Treatment Plant) for landfilling. But in fu
land available for landfilling if do not find technological option for reuse, recycle or
Pulp goes to effluent from diabole equipment and centricleaner about 500
Steam losses from open drying system is about 15% to 20 %.No steam recovery
Equipment modifications are required for better process control, reduce water
consumption and also energy consumption.
Loss of fibers from centricleaner and paper M/C head box due to poor
Maintainance and handling operations.
In duplex board, newsprint and printing press industries, are using alum as a
sizing agent which reduce drainability, fiber retention and disables manufacturing
paper. It also increases total suspended particles in effluent.
Consistency indicator and regulator do not install for better quality of paper.
Lower consistency pulper is used for pulp preparation which consumes large
number of dryers are increased for removal of water or
moisture from paper for better quality of it which consumes large quantity of
12 | P a g e
50 micron can agglomerate and skimmed out from the slurry. The
factors like stock consistency, temp, pH, collector
chemicals, water hardness, ink particle size, air bubble diameter, air to stock ratio and foam
removal system. Ink removal efficiency is better at the lower consistency. At a temperature range
Plastic waste is generated after screening in poire. It is hazardous material as per
GPCB norms. Normally Paper industries send the plastic waste to the cement
/recovery/recycle/reduce.
Fly ash is generated from boiler in very high amount. But the industry sold it
reuse.
news print, duplex
industry. This type of solid waste is directly goes
to the CETP (Common Effluent Treatment Plant) for landfilling. But in future there is no
land available for landfilling if do not find technological option for reuse, recycle or
Pulp goes to effluent from diabole equipment and centricleaner about 500 kg/day.
0 %.No steam recovery
Equipment modifications are required for better process control, reduce water
In duplex board, newsprint and printing press industries, are using alum as a
sizing agent which reduce drainability, fiber retention and disables manufacturing
paper. It also increases total suspended particles in effluent.
Consistency indicator and regulator do not install for better quality of paper.
Lower consistency pulper is used for pulp preparation which consumes large
number of dryers are increased for removal of water or
moisture from paper for better quality of it which consumes large quantity of
Gujarat Cleaner Production Centre
Solid By Streams From Paper Industries
Solid By-
Streams
Dry
solid
(%)
Primary
Sludge
50
Secondary
(Biological)
Sludge
40-50
Deinking
Sludge
56
Coarse
Rejects
(Plastic)
55
Screen
Rejects
(Stickies)
55
1.11 Cleaner Production Inventory Of Application Technologies For Waste
Stream
(1) Use of By-Streams as Such
Land management options
(land spreading, land
restoration)
Absorbent, animal bedding
Gujarat Cleaner Production Centre - ENVIS Centre
Solid By Streams From Paper Industries
Organic
matter
(%)
Mineral
matter
(%)
Energy
content
(MJ/tonwet)
Dry Matter
Contents
40 60 2690 Fibres, fillers,
coating clay, calcium
carbonate
50 50 4000-5000 Calcium carbonate,
cupper, micro
organisms,
fibres, proteins.
50 50 3000 Cellulose fibres,
calcium carbonate,
kaolin, ink
92 8 12000 Recyclable fibres,
wet strength fibres,
plastics,
wood, metal, others
90 10 8000 Cellulose, plastics,
hair, stickies
Cleaner Production Inventory Of Application Technologies For Waste
Streams as Such
On-site or
external
Deinking Effluent
sludge
Land management options N/A
N/A
13 | P a g e
Dry Matter
Contents
Fibres, fillers,
coating clay, calcium
carbonate
Calcium carbonate,
cupper, micro
organisms,
fibres, proteins.
Cellulose fibres,
calcium carbonate,
kaolin, ink
Recyclable fibres,
wet strength fibres,
plastics,
wood, metal, others
Cellulose, plastics,
hair, stickies
Cleaner Production Inventory Of Application Technologies For Waste
Coarse
rejects
Screen
rejects
Gujarat Cleaner Production Centre
Anti-dust
(2) Conversion To Product
Feedstock for other paper grades,
softboard production and cement
bonded sludge board
production
Pyrolysis (chemicals)
For use in cement/asphalt/etc.
production
Synthetic Calcium Carbonate
CDEM
(3) Conversion To Energy
Gasification
Supercritical gasification
Combustion
Gujarat Cleaner Production Centre - ENVIS Centre
N/A
On-site
or
external
Deinking Effluent
sludge
Coarse
rejects
Feedstock for other paper grades,
softboard production and cement
External
Onsite
For use in cement/asphalt/etc. External
Both
Both
On-site or
external
Deinking Effluent
sludge
Coarse
rejects
Both
Unknown
Both
14 | P a g e
Coarse
rejects
Screen
rejects
Coarse
rejects
Screen
rejects
Gujarat Cleaner Production Centre
1.11.1 Eco-Friendly Clean Emerging Techniques
(1) Plastic Waste To :
� Cement Industry By Co
� Fuel/Energy By Plasma Pyrolysis
� Feed Stock For Bituminous Road Construction
� Eco-Friendly Crude Oil By Agilyx Process
(2) De-Inking Sludge To “Topcrete” Substitute Of Cement By
(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
(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 Dryi
1.11.2 General CP Guidelines for Pulp and Paper Industry
1. Cleaner production measures Raw materials:
� Maintaining moisture content of the raw materials constant all year around.
� Keeping chemical inventory to a minimum and buying small
used materials.
� Steam explosion can be applied as the raw material pretreatment before the digestion step
to reduce the NaOH consumption
2. Cleaner production measures Wood
� Pulp mills integrated with lumbering facilities: a
during debarking; residual or waste wood from lumber processing is returned to the
chipping process; in-house lumbering rejects can be a significant source of wood furnish.
Gujarat Cleaner Production Centre - ENVIS Centre
Friendly Clean Emerging Techniques
Cement Industry By Co-Processing
Fuel/Energy By Plasma Pyrolysis
Feed Stock For Bituminous Road Construction
Friendly Crude Oil By Agilyx Process
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
(5) Reduction Of Tds (Total Dissolved Solid) In Kraft Paper Mill By Surface Sizing And New
(6) New Drying Technology For Reduction In Energy
Condebelt Drying Technology
Boost Drying Technology
General CP Guidelines for Pulp and Paper Industry
Cleaner production measures Raw materials:
Maintaining moisture content of the raw materials constant all year around.
Keeping chemical inventory to a minimum and buying small containers of infrequently
Steam explosion can be applied as the raw material pretreatment before the digestion step
to reduce the NaOH consumption
Cleaner production measures Wood-yard:
Pulp mills integrated with lumbering facilities: acceptable lumber wood is removed
during debarking; residual or waste wood from lumber processing is returned to the
house lumbering rejects can be a significant source of wood furnish.
15 | P a g e
Technology
(4) New Ecofriendly Technique For Removal Bod,Cod And Colour From Paper Mill Effluent
(5) Reduction Of Tds (Total Dissolved Solid) In Kraft Paper Mill By Surface Sizing And New
Maintaining moisture content of the raw materials constant all year around.
containers of infrequently
Steam explosion can be applied as the raw material pretreatment before the digestion step
cceptable lumber wood is removed
during debarking; residual or waste wood from lumber processing is returned to the
house lumbering rejects can be a significant source of wood furnish.
Gujarat Cleaner Production Centre
� Avoiding hydraulic debarking
wastewater amount.
� Reusing leachate water.
� Co-production from bark: mulch, ground cover, charcoal.
� Burning bark from debarking and small chips from chipping for energy production
(depends on the moisture content).
� Dry de-dusting of straw for removal of fines and dust / Dry depithing of Bagasse / Dry
debarking of Wood
� The indirect steam digesters are used instead of current direct steam digester for a better
heat contribution. This modification will improve the consistency of cook
3. Cleaner production measures Pulp production:
� Increasing brown stock washing efficiency. Any remaining cooking liquor will increase
the chemical consumption in subsequent stages.
� The quality of bark must be consistent in one cook to obtain the h
cooked pulp.
� Counter current pulp wash is recommended in the washing step instead of batch washing
to save water. The applications of air bubbling and ultrasonic techniques are also of
interest to increase the efficiency of rinsing.
� Water reuse from evaporators. The evaporation plant is always one of the largest steam
consumers in the mill. Condensate might be used instead of fresh water in the mill.
� Repulping the rejects from screening rather than putting them into the landfill.
� Using pulp centrifuging to remove any remaining impurities.
� Sludge utilization by means of land
of concern, as sludge constituents are not well identified.
Gujarat Cleaner Production Centre - ENVIS Centre
Avoiding hydraulic debarking – saving energy and water consumption, reducing
production from bark: mulch, ground cover, charcoal.
Burning bark from debarking and small chips from chipping for energy production
(depends on the moisture content).
of straw for removal of fines and dust / Dry depithing of Bagasse / Dry
The indirect steam digesters are used instead of current direct steam digester for a better
heat contribution. This modification will improve the consistency of cook
Cleaner production measures Pulp production:
Increasing brown stock washing efficiency. Any remaining cooking liquor will increase
the chemical consumption in subsequent stages.
The quality of bark must be consistent in one cook to obtain the homogeneity of the
Counter current pulp wash is recommended in the washing step instead of batch washing
to save water. The applications of air bubbling and ultrasonic techniques are also of
interest to increase the efficiency of rinsing.
r reuse from evaporators. The evaporation plant is always one of the largest steam
consumers in the mill. Condensate might be used instead of fresh water in the mill.
Repulping the rejects from screening rather than putting them into the landfill.
lp centrifuging to remove any remaining impurities.
Sludge utilization by means of land-spreading. This method of sludge disposal is an area
of concern, as sludge constituents are not well identified.
16 | P a g e
ater consumption, reducing
Burning bark from debarking and small chips from chipping for energy production
of straw for removal of fines and dust / Dry depithing of Bagasse / Dry
The indirect steam digesters are used instead of current direct steam digester for a better
heat contribution. This modification will improve the consistency of cooked bark.
Increasing brown stock washing efficiency. Any remaining cooking liquor will increase
omogeneity of the
Counter current pulp wash is recommended in the washing step instead of batch washing
to save water. The applications of air bubbling and ultrasonic techniques are also of
r reuse from evaporators. The evaporation plant is always one of the largest steam
consumers in the mill. Condensate might be used instead of fresh water in the mill.
Repulping the rejects from screening rather than putting them into the landfill.
spreading. This method of sludge disposal is an area
Gujarat Cleaner Production Centre
4. Cleaner production measures Chemicals
� Using of new technologies (CHP, BLG, heat transfer, heat exchanger).
� Improvements technical parameters of recovery boiler or furnace (geometrical shape
etc.).
� Using light gas strippers and gas collection systems which will remove hazardous and
foul smelling pollution from the air and increase workplace safety.
� Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.
5. Cleaner production measures Bleaching:
� Avoiding chlorine bleaching.
� Continuing research on biotechnological
� Oxygen and ozone with and without hydrogen peroxide can b
step.
6. Cleaner production measures Paper production:
� Cleaning the roll in the paper machines to avoid broken paper line.
� Adjustment of edge cutter to reduce side trimming loss.
� Use of soft water as a boiler feed water.
� Recycling water evaporated from drying process by condensing.
� Optimizing the thermal effects on water used in the paper machine and stock preparation
area.
� Providing disk save-all for paper machine.
� Repulping rejected paper in a closed loop manner.
7. Cleaner production measures Products processes and recycling, reduce:
� Increasing recycling rates. Recycling reduces energy consumption, decreases combustion
and landfill emissions, and decreases the amount of carbon dioxide in the atmosphere.
This process also saves money.
� Possibility for easy packaging recycling.
� Water from the washing step is encouraged for reuse in soaking step.
Gujarat Cleaner Production Centre - ENVIS Centre
Cleaner production measures Chemicals recovery:
Using of new technologies (CHP, BLG, heat transfer, heat exchanger).
Improvements technical parameters of recovery boiler or furnace (geometrical shape
Using light gas strippers and gas collection systems which will remove hazardous and
ul smelling pollution from the air and increase workplace safety.
Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.
Cleaner production measures Bleaching:
Avoiding chlorine bleaching.
Continuing research on biotechnological bleaching and electrochemical bleaching.
Oxygen and ozone with and without hydrogen peroxide can be utilized in the bleaching
Cleaner production measures Paper production:
Cleaning the roll in the paper machines to avoid broken paper line.
ustment of edge cutter to reduce side trimming loss.
Use of soft water as a boiler feed water.
Recycling water evaporated from drying process by condensing.
Optimizing the thermal effects on water used in the paper machine and stock preparation
all for paper machine.
Repulping rejected paper in a closed loop manner.
Cleaner production measures Products processes and recycling, reduce:
Increasing recycling rates. Recycling reduces energy consumption, decreases combustion
and landfill emissions, and decreases the amount of carbon dioxide in the atmosphere.
This process also saves money.
Possibility for easy packaging recycling.
m the washing step is encouraged for reuse in soaking step.
17 | P a g e
Improvements technical parameters of recovery boiler or furnace (geometrical shape
Using light gas strippers and gas collection systems which will remove hazardous and
Deaerator tanks ahead of the boilers to help reduce the intake of freshwater.
bleaching and electrochemical bleaching.
e utilized in the bleaching
Optimizing the thermal effects on water used in the paper machine and stock preparation
Cleaner production measures Products processes and recycling, reduce:
Increasing recycling rates. Recycling reduces energy consumption, decreases combustion
and landfill emissions, and decreases the amount of carbon dioxide in the atmosphere.
Gujarat Cleaner Production Centre
� Turning or mixing is recommended to reduce time of soaking, digestion, and washing.
� Waste water in each step should be separated and treated separately. Extra treatment need
to be considered for waste water from the pulping step which contains long molecules of
lignin and tannin.
� Recycling piping system need to be installed at the washing and soaking steps.
Installation of Indirect & More Efficient Heat Transfer System for Blow Heat Recovery in
Digester Section: This avoids generation of contaminated wastewater (in direct heat transfer,
waste gases are directly injected to water) and enables reuse of cooling wastewater.
Gujarat Cleaner Production Centre - ENVIS Centre
Turning or mixing is recommended to reduce time of soaking, digestion, and washing.
Waste water in each step should be separated and treated separately. Extra treatment need
waste water from the pulping step which contains long molecules of
Recycling piping system need to be installed at the washing and soaking steps.
Installation of Indirect & More Efficient Heat Transfer System for Blow Heat Recovery in
gester Section: This avoids generation of contaminated wastewater (in direct heat transfer,
waste gases are directly injected to water) and enables reuse of cooling wastewater.
18 | P a g e
Turning or mixing is recommended to reduce time of soaking, digestion, and washing.
Waste water in each step should be separated and treated separately. Extra treatment need
waste water from the pulping step which contains long molecules of
Recycling piping system need to be installed at the washing and soaking steps.
Installation of Indirect & More Efficient Heat Transfer System for Blow Heat Recovery in
gester Section: This avoids generation of contaminated wastewater (in direct heat transfer,
waste gases are directly injected to water) and enables reuse of cooling wastewater.