CPCB Paper Guideline

FINAL REPORT
ON
DEVELOPMENT OF GUIDELINES FOR

WATER CONSERVATION IN PULP AND
PAPER SECTOR
Sponsored by
CENTRAL POLLUTION CONTROL BOARD

Delhi
Submitted by:
{Environment Group}
NATIONAL PRODUCTIVITY COUNCIL
New Delhi
(March, 2006)
TABLE OF CONTENT
SL. NO. TITLE PAGE NO

Chapter 1: Background
1.1 Introduction 1
1.2 Objective of the study 2
1.3 Scope of work 2
1.4 Methodology 3
Chapter 2: Industry Profil;e: Pulp and Paper
2.1 Status of Pulp and Paper Mills in India 5
2.2 Classification of Pulp and Paper Mills in the country 11
Chapter 3: Manufacturing Processes
3.1 Generalised Paper /Paper board making process 16
3.2 Different industrial processes in pulp and paper sector 17
3.3 Chemical recovery from black liquor 36
Chapter 4: Water consumption pattern in other countries 48
Chapter 5: Present Water consumption pattern prevailing
in pulp and paper sector in India
5.1 Background 52
5.2 Water consumption Scenario 52
5.3 Water consumption: Norms/Standards for paper and pulp 52
5.4 Water consumption: Latest Trends 54
Chapter 6: Unit Process/operation specific water
consumption factors
6.1 Background 58
6.2 Existing Water Consumption Status 62
Chapter 7: Formulation of Standards for water
consumption by different categories of pulp and paper
manufacturing units
7.1 Background 79
7.2 Proposed categaries of pulp anf paper mills for standards 78
7.3 Proposed types of Water consumption standards 82
7.4 Development of category specific water consumption standards 83
7.5 Proprosed category specific wastewater discharge standards 90
Chapter 8: Water conservation options identified for 92
different categories of pulp and paper mills
Conclusion 115
Annexure I: Copy of Questionnaire

Annexure II: List of pulp and paper mills in India
Annexure III: Compilation of Questionnaire data
STUDY TEAM
PROJECT ADVISOR
Dr. A. K. Saxena, Group Head
TEAM LEADER
Mr. Rajat Gupta, Senior Consultant
TEAM MEMBERS
Mr. K. K. Sinha, Senior Consultant

Ms. Shukla Pal, SeniorConsultant
Mr. S. Baskaran, Consultant
From other Regional Offices
Mr. Kaliprasad V, Senior Consultant, RPMG, Hyderabad

Mr. Hemantha S S, Consultant, RPMG Bangalore
SECRETARIAL ASSISTANCE
Mrs. H. K. Sarna
Mr. R.K. Ahuja
LABORATORY ASSISTANCE
Mr. S. K. Jain, Laboratory Analyst

Mr. Bhupinder Singh Yadav
ACKNOWLEDGEMENT
National Productivity Council (NPC) places on record its sincere thanks to the
Central Pollution Control Board for entrusting the study on “ Development of
Guidelines for Water conservation in Pulp and Paper sector”. NPC is grateful
to Shri P. M. Ansari, Additional Director, CPCB and Shri S. K. Gupta, Senior
Environmental Engineer, CPCB for their cooperation and assistance at
various stages of the project in collecting information from State Pollution
Control Boards and in selecting representative pulp and paper mills. NPC is
also thankful to all State Pollution Control Boards for providing list of operating
pulp and paper mills in their respective states.
NPC places on record its sincere thanks to all the management of following
pulp and paper mills for their full cooperations during conduction of field
studies in their mills:
1. M/s Tehri Pulp & Paper Ltd, Muzaffarnagar
2. M/s Shreyan Industries Ltd., Ahmedgarh
3. M/s HNL, Kottayam
4. M/s ITC (PSPD) Ltd., Bhadrachalam
5. M/s Seshasayee Paper & Boards Limited, Erode
6. M/s Indo Afrique Paper Mills (P) Ltd., Pune
7. M/s Pudumjee Pulp & Paper Mills Ltd. Pune
8. M/s. Shalimar Paper Mills (p) Ltd., Muzaffarnaga
9. M/s The Simplex Mills Co. Ltd. (Paper Division), Gondia
10. M/s KAWATRA PAPER Mills Ltd., Dadri
NPC also extends its thanks to various pulp and paper associations for
providing information on pulp and paper mills operating in India.
Last but not the least, NPC is thankful to all those who have been associated
with the project studies either directly or indirectly.
EXECUTIVE SUMMARY
The pulp and paper industry is one of India's oldest and core industrial sector.
The socio-economic importance of paper has its own value to the country's
development as it is directly related to the industrial and economic growth of
the country. Although paper has many uses, its most important contribution to
modern civilization is its use as a medium to record knowledge.
Paper manufacturing is a highly capital, energy and water intensive industry. It
is also a highly polluting process and requires substantial investments in
pollution control equipment. In India, around 905.8 million m3 of water is
consumed and around 695.7 million m3 of wastewater is discharged annually
by this sector1.
India’s current average fresh specific water consumption of about 150
m3/tonne of product is far above the global best specific water consumption of
28.66 m3/tonne (for large scale wood based pulp and paper mill) and this
large gap is primarily attributed to the use of obsolete technology /
equipments and poor water management practices.
The large water requirements and consumption by the Indian pulp and paper
industries has led to, water fast becoming a scarce commodity and lowering
of the groundwater table and thus increased pumping costs and more
importantly water shortage in many regions. Realizing the importance of water
and excessive usages of water by pulp and paper sector, Central Pollution
Control Board (CPCB) has taken initiative to develop the water conservation
guidelines and water consumption standards and entrusted National
Productivity Council to undertake the study to address these issues.
India produces 5.96 million tones of paper per year (2003 – 2004) through
309 paper manufacturing mills at a capacity utilization of approximately 60
percent. The number of paper manufacturing mills has increased consistently
from just 17 in 1951 to around 600 in Year 2002 with an annual installed
capacity of 6.2 million to meet the increasing demand. However since 2001 –
02, the number of mills have fallen sharply to 309 in the year 2004 primarily
due to increased environmental regulatory pressure, water shortage etc.
The profile of Indian pulp and paper sector including the various aspects like
product consumption pattern, operational scale, state wise industry inventory,
production process used, raw material used is presented in the Figures E-1
to E-3 and tables E-1 to E-3.
Table E-1: Consumption pattern of paper and paper board products in
India
Type of paper Main varieties % of total
consumptions
Cultural paper cream woven, maplitho, bond paper, 41%
Chromo paper
Industrial paper kraft paper, paper board – paper 43%
board - single layer board, multilayer
board, duplex board,
1
Source: Estimated by CSE based on the wastewater discharged data published by CPCB in "Water quality in India (Status and trends)
1990 - 2001".
National Productivity Council, New Delhi

Specialty paper Security paper, grease proof paper, 4%
electrical grades of paper
Newsprint glazed, non-glazed 12%

Figure E-2: Distribution of Pulp and Paper Mills
Based on Products Manufactured
250 227
200 187
174
150
No of
Mills
100
66 62
57
Producti
50 22 on, 104
20 21
3 12 12 TPA
0
high grade
low grade
Industrial
Newsprint
Pulp
Specialty
Cultural -
Cultrual -
Table E-2: Distribution of Pulp and Paper Mills (Number of Mills) Based
on Pulping Processes and Operational Scale
Sl. Pulping Process No of Mills Installed Capacity,
No million tonnes/yr
Large Small Grand Large % Small %
Scale Scale Total Scale Scale
1 Chemical Soda 54 18.2
29 26 0.666 4.26 0.106
Process 8
2 Hydro Pulping 219 12.80 80.0
92 113 81.88 0.462
7 7
3 Kraft/Sulphite 36
34 2 2.169 13.87 0.010 1.65
process
Table E-3 : Summary of classification of pulp and paper sector in

different categories
Sl. Product Large/Medium scale Small Scale
No type Agro Integrated Pape Wast Woo Agr Integrated Paper Waste Total
based 2 r Mill3 epap d o Mill paper
er base
d
1. Cultural - 15 1 15 14 7 1 12 65
high
2
Integrated refers to mill using wood, agro residue and waste paper as raw material
3
Paper Mill refers to mill using pulp produced from other mills to produce directly paper and
paper products

Sl. Product Large/Medium scale Small Scale
No type Agro Integrated Pape Wast Woo Agr Integrated Paper Waste Total
based 2 r Mill3 epap d o Mill paper
er base
d
grade
2. Cultural - 2 1 8 1 1 7 20
low grade
3. Industrial 19 2 50 18 1 90 187
4. Newsprint 1 1 15 2 2 21
5. Pulp 4 4
6. Specialty 2 4 3 3 12
Total 39 3 2 92 21 26 1 4 114 309
In order to develop water conservation measures for different types of

industries in the pulp and paper sector and also the water consumption /
discharge standards, 10 mills were identified (in consultation with CPCB) in
accordance with the above referred distribution of pulp and paper mills based
on operational scale, raw material used, pulping process, end product etc.
Detailed studies were conducted in these 10 mills to identify the water
conservation measures and also to generate the water consumption profile.
The detailed studies in conjunction with the data from questionnaire survey,
literature search and international water consumption norms have been used
to develop water consumption standards in the country.
Existing Water Consumption Norms / Standards: India
In India so far, no standards have been set for water consumption by any
agency. However CPCB has prescribed standards in terms of wastewater
discharge for different categories of pulp and paper industry. The wastewater
discharge quantum with additional 21 % (towards evaporation losses) is
generally used to give a fair picture of water consumption. The wastewater
discharge standard of 150 and 50 m3/tonne of product for small agro and
wastepaper based mills respectively and 200 m3/tonne for large scale mills
prescribed by CPCB do not appear appropriate as it does not cater to different
categories of pulp and paper manufacturing mills prevailing in India presently.
Further, this standard in the current scenario seems to have outdated as the
current average water consumption is itself 150 m3/tone of product.
As per Corporate Responsibility for Environment Protection (CREP)-
2002, following water discharge standards have been agreed upon by
different pulp and paper manufacturing associations:
A. Large scale pulp and paper mills:
¾ Less than 140 cum/tonne of paper within 2 years
¾ Less than 120 cum/tonne of paper in 4 years for mills installed before
1992
¾ Less than 100 cum/tonne of paper in 4 years for mills installed after
1992

B. Small scale pulp and paper mills:
This standard is also discharge specific but takes into consideration the
operational scale and the age of the mill. This standard also does not
differentiate on the basis of pulping process, raw material used, end product
etc.
Centre for Science & Environment through their Green Rating Project has
reported significant reduction in water consumption in large-scale Indian
paper mills and average figure has been reduced to 135 m3 per tonne paper
in the year 2002 due to increasing awareness regarding water conservation,
ever increasing pressure from government regulatory agencies and also due
to increasing water scarcity in many regions. The CSE finding gives an
indication that most of the industries are already achieving the water
consumption norms as agreed upon by them under CREP programme –
2002.
Existing Water Consumption Norms / Standards: World
In developed countries, most of the pulp and paper manufacturing mills are
wood based, however, due to environmental implications, trend is changing
towards use of recycled fibre as is the case with India.
The average water consumption for wood based large pulp and paper
industries primarily producing paper & paper board products from 6 regions /
countries namely United States, Australia, Europe, Canada Finland & Spain
have been compiled from various documents available on the web and the
same is presented in the Table E-4 below :
Table E-4: Region / Country Specific Average Water Consumption in

Large Scale Wood Based Pulp and Paper Mills
Sl. Region / Average Specific Source

N Country water
o. consumption
(m3/T of product)
1 U.S. 64 Appendix “W” of Report on Status of Pulp
(Average value in & Paper in US by Michiel P. H. Brongers
the year 2000) and Aaron J. Mierzwa
2 Australia 28.66 APIC Public Eco-efficiency Report 2003
. ( Average value
for the year 2003)
3 Europe APIC Public Eco-efficiency Report 2003
. 40
4 Canada APIC Public Eco-efficiency Report 2003
. 67
5 Finland 40 Pulp Fact - Environmental Implications of

Sl. Region / Average Specific Source
N Country water
o. consumption
(m3/T of product)
. the Paper Cycle” by Nigel Dudley, Sue
Stolton and Jean-Paul Jeanrenaud WWF
International 1996
6 Spain 30 Pup Fact – Environmental Implications of
. the paper Cylcle by Nigel Dudley, Sue
Stolton and Jean Paul, Jean Renaud –
WWF International 1996
The average water consumption for wood based large pulp and paper
industries primarily producing paper & paper board products in
developed countries varies from 30 – 70 m3/tonne of Product. Whereas
average water consumption in waste paper based pulp and paper mills
in developed countries varies from 8 – 10 m3/Tonne of product.
Current Water Consumption: A Revisit - Questionnaire Response
In order to review present water consumption levels in pulp and paper sector
in India, questionnaires were circulated to all the pulp and paper
manufacturing mills. Based on the questionnaire responses by industries (44
mills responded out of total of 309), specific fresh water consumption range
(excluding domestic) has been compiled and is as given below:
Specific Water Consumption

S.No. Raw Material End Product (M3/T of product)
Min Max Remark
Large Scale category
Cultural high grade
1 Integrated including newsprint 105 202
Cultural grade
2. Wood Based including newsprint 68 168
3. Wood Based Newsprint only 74 There is only one mill
Only one mill in this
4. Wood Based Rayon pulp 130 category responded
5 Agro Based Cultural - high grade 73 -do-
Cultural - low grade
6 Agro Based including newsprint
46 -do-
3 Waste paper Newsprint 29 -do-
Medium Scale category
1 Agro Residue Cultural – high grade 102 219
2 Agro Residue Industrial grade 28 category responded
Waste Paper
3 Based Cultural – high grade 40 -do-
4 Waste Paper Newsprint 16 -do-

S.No. Raw Material End Product (M3/T of product)
Min Max Remark
based
One mill reported 5.5
Waste paper m3/T & operating with
5 Based Industrial grade 5.5 35 zero discharge system
Small Scale category
1 Agro Residue Cultural - high grade 156 category responded
Straw board making
2 Agro Residue Industrial 7 mill
3 Waste paper Cultural - high grade 18 category responded
4 Waste paper Cultural - low grade 14 25
5 Waste Paper Industrial 7 80
Current Water Consumption: In depth Study Findings

Keeping in view, the above mentioned variation prevailing in Indian pulp and
paper sector, ten representative mills were selected in consultation with
CPCB official for carrying out detailed field studies. During the field studies,
detailed water balance, material balance (with respect to fibre and water)
audits were carried out. And based on studies, specific water consumption in
each mill was estimated. The specific fresh water consumption estimated in
each representative mill is as given in table E-5 below:
Table E-5: Specific Water Consumption in Selected Field Study Mills

Mill Operational Scale & Raw End Product Water
Code Material consumption,
m3/T
Large Scale
1 Wood & Wastepaper based Newsprint 80
manufacturing
2 Wood & wastepaper Based Cultural – high 77
grade
3 Wood, Agro& wastepaper Cultural – high 67
grade
Medium Scale
4 Agro & waste paper based Cutural – high 80
grade
5 Agro & waste paper based Industrial grade 47
6 Waste paper based Cultural – high 48
grade
Small Scale
7 Agro & waste paper Cultural – high 110
grade
8 Agro & wastepaper based Industrial grade 93

Mill Operational Scale & Raw End Product Water
Code Material consumption,
m3/T
9 Waste paper based Cultural – low 13
grade
grade
Proposed standards for water consumption in pulp and paper sector
Based on the detailed pulp and paper mill’s inventorisation and observations
from the dry and detailed field studies conducted during the course of this
study, it became evidently clear that water consumption varies significantly
depending upon the raw material used, scale of operation and the end
product. Realizing these variation it was clear that one or two general
standards would not suffice for the entire pulp and paper sector. Accordingly,
considering the prevailing characteristics of Indian pulp & paper mills in the
country, following six categories of pulp and paper mills with respect to water
consumption pattern have been proposed for formulation of standards:
A. Large scale Wood based and integrated pulp and paper mills
manufacturing cultural grade paper & paper board and / or
Newsprint
B. Small/Medium Scale Agro based pulp and paper mills
manufacturing high grade cultural paper
C. Small/Medium Scale Agro based pulp and paper mills
manufacturing industrial grade paper
D. All wastepaper based pulp and paper mills manufacturing high
grade cultural paper with “De-inking”
E. All wastepaper based pulp and paper mills manufacturing cultural
grade paper without De-inking
F. All medium / small scale waste paper based mills manufacturing
industrial grade paper
While developing the water consumption standards for the above referred
categories following factors have been considered.
¾ The standards developed should ensure continuous reduction in water

consumption.
¾ The standards should be such that they trigger technological
interventions as well as reuse / recycling opportunities and thus lead to
quantum reduction in water consumption in long term.
¾ The standards should be India specific and practicable and feasible to
implement.
¾ The standards should also even out the huge water consumption
disparities among the similar type of mills in short term.
Considering all the above factors, three levels of standards have been
formulated. The three levels are
• Benchmark Standard: This standard refers to minimum water

consumption required after implementation of best available technology
(economically viable and currently practiced / demonstrated in India),
recycle and reuse practices. This standard has been developed by
identifying the various mill operations involved in each specific category
and also identifying the least water consumption actually achieved by
any of the mills studied in that particular category. The total of water
consumption in each of the mill operation / process would be the
benchmark standard for that specific category.
The idea of developing this standard is to ensure
o Quantum reduction in water consumption: No mill in the
above referred categories is currently operating at this level. To
achieve this level most of the mills would need to undertake
certain technological modifications and complex recycling /
reuse measures to achieve the quantum reduction in the water
consumption and comply with these standards
o Development of feasible standards: Further these standards
reflect the feasible and demonstrated mill operation specific
water consumption norms already practiced in one or the other
industry in India and thus expected to be appreciated and
followed by industries.
Since complying with these standards would need technological and complex
recycling / reuse systems interventions, which require significant time and
resources at the industries end, it is proposed that these standards to be
considered for implementation after four years from the acceptance year of
this report.
• Best Achieved Standard: This standard refers to the minimum water

consumption already achieved by a mill (or can be achieved by
implementation of simple recycling / reuse measures) simple in the
specific category.
This standard is developed with the perspective of bringing the other mills to
the currently best achieved and demonstrated level in the country. This
standard can be achieved by implementation of simple water recycling and
reuse practices and minor technological changes.
This standard is proposed to be considered for implementation from two years
from the acceptance year of this report. The three years grace period is
proposed to enable other industries to undertake technologies feasibility
(technical, economical, environmental etc) and implementation.
• Relaxed Standard: This standard provides 20 % relief over the best

achieved standard in each specific category. This standard is proposed

for immediate reduction in water consumption by most of the high
water consuming industries and thus bridge the huge gap between
best performing and worst performing mills in a short time. It is
estimated that this standard can be achieved by other industries in
each categories by implementing simple reuse, recycling and other
minor modification.
This standard is proposed to be implemented after six months from the
acceptance of this report. The six months grace period is proposed to enable
other industries to undertake the reuse, recycling and other minor
modifications.
The process of developing above referred benchmark standards would also
identify mill operation / process or section specific water consumption
benchmark figures that can be used by the industries for continuous
improvements.
The consolidated proposed water consumption/wastewater discharge*

standards for each category of the pulp & paper mills are compiled and
tabulated below in table E-6:
Table E-6: Proposed Water Consumption/Wastewater Discharge

Standards
Sl Category Description Proposed water
consumption/wastewater discharge
standard in m3 / Tonne of product
Benchmark Best Relaxed

achievable
1 Large scale Wood based and integrated pulp 63 / 50 67 / 53 80 / 63

and paper mills manufacturing Newsprint,
Cultural grade paper and paper board
2 Small/Medium Scale Agro based pulp and 38 / 30 80 / 63 95 / 75

paper mills manufacturing cultural grade paper
3 Small/Medium Scale Agro based pulp and 18 / 15 47 / 37 56 / 44
paper mills manufacturing industrial grade
4 All wastepaper based pulp and paper mills 19 / 15 41 / 32 49 / 38

manufacturing high grade cultural paper and /
or news print with “De-inking”
5 All waste paper based pulp & paper mills 9/7 13 / 10 15 / 12

manufacturing high grade cultural paper without
“De-inking”
6 All Medium / Small scale wastepaper based 6/5 6/5 7/6

pulp and paper mills manufacturing industrial
grade paper

* Wastewater discharge standards have been evolved with an assumption
that around 21% of the input fresh water is lost as vapour in fourdreineir
machine (drier section) and in boiler section and the balance is discharged as
wastewater.
Further, it is recommended to reuse this wastewater as much as

possible for irrigation purpose.
Water Conservation Options Evolved and Recommended to Achieve

Quantum Reduction in Fresh Water Consumption in Pulp and Paper
Sector
The high water consumption in Indian pulp and paper industry is mainly due to
obsolete process technology, poor water management practices and
inadequate wastewater treatment.
In order to evolve techno economically feasible option, detailed field studies
were carried out as mentioned earlier. Depending upon the category and
scale of operations, water conservation options have been recommended.
They are briefly described below:
Low – cost improvements
• General Housekeeping Measures: General housekeeping measures

deals with low-cost improvements like leak detection, repair, production
scheduling, use of press type tap, auto close valve hose to reduce
wastage due to negligence, etc
• Using better quality raw material to achieve desired brightness:
Manipulation of raw material quality enables use of lesser quantity of
bleaching chemicals, hence requires less water quantity for bleaching
and washing
• Dry de-dusting of straw for removal of fines and dust / Dry depithing of
Bagasse / Dry debarking of Wood
• Collection of black liquor spills in a common tank: This reduces fresh
water consumption required for floor washing.
Design stage procedures (new plant/equipment)
• Use of Better pulp washing technology: Various technologies available

in decreasing specific water consumption are potcher washing,
hydraulic washing, vacuum drum washing, Pressure washing, diffusion
washing, chemi or belt washing, twin roll press washing. Among all,
potcher washing has maximum specific water consumption (55 - 60
m3/BDMT bleached pulp) and twin wire roll press has minimum
specific water consumption (26 m3/BDMT bleached pulp). However, a

twin wire roll press washer for a 300 OD TPD fiberline costs approx.
1081 million INR. Where as a vacuum drum washer would cost only 10
– 25 million INR, hydraulic washer would cost 2.5 million (works good
with lower capacity). Therefore, techno-economic feasibility is required
before identification of suitable washer in the individual mill.
• Use of More Efficient Deinking Plant : The clarified water is reused in
different mill operations: Helicopulper, H D Cleaner, Pulp Dilution,
Centricleaner, Pressure screen
• Membrane filtration technique in deinking process instead of
conventional floatation method: Membrane separation technology is a
potentially attractive method for the removal of flexographic ink
residues from the wash filtrate effluent of deinking mills and thereby
enabling recycle of wash filtrate
• Installation of Indirect & More Efficient Heat Transfer System for Blow
Heat Recovery In Digestor Section: This avoids generation of
contaminated wastewater (in direct heat transfer, waste gases are
directly injected to water) and enables reuse of cooling wastewater.
• Replacing barometric leg (direct) condensor cooling by surface
(indirect) condensor cooling: The wastewater from barometric leg is
generally discharged to ETP and cannot be completely recycled back
Process modifications including recycle/reuse
• Optimum use of cooling wastewater:

A. Collection of once-through cooling water and reuse it in different
process operation
B. Converting once-through system into a closed –loop system by
installing a cooling tower
• Recovery and re-cycling of clean water from vacuum pumps
• Installation of Vacuum flume tank to recycle vacuum pump sealing
water
• Replacement of water seals in Process Pumps: Mechanical seal
pumps can be used to avoid usage of sealing water. Also seal less
pumps are extensively used in chemical industries which can also be
used pulp and paper manufacturing mill.
• Use of modified design of nozzle in Decker thickener shower
• Use of efficient Decker thickener/ vacuum drum showers
• Use of efficient shower system and Regular monitoring of low pressure
and high pressure showers and in the paper machine section
• Use of Enzymatic deinking process
• Recovery of bleaching chemicals through membrane separation &
reuse (closed loop bleaching): For Mills with Elemental Chlorine free
bleaching process.
• Reuse of secondary condensate in raw material preparation section,
Brown Stock Washing / Bleach Washing

• Reuse of Spout cooling wastewater
• Reuse of barometric leg wastewater: This wastewater is suitable for
reuse in Brown stock washing.
• Reuse of wastewater from DM plant (regeneration & sandfilter
backwash), softner (regeneration & sandfilter backwash) for ash
conditioning / quenching
Process redesign which includes improvement in quality and

management of paper machine wastewater
• Choosing right type of saveall system: There are different technologies

to clarify paper machine white water like polydisc saveall, Krofta
saveall, sedimentation type saveall, drum filter, inclined or Hill screens,
etc. Depending upon the usage of clarified water and quality required,
type of saveall needs to choosen. In large scale mills, polydisc saveall
is advantageous. The clear filtrate generated from the saveall can be
directly used in high pressure paper machine showers.
• Optimum use of paper machine clarified wastewater in sections other
than paper machine: Various application areas are :Decker thickener
showers, Vacuum washers, Centricleaner reject dilution, Pulp dilutions
before bleaching stage, Johnson screen showers, etc. this requires
provision of sufficient storage capacity. A modified storage capacity
similar to ‘Stawford” separator helps in further separation of solids and
fibres from the clarified water
• Use of back or recycled water in low pressure showers: Various
locations in paper machine section where back water can be used are:
Wire section - Breast roll, wire turning and wire-return rolls, knock – off
shower, trim knock – off shower, wire cleaning shower ( low
pressure).,Press section - Cleaning of rolls
Total system closure with zero liquid effluent
• Tertiary treatment of wastewater for recycling: In tertiary treatment,

Aluminum oxide, ferric oxide and poly electrolytes assist coagulation of
waste in the effluents, which are then sand filtered. The quality of
treated wastewater after the tertiary treated is fit for recycling back
completely to the system especially in wastepaper based mills and
partially for other mills.
However, there is a limitation to continuous recycle of wastewater within the

plant for a long period as it leads to slime generation. This is prevented by
optimized addition of biocide and chemicals in the water at regular intervals.

Conclusion
Existing standards are passé.

The questionnaire responses, CSE’s green rating project and the detailed
field studies have clearly indicated that the majority of industries in-fact
actually performing better than both the existing standards and the CREP
standards they have agreed to.
Common standard not far-sighted

It has also clearly emerged from the in depth studies that water consumption
varies significantly based on the scale of operation, raw material used and the
end products manufactured. Hence a common standard for all type of
industries would not be prudent and accordingly standards have been
developed for six categories of pulp and paper industries considering
operational scale, raw material used and the end product manufactured.
Recommended standards a challenge already conquered

While comparing with the existing standards, the currently recommended
standards may seem to be a challenging task to achieve but actual practice
these have already been achieved in totality by an Indian enterprise (Best
achieved standard) or partially i.e. at a mill process level by one or the other
Indian enterprise (benchmark standard). Hence the proposed standards are
practical and feasible to achieve. The industries may refer to the water
conservation measures identified under the study to achieve the water
consumption standards.
Let’s not stop, we need to go further

The currently developed and recommended water consumption standards are
still comparably high in light of the latest world wide trends on water
consumption. The currently developed standards should be treated as short
term applicable for about 8 years. It is further recommended that these
standards should again be revisited after 6 years.
***************

Final report on water conservation in Pulp and Paper Sector Page No.1
CHAPTER 1
BACKGROUND
1.1 INTRODUCTION
The pulp and paper industry is one of India's core sector industries. The average
production in the year 2003 – 2004 is 5.96 million tonnes per annum.
The socio-economic importance of paper has its own value to the country's
development as it is directly related to the industrial and economic growth of the
country. Although paper has many uses, its most important contribution to modern
civilization is its use as a medium to record knowledge. Paper represents the perfect
adjustment of a basic material to any use and purpose.
Paper manufacturing is a highly capital, energy and water intensive industry. It is
also a highly polluting process and requires substantial investments in pollution
control equipment. In India, around 905.8 million m3 of water is consumed and
around 695.7 million m3 of wastewater is discharged annually by this sector1.
Looking into the serious nature of pollution, the pulp and paper industry in India has
been brought under the 17 categories of highly polluting industries.
In global comparison on specific water consumption (the global best specific water
consumption is 28.66 m3/tonne for large scale wood based pulp and paper mill),
India is still far behind ( India’s average fresh water consumption in pulp and paper
sector is 150 – 200 m3/tonne of product) and this is largely attributed to the use of
obsolete technology / equipments and poor water management practices.
At the same time, water has been increasingly becoming a scarce commodity and
several industries are experiencing acute water shortages especially during non-
monsoon periods. While most large industries are located near abundant water
supply source (the rivers), The majority of small / medium scale agro residue/waste
paper based mills are in clusters and have to depend on groundwater. The
continuous exploitation of ground water by these industries has led to lowering of the
groundwater table and thus increased pumping costs and more importantly water
shortage in many regions. This has forced many industries to curtail their production
levels and some closed down their mills for want of adequate amounts of water.
However, in large scale mills, the situation is slightly better with regard to water
conservation and environmental compliance because of better technology /
equipment employed by them, large scale of operation and also access to latest
information / developments. Despite this, water management is very poor in pulp
and paper industry and it requires immediate attention as its excess use is affecting
the water availability particularly during non-monsoon.
1
Source: Estimated by CSE based on the wastewater discharged data published by CPCB in "Water quality in India (Status and trends) 1990 -
2001".

Central Pollution Control Board (CPCB) has therefore approached National

Productivity Council (NPC) to develop suitable guidelines for water management in
different types of pulp and paper mills through out the country.
1.2 OBJECTIVE OF THE STUDY

The objective of the study is to evolve appropriate guideline for conservation of
water based on the existing water management practices and identify optimum
recycle/reuse options for water.
1.3 SCOPE OF WORK

For the above objective, following scope of work has been defined:
(i) Inventorisation of pulp and paper manufacturing mills through out the country
(ii) Classification of the mills in different categories according to scale of
operation, raw material usage, products manufactured
(iii) Selection of 10 representative mills for detailed studies
(iv) Preliminary survey of the selected mills, followed by detailed studies. Detail
study comprises of:
• Collection of background data regarding the raw material consumption, product
output, installed and operating capacity of existing process and utilities etc.
• Study of the manufacturing process.
• Identification of the sources and characterisation of the wastewater generated
from each process operation
• Compilation of material balance for complete process
• Identification of the water conservation, waste recycling/reuse options, if any
adopted by the mill
• Compilation of the water balance for the complete mill and
• Generation of water recycle/ reuse and other conservation options with or without
mild treatment.
(v) Cost benefit analysis for optimum reuse and recycling of waste water in terms
of reduction in pollution load reaching ETP and fresh water consumption for
each type of pulp and paper industry
(vi) Evolve limits for water consumption and discharge from the processes
assuming the optimum water consumption level for each type of industry
(vii) Formulation of guidelines for water conservation for each type of pulp and
paper industry

1.4 METHODOLOGY
The following methodology is being adopted to accomplish the above said scope of
work:
Phase I
(i) Questionnaire for seeking information on the type of product, scale of
operation, production process, water management practices followed, etc was
prepared in consultation with CPCB officials and Pulp and Paper
manufacturing Association’s members. A copy of questionnaire is placed as
Annexure I.
(ii) The inventorisation of pulp and paper mills and other relevant information on
pulp and paper mills was compiled through various agencies, research
institutes, pulp and paper manufacturing associations, state pollution control
boards, and associated bodies.
(iii) Questionnaires were sent to around 622 pulp and paper manufacturing mills
through out the country.
(iv) Responses received from the Questionnaire survey has been compiled.
Based on the responses, typical wastewater characteristics from pulp and
paper mill has been generated.
(v) Literature survey was carried out with respect to production process, water
consumption, wastewater generation, etc for different types of pulp and paper
mills has been procured from pulp and paper manufacturing associations,
printed matters and internet.
(vi) Based on the literature survey and questionnaire survey, criteria for selection
of representative mills has been developed.
Phase II
(vii) Based on the information obtained from Pulp and paper mill associations and
other Institutions, pulp and paper mills through out the country have been
classified according to scale of operation, raw material usage and product
manufactured.
(viii) Ten representative mills were identified as per the criteria developed in
consultation with CPCB and based on the questionnaire responses.
(ix) Detailed studies at the individual mill were carried out as given below:
− Background data with respect to raw material consumption, product
output, installed and processing capacity, existing process and utilities,
etc. were collected from stores and inventory, raw material preparation
section, pulp mill section, chemical recovery section, stock preparation
section, paper machine section, utilities department, engineering
department, projects, quality control and technical services department.
− The manufacturing process was studied in a detailed manner. Following
general process related information were collected:

- Yield
- Cooking temperature and time
- Cycle time
- Makeup chemical type and amount
- Bleaching stages and time
- Temperature and charge to bleaching towers
- Dilution factor in washing
- Black liquor solids content before and after evaporation
- Black liquor quantity
- Product target data
This was followed by collection of specific process related details,
engineering drawings and verifying them by conducting a shop floor walk
through. Simultaneously, different input and output streams were identified
at each process step
− Different sources of wastewater generation was identified and marked.
Sampling and monitoring of wastewater at these points was carried out.
The samples were analysed for relevant parameters for characterization of
inlet process water and wastewater stream.
− Material balance for the complete process was compiled. TSS balance
was also carried out to ascertain the fiber loss from the process.
− Water conservation measures as adopted by the mills were identified and
the total water saved per unit of the product was computed.
− Water balance for the complete mill along with the water used in the utility
was made.
− Water conservation techniques/technologies were identified and techno-
economic feasibility of the identified technologies/techniques were studied.
The impact of implementation of these were also ascertained so as to
determine the effect on the pollution load.
Phase III
(x) On the basis of the studies carried out in all the ten mills, limits for water
consumption level for each type of industry was established.
(xi) Subsequently, general guidelines for water conservation for each type of pulp
and paper industry were evolved.

CHAPTER 2
INDUSTRY PROFILE : PULP AND PAPER
2.1 STATUS OF PULP AND PAPER MANUFACTURING MILL IN INDIA
Growth Pattern
The pulp and paper mill sector in India is one of the oldest industries. The first paper
manufacturing mill was commissioned in 1812 in the eastern state of West Bengal.
At the time of independence (1947) there were less than 20 mills in India with a total
annual capacity of 100,000 tonnes. The number of paper manufacturing mills has
increased from just 17 in 1951 to around 600 in Year 2002 with an annual installed
capacity of 6.2 million tonnes and has then fallen to 309 in year 2004. The reason
has been non-availability of techno –economic solution for black liquor
recovery/treatment for agro based pulp and paper manufacturing process. Due to
regulatory pressure, several small/medium scale agro based pulp and paper
manufacturing mills have been forced to closed down in recent years.
The capacity utilization is estimated at around 60-65 percent of the total installed
capacity. The growth of paper mills from 1950 onwards along with average installed
capacity is as given in the Table 1.
Table 1: Number of paper mills in India with installed capacity during 1950 to
20042
Year No of Installed Capacity Actual Production
Mills (million tonnes/ (million tonnes/
annum) annum)
1950 – 51 17 0.137
1970 – 71 55 0.768
1980 – 81 137 1.816
1990 – 91 325 3.304
1999 – 01 600 6.2
2001 – 02 594 8.500
2003 – 04 309 7.8 5.6
In India, the average size of a pulp and paper mill is only about 25,000 tonnes per
annum (tpa) when compared to 85,000 tpa in Asia and about 300,000 tpa in Europe
and North America.
The low capacity utilisation in the industry is due to high incidences of sickness in
many small / medium mills and thus most of these are operating either at lower
capacity or closed. The state wise distribution of the closed mills during 1999 to
2002 is given in Table 2 below.
2
Source: IARPMA & indiastat.com

Table 2:No of mills closed between 1999 and 20023

State-wise Number of Paper Mills Closed Down in India
(01.01.1999 to 31.10.2002)
State No. of Sick Paper Mills
Andhra Pradesh 3
Bihar 1
Chattisgarh 1
Goa 0
Gujarat 11
Haryana 0
Kerala 2
Karnataka 2
Madhya Pradesh 2
Maharashtra 18
NCT Delhi 9
Orissa 0
Punjab 7
Rajasthan 0
Tamil Nadu 7
Uttar Pradesh 13
West Bengal 4
Total 80
Product Portfolio
Indian industries produces different types / grades of paper for variety of uses. The
paper and paperboard product segment constitutes of cultural paper, industrial
paper and specialty paper. Cultural paper comprises of writing and printing paper,
Art/Media paper, Bond paper, Copier paper, Cream wove, Maplitho, Ledger paper,
etc. Industrial paper comprises of Duplex Board/Paper, Kraft Paper, Other
Board/Paper.
The major types of paper that are produced in the country along with main varieties
and their consumption pattern (demand indicator) are presented in the Table 3
below:
Table 3: Consumption pattern of paper and paper board products in India
consumptions
Cultural paper cream woven, maplitho, bond paper, 41%
3
Source: (www.indiastat.com)


consumptions
Chromo paper
Industrial paper kraft paper, paper board – paper 43%
board - single layer board, multilayer
board, duplex board,
Specialty paper Security paper, grease proof paper, 4%
electrical grades of paper
Newsprint glazed, non-glazed 12%
In India, the cultural varieties (writing and printing paper) account for about 41% of
the production, specialty papers including coated papers for about 4% and newsprint
for about 12 %. This leaves about 43% for kraft and boards.
The world consumption of paper and paperboard at present has been estimated to
be over 300 million tonnes a year which includes 30% of cultural papers, 14% of
newsprint, and the balance of kraft / packaging paper and specialty paper.
State wise Distribution of Pulp & Paper Mills
The statewise distribution of pulp and paper mills (including further distribution based
on raw material used) in the country from 2000 to 2004 is given in Table 4 through
Table 6.
Figure 1 depicts the present distribution of pulp and paper mills in India. Annexure
II gives the list of industries operating in 2004
Table 4: No of pulp and paper mills as on 20004
State-wise Number of Paper Mills in India
(As on June 2000)
No. of Paper
States/Uts
Mills
Andhra Pradesh 22
Assam 4
Bihar 9
Chandigarh 8
Gujarat 68
Haryana 15
Himachal Pradesh 15
Jammu & Kashmir 1
Kerala 7
Karnataka 17
Madhya Pradesh 21
4
Source: IARPM

State-wise Number of Paper Mills in India

(As on June 2000)
No. of Paper
States/Uts
Mills
Maharashtra 115
Meghalaya 1
Delhi 6
Nagaland 1
Orissa 9
Pondicherry 3
Punjab 37
Rajasthan 8
Tamil Nadu 22
Uttar Pradesh 100
West Bengal 26
India 515
Table 5: No of Pulp and Paper Mills as on 20025

State Agro based Waste Paper Wood Based Grand Total
Andhra Pradesh 17 20 5 42
Assam 1 2 3
Bihar 4 3 7
Chattisgarh 2 7 9
Gujrat 4 91 2 97
Haryana 7 9 1 17
Himachal Pradesh 1 5 1 7
Jammu & Kashmir 1 1
Jharkand 2 2
Karnataka 2 15 3 20
Kerela 10 2 12
Madhya Pradesh 3 26 1 30
Maharashtra 13 83 4 100
Nagaland 1 1
Orissa 1 2 3 6
Pondicherry 1 6 7
Punjab 16 59 75
Rajasthan 1 9 10
Tamil Nadu 2 33 2 37
Uttar Pradesh 32 64 1 104
Uttaranchal 8 7 1 16
West Bengal 8 14 4 26
Grand Total 122 466 33 622
5
Source: (www.indiastat.com)

Table 6: No of Pulp and paper mills as on 20046

State Agro Wastepaper Wood PaperMill Integrated Sub Total
Andhra Pradesh 6 6 4 16
Assam 1 1
Bihar 1 1 2
Chattisgarh 3 1 4
Gujarat 2 46 1 49
Harayana 7 4 1 1 13
Himachal
Pradesh 1 1 2
J&K 2 2
Karnataka 1 8 3 12
Kerela 9 2 11
Madhya
Pradesh 2 7 1 10
Maharastra 107 53 1 4 1 69
Nagaland 1 1
Orissa 4 2 6
Pondicherry 5 5
Punjab 9 11 1 21
Rajasthan 8 8
Tamil Nadu 22 2 2 26
Uttar Pradesh 17 20 1 38
Uttaranchal 4 1 1 6
West Bengal 2 5 7
Total 65 213 21 6 4 309
6
Source: (IPPTA)
7
Out of 10 Agro based mills, 9 have now shifted to waste paper based.


2.2 CLASSIFICATION OF PULP AND PAPER MILLS IN THE COUNTRY
At present, around 3098 pulp and paper manufacturing mills are operating in the
country. Out of these, 198 mills are operating under large scale category with actual
capacity of 5.2 million tonnes per annum and 111 mills are operating under small
scale category with actual capacity of 0.3 million tonnes per annum.
(a) Based on Scale of operation

The pulp and paper mills based on the scale of operation are classified as those
having an installed capacity of 25,000 tonnes per year & above as large scale and
less than 25,000 tonnes but greater than 5,000 tonnes per year as medium scale
and up to 5000 tonnes per year as small scale. The distribution of large/medium and
small scale pulp and paper mills in the country is given below in Table 7.
Table 7: Distribution of Large/Medium and Small scale pulp and Paper Mills
Sl. Scale of operation No of Mills Actual
No Capacity,
million tonnes
per annum
1 Large/Medium Scale 198 5.2 94.5%
2 Small Scale 111 0.3 5.5%
(b) Based on Raw material Usage

The pulp and paper industry is segmented as wood/forest-based, agro-based and
waste paper based with the former accounting for 21 %, agro-based 71 %, waste
paper based 7% wood based and integrated for 1 % of the total actual production.
The number of pulp and paper mills under each classification is given below in Table
8
Table 8: Distribution Pulp and Paper Mills Based on Raw Material Used
Agro Integrated Wastepaper Wood
No of Mills 66 3 219 21
% No. of Mills 21 1.0 71 7

Production, million TPA 1.0 0.14 2.8 1.6
% Production 18.0 2.5 50.5 28
In Large/medium Scale Category.

In the large/Medium scale category, 63% of the mills are wastepaper based, 25%
agro based, 11% wood based and 1% integrated pulp and paper mills
8
Source: IPPTA Directory, 2004

Category No of Mills % Production, %

million TPA
Agro 49.0 24.6 0.89 16.8
Integrated 2.0 1.0 0.1 1.8
Wastepaper 126.0 63.3 2.5 47.2
Wood 21.0 11.1 1.8 34.2
In Small Scale category,

In the small-scale category, 83.6 % of the mills are wastepaper based, 15.3 % agro
based, and 0.1% integrated pulp and paper mills
Category No of Mills % Production, %
million TPA
Agro 17.0 15.3 0.0460 18.4
Integrated 1.0 0.1 0.0015 1.6
Wastepaper 93.0 83.6 0.2025 80
(c) Based on Products manufactured

The Indian paper industry is classified broadly into two categories based on product
manufactured:
• Paper and Paper board products
• Newsprint
The number of pulp and paper mills producing Paper and Paper board and
Newsprint along with actual production in the country is given in Table 9 below:
Table 9: Distribution of Pulp and Paper Mills Based on Raw Material Used
Category No of Mills % Production, million TPA %
Cultural - high grade 66 21.3 2.27 41
Cultural - low grade 20 6.5 0.57 10.2
Industrial 187 60.5 1.74 31.4
Newsprint 21 6.8 0.62 11.2
Pulp 3 1 0.22 4
Specialty 12 3.9 0.12 2.2
In the Large/Medium Scale category, 28% are involved in manufacture of high

quality cultural paper and paper board while only 7.5% are involved in low quality
cultural paper, 1.51 % only pulp, 3% only specialty paper and rest industrial and
newsprint grade paper as shown below:

Category No of Mills % Production, million TPA %

Cultural - high grade 56 28.28 2.24 42
Cultural - low grade 15 7.57 0.55 10.4
Industrial 97 48.98 1.55 29
Newsprint 21 10.60 0.62 11.5
Pulp 3 1.51 0.22 4.1
Specialty 6 3.03 0.11 2
In Small Scale Category, maximum mills (about 81%) are involved in the production
of industrial grade paper followed by 9% high grade cultural paper manufacturing,
4.5% are involved in low grade cultural paper manufacture, 9% are involved in high
quality Cultural grade paper, 5.45% specialty and rest industrial grade as shown
below:
Category No of Mills % Production, TPA %

Cultural - high grade 10 9.0 32879 13.1
Cultural - low grade 5 4.5 16734 6.7
Industrial 90 81.1 194970 78.0
Specialty 6 5.4 5415 2.2
(i) Paper and Paper board products

The major producers of paper in the country along with their installed capacities are
given in Table 10.
Table 10: Major players in paper board product segment
Major players Capacity in Product mix
tpa (FY2002)
AP Paper Mills 98,500 creamwove, maplitho, kraft
Ballarpur Industries 2,47,500 maplitho,creamwove, bond,others
Hindustan Paper Corp. 2,00,000 creamwove
ITC Bhadrachalam 1,82,500 duplex board, maplitho, kraft, security
paper, MG poster
Orient Paper & Industries 1,61,000 creamwove, kraft, maplitho, duplex
board
Sinar Mas 1,10,000 coated writing & printing paper
The West Coast Paper 1,19,750 creamwove, maplitho, kraft, MG poster
Mills

(ii) Newsprint
In the News print segment around 21 mills in Large scale category (4 in central
public sector, 2 in state public sector and 15 in private sector) with an installed
capacity of about 0.658 million TPA are operating.
The major mills in the newspaper/newsprint segment with their production capacities
are given in Table 11.
Table 11: Major mills in Newsprint segment
Company Capacity Million tpa
Hindustan Newsprint 0.1
NEPA 0.08
TNPL 0.18
Rama Newsprint 0.15
(d) Based on Pulping Process

Generally speaking, the pulp and paper industry divides itself along pulping process
lines: chemical pulping (e.g., kraft chemical pulping), mechanical pulping, and semi-
chemical pulping. The pulping process affects the strength, appearance, and
intended use characteristics of the resultant paper product. Pulping processes are
the major source of environmental impacts in the pulp and paper industry; each
pulping process has its own set of process inputs, outputs, and resultant
environmental impacts. The different types of products resulting from various pulping
processes are listed as below:
• Bleached Paper grade Kraft and Soda / Unbleached Kraft: Bleached or
unbleached kraft process wood pulp usually converted into paperboard, coarse
papers, tissue papers, and fine papers such as business, writing and printing.
• Paper grade Sulfite: Sulfite process wood pulp with or without bleaching used for
products such as tissue papers, fine papers, and newsprint.
• Semi-chemical: Pulp is produced by chemical, pressure, and mechanical
(sometimes) forces with or without bleaching used for corrugating medium (for
cardboard), paper, and paperboard.
• Mechanical pulp: Pulp manufacture by stone groundwood, mechanical refiner,
thermo-mechanical, chemi - mechanical, or chemi-thermo - mechanical means
for newsprint, coarse papers, tissue, molded fiber products, and fine papers.
• Non-wood Chemical pulp: Production of pulp from textiles (e.g., rags), cotton
linters, flax, hemp, tobacco, and abaca to make cigarette wrap papers and other
specialty paper products.
• Secondary Fiber Deink: Pulps from waste papers or paperboard using a
chemical or solvent process to remove contaminants such as inks, coatings and
pigments used to produce fine, tissue, and newsprint papers.

• Secondary Fiber Non-deink: Pulp production from wastepapers or paperboard

without deinking processes to produce tissue, paperboard, molded products and
construction papers.
• Fine and Lightweight Papers from Purchased Pulp: Paper production from
purchased market pulp or secondary fibers to make clay coated printing,
uncoated free sheet, cotton fiber writing, and lightweight electrical papers.
The distribution of pulp and paper mills in the country based on pulping processes is
given in Table 12 and Table 13 based on number of mills and installed capacity.
Table 12: Distribution of pulp and paper mills based on pulping processes (
number of mills)
No of Mills
Sl. No Pulping Process Large Scale Small Scale Grand Total
1 Chemical Soda Process 29 26 54
2 Hydro Pulping 92 113 219
3 Kraft/Sulphite process 34 2 36
Table 13: Distribution of pulp and paper mills based on pulping processes
(installed capacity)
Sl. Installed Capacity, million tonnes/yr
No.
Pulping process Large Scale % Small Scale %
1 Chemical Soda Process 0.666 4.3 0.106 18.3
2 Hydro Pulping 12.807 81.9 0.462 79.9
3 Kraft / Sulphite process 2.169 13.9 0.01 1.7
15.642 0.578
Grand Total

CHAPTER 3
MANUFACTURING PROCESSESS
This section describes the major industrial processes within the pulp and paper
industry, including the materials and equipment used, and the processes employed.
This section specifically describes the details of commonly used production
processes, associated raw materials, the products produced, and the materials
recycled. This discussion, coupled with schematic drawings of the identified
processes, provide a concise description of where wastes may be produced in the
process.
3.1 Generalised Paper/Paper board making process
In general, paper is manufactured by applying a liquid suspension of cellulose fibers
to a screen, which allows the water to drain, and leaves the fibrous particles behind
in a sheet. The liquid fibrous substrate formed into paper sheets is called pulp.
Processes in the manufacture of paper and paperboard can, in general terms, be
split into three steps: pulp making, pulp processing, and paper/paperboard
production. Paperboard sheets are thicker than paper sheets; paperboard is
normally thicker than 0.3 mm. Generally speaking, however, paper and paperboard
production processes are identical. First, a stock pulp mixture is produced by
digesting a material into its fibrous constituents via chemical, mechanical, or a
combination of both. In the case of wood, the most common pulping material,
chemical pulping actions release cellulose fibers by selectively destroying the
chemical bonds in the glue-like substance (lignin) that binds the fibers together. After
the fibers are separated and impurities have been removed, the pulp may be
bleached to improve brightness and processed to a form suitable for paper-making
equipment. Currently, one-fifth of all pulp and paper mills practice bleaching. At the
paper-making stage, the pulp can be combined with dyes, strength building resins,
or texture adding filler materials, depending on its intended end product. Afterwards,
the mixture is dewatered, leaving the fibrous constituents and pulp additives on a
wire or wire-mesh conveyor. Additional additives may be applied after the sheet-
making step. The fibers bond together as they are carried through a series of
presses and heated rollers. The final paper product is usually spooled on large rolls
for storage.
A typical process for the manufacture of paper is shown in Figure 2.

Figure 2: A typical process for Paper manufacture
Raw material Raw material Wastewater

Water Preparation section
Chemicals Pulping Section

Water
Pulp Washing &

Water Bleaching Section Wastewater
Alum, Rosin Stock Preparation

Water system
Additives Paper Machine Wastewater
Finished Paper
3.2 Different industrial processes in pulp and paper sector

Based on the type of raw material used, the manufacturing processes are classified
into
− Wood Based Pulp and Paper manufacturing Process
− Agro residue based Pulp and Paper manufacturing Process
− Secondary fibre based Pulp and Paper manufacturing Process
Figure 3 shows the schematic diagram of different manufacturing processes of pulp
and paper making from raw material sources.

Figure 3: Generalisedl Process of Paper making from different types of

raw material
Chipping
Mechanical Pulping
Timber
Paper making
Chemical Pulping
Agro residue
Washing & Bleaching
Chemical Additives
Wastepaper Product
De- Inking
Hydro- Pulping

3.2.1 Wood Based Pulp and paper manufacturing Process

Pulp Production: Various Methods of Pulping
Wood consists of two primary components: cellulose and lignin. Cellulose, which is
the fibrous component of wood, is used to make pulp and paper. Lignin is the “glue”
that holds wood fibers together. Pulping is the process, which reduces wood to a
fibrous mat by separating the cellulose from the lignin.
Pulping processes are generally classified as chemical, mechanical, or semi-
chemical.
Mechanical Pulp (yield 90%): Mechanical pulp uses mechanical abrasion to
separate cellulose fibres which are held together by lignin. In the process called
“Groundwood”, wet wood is ground by large stones. In Thermo mechanical pulping
(TMP), metallic plates rub steam heated chips at high speeds, separating fibers.
Mechanically produced pulp has a higher proportion of broken cell fragments (called
'fines') among the fibres. Thus, when used to make paper, the long fibres form the
matrix of the sheet within which the fines are trapped. Paper derived from
mechanical pulps, therefore, tend to be denser and is often a component of
newsprint and other printing papers.
However, because mechanical pulps are not chemically processed they still contain
lignin and other natural wood substances, and paper with a high component of
mechanical pulp tends to yellow quickly in sunlight.
Mechanical pulping processes all use a lot of electrical energy and water. However,
they also provide 80-90% recovery of total fibre. Mechanical pulp processes are
cheaper to operate than more sophisticated chemical based systems. There are also
fewer environmental issues, such as chemical contamination of sites and unpleasant
smells.
Chemical Pulp (yield 50%): Chemical pulping achieves fiber separation by
dissolving the lignin that cement the fibers together. In chemical pulping, fibres are
less likely to be damaged than in other pulping processes. Chemical pulp is more
expensive then mechanical pulp, but it has better strength and brightness properties.
There are three chemical pulping methods known as Soda, Kraft (or Sulfate), and
Sulfite. The choice of the chemical pulping method depends upon the type of raw
material available and the product end use.
1. Soda Pulping
Soda pulp is the original chemical pulp and is produced by cooking chips of (usually)
deciduous woods in a solution of caustic soda under pressure. This leaves a
relatively pure cellulose pulp which is then washed and bleached. Soda pulp
produces relatively soft, bulky papers (as a filler with other pulps) used in books,
magazines and envelopes. Caustic soda dissolves most of the lignin in wood while
having little effect on the cellulose. Cooking liquor is recovered during the washing
process. Currently this process is primarily used for agro residue based material
pulping.

2. Kraft / Sulfate Pulping

In a chemical pulping process, heat and chemicals are added to wood chips in a
pressure cooker called the digester. In the kraft process, an aqueous solution of
sodium hydroxide and sodium sulfide, known as white liquor, selectively dissolve the
lignin and make it soluble in the cooking liquid. After 2 to 4 hours, the mixture of
pulp, spent pulping chemicals and wood waste is discharged from the digester. The
pulp is washed to separate it from the black liquor - the pulping chemicals and wood
waste. Kraft pulping is a low yield process - only 45% of the wood used becomes
pulp. The pulp, called brownstock at this point in the process, is ready to be
bleached. Softwood pulp from a conventional cooking process contains about 4.5%
lignin. This lignin will be removed and the pulp will be brightened during the
bleaching process.
In response to concerns about the amount of organic waste in the effluent, as
conventional pulping processes remove only about 95% of the lignin from the pulp,
there are few mills that have started extended / oxygen de-lignification for further
lignin removal. Today, a well run oxygen de-lignification system can remove 55% of
the lignin from the unbleached pulp. Figure 4 shows the oxygen delignification tower
installed in one of pulp and paper mill in India.
Fig 4: Oxygen De-lignification Tower
The kraft process is applicable to almost any wood and produces a pulp with strong
fibres, but which also takes more bleaching that other chemical pulps. It is suitable
for even quite resinous pine species. Kraft pulp is used where strength, wear and

tear resistance and colour are less important. the most obvious examples are brown
paper bags, cement sacks and similar sorts of wrapping paper.
3. Sulfite Pulping
Sulfite pulping uses sulfurous acid and an alkali to produce pulps of lower physical
strength and bulk, but exhibits better sheet formation properties. The yield on the
basis of chipped wood is again about 45 percent. These pulps are blended with
ground wood for newsprint and are used in printing, bond papers, and tissue. Sulfite
pulping was originally designed with a recovery system similar to the older soda
process still used in some plants. Environmental pressures have often forced these
plants to develop a recovery process. The pulp produced is made up of longer,
stronger and more pliable fibres and is favoured where strength properties are
particularly important.
Chemical pulping requires significant quantities of energy, mostly for process heat
but uses less electrical energy than mechanical processes. However, many modern
kraft pulp mills are totally self-sufficient in energy, with combustion of residues and
waste products meeting all heat and electrical energy needs.
Semi-Chemical Pulps Semi-chemical pulps are essentially mechanical pulps

that have been pre-treated with a sulphite or sodium hydroxide liquor to improve
breakdown and reduce energy requirements during processing. Pulps tend to retain
some of the properties of mechanical pulp, including good yields of fibre, but are
also suitable for better classes of paper manufacture.
Pulp & Paper Manufacturing Process

In general, pulping process is described in following 3-steps:
Step 1: Pulping
Raw Material Preparation
The wood logs are fed to a log chain conveyor and from log chain conveyor, the
wood is fed to the chipper by means of a belt conveyor (Figure 5). The wood after
chipping goes to a cyclone. The chips from the cyclone are fed on the vibrating
screen where oversize chips are removed and the accepted chips go to the silo via a
conveyor belt. The oversized chips are fed back to the crusher.
Digester House
The chips from the silo are fed in the Digester through a belt conveyor. There are
two types of digestion processes employed; Batch digestion carried out in spherical
digestors and Continuous digestion process carried out in a pandia type digester.
A shuttle conveyor helps in filling up the digester. The chips in a vertical digester
provided with liquor circulation pumps and pre heaters. In this process, wood is
cooked in a “digester” at elevated pressure (upto 11 bar) with a solution of the
appropriate chemicals, which dissolve the lignin and leave behind the cellulose. The

cooking process results in emissions of a variety of hazardous air pollutants

including formaldehyde, methanol, acetaldehyde, and methyl ethyl ketone.
The cooked material is blown into a blow tank provided with blow heat recovery
system. The blown material from the blow tank is taken into the unbleached knotters
where the uncooked chips are removed.
Fig 5: Chipper Section
Step 2: Pulp Washing

After the wood is pulped, the pulp that is created is washed to remove the dissolved
lignin and chemicals. In the washing process, the pulp is passed through a series of
washers and screens. The washing process occurs at high temperatures (above
room temperature), which generates a large volume of exhaust gases containing
hazardous air pollutants which are released to the atmosphere.
The liquid that results from the washing process contains lignin as well as the
chemicals used to separate the lignin from the cellulose. The chemical recovery
processes are used to recover these chemicals.
Step 3: Pulp Bleaching
After washing, if a white product is desired, the pulp must be bleached to remove
color associated with remaining residual lignin. The three general approaches to
bleaching are:
Elemental Chlorine Bleaching is the process currently in place at some existing
bleaching plants, and uses chlorine (Cl2) and twice hypochlorite to brighten the pulp.
In addition, Sodium hydroxide with or without peroxide is used for extraction of
chlorine from the pulp.
When elemental chlorine and hypochlorite react with the lignin, they form chlorinated
pollutants such as chloroform, dioxins, and furans in the wastewater stream.
Elemental Chlorine Free Bleaching (ECF) replaces chlorine with chlorine dioxide
as a bleaching agent and hypochlorite in no longer used. The use of ECF bleaching
results in reduced levels of chlorinated pollutants in the wastewater stream. Figure 6
shows a ClO2 plant installed in one of Indian pulp and paper mill.

Fig 6:ClO2 Plant
Totally Chlorine Free (TCF) bleaching uses no chlorinated bleaching agents to

bleach the pulp. Instead, bleaching agents such as oxygen and peroxide are used.
TCF bleaching eliminates chlorinated pollutants in the wastewater stream.
Typically, in the bleaching process, the bleaching chemicals are injected into the
pulp, and the resulting mixture is washed with water. This process occurs several
times and generates a large volume of liquid waste. Additionally, vents from the
bleaching sections emit hazardous air pollutants including chloroform, methanol,
formaldehyde, and methyl ethyl ketone9. Figure 7 shows bleached and unbleached
pulp.
9
Source: EPA Fact sheet – The Pulp and paper Industry, The Pulping Process and Pollutant Releases to the
Environment, November 1997

Fig 7: Bleached and unbleached pulp
Depending on the bleaching chemicals used, the waste stream from the bleaching
process may contain chlorine compounds and organics. The mixture of chemicals
may result in the formation of a number of toxic chemicals (such as dioxins, furans,
and chlorinated organics).
Different types of equipment/technologies used for bleaching are listed below:
1. Batch process: Potcher washing is the oldest technology (shown in Figure 8)
used in batch washing. Potcher consists of a series of beaters or engines used in
washing and preparing pulp. This process consumes huge quantity of water.
Fig 8: Potcher washer
2. Continuous countercurrent processes: Different continuous processes are

highlighted below:
a. Hydraulic drum washing:
A hydraulic drum washer does not require Barometric leg and works on hydraulic
principle therefore has minimum operating costs. A sketch of hydraulic drum is
shown in Figure 9 below:

Rubber roll of 500 mm dia

Doctor's Knife
Washed Pulp consistency = 10%
Unwashed Pulp
200 mm
Perforation of 25 mm
40# wire over the drum
Figure 9: Hydraulic Washer
b. Vacuum Drum washing:

In vacuum drum washing, each stage consists of a rotating screen drum which has a
partial vacuum applied to interior. The drum sits in a tank where pulp is diluted with
wash water. The vacuum draws a pulp mat against the surface and wash water
through the mat. The drum rotation advances the washed pulp mat to the next
dilution tank. Wash water discharged from this wash stage is sent to the previous
washing stage.
c. Pressure washing:
Pressure washing is similar to vacuum drum, but differs by spraying water under
pressure through the pulp mat as the drum rotates.
d. Diffusion washing:
Diffusion washing is a counter flow process that takes place in one or more stages.
Pulp flow is upward and is carried on a perforated plate. Water flows downward
through a series of baffles.

e. Chemi or Belt washing:

A Chemi or belt washer10 is perhaps the simplest washing system in terms of
design. It offers excellent washing with reduced water usage. Belt washing is a
counter flow process where pulp enters the washer area on a wire belt. Washing
takes place under a series of showers. Clean water enters on the opposite end from
the pulp and is sprayed vertically through the pulp. The used wash water is then
collected and reapplied to the dirtier pulp by the next washing head. Countercurrent
to the direction that the pulp moves. This process is continued through at least
seven stages until the wash water is saturated with liquor after washing immediately
coming pulp. The wash water is then sent to the recovery process.
Diffusion washing and belt washing can reduce the amount of water used per tonne
of pulp in brownstock washing by 50% or more according to published data.
f. Twin roll press washer
Twin wire roll press washer works on the general principle of dewatering,
displacement and pressing. It consists of a twin-wire dewatering unit which allows
controlled washing of the pulp. The two-sided dewatering and strong turbulence of
the washer facilitate two to three times higher capacities per unit of width than
conventional washer technologies. An additional main feature of this technology is
that the ash and fines removal can be controlled depending on the targeted levels.
This technology can be used for high consistency pulp washing and resulting in
reduced water consumption. Figure 10 shows a twin wire roll press washer installed
in one of pulp and paper mill in India.
Fig 10: Twin wire press roll washer
10
Source: U.S. EPA, 1993b. Pollution Prevention Technologies for the Bleached Kraft Segment of the U.S.
Pulp and Paper Industry

3.2.2 Agro Based Pulp and paper manufacturing Process

The process of pulp and paper making from agro-based residues is described
below:
The various production stages are as given below:
(i) Raw material preparation: Dedusting, depithing, leaf removal
(ii) Pulping section: Cooking, beating, pulp washing, refining, bleaching,
cleaning and, thickening
(iii) Stock preparation: Blending, pulp conditioning
(iv) Paper machine: Refining, Centricleaning, dewatering, drying of paper
Raw material preparation
The agro residue based raw material (RM) is procured by the mills from nearby
farms. In some mills raw material is screened at the site itself. The dust from the
screening section is disposed of as solid waste along with municipal waste. In very
small mills, bagasse is not depithed. The prepared agro raw material is then
conveyed to spherical digesters. Figure 11 through 13 below shows a raw material
preparation sections of agro residue based pulp and paper mill.
Fig 11: Raw material Preparation section

Fig 12: Wheat straw washing section
Fig 13: Wheat straw washing section
Pulping Section
Pulping comprises of cooking or digestion followed by washing, bleaching and
centricleaning.
Cooking

There are two types of digestion processes employed similar to wood pulping;
Batch digestion carried out in spherical digesters and Continuous digestion
process carried out in a pandia type digester. Figure 14 and 15 shows batch and
continuous digesters
Also unlike wood pulping two different chemical pulping processes are employed,
namely, Kraft process and soda process.
The agro residue is chemically digested in a digester at 150 – 160oC and 6 – 7
atm pressure for about six hours. Charging and discharging takes 1.5 hours and
0.5 hours respectively. The cooking in small agro-based mills is done with caustic
soda (NaOH) and steam. The quantity of NaOH charged, varies from 6 to 14
percent of raw material, depending on the type of agro residue. For every tonne
of agro residue, about 1.5 – 2.0 tonnes of steam is used, depending on the pulp
required (hard cooked or soft cooked). During digestion, solid to liquid (bath ratio)
in the range of 1:3 to 1:4 is maintained.
Fig 14: Spherical (Batch) Digester

Fig 15: Pandia digestor (Continuous

digester)
Blow tank
After cooking, the content of the digester is discharged, under pressure, either into a
blow tank where the pressure is released or directly into potchers. Water is added to
reduce the pulp consistency from an inlet value of 12 – 14 percent to about 3 – 4
percent, so that it can be pumped to the washing and cleaning section.
Washing
The pulp is then pumped to the washers for washing with fresh water in the final
stage and backwater in the previous stages. The washing operation takes about four
to six hours. The wash water called black liquor, which has total solids content of
around 7-10% due to residual alkali and lignin. This liquor is mostly discharged to
drains as chemical recovery has so far been economically unviable.
Screening
The washed pulp contains sand and uncooked agro residue as impurities. The
impurities are removed through screening and centricleaning. The rejects from the
screening (Johnson and / or Hill screen) are normally drained out. After screening,
which is carried out at 1% consistency, the pulp is thickened to about 4% for next
operation, namely bleaching. The filtrate, called back water, generated during
thickening operation, is generally collected and used for pulp washing (previous
operation). The pulp for making unbleached kraft paper (for packaging purpose) is
not bleached and is taken directly for stock preparation.

Bleaching
The bleaching in small mills is carried out using calcium hypochlorite (hypo), which is
added in two stages in order to provide sufficient retention time for hypo and to
minimize the fibre degradation. Fifty percent of the hypo is added in the screened
pulp storage chest and the rest is added in the bleacher. A retention time of about
two hours is provided in the storage chest. After bleaching, the pulp is washed,
partly with fresh water and partly with white water (paper machine back water). The
wash water from bleaching operation contains chloro-lignates and residual chlorine
preventing the wash water from direct reuse. A typical vacuum drum bleach washer
is shown in Figure 16
Fig 16: Conventional vacuum drum washer after bleaching
Stock Preparation
The bleached pulp is mixed with the long fibre pulp, comprising mainly rags and
wastepaper pulp. The mix depends upon the agro residue being processed and the
type of paper to be manufactured. The mix pulp is blended with additives and fillers
in the blending chest. The chemicals added to the blending chest are rosin, alum,
talc, dye (optional), optical whitener and high gum. The chemicals (additives, fillers
etc) solutions are prepared and added manually in every batch.

Paper machine
The blended pulp is again centricleaned to remove impurities and finally fed to the
paper machine through a head box. From the dewatering and paper making angle,
the machine has three principal stages:
• The gravitational and vacuum dewatering stage (wire part)
• The mechanical dewatering stage (press rolls part)
• The thermal drying stage (indirect steam dryers)
On the wire part of the paper machine, the dewatering of pulp takes place by gravity
and vacuum. The water from the wire mesh is collected in a fan pump pit and is
continuously recycled to dilute the pulp fed into the paper machine centricleaner. In
some mills, the wire is continuously washed with fresh water showers. The water is
collected and fibre is recoverd through Krofta saveall. The clear water from saveall is
recycled back to different consumption points. Excess is discharged to drain.
After the wire part, the edge cutting operation is carried out to obtain paper of a
definite width. The edge cuts of the pulp web falls in the couch pit and are recycled
to the machine chest.
Towards the end of the wire part of the machine, the consistency of pulp rises to
about 20 per cent. Further dewatering is carried out by press rolls to raise the
consistency to about 55%. The paper is finally dried through an indirect steam dryer
to about 94% solids and is collected in rolls as the final product. Figure 17 shows a
typical paper machine section.
Fig 17: Paper machine section

3.2.3 Waste paper pulping

Secondary fibre recycling or wastepaper pulping is another important sector. Figure
18a and b shows wastepaper storage yards.
Fig 18 a: Wastepaper Storage Yard
Fig 18 b: Wastepaper Storage Yard

The repulping of recycled paper and deinking is described below.
Recycled paper, newsprint and magazine is charged in Hydraulic pulper (Figure 19 )

with adding water and it is being processed till waste paper is converted into slurry
form with high consistency pulp. The hydro pulped pulp is cleaned in High density
cleaner followed by turbo separator for heavy weight and light weight impurities
respectively. Then it is continuously forwarded to centricleaner after passing through
screen. At centricleaner, the sand is separated due to centrifugal force. The pulp is
then taken to Decker thickener where the wastewater is removed and pulp is
thickened. The thickened pulp is processed to a chest through refiner by which the
pulp is thickened. The thickened pulp is processed to a chest through refiner by
which the pulp becomes finer as per process requirement. Then it is transferred to
machine chest where addition of dye, chemical takes place. This pulp then is fed to
the machine chest (Flow sheet is shown in Figure 20).
Fig 19: Hydropulper used for pulping wastepaper/recycled material

Fig 20: A typical process in pulp manufacture from wastepaper/recycled material

Waste paper
Helico
Cloudy Filtrate
Pulper
Dumping
Paper m/c back water Poir Reject
Constant
Level Chest
H D Cleaner
Horizontal Reject Diabole

To Reject handling system
Screen Screen
SR Box
Clear Filtrate Clear Filtrate
Pr. Reject Sec. Reject Tert. Reject

Centriclean Centricle Centricle
er aner aner
Accept Accept
Clear Filtrate Algus

Thickener
SR Box
Dewaterer Clear & Cloudy Filtrate Tank
Screw
Press
Plug Screw
Shredder
Pre Heater
Mixer
In Feeder
Screw
conveyor
Disperser
Storage
Deinking process:
Deinking is a recycling technique that can produce high quality recycled pulp from
recovered papers. Ink detachment is an important step. Flotation method is
commonly used for this purpose. Flotation Deinking which makes ink particles
hydrophobic by means of a collector in a flotation cell. The air bubbles generated at
the bottom of the cell carry the ink particles to the surface where they are confined in
foam which is removed.
Paper Making
Papermaking is common to all types of categories.
3.3 CHEMICAL RECOVERY FROM BLACK LIQUOR

Another very important process in line with the chemical pulping mills is the recovery
of the pulping chemicals from the concentrated black liquor generated from the pulp
washing process. The entire chemical recovery process from spent cooking liquor of
Kraft and Soda process is described separately in the following section.
The recovery of chemicals in the spent cooking liquor in general is described below.
The weak black liquor from brown stock washers goes through the following steps:
a. Concentration in multiple – effect evaporators
b. Incineration in recovery furnaces/boiler with addition of salt cake to make up
loss
c. Dissolving smelt from furnace in water to form green liquor.
d. Causticising of green liquor with lime to form white liquor which, after settling
and filtering is ready for next cooking cycle.
e. Burning of lime mud to recover lime.
Figure 21 shows a flow diagram of the process.
Black Liquor Pulping Area
Evaporator, Green Liquor Recausticising White Liquor

Recovery
Boiler
Lime Mud
Lime (CaO) (CaCO3) to
Cement
Fig 21 : Schematic diagram of chemical recovery flow process

3.3.1 Chemical Recovery: Kraft Process

Conventional Chemical recovery Process comprises of mainly soda recovery,
Causticising and lime kiln plant. Weak Black liquor generated from the brown-stock
washing is concentrated to 70% solids in multiple effect evaporator and is mixed with
flue gas residue from Soda recovery boiler. The thick concentrated black liquor is
then preheated in super heater and is injected via high-pressure spray guns into the
soda recovery boiler. Hot air is injected into the boiler. Combustion process is
initiated by fuel oil. Once, required temperature is attained, fuel oil supply is cut off.
The heat generated by the combustion reaction of black Liquor is used for
generation of steam. Flue gases from the boiler passes through superheater,
economizer and ESP and is then let off to atmosphere. Molten Sodium carbonate is
tapped from the bottom section of the boiler (Figure 22 & 23).
The molten sodium carbonate is send to the Recausticising Plant for production of
white Liquor. Molten sodium carbonate is dissolved in weak white liquor generated
by washing of lime mud. The resultant green liquor is clarified and is mixed with lime
in a slaker. The slurry is clarified through slaker clarifier, from where clear white
liquor overflows and the underflow, lime mud is washed in four-stage counter current
washer with Process condensate (vapour condensate from multi effect evaporator).
Weak white liquor is generated from the first stage washer as depicted in Figure 24.
Fig 22: Conventional Chemical

Weak Black Liquor, 18% solids

steam condensate To Boiler
Falling film
o
LP Steam 150 C, 20 T/h Evaporator (7
effects) Process condensate
Foul condensate To causticisation Plant
High To ETP
Concentrated
LP Steam 70% solids
Black Liquor
storage
steam condensate To Boiler
SRB Flue gas residue Ash Tank

Salt slurry (ClO2 Plant)
LP Steam
through 73% Solids
guns
Ambient air
Flue gas
Soda Recovery Super Economi
Pr Air Heater
Boiler (SRB) Heater ser
molten smelt
Sec Air Ash
To atmosphere ESP
Spout Cooling
Fresh water Wastewater to ETP
System
Dissolver
Weak White Liquor
Green Liquor
60% carbonate, 20% Na2S, 20% NaOH
Fig 23: Soda Recovery Process

Green Liquor from SRB

Process Condensate from SRB
Dreg To
Clarifier
Washer Lagoon
Underflow
Filtrate
(Weak White Liquor)
Constant
Overhead
tank
Process Condensate
Lime from Lime Kiln Slaker Impurities Landfill
Slurry Wastewater to ETP
Causticis
er 8 Nos
in series
overflow
White Clear White liquor

Liquor
Clarifier
Underflow
(Mud)
Fig 24 : Re –Causticisation process

Lime mud sludge generated from the recausticising plant is either utilized in cement
industries or sent to landfill facility or to lime kilns. In lime sludge burning process (
lime kilns), lime i.e CaO is regenerated from CaCO3.
Figure 25 shows one such lime sludge burning plant installed within a pulp and
paper mill.
Fig 25: Lime sludge burning plant

3.3.2 Chemical Recovery: Soda Process

Process description of non-conventional chemical recovery
Black Liquors from agro residue based mills pose problem in chemical recovery
process in conventional system due to following reasons:
• High viscosity of the liquor resulting in low heat transfer
• Low concentration of black liquor (7 – 10%) compared to wood based (14 –
17%)
• Higher silica content causing fouling and sealing at evaporators
• Low combustibility
In order to overcome the above-mentioned limitations, conventional recovery
process has been modified and instead of chemical recovery boiler, Fluidised bed
reactor is used. Also, the non-conventional recovery process does not generate
Power. A typical non-conventional chemical recovery plant installed and being
operated successfully in one of the Agro residue based pulp and paper mill in India
is shown in Figure 26. The process of chemical recovery from a non-conventional
process is briefly described below;
The black liquor generated from brown stock washing operation, also called weak
black liquor (WBL) contains 8% solids and has a residual alkali of 4.5 gpl. This weak
black liquor is concentrated to 25% solids in a multiple effect evaporator called semi
concentrated black liquor (SBL). The semi concentrated black liquor is then burnt in
a fluidized bed reactor at a temperature of 650oC to produce soda ash. In order to
maintain a temperature of 650oC, fresh water is injected through three cooling guns
at top chamber of the fluidized bed reactor. The flue gases containing considerable
amount of heat is used for preheating the strong black liquor. The product is cooled
by passing it through a double sludge water-jacketed product cooler and passing
part of fluidizing air through it. The flow sheet for chemical recovery process is
depicted in Figure 27. Figure 28 & 29 shows the schematic of a fluidising process
and Fluidised Bed reactor respectively.

Fig 26: Non conventional chemical recovery plant for Agro
Weak Black
Liquor 8% solids
Multiple Combined (Process)

Effect C d t
Steam Evaporator
Steam condensateTo Boiler
Semi
Concentrate
d Black
Liquor 25% solids
Exhaust gases to Economiser

atmosphere 45% solids
Fluidised
Fresh water (cooling) Bed reactor Hot flue gases
thro guns
Sodium
carbonate
pellets
Fig 27: Process flow sheet for Non Chemical Recovery process

Fig 28: Schematic of Fluidised bed process
Source: “An Experience in Running a fluid bed recovery system for agriculture
residues black liquor at M/s Shreyans Industries Limited, Sangrur”, IPPTA Vol 9,
No-3, Sept. 1997

Fig 29: Schematic of Fluidised Bed reactor
Source: “An Experience in Running a fluid bed recovery system for agriculture
residues black liquor at M/s Shreyans Industries Limited, Sangrur”, IPPTA Vol 9,
No-3, Sept. 1997

3.4 ENVIRONMENT IMPACT / CONCERNS OF PULP AND PAPER

MANUFACTURING PROCESS
The major environmental concerns from a pulp and paper manufacturing process
are contaminated effluents and malodorous gases.
Pulping often releases a range of pollutants, including organic products which cause
eutrophication in water, aluminum salts and sometimes also generation of sulphur
dioxide. Both of the two main pulping methods - mechanical and chemical pulping -
can cause pollution. Most papers require bleaching. When bleaching is carried out
with chlorine or hypochlorite, it may generate dioxin. These pollutants have direct
impacts on freshwater and marine ecosystems near pulp mills.
Pollutants can also have direct effects on human health, through impacts on pulp
workers, as a result of people eating contaminated fish, and through air pollution.
The various contaminants/components that cause environment concerns in pulp and
papermaking are enumerated below:
• Liquid effluents
The different sources of liquid effluent from a pulp and paper industry are as given
below:
Section / Equipment Typical Sources
Raw material preparation Wet depithing of bagasse
Wet debarking
Wet cleaning of straw and grasses
Chip wash water
Pulping
Blow condensate
Leaks and spills of black liquor
Gland cooling water from refiners,
pumps, etc.
Unbleached pulp wash (Black Liquor)
Centricleaner rejects containing high
concentration of fiber, grit or sand
Filtrate from pulp thickening
Bleaching Bleach wash water containing chloro-
lignin in case of chlorine or hypochlorite
bleaching
Stock Preparation and paper machine Leaks and spills of chemicals and
additives
Floor wash
Spills of pulp
Centricleaner rejects containing fibers,
grit or sand
White water overflow

Wire section and press section felt wash

water
Utilities Boiler blow down
Softener regeneration discharges
Chemical recovery Evaporator condensate
Weak liquor from dregs washer
Weak liquor from mud washer
Gland cooling and mud washer
Foul condensates
‘The major concerns from these effluent are:
o pulping liquors containing

VOCs ( terpenees, alcohols, phenols, methanol, acetone)
o bleaching effluents
chlorinated hydrocarbons like dioxins and furans
chloroform
other chlorinated compounds
o nonyl phenol ethoxylates (NPE)
used as nonionic surfactants in some papermaking processes
break down to nonylphenol, (NP), a suspected endocrine
disrupter
o discharge color
• Air emissions
Air pollution mainly occurs from digesters blow tanks, steam boilers, chemical
recovery boilers and limekiln. The major concerns from these emissions are as
given below:
o hazardous air pollutants (HAPs) and other toxic substances, including:
reduced sulfur compounds (hydrogen sulfide, mercaptans, and
alkyl disulfides)
VOCs (acetaldehyde, methanol, propionaldehyde, methyl ethyl
ketone, phenols, terpenes, etc.)
o odor (including sulfides generated during chemical recovery of kraft
process "black liquors")
o acid gases (sulfuric, hydrochloric, hydrofluoric)
o emissions from boilers and lime kilns (including particulates, and sulfur
and nitrogen oxides)
• Solid waste
Solid waste is generated in the form of sludge, ash, wood waste, screening,
centricleaner rejects, sand and grit. The main source of solid waste is wastewater
sludge from primary and secondary clarifier. Ash from boilers is also significant.

The other major waste that is generated in good quantity is lime sludge from
recausticisation process of chemical recovery plant.
The major concerns with these wastes is their disposal.

CHAPTER 4
WATER CONSUMPTION PATTERN IN OTHER COUNTRIES
In developed countries, most of the pulp and paper manufacturing mills are wood
based, however, due to environmental implications, trend is changing towards use of
recycled fibre. This has been possible due to more efficient collection activity and
development in process technologies. However, all the pulp, paper and board
products cannot be produced from recovered fibres due to technical, environmental
or health requirements.
The average water consumption for wood based large pulp and paper industries
primarily producing paper & paper board products from 6 regions / countries namely
United States, Australia, Europe, Canada Finland & Spain has been compiled from
various documents available on the web and the same is presented in the Table 14
below:
Table 14: Region / Country specific Average Water Consumption in large scale
wood based Pulp and Paper mills
Sl. Region / Average Specific water Source

No. Country consumption
(m3/ tonne of product)
1 U.S. 64 Appendix “W” of Report on Status
(Average value in the of Pulp & Paper in US by Michiel
year 2000) P. H. Brongers and Aaron J.
Mierzwa
2. Australia 28.66 APIC Public Eco-efficiency Report
(Average value for the 2003
year 2003)
3. Europe APIC Public Eco-efficiency Report
40 2003
4. Canada APIC Public Eco-efficiency Report

67 2003
5. Finland 40 Pulp Fact - Environmental
Implications of the Paper Cycle” by
Nigel Dudley, Sue Stolton and
Jean-Paul Jeanrenaud WWF
International 1996
6. Spain 30 Pup Fact – Environmental
Implications of the paper Cylcle by
Nigel Dudley, Sue Stolton and
Jean Paul, Jean Renaud – WWF
International 1996

Water consumption in these countries have been found to be much lower then in
developing countries like, India, Pakistan, China, etc. The best performances in few
industries employing close cycle have even touched the specific water consumption
of around 20 m3/tonne of paper.
Realizing the huge costs of, energy, water, chemicals and environment from virgin
paper production, the recent trends have been to shift to paper recycling i.e.
producing paper from waste paper. Beyond saving trees, making new paper from old
takes a fraction of the energy and chemicals used in virgin paper production and
thus expanding the recycling of used paper has enormous potential to bring
environmental and economic benefits. The specific water consumption in various
European and Scandinavian countries varies from 8 to 10 m3 / tonne of paper. A few
industries in Netherlands in fact claim of only 4.4 m3 of water consumption per tonne
of paper production from waste paper.
A brief scenario of pulp and paper industries in few of the developed countries is
given below:
UNITED STATES OF AMERICA11: US, is one of the largest producers of pulp and
paper (around 38% of the world production share). It has more than 300 pulp mills
and more than 550 paper mills to support its production. Due to the fierce
competition within the pulp and paper industry, many companies merged resulting in
a smaller total number of pulp and paper mills, and significantly increased production
capacity per mill. Furthermore, factories in US are no longer allowed to "run a river
through their plant" and dump the processed water back into the environment
without cleaning it first. There is a clear trend of decreasing the amount of process
water, recycling and reusing the water in closed-loop systems, and cleaning the
water before releasing. A typical pulp mill uses about 64 m3 (17,000 gal) of water per
tonne of bleached pulp produced, which is a decrease from approximately 379 m3
(100,000 gal) per metric tonne in the 1940s.(3) Today, the pulp and paper industry in
US uses a lower volume of process water, recycles and reuses more water, and
cleans water before releasing it, all in an effort to reduce costs as well as respond to
increasingly strict environmental regulations.
AUSTRALIA1: In Australia, five major papermaking facilities, four large saw mills
and numerous smaller wood processing plants are operating.
The Australian paper industry is acutely aware of the need to minimise its water use.
In 2001-02 the industry used an average of 28.66 kilolitres per tonne of paper
production. This represents a 62 per cent reduction in water use since 1990. The
Australian paper industry’s water use compares favorably to the industry elsewhere
in the world.
EUROPE12: In Europe, around 60% of the pulp and paper produced comes from
mills certified in one of the major eco-management schemes. Recovered paper
11
Source: APIC Public Eco-efficiency Report 2003
12
Source: EUROPA - Forest-Based industries - Pulp and paper manufacturing,
http://europa.eu.int/comm/enterprise/forest_based/pulp_en.html

forms more than 40% of the raw materials used in paper production in Europe with
the packaging sector the biggest consumer. Newsprint, sanitary and household
papers, are produced from recovered paper. However, printing and writing papers -
which represent 40% of total paper and board production - mostly rely on virgin
fibres. Levels of paper recycling has increased in Europe, however performance
varies greatly from one country to another due to differences in market and industry
structures, population density, education, transportation distances, etc.
CANADA13: Canadian pulp and paper industry is a cornerstone of the Canadian
economy. Canada is a leading producer of high quality, recycled content paper
products. Today, 22 mills across Canada are capable of recycling, and 62 mills use
recovered paper in whole or in part as a source of fibre.
Water consumption per tonne of pulp is less than half of what it was 20 years ago.
Since 1990, the pulp and paper industry has invested over $6 billion in pollution
prevention technologies, resulting in the virtual elimination of dioxins and furans.
These reached non-measurable levels in 1995. TSS (Total Suspended Solids) and
BOD (Biological Oxygen Demand), two leading indicators of mill effluent pollution
have also dropped drastically. In this decade, levels of BOD have dropped ten fold
and TSS, by more than half. The use of elemental chlorine in bleaching had
dropped to 87% between 1988 and 1999. Further, a level of dioxins and furans in
mill effluent has gone down by 99%.
DUTCH14: In Dutch, fresh water consumption in wastepaper based pulp and paper
mill is at present 8.4 m3/tonne of production.
The production process in Dutch operates in water system closure. In water system
closure, water system is basically divided in two large process water cycles, which
are separated by the thickener: the Stock Preparation (SP) cycle with comparatively
contaminated water and the Paper Machine (PM) cycle with comparatively clean
water.
The current paper production process in Dutch is as given below:
13
Source: Pulp and operations in Canada, http://www.cppa.org/english/info/work.htm
14
Source: Towards Water System Closure in the Paper Industry & Assessment of an improved separation of
the stock preparation and paper machine based on the quality of the paper production, environmental impacts
and economic aspects” by Leo Breedveld, Wiely Luttmer, Henk Senhorst Institute of Inland Water Management
and Waste Water Treatment RIZA, P.O. Box, 17, NL-8200 AA, Lelystad, the Netherlands

The current production process is further improved by inserting an extra thickener in

the process. As a result, an extra water cycle is created between refiner and cleaner
as shown in below. The new cycle comprises refiner and thickener, while the PM
cycle comprises cleaner and paper machine.
The improved process reduces the fresh water consumption further to 4.4 m3/tonne
of production.

CHAPTER 5:
PRESENT WATER CONSUMPTION PATTERN PREVAILING IN PULP

AND PAPER SECTOR IN INDIA
5.1 Background
Pulp and paper sector is one of the water intensive industry. Water is one of the
major inputs without which it is impossible to produce pulp and paper. Apart from
large volume of water that is consumed at each and every process stage of paper
manufacturing, water is also required for utility sections like boilers and co-
generation plants to generate steam and power. Off late, water, the most sought out
commodity is depleting very fast and already started giving alarming signals in many
parts of the country. The demand for water in a specific industry depends on the
quality of paper and type of raw material used and the extent of recycling adopted in
the mill.
5.2 Water Consumption Scenario
The most water consuming category is wood based and agro based integrated pulp
and paper mills. The average water consumption15 (in 1998) by a integrated pulp
and paper mill in India was 200 m3 per tonne of paper, varying from 175 m3 to as
high as 415 m3 of water per tonne of paper.
Average water consumption16 in wood based and waste paper based Indian pulp
and paper industry as reported by Central Pollution Control Board (CPCB) and
MoEF (Ministry of Environment & Forests) is given below:
¾ Wood based mills: 150 - 200 m3 / tonne
¾ Waste paper based mills: 75 -100 m3/ tonne
5.3 Water Consumption/ Wastewater discharge: Norms / Standards For
Paper And Pulp
1. CENTRAL POLLUTION CONTROL BOARD (CPCB)
So far, no water consumption standard has been set for water consumption by
CPCB. Standards are prescribed in terms of wastewater discharge for different
categories of pulp and paper industry as given below:
A. Small Pulp & Paper Industry:
As per Standards, pulp and paper mill established before January, 1992
¾ Agro based are allowed to discharge 200 cu.m /tonne of product. And for
wastepaper based pulp and paper mills are allowed to discharge 75
cum/tonne of product
15
Source: CSE ‘s Green Rating Project report for pulp and paper sector for second time, 2004.
16
Source: Environmental management in selected industrial sectors - status and need, CPCB & MoEF,
February, 2003.

And those mills established after January, 1992

¾ Agro based mill are allowed to discharge 150 cum/tonne of product and that
wastepaper based mill is 50 cum/tonne of product
B. Large Pulp and Paper Industry above 24000 tonne/annum
Large pulp and paper mills are allowed to discharge 200 cum/tonne of product
whereas newsprint-manufacturing mill are allowed to discharge 175 cum/tonne of
product.
2. CHARTER ON CORPORATE RESPONSIBILITY FOR ENVIRONMENTAL
PROTECTION (CREP)
Central Pollution Control Board has issued a directive in the form of Corporate
Responsibility for Environment Protection to 17 most polluting industries. Pulp and
paper industry is one among them. CREP for Pulp and paper industry is as given
below:
Large scale pulp and paper mills has agreed to comply with following standards with
respect to wastewater discharge quantity:
¾ Less than 120 cum/tonne of paper in 4 years for mills installed before 1992
¾ Less than 100 cum/tonne of paper in 4 years for mills installed after 1992
Small-scale pulp and paper mills have agreed to comply with following standard with
respect to wastewater discharge:
Less than 150 cum/tonne of paper within 3 years
In addition, all the pulp and paper mills have agreed to utilize the treated effluent for
irrigation wherever possible.
3. NORMS FOR PAPER AND PULP INDUSTRY ISSUED BY KARNATAKA
STATE POLLUTION CONTROL BOARD (KSPCB)
KSPCB has set norms for maximum consumption of fresh water by the pulp and
paper mill. As per the norms, different categories of pulp and paper mill can
consume fresh water upto the maximum limit as given below:
A. Small Pulp and Paper Mills
¾ Agro – residue based mill can consume upto a limit of 200 cum/tonne of
paper
¾ Wastepaper based mills can consume upto a limit of 75 cum/tonne of paper
B. Large Pulp and Paper Mills
¾ All large scale mill can consume upto a limit of 250 cum/tonne of paper

5.4 Water Consumption: Latest Trends

With increasing awareness regarding water conservation, ever increasing pressure
from government regulatory agencies and also due to increasing water scarcity
many large industries have taken proactive steps like regular water auditing,
technology modifications etc for reducing the water consumption. These efforts have
also been reflected in the CSE’s finding through their green rating project in pulp and
paper sector, water consumption has come down significantly in large-scale Indian
paper mills and average figure has been reduced to 135 m3 per tonne paper in the
year 2002.
However, this figure is still very high when compared to the average water
consumption in US and European pulp and paper mills as indicated in chapter 4.
In view of the large water requirements, most of the large mills had setup their
production facility close to perennial water sources. In many of the cases the easy
and cheap availability of the water had in fact caused the excessive water usages
and thus high specific water consumption figures.
In small-scale industries, despite being dependent on ground water have high
specific water consumption primarily due to use of obsolete technologies.
The latest / current water consumption pattern in different categories of Indian pulp
and paper mills (based on scale of operation, raw material used and the final product
manufactured) as arrived through industries response to the questionnaire is
compiled and is as tabulated below in Table 15: The details of questionnaire data is
compiled and is given in Annexure III.
Table 15: Water consumption in pulp and paper sector as per Questionnaire
survey
S.No. Raw Material End Product (M3/ tonne of product)
Min Max Remark
Large Scale category
Cultural high grade
1 Integrated including newsprint 105 202
Cultural grade
2. Wood Based including newsprint 68 168
There is only one
3. Wood Based Newsprint only 74 mill
Only one mill in
this category
4. Wood Based Rayon pulp 130 responded
5 Agro Based Cultural - high grade 73 -do-
Cultural - low grade
6 Agro Based including newsprint 46 -do-
3 Waste paper Newsprint 29 -do-
Medium Scale category
1 Agro Residue Cultural – high grade 102 219


S.No. Raw Material End Product (M3/ tonne of product)
Min Max Remark
Only one mill in
this category
2 Agro Residue Industrial grade 28 responded
Waste Paper
3 Based Cultural – high grade 40 -do-
Waste Paper
4 based Newsprint 16 -do-
One mill
reported 5.5 m3/
tonne, operating
with zero
Waste paper discharge
Based Industrial grade 5.5 35 system
Small Scale category
Only one mill in
this category
1 Agro Residue Cultural - high grade 156 responded
Straw board
2 Agro Residue Industrial 7 making mill
Only one mill in
this category
3 Waste paper Cultural - high grade 18 responded
4 Waste paper Cultural - low grade 14 25
5 Waste Paper Industrial 7 80
With the background information generated through above referred literature and
questionnaire survey, detailed studies were undertaken in ten representative
industries from various categories of pulp and paper manufacturing mills with the
intention of identifying current water consumption levels, developing further water
conservation measures and water conservation guidelines for use by different
industries. The current water consumption pattern as identified through extensive
water and fiber balance study in above mentioned 10 industries is as tabulated in
Table 16:

Table 16: Overall water consumption (excluding domestic) in ten

representative mills
Water
consumption,
m3/ tonne
Large Scale
manufacturing
grade
grade
Medium Scale
4 Agro & waste paper based Cultural – high 80
grade
grade
Small Scale
grade
grade
grade
During the detailed study efforts were also made to quantify / standardize the mill
process / operation specific water consumption figures for various category pulp and
paper manufacturing industries. The unit process / operation specific water
consumption figures as developed during the detailed studies in 10 representative
pulp and paper mills are discussed in the next chapter.
5.4 Waste Water Discharge: Latest Trends

Through extensive detailed field studies in ten representative mills, wastewater
discharge quantities (excluding domestic) have been estimated for different
categories of pulp and paper manufacturing mills and are compiled below in table
17.

Table 17: Compilation of Water consumption figures from Questionnaire

response
Waste Water
discharge, m3/
tonne
Large Scale
manufacturing
grade
grade
Medium Scale
4 Agro & waste paper based Cultural – high 61
grade
grade
Small Scale
grade
grade
grade
From the above, it has been observed that wastewater discharge to fresh water
consumption ratio varies between 0.72 and 0.86.

CHAPTER 6
UNIT PROCESS / OPERATION SPECIFIC WATER CONSUMPTION

FACTORS
6.1 Background
Ten representative mills were studied in different categories of pulp and paper sector
as mentioned in Chapter 2.
Methodology adopted for estimation of specific water consumption
In order to determine the existing specific water consumption, detailed water balance
were prepared for both overall plant as well as individual unit
process/operation/equipment wise. The following methodology was followed in
preparing a detailed water balance:
a. Detailed study of the production process through available process flow
sheets, shop floor walk through, detailed discussions with plant personnel.
b. Identification of unit processes/operations/equipments using fresh water
c. Identification of sources of back water generation and their characteristics
d. Measurement of metered fresh water intake volume inlet to the plant and
metered effluent discharged out
e. Detailed fiber and water balance across the whole production process: The
requires estimation of moisture content of input raw material and output
product and pulp consistencies at various stages of production processes
f. Measurement of unit process/operation fresh water consumption and
wastewater discharge
g. Estimation of ratio of recycled water used to fresh water consumption
The above mentioned methodology required extensive waste water monitoring (24
hours for 3 days), measurement of inlet water to the mill (using Ultrasonic flowmetre
as well as mill’s water metre), collection of corresponding production related data,
measurement of pulp consistencies at various stages of production, collection of
data on chemical addition, steam used etc in the process. Prior to wastewater
monitoring, preparatory work like identification of channels carrying wastewater from
individual unit processes and the total, cleaning of the channels, removal of foams
from the wastewater, fixing of weirs wherever required, etc. The impeller-based
instrument was used for monitoring wastewater flow through channel. Fresh water
flow through closed pipes was measured using ultrasonic flowmetres.
The above information was used to construct a water balance diagram and material
balance (fibre + water) charts, showing water use in different parts of the process (A
typical water balance and material balance diagram constructed is shown in Figure
30 & 31). Further a detailed breakdown of unit process/operation fresh as well as
recycled water use was made. Based on them, water conservation options were
evolved.

The current specific water consumption factors and further water conservation
potential, unit operation/process wise for different categories of pulp and paper
sector estimated is described in subsequent section.

Final report on water conservation
Pith in Pulp
press and Paper
filtrate Sector
4000 m3/d Page No.60
Anaerobic
Fig 30 : Typical lagoon
Water Balance
PULP MILL
6000 m3/d
Digestor Bleach
House Plant PM 1-4
5000 m3/d 1000 m3/d
7500 m3/d
15000 m3/d 14000 m3/d
18000 m3/d
9500 m3/d 5000 m3/d
6000 m3/d 12000 m3/d 21000 m3/d

Turbo generator,
Raw Compressor ETP
Water Under sludge 100 m3/d
Cooling 1800 m3/d Per
Water 3000 m3/d
3000 m3/d
3500 m3/d
100 m3/d 300 m3/d
WTP
500 m3/d WPPS
2200 m3/d 2000 m3/d
1200 m3/d
2200 m3/d
SRP PM 5
Hypo DM Plant Boiler
Preparation House
1900 m3/d
500 m3/d
500 m3/d Cooling
Tower
Paper m/c back water

River water (raw) Per water
River water (treated) Water along with. pulp Wastewater

Fig 31: Typical Material balance chart

Wheat straw
/Bagasse 52.0 MT OD
12.8 m3
Caustic flakes 6500 Kg

Caustic lye 0.0 m3 Digester
Black Liquor 141.8 m3 12.74% 26.3 MT
Steam (condenses) 25.2 m3 179.9 m3
Flash vapours to atmosphere

Black Liquor 289.3 m3 Blow tank
5.30% 26.3 MT
469.2 m3
Black liquor 1003.7 m3
26.3 MT
1646.4 m3 1.57%
Johnson
Screen 10.25 MT
642.6162 m3 WW to ETP
Hill
Screen 402
4%
1424.7 399.1534
Fresh water 430.0 m3 2.82% 10.25 MT
2 STAGE 243.4629 m3
COUNTER
CURRENT
BSW 26.3 MT
9.42% 252.5 m3
HD Tower
Pulp Mill thickener ww 739.1 m3 2.58% 26.3 MT
991.6 m3
Fresh water + Pulp Mill Centrifugal

thickener ww Screen
379.0 m3
1.88% 26.3 MT
1370.5 m3
Pulp Mill Thickner ww Centricleaner Tert
(3 stage) C.C
28.0 m3 reject 28 m3 R
1.88% e
Thickner ww c
Fresh water 700.0 m3 Thickner 1071.027 m3 y
2.56% 26.3 MT c
999.5 m3 l
Bleaching ww e
Backwater Bleaching
1078.0 m3 CEPH 1933.281 m3
Cl2 10.40% 26.3 MT
Caustic 2.0 m3 226.2 m3
Peroxide
Hyposolution 80.0 m3
Paper m/c B/w 5.62% 26.3 MT

214.8 m3 H D Tower 441.0 m3
Paper m/c B/w
412.5 m3 2.99% 26.3 MT
853.5 m3
Blending chest
Wastepaper pulp 0.0
7.5 MT 33.8 MT

6.2 Existing Water Consumption Status

Based on the detailed studies as mentioned above in various categories of pulp and
paper industries, the unit operation wise specific water consumption figures have
been evolved and the same are elaborated below:
6.2.1 Raw material preparation Section
In raw material preparation section water is primarily used for de-pithing, wet
cleaning (in case of agro residues), log washing, chipping (in case of wood). Existing
Water consumption status in raw material preparation section for various categories
of pulp and paper mills has been generated, compiled and presented below in Table
18 in terms of specific fresh water consumption and specific total water
consumption17.
Table 18: Specific Water Consumption – Raw Material Preparation Section
Cat Category Description Specific water Remarks
Cod consumption (m3 /
e tonne of product)
Fresh Total
water water
A Medium Scale Agro & Waste 0 0 It is a bagasse-based
paper based Industrial paper mill and only dry de-
manufacturing mill pithing is carried out, so
no water is used.
B Medium Scale Agro & Waste 0.2 7.58 Process condensate
paper based Cultural – high from chemical recovery
grade paper manufacturing plant is used for washing
mill of agro residues viz.,
wheat/rice straw and
fresh water is used only
C Large scale wood and 0.7 0.7 No recycling practiced
wastepaper based newsprint
manufacturing mill
D Large scale wood and 0.3 0.3 No recycling practiced
wastepaper based Cultural –
high grade paper and paper
board manufacturing mill
E Large scale Wood, Agro and 0 13.5 Recycled water is used
wastepaper based (Integrated) for depithing of bagasse
Cultural – high grade paper and log washing and no
and paper board fresh water is consumed
manufacturing mill in this section
17
Includes fresh as well as recycled water. This is the maximum water consumption needed for the specific
process / operation.

Cat Category Description Specific water Remarks

Cod consumption (m3 /
e tonne of product)
Fresh Total
water water
F Small Scale Waste paper - - Wastepaper based mill
based Cultural – low grade and does not warrant
paper manufacturing mill any raw material
preparation
G Medium Scale Wastepaper - - Wastepaper based mill
based Cultural – high grade and does not warrant
paper manufacturing mill any raw material
preparation
H Small Scale Agro – residue 0 0 Dry dedusting of wheat
based Industrial paper straw and dry depithing
manufacturing mill of bagasse
I Small Scale Agro- residue 0 0 Dry depithing of bagasse
based Cultural – high grade
paper manufacturing mill
J Small Scale Wastepaper - - Wastepaper based mill
based Cultural – low grade
Observations
1. Agro residue based pulp and paper mills using bagasse as raw material:
It may be noticed from the above table that two mills using bagasse as raw material
(category code A & E) has huge difference in water consumption. The variation is
due to de-pithing technology. De-pithing of bagasse can be carried out by both dry
and wet method. Wet de-pithing has following advantages over dry de-pithing
process:
a. Maximum removal of pith is possible in wet de-pithing around 90 % when
compared to dry de-pithing process which removes only 46 – 50% of the total pith
present in bagasse
b. Other impurities like sand is also removed in the wet de-pithing process
c. Removal of residual sugar content
Pulp and paper mills involved in the manufacture of unbleached paper and paper
board need not remove 90% of the pith and hence can go for dry depithing.
However, those involved in the manufacture of Cultural papers have to remove
maximum pith in order to avoid excessive use of bleaching chemicals. Further, those
mills with continuous digesters need to remove sand or any such impurities in order
to avoid damage to the screw feeder.

Dry depithing can be improvised by increasing the mesh size of the perforations in
the dry depither from standard 6mm to 8 mm. This can result in pith removal from
50% to 66 - 73% of the total pith content
Efforts should be made to purchase the bagasse having low sugar content and using
dry de-pither as a precedent to wet depithing.
2. Agro residue based pulp and paper mills using wheat/rice straw:
The water consumption variation in mills processing rice / wheat straw as raw
material (Code B and H) is primarily due to the sand & chlorides present in them
(farm sand sticked to raw material). Presence of Sand & chloride in the agro residue
effects the chemical recovery from the waste pulping liquor (black liquor). Mills not
adopting chemical recovery process can go for dry de-dusting, however others with
chemical recovery plant needs wet de-dusting of agro residue. The acceptable
chloride content (as NaCl) in the agro residue is below 0.2%.
Mills processing wood needs water for log washing to remove the sand adhered with
the wood logs. Most of the mills uses recycled water however a few large scale mills
having log washing section far away from rest of the plant, uses fresh water with the
recycling provision.
6.2.2 Pulping section: Agro Residue and Wood Based
The major processes in pulping section are the actual digestion of the raw material
(agro residue, woodchips etc), pulp washing and pulp bleaching. In pulping section
water is primarily required for following unit processes /operations:
(a) Blow heat recovery system
(b) Brown stock washing
(c) Bleaching, washing and bleach chemical preparation
(d) Decker thickener showers
(e) Pulp dilution at different stages
Other than the above water is also required for pump gland cooling/sealing, and floor
washing. However there could be few areas which are either not pertinent or no
water is used depending upon the type of raw material used and / or type of pulping
process employed. The specific water consumption for different water use areas
(e.g. brown stock washing, pulp dilution etc.) in pulping section for pulp mills studied
in various categories is presented in the table below. The specific water
consumption has been expressed as fresh water per tonne of product, total water
consumption per tonne of product and also as fresh water consumption per tonne of
bleached pulp as this particular data can be used more reliably18 as benchmark by
industries for comparing water consumption in pulping section.
The water consumption pattern for pulping section is as given below in Table 19:
18
Water consumption per tonne of finished product would be a misleading figure because of variety of raw
materials (wood, agro residue, waste paper, imported pulp etc) used in varying proportions.

Table 19: Specific Water Consumption – Pulping Section
Cat Category Specific Water consumption Remarks

cod Description
Fresh Fresh Total
e
Water, water water
(m3/tonne
(m3/BDM (m3/tonne
of finished T of of finished
product) bleached product)
pulp)
A Medium Scale Agro & Waste paper based unbleached Kraft paper
manufacturing mill
¾ Brown stock 16.20 20.25 27.20 Recycled water is used
washing
¾ Pulp dilution 4.40 5.47 18.40 -do-
¾ Pump gland 0 0 5 Recycled water is used
cooling for pump gland cooling
Sub Total 20.6 50.6
B Medium Scale Agro & Waste paper based bleached writing & printing
¾ Brown stock 8.84 12 8.8419
washing
¾ Bleaching & 12.6 17.4 70.90 Save-All filtrate is
washing reused in Bleach
washing.
Sub Total 21.5 79.6
C Large scale wood and wastepaper based newsprint manufacturing mill
Chemical Pulping (CP)
¾ Brown stock 0 0 2.4020 Recycled water is used
washing
¾ Pulp dilution 0 0 3.50 -do-
¾ Centricleaning 0.26 2
(Fibre saver)
¾ Bleaching & 1.61 12.10 3.20 Recycled water is used
washing
19
The figure is on a lower side as only partial washing is taking place in the brown stock washing section and
remaining washing is achieved in bleaching section. This also causes relatively higher water consumption figure
for bleaching operation.
20
Comparatively less water consumption (w.r.t. integrated mills producing high grade cultural paper) because
of relatively less stringent washing requirements for news print grade paper.


cod Description
Fresh Fresh Total
e
Water, water water
(m3/tonne
(m /BDM (m3/tonne
3
pulp)
¾ Bleach pulp 0 0 2.40 -do-
dilution
Chemi- Mechanical Pulping (CMP)
¾ Hill Screen 0.13 0.12 0.13
¾ Bleaching & 0 0 8.50 Recycled water is used
washing
¾ Non process 7.90 - 7.90
like pump
gland cooling,
sealing, AC
plant cooling,
agitator,
compressor,
raffinator
cooling, etc.
Sub Total 9.90 27.90
D Large scale wood and wastepaper based paper and paper board
manufacturing mill
¾ Brown stock 4 10 4 Better brown stock
washing washing technology
¾ Bleaching & 6.60 16.60 6.60 Better bleach washing
washing technology
¾ Pulp dilution 5 4 5
¾ Non process 3.76 - 3.76
like pump
gland cooling,
sealing, floor
washing
¾ Sub Total 19.36 19.36
E Large scale Wood, Agro and wastepaper based (Integrated) paper and
paper board manufacturing mill
¾ Brown stock 6.90 9.60 6.90
washing


cod Description
Fresh Fresh Total
e
Water, water water
(m3/tonne
(m /BDM (m3/tonne
3
pulp)
¾ Bleaching & 14 23.90 17.30 Recycled water is also
washing used
¾ Pulp dilution 0 0 18 –do-
¾ Non process 5.70 - 16.50 -do-
like pump
gland cooling,
sealing
Sub Total 27.4 58.7
H Small Scale Agro – residue based Industrial paper manufacturing mill
¾ Potcher 0 - - Recycled water is used
washing
I Small Scale Agro- residue based Cultural – high grade paper
manufacturing mill
¾ Brown stock 11 16.3 11
washing
¾ Bleaching & 5.89 8.75 41.79
washing
¾ Pulp dilution 0 0 39.2 Recycled water is used
¾ Centrifugal 14.1 20.9 14.1
Screen
shower,
Decker
thickener
shower
¾ Pump gland 9 9
cooling, floor
washing
It may be noted from the above table that the water consumption varies significantly
from industry to industry for the same unit processes using similar raw materials.
These variations are caused by type of technology being used, water management
practices etc. The minimum water consumption for different unit processes /
operation in the pulping section for various categories of pulp and paper mills is
compiled below.

6.2.3 Pulping section: Waste Paper Based

Wastepaper pulping
The major processes in waste paper pulping section are the hydro pulping, de-inking
and sand / silica removal. In waste paper pulping section water is primarily required
for following unit processes /operations:
(a) Hydropulper
(b) De-inking plant (floatation cells)
(c) Decker thickener shower
(d) Pulp dilution
(e) Centricleaning
washing. The specific water consumption for different water use areas (e.g. hydro
pulping, de inking, dilution, centricleaning etc brown stock washing, pulp dilution
etc.) in waste paper pulping section of pulp mills studied in various categories is
presented in the table below. The specific water consumption has been expressed
as fresh water per tonne of product, total water consumption per tonne of product
and also as fresh water consumption per tonne of waste paper pulp as this particular
data can be used more reliably as benchmark by industries for comparing water
consumption in waste paper pulping section. Specific water consumption factors
have been compiled and given below in Table 20.
Table 20: Specific Water Consumption – Waste Paper Pulping Section
Specific Water consumption

Cat Category Fresh Fresh Total water Remarks
3
Cod Description water water m /tonne of
e m3/tonne m3/BDMT finished
of of waste product
finished paper
product pulp
A Medium Scale Agro & Waste paper based unbleached kraft paper
manufacturing mill
Hydropulper 0 0 16.40 Recycled water is
used
Decker 7 35 14 -do-
thickener
Sub Total 7 30.40
Hydropulper 0 0 4.76 -do-


Cod Description water water m3/tonne of
3 3
e m /tonne m /BDMT finished
of of waste product
finished paper
product pulp
Decker 2.50 68.50 2.50
thickener
Sub Total 2.50 7.26
De-Inking Plant (DIP)
Process 4.40 23 13.10 Recycled water is
(Pulper, used
Screens etc)
Non process 1.50 - 1.50
like pump gland
cooling, agitator
cooling, etc.
manufacturing mill
Wastepaper 0.20 0.40 8.37 Recycled water is
pulping used
(Process)
Wastepaper 0.75 - 0.75
pulping (non
process like
pump gland
cooling, etc.)
Imported pulp 1.60 3.7 1.60
pulping
Hydropulper 0 0 4.80 Recycled water is
used
Pulp dilution 0 0 1.50 -do-
Sub Total 0 6.30
F Small Scale Waste paper based Cultural – low grade paper manufacturing
mill


Cod Description water water m3/tonne of
3 3
e m /tonne m /BDMT finished
of of waste product
finished paper
product pulp
Waste paper 0 31 Recycled water is
pulping, used
cleaning
Pulp dilution 5 -do-
G Medium Scale Wastepaper based Cultural – high grade paper
manufacturing mill
De inking Plant: 9.6 23.2 9.6
Thickener, back
water tank make
up
Wastepaper/ 1.66 27.33
Imported pulp
pulping,
cleaning
Pulp dilution 0 0 16.6
Pump gland 3.3 3.3
cooling
Waste paper 0 46.5 Recycled water is
pulping used
Decker 0 79.5 -do-
thickener
I Small Scale Agro- residue based Cultural – high grade paper
manufacturing mill
Wastepaper 0 5.12 -do-
pulping
Decker 0 1.38 -do-
thickener
J Small Scale Wastepaper based Cultural – low grade paper manufacturing
mill
Wastepaper 0 29.8 Recycled water is
pulping, used
cleaning,
Potcher 0 55.18 Recycled water is
washing used

6.2.4 Stock Preparation and Papermaking
Paper machine section

The major processes in stock preparation and paper making section are the
chemicals preparation, Pulp dilution, paper making. In this section water is primarily
required for following unit processes /operations.
(a) Chemical preparation
(b) Pulp dilution
(c) Centricleaning
(d) Felt cleaning shower
(e) Wire section high pressure shower
(f) Couch press roll lubrication tower
(g) Felt lubrication shower
(h) Pick up roll lubrication
(i) Breast roll shower
(j) Broke pit showers, couch pit showers, etc
(k) Thickener showers
Other than these water is also required for refiner gland cooling, compressor
cooling/sealing, pump gland cooling/sealing, rewinder drum cooling, paper roll
and pope reel cooling, Floor washing, etc
The specific water consumption for different water use areas (e.g. chemical
preparation, paper machine, showers vacuum sealing etc) in stock preparation and
paper making section for pulp mills studied in various categories is presented in the
Table 21 below. The specific water consumption has been expressed as fresh water
per tonne of finished product and total water consumption per tonne of finished
product.
Table 21: Specific Water Consumption – Stock Preparation and Paper Making
Section
Categ Category Specific water Remarks
ory Description consumption (m / 3
Code tonne of product)

Fresh Total
water water
A Medium Scale Agro & Waste paper based unbleached Kraft paper
manufacturing mill
¾ Chemical preparation 0.50 0.50 No recycled water is used
¾ Paper machine
Showers 10 10


ory Description consumption (m3 /
Fresh Total
water water
Vacuum pump 5 5
sealing
Pump gland cooling, 1.92 1.92
Floor washing
Sub Total 17.42 17.42
¾ Chemical preparation 21.50 21.50 No recycled water is used
¾ Paper machine
Showers 10.50 10.50
Vacuum pump 6.30 6.30
sealing, compressor
cooling, pope reel
cooling
Sub Total 38 38
C Large scale wood and wastepaper based newsprint manufacturing
mill
¾ Chemical 2.90 2.90 No recycled water is used
Preparation
¾ Stock preparation & 16.10 16.10
Paper machine
(Process)
Showers 4.40 4.40
Broke thickener 0.88 0.88
Others white water 6.4 6.40
silo make up, saveall
filtrate tank make up,
water conservation
tank make up
Vacuum flume tank 4.40 4.40
make up (vacuum
pump sealing)
AC plant cooling, etc.
Sub Total 20.90 20.90
manufacturing mill
Chemical preparation 0.08 0.08 No recycled water is used
Showers 14.40 14.40


Fresh Total
water water
Cooling tower make 24.12 24.12
up, pump gland
cooling/ sealing,
rewinder drum
cooling, COL, cooling
cylinder water, etc
¾ Pulp sheeting 1 1
Sub Total 39.52 39.52
¾ Stock Preparation 2.35 9.95 Recycled water is used
Showers 21.28 22.18
dryer surface
condenser, hot press
cooling, rewinder
break cooling, etc.
Sub Total 28.20 51.71 Recycled water is used
F
Small Scale Waste paper based Cultural – low grade paper
manufacturing mill
High & Low Pressure 11 11 No recycled water is used
showers
Vacuum pump 1.5 1.5 -do-
sealing
G
Medium Scale Wastepaper based Cultural – high grade paper
manufacturing mill
Chemical 2.38 1.96
Preparation
High & Low Pressure 21.6 23.3
showers
Back water tank 3.3 3.3
make up
vacuum pump
sealing, rewinder
cooling, Floor
washing


Fresh Total
water water
H
Small Scale Agro – residue based Industrial paper manufacturing mill
High & Low pressure 90.65 90.65
showers
sealing/cooling
I
Small Scale Agro- residue based Cultural – high grade paper
manufacturing mill
Showers 47.58 47.58
pope reel cooling,
rewinder cooling,
floor washing
Back water tank 0.17 0.17
make up
J
Small Scale Wastepaper based Cultural – low grade paper
manufacturing mill
Showers 64 64
Vacuum pump 60 60
sealing
6.2.5 Chemical recovery Plant
The major processes in chemical recovery plant are concentration of black liquor
through multi effect evaporator, salt recovery by black liquor burning, generation of
pulping liquor etc. In chemical recovery plant the water is primarily required for
following unit processes /operations:
(a) For maintaining barometric leg in the evaporator (Old evaporators without
surface condenser) and in the lime kiln
(b) Vacuum pump sealing, centrifugal pump gland cooling/sealing
(c) Spout cooling
(d) Evaporator tube cleaning
(e) Lime kiln dryer bearing and roller cooling
(f) Floor washing

washing. However there could be few areas which are either not pertinent or no
water is used depending upon the type of recovery process employed. The specific
water consumption for different water use areas (e.g. For maintaining barometric leg
in the evaporator, Vacuum pump sealing, centrifugal pump gland cooling/sealing
brown stock washing, pulp dilution etc., Spout cooling, Evaporator tube cleaning,
Lime kiln dryer bearing and roller cooling etc) in Chemical recovery section for pulp
mills studied in various categories is presented in the Table 22 below. The specific
water consumption has been expressed as fresh water per tonne of finished product
and total water consumption per tonne of finished product.
Table 22: Specific Water Consumption – Chemical Recovery Section

Category Specific fresh Specific total Remarks
water water
consumption, consumption,
m3/tonne of m3/tonne of
finished finished product
product
B Medium Scale Agro & Waste paper based bleached
writing & printing paper manufacturing mill
¾ Pump gland 0.42 0.42
cooling/sealing, etc
Sub Total 0.42 0.42
¾ Pump gland 11.10 11.10
cooling/sealing, etc
Sub Total 11.10 11.10
manufacturing mill
¾ Soda recovery boiler
& evaporator
Spout cooling 0.2 0.2
floor washing,
cooling tower make
up, tube cleaning
¾ Causticisation
Barometric leg 0.56 0.56
sealing
floor washing
¾ Lime kiln
sealing

Category Specific fresh Specific total Remarks

water water
consumption, consumption,
m3/tonne of m3/tonne of
finished finished product
product
Moisture trap 0.24 0.24
bearing 7 roller
cooling
Sub Total 6.52 6.52
¾ Evaporator & reboiler
Pump gland cooling 1.44 8.07 Recycled water
& cooling tower make is used
up
Spout cooling 0.11 0.11
¾ Causticisation Plant
Pump gland cooling, 0.08 2.65 Recycled water
slaker roller cooling is used
Mill A, F, G, H, I, J does not have chemical recovery plant and are therefore not
appearing in the above table.
6.2.6 Utilities
Utilities
(a) DM plant
(b) Chemical recovery plant: reactor cooling, product cooling, etc.
Scrubber (Boiler House)
Other than these water is also required for pump gland cooling/sealing, and floor
washing.
Water consumption pattern in Utility section is as given below in Table 23:

Table 23 : Specific Water Consumption – Chemical Recovery Section

Category Specific fresh water
consumption, m3/tonne of
finished product
A Medium Scale Agro & Waste paper based unbleached kraft paper
manufacturing mill
¾ DM Plant, cooling tower make up 2.21
Sub Total 2.21
B Medium Scale Agro & Waste paper based bleached writing & printing paper
manufacturing mill
¾ DM Plant, Boiler House
DM Plant Feed + Back wash 6.80
Boiler scrubber 10.52
Sub Total
¾ DM Plant, Boiler House, Miscellaneous
DM Plant Feed + Back wash 2.50
Boiler house: cooling water make up, compressor, ID 19.4
Fan’s bearing, pump gland cooling & sealing, etc.
Miscellaneous like road washing, etc. 1.50
Sub Total 20.90
D Large scale wood and wastepaper based paper and paper board manufacturing
mill
¾ DM Plant, Coal Fired Boiler, Softener
DM Plant Feed + backwash 4.19
Pump gland cooling, spreader cooling, etc. 0.83
Coal fired boiler- cooling tower make up, dust 1.60
suppression, etc.
Softener regeneration + Sand filter backwash 4.83
Sub Total 11.45
E Large scale Wood, Agro and wastepaper based (Integrated) paper and paper
board manufacturing mill
¾ Water treatment plant
Chemical preparation
Sand filter backwash & regeneration
¾ DM Plant, Boiler House
DM Plant + Backwash 6.28
Pump gland cooling
Sub Total 14.74
F Small Scale Waste paper based Cultural – low grade paper manufacturing mill
DM Plant, Cooling Tower 4.5
G Medium Scale Wastepaper based Cultural – high grade paper manufacturing
mill
Softening Plant, Cooling Tower, DG Set, & others 5

Category Specific fresh water

consumption, m3/tonne of
finished product
None
I Small Scale Agro- residue based Cultural – high grade paper manufacturing mill
DM Plant/Boiler House 3.94
J Small Scale Wastepaper based Cultural – low grade paper manufacturing mill
Softener Plant/Boiler House, Wastage 3.7

CHAPTER 7
FORMULATION OF STANDARDS FOR WATER CONSUMPTION /

WASTEWATER DISCHARGE BY DIFFERENT CATEGORIES OF
PULP AND PAPER MANUFACTURING MILLS
1. BACKGROUND
Based on the detailed pulp and paper mill’s inventorisation and observations from
the dry and detailed field studies conducted during the course of this project, there
are various salient features about pulp and paper sector in India that would be useful
in developing water consumption standards in the country. These salient features
are discussed below in detail.
Primarily three distinct level / range of “scale of operation” in the whole pulp and
paper sector across the country and these may be defined as
Large scale : > 25000 TPA of production,

Medium scale : between 5,000 and 25000 TPA
Small scale : < 5000 TPA
Large-scale pulp and paper sector in India exhibits following distinct features:
• Most of the large-scale mills are either wood based or integrated mills and
some yet significant number of only wastepaper based mills.
• There are few large-scale newsprint manufacturing mills but also involved in
manufacturing high-grade paper and paperboard.
• There is only one large scale mill manufacturing only newsprint
• Nearly all mills manufacture high-grade paper and paper board.
• All the large-scale mills have already undergone modernization and have
reduced their fresh water consumption substantially.
• All of them have installed chemical recovery plant.
Medium Scale pulp and paper mills in India exhibits following distinct features:
• All medium scale mills are either agro based and / or only waste paper based
mills.

• Maximum mills in this category are involved in industrial grade paper

production
• There are some agro and waste paper based medium scale mills involved in
the manufacture of high grade cultural paper production
• Very few agro based medium scale mills have chemical recovery plant.
• There is not significant difference in water consumption due to use of
chemical recovery plant.
• Technological level is similar to that of large scale and small scale mills in
respect of waste paper based mills
• Significant variations in water consumption exist among waste paper based
mills, with or without de-inking process, manufacturing cultural grade paper.
Small Scale pulp and paper mills in India exhibits following distinct features:
• All small-scale mills are either agro based and / or only waste paper based
mills.
• Maximum mills in this category are involved in industrial grade paper
production
• There are very few agro based small scale mills involved in the manufacture
of high grade cultural paper production
• Most of the small scale wastepaper based mills are involved in industrial or
low grade paper manufacture
• None of the agro based small-scale mills have chemical recovery plant.
• Significant variation / difference in water consumption in high grade and low
grade paper manufacturing exists
• Technological level is at par with most of the medium scale mills both in high
grade and low-grade paper manufacturing facilities.
2. PROPOSED CATEGORIES OF PULP & PAPER MILLS FOR STANDARDS
Keeping the above referred salient features and characteristics of Indian pulp &
paper mills prevailing in the country in view, following categories of pulp and paper
mills with respect to water consumption pattern are considered for formulation of
standards:
A. Large scale Wood based and integrated pulp and paper mills
manufacturing cultural grade paper & paper board and / or Newsprint
B. Small/Medium Scale Agro based pulp and paper mills manufacturing high
grade cultural paper

C. Small/Medium Scale Agro based pulp and paper mills manufacturing

industrial grade paper
D. All wastepaper based pulp and paper mills manufacturing high grade
cultural paper with “De-inking”
E. All wastepaper based pulp and paper mills manufacturing cultural grade
paper without De-inking
F. All medium / small scale waste paper based mills manufacturing industrial
grade paper
Category A represents all the large-scale mills which primarily uses wood and or
agro residue along with recycled fibre. In India, all such large-scale mills
manufacture high-grade cultural paper including newsprint and none are involved in
manufacture of industrial grade alone. Further, all of them have installed chemical
recovery mill. Water consumption pattern in all the mills under this category is of
similar order due to similar mill operations/processes being carried out with similar
scale of operation.
Category B represents Medium and small-scale agro residue based mills involved
in the manufacture of high-grade cultural grade paper. This category does not
differentiate between mills with wet or dry raw material preparation, with or without
chemical recovery, type of agro residues used.
Category C represents medium and small-scale agro residue based mills involved
in the production of industrial or low-grade paper. This category does not
differentiate between mills with wet or dry raw material preparation, with or without
chemical recovery, type of agro residues used. This mills in this category will not be
having bleaching and post bleaching wash processes and thus allowing large extent
of waste water recycling (may require simple physico-chemical treatment).
Category D represents all waste paper based mills irrespective of production scale
involved in the manufacture of high-grade cultural paper including newsprint with “de
inking”. The major mill operation / processes being employed are hydro pulping, de-
inking, pulp bleaching (may or May not) and papermaking.
Category E represents all waste paper based mills irrespective of production scale
involved in the manufacture of high-grade cultural paper without “de inking”. The
major mill operation / processes being employed are hydro pulping, pulp bleaching
(may or May not) and papermaking.
Category F represents all the small-scale wastepaper based mills involved in the
manufacturing of industrial low-grade paper. The major operations in mills of this
category are primarily hydro pulping and paper making with water recycling system.
The various types of paper products referred in the above-mentioned categories are
detailed below:

High grade Cultural Paper: Bond paper, Copier Paper, Writing & Printing, Paper
with brightness above 60 Also includes specialty paper like tissue paper, security
paper, etc
Low grade Cultural paper: Art paper/media paper, Creamwove, etc
Industrial grade: Duplex Board/Paper, Kraft paper
Newsprint
3. PROPOSED TYPES OF WATER COMSUMPTION STANDARDS

Based on detailed studies in ten representative mills, based on the literature survey
and also questionnaire response, mill operation/process wise water consumption
standards have been formulated. While developing the standards following factors
have been considered.
¾ The standards developed should ensure continuous reduction in water
consumption.
¾ The standards should be such that they trigger technological interventions as
well as reuse / recycling opportunities and thus lead to quantum reduction in
water consumption in long term.
¾ The standards should be India specific and practicable and feasible to
implement.
¾ The standards should also even out the huge water consumption disparities
among the similar type of mills in short term.
Considering all the above factors, the standards have been formulated in terms of
• Benchmark Standard: This standard refers to minimum water consumption
required after implementation of best available technology (economically
viable and currently practiced / demonstrated in India), recycle and reuse
practices. This standard has been developed by identifying the various unit
operations involved in each specific category and also identifying the least
water consumption actually achieved by any of the mills studied in that
particular category. The total of water consumption in each of the unit
operation / process would be the benchmark standard for that specific
category.
The idea of developing this standard is to ensure
o Quantum reduction in water consumption: No mill in the above-
referred categories is currently operating at this level. To achieve this
level most of the mills would need to undertake certain technological
modifications and complex recycling / reuse measures to achieve the
quantum reduction in the water consumption and comply with these
standards
o Development of feasible standards: Further these standards reflect
the feasible and demonstrated unit operation specific water

consumption norms already practiced in one or the other industry in

India and thus expected to be appreciated and followed by industries.
Since complying with these standards would need technological and complex
recycling / reuse systems interventions, which require significant time and resources
at the industries end, it is proposed that these standards to be considered for
implementation after four years from the acceptance year of this report.
• Best Achieved Standard: This standard refers to the minimum water

consumption already achieved by a mill (or can be achieved by
implementation of simple recycling / reuse measures) simple in the specific
category.
This standard is developed with the perspective of bringing the other mills to the
currently best-achieved and demonstrated level in the country. This standard can be
achieved by implementation of simple water recycling and reuse practices and minor
technological changes.
This standard is proposed to be considered for implementation from two years from
the acceptance year of this report. The three years grace period is proposed to
enable other industries to undertake technologies feasibility (technical, economical,
environmental etc) and implementation.
• Relaxed Standard: This standard provides 20 % relief over the best-
achieved standard in each specific category. This standard is proposed for
immediate reduction in water consumption by most of the high water
consuming industries and thus bridge the huge gap between best performing
and worst performing mills in a short time. It is estimated that this standard
can be achieved by other industries in each categories by implementing
simple reuse, recycling and other minor modification.
This standard is proposed to be implemented after six months from the acceptance
of this report. The six months grace period is proposed to enable other industries to
undertake the reuse, recycling and other minor modifications.
The process of developing above referred benchmark standards would also identify
unit operation / process or section specific water consumption benchmark figures
that can be used by the industries for continuous improvements.
4. DEVELOPMENT OF CATEGORY SPECIFIC WATER COMSUMPTION

STANDARDS
The unit operation / process specific water consumption figures developed during
the detailed field studies have been used to develop the water consumption
standards for above referred categories of the pulp & paper mills. The category
specific water consumption standards development for all categories is detailed in
the tables 24 to 29 in the following pages.

CATEGORY A: Large scale Wood based and integrated pulp and paper
mills manufacturing high grade cultural paper and paper
board and / or Newsprint,
Table 24: Water Consumption Standards for Category A
Unit Processes/Operations Specific fresh water Remarks
Sl
consumption, m3/
tonne of product
(Minimum required)
1 Raw material Preparation 0 100% recycled water can be used as this
process does not require quality water
2 Pulping Section
a 4 Counter current washing, Best technology to
achieve min limit: Twin roll wire press washer
Brown stock washing
and extended delignification using oxygen
after digestion
b 6.6 Recycle of waste bleach liquor partly, Use of
Bleaching and washing recycled water, Best technology to achieve
min limit: Twin roll wire press washer
c Pulp dilution 5
d Other non process like pump 3.76
gland cooling, floor washing,
etc.
3 Waste paper 6.32 100% recycled water can be used
4 Stock Preparation 0.08
(Chemical preparation)
5 16.1 Self cleaning showers, well maintained
pressurised showers, Use of recycled water in
Paper machine low pressure showers, 100% recycling of
vacuum pump sealing wastewater, recycling
of pump gland cooling
6 6.52 Using surface condenser in the multiple effect
Chemical Recovery evaporator replacing barometric leg, recycling
pump gland cooling waste water,etc
7 11.45 Installation of cooling tower to recycle cooling

Utilities water from pumps, compressors, turbines,
etc.
60
Total
3
Other Miscellaneous (5% of
total)
Overall (Benchmark 63
Standard)
Benchmark Standard : 63 m3/ tonne of product
Best Achieved standard : 67 m3/ tonne of product (M/s Seshasayee Paper and
Paper board Ltd., Erode)
Relaxed Standard : 80 m3 tonne of product

CATEGORY B: Small/Medium Scale Agro based pulp and paper mills

manufacturing high-grade cultural paper with or without
chemical recovery
Table 25: Water Consumption Standards for Category B

Sl Unit Processes/Operations Specific fresh water
Remarks
consumption, m3/
tonne of product
(Minimum required)
1 Raw material Preparation 0.2 100% recycled water can be used as this
process does not require quality water
2 Pulping Section
a Brown stock washing 11 Counter current washing, Use of recycled
water
b Bleaching and washing 5.89 Recycle of waste bleach liquor partly, use of
recycled water
c Pulp dilution 0 Use of recycled water
d Other non process like pump 0 Recycling gland cooling wastewater
etc.
3 Waste paper pulping 0 100% recycled water can be used
5 Paper machine 16.1 Self cleaning showers, well maintained
pressurised showers, Use of recycled water
in low pressure showers, 100% recycling of
6 Chemical Recovery 0.42 Using surface condenser in the multiple effect

evaporator replacing barometric leg, recycling
pump gland cooling wastewater,etc
7 Utilities 2.2 Installation of cooling tower to recycle cooling

water from pumps, compressors, turbines,
etc.
Total 36 Rounded off
Other Miscellaneous (5% of 2
total)
Standard)

Best Achieved standard : 80 m3/ tonne of product (M/s Shreyan Industries)
Relaxed Standard : 95 m3/ tonne of product
Present consumption in other mills ranges from 110 to 160 m3/tonne of product

CATEGORY C: Small/Medium Scale Agro based pulp and paper mills

manufacturing industrial grade paper with or without
chemical recovery
Table 26 : Water Consumption Standards for Category C

Remarks
consumption, m3/ tonne of
product (Minimum
required)
1 Raw material Preparation 0 Dry depithing, dry dedusting can be

practiced
2 Pulping Section
a Brown stock washing 11 Counter current washing, Use of recycled
water
c Pulp dilution 0 Use of 100% recycled water
d Other non process like pump 0 Recycling gland cooling wastewater
etc.
4 Stock Preparation (Chemical 0.08

preparation)

6 Chemical recovery 0.42
7 Utilities 2.2 Installation of cooling tower to recycle
cooling water from pumps, compressors,
turbines, etc
Total 17 Rounded off
total)
Standard)

Best Achieved standard : 47 m3/ tonne of product (M/s Tehri Pulp and Paper Ltd)
Relaxed Standard : 56 m3 / tonne of product

CATEGORY D: All wastepaper based pulp and paper mills manufacturing

high-grade cultural paper and / or Newsprint with “De-
inking”
Table 27: Water Consumption Standards for Category D

Sl. Unit Processes/Operations Specific fresh water
Remarks
consumption, m3/
tonne of product
(Minimum required)
1 Waste paper pulping 9.6 100% recycled water can be used

Paper machine vacuum pump sealing wastewater, recycling
4 5 Installation of cooling tower to recycle cooling

Utilities water from pumps, compressors, turbines,
etc.
Total 18
total)
Standard)

Best Achieved standard : 41 m3/ tonne of product (M/s Pudumjee Pulp and
Paper: anticipated after implementation of simple
recycle/reuse options)

CATEGORY E: All waste paper based pulp & paper mills manufacturing cultural
grade paper without “De-inking”
Table 28: Water Consumption Standards for Category E

Remarks
consumption, m3/
tonne of product
(Minimum required)
1 Waste paper pulping 2.32 100% recycled water can be used

4 Utilities 2.2 Installation of cooling tower to recycle cooling

water from pumps, compressors, turbines,
etc.
Total 8 Rounded off
total)
Standard)

Best Achieved standard : 13 m3/ tonne of product (M/s Indo Afrique paper Mill)

CATEGORY F: All Medium / Small scale waste paper based pulp & paper mills
manufacturing industrial grade paper
Table 29: Water Consumption Standards for Category F

Sl. Unit Processes/Operations Specific fresh water
Remarks
consumption, m3/
tonne of product
(Minimum required)

Paper machine vacuum pump sealing wastewater,
recycling of pump gland cooling
4 2.2 Installation of cooling tower to recycle

Utilities cooling water from pumps, compressors,
turbines, etc.
Total 5.6
Other Miscellaneous (5% of 0.4
total)
Standard)

Best Achieved standard : 6 m3/ tonne of product (M/s Paper Packaging (P) Ltd.)

The consolidated proposed water consumption standards for each category of the
pulp & paper mills are compiled and tabulated below in Table 30.
Table 30: Proposed Water Consumption Standards
Sl Category Description Proposed water consumption standard
3
(m / tonne of paper)
Benchmark Best Relaxed
achievable
1 Large scale Wood based and integrated pulp 63 67 80
and paper mills manufacturing Newsprint,
Cultural grade paper and paper board
2 Small/Medium Scale Agro based pulp and 38 80 95
paper mills manufacturing cultural grade paper
3 Small/Medium Scale Agro based pulp and 18 47 56
paper mills manufacturing industrial grade
4 All wastepaper based pulp and paper mills 19 41 49
manufacturing high grade cultural paper and /
or news print with “De-inking”
5 All waste paper based pulp & paper mills 9 13 15

manufacturing high grade cultural paper without
“De-inking”
6 All Medium / Small scale wastepaper based 6 6 7

pulp and paper mills manufacturing industrial
grade paper
5. PROPOSED CATEGORY SPECIFIC WASTEWATER DISCHARGE

STANDARDS
From the water balance studies carried out at different representative pulp and
paper, it has been found that the ratio of wastewater discharge to fresh water
consumption (only process) varies between 0.72 and 0.86. Considering an average
ratio of 0.79, following waste water discharge standards based on the above water
consumption standards proposed (Table 31).

Table 31: Proposed Water Consumption Standards

Sl Category Description Proposed wastewater discharge
standard in m3 / Tonne of product
Benchma Best Relaxed

rk achievable
1 Large scale Wood based and integrated pulp and 50 53 63

paper mills manufacturing Newsprint, Cultural grade
paper and paper board
2 Small/Medium Scale Agro based pulp and paper 30 63 75

mills manufacturing cultural grade paper
3 Small/Medium Scale Agro based pulp and paper 15 37 44
mills manufacturing industrial grade
4 All wastepaper based pulp and paper mills 15 32 38

manufacturing high grade cultural paper and / or
news print with “De-inking”
5 All waste paper based pulp & paper mills 7 10 12

manufacturing high grade cultural paper without “De-
inking”
6 All Medium / Small scale wastepaper based pulp and 5 5 6

paper mills manufacturing industrial grade paper
It is further recommended to use the treated wastewater as much as possible

for irrigation purpose.

CHAPTER 8
WATER CONSERVATION OPTIONS IDENTIFIED FOR DIFFERENT

CATEGORIES OF PULP AND PAPER MILLS
The high water consumption in Indian pulp and paper industry is mainly due to
obsolete process technology, poor water management practices and inadequate
wastewater treatment. Water once used is generally thrown without any further use,
even if the water is not much contaminated.
Segregation of wastewater from various processes into clean wastewater, (that can
be reused) and contaminated water is therefore one of the very important step to be
taken towards water conservation. This would avoid the uncontaminated water
getting contaminated after mixing and is discharged as effluent. Another important
step towards water conservation would be rainwater harvesting. This would help the
industries to meet a substantial part of their annual water requirement even as
demand on local sources is minimised.
In order to evolve techno economically feasible option, detailed field studies were
carried out as mentioned in earlier chapter. Depending upon the category and scale
of operations, water conservation options have been recommended. They are as
detailed below:
I. General Housekeeping Measures
1. Instituting a repair and replacement system to reduce water loses from valve
leaks: Good maintenance of seals, flanges and water pumps can substantially
reduce the fresh water consumption. Large quantities of water are wasted as spills
and overflows. A preventive maintenance schedule needs to be developed.
2. Monitoring and follow up of automatic shut down procedure for the water turbines
when pulping or paper machine sections are out of production. It has been observed
that auto-shut down procedure of water turbines is not strictly followed with the result
water turbines remain in operation while pulping and paper machine sections are
down.
3. Installation of Press type taps to avoid leakages from all taps inside plant: Press
type taps will avoid water wastage through open taps due to negligence of a worker.
Cost of a single press type tap ranges between Rs 50 to 100.
4. Auto close valve for hosepipes: Press type clutches in the hosepipes, similar to
one used for delivering oil in Petrol pump stations. This would prevent water loss
due to negligence. Cost of one such hosepipe is Rs. 1000/-.
5. Daily reporting of water consumption and drain losses from individual sections like
pulp mill, wastepaper pulping section, paper machine sections, utility, etc). This
allows rapid identification of non-routine conditions so that prompt remedial action
can be taken. This requires installation of online flowmetres. Further, monitoring of

water use/drain losses can be done over a specific financial periods and
management can place a specific target to the individual sections. This would
motivate the plant supervisors, operators and would encourage them to improve the
standards.
The standards achieved should be reviewed time to time to enable continuous
improvement.
II. Common Measures
1. Use of Better pulp washing technology instead of obsolete technologies like
potcher washing
Conventional potcher washing consumes huge quantity of water as it is a batch
process. Compared with this continuous countercurrent processes consume less
water. Usually three washings are applied in these processes. It is suggested to use
fresh water only at the last stage (i.e. at third stage) and recycle the effluent in first
and second washings. This system not only reduces water consumption but also
allows recycle of wastewater to some extent leading to saving of bleaching
chemicals.
Some of the continuous processes are as detailed below:
a. Hydraulic drum washing: A hydraulic drum washer does not require Barometric
leg and works on hydraulic principle therefore has minimum operating costs. A
hydraulic drum would cost around Rs. 2.5 Lakhs including civil costs.
A sketch of hydraulic drum is shown in Figure 32 below
For a 30 TPD pulping mill

Rubber roll of 500 mm dia

Doctor's Knife
Washed Pulp consistency = 10%
Unwashed Pulp
200 mm
Perforation of 25 mm
40# wire over the drum
Figure 32: Schematic design of a hydraulic washer
b. Vacuum Drum washing: In vacuum drum washing, each stage consists of a

rotating screen drum which has a partial vacuum applied to interior. The drum sits in
a tank where pulp is diluted with wash water. The vacuum draws a pulp mat against
the surface and wash water through the mat. The drum rotation advances the
washed pulp mat to the next dilution tank. Wash water discharged from this wash
stage is sent to the previous washing stage.
For a 30 TPD pulping mill, a vacuum drum washer would cost around Rs. 20 – 25
Lakhs including civil costs.
c. Pressure washing: Pressure washing is similar to vacuum drum, but differs by
spraying water under pressure through the pulp mat as the drum rotates.
d. Diffusion washing: Diffusion washing is a counterflow process that takes place in
one or more stages. Pulp flow is upward and is carried on a perforated plate. Water
flows downward through a series of baffles.
e. Chemi or Belt washing: A Chemi or belt washer is perhaps the simplest washing
system in terms of design. It offers excellent washing with reduced water usage. Belt
washing is a counter flow process where pulp enters the washer area on a wire belt.
Washing takes place under a series of showers. Clean water enters on the opposite
end from the pulp and is sprayed vertically through the pulp. The used wash water is
then collected and reapplied to the dirtier pulp by the next washing head.
Countercurrent to the direction that the pulp moves. This process is continued
through at least seven stages until the wash water is saturated with liquor after
washing immediately coming pulp. The wash water is then sent to the recovery
process.
Diffusion washing and belt washing can reduce the amount of water used per tonne
of pulp in brownstock washing by 50% or more according to published data.

Capital equipment Costs – including all support facilities21 : $ 10.2 to $ 12.3 MM

Operating Cost reduction compared to vacuum drum washing: $4.67 per Tonne of
pulp
Payback period : 4.25 to 4.9 years.
Due to long pay back period, Chemi washer is more feasible in a new installation or
when new washer is required to replace a vacuum drum washer that has reached
the end of its service life.
f. Twin roll press washer: Twin wire roll press washer consists of a twin-wire
dewatering unit which allows controlled washing of the pulp. The two-sided
dewatering and strong turbulence of the washer facilitate two to three times higher
capacities per unit of width than conventional washer technologies. An additional
main feature of this technology is that the ash and fines removal can be controlled
depending on the targeted levels. This technology can be used for high consistency
pulp washing and resulting in reduced water consumption.
The cost (rough estimate) for 300 OD TPD fiberline (excluding cost of civil
construction, land and detail engineering design cost) can be as follows:
1. Brown stock washing & Screening including ODL- price SEK 65 million or 413
million INR
2. Bleach plant- price SEK 45 million or 286 million INR
3. Instruments electrical DCS- price SEK 35 million or 222.28 million INR
4. Tanks & pressure vessels- price SEK 25 million or 159 million INR
2. Optimum use of cooling wastewater.

In every mill, cooling with water is required at various sites like pump gland
cooling/sealing, steam turbine cooling, compressor cooling, refiner gland cooling,
rewinder brake cooling, etc.
In most of the industries, fresh water is being used for pump jacket cooling on once
through basis. This water is most of the time non-contaminated. There are different
alternatives in which this water use can be optimized as described below:
A. Collection of once-through cooling water and reuse it in different process
operation: Collection involves installation of several small sumps or tanks from which
water is subsequently pumped to process water tanks. It is also possible to directly
use the water for specific applications like shower systems. The higher temperature
of cooling wastewater is advantageous to the shower system as it increases the
water drainage property of the web.
B. Converting once-through system into a closed –loop system: This requires
installation of cooling tower, a temperature controller and a cartridge filter to remove
21
Source: U.S. EPA, 1993b. Pollution Prevention Technologies for the Bleached Kraft Segment of the U.S.
Pulp and Paper Industry.

any suspended particles present in the waste cooling water. Further, periodic
injection of fresh water is required as a make up for the evaporation loss. One such
figure of a closed loop re-circulation system is shown in Figure 33.
Figure 33: Temperature controlled re – circulation system
3. Recovery and re-cycling of clean water from vacuum pumps.

In most of the industries, fresh water is used for sealing/cooling in vacuum pumps of
paper machine section. Vacuum pumps are used to supply vacuum to vacuum
drum pulp washers, wire section, press section and dryer section of the paper
machine. Vacuum pumps are typically liquid ring pumps which use water for sealing
and cooling. Water usage is continuous and high depending upon the size of the
pump.
The wastewater is mostly non-contaminated and suitable for recycling back after
passing through a cartridge filter. At present, the wastewater from this source is
either discharged outside directly or sent to ETP. This filtered water can also be
used in the pulp mill for pulp dilution, decker thickener showers, brown stock
washing, etc.
This requires similar arrangement as discussed in Option 2.
4. Installation of Vacuum flume tank to recycle vacuum pump sealing water
Sealing wastewater from all the vacuum pumps in paper machine section is
collected in a tank and by the action of centrifugal action, suspended particles are
separated from it. 50% of the clear filtrate goes back to vacuum pump as sealing
water and rest is collected in water conservation tank. In the water conservation
tank, fresh water is added as make up and is recycled back to the plant for different
uses as mentioned above.
The schematic diagram for flume tank water usage and water conservation tank is
shown in Figure 34 below:

Fresh water
Flume tank Paper machine
water to
vacuum pump
sealing
Flume tank
Waste water (Hot)
To Water
Conservation
tank
Freshwater
make up
Flume
tank water Water To Process
Conservation tank
Figure 34: Schematic of vacuum sealing wastewater recycling through Flume

tank
Saving in fresh water consumption by this option has been estimated to be 14.3
m3/tonne of product.
5. Replacement of water seals in Process Pumps
Seal water used in various pumps can be eliminated by replacing with mechanical
face and lip seals. Seal water flows are typically not very high, but are continuous
and can add up to large volumes over time. Replacing water seals with mechanical
seals usually increases energy consumption due to friction. Sealless pumps are
commonly used in Chemical industries. An example of a sealless pump is a diastolic
tube pump where magnetically coupled pump transmits power from the motor to the
pump with a magnetic pump. Pumps with braided packing seals and a self –
lubricating compound are also available. These lubricants have a colloidal mixture of
lubricants amalgamated with Aragraphe fibers.
Replacement of water lubricated seals not only reduces water consumption but also
reduces the occurrence of equipment damage, maintenance time and wastewater
generation.
In some mills, pressurized air has been found to be used instead of water as sealing
agent in vacuum pumps.
6. Use of efficient Decker thickener/ vacuum drum showers:
It was found that in most of pulp and paper mills, Decker thickener as well as
vacuum drum shower contained drilled perforation instead of nozzles. This results in
large consumption of fresh water. An optimum nozzle design (e.g. Needle jet type,

flat type, etc) with maintenance of appropriate pressure in the pipeline ensures
optimum water consumption.
Also with the passage of time, nozzle diameter gets widen due to corrosion. It is
therefore recommended to monitor the functioning of showers regularly maintaining
required pressure in the showers. Further by installing oscillating showers at
bleaching and high pressure nozzles at pulp and paper sections improve the
washing efficiency and reduce quantity of water required for washing.
7. Use of efficient shower system and regular monitoring of low pressure and
high-pressure showers and in the paper machine section
Paper machine showers are one of the largest users of fresh water in any pulp and
paper mill, it is necessary to optimize water use in paper machine shower system.
Design of an efficient shower system depends on the total number of shower
nozzles, type of nozzle: needle jet, flat type, etc, the locations of the nozzles, jet
angles and the distance between nozzles. Figure 35 depicts efficient paper machine
shower system. For new plants, it is advisable to have only optimum numbers of
paper machine felt/wire to minimize the water use.
Further, It has been observed during field studies that most of the pulp and paper
mills do not have any pressure gauge attached to the showers. Further, nozzle
shape gets deformed due to corrosion and other reasons with time. This results in
large consumption of fresh water.
Fig 35: Efficient design of a paper machine shower

system

8. Use of High-pressure low volume showers:

It is known fact that high-pressure showers consume lesser quantity of water and
therefore can save water.
9. Use of back or recycled water in low-pressure showers:
Clarified paper machine wastewater can be used in low pressure showers used as
felt sprays after passing through a multiplex filter unit or so depending upon the
quality of clarified paper machine wastewater achieved in the saveall.
The various locations where this water can be used are:
Wire section: Breast roll, wire turning and wire-return rolls, knock – off shower, trim
knock – off shower, wire cleaning shower (low pressure).
Press section: Cleaning of rolls
The characteristics of recycled water that can be used in the paper machine section
is as given below22:
Solids content (mg/l) Recommended use
0-50 Equivalent to filtered fresh water and can be used

anywhere
50-75 Can be used in fixed orifice nozzles of 1 mm diameter

and larger
75-100 Can be used in fixed orifice nozzles of 1.5 mm

diameter and larger
100-200 Can be used in fixed orifice nozzles of 3 mm diameter

and larger
10. Use of self-Cleaning showers in paper machine section

It has been found that mills having self-cleaning showers in low-pressure showers
only in paper machine section have been consuming fresh water 55 to 60% less23.
11. Choosing right type of saveall system
There are several proven technologies to clarify paper machine wastewater or also
called white water. Some of the popular ones used in the industry are listed here:
A. Poly disc filtration system:
Polydisc filtration system uses a number of hollow discs to achieve a high surface
are of filtration. They produce two different qualities of filtrate. The filtrate initially
22
Source: A Good practice guide ‘ Practical Water Management in Paper and Board Mills” produced by
accepta, www.accepta.com
23
Source: A paper on “ Water conservation in pulp and paper industry” by (Late) S. G. Rangan, Past President
of IPPTA

produced has relatively high-suspended solids content is called cloudy filtrate and
can be re-used for pulp dilutions. The next stage filtrate is produced once a mat of
fibres has been built up on the disc surface which acts as a filter medium. The
suspended solid concentrations in this filtrate is much less and can be easily used
for variety of applications like paper machine showers, pump gland cooling/sealing,
vacuum pump sealing, etc.
Cloudy filtrate is suitable for use in pulp dilution, etc whereas clear filtrate is suitable
for use in self-cleaning showers. Figure 36 &37 depicts the schematic diagram and
a view of polydisc saveall system.
Fig 36: Clear/Cloudy Filtrate recycling system
Fresh water make up

Consistency control Clear Filtrate
Filter drains
Cloudy Filtrate Paper m/c 4 white water
make up
White WaterTank Clear Filtrate

250 Cu. M 100 Cu. M Centricleaner Reject
dilution
Excess to ETP
For Screen Dilution For Pulper Dilution To Showers
Fig 37: Polydisc Saveall

The saving in fresh water consumption by this system is expected to be 13.3

m3/Tonne or 26.6 m3/ tonne of pulp.
B. Krofta / Gravity sedimentation type saveall:
Krofta saveall is based on dissolved air floatation principle where as other on works
on sedimentation. This has been effectively used in wastewater treatment system
and has been also found very effective in fibre separation from the paper machine
wastewater. Flocculating agents are used in both the system. Figure 38 depicts a
krofta saveall installed in one of the pulp and paper mill in India.
Figure 38: Krofta saveall installed in a wastepaper-based mill

C. Drum filters
Drum filters use a rotating cylinder covered with a mesh that acts as the filtration
medium. The filtrates produced contain suspended solids concentrations of 120 –
150 mg/l. These types of filters are frequently used in broke pulp thickening, decker
thickeners, etc.
D. Inclined / Hill Screens
Inclined/Hill screens provide a simple separation system for the recovery of fibre and
clarification of paper machine wastewater. However, they are less frequently used

due to lower quality of filtrate produced. Figure 39 depicts a Hill screen used in a
mill in UK24
Figure 39: Hill Screen used for clarification of paper machine wastewater in a
mill in UK
12. Optimum use of paper machine clarified wastewater in sections other than
paper machine
In order to make maximum use of paper machine clarified wastewater, it is important
to have a sufficient storage capacity. The requirement of backwater in other sections
is not regular and is often intermittent. The various applications of this water are
¾ Decker thickener showers
¾ Vacuum washers
¾ Centricleaner reject dilution
¾ Pulp dilutions before bleaching stage, etc
¾ Johnson screen showers, etc.
Further, clarified water storage tank can be modified to enable further separation of
fibres from the filtrate. One such design has been suggested by Arjo Wiggins5 called
‘Stowford ‘ separator. Figure 40 depicts stowford separator used as filtrate storage
tank.
24
5

Figure 40t: The ‘Stowford’ separator that can be used as clarified wastewater
storage tank
13. Recycling of treated effluent for use within the mill for non-process
In most of the mills, fresh water is used for the following purposes:
Plantation
Gardening
Floor washing & toilet flushing
Since quality of water is not essential for these activities, treated wastewater from
ETP can be used. This will reduce fresh water consumption
The saving in fresh water consumption by this system is expected to be 50 - 100
m3/d

14. Tertiary treatment of wastewater for recycling

In order to recycle the wastewater completely back to the system, biologically
treated wastewater requires to undergo a number of treatment processes to achieve
nearly inlet water quality. In a pulp and paper mill, color removal is an important
requirement to use the finally treated wastewater as process water. Figure below
gives schematic diagram of treatment process.
The wastewater after primary treatment involving physio-chemical separation is
given secondary treatment. Secondary treatment uses microorganisms to accelerate
the natural decomposition of organic waste. The two main methods used are
aerated stabilisation and activated sludge treatment - both are known as aerobic
treatments.
The efficiency of these two systems varies widely, depending on climate, influent
quality, pulp type, fibre source and mill practice. In ideal conditions, activated sludge
performs better at reducing BOD and removing suspended solids.
Other methods include anaerobic processes like USAB processes followed by
aerobic systems have been successfully been used in the pulp and paper industry.
The secondary treated wastewater is then sent to tertiary treatment plant. In tertiary
treatment, Aluminum oxide, ferric oxide and polyelectrolytes assist coagulation of
waste in the effluents, which are then sand filtered.
Secondary
Filtration process Activated Membrane
treatment (e.g
e.g, Rapid Sand carbon process or ion
Aerobic /
Bed Filter, PSF, process exchange, etc
Anaerobic
etc.
process)
Figure: Schematic diagram for tertiary treatment process

The quality of treated wastewater after the tertiary treated is fit for recycling back
completely to the system especially in wastepaper based mills and partially for other
mills.
III. Measures specific to individual category

A. Small/Medium Scale wastepaper based Cultural – high-grade paper
manufacturing mill
1. Using better quality raw material to achieve desired brightness: Manipulation of
raw material quality enables use of lesser quantity of bleaching chemicals, hence
requires less water quantity for bleaching and washing.

B. Small/Medium Scale waste paper based Industrial and Cultural – low-grade

paper manufacturing Mills
Such mills can operate in closed loop water system. Following water conservation
options can be adopted to achieve a nearly closed loop water system:
1. Segregation of different streams: First step is to segregate high COD stream from
low COD stream. Wastewater generated from Vibratory screens, Centricleaners,
Decker thickener, etc are high COD containing wastewater and those generated
from paper machine section i.e. shower wastewater, vacuum pump sealing
wastewater, floor washing, etc are low COD containing stream.
The COD and BOD values of two streams are approximately as given below:
High COD stream: COD = 25,000 to 30,000 mg/l, BOD = 10,000 to 12,000 mg/l
Low COD Stream: COD = 2000 to 3,000 mg/l, BOD = 900 to 1000 mg/l
2. The two streams are to be treated separately. On such scheme is depicted in
Figure below. :

Air
Chemical
Sludge Drying Bed
Flash Collectio
High COD Stream
Mixer n Sump
Pump
Primary Clarifier
Upflow Anaerobic Filter

Sludge
Treated Effluent
Low COD stream
Equalisation cum Activated Sludge Process Secondary Clarifier

Neutralisation Tank Primary Clarifier
Sludge
Filtrate

3. The final treated effluent will have following characteristics:

pH: 7.0 – 8.0, TSS: 2000 – 2500 mg/l, COD: 80 – 120 mg/l, BOD: 20 – 30 mg/l
4. The treated effluent is suitable for recycling back in the process for following unit
operation/process:
¾ Hydropulper: For preparing wastepaper slurry
¾ Decker thickener: For washing and thickening of wastepaper slurry
¾ Centricleaning
¾ Vibratory screen showers
5. A part of treated effluent can be discharged out which can again be used for land
irrigation, gardening, etc.
Use of Fresh water will be limited to paper machine showers, for steam generation in
the Boilers and for chemical preparation only. Fresh water requirement will be equal
to the amount of water vapour lost during drying and the evaporation losses.
C. Small/Medium Scale Agro based Cultural – high-grade paper
manufacturing mill
1. Dry dedusting of straw for removal of fines and dust:
Dry dedusting of straw will not only reduce water consumption for washing of raw
material but also would avoid wastewater generation. A dry dedusting system would
require Vibratory/ rotary screens, conveyers & dust handling system required.
2. Collection of black liquor spills in a common tank
Black Liquor spills can be collected in tank and recycled back to the system. This
reduces fresh water consumption required for floor washing.
3. Recycling of chlorine wash backwater completely into the system:
After passing the unbleached pulp through a chlorination tower, it is washed in a
conventional vacuum drum thickener cum washer. The filtrate generated from this
washer contains mainly organo chlorine compounds. It has been observed that
recycling of this filtrate completely back to the system with occasional bleeding does
not effect the quality of bleached pulp produced. This not only saves fresh water
consumption but also reduces AOX containing wastewater generation.
This would result in saving of saving in fresh water consumption by 1.4. m3/ tonne
of product
4. Recycling of part of the bleach wash back water into the system.
Similar to chlorine wash backwater wash water generated from the Hypochlorite
washer, Alkali extraction washer, etc can be partly recycled back to the system.
Complete recycle is not possible.
This would result in saving of saving in fresh water consumption by 76 m3/ tonne of
product.

D. Small/Medium Scale Agro based Industrial grade paper manufacturing

1. Dry depithing of Bagasse:
Pulp and paper mills involved in the manufacture of unbleached paper and
paperboard need not remove 90% of the pith and hence can go for dry depithing.
This will not only reduce fresh water consumption for washing of raw material but
also would avoid wastewater generation. Not only this, wastewater generated from
wet depithing of Bagasse is more difficult to treat.
E. Large/Medium Scale wastepaper based high-grade Cultural paper

manufacturing mills
1. Use of More Efficient Deinking Plant
Use of efficient Floatation system for deinking and reuse of back water generated
from thickener washer and screw press in the deinking process again. This requires
use of good flocculating aid at optimized quantity. Figure 41 depicts the one such
scheme.
Cleaned pulp
Consistency = 0.7%
Fresh water
DNT
Fresh water Thickener
Boseidon
Wastewater Clear water
System (DAF)
for reuse
Screw Press Sludge
Sludge
Decanter
Pulp
Consistency = 30%
Figure 41: Recycling system in deinking plant
The clarified water is reused in different unit operations:

• Helicopulper
• H D Cleaner
• Pulp Dilution
• Centricleaner
• Pressure screen

This results in saving in Fresh water consumption by 76.5 m3/ADMT of DIP pulp
2. Manipulation of raw material quality
To achieve desired brightness in the finished product, better quality wastepaper can
be used. This reduces use of water for washing and bleaching.
3. Enzymatic deinking process
Enzymatic deinking has been proved as environmental friendly solution for
recovered paper recycling. Enzyme in deinking reduces conventional chemical use.
This would reduce washing water usage. Figure 42 below depicts one of the
schemes for enzymatic deinking:
Wastepaper
Enzyme
Backwater
13 - 16% Consistency
Pulper
Vacuum filter
High
Density
Coarse screen Cleaner
screw press
Bleaching chemical
Perforated screen Centricleaner kneader
Floatation cells
Storage Tower
Figure 42: Enzymatic deinking system (one stage)

4. Membrane filtration technique in deinking process instead of conventional

floatation method25
Water-based inks used in flexographic news printing remain one of the most
troublesome contaminants and present a unique challenge to the deinking operation.
Most newspaper deinking plants are designed to remove the oil-based inks most
commonly used in newsprint publication. These facilities tend to rely on froth
flotation for ink removal. However, it is well established that the conventional
flotation process is ineffective at removing flexographic inks. Under alkaline
repulping conditions, flexographic inks form colloidal dispersions of small hydrophilic
particles (<5 µm) stabilized by the ionized binder via an electrostatic mechanism.
Flexographic ink particles dispersed in the pulp suspension are then too small and/or
too hydrophilic to float at a good rate in flotation cells. Since flexographic inks form
very small hydrophilic dispersions under alkaline repulping conditions, they are
particularly well suited for removal by washing deinking technology. However, large
quantities of filtrate are produced by washing which cannot be directly recycled to
the process without detrimental effects on brightness of the deinked pulp or
discharged to the environment. However, the deinking efficiency of a wash deinking
process is strongly dependent on removal of the ink from the washer effluent.
Therefore, the wash effluent must be clarified of the flexographic pigments. In
practice, most deinking plants have some process water clarification as part of a
washing stage. Dissolved air flotation (DAF) is one of the most common types of
process water clarification used in deinking mills. However, the presence of flexo-
printed materials in the furnish seriously impacts DAF clarification and necessitates
significantly higher levels of coagulant to achieve a proper clarified water quality.
Membrane separation technology is a potentially attractive method for the removal of
flexographic ink residues from the wash filtrate effluent of deinking mills. One such
scheme is shown in Figure 43.
25
Source: Flexographic Newspaper Deinking: Treatment of Wash Filtrate Effluent by Membrane
Technology B. CHABOT, G.A. KRISHNAGOPALAN and S. ABUBAKR, JOURNAL OF PULPAND
PAPER SCIENCE: VOL. 25 NO. 10OCTOBER 1999

Figure 43: Membrane based de-inking system
H. Large/Medium Wood based high-grade Cultural Paper and Paperboard

manufacturing Mill
1. Dry debarking of Wood
2. Recovery of bleaching chemicals through membrane separation & reuse
(closed loop bleaching)
For Mills with Elemental Chlorine free bleaching process
Results have proven that both the coagulation/flocculation and the ultra/
nanofiltration technologies26 can be considered as an available kidney to remove
organic materials from the alkaline bleach plant effluents.
In closed-loop bleach plant operation, the build-up of COD in the bleaching stages
leads to an increased chemical consumption. By using membrane filtration, this
negative effect could be strongly reduced in an ECF sequence where EOP stage
filtrate can be recycled to the post oxygen washing system. The risk for scaling of
calcium carbonate (EO and EOP stages) and calcium oxalate (Ql or Do stages)
Source:FAIR-CT96-1360: Separation Methods for Closed-Loop Technology in Bleached

26
Kraft Pulp Manufacture, November 2000, Final Report Abstract

would increase by increased closure. Addition of magnesium would be

recommended in order to avoid the formation of calcium oxalate.
This would result in saving of saving in fresh water consumption by 18.7 m3/BDMT
of bleached pulp or 6.6 m3/ tonne of product
3. Indirect & More Efficient Heat Transfer System for Blow Heat Recovery In
Digester Section
In most of the mills, blow heat recovery system consists of direct heat transfer
system as depicted below.
Condensate
Primary
Conden Vapors to
Flash vapor atmosphere
ser
Blow Seconda
tank ry y
Conden
Flash vapor + ser
condensate Dirty
Accumulato
r
Fresh Water
Overflow Hot water to Hot

water tank
In this system, hot water generated is contaminated due to lignin presence in the
flash vapors. If instead of direct injection of fresh water into the dirty accumulator,
indirect heat transfer is installed, hot water produced can be used for other
operations in the pulp mill like bleach washing, pulp dilution after bleaching operation
etc. Condensate generated can be either drained to ETP or can be recovered by
installing online conductivity meter in the condensate collection pipe. And only pure
condensate can be sent back for recovery to boiler house.
Measures in Chemical recovery Section

1. Replacing barometric leg (direct) condenser cooling by surface (indirect)
condenser cooling
In older plants, multiple effect evaporators work on barometric leg principle.
Barometric leg requires around 3000 ~ 400 m3/d of water. The wastewater from

barometric leg is generally discharged to ETP. Replacing barometric leg with surface
condenser.
2 Reuse of secondary condensate in raw material preparation section:
Combined condensate of chemical recovery plant can be used for washing in final
brown stock washer and in raw material wet cleaning system.
3. Secondary Condensate from Soda Recovery Plant to be Used For Brown
Stock Washing / Bleach Washing
Secondary condensate can be used in brown stock washing. This would result in
saving of fresh water consumption by 200 m3/d.
4. Reuse of Spout cooling wastewater: Spout cooling water is a non contact water
and is therefore not contaminated back after passing through cooling system
5. Reuse of barometric leg wastewater: In the old plants, vacuum in the
evaporators, Limekiln is generated by barometric leg condensers which uses large
amount of fresh water for cooling. Since cooling of the vapours is done by direct
contact with the water, the wastewater sometimes is contaminated with organics
present in the vapour in case of multiple effect evaporators in Chemical recovery
section. This wastewater is suitable for reuse in Brown stock washing. Further,
instead of using fresh water for cooling in the barometric leg, backwater can be
used.
However in case of limekiln section, the wastewater is not contaminated and can be
recycled back after passing through cooling system.
6. Reuse of vacuum pump sealing wastewater: Vacuum pump sealing
wastewater from Chemical recovery plant and causticisation plant is non-
contaminated wastewater and can recycled back.
Measure in Utility Section

1. Reuse of wastewater from DM plant (regeneration & sand filter backwash),
softener (regeneration & sand filter backwash) for ash conditioning /
quenching
Since ash conditioning/quenching is a physical process and it does not require very
good quality water, DM plant regeneration and sand filter backwash can be used.
Saving in fresh water consumption, m3/ tonne of product= 1.68
2. Reuse of Water Drained from Pressure Sand Filters & Activated Carbon
Filters
It has been observed in some of the mills that during back-washing/regeneration of
Pressure sand bed filter (PSF) & activated carbon filter (ACF), first the filters are
taken out of service line and the water present in the filters are being drained to
ETP. This water is raw fresh water and can be directly taken to raw water storage
tank. This requires installation of an additional pipeline.
3. Re use of Backwash water from PSFs & ACF

The backwash water from PSF & ACF contains only suspended particles and
instead of discharging it to the ETP, it can be reused for gardening, plantation, etc.
This will lead to a saving of about 86.4 m3/day of raw water consumption.
Limitation In Continuous Recycle/Reuse Of Wastewater

A. Product quality specifications often limit the extent of recycling. For example food
grade products have an upper limit for chloride ion concentration. This limits the
maximum recycling of paper machine wastewater.
B. Continuous water recycling system also causes slime formation. This can be
prevented by optimized addition of biocide and chemical.
C. Closing the paper machine white water system can cause increase in
temperature and this requires use of suitable material of construction, greater use of
plastics

CONCLUSION
Existing standards are passé.

The questionnaire responses, CSE’s green rating project and the detailed field
studies have clearly indicated that the majority of industries in-fact actually
performing better than both the existing standards and the CREP standards they
have agreed to.
Common standard not far-sighted

It has also clearly emerged from the in depth studies that water consumption varies
significantly based on the scale of operation, raw material used and the end
products manufactured. Hence a common standard for all type of industries would
not be prudent and accordingly standards have been developed for six categories of
pulp and paper industries considering operational scale, raw material used and the
end product manufactured.
Recommended standards a challenge already conquered

While comparing with the existing standards, the currently recommended standards
may seem to be a challenging task to achieve but actual practice these have already
been achieved in totality by an Indian enterprise (Best achieved standard) or partially
i.e. at a mill process level by one or the other Indian enterprise (benchmark
standard). Hence the proposed standards are practical and feasible to achieve. The
industries may refer to the water conservation measures identified under the study to
achieve the water consumption standards.
Let’s not stop, we need to go further

The currently developed and recommended water consumption standards are still
comparably high in light of the latest world wide trends on water consumption. The
currently developed standards should be treated as short term applicable for about 8
years. It is further recommended that these standards should again be revisited after
6 years.
***************

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FINAL REPORT

DEVELOPMENT OF GUIDELINES FOR

CENTRAL POLLUTION CONTROL BOARD

SL. NO. TITLE PAGE NO

Annexure I: Copy of Questionnaire

Dr. A. K. Saxena, Group Head

Mr. Rajat Gupta, Senior Consultant

Mr. K. K. Sinha, Senior Consultant

From other Regional Offices

Mr. Kaliprasad V, Senior Consultant, RPMG, Hyderabad

Mr. S. K. Jain, Laboratory Analyst

National Productivity Council, New Delhi

National Productivity Council, New Delhi

Table E-3 : Summary of classification of pulp and paper sector in

National Productivity Council, New Delhi

In order to develop water conservation measures for different types of

Existing Water Consumption Norms / Standards: India

National Productivity Council, New Delhi

Existing Water Consumption Norms / Standards: World

Table E-4: Region / Country Specific Average Water Consumption in

Sl. Region / Average Specific Source

National Productivity Council, New Delhi

Current Water Consumption: A Revisit - Questionnaire Response

Specific Water Consumption

National Productivity Council, New Delhi

Current Water Consumption: In depth Study Findings

Table E-5: Specific Water Consumption in Selected Field Study Mills

National Productivity Council, New Delhi

Proposed standards for water consumption in pulp and paper sector

¾ The standards developed should ensure continuous reduction in water

• Benchmark Standard: This standard refers to minimum water

• Best Achieved Standard: This standard refers to the minimum water

• Relaxed Standard: This standard provides 20 % relief over the best

National Productivity Council, New Delhi

The consolidated proposed water consumption/wastewater discharge*

Table E-6: Proposed Water Consumption/Wastewater Discharge

Benchmark Best Relaxed

1 Large scale Wood based and integrated pulp 63 / 50 67 / 53 80 / 63

2 Small/Medium Scale Agro based pulp and 38 / 30 80 / 63 95 / 75

4 All wastepaper based pulp and paper mills 19 / 15 41 / 32 49 / 38

5 All waste paper based pulp & paper mills 9/7 13 / 10 15 / 12

6 All Medium / Small scale wastepaper based 6/5 6/5 7/6

National Productivity Council, New Delhi

Further, it is recommended to reuse this wastewater as much as

Water Conservation Options Evolved and Recommended to Achieve

Low – cost improvements

• General Housekeeping Measures: General housekeeping measures

Design stage procedures (new plant/equipment)

• Use of Better pulp washing technology: Various technologies available

National Productivity Council, New Delhi

Process modifications including recycle/reuse

• Optimum use of cooling wastewater:

National Productivity Council, New Delhi

Process redesign which includes improvement in quality and

• Choosing right type of saveall system: There are different technologies

Total system closure with zero liquid effluent

• Tertiary treatment of wastewater for recycling: In tertiary treatment,

However, there is a limitation to continuous recycle of wastewater within the

National Productivity Council, New Delhi

Existing standards are passé.

Common standard not far-sighted

Recommended standards a challenge already conquered