PAPER BOARD PRODUCTION AT ITC, LIMITED, PSPD, UNIT: KOVAI
←
→
Page content transcription
If your browser does not render page correctly, please read the page content below
CHAPTER II
PAPER BOARD PRODUCTION AT ITC, LIMITED, PSPD,
UNIT: KOVAI
2.1. Preamble about ITC Limited
ITC was established on August 24, 1910 under the name Imperial Tobacco
Company of India Limited. As the Company's ownership progressively Indianised, the
name of the Company was changed from Imperial Tobacco Company of India Limited to
India Tobacco Company Limited in 1970 and then to I.T.C. Limited in 1974. In
recognition of the Company's multi-business portfolio encompassing a wide range of
businesses - Cigarettes and Tobacco, Hotels, Information Technology, Packaging,
Paperboards and Specialty Papers, Agriculture business, Foods, Lifestyle Retailing,
Education and Stationery and Personal Care the full stops in the Company's name were
removed effective September 18, 2001. The Company now stands rechristened ITC
Limited.
In the first six decades of the Company's existence were primarily devoted to the
growth and consolidation of the Cigarettes and Leaf Tobacco businesses, the Seventies
witnessed the beginnings of a corporate transformation that would usher in momentous
changes in the life of the Company. ITC's Packaging and Printing Business was set up in
1925 as a strategic backward integration for ITC's Cigarettes business. In 1979, ITC
entered the Paperboards business by promoting ITC Bhadrachalam Paperboards Limited,
which today has become the market leader in India. In 2000, ITC forayed into the
Greeting, Gifting and Stationery products business with the launch of Expressions range of
greeting cards. A line of premium range of notebooks under brand “Paperkraft” was
launched in 2002. Years 2007- 2009 saw the launch of Children Books, Slam Books,
Geometry Boxes, Pens and Pencils under the “Classmate” brand. In 2008, ITC
repositioned the business as the Education and Stationery Products Business and launched
India's first environment friendly premium business paper under the “Paperkraft” Brand.
“Paperkraft” offers a diverse portfolio in the premium executive stationery and office
12consumables segment. Paperkraft entered new categories in the office consumable segment
with the launch of Textliners, Permanent Ink Markers and White Board Markers in 2009.
ITC Limited has demonstrated outstanding achievement in the environmental and
social dimensions of the Triple Bottom Line. For the 9th year in a row, ITC has sustained
its ‘water positive’ status, creating freshwater potential that is twice its consumption. For
the 6th year in succession, ITC is ‘carbon positive’ sequestering twice its emissions. It has
also been ‘solid waste recycling positive’ for 4 years now. As a result, ITC is the only
enterprise in the world of comparable size to have achieved and sustained these three
global environmental distinctions. In addition, the inclusive strategy that defines ITC’s
innovative business models has also led to the creation of sustainable livelihood
opportunities for over 5 million people.
2.2. Paperboards and Specialty Papers
ITC's Paperboards and Specialty Papers Division is India's largest, technologically
advanced and most eco-friendly, paper and paperboards business. The business caters to a
wide spectrum of packaging, graphic, communication, writing, printing and specialty paper
requirements through its four world-class manufacturing units. Having pioneered many
specialty applications, ITC's Paperboards and Specialty Papers business enjoys market
leadership in the value-added paperboards segment, and also has a significant share of the
Indian fine papers market. It is the largest exporter of coated boards from India. The
product range includes:
Packaging
Virgin Recycled
1 Folding Box Boards 1 Coated Duplex Whiteback
2 Solid Bleached Boards 2 Coated Duplex Greyback
3 Coated High Burst Liner
Specialty
1 Liquid packaging 1 Barrier coated carton boards
2 Food grade packaging board 2 Biodegradable barrier boards
3 Cupstock 3 Cast coated boards
4 Antifungal Coated boards
13Papers
1 Woodfree fine papers 1 Unbleached Kraft base
2 Absorbent Kraft 2 Cigarette Tissues
3 Opaque papers 3 Electrical insulation papers
4 Decor Surface, Printing & 4 Pharma Inserts
barrier papers Niche papers Superfine Printing
Graphic
1 Art boards 1 Playing card boards
2 Ivory boards 2 Cigarette Tissues
ITC takes great pride in servicing a large cross-section of industry requirements -
from cigarette tissues to Fast Moving Consumers Goods (FMCG) cartons, from electrical
insulation papers to Poly Lactic Acid (PLA) Coated Boards, from decorative laminate base
to writing and printing papers and much more. ITC straddles the entire spectrum of
paperboards from 100 per cent virgin, food-grade boards which are from renewable and
sustainable resources to 100 per cent recycled boards.
Some of ITC's prominent paperboard brands are:
Sl.No Varieties Brands
1 Folding Box Boards Cyber XLPac, Cyber Cypak, Cyber Propac,
Cyber Premium, Pearl XL Pac
2 Solid Bleached Sulphate Safire Graphik, Art Maestro, Carte Persona,
Boards Carte Lumina, Safire XL Pac, Digiart
3 Poly coated boards Indobev, Indobarr
4 PLA Coated boards Omegabev, Omegabarr, Omegawrap
5 Recycled boards Eco Blanca, Eco Natura
6 Fine Papers AlfaZap, Alfa Plus, Hi Brite, Paperkraft , Alfazine,
Perma White
Each of the units specializes in a range of products. Together, these units produce
close to 5,50,000 ton/year of paper and paperboards that meet stringent quality
14requirements across the world. All manufacturing units are ISO 9001, ISO 14001 and
OHSAS 18001 certified and meet strict Environment, Health and Safety norms.
The unit in Bhadrachalam (Andra Pradesh State) is India's largest integrated
pulping and paperboard manufacturing unit. Currently the unit produces high-end virgin
and recycled boards for packaging and graphic applications, and fine printing papers. The
Bhadrachalam unit manufactures and uses pulp made from ozone bleaching process known
as light Elemental Chlorine Free (ECF) process. The use of ozone technology significantly
reduces the load of toxins in the effluent discharged, and helps customers get a brighter,
stronger product that is also environmentally responsible with the BOD (Biochemical
oxygen on demand) and COD (Chemical oxygen on demand) level way below the National
Standards Limits. ITC's focus on being a carbon-positive, water-positive, zero-solid waste
disposal organization leads it to constantly develop ways of reducing, reusing and
recycling.
2.3. ITC Ltd PSPD Unit: Kovai
In 2004, ITC acquired the paperboard manufacturing facility of BILT Industrial
Packaging Co. Ltd (BIPCO), Coimbatore, Tamil Nadu and renamed as ITC Ltd PSPD
(Paperboards and Specialty Papers Division) Unit: Kovai. It is geographically located
(Latitude E 76o52'29.4" and Longitude N 11o15' 1.2”) at the foothills of Western Ghats at
Thekkampatti village, Mettupalayam Taluk, Coimbatore District. Today this unit is a
major producer of the recycled paperboard in the country (www.bhadranet.itc.in). It is a
also pioneer industry in perfecting the Technology of making fine quality Duplex Paper
Board from waste paper. The production capacity of the factory is around 250 tons of
Duplex board per day and its consumes 250 tons of waste paper, 21 tons of chemicals,
300 tons of fuels, 3000 m3 of water for production of 250 tons of paper Boards. It
consumes around 2500 to 3000 m3 of water and discharge around 2100 to 2600 m3 of
effluent per day. The effluent after treatment is completely utilized for irrigation in about 100
ha of land within the factory premises.
152.3.1. Manufacturing process
The raw material for the manufacture of coated multilayered board is bleached
chemical pulp and waste paper, assorted paper waste, box board cuttings, coated book
stock, duplex cuttings, mixed waste, MWL (Manifold White Ledger), magazine, old news
paper, printer off cuts, pure white cuttings, sorted office paper, virgin duplex trimmings,
waste broke cut sheets, white blank news, news and pams, white broke and white office
record.
Aforesaid multilayered board consists of three layers of sheet couched together in
wet stage on the board machine. The quality of raw material used for each layer is
qualitatively different as shown below,
Sl.No Layers Waste paper used
1 Top layer Pure white cuttings, Coated Book Stock, Manifold
White Ledger, Printer of cuts, Shorted office paper,
Virgin duplex trimmings.
2 Middle layer Box Board Cuttings, Duplex cuttings, Mixed waste,
Waste paper pulp
3 Base layer Assorted paper waste paper pulp
The purchased waste papers are in form of bales. The bales are charged to the
pulper through the conveyor belt. The slushed pulp from pulper at a consistency of 4 per
cent is sent to high density cleaner for removing heavy weight contraries and then to
double disc refiners for refining pulp to make it suitable for board making. The refined
pulp is sent to blend chest where rosin is added. The blended pulp is sent to machine chest,
where alum is added for maintaining required pH of the system. The chemicals rosin, alum
etc., are prepared in chemical additive plant which is situated near to the stock preparation
building. From the machine chest the pulp is sent to one overhead stock-regulating box
through one control refiner where final control of refining is done.
From the stock-regulating box, the pulp is metered to the approach flow systems of
top layer through basis weight value. The approach flow system consists of one off
16machine white water silo, three stage centric leaning and three stage screening systems
where the pulp is cleaned to remove contraries like sand particles and shives from pulp.
After screening the pulp of a consistency of 0.6 - 0.8 per cent is sent to head box, which
delivers this pulp suspension on a moving endless forming wire. The water is drained from
the web formed on the wire and routed to machine silo where it is recycled back into
approach flow system.
The wet web leaves the top layer wire at around 11-12 per cent consistency.
Similarly for middle layer mixed waste paper are charged to the pulper through the
conveyor for slushing. The slushed pulp is processed through detrasher and high density
cleaner for removing the contraries. The pulp is further processed through three-stage
coarse cleaning, five stage centi cleaners, three stage fine screening and lightweight
screening. The cleaned pulp is then sent to thermo dispersion system for dispersing the
remained ink and other contraries uniformly throughput the pulp. The thermo-disposed
pulp is sent to blend hest from where the process is similar to that of top layer. For base
layer waste paper is used and the process is similar to that of middle layer. The raw
material used in the base layer is of better quality compared to middle layer.
The excess backwater from top layer is sent to flotation saveall where useful fiber
is recovered and sent back to process and clarified water is recycled back into process. The
backwaters of base layer and middle layer are combined and treated in a common flotation
saveall. The wet web from the all layers is couched into one single layer. The combined
layer is further dewatered to around 18 per cent on the base layer wire part, from where the
sheet is transferred to press for further dewatering takes place with the help of steam
heated cylinders. The steam is drawn from boiler. A precoating of starch is applied on the
surface of the board in the size press located within the dryer part.
The surface sized board is then is coated in the coating kitchen situated adjacent to
board machine building. The coated board is then passed through calendar for improving
the smoothness before it is reeled on the reel drum in roll form. The roll from reel drum,
weighing about 10 tons is taken to winder where it is cut into reels of the required size. The
cut reels are transferred to the finishing house area through reel handling conveyors and
17lowerator. Here the reel order reels are packed in the reel-packing machine, sheet order
reels are processed in sheet cutters. The cut sheet is packed into reams and bales. The
packed reels and bales are weighed and sent to the godown from where they are dispatched
for market.
2.3.2. Resource for production of Paperboard
2.3.2.1. Raw materials
The following recycled fibre of raw materials needed for the manufacture of
paperboards are obtained from assorted paper waste, box board cuttings, coated book
stock, duplex cuttings, Indian mix waste, MWL (Manifold White Ledger), magazine,
mixed waste paper, news and pams, old news paper, printer off cuts, pure white cuttings,
sorted office paper, virgin duplex trimmings, waste broke cut sheets, white blank news,
white broke, white office record etc.
2.3.2.2. Water resources
The required 3000-3500 m3 of water per day for processing is drawn from the River
Bhavani which is located 6 Kms away from the manufacturing unit. The raw water is
passed through flash mixer and clarifloculator. The clarified raw water is led to storage
tank and then the water is pumped through pressure sand filters for mill uses.
2.3.2.3. Energy
Agro wastes such as saw dust, de oiled rice bran, fossil fuels, raw lignite and coal
are fuels are used for energy generation.
2.3.3. Final Product
The major varieties of paperboards are Coated Board Gray Back (CBGB), Coated
Board White Back (CBWB), Duplex board, Cone board, Fusion board and coated highbulk
board.
2.3.4. Waste generation
The solid and liquid waste generation from different process of paperboard
manufacturing is furnished in table 2.1.
18Table 2.1. Generation of solid wastes
Waste Generation
Processes
Liquid Solid
Raw materials sorting - Plastics, wooden waste, iron waste, broken
glasses and mud
Paper feeding - Iron waste, Plastics and Jute waste
Pulping Effluent Metal waste, broken glasses, Plastics and
sludge
De-inking Effluent Sludge
Board manufacturing Effluent -
Coating Effluent Sludge
Rewinding - Solid waste
Packing - Plastics and wooden
Raw water treatment - Silt
Demineralization plant Effluent -
Boiler Effluent Flyash, Bed materials and packing waste
Effluent Treatment Plant Effluent Primary and Secondary sludge, Plastics
2.3.5. Air emission
The air emissions like Suspended Particulate Matter (SPM), SOx and NOx are
released during the burning of fuels for production of steam and electricity.
2.3.6. Waste management
• Electrostatic precipitator (ESP) is used to collect dust particulates from the flue
gas.
• Ash Handling System is used for collection of ash from the boiler while
generating the stem and the ash is removed by two ways.
a) Bottom ash removal
In the FBC (Fluidized Bed Combustion) boilers, the bottom ash constitutes around
30-40 per cent of the total ash, the rest being fly ash. The bed ash is removed by
intermittent draining.
b) Fly ash removal
The amount of fly ash to be handled in FBC (Fluidized Bed Combustion) boiler is
relatively high, when compared to conventional boilers. This is due to elutriation of
particles at high velocities. Fly ash carried away by the flue gases is removed in number of
19stages, from the bottom of convection section, from the bottom of Economizer and finally
from ESP.
The design details of ash handling system for 8 MW co-generation plant
Hourly fuel firing rate at Maximum continues rating (MCR) per unit 20 TPH (ton
per hour).Total ash content in fuel considered for design of ash handling system 6.3 per
cent. Distribution of total ash produced for design of ash handling system (Bed ash 10 per
cent, Fly ash 90 per cent). The system adopted for bed ash removal is continuous scraper
chain feeder system and for fly ash removal, pressure type pneumatic system. Fly ash
disposal from silo is carried out in dry form using open trucks. Cooling tower blow down
is used for scraper through make-up, fly ash conditioner. Water tapped from circulating
water system is used for silo/ESP aeration blowers.
• The condensate (waste steam) from the process having temperature of 80° C is
collected separately and used in boiler, which minimizes the fuel usage.
• PETAX filter is used for recycling of water as well as recovery of fiber from the
effluent.
2.3.7. Effluent Treatment Plant
The raw effluent is led through a manual coarse bar screen to remove any large
sized foreign material that may come along with the effluent. The effluent from coarse
screening is coagulated with alum/ poly aluminum chloride in a flash mixer and then led to
a primary clarifier. Suspended solids removal to the extent of about 90 per cent with
consequential BOD reduction takes place in the primary clarification. The clarified effluent
is led to the aeration basin for BOD reduction (Activated Sludge Process). The basin is
provided for biological treatment of the organic matter, which is easily bio-degradable.
Extended aeration system is practiced with a mixed liquor suspended solids level of 3500
mg/l. Urea and DAP are added as nutrients and the ratio of nutrients generally meets the
requirement 100:5:1 (BOD: N: P) the outlet of the aeration basin is led to a secondary
clarifier. The excess biomass, after re- circulation to the aeration basin is pumped to the
thickener for subsequent removal.
202.7.8. Sludge Handling System
The primary clarifier underflow sludge and the excess secondary clarifier biomass
are pumped to a thickener. The thickened sludge is pumped to a press filter for dewatering
and the dewatered sludge is disposed of as land fill /sold to sundry paper mills.
Effluent Treatment Plant (ETP)
Inlet
Primary Aeration tank
Flash mixer clarifier
MLSS
Filter Thickener
sludge press
Outlet Secondar
Irrigation tank y clarifier
S- sludge 51
Fig. 2.1. Effluent Treatment Plant
2.3.8. Usage of paperboard
The usages of different variety of final paperboard are given in table 2.2.
Table 2.2. Paperboard usage
Board Varity Usage
CBGB For all types of packaging industry (i.e. after printing)
SCB Match box industry outer box only WIMCO.
Un-Coated board Match box inner and shoe packing boxes
Cone board Match box Inner
Fusion Boards Dairy Outer, Calendar, Wallet Boxes, Pen Stand and etc.,
(Source : ITC Ltd PSPD, Unit: Kovai)
21CHAPTER III
ENVIRONMENTAL INVENTORY
Inventory analysis is a systematic, objective, stepwise procedure for quantifying
energy and raw materials requirement, atmospheric emissions, water borne emissions,
solid wastes, and other releases for the entire life cycle of a product or at different stages of
production (Manjare and Babu, 2005). This process involves data collection and
calculations to quantify the inputs and outputs of a product system. These inputs and
outputs may include resources used, as well as release to air, water, or land (SAIC, 2006).
A system refers to a collection of operations that together perform some defined function.
The system begins with all the raw materials taken from the environment and ends with the
outputs released back to the environment as shown in fig. 3.1 (Susan, 1995). This will be
specific to the actual technology chosen. For example, in the combustion of each particular
fossil fuel a known amount of carbon dioxide will be emitted per joule of energy released.
Fig. 3.1.Inputs and outputs of a system
Inventory analysis is developed primarily for evaluating the environmental performance of
industrial products.
Methodology
In this study, system boundaries were set for production (Fig.3.2). Data collected
for this subsystem includes all energy, material, water inputs and environmental releases
that occur during the manufacturing processes. This process was repeated for several
22You can also read
