Indo-German Environment Partnership Environment Partnership Partner for Sustainable Urban and...

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Review of some of the Emerging Technologies/Techniques in the Indian

context

By: N.K.Kuttiappan

Date: 26.11.2013 (1610 to 1630 Hrs)

Indo-German Environment Partnership

Partner for Sustainable Urban and Industrial Development

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1. Typical Features of Study Units

2. Pollution Control Norms

3. Environmental Issues of concern

4. Understanding Wastepaper Mills

5. Typical Production Process Flowchart

6. Project Study & typical Mill case study for

broad approach & solutions


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TYPICAL FEATURES OF STUDY UNITS (7 covered so far)

• Raw Material Mix/Furnish: Local & imported wastepaper, kraft paper,

newspaper etc and virgin pulp of various origin; no on-site pulp

production (agro or wood or any other resource based)

• Product Mix: M.G. Kraft Paper, Kraft Board, Duplex Board, Newsprint /

Writing & Printing/ OTC & Absorbent Carbon / Poster Paper

• Production Capacity: 1200 to 6000 TPM; 40 to 200 TPD

• Water Consumption Range : 77 to 1656 cum/day; say 1.9 to 8.3 cum/T

• Power Consumption: One unit fully on Captive Power Generation based

and rest through Grid supply

• TDS & Bio-treatment problem faced by : more than 90% of the

participating units

• On-site sludge considered as fuel value: Regulatory permission

• Plastic waste residue as post management: OK for co-incineration

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POLLUTION CONTROL NORMS • Wastewater discharge Norm (Units after 1992) – 50 cum/T

• MINAS (Inland Surface Water Disposal):

pH 5.5 to 9.0

TSS < 100 mg/l

BOD < 30 mg/l

• Discharge Norm for Land Irrigation:

pH 5.5 to 9.0

TSS < 100 mg/l

BOD < 100 mg/l

SAR < 26

Adsorbable AOX < 2 or < 1.5 or < 1 Kg/T based on size of Mill, if pulp produced

• SPCB can prescribe more stringent norm and also “Core & Special parameters”

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FUTURE STRINGENT NORMS (Draft)

22.01.2014


Mill

Category

Existing

Water

Consumpti

on

(cum/T)

Achievable

Water

Consumpti

on

(cum/T)

Best

Achieved

water

consumptio

n norm

(cum/T)

Bench

Mark

water

consumptio

n Norm

(cum/T)

Agro based

Writing &

Printing

grade Mills

100 80 60 50

Agro based

Kraft grade

Mills

75 45 45 30

Recycle

Fibre based

Writing &

Printing

grade Mills

50 20 30 20

Recycle

Fibre based

Kraft Mills

35 10 15 10

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ENVIRONMENTAL ISSUES OF CONCERN

• Increase in TDS in the circulating water loop, and on/off purge water

exceeding COD, TDS & TSS norms to CETP system (Build-up of inorganic

impurities with increased water looping, recalcitrant organic build-up and

build-up of fillers as part of in-coming raw material mix).

• Poor filtrate quality of thickener & paper machine white water circulating

systems, leading to bio-fouling and fluctuating performance of primary &

secondary wastewater treatment system

• Appropriate biological treatment system, linked to quality of circulating

water characteristics for “Purge” treatment and back to water circuit

• Lack of Effective Management system for “Primary sludge dewatering” to

deliver high solids content (> 45%) for possible fuel option; Plastics

residues not having moisture control, adequate size etc for direct up-take

by Mills to use it as fuel (at-site Pellet production)

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UNDERSTANDING WASTE PAPER MILLS

• Processes with exclusively mechanical cleaning, without De-Inking:

Corrugated, Uncoated and carton products fall in this category

• Processes with mechanical cleaning & De-Inking : Newsprint, Tissues,

Magazine, Coated Boards etc fall in this category

• Hydro-Pulper & De-Inking System generates “Pulp” from wastepaper;

additionally virgin pulp may also be required; The consistency of the pulp

undergoes various changes and hence the quality & quantity of

associated water, viz-a-viz wastewater

• After pre-cleaning with appropriate chemicals, post additives to

“Processed Pulp” is made, like Fillers, Sizing agents, Fixing agents,

dry/wet strength agents, dyes, optical brighteners, coating chemicals,

retention aids to get final desired product

• Paper Machines with Fourdrinier system in Wet End

• Paper Machines with Cylinder Mould system in Wet End

22.01.2014 Partner for Sustainable Urban and Industrial Development

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Participating

Mills

Raw Material Mix Product Mix Paper M/C Details Specific Water

Consumed

(m3/T) Mill - 1 Local OCB (75%) & Core

(15%); h imported

Corrugated sheet (10%)

High GSM Kraft Board

(300-500); 60 TPD

Cylinder Mould; 55 to

100 Metrs/Minute;

Machine width 1730 mm

1.16

Mill – 2 Local OCB (85%), Core

(2%) and imported waste

paper (13%)

Kraft paper of GSM 80 to

180; 50 TPD

Fourdrinier; 75 to 180

metres/minute; Machine

width 2200 mm

1.42

Mill – 3 80% imported wastepaper

(NCC & NDL variety) and

20% virgin pulp

Paper M/c-1: Absorbent

Kraft of 50 TPD @ 100 to

150 GSM

Paper M/c-2: One Time

Carbon of 18 TPD @ 18 to

19 GSM

Fourdrinier ; 100 to 110

metres/minute; width

2550 mm

Paper M/c-2 at 300 to 320

metres/minute; width

2300 mm

3.3

Mill – 4 Local Newspaper,

Magazine and records 90%

and imported wastepaper

10%

Standard Newsprint @ 45

GSM of 150 TPD and

Writing & Printing paper @

45 to 100 GSM of 150 to

200 TPD in one Paper

Machine by dedication of

mix

Fourdrinier; speed as per

product variety; width

3750 mm

4.5 to 5

Mill – 5 Local wastepaper &

imported wastepaper

Kraft paper; 100 to 120 TPD

(expanding to 200 TPD); 50

to 350 GSM;

Fourdrinier; speed 130 to

300 metres/minute;

machine width 2500 mm

3.77

Mill – 6 Local OCB & Core (85%),

Core and imported waste

paper (15%)

Kraft paper; 50 TPD; 80 to

350 GSM


200 metres/minute;


1.52

Mill - 7 OCC local & Imported

variety, POY Tube; Paper

M/C Broke and trimmings

Kraft paper; 60 TPD; 120 to

220 GSM


250 metres/minute;


2.0

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Pre-cleaning

Hydro-Pulping

Pulp Chest

HD Cleaner

Vibro-Screen

Riffler

Centri-cleaner

Thickener

Refiner

Mixing Chest

Machine Chest

Post Cleaning - Options

Fan Pump

Head Box

Paper M/C Approach

* Wire Pit

* Couch Pit

* Press Roll

Drier Range

Packing

Waste paper

Typical

Process

Sequence

Case-1

22.01.2014 Seite 10

OVERALL MATERIAL & WATER BALANCE


Month, 2013 GIDC water

(KL)

Bore Well

(KL)

Production

(Tonnes)

Raw Material

Furnish

(Tonnes) March 711 905 1204 -

April 991 845 1284 1408

May 1034 846 1209 1261

June 797 743 1064 1226

July 848 460 1085 1305

Aug 935 413 777 939

Sept 876 444 1102 1342

Specific water

consumption

(cum/T)

1.34, 1.48, 1.56, 1.45, 1.20, 1.79 & 1.12 or average of 1.42; allowing 0.8

cum/T for drying loss, wastewater discharge is 0.62 cum/T

Overall yield

(Product/raw

material)

86 % ; thus the balance 14% is expected to be ETP sludge + plastic

waste + build-up in circulation water; Plastic waste account for 1.8%

(99% as Hydro-pulper float and balance from Turbo separator)

Check fresh water usage areas; circulating water quality for bio-fouling and solids balance

22.01.2014 Seite 11

Specific Electricity Consumption for 38 TPD production


Process

group

HP Load KWHr KWHr/M

T

Stock

Preparatio

n

374 303 3568 94

Refining 390 291 2946 78

Boiler 39 43 465 12

Re-winder 27 23 257 7

ETP 41 47 594 16

Others 43 39 263 7

Paper

Machine

460 337 4723 124

Total 1374 1083 12816 337

Energy conservation drives: VFD, Capacitor based on PF, Control over refining time etc

22.01.2014 Seite 12

FRESH WATER USAGE AREAS

•Edge cutter (continuous)

•Oscillating shower (intermittent); these 2 sources measured

@ 16 to 26 cum/hr

•Chemical preparation needs (stock solutions)

•Boiler water requirements via softener (Make-up water,

based on condensate recovery system)

•Domestic needs – directly proportional to number of

employees @ 25 to 30 Litre/Person/day


22.01.2014 Seite 13

BOILER WATER CONSUMPTION DETAILS

Month/2013 Softened water (KL) Boiler Feed water (KL)

March 235 2073

April 237 1941

May 277 1885

June 273 1730

July 299 1901

Aug 167 1382

Sept 160 (1648) 1946 (12858)

Percentage make-up 1648 X 100/12858 = 12.8%

Condensate recovery is about 77.2%, which can be

improved further

Drier condensate is still flashing and the temperature of Boiler Feed water is 97 to 98 Deg C


22.01.2014 Seite 14

KEY CIRCULATING WATER DEMANDING AREAS (apart from fresh water)

HYDRO-PULPER

Water required for Hydro-pulping @ 2.0% consistency for 50 TPD production assuming

overall yield as 86% is 145 cum/hr (50000/0.86 = 58139 Kg/day; water required for 2.0%

consistency is 2907 cum/day or 145 cum/hr for 20 hours of processing)

After thickener, the filtrate generation will be 75 cum/hr

PAPER MACHINE APPROACH SYSTEM

The pulp from Machine service chest @ 4% is taken to Paper M/C via Fan Pump after

post cleaning with a resultant consistency of 0.9 to 1.1% for paper formation. Thus water

circulation in paper machine approach system @ 1.1% pulp consistency for 50 TPD

production assuming overall yield as 86% is 145 cum/hr (50000/0.86 = 58139 Kg/day;

water required for 1.1 % consistency is 5285 cum/day or 240 cum/hr for 22 hours of

average production).

Hence water required for Hydro-pulper cannot be met from thickener filtrate

alone, but to be supplemented from paper machine approach system as well

High consistency Hydro-pulper can bridge this gap – the need has to be felt


22.01.2014 Seite 15

Thickener Filtrate Storage Tank = 50 cum and

distributed to

•To Hydro-Pulper directly by gravity flow

•10 HP pump discharge to Hydro-pulper

•12.5 HP pump discharge for Turbo separator screen wash

•2 HP pump discharge to High Density Cleaner dilution

•3 HP pump discharge to Drum Thickener shower

•Any surplus (as overflow) to ETP

Problems & Solutions: a) Storage capacity is low b) Filtrate

quality in terms of TSS is poor – SV site tested is 150 to 200

ml/litre !! c) too many pump operations ; Good “Fibre Recovery

Save All” or better thickener to leave least TSS in filtrate

required


22.01.2014 Seite 16

Wire part sump volume is about 15 cum and distributed

to following areas

•Fan Pump (major portion)

•Couch Pit for dilution

• Wire part overflow @ 18 to 20 cum/hr to ETP system, from where

recycled to a) Wire shower b) Side Hill screen grit dilution (post pulp purification

prior to Machine feed) c) Couch pit dilution and d) Wire Roll wash;

Problems & Solutions: a) No dedicated sump to FAN pump to close the

primary circuit b) Couch pit content is processed in side hill screen

thickener, whose SV site tested shows a TSS level of 150 to 200 ml/litre !!

c) Deckle guard is not in operation and hence edge cutter generates high

level of pulp loss;

Rectify Deckle guard and at-source reduction 100 Kg/hr possible; opt for

better thickener system for couch pit and close primary white water

circuit


22.01.2014 Seite 17

PRIMARY CLARIFIER SYSTEM

The ETP clarifier is of 10 m dia and volume of 200 cum is capable of handling a

maximum throughput of 95 cum/hr @ a surface loading of 1.2 cum/SQM/hr. For a

production of 50 TPD and at a consistency of 2.5%, the above discharge of 95

cum/hr would be equivalent to a specific discharge of 38 cum/T

The primary treatment system declared above is an integral part of “Fibre & White

water” recovery system

The under-flow of above is automatically dislodged into a sump and pumped back

to Hydro-pulper (no control over consistency and quality).

Problems & Solutions: a) Clarifier has no scum baffle, weir plate and under flow

control is via valve system (no precise control over volume) b) Storage system for

clarifier outlet is not dedicated c) too many pumps in operation;

Rectify auto-valve system to timer controlled pump operation; divert all surplus

flow, including thickener filtrate to Clarifier for overall “Fibre & Water Recovery”

and secure post storage system for centralised water distribution system.


22.01.2014 Seite 18

SECONDARY BIOLOGICAL TREATMENT SYSTEM

•Purged water of 10 to 30 cum/day is subjected to biological treatment, with

following steps (equivalent to specific discharge of 0.2 to 0.6 cum/T):

•Manual diversion of primary clarifier overflow to aeration tank of 200 cum capacity

•2 Nos Surface Aerator each connected to 5 HP Motor and reduction gear box

system to deliver required Oxygen for bio-process

•Aeration tank outflow is collected in a sump and pumped to a Lamella separator

system for solid/liquid separation (conceptual failure, as Lamella separator is meant

for poor settleable solids with TSS < 300 mg/l and not for an MLSS of 3000 to 3500

mg/l)

•The lamella separator overflow to main sump of primary effluent system for re-

circulation back in the loop.

•The excess bio sludge is periodically pumped to an adjoining 3 Nos sludge drying

bed.


22.01.2014 Seite 19

WASTEWATER TEST PARAMETERS

Parameters Clarifier Inlet Clarifier outlet Bio-outlet Test Data as part of GIZ study during 8-12 October, 2013

TSS, mg/l 3780 1170 -

TDS, mg/l 40756 40644 9268

TVS, mg/l 25684 19704 1784

COD, mg/l - 3025 988

Dec 21, 2009 Test data

COD, mg/l - 11415 1076

TSS, mg/l - 78 29

TDS, mg/l - 24720 5000

Nov 25, 2010

COD, mg/l - 22260 1509

TSS, mg/l - 108 54

TDS, mg/l - 41572 7092

Total Hardness, mg/l - 3026 -

Another Factory of same Group, making similar product tested during 8-12 October, 2013

TSS, mg/l 3850 1068 Samples not asked for

typical testing TDS, mg/l 68438 58020

TVS, mg/l 29160 26420

COD, mg/l - 32129


TDS reduction is not expected in bio-process; anaerobic followed by aerobic

system required

22.01.2014 Seite 20

ADEQUACY ASSESSMENT OF BIO-PROCESS

Design flow rate = 30 cum/day

Design COD value = 25000 mg/l

Calculated BOD value = 10000 mg/l

Ideally an anaerobic followed by aerobic system is strongly recommended for

BOD beyond 4000 mg/l (Oxygen supply limitation)

Aeration Tank volume = (Flow X BODr)/(F/M * MLSS)

= (30 X 9.6)/0.1 X 3.5 = 823 cum

Volume provided is 200 cum

Oxygen required is @ 1.6 Kg/Kg BOD; this is also not supported

Alternatively, Bio-gas potential for 85% COD removal in UASB system would

be 319 cum/day ( @ 0.5 cum Bio Gas/Kg COD X 30 X 25 X0.85 = 319 cum/day)


22.01.2014 Seite 21

Test Data of Mill carrying out continuous wastewater discharge @ 2.5 to 3 cum/T

(No biological treatment system exists as of now)


Continuous purge from circulating loop at 2.5 to 3 cum/T is reducing the

wastewater treatment burden and improves the overall in-process controls in

terms of product quality

Parameters Synthetic Sample

(Feed to Hydro-

pulper)*

Thickener

Filtrate

ETP Inlet ETP Outlet

TDS, mg/l 1100 3870 3024 3160

TSS, mg/l 80 670 620 300

TVS, mg/l 644 2484 1784 1712

COD, mg/l 1020 5586 3481 3562

Dewatered sludge analysis (Centrifuge system)

Moisture, % 70.11

Bulk Density, gm/cc 0.8674

Ash content of solids portion, % 8.09

Calorific value, Kcals/Kg (On Dry Solids

basis)

3193

22.01.2014 Seite 22

NEAR CLOSING WATER LOOP: REPORTED PROBLEMS

Bio-fouling

Purge of effluent via secondary biological treatment

system

Increased consumption of process chemicals like

Alum, Rosin, Retention aids, Anti-foaming

chemicals and Fungicide

Frequent cleaning of : a) M/C once a day b) Fixed

shower once a week c) Oscillating shower once a

month and d) Felt cleaning once a week


22.01.2014 Seite 23

NATURE OF CHEMICAL & TYPE CONSUMED

Specific consumption of liquid Alum is 60 Kg/T and

dosed manually to the Chest

Specific consumption of Rosin is 7 Kg/T and dosed

manually to the chest

Retention aid chemical is prepared for a stock

concentration of 15 Grams/Litre and dosed using

metering pump; specific consumption is 0.5 Kg/T

Fungicide is prepared and manually dosed at inlet

& outlet of ETP clarifier once a week @ 10 Kg/Week;

Anti-foaming chemical is consumed at 1 to 2 Kg/T


22.01.2014 Seite 24

PROFILE OF MOISTURE REMOVED ACROSS SYSTEM

Wire part outlet @ 72%

Press stage 1 outlet @ 60%



Or Inlet to Drier @ 50%

Final moisture @ 6% to 8%

Evaporation for 50 TPD production = 44% or 22 cum/50 T or

0.44 cum/T

@ TDS of 40,000 mg/l & COD of 25000 mg/l, residue deposited

on paper due to evaporation is 17.6 Kg/T (1.76%) & 11 Kg/T

(1.1%) respectively


22.01.2014 Seite 25

OTHER SIGNIFICANT ISSUES

Total Driers 12 Nos, each of 6 feet dia; The ends are not

insulated. The total surface area for insulation is about 253

SQM. So energy saving potential is good

The Vibro-screen installed for processing the Turbo separator

reject is not working and resorted to manual method for

picking-up plastic residues (Crude handling, with associated

process downtime). Lack of hardware, which again cascades

in water loop system

Machine Broke and Trimmings from wide paper width to

required size are re-processed via Hydro-pulper, as against

“Dedicated Broke Pulper” and direct mixing in to

Machine Chest


22.01.2014 Seite 26

REGIONAL PERSPECTIVE - IS THERE POLICY DRIVE

FOR EXTERNAL RECYCLE?

Membership is based on GIDC water consumption declaration and share

capital is levied @ Rs 20/KL for capital Investment

Operational charges are based on actual discharge. If there is no discharge,

then minimum fee is levied on the basis of consented discharge @ Rs

11.5/KL

Supplementary charges are levied, based on Team’s Monitoring report &

assessment. For every incremental increase in COD of 500 mg/l beyond CETP

norm of 1000 mg/l, penalty is levied @ Rs 5/KL; No COD beyond 5000 mg/l is

permitted in any case (Maximum penalty of Rs 40/KL).

The CETP has 740 members as of today; out of which 30 are Pulp & paper

Mills

The design flow rate or base volume contribution by Pulp & paper Mills is

13300 cum/day; the CETP design volume is 55000 cum/day; against this, the

current contribution of effluent volume to CETP by Pulp & paper Mills is not

known (to be taken from Corporate Office of VWEMCL)


22.01.2014 Seite 27

CETP Performance Values Versus Pre-Treatment Norm

& Circulation Water Quality

PARAMETERS CETP AVERAGE

PERFORMANCE DATA

PRE-TREATMENT

NORMS TO MEMBERS

pH 6.5- 8.5 6.5-8.5

Temperature, Deg C - < 40

TSS, mg/l 185 300

Oil & Grease, mg/l - 10

Sulphides, mg/l - 2

BOD, mg/l 99 400

COD, mg/l 556 1000

Cl, mg/l 3000-4000 600

SO4,mg/l 1700-2100 1000

TDS, mg/l 7000-8000 2100

Colour, Co-Pt unit 1000 -

22.01.2014 Seite 28

PULP & PAPER MILL IMPROVEMENT IS A REGIONAL ISSUE

Since Pulp & Paper Mills are connected to CETP (or any way Members and follow regulatory

requirements), following are to be futuristic factors to be considered:

a) Will GIDC be able supply the required quantity of fresh water to Members, keeping in

view increasing demand for other sectors in future (Human, commercial, agricultural

etc)?

b) Is the current CETP operating cost passed on to “Individual Members” fully or there is

likely to be increased liability cost?

c) The CETP performance characteristics are better than the “Circulating water Quality of

Pulp & Paper Mills” and so can there be a push to promote regional water recycling

(Treated CETP back to member units; and Member Units in turn opt for better

consumption without compromising on product quality)

d) If on-site “Environmental Residue Management (Water, Air, Solid wastes) is feasible for

Pulp & Paper Mills, will there be a changed legal scenario (on-site versus CETP logic)

and if so what will be the risk scenario?

e) The tendency of “CETP” getting into “Water Recovery Plants” is high through Techno-

legal maturity across India. If so possibility of Pulp & paper sector drawing treated water

from CETP will be high


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TYPICAL SUSTAINABLE IMPLEMENTATION OPTIONS

• Input Substitutions: Extent of virgin pulp usage, use of non-toxic

dyes, better retention aids for fines agglomeration etc

• On-site recovery: Whitewater looping linked with process

• Equipment modifications: Install efficient showers, have a dedicated

broke pulper, review Paper machine approach system for enhanced

white water & fibre recovery

• Technology Changes: Review consistency handled in Hydro-pulper

and opt for right choice, review preparation & dosing system of

various chemicals and modernize; Save-all systems like DAF,

Screens, MF etc not exploited/contemplated

• Better process control: Explore hot refining, install consistency

controller/regulator, high solids sludge dewatering etc

• House-keeping: Introduce “LDAR” for water & pulp, inspect

periodically steam traps, check various water showers for its integrity

22.01.2014


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TYPICAL IMPACT OF POLLUTION CONCENTRATION WITH

INTENSIFIED WATER LOOPING

22.01.2014


S.NO PARAMETER FOR 770 KLD

SITUATION (FOR 30

TPD UNIT = 25.7

CUM/T)

ESTIMATED

CONCENTRATION OF

VARIOUS POLLUTANTS IN

192 KLD (75% RE-

CIRCULATION= 6.4 CUM/T)*

1. Flow Rate, cum/day 770 KLD LINEAR

CONSUMPTION

192 (578 circulating + 192 make-

up)

1. Color Brownish Intensive brownish

2. Odor Acidic Expected to be more

3. PH 6.6 Organic acidity

4. Conductivity 3285 µmhos/cm 4 times

5. TS 5700 mg/l 22859 mg/l

6. TSS 3000 mg/l 12031 mg/l

7 TDS (TS-TSS) 2700 mg/l 10828 mg/l

8. Chlorides 355 mg/l 1424 mg/l

9. Sulphates 860 mg/l 3449 mg/l

10. BOD 1000 mg/l 4047 mg/l

11. COD 2100 mg/l 8422 mg/l

12. TOC 1600 mg/l 6417 mg/l

Page 31

TYPICAL GLOBAL SCENARIO OF SPECIFIC WATER CONSUMPTION

22.01.2014


Process/Product category Specific Consumption of water (m3/T)*

Uncoated folding box board 2 to 10

Coated folding box board 7 to 15

Corrugated Medium & packaging Paper 1.5 to 10

Newsprint 10 to 20

Tissue 5 to 100

Writing & Printing 7 to 20

* About 1 to 1.25 m3 water per tonne of paper is vaporised in the dryer section of the

paper machine i.e. do not appear as wastewater

Page 32

TYPICAL FIBRE RECOVERY TECHNOLOGIES

22.01.2014


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SOME ELECTRO-CHEMICAL ROUTE OF TREATMENT

• Electroplating/Metal Finishing

• Paper Mills (speciality and 100% waste paper)

• Textile decolourising

• Lacquer/Paint Industries

• Print shops, Photography, Cine films

• Photo-Oxidation for Refinery wastewater recycling applications

• Etc

22.01.2014


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SOME ELECTRO-CHEMICAL ROUTE OF TREATMENT

• In the KLOSE CLEROX SYSTEM (KCS process), the wastewater after pH adjustment (if required) is passed through Iron & Aluminium Electrodes, which impart:

• Oxidation: O2 released due to electrolysis promote in-situ Oxidation, metal precipitation etc

• Flotation: The Hydrogen developed at the other electrode will raise bubbles, thereby promoting in-situ Electro-flotation

• Complex Formation: Depending on residual organic types, Organo-metallic complex is formed

22.01.2014


Page 38 22.01.2014


WWTP OPTIONS COST RANGE (in

EUR/KL)

Transfer to

Landfill/CETP

50 to 250

Evaporation 15 to 25

Evaporation with heat

recovery

5 to 15

Salt split with

centrifuge

4 to 12.5

Chemical split 5 to 15

Acid split 5 to 12.5

Ultra-filtration 3.5 to 15

Electro-floatation (KCS) 1 to 5

Page 39

WHAT NEEDS TO BE DONE?

• For all the 12 Participating Units, following key specific data to be

evolved through “Consultancy-cum-Training” mode of project

study:

• - Recovered paper consumption or “Yield” for a given RM Furnish

- Water use Mapping (Water Balance)

- Use of additives and consumption profile

- Energy Consumption profile

- Wastewater load and regulatory issues

- Process related Solid waste profile

- Solid Waste Management issues and opportunities

- Specific consumption profile of various Chemicals and “Best

Norm”

22.01.2014


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• SI Team, Facilitating Team and Steering Committee will secure the

following:

- Short Term implementable schemes : By respective Units through

“Competitive Spirit”

- Medium Term implementable schemes: By respective Units through

select vendor participation and part external funding

- Long Term implementable schemes: Need to conclude on select

schemes, extent of external assistance, but having “Game Changer”

role in achieving high level of Pollution reduction or Resource Use

Efficiency

• The Regulatory issues have to be examined and “Participatory

Approach” followed in evolving possible remedy.

22.01.2014


Page 41

• The flow meters are available for softener production, combined

soft water & condensate feed to boiler, bore well water and GIDC

supply

• Re-circulation water from clarifier overflow to process is governed

by an Electro-magnetic flow meter. The Clarifier outlet is allowed

to flow by gravity via a side hill screen and to a sump. A dedicated

pump is available to divert required purge effluent to biological

treatment; there is also another dedicated pump, with feed line via

magnetic flow meter and bye-pass line to ETP main sump

• The treated effluent via Electro-magnetic flow meter is recycled to

a) Wire shower b) Side Hill screen grit dilution (post pulp

purification prior to Machine feed) c) Couch pit dilution and d)

Wire Roll wash;

22.01.2014


We thank the Mill Management Team for having cooperated to get the

following on-site flow measurement to arrive at above conclusions:

Page 42

• Electro-magnetic flow meter reading has been 29.6 cum/hr, 30.6 cum/hr and 32.2

cum/hr

• Couch pit dilution water is at 1.9 cum/hr, 2 cum/hr and 2.6 cum/hr (average 2.2

cum/hr)

• Side hill screen grit dilution water flow rate 1.8 to 2 cum/hr

• Based on above, the fixed shower flow rate is at 16 to 26 cum/hr

• Sludge volume of Thickener filtrate is 150 to 200 ml/litre; also same level for couch

pit filtrate after side hill screen thickening

• The bye-pass flow measured in the range 5.8 to 8.6 cum/hr (No Equalization Tank and

pumping hours not matching with inflow; Submersible pump is better for energy

efficiency);

• Wire part overflow constantly getting discharged into effluent drain has been

measured @ 17.5 cum/hr, 20.2 cum/hr and 18.2 cum/hr

• The extent of edge cutter waste : 0.2032 m (8 Inch) X 36 metre = 7.32 SQM X 100 GSM

= 732 grams X (170 metre/min/36) X 60 = 207 Kg/hr. This can be reduced by 50% by

proper installation of Deckle Guard

22.01.2014


Page 43 22.01.2014


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