6/20/2018

ELIMINATION OF SODIUM
HYDROXIDE IN CEHMICAL BAGASSE
STREET OXYGEN DELIGNIFICATION
STAGE IN TNPL

Date of commencement: October 2015

Date of completion : on going

Presented by
Dr. S. SUBRAMANIAN
DGM (Lab and R&D)

TAMIL NADU NEWSPRINT AND

PAPERS LIMITED-TNPL

UNIT-1 KAGITHAPURAM

UNIT-2 MONDIPATTI 2

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PAPER AND BOARD PRODUCTION

CAPACITY GROWTH,TPA
Writing &Printing paper,MT
200000
Board,MT

400000 400000

230000 245000
180000
90000

1984 1996 2002 2009 2011 2015

3

SELF SUFFICIENT IN POWER (100%)

About 2.0MW of surplus power is exported to TANGEDCO
Wind power is exported to state grid
2 No’s of 3 KW Solar Panel installed in Wind Farm
160
140 3 6
Thermal power,MW
120 35.5 35.5 35.5
Wind Power,MW
100 35.5
Solar Power,KW
80 28
18 21.8
60
103.6

103.6

103.6
81.1

40 15
61.1

61.1

61.1

15
36.5

20
26

26

0
1984 1994 1995 2001 2004 2006 2007 2013 2017 2018
4

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PULP AND PAPER PRODUCTION

PROCESS IN TNPL UNIT-1
- TAPCON - Global procurement
- Captive Plantation - Procurement from all
- Farm Forestry educational institution

Baggase Hard Wood Waste Paper

Sugar

Sugarcane crop Sugarcane Sugar mill Bagasse

Forest
Paper loading Paper Bagasse pulp Bagasse storage
Preservation

COMPANY PROFILE
 World’s largest bagasse based paper plant promoted
by Governemnt of Tamil Nadu in early 80’s
 Exporting over 80000 MT of Writing and printing
paper to more than 30 countries per annum
 IMS (ISO 14001:2015, ISO 9001:2015),
ISO 27001:2013 and CW/COC Certified
 TNPL Cement - First of its kind in pulp and paper
industry in India by using Lime Sludge and Fly Ash
 Over one lakh acres of pulp wood plantation since
2004 involving more than 22,200 farmers
 Commissioned multilayer double coated board
machine 2.0lakh MT per annum for folding box and
solid bleached sulphite board 6

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CBECF PLANT PROCESS FLOW DIAGRAM

5 NUNMBER OF
CONTINUOUS DELTA COMBI THREE STAGE
DIGESTER FOR SCREENING (TRP) WASHING
BAGASSE PULPING

POST ODL POST ODL

ODL
WASHING WASHING D0 STAGE
STAGE
NO.1 NO.2

PULP
EOP D1
TO
STAGE STAGE
MACHINE

CHEMISTRY OF OXYGEN
DELIGNIFICATION
Using oxygen and alkali to remove the residual and
dissolved lignin in the unbleached pulp that remains
after cooking in order to improve the brightness of the
pulp.
Oxygen is weak oxidizing agent, but its power is
promoted by an increase in temperature under
alkaline conditions.
 During ODL, oxygen reacts predominantly with
residual lignin and soluble the lignin in dissolved
form.

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OXYGEN DELIGNIFICATION(ODL)PROCESS
 The Bagasse pulp from the digester is screened, washed in three
stage Twin Roll Press (TRP) and mixed with sodium hydroxide.
 The pulp is deposited in the oxygen reactor, steam heated and
injected with gaseous oxygen to undergoes oxidative
delignification.
 After ODL, pulp is washed to remove the dissolved lignin before
moving to the bleaching plant.
 The lignin content in Bagasse ODL pulp is reduced by maximum
20%, resulting in marginal reduction in bleaching chemicals and
chlorinated compounds.
 Effluent from the oxygen reactor is recycled in pulp mill and
recovery cycle, further reducing the dissolved solids going to the
bleaching plant, as well as effluent load from the bleach plant.
 The net effect is reduced effluent flows and less solids generation.

BEFORE CONCEPTION IN CBECF :

(ODL) STAGE

Third stage
NaOH O2
washed ODL Stage
BSW pulp STEAM

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UNIQUENESS OF THE PROJECT

Concept :
 Normally oxygen delignification in CBECF is carried out in
alkaline pH range of above 10.5 to control effective solubility
of dissolved lignin from Kraft pulping.
 This higher pH >10.5 increases the delignification efficiency
but simultaneously decreases the dissolved lignin content in
bagasse washed pulp.
Application :
 In this project through extensive Laboratory studies and
kappa number reduction data were carried out before
implementation.
 In plant trial, sodium hydroxide is eliminated in ODL stage
without any process modification.
 Decreased alkali carry over to post oxygen pulp for bleaching
stage was observed.

DISADVANTAGE OF OXYGEN
DELIGNIFICATION IN BAGASSE PULP
 Bagasse pulp contains more pith fines, which surface
area were higher than bagasse fiber.
 Pith fines holds more residual cooking chemicals
from pulping, which removal is very difficult in Twin
Roll Press (TRP) washing even at higher press load.
 Due to sponging nature of the pith fines, swelling
with alkali is happened during sodium hydroxide
addition in ODL stage.
 Therefore, residual active alkali carrying over from
washed pulp is sufficient to maintain the alkaline pH
in ODL stage.

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IMPROVED ODL STAGE IN CBECF PULP

 This project was implemented in CBECF from
October 2015 onwards.
 Oxygen delignified pulp without NaOH shows minor
change in kappa number with decreased alkali loss.
 Post oxygen washer number-2 filtrate contains lower
dissolved solids and residual alkali, which is used as
counter current washing liquor of previous stage pulp.
 This lower alkali carrying over ODL pulp requires
lower sulphuric acid in D0 stage to maintain the pulp
pH for chlorine dioxide bleaching.
 Bleach filtrate pH is observed as on higher side in D0
stage and contains lower COD and BOD.

AFTER CONCEPTION IN CBECF :

(ODL) STAGE

Third stage
O2
washed ODL Stage
BSW pulp STEAM

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BEFORE IMPLEMENTATION IN ODL STAGE

CHEMICAL CONSUMPTION & COST

2014-2015
S. No. Chemicals
cost / t
kg/t of pulp
of pulp

1 Sodium hydroxide 4.90 171.50

2 Sulphuric acid 11.80 82.60

Total 16.70 254.10

PULP PROPERTIES OF POST OXYGEN

WASHER NUMBER (POW2)

S. No. Properties Unit 2014-2015

1 Alkali loss Kg/t 10.9

2 Kappa number - 8.8

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CHEMICAL REUCTION PER TON OF

BLEACHED PULP
Before After
Chemical saving
Implementation Implementation
Kg/MT
S. Kg/MT Kg/MT
Chemical
No.
2015- 2016- 2017- 2015- 2016- 2017-
2014-15
16 17 18 16 17 18

1 NaOH 4.90 0.00 0.33 0.00 4.90 4.57 4.90

2 H2SO4 11.80 5.52 7.84 7.69 6.28 3.96 4.11

Total 16.70 5.52 8.17* 7.69* 11.18 8.53 9.01

* Open Market bagasse

COST REUCTION IN Rs. PER TON OF

BLEACHED PULP
Before
After
S. Implementat Cost saving in Rs.
Implementation
Chemical ion
No.
2015- 2016- 2017- 2015- 2016- 2017-
2014-15
16 17 18 16 17 18

1 NaOH 171.50 0.00 11.6 0.00 171.5 160.0 171.5

2 H2SO4 82.60 38.6 54.9 53.8 44.0 27.7 28.7

TOTAL 254.10 38.6 66.5 53.8 215.5 187.7 200.2

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ANNUAL TANGIBLE BENEFITS

(chemical and cost saving)
2015-16
2016-17 2017-18
(Oct.15-Mar.16)
S. Chemi
No. cals T / Cost Rs. / T / cost Rs./ T/ cost Rs./
annum annum annum annum annum annum

1 NaOH 287.45 1,00,60,750 530.62 1,85,71,700 351.74 1,23,40,900

2 H2SO4 368.40 25,78,800 447.66 31,33,620 295.03 20,65,210

Total 655.85 1,26,39,550 978.28 2,17,05,320 646.77 1,43,76,110

ANNUAL COST ECONOIMICS FOR

IMPLEMENTATION OF THIS PROJECT

S. No. Cost 2015-16 2016 -17 2017-18

1 Investment made nil nil nil

Cost saving per 126*Lakhs 217 144*

2
annum (Oct.-Mar) Lakhs Lakhs

3 Payback period IMMEDIATE

* Plant stopped due to water crisis

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PULP PROPERTIES OF POST OXYGEN

WASHER NUMBER 2 AFTER
IMPLEMENTATION
S. 2015-2016
Properties unit 2016-2017 2017-2018
No. (Oct.-March)

1 Alkali loss Kg/t 8.1 8.3 7.8

Kappa
2 - 9.1 9.1 9.4
number

STRTENGTH PROPERTIES OF
BLEACHED PULP
Before
After
S. implement
implementation
No. ation
Parameters Unit
2015-16 2016-17 2016-17 2017-18
1 CSF ml 280 300 300 260*
2 Bulk cc/ g 1.48 1.44 1.44 1.41*
3 Breaking M
length
6140 6260 6250 6000*
4 Tear Factor - 62.2 62.5 62.3 61.4*
5 Burst -
Factor
42.8 44.6 43.5 41.0*
*Open market bagasse

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REUCTION OF BLEACHING EFFLUENT

LOAD PER TON OF BLEACHED PULP
Before
Pollution load
Implementa After Implementation
Reduction
S. Filtrate tion mg/l
%
No. parameters mg/l

2014-15 2015-16 2016-17 2017-18 2015-16 2016-17 2017-18

1 COD, kg/t 2030 2016 1874 1864 0.69 7.68 8.18

2 BOD, kg/t 916 889 772 763 2.95 15.72 16.70

Total 2946 2905 2646 2627 3.60 23.40 24.90

* Water crisis period

COST ECONOMICS OF THE PROJECT

S. No. Parameters Benefit

1 Project cost (INR Lakhs) NIL

2 Intangible benefits ENCLSOED

3 Tangible benefits ENCLOSED

4 Savings ( in MT) 2281

5 Savings ( INR Lakhs) 487

6 Pay Back (Years) Immediate

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INTANGIBLE BENEFITS
 Improvement in initial alkali loss carried over to
bleaching stage.
 Decreased alkali loss carry over to bleaching stage, require
lower sulphuric acid to maintain the D0 stage pH with same
bleaching chemicals.
 Decreased suphuric acid addition in D0 stage is increased pulp
pH and thereby reduce the organic acid generation in
bleaching filtrate and pulp.
 Higher end pH in chlorine dioxide bleaching is decrease the
residual chlorine content in pulp, which eliminate the sulphur
dioxide usage.
 Reducing sulphuric acid addition in D0 stage is reducing
caustic consumption in extraction stage and thereby reduces
the recycling filtrate dissolved solids.

CHALLENGES / BOTTLENECKS

 Before implementing of this project, R&D officials

called for meeting with top management and pulp
mill executives to discuss about the Laboratory trial
results of bagasse pulp properties before and after
ODL, pollution load reduction and cost saving etc.
 Machinery supplier cautioned us, elimination of
sodium hydroxide will increase ODL outlet kappa
number and require more bleaching chemical.
 There is no significant bottlenecks observed for
implement this project.

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REPLICATION POTENTIAL
OF THIS PROJECT

 This project can be implemented in any Bagasse pulp

mill having ODL stage immediately without using
any modification or material cost.

 This project can be implemented in agro based pulp

and paper Industry.

ACHIEVING NATIONAL / INTERNATIONAL

BENCHMARK / STANDARDS
 After elimination of sodium hydroxide in ODL stage,
discharge CBECF effluent contains lesser pollution
load is helps to meet the pollution control board
standards.
 Decreased pollution load and raised end pH is an
advantage for effluent treatment plant.
 At source chemical reduction or elimination is to
decrease the pollution load at source itself.
 After implementation, the treated effluent COD and
BOD values are decreased below to the National and
International discharge standard.

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EMPLOYEE INVOLVEMENT, TRAINING

AND CAPACITY BUILDING
 Before implementation, process personnel were
thoroughly educated the advantages of this project .
 Process personnel are well versed of this project
objectives and after implemention it is running
continuously.
 To reduce the pulp deposition in press part and feed
lines were cleaned periodically and run the plant
with maximum production rate.
 Continuous process monitoring of plant and if any
process parameter deviation is attended immediately
without time delay.

FUTURE TARGETS AND ACTION PLANS

 This project is not implemented in HWECF plant

due to the usage of oxidized white liquor (OWL)
instead of sodium hydroxide.
 Two stage oxygen delignification is carried out in
HWECF plant instead of one stage ODL stage in
CBECF plant.
 Unbleached kappa number in Hard wood pulp is
higher than Bagasse pulp.
 Laboratory trail is carried out to reduce the OWL
addition in HWECF ODL stage.

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June2018

Thanking you for

listening our
achievements

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