DEVELOPMENT OF GUIDELINES FOR WATER CONSERVATION IN PULP AND PAPER SECTOR doc

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 different categories of pulp and paper mills 92 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. National Productivity Council, New Delhi 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 m 3 of water is consumed and around 695.7 million m 3 of wastewater is discharged annually by this sector 1 . India’s current average fresh specific water consumption of about 150 m 3 /tonne of product is far above the global best specific water consumption of 28.66 m 3 /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, Chromo paper 41% Industrial paper kraft paper, paper board – paper board - single layer board, multilayer board, duplex board, 43% 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, electrical grades of paper 4% Newsprint glazed, non-glazed 12% National Productivity Council, New Delhi 66 227 20 57 187 174 21 62 3 22 12 12 0 50 100 150 200 250 Cultrual - high grade Cultural - low grade Industrial Newsprint Pulp Specialty Figure E-2: Distribution of Pulp and Paper Mills Based on Products Manufactured No of Mills Producti on, 104 TPA Table E-2: Distribution of Pulp and Paper Mills (Number of Mills) Based on Pulping Processes and Operational Scale No of Mills Installed Capacity, million tonnes/yr Sl. No Pulping Process Large Scale Small Scale Grand Total Large Scale % Small Scale % 1 Chemical Soda Process 29 26 54 0.666 4.26 0.106 18.2 8 2 Hydro Pulping 92 113 219 12.80 7 81.88 0.462 80.0 7 3 Kraft/Sulphite process 34 2 36 2.169 13.87 0.010 1.65 Table E-3 : Summary of classification of pulp and paper sector in different categories Large/Medium scale Small Scale Sl. No Product type Agro based Integrated 2 Pape r Mill 3 Wast epap er Woo d base d Agr o Integrated Paper Mill Waste paper Total 1. Cultural - high 15 1 15 14 7 1 12 65 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 National Productivity Council, New Delhi Large/Medium scale Small Scale Sl. No Product type Agro based Integrated 2 Pape r Mill 3 Wast epap er Woo d base d Agr o Integrated Paper Mill Waste paper Total grade 2. Cultural - low grade 2 1 8 1 1 7 20 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 m 3 /tonne of product for small agro and wastepaper based mills respectively and 200 m 3 /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 m 3 /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 National Productivity Council, New Delhi B. Small scale pulp and paper mills: ¾ Less than 150 cum/tonne of paper within 3 years 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 m 3 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. N o. Region / Country Average Specific water consumption (m3/T of product) Source 1 U.S. 64 (Average value in the year 2000) Appendix “W” of Report on Status of Pulp & Paper in US by Michiel P. H. Brongers and Aaron J. Mierzwa 2 . Australia 28.66 ( Average value for the year 2003) APIC Public Eco-efficiency Report 2003 3 . Europe 40 APIC Public Eco-efficiency Report 2003 4 . Canada 67 APIC Public Eco-efficiency Report 2003 5Finland 40 Pulp Fact - Environmental Implications of National Productivity Council, New Delhi Sl. N o. Region / Country Average Specific water consumption (m3/T of product) Source . 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: S.No. Raw Material End Product Specific Water Consumption (M 3 /T of product) Min Max Remark Large Scale category 1 Integrated Cultural high grade including newsprint 105 202 2. Wood Based Cultural grade including newsprint 68 168 3. Wood Based Newsprint only 74 There is only one mill 4. Wood Based Rayon pulp 130 Only one mill in this category responded 5 Agro Based Cultural - high grade 73 -do- 6 Agro Based Cultural - low grade 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 Only one mill in this category responded 3 Waste Paper Based Cultural – high grade 40 -do- 4 Waste Paper Newsprint 16 -do- [...]... general guidelines for water conservation for each type of pulp and paper industry were evolved National Productivity Council, New Delhi Final report on water conservation in Pulp and Paper Sector Page No.5 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. .. water consumption level for each type of industry (vii) Formulation of guidelines for water conservation for each type of pulp and paper industry National Productivity Council, New Delhi Final report on water conservation in Pulp and Paper Sector 1.4 Page No.3 METHODOLOGY The following methodology is being adopted to accomplish the above said scope of work: Phase I (i) Questionnaire for seeking information... report on water conservation in Pulp and Paper Sector Figure 2: A typical process for Paper manufacture Raw material Water Raw material Preparation section Chemicals Water Pulping Section Water Pulp Washing & Bleaching Section Alum, Rosin Water Stock Preparation system Additives Paper Machine Wastewater Wastewater Wastewater Finished Paper 3.2 Different industrial processes in pulp and paper sector Based... 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... No.7 Final report on water conservation in Pulp and Paper Sector Type of paper Industrial paper Specialty paper Newsprint Main varieties Chromo paper kraft paper, paper board – paper board - single layer board, multilayer board, duplex board, Security paper, grease proof paper, electrical grades of paper glazed, non-glazed % of total consumptions 43% 4% 12% In India, the cultural varieties (writing and. .. pulping process lines: chemical pulping (e.g., kraft chemical pulping), mechanical pulping, and semichemical 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... 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... 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. .. 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. .. 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) Sl No 1 2 3 Pulping Process Chemical Soda Process Hydro Pulping . 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. 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