1. 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
India

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

3. 1. TNPL – Briefly…

4. 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

5. 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 MW to 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

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

7. 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.

8. 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

9. Wood Saved by Usage of Bagasse
Year
Bagasse Pulp Produced in MT
Equivalent Wood Conserved in MT
1,65,914
7,30,056
1,70,632
7,09,786
1,57,898
6,78,909

10. 3. Value Addition to Solid Waste

11. Quantity of In-organics Solid Wastes Generation
S. No
Parameter
Unit 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

12. Quantity of Organics Solid Wastes Generation
S. No
Parameter
Unit 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

13. Properties of solid wastes Major constituents (on OD basis)
S. No
Description
Major constituents (on OD basis) 1
Fly Ash
Ash: %, LOI: 8 to 12% 2
Wet Ash
Ash : % , 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: %
Magnesium as MgCO3:1 – 1.5%
Free CaO: 0.8 , Sodium as Na2O: 18%

14. 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: %
Magnesium as MgCO3:3%
Free CaO: 1.% , Sodium as Na2O: 1.8% 5
Bagasse Pith
(Moisture:45-50%)
GCV: Kcal/kg , Ash: 9%
Volatile matter: 72% , Fixed carbon:13%

15. 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: Kcal/kg,
Ash: 2.4%
Volatile matter: 72% ,
Fixed carbon:19% 7
ETP primary sludge
(Moisture:75-80%)
GCV: Kcal/kg
Organics: 60-70% ,
Inorganics:30-40% 8
ETP Secondary sludge (Moisture: 83-85%)
GCV: Kcal/kg

16. Quantity of Solid Wastes Recycled or used
S. No
Parameter
Unit 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

17. 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

18. 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

19. 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

20. Inorganic Solid Waste Used MT/annum for Production of Cement

21. Reduction In Quantity of Solid Wastes Disposed MT/annum

22. 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

23. Organic Waste Utilization

24. Energy Generation and GHG Emission
Redun. by Utilization of Organic Waste as Fuel
S. No
Parameter
Unit 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

25. 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

26. Quantity of Wastes Disposed to Other Industries
S. No
Parameter
Unit 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

27. 4. Value Addition to Liquid Waste

28. 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

29. 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

30. Bio-methanation Plant Concept

31. Bio-methanation: Environmental and Economic Benefits
Particulars
Units
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

32. 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 4.
Total Suspended Solids
100 5.
Total Dissolved Solids (in organics)
2,100
1,400-1,600 6.
Color, Pt.co units - 7.
AOX
Kg/T
1.0
<0.1

33. Pollution Load per Day

34. Specific Pollution Load per MT of Paper

35. Recycling Paper Machine Effluent After Clarification
Parameter
Unit
Paper machine effluent
Colour
Pt Co
Total Solids
ppm
Total Dissolved Solids
COD
221
Chlorides as Cl
200

36. 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

37. 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

38. 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

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

40. Any Questions !
Any Questions !
Thanking you
Thanking you