FIBRE AND WATER RECLAIMING SECONDARY FIBRE PAPER MILLS. FROM SECONDARY FIBRE PAPER MILLS. By SHEKHAR DESARDA MANAGING DIRECTOR PARASON MACHINERY (I) PVT. LTD.

Parason ...... the Refining People REJECT (Fibre + Water + Contaminants) REJECT HANDLING Reclaimed Fibre Contaminants Of Higher Solid Contents Reclaimed water Yield Improvement Raw Material Saving Money Reclaim Less Handling cost Reduce Environment hazard Reduce Effluent Load Less Fresh Water Required Less effluent discharge Less Chemical Consumption ECONOMY INCREASE PROFITABILITY

LIQUID IN DRAIN IS LIABILITY LIQUID IN PIPE LINE IS AN ASSET LIQUID IN DRAIN IS LIABILITY

REMEMBER Fibre and water in process is Asset to Mill. Will be converted into Finished Paper. Fibre and water once went into drain becomes Liability to the Mill. Required to invest to recover it. Dry drain is indication of efficient and economical running of Paper Mill.

GOLDEN RULES FOR FIBRE RECLAIMING Control Fibre loss by proper Selection, Operation & Maintenance of Equipment. To avoid converting Asset into Liability. Rule-2 Recover the Fibre from the Rejects as soon as possible. It is difficult to extract the Fibre once mixed with different types of contaminants.

INTRODUCTION Removing contaminants from a Deinking system is a complicated process that can involve many steps, viz. Pulping High-density cleaning Coarse screening Fine screening Flotation Deinking Washing Low Density cleaning

Each step removes : Different sizes of contaminants Ink Some Fibre that in an ideal system, would not be removed. The weight of incoming contaminants can very from less than 0.5% of total furnish weight for some grades to 5.0% or more for mixed office waste. Proper rejects-handling equipment and procedures can significantly reduce the total weight hauled and landfilled and thus reduce the cost of waste disposal. The proper handling of rejects also reduce fibre losses, labor requirements, improves housekeeping and safety.

Contaminants vs. Rejects Contaminants are materials that should not be present in the stock sent to the paper machine. Rejects are the materials that are actually discharged contains: Reject = Contaminants + Fibre + Water. Ideally, all contaminants, & only contaminants, would be discharged as rejects. In reality, only part of them is removed. As this percentage increases, the loss of usable fibers also tends to increase.

Equipment for handling rejects must convey, compact, and dewater them to reduce handling and disposal costs. It is difficult to recover the usable fibers once they have been rejected and mixed with other rejects. Reclaiming of Fibre from the Rejects increases risk of reintroduction of previously removed contaminants. The best way to control fiber loss is by the proper selection, operation, and maintenance of equipment rather than by trying to recover fibers after they have been rejected.

Contaminants can be broadly classified as TYPE OF CONTAMINANTS Contaminants can be broadly classified as Heavy Metal Rocks Ceramics Wire Sand Grit and Light Plastics Polystyrene foam Wax, Hot-melt adhesives Ink Ash Discharged from: Coarse screens Fine screens Reverse cleaners. Deinkng Flotation Sludge Clarifier Washer Discharge from: Ragger (wires) Pulper detrashing unit High- density cleaners Low density cleaners.

Heavy Contaminants Light Contaminants Non compressible & highly abrasive. No fuel value if burned. Self-drain to a solids concentration of 40-80% if allowed to do so in the absence of fiber. Normally landfilled after free draining. Light Contaminants Highly compressible and generally nonabrasive. Substantial fuel value if dewatered sufficiently before burning. Self-drain to a solids content of 10-20% in the absence of fiber.

Most discharge points also discharge some fiber, and many discharge both heavy and light contaminants. Also, it is common practice to discharge rejects from several sources into the same dump bins or rejects-handling equipment. Thus, rejects handling is much more complicated than it first appears and must be customized to some extent for each installation.

EQUIPMENTS FOR REJECT HANDLING

RAGGER Ragger is often used to remove very coarse contaminants like Wires, Ropes, Plastics from continuous LC Pulpers. It reduce load on further screening equipment. Increase efficiency of existing LC Pulper.

FIBER SAVER Reduce fibre loss. Increase in Capacity. Reduce down time of Pulper. Eliminate tedious labour work of removing reject from LC Pulper.

COST BENEFIT TO PAPER MILL OF 100 TPD Fiber Saver having 2.5M3 volume, say 2.5M3 per batch water along with plastics will drain.   Back Water 2.5 M3 x No. of Batches (40)/day 100M3 or 100,000 liters of water / Day Say back water consistency 0.3 – 0.5% 500 Kgs/ Day of Fiber at 0.5% Consistency. Say Fiber cost Rs. 15,000/MT, Fiber cost Rs. 7,500 / Day Say water cost Rs. 15 / M3 Water cost Rs. 1500 / Day Total saving Rs. 9000 / day Equipment payment is recovered in 6 Months

SAVINGS PARASON EQUIPMENTS WORTH FOR 10 YEARS Total saving: Rs. 9000 / day   Total saving: Rs. 9000 X 30 days X 12 Months = Rs. 32.4Lakhs Total saving: Rs. 32.4 Lakhs / Year Total saving: Rs. 1,62,00,000 / 5 Years PARASON EQUIPMENTS WORTH FOR 10 YEARS Total Saving Rs. 9000 X 360 X 10 TOTAL SAVINGS Rs. 324.0 Lakhs / 10 YEARS

PARASON REJECT FIBER SAVER BENEFITS Fiber and Water recovery Rs. 32.4 Lakhs / Annum Humans Safety. Avoiding to go plastics into the back water system Reducing the load in back water treatment plant Saving in Pumping Cost Neat & Clean Pulper area Remember Fiber Is Money /Remember Water is Natural Resource.

TROMMEL SCREEN Useful for recovering fibre from the reject of Dilution Pulper Unit. Water from the reject also can be reclaimed. Useful for Handling large amount of plastic contaminated waste paper. Increase capacity of Hicon Pulper by reducing discharge time of Pulper.

SHAFTLESS HELICAL SCREW CONVEYOR For Solids Separation Convey fairly Wet Solids disposed from Dilution Pulper & Coarse Screen. More compact than belt conveyors and can convey fairly wet solids. A modified screw conveyor consisting of a shaftless, helical screw. Because it is shaftless, the non-driven end has no bearing to maintain, and alignment is not as critical.

BALE COMPACTOR For Compacting plastic reject. Dewatering rejects from approximately 10% water content to 40-50%. Reduce hauling and landfill costs by 50-80%. Facilitate burning thickened rejects in bark burners, hogged fuel boilers, or special fluidized-bed incinerators. At 35% solids, the rejects have at least a break-even fuel contribution.

SAND SEPARATOR For Separating Heavy Contaminants from the reject. Used to dewater rejects from the Low consistency cleaner and High density Cleaner. The lower end of the conveyor is submerged in a receiving pond, and the upper end is well above the water level. Large amounts of water must be added to separate the fiber from the grit. Fibers must be kept in suspension using velocity or turbulence until they can overflow out of the receiving pond.

Parason ...... the Refining People SLUDGE SCREW PRESS Used for Dewatering of Sludge disposed of from Deinking process. Equipment now available that are capable of attaining as high as sludge dryness of 50-55%. Equipment selection is based on suitability for end use. High levels of final dryness come a price. Each sludge must now be individually evaluated with respect to disposal method as well as attainable vs. economically feasible cake dryness.

Parason ...... the Refining People PRESSURE FILTER fine fraction shower pipes No Blockage pressure filter shower water chest waste water chest coarse fraction Most efficiently used for recovering fibre from the back/white water and reuse of cleaned filtered water for showers, sealing water etc. Mechanical filtration No Chemicals Fibre Recovery as well as Water Reuse

DISC FILTER For Recovery of Fibre & Filler. Clarification of White water. Produce Clear & Super clear Filtrate for dilution and Machine Shower. Minimize Fresh water consumption. Thick stock Inlet Clear Filtrate Super Clear Filtrate

Parason have wide range of equipment for Fibre and water reclaiming. Equipment are designed keeping in view Indian Paper Mill environment and operating conditions. Parason also offered specific solution for each individual Paper Mill requirement to suit their condition.

100 TPD WRITING PRINTING PULPLINE

100 TPD KRAFT PULPLINE

Parason ...... the Refining People CONCLUSION REJECT (Fibre + Water + Contaminants) REJECT HANDLING Reclaimed Fibre Contaminants Of Higher Solid Contents Reclaimed water Yield Improvement Raw Material Saving Money Reclaim Less Handling cost Reduce Environment hazard Reduce Effluent Load Less Fresh Water Required Less effluent discharge Less Chemical Consumption ECONOMY INCREASE PROFITABILITY

GOLDEN RULES Rule-1 Control Fibre loss by proper Selection, Operation & Maintenance of Equipment. Rule-2 Recover the Fibre from the Rejects as soon as possible.

LIQUID IN DRAIN IS LIABILITY LIQUID IN PIPE LINE IS AN ASSET LIQUID IN DRAIN IS LIABILITY