Overall Recovery Efficiency_Pulp and Paper_Project Report

Indian Institute of Technol Technology ogy Delhi Hauz Khas, New Delhi India-110016 http://www.iitd.ac.in

Trident Complex, Raikot Road, Barnala, Punjab, India-148101 Tel: +91-161-5039999, Fax: +91-161-5038800 http://www.tridentindia.com

CHC410

Internship Project Report

Submitted by

Lavanya Kumar Jain 2007CH10069, Student Chemical Engineering Department, IIT Delhi, New Delhi, India Phone: +91 9953181003; Email: [email protected]

Faculty Supervisor

Anurag S. Rathore Associate Professor Chemical Engineering Department, IIT Delhi, New Delhi, India Phone: +91-9650770650; Email: [email protected]

INTERNSHIP SUMMARY Name of the Company:

Abhishek Industries Ltd (Trident Group)

Internship period:

17 May – 16 July 2010

No. of days:

52

Location:

Dhaula complex, Barnala, Punjab

Department:

Production

Unit:

Paper (PPR)

Project Supervisor:

Mr. Sumit Jindal, FLE, Recovery 2, PPR Abhishek Industries Limited Phone: +91 9878997774; 9878997774; Email: [email protected]

Project Title:

Reduction of chemical losses in Recovery

th

th

ABSTRACT The project at Abhishek Industries is concerned to ana lysing ORE and identifying sources of soda loss in the whole process and suggesting measures to reduce soda loss. The streams carrying alkali are studied and all the possible exit points for alkali are identified. The major sources of loss are individually studied and various measures are suggested to increase their performance and reduce soda loss. Experiments are conducted at several occasions to analyze the affects of suggested measure. The method of ORE calculation is also corrected and automation is suggested at several points for better control of process. ORE is calculated based on individual indivi dual losses from soda loss sources. Summary of the Report: 1.

IDENTIFICATION OF ALKALI EXIT POINTS: Recovery 2 plant and Pulp mill are rigorously

analyzed and all the possible exit points of alkali from the system are identified. Process flow diagram for each unit is provided. 2.

FMEA ON ALKALI EXIT POINTS: Results are derived from FMEA and a final list of prominent

alkali loss points is made based on Perito hypothesis. 3.

WBL SAMPLING TO STUDY VARIATION IN COMPOSITION: WBL samples are analysed at

frequent intervals to study variation in actual WBL composition to value used for ORE calculation. Error in SRE and ORE values due to above variation is calculated. 4.

COMPOSITE SAMPLING AND AUTOMATION: Collection tank design for composite sampling is

proposed. Advantages of Automation and suppliers of online analyzers anal yzers are provided. 5.

MUD FILTER ORE LOSS: ORE loss from mud filter is calculated from lime consumption and %

composition data of mud cake. Loss from Grifts and stones is also calculated.

2|P a g e

INTERNSHIP SUMMARY Name of the Company:

Abhishek Industries Ltd (Trident Group)

Internship period:

17 May – 16 July 2010

No. of days:

52

Location:

Dhaula complex, Barnala, Punjab

Department:

Production

Unit:

Paper (PPR)

Project Supervisor:

Mr. Sumit Jindal, FLE, Recovery 2, PPR Abhishek Industries Limited Phone: +91 9878997774; 9878997774; Email: [email protected]

Project Title:

Reduction of chemical losses in Recovery

th

th

ABSTRACT The project at Abhishek Industries is concerned to ana lysing ORE and identifying sources of soda loss in the whole process and suggesting measures to reduce soda loss. The streams carrying alkali are studied and all the possible exit points for alkali are identified. The major sources of loss are individually studied and various measures are suggested to increase their performance and reduce soda loss. Experiments are conducted at several occasions to analyze the affects of suggested measure. The method of ORE calculation is also corrected and automation is suggested at several points for better control of process. ORE is calculated based on individual indivi dual losses from soda loss sources. Summary of the Report: 1.

IDENTIFICATION OF ALKALI EXIT POINTS: Recovery 2 plant and Pulp mill are rigorously

analyzed and all the possible exit points of alkali from the system are identified. Process flow diagram for each unit is provided. 2.

FMEA ON ALKALI EXIT POINTS: Results are derived from FMEA and a final list of prominent

alkali loss points is made based on Perito hypothesis. 3.

WBL SAMPLING TO STUDY VARIATION IN COMPOSITION: WBL samples are analysed at

frequent intervals to study variation in actual WBL composition to value used for ORE calculation. Error in SRE and ORE values due to above variation is calculated. 4.

COMPOSITE SAMPLING AND AUTOMATION: Collection tank design for composite sampling is

proposed. Advantages of Automation and suppliers of online analyzers anal yzers are provided. 5.

MUD FILTER ORE LOSS: ORE loss from mud filter is calculated from lime consumption and %

composition data of mud cake. Loss from Grifts and stones is also calculated.

2|P a g e

6.

MUD FILTER PROCESS PARAMETER ANALYSIS: Process parameters that affect performance of 

mud filter are identified and analyzed. Experiments are done to test vat solid composition, homogeneity in vat mixture. Impact of displacement washing on alkali content in mud cake is discussed. 7.

CAUSTICIZING CONTROL MODELS: 3 causticizing control models, including Advanced control

are discussed to maintain consistent causticizing efficiency and avoid excess lime addition. 8.

PULP MILL SODA CARRYOVER ORE LOSS: From production data and Soda as kg/MT TTA as

Na2O, total soda loss and loss in ORE is calculated. 9.

PULP MILL PRODUCTION VERSUS SODA CARRYOVER LOSSES: Soda carryover with production

for SFL and WFL are plotted and the trend is analysed. 10.

WASHER EFFICIENCY FOR SFL AND WFL: Project in SFL and WFL to reduce soda loss are

discussed. 11.

TOTAL WASHABLE ALKALI AS SODA CARRYOVER IN WFL: Elemental analysis of filtrate of 

thoroughly washed pulp is done to calculate total washable alkali of total alkali as soda carryover in WFL. 12.

PULP MILL REJECT ORE LOSSES: Total soda loss and total washable soda loss calculations are

done for reject streams in SFL and WFL. ORE loss through reject stream is calculated using these data. 13.

REJECT STREAM WASHING SOLUTIONS: Reject streams in SFL and WFL are thoroughly studied

with sufficient flow diagrams. Solutions are suggested sug gested to reduce soda loss through reject. 14.

ESP PROCESS PARAMETER ANALYSIS: Various process parameters are identified and analy sed

that affect the performance of ESP. 15.

COLLECTION EFFICIENCY CALCULATION: Ash collection rate from ESP is calculated from AMT

density sampling at specific intervals of time. Inlet gas flowrates are noted during the sampling period. With other parameters constant collection efficiency i s calculated for the ESP. 16.

DUST COMPOSTION: ESP dust composition and Chlorine Enrichment Factor (CEF) and

Potassium Enrichment Factor (PEF) are calculated. 17.

POTASSIUM AND CHLORIDE PURGING: T he problem of high content of chlorides and

potassium in the system is discussed. Methods for their removal and systems based on Ash Leaching are provided. 18.

ORE LOSS DATA: Tentative % Loss in ORE from all the loss points is presented. ORE based on

individual losses is calculated.

3|P a g e

INDEX Contents

Page Number

Internship Summary

2

Abstract

2

Abhishek Industries

6

1.

11

Introduction

1.1. Paper making process

11

1.2. Paper plant at Abhishek Industries

11

1.3. Recovery units

12

1.4. ORE

16

2.

Objective

17

3.

Project Plan

17

4.

Alkali Exit Points

18

4.1. Recovery 2

17

4.2. SFL

24

4.3. WFL

26

4.4. Significant permanent loss points

26

5.

WBL Sampling

30

5.1. ORE fluctuations

30

5.2. WBL sampling

32

5.3. Composite sampling

36

5.4. Automation

38

6.

Mud Filter

39

6.1. Lime Mud ClariDisc system

39

6.2. Mud Filter ORE loss

40

6.3. Process parameter testing

41

6.4. Causticizing control models

48

7.

Pulp mill soda carryover

49

7.1. Pulp mill soda carryover ORE loss

49

7.2. Pulp mill production versus soda carryover losses

50

7.3. Washer efficiency for SFL and WFL

54

8.

Pulp mill Reject

56

8.1. Pulp mill Reject ORE losses

56

8.2. Reject stream washing

59

9.

ESP

63

9.1. BHEL ESP system

64

9.2. Process parameters

65

9.3. Collection Efficiency

70

9.4. Dust Composition

74

9.5. Potassium and Chloride Purging

75

9.6. ESP ORE Loss

77

10.

ORE Loss data

78 4|P a g e

11.

Future Work

79

12.

References

80

List of Experiments

81

List of Tables

81

List of Figures

82

Appendix A (Data Tables)

84

5|P a g e

ABHISHEK INDUSTRIES Trident Group commenced its operations in 1985 with Single Super Phosphate (capacity 66000 tonnes per annum) & Sulphuric Acid (capacity 33000 tonnes per annum). Since then, the business of  the group witnessed a wide range of diversification and expansions and today, Trident Group is a Rs. 25 billion global conglomerate with an employee headcount of more than 10,000, and providing indirect employment to 20,000 people. Therefore, Trident is a pioneer at implementing sound Corporate Governance as the basic management princi ple. Abhishek Industries Limited (AIL) is the flagship company of the Trident Group and deals in Yarns, Towels, Papers, and Chemicals & Energy. The company is among the top 5 global terry towel giants of the world. It is one of the world's largest agro-based paper manufacturers and one of the largest yarn producers in India. Abhishek Industries has 3 plants located at Dhaula (Punjab), Sangheda (Punjab) and Budhni (Madhya Pradesh). At present the company is having following manufacturing facilities: • • • • • •

Yarns Yarn Processing Open end Yarn Terry Towels Writing & Printing Papers Sulfuric Acid

In brief, Leadership: Ownership: Total Assets: CAGR: Employees: Exports:

12592 spindles 6825 tonnes/ day 1920 rotors 268 looms 400 tonnes/ day 100000 tonnes/ annum

Mr. Rajinder Gupta, CEO and MD Public limited company with Public shareholding 36.52 %, and Foreign shareholding 6.32 %. Rs. 25 billion 30% Over 10,00 (Indirect employment to 20000 people) 47% of Net Sales across 65 countries

Financial Performance, (Rs. millions) PERIOD ENDED

MAR 2009

MAR 2010

NO. OF MONTHS

12

12

GROSS TURNOVER

15456

19768

NET SALES

13981

18034

EXPORTS

6862

8392

GROSS PROFIT (PBIDT)

2605

3560

NET PROFIT AFTER TAX

(530)

565

NET WORTH

4463

5028

FIXED ASSETS (GROSS BLOCK)

21032

23388

CURRENT ASSETS (NET)

2365

5285

6|P a g e

MUSKAAN, SHAAN, SGA

Several employee engagement initiatives including Total Quality Assurance (TQA), Kaizen (MUSKAAN), SHAAN, Small Group Activity (SGA) etc have been taken up for creating a quality driven culture through the involvement of ground level employees. These initiatives focused on building awareness and developing skills in Kaizen, 5 S, etc. MUSKAAN

MUSKAAN is company’s own nomenclature for KAIZEN. This initiative has been undertaken so as to ensure that members in the Organization undertake small improvements of permanent nature in their own work area and department. The focus of the initiative is to help reduce strain and extra effort, improve quality and reduce inconsistencies and any wasteful activity. The Organization i s now moving towards Phase II and the focus is towards facilitating innovation, creativity and process improvements. SHAAN

Like Muskaan, SHAAN is company’s own nomenclature for 5 S. The program has been initiated to harness the benefits of increased efficiency due to reduced time in looking for tools and equipment, improved quality, work standardization, reduced changeover time, and improved safety, reduced space requirements & storage costs, reduced machine down time and simplified work environment, etc. Regular trainings are being imparted to our members on the same. SGA

Small Group Activities have been undertaken by members for improving the process capability in all the production and support processes and to make the processes more efficient.

ABHISHEK YARN, TEXTILES, PAPER, SAP, COGEN, UTILITY ABHISHEK YARNS

The Yarn Division of the company manufactures both Combed and Carded yarn in addition to polyester cotton and PVA yarn. Besides catering to the captive consumption by Home Textiles Division, the Yarn Division has developed a significant presence in the export market with its quality products. Currently, AIL has 125,952 spindles operating at almost 100% capacity producing value added yarns such as yarn made from Egyptian cotton, PVA fiber and Bamboo fiber. Also, AIL has upgraded its existing spinning facilities through automation and increasing the value adding processes. Abhishek Yarns supplies the processed yarns to the following mills: Arvind Mills; Elegant Overseas; Kapoor Industries; Abhitex Industry; Chemitax, Belgium; SPL Industries; Aashima Industries and Alok Industries. ABHISHEK TEXTILES

The Home Textiles Business of the company is the prime source of Export Earnings and International Recognition to the company. AIL supplies its Toweling products to world’s biggest and most reputed companies and retail chain stores like Wal*Mart, Luxury Linens, JC Penney, Target, BBB, Chris 7|P a g e

Madden, TJ Maxx, Franco and Sears. Among the top 20 retailers of the world, AIL has business relationship with at least 11 of them. The company has a significant presence in the mid and high segment of the Terry Towel market, with an impressive product profile. Currently, the division operates with an installed capacity of 268 looms of towels and 6825 TPA of processed yarn. Ultramodern German, Swiss and Italian technology has been adopted in order to provide consumers the products that they cherish. ABHISHEK PAPER

The Paper Division of Trident was commissioned in 1992 and presently the production capacity is 400 TPD. The focus is on manufacturing Writing and Printing grades of paper for different segments. The unit specializes in using Wheat Straw, an Agro residue as its prime raw material, thus facilitating an eco-friendly environment and maintaining the ecology of the place. Applications: a. Calendar & Diary Printing b. Business & Computer Stationery c.

Multicolor High End Printing & Publishing

d. Base paper for coated papers e. Novels publication f.

High Speed Photocopying

g. Laser & Inkjet Printing h. Multipurpose Office Use Paper At Abhishek Industries there are two pulp units, Pulp 1 for producing pulp from wood i.e. wood fiber line (WFL) and Pulp 2 for producing pulp using wheat straw i.e. straw fiber line(SFL). The SFL unit is the biggest pulp producing unit in the world that utilizes wheat straw as a raw material. SAP (SULFURIC ACID PLANT)

Sulfuric acid is produced from sulfur, oxygen and water via the conventional contact process (DCDA) In the first step, sulfur is burned to produce sulfur dioxide. S (s) + O2 (g) → SO2 (g) This is then oxidized to sulfur trioxide using oxygen in the presence of a vanadium (V) oxide catalyst. 2 SO2 (g) + O2 (g) → 2 SO3 (g) (in presence of V2O5) The sulfur trioxide is absorbed into 97-98% H2SO4 to form oleum (H2S2O7), also known as fuming sulfuric acid. The oleum is then diluted with water to form concentrated sulfuric acid. H2SO4 (l) + SO3 → H2S2O7 (l) H2S2O7 (l) + H2O (l) → 2 H2SO4 (l)

8|P a g e

The production of SAP is 100000 tonnes/ annum

Figure 1. Sulfuric Acid Plant (SAP) at Abhishek Industries, Dhaula complex COGEN

The units of Abhisehk Industries meet their own energy demands. There are 5 COGEN units with 2 large units of 20 MW each and 3 units of combined capacity of 9.34 MW. The to tal power generation capacity is 49.34 MW. The requirement is 40 MW. Steam is the main product of these units and is converted to different temperature and pressure conditions depending on r equirements.

Figure 2. COGEN-1, a 20 MW unit at Abhishek Industries, Dhaula complex

9|P a g e

UTILITY

There is waste water treatment plant and effluent treatment plant in the Dhaula industrial campus. It reduces BOD and COD of streams and protects environment. Also, a demineralised water plant supplies demineralised water to all the units.

Figure 3. Demineralised water plant at Abhishek Industries at Dhaula complex In brief,

BUSINESS UNIT

CAPACITY

PRODUCTION (2010)

REVENUE (Rs. millions)

Abhishek Home Textiles (AHT) 1998

374 looms

29,152 tonnes

8,482.5

Abhishek Yarn 1992

224,448 spindles and 1,920 rotors

48,115 tonnes

6,187.0

Abhishek Paper 2002

175,000 175,000 tpa tp a

123,629 tonnes 4,951.8

Abhishek Chemicals 1985

1,00,000 tpa

84,038 tonnes

COGEN Power

50 MW

328,534 Mwh units

10 | P a g e

1.

INTRODUCTION

1.1.

PAPER MAKING PROCESS

Paper making process involves pulping of the raw material. Pulping can be carried out through chemical pulping or mechanical pulping. For chemical pulping there could be various processes, viz. Kraft process, sulphite process and soda pulping. Sulfite pulping is carried out between pH 1.5 and 5, depending on the counterion to sulfite (bisulfite) and the ratio of base to sulfurous acid. The pulp is in contact with the pulping chemicals for 4 to 14 hours and at temperatures ranging from 130 to 160 1 °C. In the Soda-AQ process, anthraquinone (AQ) may be used as a pulping additive to decrease the

carbohydrate degradation. The soda process gives pulp with lower tear strength than other chemical 2

pulping processes.

Kraft process is the most common applied process and entails treatment of raw fiber with a mixture of sodium of sodium hydroxide and sodium sulfide, sulfide, known as white liquor, liquor, that break the bonds that link lignin to the cellulose. Cooking produces black liquor that contains lignin fragments, carbohydrates from the breakdown of hemicellulose, sodium carbonate, carbonate, sodium sulfate and other inorganic salts. A Recovery plant process black liquor and produces White liquor to be reused in the digester for cooking.

Figure 1.1. Paper making process

1.2.

PAPER PLANT AT ABHISHEK INDUSTRIES

The paper plant at Abhishek Industries is based on Kraft Process. The capacity of paper plant is 400 MT/day. However, current production is 420 MT/day. The raw material used for making paper is a mixture of wheat straw and wood chips in ratio of approximately 70:30. By using the wheat straw as 1 2

http://en.wikipedia.org/wiki/Sulfite_process http://en.wikipedia.org/wiki/Soda_pulping

11 | P a g e

raw material, Abhishek industries has saved thousands of trees for being used to make paper, but using wheat straw has its own disadvantages in purity and paper quality. It also faces problem of  limited research on plant processes. A paper plant basically consists of a Pulp Mill, Paper Machine and Finishing section and utility as Recovery. At Abhishek Industries there are 2 pulp mills, SFL and WFL. Straw Fiber Line (SFL) processes wheat straw and produces pulp, with present production around 230 tonnes of bleached pulp per day. Wood Fiber Line (WFL) processes wood chips and produces pulp, with present production around 100 tonnes of bleached pulp per day. There are 2 paper machines, Paper Machine 1 and Paper Machine 2. There are 2 Recovery Units, Recovery 1 and Recovery 2.

Figure 1.2. Paper making flowchart fl owchart3 1.3.

RECOVERY UNITS

The first step of chemical recovery is the evaporation process, which increases the concentration of  solids from approximately 15 percent to more than 60 percent. The concentrated slurry contains approximately 50 percent organic solids and 6 percent total sulfur in the form of sodium sulfate 3

Mckean W. and Jacobs R. S. (1997) Wheat Straw as a Paper Fiber Source

12 | P a g e

(Na2SO4) and sodium thiosulfate (Na2S2O3) and is placed into a recovery boiler. The organic solids are burned for energy while the inorganic process chemicals, also known as smelt, flow through the floor of the recovery boiler to be recausticized.4 Raw Material [Wheat Straw/ Wood Chips]

Weak Black Liquor White Liquor

Pulping

(WBL) [10-12 % Solids]

Quick Lime To Energy Lime Kiln

Causticizer

Steam

Evaporator

Combustion

Heavy Black

[Recovery Boiler]

Liquor (HBL)

Lime Mud Green Liquor Limestone Makeup

Figure 1.3. Chemical Recovery Cycle

At Abhishek Industries, Recovery 1 has a capacity of around 130 tonnes of dry solids fired per day and Recovery 2 has a capacity of 400 tonnes of dry solids fired per day. 1.3.1. MULTIPLE EFFECT EVAPORATORS

Figure 1.4. Multiple effect evaporators

4

M. Brongers, A. J. Mierzwa. Pulp and Paper 

13 | P a g e

The first step in recovering the chemicals from the black liquor is evaporation. This removes excess water from the black liquor and maximizes the fuel value for the rec overy furnace. 1.3.2. RECOVERY BOILER

Figure 1.5. Recovery Boiler Process flow

Figure 1.6. Recovery Boiler

14 | P a g e

A recovery boiler consists of heat transfer surfaces made of steel tube; furnace-1, superheaters-2, boiler generating bank-3 and economizers-4. The steam drum-5 design is of single-drum type. The air and black liquor are introduced through primary and secondary air ports-6, liquor guns-7 and tertiary air ports-8. The combustion residue, smelt exits through smelt spouts-9 to the dissolving tank-10.

1.3.3. RECAUSTICIZING PLANT

Figure 1.7. Recausticizing Process flow

Recausticizing is the process used to transform the inorganic smelt recovered from the recovery boiler into white liquor so that the chemicals may be recycled. The recycled inorganic chemicals are discharged as molten smelt from the recovery boiler and then dissolved using water to form green liquor. Any unwanted substances are precipitated out. Lime is then added to the clarified green liquor to produce sodium hydroxide (NaOH) from the remaining sodium carbonate (Na2CO3). The resulting solution (white liquor) contains sodium hydroxide, sodium sulfide (Na2S), and a solid phase of calcium carbonate (lime mud). Before the white liquor is recycled back to the digester, the white liquor is clarified further to remove the lime mud.5

The main necessities for Soda Recovery Plant are: a. Maintaining required Chemical Oxygen Demand (COD) and Biochemical Oxygen Demand (BOD) levels as per Environmental regulations. COD of inlet liquor to recovery plant is in lakhs, while regulations are 300 for COD and 30 for BOD. b. Recovery of caustic soda (NaOH) that results in cost benefits. c. 5

Energy production as steam by burning organic material in black liquor, lignin.

M. Brongers, A. J. Mierzwa. Pulp and Paper 

15 | P a g e

1.4.

OVERALL RECOVERY EFFICIENCY

As the purpose of a Soda Recovery unit is to recover caustic soda from Black liquor, it calculates the total efficiency of caustic soda recovered through a generalized term as Overall Recovery Efficiency (ORE) which incorporates caustic soda losses both at pulp mills and in recovery units. ORE = SRE X PME Soda Recover Efficiency, SRE

=

(WL supply to Pulp mill) ± (Recovery stock difference) WBL Received

Pulp Mill Efficiency, PME

=

(WBL received by recovery) ± (WBL stock difference of Pulp mill) (WL supply to Pulp mill) + (Purchased caustic) ± (WL stock difference of PM)

1.4.1. ORE CALCULATIONS

Basis: TTA as Na2O

Glossary:

A

WL used in cooking in SFL and WFL

B

OS of WBL+WL in SFL and WFL

C

OS of WBL+SCBL+GL+WWL+WL in Rec-1

D

OS of WBL+HBL+GL+WWL+WL in Rec-2

Total Active Alkali (TAA):

E

CS of WBL+WL in SFL and WFL

NaOH, Na2S

F

CS of WBL+SCBL+GL+WWL+WL in Rec-1

G

CS of WBL+HBL+GL+WWL+WL in Rec-2

J

Purchased caustic used in cooking in SFL and WFL

P

=

B+C+D

Q

=

E+F+G

R

=

A + [J x 31/40]

Total Titrable Alkali (TTA): Na2CO3, NaOH, Na2S

OS: Opening Stock CS: Closing Stock WL: White Liquor WBL: Weak Black Liquor SCBL: Semi-Conc. Black

Loss % =  ORE % =

∗ 

Liquor

∗100

100 – Loss %

HBL: Heavy Black Liquor GL: Green Liquor WWL: Weak White Liquor

The present ORE varies between 94-95 % on a general basis for the paper plant at Abhishek Industries.

16 | P a g e

2.

OBJECTIVE

The objective of the project is to identify the potential sources of soda loss in the whole stream including both pulp mill and recovery units and present some solutions for further increment in ORE.

3. PROJECT PLAN 17.05.10 25.05.10

• Induc Inductio tion n progr programm amme e

26.05.10 03.06.10

• WBL WBL Samp Sampli ling ng

04.06.10 15.06.10

• Mud Mud Fil Filtter

16.06.10 24.06.10

• Pulp mill soda soda carr carryov yover er

25.06.10 01.07.10

• Pulp Pulp mil milll Reje Reject ct

02.07.10 08.07.10

• ESP

09.07.10 12.07.10

• ORE ORE Loss Loss data data

17 | P a g e

4.

ALKALI EXIT POINTS

4.1.

RECOVERY 2

Pulp Mill

WBL from pulp mill

WL Storage Tank

WBL Storage Tank Rotary Lime Kiln Evaporator, 7 effects and 11 bodies [10% to 65%, 170T/hr]

Causticizing [110 MT/day]

Lime Mud Steam, 460 °C, 64 kg/cm

Recovery Boiler [Total heat transfer area = 7283 m 2]

HBL Storage Tank [65-67% [65-67% solids] sol ids]

2

Smelt Dissolving tank, Green liquor [97-102 [97-102 GPL Na N a2O TTA]

Figure 4.1. Process Flow Diagram of Recovery 2

4.1.1. EVAPORATOR

Before WBL is sent to evaporation it is filtered to remove fibers (cellulose) that has come along it. It is necessary to remove it else it will scale the evaporator. These fibers are recycled and some amount is thrown away with some amount of Black liquor. Before feeding into evaporator WL is added to WBL to reduce the viscosity and fraction. LP steam is preferred in evaporators. First it’s difficult to deal with very high pressures. More importantly latent heat, λ of steam decreases with increasing temperature or high pressure. It is advisable to feed the steam at saturation temperature as retention time of steam in evaporator is less and latent heat transfer is more effective. Effects 1(A, B, C) and 2(A, B, C) have high pressure, while rest work in vacuum. Inl et temperature and pressure of steam is 140 °C, 2.5 kg/cm 2. Pressure in the last effect is 0.14 kg/cm 2. It is feed backward system of evaporator. The concentration in outlet of 3rd effect is 25% solids. Concentration in inlet of  th

7 effect was 10% solids. In 2

nd

st

effect concentration rises to 36% solids. In 1 effect it rises to 65-

67% solids. As there is significant change in concentration in first 2 effects there is considerable rise in viscosity. Thus, first 2 effects are divided into 3 separate bodies. Same steam is fed in 3 bodies of  an effect, while flow of Black liquor is continuous and simultaneous. First body is called wash, second as intermediate and third as product. Vapors from each effect sent to condenser. It contains same amount of soda.

18 | P a g e

Black liquor [11-12% solids]

Vibratory Screens [5 Nos]

Fibres

WBL Storage Tank [3 Nos]

WWL (to reduce viscosity)

BL Pit LP Steam

Thrown Out Evaporator 7 effects

Boiler

HBL Storage Tank [65-67% solids]

Vapor to condenser [40 ppm]

BL Pit Washing Figure 4.2. Evaporator Process Flow Diagram

The identified exit points of soda for permanent losses are: a. Vibratory Screens reject b. Vapors to Condensers c.

Washing/Scaling

d. Tank overflows e. Seepages and Pump leakages

Figure 4.3. 7 effect-11 body Evaporator at Recovery 2 at Abhi shek Industries, Dhaula complex

19 | P a g e

Figure 4.4. Condensers at Recovery 2 at Abhishek Industries, Dhaula complex

4.1.2. RECOVERY BOILER

The Recovery boiler has 3 main parts: a. Black liquor burning and Green liquor collection b. Flue gas flow and heat transfer c.

Demineralised and deaerated water flow and heat transfer

4.1.2.1. Black liquor firing

HBL from storage tank is preheated to reach a desired temperature of 120 °C in an indirect heater. If  indirect heater is not able to heat it, direct heater is used. The liquor stream distributes into 6 nozzles. With pressurized steam, BL is sprayed in furnace from these 6 nozzles. Initially fuel oil is used by its own component, lignin. Green liquor falls at the bottom and is collected in Main Dissolving Tank (MDT). It is highly concentrated and very hot at temperature of around 1000 °C. Precautions are taken in dissolving GL. As it’s very hot direct addition of water will convert it into steam and explode. Thus, hot water/steam jets hit the fine stream of GL falling and dilute it. Instead of using hot water, WWL from Mud Washer 1 is used to dilute to GL that helps to maintain desired concentration.

20 | P a g e

MDT has outlet for vapors. The soda carryover is very limited as WWL is sprinkled at 2 points in exiting vapors that settles solid particles in the stream. 4.1.2.2. Flue gas flow

Air is pumped in furnace at 3 levels, viz. Primary, Secondary and Tertiary. ID fan sucks the air from furnace and pushes it through chimney. Flue gas generated on burning lignin travels through superheaters, boiler bank and then economizer. It passes through ESP and exits from chimney top. 4.1.2.3. Water and steam system

Demineralised water is pumped in deaeration tank. The water is then pumped in economizer, then to boiler bank and then to superheaters to produce to produce high pressure superheated steam, which is sent to power boiler. The water from deaeration tank is passed through economizer and not through superheaters as flue gas has enough heat to provide latent heat to water, which if otherwise had been passed through superheaters would have extracted heat from high temperature flu gas. Thus, final temperature of the steam would be less and exit temperature of the flue gas would be high. Steam

HBL Storage Tank [65-67% solids]

Indirect

120 °C

heater

Direct heater 3 air pumps

Hot Water

Stem Drum

(Pri-Sec-Ter) Flue Gas

Pri - Sec -Ter Superheaters

Boiler Bank

Furnace [6 firing guns]

Fuel Oil

Steam Economiser – 1, 2

De-aeration Tank

Power Boiler [HP steam, 460 °C, 63 bars]

ESP

WWL

MDT Outlet

GL Storage Tank

DM water

Chimney Soot Blower

Main dissolving tank

WWL

Ash Mixing Tank Figure 4.5. Recovery Boiler Process Flow Diag ram 21 | P a g e

The identified exit points of soda for permanent losses are: a. Flue gas carryover [ESP] b. MDT Outlet c.

Dregs washer [Recovery 1]

d. Washing/Scaling e. Tank overflows f.

Seepages and pump leakages

4.1.3. RECAUSTICIZING PLANT

Raw material to this unit is Green Liquor. The GL feed contains sodium carbonate in large proportion and some amount of sodium hydroxide and sulfide. The basic reaction that occurs in a Lime slaker is: Ca(OH)2 + Na2CO3

↔

2 NaOH + CaCO3

85% of equilibrium concentration is achieved in slakers. The rest is achieved in causticizers that provide retention time for completion of reaction. Rakes installed in clarifier and mud washers are bottleneck in the process. To prevent rake failure automatic rake lifting mechanism is put where rakes lift automatically on reaching certain limit loads. Rakes do not disturb the settling of suspended limestone and silica particles in clarifier and mud washer as it rotates at speed of 7 rev/min. Its purpose is to prevent deposition at the bottom and maintain continuous flow underflow concentrated with solids. The vacuum based rotating disk mud filters remove calcium carbonate as mud cake. It is fed to lime kiln to produce lime. Lime kiln is not functional at present as cost of furnace oil fed to lime kiln is higher than purchased lime. Lime kiln is 76m long and 4m wide huge rotary kiln.

Figure 4.6. Rotary lime kiln

22 | P a g e

Lime (Lime bin) Agitator

GL Storage Tank [32-34% TTA as Na2O]

Recovery Boiler

GL Heater

Rake

WL Storage Tank [95 GPL TTA as Na2O]

Classifier

Steam

Agitator Grits

Causticizer (4) [100°C, each gives retention time of 27-30 min]

White liquor clarifier

Overflow

Rake

Slaker

Steam

Rake

[Stones & Silica]

Underflow

Lime Mud [25 GPL as TTA as Na2O] Washer 1

Overflow

Hot Water

Underflow

Weak White Liquor Storage Tank [25 GPL as TTA as Na 2O]

Overflow

MDT

Rake [5 GPL as TTA as Na2O]

To Pulp Mill LMW 2

Hot Water Lime Mud

Underflow

Storage Tank

Hot Water Overflow

Mud Filter (Vacuum disk filters) [Pr = 550mmHg]

Thrown Out

Sludge Cake

Limestone

Lime Kiln

Lime to Lime bin

Furnace Oil Figure 4.7. Recausticizing Process Flow Diagram The identified exit points of soda for permanent losses are: a. Sludge/Mud cake carryover b. Grits and stones carryover c.

Washing/Scaling

d. Tank overflows e. Seepages and leakages 23 | P a g e

4.2.

STRAW FIBER LINE (SFL)

Figure 4.8. Wet Washing in SFL

Figure 4.9. Digester in SFL

24 | P a g e

Figure 4.10. Pulp washing in SFL

Brownstock washing is a counterflow washing system with pulp and liquor stream flowing in opposite direction. The nomenclature of washer is based on pulp flow. The amount of water used for pulp washing is constrained at both lower and upper ends: a. For Recovery, more water for washing implies more load on evaporator and thus higher steam consumption. Thus, Recovery would like to reduce water content. b. For pulp mill, more water for washing implies better washing or more soda recovery. Thus, pulp mill would prefer high water usage. Soda carryover in pulp has 2 major disadvantages for pulp mill: a. Reduced paper quality, i.e. Brightness. b. Increased use of chemicals in bleaching and further processes in paper making. The identified exit points of soda for permanent losses are: a. Soda carryover with pulp b. Reject from HD cleaner c.

Reject from Delta Knotter through Vibratory Screen 1

d. Reject from Delta Screen through Vibratory Screen 2 e. Reject from Centricleaner 25 | P a g e

f.

Carryover with Blow Tank vapors

g.

Washing/Scaling

h. Tank overflows i.

Seepages and Leakages

Figure 4.11. Digester Feed Belt in SFL at Abhishek Industries, Dhuala complex

4.3.

WOOD FIBER LINE (WFL)

The process stream for WFL is almost similar with slight modifications. WFL has 3 Batch digesters as compared to continuous digesters in SFL. There are 5 simultaneous washers and no press. The different in the reject streams is discussed in detail s later. The identified exit points of soda for permanent losses are: a. Soda carryover with pulp b. Reject from Vibratory Screen c.

Reject from Pressure Screen through centricleaner and vibratory screen

d. Carryover with Blow Tank vapors e. Washing/Scaling f.

Tank overflows

g.

Seepages and Leakages

4.4.

SIGNIFICANT PERMANENT LOSS POINTS

On discussion with experts, as well as workers employed in the company and on the basis of general information derived from case studies of paper plants around the globe, significant permanent loss points are identified as follows: a. Mud cake carryover b. Flue gas carryover c.

Reject streams in Pulp mill

d. Grifts and stones e. Soda carryover with pulp f.

Carryover with Blow Tank vapors 26 | P a g e

To confirm the identified loss points, FMEA (Failure Mode Effectiveness Analysis) statistical analysis was performed.

Experiment:

FMEA on identified exit points of soda for permanent losses

Objective:

To identify the significant permanent loss points

Survey Format:

FMEA on identified exit points of soda for permanent losses Cause No.

Cause

Severity Occurrence

Detection

RPN No.

C1 C2 C3 C4

Soda carryover with pulp Mud cake carryover Reject streams in Pulp mills Flue gas carryover [ESP] Carryover with Blow Tank C5 vapors MDT Outlet C6 Dregs washer [Recovery 1] C7 Grifts and stones C8 Seepages and Leakages at WFL C9 Vibratory Screens reject in C10 Evaporator Washing/Scaling at WFL C11 Washing/Scaling in C12 Recausticizing Vapors to Condensers C13 Washing/Scaling in Evaporator C14 Seepages and Pump leakages C15 in Evaporator Seepages and Pump leakages C16 in SFL Tank overflows in WFL C17 Tank overflows in Evaporator C18 Washing/Scaling in Recovery C19 Boiler Tank overflows in Recovery C20 Boiler Seepages and Pump leakages C21 in Recovery Boiler Tank overflows in C22 Recausticizing Seepages and Pump leakages C23 in Reausticizing Washing/Scaling at SFL C24 Tank overflows in SFL C25 *Fill with 1, 3 or 9

27 | P a g e

   e    g    a    P     |    8    2

   e    v    i    t    a     l    u   %    m    u    C

  :    s    t     l    u    s    e    R    d    n    a    e     l     b    a    t    n    o    i    t    a    v    r    e    s     b    O

   s     l    e    a    s    s    u    t    %    o    c     l    A    t    n    e    N   o  .    n    P   N    a    R    m    r    e    9    p    P    r    o    8     f    a    P     d    7    o    s    P     f    o    6    P    s    t    n    i    5    o    P    p    t    i    x    4    P    e     d    3    e    i    P     f    i    t    n    2    e    P     d    i    n    1    o    P    A    E    M    F    e    s    u    a    C

   e  .    s    o    u    a    N    C

   5    1    5    9  .    4    2

   5    6    0    2  .    6    4

   1    7    9    9  .    4    6

   7    1    7    1  .    3    8

   2    0    6    5  .    6    8

   6    3    8    5  .    9    8

   6    8    4    6  .    1    9

   2    3    4    1  .    3    9

   5    6    4    5  .    4    9

   8    8    9    6  .    5    9

   5    4    5    5  .    6    9

   7    9    7    3  .    7    9

   6    4    7    1  .    8    9

   5    1    5    9  .    4    2

   5    5    2  .    1    2

   6    0    9    7  .    8    1

   6    4    7    1  .    8    1

   8    4    8    8    3  .    3

   9    3    3    2    0  .    3

   3    0    5    6    0  .    2

   8    5    4    9    4  .    1

   1    3    3    0    4  .    1

   1    3    2    5    1  .    1

   8    6    5    5    8  .    0

   5    2    5    2    8  .    0

   3    8    4    9    7  .    0

   3    3    3    3  .    0    6

   7    6    6    6  .    3    4

   1    4

   7    6    6    6  .    3    3

   5    2

   1    1    1    1  .    4    2

   2    2    2    2  .    3    2

   9    2    7

   1    2    6

   9    4    5

   1    3    5

   9    9

   3    3    3    3  .    8    8

   9    2    7

   9    2    7

   9    2    7

   9    2    7

   1    8

   3

   7    2

   9

   3

   9

   7    2

   3

   9

   9    2    7

   9    2    7

   9    2    7

   9    2    7

   1    8

   7    2

   9

   3

   3

   3

   9

   9

   7    2

   9    2    7

   9    2    7

   3    4    2

   9    2    7

   7    2

   7    2

   3

   3

   9

   9

   9

   7    2

   1    8

   9    2    7

   3    4    2

   9    2    7

   9    2    7

   7    2

   1    8

   9

   1    8

   3

   3

   7    2

   9

   7    2

   9    2    7

   9    2    7

   9    2    7

   1    8

   1    8

   3    4    2

   1    8

   1    8

   3    4    2

   1    8

   1    8

   1

   1

   9    2    7

   9    2    7

   1    8

   9    2    7

   7    2

   3    4    2

   9

   1    8

   9

   9

   7    2

   3

   9

   9    2    7

   9    2    7

   9    2    7

   1    8

   3    4    2

   1    8

   1    8

   7    2

   9

   7    2

   9

   1    8

   7    2

   9    2    7

   3    4    2

   9    2    7

   9    2    7

   3    4    2

   9

   1    8

   7    2

   1    8

   1    8

   7    2

   3

   1

   9    2    7

   9    2    7

   3    4    2

   3    4    2

   1    8

   1    8

   3    4    2

   1    8

   9

   1    8

   9

   1    8

   7    2

   s    p     l    r    r    u    r    e     h    w    t    t    s    e    P    r     l    o    i    a    n    i    t    s    v    n    e    o    n    s    w    L    n   a    g    g    o    i    B    e    v    r    e    F    y    e    o    n    r    n     d    s    o     h    i    i    n    r    e     l     l    e    g    n    t    r    ]    o     d   W   r    p    a    a    r    m    y    i    s    v    n    e    1    t    n   t    c    a    c    o    a    i    t     h    r    c    a    r    o    w    s    c    r    z    a    S    v    a    e    a    S    S    i    e    y    s    y     d    s    s    y    E    /     /    c    C    r    o     l    c    e    r    r    o    t    e    p    u    a    r    r    g    g    i    t     k    t    e    e    r    n    s    t    s    e    n    v    a    a    w    i    a    n    n    o    a    g    s    s    a    g    v    i    i    c    o    v    O    t    c    t    a    a    a    t    g    ]    y    s    o    s    u    r     h     h    c    o    t    a    p     d    c    s     k    g    c     f    p    k    r    e    s    L    s    a    r    e    P    j     l     l    c    p    r    n    T     d    l    u    e    i    e    e    a    a    F    a    D    e    j    i     b    S    u    r    r    R    e     l    E    a    a    e    a    o   u    e    e    i    e    S    p    M    R   m   F    [    C   T    M    D    [    G    S    L    V   r    W   W   W   R    V    1    C

   2    C

   3    C

   4    C

   5    C

   6    C

   7    C

   8    C

   9    C

   0    1    C

   1    1    C

   2    1    C

   3    1    C

   e    g    a    P     |    9    2

   2    9    7    7  .    8    9

   4    1    0    2  .    9    9

   2    6    5    4  .    9    9

   1    2    1    6  .    9    9

   4    2    2    7  .    9    9

   6    4    9    7  .    9    9

   9    8    2    8  .    9    9

   1    3    6    8  .    9    9

   3    7    9    8  .    9    9

   5    1    3    9  .    9    9

   8    5    6    9  .    9    9

   0    0    0    0    1    1

   8    6    4    0    6  .    0

   3    1    2    2    4  .    0

   8    4    5    2  .    0

   2    9    5    5    1  .    0

   9    2    0    1    1  .    0

   6    2    2    7    0  .    0

   3    2    4    3    0  .    0

   3    2    4    3    0  .    0

   3    2    4    3    0  .    0

   3    2    4    3    0  .    0

   3    2    4    3    0  .    0

   3    2    4    3    0  .    0

   7    6    6    6  .    7    1

   3    3    3    3  .    2    1

   4    4    4    4    4  .    7

   6    5    5    5    5  .    4

   2    2    2    2    2  .    3

   1    1    1    1    1  .    2

   1

   1

   1

   1

   1

   1

   3

   3

   3

   1

   3

   1

   1

   1

   1

   1

   1

   1

   3

   3

   9

   3

   1

   1

   1

   1

   1

   1

   1

   1

   7    2

   7    2

   9

   3

   9

   1

   1

   1

   1

   1

   1

   1

   9

   9

   3

   9

   1

   3

   1

   1

   1

   1

   1

   1

   7    2

   9

   7    2

   3

   1

   1

   1

   1

   1

   1

   1

   1

   7    2

   7    2

   1

   3

   9

   1

   1

   1

   1

   1

   1

   1

   9

   3

   3

   9

   1

   1

   1

   1

   1

   1

   1

   1

   7    2

   3

   9

   1

   3

   9

   1

   1

   1

   1

   1

   1

   7    2

   7    2

   3

   9

   1

   1

   1

   1

   1

   1

   1

   1

   p    p    p   y    r    p    t    n    n    e    i    a    m    m    n    n    i    m    m    v    n    n    i    i    i    i    u    u   o    u    g    u    g    r    g    r    P    P    P    P    s    s    e    c    s    n    n    n    L    s    e    i    i     l     l     l     l    e     l    g     d     d   F    w    w    a    i    w   i     d   R    w   n    d    g    i    a    S    n     l    o     l    o   r    c    o    l    o   o    n    o   i    n    n    a    c    r    n    c     l    r    z    a    a    a    a    n    i     f     f     f     f    n    n    B    B    n    S    S    S    i    i    i    i    i    z    r    r    r    r    o    o     /    o     /     /    s    s    t    s    s    e    e    t    g    y    e    y    s    s    s    s    i    c    i    e    g    t    g    c    r    r    e    e    e    e    a    g    e    a    v    v    a    v    t    e    i    n    n    r    g    e    r    n    s    g    e    v    e    g    e    t    i    r    i    i    g    g    o    o    o    g    o    g    v    a    a    r    o    a    a    o    a    a    o    h   v    u    a    a    s     h     h    e    u     k     k     k     k    p    k    p    p    k    o    p    a    p    p    s    o    s    p    s    L     l     k     k    e    a    e    a    n   F    n   a    a    c    n   c    e    a    i    n   c    e    a    a    a    a    a    L    e    e    o    e    e    v    e    a    v    a    a    v    a    a    e    e    e    F    e    e    e    e    W   E    S    l    E    S    l    T    W   T    E    W   R    T    R    S    l    B    T    R    S    l    R    W   S

   L    F    S    n    i    s    w    o     l     f    r    e    v    o     k    n    a    T

   4    1    C

   5    2    C

   5    1    C

   6    1    C

   7    1    C

   8    1    C

   9    1    C

   0    2    C

   1    2    C

   2    2    C

   3    2    C

   4    2    C

800

120

700

100

600 80

500 400

60

Average RPN Np. Cumulative %

300

40

200 20

100 0

0 1 2 3 4 5 6 7 8 9 10111213 14 1516 17 18 19 20 2122232425 26

Conclusion: The finally identified significant permanent loss p oints based on Perito hypothesis are as follows: a. Mud cake carryover  b. Flue gas carryover [ESP] c.

Reject streams in Pulp mill 

d. Soda carryover with pulp

Experiment 4.1. FMEA on identified exit points of soda for permanent losses

5.

WBL SAMPLING

5.1.

ORE FLUCTUATIONS

SRE and PME fluctuate between 80 to 120 on per day basis and thus, ORE fluctuates. With approximately steady process, the losses are also steady. Thus, fluctuations in SRE, PME and ORE values should be low. The reasons identified are: a. Measurement error of WBL GPL: There is high variability in WBL GPL values. Sampling followed is Grab sampling which doesn’t normalize these variations. b. Increase or decrease in processed liquor: When more liquor is processed losses associated with processing are higher, thus ORE decreases. Increase in processing liquor can be associated with decrease in stock. Thus, when stock i ncreases, ORE increase and vice versa. The process streams are sampled once per shift for GPL TTA as Na 2O. These values when multiplied with the stock volumes give stock data as TTA as Na 2O. The same data is used for ORE calculation.

30 | P a g e

The GPL values fluctuate drastically during a shift. Thus, even small errors in measurement get magnified when multiplied with stock values and produce incorrect SRE, PME and ORE values.

Period

PME

SRE

ORE

120

Feb-09

102.69

89.58

91.99

100

Mar-09

96.41

93.87

90.50

80

Apr-09

94.93

98.55

93.55

May-09

95.33

97.86

93.29

Jun-09

98.88

94.99

93.93

40

Jul-09

98.64

94.53

93.24

20

Aug-09

108.11

85.91

92.88

0

Sep-09

103.6

90.62

93.88

Dec-08 Mar-09

Oct-09

101.39

93.98

95.29

Dec-09

103.04

90.5

93.25

Jan-10

103.89

91.44

95.00

Feb-10

103.26

92.29

95.30

120

Mar-10

97.22

97.22

94.52

100

Apr-10

94.77

101.29

95.99

May-10

92.49

102.42

94.73

Jun-10

88.42

106.68

94.33

PME y = -0.0092x + 466.33 R² = 0.0802

60 PME Linear (PME)

Jul-09

Oct-09

Jan-10 May-10 Aug-10

Figure 5.1. PME versus Time plot

SRE y = 0.0164x - 560.5 R² = 0.2338

80 60

sre

40

Average 98.94 95.10 93.85 Coeffici ent of  0.08 0.233 0.564 Determi nation Table 5.1. PME, SRE and ORE over Time

Linear (sre)

20 0 Dec-08 Mar-09

Jul-09

Oct-09

Jan-10 May-10 Aug-10

Figure 5.2. SRE versus Time plot

ORE

97.00 96.00

y = 0.0065x - 167.26 R² = 0.5649

95.00 94.00 93.00

ORE

92.00

Linear (ORE)

91.00 90.00 Dec-08

Mar-09

Jul-09

Oct-09

Jan-10

May-10

Aug-10

Figure 5.3. ORE versus Time plot The low coefficient of determination, R2 values signify high unexplained variations in SRE, PME and ORE values. 31 | P a g e

5.2.

WBL SAMPLING

For Soda recovery unit, the minimum GPL concentration is for incoming WBL, and thus highest volume. Also the GPL values of incoming WBL stream fluctuates heavily. Discrete sampling neglects these fluctuations and is based on assumption of uniform flow. Under failure of such assumption, the error is further highly magnified due to huge volumes. WBL GPL measurement was identified to be the bottleneck in SRE and thus ORE calculation. More frequent WBL samples were taken and analyzed with generally accepted GPL for a day to measure the variation in total WBL TTA and thus, variation in actual ORE to calculated ORE.

Experiment:

Frequent sampling of WBL from SFL and WFL for measuring TTA & RAA as Na2O and %solids for 2 days

Objective:

To study variation in WBL TTA, RAA and % solids. Analyzing effect of error in WBL GPL value on ORE 

Observation table and Results: For WFL:

Day 1: 26th May 2010

(Na2O GPL) Time

Sample

Stream

% Solids

RAA

Factor

600

1

WFL

17.02

6

2.5

900

2

WFL

16.56

7.3

2

1030

3

WFL

16.9

7.94

1.5

1200

4

WFL

16.18

7.62

2

1400

5

WFL

15.24

7

2.5

1630

6

WFL

12.2

5.39

5.5

2200

7

WFL

15.86

7.3

8

AVG

15.2275

6.762292

STD DEV Avg selected for a day GPL Error (Positive) Avg Stock m3 Total Error MT

1.55111

0.848317

With Composite sampling the error is zero Avg for Pulp Mill

16.04 6.766667 0.8125 0.004375 1350 1350 1.096875 0.005906

13

6

Error (Positive)

-2.2275

-0.76229

Total Error (g)

3007125

1029094

32 | P a g e

20 18

R² = 0.4123

16 14 12 10 8

% Solids RAA Linear (RAA)

6 4 2 0

R² = 0.0053

0

2

Linear (RAA)

4

6

8

Day 2: 27th May 2010

(Na2O GPL) Time

Sample

Stream

% Solids

RAA

TTA

Factor

600

1

WFL

15.8

6.6

31.7

2.5

830

2

WFL

17.57

8.25

41.98

2

1030

3

WFL

14.4

7.93

36.39

1.5

1200

4

WFL

15.7

7.61

36.81

2

1400

5

WFL

14.5

6.6

31.7

2.5

1630

6

WFL

15.07

8.56

38.75

5.5

2200

7

WFL

15.48

6.6

34.4

8

AVG

15.44229

7.353958

35.79125

STD DEV

0.986578

0.784098

3.457622

Avg selected for a day GPL

15.26

6.6

32.6

Error (Positive)

-0.18229

-0.75396

-3.19125

Avg Stock m3

1350

1350

1350

Total Error MT

-0.24609

-1.01784

-4.30819

13.07

6

34.67

Error (Positive)

-2.37229

-1.35396

-1.12125

Total Error (g)

3202594

1827844

1513688

With Composite sampling the error is zero Avg for Pulp Mill

33 | P a g e

45

R² = 0.004

40 35

% Solids

30

RAA

25

TTA

20

R² = 0.1801

15

Linear (% Solids)

10

Linear (RAA)

5

Linear (TTA)

R² = 0.0042

0 0

2

4

6

8

For SFL:

Day 1: 26th May 2010 Time

600 900 1030 1200 1400 1630 2200

Sample 1 2 3 4 5 6 7

Stream SFL SFL SFL SFL SFL SFL SFL

AVG STD DEV Avg selected for a day GPL Error (Positive) Avg Stock m3 Total Error MT

(Na2O GPL) % Solids RAA 11.37 7 11.32 7.3 10.92 7.61 10.81 6.98 10.63 7.6 11.18 6.66 11.45 7.6 11.19813 7.239792 0.291906 0.350651

Factor

3 1.5 1.5 2 2.5 5.5 8

11.15 7.4 -0.04812 0.160208 3300 3300 -0.15881 0.528688

With Composite sampling the error is zero

14 12 10 8 6 4 2 0

R² = 0.0066 % Solids RAA R² = 0.0108

Linear (% Solids) Linear (RAA)

0

2

4

6

8

34 | P a g e

Day 2: 27th May 2010 Time

600 830 1030 1200 1400 1630 2200

Sample 1 2 3 4 5 6 7

Stream SFL SFL SFL SFL SFL SFL SFL

(Na2O GPL) RAA TTA 7 23.1 7.61 25.14 7.3 22.75 6.98 22 7.3 23.1 7.61 22.94 7.7 24.3 7.459583 23.47729 0.275402 0.97089

% Solids 11.43 11.4 11.06 10.92 10.29 10.8 12.03 11.29938 0.512186

AVG STD DEV Avg selected for a day GPL Error (Positive) Avg Stock m3 Total Error MT

11.25 -0.04937 3300 -0.16294

7.333333 -0.12625 3300 -0.41663

23.5 0.022708 3300 0.074937

With Composite sampling the error is zero

30 R² = 0.0011

25

% Solids RAA

20

TTA

15

R² = 0.0006

Linear (% Solids)

10

Linear (% Solids)

5

R² = 0.3019

Linear (RAA)

0 0

2

4

6

8

Linear (TTA)

*While calculating Average GPL, weighted average is taken with weights equal to time gap between present and next sample. Calculation: th

Considering for 27  May, total error in Na2O TTA = -4.308 (WFL) + 0.075 (SF L) MT  = -4.233 MT 

 + 1350∗35.791 = 125.792    = 3300∗23.4771000 Thus, % error in WBL received

=

3.365 %

   −  125. 7 92 121. 5 59 ℎ,%    =    ∗100 = 3.5 % 125.792 35 | P a g e

Individual errors in WFL and SFL streams are: SFL

=

8.92 %

WFL

=

0.1 %

 Assuming PME as 97 %, the error in ORE = 3.4 %

Conclusion: Very low R2 values imply the high variability in WBL streams TTA, RAA and % solids value.  Also, the analysis of error in sampling results 3.5 % in SRE and 3.4 % error in ORE. Thus, it is immediate requirement to adopt some other sampling method for correct calculation of SRE, PME and ORE and avoid per day fluctuations.

Experiment 5.1. Frequent sampling of WBL from SFL and WFL

5.3.

COMPOSITE SAMPLING

There are different kinds of sampling methods: a. Grab Sampling / Discrete Sampling

Advantage: Gives values of specific types of unstable param eters; No infrastructure cost Disadvantage: For highly varying values results can be very misleading due to huge errors; Human intervention b. Grab and composite sampling

Advantage: Higher precision in sampling; No infrastructure cost Disadvantage: High labor hours are required; Human intervention c.

Composite sampling

Advantage: High precision in sampling; No human intervention Disadvantage: Moderate infrastructure cost; Issues of tank fouling d. Automation/online analyzer

Advantage: High precision in sampling; Discrete values available instantly; Better process control Disadvantage: High infrastructure cost Grab sampling is presently followed by QC lab to analyze the samples. It has advantage that it gives values of specific types of unstable parameters like temperature at a given moment of time. But as experimental results have shown it gives large errors as fluctuations are large. In composite sampling sample is collected continuously with constant flow rate in a collection tank through sampling pipe. After every shift the liquor collected in sampling tank can be analyzed and average value can be noted down.

36 | P a g e

The following design of the collection tank is proposed:

SFL/WFL receive

Hot Water Discrete Sampling Point

Overflow outlet Temp. measurement device Valve head

Agitator

Sampling Point

Drain

Figure 5.4. Proposed collection tank design for WBL composite sampling

After every shift sample is collected and the tank is emptied in BL pit. It is then washed with hot water to prevent fouling. Advantage and disadvantage: It has a limitation that composite liquor will be cooler than current measurement temperature i.e. 70 °C. Thus, new basis needs to be chosen. However, it has advantage that error in measurement will be negligible. Also the tank is designed keeping in mind the fouling problem. Significant design parameters: a. Hot water washing: To remove fouling due to deposition of WBL solids on cooling of WBL in the tank, hot water washing needs to be done for few moments after draining the tank. b. Valve head: it provides liquid for point temperature measurement. c.

Agitators: With time WBL cools and solids start settling, thus, agitation helps in maintaining uniformity of the sample. In case, tank volume is reduced due to fouling then hot incoming liquor will float at top and may exit from overflow without mixing, thus, agitation helps in proper mixing.

d. Composite sampling point: It is provided at an intermediate point where concentration can be assumed equal to general volume concentration. e. Temperature measurement device: It helps to record temperature of inl et stream. f.

Discrete sampling point: Discrete samples can be taken, when required.

g. Overflow outlet: In case of overflow or if due to fouling inside tank volume is reduced, the liquor flows to drain through overflow outlet.

37 | P a g e

5.4.

AUTOMATION

Online analyzers can be installed at WBL stream pipes that give value of TTA, RAA, temperature etc almost instantly. It gives value of measured variable almost instantly and can exactly measure the total amount of  incoming black liquor as TTA. There are negligible errors and there is no human intervention. It is suggested to have a service tank where both SFL and WFL streams mix in desired proportion. Online analyzer measures the stream composition and helps to maintain desired flow rates to attain desired ratio. If streams are uniform the recovery process can be standardized easily and attainable performance can be reached. Also, operators can operate processes more uniformly as incoming stream composition is uniform.

A list of suppliers for online Analyzers is prepared: a. Duralyzer-NIR [Canmark] b. Process NIR Analyzer [MODCON] c.

kajaaniALKALi Alkali analyzer [Metso]

d. Process Analytical systems e. Online TCC/TC Analyzer [AppliTOC] f.

In-line Process Refractometer [Liquids Solids Control, Inc]

A standard of minimum deviation in WBL measurements should be targeted.

38 | P a g e

6.

MUD FILTER

Figure 6.1. Lime mud filter flowsheet

6.1.

LIME MUD CLARIDISC SYSTEM

Figure 6.2. Vacuum disk filter sketch

Figure 6.3. Vacuum disk filter in operation

ClariDisc system consists of 3 meter diameter filter discs consisting of 18 separate sectors each mounted on the central barrel. The sectors are made of 316L stainless steel perforated plate and dressed with an underbag to improve liquor flow and an outer shrunk on filter bag of special polypropylene material. The outer layer of the cake is scrapped off the filter disc with a scrapper; the inner layer of lime mud is retained on the filter discs to act as a filtration precoat. HiPac system breaks the precoat and helps in its removal to prevent cake hardening.

39 | P a g e

6.2.

MUD FILTER ORE LOSS

The total amount of mud cake produces is not known, but the % composition of it is known. By using lime consumption data and % composition of mud cake, total quick lime produced can be calculated, The Mud cake sampling is done on composite basis to minimize the errors. Lime consumption data is taken from shift in-charge of both the units. The soda loss from Mud filters is calculated based on these data. Recausticizing reaction: CaO + H 2O →

Ca(OH)2 [74] + Na2CO3 →

CaCO3 [100] + 2 NaOH

In reaction between Ca(OH)2 and Na2CO3, Ca(OH)2 is the limiting reagent. Thus, the whole CaO that converts to Ca(OH)2 can be assumed to convert to CaCO3. As the concentration of impurities in mud cake is very low, the dry solids in mud cake can be assumed to be 100% limestone. CaO Initial Final

→

A yX/100

CaCO3 0 (A – yX/100) * (100/56)

X = mass of dry solids y = % CaO in dry mud Now, (A – yX/100) * (100/56) = X; Thus, X can be calculated And if z = % TTA as Na2O, Total TTA as Na 2O = Zx/100

Data table 6.1, 6.2, 6.3, and 6.4 in Append ix A

The combined loss from Recovery 1 and Recovery 2 of the total soda loss through MUD CAKE in MUD FILTER is 7.232 %.

The corresponding loss in ORE from Recovery 1 and Recovery 2 through MUD CAKE in MUD FILTER is 0.677 %. The combined loss from Recovery 1 and Recovery 2 of the total soda loss through GRIFTS and STONES is 0.269 %.

The corresponding loss in ORE from Recovery 1 and Recovery 2 through GRIFTS and STONES is 0.035 %.

The combined loss from Recovery 1 and Recovery 2 of the total soda loss through MUD CAKE in MUD FILTER and GRIFTS and STONES is 7.232 %.

The corresponding loss in ORE from Recovery 1 and Recovery 2 through MUD CAKE in MUD FILTER and GRIFTS and STONES is 0.677 %.

A standard of 0.3% TTA as Na2O and 1% Ca(OH)2 by weight in Mud cake should be sought. 40 | P a g e

6.3.

PROCESS PARAMETER TESTING

Based on information collected through journals and case studies and on discussion with experts, a few process parameters that could affect the performance of mud filter were analyzed. The parameters are: a.

Vacuum

b.

Precoat mud cake thickness

c.

Vat solid composition

d.

Vat solid concentration

e.

% Moisture content

f.

Homogeneity in vat mixture

g.

Temperature

h.

Disc RPM [Retention time]

i.

Pre-Scrapper washing [Displacement washing]

 j.

Proper disc cleaning/Disc maintenance

6.3.1. VACUUM

For proper process the pressure should be close to 550 mmHg vacuum. The vacuum is manually controlled through vacuum pump. The pressure kept i s 530-560 mmHg, which is ideal requirement. 6.3.2. PRECOAT MUD CAKE THICKNESS

Less thickness would imply better effective pressure and better moisture control. The operation is done with mud cake thickness of 10 mm approximately. The designed value is 12 mm. 6.3.3. VAT SOLID COMPOSITION

Vat solid sampling is done to quantify the % TTA as Na 2O, % CaO and % Moisture in the mud cake. The results are discussed later. Minimum % TTA, % CaO and % Moisture are desirable. 6.3.4. VAT SOLID CONCENTRATION

In ideal condition, the vat solid concentration should be 15-18% solids. There are 3 points of dilution of feed from Mud Washer 2. First, a hot water stream dilutes the feed to 1.12-1.13 kgpl; this is maintained by an autovalve. Second, the hot water from HiPac system, used to scrap mud cake from filter, dilutes vat. Third, to maintain vat level hot water dozers are placed at bottom, however, they rarely open. Vat solid concentration sampling is done and results are discussed later. 6.3.5. % MOISTURE CONTENT

Lower the moisture implies lower the dissolved alkali content in a sample of mud cake. The % moisture in mud filter in recovery 1 is around 50, whi le in recovery 2 is 45. It is considerably high and should be reduced to 35-40%. Moisture content could be reduced by lowering disc RPM or lowering cake thickness

41 | P a g e

6.3.6. HOMOGENEITY IN VAT MIXTURE

As pressure is uniform across disc, homogeneity of vat solution is important for uniform functioning of disc. Vat homogeneity sampling is done and results are discussed later. 6.3.7. TEMPERATURE

Ideally, vat temperature should be 72-75 °C. Temperature results are discussed later. 6.3.8. DISC RPM

Disc RPM is kept at 85%. It could be decreased to provide sufficient time for moisture absorbance. 6.3.9. DISPLACEMENT WASHING

The rising side of the disc should be washed with hot water to facilitate displacement washing and thus reduction content in the mud cake. Samples are taken at different flow rates of washing; results are discussed later. 6.3.10. PROPER FILTER DISC CLEANING

As silica content is high in vat, around 8% as compared to wood based plants as 3%, choking of pores is more frequent. Cleaning is done with hot water once in every shift. Once in every 2 or 3 weeks cleaning is done though acid.

Experiment:

Mud cake (from Mud filter of recovery 2) sampling to test % Moisture, % TTA as Na2O and % Ca(OH) 2. Grits tested for % TTA as Na 2O and % Ca(OH)2.

Objective:

To analyze variation in mud cake composition that could adversely affect  mud filter performance. Also, to confirm the values of % TTA for ORE  calculations

Observation table:

Time

Units

Hours 930 1100 1500 930 1100 1500

Sample

1MC 2MC 3MC 1G 2G 3G

W1

g 47.87 49.02 48.32 49.01 50.14 47.28

W2

G 65.7 71.21 70.4 103.89 69.18 71.28

W3

g 57.57 61.62 60.15 93.28 65.14 65.65

Co de

W 5 M N E 3

% Moist ure

% 45.6 43.21 46.42 23.97 21.22 23.47

% TTA as Na2O Dry wt g 11.03 8.32 9.58

m 1.7 1.4 1.5

% TTA % 0.44 0.45 0.44 0.32 0.93 0.91

% Ca(OH)2 Dry wt

p

%

4.38 3.79 4.92

6.7 4.5 4.1

5.27 3.84 2.85 2.02 3.2 3.4

42 | P a g e

Conclusion: `The % TTA is around 0.45, approximately same as generally reported by QC laboratory. However, % Ca(OH)2 value is highly different and highly varying as well. The excess presence of lime decreases cake porosity and thus higher amount of alkali is retained in mud cake. The inefficient process of lime addition in slaker results in highly varying concentrations of  lime in the liquor that adversely affects the performance of the Mud filter. Causticizing control models are discussed later .

Experiment 6.1. Mud cake sampling from Mud filter of Recovery 2

Experiment:

Vat and Mud sampling to test for % Solids, Twaddell, GPL TTA as Na 2O, % Ca(OH)2 and Temperature at different zones in vat and mud filter 

Objective:

To analyze vat solid concentration, homogeneity in vat and mud cake and  temperature of vat 

Theory: The vat samples were taken at 3 different zones from vat to check for homogeneity. Zone A is deadzone with little turbulence, zone B is central volume, and zone C is highly turbulent just  above feed inlet.

AP

A

BP

C Disk

Vat

B

INLET

43 | P a g e

Observation table and Results:

Vat Homogeneity Sampling Time

Sample

% Solid

Twaddell

1045 1045 1045 STD DEV 1300 1300 1300 STD DEV 1600 1600 1600 STD DEV

A1 B1 C1

12.42 15.69 13.4 12.12 19.57 29.34 30.81 22.99 23.36 21.05 20.64 6.76

18 24 19 15.80 24 26 22 8.3 27 26 27 2.16

A2 B2 C2 A3 B3 C3

TTA (Na2O GPL) 1.84 2.27 1.97 10.88 2.46 2.4 2.4 1.43 2.21 2.77 2.58 11.30

40

Ca(OH)2 (%) 3.23 2.15 2.55 20.65 1.61 1.42 1.42 7.39 2.02 1.55 1.9 13.39

Temp (°C)

Avg % Solid

65

13.83

65

26.57

64

21.68 31.04

% Solid

30 Sample 1

20

Sample 2

10

Sample 3

0 0

4

2

% Ca(OH)2

3 Sample 1

2

Sample 2

1

Sample 3

0 0

2

4

3 2.5 2 1.5 1 0.5 0

4

Mud Cake Homogeneity Time Sample % Moisture 1045 AP1 41.88 1045 BP1 42.73 STD DEV 1.42 1300 AP2 46.7 1300 BP2 49.96 STD DEV 4.76

TTA (GPL) Sample 1 Sample 2 Sample 3 0

2

4

TTA, % Na2O 0.347 0.357 2.00 0.483 0.447 5.47

44 | P a g e

0.6

52

0.5

50

0.483

0.447 0.347 0.357

0.4 0.3 0.2

48 Sample 1 Sample 2

0

40 2

Sample 1

44 42

1

46.7

46

0.1 0

49.96

3

41.88 0

1

Sample 2

42.73

2

3

Conclusion: a.

The % Solid variation is huge. It should remain between 15-20 % for proper moisture absorbance. The last 2 observations were taken with autovalve maintaining density of 1.135 kgpl, and first observation was taken with 1.12 kgpl. -3

Density (solid phase) of limestone = 2.25 gcm  ; thus, K = 1.8 Thus, for 1.135 kgpl, %Solid = 21.41 % & for 1.12 kgpl, % Solid = 19.28 % Glossary: -3

Twaddell:

It helps to measure density instantly. To convert °Tw to kg/l or gcm  , remove the decimal and 1 before it. Multiply the rest with 2. E.g. 1.12 kg/l = 24 °Tw.

% Solid  and Density:

b.

 %  =    =  −1

=,  =   ℎ

There is contrasting difference in concentrations at different zones in vat and mud cake. The difference in vat concentration result in non-uniform mud cake formation on mud   filter and thus, performance of the filter suffers. However, the deviations are minimized  over mud cake as disk passes through huge volumes. The %Standard Deviations are calculated that give standard deviation over average of that quantity. A proper agitation system needs to be installed to maintain homogeneity and reduce alkali loss. Such system is installed in Drum filter of Recovery 1.

c.

The temperature of vat solution is 65 °C, but it should be 72-75 °C. The feed to the Mud filter is received from LMS tank, which is dozed by hot water to maintain required density. LMS tank has supply of steam from power boiler (Pr. 4.55 atm and temp. 150 °C). With complete opening of steam valve the temperature inside LMS tank is 70 °C, thus it cannot be further increased. There is no steam line in Mud   filter. The hot water is received from evaporator at approximately 67-70 °C. The reason of loss in temperature from LMS to vat is due to presence of no insulation of feedline to Mud filter. By providing insulation temperature can be kept at around 70 °C.

Experiment 6.2. Vat and Mud sampling to test homogeneity from Mud filter of Recovery 45 | P2a g e

A washer system is installed in the mud filter that is used to clean the disk. The same washer can be used with less flowrate during process for displacement washing. The experiment was conducted with different flowrates of washing.

Experiment:

Calculation of % TTA as Na2O at different flowrates of washing

Objective:

To analyze effect of displacement washing on Mud cake at different   flowrates of washing

Observation table and Results:

Day 1 Sample

Flowrate (%)

% Moisture

A1

0

50.63

TTA (NA2O %) 0.543

A2

20

48.97

0.34

Sample

Flowrate (%)

% Moisture

B1

0

48.58

TTA (NA2O %) 0.796

B2

10

48.76

B3

20

B4 B5

% Reduction

Cumulative % Reduction

37.39

37.38

% Reduction

Cumulative % Reduction

0.442

44.47

44.472

48.54

0.478

39.94

-8.14

30

48.41

0.486

38.94

-1.67

40

48.28

0.423

46.85

12.96

Sample

Flowrate (%)

% Moisture

C1

1

43.52

TTA (Na2O % ) 0.61

C2

10

43.71

C3

20

C4 C5

Day 2

Day 3 % Reduction

Cumulative % Reduction

0.51

16.39

16.39

45.76

0.55

9.83

-7.84

30

46.78

0.5

18.03

9.09

40

47.4

0.56

8.19

-12

46 | P a g e

% Moisture - B 48.8

% Moisture - C

48.76

48.6

48.58

48.54 48.41

48.4

% Moisture

48.28

48.2 0

20

40

48 47 46 45 44 43

60

47.4 46.78 45.76 % Moisture 43.5243.71 0

20

% TTA Na2O - B

40

60

% TTA Na2O - C

1

0.8

0.8

0.796

0.6

% TTA

0.2 0

0 20

40

0.56

% TTA 0.2

0

0.51 0.55 0.5

0.4

0.442 0.478 0.486 0.423

0.4

0.61

0.6

60

0

20

40

60

*Composite sampling is done to minimize variation due to non-homogeneity. Conclusion: There is considerable reduction in alkali content on displacement washing. However, the curve is not linearly decreasing as assumed; thus, there is no considerable difference on increasing the flowrate. There is no major difference in % Moisture content of mud cake on washing, thus, most of the water reabsorbed by mud cake is extracted back with filtrate. The effects of displacement washing can be increased by increasing the porosity of the cake. Lime mud cake has very less porosity and thus, displacement washing is not much effective. Considerable decrease in moisture content on displacement washing can be achieved by  using Filter Aids. Principle types of Filter Aids include Diatomaceous Earth (DE), Perlite, cellulose and Rice hull ash. Each type has its own characteristics, advantage and  disadvantages. NALCO supplies filter aids for mud washing in lime mud filters with a product  code NALCO 7560. It is a surfactant based filter aid, which is currently used by BILT and ITC. The feed is very small as 200g/T i.e. 0.02% by wt. Thus, there is no increase in impurity of  mud cake. Also it evaporates at 800 °C and thus, will not stick on walls of lime kiln, if  operated.

Experiment 6.3. Displacement washing in mud filter of Recovery 2

47 | P a g e

6.4.

CAUSTICIZING CONTROL MODELS

In the slaker the amount of lime to be added depends upon causticizing efficiency required and feed TTA (as Na2O). Presently, the operator measure the °Tw in inlet GL and keeping the °Tw difference to a certain value depending upon GL TTA in slaker outlet, adds lime. The lime addition is manually controlled and temperature variation provides information to operator when to stop adding further lime. GL TTA

°Tw difference

92-93

8

85-86

9-10

The objective is to maintain TAA above 80. But causticizing efficiency is compromised and this leads to excess lime addition in the system.

6.4.1. CAUSTICIZING EFFICIENCY

TTA is measured in lab once in 2 hours (as done presently). TTA and density (Twaddell) are used to calculate a conversion factor for converting TTA values into density (Twaddell) and vice versa. The conversion factor is calculated form results in the previous 8 or 24 hours. Now, based on Goodwin’s curve the degree of causticizing is decided. The sulfidity can be taken as 5% (based on general observation). TTA (Na2O GPL)

80

85

90

95

100

105

CE%

89

88

87

87

86

85

The NaOH (GPL Na2O) can be related to continuous temperature difference measurement and density (Twaddell) measurement, verified by titration results.

6.4.2. GREEN LIQUOR CONTROL AND CAUSTICIZING CONTROL

In this model the incoming GL is made uniform by WWL dozing. The TTA is maintained at around 85 GPL as Na2O. The corresponding CE% is 88 and NaOH GPL as Na 2O is 70. Particular lime feeding rate can be noted based on temperature and density. Uniform lime feeding needs to be done.

6.4.3. ADVANCED CAUSTICIZING CONTROL WITH KAJAANI ALKALI

In causticizing control there are 2 different control loops, GL TTA control and WL CE% control. GL TTA control stabilizes the TTA value of GL flowing to the slaker. WL CE% control stabilizes the causticizing degree of produced white liquor. The CE% of lime milk is used as a short feedback signal to the dT controller. Recovery 2 doesn’t have a proper lime feeding system and it’s presently manually controlled. In order to switch on to advanced control, the feeding system needs to be automated as well. Metso Kajaani Causticizing Control and Kajaani Alkali Analyzers are 2 such causticizing control models supplied by Metso.

48 | P a g e

7.

PULP MILL SODA CARRYOVER

7.1.

PULP MILL SODA CARRYOVER ORE LOSS

Data table 7.1, 7.2 and 7.3 in Appendix A

The loss through SODA CARRYOVER WITH PULP in SFL from total soda losses is 36.75 %. The loss through SODA CARRYOVER WITH PULP in WFL from total soda losses is 32.84 %. The corresponding loss in ORE in SFL as SODA CARRYOVER WITH PULP is 4.975 %. The corresponding loss in ORE in WFL as SODA CARRYOVER WITH PULP is 5.427 %. The combined loss through SODA CARRYOVER WITH PULP in SFL and WFL from total soda losses is 69.59 %.

The corresponding loss in ORE in SFL and WFL as SODA CARRYOVER WITH PULP is 5.108 %.

The losses from Soda carryover with pulp in SFL and WFL lines are huge and solutions must be sought for reduction in these losses. The solutions are discussed later in this section A standard of 8-10 kg/MT of TTA as Na 2O as soda carryover with pulp in both SFL and WFL individually needs to be targeted.

49 | P a g e

7.2.

PULP MILL PRODUCTION VERSUS SODA CARRYOVER LOSSES

Soda carryover as kg/MT TTA as Na2O for WFL is very high. It is suggested that as the WFL production has increased, Soda carryover as kg/MT has also increased manifold. Soda carryover versus Production curves are plotted for SFL and WFL and their relationship is studied. Data table 7.4 and 7.5 in Appendix A

For WFL,

Production 1000 800 y = 0.5626x - 21966

600

Production

400

Linear (Production)

200 0 03-Dec

22-Jan

13-Mar

02-May

21-Jun

Figure 7.1. Production versus Time in WFL

Soda carryover 30 25 20

y = 0.0859x - 3437.6

15

Soda carryover as kg/MT

10 Linear (Soda carryover as kg/MT)

5 0 03-Dec

22-Jan

13-Mar

02-May

21-Jun

Figure 7.2. Soda carryover as kg/MT of unbleached pulp versus Time in WFL

50 | P a g e

Production and Soda Carryover 900

30

800

25

700

y = 0.5626x - 21966

600

20

500

Weekly Production

15

400 300

Soda Carryover as kg/MT Linear (Weekly Production)

10

200

5

100 0

y = 0.0859x - 3437.6

0

03-Dec

22-Jan

13-Mar

02-May

21-Jun

Figure 7.3. Production and Soda carryover versus Time in WFL

Soda Loss vs Production 50 45 40 y = 0.0301x - 2.0499 R² = 0.1547

35 30

% Soda Loss vs Production

25 20

Linear (% Soda Loss vs Production)

15 10 5 0 500

550

600

650

700

750

800

Figure 7.4. Soda carryover versus Production in WFL

51 | P a g e

For SFL,

Production 1800 1600 1400 1200 1000 800 600 400 200 0 03-Dec

y = 1.2705x - 49723 Production Linear (Production)

22-Jan

13-Mar

02-May

21-Jun

Figure 7.4. Production versus Time in SFL

Soda carryover 40 35 30 25

Soda carryover as kg/MT

20 y = -0.0013x + 68.687

15 10 5 0 03-Dec

22-Jan

13-Mar

02-May

21-Jun

Figure 7.5. Soda carryover as kg/MT of unbleached pulp versus Time in SFL

52 | P a g e

Production and Soda Carryover 1800

35

1600

30

1400

25

1200

y = 1.2705x - 49723

1000

20

Production

800

15

Soda Carryover as kg/MT

10

Linear (Production)

600 400 200

5

0

0

03-Dec

22-Jan

13-Mar

02-May

y = -0.0013x + 68.687

21-Jun

Figure 7.6. Production and Soda carryover versus Time in SFL

Soda Loss vs Production 40 35 30

% Soda Loss vs Production

25 Linear (% Soda Loss vs Production)

20

y = -0.0009x + 17.369

15 10 5 0 500

700

900

1100

1300

1500

1700

1900

Figure 7.8. Soda carryover versus Production in SFL

A standard of constant soda carryover with production is targeted.

53 | P a g e

Observation (WFL): The production has risen over last few months but soda loss as kg/MT has also risen very swiftly over the same period.

Observation (SFL): There has been an increase in production, but the soda loss has remained constant over the same period.

Conclusion: As soda loss as kg/MT is rising with production, it shows the maximum capable load of washers has been reached. Further increase in production affects the washer performance. It is necessary that steps should be taken to improve the efficiency of washers to make them capable of handling the increased load. Else, new washers need to installed in the process line to reduce the load on individual washers. On the other hand, for SFL, the operation is within the maximum capable load of washers and even an increase in production doesn’t affect the washers’ p erformance.

7.3.

WASHER EFFICIENCY FOR SFL AND WFL

Figure 7.9. Brown Stock Washer

54 | P a g e

Presently, Soda carryover as kg/MT of unbleached pulp TTA as Na2O for SFL is around 15 and for WFL is around 24. It is necessary to further reduce the soda loss as it contributes approximately 70% to the total soda loss in the system. Various steps can be taken to reduce soda loss from washers. Presently 2 projects are going on, one in each, in SFL and WFL to reduce soda loss by increasing the efficiency of washers. Solutions given in WFL are maintaining proper vat concentration, proper nozzle (for displacement washing) flow rate, maintenance of nozzles and proper vacuum. In SFL, the project is focused on increasing the vacuum in the washers, which are inefficient presently.

7.3.1. TOTAL WASHABLE ALKALI AS SODA CARRYOVER IN WFL

It was suggested that the increase in loss in WFL is due to increase in bound soda loss and it cannot be retrieved. Elemental analysis of washed pulp is conducted to calculate washable alkali in the sample. Thus, % of bound alkali to total alkali is calculated.

Experiment:

Elemental analysis of filtrate of thoroughly washed pulp from final washer in WFL to calculate total washable alkali as kg/MT of dry unbleached pulp TTA as Na2O.

Objective:

To calculate total washable alkali in a sample of pulp from final washer 

Observation table and Results:

Sample

TWA1

Wet Wt

Dry Wt

Vol. of  Solution

Density

Wt. of  solution

g

g

ml

g/ml

g

10.701

1.626

1000

0.9758

975.48

Na

TWA

PPM

g

as Na2O

kg/MT TTA as Na2O

15.8

0.0154

0.0208

14.79

Total soda carryover as kg/MT TTA as Na 2O for same sample is 24.19 and % Moisture is 84.8. Thus, % washable alkali =

Conclusion:

62.87 of total soda carryover in unbleached pulp.

A large percentage of total soda carryover in unbleached pulp is washable and can be retrieved.

Experiment 7.1. Analysis of total washable alkali in washed pulp in WFL

55 | P a g e

8.

PULP MILL REJECT

8.1.

PULP MILL REJECT ORE LOSSES

8.1.1. TOTAL SODA LOSS CALCULATIONS

To calculate soda losses from pulp mill reject the amount of reject and its composition is required to be known. There are 3 reject streams in SFL. The total reject is 1.2 % of unbleached pulp. The ratio of reject from these exit streams is: Screen 1 (Thick mesh) : Sand Box : Screen 2 (Thin)

=

0.35 : 0.15 : 0.50

There are 2 reject streams in WFL. The total reject is 1 % of unbleached pulp. The ratio of reject from these exit streams is: Vibratory Screen (Thick) : Pressure Screen (Thin)

=

0.42 : 0.58

Samples were collected from the reject streams in SFL and WFL respectively with weights from different streams in the ratio of their reject ratio.

Experiment:

Reject stream analysis for TTA as Na2O in kg/MT of dry sample rejected 

Objective:

To calculate TTA as Na 2O in kg/MT for ORE loss calculation

Observation table and Results: For SFL,

Sample

% Moisture % 82.29 82.77 80.72 81.31

D11 D12 D21 D22

Wet wt g 11.988 11.405

TTA (as Na2O in kg/MT) Dry wt m g ml 6.8 7.2 1.381 3.221

TTA kg/MT 49.2 56.27 52.79 52.76

For WFL,

Sample

D11 D12 D21 D22

% Moisture % 68.71 63.02 64.10 68.21

Wet wt g 8.32 7.97

TTA (as Na2O in kg/MT) Dry wt m g ml 13.56 16.10 4.597 2.068

TTA kg/MT 80.06 83.95 52.79 52.76

TTA as Na2O in kg/MT for SFL is 52.76 and for WFL is 81.82.

Experiment 8.1. Reject stream analysis for TTA in WFL and SFL 56 | P a g e

8.1.2. TOTAL WASHABLE SODA LOSS CALCULATIONS

Experiment:

Elemental analysis of filtrate of thoroughly washed pulp from reject streams to calculate total washable alkali as kg/MT of dry unbleached pulp TTA as Na2O.

Objective:

To calculate total washable alkali in a sample of pulp from reject stream

Observation table and Results:

Sampl e

Unit

A Wet wt g

B Sol. Density g/ml

Form ula

C Sol. Wt g

D Dry wt g

H

E Na as Na2CO3 g

F Na as Na2O g

H* (C/10 ^6)

I*(53/2 3)

I*(31 /23)

0.114

0.262

0.153

Na

PPM

100 0*B

S Thick 9.096 0.966 966 1.042 1 S Thin 20.026 0.952 952 5.429 1 WThic 11.079 0.97 970 2.404 k1 W Thin 7.676 0.968 968 1.922 1 S Thick 10.616 0.963 963 1.112 2 S Thin 8.381 0.978 978 2.213 2 WThic 9.612 0.979 979 2.118 k2 W Thin 14.781 0.959 959 2.927 2 *For average TWA, the weights are taken as

I

117. 6 120. 4 238

g

G % Moist % [1(D+E) /A]*1 00 85.65

TWA as Na2O kg/MT

TWA avg kg/MT

[F/(E+D) ]*1000

117.440 50.990

0.115

0.264

0.154

71.57

27.136

0.231

0.532

0.311

73.5

105.981 55.3

28.9

0.028

0.064

0.038

74.13

18.981

178. 6

0.172

0.396

0.232

82.73

153.690

46.3

0.045

0.104

0.061

76.32

26.337

178. 1

0.174

0.402

0.235

68.28

93.265

52.6

0.050

50.82

57.28 0.116

0.068

69.71

22.345

equal to reject ratio.

Conclusion: Assuming the total soda content same as for previously done sampling, % Soda as washable with respect to total soda are: SFL:

96.54%

WFL:

68.96%

57 | P a g e

Thus, a large fraction of soda rejected in the reject stream can be retrieved by hot water washing. Assuming that we can retrieve 50% of washable alkali content, then we soda washable in SFL is 24.45 kg/MT and in WFL 28.145 kg/MT.

Thus, % alkali retrieved of total alkali content is: SFL:

48.27%

WFL:

34.48%

Average pulp loss through reject in MT (from June 1 to June 17): SFL:

2.369 MT

WFL:

1.399 MT

Thus, % Alkali that can be retrieved,

 + 34.48∗1.399 = 48.27∗2.2.369369+1. 399 = 43.15 % Thus, Reduction in ORE, = (0.4315) * 0.201 = 0.087 % Or, New ORE loss, = 0.114 %

Experiment 8.2. Analysis of total washable alkali in pulp from reject stream in WFL and SFL Based on above data, ORE losses are calculated for Reject stream in SFL and WFL. Data table 8.1 and 8.2 in Appendix A

The total soda loss as SODA CARRYOVER WITH REJECT in SFL and WFL from total soda losses is 2.81 %.

The corresponding total soda loss in ORE as SODA CARRYOVER WITH REJCT in SFL and WFL is 0.201 %.

The total washable soda loss as SODA CARRYOVER WITH REJECT in SFL and WFL from total soda losses is 2.34 %.

The corresponding total washable soda loss in ORE as SODA CARRYOVER WITH REJCT in SFL and WFL is 0.167 %.

A standard of reduction of loss in ORE from Reject to 0.1 % should be set. 58 | P a g e

8.2.

REJECT STREAM WASHING

The reject streams in SFL and WFL are thoroughly studied and measures are suggested to decrease soda loss. To reduce washable soda loss in reject stream principle solutions are hot water alkali washing and pressure drying for reduction in moisture content. The devices related to reject stream in SFL line are HD (High density) Cleaner, Delta Knotter, Delta Screen, Opti Screen, Centricleaner and Vibratory Screen. The devices related to reject stream in WFL line are Vibratory Screen, Pressure Screen and Centricleaner.

For SFL,

Blow tank

Pulp + liquor

Filtrate tank 1

Liquor for dilution

HD Cleaner

[Conc. WBL]

Reject [Sand]

Sand Box (Mixed with Reject from Centricleaner and

Accept

thrown out) Liquor for dilution

Delta Knotter

Liquor for washing

Accept tank

Accept

Accept

Washer 1 & 2

Reject

Vibratory Screen [Thick mesh]

Reject

Thrown

[Wood chips, uncooked waste]

out

Blow tank Figure 8.1. HD Cleaner, Delta Knotter and Vibratory Screen in SFL

HD Cleaner is a centrifugation based filtering device similar to cyclone separator but for liquids. High density sand is settled at bottom and accept comes from top. In the system as there is no pressure drying moisture content is very high in reject and thus soda content is high. Also, concentrated liquor of Filtrate tank 1 is used which has highest BL content of all Fil trate tanks. Delta Knotter has pressure screens. High pressure difference in inlet and outlet pushes material through the screen. Again, washing is done with liquor from Filtrate tank 1. Vibratory Screen [Delta Knotter stream] receives reject from Delta Knotter, where vibratory action filters the pulp. The reject falling down is washed with liquor from Filtrate tank 1 that increases moisture and alkali content of the reject.

59 | P a g e

Figure 8.2. HD cleaner

Figure 8.3. Delta Knotter

Figure 8.4. Vibratory Screen

Press 1

Delta Thickener

Low Consistency Tank

Accept Liquor for dilution

Delta Screen

Liquor for dilution

Reject

Filtrate tank 3

Liquor for dilution

Opti Screen

Accept

Accept

Reject

Liquor for washing

Vibratory Screen [Thin mesh]

LC tank

Accept

Centricleaner [Pri-Sec-Ter-Quar]

[Sand] Reject

Sand Box

Dump tank

Reject [Shives]

Thrown out

Figure 8.5. Delta Screen, Opti Screen, Centricleaner and Vibratory Screen in SFL Delta Screen and Opti Screen are similar to Delta Knotter but the screens are thin. Also, a pressure plug, moved by a rotor pushes material through screen. The outlet is dry but the moisture content is increased on washing at Vibratory Screen. Centricleaner is based on principle same as cyclone separator. In the 4 units, pulp and paper flow counter wise.

60 | P a g e

For WFL,

Blow tank

Filtrate tank 1

Liquor for washing

[Conc. WBL]

Vibratory Screen

Reject

Accept

Washer 1

[Uncooked waste]

Thrown out

Figure 8.6. Vibratory Screen in WFL

The alkali content in reject from vibratory screen is very high as there is no washing or pressure drying.

Figure 8.7. Centricleaner

Figure 8.8. Delta Screen

Figure 8.9. Pressure Screen

Washer 3 Liquor for washing

Accept

Pressure Screen

Filtrate tank 4

Washer 4

Reject

Centricleaner [Pri-Sec-Ter-Quar] Reject

Vibratory Screen [Shives]

Dilution tank

Thrown out

Figure 8.10. Pressure Screen, Centricleaner and Vibratory Screen in WFL

61 | P a g e

Solutions suggested to reduce alkali loss from reject stream are: a.

Hot water header for washing

Instead of using liquor for washing the pulp in Vibratory Screens and especially liquor from Filtrate tank 1, a common hot water header can be made that takes its feed from hot water tank used to wash pulp in final washer or press. To avoid increase in hot water consumption and black liquor dilution, the Accept can be fed back to the hot water tank.

Hot water tank

Hot Water

Hot water for washing

Header

Vibratory Screen [Thick mesh]

Vibratory Screen [Thin mesh]

Sand Box

Accept Figure 8.11. Hot water header for washing

b.

Parallel cleaning in Centricleaner

Presently, flow in centricleaner bodies is anti-parallel. The liquor in the first stage gets highly concentrated. To incorporate soda washing in the process, a system of parallel flow of liquor into the different bodies can be provided.

c.

Pressure filter dryer

A pressure filter dryer can be installed common to both SFL and WFL. In these dryers, the reject streams are first washed with hot water. They are then dried by applying pressure. Thus maximum washable alkali can be extracted. The required size of such dryers is less considering the load. Thus, the capital cost is not too high. Further, depending upon the extent of alkali washing, best suitable size can be selected. Some of the suppliers of such filters are: a. 3Di Equipment Ltd b. Dhananjaya Global Business Solutions c.

GEA Barr-Rosin Inc.

d. Aeroglide Corporation e. MET-CHEM Inc. f.

Bhagwati Machines India Pvt Ltd

g. Arjun Technologies (I) Ltd 62 | P a g e

9.

ESP – ELECTROSTATIC PRECIPITATOR

ESP PHOTO!! Figure 9.1. ESP

Electrostatic precipitator (ESP) essentially consists of 2 sets of electrodes, viz. collecting electrodes and emitting (discharge) electrodes. These two electrodes are arranged in alternate rows. A unidirectional high voltage from a rectifier is applied between these 2 electrodes, connecting its negative polarity to the emitting electrodes and the positive polarity to the collecting electrodes which are earthed. Because of physical configuration field in the neighborhood of the emitting electrode is very high. The dust laden flue gas from boiler passes between rows of collecting and discharge electrodes. The gas molecules which are normally neutral are ionized due to the presence of high electric field. The positive charges of the ions created travel towards the discharge electrodes and the negative charges (ions and electron) towards the collecting electrodes. On the way to the collecting electrode, the negative charges get attached to the dust particles. Thus the dust particles are electrically charged. In the presence of hig h electric field between emitting and collecting electrodes the charged dust particle experience a force whi ch causes the particles to move towards the collecting electrodes and finally get deposited on them. A minor portion of dust particles which have acquired positive charges get deposited on the emitting electrodes also. Periodically these particles are dislodged from the electrodes by rapping the electrodes. The particles then fall into the bottom from where they are removed by the ash deposal system.

63 | P a g e

Various parts of the precipitator are: a. Precipitator chamber b. Discharge system c.

Collecting system

d. Gas distribution system e. Dust conveying system f.

Flue gas valve

g. Rectifier-Transformers

9.1.

BHEL ESP SYSTEM

Design Parameter

Design Value

Unit

31.45

m /s

170

°C

Inlet dust concentration

16

g/Nm

Outlet dust concentration

75

mg/Nm3

99.53

%

No. of fields in series

3

Units

Press. drop across precipitator

25

mmWC

Gas velocity (inside ESP)

0.66

m/s

Treatment time

14.65

s

8

Units

25 for field 1 and 21 for field 2 and 3

Units

97.68

s/m

Gas Flow rate Inlet Temperature

ESP efficiency

No. of collecting electrode in a row in a field No. of rows of CEs per field Specific collection area

3

3

Table 9.1. BHEL ESP Design Conditions

64 | P a g e

9.2.

PROCESS PARAMETERS

The parameters are divided as constant and variable parameters based on the scope of variation in their values in the installed ESP at Recovery unit in Abhishek Industries. Constrained/constant parameters are: a.

Aspect ratio; Height, length and spacing of collection plate i. e. crossection area of ESP

b. Diameter of entering particles c.

Gas uniformity/Gas distribution

d. No. and type of discharge electrodes and collection plates e. Sneakage f.

Particulate size distribution

Variable parameters are: a. Gas flow rate; Treatment time; Velocity b. Temperature c.

Moisture

d. Gas composition [Flue gas conditioning] e. Gas viscosity f.

ESP ash composition

g. Peak Voltage; Spark rate; Energization h. Pressure drop i.

Resistivity

 j.

Re-entrainment

k. Specific Collection Area l. Inlet dust load m. Effectiveness of dust removal system Many of the above mentioned parameters are inter-related. All the parameters can be reduced to 5 basic variables: a.

Collection Efficiency

Theoretical collection efficiency is given by Matts-Ohnfeldt equation6,

6

Rose, H. E., and A. J. Wood.  An Introduction to Electrostatic Precipitation in Theory and Practice

65 | P a g e

Or,

Certain values like particle size distribution and gas viscosity could not be calculated, thus, theoretical collection efficiency could not be calculated. Practical collection efficiency is calculated from inlet dust concentration and outlet dust concentration of an ESP under process. Practical Collection Efficiency,

  =      

*100

Practical Collection Efficiency calculations are done and results are discussed later.

b.

Resistivity

Resistivity, which is a characteristic of particles in an electric field, is a measure of a particle's resistance to transferring charge (both accepting and giving up charges). Resistivity is a function of a particle's chemical composition as well as flue gas operating conditions such as temperature and moisture. Particles can have high, moderate (normal), or low resistivity7.

7

Rose, H. E., and A. J. Wood.  An Introduction to Electrostatic Precipitation in Theory and Practice

66 | P a g e

Table 9.2. ESP characteristics with Resistivity;

Source: Adapted from U.S. EPA 1985

Fly ash from Recovery boilers tends to have a good resistivity. The reason for this good resistivity comes from the chemistry of the process. Typical alumina (Al2O3) and silica (SiO2) content (which are poor electrical conductors) is high. Also since combustion is commonly done with a wet fuel in a mass type firing mode, it typically generates a higher level of conductive carbon in the ash. Lastly, the surface moisture of the fuel and inherent hydrogen in cellulose, cause the flue gas to have appreciable moisture (typically 15-25%). This flue gas moisture tends to give some "surface conditioning", or a conductive liquid film to the particulate. These factors result in "good" resistivity for ESP ash8. Resistivity measurements could not be done in laboratories of the company. The company can send sample for resistivity to some other labs which will provide important information on flue gas characteristics. Also, the reason of ash build up on ESP and frequent conveyor failures can be high resistivity of ESP ash that means high cohesivity. Thus, the correct reason for current problems in ESP can be known. 8

Prakash H. Dhargalkar, Jose Astolphi, Jr.  Advancements in air pollution control for pulp and paper industry 

67 | P a g e

c.

Specific Collection Area (SCA)

The specific collection area (SCA) is defined as the ratio of coll ection surface area to the gas flow rate into the collector.

Most conservative designs call for an SCA of 20 to 25 m 2 per 1000 m 3/h to achieve collection efficiency of more than 99.5%. Total collection area in Recovery 1 = 3276.8 m2 [(48*8*0.4*8) + 2*(40*8*0.4*8)]

d.

Aspect Ratio

Aspect ratio relates the length of an ESP to its height and is an important factor in reducing rapping loss (dust re-entrainment).

Aspect ratios for ESPs range from 0.5 to 2.0. However, for high-efficiency ESPs (those having collection efficiencies of > 99%), the aspect ra tio should be greater than 1.0 (usually 1.0 to 1.5). For Recovery 1, Length of each plate

= 0.4 m

No. of plates in each field

=8

Thus, total length of plates in each field = 3.2 m

e.

No. of fields

=3

Thus, total length of plates

= 9.6 m

Thus, Effective length

= 9.6 m

Effective height

=8m

Thus, AR

= 9.6/8

= 1.2

Corona Power

The corona power is the power that energizes the discharge electrodes and thus creates the strong electric field. A strong electric field is needed for achieving high collection efficiency of dust particles.

68 | P a g e

The following values are recorded for Recovery 1 and 2: For Recovery 1, Field 1 2

Peak Voltage Average Voltage Current [mA] (Supplied) [kV] [kV] 65 50 80 65 50 100 Table 9.3. Corona power of ESP of Recovery 1

Corona Power, Pc [kW] 4 5

*The values are taken normal performance; ESP at Recovery 1 is producing less corona power most of the time

For Recovery 2, Field 1 2 3

Peak Voltage Average Voltage Current [mA] (Supplied) [kV] [kV] 65 62 53 95.5 83.6 154 55 45 250 Table 9.4. Corona power of ESP of Recovery 2

For Recovery 1, total Pc =

9.00 kW

For Recovery 2, total Pc =

27.41 kW

Corona Power, Pc [kW] 3.286 12.874 11.250

The corona power generated in Recovery 1 and Recovery 2 at normal conditions is close to ideal values. However, as mentioned ESP of Recovery 1 often produces reduced Corona power and thus its performance is adversely affected.

f.

Dust dislodging system

Dust build up on collection plate reduces corona power of the field and sometimes lead to back corona, further reducing electric field strength. With the installment of Alstom controller for rapping, dust dislodging is highly improved. The problem of inefficient performance of ESP and frequent failures of conveyor belt was supposed to be due to rapping problems.

69 | P a g e

9.3.

Collection Efficiency

Practical Collection Efficiency,

  =      

*100

The outlet dust concentration is taken from flue gas analyzer. For inlet dust concentration, an experiment is performed on Ash mixing tank.

Experiment:

For Recovery 2, density of AMT is noted at different time intervals with ESP ash falling rate as the only variable and rest as constants. Gas flowrates are noted down for different sampling periods.

Objective:

To calculate rate of ash collected in ESP through sampling AMT density. With known gas flowrate practical collection efficiency is calcul ated.

Procedure: To calculate inlet dust concentration, two parameters can be evaluated – ash collection rate and inlet gas flow rate. The ratio of Ash collection rate to Inlet gas flow rate when added  with outlet dust concentration will give Inlet dust concentration.

     +  .     =  ℎ    To calculate ash collection rate AMT density sampling is done. The outlet flow to MDT from  AMT was closed and the level in the tank is made to rise to 65% as displayed on DCS. WWL and hot water inlet supply is then closed to maintain the volume constant during sampling  period. Density of AMT sample was taken at an interval of 15 minutes. The solids fired in the boiler remained constant during the experiment. The soot blowing was switched off to prevent ash from superheaters, boiler bank and economizer from falling into the tank. The system is assumed to be in steady state with no excess ash falling and no ash building on collection plate. Multiple samples are taken to determine average ash collection rate as there is variability in ash falling rate depending upon rapper frequency. We assume that all the ash falling is collected and is falling from ESP only during the experiment. Constants during the experiment are time interval, tank le vel, MDT outlet flow = 0, Hot water  inlet flow = 0, WWL inlet flow = 0, firing rate, % solids in BL, soot blower = off. Variables during the experiment are Gas flow rate and ESP ash quantity.

70 | P a g e

Gas flowrates and their temperatures are taken are taken from DCS. Collection efficiency is calculated after processing these values in appropriate units.

Observation table and Results:

Tank Volume = 10 m3 Tank Level = 63.5 % Thus,

Volume of tank filled = 6.35 m3

 ρ 0.75 (kg/m3) Temp 200 (°C) Pressure = 1 bar 

0.8

1.2

160

30

Firing rate = 26 TPH Solids firing rate = 17.5 TPH  Amount of water = 8.5 TPH Vapor generation rate = 3.11 3 (m  /s)

Symbol Sample

Time

Hours

Unit

Temp. at density calculation

Twaddell

°C

Density

Weight

Volume

Ρ

g

ml

kg/m3

A

B

∆ρ

ESP Ash collected (/15 min)

kg/m3

kg A*6.35

Formula

1

1445

39

15

53.138

50

1062.76

2

1500

40

16

53.29

50

1065.8

3.04

19.304

3

1515

41

17

53.558

50

1071.16

5.36

34.036

4

1530

40

18

53.724

50

1074.48

3.32

21.082

5

1545

40

19

54.01

50

1080.2

5.72

36.322

71 | P a g e

   0    1    D

   9    D

   8    D

   t    e    N

   s     /    3    m    N

   3    D    +    2    D    +    1    D

   4    4    5    5    5    7    7    8    9    9    4    4    3    2    2    6    6    1    6    6    6  .    6  .    3  .    9  .    9  .    4    4    4    3    3    1    1    1    1    1

   8    7    7    7    7    7    R    9    9    9    9    F    s    6    4    9    0    0    0    0    0     l     /     /    5    5    5    5    a    3    3    5    0    0    0    0    9    0    m    3    3    3    3    m    2    4    3    r    N     *    4    4    4    4    o    3    3    8  .  .    3  .    3  .    3  .    N    1    1    1    1    1    D    9    9    9    9     /    )    5    9    y    8    8    8    8    8    r    w   e    /    s    0    7  .    8    8    8    8    a    1    0    8    8    i    8    8    8    8    3    *    o   t    t    a     l    8    8    8    8    8    r    F    r    m   7    *    6    3    e  .    3  .    3  .    3  .    3  .    D    3    T     (    1    1    1    1    1    p    m    °    e    T

   0    0    0    0    0    3    3    3    3    3

   w   e    H    o   t    P    a     l    F    r    T

   7    D

   6    6    6    6    6

   8    1    1    3    5    5    R    8    4    0    0    F    s    6    4    8    6    6    0    4    4     l     /     /    1    6    0    0    a    3    3    5    1    6    5    5    6    6    9    D   e    m    8    3    8    8    2    8    t    r    m    8    8    5    1    1    a    o    N     *    9    5  .    9  .    7  .    5  .    5  .    R    N    D    7    7    7    7    7    w    o     l    6    3    1    1     /    )    F    y    5    6    r    5    5    3    1    1    s    0    7    s    a    w   e    /  .    5    8    1    1    5    a    d    o   t    3    1    0    0    5    0    5    1    1    a     *    D   G   n    l    8  .    8  .    4  .    1  .    1  .    F    r    m   4    *    o    6    1    1    1    1    1    c    D    3     (    1    1    1    1    1    e    S    p    9    9    9    0    9    m    °    5    5    5    6    5    e    1    1    1    1    1    T    w   e    H    o   t    P    a     l    F    r    T

   4    D

   3    D

   2    D

   4    4    3    2    2    3    3    3    3    3

   8    1    1    5    9    9    R    F    s    6    5    6    7    7    4    5     l     /     /    7    3    9    9    a    3    3    1    7    1    2    2    2    9    3    3    7    1    1    m    2    3    3    1    0    0    r    m    3    o    N     *  .    3  .    2  .    1  .    1  .    2    5    5    5    5    5    N    D    9    3    8    8     /    )    5    9    y    1    1    3    4    4    s    0    7    r    w   e    /  .    5    5    3    1    1    a    o   t    3    1    0    8    8    3    8    8    a     *     l     *    1    1    3    4    4    m    i    6    5    r    F    r    m   1  .    5  .    3  .    1  .    1  .    D    (    3    8    P    8    8    8    8

   1    D    e    m    i    T

   p    m    C    e    °    T

   5    7    6    7    6    9    9    9    9    9    1    1    1    1    1

   w   e    H    o   t    P    a     l    T    r    F

 .    2    2    3    3    5    2    2    2    2    2    2

   s    r    u    o    H

   5    0    5    0    5    4    0    1    3    4    4    5    5    5    5    1    1    1    1    1

   e     l    p    m    a    S     l    o     b    m    y    S

   1    2    3    4    5

   t    i    n    U

   a     l    u    m    r    o    F

   e    g    a    P     |    2    7    n   y    o   c    i    n    t    c    e    e    i    c     l    i     l     f    o    f    C   E

   0    0    1     *     )    I     /    G     (

   2    8    4  .    9    9

   t    s    n    i    u   o    D   t    r    t    a    e    t    I     l    n    n    I    e    t    c    e    n    N   o    C

   3    m    H    N    +    G     /    g

   6    6    1  .    3    2

   n    t    s    o    i    u   t    D   a    r    t    H   t    n    e     l    t    e    u   c    n    O   o    C

   3    m    N     /    g    m

   0    2    1

   n    o    t    t    e    s    i    g    u   a    r    a    t    D    G   t    n    r    e    e    e    v     l    c    n    n    I    o    A    C

   3    m    N     /    g

   n    o    t    t    s    i    u   a    r    t    F    D    t    n    e    e     l    c    n    I    n    o    C

    /    E    3    0    /     ]     )    m   0    0    0    N    6    1    *     /    *    g    B   5     [    (    1

   t    o    e    t    l    I    E    w   n    o     l    P    F    S    E

   s     /    3    m    N

   e    m    i    T

   e    g    a    r    e    v    a    F

   1    1  .    3    +    0    1    D

   s    r    u    o    H

   1    3    8    2    0    4    9    2    8    3    0    1    7    0    9    1    8    4    8    9    3    5    3    2    1    8    3    6    7  .    1  .  .    6  .    5    8    0    1    2    7    1    3    4    4    5    5    5    7    7    8    9    9    4    4    3    2    2    7    7    2    7    7    7  .    7  .    4  .    0  .    0  .    7    7    7    7    7    1    1    1    1    1    5    0    5    0    5    4    0    1    3    4    4    5    5    5    5    1    1    1    1    1

   e     l    p    m    a    S     l    o     b    m    y    S

   6    4    0  .    3    2

   1    2    3    4    5

   t    i    n    U

   a     l    u    m    r    o    F

Conclusion: The collection efficiency is close to designed value of 99.53. But to meet environmental  3

norms outlet dust concentration, must be 75 mg/Nm . Thus, required CE = 99.676. When the amount of liquor burned is increased to 27 TPH or 28 TPH, it is believed that outlet  dust concentration increases significantly. Thus, it can be deduced that maximum capable load of ESP is reached at firing rate of 26 TPH. It can be concluded that maximum collection efficiency of ESP is 99.50, under these conditions. To get 75 mg/Nm

3

outlet dust 

3

concentration inlet dust concentration should be 15 g/Nm . Thus, either process conditions can be varied like moisture or dust composition or inlet dust  load can be reduced to reduce outlet dust concentration. A multi-cyclone or other mechanical  dust collector is used to reduce the inlet dust load.

Specific Collection Area calculation: Total collection area =

3276.8 m2

Gas flow rate =

17.424 Nm3/s

Inlet temperature =

180 °C 

Outlet temperature =

160 °C 

Gas flow rate (@170 °C) =

26.344 m3/s

Thus,

SCA =

124.38 m2/m3s-1

For

1000 m3/hr, CA =

34.55 m2

For 99.5 % above efficiencies conservative SCA is 20-25 m2 for 1000 m3/hr. The SCA in operation is sufficiently above the ideal value.

Experiment 9.1. Calculation of Practical Collection Efficiency

3

A standard of outlet dust concentration equal to 75 mg/Nm in ESPs of both the units is targeted.

Figure 9.2. Dust collection systems

9.4.

DUST COMPOSITION

To understand dust characteristics, dust composition is very important. Quantity

Unit

Value

As Base Group

Moisture

% by weight

0.31

Loss on Ignition

% by weight

24.8

Carbonates as Na2CO3

% by weight

28

15.85

Sulfates as Na2SO4

% by weight

27.9

18.86

Chlorides as NaCl

% by weight

33.1

20.09

Acid insoluble

% by weight

0.42

Water insoluble

% by weight

0.19

Table 9.5. ESP dust composition Elemental analysis of ESP is also done to determine the amount of Na and K in the ash.

Experiment:

Elemental analysis of ESP ash to determine Na and K 

Objective:

To determine % of Na and K in ESP ash

Observation table and Results:

Sample 1 2

Wt of sol. (g) 10002 6251.88

PPM Na 39.8 76.3

K 67.8 108.8

Wt in g Na 0.398 0.477

% Wt K 0.678 0.68

23.044 - Na 35.765 – K

Conclusion: Based on above data and various journals, articles and discussions, the final composition of  ESP ash is concluded to be:

74 | P a g e

Quantity Na2SO4 K2SO4 NaCl KCl Na2CO3 K2CO3

Units mole mole mole mole mole mole

Value 0.098 0.098 0.283 0.283 0.198 0.066

The presence of K and Cl expressed as ratios: Chloride Enrichment Factor (CEF), Cl/(Na + K) mole %

=

29.525

For wood based paper plants, the general CEF value is 1.5-2.5 %. Potassium Enrichment Factor, (PEF), K/(K + Na) mole %

=

47.835

For wood based paper plants, the general PEF value is 1.2-2 %.

Experiment 9.2. ESP Dust elemental analysis To increase the collection efficiency of ESP, treating K and Cl can help.

9.5.

POTASSIUM & CHLORIDES PURGING

The chloride and potassium content in the ESP dust are very large. The presence of these elements adversely affects ESP and Recovery Boiler. High content of Chlorides and Potassium causes corrosion, cracking and fouling in Recovery boilers and causes ESP problems in form of inlet corona suppression and build ups on the ESP internals. Also, it is important to note that at low chloride concentrations, potassium has very little effect on sticky deposit temperature. On the other hand, when the chloride mole % [Cl/(Na+K)] exceeds 10%, potassium has a significant effect on lowering the sticky temperature.9

Figure 9.3. Effect of Chloride and Potassium on Sticky Deposit Temperature (TSTK) 9

Moyer S., Wiggins D., Blair M.A. and Hiner L.A. (2000). Liquor Cycle Chloride Control Restores Recovery Boiler   Availability 

75 | P a g e

The sticky temperature is the temperature that results in a sticky deposit with 15% liquid phase (TSTK). Of the various sources of potassium and chlorides in the system the important ones are10: a. Bound to wheat straw or wood b. Makeup caustic c.

Make up lime

d. Fresh water The 2 major points that can be interfered for reduction of potassium and chlori des are: a.

Wet washing

By adapting to rigorous wet washing and using hot water with minimum reuse of water, potassium and chloride content can be reduced. Potassium and chlorides easily dissolve in water and can be removed at the potential source. b.

Purging precipitator dust

The potassium and chlorine content is highest in precipitator dust. Thus purging precipitator dust and treating it is one important method of potassium and chlorides removal. Various methods for potassium and chlorides removal through preci pitator dust purging are: a. Ash Purging By purging some amount of ESP ash highly concentrated with potassium and chlorides, a proper balance can be maintained. It is practiced at Alabama River Pulp and Alabama Pine Pulp of 1200 and 1600 TPD capacity. It has disadvantage that alkali is also lost with ash and needs to be covered by makeup caustic. b. Ash leaching It is the most popular method where ash and water are mixed in a slurry. Most of the alkali remains solid while most of the potassium and chlorine dissolve. By centrifuge liquid fraction is separated from solid fraction, where liquid fraction is sent to waste water treatment and alkali is returned to liquor cycle. c.

Electrodialysis using a bipolar membrane

d. Specific crystallization processes Sodium sulfate and carbonate crystals are selectivel y removed from a concentrated filtrate stream containing potassium and chlorine. It is used in Champion International Corporation’s bleach filtrate recycle process in Canton, North Carolina. Systems based on Ash Leaching: a. AshLeach [Metso Power] b. ARC [Andritz] CEF in the range of 1.5 – 2.5 % and PEF in the range of 1.2 – 2 % are targeted. 10

Michael A., Craig J., A. Mark and Douglas W.  An overview of various strategies for balancing saltcake, chloride and potassium levels in an ECF kraft mill 

76 | P a g e

9.6.

ESP ORE LOSS

For Recovery 2

Outlet gas concentration = 120 mg/Nm3

Inlet dust concentration = 23.166 g/Nm 3

Gas Flow Rate = 17.424 Nm 3/s Thus,

With ESP shutdown,

Outlet SPM flow rate = 2.091 g/s or 0.181 MT/day

Outlet SPM flow rate = 403.64 g/s

% Weight of Na as Na2O = 31.06 Thus,

Thus,

Outlet Na flow rate = 0.0561 MT of Na as Na 2O/day

Outlet Na flow rate = 10.83 MT of Na as Na2O/day

Outlet Na flow rate (considering 2 hour ESP shut down) = 0.954 MT of Na as Na 2O/day

For Recovery 1 3

Inlet dust concentration = 23 g/Nm (Considering similar performance as Recovery 2 boiler) 3

With 80% collection efficiency, outlet dust concentration = 4.6 g/ Nm Gas flow rate = 5.5 Nm 3/s Thus, Outlet SPM flow rate = 25.3 g/s or 2.186 MT/day Thus, Outlet Na flow rate = 0.6789 MT of Na as Na 2O/day

Data table 9.6 in Appendix A

The soda loss in Recovery 2 through Flue gas carryover of total soda losses is 11.48 %. The corresponding loss in ORE in Recovery 2 through Flue gas carryover is 0.817 %. The soda loss in ORE in Recovery 1 through Flue gas carryover is 8.15 %. The corresponding loss in ORE in Recovery 1 through Flue gas carryover is 0.580 %. The combined soda loss in ORE in Recovery 1 and Recovery 2 through Flue gas carryover is 19.63 %. The corresponding loss in ORE in Recovery 1 and Recovery 2 through Flue gas carryover is 1.397 %

A standard of 75 mg/Nm3 of outlet dust concentration is targeted for Recovery 1 and Recovery 2. Also identified performance parameters must be in desired r ange.

77 | P a g e

10. ORE LOSS DATA

Mud Filter, Grifts and Stones

Flue gas carryover [ESP]

Soda Carryover with Pulp

Screen Losses in Pulp mill

Total

% Loss of Total soda loss

7.50

19.63

69.59

2.81

99.53

% Loss in ORE

0.712

1.397

5.108

0.201

7.418

Table 10.2. % Loss from significant loss points

99.53 % of the total soda losses are explained by these 4 major loss points. Steps to reduce soda losses from these points and set targets are discussed in the report before.

% Loss (ORE)

Recovery I & II

Date

01-Jun 17-Jun

Mud Filter

Grifts and Stones

0.677 0.035

SFL and WFL

Dregs Washer

Flue gas carryov er [ESP]

Condenser, Vibro Screen, & MDT Outlet

Seepage & Overflow

Soda Carryover with Pulp

Screen Losses in Pulp mill

Seepage & Overflow

0

1.397

0.05

0

5.108

0.201

0

Table 10.3. % Net Loss in ORE from individual loss points

ORE based on individual losses is 92.532 %.

Data table 10.1 in Appendix A

The average ORE based on stock (June 1st – June 17th 2010) is 94.000 % . If the suggestions are implemented and standards are met, ORE can be increased to 97-97.5 %. While the ORE from stock has come out to be 94 %, in general the ORE on average basis is approximately 94.5 %. However ORE based on individual losses has come significantly higher than that based on stock. The reason of difference in ORE based on stock and ORE based on individual losses could be: a. Screen losses are calculated based on limited number of sampling and could be lower than estimated. b. Due to very high soda carryover through pulp in WFL, ORE could have been affected. 78 | P a g e

11. FUTURE WORK a. A rigorous study can be done by quantifying loss data from every possible major soda loss source. b. WBL sampling should be done for few weeks and results should be analyzed. c.

Quotations for online analyzers can be invited from suppliers and the economic viability of  the change can be analyzed.

d. Samples should be analyzed while displacement washing for weeks and results should be tabulated to see any benefits. e. Mud cake sampling can be done with Filter Aids and benefits can be noted. f.

Causticizing control models can be studied for better lime control.

g. Proper steps should be taken to reduce soda loss in pulp carryover. h. % Charging (White liquor charged per tonne of fibres cooked in the digester) could be plotted against the soda carryover as kg/MT and production. A relative study can be done whether higher production has resulted in increased c harging and thus, increased soda loss. i.

Pulp mill reject should be treated with hot water and moisture should be reduced. Samples should be analyzed to observe any benefits.

 j.

ESP process parameters like resistivity and theoretical collection efficiency should be evaluated through an external lab for better u nderstanding of performance limitations.

k. The amount of Potassium and Chlorine needs to be reduced through proper steps.

In brief, First, Check Technical and Economic viability for a. Composite sampling or Automation in WBL testing b. Automation in lime slaking c. Filter Aid use in Mud filter d. Pulp mill reject washing e. Potassium and Chlorides purging With the proposed benefits if technical and economica l viability is found then, Perform rigorous sampling for a month to validate observations in a. WBL TTA b. Mud cake displacement washing c. ESP collection efficiency d. ESP Dust composition

79 | P a g e

12. REFERENCES Dalmon J. (1980). Electrostatic precipitators for large power station boile, Dalmon J. and Tidy D. (1972). A comparison of chemical additives as aids to the electrostatic  precipitation of fly ash Johnson M. (1996). The effect of humidity on the performance of electrostatic precipitators at  Tarong Power Station Harker J.R. and Pimkarkar P.M. (1988). The effect of additives on the electrostatic precipitation of flu ash Tran H.N. Kraft Recovery Boiler Plugging and Prevention Jaye P. H. History of Alabama River Pulp Company and The Claiborne Mill Complex  Unified Air Toxics, (August 2000). www.epa.gov/ttn/uatw/pulp/pulppg.html  Moyer S., Wiggins D., Blair M.A. and Hiner L.A. (2000). Liquor Cycle Chloride Control Restores Recovery Boiler Availability  Mckean W. and Jacobs R. S. (1997). Wheat Straw as a Paper Fiber Source M. Brongers, A. J. Mierzwa. Pulp and Paper  American Forest & Paper Association (AF&PA). (October 1999). www.afandpa.com Michael A., Craig J., A. Mark and Douglas W. An overview of various strategies for balancing sal tcake, chloride and potassium levels in an ECF kraft mill  Uschan R.M. and Trick L.C. (Sept. 1994). Corrosion Control Needs of the Pulp and Paper Industry  Rose, H. E., and A. J. Wood. An Introduction to Electrostatic Precipitation in Theory and Practice U.S. EPA 1985 Pirita Mikkanen. Fly ash particle formation in Kraft Boilers Hein A.G and Gibson D. Skewed Gas Flow Technology Improves P recipitator Performance Prakash H. Dhargalkar, Jose Astolphi, Jr. Advancements in air pollution control for pulp and paper  Industry  Ibach, S. Conversion to high solids firing Kraft Recovery Boilers, TAPPI Press ESP Design Parameters and Their Effects on Collection Efficiency, Lesson 3 Gallaer C. A. (1983). Electrostatic Precipitator Reference Manual . Electric Power Research Institute Coal and Ash Testing and Predictive Analyses, Neundorfer, Inc. Chandra A., Sanjeev Kumar, Subodh Kumar and Sharma P.K. Investigations on Fly Ash Resistivity: Development of Empirical Relations Based on Experimental Measurement  Thomas e. Sulpizio. Advances in filter aid and precoat Filtration technology. Presentation at the American filtration & separations society Rees, R. H. and Cain, C. W. (1990). Let Diatomite Enhance Your Filtration Environmental, Health, and Safety Guidelines Pulp and Paper Mills Arpalahti.O., White liquor preparation, Paper Making Science and Technology 

80 | P a g e

LIST OF EXPERIMENTS Experiment 4.1. FMEA on identified exit points of soda for permanent losses [Page 27] Experiment 5.1. Frequent sampling of WBL from SFL and WFL [Pag e 32] Experiment 6.1. Mud cake sampling from Mud filter of Recovery 2 [Page 42] Experiment 6.2. Vat and Mud sampling to test homogeneity from Mud filter of Recovery 2 [Page 43] Experiment 6.3. Displacement washing in mud filter of Recovery 2 [Page 46] Experiment 7.1. Analysis of total washable alkali in washed pulp in WFL [Page 55] Experiment 8.1. Reject stream analysis for TTA in WFL and SFL [Page 56] Experiment 8.2. Analysis of total washable alkali in pulp from reject stream in WFL and SFL [Page 57] Experiment 9.1. Calculation of Practical Collection Efficiency [Page 70] Experiment 9.2. ESP Dust elemental analysis [Page 74]

LIST OF TABLES Table 5.1. PME, SRE and ORE over Time [Page 31] Table 6.1. Loss through Mud filter for Recovery 1 and 2 [Page 84] Table 6.2. Loss through Mud filter for Recovery 1 and 2 combined [Page 85] Table 6.3. Loss through Grifts and stones for Recovery 1 and 2 [Page 86] Table 6.4. Combined loss through Mud filter and Grifts and stones for Recovery 1 and 2 [Page 87] Table 7.1. Soda carryover with pulp in SFL [Page 88] Table 7.2. Soda carryover with pulp in WFL [Page 90] Table 7.3. Combined soda carryover with pulp in SFL and WFL [Page 92] Table 7.4. WFL production and total soda loss [Page 94] Table 7.5. SFL production and total soda loss [Page 98] Table 8.1. Soda loss from Screens as Reject in WFL and SFL [Page 101] Table 8.2. Combined soda loss from Screens as Reject i n WFL and SFL [Page 104] Table 9.1. BHEL ESP Design Conditions [Page 64] Table 9.2. ESP characteristics with Resistivity [Pag e 67] Table 9.3. Corona power of ESP of Recovery 1 [Pag e 69] Table 9.4. Corona power of ESP of Recovery 2 [Pag e 69] Table 9.5. ESP dust composition [Page 75] Table 9.6. ESP ORE Loss [Page 106] Table 10.1. Average ORE based on stock [Page 108] Table 10.2. % Loss from significant loss points [Page 31] Table 10.3. %Loss in ORE from individual loss points [Page 31] 81 | P a g e

LIST OF FIGURES Figure 1. Sulfuric Acid Plant (SAP) at Abhishek Industries, Dhaula complex [Page 9] Figure 2. COGEN-1, a 20 MW unit at Abhishek Industries, Dhaula complex [Page 9] Figure 3. Demineralised water plant at Abhishek Industries at Dhaula complex [Page 10] Figure 1.1. Paper making process [Page 11] Figure 1.2. Paper making flowchart [Page 12] Figure 1.3. Chemical Recovery Cycle [Page 13] Figure 1.4. Multiple effect evaporators [Page 13] Figure 1.5. Recovery Boiler Process flow [Page 14] Figure 1.6. Recovery Boiler [Page 14] Figure 1.7. Recausticizing Process flow [Pag e 15] Figure 4.1. Process Flow Diagram of Recovery 2 [Page 18] Figure 4.2. Evaporator Process Flow Diagram [Page 19] Figure 4.3. 7 effect/11 body Evap. at Recovery2 at Abhishek Industries, Dhaula complex [Page 19] Figure 4.4. Condensers at Recovery 2 at Abhishek Industries, Dhaula complex [Page 20] Figure 4.5. Recovery Boiler Process Flow Diag ram [Page 20] Figure 4.6. Rotary lime kiln [Page 21] Figure 4.7. Recausticizing Process Flow Diagram [Page 23] Figure 4.8. Wet Washing in SFL [Page 24] Figure 4.9. Digester in SFL [Page 24] Figure 4.10. Pulp washing in SFL [Page 25] Figure 4.11. Digester Feed Belt in SFL at Abhishek Industries, Dhuala complex [Page 26] Figure 5.1. PME versus Time plot [Page 31] Figure 5.2. SRE versus Time plot [Page 31] Figure 5.3. ORE versus Time plot [Page 31] Figure 5.4. Proposed collection tank design for WBL composite sampling [Page 37] Figure 6.1. Lime mud filter flowsheet [Page 39] Figure 6.2. Vacuum disk filter sketch [Page 39] Figure 6.3. Vacuum disk filter in operation [Page 39] Figure 7.1. Production versus Time in WFL [Page 50] Figure 7.2. Soda carryover as kg/MT of unbleached pulp versus Time in WFL [Page 50] Figure 7.3. Production and Soda carryover versus Time in WFL [Page 51] Figure 7.4. Soda carryover versus Production in WFL [Page 51] Figure 7.5. Production versus Time in SFL [Page 52] 82 | P a g e

Figure 7.6. Soda carryover as kg/MT of unbleached pulp versus Time in SFL [Page 52] Figure 7.6. Production and Soda carryover versus Time in SFL [Page 53] Figure 7.8. Soda carryover versus Production in SFL [Page 53] Figure 7.9. Brown Stock Washer [Page 54] Figure 8.1. HD Cleaner, Delta Knotter and Vibratory Scr een in SFL [Page 59] Figure 8.2. HD cleaner [Page 60] Figure 8.3. Delta Knotter [Page 60] Figure 8.4. Vibratory Screen [Page 60] Figure 8.5. Delta Screen, Opti Screen, Centricleaner and Vibratory Screen in SFL [Page 60] Figure 8.6. Vibratory Screen in WFL [Page 61] Figure 8.7. Centricleaner [Page 61] Figure 8.8. Delta Screen [Page 61] Figure 8.9. Pressure Screen [Page 61] Figure 8.10. Pressure Screen, Centricleaner and Vibratory Screen in WFL [Page 61] Figure 8.11. Hot water header for washing [Page 62] Figure 9.1. ESP [Page 63] Figure 9.2. Dust collection systems [Page 74] Figure 9.3. Effect of Chloride and Potassium on Sticky Deposit Temperature (TSTK) [Page 75]

83 | P a g e

   5    3    9    9    7    2    4    3    1    1    1    6    2    4    4    6    9    2    s    7    2    1    1    7    2    9    9    2    8    8    9    9    7    7    0    6    6    4    6    0    9     l    s    2    7    6    4    2    9    5    6    0    1    2    5    3    8    2    1    4    7    8    2    o   O     )    3     l    a    2    5    3    7    6    6    9    3    7    6    9    4    2    7    1    5    6    8    8    4    t    a    a    T    5    9    4    7    2    7    8    7    5    9    9    6    7    8    1    3    0    1    3    6    0    o   d   N   M   3    0    0    1    1    0    2    1    8    4    6    6    1    1    3    2    2    4    3    9    9    8    T    o    (  .  .    1    2  .    1  .    2  .    2  .    2  .    2  .    2  .    2  .    0    1  .    2  .    1  .    1  .    0    1  .    0  .    2  .    2  .    2  .    2  .    0  .    S    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

   I    I    y    r    e    v    o    c    e    R

   a     )    d   A   O    8    6    5    6    5    4    5    4    6    6    4    3    4    5    5    4    5    6    6    5    5    o   T    2    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    S    (    T    a    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    N    %    n    O   t    c    C   u   T    M    a    d    (    C   o    r    P    o    3    i     )

   2    6    6    1    4    4    2    6    6    5    1    3    6    8    8    3    2    4    2    7    8    3    8    8    8    0    0    4    3    3    8    1    9    3    2    6    8    3    3    4    6    4    0    4    4    7    5    5    5    1    1    7    4    7    1    5    3    2    0    5    5    4    4    7    0    0    1    5    5    5    6    6    2    0    5    6    2    9    2    7    7    5    5    0    0    8  .    5  .    5  .    3  .    2  .    2  .    7  .    3  .    3  .    3  .    5  .    6  .    3  .  .    1  .    0  .    5  .    7  .    7  .    0  .    0    9    5    5    7    7    7    0    0    0    4    8    8    0    6  .    0    9    2    0    3    2    2    4    4    4    4    4    4    5    4    4    5    3    3    4    7    5    4    5    5    4    4

   2     )    d   e    H   u    k  .    5  .    5  .    4  .    5  .    5  .    5  .    3  .    3  .    4  .    5  .    2  .    3  .    5  .    3  .    4  .    4  .    4  .    5  .    5  .    5  .    O   M   a    4    %    (    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    C    a    i    C   n

   r    e    t     l    i    F    n    )    d    e    m    u    o   T    8    6    6    7    7    7    9    3    3    1    2    2    3    5    4    9    8    0    9    5    4    s    i    u    m    2    2    2    2    2    2    2    2    2    3    2    2    2    1    2    2    3    2    2    2    i    t    (    n    p   M    M    L    o    c     h    g    u    2    5    5    2    5    6    8    5    9    7    7    8    6    6    7    1    3    3    8    7    s    o    s    0    3    3    4    9    7    2    0    0    7    5    1    7    7    7    2    1    3    2    7    r     l    4    6    6    9    3    4    9    5    0    9    9    1    9    1    7    4    1    o    O     )    0    0    0    0    2    9    3    4    2    1     l    a    2     h    4    6    7    7    6    0    0    3    3    6    T    t    a    a    7    6    6    t    0    4    6    6    0    8    8    8    8    6    8    2    6    8    8    8    8    4    4    8    8    o    M    8    8    8    9    7    7    8    8    7    0    0    0    8    9    8    7    0    s    N    T    d    0    0    0    s    0    0    0    0    0    0    0    0  .  .  .  .  .  .    0  .    o    (  .  .  .  .  .  .  .  .    0  .    0  .    0  .    0  .    0  .    0    o    0    0    0    0    0    0    0    0    S    0    0    0    0    0    0    0    0    0    0    L

   I    y    r    e    v    o    c    e    R

   A    X    I    D    N    E    P    P    A

   2     d    n    a    1    y    r    e    v    o    c    e    R    r    o     f    r    e    t     l    i     f     d    u    M     h    g    u    o    r     h    t    s    s    o    L  .    1  .    6    e     l     b    a    T

   a     )    d   A   O    4    5    5    5    5    6    5    5    5    5    3    4    6    6    5    6    5    4    5    5    o   T    2    4    4    4    4  .    4    4    4    4    4    4    0  .  .  .  .  .  .  .  .  .  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    4  .    S    (    T    a    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    N    %    i     )    O   u   M    C   d    (    a    o   n    C   r    o    P    3    t    c    T

   5    2    2    3    1    2    5    2    5    5    4    5    5    2    2    5    5    4    5    5    5    0    2    2    9    9    2    9    1    7    4    1    7    9    2    2    4    4    1    7    9    4    0    5    5    0    7    5    0    1    5    0    7    5    0    5    5    0    0    9    5    0    0    0    2    2    2    4    2    4    0    7    5    5    7    4    2    2    5    5    8    7    4    5    1  .    1  .    1  .    1  .    1  .    1  .    0  .    6  .    1  .  .    2  .    1  .    1  .    8  .    1  .    7  .    1  .    1  .    1  .    0  .    7  .    9    9    9    0    5    9    7    9    9    9    7    9    9    9    9    9    9    9    1    1    1    2    1    1    1    1    1    1    1    1    1    1    1    1    1    2    1    1    1

   2     )    d   e    H   u    k  .    2    2    9  .    2    2    9  .    7  .    8  .    9  .    0    8  .    9  .    2    2    9  .    9  .    9  .    8  .    9  .    9  .    O   M   a    1    %    (    2    1    1    1    1    1    1    1    1    1    1    1    1    1    C    a    n    C   i

   n    )    e    m    u  .    9    1    0    1    1    1    0    1    0    1    1    1    1    2    1    0    1    o   T    1    1    1    5    s    i    m    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    i    t    n    M    1    L    o   p    (    c    d   O    5    2    4    4    6    2    8    6    2    6    7    8    8    2    4    e    2    5    1    3    2    4    7    6    9    4    1    1    2    8    1    2    4    7    2    7    9    a    )    0    4    2    4    7    4    6    2    6    4    7    7    0    2    6    3    2    1    7    0    2    6    1    L    m    3    2    0    1    T    N    3    4    6    9    4    4    8    2    9    3    0    8    7    4    2    4    4    0    5    6    9    u    8    s    8    3    2    2    4    7    3    W    A   M  .  .  .  .  .  .  .  .  .  .  .  .    9  .    4  .    2  .    5  .    7  .    5  .    6  .    7  .    4  .    n   T    8    7    6    8    7    6    4    5    8    2    9    0    0    0    1    4    1    9    5    0    1    4    3    4    3    2    o   T    4    4    3    3    4    3    3    4    4    4    4    4    4    4    4    4    C    (     l    s    )    a    T    t    s    o   o    M    T    L    (

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A    B

   e    t    a    D

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

   e    g    a    P     |    5    8

    )    %   s    E    g    s    R    o    v    L    O    A     (

   7    7    6  .    0

   s    s    )    E    o    L    R    O    %    (

   1    7    4    5    9    5    7    1    3    6    5    9    9    6    9    5    7    6    5    9    6    4    2    1    7    3    8    2    1    9    4    3    2    4    2    4    9    3    5    5    3    8    0    3    8    2    3    5    9    9    0    9    3    6    0    5    9    4    2    1    2    8    2    9    3    9    6    0    9    0    9    5    9    1    0    9    0    5    9    7    6    5    3    8    0    7    6    6    9    3    4    5    9    2    0    9    9    3    6    9    7    6  .    2    7    6  .    6  .    7  .    0    6  .    7  .    8  .    6  .    6  .    8  .    5  .    8  .    6  .    5  .    2  .    6  .    7  .  .    6  .    6  .    6  .    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

   r    e    t     l    i     l    F    a    r    %    )    d    e    s    u    %    n   s     (    e    o    M    L    G     h    g    u     h    f    o    g    o    r    u   r    s     h     d    s    t    e    o    r    e    o     l    t    s    n    i     h     l    s    b    i    t    l     f    a    o    L    m    s    s    d   t    o

   2    3    2  .    7

   u   T    o    o    C    L    M    %

   s     l    s    o   O     )    a    2    T    t    l    a    a    o   d   N   M    T    o    (    S     d    e    n    i     b    m    o    c    2     d    n    a    1    y    r    e    v    o    c    e    R    r    o     f    r    e    t     l    i     f     d    u    M     h    g    u    o    r     h    t    s    s    o    L  .    2  .    6    e     l     b    a    T

   4    3    3    0    7    2    3    8  .    0    6

   3    5    6    1    4    7    7    5    5  .    6

   7    2    1    2    1    5    4    2    3  .    8

   2    0    4    4    0    4    6    1  .    7    1

   3    0    1    2    7    4    7    4    2  .    3

   4    1    3    4    3    8    7    5    2  .    4

   4    3    4    0    2    7    7    3    8  .    3

   9    9    7    5    0    9  .    0

   5    1    4    5    4    9    8  .    0

   4    0    9    6    2    4    8  .    0

   1    8    8    1    4    5    7  .    0

   6    8    6    8    9    7    5  .    0

   9    3    6    5    4    5    9  .    0

   2    4    8    2    8    6    8  .    0

   d   O    5    2    4    4    6    8    6    2    6    7    8    8    2    4    e    2    1    3    4    7    0    5    4    2    6    6    9    4    1    2    2    8    1    2    4    7    2    7    9    a    4    2    7    4    1     )    2    6    4    7    7    0    2    3    2    1    7    0    2    6    1    m    L    2    9    0    1    8    2    9    3    0    8    6    N   T    3    3    7    4    2    4    4    0    5    6    9    u    4    6    4    4    8  .    3  .    2    W   s    A   M   8  .  .    7  .  .    8  .    2  .    4  .    7  .    3  .  .    9  .    4  .    2  .    5  .    7  .    5  .    6  .    7  .    4  .    n   T    6    8    4    6    5    8    2    9    0    7    0    0    1    4    1    9    5    0    1    4    3    4    3    2    o   T    4    4    3    3    4    3    3    4    4    4    4    4    4    4    4    4    C    (     l    s    )    a    T    t    s    o   o    M    T    L    (    t     f    i     h    S    e    t    a    D

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

    )    %   s    E    s    g    o   R    v    L    O    A     (    s    s    )    E    o    L    R    O    %    (

   2    3    0  .    0

    d    e    n    i     b    m     l    o    a    %    )    C    r    e    s    %    n   s     (    e    o    L    G

   3    3    0  .    0

   7    3    0  .    0

   3    4    0  .    0

   5    3    0  .    0

   1    3    0  .    0

   3    3    0  .    0

   9    6    2  .    0

    l    a    s    )    O    a    t    d   s    2    o   a    o   o    l    T    S     (    N

   5    2    4    0  .    0

   5    2    4    0  .    0

   5    2    4    0  .    0

   5    2    4    0  .    0

   5    2    4    0  .    0

   5    2    4    0  .    0

   5    2    4    0  .    0

   3    0  .    0

   3    0  .    0

   3    0  .    0

   3    0  .    0

   3    0  .    0

   3    0  .    0

   3    0  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   R     l    s     )    T    3    a    O    t    s    M   C    o   o     (    L    a    T    C

   6

   6

   6

   6

   6

   6

   6

    l    a    s    )    O    a    t    d   s    2    o   a    o   o    l    T    S     (    N

   5    2    1    0  .    0

   5    2    1    0  .    0

   5    2    1    0  .    0

   5    2    1    0  .    0

   5    2    1    0  .    0

   5    2    1    0  .    0

   5    2    1    0  .    0

   a     )    d   A   O    o   T    2    S    (    T    a    %    N

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

   5  .    0

    l    s     )    T    3    a    O    t    s    M   C    o   o    T    L    (    a    C

   5  .    2

   5  .    2

   5  .    2

   5  .    2

   5  .    2

   5  .    2

   5  .    2

   s     l    e    a    a    s    )    n    t    d   s    O    2    o    o   a    o   o    l    t    N    S    T    S     (    d    I    n    I    a    y     )    r    a    s    A   O    e    d    t    o    2    v    S    T     f    i    T    a    r    o    c    %    (    N    G   e

   2     d    n    a    1    y    r    e    v    o    c    e    R    r    o     f    s    e    n    o    t    s     d    n    a    s    t     f    i    r    G     h    g    u    o    r     h    t    s    s    o    L  .    3  .    6    e     l     b    a    T

   e    g    a    P     |    6    8

   5    3    0  .    0

   I    y    r    e    v    o    c    e    R

   d   O    5    2    4    4    6    8    6    2    6    7    8    8    2    4    e    2    1    3    4    7    0    5    4    2    6    6    9    4    1    2    2    8    1    2    4    7    2    7    9    4    2    7    4    1    a     )    6    0    1    4    7    7    0    2    8    6    3    2    1    7    0    2    6    1    L    m   N   T    2    3    2    3    9    8    2    9    3    0    7    4    2    4    4    0    5    6    9    u    4    4    8  .    6  .    3  .    4  .    2    2    4    7    3  .    9    W   s    A   M   8  .  .  .  .  .  .  .  .    4  .    2  .    5  .    7  .    5  .    6  .    7  .    4  .    n   T    8    7    4    6    8    5    8    2    9    0    7    0    6    0    1    4    1    9    5    0    4    3    4    4    3    3    3    4    3    3    2    4    4    4    4    4    4    4    4    1    o   T    4    4    C    (     l    s    )    a    T    t    s    o   o    M    T    L    (    t     f    i     h    S    e    t    a    D

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

   e    g    a    P     |    7    8

   s    t     f    i    r    G    d    d    n    e    n    i    a    b    r    e    t    m     l    i    o    F    C    d    u    M    2     d    n    a    1    y    r    e    v    o    c    e    R    r    o     f    s    e    n    o    t    s     d    n    a    s    t     f    i    r    G     d    n    a    r    e    t     l    i     f     d    u    M     h    g    u    o    r     h    t    s    s    o     l     d    e    n    i     b    m    o    C  .    4  .    6    e     l     b    a    T

    )    %   s    E    s    g    o   R    v    L    O    A     (

   2    1    7  .    0

    l     )    %    a    r    (    e    %    n   s    e    s    G   o    L

   1    0    5  .    7

   d   O    5    2    4    4    6    8    6    2    6    7    8    8    2    4    e    2    1    3    4    7    0    5    4    2    6    6    9    4    1    2    2    8    1    2    4    7    2    7    9    4    2    7    4    1    a     )    2    6    4    7    7    0    2    3    2    1    7    0    2    6    1    L    m   N   T    3    3    2    9    0    1    8    2    9    3    0    8    6    7    4    2    4    4    0    5    6    9    u    4    6    4    4    8  .  .    3  .  .    2  .    9    W   s    A   M   8  .    8  .    6  .    2  .    4  .    7  .    3  .    7  .    4  .    2  .    5  .    7  .    5  .    6  .    7  .    4  .    n   T    7    4    8    5    6    8    2    9    0    0    0    1    4    1    9    5    0    1    4    3    4    3    2    o   T    4    4    3    3    4    3    3    4    4    4    4    4    4    4    4    4    C    (     l    s    )    a    T    t    s    o   o    M    T    L    (    t     f    i     h    S    e    t    a    D

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   A    B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0

   L    F    )    %    (    S    E    g    s    M    v    s    A   o   P    L     )    E    s    s    M    o    L    P    L    %   F    S     (

   e    g    a    P     |    8    8

   5    7    9  .    4

   5    7    9  .    4

   4    1    2    7    4    1    9    7    4    3    3    5    9    6    9    4    2    9    5    6    1    8    5    3    2    2    3    4    3    4    6    8    2    7    5    0    2    4    1    3    8    5    5    6    3    3    8    1    0    3    8    0    7    5    9    1    4    7    2    8    1    2    7    1    1    5    2    0    1    4    4    1    2    0    5    5    7    6    3    1    9    1    5    1    4    3    8    2    4    5    6    3    7    1    3    6    9    0    1    0    3    1    7    1    9    0    3    2    8    9    8    4    3    5    5    0    4    1    4    7    5    0    7    0    1    9    0  .    7  .    0  .    2  .    0  .    0  .    9  .    3  .    0  .    7  .    7  .    7  .    7  .    8  .    0  .    5  .    7  .    6  .    7  .    1  .    5  .    5    4    6    4    5    5    4    4    4    4    4    4    4    4    5    4    4    4    4    5    4

   d     )    5    5    1    3    2    4    7    2    4    4    6    2    8    6    2    6    7    8    8    2    4    e    T    0    4    5    4    4    7    6    6    9    4    1    6    2    8    1    2    4    7    2    7    9    7    5    9    3    9    2    8    3    3    6    1    2    7    2    9    8    0    2    9    1    9    A   M    L    m    8    1    1    7    6    0    6    2    8    3    1    7    2    3    0    5    5    5    0    1    2    u   T    O    9  .  .    4  .  .    6  .    2    W   s    (    T    2  .    6  .    4  .    3  .    7  .    6  .    4  .    6  .    6  .    6  .    3  .    5  .    3  .    2  .    2  .    6  .    n    a    1    7    2    8    4    1    5    2    3    4    3    4    8    4    7    3    4    4    2    2    2    2    1    o    2    2    1    2    2    2    1    2    2    2    2    2    2    2    2    2    C    N     l     l    a    5     )    5    r    s    a    7    7    s    t    s    e    s  .  .    %   n   o   o   o    6    6    L    T    e     (    L    3    3    G

   r    e    r    v    n    e    i    o    a    v    s    y    s    d   o    r    y    r    L    r    F    a    S    o    L    o    r    S    C    a    %    C    a    d    o    S     l    a   s    )    a    t    d   s    T

   o   o   o    M    T    S    L    (     )    a   s    T    d   s    o   o    M    S    L    (

   L    F    S    n    i    p     l    u    p     h    t    i    w    r    e    v    o    y    r    r    a    c    a     d    o    S  .    1  .    7    e     l     b    a    T

   n    o    i     )    p   t    c    T     l    u   u   M    P   d    (    o    r    P  ,    O    a   2    )    d   a    T    o   N   M    S     /    A   g    %   T    K    T     (     l    s    )    a    T    t    s    o   o    M    T   L    (

   5    8    6    2    9  .    2    5    2

   7    4    7    7    5    0  .    6    2

   4    6    1    4    8    5  .    8    2

   9    8    3    9    9    8  .    6    5

   6    5    1    0    0    8  .    9    1

   2    8    2    6    0    6  .    6    1

   5    1    4    5    0    3  .    5    1

   1    8    0    6    6    7  .    3

   7    3    5    4    5    5  .    3

   5    7    5    3    9    8  .    2

   9    5    1    0    0    5  .    2

   6    1    5    5    3    5  .    3

   2    6    9    2    2    7  .    3

   5    8    2    6    4  .    3

   2    6    4    6    3    8    8    5    2    4    7    8    3    6    6    9    7    7    9    4    9    3    5    7    4    1    2    4    0    0    3    1    4    4    8    0    3    1    8    8    7    3    9    7    4    9    1    4    0    1    5    7    9    3    4    0    4    6    9    4    5    7    0    7    7    6    7    0    3    4    6    5    0    3    4    1    8    0    4    7    2    7    2    5    3    7    7    5    2    2    2    4    7    3    9    1  .    4    9    5    7    9    3    3    2  .    2  .    2  .    1  .    2  .    1  .    9  .    9  .    0  .    0  .    6  .    7  .  .    1    2  .    2  .    1  .    2  .    0  .    2  .    1  .    1    1    1    1    1    1    0    0    1    1    0    0    1    1    1    1    1    1    1    1    8    8    9    1    7    7    7    1    7    1    3    8    2    1    7    9    3    9    7    4  .    6    6    8  .    5  .  .    5  .    6  .    4  .    4  .    4  .    0  .    1  .    4  .    8  .    1  .    6  .    9  .    6  .    6  .    2  .    3  .    8    8    4    1    3    6    4    0    8    4    3    1    7    9    6    6    7    5    0    9    8    8    8    8    8    8    7    8    8    8    5    6    8    8    8    8    8    8    9    7    6    9    3    7    3    7    6    4    7    3    7    6    7    6    4    4    6    8    2    8    6    6    2    8    0    3    8    4    7    6    3    7    9    4    2    9    8    5    9    4    3    1    4    8    8    4    9    9    5    5    4    6    1    7    3    3    9    9    5    6    4    8    0    7    3    9    4    0    3    9    0    9    2    6    7    7    2    0    2    8    4  .    9    2    7    4    3    3    2    3    2    2    6    3    1    6    5    8    3    3    9    9    7    3    9    0    6    6    2    1    8    3    9    7    2    1    3    9    8    7    8    4    0    7    5    4  .  .    1  .    3  .    0  .    9  .  .    8  .    7  .    8  .    9  .    0  .    8  .    4  .    8  .    2  .    5  .    7  .    7  .    2  .    4    3    5    4    5    2    1    1    2    1    2    3    2    4    4    3    4    2    3    4    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    E    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    7    0    R

   e    g    a    P     |    9    8

   9    7    3    2    1    6    6    4    7    2    5    9    7    5    1    5    7    3    2    1    8    8    9    4    6    8    3    6    9    9    3    8    9    7    6    0    9    6    3    0    9    6    1    3    0    5    5    1    7    3    5    0    6    3    7    0    8    8    2    5    8    9    5    7    4    5    7    8    7    7    4    7    9    8    0    5    5    8    2    3    1    1    5    5    1    0    8    9    4    6    0    3    4    0    3    9    5    0    9    0    4    1    1    1    5    5    4    1    9    2    8    8    8    0    4    9    7    9    1    7    4    2    9    2    9    0    8    7    5    9    2    2    4    6    4    6    7    4    8    4    5    5    0    7    0    0    5    1    5    7    4    5    0    8    8    8    3    9    7    1    9    9    3    4    6    4    7    4    4    3    1    3    7    4  .    3    4    0    3    6    9    5    1    1    6    9    5    1    0    2    6    4    8    4    0    9  .  .  .  .  .  .    0  .  .  .  .    5  .  .  .  .    5  .  .  .  .  .  .  .  .  .    4  .    2  .    4  .    7  .    2  .    5    5    5    4    4    4    4    4    6    3    2    1    4    5    6    5    3    5    3    4    4    4    4    4    5    4    5    5    6    8    9    2    4    9    6    6    2    3    6    2    2    6    2    8    7    9    6    8    6    9    2    8    2    1    4    1    5    0    7    3    0    1    9    4    1    5    6    8    7    1    5    8    6    4    6    1    4    9    0    2    8    2    6    8    7    2    5    6    9    8    1    4    4    3    4    5    4    2    1    0    1    0    8    7    7    4    6    1    6    1    5    9    9    4    8    0    6    4    7    8    0    1    6    5    3    2    7    5    8    4    9    5    2    8    3    8    3    2    0    2    8  .    5    1    1  .    4    2    6    1    7    6  .    6    4  .  .    4    5    6    1    8  .  .    9  .  .    4    9  .  .    4  .  .  .  .  .  .    3  .  .    2    3  .  .  .  .  .    5    9  .  .    3  .    3  .    9  .    6    5    1    0    3    2    1    4    3    6    6    2    2    3    2    2    9    9    9    9    4    2    6    1    4    0    2    2    2    2    2    2    2    2    2    2    1    2    1    2    1    1    1    1    2    2    2    2    2

   6    4    8    4    7  .    4    2    1

   7    2    0    9    5  .    2    5   -

   2    0    7    7    9  .    2    3   -

   3    0    1    0    6  .    7    4    1

   6    8    2    2    3    9  .    2    7

   5    3    7    2    4    5  .    8    1

   4    5    4    2  .    0    4    1   -

   9    9    1    0    6    6  .    7    4

   4    9    7    4    9  .    8    2

   2    1    7    5    2    9  .    2    7

   2    9    7    8    7    0  .    3

   9    1    0    4    9    5  .    3

   1    9    5    8    1  .    3

   9    1    4    5    3    6  .    1

   1    1    1    5    6    4  .    2

   6    5    5    8    4    1  .    3

   3    0    1    7    1    9  .    2

   2    5    8    2    0    3  .    3

   1    5    7    3    6    3  .    3

   9    5    2    0    7    7  .    3

   7    8    7    9    7    3    7    1    1    1    8    3    2    2    2    2    2    1    9    9    7    4    7    6    7    6    2    0    5    2    9    2    9    0    4    6    6    5    5    4    5    6    4    1    0    9    1    9    4    0    5    8    8    4    2    4    5    9    9    9    3    1    4    4    1    3    6    7    2    2    9    3    2    9    3    2    0    8    9    3    1    2    8    4    9    8    9    9    2    1    0    6    3    6    4    0    0    4    8    4    8    8    1    1    9    9    3    5    3    5    8    3    7    4    7    1    9    2    2    6    6    5    1    9    6    3    0    7    7    3    3    0    3    1    3    9    6    4    3    8    5    1    9    2  .    0    0  .    0  .    0  .    9  .    1  .    2  .    2  .    0  .    0  .    0  .    8  .    8  .  .    1    3  .    0  .    7  .  .    7  .    1  .    1  .    0  .    0  .    2  .    1  .    9  .    4  .    2  .    0  .    0    1    1    1    0    1    1    1    1    1    1    0    0    1    1    0    1    0    1    1    1    1    1    1    0    1    1    1    3    2    3    2    7    7    2    6    1    3    1    4    8    6    1    4    2    1    4    1    8    3    4    3    8    6    7    3    8    8  .  .    7  .    9  .    4  .    9  .    6  .    2  .    6  .    3  .    9  .    0    1  .    1  .    0  .    5  .    8  .    4  .    1  .    8  .    4  .    5  .    3  .    3  .    1  .    8  .    6  .    5  .    5  .    1  .    3    2    8    8    0    3    9    8    8    1    1    4    0    0    6    0    9    9    1    5    5    0    9    7    9    8    2    6    4    4    7    7    7    8    8    8    7    7    5    2    8    7    9    7    5    8    5    8    9    8    8    8    8    8    9    9    9    6    7    8    7    5    3    9    7    7    5    6    2    3    3    8    7    2    5    5    6    9    1    1    1    8    3    3    7    5    6    3    5    8    4    7    3    9    2    8    8    8    7    8    3    1    8    5    5    7    7    6    0    3    5    8    2    9    6    3    4    9    8    8    8    2    1    1    0    9    2    8    1    3    8    2    1    1    6    4    7    9    8    9    1    4    1    4    4    9    2    7    0    8    3    6    1    4    0    0    8    7    2    0    9    9    2    6    6    6    1    2    7    0    6    7    9    3    9    4    4    7    7    6    2    1    3    0    8    7    9    6    0    8    5    5    1    4    2    1    9    9    7    6    7    5    3    2    4    6    1    4    8    3    5    0    8    3    4    1    4    8    3    8    8    1    7    1    8    7    4    1    0    3    5    9    5    9    7    3    7    4    4    8    4    7    5    1    4    0  .    8    1    1    1    0    5    3    1  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .    5  .  .  .  .  .  .  .  .    3    7  .    9  .    1  .    8  .    6  .    4    2    2    4    4    3    2    2    4    1    4    2    3    5    1    2    2    3    3    3    2    2    2    1    2    1    5    2    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    8    6    4  .    2

   4    3    8  .    6   -

   1    6    6  .    9   -

   8    0    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      8    8    8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

   L    F    )    %    (    S    E    g    s    M    v    s    A   o   P    L     )    E    s    s    M    o    L    P    L    %   F    S     (

   e    g    a    P     |    0    9

   7    2    4  .    5

   7    2    4  .    5

   2    2    2    8    6    1    8    5    1    7    1    6    5    1    5    5    9    2    6    8    5    9    9    8    0    6    4    0    4    9    7    4    6    0    9    9    4    2    0    8    0    6    3    7    9    5    8    6    8    0    0    1    6    4    8    8    7    7    7    7    6    7    2    2    5    9    1    5    7    6    4    3    5    1    8    4    2    0    8    9    6    2    8    2    0    0    8    9    6    6    9    9    2    5    3    5    1    6    6    1    9    0    6    9    7    8    3    7    3    4    9    2    6    0    6    8    1    6    1    8    7    3    9    0    5    9    0    8    3    5    0    4    3  .    6  .    2  .    2  .  .  .    4  .    6  .    7  .    7  .    4  .    1  .    7  .  .    3  .    5  .    1  .    3  .    6  .    7  .    2  .    4  .    5    5    5    4    5    5    5    4    4    5    5    5    4    7    5    5    5    5    4    5    7    4

   d     )    e    T    5    8    7    3    3    7    6    4    4    4    1    5    9    1    3    3    7    8    3    5    2    4    4    2    2    2    1    8    1    0    1    9    9    5    4    1    1    8    9    4    4    5    6    5    A   M    L    m    8    u   T    O  .  .    4  .    9  .    7  .    3  .    6  .    9  .    7  .    0  .    8  .    1  .    7  .    8  .    6  .    1  .    1  .    1  .    4  .    5  .    8  .    3  .    W   s    (    T    2    1    2    6    6    1    6    6    6    6    7    6    1    6    6    6    6    7    2    2    6    6    1    n    a    2    2    1    1    2    1    1    1    1    1    1    1    1    1    1    1    1    2    2    1    1    1    o    C    N     l     l    a    4     )    4    r    s    a    8    8    s    t    s    e    s  .  .    %   n   o   o   o    2    2    L    T    e     (    L    3    3    G

   r    e    r    v    n    e    i    o    a    v    s    y    s    d   o    r    y    r    L    F    o    r    a    L    o    S    C   W    %    r    a    C    a    d    o    S     l     )

   a    s    T    a    t    d   s    o   o   o    M    T    S    L    (     )    a    s    T    d   s    o   o    M    S    L    (

   L    F    W    n    i    p     l    u    p     h    t    i    w    r    e    v    o    y    r    r    a    c    a     d    o    S  .    2  .    7    e     l     b    a    T

   n    o    i     )    p   t    c    T     l    u   u   M    P   d    (    o    r    P  ,    O    a    2    )    d   a    T    o   N   M    S     /    A   g    %   T    K    T     (     l    s    )    a    T    t    s    o   o    M    T    L    (

   1    2    5    9    4  .    1    2    2

   7    6    0    7    0    2  .    1    2

   8    0    6    5    5    4  .    4    2

   5    7    6    8    8    5  .    6    5

   1    4    6    5    8    0  .    6    1

   1    4    0    3    8    2  .    3    1

   2    4    1    7    7    1  .    4    1

   3    3    4    2    1    8  .    9    9

   4    6    0    8    9    2  .    3

   6    5    8    2    9    8  .    2

   1    4    6    5    7    4  .    2

   6    0    5    6    8    4  .    2

   2    5    2    2    7    8  .    2

   5    2    9    7    7    9  .    2

   8    7    5    7    0    2  .    3

   1    7    3    3    6    4  .    2

   7    7    2    3    1    8    2    1    5    9    2    2    6    4    9    6    9    6    4    5    8    9    6    0    2    3    0    9    4    3    9    7    3    1    0    3    9    9    8    7    1    8    1    8    5    6    4    3    1    5    5    5    1    9    3    9    4    9    6    3    3    7    0    7    6    7    3    5    2    1    9    9    8    7    9    4    2    3    8    9    0    8    3    9    3    4    4    1    1    2    5    9    8    8    8    2    7    0    7    8    9    7    9    3    5    1    0  .    5    6    1    2  .    8  .    7  .    2  .    9  .    8  .    7  .    7  .    9  .    9  .    5  .    8  .    1  .    8  .  .    8  .    1  .    0  .    9  .    2  .    5  .    1    0    0    1    0    0    0    0    0    0    0    0    1    0    0    0    1    1    0    1    0    7    9    6    8    7    8    1    7    7    3    4    9    3    1    6    2    7    9    9    1    8    9    6    7    4    9    8    8    8    0    8    0    2    4    3    4    5    6    8    8    5    9    6    5    2  .    7  .    1  .    2  .    6  .    1  .  .    0  .    2  .    6  .    2  .    1  .    5  .    5  .    3  .    4  .    8  .    1  .    0  .    5  .    8  .    0  .    9    1    6    2    2    8    0    4    4    8    0    4    6    9    8    6    7    1    9    0    2    3    3    4    5    3    3    5    4    3    3    3    4    2    3    4    3    3    3    5    3    5    2    6    2    6    9    9    1    5    1    4    3    1    3    8    6    1    1    8    9    7    2    6    2    0    6    8    3    6    4    3    1    5    9    1    9    3    8    5    0    6    4    0    6    0    3    6    6    9    2    1    1    5    2    2    4    2    4    3    9    4    9    2    5    5    6    6    7    7    3    0    3    8    0    2    5    2    5    5    5    6    0    8    6    1    1    4    3    7    8    6    4    3    7    2    9    2    3    4    1    3    1    5    3    0    1    1    9    8    4    6    8    2    9    8    8    0    6    4    5    0    9    5    3    0    8    4    8    2    5    2    9    2    7    9  .    4  .    4  .    8  .    7  .    4  .    6  .    4  .    0  .    7  .    8  .    0  .  .    0  .    8  .    1  .    5  .    6  .    3  .    6  .    9  .    8  .    3    4    3    1    3    4    2    3    2    5    3    3    2    3    3    4    3    3    4    3    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   8    6    4  .    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    8    E    0    1    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    R

   e    g    a    P     |    1    9

   7    4    6    9    7    7    4    7    4    5    1    5    2    2    1    4    4    8    3    1    2    6    1    9    6    7    4    4    9    0    0    7    3    2    1    8    3    9    1    8    5    3    4    1    9    3    6    5    7    3    9    6    7    9    1    8    0    1    4    8    2    2    2    2    5    7    8    7    4    2    8    1    9    7    2    8    9    0    5    0    3    8    9    8    6    5    2    0    2    5    3    6    9    4    4    2    8    6    1    0    6    4    8    3    7    3    2    1    7    2    9    5    9    0    3    1    5    4    6    4    1    3    7    0    7    2    2    2    9    0    7    0    6    6    7    4    6    9    2    3    6    5    9    7    7    6    7    7    9    4    1    0    5    0    1    0    0    1    3    3    0    7    4    3    1    4    3    1    4    5    3    5    2    5  .    4  .    1  .    0  .    0  .    5  .  .    1  .    7  .    8  .    2  .    3  .    2  .    0  .  .    7  .  .    4  .    8  .    6  .    3  .    3  .    8  .    3  .    5  .    8  .    4  .    7  .    4  .    1    5    6    6    5    5    4    7    5    4    5    6    7    5    3    4    5    5    7    5    4    4    5    5    4    4    4    2    4    1    6    7    2    3    2    6    8    7    1    7    4    9    2    7    4    3    3    8    3    6    9    2    5    6    1    3    9    2    8    7    9    0    8    8    0    6    0    7    1    3    6    5    9    7    0    1    3    4    0    4    7    9    6    2    5    3    1  .  .    7  .    1  .    0    8  .    7  .    5  .    1  .    3  .    8  .    7  .    7  .    0  .    3  .    8  .    8  .    4  .    0  .    7  .    4  .    2    7  .    0  .    5  .    8  .    2  .    6  .    3  .    4  .    2  .    6    6    6    2    6    1    1    1    1    2    1    6    6    1    1    1    7    6    6    2    1    2    6    1    2    6    9    3    0    1    1    1    2    1    2    2    2    1    1    1    2    1    1    1    1    2    2    1    2    2    1    1    2    1

   2    8    3   -    3    1    5  .    4    4

   3    5    7   -    8    9    8  .    4    3

   9    9    8    7  .    0    4    2

   6    2    6    3    3    2  .    1    8

   2    7    7    5    5    8  .    1    1

   7    3    7   -    6    0  .    4    5    1

   4    5    3    6    9    8  .    4    4

   3    6    2    3    1    2  .    4    2

   3    3    1    6    5    2  .    3    5

   4    4    0    2    4    0  .    3

   9    6    5    1    7    3  .    3

   2    5    9    7    6    6  .    2

   7    9    6    5    4    7  .    2

   1    1    3    1    0  .    2

   1    0    6    4    0    2  .    3

   7    1    3    1    1    1  .    3

   1    8    5    3    1    8  .    2

   2    4    3    3    5    7  .    2

   7    9    7    8    9    9    4    6    2    9    4    5    8    3    7    4    9    6    3    2    6    8    4    6    7    5    3    7    3    2    5    1    9    2    0    5    0    7    5    7    5    1    2    2    4    3    2    9    8    7    9    4    0    3    0    6    2    5    8    8    2    9    8    9    9    7    7    0    1    7    3    6    5    4    1    8    3    3    3    5    3    9    1    3    9    7    6    2    5    8    5    7    5    3    1    1    6    4    6    6    2    4    7    1    1    6    6    3    7    0    4    8    7    3    7    1    2    3    0    2    0    0    1    5    8    5    9    7    4    2    4    3    3    1    2    6    4    8    8    9    0    3    3    3    8    9  .    0  .    0  .    1  .    9  .    9  .    2  .    2  .  .    1  .    6  .    1  .    8  .    7  .    5  .    5  .    9  .    3  .    9  .    9  .    9  .    2  .    8  .    9  .  .    7  .    5  .    0  .    1  .    0    1    1    1    0    0    1    1    0    1    0    1    0    0    0    0    0    1    0    0    0    1    0    0    1    0    0    1    1    6    3    6    4    2    3    6    2    2    3    4    6    1    2    1    4    3    1    6    6    7    1    7    6    8    3    6    6    1    0    4    7    9    6    5    4    7    4    1    2    2    1    5    3    3    3    3    5    4    6    2    1    1    4    3    5    8    4    5  .    6  .    1  .    6  .    2  .    3  .    8  .  .    4  .    7  .    6  .    2  .    7  .    7  .    5  .    5  .    9  .    9  .    3  .    4  .    6  .    7  .    0  .    6  .    4  .    0  .    7  .    7  .    8  .    9    0    9    8    8    6    0    0    2    1    7    9    6    4    3    0    0    4    6    2    6    1    7    0    8    4    6    9    5    4    3    4    3    4    3    3    5    3    5    2    4    3    3    2    2    4    5    3    4    4    5    3    5    3    2    4    4    9    4    6    3    7    1    5    9    5    5    7    1    5    1    4    3    4    6    4    1    7    9    5    2    5    1    7    7    4    5    7    9    8    0    6    7    1    1    8    1    4    5    9    7    0    7    3    3    9    6    7    4    5    4    1    0    5    2    6    4    8    9    4    4    9    9    8    2    8    4    3    8    7    6    6    8    1    1    7    0    1    1    8    5    1    2    2    5    7    6    7    8    6    5    5    7    5    0    8    2    8    0    2    5    6    8    5    7    9    0    2    4  .    9    4    1    1    4    1    7    4    4    8    8    4    3    4    0    3    7    5    1    0    1    6    2    9    0    5    9    0    8    7    5    0    1    3    6    8    5    2    7    9    9    6    5    1    4    7    4    4    1    6    1    3    0    2    5    8    6    8    0    3    8    4  .    6    5    0    9    3    4    6    0    9    1    6    7    1    4    6  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .    0    2  .    4  .    5  .    3  .    3  .    5  .    1  .    7  .    3    5    5    3    3    4    4    4    2    5    3    3    0    3    5    2    4    5    2    5    3    2    1    9    1    2    3    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    2    1    2    2    2    4    3    8  .    6   -

   1    6    6  .    9   -

   8    0    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   A   B    C    A   B    C    A   B    C    A   B    C    A    B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      8    8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

   e    g    a    P     |    2    9

    )    %   s    E    g    s    R    o    v    L    O    A     (

   r    e    v    d    o   e    y    r    n    i    r    b    a    C   m    a    o    d   C    o    S

   L    F    W     d    n    a    L    F    S    n    i    p     l    u    p     h    t    i    w    r    e    v    o    y    r    r    a    c    a     d    o    s     d    e    n    i     b    m    o    C  .    3  .    7    e     l     b    a    T

    )    s    s    E    %   o   R    O    L    (     l    a    r    s    s    %   e    n   o    e    L    G

   8    0    1  .    5

   8    0    1  .    5

   9    4    0    5    4    1    7    8    1    0    3    0    5    4    9    3    7    9    7    7    6    5    4    1  .    1  .    7  .    2  .    3  .    4  .    1  .    4  .    3  .    2  .    1  .    9  .    7  .    7  .    1  .    9  .    8  .    9  .    6  .    3  .    6  .    0  .    2  .    5    5    5    4    5    5    5    4    4    5    5    4    4    5    5    4    4    4    4    5    5    5    5

   9    5  .    9    6

   9    5  .    9    6

   r    n    e    i    a    v    s    s    d   o    y    o    L    o    r    S    r    %    a    C

   6    0    2    2    4  .    4    7    4

   4    1    8    4    6    2  .    7    4

   2    7    7    9    3    0  .    3    5

   6    0    8    8    4  .    3    1    1

   8    9    7    5    8    8  .    5    3

   3    2    3    9    8    8  .    9    2

   7    5    5    2    8    4  .    9    2

   9    0    6    5  .    4    2    2

    l    a    s    )    a    T    t    d   s    o   o   o    M    L    T    S     (

   5    4    1    4    6    0  .    7

   3    9    3    7    4    4  .    6

   6    1    2    9    6    3  .    5

   6    6    6    6    8    9  .    4

   8    6    7    7    0    4  .    6

   7    8    8    0    0    7  .    6

   9    2    4    0    7    6  .    6

   3    6    1    2    4    5  .    5

    l    s    )    a    T    t    s    o   o    M    T    L    (

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   8    6    4  .    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    8    8    E    0    1    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    R

   e    g    a    P     |    3    9

   9    2    1    8    6    9    4    6    2    0    1    7    5    9    9    2    4    7    9    8    7    1    6    9    1    1    1    2    0  .    2  .    4  .    1  .    3  .    2  .    9  .    1  .    5  .    3  .    9  .    7  .    2  .    5  .    1  .    5  .    5  .    6  .    3  .    3  .    8  .    1  .    9  .    6  .    3  .    3  .    6  .    3  .    5    5    5    5    4    5    5    4    7    6    4    4    4    5    5    4    6    4    4    4    4    5    4    4    4    4    4    7

   5    6    3    0    1  .    7    9   -

   7    7    5    7    8  .    7    6   -

   3    9    0    9    3  .    8    8    3

   1    9    5    6    1  .    4    5    1

   7    0    5    8    9    3  .    0    3

   7    2    1    3  .    4    9    2   -

   3    5    5    6    5    5  .    2    9

   3    0    2    1    6    1  .    3    5

   4    8    1    8    1  .    6    2    1

   4    6    0    6    3    6  .    6

   8    7    4    7    5    5  .    6

   1    7    3    3    0    3  .    4

   8    0    8    0    1    2  .    5

   7    6    6    1    6    1  .    5

   5    0    7    1    2    1  .    6

   9    6    1    4    1    4  .    6

   2    3    3    7    7    1  .    6

   1    0    6    3    2    5  .    6

   4    3    8  .    6   -

   1    6    6  .    9   -

   8    0    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B

   n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

Table 7.4. WFL production and total soda loss

WFL Period

Production Bleached Pulp (MT)

01-Jan 02-Jan 03-Jan 04-Jan 05-Jan 06-Jan 07-Jan 08-Jan 09-Jan 10-Jan 11-Jan 12-Jan 13-Jan 14-Jan 15-Jan 16-Jan 17-Jan 18-Jan 19-Jan 20-Jan 21-Jan 22-Jan 23-Jan 24-Jan 25-Jan 26-Jan 27-Jan 28-Jan 29-Jan 30-Jan 31-Jan 01-Feb 02-Feb 03-Feb 04-Feb 05-Feb 06-Feb 07-Feb 08-Feb 09-Feb 10-Feb 11-Feb

81.11 85.71 61.59 88.6 94.91 89 98.32 89.61 92.47 95.71 58.43 92.3 98.13 96.14 87.55 97.42 95.67 94.53 97.33 90.21 95.77 92.38 96.56 90.67 80.33 97.85 98.25 90.52 93.43 79.55 97.4 105.27 106.83 105.45 106.24 92.04 105.13 103.18 100.65 96.73 42.99 39.84

Weekly Bleached Production

532.956667

648.62

625.64

657.45

637.33

724.14

596.93

Unbleached Pulp (MT)

102.63 99.23 86.44 88.72 87.95 103.89 94.74 97.06 106.75 98.45 76.42 96.79 115.43 102.42 99.28 113.05 98.5 112.23 100.44 109.23 110.11 90.94 94.29 122.05 108.46 91.72 103.17 111.08 119.31 90.39 103.22 107.97 127.9 109.46 120.15 99.57 123.91 121.84 111.63 105.47 28.24 64.06

Soda Loss % Soda Soda Loss (TTA (Weekly Na2O, basis MT) Kg/MT)

10.69718

7.1959951

10.60986

7.1888162

11.70141

8.2131016

14.62676

10.813418

11.30845

8.2252016

12.31268

9.9831177

15.1507

9.778416

12-Feb 13-Feb 14-Feb 15-Feb 16-Feb 17-Feb 18-Feb 19-Feb 20-Feb 21-Feb 22-Feb 23-Feb 24-Feb 25-Feb 26-Feb 27-Feb 28-Feb 01-Mar 02-Mar 03-Mar 04-Mar 05-Mar 06-Mar 07-Mar 08-Mar 09-Mar 10-Mar 11-Mar 12-Mar 13-Mar 14-Mar 15-Mar 16-Mar 17-Mar 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar 25-Mar 26-Mar 27-Mar 28-Mar 29-Mar 30-Mar 31-Mar 01-Apr 02-Apr

105.2 105.33 106.19 103.11 92.4 90.01 105.68 106.32 106.75 102.56 83.72 98.37 103.83 94.26 108.73 110.31 109.07 109.48 110.65 92.54 111 109.36 110.59 110.8 108.13 70.74 91.16 107.62 87.57 102.06 98.01 114.4 106.32 112.28 101.94 96.44 112.47 109.18 104.05 109.73 112.95 100.11 108.14 106.21 92.7 95.53 79.76 52.31 98.02 83.34

706.83

708.29

754.42

665.29

753.03

733.89

619.73

107.69 114.13 114.19 116.56 104.67 108.41 107.92 42.64 120.11 94.45 111.02 131.3 112.87 105.23 115.22 113.96 123.19 121.25 116.04 108.33 126.83 128.31 118.77 107.41 110.65 84.59 110.28 121.58 107.8 109.9 118.2 118.61 112.63 118.45 133.76 106.16 115.07 122.02 105.81 121.33 120.9 122.24 112.06 112.61 100.6 115.04 94.62 71.82 74.91 99.6

17.55211

12.194506

22.79155

18.524743

18.9493

15.669931

19.34225

14.758139

18.20704

15.051762

18.42535

14.658289

19.42958

13.468195

95 | P a g e

03-Apr 04-Apr 05-Apr 06-Apr 07-Apr 08-Apr 09-Apr 10-Apr 11-Apr 12-Apr 13-Apr 14-Apr 15-Apr 16-Apr 17-Apr 18-Apr 19-Apr 20-Apr 21-Apr 22-Apr 23-Apr 24-Apr 25-Apr 26-Apr 27-Apr 28-Apr 29-Apr 30-Apr 01-May 02-May 03-May 04-May 05-May 06-May 07-May 08-May 09-May 10-May 11-May 12-May 13-May 14-May 15-May 16-May 17-May 18-May 19-May 20-May 21-May 22-May

100.5 110.27 76.3 110.1 110.02 110.73 110.81 104.47 105.95 90.2 102.45 103.83 84.99 103.18 99.26 98.81 100.04 90.35 99.37 98.04 91.17 77.29 60.62 83.82 96.58 101.17 70.5 96.34 94.98 100.79 100.15 100.49 103.13 103.26 103.67 96 104.66 104.13 105.23 102 112.35 114.04 112.58 112.53 106.11 60.55 104.61 98.5 92.66 108.66

728.38

682.72

616.88

644.18

711.36

762.86

677.4

117.66 119.53 91.28 128.84 106.25 121.03 129.43 121.57 95.32 108.52 114.53 121.37 103.43 94.44 108.28 110.19 109.16 107.38 106.41 108.93 109.3 97.88 65.76 95.34 105.71 111.61 83.49 110.99 97.23 97.39 109.28 110.16 109.58 122.74 106.09 114.87 113.98 119.7 105.92 155.33 113.03 135.51 118.09 121.53 120.6 74.83 115.98 104.95 122.96 108.84

20.7831

16.495961

21.48169

16.342411

23.75211

16.740964

24.97465

17.526209

22.57324

17.758367

19.95352

17.341805

21.39437

16.610158

96 | P a g e

23-May 24-May 25-May 26-May 27-May 28-May 29-May 30-May 31-May

106.31 68.06 86.78 111.82 114.36 74.82 110.89 102.04 110.02

668.77

770.14

128.22 101.92 73.13 103.35 126.26 88.14 130.71 123.98 112.24

23.27183

17.395461

23.5338

18.490038

97 | P a g e

Table 7.4. SFL production and total soda loss

SFL Period

Production Bleached Pulp (MT)

01-Jan 02-Jan 03-Jan 04-Jan 05-Jan 06-Jan 07-Jan 08-Jan 09-Jan 10-Jan 11-Jan 12-Jan 13-Jan 14-Jan 15-Jan 16-Jan 17-Jan 18-Jan 19-Jan 20-Jan 21-Jan 22-Jan 23-Jan 24-Jan 25-Jan 26-Jan 27-Jan 28-Jan 29-Jan 30-Jan 31-Jan 01-Feb 02-Feb 03-Feb 04-Feb 05-Feb 06-Feb 07-Feb 08-Feb 09-Feb 10-Feb 11-Feb

210.9 161.76 110.88 190.81 195.73 173.98 124.68 255.84 203.76 219.74 175.76 226.86 198.93 226.01 241.11 150.85 227.13 217.41 234.27 204.78 207.34 225.1 216.96 226.43 135.45 170.71 211.03 200.98 183.38 226.45 240.06 202.779 211.93 198.86 190.08 169.13 179.18 222.06 205.01 205.91 57.1 81.83

Weekly Bleached Production

1128.26

1364.54

1446.65

1532.29

1368.06

1374.019

1151.77

Unbleached Pulp (MT)

267.36 218.92 160.11 134.03 198.33 234.3 127.86 268.38 213.35 219.52 165.62 240.51 193.95 244.67 239.17 177.26 208.19 231.07 209.28 232.66 215.89 227.42 219.44 248.21 228.4 206.68 199.6 236.3 189.29 222.03 250.59 237.27 204.82 237.81 196.68 173.78 142.06 226.45 212.54 203.57 96.44 52.83

Weekly Unbleached Pulp (MT)

Soda Loss % Soda Soda Loss (TTA (Weekly Na2O, basis MT) Kg/MT)

1508.243333

17.94507

27.065533

1395.77

14.88873

20.781246

1469.37

17.3338

25.46977

1583.97

17.11549

27.110427

1532.89

14.80141

22.688931

1418.87

15.10704

21.434929

1220.48

15.41268

18.810863

98 | P a g e

12-Feb 13-Feb 14-Feb 15-Feb 16-Feb 17-Feb 18-Feb 19-Feb 20-Feb 21-Feb 22-Feb 23-Feb 24-Feb 25-Feb 26-Feb 27-Feb 28-Feb 01-Mar 02-Mar 03-Mar 04-Mar 05-Mar 06-Mar 07-Mar 08-Mar 09-Mar 10-Mar 11-Mar 12-Mar 13-Mar 14-Mar 15-Mar 16-Mar 17-Mar 18-Mar 19-Mar 20-Mar 21-Mar 22-Mar 23-Mar 24-Mar 25-Mar 26-Mar 27-Mar 28-Mar 29-Mar 30-Mar 31-Mar 01-Apr 02-Apr

192.16 194.78 214.98 145.29 189.83 165.1 196.56 193.63 220.43 212.14 205.08 233.91 205.41 223.68 177.19 225.35 202.49 186.42 220.63 227.64 230.68 240.33 232.86 197.06 179.58 215.88 216.81 215.2 85.61 125.51 182.13 224.06 168.05 181.68 180.98 271.06 221.41 177.48 198.61 223.51 268.87 204.16 204.65 218.66 161.53 303.02 99.52 211.08 208.3 221.63

1322.98

1473.11

1535.62

1220.72

1424.72

1479.99

1481.47

208.4 210.22 236.48 198.25 162.34 198.59 176.79 258.11 234.16 216.23 196.82 211.89 223.29 249.81 279.19 231.51 248.99 218.26 235.87 244.09 231.93 241.53 231.83 247.89 180.96 195.55 296.68 262.92 86.6 151.98 266.44 230 230.41 224.24 228.82 237.96 253.84 213.97 223.67 211 272.71 216.14 226.19 241.23 180 341.12 135.44 247.62 186.76 251.49

1444.47

18.6

26.867142

1641.5

15.67465

25.729935

1651.4

14.40845

23.794115

1441.13

15.76197

22.71505

1619.24

16.32958

26.441505

1570.94

16.94085

26.613051

1662.56

14.93239

24.826002

99 | P a g e

03-Apr 04-Apr 05-Apr 06-Apr 07-Apr 08-Apr 09-Apr 10-Apr 11-Apr 12-Apr 13-Apr 14-Apr 15-Apr 16-Apr 17-Apr 18-Apr 19-Apr 20-Apr 21-Apr 22-Apr 23-Apr 24-Apr 25-Apr 26-Apr 27-Apr 28-Apr 29-Apr 30-Apr 01-May 02-May 03-May 04-May 05-May 06-May 07-May 08-May 09-May 10-May 11-May 12-May 13-May 14-May 15-May 16-May 17-May 18-May 19-May 20-May 21-May 22-May

225.83 212.09 175 223.82 227.31 210.9 228.28 190.29 200.36 230.92 177.93 211.74 231.06 221.66 170.44 235.76 163.16 147.35 206.49 200.81 197.49 210.53 214.96 225.53 98.84 213.6 236.3 239.23 244.69 232.15 171.13 241.09 227.04 226.18 242.45 238.14 243.14 220.75 238.63 240.56 245.45 245 245.93 240.8 205.36 224 205 193 204 222

1455.96

1479.51

1340.79

1490.34

1589.17

1677.12

1449.36

267.71 232.42 230.41 257.37 258.7 244.38 263.2 220.63 240 240 200.59 216.3 253 228.21 174.36 255.89 190.61 158.05 242.1 213.52 239.43 229.05 235.41 239.62 124.72 243.13 257.99 272.63 268 272.33 185.68 271.98 252.06 247.94 278.68 271.53 274.78 230.59 277.73 276.94 269.35 276.22 277.99 284.51 248.82 225.06 230.97 227.64 216.8 258.59

1714.69

13.3169

22.834358

1568.35

16.02394

25.131152

1508.17

16.15493

24.36438

1678.42

16.19859

27.18804

1782.65

16.80986

29.966095

1893.33

17.72676

33.562608

1657.66

17.72676

29.384942

100 | P a g e

23-May 24-May 25-May 26-May 27-May 28-May 29-May 30-May 31-May

196 46 210.01 224.01 208 169 210 225 222

1292.02

1554

249.78 73.6 222.13 172.54 331.46 172.18 241.17 247.44 255.97

1460.52

16.7662

24.487366

1791.79

13.70986

24.565189

101 | P a g e

   e   s     l     l     b   s    a    a   o    L    )    T    t    h    o   s    a    M    T    a   d    (    o    W   S

   9    3    4    9    6    7    0  .    0

   3    7    6    6    9    6    0  .    0

   2    4    3    1    6    0  .    0

   9    8    0    9    7    5    0  .    0

   4    2    8    9    3    8    0  .    0

   2    8    2    5    4    8    0  .    0

   7    9    2    7    8    0  .    0

   7    1    0    7    8    6    0  .    0

    l    a   s    )    a    T    t    d   s    o   o   o    M    T    S    L    (

   1    4    8    1    1    1  .    0

   5    6    2    1    0    1  .    0

   3    6    1    9    8    0  .    0

   3    7    1    4    8    0  .    0

   2    7    0    2    2    1  .    0

   5    6    8    2    2    1  .    0

   9    8    6    2    1  .    0

   1    6    8    9    9    0  .    0

   2    9    6    6    3  .    1

   5    6    7    3    2  .    1

   5    7    9    8    0  .    1

   6    7    8    2    0  .    1

   6    9    1    9    4  .    1

   6    5    6    1    0    5  .    1

   4    4    8    0    5    5  .    1

   6    9    4    0    2    2  .    1

   e   s     l    s     b    l    a   o    %    h    s    a    a   d    o    W   S

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

    l    A    T  ,     )    a    T   O   T    t    (    o   a   2    /    M    T    a    g    d   N    %   o    K    S

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   e   s     l     l     b   s    a    a   o    L    )    T    t    h    o   s    a    M    T    a   d    (    o    W   S

   1    5    6    0    2    3    1  .    0

   7    8    0    3    8    2    1  .    0

   2    5    6    8    3    2    1  .    0

   5    2    9    0    1    0    1  .    0

   9    7    1    9    3    3    1  .    0

   6    6    9    9    2    3    1  .    0

   7    7    4    9    9    2    1  .    0

   6    1    6    1    7    1    1  .    0

    l    a   s    )    a    T    t    d   s    o   o   o    M    L    T    S     (

   1    9    8    6    3    1  .    0

   7    9    9    2    3    1  .    0

   1    9    3    8    2    1  .    0

   7    8    7    4    0    1  .    0

   2    1    8    8    3    1  .    0

   7    5    8    7    3    1  .    0

   6    9    6    4    3    1  .    0

   3    4    4    1    2    1  .    0

   6    4    9    5  .    2

   8    0    2    5  .    2

   5    3    3    4  .    2

   1    6    8    9  .    1

   1    3    6  .    2

   9    2    1    6  .    2

   3    5    5  .    2

   8    1    0    3  .    2

   e   s     l    s     b    l    a   o    %    h    s    a    a   d    o    W   S

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

    l    A    T  ,     )    a    T   O   T    t    (    M    o   a   2    /    T    a    g    d   N    %   o    K    S

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

    f    o   p    )    T    L    s    F    s    l    M    a    u    P    W    M     (

   s    s    o    L    n    e    e    r    c    S

    f    o   p    )     l    T    L    s    u   M    F    s    a    P    (    S    M    L    F    S     d    n    a    L    F    W    n    i    t    c    e    j    e    R    s    a    s    n    e    e    r    c    S    m    o    r     f    s    s    o     l    a     d    o    S  .    1  .    8    e     l     b    a    T

    )    3    A   O    T   C    T   2    a    N     (     l    s    )    a    t    s    T    o   o    M    T    L    (

   3  .    9  .    6  .    9  .    5  .    6  .    4  .    3  .    1  .    3  .    2  .    6  .    8  .    4  .    2  .    1  .    4  .    4  .    2  .    4  .    7  .    3  .    3    1    4    2    4    9    8    6    7    9    7    9    9    9    3    4    0    3    9    1    2    3    3    3    3    3    3    2    2    2    2    2    2    2    2    2    3    3    3    3    2    3    3    3

   9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   8    6    4  .    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    8    E    0    1    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    R

   7    4    3    3    5    8    0  .    0

   1    7    0    3    9    0  .    0

   4    9    6    3    5    7    0  .    0

   6    5    2    7    1    8    0  .    0

   6    4    8    6    7    5    0  .    0

   3    1    3    1    0    9    0  .    0

   4    3    6    4    1    9    0  .    0

   4    1    3    7    9    8    0  .    0

   8    1    9    9    1    8    0  .    0

   8    3    0    4    2    1  .    0

   3    8    2    5    3    1  .    0

   3    5    5    9    0    1  .    0

   2    9    7    8    1    1  .    0

   7    4    8    3    8    0  .    0

   1    0    1    3    1  .    0

   6    4    9    2    3    1  .    0

   9    2    4    0    3    1  .    0

   9    7    1    9    1    1  .    0

   4    8    9    5    1    5  .    1

   2    4    3    5    6  .    1

   8    4    9    8    3    3  .    1

   8    6    8    1    5    4  .    1

   6    7    7    4    2    0  .    1

   6    9    1    1    0    6  .    1

   6    8    4    2    6  .    1

   2    9    0    4    9    5  .    1

   6    9    5    6    5    4  .    1

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   9    2  .    6    5

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   2    8  .    1    8

   7    4    1    2    9    2    1  .    0

   6    8    2    9    2    2    1  .    0

   2    6    5    2    4    6    0  .    0

   4    7    7    7    9    8    0  .    0

   9    2    5    9    6    1    1  .    0

   2    1    8    1    3    1    1  .    0

   3    0    3    0    6    3    1  .    0

   1    8    6    2    3    1  .    0

   5    7    0    2    5    4    1  .    0

   7    3    9    3    3    1  .    0

   1    2    4    7    2    1  .    0

   4    0    6    6    6    0  .    0

   8    5    0    3    9    0  .    0

   7    2    2    1    2    1  .    0

   7    1    3    7    1    1  .    0

   1    0    0    1    4    1  .    0

   9    2    5    7    3    1  .    0

   4    1    5    0    5    1  .    0

   6    8    3    5  .    2

   1    5    1    4  .    2

   4    2    6    2  .    1

   8    3    6    7  .    1

   7    7    9    2  .    2

   6    3    2    2  .    2

   5    2    7    6  .    2

   7    6    0    6  .    2

   8    2    5    8  .    2

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   9  .    0    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    7  .    2    5

   6    8    2  .    2  .    9  .    7  .    8  .    6  .    4  .    1  .    8  .    4  .  .    8  .    4  .    4  .    5  .    8  .    2  .    2  .    8  .    8  .    2  .    9  .  .    3  .    6  .    4  .    7  .    9    9    2    3    0    8    9    3    6    3    0    7    0    4    5    9    7    0    0    9    8    8    7    2    9    7    4    9    6    3    2    2    3    3    3    2    2    3    2    3    2    3    3    3    2    2    3    3    2    2    2    2    2    2    3    2    2    4    3    8  .    6   -

   1    6    6  .    9   -

   8    0    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   A   B    C    A   B    C    A   B    C    A   B    C    A    B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      8    8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

   e    g    a    P     |    3    0    1

   e    r    l     )    7    o    b    %    f    E    a    a    d    g    s    h   o   R    6    v    s    s    S    O   1  .    A   o    L    a     (    0    W    r    l    e    o    b     f     )    a    a    E    s    s    h   d    R    s    o    o    O    S    L    a     (    %   W

   7    6    1  .    0    4    1    8    2    7    5    1  .    0

   8    0    1    2    3    5    1  .    0

   3    7    4    6    9    5    1  .    0

   r    l     )    o   a    a    E    1    %    f    d   R    0    g    s    t    o   O   2    v    s    o  .    T    S    (    0    A   o    L     l    a     )    s    s    t    E    o   a    o    R    L    T    d    o    O    r    S     (    %    f    o

   5    1    7    6    7    7    1  .    0

   7    2    9    1    0    6    1  .    0

   6    0    4    8    9    6    1  .    0

   9    1    7    2    1    2  .    0

   5    0    0    2    9    1  .    0

   7    0    5    4    0    2  .    0

   1    0    2  .    0    4    7    1    7    8    1  .    0

   2    9    2    1    8    1  .    0

   1    3    5    7    8    1  .    0

    l     b   a    a    a    d   s    4    r    h    e    o   s    3    %    s  .    s    o    a    s    d    n    L    2    e    S    e    o     l    G   W    L    e    n    i    n    b     l    e    m    a    l    e    a    s    o    r    a    r    t    d   s    1    8    c    C    %   e  .    n   o   o   o    S    e    T    S    L    2    G

   L    F    S     d    n    a    L    F    W    n    i    t    c    e    j    e    R    s    a    s    n    e    e    r    c    S    m    o    r     f    s    s    o     l    a     d    o    s     d    e    n    i     b    m    o    C  .    2  .    8    e     l     b    a    T

   2    9    8    3    2    6    1  .    0

   6    8    9    2    9    1  .    0

   0    4    3  .    2    9    0    8  .    2

   e     l    n     b   n    e    a    i    s     h    %   s    s    e    r    c    a    o    L    S    W

   9    4    7    8    6    3    0  .    4    1

   3    8    0    3    3    1    5    4  .    1

   9    0    8    6    5    9    2    8  .    1

   2    4    2    0    6    8    1    6  .    3

   4    9    9    1    3    0    2    2  .    1

   8    9    9    6    2    0    7    9  .    0

   1    6    7    9    1    0    6    9  .    0

    l    a    i    n    t    n    e    o   s    e    r    T    s    c    o    %   L    S

   7    6    4    0    7  .    6    1

   7    3    3    7    1    7  .    1

   4    1    1    9    4    1  .    2

   5    0    4    0    0    3  .    4

   2    4    0    1    6    4  .    1

   2    5    9    2    6    1  .    1

   3    8    1    6    5    1  .    1

   e    s     l     l     b   s    a    a    o    L    )    T    t    h    o   s    a    M    T    a    d    (    o    W   S

   1    9    0    0    9    0    2  .    0

   6    7    9    7    9    1  .    0

   2    7    0    2    5    8    1  .    0

   4    1    0    0    9    5    1  .    0

   3    0    0    9    7    1    2  .    0

   8    4    2    5    7    1    2  .    0

   7    4    4    2    7    1    2  .    0

    l    a    s    )    a    T    t    d   s    o   o   o    M    T    S    L    (

   2    3    7    8    4    2  .    0

   2    6    2    4    3    2  .    0

   5    5    5    7    1    2  .    0

   6    9    8    8    1  .    0

   4    8    8    0    6    2  .    0

   2    2    7    0    6    2  .    0

   6    8    5    1    6    2  .    0

    )    A   2    3    a    T    N   O    T    (    C     l    s    )    a    T    t    s    o   o    M    T    L    (

   3  .    9  .    6  .    9  .    5  .    6  .    4  .    3  .    1  .    3  .    2  .    6  .    8  .    4  .    2  .    1  .    4  .    4  .    2  .    4  .    3    1    4    2    4    9    8    6    7    9    7    9    9    9    3    4    0    3    9    1    3    3    3    3    3    2    2    2    2    2    2    2    2    2    3    3    3    3    2    3    9    8    4  .    1

   1    4    6  .    3    1

   3    2    1  .    0    1

   4    9    3  .    4

   6    5    8  .    7    1

   9    1    4  .    2    2

   5    2    6  .    2    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    E    0    1    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    R

   e    g    a    P     |    4    0    1

   e    g    a    P     |    5    0    1

   2    9    7    1    2    7    1  .    0

   6    9    8    5    0    7    1  .    0

   9    8    4    7    9    6    1  .    0

   5    7    1    0    2    8    1  .    0

   5    2    1    5    1    5    1  .    0

   1    9    3    1    2    7    1  .    0

   1    4    8    4    0    7    1  .    0

   3    3    9    8    6    1  .    0

   7    2    5    9    7    6    1  .    0

   5    2    0    0    8    1  .    0

   1    1    0    5    0    2  .    0

   7    1    1    5    0    2  .    0

   2    5    4    6    0    2  .    0

   4    6    9    2    2  .    0

   7    5    1    7    8    1  .    0

   4    1    2    0    2  .    0

   3    2    8    0    2  .    0

   9    2    4    3    0    2  .    0

   6    4    3    2    0    2  .    0

   5    9    6    3    1    2  .    0

   9    4    9    2    9    0    3    5  .    7

   2    2    4    4    9    3    1  .    3   -

   3    9    8    7    5    3    2  .    2   -

   3    3    8    5    1    0    6  .    2    1

   2    3    5    5    0    4    7    0  .    5

   2    8    9    8    4    8    2    0  .    1

   4    2    4    6    4    7    7  .    9   -

   1    2    6    3    7    2    8    2  .    3

   8    7    8    4    0    4    1    9  .    1

   7    7    0    7    5    4    9    3  .    4

   5    3    9    6    6    9  .    8

   7    8    4    7    7  .    3   -

   2    2    9    1    7  .    2   -

   4    6    8    9    8  .    5    1

   9    4    7    7    6    2  .    6

   7    3    7    7    0    2  .    1

   8    8    3    9  .    1    1   -

   1    6    0    3    5    9  .    3

   8    0    0    6    0    3  .    2

   8    8    4    6    1    2  .    5

   3    3    6    8    5    8    1  .    0

   5    9    4    5    4    1    2  .    0

   6    9    9    9    5    1    2  .    0

   5    5    2    6    9    3    1  .    0

   1    3    0    5    1    7    1  .    0

   6    7    3    6    4    7    1  .    0

   6    2    1    3    3    0    2  .    0

   6    3    9    4    7    2    2  .    0

   5    2    1    4    2    2    2  .    0

   3    9    9    1    7    2    2  .    0

   4    0    3    1    2    2  .    0

   4    7    9    7    5    2  .    0

   4    0    7    2    6    2  .    0

   7    5    1    6    7    1  .    0

   5    8    1    1    2  .    0

   4    7    0    5    0    2  .    0

   7    2    3    8    4    2  .    0

   7    4    9    3    7    2  .    0

   8    5    9    7    6    2  .    0

   2    9    6    9    6    2  .    0

   7    8    2  .    3  .    6  .    2  .    9  .    7  .    8  .    6  .    4  .    1  .    8  .    4  .  .    8  .    4  .    4  .    5  .    8  .    2  .    2  .    8  .    8  .    2  .    9  .  .    3  .    6  .    4  .    7  .    2    3    9    9    2    3    0    8    9    3    6    3    0    7    0    4    5    9    7    0    0    9    8    8    7    2    9    7    4    9    6    3    3    3    2    2    3    3    3    2    2    3    2    3    2    3    3    3    2    2    3    3    2    2    2    2    2    2    3    2    2    8    6    4  .    2

   4    3    8  .    6   -

   1    6    6  .    9   -

   8    0    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      7    8    8    8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

    l    a    t    o    T

   1    y    r    e    v    o    c    e    R

    l    a    3    r    s    h    P    6    s    g    u  .    S    %   e    o    n   L    o   E    9    e     h    1    G    t     )    %   s    E    g    s    R    v    o    O    A   L    (

   3    6  .    9    1

   7    9    3  .    1

   0    4  .    1

    l    a    r    s    h    5    s    g    u   P    S    1    %   e  .    n   o    o    E    e    L    h    8    G    t

   5    1  .    8

    h    s    s    g    P    u   S    o    L    o    r    E    %    h    t     )    %   s    E    g    s    R    o    v    L    O    A     (

   3    5  .    5    4

   7    9  .    4

   0    8    5  .    0    1    5  .    0

   2    5  .    0

   8    5  .    0

    l     h    a    r    s    g    P    8    s    u   S    4  .    %   e    n   o    o   E    1    e    L    h    1    G    t    8    0  .    4    6

   9    9  .    6

   9    6  .    0

   1    7  .    1    2

   3    4  .    9

   7    1    8  .    0

   0    0  .    3

   5    5  .    0

   0    5  .    0

   3    5  .    0

   4    3  .    5

   6    2  .    4

   2    2  .    4

   8    7  .    0

   0    7  .    0

   5    7  .    0

   2    8  .    0

   s    s    )    E    o    L    R    O    %    (

   s    s    o    L    E    R    O    P    S    E  .    6  .    9    e     l     b    a    T

   2    0  .    3

   8    4  .    1    1

    h    s    s    g    P    u   S    o    L    o    r    E    %    h    t     )    %   s    E    g    s    R    v    o    O    A   L    (

   0    8  .    3

   8    5  .    0

   s    s    )    E    o    L    R    O    %    (

   2    y    r    e    v    o    c    e    R

   3    4  .    5    1

   0    7  .    6

   2    7  .    0

   4    7  .    0

   2    8  .    0

   7    9  .    0

   d   O    e    2     )    L    L    m   a    N   T    F    u    S    W   s    A   M    n   T    o   T    C    (

   0  .    2  .    2  .    5  .    7  .    0  .    7  .    3  .    8  .    6  .    4  .    7  .    2  .    6  .    6  .    4  .    6  .    4  .    2  .    2  .    6  .    5    6    1    7    4    2    8    1    5    2    3    6    4    3    4    8    4    7    3    4    4    2    2    2    2    2    2    1    2    2    2    1    1    2    2    2    2    2    2    2    2    2

   d   O    e    2    L    L    m   a    )    F    u   N   T    M    W    W   s    n   A    o   T    T    C    (

   8  .    3  .    4  .    9  .    7  .    4  .    6  .    9  .    7  .    1  .    9  .    2  .    7  .    8  .    6  .    2  .    2  .    1  .    4  .    6  .    9  .    1    2    6    6    1    6    6    6    6    7    6    1    6    6    6    6    7    2    2    6    6    2    2    1    1    2    1    1    1    1    1    1    1    1    1    1    1    1    2    2    1    1

    l    s    )    a    T    t    s    o   o    M    T    L    (

   9    4  .    1

   4    6  .    3    1

   2    1  .    0    1

   9    3  .    4

   6    8  .    7    1

   2    4  .    2    2

   3    6  .    2    2

   t     f    i     h    S

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B

   e    t    a    D

   T    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    L    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    U   u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      S    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    E    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    0    7    0    R

   e    g    a    P     |    7    0    1

   7    4  .    7    2

   2    9  .    9   -

   2    0  .    7   -

   9    1  .    1    6

   6    0  .    0    2

   9    9  .    3

   0    6  .    2    3   -

   8    7  .    9

   3    8  .    5

   1    1  .    3    1

   3    6  .    0

   4    5  .    0

   3    5  .    0

   8    8  .    0

   0    6  .    0

   7    6  .    0

   7    5  .    0

   0    5  .    0

   1    5  .    0

   4    5  .    0

   6    6  .    8    3

   6    9  .    3    1   -

   8    8  .    9   -

   1    1  .    6    8

   3    2  .    8    2

   2    6  .    5

   7    8  .    5    4   -

   7    7  .    3    1

   1    2  .    8

   5    4  .    8    1

   8    8  .    0

   6    7  .    0

   5    7  .    0

   4    2  .    1

   4    8  .    0

   4    9  .    0

   0    8  .    0

   1    7  .    0

   2    7  .    0

   6    7  .    0

   6    6  .    2  .    2  .    0  .    4  .    3  .    6  .    2  .    7  .    7  .    8  .    5  .    1  .    3  .    4  .    5  .    7  .    2  .    9  .    8  .    0  .    5  .    3  .    0  .    4  .    8  .    4  .    9  .  .    0  .    2    9    0    3    5    1    4    3    6    6    2    3    3    2    3    9    9    9    9    4    5    7    1    3    5    3    6    5    0    0    1    2    2    2    2    2    2    2    1    2    1    2    2    2    1    1    1    1    2    2    2    2    2    2    2    2    2    2

   4  .    9  .    8  .    6  .    1  .    4  .    9  .    1  .    8  .    0  .    2  .    0  .    3  .    9  .    9  .    5  .    7  .    0  .    7  .    4  .    4  .    7  .    0  .    6  .    9  .    3  .    6  .    4  .    4  .    2  .    1    6    6    6    2    6    1    7    1    7    2    1    6    6    1    1    0    7    6    6    2    1    2    6    1    2    6    9    3    0    1    1    1    1    2    1    2    1    2    1    2    1    1    1    2    1    1    1    1    1    2    2    2    1    2    2    1    1    2    1

   7    4  .    2

   3    8  .    6   -

   6    6  .    9   -

   1    1  .    1

   8    3  .    3

   8    9  .    6    1

   8    0  .    2   -

   3    9  .    6

   2    6  .    1    1

   7    1  .    5

   C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    C    A   B    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    n    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    u    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J   -    J      8    8    8    9    9    9    0    0    0    1    1    1    2    2    2    3    3    3    4    4    4    5    5    5    6    6    6    7    7    7    0    0    0    0    0    0    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1    1

Table 10.1. Average ORE based on stock

Date

Shift

01-Jun 01-Jun 01-Jun 02-Jun 02-Jun 02-Jun 03-Jun 03-Jun 03-Jun 04-Jun 04-Jun 04-Jun 05-Jun 05-Jun 05-Jun 06-Jun 06-Jun 06-Jun 07-Jun 07-Jun 07-Jun 08-Jun 08-Jun 08-Jun 09-Jun 09-Jun 09-Jun 10-Jun 10-Jun 10-Jun 11-Jun 11-Jun 11-Jun 12-Jun 12-Jun 12-Jun 13-Jun 13-Jun 13-Jun 14-Jun

C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C A B C

Total Loss (MT)

1.489

13.641

10.123

4.394

17.856

22.419

22.625

2.468

-6.834

-9.661

1.108

3.38

16.98 -2.08

SFL

WFL

WL Consumed (TTA Na2O MT) 24.98705 26.1545 21.1951 27.47343 24.6942 22.0274 18.66867 21.32362 25.78394 22.63644 13.41116 16.7262 24.22728 23.63286 24.60912 28.35826 24.55047 27.35278 23.20928 24.21172 24.62994 19.581 20.15745 23.19216 24.9565 21.44608 24.28979 23.60832 26.16104 16.74419 22.67496 3.834 0 12.61416 23.46552 22.0563 23.2686 19.43172 19.52412 19.67256

WL Consumed (TTA Na2O MT) 21.845 22.28 16.427 16.923 21.713 16.387 16.616 16.904 16.714 17.094 16.891 11.155 16.749 16.811 16.613 16.183 17.197 22.148 22.443 16.555 16.862 11.354 16.886 16.777 16.592 22.103 16.382 21.886 17.08 21.767 17.01 22.177 11.014 16.339 16.862 21.857 11.494 10.73 17.003 16.718

Total WL Consumed

46.83205 48.4345 37.6221 44.39643 46.4072 38.4144 35.28467 38.22762 42.49794 39.73044 30.30216 27.8812 40.97628 40.44386 41.22212 44.54126 41.74747 49.50078 45.65228 40.76672 41.49194 30.935 37.04345 39.96916 41.5485 43.54908 40.67179 45.49432 43.24104 38.51119 39.68496 26.011 11.014 28.95316 40.32752 43.9133 34.7626 30.16172 36.52712 36.39056

% Loss

ORE

1.1205

98.88

10.557

89.443

8.726

91.274

4.4876

95.512

14.559

85.441

16.51

83.49

17.688

82.312

2.2863

97.714

-5.434

105.43

-7.592

107.59

1.4444

98.556

2.986

97.014

16.737

83.263

-1.744

101.74

Average ORE

94.0003