About us

The Confederation of Indian Industry (CII) works to create and The Centre is housed in a Green Building which received the sustain an environment conducive to the growth of industry in prestigious LEED (Leadership in Energy and Environmental Best Practices Manual India, partnering industry and government alike through Design) Platinum Rating in 2003. This was the first Platinum advisory and consultative processes. rated Green Building outside of U.S.A and the third in the world. The Centre was inaugurated by H.E Dr A P J Abdul Kalam, the CII is a non-government, not-for-profit, industry led and then President of India, on July 14, 2004. Pulp & Paper industry industry managed organisation, playing a proactive role in India's development process. Founded over 117 years ago, it is Volume 5 India's premier business association, with a direct membership of over 6600 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 250 national and regional sectoral associations.

With 63 offices including 10 Centres of Excellence in India, and 7 overseas offices in Australia, China, France, Singapore, South Africa, UK, and USA, as well as institutional partnerships with About IPMA 223 counterpart organisations in 90 countries, CII serves as a reference point for Indian industry and the international Indian Paper Manufacturers Association (IPMA) has emerged as business community. a national level organisation and is an apex Association provides a broad based common platform to project Industry's view and CII – Sohrabji Godrej Green Business Centre (CII – Godrej GBC) is to articulate its strategy to cater to the growing need and global one of the 10 Centres of Excellences of the Confederation of vision of the Paper Industry. Large Paper Mills from private and Indian Industry (CII). public sector with a product mix of all varieties of Paper (Writing, Printing, Packaging, Speciality, Paper boards and CII-Sohrabji Godrej Green Business Centre offers advisory Newsprint) located in all regions and using conventional fibre services to the industry in the areas of Green buildings, energy such as wood and bamboo and also unconventional raw efficiency, water management, environmental management, materials like bagasse, recycled paper, etc. Comprise the renewable energy, Green business incubation and climate Membership of IPMA in broad spectrum. The Association is change activities. registered with the Registrar of Societies, Government of NCT of Delhi. The Centre sensitises key stakeholders to embrace Green practices and facilitates market transformation, paving way for IPMA strives to promote, protect and improve trade, commerce India to become one of the global leaders in Green businesses and Industry in general, with a focus on Industry connected with by 2015. Paper in particular.

For further details, please contact:

Mahesh Puranam Survey No 64, Kothaguda Near HITEC City, Hyderabad - 500 084 [email protected] Tel: +91 40 44185 101 +91 40 44185146 Fax: +91 40 23112837 www.greenbusinesscentre.com Best Practices Manual Pulp & Paper industry Volume 5

1 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Disclaimer

© 2012, All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted, in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without the prior written permission from CII- Sohrabji Godrej Green Business Centre, Hyderabad. While every care has been taken in compiling this Manual, neither CII-Godrej-GBC nor Indian Paper Manufactures Association (IPMA) accepts any claim for compensation, if any entry is wrong, abbreviated, omitted or inserted incorrectly either as to the wording space or position in the manual. The Manual is only an attempt to create awareness on Energy, Water and Environmental management and sharing of best practices being adopted in Indian Paper industry and the international cleaner production technologies. Published by Confederation of Indian Industry CII – Sohrabji Godrej Green Business Centre, Survey # 64, Kothaguda Post, R R District, Hyderabad –500 032 India.

2 Best Practices Manual - Pulp & Paper Industry The Indian paperForeword industry is growing at a fast clip and, given that the Indian economy is expected to continue to grow at the present rate (or higher) for the next 20 years with a corresponding increase in literacy rate and affluence, the demand for paper will only continue to grow. The Indian paper industry, with a long legacy of over a century and a mix of large and small firms using old and new technology, is building up capacity to cater to this increasing demand. A large number of the units are embracing newer, more energy efficient technologies and ecologically sustainable practices, and are showing increasing awareness of the environmental problems facing the world today. CII – Sohrabji Godrej Green Business Centre has the vision of making India a global leader in green business by 2015, and one of its focus sectors is the Indian pulp and paper sector. As a means of achieving this vision, the Centre facilitates industries in adopting best available technologies and best operating practices, thus enabling them to become world class energy efficient units. To take this idea forward, the Indian consortium of CII – Sohrabji Godrej Green Business Centre and Indian Paper Manufacturers Association (IPMA) are presently involved in a two year project with IVL and Innventia, both Swedish research institutes with extensive experience in the paper sector, to identify the needs of the Indian pulp and paper sector and to develop a roadmap for implementation of clean technologies. This activity is funded by the Swedish International Development Agency (SIDA). The key objectives of the project are: ƒƒ Transfer and exchange of know-how and experiences, increase awareness and capacity to protect the environment and manage climate change; thus contribute towards socially, economically and environmentally sustainable development in India. ƒƒ Broaden and deepen bilateral collaboration between Sweden and India for improving the environment performance by introduction of cleaner technologies in Indian pulp and paper sector The expected outcomes of the project are knowledge sharing/ transfer in pulp and paper sector and introduction of new cleaner production technologies best suited to the Indian context. The annual event ‘Papertech’ and this manual on Cleaner Production Technologies & Best practices are also efforts that enable stakeholders to interact with others and learn from them. I would like to express my gratitude to all the CEOs of the various pulp & paper mills in the country for their contributions, guidance and support in shaping this initiative. I would also like to thank Mr Pradeep Dhobale, Executive Director, ITC Ltd for his continued support for all our initiatives related to making Indian Pulp & paper Industry world class. My congratulations to Mr K S Kasi Viswanathan, Chairman, Paper Tech 2012 and all the members of the core working group for their efforts and contributions. I am sure that this manual would go a long way in facilitating quicker adoption of best practices in Indian pulp and paper industry. Dr Naushad Forbes Chairman Energy Efficiency Council, CII-Godrej GBC & Director, Forbes Marshall

3 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre

Preface The year 2011 was an eventful year for the Indian pulp and paper Industry. Many large capacity, high speed, state of the art paper machines have been commissioned during this year. Quality of paper manufactured in the country has jumped. The utilization of secondary fiber has also shown a significant jump. With increasing pressures on availability and cost of input materials , cost of manufacturing paper has become the real focal point. Energy is simply not available and it’s price is going up by the day. This will continue. Needles to mention, same is the case with water. Stakeholders are becoming more environmentally conscious and the corporate social responsibility & “Environment friendliness” of a company is increasingly used as a measure to assess a company’s performance. The industry has proactively reacted to these challenges, addressing the Energy and Environmental concerns at all levels of manufacturing. Meantime, Government of India has also provided an impetus for Energy efficiency by introducing the Perform, Achieve and Trade (PAT) scheme under the “National Mission for Enhanced Energy Efficiency (NMEEE)”. The PAT scheme has been notified to the Designated Consumers (DCs) on March 30th, 2012. Under the scheme, the DCs in the pulp and paper sector are required to reduce their specific energy consumption within a specified time frame. Companies meeting the Target SEC will be benefitted, while companies not meeting will be penalized. However the scheme provides a great opportunity for the paper sector to explore new ideas and technologies to reduce energy , become green and also reduce their cost of production. When CII – Sohrabji Godrej Green Business Centre, on it’s part, embarked upon its journey to “Make Indian Pulp and Paper Industry World Class” in the year 2008, it was our vision that the Indian paper industry should improve it’s performance particularly relating to Energy, Environment and water and be a leader for the world. Over the last four years, this journey has been extremely rewarding and the Indian paper industry has certainly gone from strength to strength. For us, developing a “Best Practices Manual” for the sector every year, has been a small way to help stakeholders to continue with their good work in this initiative. Earlier versions received encouraging response by the sector, buoyed by which, we present to you this latest edition of the best practices manual. In this manual, apart from the best practices identified from various plants in India by a core expert group, we have also included a few cleaner production technologies identified from Sweden. This manual has been prepared with extreme care, and the case studies presented here have good potential for replication and adoption. I am confident that this manual will enable wider adoption of environmentally sound work practices and technologies in our paper industry. I invite all stakeholders to make the best use of this manual as well as other similar publications brought out by the CII Sohrabji Godrej Green Business Centre, on their path to becoming world class performers. I wholeheartedly appreciate all the support and cooperation extended to the working group in creating this manual on best practices in the pulp and paper sector. I thank all those who were part of this initiative for sparing their valuable time in preparing this manual.

K S Kasi Viswanathan Chairman Paper Tech 2012 & Deputy Managing Director, Seshasayee Paper & Boards Limited

5 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Acknowledgement

It is our privilege to express our sincerest regards to Mr. Pradeep Dhobale, Past Chairman – Energy Efficiency Council, CII – Godrej GBC and Mr. K S Kasi Viswanathan, Chairman – PAPERTECH 2012 & Working group on “Make Indian Pulp & Paper Industry World Class” for their invaluable contribution by leading the initiative from the front. We thankfully acknowledge the contributions by Dr Naushad Forbes, Chairman – Energy Efficiency Council, CII – Godrej GBC in providing valuable suggestions to guide us. We also thank the following friends for working in a team and organizing a visit of an Indian and a Thai delegation to Sweden during April 15 – 19, 2012. We are grateful to each and every one of them for their meticulous planning to showcase Swedish services and technologies for cleaner production in the Pulp & Paper sector. The list of members in the Indian delegation is attached as Annexure A. 1. Ms. Arati Davis, National Advisor - Energy and Environment, Environment Office, Embassy of Sweden 2. Ms. Anjali Bhola, Program Oifficer, Export Radet, 3. Mr. Ulf Frölander, President, Swedish Pulp and Paper Technology group of Sweden 4. Ms. Marita Erikson Wernius, Swedish Pulp & Paper Technology Group 5. Mr. Jonas Rottorp, Department Manger, IVL – Swedish Environmental Research Institute 6. Dr. Richard Holm, Business Development Manager, Innventia 7. Mr. Mattias Drotz, Senior Consultant, Innventia, 8. Mr. Narayan Moorthy, Secretary General, IPMA. We deeply express our sincere thanks to the managements of the host mills, especially the West Coast Paper Mills limited, for openly sharing the technical information with the working group and also for providing the local hospitality and support to the visiting working group members. Also, the write ups provided for the identified best practices deserve a special mention. We take this opportunity to thank all the working group members who, inspite of their busy schedules, have visited the identified mills and with great zeal contributed in identification of the best practices. The list of working group members who visited West Coast Paper Mills Limited is attached as Annexure B. We are thankful for the management of the companies to nominate them to participate in the working group visits.

6 Best Practices Manual - Pulp & Paper Industry Contents S.No. Description Page Number 1 Executive Summary 9 2 How to use this Manual 11 3 Part 1: Facilitation of Implementation of Cleaner Production Technologies in Indian 15 Pulp & Paper Industry 4 Part 2: Best Practices Identified by CII - Working Group in Indian Pulp and Paper 145 Industry 5 Action Plan & Conclusion 231 6 Annexures A: Indian Delegation attended the workshop in Sweden during 15 - 19 April, 2012 233 B: Attendees of the CII - Working group visit to West Coast Paper Mills, Dandeli during 235 8th and 9th May 2012

List of Swedish Companies included

S.No. Company 1 ÅF 2 AkzoNobel 3 Alfa Laval 4 Andritz 5 Aqua-Q 6 Cellwood Machinery 7 Chemrec 8 Cortus 9 Elof Hansson 10 Entrans group 11 GL&V Sweden 12 Innventia 13 IVL 14 Kemira 15 Lorentzen & Wettre 16 Meva Innovation 17 MoRe Research 18 NOSS 19 Promt and Frontway 20 Purac 21 SOMAS 22 SootTech 23 Swedish Exergy 24 UMV Coating Systems

7 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 8 Best Practices Manual - Pulp & Paper Industry CII’s efforts in Promoting World Class Energy Efficiency in Pulp & Paper Industry EXECUTIVE SUMMARY Paper industry in India is the 15th largest paper industry in the world. It provides employment to nearly 1.5 million people and contributes Rs 25 billion to the government’s revenue. The government regards the paper industry as one of the 35 high priority industries of the country. In 1951, there were 17 paper mills, and today there are about 515 units engaged in the manufacture of paper and paperboards and newsprint in India. Growth of paper industry in India has been constrained due to high cost of production caused by inadequate availability and high cost of raw materials, power cost and concentration of mills in one particular area. Government has taken several policy measures to remove the bottlenecks of availability of raw materials and infrastructure development. The higher production cost needs to be tackled by the sector as a whole by increased cooperation in terms of sharing of best practices and moving towards cleaner production. The CII-Sohrabji Godrej Green Business Center (CII-Godrej GBC) under the leadership of Mr. Jamshyd Godrej, Chairman, CII Godrej GBC and Managing Director, Godrej & Boyce has adopted the vision of “Facilitating India to become a global leader in green business (environment) by 2015”. Towards this objective, the Energy Efficiency Council of CII-Godrej GBC under the chairmanship of Dr Naushad Forbes, Director, Forbes Marshall has undertaken the development of “World Class Energy Efficient Units” in energy intensive sectors, such as Cement, Power Plant and Pulp & Paper Industry. The Paper sector initiative through a project titled “Make Indian Pulp & Paper Industry world class” is guided by a working group chaired by Mr. K S Kasi Viswanathan, Deputy Managing Director, Seshasayee Paper & Boards Limited (SPB), Pallipalayam. The activities were initiated in a CEO meet organized in conjunction with Paper Tech 2007 at Hyderabad, a national conference jointly done by CII-Godrej GBC and Indian Paper Manufactures Association (IPMA). The CEO’s meet was attended by 19 CEO’s representing all the major Pulp and Paper Manufactures in the country.

Core working group: A core working group was formulated with participation for Paper Mills, consultants and equipment suppliers. The Paper Industry is sub divided into three groups namely Wood, Agro and Recycled fibre group. These groups visited different paper mills, perceived to be doing well in terms of energy, water and environmental management, and identified best practices followed in those mills. The working group visited various Indian Pulp and Paper Industries in order to identify the best practices. The out come of the working group plant visits is identification of 37 best practices from the Indian Pulp and Paper Industry and released as the first edition of the National Best Practices Manual. Subsequently the CEO's have been meeting every year (2008, 2009, 2010 & 2011) on the previous night of the Papertech conference. The objective of the CEO meet is to review the activities of the previous year and chalkout the plan fot the subsequent year.

Facilitator – Pulp and Paper Cleantech Project As part of the world class initiatives CII partnered with IPMA, IVL and Innventia to initiate a project for bringing in latest cleaner production technologies from Sweden to India. “Facilitator – Pulp and Paper Cleantech Project” is a two year programme for the exchange of knowledge and experiences for the dissemination of environmental friendly clean technologies to the Indian industrial sector with special emphasis on the pulp and paper industry. This project is funded by the Swedish International Development Agency. 9 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre As a first step CII and IPMA took a delegation to Sweden to attend a 5 day workshop on cleaner production technologies with regards to the pulp and paper industry. The delegation also visited 2 Paper mills during the event. The workshops and plant visits were organised by the Pulp & Paper Technology Group of Sweden. (PPT of Sweden) and IVL.

Development of “Best Practices Manual – Pulp & paper Industry, Volume 5” This volume of the best practices manual, namely “Best Practices manual – Pulp & Paper Industry”, contains two parts. The first part was developed based on the interactions and learning that happened during the workshop conducted by Pulp and Paper Technology group of Sweden and IVL / Innventia in coordination with IPMA and CII. (The list of Indian participants to the workshop is attached as annexure A. The second part of the manual was developed based on the learning from the working group visit to The West Coast Paper Mills at Dandeli, Karnataka. The information collected was collated together with the best practices implemented in ITC – PSPD Bhadrachalam unit, J K Paper Mills, Rayagada, Seshasayee Paper & Boards Ltd and TamilNadu Newsprint and Papers Limited into a document which could be widely circulated through out Indian Pulp and Paper Industry. The fifth volume in the series compiled the best practices implemented in the visited mills and the best practices of the other mills and contains their operational experiences latest as on May 31 2012. During Papertech 2012, this volume of the “Best Practices Manual – Pulp & paper Industry” was released on June 7, 2012 at Hyderabad.

10 Best Practices Manual - Pulp & Paper Industry How To Use This Manual

The objective of this manual is to act as a catalyst to promote activities in Indian Pulp & Paper Plants towards continuously improving the performance of individual units and there by achieving world class levels (with thrust on energy, water & environmental management). ƒƒ To set a clear goal for improving the performance and move towards the world class standards, the best practices adopted in some Indian Pulp & Paper Plants & Latest Cleaner Production Technologies and Services from Swedish Companies have been included in this manual as part of “Best practices Manual Pulp & Paper Industry”. ƒƒ The description of the best practices identified during the paper mill visit to The West Coast Paper Mills Ltd., Dandeli, Karnataka by the working group forms a part of this manual. The details of the best practices implemented by some other paper mills (ITC – PSPD Bhadrachalam unit, J K Paper Mills, Rayagada, Seshasayee Paper & Boards Limited and TNPL) have also been included. ƒƒ These best practices may be considered for implementation after suitably fine tuning to meet the requirements of individual units. ƒƒ Suitable latest technologies may be considered for implementation in existing and future Pulp & Paper Plants for achieving the world class energy efficiency. Further investigation needs to done for the suitability of these technologies for individual plant conditions. ƒƒ The collated best operating parameters and the best practices identified from various plants need not necessarily be the ultimate solution. It is possible to achieve even better energy efficiency and develop better operation and maintenance practices. ƒƒ Therefore, Indian Pulp & Paper Plants should view this manual positively and utilize the opportunity to improve the performance and “Make Indian Pulp and Paper Industry World Class”.

11 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 12 Best Practices Manual - Pulp & Paper Industry PART 1

Facilitator - Pulp and Paper Cleantech Project

“Facilitator – Pulp and Paper Cleantech Project” is a two year programme for the exchange of knowledge and experiences for the dissemination of environmental friendly clean technolgoies to the Indian industrial sector with special emphasis on the pulp and paper industry. This project is funded by the Swedish International Development Agency, and is for a period of two years.

The project partners are ƒƒ India: CII – Sohrabji Godrej Green Business Centre (CII –Godrej GBC) and Indian Paper Manufacturers Association (IPMA) ƒƒ Sweden: IVL – Swedish Environmental Research Institute and Innventia, the Swedish pulp and paper research institute

Background In 2009 a Memorandum of Understanding was signed between India and Sweden, where clean technology was highlighted as one of the main areas for partnership. This was reinforced during the first Joint Working group on Environment, held on December 1, 2010 where clean technology and pulp and paper were selected as areas for immediate action. Sweden is understood to be one of the world’s leaders in paper production and technology solutions. Indian paper mills have been in discussion with Sweden for some time. SIDA supported a partnership project in 2008 on clean technology development, and the strongest interest for future business partnership opportunities came out from the pulp and paper sector. SIDA, therefore, decided to commission a facilitator for industrial clean-tech focusing on pulp and paper for India. The facilitator will focus on inclusive project goals, and the introduction of a broad range of relevant sector actors in both India and Sweden. The project was inaugurated during the “Nobel Week” in India during October 2011.

Project Objectives and Outcomes The key objectives of the project are: ƒƒ Transfer and exchange of know-how and experiences, increase awareness and capacity to protect the environment and manage climate change; thus contribute towards socially, economically and environmentally sustainable development in India. ƒƒ Broaden and deepen bilateral collaboration between Sweden and India for improving the environment performance by introduction of cleaner technologies in Indian pulp and paper sector The expected outcomes of the project are knowledge sharing/ transfer in pulp and paper sector and introduction of new technologies best suited for Indian context.

Project Progress ƒƒ Kick off meeting by SIDA (Swedish International Development Cooperation Agency) amongst the project consortium partners (IVL, Innventia, CII and IPMA) during the Nobel week. ƒƒ Four paper mills in India were visited by a team comprising of experts from CII - GBC and Sweden to identify key areas of concern and subsequent intervention. CII, IVL and Innventia participated in PAPEREX 2011 to meet the various stakeholders of the Indian pulp & paper industry. ƒƒ A 7-member IPMA delegation visited Sweden at the invitation of The Swedish Pulp & Paper Technology Group and The Swedish Trade Council in April 2012 and gained exposure to new generation products and

15 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre technologies in the pulp and paper segment. A few representatives from the Agro and Newsprint segments, besides CII – GBC, also joined the delegation. The specific areas of interest evinced by Indian delegation during the visit were environmental technology solutions, energy efficiency measures, water conservation, mitigation of carbon footprint, recycling fibre and enhancement of production efficiencies. On the last two days of the visit, the delegation exclusively interacted with IVL and Innventia. ƒƒ The suppliers of Swedish technologies identified to be of immediate relevance to the Indian pulp & paper sector were invited to participate at PAPERTECH 2012. The consortium will be monitoring the progress of interactions between the Swedish technology / equipment suppliers / service providers with the stake holders of the Indian pulp & paper industry. ƒƒ This section of the manual enlists the profile and technologies / services offered by the Swedish companies that participated in the above said workshops.

16 Best Practices Manual - Pulp & Paper Industry ÅF 1. Introduction to ÅF The ÅF Group is a leader in technical consulting, with expertise founded on more than a century of experience. They offer highly qualified services and solutions for industrial processes, infrastructure projects and the development of products and IT systems. They are specialists in effluent treatment in the pulp and paper industry. 2. Profile of the company: Areas of expertise ÅF is the Northern Europe's leading industrial consultant and the largest independent consultant. They offer a portfolio of services for all types of industrial production companies that covers the entire chain from initial idea through feasibility studies, process analyses, calculation and project engineering to the construction, programming and commissioning of plant. The ÅF consultants can work either as an integral part of the client's own organization, or assume total responsibility for the delivery of an entire project or a specific function. ÅF's core values are Great people, Teamwork ƒƒ Indisputable independence

Services offered: ƒƒ Consulting services - where technology and economy go hand in hand ƒƒ Strategic planning, investments and environmental permits ƒƒ Process and technical expertise in: ¾¾ Wood handling ¾¾ Chemical, mechanical and waste paper pulp ¾¾ Bleaching ¾¾ Chemical recovery ¾¾ Paper manufacturing and finishing ¾¾ Coatings and additives ¾¾ Conversion and logistics ¾¾ Steam and power generation ¾¾ Systems power supply and heat recovery ¾¾ Water and water purification technology ƒƒ Biorefinery ƒƒ Energy audits and energy optimisation ƒƒ Environmental services ƒƒ Materials technology ƒƒ Inspections and guarantee inspections ƒƒ Project management ƒƒ Plant design - all aspects

17 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Ongoing Assignments in Pulp & Paper sector:

Specialist Services ƒƒ BAT Mechanical Pulping, Mid Sweden University ƒƒ Digester Yield, Portucel Setubal ƒƒ Support in moving equipment from Pulp Mill in Finland to India, Metso

Projects ƒƒ Basic Design New Bleaching Plant, Stora Enso Skutskär (Sweden) ƒƒ Basic Design New Line, Arauco (Chile) ƒƒ Implementation New Power Unit, Bomhus Energi – EPCM ƒƒ Implementation New Fibre Line + Rebuild Fibre Line, Sappi Ngodwana (South Africa)

Contact Details ÅF-Industry AB SE-169 99 Stockholm, Sweden +46 10 505 00 00 Fax: +46 (0)10 505 00 10 Email: [email protected] Website: http://www.afconsult.com India Office 1. AF-Mercados EMI 122001 New Delhi, India Ph:+91 124 4241750 Fax:+91 124 4241751 Email: [email protected] B - 206 Millennium Plaza, Sector - 27, Gurgaon, Haryana New Delhi 3. AF-Consult India Pvt. Ltd. 201301 Noida, India A-152, Sector 63 Noida Ph: +91 0120 30961 31 / 45 Fax: +91 0120 30961 50 Email: [email protected]

18 Best Practices Manual - Pulp & Paper Industry AkzoNobel

1. Introduction to AkzoNobel AkzoNobel is the largest global paints and Coatings Company and a major producer of specialty chemicals. They supply industries and consumers worldwide with innovative products and are passionate about developing sustainable answers for their customers. Their portfolio includes well known brands such as Dulux, Sikkens, International and Eka. Eka is one of the world's leading manufacturers of bleaching and performance chemicals for the pulp and paper industry. Their long experience gives them a result-oriented approach to pulp and paper chemicals and their use. 2. Profile of the company: Areas of expertise The areas of expertise of the company are Paper chemicals, Pulp chemicals, Water treatment, Microbiological control and Plant, Equipment & Industrial IT (Eka Engineering & Industrial IT).

3. About the latest services on the offering a. Pulp Chemicals Eka Chemicals is one of the world’s leading manufacturers of chemicals for the pulp industry. They have a vast experience and competence in the supply and operation of plants and equipment for the processing of pulp chemicals. This includes vendor managed inventory (VMI) and onsite production.

(i) Bleaching Chemicals: Eka Chemicals is the largest producer of sodium chlorate worldwide and one of the largest suppliers of hydrogen peroxide to the pulp and paper industry. The combination of sodium chlorate, hydrogen peroxide and chlorine dioxide technologies makes Eka a unique supplier of bleaching chemistry to pulp bleaching plants. Over the last few years, they have developed their product offers to include: ƒƒ Eka SC - Sodium Chlorate: Delivered as crystals by truck or rail. Eka SC is converted to chlorine dioxide, which is used for ECF (Elementally Chlorine Free) bleaching of chemical pulp. ƒƒ Eka HP - Hydrogen Peroxide: Eka HP is delivered as a 19 % – 70 % ready-to-use solution by truck or by rail. Eka HP is primarily used for bleaching of chemical pulp, mechanical pulp and recycled fiber. Eka HP can also be used for various special applications outside the pulp and paper industry. ƒƒ Eka ClO2 - Chlorine dioxide : This concept is the most efficient method for large-scale conversion of Eka SC to chlorine dioxide. Eka Chemicals owns and operates the onsite generator. Eka SC, Eka HP or another reducing agent, together with sulphuric acid, are used as raw materials. Optimal operating conditions, highest safety standards and cost efficient operation are ensured via remote supervision or control of the onsite generator. Eka ClO2 generators can be supervised from one control room, around the clock, by highly skilled operators. This ensures the highest availability and makes it easy to implement process improvements. ƒƒ Eka Purate® : Eka Purate is a patented concept for onsite small-scale generation of chlorine dioxide, up to 4 MT/day. Used for chemical pulp bleaching in special pulp grades or when some additional capacity is required in large scale operations.

19 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre (ii) Chelating Agents Eka’s Dissolvine® chelating agents are used to remove unwanted metal ions and de-activate any remaining ones. By combining amine and carboxylic acid chemistry in one molecule, this powerful chemical bond yields aminopolycarboxylates, which form more highly stable chelates with metal ions than other types of chelating agents. Dissolvine chelates are used for production of mechanical pulps using hydrogen peroxide as bleaching agent in BCTMP and bleached TMP pulp. Also for TCF (Totally Chlorine Free) kraft and sulphite pulp.

(iii) De-inking Chemicals With the numerous chemistries used at a deinking mill, one of the main difficulties is controlling interactions. Eka Chemicals total-system approach ensures that chemistry used for one particular purpose will not cause problems in some other area of the deinking plant or paper machine. Mill specific solutions: Eka Chemicals focuses on providing the best solution possible for customers’ de-inking mill. They combine industry-leading services, such as FreeInk (a comprehensive study of ink removal parameters in North America), EVOP (Evolutionary Optimization - software for optimizing the use of chemical additives) and mill surveys with the widest array of de-inking and bleaching chemistry. The result is a mill-specific solution matching the best chemical technology with customers’ water, furnish mix, flow sheet and performance targets. ƒƒ Eka RF Series - A range of chemicals for flotation deinking processes. ƒƒ Eka RF 4000 Series Soaps ƒƒ Eka RF 4200 Series Surfactants ƒƒ Eka RF 4400 Series Emulsions ƒƒ Eka RF 4600 Series Blends S-Quad™ - A deinking system, which lowers chemical costs while improving stickies removal by enabling the flotation deinking process to operate at a neutral pH.

(iv) Non-Wood Bleaching Bleaching of non-wood pulps: In regions where there is a lack of wood sources non-wood material is very often used for pulp, paper and board production. Non-wood fibers are fibers from agricultural residues such as wheat straw and sugar cane bagasse but also bamboo, reed, flax, kenaf, cotton linters. The lignin and morphological structure of non-wood fibers make them easier to pulp compared to wood fibers. However, during bleaching, substantial amounts of bleaching chemicals are consumed. The most common chemicals used for bleaching of non-wood pulps still are chlorine and hypochlorite. These create pollution problems. Eka has developed more modern bleaching technology based on chlorine dioxide and hydrogen peroxide for non- wood pulps. The results are higher pulp brightness, better pulp strength, higher pulp yield and significantly lower environmental impact. Eka Purate® technology is ideal for small, non-wood pulp mills, which typically have a daily requirement of 5 ton ClO2, or less. Eka Purate technology is supported globally via strategic manufacturing and distribution sites. (v) Fluff Pulp Additives: Eka Chemicals' fluff pulp additives help customers manufacture pulp with low burst strength and lowrequired defibration energy without deteriorating the absorbent properties of the fluff. These fluff pulp debonders are responding and even anticipating present and future regulatory demands. ƒƒ Eka Soft F 587K and 639 -Formulated cationic surfactants of quarternary ammonium compound type. Used as debonders in fluff pulp manufacture. Note that these Eka Soft F products are formulated so that the wetting characteristics are only marginally affected. 20 Best Practices Manual - Pulp & Paper Industry ƒƒ Eka Soft F60 Series - Designed for the latest European legislation with a very high efficiency b. Paper Chemicals Paper has all kinds of properties; whiteness, strength, bulk - it even rustles and sounds. Eka Chemicals helps customers use the most cost-efficient chemistry in the most effective way. Their aim is to improve the performance, productivity and profitability of customers business by optimizing your use of chemicals. As a global supplier ofadvanced bleaching, papermaking, and coating chemistries, Eka Chemicals focuses on intelligent and interactive chemistry. Eka makes high-performance chemicals work synergistically so that customers can take control of all their processes and actually reduce the amount of chemicals in their system.

(i) Retention, dewatering, dry strength Eka’s Compozil® systems are the most advanced and flexible retention, dewatering and dry strength systems available. They offer custom designed systems to meet the challenges of any paper machine application. Retention impacts efficiency in at least three ways. It cuts down on solids losses, decreases downtime, and reduces the frequency of web breaks. Effective retention is the key to optimized runnability and reduced furnish costs. Their Compozil® retention systems are based on a wide range of engineered colloidal silica nanoparticles or polymers that together with other components can be used for virtually all types of paper grades. One of their latest innovations is the Compozil Fx systems, suitable for very fast paper machines.

System components: ƒƒ Eka NP Series - Nine distinct colloidal silica nanoparticle products, whose properties allow maximum performance and efficiency in polymer or starch-based retention systems, acid or alkaline pH, and with any grade. ƒƒ Eka PL Series - A complete line of polyacrylamides available as powder, emulsion or dispersion, in a wide range of charge densities and molecular weights. Includes unique products developed for specialized performance and specifically for enhanced interaction with Eka NP in Compozil systems. ƒƒ Eka ATC Series - Anionic trash catchers (Fixatives), organic or inorganic, for charge control and fixation. In addition, a variety of new products and chemistries provide enhanced colloidal retention, improved wood pitch, white pitch and stickies control, and better ash retention. ƒƒ Eka CS Series - Cationic starch products. Include all common starch varieties, at a wide range of cationicity levels. ƒƒ Eka DS Series - A broad range of dry strength polymers used to develop strength properties in paper and board.

(ii) Sizing Products Eka Chemicals sizing products significantly increase customers’ efficiency and profitability. Offering both internal and surface-sizing products, they enable customers to find the perfect combination to achieve targeted paper properties, cut costs and improving runnability. Internal sizing - for increased sizing control: Eka Chemicals offers rosin emulsions as well as synthetic sizing agents to suit all internal sizing needs in paper and board production: ƒƒ Eka CR Series - Cationic rosin dispersions ƒƒ Eka DR Series - Alkylketene dimer (AKD) dispersions ƒƒ Eka SA Series - Alkenyl succinic anhydride (ASA)

21 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Surface sizing - for excellent printability: Surface size protects the base paper from excessive wetting, enhances surface strength and reduces linting and dusting, which, in turn, improves paper printability. Eka Chemicals advanced surface sizing products help customers enhance quality without increasing cost. ƒƒ Eka SP Series - Anionic, cationic and amphoteric size press products

(iii) Coating Products Innovative coating : Eka always look at the big picture to ensure customers coated grades are optimized. The formulation of high-performance paper coatings is complex and requires advanced rheological characteristics for a first class finished sheet. The importance of premium rheology and superior water retention is a priority for runnability and exceptional finished sheet quality. Innovative thinking: Eka have an in-depth understanding of the dynamic relationship between the fiber and furnish which makes up the base. Couple that with the pigment and binder package that makes up the coating formulation, which results in a complex system that is a finished product. Eka’s coating product line gives the formulator the tools needed for optimum runnability and the best possible finished sheet properties. ƒƒ Eka Flow L Series – Rheology Modifiers: Acrylic based thickeners to improve water retention and coating rheology for optimum machine runnability. ƒƒ Eka AZC/PZC Series - Crosslinkers & insolubilizers: Ammonium or potassium-based zirconium crosslinkers. The crosslinker of choice for coated paper and board. They also help reduce linting and dusting when used in uncoated papers. ƒƒ Eka RC Series – Insolubilizer: Glyoxal-based resins for starch based coating and size press applications ƒƒ Eka Sperse Series – Dispersants: Acrylic based dispersants to improve paper coating performance. ƒƒ Eka LC Series - Lubricants: Calcium stearate and polyethylene lubricants that offer superior lubrication, release properties, and surface texture. ƒƒ Eka Structurecote – Starch based, green, renewable chemistry to replace protein, improve coating structure, and improve surface properties. ƒƒ Eka DC Series – Defoamers: Highly efficient for use in coating and size press applications. ƒƒ Eka CC Series - Rheology aid & dispersant: Specialty products that include a multi-purpose rheology aid that can reduce the viscosity of coating formulations to allow for higher solids. Also included in this range are products such as coating dispersants. ƒƒ Eka Stat Series – Anti static products: SSMA and MA chemistry used to reduce and neutralize static electricity in paper and paperboard applications. With Eka’s approach and utilizing a specialized, technical, paper sales force and listening to customers requirements and understanding your needs, Eka Chemicals has become the industry leader in coating additives. Through decades of research, applications support, and production, they have developed a wide range of multi- functional products and performance options that are optimized for customers’ formulations, equipment, and product requirements. Whether product is either coated board or ultra lightweight coated paper, Eka can develop a cost-effective solution to meet customers’ needs anywhere in the world.

(iv) Wet Strength Products Eka Chemicals has extensive knowledge about manufacturing paper products for use under wet conditions. They have designed wet-strength products for all applications including liquid packaging board, kraft packaging, linerboard, tissue and specialty grades. These wet strength resins have been developed with two main targets: purity and efficiency.

22 Best Practices Manual - Pulp & Paper Industry ƒƒ Eka WS X14 and WS X0: Wet strength resins with extremely low CPD and DCP content. They respond to the most demanding AOX targets in the effluent and OX in the paper. These are unique characteristics on the market. Note that the Eka WS X14 provides the highest wet/dry ratio available on the market. ƒƒ Eka WS 325 and Eka WS 505: Strong and stronger, with an efficiency uncommon in second generation technologies. Used in a wide range of applications from board and label, to the top premium tissue grades.

(v) Tissue Additives Strong yet soft tissue products: Eka Chemicals is a complete supplier of first-class ingredients for demanding tissue makers. They offer customers the best chemicals, combined with extensive know-how and application equipment. A complete portfolio now available covering a wide array of applications: ƒƒ Eka Soft T Series: Eka’s most advanced softeners and debonders provide bulk and surface softness. Applied to the stock or sprayed on the sheet surface. ƒƒ Eka Soft S Series: The latest softener designed to respond to the most stringent regulatory challenges. Very efficient and allows to reach new level of softness. ƒƒ Eka Soft B, M, R: For a very efficient Yankee surface protection - a full range of creping adhesives, coating modifiers and release agents, with chemistries to respond to bulk and surface enhancement aswell performance. Tailor-made products for customers’ particular demands. c. Water Treatment Maintaining and improving water quality: Today, papermaking involves increased process temperatures, greater recycled raw material content, and higher rates of re-used water along with increased productivity demands. These have made microbial fouling a more important factor to paper machine economy and performance efficiency. With effective anti-fouling tools, machine productivity is improved by an increased effective run time and a decreased number of breaks. Good water quality leads to increased production and improved quality, especially under alkaline conditions. For a sustainable environment: Pulp and paper mills also pollute water, which must be cleaned before it is released into the environment. The composition of paper production pollutants in waste water depends on the paper produced as well as on fillers and chemicals used. The pulp production and bleaching process generate other effluents and require different treatment. Strict environmental regulations and demands to improve process efficiency make water treatment and effluent control a daily challenge for Eka as chemicals supplier – customers’ partner in water chemistry. ƒƒ Eka Pam: Polyacrylamides for efficient flocculation in water treatment and sludge dewatering applications. ƒƒ Eka WT: Polyaluminium chlorides for internal and external water treatment applications. ƒƒ Eka Purate: Solution for small scale water treatment applications in a pulp and paper mill sites.

Contact Details Lene Schack, Manager Business Intelligence, T: +46 31 58 74 79; F: +46 31 58 77 45 Email: [email protected] Eka Chemicals AB SE-445 80 Bohus, Sweden T +46 31 587000 Website: akzonobel.com/eka

23 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Alfa Laval AB

1. Introduction to the Company Alfa Laval focuses on energy optimization, environmental protection and food production through their technological leadership in heat transfer, separation and fluid handling. With more than 300 patents, they cover globe with worldwide solutions to areas vital to society. 2. Profile of the company: Areas of expertise

Added value for customers Over the years, Alfa Laval has built up a reputation primarily on the strength of supplying high-quality products. This is still valid, but they also want to provide value for their customers. This value is summarized in their mission: “To optimize the performance of our customers’ processes. Time and time again.”

Key technologies Alfa Laval is the global leader in its three key technologies ƒƒ Heat transfer ƒƒ Separation ƒƒ Fluid handling 3. About the latest technology on the offering

Compact Heat Exchangers - Uniquely Efficient for Energy Recovery ƒƒ Save money by maximizing heat recovery ƒƒ Save cooling water by perfecting temperature approach

Compact Heat Exchangers - Dealing with fibrous fluids ƒƒ Perfect fit for each duties ƒƒ Accessibility on both sides ƒƒ Minimum maintenance costs ƒƒ Self-cleaning effect

24 Best Practices Manual - Pulp & Paper Industry Heat Exchangers for P&P industry

Plate Heat Exchagers Alfa Laval is the world’s leading supplier of plate heat exchangers, all characterized by their compact design and high thermal efficiency. The product portfolio includes various types of plate heat exchangers such as: ƒƒ gasketed ƒƒ semi-welded and fully welded ƒƒ brazed ƒƒ fusion-bonded Plate heat exchangers are made up of a series of assembled, corrugated plates. Between the plates there are two channels with a cold and a warm medium. These pass on each side of the plates and in opposite direction to each other.

Gasketed plate heat exchangers, which are used for a large number of applications, are sealed with rubber gaskets. Brazed plate heat exchangers have been developed to cope with higher pressures and temperatures. Welded plate heat exchangers are used to handle even higher pressures and temperatures. Fusion-bonded plate heat exchangers made of 100% stainless steel open possibilities in new areas and applications.

25 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Spiral Heat Exchangers The Compabloc is a breakthrough plate heat exchanger design that combines a whole range of technological advantages into one compact unit. The all-welded plate pack does away with all gaskets between plates, and makes it possible to operate with a wide range of aggressive media and at high temperatures and pressures. Corrugated plate patterns generate high turbulence that results in overall heat transfer coefficients three to five times greater than a shell-and-tube heat exchanger. In addition to minimizing fouling, this makes it financially viable to use corrosion-resistant exotic metals.

This makes the Compabloc perfect for heat recovery in corrosive operating environments and for handling aggressive, high-temperature fluids of all kinds. The compactness of this all-welded unit means it can be installed virtually anywhere – as a condenser or reboiler for distillation and stripping columns, as a condenser on top of reactors and in a wide range of other heat exchanger applications.

Spiral Heat Exchangers Spiral heat exchangers exhibit ideal heat transfer and fluid handling characteristics for a wide range of rough industrial applications.

These heat exchangers are suitable for viscous products and products with particles that could cause severe fouling or corrosion in other types of heat exchangers.

26 Best Practices Manual - Pulp & Paper Industry Selection of product range

Separation – chemical recovery Extract and Purify by-products from process ƒƒ Comprehensive range of technologies ƒƒ More efficient extraction ƒƒ Fully automated operation Alfa Laval centrifuges will save money for ƒƒ Installation cost ƒƒ Solids disposal cost ƒƒ Maintenance cost ƒƒ Water consumption ƒƒ Chemicals cost (due to higher chemical recovery)

P2 Decanter Together with their other decanter ranges SG2 and STNX, the P2 range of decanter centrifuges is specially designed for handling aggressive slurries and sludges in process industries. Alfa Laval decanters are the perfect choice for separation duties in steelmaking, mining, industrial fermentation, production of pulp, paper, coke, chemicals, petrochemicals, polymers, ethanol, starch, biodiesel and sugar processing. ƒƒ Lowest power consumption on the market, minimum lifecycle costs ƒƒ High performance and reliability ƒƒ Dryer cake and reduced disposal costs compared to other technologies ƒƒ Easy access and low noise levels ƒƒ 2Touch automatic control system guarantees continuously optimized operation ƒƒ Easy cleaning using automatic Cleaning-in-Place (CIP) programs ƒƒ Many upgrades and service possibilities available, such as videoscopy and online monitoring ƒƒ Available in 2-phase and 3-phase versions, and in ATEX-compliant configurations. Special sealed and purged versions are available for processing flammable feeds

27 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Fluid handling

Applications ƒƒ Digester ƒƒ Black liquor ƒƒ Recovery boiler ƒƒ Bleaching ƒƒ By-products ƒƒ Paper machine ƒƒ Power Plant ƒƒ Mechanical pulping (TMP) ƒƒ Waste Water Treatment The use of inexpensive cooling water has become a widely accepted and successful solution to cooling problems in pulp & paper industry, ships, power plants and district heating & cooling systems. As the availability of cooling water quality has declined, the need for cost-effective solutions to eliminate clogging and biological body and corrosion become apparent. In a refrigeration system containing a heat exchanger and an Alfa Laval Filter, contaminated or corrosive water can now cool even the most sensitive process equipment.

28 Best Practices Manual - Pulp & Paper Industry

ALF FILTER Alfa Laval's filter, ALF, is used as an integral part of a cooling system to remove dirt and debris that can cause clogging or biological body in a plate heat exchanger or a condenser. Alfa Laval's filter is also suitable for many process fluids where filtering is required. Despite effective grating or coarse filtration at the water intake, mussels and other marine small animals get into the heat exchanger and being caught the heat transfer surface. Such environments are ideal for this type of marine life, and they multiply rapidly, resulting in reduced heat transfer and even failure of the heat exchanger. Measures such as back flushing of the heat exchanger or chlorination is not always enough if the blockage is severe and in some cases prohibited chlorination by environmental laws. Alfa Laval's filter protects the heat exchanger from clogging and biological body and also protects against blocking or clogging of the cooling system. The filter is normally installed near heat exchanger inlet, removes dirt and debris, and marine animals and backwash automatically at regular intervals.

Dynamic Spray Devices - Industrial Rotary Jet Heads

Cost -effective cleaning Toftejorg rotary jet heads provide high cleaning efficiency at significantly reduced cycle times to meet the tank- cleaning requirements of various process industries – from the pulp and paper and chemical processing industries to the bioethanol and starch industries. Toftejorg rotary jet heads also provide measurable savings by cutting energy, chemicals and water consumption for virtually any tank size and configuration. To achieve the best cleaning results, Toftejorg rotary jet heads use an optimized jet impact pattern to ensure efficient distribution of rinse water to all inner tank surfaces. The high-impact dense spray pattern removes any residue after the production cycle more quickly and effectively than the much more expensive and time-consuming cleaning methods of soaking in chemicals or manual cleaning. Self-draining and self-cleaning, inside and out, all Toftejorg rotary spray head devices comply with Good Manufacturing Practice. The Alfa Laval Rotacheck system verifies every cleaning cycle to ensure compliance with today’s strict hygiene standards.

Performance reliability and long service life Capable of operating at pressures of less than 0.3 bar, Toftejorg rotary jet heads offer very low inner resistance. However, for optimal cleaning performance, the recommended operating pressure is between 5 and 12 bar. For over half a century, rotary jet head and rotary spray head technology has proven successful in providing reliable and repeatable cleaning performance and a long service life.

29 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Cost-effective maintenance with minimal downtime Proper maintenance is critical to optimizing any tank cleaning system, improving performance and extending nozzle life. Spare part service kits are available with full parts traceability to facilitate parts replacement and provide customers with complete documentation. Upon request, a video clip of maintenance procedures can be supplied.

High product integrity To ensure product integrity and extend equipment service lifetime, all Toftejorg rotary spray head devices are made of safe and non-reactive hygienic materials. Upon request, 3.1.B certificates to show conformance with EN 10204 and ATEX category 1 certificates for to show conformance with the Atex 94/0/EC Machinery Directive can be supplied.

Documentation All Toftejorg rotary jet heads are supplied with operator’s manual, CAS selection criteria (CAS is Alfa Laval´s design and selection tool) and appropriate certificates, such as 3.1B or ATEX certificates. To determine the right parameters for a specific tank, optional TRAX software may be used to simulate actual cleaning performance of a specific Toftejorg rotary jet head configuration – prior to finalizing specifications and before installation.

Supply and delivery Available in wide range of sizes and configurations, Toftejorg rotary jet heads provide coverage for virtually any tank size. All standard components are kept in stock to shorten lead times and prevent unplanned downtime. Most standard configurations can be supplied within a few days.

Part of a broad range of tank cleaning devices Alfa Laval offers a comprehensive range of portable and fixed tank cleaning devices for use in the process industries. These include: ƒƒ Toftejorg Rotary Spray Heads (Dynamic tank cleaning devices) ƒƒ Toftejorg Rotary Jet Heads (Dynamic tank cleaning devices) ƒƒ Toftejorg Static Spray Balls (Static tank cleaning devices) To meet the specific and varied requirements of the process industries, Alfa Laval can customize tank cleaning equipment solutions based on their extensive product range, which has proven successful for the marine, sanitary and pharmaceutical industries.

30 Best Practices Manual - Pulp & Paper Industry Contact details Main office Alfa Laval Lund AB, P.O. Box 74 SE-221 00 Lund Sweden Indian office Alfa Laval (India) Limited |Head Office Country, Manufacturing Unit Mumbai-Pune Road, Dapodi, Pune - 411 012 India Phone: + 91 202 710 71 00 Fax: + 91 202 714 77 11 E-mail: [email protected] Web page: www.alfalaval.com

31 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ANDRITZ

1. Introduction to Andritz Pulp & Paper Andritz is reliable and committed technology and service provider for the production of pulp, paper, tissue, board, fiberboard and power generation products. Their range of technologies includes full lines for the processing of logs and annual fibers; production of chemical, mechanical, and recycled fiber pulps; recovery and reuse of chemicals in the pulping process; generation of energy from biomass and other fuels; stock preparation; paper, board and tissue machine approach flow; production of paper, tissue, and board; coating and finishing; and handling of reject materials and sludge. 2. Profile of the company: Areas of expertise Andritz services include complete mill maintenance, equipment optimizations, upgrades and rebuilds, engineered wear products, replacement parts, and technical field support. Every industrial process occasionally encounters disturbances, obstacles, or bottlenecks. Andritz have a world of experience, hundreds of installations and a long track record of success.

The challenge The major challenge facing pulp producers is to achieve steady-state production of uniform pulp quality with the highest yield and lowest possible consumption of chemicals and water regardless of the fiber source. And all this within ever-tightening environmental regulations.

The solution ANDRITZ is one of the few technology suppliers to deliver a complete chemical pulp mill and to have it perform with world-renowned environmental excellence. Andtitz technologies for mechanical pulp production and recycled fiber processing are among the best available. Andritz technology portfolio for pulp production comprises equipment for every process in the modern pulp mill: wood processing, fiberline, bleaching, deinking, chemical recovery, and pulp drying/baling. Every component is designed to work independently in a rebuild or modernization application, or perfectly integrates with other ANDRITZ systems in a complete line for new installations. Experienced ANDRITZ project teams gives support during engineering, planning, erection, and start-up of mills. Technical and service support is at-the-ready throughout the life of the equipment.

Special focus 1: ANDRITZ technologies for dissolving pulp production Demands for environmentally friendly fiber sources have dramatically increased the interest in utilizing dissolving pulp, particularly in textile processes. ANDRITZ has a cost-effective approach to dissolving pulp production that includes a new continuous pre-hydrolysis kraft cooking process coupled with efficient washers and other proven downstream pulp processing equipment.

32 Best Practices Manual - Pulp & Paper Industry Fig: Dissolving Cooking Fiberline

The challenge The key challenges are maintaining high yield and productivity while ensuring consistent pulp quality.

The solution ANDRITZ technology for the production of dissolving pulp is based on many years of experience with chemical pulp fiberlines and intensive R&D on high alpha-cellulose dissolving pulp grades. Their experience with biofuels has further led them to design the system with special features considering the optimal methods for by-product recovery and reutilization. Many of the existing ANDRITZ process technologies used in chemical pulping are already suitable for dissolving pulp production. For this reason, existing chemical pulp lines can easily be converted to the production of dissolving pulp with only minor modifications to the existing wood processing equipment, fiberline, drying plant, and evaporators. ANDRITZ has experience integrating all of the existing process areas with this new technology specifically for dissolving pulp production. Experienced ANDRITZ project teams gives support during engineering, planning, erection, and start-up of dissolving pulp production line. Global and local technical and service support is at-the-ready throughout the life of the equipment.

Special Focus 2: ANDRITZ LimeLine White Liquor Plant - Ecologically sound, economically efficient ANDRITZ PULP & PAPER continues to develop technologies which minimize environmental impact by recycling and reusing process streams inside a mill, rather than relying on end-of-pipe removal. This is particularly true in the white liquor plant, where the conversion of green liquor into high quality cooking liquors is performed with great efficiency.

The Challenges: The major challenge in the white liquor plant is turning green liquor (the smelt from a recovery boiler) into pure white liquor that can be reused in the pulping process – with minimal energy consumption and environmental impact. Critical factors such as air emissions, energy efficiency, solid waste (dregs), and white liquor purity must be considered when selecting the equipment for the white liquor plant.

33 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre The Solutions: ANDRITZ has been an innovator for decades in recausticizing and lime reburning, and auxiliary processes and offers a strong portfolio of LimeLine components for each process stage and support operation. The scope includes process solutions for chemical conversion and filtration, equipment for the various steps in preparing cooking liquors, and on- going services. The product portfolio includes not only traditional white liquor production, but also other modified delignification liquors for kraft pulping. With 70+ new recausticizing plants, 200+ plant modernizations, 100+ new lime reburning kilns, 30+ kiln modernizations, and several plants for white liquor oxidation or modified white liquors – ANDRITZ has the experience to handle any project around the world. LimeLine components are designed to excel as standalone unit processes, and offer truly superior performance when integrated into a modern, energy-efficient, and environmentally safe production line. The results are reduced and cleaner air emissions, excellent energy efficiency, reduced loads to the landfill, and very high white liquor quality – even with the closed-cycle process loops.

ANDRITZ capabilities for paper production Andritz provides all the paper technology and services such as from individual components for paper mill up to complete production lines.

The challenge The major challenge facing paper producers is to improve margins for commodity and specialty grades through steady-state production of on-spec paper at the highest efficiencies with the lowest possible consumption of chemicals and energy.

The solution ANDRITZ delivers complete paper/board/tissue production lines for new installations and individual machine components – from stock preparation to winders – for rebuild and modernization projects. Andritz’s paper technology portfolio comprises well-proven equipment and innovative solutions for stock preparation, paper/board/tissue production, paper finishing, coating, and winding, including automation systems. Every component is designed to work independently in a rebuild or modernization application, or integrated into a complete line for new installations.

34 Best Practices Manual - Pulp & Paper Industry 3. About the latest technology on the offering a. Recausticizing ANDRITZ LimeLine technology for recausticizing is the result of high expertise, long experience and innovative process solutions. LimeGreen - falling film cross-flow green liquor filter ƒƒ Efficient separation of even small impurities ƒƒ High availability ƒƒ Less make-up lime required ƒƒ No need for lime mud precoat ƒƒ Long filter cloth life ƒƒ Stable operation LimeFree - lime mud free dregs handling ƒƒ No lime mud needed – minimizes the amount of waste to landfill ƒƒ Optimized lime purging ƒƒ Small footprint required for installation Green Liquor Cooler - efficient and trouble-free ƒƒ Less over-liming and over-boiling ƒƒ No cleaning required ƒƒ Less acid washing shutdowns in white liquor filtration ƒƒ Easier causticizing control ƒƒ Efficient droplet separation LimeSlake - multi-compartment lime slaker ƒƒ Big lime mud particles ƒƒ Improved separation of white liquor – alkali savings ƒƒ Improved filtration of lime mud – alkali savings ƒƒ Higher dry solids in lime mud ƒƒ Self-cleaning ƒƒ Effective scrubber ƒƒ Clean working environment LimeMilk – one- to-three compartment causticizer ƒƒ Optimal sizing due to compartment flexibility ƒƒ Carefully agitated ƒƒ No lubrication water ƒƒ No bottom bearing LimeWhite - white liquor filter ƒƒ Continuous operation ƒƒ Clean and hot white liquor

35 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Fully automated ƒƒ Higher white liquor yield ƒƒ Reduces water circulation ƒƒ Less white liquor dilution LimeDry - lime mud washing and dewatering ƒƒ High capacity in a single unit ƒƒ CPR – Continuous Precoat Renewal ƒƒ Reliable, continuous feed to kiln ƒƒ Continuously high dry solids ƒƒ Filter cloth washing during operation ƒƒ Energy savings and less ring formation in kiln ƒƒ Less TRS emissions ƒƒ Totally closed design - dust proof, clean working environment b. Lime reburning The modern and proven ANDRITZ lime reburning solution consists of a LimeKiln reburning kiln, a flash dryer, a LimeCool cooler and a LimeFire burner. LimeKiln - efficient and reliable lime reburning ƒƒ Low fuel consumption with two-layer brick lining ƒƒ Low emissions ƒƒ Highly reliable carrying and thrust rollers ƒƒ Low NOx Technology ƒƒ Precise control of flue gas temperature ƒƒ Easy and fast start-up ƒƒ No internals needed ƒƒ Integrated with LimeCool cooler and LimeFire burner LimeCool - compact lime handling, cooling, and primary air heating ƒƒ Low heat loss ƒƒ Optimum cooling of lime ƒƒ High capacity with efficient use of space ƒƒ Internal dam ƒƒ Clean working environment ƒƒ No burner tunnel ƒƒ Less overhanging weight c. White liquor modification StiroX - pressurized white and green liquor oxidation with oxygen gas ƒƒ White liquor with low residual sulfide content for oxygen delignification ƒƒ Oxidized white liquor helps to control mill sodium and sulfur balances

36 Best Practices Manual - Pulp & Paper Industry ƒƒ Excessive heat energy from exothermic oxidation reactions is recovered as hot water ƒƒ Less emissions MOXY - white liquor sulfide-to-polysulfide conversion ƒƒ Polysulfide cooking offers a way to increase cooking yield ƒƒ Optimal conditions for polysulfide reaction are achieved by blowing air and white liquor through a catalyst bed with activated carbon

Strong presence in India From mill wide systems to the largest drum pulper — latest ANDRITZ references on the Indian market: 1. JK Paper Ltd., Rayagada, ordered woodyard equipment, including the first HHQ-Chipper in India, as well as a complete fiberline, recausticizing and lime kiln – the largest mill-wide scope of equipment from ANDRITZ in India 2. To ITC Ltd., ANDRITZ delivers a FibreFlow drum pulper and dispersion system. This will be the largest drum pulper in India! 3. Three-loop ANDRITZ deinking plant for Tamil Nadu Newsprint & Papers Ltd. — the first of this kind to be commissioned in India!

Contact Details Sweden Address ANDRITZ AB P.O. Box 126 Tynäsgatan 14 SE-651 04 Karlstad Sweden Phone +46 (54) 77145 00 [email protected] Gopalan Sridhar General Manager ( Chennai Facility) ANDRITZ Technologies Pvt. Ltd., The Lords, Block II, Plot No. 1&2 (NP), III Floor, Thiru Vi-Ka Industrial Estate, Jawaharlal Nehru Road, Ekkatuthangal, Guindy Chennai 600032. India. Tel: +91 44 4293 9351 Mob: +91 97890 59351 Email: [email protected] Website: www.andritz.com

37 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre AQUA – Q

1. Introduction to Aqua-Q Aqua-Q is a Swedish cleantech company focused on applied research and provides innovative cost effective solutions for safe and clean water. The company develops and market/sale real time online microbial monitoring and sampling system for drinking water and quality control of recycled water as well as related services like consulting and water analysis. 2. Profile of the company: Areas of expertise Clean and safe water is of fundamental importance for human life, health care, industrial process, irrigation and so on. Access to water of good quality is a scarce commodity. Its requirement is growing twice the rate of population growth while the water resources are dwindling and rapidly depleted. Contaminated water is a concern. Aqua-Q provides innovative environmental friendly and sustainable technological solutions to remove the contamination in water and assuring the quality in real time. 3. About the latest technology on the offering Aqua-Q’ offers real time monitoring system which keeps an eye on produced water quality 24/7 at public/ industrial water plant. When the system observes abnormal level of bio/micro contamination as they occur in real time it immediately alerts the authorities so that the management of the water plant can take proper and quick action and save money. Aqua-Q’s system not only alerts the authority but grabs automatically relevant water sample for analysis which even serves as evidence. Depending upon the nature of the contaminants Aqua-Q software can actuate disinfection system or can execute other pre-programmed action plans. This not only protects the citizens’ agony by being sick, it also saves millions of dollars.

Background Drinking water is our most common and valuable commodity. Globally more than 2.2 million people die by drinking unsafe contaminated water, distributed not only in developing countries but also in the most technologically advanced countries. This is because the management of the drinking water plants is much too often not aware when contamination occurs. At current water consumption rate it is estimated by United Nations Population Fund that by 2025 there will be over 60% of world population will live in areas where safe water is scarce. And the need for re-use of water will be of utmost importance. These are incredible numbers which demonstrate the growing need to develop sustainable and environmental technologies which are robust, accurate and cost effective for drinking water quality monitoring and water resources. Today most water works check the quality of the water they supply by taking several random samples. Even if those samples are taken fairly often they do not give any information about the current level of contamination as analysis result take 3-4 days. Aqua-Q, offers a more cost effective and safer alternative: real time monitoring by laser technology and automatically capturing a sample when there is threat for contamination with time and date. During 2010 and 2011 outbreaks of Cryptosporidium Parvum infection occurred in two municipalities in northern Sweden causing disease in thousands of individuals and disrupting everyday life as water had to be boiled before being used. Many hospitals in Sweden are very much concerned about the water quality. Several county council plans to have their own water reservoirs so that they can manage at least 2 days.

38 Best Practices Manual - Pulp & Paper Industry Aqua-Q’s real time monitoring system is optimized among other features to give immediate alarm when surface water or sewage water accidentally or by reason enters the drinking water pipeline creating risk for Cryptosporidium Parvum infection. In paper industry slime in water is a problem and a concern. Slime can be controlled by knowing the water quality and with advanced disinfection system (ozone).

Principle of operation Based upon the previous research and field experience the product WQM-100 was developed (Early Warning System). The principle of the operations of WQM-100 is optical laser scanning on a partial flow 24/7. The product is a modular based real time monitor to detect the possible microbial contamination in both source water and in drinking water. The system comes with laser sensor, software with mathematical algorithm to cluster the contaminants, monitor and automatic sampler. Aqua-Q’s early warning system, WQM-100, detects immediately the abnormal level of micro contaminants as they occur in real time and alert the plant management and responsible caretaker of apartments, offices and important buildings wherever the WQM-100 is placed. To be able to capture relevant water samples a modular hygienic sampler AQS is developed. The sampler can be placed at different locations and be controlled by the software.

User friendly software was developed for collection of data, visualize on a monitor and real time evaluation of the fingerprinting of the water. All data from the sensors are saved and traceable.

Ozone Application Besides real time monitoring of drinking/recycled water and sampling the founders of Aqua-Q have practical experience (consulting) of the use of ozone. Ozone is a strong oxidizing agent and used in various water treatment processes. Aqua-Q has patent for disinfection of Legionella and some innovative applications.

Potential benefits The potential benefits of WQM-100 is an early warning system which gives immediate information to plant operation for a potential microbial threat and gives continuous information, in real time, of the water quality and the possibility of the growth of biofilm inside the pipe line and its loosening. This is an ideal equipment to avoid slime problems and maintain the level of biofilm. By knowing the optimization of the process the biofilm can be controlled.

39 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Case studies

Ongoing case studies: 1. Hammarby Sjöstadsverk (research test bed) in Stockholm. This research test bed is owned by IVL (Swedish Environmental Institute) and KTH (Royal Institute of Technology). WQM-100 is integrated on a treated waste water treatment line to show the variations of the treated waste water. 2. WQM-100 is also installed at the biggest water plant in Sweden, Norrvatten. The equipment monitors the source water intake from the lake Mälaren, just outside Stockholm. So far the case studies are very promising.

Other benefits Other benefits that can be obtained is the optimization of the process i.e. dosing of the chemicals for the treatment of water, filter backwash, filter break through, quality control of boiler feed water and water formembrane application.

Approximate Investment at Present Value The investment cost for one system is about 600-800000 SEK depending upon the configuration.

Payback period WQM-100 can be considered as an insurance against unwanted events. The maintenance cost is low and Aqua-Q considers payback time to be very short, it all depends on the costs of the incidents. If the water in the boiler is contaminated the cost is very high and the payback time is negligible. Prevention is better.

Sources of further information For further information, please visit http://www.aqua-q.se/

Contact Details Main Office Aqua-Q AB, Vidjavägen 53, S-123 52 Farsta, Sweden Phone: +46 (0)73-6870306 / +46 (0)73-6781425 India Representatives Mahant Advisory Services Website: http://www.mahantadvisory.com/

40 Best Practices Manual - Pulp & Paper Industry Cellwood Machinery AB

1. Introduction to the company Cellwood Machinery’s concept is to develop, design, manufacture and market high-tech machinery and complete systems adapted to suit the needs of customers in the pulp and paper industry across the world for the environmentally friendly processing of pulp and the recycling of waste paper, and manage after sales including training, start up, service and spare parts supply. Now they have over 500 systems in operation. The total quantity of waste paper pulp processed through all Krima Disperging Systems world wide is over 90 000 tons per day. 2. Profile of the company: Areas of expertise Cellwood Machinery’s business concept is to provide energy-efficient machinery and services for disintegration and grinding of recycled paper and other fibres in large volumes. They customise their standard machines. Their equipment is unique and is based on the needs of the customer. They provide in-depth technical solutions, extensive experience and creative ideas for the best possible solutions. 3. About the Latest technology on the offering a. Pulper Rotor type G Grubbens rotors are specially designed to operate at high consistency with baled pulp or broke. Regardless of whether it is bales, paper machine web or guillotine broke, high consistency is essential for achieving optimum results.

The rotor design is the main reason for the pulpers being able to operate at a high consistency and low power demand. The consistency range in the pulpers varies between 3 – 9%, depending on the material and whether the pulpers are operating continuously or batchwise. The primary breaking up of paper and pulp is made by the friction in the pulp stream at high consistency. It is therefore important to have good circulation also with high consistency. b. Pulper Rotor type S Grubbens new rotor type S is a further development from the well proven SRM-rotor. The rotor Type S was specially developed for breaking up wet strength and other difficult paper qualities. The rotor Type S can be equipped with counter knives in exactly the same way as the rotor Type SRM.

41 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Advantages with the rotor Type S: ƒƒ The rotor combines hydrodynamic and mechanical breaking of the pulp ƒƒ The design of the vane at the rotor prevents plugging of the strainer holes ƒƒ The rotor can break up tough paper qualities, especially wet strength qualities ƒƒ The rotor allows higher pulp consistency through the strainer holes ƒƒ The rotor gives a higher flow of the pulp over the strainer plate ƒƒ The rotor assists emptying of the pulper because it normally gives an overpressure on the suction side ƒƒ Rotor Type S fits on the existing bearing unit for Type SRM without modifications c. Grubbens Stock Pump Grubbens centrifugal pumps are specially designed for transportation of liquids with variable consistency, or liquids containing air bubbles and lumps. Stock concentration of up to 8% can be pumped without in-feed pressure. With in-feed pressure it can even manage to pump up to 12%

The self-ventilating rotor has no constrictions and therefore minimises the risk of blocking.

42 Best Practices Manual - Pulp & Paper Industry The pump characteristics can be adjusted by changing the pump speed, which, in the case of V-belt drive, is easily done by changing the pulleys. When the power transmission is by V-belt drive the motor can be placed above the pump, if so desired, so that drenching of the motor is avoided. The alternative to V-belt drive is a motor with frequency converter. d. High Density Cleaner Grubbens High Density Cleaner takes care of unwanted particles and removes them from the suspension using the vortex separation principle. Parts that have a higher density than the pulp, such as screws, nails, staples, steel parts, stones and pebbles are effectively removed and gathered in the reject chamber.

When installed in an existing plant the cleaner comes with separate rotor, which allows it to operate without any pressure drop. When the cleaner is installed in a new system the capacity of the pump will determine the pressure in the cleaner. e. Deflaker Grubbens Deflaker is used for the separation of fibres in broke systems, virgin pulp systems and waste handling. Even wet strength paper qualities can be deflaked

In the Grubbens Deflaker the pulp passes through eight vibration zones under continuous flow reversals and is therefore well processed without fibre boundless in spite of the low peripheral speed.

43 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre The design of the deflaking discs allows compensation of wear trough axial movement of the rotor disc. The discs are made of hardened, acid-resistant steel with Brinell hardness of about 400 HB. High corrosion resistance ensures negligible abrasive wear. Grubbens Deflaker types GLD 200 and 360 have fixed axial rotor discs. On type GLD 360 HW the rotor disc is axially adjustable. The disc gap can easily be adjusted using a hand wheel which will enhance the performance of the deflaker. f. Dewaterer

Dewaterer type SD Practically all fibre suspensions can be treated with the Krima Screw Dewaterer, normally within the consistency range of 3–20%. The Krima Screw Dewaterer can, for example, be used for dewatering of: Screen reject, Knots, Waste paper fibre, Cleaner reject, Semi-chemical pulp, Chemi-mechanical pulp, High-yield pulp

Basically, all Krima screw dewaterers comprise a rotating screw in a perforated basket. Dewaterers should always be inclined. Type SD has a straight cylindrical core. The design is used for the simplest form of dewatering, i.e. material which is easily dewatered, for example, knots before refining and long-fibre materials.

Dewaterer type SDC Type SDC has a cone-shaped screw core. The cone-shaped core gives a radial compression which increases the outlet consistency up to 8-12% at an inlet consistency of 3%. This type can, for example, be used as pre-thickener before the Krima screw press in a waste paper system.

Dewaterer Screw type SDPP Type SDPP is the most advanced type of screw dewaterer. The SDPP unit has both a conical screw core and pneumatically controlled counter-pressure cone. The counter-pressure cone enables hydraulic pressure to build up in the dewaterer and this ensures that the holes in the screen basket are kept clean. The SDPP unit is recommended when the in-feed volume and/or freeness vary considerably and is therefore particularly suitable in waste paper plants. This unit can thicken up to an outlet consistency of 20%.

44 Best Practices Manual - Pulp & Paper Industry g. Screw Press

Screw Press type KSR Screw press type KSR for an inlet consistency of 3%. The screw press gives excellent results on recycled paper as well as virgin pulp.

Advantages with the Krima screw press type KSR: ƒƒ Good dewatering due to thin pulp cake. ƒƒ Blockage free discharge due to pneumatic backpressure cone. ƒƒ Low wear due to low operation speed. ƒƒ Good accessibility during maintenance due to horizontally split screen baskets and a screw with dismountable shafts. ƒƒ The screen baskets of the press have good accessibility for inspection and cleaning due to the external hoops which can be dismantled easily by hand.

Screw Press type RR Screw press type RR for an inlet consistency of 8%. The screw press gives excellent results on recycled paper as well as virgin pulp

45 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre h. Disperging system

Disperging system Krima Disperging System is exclusively designed for disperging waxes, hot melts, bitumen, stickies, laser ink as well as heavy colours. The Krima Disperging system is the most advanced system. Apart from producing the best disperging result for all kind of dispergible contaminates in waste paper, this is also the most flexible disperging system. The discharge side of the screw press does not need to be pressurized as the following plug screw is designed to seal the system against the atmosphere. This design allows existing dewatering system to be used. Shear forces introduced to the stock by the plug screw create a pre-disperging effect and at the same time an excellent distribution of bleach chemicals when so required.

Retention time of the pulp in the standard design pre-heater is 2 min. which is enough for reductive bleaching with FAS and a reduction of bacteria and spores in the stock.

Compact Disperging system The Krima Compact Disperging System includes the Krima screw press type KSR with pressurized discharge outlet chamber. Automatic torque control on the screw press drive ensures constant outlet consistency. Retention time for the pulp in the steam heater is between 15 and 20 seconds.

46 Best Practices Manual - Pulp & Paper Industry Ultra Compact Disperging system The Krima Ultra Compact Disperging System consists of only three machines. Krima screw press type KSR with automatic torque control and as option equipped with a pressurized discharge outlet chamber. Existing dewatering equipment can also be used.

An in-feed steam heater for introduction of shear forces to the pulp to create pre-disperging effect. Retention time for the pulp in the heating zone is between 5-10 seconds. This system can for example be used to avoid yellowing of mechanical fibres. i. Bleaching System In the Krima sequence Bleaching System the pulp will be continuously bleached under pressure at high pulp consistency. The bleaching system is installed directly in connection with the Krima Disperging System. Because of this it is possible to both pre-bleach and post-bleach with different chemicals.

The advantages with Krima Bleaching System: ƒƒ High temperature is utilised in the bleaching process ƒƒ Less energy consumption ƒƒ Less chemical consumption ƒƒ Minimum dilution effect on bleaching chemicals due to high pulp consistency

47 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Different temperatures during pre-bleaching and post-bleaching ƒƒ Different pulp consistency during pre-bleaching and post-bleaching ƒƒ Different bleaching chemicals during pre-bleaching and post-bleaching ƒƒ Possibility to make fast changes to conditions for bleaching efficiency j. Refiner The Krima refiner is designed for high consistency fibre treatment. The best results are reached when theinlet consistency is between 20 and 30%. One of the most significant features of the unit is the patented and technically superior in-feed zone, which allows treatment of all types of fibres without the risk of blocking.

The in-feed zone also contributes to the very low energy consumption. The power consumption varies according to the type of refining discs. The refiner provides a high pumping effect which feeds the pulp directly to the required station, i.e. machine vat or storage tower. The rotor can be equipped with special pump flights to achieve the maximum pumping effect.

Contact Details For further details: www.cellwood.se Sweden Office Box 65 SE-571 21 Nässjö Sweden Tel: + 46 (0)380 76000 Fax: + 46 (0)380 14123 e-mail: [email protected] India Office Eintec G#17, Sreevatsa Square 7/31-A, Mettupalayam Road Coimbatore, India 641 034 Telephone: +91- 422 264 5815 E-mail ID: [email protected]

48 Best Practices Manual - Pulp & Paper Industry CHEMREC

1. Introduction to Chemrec CHEMREC helps pulp and paper mills dramatically increase their cash flow and profitability by enabling them to become Biorefineries. Application of its unique, proprietary black liquor gasification technology opens upnew markets for mills, producing sustainable, low-carbon chemicals and fuels.

Low carbon footprint A recent CONCAWE/EUCAR study reviewed the carbon footprint of a variety of bio- and fossil fuels. Chemrec’s biofuels clearly stand out in the study, with all of the various potential fuel products reducing overall footprint by greater than 90 percent. With the additional benefit of not competing for food or agricultural land, Chemrec biofuels are a true leader in the move to sustainable mobility

Fig: Carbon footprint of various fuels

Intellectual Property Chemrec has a broad patent portfolio protecting their technology globally. They hold more than a hundred patents across 26 patent families covering gasification, gas cleaning and pulp mill integration aspects. They innovate and constantly strive to add patents protecting a wide range of aspects of their technology. 2. Profile of the company: Areas of expertise Chemrec has some 20 years of experience in the field of black liquor gasification technology. During these years, they have developed iterations of the technology in demonstration plants. The technology has now matured into a proven concept which they offer on commercial terms to mills looking to expand their operations and enter the new pulp mill paradigm – the Biorefinery.

Gasifier products

A300 Booster The 150-300 tons/day atmospheric air-blown unit increases pulp production through improved black liquor recovery capacity and flexibility in chemical recovery. The A300 Booster can be installed in parallel with the mill’s existing

49 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre recovery boiler. A significant benefit of this system is that it can be installed while the recovery boiler continues to operate, thus avoiding down time and lost production.

OX450 Booster The OX450 atmospheric oxygen-blown Booster with capacities up to 450 tons/day not only increases the black liquor recovery capacity but also produces a fuel gas suitable as lime kiln fuel. In this way lime kiln fuel costs and the mill carbon footprint can be significantly reduced.

P500 Expansion Unit The 500-550 tons/day pressurized oxygen-blown unit offers mills additional capacity and increased yield, while producing significant volumes of sustainable, low-carbon biofuels or high heating value fuel gas.

P2000 Replacement Unit The 1000-4000 tons/day pressurized oxygen-blown unit replaces recovery boilers entirely, granting improved pulp yield, while producing significant volumes of sustainable, low-carbon biofuels.

X2000 Combined Cycle Unit The 1000-4000 ton/day pressurized unit oxygen-blown replaces recovery boilers entirely, granting improved pulp yield, while doubling “green" power production. 3. About the latest technology on the offering a. Chemrec - a gasification technology inherently more efficient Low-cost feedstock, very high conversion efficiency and inherently lower investment cost are features of the Chemrec process that makes production of lower cost biofuels possible. Building on existing industrial infrastructure Chemrec transforms pulp and paper mills into biorefineries with its proprietary black liquor gasification technology. The excellent quality syngas that is produced can be converted into sustainable, low-carbon fuels and chemicals such as: ƒƒ Dimethyl ether ƒƒ Methanol ƒƒ Synthetic diesel ƒƒ Synthetic gasoline The Chemrec process has been shown to be very close to carbon dioxide neutral with a reduction of fossil CO2 emissions of 95%. The technology has potential to globally provide motor fuels equivalent to over 45 billion litres or 12 billion gallons per year of gasoline.

Gasification – gas quality, energy efficiency and integration Gasification is already a large and mature component of the existing fossil petrochemical industry. The use of green feedstock for gasification is however attracting more and more attention around the world. For the outsider it can be difficult to distinguish between different types of gasification. Here follows a short guide to what distinguishes the gasification process used by Chemrec as opposed to others with focus on gas quality, energy efficiency and integration benefits.

50 Best Practices Manual - Pulp & Paper Industry Fuel gas, syngas and syngas quality First, gasification processes can be divided into processes producing synthesis gas, sometimes abbreviated as syngas, and processes producing fuel gas. As syngas must consist essentially completely of carbon monoxide and hydrogen, gasification processes that produce syngas must not let nitrogen from the air enter the process. This means that a gasification process that is to produce syngas must either be fed only pure oxygen as oxidant or be indirectly heated. If air is used as the oxidizing agent only fuel gas can be produced. Syngas must for most synthesis processes be free from particulates and tar compounds and must hold only low concentrations of methane. So-called low temperature processes whether indirectly heated or oxygen-blown will form substantial amounts of tars and methane. If the feedstock is Municipal Solid Waste (MSW), wood or agricultural residues the gas will also include substantial amounts of particulates. For raw syngas from a low temperature process to be acceptable for synthesis gas, upgrading it must, therefore, first be treated to remove particulates and tars and catalytically treated to transform the major part of the methane to carbon monoxide and hydrogen. Principle of operation The Chemrec process in contrast is operated in the entrained-flow high temperature mode. This has the advantage of suppressing methane formation and almost completely eliminating the formation of tars. The process also gives very high carbon conversion so almost no char is formed. As a wet quench method and counter-current condensation under pressure is used in the Chemrec process the particulate removal is very efficient, giving only parts per billion of particulates in the cooled gas. The host pulp mill is already equipped with a system to separate particulates from the excess quench liquid as this liquid will also contain the recovered cooking chemicals which are reused in the pulp mill.

Fig: Schematic of a Chemrec gasifier with gas cooler steam generator

Energy efficiency through heat generation A gasification process and a fuel synthesis plant will always generate heat as a by-product. Some of this heat can be recovered internally, how much depends on temperature levels of producers and consumers within the plant and on

51 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre how much heat recovery equipment such as heat exchangers are installed in the plant. For energy efficiency it is essential that the heat generated as a by-product of the gasification process is re-used. It can be used internally, in the gasification plant and the pulp mill, but can also be integrated with a districy heating system. Övik energi, Örnsköldsvik, Sweden, distributes heat generated at the biorefinery Domsjö Fabriker, to the industrial areas in the surroundings. Nevertheless a substantial amount of heat will have to be removed from the plant. This can either be done through the application of cooling systems from which the heat is dissipated to the air or water bodies around the plant or it can be exported as useful heat from the plant to for example a neighboring industry with need of lower level heat or a district heating network heating buildings around the plant. Stand-alone plants without possibility to export heat will invariably have lower effective energy efficiency than plants that are externally heat integrated.

Case studies 1. The New Bern Booster gasifier, > 47000 h of full-scale operation ƒƒ Commercial atmospheric, air-blown gasifier to boost recovery capacity ƒƒ Capacity 300 t BLS/d, about 15% of total mill recovery capacity ƒƒ Installed in 1996, operated >47 000 h until October 2008 ƒƒ Reached 95% annual availability and 2 years refractory life ƒƒ Of great importance for development of refractory system and other components

2. Oxygen-blown high pressure gasifier consistently produces high quality syngas and green liquor ƒƒ Located at the Smurfit Kappa mill in Piteå, Sweden ƒƒ Used for development and technical demonstration ƒƒ Oxygen-blown and operated at 30 bar(g) ƒƒ Capacity 20 t BLS/d (3 MWth), >13 000 operating hours ƒƒ Provides BioDME plant with syngas

52 Best Practices Manual - Pulp & Paper Industry Other benefits The practical implications of black liquor and Chemrec technology are a simpler plant using fewer and commercial processes

Fig: Schematic of Chemrec and conventional gasification processes

Chemrec plants are always heat integrated with the host pulp mill. As the Chemrec process is also energy efficient it can deliver substantial amounts of process steam back to the pulp mill. This reduces the net amount of external energy needed for the combined pulp mill and Chemrec plant.

Integration benefits Integration with existing activities along the value chain is crucial for second generation biomass-based biofuels production to be competitive. Moving through the value chain such integration can include: ƒƒ Using the waste product of another value chain as the feedstock can substantially reduce feedstock cost. In the Chemrec case, they use forest harvest residues, essentially tops and branches left from the timber harvesting, as make-up energy feedstock for the host pulp mill. As gasification feedstock they use black liquor, a pulp mill waste stream left over from the production of cellulose. ƒƒ Providing by-products or services in addition to the primary product. In the corn ethanol industry this is key to profitability; in addition to the ethanol also protein-rich livestock fodder in the form of distillers grain is produced. In the case of the Chemrec process it provides two utilities to the pulp mill; it recovers and returns for reuse hundreds of tons per day of spent cooking chemicals dissolved in the black liquor and it produces process steam for use in the pulp mill.

53 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Being located where logistics systems for the raw material and product is already in place. Being in a location where infrastructure costs are high adds to investment and operating cost. A Chemrec plant is always located directly at an operating pulp mill where thousands of tons of woody biomass is already brought in and processed every day. The Chemrec biofuels plant simply receives the already prepared and uniform feedstock black liquor. ƒƒ Using the product to enhance the associated value chains. In the BioDME demonstration project already fuelling trucks bringing logs into the mill and paper from the mill with high performance fuel produced in the mill. The pulp and paper industry could thus not only be fossil fuel independent for their production processes but also for a large part of their transport needs. Black liquor -Liquid biomass with properties uniquely suitable for gasification for biofuels production ƒƒ Single-step gasification without tar or methane reforming to high-quality syngas and green liquor ƒƒ Gasification in an entrained flow high-temperature mode gives ƒƒ Full carbon conversion ƒƒ No tar formation ƒƒ Low methane formation ƒƒ Small reactor volume (~25 m3/1000 t BLS/d) ƒƒ Simple gas clean-up The technology has intrinsically lower investment and operating cost. ƒƒ Installation on existing industrial size with shared services and utilities ƒƒ Feedstock already prepared and ƒƒ Feedstock is liquid and highly reactive ƒƒ Two services in one unit –produces syngas and recycles valuable cooking chemicals ƒƒ Heat integration with pulp mill provides outlet for surplus LP steam and increases net conversion efficiency ƒƒ Low quality make-up energy source –forest harvest residues or natural gas Highest Efficiency and lowest emissions are possible with DME and syndiesel gasified from Blackliqor.

Chemrec is well within commercial fossil gasification parameters such as energy flow / gasifier size, gasifier type, pressure and temperature.

54 Best Practices Manual - Pulp & Paper Industry PerstorpOXO BASF Germany Eastman Uba Ammonia Domsjö Sweden Sweden Chemicals USA Japan Feedstock Oil/ Nat. gas HVR HS Coal HS Coal/ Petcock Thick Liquor Start up year 1980 Before 1970 1983 1984 2014 Gasifier size/ # of > 100 MW/1x 150 MW? / 4 x 33% 300 MW / 2x 100% 150 MW / 4 x 33% 100 MW/ 3 x 50% trains 100% Pressure bar 30 30 65 40 30 Temp., deg C 1300 1300 ~ 1400 1450 ~1000 Products Oxo chemicals Petrochemicals Photo chemicals Ammonia DME/ Methanol 3x50% gasification trains ensure 100% capacity always available

Fig: Gasification Trains

Thermal efficiency of gassifier: 92%

(LHV) MWth BL feed (500 TPD BLS @ 73% concentration) 75 MW (input) LP steam generation 23 MW Feed Water heating 2 MW Syn Gas 44 MW Total useful Output 69 MW b. Chemrec Boosters-Technology for recovery capacity increase and fuel cost reduction

Chemrec Boosters, purpose and profile: Chemrec Boosters is proven technology that provides solution to increase pulp capacity even with the customer has severe recovery boiler limitations.

The advantages are: ƒƒ No recovery boiler rebuild shutdown is required ƒƒ The investment is moderate ƒƒ Easy to operate

55 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Can produce fuel gas for lime kiln, natural gas or fuel oil replacement ƒƒ Reduced fuel costs ƒƒ Reduced carbon footprint

The boosters come in two versions: A300 and P500. A300 ƒƒ Atmospheric, air-blown unit ƒƒ Standard size is of 300 t BLS/d ƒƒ Produces gas for steam generation ƒƒ Well-proven with 47000 hours of operation ƒƒ Low cost, high profitability when the recovery boiler is the mill bottle-neck P500 ƒƒ Pressurized, oxygen-blown unit ƒƒ Size up to 550 t BLS/d ƒƒ Produces high value fuel gas for lime kiln firing ƒƒ High thermal efficiency, produces fuel gas and LP steam Typical cost economics for an Indian integrated pulp & paper mill (May vary from case to case)

Description Quantity / rate In rupees Basis 100 TPD of BLS Present Scenario : Black liquor HP Steam generation from 100 TPD 350 TPD fired in the soda recovery boiler of BLS that now has to be generated to generate steam by coal fired boilers Cost of steam generation by coal Rs. 1000 / Ton Total value of output Rs. 0.35 million /day Using booster type BL gassifier Replaced Furnace oil from lime kiln 18 kL /day (Refer to above Rs. 0.81 million / day to replace Furnace Oil in lime table) kiln Cost of FO Rs. 45000 / kL Quantity of LP steam generated 5.8 TPH Cost of LP steam Rs. 500 / Ton (assumed) Rs. 0.07 million / day Total value of output Rs. 0.88 million / day Nett additional benefit of by booster type gassifier Rs. 0.53 million/day Investment Rs. 350 million Simple payback period 2.2 years Maintenance cost of booster ƒƒ Inspection to be carried out once every 6 months ƒƒ Nozzles have to be regularly cleaned ƒƒ Refractory life is 2 years (cost of refractory for a 550 TPD system is Rs. 25 million)

Entrained flow high temperature gasification Combustion oxygen is mixed with atomized liquor to form hot flame at 1700-1800°C / 3100-3300°F. The result is low tar and methane formation. Secondary gasification reactions outside flame consumes residual char and lowers gas temperature to about 950°C / 1750°F. It results in a very low green liquor char content and moderate temperatures at reactor lining surface.

56 Best Practices Manual - Pulp & Paper Industry Case Studies

(i) A300 BOOSTER –INCREASED BLACK LIQUOR RECOVERY CAPACITY AT MODERATE INVESTMENt COST

The New Bern Booster gasifier ƒƒ Commercial atmospheric, air-blown gasifier to boost recovery capacity ƒƒ Capacity 300 t BLS/d, about 15% of total mill recovery capacity ƒƒ Installed in 1996, operated for more than 47000 hours until Oct 2008 ƒƒ Of great importance for development of refractory system and other components ƒƒ Reached 95% annual availability and 2 years+ refractory life

Fig: CHEMREC® New Bern A300 Booster ii) P500 BOOSTER -INCREASEDBLACK LIQUOR AND LIME RECOVERYCAPACITY

Improved Booster Concept Chemrec’s revised Booster concept using their pressurized P500 gasifier provides the following benefits: ƒƒ Gas cooling produces steam improving total heat economy ƒƒ Fuel gas replaces natural gas or fuel oil in lime kiln ƒƒ Higher lime kiln capacity than on natural gas or oil ƒƒ Very low gas sulfur content ƒƒ Attractive operating cost P 500 Gasifier- Merits ƒƒ It is the standard Chemrec unit for syngas generation for motor fuels production ƒƒ The system can be pressurized to 30 bar (g)

57 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ It is Oxygen-blown ƒƒ Standard size 500 ton black liquor DS/d ƒƒ Very good overall thermal efficiency -syngas cooler steam generator recovers sensible and condensing heat of gas ƒƒ Suitable to feed acid gas removal system

Thermal efficiency of P500 unit (typical)

Fig: P500 Booster system solution

The gas treatment unit ƒƒ An amine wash unit has been selected ƒƒ Same principle as for the Chemrec BioDME plant amine wash ƒƒ Removes sulfur and carbon dioxide from the syngas, 0.1 % H2S, 2% CO2 residual selected ƒƒ Skid-mounted unit ƒƒ Gives two gas streams ƒƒ Sweet syngas ƒƒ Odorous gas to incineration

58 Best Practices Manual - Pulp & Paper Industry Fig: Gas treatment unit

Fig: Amine Wash Unit under construction in Munich for Chemrec BioDME Total space requirement (preliminary) for gasifier unit is 20 m x 40 m, for gas treatment unit is 20 m x 8 m and for oxygen plant is 20 m x 35 m besides location for flare.

Fuel gas gives higher lime kiln capacity The upgraded syngas has a capacity advantage over natural gas and fuel oil due to ƒƒ Higher flame temperature ƒƒ Lower combustion air volume gives lower load on lime cooler ƒƒ Lower flue gas volume gives lower load on kiln, flash dryer, electrostatic precipitator and ID fan

59 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Example at 500 t black liquor DS/d with 73% DS, 35.6 MWLHV kiln heat input:

Natural gas Upgraded syngas Difference Combustion air flow Nm3/s 10.02 7.93 -21% Flue gas flow Nm3/s 11.03 9.48 -14% Adiabatic flame oC 1971 2191 +220 temperature

Key stream data Typical key utilities production / consumption at 500t DS/d and 73 % DS content ƒƒ Net steam generation ~15 t/h ƒƒ Net power consumption including oxygen plant ~5.6 MW ƒƒ Oxygen demand 1.71 kg/s ƒƒ Gas energy content: 35.6 MW (lower heating value)

Contact Details Patrik Löwnertz VP Marketing & Sales Chemrec AB Floragatan 10B SE-114 31 Stockholm, Sweden Ph:+46 8 440 40 67 Fax: +46-8-440 4066 Email: [email protected] Website: www.chemrec.se

60 Best Practices Manual - Pulp & Paper Industry CORTUS 1. Introduction to Cortus Cortus aims to be the leading provider of clean energy to customers in the Process, Power, Transport and Waste Management industries. Potential markets are forest rich countries in the Nordic region, the European Union and North America. Their expansion phase will penetrate into emerging markets like Brazil, China, South Africa and India. 2. Profile of the company: Areas of expertise

Mission Statement Cortus AB aims to become an international leader in supply of clean renewable energy gas to high temperature combustion in process and power industries based upon high thermal efficiency and cost effective gasification of biomass.

Carbon and Climate Change Carbon emissions are the leading cause of global warming and climate change. A primary source of carbon emissions are fossil fuels. Realising the turn of environmental issues that could occur in the future if carbon emissions are not controlled, The Kyoto Protocol was introduced to provide businesses with economic opportunities to be more energy efficient by reducing emissions. Cortus sees this as a great economic opportunity by supplying affordable, clean and renewable Synthesis Gas generated from gasification of biomass, as a way to replace fossil fuels.

Green Power for Process & Power Industries Cortus is building the future of innovative and sustainable energy supply for the process and power industries. High temperature combustion in process and power industries demands high calorific and clean fuels. Cortus is now introducing Green Power based upon their new biomass gasification technology - WoodRoll®. WoodRoll® is Cortus way of solving global and environmental issues by providing sustainability. They replace fossil fuels with green gas generated from biomass. WoodRoll® has the unique ability of being able to accept a huge variety of feedstock while maintaining a high thermal efficiency of up to 80%. In addition, their patented indirect heating technique produces a cleaner green gas than conventional gasification methods, hence translating into better cost savings for their customers. WoodRoll® will help to reduce millions of tons of carbon released while at the same time, providing their customers with cost savings in millions of dollars through the circumvention of emission permits.

Cortus Advantage The clean high calorific Syngas produced can substitute fossil fuel in any process. Cortus’ process is builtupon subsystems proven in other industrial processes but put together in a new fashion. Cortus' WoodRoll® thermal efficient gasification technology and fuel flexibility makes it feasible and profitable to build on-site plants that process locally available biofuels into clean energy. Besides, the WoodRoll® produced Syngas has high purity as it is an indirectly heated process. Syngas is not diluted with nitrogen from the air or polluting elements, hence eliminating the need to include an additional filtration system which translates to additional cost savings for their customers.

61 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 3. About the latest technology on the offering - WoodRoll® What is Biomass? Biomass refers to any living or dead biological material that can be used as fuel or production. Second generation biomass (non-food based products) like wood waste and industrial sludge is slowly gaining popularity as use of first generation biomass (sugar, starch and vegetable oil) have been questioned over issues of increasing price of food and the relatively low energy density of crops. Currently, such second generation waste biomasses are normally incinerated or landfilled. Both have been heavily criticized: in landfilling, escape of methane is 25 times more potent than carbon dioxide; incineration produces toxic byproducts which need to be further processed. Gasification would be an important future waste management technology. What is Gasification? Gasification is a process that converts carbon materials, such as coal, petroleum or biomass, into carbon monoxide and hydrogen (synthesis gas). This is done by reacting the raw material at high temperatures with carefully controlled amount of oxygen or steam. The synthesis gas is often used as intermediate raw material or as a fuel, depending on its purity. Gasification is an efficient method for extracting energy from different sources of organic materials, andalso considered as a clean waste disposal technique. Biomass gasification is much cleaner and more efficient than direct combustion of biomass.

Gasification of Biomass In general, gasification of biomass generally consists of 3 major processes: ƒƒ Drying ƒƒ Pyrolysis ƒƒ Gasification The drying step is usually the first step in any biomass gasification process. The drying step removes moisture from biomass. Pyrolysis is the chemical decomposition of carbonaceous material that produces char at elevated temperatures. Pyrolysis produces combustible components, a variety of condensable organic compounds referred to collectively as tar. Several non-combustible gases are also released, primarily N2, CO2, and water vapor. Gasification process occurs as the char reacts with steam to produce carbon monoxide and hydrogen (Syngas) in the reaction. In conventional gasification processes, the 3 processes are combined into one gasifier. Cortus innovates this further through the WoodRoll® gasification process, where these 3 processes are separated into 3 separate systems, resulting in a much cleaner syngas that is undiluted with nitrogen.

Principles of WoodRoll® Technology The core technology has three parts: drying, pyrolysis and gasification each of which are very well established industrial components - with the arrangement of the components unique to Cortus. Cortus’s first patent was granted in December 2008. They now have 3 granted patents and 2 more have been filed and pending approval.

62 Best Practices Manual - Pulp & Paper Industry A Cleaner SynGas A distinctive element of the WoodRoll® process is that the produced char is gasified with steam in an indirectly heated reactor to produce synthesis gas. The char and steam are thus not mixed with the exhaust from combustion or nitrogen from the air. This produces a clean synthesis gas which is free from condensable tar residues and nitrogen aggregates compared to existing conventional gasifier reactors. The cleaner syngas produced via WoodRoll® eliminates further downstream filtering or purification processes to remove unwanted substances within the gas stream. This translates to additional savings for their clients. Typical composition of the dry Syn gas would be 60% Hydrogen, 30% Carbon monoxide and 10% Carbon dioxide and is likely to have calorific equal to or more than that of Natural gas. The uniqueness of this biomass gasification technology is the use of steam (H2O), and not air, as a source of oxygen.

Feedstock Flexibility Over 100 different types of feedstock have been tested and analyzed by Cortus using the WoodRoll® process. They have good knowledge of characteristics and reactivity of different fuels ranging from wood, bark, microalgae to sludge. This essential experience of conducting multiple tests adds innovation to WoodRoll® process, such that the system could accept and process a large variety of feedstock.

High Thermal Efficiency The creative usage of heat exchangers to conserve heat energy translates to 80% overall thermal efficiency for WoodRoll® process with 20% moisture in biomass. However, the thermal efficiencies can be lower with higher moisture in the feedstock. One ton of dry biomass equals 5 MWth of input fuel. Quantity of dry biomass needed to give 5 MWth of output Syn gas is 1.25 Tons. This will need about 600 kg/hr of steam as input.

Cortus Next Step Cortus is ramping up to the next phase which is 5MW demonstration plant which will be ready by 2011. In August 2010, Cortus AB and Nordkalk AB signed a 12-year contract for supply of biogas to the Nordkalk factory in Köping, Sweden. Cortus will supply biogas to Nordkalk corresponding to a reduction in carbon emission by 70000 tons annually in maximum capacity. After 2 years, the plan is to expand the facility to 25MW thus becoming the dominant energy source for the Köping factory.

Laboratory Testing Cortus has done extensive testing on over 100 fuels and feed stocks in their laboratories. TGA has been used to identify various characteristics of fuels such as gasification/pyrolysis temperature and mass/heat flow attributes. These critical experiments in the laboratory help Cortus to calibrate their parameters before moving on towards larger pilot scale testing. Moreover, it also gives them technological validation and helps them decide on feasibility of fuels.

63 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Fig: Laboratory testing

Pilot Plant Testing Fuel that passes their laboratory tests are further tested in their pilot gasification reactor. The tests allow them to optimize various parameters at an industrial level. They have learnt much from those campaigns which will crucially aid in the design of their demonstration plant.

Fig: Pilot plant testing

Engineering Design At Cortus, people are working to improve their engineering design based on the results of their extensive laboratory and pilot testing. Their partners and suppliers are also experts in their respective components of the demonstration plant.

64 Best Practices Manual - Pulp & Paper Industry Contact Details Sweden Office Rolf Ljunggren, CEO, Email: [email protected] Ram Alzuheri, Project Engineer, Email: [email protected] Address CORTUS AB, Skalholtsgatan 2, 164 40 Kista, Stockholm, Sweden Office: +46 (0)8 5888 6630 Fax : +46 (0)8 752 8105 Website: www.cortus.se

65 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ELOF HANSSON

1. Introduction to Elof Hansson

Elof Hansson International Elof Hansson International supplies equipment and components, machinery and complete plants and process segments to the pulp and paper, corrugating, converting, printing, packaging and sugar industries. Elof Hansson International also plays a leading role in major projects such as new plants and renovation of existing facilities, as well as all kinds of projects utilizing concession loans. 2. Profile of the company: Areas of expertise For more than five decades Elof Hansson has been successfully associated with the pulp, paper and converting industries in India. They are actively engaged in the marketing and supply of pulp, paper and secondary fiber, machinery and technical services, consumables and specialty chemicals. Elof Hansson India’s head office is located in Chennai in the southeast of India. To cover the entire Indian market as well as Sri Lanka, Pakistan, Bangladesh and Nepal they also have branch offices in Hyderabad, Mumbai, Delhi and Kolkata. The products and services of Elof Hansson are Pulp, paper and secondary fiber; Chemicals; Machinery, components and spares; Process and quality control instruments; and Services and engineering. 3. About the latest services on the offering a. Chemicals Elof Hansson India offers chemicals for the following applications:

Water & Waste Water Treatment Boiler feed water treatment ƒƒ Single product, all organic filming & neutralizing amines based ELOGUARD® program. ƒƒ Phosphate free program eliminates HP dosing, requires LP dosing only. ƒƒ Superior and comprehensive protection against corrosion to pre boiler, boiler & condensate system. ƒƒ Over 170 customers in industries like paper, oil refinery, sugar, textile, steel, power etc., with steam pressures ranging from 8 Bar to 100 Bar rely on ELOGUARD. In addition to above, Elof Hansson in cooperation with BKG Water Solutions, Germany offers comprehensive solutions for the following: ƒƒ Cooling Water treatment - Antiscalants, Corrosion inhibitors, Dispersants and Biocides. ƒƒ Raw Water Pretreatment - Flocculants and Co aggulants. ƒƒ RO Membrane Treatment - Antiscalants, Prereservation, CIP cleaning chemicals and programs. ƒƒ Waste Water Treatment - Flocculants and Co-aggulants, Defoamers, Color removal, Odour control and Water reuse / Recycle programs. ƒƒ Selective process additives for Refinery / Petrochemical, Sugar mills, Paper mills, Paper mills andFood industry.

66 Best Practices Manual - Pulp & Paper Industry ƒƒ Complete water treatment package, with control equipment for dosing, monitoring, control and Onsite Service and Support. ƒƒ For more information on BKG Water Solutions, please visit their website www.bkgwater.com Corrosion Inhibition in Refinery Overhead systems ƒƒ Filming and neutralizing amines based corrosion inhibitor, ELOGUARD P 86 for protection against corrosion & scaling in overhead systems of crude/atmospheric distillation units, vacuum distillation units, delayed coker unit (DCU) etc. ƒƒ Paper/Board making ƒƒ Fine and ultrafine high brightness kaolin clays from Thiele Kaolin, Georgia, USA. b. Machinery, components and spares Elof Hansson India offers the following products: ƒƒ Stock and liquor pumps, energy efficient agitators ƒƒ NCG, white liquor oxidation system ƒƒ Blow heat recovery system ƒƒ Rex technology and evaporator retrofitting ƒƒ Dynablade for blade coaters and tissue creeping ƒƒ Pulp Screening Components and Systems ƒƒ Compact Wet End Systems ƒƒ Low Consistency refining components ƒƒ Water treatment plants, microfilters for solutions to recycle water in paper mills ƒƒ Handling and wrapping systems for paper rolls and pallets c. Process and quality control instruments Elof Hansson India offers for the following products: ƒƒ Lab instruments for paper testing and process optimization ƒƒ Lab instruments for fiber rising, hygroexpansitivty, dynamic absorption ƒƒ Lab reactors for pulping and bleaching, lab digesters ƒƒ Consistency transmitters, on line analyzer, basis weight valves ƒƒ Instruments for packages testing ƒƒ On line gloss meter for paper and paper boards ƒƒ PTS Domas formation, dirt, specs, sticky wire and felt mark modules and paper bale sensors for portable measurements ƒƒ Wet end charge analyzer, polymer control systems, lab charge analyzer, turbidimeter ƒƒ BASIS weight valves ƒƒ Optical consistency transmitter, paper machine retention monitoring and controls

67 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre d. Services and engineering Elof Hansson India offers: ƒƒ Systems for white liquor oxidation, non-condensable gases incineration ƒƒ Steam and condensate system optimization ƒƒ Instrument calibration and troubleshooting

Case studies 1. Undertake projects on EPS basis wherein EHI is the face to the customer. 2. Executed 60 TPD Deinking line in Vietnam for a Tissue Mill 3. Executed a 400TPD Pulp mill in Vietnam 4. Executed few White Liquor oxidation Plants and NCG plants with Know How from Lundberg of USA in India

Contact Details Sweden Office Tomas Hultgren, Vice President, Direct Ph: +46 31 85 62 35 Fax: +46 31 85 68 54 Email: [email protected] Web : www.elofhansson.com Address Elof Hansson International AB Elof Hansson Industry SE-41380 GÖTEBORG, Sweden. Visiting adress: Första Långgatan 17 Tel +46 31 85 60 00 Fax +46 31 12 67 35 E-mail [email protected] India Office Manos Mukherjee, President Elof Hansson (India) Pvt Ltd New no. 149, Chamiers Road R. A. Puram Chennai 600 028 Tel: +91 44 2431 5110 Fax: +91 44 2431 5116 E-mail: [email protected] Or [email protected] Website: www.elofhansson.com/india

68 Best Practices Manual - Pulp & Paper Industry ENTRANS GROUP

1. Introduction to the company Focused on heat recovery with ORC technology, the Entrans team has rich experience in the energy and process industry, especially in large heat pump and chiller systems, foundries, sawmills and paper industry. Entrans is highly experienced in optimizing heat and cooling production within energy industry, identifying synergies that can be reached by optimizing and integrating new systems into existing processes within process and energy industry and in maintenance and overhaul of large heat pumps and chillers. 2. Profile of the company: Areas of expertise FlexiGen is the product from Entrans group for optimizing the efficiency of industrial processes, marine vessels and geothermal sources by harnessing excess heat and achieving maximum performance from current available resources and equipment. The Organic Rankine Cycle (ORC) enables FlexiGen to generate electricity or mechanical power from low temperature heat with a conversion efficiency of 5-20%. FlexiGen is able to operate with temperatures as low as 50oC (up to a maximum of 220oC), maximising the use of all heat sources available. Heat can be converted to electricity as it is harnessed by FlexiGen from various sources. Every MWh of electricity produced by FlexiGen translates to cost savings in producing or buying one MWh of electricity. FlexiGen is self contained, with no gaseous emissions or any other associated environmental pollutants. Every FlexiGen unit is designed using FlexiGen EOS™, a system configuration tool developed by the Entrans team over more than 10 years, customizing each FlexiGen unit to the target system. All components used in FlexiGen are obtained only from large and respected ISO 9001 certified vendors. 3. About the latest technology on the offering With a wide operating temperature range, FlexiGen is able to make use of many different heat sources across various industries. a. Industrial Applications FlexiGen eliminates the problem of excess heat wasted in industrial processes such as those in cement plants and steel mills. Facilities such as biofuel and waste incineration plants can make use of FlexiGen’s ability to generate electricity to maximize the efficiency of current equipment. This can be done without risk of disruption to original operations.

69 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre *When used in district heating systems, the district heating return flow can be used as a heat sink.

b. Geothermal Energy Geothermal wells of “low-value heat” and the return flow of existing geothermal plants can utilize FlexiGen to achieve a high conversion efficiency of heat to electricity due to its use of the Organic Rankine Cycle and optimized custom design to each well/plant.

Principle of operation FlexiGen’s ability to utilize excess heat at low temperatures is due to the Organic Rankine Cycle (ORC). The ORC is a thermodynamic cycle that uses an organic working fluid that has a lower boiling temperature as compared to water,

70 Best Practices Manual - Pulp & Paper Industry such that the operating temperature of the system is lower. This cycle is best explained using the pressure-enthalpy graph of R134a, one of the refrigerants which are used in FlexiGen, as seen below.

1-2 Compression The working fluid is first pressurized in liquid phase, using a pump.

2-3 Preheating Heat transfer occurs from the heat source to the working fluid in the preheater, raising its temperature. The working fluid is still in liquid phase here.

3-4 Evaporation Heat transfer occurs from the heat source to the working fluid in the evaporator. The working fluid undergoes a phase change here to become gas.

4-5 Expansion The vapor is allowed to expand in the expander and is connected to a generator. This step produces electrical energy.

5-1 Condensation The remaining heat is removed from the working fluid in a condenser, where heat is transferred from the vapor to a cooling source. The working fluid is now a low pressure liquid once again.

71 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Generated power depends on the amount of released heat energy and the efficiency. Higher efficiency is achieved with higher ΔT. Entrans helps to find the optimum configuration of efficiency and generated power for FlexiGen which fulfils operating constraints and achieves customer-specific objectives.

Product Specifications

Electrical Output 25-70 kWel 70-150 kWel 150-300 kWel Weight (tons) 3 4 7 Dimensions (hxwxl; m) 2 x 1.6 x 3 2.2 x 2.2 x 4 2.4 x 2.2 x 6

Note: FlexiGen P refers to the product line FlexiGen P50, FlexiGen P100, FlexiGen P250 with power drive only and are available worldwide.

The product line FlexiGen 50, FlexiGen 100, FlexiGen 250 with power drive, heat pump and chiller mode. They are available in the EU, US and Japan only.

Sources of further information

Further information is available at the website: www.entransgroup.com or can be obtained from the email info@ entransgroup.com.

Contact Details

Main Office Entrans AB, Hammarby Fabriksväg 23, 120 33 Stockholm, Sweden

Local Partner (India) Nordic Cleantech Pvt.Ltd, 20/20 CDS Evergeen Enclave, Velacherry, Chennai-42, Ph - +91-9840933237

72 Best Practices Manual - Pulp & Paper Industry GL&V Sweden AB

1. Introduction to the Company

GLV Inc. is a leading global provider of technological solutions used in water treatment as well as in pulp and paper production. The Corporation operates in some 30 countries and has approximately 2,300 employees (as at December 31, 2010).

The Pulp and Paper Group designs and globally markets equipment used in various stages of paper production, from pulp preparation to sheet formation and finishing. It also serves the global market with rebuilding, upgrading and optimization services for existing equipment, as well as the sale of replacement parts. It ensures that its portfolio consists of innovative products and technologies that bring added value to the customer, such as lower energy consumption.

2. Profile of the company: Areas of expertise

GLV’s main goal is to continue to strengthen its business groups’ position as leading global providers of water and wastewater treatment and pulp and paper technological solutions to the market. In line with this, GLV will continue to implement the Water Treatment and Pulp and Paper Groups’ business strategy.

3. About the Latest technology on the offering a. Pulp & Paper Group

The Pulp and Paper Group of GLV is one of the largest suppliers of pulp and paper production equipment and a world leader in existing equipment rebuilds, upgrades and optimization.

Key Strengths

The Pulp and Paper Group is a world leader in the sale of spare parts, in existing equipment rebuilds, upgrades and optimization, as well as in the supply of new equipment.

The Pulp and Paper Group is recognized worldwide for its selection of fibre processing and pulp preparation equipment. Many of its products are industry standards, such as Compact Press®, DUFLO® pumps, DUALOX® mixers, SuperBatch® cooking process, Celleco™ pulp cleaners and disc filters, Beloit screening, washing and refining technologies and IMPCO™ oxygen delignification systems. Among its innovative new products, the new DD®6000 refiner can improve fibre quality while reducing energy consumption and maintenance costs. Another leading technology, the BTF™ automatic dilution system for paper machine headboxes, is the most efficient technology on the market for improving sheet uniformity and operational flexibility. The Pulp and Paper Group also offers advanced sheet formation technologies for improving stock drainage and sheet formation using an adjustable system. Finally, it should be noted that some of the group’s equipment is recognized for its energy-efficient performance.

The Water Treatment Group (Ovivo) has a portfolio of technologies that include Moving Bed Bio-Reactors (“MBBR”) and Submerged Aerated Filters (“SAF”) used by industrial and municipal systems for biological wastewater treatment. Other products include Brackett Green’s technology for the screening of high-volume seawater and river water intakes for power stations, refineries and desalination plants, which incorporate devices to protect marine life, as well as a range of complementary technologies, notably for the washing and evacuation of wastewater. Furthermore, clarifiers are on the list of the portfolio components most often targeted by the contracts awarded to the Group.

73 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre With the recent acquisition of CWT, the scope of its portfolio has expanded with additional technologies for seawater desalination as well as water purification and ultrapurification. These are used in applications where obtaining a high degree of purity is a critical factor, notably for the manufacture of components used in microelectronics.

Contact Details

Sweden Office

GL&V Pulp and Paper - an office of Groupe Laperrière & Verreault Sweden AB. Unit 7, 53 Gateway Boulevard / PO Box 1090 Epping VIC 3076

India Office

GL&V India Pvt Limited Survey No 162/4A 5A, Plot No 2 C, Off D P Road, Opposite Tangent Furniture Showroom, Aundh, Pune – 411007 Phone: +91 20 25800000 Fax: +91 20 25800213 Email : [email protected] Website: glv.com

74 Best Practices Manual - Pulp & Paper Industry INNVENTIA

1. Introduction to Innventia Innventia AB is a world leader in research and development relating to pulp, paper, graphic media, packaging and biorefining. They generate, interpret and apply research results to create innovative products and processes. Their science-based way of working allows them, in cooperation with their customers, to enhance all or any of the stages in the innovation chain, from conception to final product, service or process. They contribute thereby to their customers’ value creation. They call their approach boosting business with science. In April 2009 they changed their name from STFI-Packforsk to Innventia. 2. Profile of the company: Areas of Expertise Innventia is one of the world’s leading R&D companies with customers world-wide in the pulp and paper industry, the packaging industry, the chemical industry, and the graphics business .

Innventia holds a unique position ƒƒ the link between academic research and industrial applications, developing demonstrators and implementing results ƒƒ an international company, serving customers from almost every part of the world and co-ordinating extensive networks ƒƒ covers a large number of different fields, such as pulp, paper, packaging, graphics media, new materials and biorefining

Industry-owned to a large extent:

The organization covering the whole value chain from material science to consumer value, from idéa to implementation with 270 employees and Turnover of EURO 37 million (2010). They are industry-owned by 71%. The Group includes PFI in Trondheim, Norway, LignoBoost Demo in Bäckhammar and Innventia UK Ltd. (Edge).

Sustainability ƒƒ Research and development of efficient new processes and materials, especially products made from renewable raw materials ƒƒ Services aimed at improving sustainability performance and reducing environmental impact

Innventia services ƒƒ Life cycle assessment (LCA)

75 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Carbon footprint ƒƒ Environmental indicators ƒƒ Implementing corporate social responsibility (CSR) ƒƒ Legislation and standardisation

Benefit from collaborative research i. Cluster Research Programme ƒƒ Several projects on different common themes run for 2 to 4 years ƒƒ Companies minimise their risks by sharing investment costs in R&D ƒƒ Partners benefit from joint results which can serve as platforms for further development and new business opportunities

ii. Trade and Industry Groups ƒƒ A number of companies work jointly to solve trade-specific issues and problems linked together by Innventia researchers

Innventia is the co-ordinator of European research

Some examples: ƒƒ SUSTAINCOMP: New advanced nanostructured wood-based biocomposites (€9.5 million, 17 partners) ƒƒ BoostEff: Boosting raw material and energy efficiency using advanced sheet structure design andfibre modifications (€11.7 million, 11 partners)

The ”EU Support Office” – an initiative that helps all Swedish actors in the Forest-based Sector to be successful in European research.

3. About the latest technology on the offering a. LignoBoost – boosting pulp mills’ profitability

From fundamental research to industrial reality in less than 10 years

76 Best Practices Manual - Pulp & Paper Industry ƒƒ the LignoBoost process is a commercial and patented technique ƒƒ extracts lignin from black liquor, a by-product from wood in the production of chemical pulp ƒƒ increase the production of a normal pulp mill

LignoBoost Demo

Fig: Innventia demonstration plant in Bäckhammar, Sweden

Lignin as bio-fuel ƒƒ lignin gives valuable income for example as a bio-fuel, replacing coal and oil ƒƒ binding agent in biomass fuel pellet production to enhance the mechanical durability of the pellet

77 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Carbon fibres and Activated carbon from Lignin ƒƒ activated carbon is a valuable product that has been made from lignin ƒƒ spinning threads of lignin for subsequent carbonation to carbon fibres ƒƒ have a potential of replacing carbon fibres from fossil oil in different high value applications

b. Mechano-active materials They respond to various stimuli as heat or electrical current. A variety of mechano-active papers are capable of moving in exciting ways. They have a self-opening package. This package was designed in a cooperation with the Swedish University College of Arts, Crafts and Design. It opens up when exposed to the heat in a kitchen oven.

78 Best Practices Manual - Pulp & Paper Industry

c. Opto-active materials Alter their appearance in response to changes in humidity, temperature, electrical current, etc. A thin paper coating based on renewable materials that reacts to the moisture in exhaled breath

d. Nanocellulose Nanocellulose is made from cellulosic fibres and forms viscous gel at low concentrations. It has many potential applications, for e.g., as reinforcement in renewable composite materials, barriers for packages and viscosity improver in food. New Pilot Plant at Innventia 2010.

79 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre

Fig: Transparent film made from nanocellulose manufactured at Innventia. e. Saliva detection paper Saliva detection paper for Magle Life Sciences ƒƒ New production technique to produce a paper which can trace the presence of saliva ƒƒ Chemically modified starch on a filter paper surface for use in forensic laboratories worldwide ƒƒ <1 year from concept to placing a finished product on the market

f. SOFA – Online Forming Analyzer ƒƒ A tool for papermakers to monitor and control the web structure ƒƒ First on-line measurement equipment in the wet end of the paper machine ƒƒ Can be used in both single-wire and twin-wire paper machines

80 Best Practices Manual - Pulp & Paper Industry Fig: The SOFA System installed at the Korsnäs Board Mill in Frövi g. Stratified forming Stratified forming 1. Reduces energy consumption and improves product properties 2. Paper grades with different properties and furnishes in the different layers 3. To be demonstrated in the BoostEff project

i. Parupu Parupu ƒƒ a new composite material based on cellulose and biodegradable PLA ƒƒ by Södra Cell, architect and design firm Claesson Koivisto Rune and Innventia ƒƒ On display at the Milan Furniture Fair 2009

Contact Details Postal address Innventia AB

81 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Box 5604 SE-114 86 Stockholm Sweden Visiting address Drottning Kristinas väg 61, Stockholm Delivery address Drottning Kristinas väg 61 B, 114 28 Stockholm Phone: +46 8 676 70 00 Telefax: +46 8 411 55 18 E-mail: [email protected] Website: www.innventia.com

82 Best Practices Manual - Pulp & Paper Industry IVL

1. Introduction to IVL Swedish Environmental Research Institute IVL Swedish Environmental Research Institute is an independent, non-profit research institute, owned by a foundation jointly established by the Swedish Government and Swedish industry. IVL Swedish Environmental Research Institute was established in 1966 and has since then been involved in the development of solutions to environmental problems, at national and international level. They work with applied research and contract assignments for an ecologically, economically, and socially sustainable growth within business and society at large. The institute employs around 190 experts, which makes IVL a leading institute for applied environmental research and consultancy services. They undertake research projects and contract assignments in the entire environmental field. The activities include, for example, climate issues, environmental technology, indoor environment, waste management, working environment, environmental measurements, and environmental quality evaluation. 2. Profile of the Institute: Areas of Expertise IVL performs studies of the environmental effects in air, water, and soil, and the institute has its own accredited laboratories for analysis. All activities are linked to six major theme areas: Climate and energy, Sustainable building, Air and transport, Sustainable production, Resource-efficient products and waste, and Water. The broad scope of IVL's activities, combined with its multidisciplinary approach, enables IVL to offer its customers holistic solutions, as well as answers to highly specific problems. IVL contributes with knowledge and tools for more environmentally-friendly products and processes in industry. With the help of effective environmental management, social responsibility and sustainable working life, IVL offers businesses and other organisations support in their work on sustainable development. Through a combination of a system perspective and tailor-made environmental technologies in industrial processes, the most cost-effective measures in from a life-cycle perspective and at plant level are identified. With internationally renowned expertise in life-cycle assessment (LCA), carbon footprints and other tools, they identify possibilities for improvements, environmentally-friendly product concepts, and environmental communication. They perform modeling and process optimisation in collaboration with the industry to combine high-quality products with reduced environmental impact. In their test laboratories, they adjust technical solutions for improved energy efficiency and minimal environmental impact. They also contribute to organizational development through improved methods of improving the physical working environment, improve operational management, enhance comfort and improve the working climate.

Contact Details IVL Swedish Environmental Research Institute Ltd. P.O. Box 210 60 SE-100 31 Stockholm The Stockholm office Visiting/delivery address: Valhallavägen 81 SE-114 27 Stockholm

83 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Tel. +46 (0) 8 598 563 00 (switchboard) Fax +46 (0) 8 598 563 90 E-mail: [email protected] Website: www.ivl.se

84 Best Practices Manual - Pulp & Paper Industry KEMIRA 1. Introduction to Kemira Kemira is a global over two billion euro water chemistry company that is focused on serving customers in water- intensive industries. The company offers water quality and quantity management that improves customers’ energy, water, and raw material efficiency. Kemira’s vision is to be a leading water chemistry company.

Kemira’s Strategy Kemira focuses on water chemistry. Their core business consists of three customer-oriented businesses, Paper, Municipal & Industrial, and Oil & Mining, which are extensively utilizing a shared product portfolio as well as their know-how in water chemistry and product applications. They implement strategy through an integrated structure and uniform processes and procedures. 2. Profile of the company: Areas of expertise Paper segment offers chemical products and integrated systems that help customers in the water intensive pulp and paper industry to improve their profitability as well as their water, raw material and energy efficiency. Kemira’s solutions support sustainable development. The business is divided according to the following customer segments: Pulp, Printing & Writing, Packaging & Board and Tissue & Specialties.

Maximizing efficient use of water

Mission of Kemira is Efficient use and reuse of water. Vision of Kemira is a leading water chemistry company.

Offering ƒƒ Competitive chemical products with reliable delivery. ƒƒ Tailored chemistry and Monitoring, control and dosing support ƒƒ Application expertise and support ƒƒ Water chemistry technology ƒƒ Production and logistics efficiency 3. About the latest technology on the offering Kidney technologies for Process water treatment. Chemical kidneys can be applied for ƒƒ Recycling of coating colours ƒƒ Treatment of highly polluted effluents ƒƒ Bleach plant closure 85 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Improvement of product quality Examples of kidney technology in pulp mills: ƒƒ Removal of extractives in Mechanical pulp production e.g. PGW/CTMP and Chemical Sulphite/dissolving pulp production. ƒƒ Removal of NPE (Non Process Elements) and recycling of chelating agents (EDTA) in Kraft mills. Closed-loop bleach plant operation can be an alternative to effluent treatment. Reduction of Water usage with improved or maintained Pulp quality. For example: Bleach Plant Effluent reduced to 3-4 m3/t pulp and COD < 10 kg/t pulp ƒƒ After the bleach plant in the Post screening/Pulp dryer area Effluent treatment: Removal of organic pollutants by oxidation and coagulation, especially: ƒƒ Low molecular mass compounds ƒƒ Chelating agents (EDTA, DTPA) ƒƒ Recalcitrant COD ƒƒ AOX, Chlorophenols ƒƒ Colour Removal efficiencies are normally 80-90%. See the following graph for % removal of organic pollutants.

Fig: % Removal of organic pollutants by Oxidation and Coagulation

Global product portfolio Coagulants, Polymers, Sizing agents, Dispersants, Defoamers, Biocides, Colorants, Specialties and related on-site chemical preparation, dosing, control and monitoring tools. For pulp production: Caustic, Acids, Chlorate, Chlorine dioxide, Peroxygens and Reductive bleaching agents. Some of the products will be available from production sites in India during 2012.

Contact Details Main office

86 Best Practices Manual - Pulp & Paper Industry Kemira Oyj Porkkalankatu 3 P.O. Box 330 FI-00101 Helsinki, Finland |Tel +358 10 8611 www.kemira.com India Office Kemira Chemicals India Pvt Limited 2nd Floor GHB House Plot No 264/a/2, Road No 10, Jubilee Hills Hyderabad – 5000033 AP India Tel +91 040 2355 7082 / 83 Fax +91 040 2355 7081

87 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre LORENTZEN & WETTRE 1. Introduction to Lorentzen & Wettre Lorentzen & Wettre is the leading manufacturer of equipment for quality control and process optimization for the pulp and paper industry worldwide.

Facts about L & W The company is founded in 1895 and have representation in 50 countries. The company is AAA-rated for more than 15 consecutive years. It is a member of the ABB group since September 2011. In India they are represented by Elof Hansson International AB, until September 12, 2012. New organization for service and support will be built up through their owner, ABB. 2. Profile of the company: Areas of expertise Lorentzen & Wettre is to provide the world's pulp and paper industry with advanced equipment for quality control and process optimization from a position as the market and quality leader. They shall analyse customers’ needs and recommend solutions that contribute to their profitability. They do this by initiating lasting improvements within quality control and process optimization. They have about 25 instruments in portfolio. All are known for high precision and reliability, easy to use, uniform operator interface and are according to standardized industry testing methods. L&W Autoline 400 is a 4th generation system which measures according to standards. It verifies quality/optimize paper machine and has fast feed back to production. It is operator independent. They have about 20 instruments in portfolio which minimize variations, improve quality and increase production. Lorentzen & Wettre’s products contribute to improving paper quality, reducing manufacturing costs, and reducing the consumption of raw materials and energy. Their solutions range from automated fibre and pulp analysis, consistency transmitters, moisture sensors, all kinds of laboratory paper testing instruments, automated paper testing system, to different kinds of service agreements. Products from Lorentzen & Wettre are a safe investment, and provide pulp and paper mills with satisfied customers and greater profitability, all over the world. 3. About the latest technology on the offering

Paper Testing The need for superior quality paper grades that are both versatile and consistent has never been greater. Therefore, today’s papermaker relies upon many sources of information and measurement tools to assist in producing a product that meets or exceeds these demands. Although there are many and varied online sensors, these are not enough to present a total and clear picture of the paper machine’s performance. Quality testing data from an off machine source is required.

Pulp Testing The fibre language gives you new possibilities. Modern optical technique makes it possible to analyze fibre properties

88 Best Practices Manual - Pulp & Paper Industry statistically and in detail. Since the measurements are automatic with good repeatability they are suitable for online measurements. For example paper strength properties can be predicted quite well from the fibre properties including coarseness. Runnability problems in the paper machine and paper quality deviations can be created from different types of fines, shives or vessel cells in the pulp. The problems can also be a result of unknown variations in fibre mix, fibre quality or refining. If appropriate pulp quality properties are measured continuously in the process it is easy to see correlations with other things happening in the process and this enables taking correct actions and strategies based on measured facts. Early detection of deviations in quality makes early corrective actions possible. A uniform pulp quality creates the best situation for optimization of the paper machine, which is the base for a uniform paper quality, and is the most important quality property in itself.

Paper Machine Optimization Paper manufacturing is one of the most complex industrial processes in the world today. It is, of course, impossible to manually control all the settings of a modern paper machine. The speed of the manufacturing process and the quality requirements of the finished product are such that it is only by using modern measurement and control techniques that it is possible to achieve quality targets. Lorentzen & Wettre’s moisture sensors are used throughout the entire paper manufacturing process; in the forming, pressing, coating and drying sections and are finally applied to the finished paper. The most common measurements carried out by Lorentzen & Wettre’s handheld portable meters are moisture content and felt permeability in the press section. Requirements for measurements of new properties in the process are continually on the increase.

Service and Support Lorentzen & Wettre offer preventive maintenance, service and calibration worldwide. To ensure customer’s access to support and service, they offer a unique network with global coverage. Their service and support covers everything from the basic service contract where they visit their customers regularly to perform preventive maintenance and calibration of the instruments, to the complete full service contract that comprises several planned visits per year and all necessary consumables. Some of the instruments that are provided by Lorentzen & Wettre are given below:

1. L&W Moisture Tester L&W Moisture Tester is the ultimate offline moisture measurement solution for paper, paperboard, corrugated board, dry pulp, and other fibre materials. It measures moisture content at all stages of the process chain. Thanks to the quick measurement procedure, L&W Moisture Tester can also be used for product checking when online moisture sensors indicate out of specifications.

89 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Benefits ƒƒ Time saving (replaces the gravimetric method), the measurement takes only a few seconds ƒƒ Measurement results are not affected by curled materials, uneven surfaces or multilayer structures. ƒƒ Well proven micro wave measurement method ƒƒ Suitable for trouble shooting ƒƒ Back-up for online moisture sensors

2. L&W Compressive Strength Tester STFI L&W Compressive Strength Tester STFI measures the compression strength of liner and fluting. Compressive strength determines the stacking ability of corrugated boxes. The aim is to produce strong boxes, and at the same time use a minimum of raw material.

Benefits ƒƒ Proven measurement technology, SCT is the best method for optimization of compressive strength ƒƒ Strip feeder for fast and easy testing ƒƒ The built-in moisture sensor corrects all measurement values to give strength at standardized moisture content

3. L&W PPS Tester L&W PPS Tester measures the surface roughness of coated and calendered printing and writing paper. The method is also used for measuring the surface roughness of newsprint. The instrument estimates the air leakage between the paper surface and a thin metal band under conditions that simulates the printing process. The result is a significant factor in determining the printability of paper and paperboard. 90 Best Practices Manual - Pulp & Paper Industry Benefits ƒƒ L&W PPS Master Kit included. Paper samples and backing traceable back to L&W PPS reference instrument ƒƒ Auto-start, a photocell detects the presence of a sample and automatically initiates a measurement sequence, thus allowing hands-free operation ƒƒ Auto-cycling function that permits the continuous cycling of the upper pressure foot to facilitate representative and continuous measurements ƒƒ Integrated check function for air pressures, three air flows and three clamping pressures for reliable readings

4. L&W Bending Tester L&W Bending Tester measures a material’s resistance to bending. This can be done either by measuring the force needed to bend a test piece to a predetermined angle or by measuring and determining the bending stiffness, which is an elastic property of the material. Bending resistance and stiffness affects the product performance in many converting operations and is important in handling and protection purposes of packaging products.

Benefits ƒƒ Pneumatic clamping of the test piece for repeatable measurements ƒƒ Test piece support for correct clamping ƒƒ Auto-touch function of the load cell against the test piece gives relaxed and operator independent test results ƒƒ Creaseability evaluation used for prediction of converting performance included

91 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 5. L&W Crush Tester L&W Crush Tester tests corrugated board, liner and fluting as well as performing compression tests on small boxes. The instrument measures new crush properties such as flat crush hardness and the total energy absorbed during a FCT measurement. A built-in plate distance sensor can also be used to measure the corrugated board thickness.

Benefits ƒƒ Easy to use with pre-programmed start position and evaluation of measurements, all for easy shift between measurements such as RCT and ECT ƒƒ Robust construction for reliable measurement results, especially important when measuring FCT so that the test piece does not shear and cause “leaning” flutes ƒƒ Gives automatically correct FCT value – Manual settings for each flute type is not needed ƒƒ Measures new crush properties such as flat Crush Hardness, flat crush energy and flat crush stiffness

6. L&W Gloss Tester L&W Gloss Tester measures gloss, which is an important property in the production of paper of high print quality. A paper with high gloss gives good print quality and contrast, but too high paper gloss can reduce readability because of reflection. To achieve a good compromise the paper’s gloss must be optimized.

92 Best Practices Manual - Pulp & Paper Industry Benefits ƒƒ Suction plate with firm holding of sample, keeping the sample flat during measurement ƒƒ Inspection hatch with light source for measuring a selected spot ƒƒ Sturdy design for data confidence, the optical system has standardized sample backing ƒƒ Check and calibration standards are easy to access meaning no specific operator skills needed. The standards are also well protected from damage and contamination. ƒƒ Immediate report of instrument check, calibration and measurements ƒƒ Automatic start of measurement with sample sensor ƒƒ Easy to replace lamp

7. L&W Bursting Strength Tester L&W Bursting Strength Tester measures (according to Mullen) bursting strength of paper, paper board, and corrugated board. Furthermore it also measures bursting energy absorption (BEA) and diaphragm-compensated bursting strength. Bursting strength is a traditional measure of paper strength and it is also a test requirement for corrugated board.

Benefits ƒƒ Very fast testing cycle gives fast feedback to the production ƒƒ Auto-start, a photocell detects the presence of a sample and automatically initiates a measurement sequence, thus allowing hands-free operation ƒƒ Auto-cycling function permits the continuous cycling of the upper pressure foot to facilitate representative and continuous measurements ƒƒ Available with automatic test strip feeder

8. L&W Autoline 400 L&W Autoline 400 is the fastest and most accurate automatic system for paper testing on the market. More than 50 properties can be measured and calculated within a few minutes. Short feedback time is a very important part of the process control. Everything from newsprint to heavy linerboard and cardboard can be measured by L&W Autoline 400.

93 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Benefits ƒƒ Measures and calculates more than 50 different properties, most of them according to international standards ƒƒ Warning alert if the measurement results are outside specified targets and limits ƒƒ Fast – about 8 minutes to measure a profile at 20 positions ƒƒ Results are easily accessible via the mill’s local area network ƒƒ Several pre-programmed testing sequences available ƒƒ Remote viewing station provides real time data

9. L&W Felt Moisture Meter L&W Felt Moisture Meter measures moisture in both machine direction (MD) and cross direction (CD) up to 3000 gH2O/ m². The instrument can also measure felt length as well as giving measurement positions. Regular measurements with L&W Felt Moisture Meter are the key to optimal dewatering in the press section and lead to fewer problems with machine disturbances and downtime – which in turn means substantial cost savings. Effective dewatering in the press section can reduce energy consumption in the drying section and increase production considerably; a 1% increase of the dry content in the press section gives 4% reduction in energy use in the dryer section.

94 Best Practices Manual - Pulp & Paper Industry Benefits ƒƒ 1% increase of the dry content in the press section = 4% reduction in energy use in the dryer section ƒƒ Pinpoints any problems in the press felt ƒƒ Access to comprehensive data ƒƒ Control felt quality and reduce production costs ƒƒ Enables you to take the right action in time

10. L&W Felt Permeability Meter L&W Felt Permeability Meter measures water permeability of the press felts. The instrument also measures felt length as well as giving measurements positions in relation to the machine width. It can be used for optimizing the conditioning system as well as for quick trouble shooting. By measuring the water permeability, clogging and wear are easily discovered, and the potential to optimize the pressing with regards to paper quality and dewatering is made possible. L&W Felt Permeability Meter provides you with the best possible knowledge about the condition of the press felts. This enables you to optimize dewatering and reduce costs significantly.

95 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Benefits ƒƒ Reduce energy consumption ƒƒ Balance chemical usage ƒƒ Reduce emissions ƒƒ Reduce wear and maintenance requirements

11. L&W Fiber Tester L&W Fiber Tester measures fibre quality quickly and easily and is at the same time an instrument for advanced analysis of fibre dimensions. The measurement technology is automated, which enables frequent analysis of pulp quality. The instrument is intended and optimized for laboratories and has a compact design.

Benefits ƒƒ Fast classification of pulp quality ƒƒ Early detection of deviations in pulp quality ƒƒ New properties to define pulp quality ƒƒ Compact design ƒƒ Sample feeder ƒƒ Proven measurement methodology ƒƒ Self cleaning measurement cell

12. L&W Pulp Disintegrator L&W Pulp Disintegrator conforms to industry standards for pulp disintegration. The pulp container is made of stainless steel for durability and ease of cleaning, and the ergonomic design ensures that the instrument is easy and safe to use.

96 Best Practices Manual - Pulp & Paper Industry Benefits ƒƒ Ergonomic – electrical lift ƒƒ Double interlock system ensures safe operation ƒƒ Direct drive – less parts and less noise ƒƒ Spill proof opening ƒƒ Waterproof controls, sealed bearings and enclosed motor ƒƒ Conforms to industry standards ƒƒ Minimum of maintenance

13. L&W Pulp Tester L&W Pulp Tester is a reliable, repeatable and cost-effective online system for process and laboratory control of pulp. No matter what pulp is produced, it is important to fully understand the process and have reliable data. L&W Pulp Tester measurements conform to established standards and together with the latest and fastest technique it is a major help in achieving uniform paper quality and stable runnability. Benefits ƒƒ Automatic and online ƒƒ Measurements according to standards ƒƒ Quantitative measurements in one system ƒƒ Minimize web breaks and optimize production ƒƒ Increase mill productivity and profitability ƒƒ Optimize usage of raw material ƒƒ Control grade changes

14. KC/3 Blade Consistency Transmitter KC/3 Blade Consistency Transmitter is a reliable and maintenance free transmitter. Its patented, shock resistant seal- less transfer mechanism with unbreakable diaphragm makes it the only transmitter in the market with no moving parts or o-rings seals in the transfer mechanism, making it impossible for process liquid to leak inside sensor. All wetted parts are constructed of titanium. It is a 2-wire transmitter with modern Hart technology, and no external AC power supply is needed.

97 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Benefits ƒƒ Installation to Sandvik NS70 Saddle ƒƒ Fits to standard process coupling of Valmet Pulp-EL and Smart-Pulp, BTG MBT and SBT. ƒƒ All parts easy to replace in the mill with standard shop tools ƒƒ Gap measurement probe and electronics can be changed and tuned without taking transmitter off from process ƒƒ Quick-Cal procedure: Automatic calibration parameter tuning and position adjustment when laboratory consistency value is entered ƒƒ Low installation and lifetime costs

15. KC/5 Rotary Consistency Transmitter With its wide range sensor, KC/5 Rotary Consistency Transmitter is applicable to all consistencies between 1.5–16% With the patented built-in gate valve assembly, the transmitter can be installed and removed while the process is running and with the revolutionary direct-drive servo motor KC/5 requires no maintenance, since there is no belt to change.

Benefits ƒƒ No wearable drive belt (direct-drive servo motor) ƒƒ No wearable motor parts- no bearings- no brushes ƒƒ Removable without process shutdown- field repairable by normal hand-tools - remote display included ƒƒ Wide-range measurement sensor, applicable to all consistencies between 1.5–16% ƒƒ Automatic maintenance like powerful self diagnostics includes friction measurement, reverse direction rotation to check zero point and automatically loosen foreign objects.

16. L & W Consistency Meter L&W Consistency Meter measures the amount of water at various stages after the forming section. Measurement results make it possible to see if all dewatering elements are correctly adjusted in relation to the product that is currently being produced. It is designed to analyse, and optimize dewatering in paper, board, and pulp machinery. With L&W Consistency Meter one can gain control of drainage at the forming section so that such things as fibre orientation, formation, and the distribution of fine particles are correct.

98 Best Practices Manual - Pulp & Paper Industry Benefits ƒƒ Reduced energy consumption ƒƒ Balanced chemical usage ƒƒ Reduced emissions ƒƒ Reduced wear and maintenance requirements ƒƒ No radioactivity (High frequency technology)

17. KB² Fibre-Optic Sheet Break Detector KB2 Fibre-Optic Sheet Break Detector is the new generation sheet break detector that with the latest RGB technology enables 50 % more light with effective power LED. This allows longer measurement distances and operation in high ambient light condition. KB2 is the perfect choice for installations in unclean, steamy and high temperature environments or where the space is limited.

Benefits ƒƒ Non-contact optical sensor ƒƒ Reliable in harsh environments ƒƒ Air purge system

99 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Not affected by dirt, steam or high temperatures ƒƒ Fast break detection ƒƒ Handles all paper and board grades and applications regardless of colours ƒƒ Detects breaks even against a cylinder ƒƒ Easy to setup ƒƒ Large graphical display and logical user interface ƒƒ Proven with hundreds of installations worldwide

18. KPM Pulp Samplers KPM Pulp Samplers provide representative sampling from the process line safely and diminishes errors by the operator. The sampler breaks through the water layer inside the pipe, eliminating dewatering from the sampling process.

Benefits ƒƒ Screened and unscreened pulp with knots, shives and trash allowed ƒƒ Cutting edge in piston ƒƒ Pneumatic operation ƒƒ Adjustable stroke length and piston orientation ƒƒ Flushing water connection ƒƒ Switch included to operate pneumatic sampler ƒƒ Material SS 316L, Titanium available on request

Contact Details Head Office Mikael Nilsson, Area Sales Manager, Email: [email protected]

100 Best Practices Manual - Pulp & Paper Industry Address AB Lorentzen & Wettre Box 4 SE 164 93 KISTA SWEDEN Visitors: Viderögatan 2 Phone: +46 8 477 90 00 Fax: +46 8 477 91 99 Sales +46 8 477 90 25 Service +46 8 477 90 10 Accounts Email: [email protected]

101 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre MEVA INNOVATION AB

1. Introduction to the Company MEVA Innovation AB is a part of MEVA group. MEVA group of companies is working in the energy sector and that purposefully maintains a high level of development in their respective technical areas. 2. Profile of the company: Areas of expertise Meva Innovation AB is a company focused on research, development and commercialization of small-scale technology for high-efficiency cogeneration gasification of biomass. The company, with very large internal and external expertise, developed VIPP - Vortex Intensive Power Process and found sustainable technical solutions to previously less-efficient technologies and can now present a highly reliable and cost concepts. 3. About the Latest technology on the offering - VIPP - Vortex Power Process Intensive

Background Department of Energy Engineering at Luleå University of Technology (LTU) began in the mid 90s to develop cyclone gasification technology in cooperation with national and international partners. The former prototype of cyclone gasifier basis was developed and built at the Energy Technology Centre in Piteå (ETC). Meva Innovation AB has acquired the rights to the technology and further develop this in collaboration with the ETC. A complete pilot plant has been built where further research and development of technology in collaboration with the ETC.

Principle of operation VIPP-concept based on the gasification of biomass in a very carefully designed cyclone reactor after which cools and purifies the gas in a multistep process. The result is a high grade fuel gas to drive an ideal gas engine or gas turbine to generate electricity. In addition, heat is recovered from the whole system to such use in a district heating or for local heating. Other applications include combustion of fuel gas in conventional Mesa boilers or furnaces. More applications are, after further conditioning of fuel gas producing automotive fuels.

Potential benefits

Economy: Then VIPP system has a high overall efficiency and significantly fewer installed components compared to other more conventional cogeneration system, the total investment cost be kept low and therefore also reduces the production cost per kilowatt hour.

102 Best Practices Manual - Pulp & Paper Industry Biomass as a fuel in turn means big savings in operating costs compared to fossil fuels when you can exercise the right to electricity certificates.

Environment: The outside world increasingly demanding low emissions is VIPP system with biomass as fuel and with its high efficiency is a natural choice of small-scale CHP technology. Development and production of VIPP system permeates large environmental thinking. All components and systems that are built into the system pass their internal environmental audit on the material content and design.

Gas Cleaning System VIPP ECP is ideally suited for purification to obtain the producer gas required to be used in the present application. Since the pure fuel gas can be used to power gas turbines, it contain only very low levels of tar and particulates. In other bio-gasification project has often overlooked this and therefore have Meva Innovation developed VIPP-ECP to ensure long-term and continuous operation of the system.

Sources of further information For further information please visit the website: ww.mevainnovation.se Contact Details Mr. Hakan Holmberg Brogatan, S-931 62 Skelleftea Sverige Tel: 091020 01 90 Email: [email protected]

103 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre MoRe RESEARCH 1. Introduction to the company

MoRe Research has been active in research, development and improving process efficiency for more than 100 years. Once, part of the MoDo Group, MoRe Research is now an independent research and development company. They offer production-related services and modern process optimisation, increasing the profitability of pulp, paper and biorefinery operations.

The best results are achieved by working closely with the customers. MoRe Research works on a project basis with mill-based development groups, from project specification to implementation and follow-up. The customers always own the results and information produced, and non-disclosure agreements for strategically sensitive projects can be signed.

2. Profile of the company: Areas of expertise

Focus areas of MoRe Research are Hela vägen® (“All the way”), Analytical Services, Biorefinery, Education and Process Emergency. MoRe Research is organised in two departments; Process Technology and Analytical Techniques.

Hela vägen®

MoRe Research’s concept, Hela vägen® (All the way) of studying and optimising every stage of the production process, has been at the heart of MoRe Research’s methodology for many years. It is a holistic, intellectual approach with an understanding of how all process steps affect each other and the end product. The methodology always keeps cost effectiveness and the quality of the end product in focus.

Hela vägen® brings together the expertise, methods, testing equipment and laboratory resources at MoRe Research and concentrates on an affordable, high-quality end product. This approach provides unique opportunities to implement rapid and economical optimisation measures in the process. Whether an entire production line or just a single process step is studied, MoRe Research has the knowledge and the understanding to manage the whole process.

Biorefinery In order to replace fossil materials as energy sources or as raw materials, biorefinery technologies are developing rapidly all over the world. MoRe Research is at the forefront of this development. A strong driving force to this is the determination to maximise the usage of wood raw material. MoRe Research has the competence and the special pilot testing equipment needed for successful developments in biorefinery technologies. The set of digesters, ultra filtering and reactor equipment, combined with their analysis methods, support the customers’ biorefinery development. It is self-evident that the work carried out to create value from the by-products of the pulp process must be done without disturbing normal production or impairing the end products.

Analytical services Analyses are an important basis for critical decisions in production, marketing and research. The analytical services are built on an advanced laboratory infrastructure, a comprehensive range of advanced analytical equipment, expertise

104 Best Practices Manual - Pulp & Paper Industry in many areas, extensive experience and good process knowledge.

Picture 1: MoRe Research has an array of advanced analytical equipments to conduct almost any analysis for the customers

MoRe Research is a powerful resource for chemical, physical and graphical analysis. Customers make good use of the services and look to MoRe for problem-solving techniques and suggestions. Irrespectively if it is a question about routine analyses or special analyses, MoRe Research acts as a central laboratory or as an integrated part of the customer’s own resources.

Process emergencyTM ProcessakutenTM (process emergency) is a new tool available to solve mills’ urgent process problems. With short notice, a hands-on team is ready to solve the problems by combining process data analysis, information from the mill’s own staff, special analyses and studies in laboratory or pilot scale.

Education MoRe Research has extensive competence about the pulp process chemistry and related analysis. Since ten years MoRe Research cooperates with the training company P&L in (e.g.) certifying process workers within pulp cooking and bleaching as well as for laboratory workers. Customised educations for any need within pulp, paper and biorefinery areas can be organised. 3. About the latest services on the offering - The pilot machines optimise customer profitability in a cost-efficient way MoRe Research has a pilot plant and laboratory resources covering the whole process, from raw material to pulp, paper and biorefinery products. In the pilot tests, realistic studies can be performed and mill trials designed in an economical and technically productive way. The pilot machines are the same scale as each other, supporting the Hela vägen® approach without bottlenecks, and all resources are located at the same premises. Along each step of the process MoRe Research can conduct comprehensive analyses of wood, pulp, paper and process liquids using advanced analytical resources.

Digester The flexible pilot digester, which is unique in the world, offers tremendous opportunities for both pulp cooking and biorefinery studies.

105 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Picture 2: MoRe Research has a purpose built pilot digester, unique in the world, for sulphite and sulphate cooking methods for pulp mills and biorefineries

Ultrafiltration Using various kinds of membranes, valuable components are filtered out of process liquids and effluents.

Oxygen delignification and bleaching All stages from oxygen delignification until final bleaching can be performed in the bleaching pilot plants.

Viscose pilot plant

All manufacturing stages from dried specialty cellulose until finished viscose solution can be simulated.

Dynamic sheet former The dynamic sheet former, the Formette, can be used to manufacture paper from 30 GSM to cardboard in several layers up to 280 GSM with the product properties achieved on a large paper machine.

Experimental paper machine A unique paper machine that can produce paper in grammages between 30 and 200 GSM. Fitted with a Yankee cylinder for tissue manufacture, the lowest grammage limit of is 15 GSM.

Coater For conventional coating and surface sizing.

Troubleshooting Various microscope techniques and chemical analyses are used to solve problems in connection with operational disruption and end products.

106 Best Practices Manual - Pulp & Paper Industry Picture 3: The experimental paper machine is very flexible and can produce tissue and paper in grammages between 15 and 300 g/m2

Picture 4: By combining the analysis results from microscopy and analytical methods, troubleshooting is done in a very efficient way

Sources of further information MoRe Research is based in Örnsköldsvik in Sweden but is active in many countries, also in India and Thailand and has hence routines for getting samples for analysis from far away. More information can be obtained via direct contact and/or by visiting the web site www.more.se.

Contact Details 1. Stefan Svensson, MD, MoRe Research AB Tel. +46 660 750 35, mobile +46 70 234 83 00, email: [email protected] 2. Magnus Edblad, Process Consultant, MoRe Research Tel. +46 660 750 23, mobile +46 70 204 98 85, email: [email protected] Address MoRe Research AB, Box 70, SE-891 22 Örnsköldsvik, Sweden

107 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre NOSS 1. Introduction to NOSS

Advanced fiber development systems Noss is a Swedish company group serving customers in the pulp and paper industry around the world. They supply advanced Fiber Development Systems comprising equipment for hydrocycloning, screening, thickening, fiber fractionation, deaeration, refining and bleaching. 2. Profile of the company: Areas of expertise Noss’s extensive technological and human resources enable them to provide complete system deliveries comprising everything from a single machine to turn-key installations. Noss focuses on customer-oriented solutions in order to enhance process performance and to achieve the fiber and paper characteristics demanded by the end-user.

Noss provides ƒƒ Feasibility studies ƒƒ Project management ƒƒ Process engineering ƒƒ Mechanical engineering ƒƒ Procurement of auxiliary equipment ƒƒ Construction management

Turn-key Installations Noss undertakes the supply of complete turn-key installations including the procurement of suitable auxiliary equipment, which enables them to take full responsibility of the installation.

Detailed Engineering Noss provides detailed engineering for all disciplines such as mechanical automation, electrification, piping etc. Noss’s highly skilled professional engineers combine their experience and know-how with the latest CAD system in order to meet today’s and the future’s rigorous demands.

108 Best Practices Manual - Pulp & Paper Industry 3D model of a Noss installation

3. About the latest technology on the offering

RADICLONE Hydrocycloning Systems for high quality pulp, paper and board RADICLONE AM80: Efficient fiber development process for heavyweight contaminant removal and fractionation RADICLONE BM80: Efficient fiber development process for separation of lightweight contaminants and thickening

RADISCREEN Pressurized screens for knotter, fine, coarse and machine screening RADISCREEN-K is a Knotter Screen. RADISCREEN-F is a Fine Screen. RADISCREEN-C is a Coarse Screen. RADISCREEN-M is a Machine Screen.

PERISCREEN PERISCREEN-M is a Machine Screen for all stock types and applications ƒƒ Low energy consumption ƒƒ Reliable operation ƒƒ Low pulse PERISCREEN-F is a Fine Screen for all pulp types and applications ƒƒ High and low consistency applications ƒƒ Low energy consumption ƒƒ Slotted or perforated screen baskets

109 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre PERIVAC Perivac is a Space-saving Deaerator for efficient air removal ƒƒ High production ƒƒ Low power consumption ƒƒ Reliable operation The PERIVAC deaerator is designed for most efficient removal of both free and dissolved air as well as other gases from paper stock suspensions.

RADITRIM Raditrim is a Secondary Knotter Screen and Tailing Fine Screen RADITRIM-K is most efficient, totally enclosed secondary knotter screen for high yield at low energy consumption. RADITRIM-F is a completely enclosed Tailing Fine Screen combining shive separation and thickening with effective fiber recovery

PERICLONE PERICLONE Hydrocycloning Systems for all stock types ƒƒ Reliable operation ƒƒ Innovative design ƒƒ Easy maintenance PERICLONE A125 is a pressurized hydrocyclone bank system used for different cleaning purposes in the pulp and paper industry, such as paper machine approach flow systems, recycled fiber systems etc.

Fig: Board Machine Approach System

Laboratories and Pilot Plant : Customer-oriented Research & Development

110 Best Practices Manual - Pulp & Paper Industry Development of new processes and equipment Noss puts high emphasis on the continuous development of new processes for the pulp and paper industry. In close cooperation with their customers Noss meets the challenge of finding solutions to future problems and requirements, taking into account customers' own experience and specific knowledge. The activities at their Research and Development Department constitute the basis for the implementation of new systems and machinery.

Fiber related studies and research In the well-equipped laboratories of Noss, they can carry out virtually any kind of fiber related study. They undertake analyses and investigations of paper characteristics, fiber properties, impurities and printability as well as dynamic flow processes.

Fig: Microscopic analysis at Noss Laboratories

Fig: Advanced analysis methods are the basis for continuous research

111 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Fig: Noss full-scale pilot plant is adapted to perform reality-based trials for a variety of processes

Customer trials Noss perform customer trials both at their pilot plant in Norrköping and on site with mobile equipment. These experiments, carried out with the collaboration of customers, are of vital importance in the constant quest of finding optimal process solutions. The pilot plant includes equipment for screening, cycloning, fractionation and selective treatment, such as beating and refining.

Contact Details

Main Office:

Noss AB, Box 20, SE-601 02 Norrköping, SWEDEN Telephone: +46 11 23 15 00 Telefax: +46 11 13 59 23 E-mail : [email protected] | www.noss.se

India Office:

1. eintec Vijay Singhal A-30 Upkar Apartments, Mayur Vihar, Phase-1 Delhi - 110 091, INDIA Telephone: +91 11 2271 5075 Telefax : +91 11 2271 5098 Mobile: +91 99 1010 6568 E-mail: [email protected]

2. eintec L.S. Meyappan GF#17 Sreevatsa Square, 7/31-A. Metupalayam Road, Thudiyalur Post, Coimbatore - 641 034, INDIA Telephone: +91 422 264 5815 Telefax : +91 422 264 5814 Mobile: +91 999 429 8526 E-mail: [email protected]

112 Best Practices Manual - Pulp & Paper Industry PROMT AND FRONTWAY

1. Introduction to PROMT and FrontWay

1.1 PROMT PROMT is an independent design and trading company, based in Sweden and committed to be their customer’s partner for complete projects and for contract management. They offer qualified services and a broad international network of experienced partners in the field of plant design, relocation- and upgrading of entire industries, chosen parts of machinery or in the matter of finding/ installing the suitable equipment.

1.2 Frontway FrontWay delivers front end simulation products, services and system solutions to the pulp and paper industry. The focus on energy savings is high. FrontWay is situated in Norrköping, privately owned and has been in operation since 2004. FrontWay is participating in several research projects and makes unique solutions on standard platforms. The combination of research, practical skills and former management experiences from the Pulp and Paper Industry, is unique in the way of delivering a system solution. FrontWay sells “system solutions” that works! 2. Profile of the company: Areas of expertise

2.1 PROMT The business idea of PROMT: PROMT is a Swedish company which relocates, upgrades and optimizes process plants for the industry and, by their unique competence, design and deliver flexible, tailor-made solutions to their customers worldwide. Their main business areas are ƒƒ Plant relocation ƒƒ Plant engineering ƒƒ Energy optimization

2.2 Frontway The business idea of FrontWay: "Deliver Products and consultant services for energy savings and CO2-minimization" FrontWay have software that supports its customers’ needs and demands. The software are named PaperFront, BalanceFront and BenchFront. The main uses are within pulp- and paper industry. The e-sim concept, is utilizing the benefits from the software above. 3. About the latest technology on the offering - Efficient Simulation and Implementation Method In joint cooperation FrontWay and PROMT has developed the energy optimization concept e-SIM, efficient Simulation and Implementation Method.

113 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Background The background for this concept is the growing need of effective and profitable solutions of energy savings within the process industry of which both PROMT and FrontWay has the competence to provide. The concept covers process systems close to the production units, e.g. stock preparation systems, WW systems, spray water systems, vacuum systems etc, etc. But is not limited to only the Pulp & Paper processes but all kind of processes where a media is transported.

Principle of operation The e-SIM concept is based upon a systematic approach, minimizing the time to find the most effective and profitable energy savings either for a complete plant or for a system. The steps are following: 1. Selection of a process section 2. Collection of data and build a model in PaperFront® 3. Simulation of all operation modes, products and recipes in PaperFront® 4. Evaluate and select sections with high potential for savings 5. Detailed, on-site mapping of the selected sections 6. Calculation and simulation of efficient alternatives 7. Analysis, report and proposal for changes or rebuild 8. Investment ecalculation and quotation for a rebuild 9. Implement the changes

Potential benefits Using the e-SIM concept will result in, after only a few weeks work, that the customer will get: ƒƒ Potential energy savings of 15-25 % ƒƒ Identified energy efficient investments with a pay-off < 2 year ƒƒ LCC savings 10 times the investment ƒƒ A qualified analysis of the complete process system(s) ƒƒ Identification of the most profitable actions ƒƒ Investment estimate ƒƒ Updated process plant documentation

114 Best Practices Manual - Pulp & Paper Industry ƒƒ A tool for continuous optimization and planning ƒƒ Improved process knowledge for the customers O&M staff

Case study As an example, e-SIM were used for a large pulp & board plant in Sweden. During 2 months the following were done: 1. Simulation covered 130 pumps, 19 production recipes, 100 settings / scenario 2. Screening (OK pumps, intermittent operation, emergency operation etc.). 3. 6 pump sections were selected 4. Mill mapping on site were made in two days 5. Detail simulation – Comparison with alternative solutions done by engineers 6. Evaluation – change of pumps, speed control, change of control philosophy 7. FrontWay made the programming and simulation 8. PROMT made all detail mapping, analysis and proposal for changes 9. PROMT offered the whole rebuild/modification project

Results: ƒƒ 6 pumps identified for large savings potential ƒƒ Savings potential = approximately 12,00,000 kWh/annum ƒƒ Reduced CO2 - emission = approx 200 MT/a ƒƒ With an energy price of 0.06 €/kWh savings were 78 000 €/annum ƒƒ In principle 3 solutions for changes : • Speed control • Change of pump wheel • Change of pump ƒƒ The customer got a State-of-the-art control over the process with the PaperFront® tool

Other benefits ƒƒ All modes of operation are simulated, also the complex ones ƒƒ Clear and overall picture over the entire process and its bottle necks ƒƒ Improved energy efficiency = increased availability (Inefficiency = heat + friction = wear) ƒƒ Customer key persons are involved ƒƒ The most profitable investments are identified ƒƒ Improved process knowledge for the staff ƒƒ New products and modes of operation can be studied and simulated

Approximate Investment and pay back period at Present Value The e-SIM concept is a flexible method, ranging from part of processes up to entire plant systems, hencethe investment will be dependant upon such factors as complexity, availability of technical data, extent of the systems, availability of the customers own operative staff etc. As an indication, the investment in the e-SIM concept will result in pay-back time of less than one year, if the proposed actions for energy savings are implemented.

115 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Sources of further Information Please refer the following websites for further information: ƒƒ PROMT : http://www.promt.se ƒƒ FrontWay : http://www.frontway.se

Contact Details PROMT PROMT International AB, Drottninggatan 40, SE-652 25 KARLSTAD, Sweden, www.promt.se Telephone: +46 (0)54-241 00 00 Telefax: +46 (0)54-241 00 10 FRONTWAY Office: +46(0)8 559 221 48 Cellphone: +46(0)708 15 58 12 E-mail: General Information: [email protected] Office Address Post Address: FrontWay AB, SE-601 86 Norrköping Visiting Address: S:t Persgatan 19, Norrköping Website: www.frontway.se 4. Conclusion The e-SIM concept is a unique method to rapidly and cost-efficient trace and find the most energy effective solutions in complex process systems, taking into consideration all different modes of current – and future – operations as well as extreme situations, e.g. shut-downs, sheet-breaks, catch-up operation etc. The customer will take the advantage of the latest simulation technology and experienced experts for analyzing his specific production plant, finding the most profitable changes in order to have an energy efficient and sound production. The concept is not only limited to Pulp & Paper industry but for all other types of process industry.

116 Best Practices Manual - Pulp & Paper Industry PURAC

1. Introduction to Purac Purac is a part of Läckeby Water Group, an independent, privately-owned Swedish Group, which offers contracting, products, and servicing for water treatment and biogas production. 2. Profile of the company: Areas of expertise Purac offers contracting for customers worldwide. They design and build treatment plants for wastewater, drinking water and process water, as well as plants for biogas production and gas treatment. To date, they have completed more than 4,000 contracts in 70 countries worldwide, primarily in Europe and Asia. The contracting business unifies their know-how on processes, design and contracting with their internally-developed and licensed technologies for increased efficiency and more economical operation. There are, for example, methods that make it possible to reduce floor-space needs and operating costs by up to 50 per cent.

Purac Key Technologies ƒƒ Separation technologies • DAF (Dissolved Air Flotation) • FlofilterTM • GEWETM Lamella sedimentation • Membranes, MF/UF/NF/RO ƒƒ Biological Aerobic effluent treatmen • MBBR (Moving Bed Biofilm Reactor) • MBR (Membrane Bio Reactor) • BAS (Biofilm Activated Sludge) concept for P&P wastewater treatment • SELAC (Selector Activated Sludge) ƒƒ Biological Anaerobic effluent treatment • ANAMET® (Anaerobi – Aearobi – Methane production) • UASB (Upflow Anaerobic Sludge Blanket) • EGSB (Expanded Granular Sludge Blanket) 3. About the latest technology on the offering - DAF and Flofilter - Superior separation of suspended solids

Superior separation of suspended solids Developed and refined since 1950s, the Purac Dissolved Air Flotation technique is an effective and rapid method for separation of particles from water and wastewater. ƒƒ Guaranteed performance ƒƒ Low investment ƒƒ Compact design a. Dissolved Air Flotation (DAF) Water flowing into the DAF tank is injected with a high-pressure air/water solution, derived from recycling some 10% of the plant flow through an air/water saturation system. Regulation of pressure release valves causes the pressure

117 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre of the recycled water to suddenly drop. This pressure change creates micro-bubbles that attach to the flocculated material and rapidly carry it to the surface, forming a stable floating sludge.

Sludge Removal Surface sludge is removed by a chain-driven flight scraper into a trough from where it is transported to storage.

Fig: Chain-driven flight scraper for surface sludge removal

Fig: PURAC DAF CLASSIC

Applications Purac DAF Classic system is a widely used particle separation solution in waterworks, industrial and municipal wastewater treatment, for sludge thickening, as well as for treatment of industrial effluents in the food, pulp, and paper industries.

Other benefits Effective Removal of suspended solids is excellent, typically >95%. Compact A hydraulic load of up to 15 m/h can be processed in environments with space limitations. Robust

118 Best Practices Manual - Pulp & Paper Industry Wide variations in flow and solid loadings can be easily handled. Low Sludge Volume The floating sludge has high dry solids content (3-6%). There is no need for further sludge thickening. b. Purac Flofilter™

Combined flotation and filtration After flocculation/DAF, the water gravitates through the filter bed, which removes the remaining contaminants to the required level. The Purac Flofilter is an established, well-proven technique for treatment of surface waters, operating as a constant level filter with an outlet-modulating valve during this phase. Flofilter is a compact and efficient plant as it combines flotation and filtration in one treatment basin. In addition to this two-stage processing, Flofilter offers other major advantages: rapid start-up, shut down and response; low volume output of sludge; excellent algae removal; and low backwash consumption (2–3%) of feed flow rate based on one wash per day. Filter backwashing can be initiated by a timer or loss of head. Conventional air scour water wash techniques are employed for filter washing.

Fig: PURAC FLOFILTER The numbers indicated in the above schematic are: 1. Inlet 2. Flocculation 3. Distribution and reaction chamber 4. Saturation unit 5. Floated sludge scraper 6. Sludge trough 7. Filter media 8. Filter bottom with nozzles 9. Clear water outlet 10. Backwash water inlet 11. Dirty backwash water channel 12. Dirty backwash water outlet 13. Backwash air inlet.

Flootek DAF units Under the brand Flootek, Purac undertakes delivery of ready-made skid mounted DAF units of stainless/acid-proof steel that are prepared for swift and simple plug-in installation. The units are widely used for wastewater treatment, mainly within the food industry, oil refineries, pulp and paper mills, and metal finishing.

119 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Case studies

1. Fors Mill, Stora Enso Fors, Sweden - Upgrading of Effluent treatment The plant has combined CTMP and FBB capacity of 400,000 t/y. Upgrading of Effluent Treatment ƒƒ Increased production + higher requirements ƒƒ Qmax = 18,000 m3/d ƒƒ CODinlet = 28,000 kg/day ƒƒ TSSinlet = 3,000 kg/d ƒƒ Contract – Q2 2010 ƒƒ Commissioning – Q2 2011 ƒƒ Taking over – Q1 2012

Effluent treatment – Process solution

Fig: Schematic of the BAS (Biofilm Activated Sludge) concept for P&P wastewater treatment

With the new effluent treatment system, the parameters are as below: CODoutlet= 10,000 kg/d TSSoutlet= 500 kg/d

120 Best Practices Manual - Pulp & Paper Industry P-totoutlet= 4,4 kg/d N-totoutlet= 110 kg/d

2. Iggesund Mill, Holmen-Iggesund Paperboard, Sweden Holmen – Iggesund Paperboard has a Pulp & Paperboard production capacity of 330,000 t/y.

Effluent treatment ƒƒ Higher requirements COD and TSS ƒƒ Tertiary treatment ƒƒ Q=75,000 m3/d ƒƒ Dissolved Air Flotation, DAF ƒƒ CODfeed 300 mg/l --> CODoutlet < 100 mg/l ƒƒ Turn-key contract - Q2 2008 ƒƒ Commissioning - Q3 2009 Tertiary treatment, capacity 75,000 m3/d

Fig: Schematic of the tertiary treatment process

3. Mondi Swiecie Mill, Mondi Swiecie A.S., Poland

Upgrading of Effluent Treatment ƒƒ New paper machine based on recycle paper ƒƒ Products are Container board & Sack Paper Kraft ƒƒ Existing ETP is not having enough capacity

121 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Results achieved ƒƒ Operational costs are considerably lower ƒƒ Investment cost gets minimized – no need for additional aeration volumes ƒƒ Less sludge handling for dewatering and disposal ƒƒ Production of biogas 23 000 m3/d can be used as fuel for boilers ƒƒ Replaces 15 ton oil equivalents per day

Contact Details Head office Purac Emdalavägen 10 SE 223 69 Lund P.O. Box 1146 SE 221 05 Lund, Sweden Phone +46 46 19 19 00 Fax +46 46 19 19 19 [email protected] www.lackebywatergroup.com

122 Best Practices Manual - Pulp & Paper Industry SOMAS 1. Introduction to Somas

Somas - The market leaders in control valve R&D SOMAS Instrument AB develops, produces and markets control- och on/off-valves made from high-grade, acid-proof stainless steel. 2. Profile of the company: Areas of expertise New or reconditioned replacement valves with full warranty means security and economy. For customers this is the key to cost reduction by minimizing spare part inventory size, lower replacement costs and shorter intervals of suspension of operation. 3. About the latest technology on the offering

Paper & pulp industry product line In the paper & pulp industry, the valves most commonly used are actuated and manual cutoff valves. SOMAS ball segment valves are the most commonly used control valves, while butterfly valves and ball valves are usually to be found in cutoff applications. SOMAS valves are made from stainless material. They also supply valves made from titanium or nickel-rich alloys. Meeting the existing control objectives is a matter of course at SOMAS. Their actuators are made from surface treated Aluminium and stainless steel. In this way SOMAS meets the paper & pulp industry’s control objectives. The safety requirements are easily met since the actuator exerts its maximum torque at the fully open or closed position. a. Ball segment valves High capacity, excellent tightness and free flow: These words aptly describe some of the superior properties of the ball segment valve. SOMAS ball segment valves have been designed to fulfill the strictest requirements of the process industry on the control valves used. Due to its free flow and choice of different materials for housing and seat, the ball segment valve is usually the best choice for the industry.

Design of the ball segment valve The ball segment valves high capacity results from the design of its seat and ball segment. Compared to other valve designs it is often possible to use smaller and more economical valve sizes. What puts SOMAS ball segment valves apart from many other suppliers is that the free flow part minimises the risk of clogging.

123 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre The valve/actuator unit The ball segment valve is first and foremost a control valve offering excellent tightness in the closed position. The properties of this valve make it useful for most applications. In combination with SOMAS pneumatic actuators and positioners the result is a flexible unit with a wide control range.

Product Line

SOMAS ball segment valves offers the following: ƒƒ Dimensions in the range DN25/2 - DN700. ƒƒ Pressure classes PN10 - PN100. ƒƒ Good tightness in IEC 534-4 class V as standard with stellite seat and IEC 534-4 class VI with PTFE seat. ƒƒ Ball segment and shaft as a one-piece design gives backlash-free operation and accurate control. ƒƒ Double trunnion supported segment gives high durability and low torque requirement. ƒƒ Body design makes maintenance easy. Seat can be exchanged or replaced without removing the actuator or dismantling the valve. ƒƒ Body for centrally mounted ball segment with continuous seat-trim contact to eliminate potential problems with dirt build-up and fluid crystallisation. ƒƒ Body option for eccentrically mounted ball segment for clean hot media like steam and gas at high temperatures - maximum 550°C. ƒƒ Trim options available as options to solve problems with noise and cavitations.

References The excellent properties of the ball segment valve are most obvious when it is put to use as a control valve. This means that it can be used in more or less all industries - chemical, petrochemical, pharmaceutical industry and paper & pulp industry to name but a few. The ball segment valve is suitable for all media, gaseous and liquid. Even in the case of wood pulp, the ball segment valve is at an advantage due to its free flow. Adaptions of the ball segment valve makes it able to deal with MC- applications (Medium Consistency). Since Somas ball segment valves can be supplied with different choices of material for the seat, they are able to adapt them to a wide range of operating temperatures ranging from the extremely cold (cryogenic) to the extremely hot (superheated stem and engine exhaust gasses). SOMAS ball segment valves can handle it.

124 Best Practices Manual - Pulp & Paper Industry b. Butterfly valves SOMAS butterfly valves helps to adjust flow, be it steam, gas, water or other fluids. SOMAS butterfly valves can handle it. Their butterfly valves are made from high-grade stainless steel with a homogenous metal seat as standard. They can be installed by mounting between flanges, with or without lugs. The valves are also available with flanges. SOMAS metal-seated butterfly valves of type VSS and MTV bears a historical relationship to the very first valves manufactured by them. Both valves have an advanced triple-eccentric design. The design of the seat and the unique construction of the disc provides for excellent shut-off and more or less eliminate the need for maintenance. The high surface pressure between seat and disc makes the valve useful for pulp applications where the fibers are easily cut. The MTV butterfly valve is the most cost-efficient choice for control- and on/off-applications.

All their valves are tested for leakage and meets the requirements of IEC 534-4 Class V for valves with SS 2377-seat (Class VI for valves with PTFE-seat). The universal design allows for a choice of many different materials in valve manufacture. This broadens the field of application. The metal seat ensures that high-velocity flow will have no effect on the valves tight shut-off ability and allows for many years of operation. Dimensions up to DN 1200, pressure classes PN 10-50 and the universal design allows for manufacture in many different materials and enables Somas to cover most applications in the process industry. The butterfly valve is useful for clean as well as contaminated media; fluids, gasses and steam. For control installations the valve is fitted with SOMAS pneumatic actuator and positioner.

Product Line SOMAS butterfly valves are used in hundreds of thousands of installations in a variety of applications. SOMAS butterfly valves have many advantages. They offer the following: ƒƒ Made of stainless steel ƒƒ Dimensions DN80 - DN1200 ƒƒ Pressure classes PN10 - PN50 ƒƒ Mounting between flanges, with lugs or flanged ƒƒ Stainless steel seat is not affected by high flow rates replaceable seat in alternative materials ƒƒ Unique disc geometry which in combination with the homogenous seat acheives tightness to IEC 534-4 Class V as standard ƒƒ Advanced triple eccentric design acheieves excellent tightness

125 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre References Maintenance-free valve is a good match for the shipping industry. One of the major advantages of SOMAS butterfly valves is that they are almost maintenance-free. This is an important feature for the shipping industry, where these valves are used as cargo valves on product tankers. The absolute strength of the butterfly valve: The strength of the butterfly valve stems from the design of its component parts. On the surface the valve appears to be of simple construction, but this is the very reason why it can cope so easily with tough applications in extreme conditions. The metal seat allows the valve to operate at very high temperatures, waste gate valve applications in exhaust gas turbines being one example. The seat is exposed to high surface pressure, making it possible to use the valve with pulp suspensions in concentrations up to 4%. Special materials allow the valve to operate in extremely demanding applications such as steam turbines, with high pressures, high temperatures and rapid shut-off time requirements. c. Ball Valves SOMAS ball valve is designed to take care of any leakage of gas or liquid. The valve is a full bore, flanged ball valve with cylindrical bore made in dimensions from DN 25 to DN 400. The valve is made from stainless steel with spring loaded seats for good tightness, even at low differential pressure. The valve ball is hard chromed as standard, but can also be supplied with Hi-Co coating. The valve can be supplied with actuator and accessories for manual operation, on/off or control applications. SOMAS 3-piece full-bore ball valves are mainly intended for use as manually operated valves or remotely actuated on/off valves. The ball valve meets ISO standards. The valve is available with threaded ends, welding ends or flanges. It is also possible to combine different types of ends. SOMAS 3-piece full-bore ball valves are equipped with seats of two materials. Fibreglass-reinforced PTFE as standard, or carbon-filled PTFE adapted for steam.

Product Line SOMAS offers two types of ball valves, SKV and S36. Below are their respective specifications.

Type SKV ƒƒ Dimensions DN25 - DN400 ƒƒ Pressure classes PN10 - 25 (DN80 - 400) PN10 - 50 (DN25 - 50) ƒƒ Full cylindrical bore for maximum capacity ƒƒ Hard chrome plated ball as standard. HiCo-coated as an option ƒƒ Seats in PTFE 53 or HiCo (High Cobolt alloy) ƒƒ Spring loaded seats for good tightness at low differential pressure ƒƒ Complete range of actuators and accessories for manual operation, on/off or control applications.

Type S36 ƒƒ Dimensions DN8 - DN100 ƒƒ Pressure class PN50 ƒƒ Full cylindrical bore for maximum capacity ƒƒ Two alternative seat materials: fibreglass reinforced PTFE or carbon filled PTFE

126 Best Practices Manual - Pulp & Paper Industry ƒƒ ISO connection flange for actuators ƒƒ Three alternative pipe connections. Threaded, weld ends or flanged

References The ball valve is used in the paper and pulp industry , mainly as a remotely or manually actuated on/off valve, but also as a control valve. The ball valves double seats makes it suitable if the direction of flow and pressure may shift. One example is around the digester in batch digester applications. The ball valves floating ball allows for pressure on the seat to be achieved by the differential pressure in either direction.

Ball valves with fully cylindrical bore: SOMAS ball valves have a fully cylindrical bore , which allows for minimal flow resistance in the fully open position. The fully cylindrical bore also provides advantages when dealing with abrasive media, since no part of the valve protrudes into the flow and no irregularities create turbulence. These conditions occur mainly in the chemical industry, the mineral industry and in the paper and pulp industry.

Contact Details For more information about the company, products or services, please contact the following: Joakim Johannesson Sales & Marketing Director SOMAS Instrument AB, Box 107 SE-661 23 SÄFFLE Sweden Email: [email protected] Phone: +46 (0)533 16700\ Fax: +46 (0)533 14136\ E-mail: [email protected] Visit- and delivery address Norrlandsvägen 26 - 28 SE-661 40 SÄFFLE Sweden Website: www.somas.se

127 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre SootTech AB 1. Introduction to the Company CleanTech Company SootTech started in 2007 based on innovation HISS sweep the Chalmers Innovation and industry innovator Erik Dahlen. Supported by the Energy Agency installed a first pilot system at Nordic Paper's recovery boiler in Bäckhammar, Sweden. 2. Latest technology on the offering - High Impact Soot System (HISS)

Background Steam soot blowing is effective, but provide greater amount of flue gases. Many boilers have to lower the load during the sweep to meet the increased flue gas quantity. Sweeping then leads a double cost of both lost production and soot blowing steam. In conventional soot blowing, soot blowers run continuously in sequence cleaning in forward and reverse direction. 50% of the steam (during reverse direction) is of no use. Sequence of cleaning is almost twice as long as it needs to be.

More than 90% cleaning is 1st stroke Time hardens ash to concrete

Principle of operation SootTech High Impact Soot System (HISS) uses steam only in forward direction. Since there is no steam during the reverse direction, HISS requires 50% less steam as compared with conventional soot blowing system.

128 Best Practices Manual - Pulp & Paper Industry Operation of soot blowers is sequential. Operation of soot blowers is overlapping. Steam is utilized in forward and reverse Steam is not utilized in reversed direction. direction

Potential benefits Main purpose of a soot blowing system is to remove soot deposited in the boiler effectively. Photographs below shows result of High Impact Soot System v/s conventional soot blowing system. HISS is much efficient in removing soot due to overlapping operation.

Result of conventional soot blowing system Result of high impact soot system (HISS)

In terms of energy saving, it utilizes steam only in forward direction, hence consumes 50% less steam as compared with traditional soot blowing system.

Case study Rebuilt recovery boilers are normally run well over design data which often results in a low thermal efficiency of the heating surfaces is too small. High load means that it quickly built ash layers on the heat surfaces inside boilers, which reduces boiler efficiency. The efficiency is especially sensitive to ash in the boiler colder parts (economizer). To determine whether a more efficient sweeping of an individual panndel may increase efficiency, experiments were performed on Bäckhammar’s recovery boiler that is equipped with SootTech’s patented LIFT-fouling systems. The experiment involved a study of the difference in steam production per unit of fuel with sweep of the boiler’s

129 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre economizer area performed and with the conventional cleaning techniques, and partly with SootTech’s patented HISS-cleaning technology. Results showed an increase in boiler efficiency with HISS technology in just over 3%, reflecting an increase in steam production of about 80 tons of steam / day during normal operation. "Raising boiler efficiency by 3% is sensational. This outcome strengthens the technology and making it far more interesting both for power boilers and recovery boilers. For Indian pulp & paper industry, this means that there is an inherent energy reserve that can be easily realized with improved cleaning "says CEO, Erik Dahlen. In general, by installing SootTech High Impact Soot System (HISS) on a recovery boiler (without advanced soot blowing systems) the energy saving can be in the range of 30 – 40% of soot blowing steam and / or increased productivity of recovery boiler by 3 – 8% (due to increased thermal efficiency). Since the benefits can vary from case to case, it is advised to conduct a preliminary study by SootTech before taking a decision.

Sources of further Information Further information is available in the website: www.soottech.com

Contact details Mr. Erik Dahlen CEO [email protected] SootTech AB Stena Center 1 412 92 Goteborg

130 Best Practices Manual - Pulp & Paper Industry SWEDISH EXERGY AB

EXERGY STEAM DRYING FOR PULP AND PAPER MILLS Prem Verma1, Claes Münter1; Staffan Bauman1 and TS Venkataraman2 ABSTRACT: Exergy Steam Drying technology has existed for past three decades or so and many new applications have been developed during this period. But during past few years the real benefits have been exploited in connection with bio-fuel production and energy integration. The steam dryer consists of a closed loop system, where the product is conveyed by superheated and pressurised carrier steam. The carrier steam is generated by the water vapours from the product being dried, and is indirectly superheated by another higher temperature energy source such as steam, flue gas, thermal oil etc. Besides the superior heat transfer advantages of using pressurised steam as a drying medium, the energy recovery is efficient and simple as the recovered energy (70-90%) is available in the form of steam. In some applications the product quality is significantly improved. Pulp and Paper industry uses enormous amount of water and hence thermal energy used for water removal should be reusable to some extent as heat source. The Exergy steam drying technology matches the advances made in evaporation. Lime mud will be a new area of application for Exergy Drying. Repalcing fossil fuel in Lime kiln with Biomass gasification will lead to” Green Lime” Keywords; Exergy, bio-fuel, bio-mass, pellets, Bed drying, steam drying, lime mud drying, gasification. 1. INTRODUCTION The Exergy steam dryer was developed in the late 70's for energy efficient drying of paper pulp. Since then a number of different applications have been developed, however the main benefits has recently evolved by the different processes for bio fuel production. Superheated steam as a drying medium brings a number of advantages; high heat transfer rate, high energy recovery, no emissions to atmosphere, no risk for fire or explosion during operation, minimal product degradation and short residence time. The dryer contains very little product to be dried. The Exergy Steam Dryer provides significant savings both for the producer and also the environment. The initial investment for the plant is comparable to conventional drying system requiring post treatment systems like thermal oxidation for the exhaust gases. Operating costs for the Exergy Steam Dryer are only about 20% of the conventional dryers. 2. STEAM DRYING TECHNOLOGY

2.1 Process description Exergy Steam drying technology is based on the drying capacity of pressurised superheated steam. Moisture from product is vaporised by the driving force as super heated steam moves towards saturation curve. At atmospheric pressure, the heat transfer rate of steam is slightly less than hot air, but by pressurising the steam the heat transfer rate increases rapidly, See table I.

1 Swedish Exergy, Gothenburg, Sweden, Email:[email protected] 2 Esvin Advanced Technologies, Chennai, India Email: tsvenkat @eth.net

131 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Media Pressure Temp Relative h bar (a) C kW/m2,K Air 1 100 1,3 Steam 1 100 1 Steam 2 120 1,7 Steam 5 150 3,4 Table I: Relative heat transfer capacity between air and steam For products, such as sawdust, peat or milled wood, the residence time required is only 5-10 seconds for drying from 50% product moisture to less than 10% in the Exergy Steam Dryer. The Exergy Steam Dryer consists of a pressurised closed loop, where the carrier steam is circulated by a fan. The carrier steam is super heated above the saturation temperature in a super-heater. The heat is indirectly transferred via a shell and tube heat exchanger (super heater) from any high-grade heat source such as medium pressure steam, flue gases, thermal oil or hot water, see figure 1.

Figure 1: Principle of Exergy Steam Dryer The product is introduced into the high velocity steam flow via a pressure lock, i.e. a rotary valve or feed screw. The product is conveyed and simultaneously dried in the drying ducts, and separated in a cyclone. The product is discharged via another pressure lock, whereas the carrier steam, still above the saturation temperature, is recirculated through the system. However, the evaporated water from the product is now increasing the amount of carrier steam, and to maintain a constant system pressure, excess carrier steam must be bled-off through a control valve. This bled-off steam is now available for energy recovery; directly or as clean steam after a steam re-boiler.

2.2 Main features Superheated steam in a closed loop system provides following main features: ƒƒ High-energy recovery is possible, available as pressurised steam.

132 Best Practices Manual - Pulp & Paper Industry ƒƒ No emissions or steam plume to the atmosphere, all volatiles are contained. ƒƒ No risk for fire or explosion during operation as no oxygen is present. ƒƒ Only a small amount of product is in the system at any given time. ƒƒ Complete sterilisation of contaminated products such as bacteria in municipal sludge. ƒƒ Less product degradation even at higher temperature as no oxygen is present and residence time is extremely short. ƒƒ Installation takes little floor space.

2.3 Gross Energy consumption The gross heat energy consumption is in the range of 750 kWh heat per ton water evaporated from the product. In addition, 40-60 kWh electrical power per ton water evaporated is required for conveyors, rotary valves and circulation fan. 3. ENERGY INTEGRATION & RECOVERY There are a number of possible ways of utilising the energy of the carrier steam, some examples are mentioned below.

3.1 Direct vapour usage The easiest way is of course if the carrier steam can be utilised directly for another purpose; district heating, evaporator system, direct steam-injection for process heating etc. In this way, 90-95% of the energy input to the dryer is available for recovery.

3.2 Low pressure steam production In many cases the product steam contains volatiles from the product, as well as fine particles not separated in the cyclone. The vapours can then be converted to low pressure clean steam in a re-boiler, and utilised in other processes. A typical heat- and mass balance is shown in Table II.

In to dryer Flow, ton,/hr Heat flux, kW Wet biomass 20 158 Heating steam, 14 bare 12,5 6763 Electrical energy 600

Out from dryer Flow, ton/hr Heat flux, kW Dry biomass, 100 ºC 11,1 574 Generated steam, 3 bare 8,9 6787 Heat losses 150 Table II: Heat- and mass balance for an Exergy Dryer drying 10 ton dry solids/hour from 50% moisture down to 10% moisture.

3.3 Power production The clean steam produced can also be used for power production in a condensing steam turbine.

133 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 3.4 Pre-drying The product steam can also be used directly in a pre-dryer. The steam is condensed in an air heater, and the air is used for conventional air drying of the product before entering the steam dryer. The total energy required for a specific drying duty can be reduced by about 50%. A simple, robust but very efficient pre-dryer is the Exergy Bed dryer; see fig. 2, suitable for drying biomass products like wood chips, bark, bagasse, coal peat etc. A fan pushes ambient air through a heat exchanger and blows the heated air through a bed of the wet product. The bed is moved by hydraulic stokers. Air leaves the bed saturated with moisture from drying the product during 1-2 hours. The bed dryer can be part of the fuel storage before the boiler fuel feeding system.

Figure 2: The principle of Exergy Bed dryer.

3.5 Mechanical Vapour Recompression When there is no external usage for the excess steam, it can be compressed with turbo or screw compressors and used for heating the dryer itself. No external heat source is required, only electrical power for the compressor. Electrical power consumption is in the range of 150-200 kWh per ton water evaporation.

Table III: Energy consumption comparing different ways of heat recovery with conventional open air dryer. 4 APPLICATIONS FOR EXERGY DRYER

4.1 Wood based bio-fuels The increased usage of wood based bio fuels is also raising demands for efficient energy production. To incinerate wet wood is the most inefficient energy production process, therefore energy efficient drying is essential for the future sustainability.

134 Best Practices Manual - Pulp & Paper Industry By using energy efficient drying system the emission of green-house gases, carbon dioxide and water vapour can be reduced, see Fig. 3. Higher fuel heat value after drying and therefore also higher boiler efficiency means that less fuel needs to be burnt. Us the Exergy Steam dryer means that fuel moisture will be leaving the plant as condensate and not as vapour from the boiler stack.

Figure 3: Emissions of carbon dioxide and water vapour as a function of moisture content in the fuel. By integrating pellet production with heat and power production, the drying process can “borrow” the energy as medium pressure (MP) steam, and give it back as low pressure LP steam. In some cases (Skellefteå Kraft and Energi E2) the LP steam is used for power production. Net energy consumption for drying is only 150 kWh per ton evaporated water.

A flow diagram of such process is shown in Fig. 4. Wood chips with about 50% moisture are first milled to particle size suitable for pelletizing after drying. The Exergy Steam dryer uses steam from HP-turbine and produces steam for the LP-turbine. Steam is produced in the boiler by using fuel wood dust as reject from the pelletizing process. Remaining low grade heat can be used for pre-drying of the raw material or for district heating.

135 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Figure 4: Flow diagram for a Bio-combine pellet plant.

Figure 5: Exergy Steam Dryer at DONG Energy pellet mill, Koege, Denmark (50 ton/h)

4.4 Industrial and municipal sludge Sludge has become a critical issue for both municipalities and industries (mainly pulp & paper) as a waste handling problem. Sludge is a bio-fuel and can contribute to the “green” heat and power production. The heat value of sludge, even if digested for bio-gas production, has enough combustion value for both steam drying and substantial production of heat. By integrating the drying and incineration of the sludge, the excess heat produced in the boiler and the carrier steam from the dryer can be utilised for electrical power production and/or district heating. The available heat value of one ton wet digested municipal sludge at 25% dry solids is in the range of 0,5-1 MWh depending upon ash content. After drying to 90% d.s. the heat value is 2-4 MWh/ton dry solids. In fig, 7 a flow diagram is showing a plant for energy production from municipal sludge. The pasty, sticky dewatered sludge is first mixed with dry sludge in a mixer to a friable feed to the dryer. After drying is the sludge immediately sent to the boiler for steam production. Steam is used for producing both electrical energy and district heat. About 80% of the fuel value can be used for power and/or heat production.

136 Best Practices Manual - Pulp & Paper Industry Figure 6: Plant for production of energy from sewage sludge.

Figure 7: Sludge dried in the Exergy Steam Dryer. 5.0 Future applications: 5.1 Drying of Lime mud In the Paper industry large pulp mill together with the chemical recovery island were able to initially achieve self sufficiency in energy using the energy from Black liquor. This was also achieved largely due to better Evaporation technology that could ensure high steam economy. The energy deficit has arisen ever since lime mud reburning became mandatory for the Indian Mills about a decade ago. Since Furnace oil (FO) is used as fuel in India in the Rotary Lime Kiln (RLK), Mills not only had to pay heavy energy penalty but also had no cost control due to the volatility of global oil prices. Mills partly offset this cost by adopting coal based Gasifier to supplement FO but this had limitations up to 50 % in RLK due to enhanced flue gas volume. Big Mills that use only wood as raw material have improved the Lime mud washing to get lower moisture levels. Some big Indian mills have achieved already dryness of 75% in Lime mud compared to others (who are constrained by high silica in their Raw material) at 55%. This means 60% reduction in water removal but problems of resultant high flue gas temperature that may affect ESP and ID fan are being addressed by diluting the flue gas- load on ID fan

137 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ENERGY BALANCE Energy Heat rate % MJ/ADt MJ/kg of CaO Energy for calcinations 786 3.18 51 Energy for drying 350 1.41 23 Energy in Flue gases @200 Deg.C 237 0.96 15 Heat in lime mud @60Deg.C &75% dry -54 -0.22 - 4 Heat in lime @200 C. 39 0.16 3 Shell heat losses 185 0.75 12 Total 1543 6.24 100 Table IV : Energy balance in a Rotary Lime Kiln

5.2 Cost benefits analysis: As can be seen from the above the second highest energy used is for the drying- so there is ample scope to improve that. If the moisture is as high as 45% instead of 25 % as above, the energy consumption would go up by nearly 1.4 MJ/kg i.e nearly 35 kgs of oil per t of CaO. In other words the FO consumption will be 190 kgs/t of lime as against standard 155 kgs/t. This means for a 260 tpd Lime production, the annual savings in FO would be about 3000t. Typical input- output is furnished in for a lime mud being fed at 47% dryness.

Table V: Mass and Heat balance

Figure 8: Elevation of a Swedish Exergy steam dryer

138 Best Practices Manual - Pulp & Paper Industry The installed cost of such a system as above would be in the range of $ 4. 0 million, with a simple pay back period of less than three years. Most of the parts, other than some critical component would be manufactured in India and engineering carried out at the Indian branch office at New Delhi.

6.0 The emergence of GREEN LIME The next logical step is to integrate the Exergy Dryer with Biomass Gasifier to produce “Green Lime”. Till a decade ago Mills were inadvertently emitting GH gases by purchasing fresh lime. It may be noted that for every tonne of lime produced nearly 0.8 t of Co2 is released in Air. The Industry has now avoided 75% of that by reburning lime mud but curiously, so far no carbon credit has been claimed by the Industry. However, the Industry has got a chance now to claim, may be retrospectively, the carbon credit if it can replace at least 50 % of the fossil fuel used in the RLK with introduction of Biomass. Biomass cannot be just burnt directly in the Lime Kiln as the salts in the Biomass impact the quality of lime and also add to the dead load in the liquor cycle. So gasification of the Biomass that enables you to remove the salts during the gas clean up system is the best option. Paper Mills have readily available Biomass source such as Bark, Chipper dust, effluent sludge (Primary) etc. Gasification is an endothermic process and the Moisture in Biomass burdens the heat load further- so Exergy steam drying complements it by recovering the steam which can be reused in gasification even if it is dirty. Further the Synergy comes from the lime kiln which gives hotter flue gas which can be used in the Exergy dryer. We are developing engineering design for pre drying system for lime mud using flue gas heat in Exergy dryer and pilot test runs are being planned at our facility near New Delhi. Commercial systems will be available soon for new RLK or may be a fluid bed calciner that will be suitably designed to take care of the shorter drying zone and higher flue gas exit temperature. Exergy dryer is better than flash dryer because the LP steam we produce can be used in causticizing. 7.0 Conclusion 1. With the global focus on Biomass energy, drying assumes greater significance than ever before as transportation cost is a major component of biomass price. Biomass pellets is lucrative business. Here Exergy dryer with steam recovery and lower emissions scores over other forms of drying. 2. Paper Industry has two major raw materials Biomass and Lime mud, both have great potential to reduce GHGs and earn carbon credits. 3. Flash dried pulp will be the thing of the past, since Exergy steam drying has proved more cost effective for India to produce pulp in Assam or abroad or even import from wood -rich countries. 4. RLK to reduce moisture from 45% to 25% Contact Details Offices Sales Agents in India Sweden Exergy Dryers Pvt Ltd. 1. IBI Chematur Swedish Exergy AB (Engineering & Consultancy) Limited Gamla Rambersgvägen 34 Andheri Kurla Road SE-417 01 Gothenburg Marol Naka, Andheri (East) Sweden Mumbai - 400 059 Phone: +46 (0)31 51 39 90 Phone: +91 (0) 22 2850 5152 Fax: +46 (0)31 51 79 60 Mobile +91 94226 15598 E-mail: [email protected] email [email protected] Website: www.swedishexergy.com Web: www.ibichematur.com

139 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre India Offices S-86, IBI House, Chimatpada 2. Esvin Advanced Technologies Limited A-274 Beta-1, Greater Noida Esvin House, Perungudi Distt- Gautambudh, 201308 (U.P), India Chennai - 600 096 Phone: +91 9818904912 Phone: +91 (0) 44 392 79 356 Fax: +91 9310826712 Mobile +91 98 40 02 5414 E-mail: [email protected] email [email protected] Web: www.swedishexergy.in Web: www.esvintech.in

140 Best Practices Manual - Pulp & Paper Industry UMV COATING SYSTEMS 1. Introduction to the company

UMV Coating Systems – Customized coating solutions UMV Coating Systems AB is a member of the Mattsson Group. With roots in BTG and UMV Machinery, UMV Coating Systems AB has become a world-leading developer and supplier of innovative surface treatment technology to the coated paper and board industry, for new machine installations and rebuilds. 2. Profile of the company: Areas of expertise Apart from advanced equipment for single or double-sided surface sizing, pigmenting and coating, UMV Coating Systems AB takes responsibility for complete coating sections, including pre-study, design, manufacture, installation supervision, training and startup. INVO® Tip is the latest of many unique products from UMV. 3. About the latest technology on the offering – INVO® Tip UMV has developed a new innovative, energy saving and quality enhancing metering element. The new product, INVO® Tip, gives excellent fibre coverage. Pilot trials and commercial mill trials shows that it is possible to reduce the amount of coat weight by 20 – 35% depending on the coating colour mix and still maintain the same print quality! Many mills are today using conventional techniques, such as airknife, for achieving good fibre coverage. The new INVO® Tip gives a possibility to replace the airknife and reduce the energy consumption by increasing the solid content from 40 to 65%, and increase the production output by 20 – 40% depending on existing drying capacity or other existing equipment limitations. Additional cost advantage is that it is possible to utilize a cheaper coating colour mix and still maintain the same paper quality. The new coating metering element gives also a possibility for easy and stable coat weight control and it is possible to maintain the coat weight through out the life time of the metering element. The INVO® Tip can easily be connected to the web break sensor and make sure that the metering element is turned away immediately during a web break. This will improve the life time of the INVO® Tip.

Potential Benefits In a board machine INVO Tip can lead to reduced thickness of top layer and reduce cost of production. This is one of the big advantages to reduce or in some cases also eliminate this fibre layer. One board producer in Europe has in pilot trials at UMV proved that it is possible to produce coated board without the bleached fibre layer, this would result in a cost saving of approximate EUR 5-6 million.

Case Study - Perfomance improvement, cost reduction and R.O.I. with INVO Tip on a Board Machine The Board Mill situation is like this. It is a three coating station i.e., with bent blade, air knife and bent blade. The production was limited by the pre drying section (under sized) and the post drying section after coating (low solids colour with air knife). Bad offset print quality such as mottling, uneven surface coverage etc. The decision is to stop the air knife and use Invo Tip on station 1 and 3, keeping the same CW (28 to 30 GSM total).

The expected benefits are:

141 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Production increase by transfer of 4 drying cylinder from post to pre drying part ƒƒ Decrease steam consumption cost ƒƒ Improvement of print quality and access to new market ƒƒ Reduction of specific energy consumption: T.steam / T. paper (higher colour solids: 65 % solids with INVO Tip instead of 45 % with Air Knife ). ƒƒ Production increase by transfer of 4 drying cyl. from post to pre drying section ƒƒ Additional benefit such as print quality improvement

Production data with Air Knife:

Production data with INVO tip:

142 Best Practices Manual - Pulp & Paper Industry Savings on production increase: Economical data

With Air Knife With INVO Tip Fixed cost € /H 4 500 € 4 500 € Fixed cost € /T 168 € 157 € Prod time H./year 8500 8500 Gross prod. /year 227052 243270 Net prod. /year 204347 218943 Broke rate 10% Savings on fixed costs 11 €/T or 2458929 €/year

Savings on specific consumption reduction: T. steam / T. paper

Savings in drying Reduction in water to evaporate (kg/h) 575 Reduction in steam consumption (2 kg /kg water) 1150 Savings €uro / h.(@18 € / T.steam) 21 €uro/annum ( 8500 h/annum) 175950

Invo Tip: Pay back period The savings that are obtained with Invo Tip are: ƒƒ Steam saving: 0.18 M€ ƒƒ Prod.increase: 2.46 M€ Total Savings are 2.64 M €. Investment cost for Invo Tip adaptation is 0.09 M€ and Relocation of cyl. (Optional) is 0.5 M€. So, the total investment is 0.59 M €. The ROI is less than 3 months.

Other Benefits The patented INVO® Tip gives ƒƒ Excellent fibre coverage ƒƒ Improved print quality ƒƒ Increasing production ƒƒ Energy savings ƒƒ Cost reduction due to cheaper raw material ƒƒ Excellent life time easy control of the coat weight ƒƒ Fits all of the existing coaters on the market It is possible to maintain the coat weight through out the life time of the metering element. If the coating colour solids is stable there is no need to adjust the INVO Tip angle to maintain the coat weight, there is no wearing effect on the soft metering tip. Also the repeatability in settings are excellent when changing INVO Tips since introduction of the new generation of diameter 14 mm INVO Tip.

143 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Conclusion from case study INVO Tip to replace Air Knife is the best investment on a Board Machine with fast payback: ƒƒ Steam consumption decrease ƒƒ Production increase ƒƒ Huge Print quality improvement ƒƒ Opening to new grades, new market

Investment details for a typical INVO Tip The installation drawing for 2 motion drives + couplings and shafts and Control & pneumatic cabinets + 1 control panel is given below:

Recurring expenditure for metering element is 1000 – 1200 SEK/m (110 – 130 EUR/m) depending on ordered quantity. Installation time is approximately 8 – 12 hours.Estimated / typical Life of an INVO Tip element is 1 – 2 days normally.

Sources for further information Further information is available at the website: http://www.umv.com/umv/about.html

Contact Details Main Office UMV Coating Systems, Industrigatan 7, PO Box 162, SE-661 24 SAFFLE, Sweden Phone: +46 522 982 80 Fax: +46 522 983 23 E-mail- General: [email protected] E-mail- Sales: [email protected] India Representative Pepco Machinery Private Ltd Prabhat Battishmira Cell: +91 98 300 59390 E-mail: [email protected]

144 Best Practices Manual - Pulp & Paper Industry Part II Best Practices Identified by CII - Working Group in Indian Pulp and Paper Industry 146 Best Practices Manual - Pulp & Paper Industry West Coast Paper Mills Ltd. Best Practices 1. Fly Ash Sold To Cement Plants Or For Brick Manufacturing. 2. Online Quality Monitoring Of Effluent Discharged To The River 3. Low Colour In Effluent (<70 Co-Pt Colour Units) 4. Low Stack Emissions From All Chimneys (70 + 10 Mg/Nm3). 5. Hot Screening Of Unbleached Pulp With Four Stage Screening 6. Reduction In Clo2 Consumption By 3 kg/Ton Of Pulp As Active Chlorine And Increased Brightness > 90% Due To Use Of Bleach Sequence

Of Dhot-Eop-Dd 7. Low Specific Energy Consumption Of Fiberline And Paper Machine. 10. Online Kappa Monitoring And Control At Multiple Locations. 11. Installation Of Tandem Shoe Press Resulting In High Dryness Of 50-53% And Retaining Of Bulk (Increased Filler Addition From 12% To 18%). 12. Stricter Monitoring Of Paper Properties By Tighter Control Of Parameters Through Autoline 400 And The Tso Module In It Measures The Fiber Orientation. 13. Installation Of Clari Disc Filter For Lime Mud With Low Chemical Losses. CD Filter Also Installed For White Liquor. 14. Energy Management In Air HandlIng Dryer –Hood Section Of Paper Machine

147 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 148 Best Practices Manual - Pulp & Paper Industry About West Coast Paper Mills Ltd. WCPM enjoys a pedigree of standing over the past 50 years. The company’s vision in constant up gradation of its process and technology to offer uniform quality of customized products, the “wood to paper” process mastery and product research have enabled the mill to produce a wide portfolio of wood free papers and boards of highest quality. The product-line features well-established brands of commercial to premium grades of paper and boards ranging from 54 to 600 GSM catered to across six different product segment namely; Writing, Printing, Business stationery, specialty, industrial and packaging. The company operates six versatile machines with an installed capacity of 3,20,000 TPA. With the latest addition of 500 TPD State of Art Voith Paper Machine, the quality standards have risen to international standards. With the installation of world’s most renowned “Bielomatik” online cut-pack converting line ,the quality standards of copier papers have been elevated to international standards. The overwhelming success of is Copier grades namely B2B, Copy Gold and Copy Plus have created a revolution in the market for cut size papers in a record short time. As an ISO 9001:2008 company, WCPM has been consistently striving to improve its quality benchmarks. At the heart of WCPM’s success is its strong customer focused research initiative backed by a sophisticated research center and a team of qualified professionals who have translated into a high degree of customer satisfaction, reflected in its loyal off take.

Technology WCPM has been constantly upgrading its technology to offer uniform quality of customized products. The “wood to paper” process mastery and product research have enabled the mill to produce wide portfolio of wood free papers and boards of highest quality. The ECF Bleached, Alkaline sized papers are processed through online process and quality control systems to facilitate excellent physical, surface and optical properties to papers that meets international quality standards.

SALIENT POINTS OF EXPANSION PROJECT AT WCPM: The Company was incorporated on March 25, 1955 and started Commercial Production on 16.05.1959 with an initial capacity of 18,000 TPA which has been increased over the period by way of regular expansion/modernization programme to 1,80,000 TPA. Once again, the expansion programme was undertaken from July 2007 to increase the capacity from 1,80,000 TPA to 3.20,000 TPA and also to enhance power generation capacity from 40.3 MW to 70.3 MW. The expansion was carried out with total investment of 1425 crores with 446.32 crores set exclusively for environmental management. The project was completed on 10th May 10, 2010. The major sections installed during expansion are;

Fiber Line 1. New Fiberline 2. Chemical Recovery Boiler 3. Causticizing Plant and Rotary Lime Kiln

Paper Line 4. Stock Preperation section 6 5. PAPER MACHINE 6 6. Autoline 400 for Quality control

149 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Converting Equipment 7. Rewinder 8. Sheet cutters 9. Ream packing machine 10. A4/A3 copier cutter 11. Reel packing & conveying system

Utilities 12. Power plant – 34.5 MW

1. New Fiberline The plant has taken proactive steps in installing a efficient new fibre line.The plant has installed 2 new chippers of 50TPH each supplied by Vecoplan, Germany. A New ECF advanced Pulp mill of 725 TPD has been installed. The new process gives high brightness (89 +1%) & high strength (7.5 -8.0 cps viscosity) pulp. The pulp mill was supplied by M/s. Metso of Sweden. The mill has 4 super batch reactor based digesters of 400m3 each capable of 150 to 160 MT of wood chips having 40% moisture. The time taken for cooking is 275 to 285 mins (from chipping to discharge). The mill has ODL followed by 4 stage bleaching (Dhot followed by EOP and DnD) with only 2 stage washing sequence. The mills is operated completely using DCS having online Kappa Analyser at 3 points (Before and after ODL and After EOP) which has resulted in better control and saving on chemical use. The new fiber line also has the advantage of significantly lower water consumption at 20m3/ Ton of pulp. LVHC (Low Volume High Concentration) non condensable gases collected from Digester and Evaporator plant are incinerated in Rotary Lime Kiln

A new efficient Chlorine Di Oxide Plant of 11 TPD supplied by M/s. Uhde India has been installed along with O2 generation plant of 1 TPH supplied by MVS Engineering has also been installed.

Fiber line Process Flow Diagram

150 Best Practices Manual - Pulp & Paper Industry ECF Fibre Line

Chlorine Di Oxide Plant

Pulping Technology In a business where it is essential to generate a part of our intermediate raw material needs, it is imperative to produce superior quality pulp at the lowest cost, with least environmental impact. West Coast Paper has a credible record to show in this regard. West Coast Paper Mills adopted a Mega expansion Programme - New Fiberline with ECF bleaching sequence with an object of ƒƒ Improved Pulp quality. ƒƒ Increased Energy efficiency. ƒƒ Improved environmental performances. ƒƒ Capacity enhancement. The company’s investment in a brand new 725 TPD (Bleached Pulp) Metso fiber-line, has replaced the old unit with eco friendly elemental chlorine–free (ECF) bleaching process. This has enabled to produce consistent quality of high- bright and hi-strength pulp with improved cleanliness & also reduced load on effluent. The high degree of bleaching has improved the optical properties of paper.

151 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre The areas covered for Capacity expansion in Fiberline are

Sl. No. Section Before expansion After Expansion (TPD) (TPD) 1 Chipper House 1000 3000 2 Cooking 330 800 3 Washing & screening 330 800 4 Oxygen delignification ---- 800 5 Bleaching 330 725 6 ClO2 4 15 7 Oxygen ------24 ƒƒ Entire equipments of of Fiberline are supplied by M/S Metso Sweden. ƒƒ Chippers and auxiliaries are supplied by Vecoplan, Germany. ƒƒ ClO2 plant is supplied by M/S UHDE (India) with an integrated process for ClO2 generation. ƒƒ Oxygen plant is supplied by M/S MVS Engineering New Delhi. Super Batch cooking process in the new fibreline facilitate to produce superior pulp quality imparting extra strength to the paper the much needed for functional superiority at the end user point. Keeping in view of the increasing quality awareness among customers in the highly competitive market scenario the need for process optimization was felt and the company’s prudent investment in modernizing the pulp mill and chemical recovery plants have resulted in overall operational efficiency with improvement in quality parameters at reduced operational cost. This was made possible through enhanced economies of operating scale and the reduction in consumption of utilities like water, steam & power and the process chemicals. Following are the new installations those have enabled increase in overall efficiency of the pulping and chemical recovery processes resulting in improved quality of Paper. a) Drum chippers 2nos. with silo capacity 1200 T b) Superbatch digesters 400 M3 x 4 nos. Metso supplied Superbatch cooking technology with 4 x 400 m3 capacity digesters. In each batch 150 – 160 Tons of chips at 38-45 % moisture is converted to 42 tons of unbleached pulp by consuming active alkali 450 kg/ton of pulp ~ 18 – 18 .5%. c) 4 stages hot screening with two stage washing and Oxygen delignification.

d) Two stages of washing are achieved with Twin roll press leading to a soda loss of 20 – 22 kg/ton as Na2SO4

e) Bleach plant with Dhot-EOP-DnD sequence An online kappa analyzer (Kajaani brand) is installed with sampling ports at three locations to control the chemical dosing and enable controlled bleaching with lesser chemicals f) 3 nos. of Twin wire roll presses in bleaching g) A sophisticated causticizing plant for improved green and white liquor generation. Compact disc filter for better white liquor clarification, &X filter for green liquor clarification h) Higher capacity falling film evaporator of 230 Mt/hr i) High-pressure boiler of 64 kg at 470ºC for higher steam and power generation, with a high-efficiency electrostatic precipitator

152 Best Practices Manual - Pulp & Paper Industry Comparison between old and new Fiberline

Note: In new fiberline additional power required for ODL and Oxygen plant.

2. Chemical Recovery Boiler A new chemical recovery boiler has been installed which has a capacity to handle 1100TDS/Day. This is a single drum boiler designed to handle high solid concentration (75%) black liquor and produce high pressure steam (65 bar). The boiler is installed with high performance MIGI® technology based ESP and is operated using Digital Control System (DCS) with inbuilt safety features.

153 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Chemical Recovery Boiler

3. Causticizing Plant and rotary lime kiln The causticising plant of 3500m3 capacity has been installed. The plant is provided with a X– Filter for green liquor filtration (< 20ppm clarity), a CD Filter for white liquor filtration (< 20ppm clarity) and a CD Filter for mud washing minimizing chemical losses (0.2% to 0.3%) & solid dryness > 70%. Also the plant has installed a 230 TPD rotary lime kiln.

Caustisizing plant and Rotary Lime Kiln

4. Stock Preperation section 6 The plant has installed advanced and efficient Stock preparation and approach flow equipments supplied by M/s. Voith for new paper machine no. 6. The section is fully integrated DCS system based and has a highly efficient broke cleaning system. The section also has Colour kitchen and wet end chemical preparation equipments from M/s. ABB Cellier, France.

5. Paper Machine 6 The plant has installed one of the most efficient and advanced paper machines supplied by M/s. Voith during its expansion. The machine is capable of producing 1, 50,000 TPA of high quality writing & printing paper and copier paper. The paper can be produced in the basis weight range of 45 – 90 GSM of sized and unsized paper with 5,300 mm deckle. The machine has a high designed speed of 1200 m/min and an operating speed of 1000 m/min.

154 Best Practices Manual - Pulp & Paper Industry Paper Machine No. 6

The machine is provided with Masterjet Headbox with Dilution Control system for uniform basis weight profile, good fiber dispersion, uniform CD profile and fiber orientation resulting in excellent sheet formation, improved strength and dimensional stability.

Masterjet Headbox with Dilution Control

The machine is also provided with advanced wire section with DuoFormer which has advantage of excellent formation, uniform drainage and Top former to improve formation and Surface smoothness.

Wire section with DuoFormer

The machine is provided with Tandem NipcoFlex Shoe Press which resulted in high bulk, higher dryness of sheet and uniform sheet structure.

155 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Tandem NipcoFlex Shoe Press

The machine’s drier section is provided with closed hood and Pocket ventilation system to improve the steam drying performance.

Dryer section with Closed Hood & Pocket ventilation system The machine is also provided with SpeedFlow Film Size Press which is a pre-requisite for high speed machine to provide uniform starch application on both sides of the paper, better printing properties, higher tensile strengths and less sheet breaks.

SpeedFlow Film Size Press

The Machine is also provided with Soft Nip Calender and Pope Wheel. The primary purpose of soft nip calender is to control uniformity, smoothness, bulk and finish of the paper by controlling: ƒƒ Nip pressure ƒƒ Roll surface temperature

156 Best Practices Manual - Pulp & Paper Industry ƒƒ Profiling ƒƒ Minimum two sidedness The pope wheel is Jumbo roll of 28 tonnes which results in jointless paper reels and Cobra auto reel change.

Soft Nip Calender

Pope Wheel The new paper machine has Power consumption of 460 – 480 kWh/ tonne, Steam consumption of 1.9 tonne/ tonne and water consumption 15-18 m3/tonne

6. Autoline 400 for Quality control The plant has installed L&W Autoline 400 equipment supplied for better quality control. The equipment is capable of measuring all Quality parameters in auto mode in 8-10 minutes for the Cross Direction strip of paper for each roll. The machine can measure 7 quality parameters in a single go. The 7 parameters that can be measured using Autoline 400 are ; a. Roughness b. Thickness c. colour, brightness, opacity and whiteness of paper using ELREPHO d. Bending resistance e. Tear/burst f. Tensile strength and g. Grammage

157 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Autoline 400

7. Rewinder The plant has installed a modern high speed rewinder supplied by M/s. Voith. It has a operating speed 2500 m/min and has good reel building capability.

Rewinder

8. Sheet cutters The plant has installed 3 advanced Sheet cutters, supplied by Milltex, Italy and Pizzolato, Italy. Each sheet cutter has a capacity of 100 - 120 TPD and has been provided with paper counter and tab inserter.

Sheet Cutter

9. Ream packing machine The plant has installed 3 automatic ream wrapping machines with labeling capability. Each machine has capacity to produce 13-15 reams per min. These have been supplied by M/s. Marushi.

Ream packing machine 158 Best Practices Manual - Pulp & Paper Industry 10. A4/A3 copier cutter The plant has installed A4/A3 copier cutter with a capacity of 150-200 TPD. The machine has auto ream packing, labeling, cartoning and strapping capability. The machine has beeb supplied by M/s. Bielomatik.

A4/A3 Copier Cutter

11. Reel packing & conveying system The plant has installed a new reel packing and conveyer system as part of the expansion. The machine packs the market reels in Kraft layer and stretch film layer and has automatic conveying. This has helped in achieving International packing quality of reels. The reels are jointless with nil joint being consistently achieved in greater then 98% of the reels produced and 1 joint in less than 2% of the reels. The reels produced are very tight with no loose winding and core collapsing problem.

Reel Packing and conveying system

12. Power plant – 34.5 MW The plant has installed a new coal fired captive power to produce 34.5 MW. The plant has a turbo generator (TG) supplied BHEL and AFBC (Atmospheric Fluidized Bed Combustion) boiler supplied by THERMAX. The plant has a Maximum continuous rating of 125 TPH, working pressure of 65 kg/cm2, steam temperature of 480±5oC and an operating efficiency of 86%.

Power Plant

159 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 1 Fly ash sold to cement plants or for brick manufacturing a. Progressively lesser fly-ash being sent to land fills. Coal is the chief source of energy in India and it will continue to do so in the near future. Indian coal having 20 – 40 % ash is widely used in the Indian Pulp & Paper industries, so also in West Coast Paper Mills. Electrostatic precipitation is the most popular and widely used method of emission control today which enables collection of dry fly ash. The characteristics of coal contribute significantly to the characteristics of fly ash collection. After arresting the fly ash in ESP, it is then transported to silos through suction or by pressurized air. When required, this can be obtained in the container for further transportation directly from the silos through chutes at the bottom, or to the delivery point by pipeline using vacuum suction or pressurized air. Although accurate data about the influence of the polluted atmosphere on the state of health of persons inhabiting the vicinity of the power station is not available, cases of pulmonary diseases, including asthma and silicosis are found to be on the increase. In association with moisture in the atmosphere, fine particles of fly ash often form aerosols which affect visibility around power stations, though to varying extent. Aerosols, being particles in colloidal dispersion and of lower bulk density, take a long time to settle down as fine precipitation of dust. These can thus be carried over considerable distances from the power station.

Utilizing Flyash as a resource: Although the scope for use of ash in concrete, brick making, soil-stabilization treatment and other applications has been well recognized, only a small quantity of the total ash produced in India is currently utilized in such applications. Most of the ash generated from the captive power plants is disposed off in the vicinity of the plant as a waste material covering several hectares of valuable land. Utilization of fly ash can result not only in reducing the magnitude of the environmental problems, but it is also to exploit fly ash as raw material for value added products (and conserve traditional materials), and for extraction of valuable materials. Amongst many uses that fly ash can be put to, that in building materials is particularly suitable. It is also anticipated, that there would be considerable short-fall in production of various building materials. According to a study, there would be a large short-fall in the production of bricks – to the tune of 25 billion bricks on an estimated demand of 100 billion bricks per year in India by the turn of the century. Considerable work has been done in various research institutions in India for utilization of fly ash. In spite of the recognition of the size of fly ash utilization / disposal problem and availability of technologies appropriate for Indian fly ashes and applications, India utilizes hardly about 3% of the total fly ash generated. Considering the colossal problem of disposal of fly ash, as well as the opportunities for conserving traditional resources like clay, cement, etc., the manufacturing of fly ash bricks is very important from the nation’s environmental and economic points of view. A West Coast paper mill has been proactive in increased utilization as a resource in the form of raw material for cement making and for utilizing them for brick manufacturing. The following table quantitatively summarizes the efforts taken by WCPM towards reduction of flyash being sent to land fill.

160 Best Practices Manual - Pulp & Paper Industry For the year \ 2010- Percentage For the year 2011- Percentage 2011 On BD basis (%) 2012 On BD basis (%) (@ 25% moisture) (@ 25% moisture) Cement Industries Katwa Cement 4,817 7.96 4336 7.10 Kanoria Cement 4,871 8.05 6065 9.93 Raghoji Cement Nil Nil Nil Nil J K Cement,Muddapur Nil Nil 4123 6.75 Sub Total 9,689 16.00 14,524 23.78 Bricks / Blocks Manufacturing Industries Hubli 7,881 13.02 12473 20.42 Kali Nirmiti Kendra, Dandeli Nil Nil Nil Nil Halmaddi, Dandeli 680 1.12 11503 18.83 Others 12,906 21.32 14846 24.30 Sub Total 21,467 35.46 38,822 63.55 Land Filling Within Mill area 594 0.98 177 0.29 Deserted mines 28,796 47.56 7564 12.38 Sub total 29,390 48.54 7,741 12.67 Grand Total 60,545 100.0 61,087 100.0 b. Research sponsored by WCPM for fly ash utilisation as manure. WCPM has signed an MOU on August 5, 2010 with UNIVERSITY OF AGRICULTURE SCIENCE for a three year research project on what effect fly ash has on crop production. The WCPM funded project, currently in its second year, aims to establish flyash as a fertilizer source to the farmer community. The initial feedback received from the scientists is given below: 1. They have involved 45 farmers for the demonstration on their lands and have used the fly ash from WCPM in the ground nut crop. 2. No adverse effects on the quality of soil have been observed 3. The crop was green even during dry spells due to increase in moisture holding capacity of the soils. 4. 5 to 15% increase in the crop yield was observed. Further work in this direction is in progress. Utilization of flyash for cement manufacturing: Cement Industry Perspective

Reducing clinker factor in fly ash based Portland Pozzolona cement:

Current Status The increased use of fly ash in Portland Pozzolona Cement (PPC) has direct impact on reduction in clinker factor (% of clinker content by mass in cement) in cement thereby reducing the CO2 emission by reduced fuel combustion and reduced limestone calcinations. Therefore exploring the newer technical avenues for maximizing the utilization levels of fly ash are the biggest challenge.

161 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre In India, the estimated generation of fly ash is of the order of 190 million tonnes in the year 2010-11 which is expected to increase to 450 million tonnes by the year 2020-21 and to 900 million tonnes by the year 2031-32 (Source-DST). At present about 100 million tonnes of fly ash is being utilized in cement, construction and other building materials. There are Indian standard specifications IS: 3812 (part 1) 2003 for quality of fly ash to be used as Pozzolona and IS: 3812 (part 2) 2003 for quality of burnt clay to be used as Pozzolona. The ASTM and EN standards for quality of fly ash are C-618-08 and ENV: 197-1-1992 respectively. While fly ash is available in abundance in India and is used widely, burnt clay Pozzolona is not much in use. Besides its use as Pozzolanic additions in manufacture of PPC, fly ash is used in many other areas such as raw material component for the manufacture of Ordinary Portland Cement, sintered fly ash light weight aggregates and concrete, cement- / silicate-bonded fly ash / clay fly ash building bricks, pre-cast fly ash concrete building units, cellular concrete, bricks and blocks, lime and cement fly ash concrete, structural fill for roads, construction sites, land reclamation etc., as a filler in mines, as a filler in bituminous concrete and manufacture of insulating and semi-insulating bricks, as a plastisizer and a pumping aid, as a water reducer in concrete, sulphate resisting concrete and as a filler in paints and pigments and so on. Fly ash use as Pozzolona in PPC, however, remains the biggest user segment. PPC production reached more than 130 million tonnes during 2010-11, which amounted to around 60% of total cement production in India. Fly ash conforming to IS: 3812 (1) 2003 can be used (up to 35% max) in the manufacture of Portland Pozzolona Cement as per IS: 1489 (part 1) 1991. The role of fly ash in PPC is attributed to the Pozzolanic action leading to a contribution towards strength development. Studies carried out on Indian fly ash samples have indicated that the range of glass content varies between 15 and 45% and the Lime Reactivity (LR) between 2.0 and 7.0 MPa. The fine fraction of fly ash below 45 micron is major portion, in general and contributes predominantly in the performance of PPC. This particular aspect of fly ash is very important with a view to enhance the percentage of use of fly ash in PPC and concrete and needs further thorough and systematic investigations to arrive at certain adoptable methodologies of using finer fly ash at higher levels. Studies have been undertaken with a view to improve the lime reactivity of dump ash / pond ash, and fly ash from initial fields of ESP so that non conforming fly ash could be made reactive conforming to IS: 3812 (1) 2003 and could gainfully be utilized. These studies have revealed that such fly ash could be utilized up to 25% on an average after activation through mechanical, chemical and thermal routes. The studies on activation of conforming fly ash also indicate that the utilization levels of fly ash could be increased by about 10–15% from the current levels, subject to revision of national standards.

Anticipated benefits Thermal savings: Saving potential: 180 – 235 kcal / kg cement PPC (27 – 35% fly ash replacement) Electrical savings: Saving potential: 13 – 17 kWh / t PPC

CO2 reduction potential: Direct:

Reduction of 220–280 kg CO2 / t PPC (for a cement with 27–35% by mass fly ash) Indirect:

1 kWh reduction in specific power consumption reduces CO2 emission by 1kg hence, reduction in CO2 emission is expected to be 13–17 kg/t PPC (for a cement with 27–35% by mass fly ash)

Note:

The above thermal / electrical savings are worked out considering OPC (95% clinker) as base level, 27% fly ash or current national average in PPC, and 35% fly ash as achievable target in future.

162 Best Practices Manual - Pulp & Paper Industry Main influencing parameters:

The permitted level of fly ash in India is (15–35%) as compared to European standards (6–55% by weight for siliceous fly ash (source: ECRA). The following are the technical reasons for lower utilization of fly ash in India: ƒƒ Poor quality of Indian fly ash in terms of • Low lime reactivity • Low glass content • High carbon content • Varying fineness levels ƒƒ Exploitation of only pozzolanicity of fly ash in cement and concrete ƒƒ Fine powder effect is limited up to 5% in OPC (performance improver)

Cost estimation Investment cost depends on size of silo at power plant complex, fleet size of tankers, type of handling equipment at plant etc. The current estimated cost of fly ash collection systems at thermal power plant, handling and transportation to cement plant in mill hopper etc. is in the range of INR 140–150 million for indigenous supplies.

Condition, barriers, constraints: Utilization of fly ash in cement, concrete and building materials will largely depend upon the factors such as availability of the fly ash in dry state, extent of variation in the quality of fly ash.

Technical: I. Provision of transportation of dry fly ash in closed wagons because otherwise transit losses are high as it is a fine powder. ii. Since bulk of fly ash is being disposed off in wet state, arrangements have to be made for extraction and supply of fly ash in dry state. Some plants have installed fly ash dryers at huge capex, to process wet fly ash iii. Provision of marketing of standard quality fly ash in bags or any other packing such as drums, etc. iv. Variation in the quality of fly ash is one of the major problems related to its bulk utilization. Efficient coal blending systems and controlled coal combustion techniques will ensure good quality fly ash generation in Indian thermal power plants. v. Further research is required concerning the activation of non-conforming fly ash for their rational use

Policy: i. Need for modifications of existing standards and codes consequent upon the acceptance of different uses of fly ash and formulation of new standards whenever necessary ii. Unawareness of consumers towards quality of fly ash based products along with confidence of builders in the conventional building materials

Finance: i. Tax relief and fly ash utilization subsidy will go a long way in promoting its larger utilization. ii. Limitation in distance over which the fly ash can be commercially transported

163 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 2 Online quality monitoring of effluent discharged to the river Maintaining effluent water quality is one of the major challenges facing the Indian Pulp and paper industry.As regulation become more stringent with regard to quality of effluents discharged and also due to varying loads on effluent treatment plants it is becoming ever so necessary to continuously monitor the quality of water being discharged from the facilities and take necessary actions immediately incase of any deviations from stipulated norms. The main objectives of having a online monitoring system is to ƒƒ Identification of state (concentration) and trends in water quality; ƒƒ Identification of the mass flow (loads) in surface water and effluent; ƒƒ Testing of compliance with the standards ƒƒ Early warning and detection of deviations from the standards West Coast Paper Mills is located in one of the more eco sensitive zones and its effluent is discharged into Kali River, home to the famed crocodiles, through Halamaddi Nala. The facility has taken proactive steps in installing the online monitoring station for continuously monitoring the quality of its combined effluent before it is discharged into Halamaddi Nala. The online monitoring system is used to monitor water quality parameters like Dissolved Oxygen, Temperature, pH and flow. The system is helping the facility in having a better control over effluent quality as well as meets the regulatory requirements with reduced scrutiny by the environmental agencies. Through implementation of On -line monitoring system, corrective action can be immediately initiated as & when any of the 4 selected parameters tend to go beyond the limits specified. Corrections taken after the pollutant level in the river is noticed later, because of continued high impurity level, would be a costly exercise as the damage had already been done. Preventive action for course correction is the gain by this scheme. This fact had been corroborated by the thriving of acqua-maritime beings.

Online Water quality Monitoring System

164 Best Practices Manual - Pulp & Paper Industry Best Practice 3 Low colour in Effluent (<70 Co-Pt colour units) The pulp and paper industry uses large amounts of process water, despite significant conservation. Thousands of gallons of water must be treated for every ton of pulp or paper produced. The industry has long dealt with the issues of BOD and TSS, and more recently with issues such as Dioxins, Furans, and AOX. Many pulp and paper operations already have permit limitations on color and others will likely follow. Pulping and bleaching processes release colored compounds into the effluent stream. Most of the color comes from removing lignin in the bleaching operation, particularly in the caustic extraction stage. The color exists in a range of physical forms, from suspensions to true solutions. Colour being one of the most easily recognizable parameter to detect the pollution levels in effluent with just visual inspection, it becomes ever so important to control the color of the effluent and maintain it as clear as possible. Alternate pulping and bleaching strategies such as extended delignification and oxygen delignification have reduced pulp mill color significantly, and these load reduction strategies will continue to be a key part of any color control plan. While in some cases process modifications may be adequate to meet local requirements, other circumstances may dictate additional modifications in the effluent treatment plant like separate treating of various effluent streams. West Coast Paper Mills has taken proactive steps to achieve better water quality in comparision to KSPCB norms, especially in terms of color reduction. The plant has been able to achieve below 70 Co-Pt colour units. The water quality parameters achieved against the KSPCB norms is as follows.

Sl. Main Parameter KSPCB stipulated std. Achieved range in our No. effluent 1 pH 7.0 to 8.5 7.0 to 7.8 2 SS, ppm 50 (max) 35 to 45 3 DS, ppm 2,100 (max) 350 to 400 4 B.O.D., ppm 30 (max) 18 to 24 5 C.O.D., ppm 250 (max) 180 to 220 6 Chloride, ppm 350 (max) 150 to 190 7 Sulphate, ppm 1,000 (max) 70 to 90 8 AOX, kg/T of product Less than 1.0 0.2 to 0.25 9 Colour Co-Pt units 500 Co-pt Colour units (Removed Below 70 Co-Pt colour units.*** to the maximum extent) The facility has been able to achieve these through a. Better control on treatment through online monitoring and Bio assay tests b. Treating the mill effluent in two separate streams; Pulp mill, Chemical recovery plant & Power house effluent along with colony sewage is being treated in one stream and Paper machine effluent in another stream c. Installation of New state of the art fiberline, ECF bleaching & Oxygen de-lignification system a. Better control on treatment through online monitoring and Bioassay tests: The plant has installed online monitoring system for combine effluent stream and also carries out bio assay test regularly. The online monitoring system measures DO, pH, Temperature and flow. This helps the facility in continuos monitoring of effluent quality and optimize the chemical use and aeration times. Bioassay (commonly used shorthand for biological assay), is a type of scientific experiment typically conducted to

165 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre measure the effects of a substance on a living organism (mostly fish of certain species common to the effluent sink) and are essential in monitoring environmental pollutants. This procedure helps in determining the potency or the nature of an effluent is estimated by studying its effects on living matter and helps the facility to take immediate steps to improve the quality of effluent if there is deviation.

Bioassay test chambers b. Treating the mill effluent in two separate streams: The plant treats the mill effluent in two separate streams; Pulp mill, Chemical recovery plant & Power house effluent along with colony sewage is being treated in one stream and Paper machine effluent in another stream. Pulp mill, Chemical recovery plant & Power house effluent along with colony sewage is being treated in one stream, first in primary treatment followed by mist cooling system to bring down the effluent temperature from 60°C to 30°C. It is then treated with Activated sludge with diffused aeration followed by secondary treatment to settle the sludge & the clear over flow is discharged into polishing pond. While Paper machine effluent needs only a primary treatment with the sludge settled in clarifier & the clear overflow flows in to polishing pond along with Pulp mill secondary clarifier overflow for extra cushion to Dissolved oxygen with 4 nos of surface aerators & the clear overflow is being discharged.

Effluent treatment plant layout

166 Best Practices Manual - Pulp & Paper Industry c. Installation of New state of the art fiberline, ECF bleaching & Oxygen de-lignification system: The facility has installed new state of the art fiber line, elemental chlorine free bleaching system and oxygen delignification system which has reduced the color of the effluent from 150 to 200 Co-Pt units to below 70 Co-Pt units.

Combined untreated effluent and treated effluent

167 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 4 Low Stack emissions from all chimneys (70 + 10 mg/Nm3) Pulp and paper mills generate a range of emissions of listed substances from pulping processes and power generation. Major sources of emissions occur at the pulping and bleaching stages, and in energy generation. One of the major component of stack emission is particulate matter. This is one of the major noticeable components of stacks and leaves visual impression on the air pollution load as well as having a negative impact on health & surrounding environment, so it is becoming more and more important to control the particulate and fly ash emissions from the stacks. The most effect way of controlling these emissions is through installation of ESPs (Electrostatic Precipitators). This aids in effective collection of fly ash and other particulate matter. Particulate which accumulates on collecting electrode surfaces and on discharge electrodes must periodically be dislodged by rapping the collecting plates and discharge electrodes. Rapping removes particulate to the hoppers for disposal and maintains both the discharge and collecting electrodes in an "operationally" clean condition for proper operation. One of the ways of improving the ESP efficiency is through the use of MIGI® rapping technology. It offers the advantage of ƒƒ High collecting efficiency ( ≥99.9% ) ƒƒ Rapper is isolated from flue gas for minimizing required space, performing maintenance without shutdown of ESP. ƒƒ Vibration force transmits from top to bottom, which is in compliance with dust collection characteristics. ƒƒ Minimize rapping unit to realize reasonable control for each rapping unit, and remove dust efficiently. ƒƒ Small section power supply make parameters of power supply are more suitable for property of dust. ƒƒ Improve liability and stability of equipment by effectively monitoring rapper system. ƒƒ Insulation compartment with penthouse shape make easy protection, maintenance and management available. ƒƒ Prevent from leakage and dew by adopting purge air system. ƒƒ Energized dura-trode discharge electrode with high rigidity. ƒƒ For MIGI rapper, rapping strength can be adjusted easily The MIGI® rapper is a simple electromagnetic coil that provides a controlled and adjustable lift for its one moving part, a 20 pound plunger. Individual rapper operation is initiated by a controlled, short duration, low voltage (110 V d.c.) pulse. This pulse energizes the coil, generating a magnetic field that lifts the plunger into the phenolic guide tube. After the coil is de-energized, the plunger drops by gravity and impacts on a stationary rapper rod that transmits the forces to the ESP collecting plates and discharge electrodes. Unlike a tumbling hammer (European) design, the MIGI® rapper has no moving parts in the gas stream and is not exposed to the erosive effects of the flue gas and particulate. The roof mounted MIGI® design permits on-line inspection and servicing. And, as service conditions change, both the frequency and the intensity of the rapping force can be easily changed from the rapper control panel. West Coast Paper Mills has proactively installed MIGI® Rapping Technology in ESPs in all the stacks which are more effective in reducing the particulate emissions much below the stipulated norms. The emissions achieved with the use this technology by West Coast Paper Mills is as follows

Stack Monitoring data for the year 2011-12 at WCPM

168 Best Practices Manual - Pulp & Paper Industry Stacks attached to Stipulated STD Tested Values CRP Boiler ( Old) Flow,Nm3 /hr 125,000 115,074 SPM, mg/Nm3 150 71 3 H2S mg/Nm 10 0.28 CRP Boiler ( New) Flow,Nm3 /hr 225,720 191,814 SPM, mg/Nm3 150 82 3 H2S mg/Nm 10 0.32 RLK (Old) Flow,Nm3 /hr 20,000 16,694 SPM, mg/Nm3 150 66 RLK (New) Flow,Nm3 /hr 39,600 26,723 SPM, mg/Nm3 150 65 FBC - 1 Flow,Nm3 /hr 92,000 74,949 SPM, mg/Nm3 150 85 3 SO2, mg/Nm - 774 FBC - 2 Flow,Nm3 /hr 1,23,912 99,063 SPM, mg/Nm3 150 78 3 SO2, mg/Nm - 717 FBC - 3 Flow,Nm3 /hr - 94,857 SPM, mg/Nm3 50 38 SO2, mg/Nm3 - 677 FBC - 4 Flow,Nm3 /hr 1,44,108 1,14,588 SPM, mg/Nm3 150 77 3 SO2, mg/Nm - 724

169 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 5 Hot screening of unbleached pulp with four stage screening Metso has released a new type of com¬binated knotter and fine screen, des-ignated DeltaCombi™, which is based on the successful DeltaScreen® and DeltaKnotter™ concept. This machine is intended for efficient separation of knots, uncooked chips, junk (metal, stones etc.), shives and other undesirable de¬bris in the accepted pulp. Design The DeltaCombiTM consists of a vertical, Cylindrical housing with a top cover, designed as a pressure vessel. Inside the housing, a rotat¬ing screen basket with holes, is mounted on a bearing unit, the same type as the one used in DeltaScreen®. Additionally for fine screening a similar rotor and Nimega™ basket as in DeltaScreen® is mounted.

Working Principle The working principle is the same as for a single knotter and as for a single fine screen. The pulp is fed tangentially into the bottom part of the screen through the rotating screen basket from the outside to the inside. The pulse gener¬ating stationary foils are located on the accept side of the screen basket. The coarse reject is taken out from the bottom part. The accept which has passed the rotating screen basket is led up through the rotor of the fine screen and downwards between the rotor and NImegaTM screen basket, as in an ordinary DeltaScreen®.

Features ƒƒ High consistency and high capacity ƒƒ Excellent knot and shive removal efficiency ƒƒ Possible light weight removal ƒƒ Unique stator design ƒƒ Unique adjustable rotor-screen bottom seal ƒƒ Same type of bearing unit as the one used in DeltaScreen®.

WCPM had hot screening in Old Pulp Mill with Three stage screening

170 Best Practices Manual - Pulp & Paper Industry 1. Delta-Combi- DC 8 Two functions are being carried out in the same screen. a. Hole screen basket with 10 mm hole – Removes Knots from the cooked pulp. b. Slot screen 0.25 mm – Removes fine rejects and acts as Primary stage.

2. Knots are taken to KFA-50 which separates knots from the fiber. Knots are recharged to Digester & accept fiber goes back to Blow tank.

3. Delta screen FS-40 as secondary screen with 0.25 mm

4. Tertiary screen- FS-40 as tertiary screen This followed by screw press (Fan separator) which removes liquor from Tertiary rejects and dispose rejects in solid form~ 35-40 % Cy. In New fiberline WCPM opted for four stage screening with additional Delta Knotter screen to reduce the fiber loss going with rejects.

1. Delta combi DC- 10. a. Hole screen with 10 mm dia. b. Slot screen with 0.3 mm slot

2. Delta knotter DK-4 with 10 mm hole basket- Purpose of delta knotter is to make Knots fiber free. Knots are carried to KFA-50

3. Delta screen DC-4 as secondary screen with 0.3mm slot

4. Tertiary screen FS-40as tertiary screen with 0.3 mm slot basket

5. Rejects are taken to KFA -50 tail screen 3mm hole. –Rejects are passed through Screw press (Fan Separator) to dispose rejects as solid (35 % Cy) Main difference between hot screening of old Pulp Mill and New fiberline is 1. Increase capacity 2. Better fiber recovery from rejects

171 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 6 Reduction in ClO2 consumption by 3 kg/ton of pulp as active chlorine and increased brightness

> 90% due to use of Bleach sequence of Dhot-EOP-DnD Chemical pulp, the raw material in paper, is not naturally white; its light color or pure whiteness is the result of a multi-phased bleaching process. Bleaching means removing or altering the color substances in the pulp. It is done in phases. The darkness of chemical pulp is caused by lignin, the natural adhesive that binds wood fibers together. A key issue in bleaching is how the lignin is processed, i.e. how much lignin is removed from the pulp. Typically, chemical pulp is bleached by removing lignin and mechanical pulp by preserving it. If lignin is removed from the pulp, the pulp remains brighter longer and yellows more slowly later. The objectives of bleaching are usually to lighten the color of the pulp, preserve brightness, improve cleanliness, or reduce pitch content. Bleaching improves the cleanliness of the pulp. When the last of the lignin is removed from the pulp, the fibers of the fiber bundles, i.e. the shives, are released and any remaining bark debris dissolves. The chemicals used in bleaching also effectively dissolve any extractives contained in the pulp. The chemical pulp stock is bleached in several separate phases. In between each phase it is washed. By alternating the bleaching and washing phases, the pulp can be made very bright without compromising its structure and strength.

Bleaching chemical pulps Chemical pulps, such as those from the kraft process or sulfite pulping, contain much less lignin than mechanical pulps, (<5% compared to approximately 40%). The goal in bleaching chemical pulps is to remove essentially all of the residual lignin, hence the process is often referred to as delignification. Sodium hypochlorite (household bleach) was initially used to bleach chemical pulps, but was largely replaced in the 1930s by chlorine. Concerns about the release of organochlorine compounds into the environment prompted the development of Elemental Chlorine Free (ECF) and Totally Chlorine Free (TCF) bleaching processes. Delignification of chemical pulps is rarely a single step process and is frequently composed of four or more discrete steps. These steps are given a letter designation, and these are given in the following table:

Chemical or process used Letter designation Chlorine C Sodium hypochlorite H Chlorine dioxide D Extraction with sodium hydroxide E Oxygen O Alkaline hydrogen peroxide P Ozone Z Chelation to remove metals Q Enzymes (especially xylanase) X Peracids (peroxy acids) Paa Sodium dithionite (sodium hydrosulfite) Y

172 Best Practices Manual - Pulp & Paper Industry A bleaching sequence from the 1950s could look like: CEHEH. The pulp would have been exposed to chlorine, extracted (washed) with a sodium hydroxide solution to remove lignin fragmented by the chlorination, treated with sodium hypochlorite, washed with sodium hydroxide again and given a final treatment with hypochlorite. An example of a modern totally chlorine-free (TCF) sequence is OZEPY where the pulp would be treated with oxygen, then ozone, washed with sodium hydroxide then treated in sequence with alkaline peroxide and sodium dithionite.

The usual bleaching sequence encountered in an ECF bleaching sequence is D0 – EOP – D1. The functions of Chlorine dioxide (D), Extraction or washing (E), Oxygen (O), Hydrogen peroxide (P) is described in brief.

Chlorine dioxide (D) Chlorine dioxide, ClO2 is an unstable gas with moderate solubility in water. It is usually generated in an aqueous solution and used immediately because it decomposes and is explosive in higher concentrations. It is produced by reacting sodium chlorate with a reducing agent like sulfur dioxide.

2 NaClO3 + H2SO4 + SO2 --> 2 ClO2 + 2 NaHSO4 Chlorine dioxide is sometimes used in combination with chlorine, but it is used alone in ECF (elemental chlorine- free) bleaching sequences. It is used at moderately acidic pH (3.5 to 6). The use of chlorine dioxide minimizes the amount of organo-chlorine compounds produced. Chlorine dioxide (ECF technology) currently is the most important bleaching method world wide. About 95% of all bleached Kraft pulp is made using chlorine dioxide in ECF bleaching sequences.

Extraction or washing (E) All bleaching agents used to delignify chemical pulp, with the exception of sodium dithionite, break lignin down into smaller, oxygen-containing molecules. These breakdown products are generally soluble in water, especially if the pH is greater than 7 (many of the products are carboxylic acids). These materials must be removed between bleaching stages to avoid excessive use of bleaching chemicals since many of these smaller molecules are still susceptible to oxidation. The need to minimize water use in modern pulp mills has driven the development of equipment and techniques for the efficient use of available water.

Oxygen (O) Oxygen exists as a ground state triplet state which is relatively unreactive and needs free radicals or very electron- rich substrates such as deprotonated lignin phenolic groups. The production of these phenoxide groups requires that delignification with oxygen be carried out under very basic conditions (pH >12). The reactions involved are primarily single electron (radical) reactions. Oxygen opens rings and cleaves sidechains giving a complex mixture of small oxygenated molecules. Transition metal compounds, particularly those of Iron, Manganese and Copper, which have multiple oxidation states, facilitate many radical reactions and impact oxygen delignification. While the radical reactions are largely responsible for delignification, they are detrimental to cellulose. Oxygen-based radicals, especially hydroxyl radicals, HO•, can oxidize hydroxyl groups in the cellulose chains to ketones, and under the strongly basic conditions used in oxygen delignification, these compounds undergo reverse aldol reactions leading to cleavage of cellulose chains. Magnesium salts are added to oxygen delignification to help preserve the cellulose chains, but mechanism of this protection has not been confirmed.

Hydrogen peroxide (P) Using hydrogen peroxide to delignify chemical pulp requires more vigorous conditions than for brightening mechanical pulp. Both pH and temperature are higher when treating chemical pulp. The chemistry is very similar to that involved in oxygen delignification, in terms of the radical species involved and the products produced. Hydrogen peroxide is sometimes used with oxygen in the same bleaching stage and this is given the letter designation Op in bleaching sequences. Metal ions, particularly Manganese catalyze the decomposition of hydrogen peroxide, so some improvement in the efficiency of peroxide bleaching can be achieved if the metal levels are controlled.

173 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Bleaching sequence at West Coast Paper Mills ECF Bleaching sequence Dhot-EOP-DnD was given by Metso to achieve target brightness of 90 degree. The advantage of this sequence over Do-EOP-D are 1. Better retention time at three Dioxide stages than two Dioxide stage 2. Reduction chemical consumption due distribution of Chlorine dioxide which is the main bleaching chemical in ECF sequence. 3. Better control over brightness at each stage. Since WCPM has conventional bleaching sequence C/D-EOP-H-D where hypo was used No data is available to compare with Dhot-EOP-D at WCPM. However as per information from M/S Metso, indicates ClO2 consumption is more in Dhot-EOP-D sequence than Dhot-EOP-DnD. This is imperative because of the reasons mentioned above.

Source: Metso.

174 Best Practices Manual - Pulp & Paper Industry Best Practice 7 Low Specific Energy Consumption of Fiberline And Paper Machine a. Fiberline 420 kWh/T, 1.4 T/Ton (MP + LP steam) b. Paper machine 470 kWh/T and 1.9 T of steam per ton of paper with size press Pulping Technology In a business where it is essential to generate a part of our intermediate raw material needs, it is imperative to produce superior quality pulp at the lowest cost, with least environmental impact. West Coast Paper has a credible record to show in this regard.

New-Gen Fiberline with ECF bleaching sequence The company’s investment in a brand new 750 TPD Metso fiber-line, replacing the old unit with environmentally benign elemental chlorine–free (ECF) bleaching process in the in-house pulping street has enabled produce consistent quality of high-bright and hi-strength pulp with improved cleanliness & lasting freshness with least pollution load. The high degree of bleaching has improved the optical properties of paper. The high capacity digesters of 400 m3 in the new fibreline facilitate produce superior pulp quality imparting extra strength to the paper the much needed for functional superiority at the end user point. Keeping in view of the increasing quality awareness among customers in the highly competitive market scenario the need for process optimization was felt and the company’s prudent investment in modernizing the pulp mill and chemical recovery plants have resulted in overall operational efficiency with improvement in quality parameters at reduced operational cost. This was made possible through enhanced economies of operating scale and the reduction in consumption of utilities like water, steam & power and the process chemicals. The installation of high capacity digesters , high-speed chippers, X filter for green liquor clarification, Compact disc filter for better white liquor clarification, Higher capacity falling film evaporator of 230 MT/hour , High-pressure boiler of 63 kg at 470ºC for higher steam and power generation , a high-efficiency electrostatic precipitator with a sophisticated causticising plant for improved green and white liquor generation etc have enabled increase in overall efficiency of the pulping and chemical recovery processes resulting in improved quality of Paper.

175 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Brief specifications of the new pulp mill at WCPM The new pulp mill at WCPM is rated for 725 TPD of unbleached pulp and is operated upto 800 TPD of unbleached pulp. The configuration of the system is as below. 1. Wood Yard: Two drum chippers of capacity 50 TPH each are installed for chipping and a silo of 1200 Tons capacity is used for chip storage. 2. Cooking: Metso supplied Superbatch cooking technology with 4 x 400 m3 capacity digesters. In each batch 150 – 160 Tons of chips at 45 – 48% moisture is converted to 42 tons of unbleached pulp by consuming 450 kg/ton of pulp with active alkali of 17.5 – 18 %. 3. Screening and Washing: Metso supplied a four stage Hot stock screening system with Delta Combi (coarse and fine) screen, Delta knotter, secondary and tertiary screen. Two stages of washing is achieved with press

type washers leading to a soda loss of 20 – 22 kg/ton as Na2SO4.

4. Oxygen Delignification and bleaching: Two stage ODL is installed with a bleaching sequence of hotD – EOP

– DnD punctuated by press type washers delivering consistency of about 30%. An online kappa analyzer (Kayaani brand) is installed with sampling ports at three locations to control the chemical dosing and enable controlled bleaching with lesser chemicals.

Parameter Value WBL 11 m3/ton of pulp with 16 – 17% solids concentration at 85oC and 180 gpl Yield 46.6 – 46.7 % unbleached yield and 43 – 43.2 % bleached yield

Washing loss 20 – 22 kg/ton as Na2SO4 Pulp viscosity 7.5 – 8 cp Kappa 17 – 18 at cooking; 15 – 16 before ODL; 8 – 8.5 after ODL Blow tank Cy 5 – 6 % Steam consumption MP (7 bar) steam at Digestors: 0.7 T/T pulp LP (3 bar) steam at Digestors: 0.2 – 0.25 T/T Bleaching: 0.5 T/T pulp

Power consumption 420 kWhr/ton of pulp (including ClO2 plant and chipper house) 225 kWhr/ton (Only ODL and fibreline)

Paper Making WCPM company operates six versatile Paper Machines with an installed capacity of 3,20,000 TPA. The varied functional characteristics of the Machines and the swing capacity have enabled the company to produce a wide portfolio of paper and boards ranging from 54 to 600 GSM , catered to a diversified application segment enabling the mill to sustain its share in a market sensitive to season and cycle. Hi-tech Machines for New Generation Papers With the latest addition of 500 TPD State of the Art Voith Paper Machine, the quality standards in WCPM have risen to international standards. The Hi-tech machine operated at 1100 MPM , with a GSM ranging from 52 to 90 is rated the best in the country and the latest of its kind in the world

Salient Feature: New generation former that features a combination of Fourdrinier wire section with a top former that facilitate uniform basis weight Profile and excellent sheet formation with least two-sidedness and MD/CD tensile ratio. Speed flow size Press: Paper is processed through a metered size press to get the "extra finish" to impart the best surface and optical properties.

176 Best Practices Manual - Pulp & Paper Industry Shoe press and soft-nip calendaring: facilitate achieving high bulk, good dimensional stability with low two- sidedness. The advanced on-line process and quality control system ensures consistency in quality in line with international standards. The sweeping success of the PM-6 made Copier papers namely B2B, Copy Gold and Copy Plus which have taken the top slot in the market for cut size papers in a record short time, is the testimony of the customer acceptance on account of functional superiority. The Sudarshan brand Maplitho papers have been rated one of the best in the industry, duly acknowledged by reputed print-houses and institutions.

Process Highlights ƒƒ Paper made using 100% virgin Wood Fiber enables excellent physical properties to paper required for strength and durability. ƒƒ Wood Pulp is processed through ECF, Eco-friendly bleaching process that enables achieve high degree of brightness while preserving the strength properties. ƒƒ Paper made using alkaline sizing. ƒƒ Usage of high grade fillers like PCC have enhanced the optical properties ensuring high brightness , opacity and scatter values imparting the paper a lasting freshness with least abrasion factor. ƒƒ Advanced Stock Preparation System enables maintain consistent quality through effective and online process control measures. Our new machine is fully integrated with the distributed control system, making it possible to control the entire machine from a single location compared with our erstwhile practice of manual intervention at each stage. WCPM believes in continuously upgrading the technology and process through its extensive R&D and adoption of State of the Art technology prevalent in the global paper industry.

Paper Machine-VI DECKLE-516-525

PRODUCTS GSM APPLICATION Range Sudarshan Classic / Ultra Shine 60 – 88 Printing & Publishing Diaries, Calandrra, Annual Reports, leaflets, high quality textbooks and notebooks Sudarshan Deluxe Maplitho 54 – 88 Printing & Publishing Diaries, Calandrra, Annual Reports, leaflets, high quality textbooks and notebooks Business Stationery / Photo 70 Photo copying, Copy paper 1.B2B Laser printing, Inkjet printing Digital printing, Copy Gold 75 Copy Plus 80

177 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Brief specifications of the new paper machine at WCPM The plant has installed one of the most efficient and advanced paper machines supplied by M/s. Voith during its expansion. The machine is capable of producing 1, 50,000 TPA of high quality writing & printing paper and copier paper. The paper can be produced in the basis weight range of 45 – 90 GSM of sized and unsized paper with 5,300 mm deckle. The machine has a high designed speed of 1200 m/min and an operating speed of 1000 m/min.

Paper Machine No. 6 Headbox: The machine is provided with Masterjet Headbox with Dilution Control system for uniform basis weight profile, Good fiber dispersion, Uniform CD profile and fiber orientation resulting in excellent sheet formation, improved strength and dimensional stability. Wire part: The DuoFormer at the wire section gives the advantage of excellent formation, Uniform drainage while Top former improves formation and Surface smoothness. Two-sidedness is also reduced. Press part: The machine is provided with Tandem NipcoFlex Shoe Press which resulted in higher bulk, higher dryness of sheet and uniform sheet structure. Drying section: The machine’s drier section is provided with closed hood and Pocket ventilation system to improve the steam drying performance. Size Press: The machine is also provided with SpeedFlow Film Size Press which is a Pre-requisite for high speed machine to provide uniform starch application on both sides of the paper, better printing properties, higher tensile strengths and less sheet breaks. Calendering: The Machine is also provided with Soft Nip Calender and Pope Wheel. The primary purpose of soft nip calender is to control uniformity, smoothness, bulk and finish of the paper by controlling: ƒƒ Nip pressure ƒƒ Roll surface temperature ƒƒ Profiling ƒƒ Minimum two sidedness The pope wheel is Jumbo roll of 28 tonnes which results in jointless paper reels and Cobra auto reel change.

178 Best Practices Manual - Pulp & Paper Industry The new paper machine (PM6) has Power consumption of 460 – 480 kWh/ tonne, with Steam consumption of 1.9 tonne/tonne (of paper) and water consumption 15-18 m3/tonne of paper.

Parameter Value WBL 11 m3/ton of pulp with 16 – 17% solids concentration at 85oC and 180 gpl Yield 46.6 – 46.7 % unbleached yield and 43 – 43.2 % bleached yield

Washing loss 20 – 22 kg/ton as Na2SO4 Pulp viscosity 7.5 – 8 cp Kappa 17 – 18 at cooking; 15 – 16 before ODL; 8 – 8.5 after ODL Blow tank Cy 5 – 6 % Steam consumption MP (7 bar) steam at Digestors: 0.7 T/T pulp LP (3 bar) steam at Digestors: 0.2 – 0.25 T/T Bleaching: 0.5 T/T pulp Power consumption 420 kWhr/ton of pulp (including ClO2 plant and chipper house) 225 kWhr/ton (Only ODL and fibreline)

179 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 8 Online kappa monitoring and control at multiple locations Chemical pulping is a harsh process for cellulose fiber. The pulp maker’s challenge is to run the fiber linecost effectively, preserving the virgin fiber quality properties for papermaking; the process management without online analyzers and controls is quite difficult. Laboratory analysis of Kappa has a disadvantage that it is based on chemical volumetric titration and gives only a relative measure of lignin content. In comparision online kappa monitoring is based on UV absorption and also can be used to measure absolute brightness. Online monitoring is more accurate compared manual laboratory analysis. Also in comparison to earlier manual control based on lab measurement techniques auto control based on online analyzers provided more accurate chemical dosing based on kappa of feed resulting in chemical savings as well as achieving consistent brightness, viscosity and strength in pulp.

Comparison of Manual Control Based on Lab Measurements and Auto Control based on Online Analyzers KAJAANI Kappa Q analyzer The new Metso Kappa Analyzer (Metso Kappa Q) launches several new features and measurements to improve the total pulp mill quality management. Metso Kappa Q is a new online analyzer for chemical pulp mills utilizing the newest Metso analyzer platform technologies and measurement capabilities. Metso Kappa Q measures pulp lignin content and brightness faster than ever before. The measurement capacity of Metso Kappa Q is easily expanded by adding measurement modules and sampling points. Furthermore, Metso Kappa Q introduces a new measurement capability - online fiber and shive analysis from cooking up to the finished pulp!

KAJAANI Kappa Q analyzer installed at WCPM At WCPM, KAJAANI Kappa Q analayzer was installed to ƒƒ Control alkali to wood ratio ƒƒ Remove 95% lignin ƒƒ Stabilize blowline kappa ƒƒ Achieve quality targets like final brightness and dirt count

ƒƒ O2 stage control ¾¾ Calculate needed kappa reduction ¾¾ Tune alkali dosage by multiplying kappa reduction by a kappa factor to maintain stable alkalinity when

pre O2 kappa is changing

¾¾ Check operator bias based on post O2 kappa

180 Best Practices Manual - Pulp & Paper Industry ¾¾ Tune O2 dosage by multiplying alkali dosage by oxygen to alkali ratio

¾¾ Decrease O2 to alkali ratio if there is foaming problem or pH is low post O2 The salient features of KAJAANI Kappa Q analyzer installed at WCPM are; ƒƒ Unique new capability: fiber properties and shive measurement online from cooking up to finished pulp ƒƒ Three sampling points with one analyzer to save cost. (models available upto six points) ƒƒ The proven Kappa and brightness measurements online ƒƒ Measurement capacity alternatives: 10, 20, 30 or 40 per hour ƒƒ Compact size ƒƒ Cost effective sampling arrangement ƒƒ New interfacing for high availability

KAJAANI Kappa Q Analyzer Layout

Kappa Factor control at Oxygen delignification stage The benefits achieved by WCPM for installing online kappa analyzer are as follows.

181 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 1. Chemical consumption reduction of 8% in ClO2 and 8% in H2O2.

a. 3 -4 kg/ton of ClO2 as active chlorine

b. 1.5 kg/ton of H2O2 c. 2 kg/ton of caustic 2. Reduction in cost of production of bleached pulp ~ Rs. 120 – 130 /Ton

Chemical consumption prior to Kappa analyzer control April’11-Aug’11

Chemical consumption after Kappa analyzer control Sept’11-March’12

Chemical savings

Note: ClO2 consumption is expressed as ClO2. Hence savings as active Cl2 ~ 4.0 - 4.4 Kg/Ton Bleached pulp WCPM operational experience of Kappa Analyzer: ƒƒ After putting Kappa control into operation the monitoring and control of chemical was much easier ƒƒ Brightness control at each stage was better than earlier ƒƒ Reduction in chemical has also resulted in improvement of pulp strength

Data on Performance

182 Best Practices Manual - Pulp & Paper Industry 183 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 9 Installation of tandem shoe press resulting in high dryness of 50-53% and retaining of bulk (increased filler addition from 12% to 18%)

Making paper or board Making paper or board1 involves three clusters of activities; furnish preparation, the paper machine and finishing operations. In the preparation of furnish, pulped wood and/or waste paper is processed and mixed with water, some chemicals and other additives. This mixture is called furnish. The percentage of dry solids in the furnish, also called the dryness of the paper sheet, is about 1%. Then, the furnish is fed into the paper or board machine. Water is removed in three sections; dryness increases as the paper sheet moves along the paper machine: ƒƒ Forming section: forming the paper sheet while draining and suctioning (1% to 20% dryness at couch) ƒƒ Pressing section: mechanical dewatering by passing the paper sheet through a number of press nips (20% to 45% dryness) ƒƒ Drying section: evaporative drying of paper sheet (45% to 90-95% dryness) Finally, finishing operations as e.g. calendaring, winding and cutting are needed to deliver the final product. The paper machine’s drying section requires the largest amount of energy per kilogram water removed. Improvements in the specific energy consumption of a ton of paper are therefore typically directed at reducing the energy requirement of the drying section. This can be achieved by improving drying technologies. A second route is to increase the amount of water removed in the pressing section. Shoe press technology does exactly that. Shoe press technology is a paper-making technology that improves dewatering of the board or paper sheet in the wet pressing section and, therefore, reduces the need for evaporating drying. Shoe press technology is an exemplary technology of the second category; it improves the dewatering capacity of the conventional pressing section by extending the time that the paper sheet remains in the press nip. This time is also called the nip residence time. The amount of water removed in the pressing section is proportional to the magnitude and the duration of the pressure applied to the paper sheet. The product of pressure and nip residence time is called the ‘press impulse’. In conventional roll presses both the pressure applied and the nip residence time were constrained. Pressure could not be increased unlimited, because the paper sheet would be damaged (especially at higher machine speeds). Nip residence time decreased with increasing machine speeds. The constrained press impulse of conventional roll presses was overcome by shoe press technology. Typical design difference of a roll press and shoe press Design parameters Roll press Shoe press Length of press or nip width (cm) 4 – 7 25 – 30 Linear load (kN/m) 150 – 450 1,000 – 1,500 Press impulse (kN*s/m2) 3.0 – 5.0 15 – 21 The major advantage of the shoe press is the higher dryness achieved at the exit of the pressing section. Depending on the grade produced, the increase is about 5 to 10% compared to conventional pressing. This results in a better runnability. The higher dryness leads to an increased production capacity (about 10 to 20%), when a shoe press is put on an existing (dryer limited) paper or board machine. When a shoe press is implemented on a new paper machine, the drying section can be shortened thus reducing capital expenditure. A second advantage is the reduced demand for steam in the drying section. This may lead to an improvement

184 Best Practices Manual - Pulp & Paper Industry in energy efficiency in spite of the increased electricity consumption. Additional driving capacity and increased pumping capacity for cleaning the felts are needed. If increased electricity consumption is not taken into account, a shoe press may save 0.5 GJ to 2.0 GJ per ton paper (0.2 – 0.8 Tons of steam /ton of paper). Savings in energy costs are of the order of Rs. 50 to Rs. 250 per ton paper. Energy cost savings make up 60 to 80% of the payback generated if the machine’s speed is not increased. If a paper machine’s production speed is increased, energy cost savings make up 10 to 20% of the payback per ton paper. A third advantage is improved product characteristics. The pressing section is important for paper properties because most physical and surface characteristics are in some way related to the density of the sheet. Pressing causes densification. The effect of a shoe press on paper properties differs among the grades produced. Installing a shoe press on a board machine induces a favorable increase in strength properties. This permits savings in refining, the use of fewer strength additives, and the application of cheaper furnishes and /or increase in filler quantity in paper. The installation of a shoe press on a paper machine leads to a higher dryness without reducing the thickness of the sheet. This results in cost saving by reducing the amount of fibre needed. With the Tandem shoe press installed in the new paper machine PM 6, the plant team is able to achieve an after press dryness of 50 – 53% (depending on the grade). This also led to the retainment of bulk which thereby lead to the increase in filler addition from 12% to 18%. NEW PAPER MACHINE : Steam - Specific steam consumption = 1.9Ton/ Ton of Paper Power - Specific power consumption = 478kWh /Ton of Paper

185 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 10 Stricter monitoring of paper properties by tighter control of parameters through Autoline 400 and the TSO module in it measures the fiber orientation The L&W AutoLine 400 Profiler overcomes the challenge faced by mills around the world to measure the immense information stream of a paper machine in an efficient and profitable way. It is designed to test paper in accordance with industry standards, regardless of the manufactured grade. Samples are cut directly from the reel in a uniform manner using the L&W Profile Sample Cutter. The sample’s identity controls the preset test sequence and report format. Once the operator has confirmed the sample’s identity, the sample is fed into the system and test results from each testing module are speedily available in real time. The L&W AutoLine 400’s speed of testing (a complete CD-profile with 20 measuring points from an 8 meter wide web takes approximately 8 minutes) combined with its transfer functions will enable the mill to integrate the quality measurements directly into the mill network systems and thus optimise performance. The return on investment for the AutoLine 400 is estimated at 1 to 2 years, with its modular design ensuring low expenses for consumables, spare parts and maintenance. L&W Autoline 400 is claimed to be the fastest and most accurate automatic system for paper testing on the market. According to L & W, more than 50 properties can be measured and calculated within a few minutes. Short feedback time is a very important part of the process control. Everything from newsprint to heavy linerboard and cardboard can be measured by L&W Autoline 400.

Benefits ƒƒ Measures and calculates more than 50 different properties, most of them according to international standards ƒƒ Warning alert if the measurement results are outside specified targets and limits ƒƒ Fast – about 8 minutes to measure a profile at 20 positions ƒƒ Results are easily accessible via the mill’s local area network ƒƒ Several pre-programmed testing sequences available ƒƒ Remote viewing station provides real time data

Reduced testing variation is the key Reducing measurement uncertainty or test variability is at the heart of what L&W Autoline 400 provides the modern paper mill. In today's competitive market place, costs have been cut to the bone. The largest potential for cost savings now comes from incremental changes in the paper making process. To achieve these cost savings an accurate measurement of the process is required. It has long been recognized that the traditional system of manually gathering and testing paper samples can produce unacceptable levels of measurement uncertainty. L&W Autoline users report significant reductions in test variation. This reliability improvement, combined with quick access to test results, allow the paper maker to shift production targets, and achieve more consistent performance. This is where the potential for savings can be found. WCPM, by installing Autoline 400, has been able to greatly reduce or even eliminate traditional sources of variation in paper testing, such as: ƒƒ Operator and instrument variation. Unlike using individual bench top instruments for testing, an automated paper testing system requires no operator involvement and no specialized skills. Thus, differences in lab results related to tester changes or different operating techniques can be completely avoided. With the automated paper testing system, the operator simply inserts the sample and is done. The sample strip is

186 Best Practices Manual - Pulp & Paper Industry automatically fed through the device and tested accordingly. ƒƒ Sample Preparation. Sample preparation is one of the most important and often overlooked areas of testing variation. Manually cutting samples from a jumbo reel is difficult to duplicate from reel to reel, much less from operator to operator. Improperly cut samples from the reel can affect how the individual test pieces are prepared as well as the orientation of the sample in the test instrument. When using a Profile Sample Cutter, samples are collected the same way every time, ensuring consistency and less variability. ƒƒ Testing in the true MD and CD direction. Manually cutting samples from the reel and again cutting the individual test pieces presents another opportunity for variation. If samples are not cut straight, one cannot test in the true MD and CD direction every time. Not testing in the true MD and CD direction will introduce variations as well as lowering test results. With the Profile Sample Cutter, the samples are cut in the true CD direction. Precise feeding of the sample ensures that the automated paper testing system will test in the true MD and CD direction every time. ƒƒ Same Position Testing. Not testing in the same position on the reel every time could simply be showing position variations, rather than an actual quality problem. Contrarily, this fault could also be hiding existing or developing problems. L&W Autoline 400 utilizes a precise feeding mechanism, to ensure it will measure in exactly the same position every time. This also facilitates long-term comparisons of a particular cross machine position in order to analyse MD variations. ƒƒ Increasing the number of data points. Increasing the number of positions tested makes the average of those measurements statistically more reliable. With automated paper testing systems testing volume is dramatically increased compared to manual testing. It is possible to test every property, every reel, every time. Other users of Autoline typically test 20 positions across the complete reel width.

Financial benefits By allowing for tighter controls, optimizing testing procedures and lowering overall costs, L&W Autolines actually make money for their owners. Users of these systems have been able to benefit by optimizing process operating conditions, lowering customer complaints and retaining or expanding market share. The speed, accuracy, and frequency of measurements allow the papermaker to make short-term process improvements and long-term process changes in order to reduce variability and produce a consistent, high quality product. This type of automation also represents a fundamental change, or paradigm shift, in attitudes both towards the work place and the role of employees. Highly skilled personnel no longer need to carry out repetitious and routine functions. This type of work can now be performed more cost effectively by machines, leaving technicians more time to concentrate on process and quality improvement, rather than measurement and data collection. It has been observed that by increasing the reliability of the testing it is possible to shift the target and therefore there is a huge potential to save money. Other possible benefits have been listed below: Increased productivity results ƒƒ Speed increase on dryer-limited grades ƒƒ Weight decrease (when sold by area or strength) ƒƒ Less downgraded product Reduced grade change losses ƒƒ Reduced start up time ƒƒ Reduced breaks

Improved quality ƒƒ Improved market share ƒƒ Reduced customer complaints

187 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre ƒƒ Preservation of existing market share ƒƒ Reduced machine direction variability ƒƒ Reduced cross-direction variability

Reduced costs ƒƒ Reduced steam costs per ton ƒƒ Reduced fibre usage ƒƒ Total weight increase (when sold by weight) ƒƒ Substitution of recycle for virgin fibre ƒƒ Substitution of fillers for fibre ƒƒ Decreased chemical additive costs ƒƒ Reduced refining ƒƒ Reduced freight costs ƒƒ Manpower optimization

Quick analysis: From start to result in less than 10 minutes

Cut the sample As it is important that the test samples are always precisely cut in a uniform manner, the use of L&W Profile Sample Cutter (code 148) is highly recommended. The sample cutter cuts samples directly from the reel and is easily handled by one operator. It also ensures that the paper samples are cut straight and perpendicular to the machine direction. Furthermore, the sample strip is rolled up onto the cutter to prevent creases. The sample is cut to the correct width, approximately 300 mm (about 12 in), to fit the feeding system of L&W Autoline 400 Profiler.

Identify the sample There are two ways to register a paper sample with L&W Autoline 400: ƒƒ Operator registration: The operator registers production information for test strips in L&W Autoline. ƒƒ Automatic registration: L&W Autoline 400 carries out registration automatically, based on data from the process computer. The operator needs only to confirm the proposed test identity and feed the sample into L&W Autoline 400. A bar code enables the test strip to be recognized directly by L&W Autoline 400's computer. For automatic registration, with or without bar code, L&W Autoline's measuring program must be connected to the mill's computer network. Start the test The sample's identity controls the pre-set test sequence and the report format. Once the operator confirms the paper sample's identity the sample is simply fed into the system. L&W Autoline 400 software is based on Windows operating system, which makes it easy to set up test sequences and other settings.

Different testing modes The operator can choose between different pre-set testing sequences. It is the testing sequence that controls which properties will be measured, the frequency and the step length between each measuring point. It also controls which type of report is printed out and/or if the data should be transferred to the mill-system. There are two different measurement options to choose from:

188 Best Practices Manual - Pulp & Paper Industry ƒƒ Position measurement – all measurements are performed in exactly the same positions. This mode is recommended when the highest possible repeatability between different measurements is required. ƒƒ Speed measurements – all measurements are carried out simultaneously, as long as there is paper under the module. This mode ensures fast feedback time of the results. L&W Autoline 400 can be configured with measurement modules that are independently selected and combined for the desired measurements. Available modules include Lorentzen & Wettre's unique formation measurement as well as dynamic absorption and wettability. The majority of modules measure according to current industry standards. The most recent innovations include L&W Autoline Compressive Strength STFI Module, L&W Autoline Stylus Roughness Module, L&W Autoline Surface Formation and L&W Autoline Smoothness Oken.

Report formats Three different types of reports can be generated: ƒƒ Reel Report – A statistical summary of the sample with mean or median value, standard deviation or coefficient of variation. The report also contains set target values and limits. ƒƒ Profile Report – A cross profile of a property. This can either be a continuous curve, including the exact testing points highlighted, or a Roll Position profile with calculation of mean/median value per roll position. ƒƒ Values Report – All data points measured in one report. This is the main report that is sent to the mill computer system.

Pre-set target and limit values All reports can also include targets and limits. If the values are outside the limits, different colours highlight the event. A complete profile report in 8 minutes The test results are ready in 5–10 minutes, depending on the test method, the number of properties tested and the length of the sample. For example, an optimized testing program of an 8 metre wide web, in 20 positions, takes approximately 8 minutes. As soon as measuring is completed the results are displayed directly on the screen as cross-direction profile graphs or in table form. Data from each reel of paper measured can be documented just as easily. The results are used to verify paper quality and optimize the process. The fast feedback to production enables the machine operator to correct any faults in the paper machine during operation, thereby preventing the next reel from also being outside specifications. Machine operators can follow the testing results and take action to optimize the production.

189 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 11 Installation of Clari Disc Filter for Lime Mud with low chemical losses. CD Filter also installed for White liquor Lime mud moisture maintained at less than 25% with stable operation of lime kiln and purity unaffected ( > 85 %)

ClariDisc® Filter The Lime Mud ClariDisc® uses the center barrel and sectors of the White Liquor ClariDisc® Filter but applies vacuum just like the drum filter. The disc design allows a much greater filtration area in a smaller footprint with a lighter floor load per unit area. Agitation is acheived by eductor, which allows lower vat solids that a mechanical agitator can safely support. The lower solids, either by feed dilution or filtrate recirculation, improve the soda recovery and discharge solids. Hard alloy scraper blades are used and the disc-type HiPAC® is standard. Other information on the features of the Clari Disc Filter for Lime Mud; chemical losses associated with lime mud. ƒƒ Sludge dryness in Lime Mud Clari Disc is 25 + or –> 5 % due to low silica in sludge. ƒƒ Purity of lime is around 82-85% and oil consumption per ton of lime is reduced considerably due to above reason.

Benefits for CD filter installed for white liquor 1. The sodium content in the sludge is less due to White Liquor CD filter being used in Causticiser for WL filtration. 2. Dryness of sludge in White liquor CD filter is high due to low silica % in sludge 3. White Liquor CD filter performance is good as compared to conventional Clarifier w.r.t clarity. 4. White Liquor conversion from Green Liquor is 90-95%. Hence soda loss is less resulting in lime mud CD filter to get good dry ness of filter cake. 5. The unit of CD filter is compact and requires very less space for installation 6. The entire operating system of White Liquor CD filter is fully automatic. 7. The clear and high quality White Liquor supply to PM gives lot of benefits like reduction of scale formation and gives good quality of pulp.

190 Best Practices Manual - Pulp & Paper Industry Best Practice 13 Energy Management In Air Handling Dryer –Hood Section Of Paper Machine

Process Background Cold Air from ambient (30 to 35°C) is being preheated in air to air heat exchanger , wherein the incoming air is heated by hot humid air leaving the hood of the paper machine dryer. The warm fresh air is further heated using LP steam & flash condensate to 95°C . The hot air is led to the dryer section using forced draught blower for removing the vapour from PV sections. As it is a closed hood, there is very little chance of the hot humid air leaking out. The warm humid air at around 75 to 80°C is drawn by blower to the heat exchanger. Heat is supplemented in the air to air heater by turbo-air exhaust (at 130°C temperature). After transferring the otherwise wasted heat is led to second heater in series wherein heat is further tapped for preheating ambient water. The cooled air is led through the exhaust duct to the atmosphere.

Benefits LP steam consumption reduction through maximization of heat recovery from all sources possible. Uniqueness Apart from the conventional waste heat recovery from the hood discharge hot humid air through air to air heat exchanger, the following schemes are additional- LP steam consumption reduction through ƒƒ Hood entry air temperature optimized at 95 °C ( < 100 °C). ƒƒ Utilization of heat in turbo-air for preheating fresh air ƒƒ Low temperature heat recovery from exhaust humid air for hot water generation for process use.

Savings LP steam consumption had reduced by approximately say 0.2 T/Tof product.

Issue Condensation of humid air (50 °C) in the water heat exchanger need to be checked for fouling.

Replication The above schemes can straight away be implemented in all other paper mills in their hood-air handling dryer section

191 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 192 Best Practices Manual - Pulp & Paper Industry JK PAPER MILLS, Rayagada

Best Practices 1. Reduction In Furnace Oil Consumption In Lime Kiln By Using Coal Tar With Fo 2. Increase In Recovery Efficiency By Using Po Back Water In Dp-2

193 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 194 Best Practices Manual - Pulp & Paper Industry About JK Paper Ltd JK Paper Limited is a flagship company of J.K.Organization. It has entered into paper manufacturing since 1938. Currently it is India’s largest producer of branded papers and a leading player in the Fine Papers and Packaging Board segments. It operates two integrated Pulp and Paper Mills in India, JK Paper Mills in Rayagada, Orissa, in eastern India which manufactures coated, uncoated and market pulp and Central Pulp Mills in Songadh, Gujarat, in western India manufacturing fine papers and packaging boards. JK Paper Ltd. has a combined manufacturing capacity of 2,90,000 tonnes per year, using contemporary technology. The company has taken up a large expansion program which would result in capacity of 4,24,000 tonnes per annum or over 46% higher capacity than the current levels. The products include a wide range of Coated and Uncoated Printing & Writing Papers and Packaging Boards. Both the manufacturing units of the company are ISO 9001-2000,ISO-14001 and OSHAS complying. Additionally TPM is also in advance stage of implementation. The company has received “ TPM Excellence as well as Consistency Award ‘’ and now proposing itself to challenge TPM Special Award. JK Paper Mills pioneering initiatives in the Indian paper industry started as far as the mid 60’s. It was the first company to manufacture surface sized printing & writing paper, followed by copier paper. The Company’s state-of-the-art Packaging Board plant at Central Pulp Mills produces international quality virgin boards like FBB, SBS and Cup Stock, in the brand names of “JK Tuffcote”, “JK Ultima” and “JK PureFil”, Nearly 95% of the Company’s product mix comprises high value products, marketed under various popular brand names such as, ‘JK Copier’, ‘JK Bond’, ‘Cedar’, ‘JK Excel Bond,’ ‘JK Cote,’ ‘JK Tuffcote’, ‘JK PureFil’ and ‘JK Pristine Cote’. JK Paper passionately believes in Environment and Safety and has been introducing cleaner and environment-friendly technologies. JK Paper Mill has been adjudged as the Greenest Paper Mills in India. Both the units of the Company are ISO 14001 certified for their eco-friendly operations and OHSAS-180001 Certified for Health, Safety and Security. The Company’s plantation, driven by in-house research programme, has coverage of more than 70,000 hectares with 7,000 hectares of plantation being added every year. By providing farmers high quality plant species through the Company’s plantations research centre, it helps farmers to improve their economic well being. A large number of farmers in the state of Orissa, Andhra Pradesh, Chhattisgarh, West Bengal, Gujarat and Maharashtra are benefiting form the programme. Theses plantations with their superior quality plants contribute towards a strong base for high quality raw materials for the Company. JK Paper is the first integrated Pulp and Paper Company in India conferred with TPM Excellence Award by Japan Institute of Plant Maintenance, apart from various accolades received over the years. The Company has an export footprint for high value branded products and Packaging Boards in the middle East, South East Asia, SAARC and various African countries.

195 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre About J.K.Paper Mills, Rayagada JK Paper Mills, a unit of JK Paper Ltd., is a premier integrated pulp and paper mill located at Jaykaypur, Dist. Rayagada, Orissa. Since its inception, JK paper mills has strived for excellence and consistently set high standards in quality, productivity, conservation of energy and water, industrial safety as well as pollution control and environment protection which are indicated by achievements like : ƒƒ Manufacture of surface sized Maplitho for the first time in the country with indigenous raw material ƒƒ Capacity utilization of 120% ƒƒ First paper mill in India to get ISO 9001 and ISO 14001. ƒƒ Adjudged first greenest paper mill in India in 1999. ƒƒ Most modern and largest paper mill in the country. JKPM was commissioned in the year 1962 with an integrated pulp and paper plant with 18000 TPA installed capacity for manufacturing high quality writing and printing papers. Over the years, the production capacity has been enhanced to a level of 127,000 TPA with the addition of 4 more paper machines manufacturing diversified product range from 29 GSM to 300 GSM of different grades of paper. In 2005, an offline coating machine has also been set up to manufacture premium grades of coated papers. The secret of success of the mill is attributed to its policy for sustained efforts for quality, new product development and offering continuous value addition to customers.

196 Best Practices Manual - Pulp & Paper Industry Best practice 1 Reduction In Furnace Oil Consumption In Lime Kiln By Using Coal Tar With Furnace Oil Furnace oil (FO) is one of the major consumables in the lime kiln. With ever increasing price of FO, which directly results in increasing production costs, it is becoming necessary for plants to look into alternatives. One of the coast effective alternatives available to reduce the cost of operation of lime kiln is substitution of FO with coal tar, produced as a by product of producer gas production. Coal tar has similar calorific value as furnace oil but has high viscosity compared to FO which makes it difficult to be used with FO. JKPM has 3 producer gas production units. Producer gas along with FO is used for lime kiln for converting lime sludge to lime. Coal tar is produced as a by product of producer gas production from coal using air & steam. Coal tar was earlier sold outside. Now the plant has taken a noval step to utilize coal tar and reduce furnace oil consumption to an extent of 20%. The plant was able to successfully reduce the viscosity of coal tar by maintaining high temperature & by adding some additives thus making it suitable to be used with FO. This is done as follows; coal tar from day tar tank is sent to tar mixing tank where it is mixed with FO and Thermopol (additive) at 70oC using steam. The ratio of FO, coal tar and additive is 4:1:0.005. This is then pumped to FO dry tank where it is further heated to reduce the viscosity. This filtered and the pump to lime kiln for firing. This procedure has reduced the consumption of FO by as much as 20% FO or Rs. 139.29 lacs/annum savings in lime kiln fuel costs.

Producer Gas & Coaltar Generation

Process Flow diagram of Producer gas, Coal tar and FO

197 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Cost benefits analysis:

198 Best Practices Manual - Pulp & Paper Industry Saving

199 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best practice No. 2 Increase In Recovery Efficiency By Using Po Back Water In Dp-2 In Pulp Mill, from Discharge tank the cooked pulp is taken to Disc Knotter where knots chips are removed. The accepted pulp from Disc Knotter is taken to Brown stock washer (BSW-1 & BSW-2) for washing purpose after processing on both the washer, the washed pulp is subjected to three stage screening through primary (D8), secondary (D4) and tertiary (D2) . The accept from the primary Delta screen is sent to the Displacement Press No.1 (DP-1) where consistency of pulp increases by removal of water & fed into ODL with Oxidized white liquor & Oxygen. Oxygen delignification is carried out to control bleach chemicals requirement in further stage and to reduce pollution load. This oxidized and delignified pulp is pumped to DP 2 where hot water is used for washer spray and pulp is squeezed to increase the consistency about 30-35%. Through dilution screw conveyor pulp is sent to unbleached tower by adding reclaimed water for dilution. After oxygen delignification pulp from unbleached pulp tower sent to post oxygen washer for washing before pulp bleaching. The plant is following the counter current washing from BSW-1 to DP-2. At DP-2 we add hot water in wash spray & warm water in Screw dilution. In PO washer the plant uses machine back water & filtrate of this washer was being drained. That was contributing around 300 kg/hr COD load & major color component to the effluent plant. As Filtrate of PO washer was being drained causing Alkali loss of 180 kg/hr, contribution of COD load on ETP of around 300 Kg/hr. The plant is using this water partially in chips washing plant & from there it was going to ET plant. After carrying out lab trials the plant started to take PO back water in DP-2 wash spray after providing a steam heating & in DP-2 screw dilution.

Block Diagram of Washing

200 Best Practices Manual - Pulp & Paper Industry Before Implementation

After Implementation

201 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Tangible & intangible benefits

202 Best Practices Manual - Pulp & Paper Industry Tamil Nadu Newsprint & Papers Ltd.

Best Practices 1. LP Steam savings Chemical Bagasse Pulping Line -3 2. LP Steam Savings in Hard Wood Fiber Line 3. Power Savings in Pulp Mill by replacing one 650 kW HT Motors with two 150 LT Motors: 4. Power savings by down sizing of Pump Impellers in Pulp Mill 6. Reduce Furnace oil consumption by 5 liters per Ton of Burnt Lime produced in Soda Recovery Section 6. Reduction in LP steam consumption by using segregated process condensate from Evaporator I and II in Soda Recovery Section 7. Other Best Practices incorporated at TNPL

203 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 204 Best Practices Manual - Pulp & Paper Industry About Tamil Nadu Newsprint & Papers Ltd: Tamil Nadu Newsprint and Papers Limited (TNPL) was established by the Government of Tami Nadu during early eighties to produce Newsprint and Printing & Writing Paper using bagasse, a sugarcane residue, as primary raw material. The Company commenced production in the year 1984 with a initial capacity of 90,000 tonnes per annum (TPDA). Over the years, the production capacity has been increased to 2,45,000 TPDA and the Company has emerged as the largest bagasse based Paper Mill in the world consuming about one million tonnes of bagasse every year. The Company completed a Mill Expansion Plan during December 2010 to increase the mill capacity to 4,00,000 TPDA

TNPL exports about 1/5th of its production to more than 30 countries. Manufacturing of quality paper for the past two and half decades from bagasse is an index of the company’s technological competence. A strong record in adopting minimum impact best process technology, responsible waste management, reduced pollution load and commitment to the corporate social responsibility make the company one of the most environmentally compliant paper mills in the world.

Technology TNPL is an acknowledged leader in the technology of manufacture of paper from bagasse – the sugar cane residue. Started with an initial capacity of 90,000 tonnes per annum (TPDA) on a single Paper Machine., the Mill doubled the capacity to 180,000 tonnes per annum in the year 1995 by addition of one more Paper Machine. Under the Mill Development Plan (MDP) completed during May 2008, the pulp production capacity has been increased from 520 TPDd to 720 TPDd. The pulp being produced by TNPL, in post-MDP is Elemental Chlorine Free (ECF). Along with this, the upgrade of the Paper Machines has resulted in reaching the paper production capacity to 2,45,000 TPDA. TNPL has completed the Mill Expansion Plan (MEP) in December 2010 to raise the mill capacity to 400,000 TPDA.

Mill Expansion Plan (MEP): The implementation of Mill Expansion Plan (MEP) was completed and commercial production started on 25th January 2011. The state-of-the-art Paper Machine 3 (PM-3) supplied by Voith Paper, Germany has a capacity to produce 155,000 TPDA of Printing and Writing paper. The PM3 has a deckle width of 5.45 m and operating speed of 1100 m/m. As part of Mill Expansion Plan, Backward integration of Chemical Bagasse pulping line has been implemented to have better pulp quality with reduction in water and bleach chemical consumption. The chemical bagasse pulp line is capable of producing 500 TPD of pulp and is the world’s largest single line for bagasse. OTHER KEY PROJECTS UNDER IMPLEMENTATION: Revamping of Steam and Power system: The Company has proposed to replace the 3 old low pressure Boilers of 60 TPH each installed during 1984 with a new energy efficient and environmental friendly Circulation Fluidised Bed Combustion (CFBC) Boiler of 125 TPH steam generation capacity of 105 ata pressure rating. In addition, the Company has proposed to replace the two old Turbo Generator sets witha new TG set of 41 MW capacity to augment the in-house power generation for meeting the

205 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre additional power requirement. The total capital outlay is Rs 135 crore. The order for main plant and machinery has been placed and civil works are in progress. The project is targeted to be completed by June 2012.

De-inking Plant: To meet the additional pulp requirement in the post- MEP, the Company has initiated steps to install a state- of-the- art Deinking plant of capacity 300 TPD, at an estimated capital outlay of Rs.174 Crore. The order for main plant and machinery has been placed. The project is targeted to be completed during second quarter of 2012.

On-site Precipitated Calcium Carbonate (PCC) plant Following the switching over to alkaline sizing in the Stock preparation, h the paper machines started using Precipitated Calcium Carbonate (PCC) as the wet end filler. In view of the huge requirement of PCC ,the Company has proposed to install an on-site PCC plant of 60,000 TPA capacity on Built, Own and Operate (BOO) basis in the Mill premises. The plant will be established by OMYA International AG, Switzerland at a capital outlay of Rs.30 crore. The project is under Environmental clearance and expected to be commissioned during next financial year.

On-site Wet Ground Calcium Carbonate (WGCC) plant While the company continues to use PCC, trials were conducted for increasing the ash content in the pape. Towards this, a combination of GCC and PCC was tried out, to improve the surface properties of paper in an economical way. As the results are found encouraging the company has been using GCC, which is currently being purchased in powder form. Considering the huge quantity of GCC requirement the company has initiated action for establishing an on-site GCC plant, in the same lines of PCC plant.

Lime Sludge & Fly Ash Management (600 TPD Cement Plant) The lime sludge generation from the Recovery Cycle and the Fly Ash generated from the power boilers are issues of concern in solid waste management of the mill. An innovative solution of combining these two wastes and converting them into high grade cement has been drawn through installation of a 600 TPD cement manufacturing plant abutting the Mill premises. Environmental Clearance and the Consent to Establish were received from Department of MOEF / GoT and theTamil Nadu Pollution Control Board. This project is undertaken at a capital outlay of Rs.68 crores. The civil works commenced during September 2010. This project is expected to be commissioned during first quarter of 2012.

206 Best Practices Manual - Pulp & Paper Industry Best Practice 1 LP Steam savings Chemical Bagasse Pulping Line -3 Recovery of heat from Weak Black Liquor before sending to Digester Discharger dilution and utilizing the heat for hot water generation for use at Bagasse ECF Bleach Plant. A set of 5 Heat Exchangers are installed in series and bring down the temperature of Weak Black Liquor (WBL) from 95°C to 50 – 55°C using shell and tube heat exchangers. The WBL is used for Chemical Bagasse 2 & 3 Digesters (totally 4 Digesters) Cold Blow system at their Dischargers before blowing the cooked pulp slurry into storage tank. Around 80 m3/hr water used for oil cooling in Twin Roll Presses (8 Nos.) of CB Washing & ECF Bleaching areas is reused along with 100 m3/hr fresh water to recover heat from the Heat Exchangers. The temperature raise in the water is from 35°C to 75°C. The hot water is used for Bagasse ECF Bleaching plant, where the required temperature is 80°C. Previously LP steam was used for hot water generation to the required temperature. Generally there is problem with clogging which normally occurs once in a month. Clogging is identified by drop in WBL outlet quantity and drop in Water outlet Temperature. Leak in Heat Exchanger tubes are identified by raise in conductivity through conductivity meter fixed in the water outlet. Cleaning and Tubes leak are attended, when changes observed in WBL Outlet quantity, Water outlet Temperature and conductivity. Tubes cleaning are done with high pressure spiral jet nozzle.

MOC of heat exchangers: 4 Heat Exchangers: Shell – MS & Pipe – SS. 1 Heat Exchanger – Shell and Tubes are SS.

Benefits: 1. LP Steam 250 TPD is saved, a cost saving of Rs. 630 Lakhs/annum 2. Flash Vapour release from storage tank through vent is controlled. 3. Odor in the environment is controlled.

207 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 2 LP Steam Savings in Hard Wood Fiber Line Recovery of Heat from existing Heat Exchangers by effective utilization of heat transfer area in optimizing the water outlet temperature in tune to the control of water inlet. Water from the following Heat Exchangers are used in Hot Water tank for Hot Water generation to use in HW ECF Bleach Plant. 1. LCHV Gas Heat Exchanger 2. HCLV Gas Heat Exchanger 3. Post Oxygen Washer Filtrate Heat Exchanger 4. Hot Black Liquor Heat Exchanger. Hot water Temperature at Hot water tank was at 75°C with the water received from all the above 4 Heat Exchangers. In order to increase hot water temperature to the required level of 80°C for HW ECF Bleaching Process, efforts are made to fine tune the utilization of heat transfer area of the Heat Exchangers by controlling the inlet water flow and optimizing the outlet temperature. After optimization, it is observed that Water inlet into Hot Water Tank got reduced to 100 m3/hr. from 136 m3/hr. This has increased the compound temperature of Hot water tank from 75°C from 80°C. Previously 1.10Tons of LP steam was used to raise the temperature to the required level. Now, use of LP steam is stopped. Tabulation shows Steam requirement to maintain 80°C at Hot Water Tank – Before & After fine tuning of Heat Exchangers utilization

Heat LP Steam required to maintain 80°C in Hot Water Tank Net LPS Exchanger Before fine tuning After fine tuning Savings Water Outlet LPS reqd. Water Outlet LPS reqd. – Tons/hr inlet m3/hr Temp °C Tons/hr inlet m3/hr Temp °C Tons/hr (S1-S2) (Q1) (T1) (S1) (Q2) (T2) (S2) 1 10 55 0.38 5 67 0.10 0.28 2 18 65 0.41 10 70 0.15 0.26 3 23 60 0.70 20 65 0.46 0.24 4 85 83 -0.39 65 87 -0.70 0.31 Total 136 --- 1.10 100 --- 0.01 1.09 Net LP Steam Savings in Tons / day 26.16 Net LP Steam Savings in Tons / annum (for 330 days) 8632.8 Savings - INR / annum 69 Lakhs

Benefits: 1. LP Steam 26 TPD is saved, a cost saving of Rs. 69 Lakhs/annum. 2. Around 136 Cu.M hot water was generated earlier. Now this quantity got reduced to 100 Cu. M/hr resulting in Fresh Water saving of 36 Cu.M/hr. 3. Effective utilization of Heat Exchangers is achieved.

208 Best Practices Manual - Pulp & Paper Industry Best Practice 3 Power Savings in Pulp Mill by replacing one 650 kW HT Motors with two 150 LT Motors In Back Water Clarification area one 650 kW HT motor pump was running for both CBP-2 and CBP-3 plants for making bagasse slurry and bagasse washing process. This pump had to run even only one of the plants is in running condition. Instead of this single pump, two pumps of 150 kW each are installed exclusively as one of CBP-2 and other for CBP-3. This has resulted in power savings of 140 kW. Energy Savings by replacing High capacity Water pumps in Black Water Clarification Plant

Particulars HT Motor- LT Motor 150 LT Motor 150 600kW (A) kW – 1 (B) kW – 2 (C) Design flow rate of pump 3400 Cu.M/hr. 1800 Cu.M/hr. 1800 Cu.M/hr. Design head of pump 55 Mtrs. 33 Mtrs. 33 Mtrs. Running Current 25 Amps 195 245 Power Factor 0.825 0.79 0.81 Voltage 11000 Volts 415 Volts 415 Volts Power Consumption 392 kW 110 kW 142 kW Power Savings: A – (B+C) = 392 – (110+142)) = 140 kW

Benefits: 140 Units/hrs. Power saved, amounting to Rs. 33.60 Lakhs/annum (Considering Running Hours as 8000 hrs./annum)

209 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 4 Power savings by down sizing of Pump Impellers in Pulp Mill In Chemical Bagasse Pulping Line – 3, Bagasse Reclaim chest pump and collection Tank pumps are with HT motor and were running with frequent ON/OFF as per the levels of the chests. The impeller of these pumps are trimmed suitably after which the pumps are run with less OFF position and longer run duration. Before and after trimming, the operating hours is same. Before trimming, excess bagasse after feeding to Digesters will return back to Bagasse Reclaim chest. Now the excess bagasse quantity returning to Bagasse Reclaim chest got reduced considerably for the same operating hours. Since energy meters are installed before and after trimming the resultant Total energy savings of around 175 kW.

Particulars Bagasse Reclaim chest pump Bagasse Collection Tank Pump Before trimming After trimming Before trimming After trimming Full Running Current 46 Amps 46 Amps 119 Amps 119 Amps Running Current 44 Amps 29 Amps 101 Amps 69.4 Amps Voltage 3300 Volts 3300 Volts 3300 Volts 3300 Volts Power Consumption 190 kW 140 kW 451 kW 326 kW

Benefits : Energy saved on account of Reclaim chest Pump : 190-140 = 50 Units Annual Savings (50units x R.Hrs 3696 x Rs.3/unit) : Rs. 55 Lakhs (approx) (considering R.Hrs 11hrs/day x 28 days x 12 months) Energy saved on account of Collection Tank Pump : 451-326 = 125 kW Annual Savings (125units x R.Hrs 7392 x Rs.3/unit) : Rs. 27 Lakhs (approx) (considering R.Hrs 22hrs/day x 28 days x 12 months)

210 Best Practices Manual - Pulp & Paper Industry Best Practice 5 Reduce Furnace oil consumption by 5 liters per Ton of Burnt Lime produced in Soda Recovery Section The high calcium carbonate and low silica lime stone is imported and used as makeup lime stone in Limekiln. The chemical properties viz calcium carbonate, silica, magnesium are control parameters in the specification of imported limestone. How ever physical properties, density and porosity, of lime stone received from different origins are varying. The lime stone having less porosity and high density is of hard burning nature and consume excess furnace oil. The Lime stone of different origin was tested in Geological department of Anna University, Chennai for physical properties. Based on the findings the porosity of lime stone is introduced as a control parameter in the specification of limestone. The density of lime stone at 0.57% porosity is 2.721 g/cm3.The density of lime stone at 4.79% porosity is 2.20g/cc.It is observed that the porosity of material increases as density decreases. The material is softer at high porosity. Heat penetration at softer material is higher than harder material. The temperature required for calcination is less for high porosity and less density. This resulted in reduction in oil consumption.

Analysis of Limestone: Moisture -3.97% Calcium as caco3 -97.39% Magnesium as MgCo3 -0.68% Sio2% -0.32% Stone size 10mm to 50mm -92.36% Porosity -4.79% Density -2.20 g/cm3

Testing method: Testing is done as per IS13030:1991 Indian standard method for Laboratory determination of water content, porosity, density and related properties of rock material.

Benefit: Saving of 5 liters of furnace oil per ton of burnt lime produced. Filtration in WLCD filter also increased.

211 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice 6 Reduction in LP steam consumption by using segregated process condensate from Evaporator I and II in Soda Recovery Section Around 350 m3 per hour of process condensate is generated from Evaporater 1 and 2 in soda recovery plant. Out of which around 100m3 per hour is used in soda recovery caustisizing plant for lime mud washing purpose and about 200 m3per hour was used for brown stock washing in pulp mill. By providing a system the process condensate is segregated in to Low BOD and High BOD condensate. The low BOD condensate is used in soda recovery plant for Lime mud washing purpose and high BOD condensate is used in pulp mill for brown stock washing. The balance high BOD condensate is cooled in cooling tower and sent to Biogas plant for biogas generation.

Characteristic properties of the water streams

Before segregation After Segregation Evaporator foul Low BOD condensate High BOD condensate Condensate Location of extraction Common foul condensate Foul condensate from 5th 7th effect and surface from evaporator I & II effect condenser Quantity& temperature 350 m3/hr at 55°c Quantityextracted100 m3/hr Balance250 m3/hr at55°c at 75°C Usage Lime mud washing BSW washing & Biomethanation 100 m3/hr for lime mud 100 m3/hr for lime mud 250 m3/hr washing (after heating to washing without heating 75oC) & 250 m3/hr for BSW

Benefits: Earlier combined process condensate at 550C is heated using LP steam to 75 0C and used for Lime mud washing. After implementation of scheme, Low BOD process Condensate at 750C from 5th effect is segregated and used for Lime mud washing. By this scheme LP steam used for heating the combined process condensate is stopped. Net saving of LP steam - 2 TPH Saving realized per annum - Rs 32 lakhs.

212 Best Practices Manual - Pulp & Paper Industry Best Practice 7 Other Best Practices incorporated at TNPL

1. Reduction in power consumption by providing VFD for WLCD filter WL Separator tank pump The pump is used to run with control valve throttled condition. By providing VFD the pump can be run as per requirement and energy can be saved. 55kW pump of WLCD filter WL separator tank is provided with VFD.

Benefit : Power Savings realized - 23kWh Annual Savings realized - Rs 3.67lakhs 2. LP Steam Savings in Paper Machine – 3 Paper Machine-3 is VOITH Machine. As per VOITH design, 4 Tons/hr. LP steam is used for Process Water and White Water heating. It is a part of standard package of VOITH because the heating of process water and white water is necessary at a Optimum Temperature (say 40oC) as the ambient climatic conditions are subject to variations. (40oC- 25oC). Hence it is necessary to heat the water (Process & White water). Normally this low temperature is rare in this tropical climatic conditions. If, such a low temperature occurs, fines in White water shall develop latency leading to clogging of Nozzles in showers. As per our operating conditions, since the ambient temperature is always above 25°C (unlike in European countries), the process and White Water does not require heating. Use of LP steam is stopped. The implementation of the project was started in April-2012 and the performance is under observation.

Benefits: LP Steam savings 4 Tons/hr, amounting to Rs. 3200 / hr. Reduction in Chemical usage: Sand filtered Water is used in Paper Machines 1 & 2 (as in PM-3) in place of clarified process water. Only Clarified Process water is being treated in Sand filter and supplied for PM#1, 2&3. The sand filtered water is having lower TSS (Total suspended solids) <100ppm. It improves the process by the way of reduction in chemical consumption.

Benefit: Consumption of AKD, OBA & Dyes got reduced.

213 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 214 Best Practices Manual - Pulp & Paper Industry ITC Limited, PSPD Unit-Bhadrachalam

Best Practice 1 1. Energy conservation in Boiler Feed Water Pumps 2. Reduction in fresh water consumption for pulp dilution at Pulp Mill

215 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 216 Best Practices Manual - Pulp & Paper Industry About ITC Limited, PSPD, Unit-Bhadrachalam

Company Profile ITC Limited - Paperboards and Specialty Papers Division - Bhadrachalam unit has emerged as one of the most modern and contemporary players in the business worldwide. Unit Bhadrachalam offers a vibrant product range for packaging and graphic solutions such as Coated SBS Board (Pearl and Safire Graphic), Coated Folding Box Board (Cyber XL Pac), Coated Board White Back, Coated Gravure Board, Coated Board Gray Back & many more. The Unit serves thousands of customers in India and abroad & to a wide range of industries from foods to personal products, office stationers to appliances and accessories. It makes the complete range of paperboards that today offer unparalleled choice for FMCG packaging.

Energy & Water Management Practices Water & energy utilization and its reduction has become a major focal point for pulp and paper mills around the world. Concern for water & energy conservation, adoption of environmental laws and forced environmental conditions have driven many pulp and paper mills in the country to reduce plant water & energy usage. Adoption of Best Available Technology and Best Management Practices with more environment friendly process, viz. oxygen delignification and elemental chlorine free (ECF)/Ozone bleaching coupled with complete recycling of white waters in paper machines and adoption of energy efficient process, plant, and machinery resulted in energy & water conservation at ITC-PSPD.

217 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice No. 1 Energy conservation in Boiler Feed Water Pumps

1.1. Background Unit Bhadrachalam has cogeneration plant with total power generation capacity of 84 MW. High Pressure steam is generated through a combination of Soda Recovery & Coal Fired boilers & then passed through a set of Turbines to generate power. As a typical installation in boilers two high pressure Boiler Feed water pump (one running and one standby) were used to pump water to boiler. The feed water flow control used was step mode by using a control valve with an average opening of 40 % of control valve. The feed water pump outlet pressure used to vary between 92 to 105 bar before control valve in accordance with the steam demand.

1.2. Objective To reduce energy loss across control valve & achieve energy conservation.

1.3. Action taken Looking at the pressure variation & higher pressure loss across control valve, optimization proposal was worked out. Out of two pumps, one pump is fixed with VFD to maintain constant boiler feed water pump outlet pressure. The set point was reduced in step manner till 80 bar reducing the loss across control valve. Thereby power consumption was reduced by 80 kW.

.4. Achievements & Benefits The power consumption is reduced by 80 kW from 390 kW to 310 kW for the pump for similar loads. This has resulted in 20% energy saving as compared to original operating practice.

1.5. Additional Benefits The pressure loss across the valve is reduced which in turn reduces wear & tear of valve. Also, pump life increased due to smoothening of discharge pressure.

Boiler Feed Water Pump Variable Frequency driver

218 Best Practices Manual - Pulp & Paper Industry Trend of pressure before & after installation of VFD

1.5. Replication potential / Learning All the boilers operated with flow control valve result in higher pressure drop across the valve. These can be considered for future application of VFD. This will result in energy conservation by minimizing energy loss across control valve. At Unit-Bhadrachalam, all Boilers’ Feed water pumps have been installed with VFD for flow control & saving of 20% is achieved for Boiler Feed water pumping.

219 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice No. 2 Reduction in fresh water consumption for pulp dilution at Pulp Mill

2.1. Background Pulp is produced from wood through stages of chipping, cooking, screening & washing and finally bleaching. The last stage of bleaching is DP, where, the pulp at 30% consistency is produced at the outlet of DP press. Process water (fresh water) is used to dilute this pulp from 30% to 10% consistency which is then transferred to Bleached tower. And finally the pulp is pumped to machines according to the demand. Thus the water added for dilution is sent to paper machine along with pulp. In process of papermaking the water is removed at various stages of paper machine. Partly it is recycled back for bleached tower pulp dilution & remaining excess is drained to ETP.

2.2. Objective To reduce fresh water consumption pulp mill process.

2.3. Action taken A study was done to find ways of reducing fresh water consumption at pulp mill. It was identified that the back water from paper machines can be utilized for DP press screw dilution, as this is the final stage & pulp is sent to paper machines from here. Storage tank for paper machine back water erected near Pulp mill to store the back water coming from paper machines. Piping laid for back water receiving & pumping to Dp stage for pulp dilution. Controls provided in fresh water line based on tank level & operating conditions.

2.4. Achievements & Benefits Fresh water consumption reduced by 2000 kL/day for Pulp Mill. The resultant is approx 8% of saving in fresh water consumption at Pulp Mill.

2.5. Additional Benefits Load on ETP for additional effluent is reduced. The pumping power for fresh water is reduced to the extent of fresh water saved. Chemicals consumption reduced at Paper Machine.

Proposal Schematic diagram

220 Best Practices Manual - Pulp & Paper Industry

Buffer Tank for Back Water Pump Machine Back water

2.6. Replication potential / Learning Wherever pulp dilution is done by fresh water, this approach can be considered after a thorough study of the process. Saving of 5-10% in fresh water consumption can be achieved by replacing it with machine back water at various stages.

221 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 222 Best Practices Manual - Pulp & Paper Industry Seshasayee Paper and Boards Limited

Best Practice 1 1. Energy Management In Condenser Cooling Water Circuit Of 21 Mw Steam Turbine

223 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 224 Best Practices Manual - Pulp & Paper Industry About Seshasayee Paper and Boards Limited (SPB)

The Company Seshasayee Paper and Boards Limited (SPB), the flagship company belonging to ‘ESVIN GROUP’, operates an integrated pulp, paper and paper board Mill at Pallipalayam, Erode-638 007, District Namakkal, Tamilnadu, India. SPB, incorporated in June 1960, was promoted by Seshasayee Brothers (Pvt) Limited in association with a foreign collaborator M/s Parsons and Whittemore, South East Asia Inc., USA. After commencement of commercial production, having fulfilled their performance guarantee obligations, the foreign collaborators withdrew in 1969. Main promoters of the Company as on date are a group of companies belonging to the ESVIN group headed by Mr. N Gopalaratnam. SPB commenced commercial production in December 1962, on commissioning a 20000 tpa integrated facility, comprising a Pulp Mill and two Paper Machines (PM-1 and PM-2), capable of producing, writing, printing, kraft and poster varieties of paper. The Plant capacity was expanded to 35000 tpa in 1967-68, by modification of PM-2 and addition of a third Paper Machine (PM-3). The cost of the expansion scheme, at Rs 34 Millions, was part financed by All India Financial Institutions (Rs 31 Millions). In the second stage of expansion, undertaken in 1976, capacity was enhanced to 55000 tpa, through addition of a 60 tpd new Paper Machine (PM-4). Cost of the project, including cost of a Chemical Recovery Boiler and other facilities for enhanced requirement of utilities, was estimated at Rs. 176 Millions. The same was part financed by term loans from Institutions and Banks to the extent of Rs. 145 Millions and the balance out of internal generation. SPB undertook various equipment balancing and modernisation programmes, since then, for improving its operating efficiency, captive power generation capacity, etc., upto 1992-93.

Expansion / Modernisation Project The Company embarked on an Expansion / Modernisation Project to enhance its production capacity from 60000 tonnes per annum, to 1,15,000 tonnes per annum and to upgrade some of the existing facilities, at an estimated cost of Rs 1890 millions. The said Expansion / Modernisation Project was completed in December 2000. After successful trials, the Commercial Production out of the new Paper Machine commenced on July 1, 2000. The current installed capacity of the Company stands at 1,15,000 tonnes per annum.

Raw Materials The Company’s paper plant was originally designed for using bagasse, as the primary raw material mixed with 20% bamboo fibre. Bagasse was being obtained from nearby sugar mill on substitution basis using oil fired boilers. With sharp increase in oil prices in 1970-71, the Company shifted over to the use of hardwood, at the time of its expansion undertaken in 1978. Raw material mix underwent a substantial change, with bamboo and hardwood forming 60% and 40%, respectively, of its raw material consumption. “National Best Practices - Pulp & Paper Industry” Soon Company started apprehending difficulties in procurement of bamboo. In 1981, it added one more digester, to increase the share of the hardwood in the furnish mix to 80% and restricting bamboo use to only 20%. With the commissioning of more wood based industries in Tamilnadu, there was again an apprehension about availability of hardwood.

225 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre s a long term strategy, the Company at this time decided on restructuring use of bagasse which was seen to be the most reliable source of fibre for the entire Industry. In 1984, the Company promoted Ponni Sugars and Chemicals Limited, as the captive source for bagasse supply. It added bagasse handling systems and modernised PM-1 and PM-2, to shift over to the use of bagasse. The furnish mix for the existing Paper Machines of the Company is 55% bagasse and 45% hardwood. The Company has vast experience in handling bagasse and is expected to be one of the major strong points vis-à-vis its competitors in India, as the Indian Paper Industry will continue to be bogged down by the problem of raw material availability. For the new Paper Machine, the furnish is imported waste paper and imported pulp which are sourced from far east countries, Europe and USA. A small quantity is supplemented out of captive pulp production.

Exports performance SPB’s exports are nearly 20% of its production and is a significant exporter in the Indian Paper Industry. Due to its excellent export performance, SPB has been awarded ‘Golden Export House’ status.

Awards SPB is in receipt of various Awards awarded by Government of India, Government of Tamilnadu, Industry Associations, etc. Some of the Awards received by SPB in the past include: ƒƒ Capacity Utilisation Award ƒƒ Energy Conservation Award ƒƒ Environmental Protection Award ƒƒ Safety Award ƒƒ Export Performance Award ƒƒ Good Industrial Relations Award ƒƒ TERI - Corporate Environmental Award

Environmental Protection The Company attaches paramount importance to the conservation and improvement of the environment. In its efforts to improve the environmental protection measures, the Company has installed: ƒƒ Two Electro Static Precipitators for its Boilers to control dust emissions ƒƒ An Anaerobic lagoon for high BOD liquid effluents ƒƒ A Secondary Treatment System for liquid effluents and ƒƒ An Electro Static Precipitator and Cascade Evaporator to the Recovery Boiler. These facilities will ensure sustained compliance by the Company of the pollution control norms prescribed by the Pollution Control Authorities. ISO 9001/ IS0 14001 Accreditation The Company’s quality systems continue to be covered by the “ISO 9001” accreditation awarded by Det Norske Veritas, The Netherlands. The Company has also been accredited with “ISO 14001” certification by Det Norske Veritas, The Netherlands, for its Environmental Quality Systems.

226 Best Practices Manual - Pulp & Paper Industry Board Of Directors The Company’s Board is broad based comprising 10 Directors: ƒƒ Sri N Gopalaratnam, Chairman and Managing Director ƒƒ Sri R V Gupta, I.A.S., (Retd.) ƒƒ Dr S Narayan, I.A.S., (Retd.) ƒƒ Sri Bimal Kumar Poddar ƒƒ Sri Arun G Bijur ƒƒ Sri V Sridar ƒƒ Smt Sheela Rani Chunkath, I.A.S (Nominee of TIIC) ƒƒ Sri Debendranath Sarangi, I.A.S (Nominee of Govt. of Tamilnadu) ƒƒ Sri K S Kasi Viswanathan, Deputy Managing Director ƒƒ Sri V Pichai, Director (Finance) & Secretary They are ably assisted by a team of qualified and experienced professionals in operations, personnel, finance and marketing disciplines.

227 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Best Practice Energy Management In Condenser Cooling Water Circuit Of 21 MW Steam Turbine

Objective To achieve Condenser Vacuum improvement and performance enhancement of Condenser of Steam Turbine

Background The Steam Turbo-generator related to CPP is one of Double Extraction Condensing type. Exhaust steam leaving the turbine is at vacuum and is being condensed in the Condenser using cooling water in closed circulation. Steam is condensed on the shell side with cooling water flows through the tubes in 2 pass arrangement.

Condenser with 2 pass cooling water circuit. Cooling water treated on a continuous basis after picking up heat from the waste exhaust steam is returned to the cooling tower having 3 cells in place. Each of the cooling tower cell has got its own fan for cooling the incoming warm water.

2of 3 cooling water pumps are being used for circulating the cooling water to the condenser

228 Best Practices Manual - Pulp & Paper Industry As the cooling water pumps were overdesigned and with throttling of outlet valve, the cooling water flow was being maintained at around 2700 to 2800 m3/h at over 4 kscg pressure. Cooling water velocity in the condenser tubes was at 1.8 m/s. The temperature rise across the condenser at rated condenser load was close to 8 Deg C. Condenser vacuum hovered between 0.88 and 0.92 at.

Scheme As there was no measurement of cooling water flow measurement in place, in order to estimate the exhaust steam dryness, the flow and temperatures across the condenser were required. Hence it was decided to measure the cooling water flow measurement using Ultra-sonic flow meter. Towards this , with joint coordination with MITCON –GEA , using Ultrasonic sensor , cooling water flow measurements were carried out. The pump throttling was removed with the result the flow increased by around 25%. The resultant gain was one of reduction in cooling water flow differential across the condenser. Consequently the cooling water outlet temperature dropped by 1.5 to 20C.

Parameter Unit Before After CWP Valve Throttling - Yes No Exhaust steam flow to Condenser TPH 40 42 CW flow rate to Condenser m3/h 2700 3600 CW inlet temp. to condenser °C 34.1 34.1 CW outlet temp. from condenser °C 41.9 40.1 CW temp. diffl.at Condenser end °C 7.8 6.0 Condenser Vacuum atm 0.90 0.90 Exhaust steam /condensate temp. °C 45.5 46 CW Pump Pressure kg/cm2 4.0 -4.1 2.4 -2.6 Power Consumption –CW Pumps kW 173-176 173-175

Benefits Increased LMTD and very small drop in condensing steam temperature and unnoticeable improvement in vacuum is to be expected. Increased cooling water velocity directly aids in increased heat transfer coefficient. The increased cooling water velocity integrated with continuous sustained cooling water treatment ensures higher Cleanliness factor. With Condenser area remaining same & the heat transfer coefficient going up, leverage on increased LMTD is on the cards. With all of the above, after the corrections as stated above, the condenser vacuum had certainly had not deteriorated at any point of time-be it summer or high condenser steam loads as was the case the previous years. The condenser vacuum ( even after correcting for site elevation) had been between 0.89 to 0.92 atm. ( Refer the Historic Operating data summarised in Table -2.

Uniqueness Through the measurements proposed in place, the dryness fraction of exhaust condensing steam leaving to the condenser could be computed using the algorithm specially developed in place. This concept probably would be first of its kind.

229 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Savings Coupled with sustained high quality cooling water treatment, the condenser vacuum had been improved, though marginally. The resultant gain is one of 0.1 MW and some times even higher.

Issue The issue of higher power consumption of cooling water pumps did not arise , as the pressure loss due to throttling had been gainfully converted to advantage of higher cooling water flow and consequent condenser tube cleanliness and marginal increase in vacuum.

Replication Quality Cooling water treatment along with increased flow velocity would aid in increased cleanliness factor of condenser tubes and is recommended for all the mills having condenser –water cooling scheme in place.. Consequent reduction in Cooling water outlet temperature needs to be assessed on case to case basis prior to replication.

Condenser –Cooling Water Cycle –Historic Data

Parameter Unit 2005 2010 2012 2012 Date - 27-12 27-09 28-01 15-05 Condensing TPH 45-48 36-40 48-49 42-45 Vacuum atm 0.885 0.875 0.90 0.895 CW flow m3/h 2800 2800 3600 3600 CW temp in ° C 29 33 31 34 CW temp in ° C 38.5 40 37.4 40

ΔTcw ° C 9.5 7.5 6.4 6 CW Pump Pressure kg/cm2 (g) 4.1 4.0 2.4-2.6 2.3 -2.5 Power consumption kW 176 173 172 175 CT –All3 Fans running - Yes Yes Yes yes

230 Best Practices Manual - Pulp & Paper Industry Action Plan & Conclusion

Action Plan ƒƒ The individual paper plants have to assess the present performance and should develop their own individual target for improving parameters concerning energy, water and environmental performance. ƒƒ Set and achieve voluntary target of at least 1 to 5% reduction in specific energy consumption every year. ƒƒ The best practices and the performance improvement projects compiled in this manual may be considered for implementation after suitably fine tuning to match the individual plant requirements. ƒƒ If required, CII-Godrej GBC will help the individual units to improve the performance by providing energy audit services and identifying performance improvement projects specific to individual units to achieve the targets. ƒƒ The present level of performance and the improvements made by the individual units have to be monitored. ƒƒ The performance improvement of these units will be reviewed in the “Papertech” every year and the information will be disseminated among the Indian Pulp and Paper plants. Conclusion The objective of the project will be fulfilled only if the performance of all the pulp and paper units improves and achieves world class standards. We are sure that the Indian Pulp and Paper units will make use of this opportunity, improve their performance and move towards the world class Energy Efficiency.

231 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 232 Best Practices Manual - Pulp & Paper Industry Indian Delegation attendedAnnexure the workshop in Sweden A during 15 - 19 April, 2012 Sl.No. Name Company 1. Mr. Vijay Patharkar Bilt Graphic Paper Products Ltd 2. Ms Anjali Bhola Export Radet 3. Mr Vijay Kumar Indian Newsprint Manufacturers Association (INMA) 4. Mr. N. Moorthy Indian Pulp Manufacturers Association 5. Mr. A.L.N. Krisnamohan ITC Limited 6. Mr. Viswanathan Murali ITC Limited 7. Mr. Sajan Kumar Sriniwas Mishra Khanna Paper Mills Ltd 8. Mr. Anil Trakroo Khanna Paper Mills Ltd 9. Mr. P.K. Garg Mysore Paper Mills Ltd 10. Mr. B.N. Srinivasa Mysore Paper Mills Ltd 11. Mr. Pawan Aggarwal Naini Tissues Limited 12. Mr. Apurve Goel Rama Paper Mills Ltd 13. Mr. Kasi Vishwanathan Seshasayee Paper & Boards Ltd 14. Mr. Anil Kumar Shreyans Industries Limited 15. Mr. Siddha Jothykrishnan Varadarajan Tamil Nadu Newsprint 16. Mr. BH Rathi The West Coast Paper Mills Ltd. 17. Mr. Karthikeyan Sattanathan Confederation of Indian Industry 18. Mr. Mahesh Puranam Confederation of Indian Industry

233 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre 234 Best Practices Manual - Pulp & Paper Industry Attendees of the CII - WorkingAnnexure group visit to West B Coast Paper Mills, Dandeli during 8th and 9th May 2012 Sl.No. Name Designation Company 1 Dr T G Sunderraman GM (Energy & Climate Change) Seshasayee Paper & Boards Limited 2 Mr. I J Singh CGM Star Paper Mills Limited 3 Mr. B S Ravindra Engineer Andhra Pradesh Paper Mills Limited 4 Mr. G Nageswara Rao Sr Manager (paper) Mysore Paper Mills 5 Mr. Narayan Mutsaddi Manager (Energy & recovery) Mysore Paper Mills 6 Mr. Satish Sankhyan Deputy General Manager - Projects Metso 7 Mr. Sujay Majumdar Start-up Commissioning Manager Metso 8 Dr. S. Chinnaraj Sr. Manager (R & D) TamilNadu Newsprints & Papers Limited 9 Mr. S. Nagarajan Sr. Manager (Energy) TamilNadu Newsprints & Papers Limited 10 Mr.P Price Tholkappian Sr. Manager (Mech) TamilNadu Newsprints & Papers Limited 11 Mr. M. Shanmugam Sr. Manager (Paper) TamilNadu Newsprints & Papers Limited 12 Mr.Mahesh Puranam Counsellor Confederation of Indian Industry 13 Mr.Ajay Ranjith V Engineer Confederation of Indian Industry 14 Mr.Ravi Teja Engineer Confederation of Indian Industry

235 Confederation of Indian Industry CII-Sohrabji Godrej Green Business Centre Notes

236 Best Practices Manual - Pulp & Paper Industry About us

The Confederation of Indian Industry (CII) works to create and The Centre is housed in a Green Building which received the sustain an environment conducive to the growth of industry in prestigious LEED (Leadership in Energy and Environmental Best Practices Manual India, partnering industry and government alike through Design) Platinum Rating in 2003. This was the first Platinum advisory and consultative processes. rated Green Building outside of U.S.A and the third in the world. The Centre was inaugurated by H.E Dr A P J Abdul Kalam, the CII is a non-government, not-for-profit, industry led and then President of India, on July 14, 2004. Pulp & Paper industry industry managed organisation, playing a proactive role in India's development process. Founded over 117 years ago, it is Volume 5 India's premier business association, with a direct membership of over 6600 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 250 national and regional sectoral associations.

With 63 offices including 10 Centres of Excellence in India, and 7 overseas offices in Australia, China, France, Singapore, South Africa, UK, and USA, as well as institutional partnerships with About IPMA 223 counterpart organisations in 90 countries, CII serves as a reference point for Indian industry and the international Indian Paper Manufacturers Association (IPMA) has emerged as business community. a national level organisation and is an apex Association provides a broad based common platform to project Industry's view and CII – Sohrabji Godrej Green Business Centre (CII – Godrej GBC) is to articulate its strategy to cater to the growing need and global one of the 10 Centres of Excellences of the Confederation of vision of the Paper Industry. Large Paper Mills from private and Indian Industry (CII). public sector with a product mix of all varieties of Paper (Writing, Printing, Packaging, Speciality, Paper boards and CII-Sohrabji Godrej Green Business Centre offers advisory Newsprint) located in all regions and using conventional fibre services to the industry in the areas of Green buildings, energy such as wood and bamboo and also unconventional raw efficiency, water management, environmental management, materials like bagasse, recycled paper, etc. Comprise the renewable energy, Green business incubation and climate Membership of IPMA in broad spectrum. The Association is change activities. registered with the Registrar of Societies, Government of NCT of Delhi. The Centre sensitises key stakeholders to embrace Green practices and facilitates market transformation, paving way for IPMA strives to promote, protect and improve trade, commerce India to become one of the global leaders in Green businesses and Industry in general, with a focus on Industry connected with by 2015. Paper in particular.

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