Green Manufacturing Practices: TNPL Case Study on Value Addition to Waste   Author :S. Chinnaraj, Co-authors :T. Vijayakumar, M.Senthil Kumar and S. V. Subrahmanyam Research and Development Division, Tamil Nadu Newsprint and Papers Ltd. Kagithapuram, Karur Dt, Tamil Nadu -639136 India

Introduction TNPL – Briefly… Value Addition to Bagasse as Paper Making Raw-material Value Addition to Solid Waste Value Addition to Liquid Waste

1. TNPL – Briefly…

TNPL – Briefly… Promoted by Govt. of Tamil Nadu in early 80’s World’s largest bagasse based paper plant at single location Presently produces 4,00,000 MT of PWP annually, Largest exporter of PWP from the country ISO 14001:2004, ISO 9001:2008 and FSC FM/COC & CW/COC Certified Uses one million MT of Bagasse every year and Installed Wind Power Capacity 35.5 MW Treated effluent water is pumped to TEWLIS consisting 430 farmers with 1660 acres. 25,000 m3/day biogas generated from bagasse wash water and used in Lime kiln resulting 15 KL F. Oil saving 1.00 Lakh acres Pulp wood plantation since 2004 involving more than 17,000 farmers Four registered CDM project reduces 2.1 Lakh MT CO2 emission Let us take a snap shot of what TNPL is about. 4

TNPL – Briefly… Installed 600 TPD mini cement plant under Lime Sludge and Fly Ash management Commissioned 3 loop 2 disperser 300 TPD deinked plant to conserve fiber Revamping steam and power system (RSPS) to augment in-house power generation from 81.12 MW to 103.62 and to reduce CO2 emission of 50,000 TPA 200 TPD Precipitated Calcium Carbonate (PCC) Plant and 120 TPD Wet Ground Calcium Carbonate (WGCC) Plant Largest exporter of PWP in the country 2.00 lakh per annum green field project : TNPL UNIT II to produce multilayer paper board

2. Value Addition to Bagasse as Paper Making Raw-material

Value addition to Bagasse TNPL is credited with unique innovation of waste to wealth. TNPL uses about one million tones of bagasse every year instead of wood thereby avoiding felling of tress around 52,000 acres of forest land every year. Value addition to sugarcane waste (bagasse) through pulp & paper production and effective utilization of biomass waste viz. residual sugars, bagasse pith and Black liquor, for bio-energy generation.

Residual sugar-Biogas Black liquor solids- bio fuel Value Addition to Bagasse Moisture 52% Dry Weight 48% 3% Fibre 31% 14% 4% 13% Residual sugar-Biogas Pith- Biofuel Loss Black liquor solids- bio fuel Bleached Pulp - Paper Bagasse

Wood Saved by Usage of Bagasse Year Bagasse Pulp Produced in MT Equivalent Wood Conserved in MT 2011-12 1,65,914 7,30,056 2012-13 1,70,632 7,09,786 2013-14 1,57,898 6,78,909

3. Value Addition to Solid Waste

Quantity of In-organics Solid Wastes Generation S. No Parameter Unit 2011-12 2012-13 2013-14 1 Fly ash MT 45,806 36,618 43,205 2 Wet ash 19,824 11,522 14,356 3 Lime sludge 2,91,645 2,94,587 3,02,644 4 Lime grits 4,204 3,973 3,834

Quantity of Organics Solid Wastes Generation S. No Parameter Unit 2011-12 2012-13 2013-14 1 Bagasse pith from Pulp Mill MT 98,036 82,816 87,053 2 Dust from Chipper House 2,257 9,129 9,078 3 ETP Primary Sludge 70,686 68,241 53,362 4 ETP Secondary sludge 3,755 4,817 5,501

Properties of solid wastes Major constituents (on OD basis) S. No Description Major constituents (on OD basis) 1 Fly Ash Ash: 88 - 92%, LOI: 8 to 12% 2 Wet Ash Ash : 90-95 % , LOI : 3 to 5% 3 Lime Sludge (Moisture:45 to 50%) Acid insolubles: 6-7%, Silica as SiO2: 6% Mixed Oxides (R2O3): 1% Calcium as CaCO3: 88 - 90% Magnesium as MgCO3:1 – 1.5% Free CaO: 0.8 , Sodium as Na2O: 18%

Properties of solid wastes Major constituents (on OD basis) S. No Description Major constituents (on OD basis) 4 Lime grits (Moisture: 25 to 30%) Acid in-solubles: 6- 7% , Silica as SiO2: 6-7% Mixed Oxides (R2O3): 3.1% Calcium as CaCO3: 85 - 88% Magnesium as MgCO3:3% Free CaO: 1.% , Sodium as Na2O: 1.8% 5 Bagasse Pith (Moisture:45-50%) GCV: 4000 -4200 Kcal/kg , Ash: 9% Volatile matter: 72% , Fixed carbon:13%

Properties of solid wastes Major constituents (on OD basis) S. No Description Major constituents (on OD basis) 6 Dust from Chipper house (Moisture: 25-30%) GCV: 4000-4600 Kcal/kg, Ash: 2.4% Volatile matter: 72% , Fixed carbon:19% 7 ETP primary sludge (Moisture:75-80%) GCV: 2300-2700 Kcal/kg Organics: 60-70% , Inorganics:30-40% 8 ETP Secondary sludge (Moisture: 83-85%) GCV: 2500-3000 Kcal/kg

Quantity of Solid Wastes Recycled or used S. No Parameter Unit 2011-12 2012-13 2013-14 1 Lime sludge: re-burnt in lime kiln MT 1,80,173 1,82,571 1,82,810 2 Chipper dust used as fuel in boiler 2,257 9,129 9,078 3 Bagasse pith used as fuel in boiler 98,036 82,816 87,053

GHG Emission Reduction Due to Lime Sludge Re-burning In 2013-14 S. No Parameter Unit Value 1 Burnt Lime production MT 1,01,351 2 Reuse of Lime sludge 1,82,810 3 Lime Stone Conserved 1,69,340 4 GHG emission reduction due to logistic reduction of lime sludge t CO2 e 1,371 5 GHG emission reduction due to burning of Lime Sludge in kilns 80,436 6 Total GHG emission reduction 81,807

LSFM : Cement plant On going Expansion Capacity : 900 Tons/ day Lime sludge from SRP 200 T/day Fly Ash from Energy boilers 100 T/day Capital Outlay Rs 100 Cr Capacity : 600 Tons/ day Lime stone On going Expansion Capacity : 900 Tons/ day

Environmental benefits of Lime Sludge & Fly ash Management (LSFM) system Parameter Unit Value Pozzalana Portland Cement MT 1,13,904 Solid waste elimination due to reuse of Lime sludge 62,631 Solid waste elimination due to reuse of Fly ash 17,010 Lime Stone Conserved 73,487 GHG emission reduction due to lime stone conservation 32,334 GHG emission reduction due to logistic reduction of lime sludge tCO2 e 470 GHG emission reduction due to logistic reduction of fly ash 156 Total GHG emission reduction due to LSFM 32,960

Inorganic Solid Waste Used MT/annum for Production of Cement

Reduction In Quantity of Solid Wastes Disposed MT/annum

GHG Emission Reduction Due to CO2 Sequestration Through PCC S. No Parameter Unit Value 1 Precipitated Calcium Carbonate per annum MT 50,000 2 GHG emission reduction per annum t CO2 e 22,000

Organic Waste Utilization

Energy Generation and GHG Emission Redun. by Utilization of Organic Waste as Fuel S. No Parameter Unit 2011-12 2012-13 2013-14 1 Chipper dust MT 2,257 9,129 9,078 2 Bagasse Pith 98,036 82,816 87,053 3 Thermal energy generated GJ 7,53,910 6,86,727 7,18,284 4 GHG emission reduction t CO2 e 73,849 67,248 70,359

Economical and Environmental Benefits of Kitchen Waste Biogas Plant.   S. No Parameter Unit Value 1 Organic solid waste utilized from canteen /day Kg 160 2 Organic solid waste utilized from guest house /day kg 60 3 Total organic solid waste utilized from tnpl per day 220 4 Emission reduction /annum by avoidance of CH4 t CO2e 7.6 5 Volume of biogas used in the heating equipment / day m3 20 6 Emissions reduction by fossil fuel displaced /annum 10.4 7 Emission reduction /annum 18.0 8 Savings /annum Rs in lakh 2.0

Quantity of Wastes Disposed to Other Industries S. No Parameter Unit 2011-12 2012-13 2013-14 1 Lime sludge MT 1,11,472 82,180 57,203 2 Lime grits MT  4204 3973 3 Fly ash 45,806 35,028 26,195 4 Wet ash 19,824 11,522 14,356

4. Value Addition to Liquid Waste

Properties Of Wastewater Generated S. No Parameter Unit High BOD Stream Low BOD Stream 1 pH 4.5 7.0 2 BOD5 ppm 4000(max) 600(max) 3 COD 6000(max) 1200(max) 4 Total Suspended Solids 7000(max) 1000(max) 5 Total Dissolved Solids 3500(max) 1800(max) 6 Color, Pt. Co units 300 350

Liquid Waste Management Sold for Secondary use: Moulded- fibre products, Fibre-boards, etc. Wastewater from Pulp Mills & Paper Machines On-Land Discharge (for Irrigation) Cooling Tower Manual Bar Screen Activated Sludge Basin Primary Clarifier Sludge Thickener Secondary Clarifier Ozone Treatment Decanter Sun Drying Burnt in Mill Boilers (mixed with pith) Wastewater from Bagasse storage, Reclaim & Washing Anaerobic Lagoon UASB Reactor Buffer Tank Neutralisation Tank Equalisation Tank Bagasse Clarifier Mechanical Bar Screen Vac. Belt Filters Mill Boilers Tertiary Treatment

Bio-methanation Plant Concept

Bio-methanation: Environmental and Economic Benefits Particulars Units 2011-12 2012-13 2013-14 COD Treated MT / Yr 22,127 24,443 21,577 COD Reduced 18,847 21,008 18,917 Biogas generation MM3 / Yr 8.73 101.33 9.66 Furnace oil saving KL / Yr 5,241 6,080 5,798 GHG reduction from CH4 avoidance MT CO2e 98,023 1,13,710 1,08,888 GHG reduction from Furnace Oil saving 17,016 19,740 19,039 Total GHG reduction 1,15,039 1,33,450 1,27,928 Revenue from Furnace Oil Saving Rs. (in Million) 181.8 241.9 265.9

Properties Of Treated Wastewater S. No Parameter Unit TNPCB Norms TNPL Results 1. pH No. 5.5 – 9.0 7.5 – 8.0 2. BOD5 ppm 30 10-13 3. COD 250 150 - 200 4. Total Suspended Solids 100 45 - 50 5. Total Dissolved Solids (in organics) 2,100 1,400-1,600 6. Color, Pt.co units - 230-260 7. AOX Kg/T 1.0 <0.1

Pollution Load per Day

Specific Pollution Load per MT of Paper

Recycling Paper Machine Effluent After Clarification Parameter Unit Paper machine effluent Colour Pt Co 100- 120 Total Solids ppm 1000-1200 Total Dissolved Solids 700 - 900 COD 221 Chlorides as Cl 200

Recycling Paper Machine Effluent After Clarification Fresh water Paper machine wastewater ETP Legend: Before Project After Project Fresh water saving : 3000m3/day Clarifier Bagasse storage & washing

Recycling of Eop Filtrate in Chemical Bagasse Bleaching Parameter Unit Value Reduction water consumption m3/day 1300 Reduction in effluent discharge volume Reduction of solids to effluent MT/day 3.25 Reduction of sodium discharge to Effluent Treatment Plant 3 Reduction in hydraulic load LP steam reduction 45 Emission reduction per annum t CO2e 4182 Savings per annum due to Energy conservation Rs in lakh 118 Fibre recovered per annum MT 1072 Savings per annum due to Fibre recovery 250 Total Savings per annum 368

Liquid Waste Management Utilization of Treated Wastewater For Irrigation Prior to TEWLIS Irrigation Treated Effluent Discharge Water Cisterns provided in TEWLIS Irrigated Land View of TEWLIS Irrigated Lands

Impact of Wastewater Irrigation Wastewater irrigated area (monitored by TNAU) TNPL River bed area Dry lands Non -irrigated area

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