Paper Tech 2008 Seminar

Implementation of New HWP Line Mill Experiences Paper Tech 2008, Hyderabad 27/06/2008

S. Udayasankar TNPL

Outline … Introduction to TNPL Project Development Flow sheet Overview Photo Tour Benefits

Paper Tech 2008, Hyderabad

TAMIL NADU NEWSPRINT AND PAPERS LIMITED Kagithapuram, Tamil Nadu - India

Paper Tech 2008, Hyderabad

Quick Look … Promoted by Govt. of Tamilnadu in early 80’s Produces 245000 tonnes of PWP annually Uses one million tonnes of Bagasse every year

Leads way in Non wood paper making

Tie up with 7 sugar mills to procure bagasse in exchange of steam Largest exporter of PWP from the country Conserves 30 000 acres of forest land from deforestation World’s largest bagasse based paper plant at single location.

Paper Tech 2008, Hyderabad

Scaling new highs... Figs in Tons

400000 Race of excellence has no finishing line

245000

PM1

1985

1996

2003

PM1+PM2 Post MDP

PM1+PM2

90000

PM1+PM2 Post rebuild

180000

2008

PM1+PM2+PM3 Post MEP

230000

2010

Paper Tech 2008, Hyderabad

Old HWP Line … Started up in 1985 RM– Eucalyptus hybrid Capacity – 120 bdtpd Conventional digesters, BSW,Bleaching Bleach sequence : C-E/P-H-H Brightness : 82 % ISO Viscosity : 5 cps

Paper Tech 2008, Hyderabad

Obsolete technology

Old HWP Line … Drawbacks Inefficient bleaching sequence Obsolete technology High residual chemicals carry over Low strength properties High alkali losses off BSW High chemical consumption High water consumption Poor cleanliness

Paper Tech 2008, Hyderabad

Under pressure from PMs & ETP

Project Concept ... Wood Yard

New Chipper House

Chipper House

Modern HW Cooking Line Closed-loop BSW & Screening

Digesters HW BSW and Screening

Conversion to ECF of old line was not feasible

HW Bleaching

O2 DeLignification ECF Bleaching Paper Tech 2008, Hyderabad

Retaine d

Retire d New

New HWP Line … Planning Idea Germinated in 1998 TNPL represented at1998 TAPPI Pulping conference in Montreal

Best Available Technology

Mill case studies of successful ECF conversions ie., Sappi, George Pacific, Western Pulp were presented in this conference US EPA recognises ECF bleaching as the BAT ECF was preferred to TCF Paper Tech 2008, Hyderabad

New Fibreline Technologies …

Closed Cycle

Closed Cycle

TCF

ECF D100 EOP

Quality Chips

Ozone

Bleaching Technologies

Peroxide

Extended Delignification

Oxygen delignification

Brown loop closure

Paper Tech 2008, Hyderabad

THE FUTURE

Foundation Technologies

ECF Vs TCF… ECF has become the dominant pulp bleaching method. ECF commands 67% of world bleached pulp production, as against 7% for TCF. TCF pulps have not reached the brightness levels of ECF bleached pulps. Higher operational costs & strength problems associated with TCF bleaching makes it a less desirable process. No difference in environmental performance between ECF and TCF bleaching.

Paper Tech 2008, Hyderabad

Mills Visited… TNPL’s team undertook visits to Zellstoff Stendal, Berlin, Germany

Technical Mission

Ostrand Mill,Sweden Glatfelter Mill,Springrove, USA ITC, Bhadrachalam,India Metso R&D Center, Sundsvall,Sweden Andritz R&D Center, Glensfalls,USA Paper Tech 2008, Hyderabad

Which one ...? Continuous cooking

Modern batch cooking

Difficult to manage Slim spouse

Crying babies

Paper Tech 2008, Hyderabad

Plan Review… Modern Batch Vs Continuous Cooking Raw material Both systems are equally sensitive to fines Batch systems are more suitable for low density woods Batch systems have slight advantage when different species are campaigned High availability (98%) can be reached in both systems Any single failure in continuous cooking stops the whole production Most failures in batch cooking lead only to decreased production

Energy consumption

Parameter

Continuous

Batch

MP Steam consumption, Kg/BD t

550

600

Power consumption, kWh/BD t

35

30

Paper Tech 2008, Hyderabad

Plan Review … Cooking yield No significant difference in cooking yield between the two systems No significant difference in Kappa variations No significant difference in Alkali charge

Others Batch cooking plant is more flexible for production increase Capacity of continuous cooking plant is limited by the size of the initially selected equipment

Conclusions Neither of the cooking systems is clearly superior to TNPL The selection should be based mainly on total cost of the plant Paper Tech 2008, Hyderabad

Layout Alternatives … Alternative-1

Where to locate ?

The location of the new HWP line in the existing workshop area The existing workshop to be dismantled and relocated Alternative-2 The location of the new HWP line would be adjacent to the planned new Bagasse fibre line

Paper Tech 2008, Hyderabad

Layout Alternatives … Alternative-2

Alternative-1

C B P L i n e # 2

Wood yard

PM#3 (future)

PM#1 & 2 New Recovery boiler

Paper Tech 2008, Hyderabad

Layout Alternatives .… Alternative-1

+ Short pumping distance to Paper machines + Short chip conveying distance to cooking plant + Wood storage near to chipping - Existing workshop to be dismantled and relocated. - Long pumping distance to Soda recovery plant Alternative-2

+ Short pumping distance to new recovery plant - Long pumping distance to Paper machines - Long conveying distance for chips - Pith handling to be dismantled and relocated Conclusion After summarizing pros and cons, Alternative-1 was chosen for locating the new HWP Line Paper Tech 2008, Hyderabad

Line Configuration ... Super batch cooking Tank Farm Hot stock screening Brown stock washing 2 stage Oxygen Delignification ECF Bleaching MC Storage Paper Tech 2008, Hyderabad

Superbatch cooking schematic ...

Tank farm Superbatch Paper Tech 2008, Hyderabad

Super Batch Digester – Plant Model

Fibreline schematic ... O2 Delignification Hot stock screening

Brown stock washing

ECF Bleaching Paper Tech 2008, Hyderabad

Bleaching Sequence ...

DHT - EOP - D1 Chlorine dioxide does not delignify as well as chlorine Bleaching sequence must be adjusted to compensate >>eg ; Oxygen and Peroxide reinforced extraction (EOP)

Paper Tech 2008, Hyderabad

Colour of pulp ...

Paper Tech 2008, Hyderabad

Key Performance figs... •

Line Capacity

300 bdtpd

•

Kappa No.

18

•

Alkali charge

18% as Na2O

•

Pulp yield

44.5%

•

Pulp Brightness

88% ISO

•

Water consumption

14 cu.m/Bdt

•

MP Steam for Cooking

600 kgs/Bdt

•

MP Steam for bleaching

260 kgs/Bdt

•

LP steam for bleaching

130 kgs/Bdt

•

AOX in bleach effluent

0.3 kg/Bdt

Paper Tech 2008, Hyderabad

Low energy Env.friendly

Key P&M suppliers ... Chipping

Fulghum, USA

Cooking plant

Metso paper

Fiber line

Metso paper

DCS

Honeywell, India

Field instruments

Metso

LC Pumps

Sulzer

MC Pumps

Metso

Paper Tech 2008, Hyderabad

Civil construction highlights... Building area

1850 M2

Building dimensions 75 x 25 x 25 M No. of floors

3 (cooking) , 2 (fibreline)

Cement

2300 T

Steel

650 T

Bleach towers

Slip form construction

Completion time

12 months

Cost of civil works

Rs.59 million (US$ 1.3 million)

Paper Tech 2008, Hyderabad

Project Implementation…

Photo Tour Paper Tech 2008, Hyderabad

Dismantling of Old Work shop

Work shop functioning at new location

Old Workshop

Ground Zero

New HW Pulp Mill –Earth excavation

New HW Pulp Mill Building in progress

Superbatch Digester enters Mill Gate

Digester unloading

Leading to the erection site

Leading to the erection site

Lifting fixture

Digester lifting to the position

Digester lifting to the position

Cap: 200 m3 Wt : 25T

Digesters in position

DCS Control room

Bleach presses

PO press

BSW-2

BSW-1

A view of the Twin roll presses

DHT,EOP,D1 Towers

Discharge tank

A view of the fibre line

Chips feed

DHT D1

EOP

Blow tank

O2-II

A view of the reaction towers

O2- I

A view of Vent gas scrubber

EOT crane

MC Storage 1000 m3

Front view with MC tower

Specific benefits ... Benefits envisaged : Brightness improvement - 82% to 88% ISO. AOX reduction to 0.3 kgs/bdt Higher Pulp strength and cleanliness

•Env. Friendly •High quality pulp •Energy efficient

Reduced Water consumption - 14 m3/ton Low Atmospheric emissions, Improved effluent quality Reduced energy consumption

Paper Tech 2008, Hyderabad

Specific benefits ... Specific consumption - LP steam 350 300 250 200 Kg/BDt 150 100 50 0

Specific consumption - MP steam 2000 1500

350

Kg/BDt 1000

290

1700

500

860

0 Old HWP

Old HWP

New HWP

Specific consumption - Power 400 300 KWh/BDt 200

365 211

100 0

Old HWP

New HWP

Paper Tech 2008, Hyderabad

New HWP

Specific benefits ... COD in bleach plant effluent

AOX in bleach plant effluent

80

8

60

6

Kg/BDt 40

80

Kg/BDt 4

20 0

2

33 Old HWP

7

0

New HWP

0.3 Old HWP

Specific consumption - Water 80 60 Cu.m/BDt 40

70

20 0

14 Old HWP

New HWP

Paper Tech 2008, Hyderabad

New HWP

Thanks

Paper Tech 2008, Hyderabad

Description

Capacity

Unit

BD tpd

Old HWP line

New Hardwood pulp mill

Guaranteed

Actual

120

300

200

Specific consumption Steam LP steam

Kg/BDt

•

Digester

--

160

470

•

Fibre line

350

130

220

MP steam

Kg/BDt

•

Digester

1700

600

1450

•

Fibre line

---

260

260

365

211

355

Power •

Digester & Fibre line

kWh/BDt

Effluent from Bleach plant •

COD

80

33

--

•

AOX

7.0

< 0.3

--

70

14

32

Water consumption

M3/BDt