1. 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

2. Emami Paper Mills Ltd.
Unit : Balasore

3. 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 and TPM – excellence & consistent certification.

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

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

6. 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

7. Water is precious

8. 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.

9. 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.

10. 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

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

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

13. 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

14. 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.)

15. Effluent Treatment Plant
ETP Flow diagram

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

17. Tertiary Treatment Plant
Multi Media Filter followed by activated carbon filter

18. 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

19. 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 -- 2
Turbidity
NTU
Nil
50 -70
20-30 3
Silica as SiO2
ppm 4
TSS
15-20 5
TDS 6
Iron as Fe
1.5 7
Total Alkalinity as CaCO3 8
Total Hardness as CaCO3 9
Chloride as Cl-
40 -55 10
Color
Hazen
45-55 11
BOD
14-18 12
COD

20. 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

21. Fresh Water Consumption Before & After Tertiary Treatment

22. 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

23. 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
26252
Used as co-fuel in power boiler along with coal
25972
(up to June 15)
5819

24. 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

25. 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

26. 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

27. 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.

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

29. 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.

30. 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

31. Monitoring Well

32. 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.)

33. WE CONTINUE OUR EFFORTS FOR BETTER SUSTAINABILITY
Thank You