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
230000

PM1+PM2+PM3
180000

Post MEP
Post rebuild
PM1+PM2

PM1+PM2
Post MDP
90000
PM1+PM2
PM1

1985 1996 2003 2008 2010

Paper Tech 2008, Hyderabad

Old HWP Line …
Started up in 1985

RM– Eucalyptus hybrid

Capacity – 120 bdtpd Obsolete

technology
Conventional digesters, BSW,Bleaching

Bleach sequence : C-E/P-H-H

Brightness : 82 % ISO

Viscosity : 5 cps

Paper Tech 2008, Hyderabad

Old HWP Line …
Drawbacks
Inefficient bleaching sequence
Obsolete technology
High residual chemicals carry over
Under pressure
Low strength properties from PMs & ETP

High alkali losses off BSW

High chemical consumption
High water consumption
Poor cleanliness

Paper Tech 2008, Hyderabad

Project Concept ...
Wood Yard

New
Chipper
House Chipper Digesters
House HW BSW
and Conversion to ECF of old
Screening line was not feasible

HW
Bleaching
Modern HW
Cooking Line
Closed-loop BSW
& Screening Retaine
d
O2 De- Retire
d
Lignification New
ECF Bleaching

Paper Tech 2008, Hyderabad

New HWP Line …
Planning

Idea Germinated in 1998

TNPL represented at1998 TAPPI Pulping Best Available

Technology
conference in Montreal

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

ECF TCF Bleaching

D100 Ozone Technologies THE
EOP Peroxide FUTURE

Quality Extended Oxygen Brown loop Foundation

Chips Delignification delignification closure Technologies

Paper Tech 2008, Hyderabad

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

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Which one ...?
Continuous cooking Modern batch cooking

Difficult to manage
Slim spouse Crying babies

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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-1 Alternative-2

C
Wood
B
yard
P
L
i
n
e
#
2

PM#3 PM#1 & 2

(future)
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

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Superbatch cooking schematic ...

Tank farm
Superbatch

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Super Batch Digester – Plant Model
Fibreline schematic ...
O2 Delignification
Brown stock washing
Hot stock screening

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 Low energy
Env.friendly
• 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
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 Chips feed

Discharge tank

A view of the fibre line

 DHT
O2-II
EOP Blow O2- I
D1
tank

A view of the reaction towers

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

•Env. Friendly
•High quality pulp
Higher Pulp strength and cleanliness
•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 Specific consumption - MP steam

350 2000
300
250 1500
200 350
Kg/BDt 290 Kg/BDt 1000 1700
150
100 500 860
50
0 0
Old HWP New HWP Old HWP New HWP

Specific consumption - Power

400

300

KWh/BDt 200 365

100 211

0
Old HWP New HWP

Paper Tech 2008, Hyderabad

 Specific benefits ...
COD in bleach plant effluent AOX in bleach plant effluent

80 8

60 6

Kg/BDt 40 80 Kg/BDt 4 7
20 33 2
0.3
0 0
Old HWP New HWP Old HWP New HWP

Specific consumption - Water

80

60

Cu.m/BDt 40 70

20
14
0
Old HWP New HWP
Paper Tech 2008, Hyderabad
Thanks

Paper Tech 2008, Hyderabad

 Description Unit Old New Hardwood pulp mill
HWP
line
Guaranteed Actual
Capacity BD tpd 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
Power
• Digester & Fibre line kWh/BDt 365 211 355
Effluent from Bleach plant
• COD 80 33 --
• AOX 7.0 < 0.3 --
Water consumption M3/BDt 70 14 32