Water & Waste Management at Emami Paper Mills Ltd. Balasore Authors: N. Panda, A.K. Sahu, M. Pati, R. Khuntia Presented by A. K. Sahu Manager (QC and R&D) Emami Paper Mills Ltd., Balasore

Emami Paper Mills Ltd. Unit : Balasore

About Emami….. Emami Paper Mills Limited, Unit – Balasore was established in 1983 having an installed capacity of 15 TPD using agro residue. The unit has expanded its capacity by adding two more Newsprint machines. Further the unit has been expanded with Board plant (132,000 TPA) & 10.5MW CPP The plant is an eco-friendly, 100% waste paper based paper with a capacity of 114,000 TPA of Newsprint, 16,000 TPA of Writing & Printing grade of paper . The plant is equipped with 30.5 MW Co-generation units to meet the 100% steam, power & utility requirement for the process. The unit has been awarded with ISO-9001, ISO-14001, OHSAS 18001 and TPM – excellence & consistent certification.

About Emami….. Paper Machine-I Paper Machine-II Paper Machine-III 5 MW Power Plant 15 MW Power Plant

Commitment to Environment Protection Environment protection through Solid waste utilization, Waste water management, Water conservation, Energy conservation, Air pollution control & GHG emission reduction.

Focus Areas Water Management Reduction of fresh water consumption Use of Tertiary treated water Rain water harvesting by recharge of storm/rain water to ground water table Solid waste management

Water is precious

Water Management Monitoring & measuring devices in various unit operation. Water audit/Water balance/Assessment of optimum water requirement in individual unit operation. Adequate fibre & water recovery system. Adequate ETP facilities & tertiary treatment plant Awareness through education & training.

Reduction of Fresh Water Consumption Save all clarified water is used as makeup water for deinking and the paper machine process. Vacuum pump sealing water is used in wire lubrication & knock down shower through booster pump in PM#1. Hydraulic heat exchangers cooling water is used at wire & press high pressure showers in PM#1 & PM#2. Vacuum sealing water is used at wire & press shower of PM#2. DIP#3 is operated with a close loop water circulation system, hence fresh water consumption is zero. Spiral condenser and pre separators water is recycled to warm water tank & used in wire & press section showers in PM#3. Vacuum pump sealing water is recycled through cooling tower. Cooling water from all hydraulic heat exchangers & gear boxes recycled through cooling tower. Fresh water from reservoir is going to compressor & instrument air dryer for cooling & return back to reservoir (50M3/hr.). Save all over flow, Uhle box separator, Trivac separator, Tertiary centri-cleaner rejects & Decker shower water of PM#2 is clarified in DIP#3 DAF for reuse.

Water Recovery & Reuse Recovery System Available Area Disc filter I and II & Potcher washing back water DIP#1(W&P Grade) Disc filter I and II, and DAF DIP#3 (News Print Grade) Disc filter, condenser cooling water & Closed loop Hydraulic cooling system. PM#3 Conical Bird Save all PM#1 & PM#2 Cooling tower & RO reject is reused. All manufacturing process Tertiary Treated Water PM#1, PM#2, PM#3, DIP#1 & DIP#3

Close Water Circuit Paper Machine - III Final Tower Pulping System Buffer tower Pulping System Final Tower DAF

Water Recovery – Power Plant RO Reject, CT Blow down water re use system.

Sealing water recovery tank Water Recovery System PM 1 vacuum pumps sealing water recovery system Sealing water recovery tank Vacuum Pump Sealing water Shower water tank To PM 1 wire showers (17M3/hr.) Fresh water

Sealing water recovery tank Water Recovery System PM 2 vacuum pumps sealing water recovery system Fresh water Vacuum Pump Sealing water Sealing water recovery tank Shower water tank To PM 2 wire showers (18M3/hr.)

Effluent Treatment Plant ETP Flow diagram

Secondary Water – Usage TOTAL : 3000 M3/day Used by farmers for cultivation. Road spray for dust suppression Coal yard for dust suppression Plantation Gardening

Tertiary Treatment Plant Multi Media Filter followed by activated carbon filter

Target Usage of Tertiary Water Area Purpose M3/day PM-I Floor cleaning, Fan pump cooling 50 PM-II Pump gland cooling, Floor cleaning, Fan pump cooling 150 PM-III & CAPP Edge knock off shower, Suction box flushing shower, Deculator shower & vacuum sealing, Gland sealing 750 DIP-I Gland sealing, Floor cleaning 100 DIP-III Mechanical/ Gland sealing, Clarified Tower 550 Sludge dewatering plant Screw press & Drum shower, Sludge pump gland sealing, Sludge tower agitator gland cooling, Screw gland cooling, Partly for chemical preparation 1400 TOTAL 3000

Quality Parameters of Fresh/Treated Water Sl. No. Parameters Unit Ground water Reservoir water after mixing with return water from power plant ETP final treated water (After secondary clarifier) Tertiary Treated Water 1 PH -- 6.9 - 7.0 6.9 - 7.2 7.6 - 7.8 7.5 - 7.8 2 Turbidity NTU Nil 50 -70 20-30 3 Silica as SiO2 ppm 32 - 35 40 - 50 75 - 80 4 TSS 35 - 40 15-20 5 TDS 220 - 240 280 - 300 1500 -1600 6 Iron as Fe 0.3 - 0.5 0.4 - 0.6 1.5 0.2-0.3 7 Total Alkalinity as CaCO3 90 - 100 110 - 120 550 - 590 500-550 8 Total Hardness as CaCO3 120 - 140 170 -180 350 - 400 300 - 350 9 Chloride as Cl- 30 - 35 40 - 45 45 - 65 40 -55 10 Color Hazen 240-290 45-55 11 BOD 20 - 25 14-18 12 COD 20 - 30 190 - 230 150 - 180

Fresh Water Consumption Before & After Tertiary Treatment Sl. No. Areas Before, M3/Day After, M3/Day 1 Paper Machine # 1 650 606 2 DIP#1 600 580 3 Paper Machine # 2 850 824 4 Paper Machine # 3 & CAPP 2800 2190 5 DIP # 3 400 100 6 Power Plant 1 & 2 1500 1400 7 ETP & Screw Press chemical preparation & dilution 8 Domestic 95 9 TOTAL 7495 6395 NET SAVING OF FRESH WATER AFTER TRTIARY TREATMENT = 1100M3

Fresh Water Consumption Before & After Tertiary Treatment

Major Problems Associated & its Counter Measures Boil out Caustic wash Chemical treatment (Sticky control, Passivation, Biocide, Antiscalant or deposit control etc.) Water recycle leads to Increase in TDS Anionic Trash Deposits Biological growth Corrosion

Solid Waste Management 100% Utilization of Primary sludge as co-fuel after dewatering in Screw Press to 50-55% dryness Year Sludge generation, MT Area of use 2013-14 26252 Used as co-fuel in power boiler along with coal 2014-15 25972 2015-16 (up to June 15) 5819

Primary Sludge Characteristics Sl. No. Parameters Unit Results 1 Ash content % (w/w) 60-62 2 Dryness 50-55 3 Carbon 23.9 4 Hydrogen 2.67 5 Sulphur 0.83 6 Oxygen & Nitrogen 24.71 7 Gross calorific value Kcal/Kg 1900-2150

Elimination of Sludge Disposal To Eliminate the sludge Disposal problem No land requirement for disposal of ETP primary sludge AIM Use of sludge as co-fuel To eradicate the Environmental impact

Sludge From ETP to Boiler Burning of 100% deinking & primary sludge in power boiler Benefits :- Avoided land fills which eliminates land pollution No fouling of near by areas. Reduction in local air pollutants and green house gases emission. Reduction in coal consumption 950MT coal/month (approx.) Savings :- Coal saved 950MT Cost of coal Rs. 2900/MT i.e. Total cost of coal saved = Rs.27.6 lacs/Month. BELT CONVEYORS SLUDGE DRAG CHAIN FEEDER BOILER SLUDGE To BOILER

Net Savings/Month from Sludge Use as Co-fuel S. No Description Unit Value 1 Operational Cost (Chemical & Power) Rs in Lacs 19.00 2 ETP Sludge Generated (BD) Tons 2200 3 *Coal saved 950 4 Benefit from Coal saving 27.6 5 Net Benefit **8.6 *1.0 MT of coal saved by burning of 2.3 MT of BD sludge in the boiler (Rs.2900/MT of coal) ** CONSIDERING TRANSPORATAION COST & CHEMICAL TREATMENT COST FOR DEWATERING SLUDGE UP TO 25% DRYNESS FOR DISPOSAL, THE NET SAVING WOULD BE 19 LACS/MONTH.

Solid Waste Management 100% Utilization of Fly Ash for brick manufacturing Year Fly ash generation, MT Area of use 2013-14 85516 Road construction, Low lying area filling, Brick manufacturing 2014-15 97380 Brick manufacturing 2015-16 (up to June 15) 24744

Solid Waste Utilization Fly Ash Fly Ash being utilized for making Bricks having better properties than clay bricks. These Bricks are used extensively in building projects near plant, work out to be cheaper than clay bricks. Employment generated for local people in fly ash brick plant.

Ground Water Table Management by Rain Water Recharge Recharge Pit - 1 Recharge Pit - 2 Recharge Pit – 6, 7, 8 & 9 Recharge Pit – 3, 4 & 5

Monitoring Well

Conclusion After implementation of Tertiary treatment system, fresh water consumption reduced by 1100M3/day & specific water consumption is reduced to 17.3 from 20.2M3/MT of paper, resulting net savings of Rs. 17.8lacs/annum. 100% Primary sludge is used as co-fuel in power boiler & resulting savings of 950MT coal/month. Discharge of effluent to river is reduced by 50% after tertiary treatment and reuse. 100% fly ash is used for Brick manufacturing. Ground water table is maintained through rain water recharge structure (9 nos.)

WE CONTINUE OUR EFFORTS FOR BETTER SUSTAINABILITY Thank You