Orient paper mills Amlai,shahdol(mp) Major vocational training
Project report on 1.chipper house 2.pulp mill 3.Tissue paper plant
Submitted to: Miss kriti sexena
submitted by: Harsh mohan pathak (G.E.C.)
Acknowledgement
The success of any project is never limited to the individual undertaking the project.The completion of the report which is presented here in was possible by the splendid cooperation of many individuals .I express my deep sense of gratitude and thanx to senior president Mr. VK Verma and vice president of human resourses of development Mr DN Swain and all others. I take this oppertiunity to extend my sensior thanx to all staffs and worker of orient paper mill for rendering their knowledge and help while the whole period of training.
Introduction Orient Paper Mills is one of India's major players in Paper with a wide range of writing, printing, industrial and speciality papers.
Fully integrated with facilities for production of high strength pulp combined with reafforestation, high speed paper machines and independent power generation, Orient Paper Mills is in total control right from raw materials to the production of a variety of superior papers and boards. The Orient Paper Mills plants at AMLAI, Madhya Pradesh have manufacturing facilities to produce a variety of grades and types of papers. Judicious deployment of new technology, abiding commitment to total quality management systems and ingenuity in research and product development have enabled Orient Paper Mills to carve out an important niche not only in the Indian market but in several other countries as well. The Company has recently set up state-of-the-art facilities to produce a spectrum of Soft Tissue Paper of world class quality. To perpetuate progress, the Paper Division of Orient Paper Mills continually improving its people, products and processes as it marches ahead in its quest for even higher standards of excellence.
Plant layout
Chipper house
Drum chipper is the production of wood products of special equipment, the products are widely used in particle board plants Drum type wood chipper,wood shredder,wood logs chipping machine Drum chipper is the production of wood products of special equipment, the products are widely used in particle board plants, medium and high-density fibreboard plant, Wo straw plant, bio power plants, wood chips and other plants and manufacturers of industrial production in the preparation section before the preferred equipment. The product mix of advanced, cutting-chip high-quality materials, raw materials adaptive light, easy operation and maintenance. Cutting path of the main raw material is wood, timber harvesting, processing residues (such as, branches, slab, slab, core logs, veneer waste, etc.), can also be used to cutting non-wood raw materials (such as sugar cane, reed, bamboo, etc.). Machine from the body, knife-roller, upper and lower feed roller, conveyor, hydraulic system components. The body using high-strength steel welded together, the whole machine is supported by the foundation. Knife roller is installed on two or three, four Flying with the Flying Bolt specializes in manufacturing, through the pressure block, the Flying roller on a fixed knife. Cutting of raw materials according to different thickness, the feed roller assembly can make use of the
hydraulic system in a certain range of plus or minus. Cutting down the qualified film material falling through the mesh holes, from the bottom of discharge, the chip is expected to be carried out in the cutting machine. Hydraulic systems: for by the oil pump to the fuel tank, you can start to build enclosures for easy blade replacement; can be looked up in the maintenance of the feed roller assembly to facilitate adjustment of Flying, at the end of the gap between the knife and removable comb plate. Technical specifications: Model BX215 BX216 BX218 BX2113 Imported materials and dimensions mm 160*400 230*500 300*680 450*700 Flying the number of 2 2 2 2 Knife roll speed 592 590 650 500 Maximum diameter of the processing of raw materials mm 160 230
300 450 Chip size mm 30 30 30 38 Production capacity 3-4 7-8 12-15 15-30 Power of main motor kw 45 55 110 200-250 Feed roller motor power kw 2.2-3 3-4 4-5 7.5*2 Pump motor power kw 1.5*1 1.5*1 1.5*1 3*1 Weightkg 2990 4070 7000 11840 Overall dimensionsmm 1470*1550*970 1800*1900*1210
2200*2150*1500 3670*2517*2050 Electrical power transmission machine kw 3 3 3 3
Pulp mill
A pulp mill is a manufacturing facility that converts wood chips or other plant fibre source into a thick fibre board which can be shipped to a paper mill for further processing. Pulp can be manufactured using mechanical, semi-chemical or fully chemical methods (kraft and sulfite processes). The finished product may be either bleached or non-bleached, depending on the customer requirements. Wood and other plant materials used to make pulp contain three main components (apart from water): cellulose fibres (desired for papermaking), lignin (a three-dimensional polymer that binds the cellulose fibres together) and hemicelluloses, (shorter branched carbohydrate polymers). The aim of pulping is to break down the bulk structure of the fibre source, be it chips, stems or other plant parts, into the constituent fibres. Chemical pulping achieves this by degrading the lignin and hemicellulose into small, water-soluble molecules which can be washed away from the cellulose fibers without depolymerizing the cellulose fibres (chemically depolymerizing the cellulose weakens the fibres). The various mechanical pulping methods, such as groundwood (GW) and refiner mechanical (RMP) pulping, physically tear the cellulose fibres one from another. Much of the lignin remains adhering to the fibres. Strength is impaired because the fibres may be cut. There are a number of related hybrid pulping methods that use a combination of chemical and thermal treatment to begin an abbreviated chemical pulping process, followed
immediately by a mechanical treatment to separate the fibres. These hybrid methods include thermomechanical pulping (TMP) and chemithermomechanical pulping (CTMP). The chemical and thermal treatments reduce the amount of energy subsequently required by the mechanical treatment, and also reduce the amount of strength loss suffered by the fibres. •
The mill
Much of the information about the technology in following subsections is from the book by C.J. Biermann.. The chemistry of the various pulping processes can be found in Sjöström's book. Preparation of fibre source
The most common fibre source for pulp mills is pulpwood. Other common sources are bagasse and fibre crops. The first step in all mills using wood (trees) as the fibre source is to remove the bark. Bark contains relatively few usable fibers and darkens the pulp. The removed bark is burned, along with other unusable plant material, to generate steam to run the mill. Almost all wood is then chipped before it processed further to free the fibers. Removal of the bark is done in a barker (or debarker ). The bark adhesion is about 3-5 kg/cm2 in the growing season (summer) and 2-3 times higher in the dormant season (winter). The bark of frozen logs is even more difficult to remove. In chemical pulp mills the bark is introducing unwanted contaminants as calcium, silica and aluminum that are causing scaling and gives an extra load for the chemical recovery system. Birch bark contains betulin, a terpenoid that easily makes deposits in a pulp mill.
Tissue and pilot plant
Tissue paper is a lightweight, light crêped paper. Tissue can be made both from virgin and recycled paper pulp. Properties
Tissue papers is used to make a huge range of products with different properties and quality demands. Key properties are: strength, absorbency, basis weight, thickness (bulk), brightness, stretch, appearance and comfort. Production
Main article: Fourdrinier machine Tissue paper is produced on a paper machine that has a single large steam heated drying cylinder (yankee dryer) fitted with a hot air hood. The raw material is paper pulp. The yankee cylinder is sprayed with adhesives to make the paper stick. Creping is done by the yankee's doctor blade that is scraping the dry paper off the cylinder surface. The crinkle (crêping) is controlled by the strength of the adhesive, geometry of the doctor blade, speed difference between the yankee and final section of the paper machine and paper pulp characteristics. The properties are controlled by pulp quality, crêping and additives (both in base paper and as coating). The wet strength is often an important paramenter for tissue paper.
Applications Hygienic tissue paper
Hygienic tissue paper is commonly used for facial tissue (paper handkerchiefs), napkins, bathroom tissue and household towels. Paper has been used for hygiene purposes for centuries, but tissue paper as we know it today was not produced in USA before the mid-1940s. In Western Europe large scale industrial production started in the beginning of 1960s. Facial tissues
Main article: Facial tissue Facial tissue (paper handkerchiefs) refers to a class of soft, absorbent, disposable paper that is suitable for use on the face. The term is commonly used to refer to the type of facial tissue, usually sold in boxes, that is designed to facilitate the expulsion of nasal mucus from the nose although it may refer to other types of facial tissues including napkins and wipes. The first tissue handkerchiefs were introduced in the 1920's. They have been refined over the years, especially for softness and strength, but their basic design has remained constant. Today each person in Western Europe uses about 200 tissue handkerchiefs a year, with a variety of 'alternative' functions including the treatment of minor wounds, the cleaning of face and hands and the cleaning of spectacles. The importance of the paper tissue on minimising the spread of an infection has been highlighted in light of fears over a swine flu epidemic. In the UK, for example, the Government ran a campaign called “Catch it, bin it, kill it”, which encouraged people to cover their mouth with a paper tissue when coughing or sneezing.
Paper towels
Main article: Paper towel Paper towels are the second largest application for tissue paper in the consumer sector. This type of paper has usually a basis weight of 20 to 24 g/m2. Normally such paper towels are two-ply. This kind of tissue can be made from 100% chemical pulp to 100% recycled fibre or a combination of the two. Normally, some long fibre chemical pulp is included to improve strength. Wrapping Tissue
Main article: Wrapping tissue Wrapping tissue is a type of thin, translucent paper used for wrapping and cushioning fragile items. Toilet Tissue
Main article: Toilet paper Rolls of toilet paper have been available since the end of the 19th century. Today, more than 20 billion rolls of toilet tissue are used each year in Western Europe.[2] Table napkins
Table napkins can be made of tissue paper. These are made from one up to four plies and in a variety of qualities, sizes, folds, colours and patterns depending on intended use and prevailing fashions. The composition of raw materials varies a lot from deinked to chemical pulp depending on quality. The Industry
Out of the world's estimated production of 21 million tonnes of tissue, Europe produces approximately six million tonnes.
The European tissue market is worth approximately 10 billion Euros annually and is growing at a rate of around 3%. The European market represents around 23% of the global market. Of the total paper and board market tissue accounts for 10%. In North America, people are consuming around three times as much tissue as in Europe. In Europe, the industry is represented by The European Tissue Symposium (ETS), a trade association. The members of ETS represent the majority of tissue paper producers throughout Europe. and about 90% of total European tissue production. ETS was founded in 1971 and is based in Brussels since 1992. Sustainability
The paper tissue industry, along with the rest of the paper manufacturing sector, has worked hard to minimise its impact on the environment. Recovered fibres now represent some 46.5% of the paper industry’s raw materials. The industry relies heavily on biofuels (about 50% of its primary energy) and it is highly energyefficient. Its specific primary energy consumption has decreased by 16% and the specific electricity consumption has decreased by 11%, due to measures such as improved process technology and investment in combined heat and power (CHP). Specific carbon dioxide emissions from fossil fuels decreased by 25% due to process-related measures and the increased use of low-carbon and biomass fuels. Once consumed, most forest-based paper products start a new life as recycled material or biofuel EDANA, the trade body for the non-woven absorbent hygiene products industry (which includes products such as household wipes for use in the home) has reported annually on the industry’s environmental performance since 2005. The industry’s impact on the environment is, in fact, relatively small. For example, less than 1% of all commercial wood production ends up as wood pulp in absorbent hygiene products. In addition, the industry contributes
less than 0.5% of all solid waste and around 2% of municipal solid waste (MSW) compared with paper and board, garden waste and food waste which each comprise between 18 and 20 percent of MSW. There has been a great deal of interest, in particular, in the use of recovered fibres to manufacture new tissue paper products. However, whether this is actually better for the environment than using new fibres is open to question. A Life Cycle Assessment study indicated that neither fibre type can be considered environmentally preferable. In this study both new fibre and recovered fibre offer environmental benefits and shortcomings. Total environmental impacts vary case by case, depending on for example the location of the tissue paper mill, availability of fibres close to the mill, energy options and waste utilization possibilities. There are opportunities to minimise environmental impacts when using each fibre type. When using recovered fibres, it is beneficial to: •
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Source fibres from integrated deinking operations to eliminate the need for thermal drying of fibre or long distance transport of wet pulp, Manage deinked sludge in order to maximise beneficial applications and minimise waste burden on society; and Select the recovered paper depending on the end-product requirements and that also allows the most efficient recycling process.
When using new fibres, it is beneficial to: •
Manage the raw material sources to maintain legal, sustainable forestry practices by implementing processes such as forest certification systems and chain of custody standards2; and
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Consider opportunities to introduce new and more renewable energy sources and increase the use of biomass fuels to reduce emissions of carbon dioxide.
When using either fibre type, it is beneficial to: •
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Improve energy efficiency in tissue manufacturing; Examine opportunities for changing to alternative, non fossil based sources, of energy for tissue manufacturing operations Deliver products that maximise functionality and optimize consumption; and Investigate opportunities for alternative product disposal systems that minimize the environmental impact of used products.
The Confederation of European Paper Industries has published reports focusing on the industry’s environmental credentials. In 2002, it noted that “a little over 60% of the pulp and paper produced in Europe comes from mills certified under one of the internationally recognised eco-management schemes”. There are a number of ‘eco-labels’ designed to help consumers identify paper tissue products which meet such environmental standards. Ecolabelling entered mainstream environmental policy-making in the late seventies, first with national schemes such as the German Blue Angel programme, to be followed by the Nordic Swan (1989). In 1992 a European eco-labelling regulation, known as the EU Flower, was also adopted. The stated objective is to support sustainable development, balancing environmental, social and economical criteria.
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