Summary of Project Based on EnvironmEnt FriEndly technologies


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Summary of Project Based on EnvironmEnt FriEndly technologies in
PulP and PaPer Industry at Vapi

OBJECTIVE:
The main objective of this study is to conduct a waste audit in a paper mill and develop new technological options in existing process. The specific objectives are:
a) To carry out a material balance for each of the unit production processes; b) To determine the possibilities for closing the water cycles in order to reduce the
discharges and emissions; c) To determine the possibilities of recovery and re-use of fibre from the waste streams; d) To implement cleaner production technologies; e) To improve its energy management strategies; f) To prepare a plan for unit to achieve zero liquid discharge.
SCOPE AND LIMITATIONS:
This study was carried out in the pulp and paper industries at vapi, which manufactures paper and board. The main focus of this research study is to find out how to reduce the Prevailing ground water extraction, minimize waste generation and utilization of wastes as a by-product to the extent possible i.e., Recycle, Recover, Reuse, Reduce, while keeping the production at the same quantity. The study will basically involve material balance, particularly the fibre and water balance. Consistency balance is another important parameter. However, this is difficult to measure in the absence of costly instrumentation. The results of this study will specifically be beneficial to Pulp and Paper Industries at Vapi. However, this research will be helpful to replicate other paper mills for cleaner production technologies.

METHODOLOGY OF INVESTIGATION:
CURRENT STATUS OF WASTE PAPER UTILIZATION IN VAPI SECTOR: The RCF/ WP as a raw material is best suited for following end products –
 Newsprint  Duplex board  Kraft paper/Test liner

WASTE PAPER UTILISATION AND PRODUCTION IN VARIOUS INDUSTRIES AT VAPI:

Name of the Industry

Type of Raw Material

Name of Product

Raw material Consumption in Consistency &

tonne / tonne of product

Types of Pulper

Ruby Macons Purchased Pulp Test Liner paper/ 1.1 tonne waste paper

1 %

Ltd.

from ind. And Kraft Paper (HSN

imported

Code 4805)

Avg. Production Capacity (t/day)
250 tonne/day

Yield 90 %

Shah Pulp & Paper Mills Ltd.

Indigenous imported paper

& waste

Newsprint & Writing paper

1.25 tonne waste paper

17 % Hydro Type

Rama Pulp and Paper

Imported Kraft Paper, Waste & news paper waste

OTC (One Time Carbon) (18 GSM, 20-25 Micron Size) & ‘A’ Grade Kraft Paper 150 GSM

PM 1 : 44.2 tonne/day (1.052 tonne/tonne of product) PM 2 : 16.67 tonne/day (1.041 tonne/tone of product)

PM 1 : 2.5% (ATS Pulper) PM 2 : 6 %

Rama NewsPrint

ONP,

OMG,

White record,

News &Pumps,

share forms & Mix

papers

News print paper

PM 1: 1.075 tonne/tonne of product PM 2 : 1.087 tonne/tonne of product

PM 1 : 2.7 % PM 2 : 5.2 %

Gayatri Shakti P Indigenous waste Duplex Board (4 1.1 tonne/tonne of product

4 %

& B Ltd

paper

Layer)

92 - 94 tonne/day 85 %

PM 1 : tonne/day PM 2 : tonne/day

42 PM 1 : 95 % PM 2 : 96 %
16

228 tonne/day

PM 1 : 93 % PM 2 : 92%

14 tonne/day

91%

Kwality Pulp Waste Paper and Paper Mill

M.G. Kraft Paper

1.044 tonne/tonne of product

Craft Pulp and Waste Paper Paper Mill

M.G. Kraft Paper

1.098 tonne/tonne of product

Damanganga Waste Paper Board Mills Pvt. Ltd.

Kraft Board (4 layer) 1.136 tonne/tone of product

R.A.Shaikh

Waste Paper

Paper Mills Pvt.

Ltd.

M.G. Kraft Paper

1.059 tonne/tone of product

Aryan Pulp and Imported Kraft

Paper Mill

paper Waste

M.G. Kraft Paper 1.11 tonne/tone of product (150 GSM)

Indian Kraft Paper Waste

Old corrugated cartoon, New Kraft corrugated cutting, New corrugated cutting

1- 2 % 1 - 2% 2.5 % 2 – 2.5 % 2.5 %

29 tonne/day
48 tonne/day
52 tonne/day
80 tonne/day

95.78 % 91.07 % 88 - 90 %
93 – 94 %

90 tonne/day

90 %

Production Detail

% Yield

Avg. Production

400

(t/D)

350

300

250

200

150

100

50

0

1.3 1.25
1.2 1.15
1.1 1.05
1 0.95
0.9

Pulp and Paper Industries In Vapi
Waste Paper Utilisation

Waste Paper (t)/(t) of Product

Pulp & Paper Industries In Vapi

WATER CONSUMPTION IN VARIOUS INDUSTRIES AT VAPI:

Name of the Industry

Water Usage in Process (m3/day)

Total Water Consumption (m3/day)

Shah Pulp & Paper

540

606

Mills Ltd

(4.1 m3/tonne of product)

Gayatri

Shakti

Paper & Board Ltd

1573

1656

Damanganga Board

30

75

Mills Pvt. Ltd.

(1.4 to 1.5 m3/tonne of product))

Ruby Macons Ltd
Craft Corner Paper Mills Ltd.
Kwality Pulp & Paper Mills
Rama Pulp and Paper Ltd.
Rama NewsPrint

(1.5 to 2 m3/tonne of product) (1.6 m3/tonne of product)
(1.7 m3/tonne of product)
(2.32 m3/tonne of product)
6406 (29.6 m3/MT)

500 97
77
135
6945 (32 m3/MT)

Total Waste Water Generated (m3/day)
296 (127 m3/day goes to CETP)
1089
10 – 15 [After treatment water is used
for gardening] (Zero Discharge)
(Zero Discharge)
(Zero Discharge)
Zero Discharge
N.A.

Aryan Pulp and Paper Mill
R.A.Shaikh Paper Mills Pvt. Ltd.

(5.82 m3/tonne of product) 2.2 m3/tonne of product)

413 225.2

Zero Discharge
50 m3/day goes to CETP

Gayatrishakti Rama…
Rama paper R.A.Shaikh Craft Kwality Aryan
Damanganga Ruby Macons
Shah
0

Water Consumption

Water Consumption (m3/tonne of product)

10

20

30

40

Gayatrishakti Rama…
Rama paper R.A.Shaikh Craft Kwality Aryan
Damanganga Ruby Macons
Shah
0

Total Water Consumption

Water Consumption (m3/Day)

2000

4000

6000

8000

ELECTRICITY/ENERGY CONSUMPTION IN VARIOUS INDUSTRIES AT VAPI:

Name of the Industry

Avg. Energy Consumption (KWH/MT of
Product)

Shah Pulp & Paper Mills Ltd

535.44

Craft Corner

335

Paper Mills Ltd.

Kwality Pulp &

360

Paper Mills

Rama Newsprint

222

Avg. Energy Consumption in
process (KWH/month)

Avg. Energy Consumption in
ETP (KWH/month)

Total Energy Consumption in Process +
ETP (KWH/month)

Remark

750353

47535

797888

Avg.Unit generated by turbine 92158 KWH/month and by G.G.Set 663221 KWH/month

457350

14400

471750

261975

8700

270675

258850

5 KWH/tonne consumed

Rama Pulp & Paper
Aryan Paper Mill

984540

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Summary of Project Based on EnvironmEnt FriEndly technologies