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Tamil Nadu Newsprint and Papers Ltd.
Green Manufacturing Practices: TNPL Case Study on Value Addition to Waste Author :S. Chinnaraj,
Co-authors :T. Vijayakumar, M.Senthil Kumar and S. V. Subrahmanyam
Research and Development Division, Tamil Nadu Newsprint and Papers Ltd. Kagithapuram, Karur Dt, Tamil Nadu -639136INDIA
Tamil Nadu Newsprint and Papers Ltd.
Introduction
1. TNPL – Briefly…2. Value Addition to Bagasse as
Paper Making Raw-material
3. Value Addition to Solid Waste 4. Value Addition to Liquid
Waste
Tamil Nadu Newsprint and Papers Ltd.
TNPL – Briefly… Promoted by Govt. of Tamil Nadu in early 80’s World’s largest bagasse based paper plant at single location Presently produces 4,00,000 MT of PWP annually, Largest
exporter of PWP from the country ISO 14001:2004, ISO 9001:2008 and FSC FM/COC & CW/COC
Certified Uses one million MT of Bagasse every year and Installed Wind
Power Capacity 35.5 MW Treated effluent water is pumped to TEWLIS consisting 430
farmers with 1660 acres. 25,000 m3/day biogas generated from bagasse wash water
and used in Lime kiln resulting 15 KL F. Oil saving 1.00 Lakh acres Pulp wood plantation since 2004 involving
more than 17,000 farmers Four registered CDM project reduces 2.1 Lakh MT CO2
emission
Tamil Nadu Newsprint and Papers Ltd.
TNPL – Briefly…
Installed 600 TPD mini cement plant under Lime Sludge and Fly Ash management
Commissioned 3 loop 2 disperser 300 TPD deinked plant to conserve fiber
Revamping steam and power system (RSPS) to augment in-house power generation from 81.12 MW to 103.62 and to reduce CO2 emission of 50,000 TPA
200 TPD Precipitated Calcium Carbonate (PCC) Plant and 120 TPD Wet Ground Calcium Carbonate (WGCC) Plant
Largest exporter of PWP in the country 2.00 lakh per annum green field project : TNPL UNIT II
to produce multilayer paper board
Tamil Nadu Newsprint and Papers Ltd.
1. TNPL is credited with unique innovation of waste to wealth.
2. TNPL uses about one million tones of bagasse every year instead of wood thereby avoiding felling of tress around 52,000 acres of forest land every year.
3. Value addition to sugarcane waste (bagasse) through pulp & paper production and effective utilization of biomass waste viz. residual sugars, bagasse pith and Black liquor, for bio-energy generation.
Value addition to Bagasse
Tamil Nadu Newsprint and Papers Ltd.
Moisture52%
Moisture52%
Dry Weight48%
Dry Weight48%
3%3%
Fibre31%
Fibre31%
14%14%
4%4%
13%13%
14%14%
Residual sugar-Biogas
Residual sugar-Biogas
Pith- BiofuelPith- Biofuel
LossLoss
Black liquor solids- bio fuel
Black liquor solids- bio fuel
Bleached Pulp - Paper
Bleached Pulp - Paper
Bagasse
Value Addition to Bagasse
Tamil Nadu Newsprint and Papers Ltd.
Wood Saved by Usage of Bagasse
Year Bagasse Pulp Produced in MT
Equivalent Wood Conserved in MT
2011-12 1,65,914 7,30,056
2012-13 1,70,632 7,09,786
2013-14 1,57,898 6,78,909
Tamil Nadu Newsprint and Papers Ltd.
Quantity of In-organics Solid Wastes Generation
S. No Parameter Unit 2011-12 2012-13 2013-14
1 Fly ash MT 45,806 36,618 43,205
2 Wet ash MT 19,824 11,522 14,356
3 Lime sludge MT 2,91,645 2,94,587 3,02,644
4 Lime grits MT 4,204 3,973 3,834
Tamil Nadu Newsprint and Papers Ltd.
Quantity of Organics Solid Wastes Generation
S. No Parameter Unit 2011-12 2012-13 2013-14
1 Bagasse pith from Pulp Mill MT 98,036 82,816 87,053
2 Dust from Chipper House MT 2,257 9,129 9,078
3 ETP Primary Sludge MT 70,686 68,241 53,362
4 ETP Secondary sludge MT 3,755 4,817 5,501
Tamil Nadu Newsprint and Papers Ltd.
Properties of solid wastes
S. No Description Major constituents (on OD basis)
1 Fly Ash Ash: 88 - 92%, LOI: 8 to 12%
2 Wet Ash Ash : 90-95 % , LOI : 3 to 5%
3Lime Sludge (Moisture:45 to 50%)
Acid insolubles: 6-7%, Silica as SiO2: 6% Mixed Oxides (R2O3): 1% Calcium as CaCO3: 88 - 90% Magnesium as MgCO3:1 – 1.5% Free CaO: 0.8 , Sodium as Na2O: 18%
Tamil Nadu Newsprint and Papers Ltd.
Properties of solid wastes
S. No Description Major constituents (on OD basis)
4Lime grits (Moisture: 25 to 30%)
Acid in-solubles: 6- 7% , Silica as SiO2: 6-7% Mixed Oxides (R2O3): 3.1% Calcium as CaCO3: 85 - 88% Magnesium as MgCO3:3% Free CaO: 1.% , Sodium as Na2O: 1.8%
5Bagasse Pith (Moisture:45-50%)
GCV: 4000 -4200 Kcal/kg , Ash: 9% Volatile matter: 72% , Fixed carbon:13%
Tamil Nadu Newsprint and Papers Ltd.
Properties of solid wastes
S. No Description Major constituents (on OD
basis)
6 Dust from Chipper house (Moisture: 25-30%)
GCV: 4000-4600 Kcal/kg, Ash: 2.4% Volatile matter: 72% , Fixed carbon:19%
7 ETP primary sludge (Moisture:75-80%)
GCV: 2300-2700 Kcal/kg Organics: 60-70% , Inorganics:30-40%
8 ETP Secondary sludge (Moisture: 83-85%)
GCV: 2500-3000 Kcal/kg Organics: 60-70% , Inorganics:30-40%
Tamil Nadu Newsprint and Papers Ltd.
Quantity of Solid Wastes Recycled or used
S. No Parameter Unit 2011-
12 2012-13 2013-14
1 Lime sludge: re-burnt in lime kiln MT 1,80,173 1,82,571 1,82,810
2 Chipper dust used as fuel in boiler MT 2,257 9,129 9,078
3 Bagasse pith used as fuel in boiler MT 98,036 82,816 87,053
Tamil Nadu Newsprint and Papers Ltd.
GHG Emission Reduction Due to Lime Sludge Re-burning In 2013-14
S. No Parameter Unit Value
1 Burnt Lime production MT 1,01,351 2 Reuse of Lime sludge MT 1,82,810 3 Lime Stone Conserved MT 1,69,340 4 GHG emission reduction due to logistic
reduction of lime sludge t CO2 e 1,371
5 GHG emission reduction due to burning of Lime Sludge in kilns
t CO2 e 80,436
6 Total GHG emission reduction t CO2 e 81,807
Tamil Nadu Newsprint and Papers Ltd.
LSFM : Cement plant
Lime sludge from SRP 200 T/day
Fly Ash from Energy
boilers 100 T/day
Capital Outlay Rs 100 Cr
Capacity : 600 Tons/ day
Lime stone
On going Expansion Capacity : 900 Tons/ day
Tamil Nadu Newsprint and Papers Ltd.
Environmental benefits of Lime Sludge & Fly ash Management (LSFM) system
Parameter Unit Value
Pozzalana Portland Cement MT 1,13,904Solid waste elimination due to reuse of Lime sludge MT 62,631Solid waste elimination due to reuse of Fly ash MT 17,010Lime Stone Conserved MT 73,487GHG emission reduction due to lime stone conservation MT 32,334GHG emission reduction due to logistic reduction of lime
sludgetCO2 e 470
GHG emission reduction due to logistic reduction of fly ash tCO2 e 156
Total GHG emission reduction due to LSFM tCO2 e 32,960
Tamil Nadu Newsprint and Papers Ltd.
Inorganic Solid Waste Used MT/annum for Production of Cement
Lime sludge Lime grits Fly ash0
10000
20000
30000
40000
50000
60000
70000
2012-13 2013-14
Tamil Nadu Newsprint and Papers Ltd.
Reduction In Quantity of Solid Wastes Disposed MT/annum
Lime sludge Lime grits Fly ash0
20000
40000
60000
80000
100000
120000
2011-12 2012-13 2013-14
Tamil Nadu Newsprint and Papers Ltd.
GHG Emission Reduction Due to CO2 Sequestration Through PCC
S. No Parameter Unit Value1 Precipitated Calcium
Carbonate per annumMT 50,000
2 GHG emission reduction per annum
t CO2 e 22,000
Tamil Nadu Newsprint and Papers Ltd.
Energy Generation and GHG Emission Redun. by Utilization of Organic Waste as Fuel
S. No Parameter Unit 2011-12 2012-13 2013-14
1 Chipper dust MT 2,257 9,129 9,078
2 Bagasse Pith MT 98,036 82,816 87,053
3 Thermal energy generated GJ 7,53,910 6,86,727 7,18,284
4GHG emission reduction
t CO2 e 73,849 67,248 70,359
Tamil Nadu Newsprint and Papers Ltd.
Economical and Environmental Benefits of Kitchen Waste Biogas Plant.
S. No Parameter Unit Value
1 Organic solid waste utilized from canteen /day Kg 160
2 Organic solid waste utilized from guest house /day kg 60
3 Total organic solid waste utilized from tnpl per day kg 220
4 Emission reduction /annum by avoidance of CH4 t CO2e 7.6
5 Volume of biogas used in the heating equipment / day
m3 20
6 Emissions reduction by fossil fuel displaced /annum
t CO2e 10.4
7 Emission reduction /annum t CO2e 18.0
8 Savings /annum Rs in lakh 2.0
Tamil Nadu Newsprint and Papers Ltd.
Quantity of Wastes Disposed to Other Industries
S. No Parameter Unit 2011-12 2012-13 2013-14
1 Lime sludge MT 1,11,472 82,180 57,203
2 Lime grits MT 4204 3973 0
3 Fly ash MT 45,806 35,028 26,195
4 Wet ash MT 19,824 11,522 14,356
Tamil Nadu Newsprint and Papers Ltd.
Properties Of Wastewater Generated
S. No Parameter Unit High BOD Stream
Low BOD Stream
1 pH 4.5 7.0
2 BOD5 ppm 4000(max) 600(max)
3 COD ppm 6000(max) 1200(max)
4 Total Suspended Solids ppm 7000(max) 1000(max)
5 Total Dissolved Solids ppm 3500(max) 1800(max)
6 Color, Pt. Co units ppm 300 350
Tamil Nadu Newsprint and Papers Ltd.
Sold for Secondary use:Moulded- fibre products,
Fibre-boards, etc.
Wastewater fromPulp Mills & Paper
Machines
On-Land Discharge(for Irrigation)
Cooling Tower
Manual Bar Screen
Activated Sludge Basin
Primary Clarifier
Sludge Thickener
Secondary Clarifier
Ozone Treatment
DecanterSun Drying
Burnt in Mill Boilers(mixed with pith)
Wastewater fromBagasse storage,
Reclaim & Washing
Anaerobic
LagoonUASB
ReactorBuffer Tank
Neutralisation Tank
EqualisationTank
Bagasse Clarifier
Mechanical Bar Screen
Vac. Belt Filters
Vac. Belt Filters
Sun DryingMill Boilers
Tertiary Treatment
Liquid Waste Management
Tamil Nadu Newsprint and Papers Ltd.
Bio-methanation: Environmental and Economic Benefits
Particulars Units 2011-12 2012-13 2013-14
COD Treated MT / Yr 22,127 24,443 21,577COD Reduced MT / Yr 18,847 21,008 18,917Biogas generation MM3 / Yr 8.73 101.33 9.66Furnace oil saving KL / Yr 5,241 6,080 5,798GHG reduction from CH4 avoidance MT CO2e 98,023 1,13,710 1,08,888GHG reduction from Furnace Oil saving MT CO2e 17,016 19,740 19,039
Total GHG reduction MT CO2e 1,15,039 1,33,450 1,27,928Revenue from Furnace Oil Saving
Rs. (in Million) 181.8 241.9 265.9
Tamil Nadu Newsprint and Papers Ltd.
Properties Of Treated Wastewater
S. No Parameter UnitTNPCB Norms
TNPL Results
1. pH No. 5.5 – 9.0 7.5 – 8.02. BOD5 ppm 30 10-133. COD ppm 250 150 - 2004. Total Suspended Solids ppm 100 45 - 50
5. Total Dissolved Solids (in organics) ppm 2,100 1,400-1,600
6. Color, Pt.co units ppm - 230-2607. AOX Kg/T 1.0 <0.1
Tamil Nadu Newsprint and Papers Ltd.
Pollution Load per DayAp
r-07
Jul-0
7O
ct-0
7Ja
n-08
Apr-
08Ju
l-08
Oct
-08
Jan-
09Ap
r-09
Jul-0
9O
ct-0
9Ja
n-10
Apr-
10Ju
l-10
Oct
-10
Jan-
11Ap
r-11
Jul-1
1O
ct-1
1Ja
n-12
Apr-
12Ju
l-12
Oct
-12
Jan-
13Ap
r-13
Jul-1
3O
ct-1
3Ja
n-14
Apr-
14Ju
l-14
Oct
-14
Jan-
15
0
2
4
6
8
10
12
14 11.9
5.2
0.2 0.4
2.71.0
COD BOD SS
MT
per D
ay
Tamil Nadu Newsprint and Papers Ltd.
Specific Pollution Load per MT of Paper
Apr-
07Ju
l-07
Oct
-07
Jan-
08Ap
r-08
Jul-0
8O
ct-0
8Ja
n-09
Apr-
09Ju
l-09
Oct
-09
Jan-
10Ap
r-10
Jul-1
0O
ct-1
0Ja
n-11
Apr-
11Ju
l-11
Oct
-11
Jan-
12Ap
r-12
Jul-1
2O
ct-1
2Ja
n-13
Apr-
13Ju
l-13
Oct
-13
Jan-
14Ap
r-14
Jul-1
4O
ct-1
4Ja
n-15
02468
101214161820
17.5
4.54.0
0.90.77 0.10
COD BOD SS AOX
Kg/M
T of
Pap
er
Tamil Nadu Newsprint and Papers Ltd.
Recycling Paper Machine Effluent After Clarification
Parameter Unit Paper machine effluent
Colour Pt Co 100- 120 Total Solids ppm 1000-1200 Total Dissolved Solids ppm 700 - 900 COD ppm 221 Chlorides as Cl ppm 200
Tamil Nadu Newsprint and Papers Ltd.
Recycling Paper Machine Effluent After Clarification
Fresh water
Paper machine wastewater
ETP
Legend: Before Project After Project
Fresh water saving : 3000m3/day
Clarifier
Bagasse storage & washing
ETP
Tamil Nadu Newsprint and Papers Ltd.
Recycling of Eop Filtrate in Chemical Bagasse Bleaching
Parameter Unit ValueReduction water consumption m3/day 1300
Reduction in effluent discharge volume m3/day 1300
Reduction of solids to effluent MT/day 3.25
Reduction of sodium discharge to Effluent Treatment Plant
MT/day 3
Reduction in hydraulic load m3/day 1300
LP steam reduction MT/day 45
Emission reduction per annum t CO2e 4182
Savings per annum due to Energy conservation
Rs in lakh 118
Fibre recovered per annum MT 1072
Savings per annum due to Fibre recovery Rs in lakh 250
Total Savings per annum Rs in lakh 368
Tamil Nadu Newsprint and Papers Ltd.
Liquid Waste ManagementUtilization of Treated Wastewater For Irrigation
Prior to TEWLIS Irrigation Treated Effluent Discharge
Water Cisterns provided in TEWLIS Irrigated Land
View of TEWLIS Irrigated Lands
Tamil Nadu Newsprint and Papers Ltd.
Impact of Wastewater Irrigation
Wastewater irrigated area (monitored by
TNAU)
Dry lands Non -irrigated area
TNPL
River bed area